JPH0379381A - Manufacture of transfer sheet - Google Patents

Abstract

PURPOSE:To obtain a transfer sheet having excellent various resistances and commodity value, on which a beautiful and precise design can be formed, by a method wherein after sequentially providing a design layer and finishing layer on one side of a basic sheet having release property, these layers are released from the basic sheet, and the design layer and the finishing layer are laminated in this order on another basic sheet. CONSTITUTION:On a basic sheet 1 of which surface 2 has release property with respect to a design layer and finishing layer, a design layer 3 is formed by printing, and the design layer 3 is set by solvent volatile drying or using a curable ink, and then a finishing varnish layer 4 is formed. After this finishing varnish layer has been set to touch, the design layer 3 is released from the basic sheet 1 at the interface, and a transfer sheet is obtained by laminating this finishing layer and the design layer in this order on a basic sheet 5. It is not necessary to prepare the basic sheet 5 separately, and the basic sheet 1 can be used by turning it upside down. By this method, a decorative laminate with excellent appearance and various resistance can be manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION [Object of the Invention] (Field of Industrial Application) The present invention relates to a method for manufacturing a transfer sheet used for manufacturing decorative laminates.

(Prior Art) The transfer method has been practiced in the past because it allows a clear printed pattern to be attached to a desired article. For example, gravure offset printing is usually used to print patterns on metal plates, but this printing method cannot produce clear prints.

For this reason, a clear and delicate pattern is provided in advance on the base sheet by offset printing or gravure printing, and this is then transferred.

The transfer sheet for this purpose is usually a base sheet with
A transfer sheet is used in which a finishing varnish layer is provided, a pattern layer is printed thereon, and an adhesive layer is provided if necessary.

However, in the production of such transfer sheets, the finishing varnish layer is uncured and has the property of being soft and easily attacked and dissolved by solvents, so it is not necessary to apply the pattern layer using normal printing methods. was difficult. In other words, the printing pressure deforms the soft finishing varnish layer, causing uneven thickness and distorting the shape of the pattern, and if the finishing varnish layer is dissolved by the solvent contained in the printing ink, the accuracy of the pattern cannot be obtained. Problems such as this arise.

Furthermore, in the case of offset printing, the transfer sheet may stick to the offset blanket, causing misregistration.

In order to solve these problems, after applying a finishing varnish made of an electron beam curable composition onto the base sheet, the finishing varnish layer is irradiated with ultraviolet rays or, if the finishing varnish layer contains a solvent, heated. A method has been proposed in which the finishing varnish layer is dried to the extent that it does not adhere to the fingertips, and then a pattern is printed (Japanese Patent Laid-Open No. 57-49591). However, with this method, if the amount of UV irradiation is large, the finish varnish layer may harden too much, the transfer sheet may lose its flexibility, and the finish varnish layer may crack when the transfer sheet is bent. Also, if the amount of UV irradiation is small or if the solvent is dried by volatilization,
-As mentioned above, various problems caused by the finishing varnish layer being soft and soluble in solvents could not be solved.

In addition, as another solution, a method has been proposed in which a base sheet provided with a pattern layer and a base sheet provided with a finishing varnish layer are laminated, and the pattern layer is transferred onto the finishing varnish (Japanese Patent Application Laid-Open No. 1983-1999-1). 244699). However, in this method, several colors of ink are overprinted, resulting in a pattern layer that is quite uneven when viewed microscopically, and a finishing varnish that evaporates the solvent and is dry to the touch (poor fluidity). It is difficult to eliminate air bubbles when laminating the decorative laminates, and the presence of air bubbles is visually observed near the interface between the pattern layer and the finishing varnish layer, significantly reducing the commercial value of the resulting decorative laminate. The problem remained.

(Problems to be Solved by the Invention) The present invention provides a method for producing a transfer sheet that can improve the various drawbacks mentioned above and form a beautiful and precise pattern with various resistances and excellent commercial value. It is something.

[Structure of the invention]

(Means for Solving the Problems) The present invention comprises (1) a step of sequentially providing a pattern layer and a finishing layer on one side of a base sheet (A) that is releasable to the pattern layer and the finishing varnish layer; (2) a substrate. A step of peeling off the sheet (A), the pattern layer and the finishing layer, and (3) peeling off the base sheet (B), the pattern layer and the finishing layer,
This is a method for manufacturing a transfer sheet, which comprises the steps of laminating a base sheet (B), a finishing varnish layer, and a pattern layer in this order.

In the present invention, the base sheet (A) includes various plastic films such as polyester film, polyamide film, cellophane film, polyethylene film, and polypropylene film, paper, polypropylene coated paper, metal foil, or a laminate of two or more of these. Alternatively, those whose surfaces have been subjected to a treatment such as a peeling treatment are used. In the present invention, the base sheet (A) that has one side releasable from the pattern layer and the finishing varnish layer is used.

According to the research conducted by the present inventors, a stretched PET film is optimal for this base sheet (A) from the aspects of heat resistance and dimensional stability, and that this film is suitable for providing peelability from the pattern layer. It is best to apply a thermosetting paint such as alkyd/melamine resin paint to one side and heat cure it.

