JP7239035B2 - Decorative material and its manufacturing method - Google Patents

Description

TECHNICAL FIELD The present invention relates to a decorative material used for the interior and exterior of buildings, and more particularly to a decorative material having a glittering and highly luminous appearance and a method for producing the same.

Decorative materials with various materials, shapes, colors and designs are used as decorative materials for the interior and exterior of buildings. In particular, decorative materials, in which patterns are applied to various materials using a printing method, have been generally used mainly for applications where mass productivity is important, because uniform products can be supplied in large quantities.

Examples of such products include various interior and exterior decorative panels. Decorative boards are roughly classified into two types. That is, there are so-called direct-printed decorative boards in which a plate-shaped base material is directly coated or printed, and so-called laminated decorative boards in which a decorative sheet having a pattern printed on a base material such as paper or film is laminated to the base material.

For all decorative boards, gravure plates have been used for many years as printing plates. Gravure plates have been widely used because of their excellent reproducibility of patterns, high durability of the plates, a wide range of ink choices, and the relative ease with which endless patterns can be produced. .

Decorative sheets can be efficiently printed by a normal gravure rotary printing machine. In the case of a direct printing decorative board, printing can be performed using a gravure offset printing machine that transfers the ink of the gravure plate to an offset roll once and then prints on the base material.

However, in recent years, in the field of design, as too much uniformity is disliked and diversification is demanded, there is a growing tendency to shift to high-mix low-volume production. Although it excels in mass productivity, it has become difficult to cope with the gravure printing method, which has a high platemaking cost.

Therefore, there has been proposed a decorative material using an ink-jet printing method that does not require a plate for printing. The decorative board described in Patent Literature 1 is a decorative board in which a printed pattern is directly inkjet-printed after providing a base film on the surface of a wooden base material. Moreover, the decorative board described in Patent Document 2 is a decorative board in which a pattern layer is formed on a base material by impregnating a decorative paper on which a printed layer is formed by inkjet printing with a resin.

On the other hand, in terms of the design properties of decorative materials, there are cases in which expression with metallic luster or glittering brilliance is required. In order to achieve high metallic luster and brightness, it is necessary to print aluminum pigments and pearl pigments having a relatively large particle size. According to the gravure printing method, it is possible to print a glitter pigment having a particle size of about several tens of μm within a range smaller than the cell diameter of the gravure plate. I couldn't.

The base paper for decorative laminate (decorative paper) described in Patent Document 3 is a base paper for decorative laminate (decorative paper) in which an ink-receiving layer, an inkjet printing layer, and a high-gloss layer containing a bright pigment are laminated in this order on a paper base material. is. According to Patent Document 3, it is described that a high-gloss layer is formed by a gravure printing method.

However, as described in Patent Document 3, it has been found that the following problems occur when gravure ink containing a luster pigment having a particle size of several tens of μm is actually used for printing.
The first problem is that the particle size of the luster pigment is just the average particle size, and in fact fine particles and coarse particles are mixed, and in the process of printing, the fine particles are preferentially consumed. Therefore, the particle size distribution of the luster pigment in the ink changes with the lapse of time, and as a result, the luster changes with time, and a stable product cannot be obtained.

A second problem is that of the ink-receiving layer formed prior to inkjet printing. Although the ink-receiving layer is effective for the reproducibility of the pattern, it was found that in the case of a decorative board in which decorative paper is impregnated with a resin, the impregnability of the resin may be hindered. Especially in the case of decorative paper using luster pigments, it has been found that this tendency is remarkable.

Japanese Patent No. 5798145 Japanese Patent Application Laid-Open No. 2001-71447 Japanese Unexamined Patent Application Publication No. 2017-81004

The problem to be solved by the present invention is to propose a decorative material having a pattern layer formed using an inkjet printing method and a bright layer formed using a bright pigment having a large particle size, and a method for producing the same. It is a thing.

