JPH04164642A - Preparation of sheet for emboss-processing - Google Patents

Abstract

PURPOSE:To inexpensively obtain a good sheet for emboss-processing by a method wherein the first thermosetting resin impregnated molded body is obtained by the hot press molding with the grain surface of the first matrix composed of natural wood and the second thermosetting resin impregnated molded body is obtained by the hot press molding with said molded body and the uneven surface of this molded body is subjected to sanding treatment to obtain the second matrix which is, in turn, subjected to hot press molding along with a thermoplastic resin sheet. CONSTITUTION:A thermosetting resin impregnated molded body is obtained by hot press molding using the first matrix composed of natural wood. A separate thermosetting resin impregnated molded body is obtained by hot press molding utilizing the obtained thermosetting resin impregnated molded body. By subjecting this molded body to sanding treatment for removing the unexpected unevenness like undulation generated when the first matrix composed of natural wood is subjected to hot press treatment, the second matrix is molded. Further, a sheet for emboss-processing is obtained by hot press molding utilizing the second matrix. Since a material is inexpensive and a process is simple, workability is good and the sheet can be inexpensively prepared.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a method for manufacturing an embossing sheet used for manufacturing polyester decorative materials having a wood grain pattern.

[Prior Art] In the field of decorative materials that are used as surface finishing materials for furniture, building materials, etc., decorative materials with embossed surfaces are often used.

A decorative material having an embossed surface is obtained by transferring the uneven surface of an embossed sheet onto the surface of the decorative material, and methods for manufacturing an embossed sheet used to form such an embossed surface include, for example, .

(1) A method of manufacturing an embossing roll having a concave portion on its circumferential surface and using the hot embossing method to create a shaped sheet (sheet for embossing) (Utility Model Publication No. 51-447
(2) A practical mold is manufactured by applying room temperature curing silicone resin to the grain surface of natural wood, curing, and removing the mold, and this practical mold is used to make an embossing sheet. Method of obtaining (Japanese Patent Publication No. 51-1739, Japanese Patent Publication No. 50-6484, Japanese Patent Publication No. 49-34750), (3) Surface where low temperature heat curing silicone resin is applied to the grain surface of natural wood. A method of obtaining a shaped sheet (embossed sheet) by stacking a base sheet on top of the base sheet, curing it with low-temperature heating, removing the mold to form a first mold, and inverting it twice. Publication No. 57-69045,
JP-A-57-173160, JP-A-57-174
(No. 251 Publication), (4) Layer thermosetting resin-impregnated paper on the grain surface of natural wood, heat and press it to obtain a matrix plate, and then use the matrix plate to shape the paper. Method for obtaining a sheet (sheet for embossing) (Japanese Patent Publication No. 50-5348).

etc.

[Problems to be Solved by the Invention] In the above-mentioned conventional method for manufacturing embossing sheets, the method using the embossing roll described in item (1) requires time and effort to manufacture the embossing roll, and the embossing roll itself is expensive. Therefore, it is unsuitable for high-mix, small-lot products, and it is difficult to reproduce the uneven shape of natural wood grain.
In the case of item (2), which uses a room-temperature-curing silicone resin, the room-temperature-curing silicone resin is expensive, and the practical type does not have good resistance to polyester resin, making it even more expensive. Items that use low-temperature heat-curing silicone resin, as described in item (3), have a high risk of damaging the original due to the large number of times it is used.
It takes several hours to a day to cure the silicone resin to manufacture the first mold, which not only delays the work, but also
The method described in item (4) that requires a large oven for heating and obtains a motherboard by stacking, heating, and pressing the thermosetting resin-impregnated paper is 1. In the heating and pressing process, natural wood is This method has disadvantages such as poor reproducibility of the original because the original plate is compressed and unnecessary unevenness appears on the master plate.

On the other hand, the method for manufacturing an embossing sheet of the present invention uses a molded article impregnated with a thermosetting resin as the second matrix, and the manuscript made of natural wood is used only once. The second matrix, which serves as the matrix for the resulting embossing sheet, is highly durable and has good reproducibility of originals.The embossing sheet is suitable for a wide variety of small-lot products. To provide a method for obtaining the same by an inexpensive manufacturing process that can correspond to the following.