The pattern layer is usually printed by a printing method, and is provided on one side of the base sheet (A) by any printing method such as gravure printing, offset printing, or screen printing on a surface that is removable from the pattern layer and the finishing varnish layer. It will be done. Various inks can be used for this purpose depending on the relationship with the above-mentioned releasability, but according to research by the present inventors, vinyl chloride/vinyl acetate copolymers can be advantageously used.

The finishing varnish layer is one that allows the pattern layer to be seen through after the decorative board is manufactured, and must have good hardenability in order to obtain the required various resistances such as scratch resistance, solvent resistance, and heat resistance. It is preferable to use a resin composition having heat and/or active energy ray curability. Further, in order to improve the coating suitability of this finishing varnish, it is preferable to use various solvents, and this solvent is removed by volatilization after coating. Since the finishing varnish layer is thus formed using a finishing varnish with a low viscosity, it is possible to obtain a transfer sheet with a good surface condition without the presence of air bubbles. In addition, although this finishing varnish layer is uncured, its properties after removing the solvent are dry to the touch, and it does not substantially flow at room temperature, but becomes fluid when heated in the subsequent transfer process and adheres to the transferred object. It is preferable to choose something that does.

As the active energy ray-curable resin composition, radically polymerizable and/or cationically polymerizable resin compositions can be used. In addition, various solvents for improving coating suitability and various known additives such as polymerization initiators, thermal polymerization inhibitors, thermal polymerization initiators, pigments, fillers, etc. can be added as appropriate depending on the purpose. .

The present invention will be described in detail below based on the drawings. In FIG. 1, a pattern layer 3 is formed by printing on a base sheet (A) 1 whose surface 2 is releasable from the pattern layer and the finishing layer, and is dried by solvent evaporation using a conventional method or coated with curable ink. The finishing varnish N4 is then applied as shown in FIG.

After this finishing varnish layer is dry to the touch as described above, it is peeled off at the interface between the pattern layer 3 and the base sheet (A) 1, and then the base sheet 1-(B) 5, this finishing layer, and the pattern layer are coated in this order. The transfer seed of the present invention can be obtained by laminating layers.

As an embodiment of the present invention, it is not necessary to prepare the base sheet (B) separately (the base sheet (A) can be used by turning it over. To implement this embodiment industrially, see FIG. 4). Using the web 6 on which a pattern layer (not shown) is formed on the surface 2 as the base sheet (A) as shown in FIG. After drying to the touch, the finishing varnish layer 4 and the pattern layer are transferred to the base sheet (A) by rollers 8 and 9.
The web 6 is peeled off from the web 6, and the peeled web 6 is reversed (turned inside out) by guide rollers 10 and 11, and the web, finishing varnish layer, and pattern layer are laminated in this order again by rollers 8 and 9, and then wound onto roller 12. It will be done. A cross-sectional view of this rolled-up long object is as shown in FIG.

When manufacturing a decorative board using the above transfer sheet,
When compared with the method disclosed in JP-A No. 62-244699, there is a significant improvement in cost, as only one base sheet is required and the bulk of the elongated transfer sheet is small.

As shown in FIG. 6, a method for manufacturing a decorative board using an active energy ray-curable adhesive and a finishing varnish layer is as shown in FIG. Roll 15 and Roll 1 on material 14
After crimping by 6, radiation irradiation is performed by an energy ray irradiation device 17.

The base sheet is peeled off after or before irradiation with active energy rays.

When using the transfer sheet according to the present invention, when two base sheets are used as in the conventional case, the roller 1 shown in FIG.
5 and rollers 16, a step of peeling off one film is required, so that the process can be simplified and work efficiency can be improved.

Decorative board base materials include iron plate, tin-free steel plate,
Metal plates such as zinc plates, copper plates, aluminum plates, tin plates, and galvanized iron plates, plastic sheets, plastic molded products such as plastic containers, plywood, wood, paper, etc. are used depending on the purpose.

As the adhesive, it is preferable to use an adhesive that is cross-linked and cured by heat or active energy rays in terms of improving various resistances.In particular, if an adhesive that is cured by electron beams is used, the adhesive can be cured together with the finishing varnish layer. , is industrially preferred. Furthermore, the clarity of the pattern can be improved by adding a pigment with hiding properties, such as titanium white, to the adhesive.

In the present invention, examples of methods for pressure-bonding the transfer sheet and the decorative laminate base material include a method using a heated press plate or a heated roll, a method of vacuum lamination, or a method that combines these methods.

Transfer may be performed by pressing the transfer sheet and the decorative laminate base material together, peeling off the base sheet, and then irradiating the base sheet with energy rays, or irradiating the base sheet with active energy rays and heating if necessary. may be removed.

Hereinafter, the present invention will be explained in more detail with reference to Examples and Comparative Examples. In the examples, parts represent parts by weight.

