JP4752430B2 - Molding sheet - Google Patents

Description

  The present invention relates to a shaped sheet having a delicate uneven shape, capable of high-quality dense molding, and excellent in releasability, and a decorative board molded by the shaping sheet.

As building materials used as furniture, desk top plates, various types of housing equipment such as counters and doors, and interior materials, generally, decorative boards formed with synthetic resin materials, such as melamine resin decorative boards, are widely used.
Conventionally, there are two types of thermosetting resin decorative plates having a concavo-convex shape on the surface, one having a concavo-convex shape formed by an embossing die or a resin concavo-convex sheet, and one having a concavo-convex shape formed by a shaping sheet. However, when an embossing mold having a concavo-convex shape is used, it is necessary to subject the die to surface treatment such as blasting or etching, which limits the concavo-convex shape and the fineness of the pattern. Furthermore, when manufacturing a thermosetting resin decorative board, an expensive template and a spare template are required, which increases the labor and cost of preparing the decorative board, greatly increasing the manufacturing cost and making the product expensive. . Also, in the case of a resin uneven sheet, it is necessary to sandwich an aluminum foil, a polypropylene film, etc. between the mold plate and the thermosetting resin decorative board because it becomes difficult to peel off after the resin is cured. It is very difficult to form a sharp.

By the way, due to the recent trend toward consumer luxury goods, furniture, desks, interior materials, etc. have been required to have a high-class feeling, and the decorative panels used for these have a high-quality appearance. Is desired. For this reason, it is also important to impart a texture, and various methods for imparting a delicate uneven shape to a decorative board have been proposed.
For example, it is a moldable sheet provided with an uneven shape with ionizing radiation curable resin on the surface of the base sheet, and is desired by having a crosslinking density such that the uneven shape is not broken when the formed sheet is peeled off. A shaping sheet has been proposed that faithfully reproduces the pattern shape to be used and can be used repeatedly (see Patent Document 1 and Claims). However, since the step of peeling from the roll intaglio is made when producing the shaping sheet, there is a limit to the expression of the uneven shape when the concave portion is thin, and the surface of the substrate when there is a concave portion with a certain thickness In addition, although a concavo-convex pattern is obtained, there is also a problem that the appearance and the touch feeling are not good.
In addition, a concave / convex layer is formed on the surface of the base sheet using a resin composition comprising an inorganic filler and a binder resin, and a fine concave / convex layer formed on a pattern formed of a liquid repellent resin is formed. A shaped sheet is proposed in which only the resin composition is repelled to form an uneven layer (see Patent Document 2 and Claims). However, because the concavo-convex layer is formed by repelling the resin composition for forming the concavo-convex layer, the lack of stability of the pattern due to the concavo-convex shape, and aging for a certain period to cure the concavo-convex layer, Since it takes a very long time to produce a shaped sheet, there is a problem that it cannot quickly respond to the diversifying needs of consumers.
JP 7-164519 A JP-A-5-92484

  Under such circumstances, the present invention provides a moldable sheet having a delicate uneven shape, capable of high-quality dense molding, and excellent in releasability, and the moldable sheet. An object is to provide a shaped decorative board.

  As a result of intensive research to achieve the above object, the present inventors have found that an ink layer provided on the entire surface of the substrate at least over the entire surface, and is present on and in contact with the ink layer, the entire surface A surface-forming layer covering the surface-forming layer, the surface-forming layer is a product obtained by crosslinking and curing the ionizing radiation-curable resin composition, and the surface of the surface-forming layer has an uneven shape It has been found that the above problems can be solved. The present invention has been completed based on such findings.

That is, the present invention
(1) A forming sheet having an ink layer provided over at least the entire surface of the substrate, and a surface forming layer that is present on and in contact with the ink layer and covers the entire surface, A molding sheet in which the surface-molding layer is obtained by crosslinking and curing the curable resin composition, and the surface of the surface-molding layer has an uneven shape;
(2) The surface shaping layer contains fine particles, and the average particle size of the fine particles is a value close to the plus side of the maximum thickness of the surface shaping layer located immediately above the ink layer. The shaping sheet according to (1) above,
(3) The moldable sheet according to (1) or (2), wherein the curable resin composition is an ionizing radiation curable resin composition,
(4) The shaping sheet according to (3), wherein the ionizing radiation curable resin composition is an electron beam curable resin composition,
(5) The above (1) to (4), wherein the ink constituting the ink layer contains a non-crosslinked urethane resin as a binder, and the curable resin composition contains a (meth) acrylate monomer. ) Molding sheet according to any one of
(6) The shaping sheet according to (5), wherein the ink constituting the ink layer contains a non-crosslinked urethane resin and an unsaturated polyester resin as a binder,
(7) The shaping sheet according to any one of (1) to (6) above, wherein the thickness of the ink constituting the ink layer is not uniform,
(8) The ink layer is composed of a thick film region having a relatively large film thickness and a thin film region having a relatively thin film thickness, and the surface layer located immediately above the thick film region and in the vicinity thereof. The convex shape on the surface of the mold layer is relatively high, and the convex shape on the surface of the surface shaping layer located immediately above the thin film region and in the vicinity thereof is relatively low. Sheet,
(9) The shaped sheet according to any one of (1) to (8), wherein the height of the convex shape is 1 to 3 μm,
(10) The shaping sheet according to any one of (1) to (9), wherein the surface shaping layer contains reactive silicone.
(11) The shaped sheet according to any one of the above (2) to (10), wherein the coefficient of variation CV value [(standard deviation of particle size / average particle size) × 100] of the particle size distribution of the fine particles is 30% or less ,
(12) The average particle diameter of fine particles is d _A , the maximum thickness of the surface shaping layer located immediately above the ink layer is t _M , and the thickness of the surface shaping layer in the region where no ink layer is present is t _G Formula (I)
1.05 × t _M ≦ d _A ≦ 1.25 × t _M (I)
The shaped sheet according to any one of (2) to (11), which satisfies the relationship:
(13) The shaping sheet according to any one of (2) to (12), wherein the content of fine particles in the surface shaping layer is 2 to 20% by mass,
(14) The shaping sheet according to any one of (1) to (13), wherein the surface shaping layer contains calcined kaolin particles,
(15) The forming sheet according to any one of (1) to (14), wherein the ink constituting the ink layer contains an extender pigment,
(16) A decorative board formed by shaping the shaping sheet according to any one of (1) to (15) on a substrate,
(17) A makeup, wherein the shaping sheet according to any one of (1) to (15) is inserted between a pressure plate and a substrate to be molded by pressing between the heated pressure plates. Board,
(18) The decorative board according to the above (16) or (17), wherein the substrate is a melamine resin decorative board, and (19) The above (16) or (17), wherein the substrate is a diallyl phthalate (DAP) resin decorative board. The decorative board,
Is to provide.

  ADVANTAGE OF THE INVENTION According to this invention, it has a delicate uneven | corrugated shape, can perform high-quality dense molding, and is excellent also in the mold release property, and the delicate mold shape | molded by this shaping sheet A decorative board having an uneven shape can be obtained.

