JPH04282248A - Polyester decorative sheet - Google Patents

Abstract

PURPOSE:To obtain a unique-designed polyester decorative sheet by providing a concealing sheet and a polyester resin layer consisting of more than two layers, one layer or more other than the top layer having a surface on which an uneven polyester resin layer is provided. CONSTITUTION:First a pictorial pattern 5 is printed on a mold lubrication-type support 7 using gravure technique. Then a printed pictorial pattern layer is embossed to obtain an uneven-surfaced formed sheet for transfer. This formed sheet is laminated on a concealing sheet 2 impregnated with unsaturated polyester resin 4 which is adhered to a base for a decorative sheet in such a manner that the uneven surface 6 comes in contact with a resin layer 4. Next, after thermally pressing this laminated product, the mold lubrication-type support 7 is peeled off and a pictorial pattern layer 5 with an uneven surface 6 is transferred to the concealing sheet 2. In addition, polyester resin 8 is applied to the surface of this transfer layer and these constituents are molded in one piece to obtain a polyester decorative sheet. The concealing sheet 2 laminated on the base 1 consists of paper containing opaque pigment such as titanium oxide has a pictorial pattern printed using gravure technique.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a polyester decorative board that has a three-dimensional effect and is highly designed, and a method for producing the same.

0002

[Prior art] Polyester decorative boards with design properties are
For example, it can be obtained by transferring a pattern during molding, or it can also be provided with irregularities using a molding film. However, since the polyester resin layer of these conventional methods is composed of only one layer, only a three-dimensional effect can be obtained.

0003

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a polyester decorative board with a more three-dimensional effect and a high design quality.

0004

[Means for Solving the Problems] The present invention solves this problem, and provides a decorative board comprising a base material for a decorative board, a concealing paper thereon, and a polyester resin layer thereon, in which the polyester resin layer has two layers. This is a polyester decorative board consisting of more than one layer, characterized in that at least one layer other than the top layer has irregularities formed on the surface. The present invention further provides a decorative board comprising a base material for a decorative board, a concealing paper thereon, and a polyester resin layer thereon, wherein the polyester resin layer is composed of two or more layers, and the surface of at least one layer other than the top layer is This is a polyester decorative board characterized by a printed pattern and unevenness formed on the surface. In the present invention, it is a particularly preferred embodiment that at least one of the polyester resin layers is colored. The present invention further provides that after printing a pattern on a releasable support, the printed pattern layer is embossed to form unevenness, and the thus obtained transfer sheet is adhered to a base material for a decorative board. The resin layer is laminated on a masking paper impregnated with an unsaturated polyester resin so that the uneven surface and the resin layer are in contact with each other, and the laminate is heated and pressurized, and then the releasable support is peeled off. This method of producing a polyester decorative board is characterized in that a pattern layer having irregularities is transferred onto the concealing paper, and then an unsaturated polyester resin is applied onto the transfer layer and integrally molded.

FIGS. 1 and 2 are cross-sectional views showing examples of the structure of the decorative board of the present invention and its manufacturing process. The decorative laminate substrate (1) provides the necessary thickness and strength to the decorative laminate. As the base material, for example, plywood or particle board is appropriately selected and used. The concealing paper (2) to be laminated on the base material is a paper called "titanium paper" which is mixed with an opaque pigment such as titanium oxide, and a pattern is printed by a known method such as gravure printing, offset printing or silk screen printing. A printed version can be used. Lamination of the base material and the concealing paper is carried out using an adhesive (3).