Example 1 A melamine-alkyd release agent was applied as a release layer on one side of a 25 μm thick polyester film to a dry film thickness of 3 μm, and the film was dried by heating at 180″C for 10 seconds. Vinyl chloride on release agent treated surface
A marble pattern was printed using vinyl acetate gravure ink and dried by heating at 100°C for 10 seconds. An active energy ray-curable resin having the composition shown below was applied as a finishing varnish layer onto the pattern layer of this film to a dry film thickness of 20 μm, and was dried by heating at 120° C. for 30 seconds.

Composition Vinyl chloride-vinyl acetate copolymer resin (Kanevirac L)
-CQ, manufactured by Kanebuchi Chemical Co., Ltd., trade name) 20 parts oligoester acrylate (NK Ester A-14G, manufactured by Shin-Nakamura Chemical Co., Ltd., trade name) 10 parts oligoester acrylate (Aloex M-7100, Toagosei Chemical Co., Ltd.) Made by Kogyo ■, trade name) 5 parts methyl ethyl ketone 30 parts toluene
35 copies Thereafter, the polyester film was turned over as shown in FIG. 4, and the finishing varnish and pattern layer were removed from the back side to obtain a transfer sheet. On the other hand, a radiation-curable resin composition having the following composition was coated as an adhesive layer on a stain-free steel plate so as to have a dry film thickness of 30 μm, and was heated and dried at 120° C. for 30 seconds to obtain a decorative board base material.

Composition Vinyl chloride-vinyl acetate copolymer resin (Vinyrite VM
CH, Union Carbide product name) 8-part oligoester acrylate (Aloex M-7100)
7 parts methyl ethyl ketone
35 parts toluene
35 part titanium white
15 copies of the resulting transfer sheet were brought into contact with the pattern layer (printing layer) and the decorative board base material, and then 110"
After crimping at C, using an electrocurtain type electron beam irradiation device manufactured by Energy Science Co., Ltd., in a nitrogen stream,
After curing the finishing varnish layer and adhesive layer by irradiating electron beams from the polyester film side at 00 KV, 100 KGy, and a dose of 100 KGy, the polyester film was peeled off to produce a decorative board.

The test results in the production of the above decorative board were as follows.

(1) Peelability of polyester film: Good (visual judgment) (2) Transferability to decorative laminate base material: Good (visual judgment) (3
) Adhesion to decorative laminate base material: Good (no peeling in base grain test using cellophane adhesive tape) (4) Boiling water resistance: Good (no change after 1 hour immersion) (5
) Solvent resistance: Good (methyl ethyl ketone/toluene 1/
(6) Impact resistance: Good (No cracks in 27 bent fold test) (7) Pencil hardness: 2H (8) Finished surface condition: Good (visual test) Comparative Example A radiation-curable resin having the same composition as in Example 1 was applied as a finishing varnish layer to one side of a polyester film having a thickness of 25 μm so that the dry film thickness was 20 μm.
It was heated for a second and dried.

The polyester film provided with only the printing layer in Example 1 and the finishing varnish layer were pressed together at 90°C with a laminator so that they were in contact with each other, and then the polyester film provided with the printing layer was peeled off to form a transfer sheet. Obtained. Using this transfer sheet, the adhesive layer of the same decorative laminate base material as in Example 1 was brought into contact with the pattern layer (printing layer) of the obtained transfer sheet, and a decorative material was obtained in the same manner as in Example 1. .

Although the test results of this decorative material were almost the same as those obtained in Example 1, the finished surface condition was such that approximately 20 bubbles/cffl were observed in the finishing varnish layer, and it had no commercial value. Ta.

〔Effect of the invention〕

The transfer sheet according to the present invention can produce a beautiful decorative board with no air bubbles and excellent durability compared to conventional transfer sheets, and in some embodiments, only one base sheet is required, which reduces the cost. Improvements have been made.

[Brief explanation of drawings]

1 and 2 are cross-sectional views showing the process for manufacturing a transfer sheet according to the present invention, FIGS. 3 and 5 are cross-sectional views of the obtained transfer sheet, and FIG. 4 is a method for manufacturing the transfer sheet. FIG. 6 shows a process diagram for manufacturing a decorative material using a transfer sheet. The main symbols in the diagram are as follows. 1-Base sheet) (A), 3-.-Picture layer, 4 Finishing varnish layer, Base sheet (B)

Claims (1)

[Claims] 1. (1) A step of sequentially providing a pattern layer and a finishing layer on one side of a base sheet (A) that is releasable to the pattern layer and the finishing varnish layer; (2) a step of sequentially providing the base sheet (A) and A step of peeling off the pattern layer and the finishing layer, and (3) separating the base sheet (B) from the pattern layer and the finishing layer,
A method for manufacturing a transfer sheet, which comprises the steps of laminating a base sheet (B), a finishing varnish layer, and a pattern layer in this order. 2. The method according to claim 1, wherein the base sheet (A) is used as the base sheet (B), and a finishing varnish layer and a pattern layer are laminated in this order on the non-releasable surface of the base sheet (A). Method for manufacturing transfer sheets. 3. The method for producing a transfer sheet according to claim 1 or 2, wherein the finishing varnish layer is curable with active energy rays. 4. The method for producing a transfer sheet according to any one of claims 1 to 3, wherein the base sheet (B) is transparent to active energy rays.