The shaping sheet of the present invention has an ink layer provided on at least the entire surface of the substrate, and a surface shaping layer that is present on and in contact with the ink layer and covers the entire surface. The surface shaping layer is obtained by crosslinking and curing the curable resin composition, and the surface of the surface shaping layer has an uneven shape.
The structure of the shaping sheet of this invention is demonstrated using FIGS. 1-3 is a schematic diagram showing a cross section of the shaped sheet 1 of the present invention. In the example shown in FIG. 1, a uniform and uniform penetration preventing layer 6 covering the entire surface of the substrate 2, an ink layer 3, and a surface shaping layer 5 in which a curable resin composition is crosslinked and cured are laminated in this order. The surface shaping layer 5 has a fine uneven surface 13 on the surface. The ink layer 3 exists over the entire surface, and the interaction region 4 is formed in the surface shaping layer immediately above the ink layer 3. The interaction area 4 is represented by a set of points in the figure.
The upper part of the interaction region 4 on the outermost surface of the surface shaping layer 5 has a fine uneven surface 13 as the ink layer 3 is formed. When the surface of the surface shaping layer 5 has such a fine uneven surface, a shaped sheet having a delicate uneven shape can be obtained.
Further, in the example of FIG. 3, by changing the thickness of the ink layer 3, the raised shape 7 is expressed on the surface of the surface shaping layer 5 according to the thickness of the ink layer 3, thereby indicating that the surface has an uneven shape. Is.

The extent of expansion of the interaction region 4 formed in the surface shaping layer 5 is not particularly limited as long as it is within the range where the effects of the present invention are achieved, and the surface of the ink layer 3 as shown in FIGS. May remain in the middle of the thickness direction of the surface shaping layer 5 or may reach the outermost surface of the surface shaping layer 5.
Moreover, the fine ridge shape 12 resulting from the fine particles and the calcined kaolin particles gives the ridge shape 7 and the fine uneven surface 13 which are expressed over the entire surface of the surface shaping layer 5 to a partially fine ridge shape. .
The effect of the fine uneven surface due to the interaction region 4 in the surface shaping layer 5, the effect of cueing of fine particles on the surface with the surface shaping layer 5, and the raised shape formed according to the thickness of the ink layer 3 Due to the effect, it is possible to obtain a shaped sheet that has a delicate uneven shape and enables high-quality and precise shaping.

[Substrate 2]
Hereinafter, the structure of the base material and each layer will be described in detail.
The base material 2 used in the present invention is not particularly limited as long as it is normally used as a base material for a shaping sheet. Various papers, plastic films, plastic sheets, metal foils, metal sheets, metal plates, A ceramic material or the like can be appropriately selected depending on the application. Each of these materials may be used alone, but may be a laminate of any combination such as a composite of paper or a composite of paper and a plastic film.
When using these substrates, particularly plastic films or plastic sheets, as a substrate, an oxidation method or a concavo-convex method may be applied to one or both sides as desired in order to improve the adhesion to the layer provided thereon. Physical or chemical surface treatment can be applied.
Examples of the oxidation method include corona discharge treatment, chromium oxidation treatment, flame treatment, hot air treatment, ozone / ultraviolet treatment method, and examples of the unevenness method include a sand blast method and a solvent treatment method. These surface treatments are appropriately selected depending on the type of substrate, but generally, a corona discharge treatment method is preferably used from the viewpoints of effects and operability.
In addition, the substrate may be subjected to a treatment such as forming a primer layer in order to enhance the interlayer adhesion between the substrate and each layer.

As various papers used as the substrate, thin paper, kraft paper, titanium paper and the like can be used. These paper base materials are used to reinforce the interlaminar strength between the fibers of the paper base material or between the other layers and the paper base material, and to prevent the occurrence of scuffing, in addition to these paper base materials, acrylic resin, styrene butadiene rubber, A resin such as a melamine resin or a urethane resin may be added (resin impregnation after paper making or embedded during paper making). For example, inter-paper reinforced paper, resin-impregnated paper, and the like.
In addition to these, various papers often used in the field of building materials such as linter paper, paperboard, base paper for gypsum board, or a vinyl wallpaper raw material in which a vinyl chloride resin layer is provided on the surface of the paper can be mentioned. Furthermore, coated paper, art paper, sulfate paper, glassine paper, parchment paper, paraffin paper, Japanese paper, or the like used in the office field or normal printing and packaging can also be used. Moreover, although distinguished from these papers, woven fabrics and non-woven fabrics of various fibers having an appearance and properties similar to paper can be used as the base material. Examples of various fibers include inorganic fibers such as glass fibers, asbestos fibers, potassium titanate fibers, alumina fibers, silica fibers, and carbon fibers, or synthetic resin fibers such as polyester fibers, acrylic fibers, and vinylon fibers.

  As a plastic film or a plastic sheet, what consists of various synthetic resins is mentioned. Synthetic resins include polyethylene resins, polypropylene resins, polymethylpentene resins, polyolefin resins such as olefinic thermoplastic elastomers; polyvinyl chloride resins, polyvinylidene chloride resins, polyvinyl alcohol resins, vinyl chloride-vinyl acetate copolymer resins, ethylene -Vinyl resins such as vinyl acetate copolymer resins and ethylene-vinyl alcohol copolymer resins; Polyester resins such as polyethylene terephthalate resins, polybutylene terephthalate resins, polyethylene naphthalate-isophthalate copolymer resins, polyester thermoplastic elastomers; Acrylic resins such as (meth) methyl acrylate resin, poly (meth) ethyl acrylate resin, poly (meth) butyl acrylate resin; polyamides such as nylon 6 or nylon 66 Fats; cellulose triacetate resins, cellulosic, such as cellophane resins; polystyrene resins; polycarbonate resins; polyarylate resin; or polyimide resins.

As metal foil, a metal sheet, or a metal plate, what consists of aluminum, iron, stainless steel, or copper, for example can be used, and what gave these metals by plating etc. can also be used. Examples of the ceramic material include ceramic building materials such as gypsum board, calcium silicate board, and wood cement board, ceramics, glass, firewood, and fired tile. In addition to these, composites of various materials, such as fiber reinforced plastic (FRP) plates, paper honeycombs with iron plates pasted on both sides, and two aluminum plates sandwiched with polyethylene resin can also be used as the base material. .
Among these, as the base material 2, a material excellent in heat resistance and dimensional stability is preferable, and among them, a polyester film such as a polyethylene terephthalate film is particularly preferable.

Although there is no restriction | limiting in particular about the thickness of the base material 2, When using the sheet | seat which uses a plastic as a raw material, thickness is about 20-150 micrometers normally, Preferably it is the range of 30-100 micrometers, and a paper base material is used. When used, the basis weight is usually about ²⁰ to 150 g / m ² , preferably 30 to 100 g / m ² .

[Penetration preventing layer 6]
The penetration preventing layer 6 shown in FIGS. 1 to 3 is a layer provided as desired, and an ink constituting the ink layer 3 described later and a curable resin constituting the surface shaping layer 5 are contained in the substrate 2. It has a function of suppressing permeation, and is particularly effective when the substrate 2 is a permeable substrate such as paper or nonwoven fabric. Therefore, the penetration preventing layer 6 may be positioned between the base material 2 and the ink layer 3. Usually, a uniform and uniform layer obtained by crosslinking and curing a curable resin having adhesiveness with the curable resin constituting the surface shaping layer 5 is provided between the substrate 2 and the ink layer 3 as shown in FIG. . This also fulfills the function of enhancing the adhesion between the base material 2, the ink layer 3 and the surface shaping layer 5.

[Ink layer 3]
The ink layer 3 in the decorative material of the present invention is laminated on the permeation preventive layer 6 or the like provided as necessary as shown in FIG. It is a layer to be made.
Although the mechanism of the generation of the fine uneven surface 13 on the surface of the surface shaping layer 5 has not yet been fully elucidated, the surface shaping layer 5 is formed on the surface of the ink layer 3 based on the results of various experiments, observations and measurements. When the uncured product of the curable resin for forming the coating is applied, the resin component of the ink layer 3 and the surface shaping layer are partly eluted by appropriate combination of materials and coating conditions. This is presumably due to the development of interactions such as dispersion and mixing. At this time, the ink of the ink layer 3 and the respective resin components in the uncured curable resin are not completely compatible in a short time, but are in a suspended state, so It is considered that the portion that is present in the vicinity and is in a suspended state forms an interaction region and develops a fine uneven surface. When this state is fixed by crosslinking and curing the surface shaping layer while having this suspended state, the interaction region 4 extends over the entire surface in the surface shaping layer as shown in FIGS. It is presumed that it is formed and forms a fine uneven surface 13.

