JP5931789B2 - Decorative plate manufacturing method - Google Patents

Description

The present invention relates to a method for manufacturing a decorative board used for interior materials such as flooring, and particularly relates to a method for manufacturing a decorative board having a pattern printed on a substrate by an ink jet printer.

  2. Description of the Related Art Conventionally, a decorative board having a printed layer provided on a substrate surface is known as a decorative board used for this type of flooring. As such a decorative plate, Patent Document 1 discloses a decorative plate on which a concavo-convex pattern synchronized with a wood grain pattern is printed. In the decorative board of Patent Document 1, a pattern layer is printed with a dye-based ink on a substrate by an ink jet printer, and a raised portion (convex pattern) synchronized with the pattern is formed on the pattern layer with a pigment-based ink. Print formed. In this way, a concavo-convex pattern synchronized with the wood grain pattern is formed by printing the convex portion.

  However, when the decorative board of Patent Document 1 is used as a flooring, there is a risk that scratches or defects may occur on the convex portion of the surface of the decorative board due to contact with a person or an object, and the pattern layer may be peeled off. It is difficult to actually apply to flooring due to lack of properties.

  As a decorative board for solving this problem of flooring use, Patent Document 2 discloses that a so-called anti-friction material such as silica or alumina is mixed with ink of an ink jet printer printed on the surface of the decorative board. A decorative board with improved wear is disclosed.

JP 2008-179073 A JP 2008-265229 A

  However, mixing an antifriction material with the ink itself of an ink jet printer as in Patent Document 2 not only impairs the stability of the ink, but also causes problems with expensive ink ejection equipment, or shortens its life. There is a risk. Moreover, in patent document 2, the indication of the structure which solves the problem of the designability of patent document 1 is not seen.

The present invention has been made in view of the above-mentioned problems, and its object is wear resistance having a concavo-convex shape synchronized with a pattern printed by the printing press without causing problems of the ink jet printing press. The object is to obtain a method for producing a decorative board having high properties.

  In order to achieve the above-mentioned problem, in the present invention, a resin material printed with an ink jet printer on a surface of a base plate of a decorative board, and a powder contained in the convex material are printed in synchronization with a pattern printed with the ink jet printer. Formed by.

Specifically, the decorative board according to the present invention forms a pattern layer by printing a pattern on the surface of a substrate having a smooth surface with an ink jet printer , and the resin is in an uncured state on the pattern layer. the timber with print and cured to tune a portion of the pattern of the previous SL pattern layer Ri by the ink jet printer, on the resin material and the pattern layer when the printed resin is uncured the powder was sprayed adhere only to the resin material, the excess powder by removing, by laminating a raised portion consisting of a powder adhering to the resin material and the powder on the pattern layer, at least the the clear coat layer so as to cover the raised portions are laminated, by the transparent Akiranuri film layer, and a convex portion positioned on the raised portion, and a recess located on a region where the raised portion is not formed It is characterized by forming.

According to the decorative board according to the present invention, the raised portion including the resin material laminated by the ink jet printer so as to synchronize with the pattern in the pattern layer printed by the ink jet printer, and the transparent coating laminated thereon. since uneven portion is formed by a film layer, unevenness feeling occurs in the veneer.

Further, in this decorative board, the powder is spread on the uncured resin material and the pattern layer and adhered only to the resin material, the excess powder is removed, and the resin material is cured to be formed. The powder in the raised portion functions as an antifriction material, and wear resistance is imparted to the raised portion. Therefore, a decorative board having high wear resistance can be obtained.

  Further, in this decorative board, the pattern layer printed by the ink jet printer and the resin material of the raised portion do not contain powder, so that there is no problem with the ink jet printer.

In the method for manufacturing a decorative board according to the present invention, the powder may include an antifriction material.

  If it does in this way, the abrasion resistance of a convex part will improve further and the decorative board with higher abrasion resistance can be obtained.

