JPH01234241A - Transfer sheet and preparation of thermosetting resin decorative board using said sheet - Google Patents

Abstract

PURPOSE:To easily form a thermosetting resin decorative board having a gloss changing pattern on the surface thereof, by providing a pattern layer to the surface of a glossy base sheet having good releasability from a transparent resin compatible with a thermosetting resin and bringing the same to a matte state to form a transfer sheet. CONSTITUTION:The entire surface of the pattern layer 2 of a base film 1 whose single surface is gloss is brought to a matte state to form a transfer sheet. When said transfer sheet is pressed along with melamine resin impregnated paper to perform curing and a base sheet is released and removed, the pattern layer is transferred to a decorative board and the upper surface thereof shows the gloss of the base sheet. The contact place with the matte part of the base film becomes a matte state. At this time, the transferred pattern layer is rigidly unified with the surface of the decorative board by the temp. and heat at a molding time to obtain sufficient surface capacity.

Description

[Detailed Description of the Invention] <Industrial Application Field> Thermosetting resin decorative boards, such as melamine resin decorative boards and diallyl phthalate resin decorative boards, are widely used for furniture, desks, tables, architectural interiors, etc. .

The present invention provides a transfer sheet that can enhance the design effect of the surface of a thermosetting resin decorative board used in these applications, as well as a thermosetting resin decorative board having a pattern pattern with varying gloss using the transfer sheet. This relates to a manufacturing method.

<Prior art> As a method for manufacturing a thermosetting i-veneer board having a pattern pattern with a change in gloss on its surface, an embossed decorative board with the purpose of forming a grooved conduit pattern with a wood grain pattern on a '144Q-treated board is used. A variety of items are offered. - As a boat fishing method, mirror plate with uneven parts formed by etching etc., resin plate with uneven parts shaped, embossed film with uneven parts embossed with an engraving roll, etc., and raised parts formed by raised printing. There are known methods such as transferring an uneven pattern such as a raised printing sheet onto the surface of a decorative board, and printing patterned paper with hardening-inhibiting ink or foaming ink to weaken the hardening of the partially thermosetting resin. .

When using a mirror plate or resin plate with uneven parts, it is necessary to prepare a mirror plate or resin plate according to the number of stages during molding, which increases the cost of producing the mirror plate or resin plate and the preparation time when changing the pattern pattern. It is difficult to cope with multi-product production as it requires

Furthermore, if the embossed film is molded as is, the unevenness will disappear due to pressure, so it is necessary to fill the depressions with synthetic resin or the like. Since the embossed printing sheet itself has no releasability to the thermosetting resin, it is necessary to insert a release sheet or metal foil between the embossed sheet and the thermosetting resin-impregnated paper. Furthermore, with the method of using a mirror plate, it is possible to create a pattern with a curved pattern, but with other methods, the release sheet or metal foil inserted in between becomes glossy, and although unevenness is created, it is difficult to create a pattern with a curved shape. .

The method of printing curing-inhibiting ink, foaming ink, etc. on pattern paper to weaken the curing of thermosetting resin is to remove the adhered resin each time it is manufactured, as the weakened resin will adhere to the mirror plate. Otherwise, a release sheet must be inserted between the mirror plate and the impregnated paper, and the weakened resin must adhere to the release sheet. In addition, this method requires high process costs, unstable concave shapes, large production losses, and weakens the physical properties, making it difficult to manufacture realistically.

Furthermore, although the embossed decorative board obtained by the above method has an excellent surface design effect, it also has the disadvantage that it is susceptible to accumulation of lumps because it forms recesses that can be irritated by touching.

Problems to be Solved> An object of the present invention is to provide a method for manufacturing a thermosetting resin decorative board having a pattern pattern with a curved pattern, in order to compensate for the disadvantages of conventionally known manufacturing methods.

The production of a thermosetting resin decorative board in which a transfer sheet is inserted and heat and pressure molded to enhance the surface design effect has already been proposed in Japanese Patent Publication No. 61-38019, etc., but the present invention The present invention relates to a method for easily and efficiently manufacturing a transfer sheet having a certain pattern.

<Means for solving the problem> In order to manufacture a thermosetting resin decorative board with a pattern with ripening on the surface, we used a mirror plate, a resin board surface transfer method, an embossing method with an embossed sheet, and curing. To make up for the shortcomings of the brittle method using blocking ink or foam ink, we use a transfer sheet with a pattern with a change in shape, and when producing a thermosetting resin decorative board, we use a hot plate or mirror plate and a thermosetting resin impregnated paper. This problem was solved by inserting the sheet between the sheets and molding it under heat and pressure, and then transferring the mature patterned luster of the transfer sheet to the surface of the thermosetting resin decorative board.