The ink that forms the ink layer 3 has a property capable of expressing an interaction such as elution, dispersion, and mixing with the curable resin composition that forms the surface shaping layer 5, and the curable resin composition It is appropriately selected in relation to a product (uncured product). Specifically, an ink having a non-crosslinkable resin as the binder resin is preferable, and for example, a thermoplastic (non-crosslinked type) urethane resin is preferable. Here, the content of the urethane resin is 50% by mass or more from the viewpoint of further strengthening the interaction with the curable resin composition forming the surface shaping layer 5 and obtaining a feeling of unevenness of the further pattern. More preferably.
As the urethane resin, a non-cross-linked type, that is, a three-dimensionally crosslinked thermoplastic resin having a linear molecular structure is selected instead of a network-like three-dimensional molecular structure. It is preferable to do. Examples of such non-crosslinked urethane resins include polyol components such as acrylic polyols, polyester polyols and polyether polyols, and isocyanate components such as tolylene diisocyanate, xylene diisocyanate, diphenylmethane diisocyanate and other aromatic isocyanates, and isophorone diisocyanate. And a urethane resin obtained by reacting an isocyanate such as an aliphatic or alicyclic isocyanate such as hexamethylene diisocyanate and hydrogenated tolylene diisocyanate. Usually, the number of hydroxyl groups in one molecule of polyol and the number of isocyanate groups in one molecule of isocyanate are two on average. The average molecular weight of the urethane resin is about 10,000 to 50,000, and the glass transition temperature (Tg) is preferably about −70 to −40 ° C. for the expression of the interaction region.

  If necessary, a saturated or unsaturated polyester resin, acrylic resin, vinyl chloride-vinyl acetate copolymer or the like can be mixed in order to adjust the degree of expression of the interaction region. Of these, polyester resins are preferable, and unsaturated polyester resins are particularly preferable. The addition amount of the unsaturated polyester resin is preferably in the range of 10 to 50% by mass with respect to the total amount of the binder of the ink. Within this range, a sufficient enhancement effect of expression of the interaction region can be obtained. The unsaturated polyester resin is not particularly limited as long as it is a reaction product of an unsaturated dicarboxylic acid and a glycol. Examples of the unsaturated dicarboxylic acid include maleic acid, fumaric acid, itaconic acid, and the like. Examples include ethylene glycol, diethylene glycol, propylene glycol, and butylene glycol.

An extender is preferably contained in the ink composition for forming the ink layer 3. By containing the extender, thixotropy can be imparted to the ink composition, and the shape of the ink composition is maintained when the ink layer 3 is printed using a plate. As a result, the sharpness of the concavo-convex shape at the end that transitions from the convex portion to the concave portion can be emphasized, and a sharp design expression is possible.
The extender pigment used in the present invention is not particularly limited, and is suitably selected from, for example, silica, talc, clay, barium sulfate, barium carbonate, calcium sulfate, calcium carbonate, magnesium carbonate and the like. Of these, silica, which is a material having a high degree of freedom in material design such as oil absorption, particle size, pore volume, etc., and excellent in designability, whiteness, and coating stability as an ink, is preferred. Is preferred. As a particle size of a silica, the range of 0.1-5 micrometers is preferable. When it is 0.1 μm or more, the thixotropy of the ink does not become extremely high when it is added to the ink, and the viscosity of the ink does not increase too much, so that printing can be controlled easily. In other words, it becomes easier to control the uneven shape. If the particle size is 5 μm or less, the head of the particle is relatively suppressed and is not conspicuous, so that the state of interaction region expression becomes natural, so that the uneven shape is unlikely to occur and a natural finish is obtained.
The content of these extender pigments in the ink composition is preferably in the range of 5 to 15% by mass. When the content is 5% by mass or more, sufficient thixotropy can be imparted to the ink composition, and when the content is 15% by mass or less, there is no reduction in the effect of imparting the raised shape and the appearance of fine irregularities, which is preferable. .

About the application quantity of the ink which forms the ink layer 3, it is preferable that it is the range of 1-30 g / m < ² >. When the amount is 1 g / m ² or more, the above-described ink and the curable resin composition interact with each other, and a sufficient interaction region is obtained, so that a sufficient uneven shape is obtained on the surface of the shaping sheet. On the other hand, when it is 30 g / m ² or less, there is no mechanical restriction in printing the ink, and it is economically advantageous. From the above viewpoint, the coating amount of the ink is preferably further range of 1 to 10 g / m ^2, is preferably in the range especially of 1 to 7 g / m ^2.

Further, by changing the coating amount of the ink composition, the thickness of the ink constituting the ink layer 3 can be made non-uniform, and the degree of the height difference of the raised portion that is expressed thereby is stepwise or continuous. As a result, the pattern of the shaping sheet can be a gradation pattern in which the uneven shape changes stepwise or a continuous pattern in which the unevenness changes continuously.
This is because, as the coating amount of the ink layer 3 is relatively increased, the interaction between the ink layer 3 and the surface shaping layer 5 is relatively increased, and the degree of the suspended state is further increased. This is considered to be because the undulation of the raised shape becomes larger.
This will be described in detail below with reference to FIG. In FIG. 3, the thicknesses of the inks 3-a, 3-b and 3-c constituting the ink layer 3 are made different. That is, the film thickness is gradually reduced in the order of 3-a, 3-b, and 3-c. By doing so, the interaction regions 4-a, 4-b, and 4-c can be changed stepwise, and the resulting concavo-convex raised shapes 7-c, 7-b, and 7-a are obtained in this order. The bulging part rises more gradually. This is because the thickness of the ink constituting the ink layer 3 is not uniform and is applied so that the thickness of the ink decreases in the order of 3-a, 3-b, 3-c. It is considered that the undulation of the raised shape becomes more remarkable in the larger portion, and changes so that the undulation of the raised shape becomes smaller in gradation in the order of 3-a, 3-b, and 3-c. By changing the thickness of the ink more finely, the concavo-convex shape can be continuously changed.
With the shaped sheet having such a structure, it becomes possible to give a more diverse and delicate texture. The method of changing the thickness of the ink constituting the ink layer 3 can usually be easily performed by changing the amount of ink applied, and by changing the amount of ink applied continuously, the above steps It is also possible to continuously change the change continuously.

  The extent of the expansion of the interaction region 4 formed in the surface shaping layer 5 is not particularly limited as long as it is within the range where the effects of the present invention can be achieved. As shown in FIG. The surface shaping layer 5 may remain in the middle of the thickness direction, or may reach the outermost surface of the surface shaping layer 5 as shown in FIG. A fine ridge shape may be formed on the outermost surface.