Method for manufacturing a decorative laminate according to the present invention, said transparency clear layer laminated on the pattern layer, the raised portion on top of the clear layer, shape formed City for tuning the pattern of the pattern layer May be.

  In this way, by providing a clear layer having a certain thickness not only on the convex part but also on the concave part, it is possible to provide a decorative board having a more three-dimensional design appearance with different design properties depending on the viewing angle.

Method for manufacturing a decorative laminate according to the present invention, the gloss of the surfaces of the projections, may be surface cross a et recess is an area which is not raised portion formed.

  In this case, the convexity formed so as to synchronize with the pattern in the pattern layer printed and formed by the inkjet printer is processed so that the glossiness of the convexity is different from the glossiness of the concave portion. The reflectance of light is different between the part and the recessed part, a more natural texture can be expressed, and a decorative board with high design can be obtained.

In the method for manufacturing a decorative laminate according to the present invention, transparent surface of the protrusion of the coating layer, provide Reinforced sanding process to the extent that the transparent coating layer is not removed, lower than luster to the surfaces of the recessed portions of the surface of the convex portion In this way, since the convex portion can give a lower gloss difference between the convex portion and the concave portion synchronized with the pattern layer on the decorative board, as described above, a more natural texture is obtained. It can be expressed and high design properties can be obtained.

In the method for manufacturing a decorative laminate according to the present invention, the surface of the protrusion of the transparent coating layer, provide Reinforced grinding process so as not to be removed a transparent coating layer, higher than the gloss of the surfaces of the recessed portions of the surface of the convex portion it may be.

  Even in this way, since the convex portion can give a higher gloss difference between the convex portion and the concave portion synchronized with the pattern layer in the decorative board, as described above, a more natural texture can be expressed, High designability can be obtained.

In the method for producing the decorative board according to the present invention, it may be formed a reduced friction material layer on the convex portion.

  Thereby, a convex part can be comprised and the raised part which synchronized with the pattern can be protected, and the abrasion resistance of a decorative board can be improved.

According to the method for manufacturing a decorative board according to the present invention, it is possible to easily obtain a decorative board having a high design property having a shape with a sense of unevenness synchronized with a pattern printed by an ink jet printer.

(A) And (b) shows typically the decorative board manufactured by the manufacturing method of the decorative board which concerns on the 1st Embodiment of this invention, (a) is a top view, (b) is (a) It is sectional drawing in the AA of (). It is sectional drawing which shows typically the decorative board manufactured by the manufacturing method of the decorative board which concerns on the 2nd Embodiment of this invention. It is sectional drawing which shows typically the decorative board manufactured by the manufacturing method of the decorative board which concerns on the 3rd Embodiment of this invention. It is sectional drawing which shows typically the decorative board manufactured by the manufacturing method of the decorative board which concerns on the 4th Embodiment of this invention.

  Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. The following description of the preferred embodiments is merely exemplary in nature and is not intended to limit the invention, its application, or its application.

(First embodiment)
First, the decorative board manufactured by the manufacturing method of the decorative board which concerns on the 1st Embodiment of this invention is demonstrated, referring Fig.1 (a) and (b). 1 (a) and 1 (b) schematically show a decorative board manufactured by the method for manufacturing a decorative board according to the first embodiment of the present invention, (a) is a plan view thereof, and (b). These are sectional drawings in the AA line of (a).

As shown in FIGS. 1 (a) and 1 (b), in the decorative board 10 manufactured by the manufacturing method according to this embodiment, for example, ink jet printing is performed on the surface of the plate-like substrate 1 having a smooth surface. The pattern layer 2 printed by the machine is formed. For the base material 1, for example, a laminated board, a plywood, a particle board, a wooden board such as a wood fiber board, an inorganic board such as a volcanic glass fiber board, a calcium board, a plaster board, a resin such as polypropylene, polyethylene, ABS, A resin plate or the like molded into a plate shape can be used. Further, a white ink receiving layer (not shown), for example, may be provided on the surface of the substrate 1 in advance in order to quickly fix the ink ejected by dots from the ink jet printer to the surface. The pattern layer 2 is a layer in which, for example, a wood grain pattern 3 is printed and formed. The wood grain pattern 3 has an autumn eye pattern portion 3a in which autumn eyes having a high density and a dark color are expressed, and a density and a color are low. And a spring pattern portion 3b in which a light spring is expressed. In the present embodiment, the pattern in the pattern layer 2 is the wood grain pattern 3. However, the present invention is not limited to this, and various patterns such as a stone pattern, a cloth pattern, or an abstract pattern can be applied.