[Means for Solving the Problems] The method for producing an embossing sheet according to the invention of Section 1 is characterized in that a film-like material having mold releasability is used to separate the grain surface of a first matrix made of natural wood from a thermosetting resin-impregnated material. a first step of obtaining a first thermosetting resin-impregnated molded product in which the unevenness of the grain surface of natural wood is molded by subjecting the stacked body superimposed on each other through thermoforming; The uneven surface of the first thermosetting resin-impregnated molded product obtained by the process and the thermosetting resin-impregnated material are superimposed via a plastic film having mold releasability, and the superimposed body is subjected to hot pressure molding. a second step of obtaining a second thermosetting resin-impregnated molded body in which the irregularities of the first thermosetting resin-impregnated molded body are molded; and a second thermosetting mold obtained in the second step. By sanding the uneven surface of the resin-impregnated molded product, unintended irregularities such as undulations that occur when the first mother mold made of natural wood is heat-pressed are removed, and the thermosetting resin-impregnated molded product is A third step of obtaining a second matrix consisting of a thermoplastic resin sheet, and a thermo-press molding of the superposed body in which the uneven surface of the second matrix obtained in the third step and the thermoplastic resin sheet are superimposed. By peeling the thermoplastic resin sheet from the molded body, an embossing sheet made of a thermoplastic resin sheet on which the irregularities of the second matrix are molded, that is, an embossing sheet that is the object of the method of the present invention can be obtained. It consists of 4 steps.

The method for manufacturing an embossed sheet according to the invention of Section 2 is such that, in the method for manufacturing an embossed sheet according to the invention of Section 1, the hot press molding in the fourth step is performed on the unevenness of the second matrix obtained in the third step. This process is performed on a stacked body in which a surface and a thermoplastic resin sheet are stacked with a gloss adjustment film interposed therebetween.

The method for producing an embossing sheet according to the invention of Section 3 is a stacked product in which the grain surface of a first matrix made of natural wood and a thermosetting resin-impregnated material are superimposed via a film-like material having mold releasability. a first step of obtaining a first thermosetting resin-impregnated molded article in which the unevenness of the grain surface of natural wood is molded by subjecting it to hot pressure molding; The uneven surface of the curable resin-impregnated molded product and the thermosetting resin-impregnated material are superposed one on top of the other with a plastic film having mold releasability interposed therebetween, and this is subjected to hot pressure molding to form the first heat. A second step of obtaining a second thermosetting resin-impregnated molded article in which the irregularities of the curable resin-impregnated molded article are molded, and the irregularities of the second thermosetting resin-impregnated molded article obtained in the second step. A third step of sanding the surface to remove unintended irregularities such as undulations that occur when the first mother mold made of natural wood is subjected to heat-pressure treatment; and a second step obtained by the third step. The uneven surface of the thermosetting resin-impregnated molded product and the thermosetting resin-impregnated material are superimposed on each other with a plastic film having mold releasability interposed therebetween, and the superimposed body is subjected to thermo-pressing molding to form a second thermosetting resin. A fourth step of obtaining a third thermosetting resin-impregnated molded object in which the irregularities of the resin-impregnated molded object are molded, and an uneven surface of the third thermosetting resin-impregnated molded object obtained by the fourth step. and a thermosetting resin-impregnated material are superimposed on each other with a plastic film having mold releasability interposed therebetween, and then subjected to hot pressure molding, whereby the irregularities of the third thermosetting resin-impregnated molded product are molded. a fifth step of obtaining a second mother mold, which is the fourth thermosetting resin-impregnated molded product, and an uneven surface of the second mother mold, which is the fourth hardened resin-impregnated molded product, obtained in the fifth step; and a thermoplastic resin sheet 5
After subjecting the combined stacked body to hot-press molding, the thermoplastic resin sheet is peeled from the obtained hot-press molded body to form a thermoplastic resin sheet on which the irregularities of the second matrix are molded. and a sixth step to obtain an embossing sheet, that is, an embossing sheet that is the object of the method of the present invention.