[Surface shaping layer 5: curable resin composition]
Next, the surface shaping layer 5 is composed of a material obtained by crosslinking and curing the curable resin composition as described above. The curable resin composition is not particularly limited. For example, melamine-based, urea-based, epoxy-based, ketone-based, diallyl phthalate-based, unsaturated polyester-based, phenol-based thermosetting resin compositions, ionizing radiation, and the like. A curable resin composition can be mentioned. Among these, an ionizing radiation curable resin composition is preferable. Here, the ionizing radiation curable resin composition is one having an energy quantum capable of crosslinking and polymerizing molecules in an electromagnetic wave or a charged particle beam, that is, crosslinking or curing by irradiating ultraviolet rays or electron beams. Refers to a resin composition. Specifically, it can be appropriately selected from polymerizable monomers, polymerizable oligomers or prepolymers conventionally used as ionizing radiation curable resin compositions.
Typically, as the polymerizable monomer, a (meth) acrylate monomer having a radically polymerizable unsaturated group in the molecule is suitable, and by including the (meth) acrylate monomer, Interaction occurs, and the difference in the undulation of the raised shape and the fine uneven surface are suitably formed. From the viewpoint of making the interaction with the ink stronger, obtaining a difference in the undulation of the further raised shape, and obtaining a fine uneven surface, the content of the (meth) acrylate monomer is further 50% by mass or more preferable.

  As the (meth) acrylate monomer, a polyfunctional (meth) acrylate is preferable. Here, “(meth) acrylate” means “acrylate or methacrylate”. The polyfunctional (meth) acrylate is not particularly limited as long as it is a (meth) acrylate having two or more ethylenically unsaturated bonds in the molecule. Specifically, ethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, neopentyl glycol di (meth) ) Acrylate, polyethylene glycol di (meth) acrylate, hydroxypivalate neopentyl glycol di (meth) acrylate, dicyclopentanyl di (meth) acrylate, caprolactone modified dicyclopentenyl di (meth) acrylate, ethylene oxide modified diphosphate ( (Meth) acrylate, allylated cyclohexyl di (meth) acrylate, isocyanurate di (meth) acrylate, trimethylolpropane tri (meth) acrylate, ethylene oxide modified trimethylo Propane tri (meth) acrylate, dipentaerythritol tri (meth) acrylate, propionic acid modified dipentaerythritol tri (meth) acrylate, pentaerythritol tri (meth) acrylate, propylene oxide modified trimethylolpropane tri (meth) acrylate, tris ( Acryloxyethyl) isocyanurate, propionic acid modified dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, ethylene oxide modified dipentaerythritol hexa (meth) acrylate, caprolactone modified dipentaerythritol hexa (meth) acrylate, etc. Is mentioned. These polyfunctional (meth) acrylates may be used singly or in combination of two or more.

  In the present invention, a monofunctional (meth) acrylate can be used in combination with the polyfunctional (meth) acrylate as long as the object of the present invention is not impaired, for the purpose of lowering the viscosity. Examples of monofunctional (meth) acrylates include methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, butyl (meth) acrylate, pentyl (meth) acrylate, hexyl (meth) acrylate, cyclohexyl ( Examples include meth) acrylate, 2-ethylhexyl (meth) acrylate, lauryl (meth) acrylate, stearyl (meth) acrylate, and isobornyl (meth) acrylate. These monofunctional (meth) acrylates may be used alone or in combination of two or more.

  Next, as the polymerizable oligomer, an oligomer having a radical polymerizable unsaturated group in the molecule, for example, epoxy (meth) acrylate, urethane (meth) acrylate, polyester (meth) acrylate, polyether (meth) acrylate System oligomers and the like. Here, the epoxy (meth) acrylate oligomer can be obtained, for example, by reacting (meth) acrylic acid with an oxirane ring of a relatively low molecular weight bisphenol type epoxy resin or novolak type epoxy resin and esterifying it. . Further, a carboxyl-modified epoxy (meth) acrylate oligomer obtained by partially modifying this epoxy (meth) acrylate oligomer with a dibasic carboxylic acid anhydride can also be used. The urethane (meth) acrylate oligomer can be obtained, for example, by esterifying a polyurethane oligomer obtained by reaction of polyether polyol or polyester polyol and polyisocyanate with (meth) acrylic acid. Examples of polyester (meth) acrylate oligomers include esterification of hydroxyl groups of polyester oligomers having hydroxyl groups at both ends obtained by condensation of polycarboxylic acid and polyhydric alcohol with (meth) acrylic acid, It can be obtained by esterifying the terminal hydroxyl group of an oligomer obtained by adding an alkylene oxide to a carboxylic acid with (meth) acrylic acid. The polyether (meth) acrylate oligomer can be obtained by esterifying the hydroxyl group of the polyether polyol with (meth) acrylic acid.

Furthermore, other polymerizable oligomers include polybutadiene (meth) acrylate oligomers with high hydrophobicity that have (meth) acrylate groups in the side chain of polybutadiene oligomers, and silicone (meth) acrylate oligomers that have polysiloxane bonds in the main chain. In a molecule such as an aminoplast resin (meth) acrylate oligomer modified with an aminoplast resin having many reactive groups in a small molecule, or a novolak epoxy resin, bisphenol epoxy resin, aliphatic vinyl ether, aromatic vinyl ether, etc. There are oligomers having a cationic polymerizable functional group.
In the present invention, the interaction between the ink constituting the ink layer 3 and the curable resin composition constituting the surface shaping layer 5 is important as described above. From this viewpoint, an appropriate ink and curable resin composition are used. In the ionizing radiation curable resin composition, it is preferable to contain a polyfunctional (meth) acrylate monomer.

When an ultraviolet curable resin composition is used as the ionizing radiation curable resin composition, it is desirable to add about 0.1 to 5 parts by mass of the photopolymerization initiator with respect to 100 parts by mass of the resin composition. The initiator for photopolymerization can be appropriately selected from those conventionally used and is not particularly limited. For example, for a polymerizable monomer or polymerizable oligomer having a radically polymerizable unsaturated group in the molecule. Benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin-n-butyl ether, benzoin isobutyl ether, acetophenone, dimethylaminoacetophenone, 2,2-dimethoxy-2-phenylacetophenone, 2,2-diethoxy-2 -Phenylacetophenone, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 1-hydroxycyclohexyl phenyl ketone, 2-methyl-1- [4- (methylthio) phenyl] -2-morpholino-propane-1 - 4- (2-hydroxyethoxy) phenyl-2 (hydroxy-2-propyl) ketone, benzophenone, p-phenylbenzophenone, 4,4′-diethylaminobenzophenone, dichlorobenzophenone, 2-methylanthraquinone, 2-ethylanthraquinone, 2 -Tertiary butylanthraquinone, 2-aminoanthraquinone, 2-methylthioxanthone, 2-ethylthioxanthone, 2-chlorothioxanthone, 2,4-dimethylthioxanthone, 2,4-diethylthioxanthone, benzyldimethyl ketal, acetophenone dimethyl ketal It is done.
Examples of the polymerizable oligomer having a cationic polymerizable functional group in the molecule include aromatic sulfonium salts, aromatic diazonium salts, aromatic iodonium salts, metallocene compounds, and benzoin sulfonic acid esters.
Moreover, as a photosensitizer, p-dimethylbenzoic acid ester, tertiary amines, a thiol type sensitizer, etc. can be used, for example.
In the present invention, it is preferable to use an electron beam curable resin composition as the ionizing radiation curable resin composition. This is because the electron beam curable resin composition can be made solvent-free, is more preferable from the viewpoint of environment and health, and does not require a photopolymerization initiator and can provide stable curing characteristics.