  In synchronism with a part of the grain pattern 3 in the pattern layer 2, an uncured resin material 4a is printed on the autumn pattern portion 3a by an ink jet printer, and powder is further formed on the resin material 4a. A raised portion 4 is formed by curing the resin material 4a after the body 4b is spread.

  As long as the resin material 4a which comprises a part of the raising part 4 is resin which can be apply | coated using an inkjet printing machine, what kind of resin may be used. However, it is necessary to select appropriately considering the adhesiveness with the pattern layer 2 and the adhesiveness with the transparent coating layer 5 formed on the raised portion 4 described later. As the resin used as the material of the raised portion 4, a synthetic resin paint such as an ultraviolet curable type, an electron beam curable type or a moisture curable type can be suitably used. For example, an acrylic type, urethane type, epoxy type or polyester type resin can be used. Can be used. Moreover, the resin material 4a may have transparency to the extent that it can pass through the printed pattern of the Akimi pattern 3a, may be colored, or may be so-called color clear.

  As the powder 4b to be distributed on the uncured resin material 4a, for example, an antifriction material, a high brightness powder, an allergen substance reducing function powder, an antibacterial function powder, or the like can be used. As the anti-friction material, for example, white alumina, green carbon, ceramic powder, or the like can be used, and it is preferable to use one having about 300 to 1500. The antifriction material can increase the wear resistance of the decorative plate 10 as its count decreases, but the surface property becomes rough. On the other hand, the degree of improvement in the wear resistance of the decorative plate 10 increases as the count increases. Since the surface can be made smoother, the antifriction material to be used may be appropriately selected depending on the desired finish level of the decorative board 10 and the intended use. In addition, as the high-brightness paint, flake-like metal thin foil, mica, metal-deposited mica, or the like can be used alone or in combination.

  The ink jet printing machine used for printing the pattern layer 2 and the resin material 4a is not particularly limited as long as it is a general ink jet printing machine. The head fixing type printing machine (line method or single pass method) and head movement are used. It is possible to use various printing machines such as a type of printing machine (serial head system). However, it is necessary to use two types, a head for printing the pattern layer 2 and a head capable of printing the raised portion 4. When using a head-fixed ink jet printer, for example, when printing a rectangular decorative board, determine a ruler measurement point, and a pattern (Akime pattern part 3a) obtained by the pattern print head by sensing from the measurement point; The raised portion 4 (resin material 4a) obtained by the raised portion printing head is synchronized. On the other hand, when using a head movement type ink jet printer, since the printing object is fixed, the pattern obtained by the pattern print head (Akime pattern portion 3a) and the raised portion obtained by the raised portion printing head. It is easy to achieve synchronization with the portion 4 (resin material 4a).

  The printing of the resin material 4a that constitutes a part of the raised portion 4 can be performed by increasing the amount of resin applied or setting the viscosity high, for example. Moreover, you may form the raised part 4 by setting a viscosity low and performing multiple times of repeated coating.

  In order to distribute the powder 4b on the uncured resin material 4a, first, the resin material 4a is printed on the autumn pattern portion 3a by an ink jet printer in synchronization with the wood grain pattern 3 in the pattern layer 2. In the uncured state of the resin material 4a, for example, the powder 4b may be sprayed from the hopper to the surface of the pattern layer 2 conveyed by the conveying device through a sieve that stops or vibrates back and forth. Similar to the method of applying the body paint, a method of spraying the powder 4b and any other method capable of supplying the powder can be applied. Thus, since the resin material 4a not containing the powder 4b is printed and formed in synchronization with the pattern of the pattern layer 2 by the ink jet printer, there is no problem with the ink jet printer.