The method of the present invention will be explained in more detail with reference to the drawings.

FIG. 1 is a cross-sectional view of a transfer sheet having a pattern with ripening.

Reference numeral 1 is a base sheet of the transfer sheet, and a sheet made of one layer or multiple layers of resin film is used. The base sheet 1 must be glossy on at least one surface, have heat resistance that can withstand heating and pressure molding during the production of thermosetting resin decorative laminates, and be easily removable from the thermosetting resin. Polyester film, polypropylene film, etc. having a thickness of about 6 to 100 μm are most suitable.

2 is a pattern layer, which is made of a resin that has an affinity for the thermosetting + resin resin to be impregnated. For example, if the thermosetting resin is melamine resin, use one of thermoplastic acrylic resin, cellulose resin, or melamine resin.
In the case of DAP (diallyl phthalate) resin, any one of thermoplastic acrylic resin, cellulose resin, and DAP resin is used.

In particular, if the same type of resin is used, the surface performance of the final decorative board will be as excellent as that of a normal decorative board.

Next, in order to make the entire surface of the base film 1 including the pattern layer 2 on the pattern layer 2 side matte, a mechanical cutting process such as sand plus process or hairline process is performed.

FIG. 2 is a cross-sectional view of a method for manufacturing a thermosetting resin decorative board in which a typical melamine resin decorative board is manufactured using the transfer sheet manufactured above. Between the upper and lower heating plates 11, the following items are stacked in order from the top.

10 is a heat-resistant cushion sheet. 9 is a mirror plate, but the lower surface does not come into direct contact with the melamine resin, and because there is the base sheet 1 of the transfer sheet 3 between the melamine resin impregnated paper, it directly contacts the surface of the molded melamine resin decorative board. Since it does not affect the gloss etc., it does not need to be sufficiently polished.To be extreme, it is not necessary.If the heat-resistant cushion sheet 10 is molded in direct contact with the transfer sheet 3, the heat-resistant cushion sheet 10 can be molded directly. The surface irregularities of the sion sheet are alleviated by interfacing with the base sheet, making it possible to produce a tasteful melamine resin decorative board with gentle irregularities on the surface. 4 is overlay paper, which is a transparent resin-impregnated paper made by impregnating rayon pulp or nonwoven fabric with a basis weight of 25 to 45 g/rrf with 40 to 100 χ of melamine resin and drying it to a semi-cured state, and it may be removed depending on the case. , 5 has a basis weight of 55 to 160 g/nf
This is a melamine resin-impregnated paper in which a pattern is optionally printed on titanium paper, impregnated with 40 to 100 χ of melamine resin, and dried to a semi-cured state.

The patterned layer is placed on the upper side.

In the present invention, the thermosetting resin decorative board having a pattern with a change in gloss has a sufficient design effect even without pattern printing on titanium paper; As a result, although it does not synchronize with a pattern with a change in its shape, it can be synergized with it to create a high design effect. 6 is a core paper, which is a paper having a tsubo of 1140 to 180 g/ld, impregnated with 30 to 60% of phenolic resin, and dried to a semi-cured state. It maintains the dimensional stability of the melamine resin decorative board and determines the thickness of the decorative board, and is used in stacks of 4 to 5 layers. 7 is backer paper, which is an impregnated paper made by impregnating titanium paper with a basis weight of 55 to taog/■ with 40 to 100χ of melamine resin and drying it to a semi-cured state. It balances with the overlay paper 4 and serves to prevent the decorative board from warping. 8 is a release sheet;
This prevents melamine resin from adhering to the lower heat-resistant cushion 10.

Laminated in the state shown in Figure 2, maximum temperature 140-150°C1
Heat and press mold at a pressure of 80-100 kg/nf for 15-30 minutes, then rinse with cold water for 15-30 minutes under pressure.
FIG. 3 is a cross-sectional view of the state in which the semi-hardened resins 4 to 7 are cured by cooling and the decorative board is taken out and the transfer sheet is peeled off.

<Function> When the base sheet is peeled off and removed, the pattern layer is transferred to the decorative board, and the upper surface thereof exhibits the gloss of the base sheet. On the other hand, the areas where the matte portion of the base film hits become matte. The pattern layer transferred at this time is firmly integrated with the surface of the decorative board due to the temperature and heat during molding, and sufficient surface performance can be obtained.

Furthermore, by incorporating wear-resistant fine powder such as silica, alumina, or tungsten carbide into the pattern layer, a product with even better wear resistance can be obtained.