[Surface shaping layer 5: fine particles]
Moreover, it is preferable that the moldable sheet | seat of this invention mix | blends microparticles | fine-particles in the curable resin composition which makes the surface moldable layer 5 in order to obtain a fine protruding shape. As the fine particles, those having an average particle diameter that is a value close to the plus side of the maximum thickness of the surface shaping layer 5 located immediately above the ink layer 3 are used. The shaped sheet of the present invention in which fine particles are blended will be described in detail with reference to FIG. The shaped sheet shown in FIG. 1 is obtained by blending fine particles with a curable resin composition.
The fine particles 8 blended in the surface shaping layer have an average particle diameter d _A having a value close to the plus side of the maximum thickness t _M of the surface shaping layer 5 located immediately above the ink layer 3, that is, d _A. The fine particles 8 are cue from the surface of the surface shaping layer 5 which is slightly larger than t _M and located immediately above the ink layer 3. Since this cueing portion forms a raised shape, a fine unevenness can be formed. At the same time, in the surface shaping layer 5, a raised shape is expressed immediately above the ink layer 3 due to the interaction between the ink in the ink layer 3 and the curable resin composition constituting the surface shaping layer 5. An interaction region 4 is formed.
Therefore, the interaction region 4 in the surface shaping layer 5, the effect of cueing of fine particles on the surface of the surface shaping layer 5, the raised shape formed with the formation of the ink layer 3, and Due to the effect of the fine concavo-convex shape, the concavo-convex shape appearing on the surface of the surface shaping layer is delicate and dense with a high-class feeling.
The maximum thickness t _M of the surface shaping layer 5 positioned immediately above the ink layer 3 is the thickness of the surface shaping layer 5 when the convex shape associated with the formation of the ink layer 3 is not formed. When the convex shape is formed, the thickness includes the portion.

As the particle size distribution is closer to monodisperse, it is easier to set the amount of use, and the above effect is favorably exhibited with a small amount of use.
In the present invention, the coefficient of variation CV value [(standard deviation of particle size / average particle size) × 100] of the particle size distribution of the fine particles is preferably 30% or less. When the CV value is 30% or less, the fine particles have a practical particle size distribution and can sufficiently exhibit the above effects with an appropriate amount of use. This CV value is more preferably 20% or less, still more preferably 15% or less.

Furthermore, when the average particle diameter of the fine particles is d _A and the maximum thickness of the surface shaping layer located immediately above the ink layer is t _M , the formula (I)
1.05 × t _M ≦ d _A ≦ 1.25 × t _M (I)
It is preferable to satisfy the relationship. If the average particle diameter d _{A of the} fine particles is within the above range, even if the fine particles sink into the ink layer, the fine particles are deposited on the surface shaping layer located immediately above the ink layer. Cueing occurs, and the above effects are sufficiently exhibited.
The shape of the fine particles is not particularly limited, and fine particles such as spherical, ellipsoidal, and polyhedral shapes can be used, but spherical fine particles are preferable. In the present invention, the particle diameter of the fine particles having a shape other than the spherical shape is a value indicated by the diameter of the circumscribed sphere.

  The content of the fine particles in the surface shaping layer is usually selected in the range of 2 to 20% by mass, although it depends on the average particle size of the fine particles and the coefficient of variation CV of the particle size distribution. When the content is 2% by mass or more, the effect of containing the fine particles is exhibited, and when the content is 20% by mass or less, the unevenness of the uneven shape formed on the surface of the shaped sheet is good. The preferable content of the fine particles is 4 to 16% by mass, and more preferably 4 to 13% by mass.

The fine particles may be either inorganic fine particles or organic fine particles. Examples of the fine particles include inorganic particles such as silica, alumina, aluminosilicate, kaolinite, calcium carbonate, barium sulfate, and glass, and organic fine particles include acrylic resin, polycarbonate resin, and urethane type. Examples thereof include particles such as resin, urea resin, benzoguanamine resin, and benzoguanamine-melamine-formaldehyde condensate.
These fine particles may be used alone or in combination of two or more. From the viewpoint of the effect of the present invention, silica particles are preferred.
The fine particles may be used together with the calcined kaolin particles described later having the same effect.

[Surface shaping layer 5: calcined kaolin particles]
The surface shaping layer 5 preferably contains calcined kaolin particles. By including calcined kaolin particles in the surface shaping layer, the uneven shape on the surface of the shaping sheet becomes more delicate, and marring resistance is improved. Here, the term “marling” means that small scratches are generated when the sheet surface is rubbed, and “excellent marring resistance” means that scratches are difficult to be made. By imparting such performance to the shaping sheet, it is possible to strengthen the surface shaping layer, obtain a shaping sheet that can withstand longer use, and reduce the manufacturing cost of the decorative board Become.

The calcined kaolin particles used to impart a more delicate uneven shape and marling resistance to the surface of the shaped sheet are kaolin particles obtained by calcining general (hydrous) kaolin particles, but as a filler By adding the calcined kaolin particles, the improvement in marling resistance, which could not be realized with silica particles or hydrous kaolin particles before firing, is realized. The particle size of the calcined kaolin particles may be appropriately selected according to the application, required physical properties, etc. For example, those having an average particle size of about 0.5 to 2 μm are used. Moreover, the amount of the calcined kaolin particles added may be appropriately selected according to the application, required physical properties, etc., and is, for example, about 5 to 50 parts by mass with respect to 100 parts by mass of the curable resin.
The calcined kaolin particles are superior in paint stability to the hydrous kaolin particles.

  As the calcined kaolin particles, those whose surfaces are further treated may be used. By using the surface-treated calcined kaolin particles, the effect of improving marring resistance can be further increased. As the surface treatment, there is a surface treatment with a silane coupling agent. Examples of the silane coupling agent include known silane coupling agents having an alkoxy group, amino group, vinyl group, epoxy group, mercapto group, chloro group and the like. For example, γ-aminopropyltriethoxysilane, γ-methacryloxypropyltrimethoxysilane, γ-methacryloxypropylmethyldimethoxysilane, γ-methacryloxypropyldimethylmethoxysilane, γ-methacryloxypropyltriethoxysilane, γ-methacryloxy Propyldimethylethoxysilane, γ-acryloxypropyltrimethoxysilane, γ-acryloxypropylmethyldimethoxysilane, γ-acryloxypropyldimethylmethoxysilane, γ-acryloxypropyltriethoxysilane, γ-acryloxypropylmethyldiethoxysilane , Γ-acryloxypropyldimethylethoxysilane, vinyltriethoxysilane, γ-glycidoxypropyltrimethoxysilane, γ-mercaptopropyltrimethoxysila Etc.

[Surface shaping layer 5: reactive silicone]
The shaped sheet of the present invention preferably contains reactive silicone in the curable resin composition. It is because the release property is improved and the resistance to repeated continuous use is improved by adding reactive silicone to the surface shaping layer 5. In addition, when an additive or filler such as a pearl pigment is included in the adherend, the detachment of the additive or filler contained in the adherend is suppressed in the process of manufacturing the decorative board. effective.
Here, the reactive silicone means a modified silicone oil in which an organic group is introduced into the side chain or terminal and has reactivity depending on the nature of the introduced organic group. Specifically, the reactive silicone is a modified silicone oil side chain type, a modified silicone oil both end type, a modified silicone oil one end type, a modified silicone oil side chain both end type, and the like. Examples thereof include epoxy modification, mercapto modification, carboxyl modification, carbinol modification, phenol modification, methacryl modification, and different functional group modification.
The reactive silicone reacts with and binds to the resin when the curable resin is cured. Therefore, when the decorative board of the present invention is molded by hot pressing, it does not bleed out (does not bleed out) on the surface of the decorative board, so that the adhesion between the shaped sheet of the present invention and the decorative board is significantly improved. Thus, it becomes possible to mold a delicate design having a fine uneven shape into a decorative material.
The amount of the reactive silicone used is in the range of about 0.1 to 50 parts by mass, preferably in the range of about 0.5 to 10 parts by mass per 100 parts by mass of the curable resin. When the amount of the reactive silicone used is 0.1 parts by mass or more, the decorative plate and the surface of the shaping sheet are sufficiently peeled off, the uneven shape of the surface of the shaping sheet is maintained, and it can withstand long-term use. sell. On the other hand, if the amount of the reactive silicone used is 50 parts by mass or less, no repellency occurs when the curable resin composition is applied to the base material, so the surface of the coating film is not roughened and the coating stability is improved. To do.