The first unsaturated polyester resin layer (4) is generally formed by applying two unsaturated polyester resin liquids on top of the concealing paper.
It is formed by coating and impregnating in an amount of 50 to 350 g/m2, curing, and molding. A polymerization initiator and, if necessary, a polymerization accelerator, as well as other common additives can be added to the resin liquid. The polymerization initiator is appropriately selected from peroxides such as methyl ethyl ketone peroxide, benzoyl peroxide, and hydroperoxide, and radical initiators such as azobisisobutyronitrile. The amount of polymerization initiator added is generally 0.5 to 3% by weight. Examples of the polymerization accelerator include cobalt compounds such as cobalt naphthenate, metal compounds such as vanadium compounds and manganese compounds, and amine compounds such as dimethylnitrile, preferably in an amount of 0.1 to 2.0% by weight based on the resin. used at a rate of Furthermore, in order to crosslink the resin and adjust the viscosity, a compound having a vinyl group such as a styrene monomer may be added in an amount accounting for 10 to 40% by weight of the resin.

In the polyester decorative board of the present invention, the polyester resin layer consists of two or more layers, at least one layer (4) of which has irregularities (6) and, if necessary, a printed pattern (5). This printed pattern and unevenness can be particularly preferably formed by a transfer method. For this purpose, for example, a releasable support (7) is prepared by adhering a polyethylene film onto a polyethylene terephthalate film using a releasable adhesive, and a pattern, preferably wood grain, etc., is printed on this resin layer using a known printing method. Preferably, after printing by a gravure method, irregularities are formed on the printed surface by embossing. As the printing ink, nitrocellulose ink is preferred.

[0008] Embossing refers to forming the unevenness of an embossing plate on the target material under heat and pressure, and can be carried out using various known embossing machines such as a press machine and a roll embossing machine. . As the shape of the embossed diaphragm, various known shapes with unevenness and gloss can be used. Examples include those that reproduce the uneven shapes of natural objects such as wood grain, stone grain, cloth grain, and sand grain, character symbols, parallel lines, various abstract patterns, various matte surfaces, and mirror gloss. Particularly preferred is an aggregate of uneven shapes that includes unevenness or grooves forming a group of parallel straight lines or a group of curved lines in a closed curve area,
This is a precision parallel line plate in which the angles formed by the directions of groups of straight lines or groups of curves that are adjacent to each other across the boundary between two arbitrary areas are all different shapes. In this shape, each closed area looks like a pattern with a different gloss,
It has a design in which the gloss of each closed area changes depending on the parallax. In particular, in order to recognize a group of parallel straight lines or curved lines as a pattern of changes in gloss, the depth and interval of the lines should be 0.1 to 1.
00 μm, it is desirable that the angle formed by the directions of adjacent groups of straight lines or groups of curves is 5° or more. In order to change all the angles formed by the directions of a group of straight lines or a group of curved lines adjacent through the boundary of two arbitrary regions, four types of angles are necessary and sufficient conditions according to the theorem of the four-color problem in topology.

The thus prepared transfer imprinting film is placed on the unsaturated polyester resin layer (4) impregnated with the concealing paper (2) as described above, heated and pressurized by a conventional method, and then released from the mold. By peeling off the sexual support (7),
The printed pattern and unevenness are transferred to the first resin layer (4). Next, a second unsaturated polyester resin layer (8) is formed by applying an unsaturated polyester resin onto the transferred printed pattern and the uneven layer and integrally molding the resin. The first and second resin layers (4) and/or (8) may be colored. In this case, the pattern layer can be omitted since the internal unevenness can be seen. When curing an unsaturated polyester resin, the resin is generally covered with an air (oxygen) blocking film (9). As shown in FIG. 2, when a forming film (10) having embossments is used as the film, corresponding irregularities can be formed on the surface. In addition,
Release support (7), air (oxygen) blocking film (9)
) and molded film (10) with good oxygen gas shielding properties such as polyethylene terephthalate, ethylene-vinyl alcohol copolymer, polypropylene, vinylon, etc.
A synthetic resin film or the like having good mold releasability from the cured unsaturated polyester resin can be used.

In addition, a pattern may be transferred onto the resin layer (8); in this case, transparent ink is used to print the pattern so that the underlying layer can be seen through. Furthermore, an unsaturated polyester resin layer can be formed on this pattern layer in the same manner as described above. The surface of the outermost resin layer may be smooth, but it can also be shaped with concavities and convexities as described above.