  In order to form the raised portion 4, the powder 4b distributed on the resin material 4a is removed except for the powder adhering to the resin material 4a as a surplus powder. As the removal method, negative pressure is used. Suctioning and removing, blowing a pressurized gas such as air, blowing it away, tilting or turning the base material 1 to which the powder 4b is attached to cause it to fall naturally, and applying this vibration to the natural fall In addition to the above, any method using the difference in adhesion between the powder 4b attached to the uncured resin material 4a and the powder 4b simply placed on the other surface, such as a method of forcibly dropping, is used. be able to. Moreover, you may make it spray these on the uncured resin material 4a of the downward or upward state. In this case, excess powder is removed by natural fall.

  Thus, the raised portion 4 includes the powder 4b, and the powder 4b functions as an antifriction material. Therefore, the raised portion 4 is provided with wear resistance and has an uneven shape synchronized with the pattern of the pattern layer 2. The decorative board 10 with high abrasion resistance can be obtained. In particular, when the powder 4b is an antifriction material, higher wear resistance is imparted to the raised portion 4, and the wear resistance of the raised portion 4 can be further improved.

  The raised portion 4 is formed by spreading the powder 4b on the uncured resin material 4a and curing it.

  In this case, the excess powder may be removed after the uncured resin material 4a is cured. Alternatively, the uncured resin material 4a may be cured after removing the powder other than that adhering to the uncured resin material 4a.

  A transparent coating layer 5 is applied and formed on the raised portion 4. Here, the transparent coating layer 5 is formed such that the surface thereof has a convex shape due to the raised portion 4. That is, the raised portion 4 and the transparent coating layer 5 positioned thereon constitute a convex portion 6a that bulges upward from the other portions, while being located in a region where the raised portion 4 is not formed. A concave portion 6b is formed by the portion.

  As the transparent coating layer 5, any resin can be used as long as the resin has transparency enough to transmit the Akimi pattern 3a of the pattern layer 2. A synthetic resin paint such as an ultraviolet curable type, an electron beam curable type, a thermosetting type or a moisture curable type can be suitably used. For example, acrylic, urethane, epoxy, or polyester resins can be used. In addition, for the application of the transparent coating layer 5 on the raised portion 4, for example, a roll coater, a sponge coater, a spray or a brush can be used for the application of the transparent coating layer 6. When the transparent coating layer 6 is selectively provided only on the raised portion 4, it may be performed in the same manner as the printing formation of the resin material 4a of the raised portion 4 using an ink jet printer, or as another method, a metal Alternatively, a flat roll coater made of hard rubber may be used, and the transparent coating layer 6 may be formed only on the convex portion of the raised portion 4. After the transparent coating layer 5 is applied on the pattern layer 2 and the raised portion 4, it is necessary to adjust the viscosity and the amount of application so that it does not flow into the recess 6b or accumulate, but if the viscosity is excessively high In order to cause streaky irregularities due to coating, it is preferable to adjust the viscosity appropriately using a monomer.

  In this embodiment, the portion that synchronizes with the Akume pattern portion 3a is the convex portion 6a, and the portion that synchronizes with the spring pattern portion 3b is the concave portion 6b. However, the present invention is not limited to this, and the pattern may be reversed. The convex part 6a should just be formed so that the glossiness of a convex part and a convex part may differ so that it may synchronize with the pattern of the layer 2 at least. Further, not only the wood grain pattern 3 but also, for example, when a stone pattern is used as the pattern in the pattern layer 2, it is possible to improve the design of the decorative board by providing a convex portion so as to synchronize with the stone pattern. it can.

