JPH04303655A - Manufacture of decorative thermoset resin board - Google Patents

Abstract

PURPOSE:To ensure that a decorative board of thermoset resin with a color pictorial pattern skin on the surface, and especially with a three-dimensional, highly decorative appearance, can be manufactured at low cost. CONSTITUTION:A patterned sheet 4 for the manufacture of a thermoset resin decorative board with at least, two differently glossy areas consists of a color pictorial pattern layer 2 of color ink provided so as to cover a base sheet 1 and its part. The glossiness of a base sheet surface 3a not covered with the color pictorial pattern layer 2 is different from that of a base sheet surface 3b covered with the color pictorial pattern layer 2. The color pictorial pattern layer 2 transits from the base sheet 1 to the surface of a decorative board at the time of forming the board.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a decorative thermosetting resin laminate and a forming sheet used in the method. More specifically, the present invention relates to a method for manufacturing a thermosetting resin decorative board in which the colored pattern and surface glossiness are harmonious or synchronized, and a forming sheet used in the manufacturing method.

0002

[Prior Art] Thermosetting resin decorative boards such as melamine resin decorative boards and diallyl phthalate resin decorative boards are used for architectural interior materials such as walls and ceilings, furniture such as storage furniture and cabinets, kitchen tables, etc. However, in order to enhance the design effect of such a thermosetting resin decorative board, attempts have been made to synchronize the colored pattern on the surface of the thermosetting resin decorative board with the surface glossiness.

[0003] Thermosetting resin decorative boards having colored patterns that match the glossiness are manufactured as embossed decorative boards by various methods. For example, as a manufacturing method for embossed decorative laminates, there is a direct embossing method, in which the thermosetting resin of the thermosetting resin decorative laminate is cured by heating and pressure, and the surface is roughened by etching, sandblasting, etc. By using a formed metal uneven plate, a resin uneven plate, a metal uneven plate obtained by electroforming, or a resin uneven plate copied from these metal plates as a template,
2. Description of the Related Art A method of manufacturing a decorative board having a colored pattern with a different degree of gloss on its surface is known. In addition, as a chemical embossing method, a colored pattern is printed on pattern paper using ink containing components that inhibit the curing of thermosetting resin, the entire pattern paper is impregnated with thermosetting resin, and then a A known method is to place a molded plate, etc., heat and pressurize it, and then peel off the molded plate to remove the uncured or weakened thermosetting resin from the colored pattern area to form surface embossing. ing.

0004

[Problems to be Solved by the Invention] However, in the conventional direct embossing method as described above, during production, plate-shaped templates called metal textured plates or resin textured plates are used in numbers according to the type of pattern. Because of the need for preparation, the equipment configuration for continuously manufacturing the decorative laminate becomes complicated, and as a result, the metal textured board is more frequently damaged during hot-pressure molding of the thermosetting resin decorative laminate. was there.

[0005] Furthermore, since the metal textured plate itself is very expensive, it significantly increases the manufacturing cost of the thermosetting resin decorative plate. Moreover, it is necessary to prepare a spare metal uneven board in case the metal uneven board is damaged, which further increases the manufacturing cost of the thermosetting resin decorative board. Furthermore, the preparation time needed to replace templates depending on the coloring pattern is not negligible, and it is not possible to support multi-product production.

In addition, resin textured plates generally do not have good releasability to the resin of the thermosetting resin-impregnated sheet.
It was necessary to interpose a release sheet or metal foil with good releasability between the resin textured plate and the resin-impregnated sheet. For this reason, the number of decorative board manufacturing steps has increased, and the manufacturing equipment configuration has also become more complex. Moreover, since the release sheet is present, large irregularities can be expressed, but differences in surface gloss due to small irregularities cannot be expressed.

[0007] Furthermore, in the chemical embossing method described above, it is difficult to control the shape of glossy areas and non-glossy areas, and brittle areas are produced, so properties such as stain resistance are required. This was an unsatisfactory method for manufacturing decorative boards.

The present invention aims to solve the problems of the prior art as described above, and provides a low-cost thermosetting resin decorative board with an excellent design and a synchronized color pattern and surface gloss. The aim is to make it possible to manufacture it at a low cost.

[0009]

[Means for Solving the Problems] The above objects have been achieved by the present invention as described below. That is, in the present invention, the surface of the base sheet has releasability to the base sheet,
In addition, a colored pattern layer made of colored ink that has adhesiveness to the thermosetting resin to be molded is provided, and the glossiness of the surface of the base sheet on which the colored pattern pattern layer is not provided and that of the colored pattern pattern layer are provided. To provide a molded sheet for producing a thermosetting resin decorative board, characterized in that the glossiness of the surface on the base sheet side is different.