As a means for solving the above problems, the invention according to claim 1 is a decorative material having a pattern layer and a glitter layer on the surface of a base material layer, wherein the pattern layer is made of inkjet ink and has a diameter of 100 μm. The glitter layer contains a glitter pigment having an average particle diameter of 1 μm or more and 200 μm or less, and the substrate layer is a resin-impregnated titanium ink that does not contain an inkjet ink receiving layer. The decorative material is paper.

In the decorative material according to the present invention, since the basic pattern is composed of inkjet ink, by printing with the inkjet printing method, it is possible to respond to high-mix low-volume production. By providing a bright layer containing pigments, it is possible to express a high level of design.

Further, the invention according to claim 2 is characterized in that the pattern layer is formed by printing by an inkjet printing method, and the glitter layer is formed by discharging a coating liquid containing a glitter pigment from a dispenser. It is a manufacturing method of the decorative material according to claim 1.

Further, the invention according to claim 3 is characterized in that the coating liquid discharged from the dispenser contains 10% by mass or more and 75% by mass or less of the bright pigment. manufacturing method.

The decorative material according to the present invention is a decorative material having a pattern layer and a bright layer on the surface of a substrate layer, and the pattern layer is composed of fine ink dots having a diameter of 100 μm or less made of inkjet ink. In other words, it is possible to print by an ink jet printing method, and therefore there is no need for plate making, so it is suitable for high-mix low-volume production.
In addition, since the bright layer contains a bright pigment having a relatively large particle size of 1 μm or more and 200 μm or less in average particle size, it is possible to obtain a glittering feeling and express a high design property.

When resin-impregnated titanium paper that does not contain an inkjet ink-receiving layer is used as the base material layer, the resin-impregnating property is good when the decorative paper, which is a decorative material, is impregnated with, for example, a melamine resin. A decorative melamine board is obtained by hot pressing. It goes without saying that this case is also suitable for high-mix low-volume production.

As in the invention described in claim 2, the pattern layer is formed by printing by an inkjet printing method, and the bright layer is formed by ejecting a coating liquid containing a bright pigment from a dispenser, thereby forming a large particle size. A coating liquid containing a bright pigment can be applied without clogging.

FIG. 1 is a cross-sectional explanatory view schematically showing one embodiment of the cosmetic material according to the present invention. FIG. 2 is a cross-sectional explanatory view schematically showing another embodiment of the decorative material according to the present invention. FIG. 3 is a cross-sectional explanatory view schematically showing a step of forming a pattern layer by an inkjet printing device in the manufacturing process of the decorative material according to the present invention. FIG. 4 is a cross-sectional explanatory view schematically showing a step of forming a bright layer with a dispenser in the manufacturing process of the decorative material according to the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION A decorative material according to the present invention and a method for producing the same will be described in detail below with reference to the drawings. FIG. 1 is a cross-sectional explanatory view schematically showing one embodiment of the cosmetic material according to the present invention. A decorative material 1 according to the present invention is a decorative material having a pattern layer 3 and a bright layer 4 on the surface of a substrate layer 2 . The pattern layer 3 is composed of fine ink dots having a diameter of 100 μm or less made of inkjet ink, and the glitter layer 4 is a cosmetic material characterized in that it contains a glitter pigment having an average particle diameter of 1 μm or more and 200 μm or less. be.

The base material layer 2 may be a base paper for resin-impregnated decorative board such as titanium paper, paper such as thin paper, a colored synthetic resin base material sheet made of synthetic resin, or a plate-shaped material obtained by applying a primer coating to various decorative board base materials. Any material, such as a substrate, can be used. The example shown in FIG. 1 is an example in which titanium paper 6 is used as the base material layer 2 .
FIG. 2 shows an example of using, as the base material layer 2, a decorative plate base material 7 coated with an undercoating 8. As shown in FIG. In this example, a transparent topcoat layer 5 is provided to protect the ink surface after printing.