(Second Embodiment)
Hereinafter, a decorative board according to a second embodiment of the present invention will be described with reference to FIG. FIG. 2 is a cross-sectional view schematically showing a decorative board according to the second embodiment of the present invention. In the present embodiment, description of the same parts as those in the first embodiment will be omitted, and only different parts will be described.

  As shown in FIG. 2, the decorative board 20 according to the present embodiment has a transparent coating layer 5 formed on both the pattern layer 2 and the raised portion 4 as compared to the first embodiment, The gloss adjusting portion 7 is formed on the surface of the convex portion 6a in the transparent coating layer 5 by performing processing for adjusting the gloss.

  For the application of the transparent coating layer 5, for example, a roll coater, a sponge coater, a spray or a brush can be used. This transparent coating layer 5 protects the region other than the raised portion 4 on the surface of the pattern layer 2.

  Further, for example, sanding can be used as the processing of the gloss adjusting unit 7. By using sanding, the surface of the convex portion 6a (gloss adjusting portion 7) can be roughened, and the gloss of the portion can be made lower than that of the concave portion 6b. As a result, it is possible to make a difference between the gloss of the convex portion 6a and the gloss of the concave portion 6b.

  On the contrary, by increasing the smoothness of the surface of the convex portion 6a (gloss adjusting portion 7) in the transparent coating layer 5 and increasing the gloss of the portion higher than the concave portion 6b, the gloss of the convex portion 6a is increased. And the gloss of the recess 6b may be different. In this case, as a process for adjusting the gloss, sanding or buffing using a polishing paper having a large count can be used. The buffing is also called a polisher, and is a method of polishing the surface of the decorative board 10 with felt or non-woven fabric in the presence of fine particle polishing powder (compound). By these, the surface (gloss adjustment part 7) of the convex part 6a in the transparent coating film layer 5 becomes smooth, and the gloss of the part can be raised. As a result, it is possible to make a difference between the gloss of the convex portion 6a that synchronizes with the autumn pattern portion 3a of the pattern layer 2 and the gloss of the concave portion 6b that synchronizes with the spring pattern portion 3b. Unlikely, natural texture can be expressed and the design of the decorative board 10 can be improved.

(Third embodiment)
Hereinafter, a decorative board according to a third embodiment of the present invention will be described with reference to FIG. FIG. 3 is a cross-sectional view schematically showing a decorative board according to the third embodiment of the present invention. In the present embodiment, description of the same parts as those in the first embodiment will be omitted, and only different parts will be described.

  As shown in FIG. 3, the decorative board 30 according to the present embodiment is transparent to the extent that the autumn pattern portion 3a of the pattern layer 2 can be transmitted over the pattern layer 2 as compared with the first embodiment. The clear layer 8 having the property is different.

  Specifically, in the decorative board 30 according to the present embodiment, the clear layer 8 is formed on the pattern layer 2, and the raised portion 4 is formed at a position corresponding to the autumn pattern portion 3a on the clear layer 8. ing. Any resin can be used for the clear layer 8 as long as the resin is transparent enough to pass through the autumn pattern portion 3a of the pattern layer 2. A synthetic resin paint such as an ultraviolet curable type, an electron beam curable type, a thermosetting type or a moisture curable type can be suitably used. For example, acrylic, urethane, epoxy, or polyester resins can be used.

  By forming the clear layer 8 on the pattern layer 2 as in the decorative board 30 of the present embodiment, by providing the clear layer 8 having a certain thickness not only on the convex portion 6a but also on the concave portion 6b, A decorative board having a more three-dimensional design appearance with different design properties depending on the viewing angle can be provided. A pattern layer may be further provided on the clear layer 8.

(Fourth embodiment)
Hereinafter, a decorative board according to a fourth embodiment of the present invention will be described with reference to FIG. FIG. 4 is a cross-sectional view schematically showing a decorative board according to the fourth embodiment of the present invention. In the present embodiment, description of the same parts as those of the second embodiment will be omitted, and only different parts will be described.