[Surface shaping layer 5: Various additives]
Moreover, various additives can be mix | blended with the curable resin composition in this invention according to the desired physical property of the cured resin layer obtained. Examples of the additive include a weather resistance improver, an abrasion resistance improver, a polymerization inhibitor, a crosslinking agent, an infrared absorber, an antistatic agent, an adhesion improver, an antioxidant, a leveling agent, a thixotropic agent, Examples include coupling agents, plasticizers, antifoaming agents, fillers, and solvents.
Here, as the weather resistance improving agent, an ultraviolet absorber or a light stabilizer can be used. It is added for long-term use of the shaped sheet. The ultraviolet absorber may be either inorganic or organic, and as the inorganic ultraviolet absorber, titanium dioxide, cerium oxide, zinc oxide or the like having an average particle diameter of about 5 to 120 nm can be preferably used. Examples of the organic ultraviolet absorber include benzotriazole-based compounds, specifically 2- (2-hydroxy-5-methylphenyl) benzotriazole, 2- (2-hydroxy-3,5-di-tert-). Amylphenyl) benzotriazole, 3- [3- (benzotriazol-2-yl) -5-tert-butyl-4-hydroxyphenyl] propionic acid ester of polyethylene glycol, and the like. On the other hand, examples of the light stabilizer include hindered amines, specifically 2- (3,5-di-tert-butyl-4-hydroxybenzyl) -2′-n-butylmalonate bis (1,2,2). , 6,6-pentamethyl-4-piperidyl), bis (1,2,2,6,6-pentamethyl-4-piperidyl) sebacate, tetrakis (2,2,6,6-tetramethyl-4-piperidyl)- 1,2,3,4-butanetetracarboxylate and the like. Further, as the ultraviolet absorber or light stabilizer, a reactive ultraviolet absorber or light stabilizer having a polymerizable group such as a (meth) acryloyl group in the molecule can be used.

Examples of the wear resistance improver include, for inorganic substances, spherical particles such as α-alumina, silica, kaolinite, iron oxide, diamond, and silicon carbide. Examples of the particle shape include a sphere, an ellipsoid, a polyhedron, a scale shape, and the like. Although there is no particular limitation, a spherical shape is preferable. Organic materials include synthetic resin beads such as cross-linked acrylic resin and polycarbonate resin. The particle size is usually about 30 to 200% of the film thickness. Among these, spherical α-alumina is particularly preferable because it has high hardness and a large effect on improving wear resistance, and it is relatively easy to obtain spherical particles.
Examples of the polymerization inhibitor include hydroquinone, p-benzoquinone, hydroquinone monomethyl ether, pyrogallol, and t-butylcatechol. Examples of the crosslinking agent include a polyisocyanate compound, an epoxy compound, a metal chelate compound, an aziridine compound, and an oxazoline compound. Used.
As the filler, for example, barium sulfate, talc, clay, calcium carbonate, aluminum hydroxide and the like are used.
As the infrared absorber, for example, a dithiol metal complex, a phthalocyanine compound, a diimmonium compound, or the like is used.

[Formation of surface shaping layer 5]
In the present invention, the polymerizable monomer, polymerizable oligomer, and various additives, which are the curing components, are homogeneously mixed at a predetermined ratio, respectively, to prepare a coating liquid made of the curable resin composition. The viscosity of the coating solution is not particularly limited as long as it is a viscosity capable of forming an uncured resin layer on the surface of the substrate by a coating method described later.
In the present invention, the coating liquid prepared in this way is applied to the surface of the substrate so that the thickness after curing is 1 to 20 μm, gravure coating, bar coating, roll coating, reverse roll coating, Coating is performed by a known method such as comma coating, preferably gravure coating, to form an uncured resin layer. When the thickness after curing is 1 μm or more, a cured resin layer having a desired function is obtained. The thickness of the surface shaping layer after curing is preferably about 2 to 20 μm.

In the present invention, the uncured resin layer thus formed is irradiated with an ionizing radiation such as an electron beam or ultraviolet rays to cure the uncured resin layer. Here, when an electron beam is used as the ionizing radiation, the acceleration voltage can be appropriately selected according to the resin used and the thickness of the layer, but the uncured resin layer is usually cured at an acceleration voltage of about 70 to 300 kV. preferable.
In electron beam irradiation, the transmission capability increases as the acceleration voltage increases. Therefore, when using a base material that deteriorates due to the electron beam as the base material, the transmission depth of the electron beam and the thickness of the resin layer are substantially equal. By selecting the accelerating voltage so as to be equal to each other, it is possible to suppress the irradiation of the electron beam to the base material, and to minimize the deterioration of the base material due to the excessive electron beam.
The irradiation dose is preferably such that the crosslink density of the resin layer is saturated, and is usually selected in the range of 5 to 300 kGy (0.5 to 30 Mrad), preferably 10 to 50 kGy (1 to 5 Mrad).
Further, the electron beam source is not particularly limited. For example, various electron beam accelerators such as a cockroft Walton type, a bandegraft type, a resonant transformer type, an insulated core transformer type, a linear type, a dynamitron type, and a high frequency type. Can be used.
When ultraviolet rays are used as the ionizing radiation, those containing ultraviolet rays having a wavelength of 190 to 380 nm are emitted. There is no restriction | limiting in particular as an ultraviolet-ray source, For example, a high pressure mercury lamp, a low pressure mercury lamp, a metal halide lamp, a carbon arc lamp, etc. are used.
The cured resin layer thus formed has various functions by adding various additives, for example, a so-called hard coat function, anti-fogging coat function, and anti-fouling coat having high hardness and scratch resistance. A function, an antiglare coating function, an antireflection coating function, an ultraviolet shielding coating function, an infrared shielding coating function, and the like can also be imparted.

[Decorative board]
Next, the decorative board of the present invention is a decorative board formed by molding the above-mentioned shaping sheet on a base material. In particular, it is preferable that the decorative plate has a fine uneven shape on the surface by inserting and molding the shaped sheet between a molded product molded by pressing between the heated pressure plates and the pressure plate. Specifically, as shown in FIG. 3, the decorative sheet 11 having a certain shape is obtained by peeling the molded sheet 1 from the decorative sheet 11 after hot pressing.
The decorative board 11 of the present invention is not particularly limited as long as it is a decorative board produced using the shaped sheet of the present invention, but the surface is hard, heat resistance and stain resistance are excellent, and design properties Since a rich color pattern can be selected in this aspect, a melamine resin decorative board and a diallyl phthalate (DAP) resin decorative board are suitable. There are no particular limitations on the production of these decorative plates as long as they are publicly known and generally used, and for example, they can be obtained by the following production methods.
The melamine resin decorative board is made by laminating a melamine resin-impregnated sheet on about 4 phenol resin-impregnated core papers, and an overlay paper impregnated with melamine resin, and sandwiching it between two specular metal plates. For example, the mold sheet is inserted, heat-pressed at 0.98 MPa and 160 ° C. for 20 minutes, allowed to cool to room temperature, and then peeled off from the mold sheet.
In addition, diallyl phthalate (DAP) resin decorative board is obtained by sequentially stacking diallyl phthalate resin impregnated paper on a plate-like base material, and in the same manner as the manufacturing method of the melamine resin decorative board, It is obtained by using and pressing at 140 to 150 ° C., 0.98 MPa for about 10 minutes, allowing to cool to room temperature, and then peeling the shaped sheet. In any case, the decorative board has a delicate uneven shape.