When a porous material such as paper is used as the substrate layer 2, an inkjet ink receiving layer may be provided in advance on the printing surface. The ink-jet ink-receiving layer has the effect of promoting the fixation of the ink-jet ink and improving the color development, but it may impair the impregnating property of the resin, and in some cases it is better not to have it.
When the substrate layer 2 is the resin-impregnated titanium paper 6, it is impregnated with a thermosetting resin such as a melamine resin, a benzoguanamine resin, or a diallyl phthalate resin in the next step to be used as a thermosetting resin decorative board. In this case, from the viewpoint of resin impregnation, it is better not to have an ink-jet ink-receiving layer.

In the case of a decorative paper that does not have a resin impregnation step in the post-process, such as precoated decorative paper, an inkjet ink-receiving layer may be provided. In either case, the order of the pattern layer 3 and the bright layer 4 may be reversed.

As the inkjet ink, oil-based, water-based, or solvent-free inkjet ink can be used. Considering the use as a building material, it is preferable to use a pigment type rather than a dye type from the viewpoint of light resistance and weather resistance.
FIG. 3 is a cross-sectional explanatory diagram schematically showing a step of forming the pattern layer 3 by an inkjet printing apparatus in the manufacturing process of the decorative material according to the present invention. The substrate layer 2 is placed on a conveyer 12 that conveys it in the direction of flow, and is printed while being scanned by the inkjet print head 10 . As a printing apparatus, there are a type in which the substrate layer is conveyed continuously and a type in which the base material layer is conveyed intermittently, and either of them may be used.

A print head usually integrates a plurality of heads for ejecting inks of a plurality of tones. Depending on the pattern to be printed, a configuration in which black is added to the three primary colors of yellow, magenta, and cyan, or a plurality of special colors prepared in advance may be used.
FIG. 4 is a cross-sectional explanatory view schematically showing the step of forming the bright layer 4 by a dispenser in the manufacturing process of the decorative material according to the present invention. The coating liquid for forming the bright layer 4 is discharged from the dispenser head 11 so that the discharge amount per unit time is constant. Since the dispenser head 11 is scanned at a constant speed, it can be programmed in advance to discharge the coating liquid containing the luster pigment in a pattern with a constant thickness.

Since the diameter of the dispenser head can be made much larger than that of a normal inkjet print head, it is possible to use bright pigments with a large average particle diameter that clogs a normal inkjet printer and makes printing impossible. can.

As the luster pigment, a leafing type or non-leafing type aluminum pigment, a synthetic pearl pigment obtained by coating the surface of mica with a pigment such as titanium oxide or iron oxide, or the like can be used. It is suitable that the average particle size of the luster pigment is 1 μm or more and 200 μm or less. If it is less than 1 μm, the feeling of glitter is insufficient, and if it exceeds 200 μm, problems such as clogging tend to occur.

It is suitable that the content of the luster pigment in the coating liquid is 10% by mass or more and 75% by mass or less. The coating liquid is water-based or oil-based, and contains a binder, a solvent (water), a dispersant, an additive, etc., in addition to the bright pigment.

The method for forming the bright layer is not limited to the dispenser, and may be a gravure printing method using a gravure printing plate.

<Example 1>
A white base paper for printing (KW-1001P manufactured by KJ Specialty Paper Co., Ltd.) (white titanium paper) with a basis weight of 100 g/m ² was used as the base material layer. The picture layer was printed using an inkjet printer. As the inkjet ink, a water-based pigment ink (LIOJET manufactured by Toyo Ink Co., Ltd.) was used. The resolution of the pattern was 1200×1200 dpi.

Subsequently, a bright layer was formed on the surface of the pattern layer. As the coating liquid for the bright layer, a bright pigment having an average particle size of 15 μm in the particle size distribution of the volume-based particle size (Iriodin 201 Rutile Gold) 11 g was used.

A gravure printing machine was used to apply the coating liquid. Subsequently, the coating liquid was dried to form a bright layer on the surface of the design layer. In the dry coating film, the mass of the glitter pigment was 22% with respect to the mass of the glitter layer.