The method for manufacturing an embossed sheet according to the invention of Section 4 is such that, in the method for manufacturing an embossed sheet according to the invention of Section 3, the hot press molding in the sixth step is performed on the unevenness of the second matrix obtained in the fifth step. This process is performed on a stacked body in which a surface and a thermoplastic resin sheet are stacked with a gloss adjustment film interposed therebetween.

In the method for manufacturing an embossing sheet of the actual invention comprising the above steps, the thermosetting resin impregnated material includes titanium paper,
Impregnation or coating of a thermosetting resin such as diallyl phthalate resin, phenol resin, melamine resin, epoxy resin, penzoguanamine resin, etc. on a carrier such as α-cellulose paper, nonwoven fabric, kraft paper, or cloth. What is obtained is used.

In the first step, a plastic film or metal foil with a thickness of 38μ or less is used as a film-like material having mold releasability to be interposed between the grain surface of the first matrix and the thermosetting resin impregnated material, As the plastic film, for example, films made of polypropylene, polyethylene, polyethylene terephcrate, ethylene-vinyl alcohol copolymer, etc. are suitable.

The thermosetting conditions for the thermosetting resin-impregnated material are 120~
160° C., 10 to 50 kg/cm 2 , and 10 to 60 minutes, which is appropriately selected depending on the type of thermosetting resin used.

When hot-press molding a stacked body of a thermosetting resin-impregnated molded product and a thermosetting resin-impregnated product, mold release is applied between the thermosetting resin-impregnated molded product and the thermosetting resin-impregnated product. The plastic film having releasability may be similar to the film described as the film-like material having releasability in the first step.

The sanding treatment performed on the uneven surface of the thermosetting resin-impregnated molding is to remove unintended unevenness such as undulations that occur when the first mother mold made of natural wood is subjected to heat-pressure treatment. be.

Unintended irregularities such as undulations that occur when the first matrix made of natural wood is subjected to heat and pressure treatment are due to differences in density in the natural wood used for the first matrix.

Incidentally, during the sanding process, if the sanding process is carried out in the grain direction (longitudinal direction) using coarse abrasive paper of 240 grit or higher, a hairline-like wood texture can be created.

For example, in the case of an embossing sheet used for manufacturing polyester decorative materials, etc., a thermoplastic sheet that is molded into an embossing sheet is preferably one that has releasability from the unsaturated polyester resin. Of course, for example, a vinylon sheet, a polyester sheet, a fluororesin sheet, a cellulose resin sheet or a composite sheet may be used.

In addition, in order to facilitate embossing using an embossing sheet, each of the above-mentioned sheets was coated with a polyvinyl chloride film,
A laminated sheet made by laminating olefin resin films such as polyethylene films and polypropylene films is suitable.

The gloss adjustment film used in the invention of Section 2 and the fourth invention is used to finish the uneven surface of the obtained embossing sheet to a desired gloss, and is used when the film is formed into the embossing sheet. film whose side in contact with the thermoplastic resin sheet has been subjected to a matte or glazing treatment;
For example, gloss processed films such as polypropylene film, polyethylene terephthalate film, and aluminum foil are used.

The final step, thermo-press molding of the stacked body of the second matrix and the thermoplastic resin sheet, involves superimposing the uneven surface of the 28th mold so that it is in contact with the release surface of the thermoplastic resin sheet. This method involves hot-press molding, and involves copying the shape of the uneven surface of the second mold onto the releasable surface of the thermoplastic resin sheet.

The hot-press molding conditions for the superposed body of the second matrix and the thermoplastic resin sheet vary depending on the heat capacity of the second matrix, the type of resin of the thermoplastic resin sheet used, etc.
20~150°C110~20kg/m", 10
It will last about 60 minutes.

The method of applying heat during hot-press molding may be either hot/hot or hot/cold, but hot/cold is preferable because it minimizes the return of the embossing. .