The decorative board 11 of the present invention can be used by being attached to various substrates. Specifically, as shown in FIG. 4, a decorative board 11 is attached to the substrate 10 via an adhesive layer 9.
The board | substrate used as a to-be-adhered body is not specifically limited, A plastic board, a metal board, woody board | plates, such as a timber, a ceramic material, etc. can be selected suitably according to a use. When these substrates, particularly plastic sheets, are used as substrates, physical or chemical surface treatment such as oxidation or unevenness is applied to one or both sides as desired in order to improve adhesion to the decorative material. Can be applied.
Examples of the oxidation method include corona discharge treatment, chromium oxidation treatment, flame treatment, hot air treatment, ozone / ultraviolet treatment method, and examples of the unevenness method include a sand blast method and a solvent treatment method. These surface treatments are appropriately selected according to the type of the substrate, but in general, the corona discharge treatment method is preferably used from the viewpoints of effects and operability.

  As a plastic sheet, what consists of various synthetic resins is mentioned. Synthetic resins include polyethylene resin, polypropylene resin, polymethylpentene resin, polyvinyl chloride resin, polyvinylidene chloride resin, polyvinyl alcohol resin, vinyl chloride-vinyl acetate copolymer resin, ethylene-vinyl acetate copolymer resin, ethylene-vinyl. Representative examples include alcohol copolymer resin, polyethylene terephthalate resin, polybutylene terephthalate resin, polyethylene naphthalate-isophthalate copolymer resin, polymethyl methacrylate resin, polyethyl methacrylate resin, polybutyl acrylate resin, nylon 6 or nylon 66 And polyamide resin, cellulose triacetate resin, cellophane, polystyrene resin, polycarbonate resin, polyarylate resin, polyimide resin, and the like.

As a metal plate, what consists of aluminum, iron, stainless steel, or copper can be used, for example, and what gave these metals by plating etc. can also be used.
Examples of wood-based boards include veneer of various materials such as cedar, firewood, firewood, pine, lawan, teak and melapie, and wood materials such as wood veneer, wood plywood, particle board, and medium density fiber board (MDF). . These can be used alone or in a laminated manner. The wooden board includes not only a wooden board but also a plastic board containing paper powder and reinforced paper having strength.
Examples of the ceramic material include ceramic building materials such as a gypsum plate, a calcium silicate plate, and a wood piece cement plate, ceramics, glass, firewood, fired tiles, plates made mainly of volcanic ash, and the like.
In addition to these, composites of various materials such as a fiber reinforced plastic (FRP) plate, a paper honeycomb on which both sides of an iron plate are attached, and a polyethylene resin sandwiched between two aluminum plates can be used as the substrate.

  In this way, the substrate 10 on which the decorative plate 11 is placed every leaf or continuously through the adhesive layer 9 is cold-pressed, hot-pressed, roll-pressed, laminator, lapping, edge pasting machine, vacuum press. The decorative plate 11 is bonded to the surface of the substrate 10 by pressing with a sticking device such as the above.

The adhesive is applied using an application device such as a spray, spreader, or bar coater. As the adhesive, vinyl acetate resin-based, urea resin-based, melamine resin-based, phenol resin-based, isocyanate-based adhesives, etc., are used alone or as a mixed adhesive obtained by arbitrarily mixing them. As needed, talc, calcium carbonate, clay, titanium white and other inorganic powders, wheat flour, wood flour, plastic powder, coloring agents, insect repellents, fungicides and the like can be added and mixed in the adhesive. . In general, the adhesive is applied to the substrate surface with a solid content of 35 to 80% by mass and an application amount of 50 to 300 g / m ² .
Adhesion of the decorative plate 11 on the substrate 10 is usually performed by forming the adhesive layer 9 on the back surface of the decorative plate 11 of the present invention and applying the adhesive on the substrate 10. For example, the decorative plate 11 is attached.

  The building materials manufactured as described above are optionally cut into the building materials and subjected to arbitrary decorations such as grooving and chamfering using a cutting machine such as a router or a cutter on the surface or the end of the wood. Can do. And various uses, for example, interior or exterior materials of buildings such as walls, ceilings, floors, window frames, doors, handrails, skirting boards, margins, surface decorative panels for fittings such as malls, kitchens, furniture, or light electrical appliances, It can be used for surface decorative boards of cabinets such as OA equipment, interiors and exteriors of vehicles.

EXAMPLES Next, although an Example demonstrates this invention further in detail, this invention is not limited at all by this example.
(Evaluation methods)
The shaping sheet and decorative board obtained in each example were evaluated by the following methods.
(1) Measurement of surface roughness The sample to be evaluated is 400 mm long by 400 mm wide, and the surface shape and surface roughness (arithmetic) are measured using a three-dimensional non-contact surface shape measurement system (Micromap manufactured by Ryoka System Co., Ltd.). The average surface roughness), the effect of formability, and the molding reproducibility when repeatedly used were confirmed.
(2) Peelability The peel strength of the shaped sheet was measured using a tensile / compression tester (Orientec Co., Ltd. RTC-1250A). The sample to be evaluated was 25 mm wide × 50 mm long, and the test was performed at a peeling speed of 300 mm / min, a peeling direction of 180 ° (vertical direction), a load cell load of 10 N, and a measurement environment temperature of 23 ° C. (room temperature).
(3) Suitability for continuous molding The molding was carried out 10 times with the same shaped sheet, the peel strength for each molding was measured, and the peel stability when the shaped sheet was repeatedly used was measured.

Example 1
Primer ink (acrylic ink “EBF tuning primer” manufactured by Showa Ink Industries, Ltd.) on the entire surface of the easy-adhesion treated polyester film (“A4100 (50 μm)” manufactured by Toyobo Co., Ltd.)) The gravure printing was performed to form a permeation preventive layer 6 (primer layer).
Next, ink (urethane-based conduit ink “conduit MINI (A)” manufactured by The Inktec Co., Ltd.) was printed on the entire surface by a pattern plate to form an ink layer 3. Further, an electron beam curable resin obtained by adding 5% by weight of calcined kaolin particles and 2% by weight of reactive silicone methacrylate to an electron beam curable resin (“REB-GE” manufactured by Dainichi Seika Kogyo Co., Ltd.) on these ink layers. The composition was applied at a coating amount of 4 g / m ² by a gravure offset coater method. After coating, an electron beam with an acceleration voltage of 175 kV and an irradiation dose of 30 kGy (3 Mrad) was irradiated to cure the electron beam curable resin composition to form the surface shaping layer 5 to obtain a shaping sheet. The shaping sheet has a convex shape in which the surface of the surface shaping layer 5 located immediately above and near the ink layer 3 is raised by 1 to 3 μm, and has a high-class and delicate uneven shape. Film.

Example 2
A sheet of melamine resin impregnated on about 4 sheets of phenol resin-impregnated core paper, and further, a laminate of approximately 35 g / m ² of impregnated melamine resin is laminated on it and sandwiched between two mirror metal plates. The shaping sheet produced in Example 1 having an uneven shape formed thereon was inserted, and heated and pressed at 0.98 MPa and 160 ° C. for 20 minutes.
After allowing to cool to room temperature, the shaped sheet was peeled off to obtain a melamine resin decorative board having a delicate uneven surface.