[0010] In addition, as a method for manufacturing such a shaped sheet, a colored ink that has releasability to the base sheet and adhesiveness to the thermosetting resin to be shaped is applied to the surface of the base sheet. To provide a method for manufacturing a shaped sheet, characterized by providing a colored pattern layer consisting of the above, and applying matte processing thereon.

[0011] Furthermore, the present invention provides a method for producing a thermosetting resin decorative board in which the colored pattern and the glossiness of the surface thereof are synchronized using such a shaped sheet.
A step of placing the above-mentioned shaping sheet and thermosetting resin-impregnated sheet so as to sandwich the colored pattern layer of the shaping sheet; (b) integrating the shaping sheet and the thermosetting resin-impregnated sheet; curing the thermosetting resin by applying heat and pressure, and adhesion-transferring the colored pattern layer of the molded sheet to the thermosetting resin-impregnated sheet; and (c) processing the base sheet of the molded sheet. (b) A method for producing a thermosetting resin decorative board is provided, which comprises the step of peeling off the cured product.

That is, in the method of manufacturing a thermosetting resin decorative board of the present invention, when a thermosetting resin-impregnated sheet is cured by heating and pressurizing, the thermosetting resin decorative board is formed using the matte surface of the base sheet as a template. At the same time as forming a matte area on the surface of the board, the colored pattern layer made of colored ink on the base sheet is adhesively transferred, and the non-matte glossy surface of the colored pattern layer on the base sheet side is thermoset. It is made to appear on the surface of the resin decorative board, thereby forming a colored pattern on the thermosetting resin decorative board that matches the gloss level.

[0013] The present invention will be explained in detail below based on the drawings. In addition, in each drawing, the same number indicates the same or equivalent component.

FIG. 2 shows a sectional view of the shaped sheet 4 of the present invention. This shaped sheet 4 is composed of a base sheet 1 and a colored pattern layer 2 made of colored ink partially provided on the surface of the base sheet 1. The glossiness of the surface 3a of the base sheet 1 where the colored pattern layer 2 is not provided is different from the glossiness of the surface 3b of the colored pattern layer 2 on the base sheet side. It is copied onto the surface of the curable resin decorative board. That is, when the thermosetting resin decorative board is molded under heat and pressure, this molding sheet 4 is also molded as one piece, and then by peeling off the molding sheet 4, the parts where the colored pattern pattern layer 2 is not provided are formed. The matte surface of the base sheet surface 3a is directly transferred to the surface of the decorative board. In addition, the colored pattern layer 2 is peeled off from the base sheet 1 of the imprinted sheet 4 and closely transferred to the surface of the thermosetting resin decorative board, and as a result, the side of the colored pattern layer 2 that was in contact with the base sheet 1 The glossy surface 3b of is exposed on the surface of the decorative board.

Such a base sheet 1 is generally a thermoplastic resin sheet (
film) can be used. As such a thermoplastic resin sheet, polyester film, acrylic film, polypropylene film, etc. can be used. Among them, polyester film can be preferably used. The thickness of the base sheet is 25 to 125 mm, considering its mechanical strength etc.
μm ones can be preferably used.

As mentioned above, the colored pattern layer 2 adheres and transfers to the thermosetting resin decorative board, so it has good releasability from the base sheet 1 and good adhesion to the thermosetting resin. It is desirable to select a colored ink. Such colored ink varies depending on the type of thermosetting resin used in the base sheet 1 and the decorative board, but generally it is made of resin such as acrylic resin, cellulose acetate resin, polyamide resin, etc., and pigment such as titanium white. and a solvent can be preferably used. Note that as the colored ink, colored transparent, translucent, or opaque ink can be used as necessary. Further, the colored ink may be either chromatic or achromatic.

Next, an example of the method for manufacturing the shaped sheet 4 of the present invention will be specifically explained with reference to the drawings.

FIG. 1 is a cross-sectional view of a printing sheet used for producing the shaped sheet 4 of the present invention. This printed sheet can be obtained by providing a colored pattern layer 2 made of colored ink on the surface of a base sheet 1 by a known method such as gravure printing or silk screen printing. The shaped sheet 4 of the present invention can be obtained by subjecting this printed sheet to a matte finish in the direction of the arrow in FIG. 1 to form a matte finish surface 3a as shown in FIG.

The degree of matte processing in this case is such that the smooth surface of the colored pattern layer 2 on the base sheet side remains sufficiently. For example, in the case of matte processing by sandblasting, the depth of the recesses on the surface of the base sheet is preferably 1 to 5 μm. As the matte processing method, known methods such as chemical etching method and sandblasting method can be employed. Among these, sandblasting can be preferably employed in order to obtain a uniform uneven surface with low gloss. Furthermore, by appropriately selecting the material for the base sheet 1, the material for the colored pattern layer 2, the sandblasting conditions, etc., the surface gloss of the imprinted sheet can be controlled over a wide range from gloss to semi-gloss to matte. be able to.