Since the transfer sheet 3 can be peeled off at any time, it can also be used as a project sheet to prevent scratches and stains on the decorative board during the manufacturing process.

Compared to normal thermosetting resin decorative boards, the manufactured thermosetting resin decorative board only has a pattern with a curved pattern transferred to the surface, and there is no change in the surface resin layer or anything else. Therefore, the physical properties of the decorative board are also the same.

<Example 1> On the surface of a base sheet made of glossy polyethylene terephthalate having a thickness of 25 μm, a transparent varnish mainly composed of a thermoplastic acrylic resin was provided with a checkered pattern layer using a gravure printing method.

Next, the entire surface of the base film, including the pattern layer on the pattern layer side, was continuously sandblasted to obtain a transfer sheet with the entire surface matte.

Decorative paper printed with a grain pattern using this transfer sheet is impregnated with melamine resin, and the dried prepreg and overlay paper are then placed between the upper and lower heating plates 11 as shown in Fig. 2, from the top to the upper cushion 10, mirror Face plate 9, the pattern printed side of the transfer sheet 3 manufactured above is facing down, the overlay paper 4, the pattern printed side of the patterned area 5 is facing up, phenolic core area 6, backer paper 7, release sheet 8, lower cushion. 10
After laminating in this order, the maximum temperature is 145℃ and the pressure is 80kg/
ad, for 25 minutes under heat and pressure molding, and then cooled with water for 20 minutes under pressure to obtain a melamine resin decorative board in which the melamine resin and phenol resin were integrated.

After molding, when the base sheet l was peeled off, a melamine resin decorative board was obtained that had an extremely clear difference in gloss, with the patterned layer having a highly glossy checkered pattern on the surface and other parts being matte. .

From the peeled transfer sheet 3, no pattern layer 2 remained on the base sheet 1. The physical properties of the decorative board were equivalent to those of a normal melamine decorative board.

<Example 2> A melamine decorative board was molded in the same manner as in Example 1, except that 100 parts of methylol melamine resin and 20 parts of finely powdered alumina were used as the pattern layer.

The obtained decorative board has an extremely clear difference in gloss as in Example 1, and the pattern layer also has excellent wear resistance, which is better than that directly formed using a conventional etched mirror board. It showed excellent performance.

<Effects of the Invention> When heat-pressing molding a thermosetting resin decorative board, simply inserting a transfer sheet can easily and stably produce a decorative board with a sharply changing pattern with a clear difference in gloss and a high design effect. can be manufactured at low cost.

The opening and transfer sheet can be printed with only one plate using a regular printing machine!
! ! Since it can be easily manufactured, there is very little manufacturing loss and quality control is easy.

C. There is no need to prepare several stages of expensive mirrored plates with patterns on them by methods such as etching, and there is no need to attach different mirrored plates to the heating plate when changing the design, which reduces time and manufacturing costs. It can be easily applied to a wide variety of products.

2. Since the transfer sheet can be peeled off at any time, it can also be used as a protective seal to prevent scratches and tearing of the decorative board during the manufacturing process.

A higher design effect can be obtained by matching the pattern of the printed titanium paper used for normal melamine decorative board for banknotes.

F. When an anti-wear agent is mixed into the resin for the pattern layer, the decorative pattern layer becomes a product with excellent abrasion resistance.

[Brief explanation of the drawing]

FIG. 1 is a sectional view of the transfer sheet. FIG. 2 is a cross-sectional view of melamine resin decorative boards laminated during heating and pressure molding. FIG. 3 is a cross-sectional view of the melamine resin decorative board and the peeled transfer sheet. 1... Base sheet 2... Pattern layer 3... Transfer sheet 4... Overlay paper 5... Melamine resin impregnated titanium paper 6... Phenol core paper 7... Backer 8 ...Release sheet 9...Mirror plate IO...Cushion sheet 11...Heating plate 12...Melamine resin decorative board Fig. 1 Fig. 3

Claims (3)

[Claims] (1) A patterned layer made of a transparent resin that has an affinity for the thermosetting resin is partially applied to the surface of the base sheet, which has good mold releasability for the impregnated thermosetting resin and has a glossy surface. A transfer sheet is provided, and the pattern layer side is in a matte state. (2) The transfer sheet of claim (1) is inserted between a hot plate or mirror plate and resin-impregnated paper with the pattern layer facing the resin-impregnated paper, heated and pressurized, and after the resin hardens, the transfer sheet is peeled off. A method for producing a thermosetting resin decorative board. (3) The transfer sheet according to claim (1), wherein the transparent resin used for the pattern layer is the same type as the impregnated thermosetting resin.