Comparative Example 1
Urethane acrylate UV curable resin (Daiichi Seika Kogyo Co., Ltd.) by the drum printing film (hereinafter referred to as DPS) system on the easy-adhesion surface of PET film (“A4100 (100 μm)” manufactured by Toyobo Co., Ltd.) that has already been subjected to easy adhesion treatment. Convex pattern layer by XD-808 manufactured by Co., Ltd. was formed.
A concave / convex pattern (depth 70 μm, convex width and concave width 35 μm each) was provided on the entire surface of the intaglio roll surface by an etching method. Note that the line speed of the DPS method was 10 m / min, and ozone high pressure mercury lamp (manufactured by Nippon Batteries Co., Ltd.) 160 W and two lamps were used for ultraviolet irradiation.
The shaped sheet thus obtained had an uneven shape. Using the shaped sheet thus obtained, the same operation as in Example 2 was performed to produce a melamine resin decorative board.

Comparative Example 2
Gravure printing on a PET film (“A4100 (25 μm)” manufactured by Toyobo Co., Ltd.), which has already been subjected to easy adhesion treatment, with a gravure printing It was printed and the pattern layer was partially provided in patches.
Next, a resin composition to be coated thereon was prepared as follows. A filler was constituted by mixing calcium carbonate CaCO ₃ having a particle size of 3 μm and silica gel SiO ₂ having a particle size of 10 μm in a weight ratio of 28 to 2. Further, a binder was composed of 100 parts by weight of acrylic polyol and 8.5 parts by weight of polyisocyanate. A resin composition for forming a fine uneven layer was prepared using 52 parts by weight of the filler, 48 parts by weight of the binder, and 4 parts by weight of amino-modified silicone oil as a release agent.
This resin composition was applied to the entire surface of the PET film on which the previous pattern was formed by slit reverse coating so as to be 15 μm (dry coating thickness), dried at 110 ° C. for 30 seconds, and then 60 ° C. The molded sheet was obtained by aging for 3 days.
Using the shaped sheet thus obtained, the same operation as in Example 2 was performed to produce a melamine resin decorative board.

The surface of the shaping sheet according to Comparative Example 2 will be described with reference to FIG. The concavo-convex shape of the shaping sheet produced in Comparative Example 2 is formed by repelling only the resin composition for forming the concavo-convex layer applied on the ink layer 3 formed of the liquid repellent resin, thereby generating a concave shape 14. To express. However, in the ink layer 3-b having an excessively wide ink width, a part of the liquid repellent resin remains on the ink layer, and an unclear concave shape 14-b appears. On the other hand, in the ink layer 3-c where the ink width is too thin, the liquid-repellent resin on the ink layer is hardly repelled, and the concave shape is not sufficiently developed as in 14-c. Thus, in the production of the shaped sheet according to Comparative Example 2, in order to repel the liquid repellent resin clearly, there is a restriction that the width of the ink layer is about 100 to 200 μm.
Therefore, compared with the shaped sheet according to the present invention that can be expressed from a width of several μm, the uneven shape generated by repelling the liquid repellent resin according to Comparative Example 2 is difficult to express a thin conduit shape, and the concave shape Since the width of is limited within a certain range, the shaping is monotonous and rough. Moreover, in the expression of the uneven shape, the stability of the pattern due to the uneven shape of the shaped sheet according to Comparative Example 2 is generally poor due to the repellent resin being repelled or not being repelled.

The decorative board obtained in Example 2 was very delicate in the concavo-convex shape, and a high-quality design expression was possible. Moreover, the shaping sheet obtained by Example 1 was rich in durability, and even if molding was repeated 10 times, the surface shape and the releasability after shaping (ease of peeling) were not changed at all.
The decorative board according to Comparative Example 1 was not able to express a delicate uneven shape although the expression of dynamic unevenness was good. In addition, the film needs to use a thick and thick sheet due to manufacturing problems, and the manufacturing cost has increased. The durability and peelability were the same as in Example 2.
Since the comparative example 2 represents the concavo-convex shape using the repelling method, the thin conduit shape cannot be expressed, and the delicateness cannot be expressed. In addition, the sheet surface was deteriorated due to thermal deformation due to repeated use, and the peelability after molding became worse.

ADVANTAGE OF THE INVENTION According to this invention, it has a delicate uneven | corrugated shape, can perform high-quality dense molding, and is excellent also in the mold release property, and the delicate mold shape | molded by this shaping sheet A decorative board having an uneven shape can be obtained.

It is a schematic diagram which shows the cross section of the shaping sheet of this invention. It is a schematic diagram which shows the cross section of the shaping sheet of this invention. It is a schematic diagram which shows the cross section of the shaping sheet of this invention. It is a schematic diagram which shows the peeling process of the shaping sheet of this invention. It is a schematic diagram which shows the cross section of building materials. It is a schematic diagram which shows the cross section of the shaping sheet of the comparative example 2.

Explanation of symbols

1. Molding sheet 2. Base material 3. Ink layer 3-a. Ink 3-b. Ink 3-c. Ink 4. Interaction region 4-a. Interaction region 4-b. Interaction region 4-c. 4. Interaction region 5. Surface shaping layer 6. Penetration prevention layer Raised shape 7-a. Raised shape 7-b. Raised shape 7-c. 7. Raised shape 8. Fine particles or calcined kaolin particles Adhesive layer 10. Substrate 11. Decorative plate 12. Fine ridge shape 13. Fine uneven surface 14. Concave shape 14-a. Concave shape 14-b. Concave shape 14-c. Concave shape

Claims (12)

A surface forming sheet having an ink layer provided on at least the entire surface of the substrate, and a surface forming layer that is present on and in contact with the ink layer and covers the entire surface, the surface forming The layer is obtained by crosslinking and curing the curable resin composition, the surface shaping layer includes fine particles, and the average particle size of the fine particles is d _A , the average particle size of the fine particles, directly above the ink layer If the maximum thickness of the surface shaping layer located was t _M in the formula (I)
1.05 × t _M ≦ d _A ≦ 1.25 × t _M (I)
The ink constituting the ink layer contains a non-crosslinked urethane resin as a binder, and the curable resin composition contains a (meth) acrylate monomer, and the surface shaping layer A shaped sheet having an uneven surface.   The shaping sheet according to claim 1, wherein the curable resin composition is an ionizing radiation curable resin composition.   The shaped sheet according to claim 2, wherein the ionizing radiation curable resin composition is an electron beam curable resin composition.   The shaping sheet according to any one of claims 1 to 3, wherein the ink constituting the ink layer contains a non-crosslinked urethane resin and an unsaturated polyester resin as a binder.   The shaped sheet according to any one of claims 1 to 4, wherein the thickness of the ink constituting the ink layer is not uniform.   The ink layer is composed of a thick film region and a thin film region having a smaller film thickness than the thick film region, and the convex shape of the surface of the surface shaping layer located immediately above the thick film region and in the vicinity thereof The shaping sheet according to claim 5, wherein the height of the surface is higher than the height of the convex shape of the surface of the surface shaping layer located immediately above the thin film region and the upper portion in the vicinity thereof.   The shaped sheet according to any one of claims 1 to 6, wherein the height of the convex shape is 1 to 3 µm.   The shaping sheet according to any one of claims 1 to 7, comprising reactive silicone in the surface shaping layer.   The shaped sheet according to any one of claims 1 to 8, wherein the coefficient of variation CV value [(standard deviation of particle size / average particle size) x 100] of the particle size distribution of the fine particles is 30% or less.   The moldable sheet according to any one of claims 1 to 9, wherein the content of fine particles in the surface moldable layer is 2 to 20% by mass.   The shaping sheet according to any one of claims 1 to 10, wherein the surface shaping layer contains calcined kaolin particles.   The forming sheet according to any one of claims 1 to 11, wherein the ink constituting the ink layer contains an extender pigment.

Images