The shaped sheet 4 of the present invention can take various other forms in addition to the above-mentioned form. for example,
Although the base sheet constituting the base sheet can be made of a single material, a plurality of resin regions having different hardnesses can be arranged in a mosaic pattern and used as one base sheet. As a result, a plurality of regions having different gloss levels can be formed on the surface of the base sheet even with a single sandblasting process.

FIG. 3 illustrates a method of manufacturing a thermosetting resin decorative board using the molded sheet 4 of the present invention shown in FIG.

As illustrated in the figure, in the method for manufacturing a decorative board of the present invention, a thermosetting resin is molded into paper, cloth, etc. according to a conventional method except that the molding sheet 4 of the present invention is used as a template. Using a thermosetting resin-impregnated sheet impregnated with a thermosetting resin, it may be subjected to heating and pressure molding. That is, between the upper and lower heating plates 11, the heat-resistant cushion sheet 10, and the metal plate 9 such as a mirror plate, there is a backer paper 8 as a thermosetting impregnated sheet that plays a role in preventing warping of the decorative board, and a backer paper 8 that serves as a base material for the decorative board. ,
A core paper 7, which mainly determines the thickness of the decorative board, a colored titanium paper or a titanium paper 6 on which a pattern is printed, and an overlay paper 5 are sequentially laminated, and the shaped sheet 4 of the present invention is further laminated.
It is placed on the overlay paper 5 from the colored pattern layer 2 side. Here, the backer paper 8 has a basis weight of approximately 55 to 160 g/
A melamine resin-impregnated paper obtained by impregnating m2 of titanium paper with about 40 to 100% by weight of melamine resin and drying it can be preferably used. The core paper 7 has a basis weight of approximately 140 to 180.
g/m2 paper impregnated with 30 to 100% by weight of phenolic resin and dried can be used;
It is preferable to use them in stacks. As the colored titanium paper or pattern-printed titanium paper 6, melamine resin-impregnated titanium paper impregnated with 40 to 100% by weight of melamine resin and dried can be preferably used. The overlay paper 5 is made of rayon pulp or nonwoven fabric with a basis weight of about 25 to 45 g/m2.
Transparent resin-impregnated paper impregnated with 0 to 300% by weight of melamine resin and dried can be preferably used.

[0023] The thermosetting resin used in the decorative board of the present invention includes not only such melamine resins and phenol resins, but also diallyl phthalate resins, which require heat and pressure for molding, and are well known to those skilled in the art. A wide variety of resins known in the art can be used.

Next, the thus laminated thermosetting resin-impregnated papers 5 to 8 and the molding sheet 4 are heated and pressed together. The heating and pressing conditions depend on the thermosetting resin used, etc.
In the case of melamine resin, the maximum temperature is about 140-150℃
, heat and pressure molding at a pressure of about 60 to 100 kg/cm2 for about 15 to 30 minutes. After that, soak in cold water while pressurized for about 1 hour.
By cooling for 5 to 60 minutes, the thermosetting resin-impregnated papers 5 to 8 are cured as one piece. During curing, the colored pattern layer 2 of the forming sheet 4 is integrated with the thermosetting resin impregnated into the overlay paper 5 and transferred from the forming sheet 4 to the decorative board side, and its surface is the same as the base sheet. The high gloss of the surface that was in contact with 1 is maintained. Further, the matte textured surface 3a of the base sheet is transferred to the surface of the decorative board.

Next, when the molded sheet 4 is peeled off from the decorative board, a thermosetting resin decorative board 12 shown in FIG. 4 is obtained. The surface of the decorative board 12 has a portion 13 to which the matte surface 3a of the imprinting sheet has been transferred, and a portion 14 to which the colored pattern layer 2 of the imprinting sheet has been transferred. As a result, a thermosetting resin decorative board having an excellent design feeling and having a high-gloss colored pattern area and other matte areas on the surface can be obtained. In particular, since the colored pattern layer on the surface is separated from the colored titanium paper or the pattern-printed titanium paper 6 through the transparent resin layer of the overlay paper, an extremely three-dimensional design is achieved. be able to.

[0026]

[Function] The shaped sheet of the present invention has a colored pattern on the surface of the base sheet made of colored ink that is releasable to the base sheet and has adhesive properties to the thermosetting resin to be shaped. The glossiness of the surface of the base sheet on which the colored pattern layer is not provided is different from the glossiness of the surface of the colored pattern layer on the base sheet side. Therefore, when this molding sheet is used as a template when manufacturing a curable resin decorative board, the colored pattern is transferred to the thermosetting resin decorative board, and the difference in glossiness mentioned above is also transferred.
It is possible to obtain a thermosetting resin decorative board that has a colored pattern that matches the glossiness and exhibits a particularly excellent three-dimensional design feeling. In that case, it is not necessary to use an expensive metal template, and the configuration of the equipment for manufacturing the decorative laminate is also simplified, making it possible to manufacture the thermosetting resin decorative laminate at low cost.