The resulting decorative paper was impregnated with a melamine-formaldehyde resin and dried to obtain a prepreg.
A prepreg was sandwiched between separately prepared core paper impregnated with phenol-formaldehyde resin and overlay paper impregnated with melamine-formaldehyde resin, and the prepreg was inserted between mirror plates and heated and pressurized to prepare a melamine resin decorative board.

<Example 2>
A melamine resin decorative board was prepared in the same manner as in Example 1, except that the order of the pattern layer and the bright layer was reversed.
<Comparative Example 1>
Decorative paper provided with an ink-receiving layer was prepared as a comparative example. As a coating liquid for the ink-receiving layer, 35 g of calcium carbonate (Shiraishi Calcium Co., Ltd. Shiraenka PZ) having an average particle size of 3.3 μm in the volume-based particle size distribution is added to 75 g of water, and a cationic emulsion (Chuo Rika Kogyo FK-820 (manufactured by Co., Ltd.) 38 g was dispersed with a stirrer and used.

The surface of the white titanium paper used in Example 1 was coated with the coating liquid using a gravure printing machine. After coating, the coating solution was dried in an oven at 120° C. to form an inkjet ink-receiving layer. The coating amount of the receiving layer was 7.5 g/m ² (dry), and the content of calcium carbonate in the receiving layer was 70% by mass. Using this titanium paper, a pattern layer and a bright layer were formed in the same manner as in Example 1 to prepare a melamine resin decorative board in the same manner.

When printing Examples 1 and 2 and Comparative Example 1, a 50% gray solid printed portion was created, and the color difference between the decorative paper and the decorative board in this portion was measured. A fluorescence spectrodensitometer (eXact Advance, manufactured by X-Rite) was used to measure the color difference. When the color difference was ΔE=2 or less, it was evaluated as a pass (◯), and when it exceeded 2, it was evaluated as a failure (x). Table 1 shows the results.

From the results in Table 1, it was found that the melamine resin decorative board should not have an ink-receiving layer containing calcium carbonate as a main component.

<Example 3>
After applying a urethane resin-based white undercoating to the surface of MDF (medium density wood fiber board) with a thickness of 10 mm, a pattern layer is formed using an inkjet printer, and a dispenser (Nordson PICO A bright layer was formed using a Pulse jet valve, a scanning speed of 0.5 m/min, and a nozzle diameter of 50 mm. As the inkjet ink and the bright layer coating liquid, the same ones as those used in Example 1 were used. Finally, as a top coat, a urethane resin-based transparent paint was applied using a roll coater and dried.

<Example 4>
A decorative board was prepared in the same manner as in Example 3, except that the order of the pattern layer and the bright layer was reversed.

<Comparative Example 2>
As a comparative example, a decorative board was produced in the same manner as in Example 3, except that no bright layer was provided.

Visually comparing the obtained three decorative boards, the decorative boards of Examples 3 and 4 including the bright layer and the decorative board of Comparative Example 2 having no bright layer were compared in terms of design. It was clearly better than 2, and the difference was clear. Moreover, problems such as clogging did not occur in the dispenser.

DESCRIPTION OF SYMBOLS 1... Decorative material 2... Base material layer 3... Pattern layer 4... Bright layer 5... Top coat layer 6... Titanium paper

Claims (3)

A decorative material having a pattern layer and a bright layer on the surface of a base material layer, wherein the pattern layer is composed of fine ink dots having a diameter of 100 μm or less made of inkjet ink, and the bright layer has an average particle size of 1 μm. 1. A decorative material comprising a glitter pigment having a size of 200 μm or more, and wherein the substrate layer is titanium paper for resin impregnation and does not contain an inkjet ink receiving layer. 2. The manufacturing of the decorative material according to claim 1, wherein the pattern layer is formed by printing by an inkjet printing method, and the glitter layer is formed by discharging a coating liquid containing a glitter pigment from a dispenser. Method. 3. The method for producing a decorative material according to claim 2, wherein the coating liquid discharged from the dispenser contains 10% by mass or more and 75% by mass or less of the luster pigment.

Images