[Function] The method for producing an embossed sheet of the present invention includes the steps of obtaining a thermosetting resin-impregnated molded product by thermoforming using a first mother mold made of natural wood, and adding the obtained thermosetting resin to the molded product. A process of obtaining another thermosetting resin-impregnated molded body by heat-pressing molding using the impregnated molded body, and a first mother mold made of natural wood was subjected to heat-pressure treatment for the thermosetting resin-impregnated molded body. A second mother mold is formed by a sanding process to remove unintended irregularities such as undulations that occur during the process, and then an embossing sheet is formed by hot pressure molding using the second mother mold. It's something you get.

In the method for producing an embossing sheet of the present invention according to the above steps, the molded body made of a thermosetting resin impregnated material is
The second mother mold, which is used as a mother mold and is made of natural wood and is used only once, is the mother mold for the embossing sheet, and is made of a molded body impregnated with thermosetting resin. Therefore, the durability of the matrix is good.

In addition, we perform a sanding process to remove unintended irregularities such as undulations that occur when the first matrix of natural wood is subjected to heat and pressure treatment, so the original can be reproduced on the resulting embossing sheet. The properties are extremely good.

In addition, although the method for manufacturing an embossing sheet of the present invention requires a large number of manufacturing steps, the materials used are inexpensive and the steps are simple, so it has good workability and can be manufactured at low cost. .

[Example] Hereinafter, the specific structure of the method for manufacturing an embossing sheet of the present invention will be described based on Examples.

Example 1 A polypropylene film with a thickness of 25 μm was placed on the surface of a veneer, and on top of that, four sheets of thermosetting resin-impregnated titanium paper impregnated with diallyl phthalate resin were layered. Set in hot press, 130℃,
The first thermosetting resin-impregnated molded product was subjected to heating and pressure molding under heat and pressure conditions of 1 Okg/n2° for 7 minutes to obtain a first thermosetting resin-impregnated molded product having a molded shape having concavities and convexities opposite to those on the surface of the veneer.

Four sheets of thermosetting resin-impregnated 10 mil kraft paper impregnated with diallyl phthalate resin were placed on the uneven surface of the obtained first thermosetting resin-impregnated molded product through a polypropylene film with a thickness of 25 μm. This was set in a hot press, 130℃, 20kg 7m'', I
After being heated and pressurized for 0 minutes under heat and pressure conditions, and further cooled to 30°C with the pressure still applied, it was taken out from the press and molded in a shape opposite to the unevenness of the first thermosetting resin-impregnated molded body. A second thermosetting resin-impregnated molded article having irregularities formed thereon was obtained.

Subsequently, the uneven surface of the second thermosetting resin-impregnated molded body was sanded with Sakai 400 sandpaper to make it flat except for the portion corresponding to the conduit concave portion of the wood grain board.
I got the e type.

A matte film made of polypropylene resin [NP-8 manufactured by Higashi Shichikuchi Co., Ltd.] is superimposed on the uneven surface of the second matrix, with the matte surface of the film facing upward, and a film with a thickness of 25 μm is placed on the upper surface. A laminated sheet of a vinylon film and a polyvinyl chloride film with a thickness of 200 μm was laminated with the vinylon film side of the laminated sheet facing upward, and this was heated at 130°C and 20kg/m2. 1
After being subjected to hot-pressure molding for 0 minutes and further cooled to 30'C while applying pressure, the laminated sheet of vinylon film and polyvinyl chloride film was peeled from the obtained molded product. An embossing sheet made of a thermoplastic resin sheet on which two matrix irregularities were molded was obtained.

When producing a polyester resin decorative board by wet unsaturated polyester resin molding, the obtained embossing sheet is placed on the surface coated with unsaturated polyester resin and left to naturally stand at room temperature to harden the resin. When the surface embossing sheet was later peeled off, the surface irregularities of the original veneer were faithfully reproduced on the surface of the cured polyester resin layer.