[0027]

[Examples] The present invention will be specifically explained below using examples. Example 1 High gloss transparent polyester film with a thickness of 50 μm (
Unitika Co., Ltd.) and cellulose acetate-based white ink (
A colored pattern layer was formed by printing a lattice pattern using a gravure printing method to a thickness of 5 μm (dry thickness) on a sheet of high tone (manufactured by Toyo Ink Manufacturing Co., Ltd.) to obtain a printed sheet.

Next, the entire printing surface of the obtained printing sheet was sandblasted so that the depth of the recesses was 3 μm to obtain a shaped sheet of the present invention.

Next, as shown in FIG. 3, a heat-resistant cushion sheet, a mirror plate, a backer paper made of titanium paper with a basis weight of 100 g/m2 impregnated with 80% by weight of melamine resin, and a backer paper with a basis weight of 150 g/m2 are placed on the lower heating plate as shown in FIG. Four sheets of core paper impregnated with 60% by weight of phenolic resin, white titanium paper with a basis weight of 80g/m2 impregnated with melamine resin and white titanium paper impregnated with melamine resin, and rayon pulp with a basis weight of 25g/m2. An overlay paper impregnated with 300% by weight of melamine resin is laminated in this order, and on top of this, the above-mentioned imprinting sheet is overlaid from the sandblasted side.
Furthermore, a mirror plate and a heat-resistant cushion sheet were placed on top, and then sandwiched between the upper heating plates. This laminate was heated at a maximum temperature of 145°C.
Heat and pressure was applied for 30 minutes at a pressure of 80 kg/cm2. After that, while pressurized, cool with cold water for 40 minutes,
The thermosetting resin layer was cured.

Next, a melamine resin decorative board was obtained by peeling and removing the molded sheet from the cured product.

The obtained melamine resin decorative board has a high gloss area and a uniform matte area on the surface, and the high gloss area has a white checkered pattern, and the checkered pattern is the base white titanium paper. It was a decorative board with an extremely excellent three-dimensional effect, as it was arranged three-dimensionally with steps interposed between the white color of the paper and the transparent resin layer of the overlay paper.

[0032]

[Effects of the Invention] According to the present invention, it is not necessary to use an expensive metal template, and the equipment configuration for manufacturing decorative laminates is simplified, and the coloring is done at low cost and in synchronization with the glossiness of the surface. A thermosetting resin decorative board with a patterned pattern and an excellent three-dimensional effect can be easily produced, and furthermore,
Fully compatible with multi-product production.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view of a printing sheet.

FIG. 2 is a cross-sectional view of a shaped sheet.

FIG. 3 is an explanatory diagram of a method for manufacturing a thermosetting resin decorative board of the present invention.

FIG. 4 is a cross-sectional view of a thermosetting resin decorative board obtained by the method for manufacturing a thermosetting resin decorative board of the present invention.

[Explanation of symbols]

1 Base sheet 2 Colored pattern layer 3a　Matte processed surface area 4 Imprinting sheet 12 Thermosetting resin decorative board

Claims (3)

[Claims] 1. A colored pattern layer made of a colored ink that is releasable to the base sheet and has adhesive properties to the thermosetting resin to be molded is provided on the surface of the base sheet, 1. A molded sheet for producing a thermosetting resin decorative board, characterized in that the glossiness of the surface of the base sheet on which the colored pattern layer is not provided is different from the glossiness of the surface of the colored pattern layer on the base sheet side. 2. A pattern layer made of a colored ink that has releasability to the base sheet and adhesiveness to the thermosetting resin to be molded is provided on the surface of the base sheet, and a pattern layer is formed on the surface of the base sheet. 2. The method for producing a shaped sheet according to claim 1, wherein the shaped sheet is subjected to matte processing. 3. (a) a step of placing the shaping sheet according to claim 1 and a thermosetting resin-impregnated sheet so as to sandwich the colored pattern layer of the shaping sheet; (b) the shaping sheet; A step of curing the thermosetting resin by heat-pressing the sheet and the thermosetting resin-impregnated sheet together, and adhesion-transferring the colored pattern layer of the imprinted sheet to the thermosetting resin-impregnated sheet; and ( c) A method for producing a thermosetting resin decorative board in which the colored pattern and the gloss of its surface are synchronized, including the step of peeling the base sheet of the molded sheet from the cured product of step (b).