  As shown in FIG. 4, the decorative plate 40 according to the present embodiment has a process for adjusting the gloss on the surface of the convex portion 6 a in the transparent coating layer 5 as compared with the second embodiment. The difference is that the antifriction material layer 9 is formed only on the surface of the convex portion 6a, not the gloss adjusting portion 7 formed by being applied.

  The anti-friction material layer 9 is formed by mixing the anti-friction material with a resin that is transparent to the extent that it can pass through the Akimi pattern 3 a of the pattern layer 2. As such a resin, an ultraviolet curable synthetic resin paint can be suitably used, and acrylic, urethane, epoxy, or polyester resins can be used. For application of the antifriction material layer 9, for example, a spray or a brush can be used. Further, as the antifriction material, for example, white alumina, green carbon, ceramic powder or the like can be used, and it is preferable to use one having about 300 to 1500. The antifriction material can increase the wear resistance of the decorative plate 40 as the count decreases, but the surface property of the antifriction material layer 9 becomes rough. On the other hand, the wear resistance of the decorative plate 40 increases as the count increases. Although the degree of improvement in the property is reduced, the surface of the antifriction material layer 9 can be smoothed, and therefore the antifriction material to be used may be appropriately selected depending on the desired degree of finish of the decorative board 40 and the intended use. Since the antifriction material layer 9 is provided on the surface of the decorative plate 40, it is preferable that the antifriction material has a large count in consideration of the smoothness.

This onset Ming, without causing a problem of ink jet printers, can wear resistance has an irregular shape that is tuned to the pattern that is printed by the printing press to obtain a high veneer, in particular inkjet printing machine Therefore, it is useful for a decorative board having a pattern printed on the surface of the substrate.

DESCRIPTION OF SYMBOLS 1 Base material 2 Pattern layer 3 Wood grain pattern 3a Autumn pattern part 3b Spring pattern part 4 Raised part 4a Resin material 4b Powder 5 Transparent coating layer 6a Convex part 6b Concave part 7 Gloss adjustment part 8 Clear layer 9 Antifriction material layer 10, 20, 30, 40

Claims (7)

On the surface of the substrate having a smooth surface, a pattern is formed by printing a pattern with an inkjet printer,
With curing by printing a resin material in an uncured state to tune a portion of the pattern of the previous SL pattern layer Ri by the inkjet printer on the pattern layer, the printed resin material uncured powder was sprayed to adhere only to the resin material onto the resin material and the pattern layer when the excess powder by removing, excitement consisting of powder adhering to the resin material and the resin material Laminate the part on the pattern layer ,
By laminating a transparent coating layer covering at least the raised portions, the translucent Akiranuri film layer, and a convex portion positioned on the raised portion, the recess which is located on a region where the raised portion is not formed A process for producing a decorative board , characterized in that The said powder contains a friction reducing material, The manufacturing method of the decorative board of Claim 1 characterized by the above-mentioned. A transparent clear layer is laminated on the pattern layer,
The method for manufacturing a decorative board according to claim 1 , wherein the raised portion is formed on the clear layer so as to be synchronized with a pattern of the pattern layer. The method for manufacturing a decorative board according to any one of claims 1 to 3, wherein the gloss of the surface of the convex portion is made different from the surface of the concave portion which is a region where the raised portion is not formed. The surface of the convex portion of the transparent coating layer is subjected to a sanding treatment to such an extent that the transparent coating layer is not removed, and the gloss of the surface of the convex portion is made lower than that of the concave portion. 4. A method for producing a decorative board according to 4. Claims in the surface of the convex portion of the transparent coating layer is subjected to a polishing treatment to the extent that the transparent coating layer is not removed, characterized by a gloss on the surface of the convex portion to be higher than the surface of the recess Item 5. A method for producing a decorative board according to Item 4. Method for manufacturing a decorative laminate according to any one of claims 1 to 6, characterized in that to form the anti-friction material layer on the convex portion.

Images