[0011] The polyester decorative board of the present invention reproduces a design with a rich three-dimensional effect by disposing a resin layer having a printed pattern and unevenness inside. In particular, it reproduces well the unevenness and shine of the grain of natural wood.

0012

[Examples] The present invention will be further explained below with reference to Examples.

[0013]

Example 1 A polyethylene terephthalate film (manufactured by Toyobo Co., Ltd., E-5101) having a thickness of 16 μm was extrusion coated with polyethylene to a thickness of 20 μm to obtain an original fabric (A) for a molded film. After solid printing (7 g/m2) on this original fabric (A) with nitrocellulose-based transparent ink, a wood grain pattern was printed with nitrocellulose-based pattern ink, and solid printing was further performed with nitrocellulose-based pearl ink.

The obtained film was embossed from the printed surface using an embossing roll having a fine uneven pattern consisting of a pattern of parallel curves each having a width of 30 μm in concave portions and convex portions to obtain a transfer imprinting sheet. On the other hand, titanium paper printing paper was pasted onto the base material (4mm plywood), and 1% of the hardening agent Kayamake was added to unsaturated polyester resin (Showa Kobunshi Co., Ltd., Rigorac) and stirred well. The resin was applied in an amount of 500 g, and the printed surface of the above-mentioned mold-forming transfer sheet was coated so as to be in contact with the resin. After being left at room temperature for 1 hour, the mold-forming film was peeled off, and the printed pattern and irregularities were transferred. Next, it was molded using a molded film with embossed conduits by a general polyester molding method.

The structure of the polyester decorative board thus obtained is as shown in FIG. 2, and has a wood grain pattern with a rich three-dimensional effect.

[0016]

[Example 2] A polyester decorative board with a smooth outermost surface as shown in Fig. 1 was produced by operating in the same manner as in Example 1 and using a smooth vinylon film instead of the conduit-embossed molding film in the final molding. did.

[0017]

Effects of the Invention The decorative board of the present invention has a design with a rich three-dimensional effect, especially the grain of natural wood, because at least one resin layer having unevenness and a printed pattern is arranged inside. Reproduces unevenness and shine well.

[Brief explanation of the drawing]

FIG. 1 is a sectional view showing an example of the structure of a decorative board of the present invention and its manufacturing process.

FIG. 2 is a sectional view showing another structure of the decorative board of the present invention and an example of its manufacturing process. 1──Base material for decorative board 2──Concealing paper 3──Adhesive 4─
─First unsaturated polyester resin layer 5─Printed pattern 6─Irregularities 7─Release support 8─First
unsaturated polyester resin layer

Claims (4)

[Claims] Claim 1: A decorative board comprising a base material for a decorative board, a concealing paper thereon, and a polyester resin layer thereon,
A polyester decorative board, characterized in that the polyester resin layer consists of two or more layers, and at least one layer other than the top layer has irregularities formed on the surface. [Claim 2] A decorative board comprising a base material for a decorative board, a concealing paper thereon, and a polyester resin layer thereon,
A polyester decorative board characterized in that the polyester resin layer is composed of two or more layers, and a printed pattern and irregularities are formed on the surface of at least one layer. 3. At least one of the polyester resin layers
The polyester decorative board according to claim 1 or 2, characterized in that the layer is colored. 4. After printing a pattern on a moldable support, the printed pattern layer is embossed to form unevenness, and the thus obtained transfer sheet is adhered to a base material for a decorative board. The uneven surface is layered on a masking paper impregnated with an unsaturated polyester resin so that the uneven surface and the resin layer are in contact with each other, the laminate is heated and pressurized, and the releasable support is peeled off. 1. A method for producing a polyester decorative board, which comprises transferring a pattern layer having the following properties onto the concealing paper, and then applying an unsaturated polyester resin onto the transfer layer and integrally molding the pattern layer.