[Effects of the Invention] The embossing sheet obtained by the method of the present invention has no irregularities on the surface of the original, whether it is a soft original without hardness or an original with uneven hardness. The unevenness of the inverted state is faithfully realized, and the unevenness of the surface of the document is faithfully expressed on the surface of the molded object obtained using the embossing sheet, and the embossing molding is of good quality. The body is formed.

Claims (1)

[Claims] 1. A superimposed body in which the grain surface of a first matrix made of natural wood and a thermosetting resin impregnated material are superimposed via a film-like material having mold releasability, is subjected to thermo-press molding. a first step of obtaining a first thermosetting resin-impregnated molded article in which the unevenness of the grain surface of natural wood is molded; and a first thermosetting resin-impregnated molding obtained by the first step. The first thermosetting resin impregnation molding is performed by subjecting the stacked body, in which the uneven surface of the body and the thermosetting resin impregnated material are superimposed via a plastic film having mold releasability, to hot pressure molding. a second step of obtaining a second thermosetting resin-impregnated molded body on which the irregularities of the body are molded; and sanding the uneven surface of the second thermosetting resin-impregnated molded product obtained in the second step. a third step of obtaining a second matrix, and after subjecting the stacked body obtained by superimposing the uneven surface of the second matrix obtained in the third step and the thermoplastic resin sheet to thermocompression molding; and a fourth step of obtaining an embossing sheet made of a thermoplastic resin sheet on which the irregularities of the second matrix are molded by peeling the thermoplastic resin sheet from the obtained hot-press molded body. Features: A manufacturing method for embossing sheets. 2. In the method for manufacturing an embossing sheet according to claim 1, the thermoforming in the fourth step is performed by combining the uneven surface of the second matrix obtained in the third step with the thermoplastic resin sheet. A method for manufacturing a sheet for embossing, which comprises performing embossing on a stacked body stacked together with a gloss adjustment film interposed therebetween. 3. A superimposed body in which the grain surface of the first mother mold made of natural wood and a thermosetting resin impregnated material are superimposed via a film-like material having mold releasability is subjected to thermo-pressing molding, whereby natural wood is formed. a first step of obtaining a first thermosetting resin-impregnated molded article having irregularities on the wood grain surface; an uneven surface of the first thermosetting resin-impregnated molded article obtained in the first step; By subjecting the stacked body in which the thermosetting resin-impregnated material and the thermosetting resin-impregnated material are superimposed via a plastic film having mold releasability to hot pressure molding, the irregularities of the first thermosetting resin-impregnated molded product are molded. a second step of obtaining a second thermosetting resin-impregnated molded article obtained in the second step; a third step of sanding the uneven surface of the second thermosetting resin-impregnated molded article obtained in the second step; The concavo-convex surface of the second thermosetting resin-impregnated molded product obtained in Step 3 and the thermosetting resin-impregnated material are superimposed via a plastic film having mold releasability, and the superimposed body is subjected to hot pressure molding. a fourth step of obtaining a third thermosetting resin-impregnated molded body in which the irregularities of the second thermosetting resin-impregnated molded body are molded by attaching the third heat obtained in the fourth step; The uneven surface of the curable resin-impregnated molded product and the thermosetting resin-impregnated material are superimposed on each other with a plastic film having mold releasability interposed therebetween, and the superimposed body is subjected to thermo-pressure molding to form a third thermosetting resin. a fifth step of obtaining a second matrix in which the irregularities of the resin-impregnated molded body are molded; and superposition of the thermoplastic resin sheet and the irregular surface of the second matrix obtained in the fifth step. A sheet for embossing using a thermoplastic resin sheet in which the irregularities of a second matrix are molded by subjecting the body to hot-pressing molding and then peeling the thermoplastic resin sheet from the obtained hot-pressing molded body. A method for producing an embossing sheet, comprising a sixth step of obtaining the following: 4. In the method for manufacturing an embossing sheet according to claim 3, the thermoforming in the sixth step is performed by:
A method for manufacturing a sheet for embossing, which comprises performing embossing on a stacked body in which the uneven surface of the second matrix obtained in the fifth step and a thermoplastic resin sheet are stacked with a gloss adjustment film interposed therebetween.