JPH04351539A - Patterned sheet and manufacture of patterned laminate - Google Patents

Abstract

PURPOSE:To provide a manufacturing process, in which a patterned sheet in the state of complete curing and a patterned laminate can be manufactured. CONSTITUTION:A patterned sheet is manufactured in such a manner that the resin coated surface 3 of a base material 2 coated with a photo-setting resin containing a foaming agent and a tabular body 1, to which a pattern composed of light-transmitting sections 12 and light-shielding sections 10, 11 is formed, are faced oppositely, the resin coated surface 3 of the base material 2 is irradiated with light from the outside of the tabular body 1, the resin on the base material 2 is brought to a cured state and a non-curing state, and the resin in the non-curing state is foamed by heating. A patterned laminate is manufactured in such a manner that a non-curing laminate, in which the photo-setting resin containing the foaming agent is held between two tabular substances, at least one of which has light transmissivity, is used in place of the base material 2 coated with the photo-setting resin containing said foaming agent.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention relates to a method for forming a decorative pattern by foaming on the surface of a base material such as a decorative board, and a laminate consisting of two plate-like materials and a resin material sandwiched between them.
The present invention relates to a method of forming a decorative pattern by foaming.

0002

2. Description of the Related Art Generally, as a method for forming a decorative pattern on the surface of a base material such as a decorative board, a method is known in which foaming using a foaming agent and photocuring using a photocuring resin are combined.

Conventionally, a method using this combination has been to apply a printing liquid containing a light absorbing agent and/or a light shielding agent in a pattern on the surface of a foamable resin sheet containing a photocuring agent, and then applying the foamed resin to the surface of a foamable resin sheet containing a photocuring agent. There is a method of irradiating a foamable resin sheet with light and then heating and foaming the foamable resin sheet (for example, see Japanese Patent Publication No. 56-4417).

According to this method, the portions of the foamable resin sheet to which the printing liquid has not been applied are first cured by light irradiation. Then, by subsequent heating, the remaining uncured portion to which the printing liquid has been applied foams and becomes convex, forming a foam pattern containing many foamed bubbles.

[0005]

[Problems to be Solved by the Invention] However, in the above conventional method, the printing liquid absorbs or blocks the light during irradiation, thereby inhibiting the photocuring of the foamable resin sheet underlying the printing liquid. Therefore, the foamable resin sheet corresponding to the lower layer of the print liquid is not completely cured in the end, and uncured portions remain. As a result, problems such as deterioration in appearance, skin irritation, and odor due to bleeding occur.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a manufacturing method capable of manufacturing a completely cured patterned sheet and patterned laminate.

[0007]

[Means for Solving the Problems] The method for manufacturing a patterned sheet of the present invention provides a pattern consisting of a resin-coated surface of a base material coated with a photocurable resin containing a foaming agent, a light-transmitting part and a light-blocking part. The resin coated surface of the base material is irradiated with light from the outside of the plate-like body, and the resin on the base material corresponding to the light-transmitting part of the plate-like body is cured. At the same time, the resin corresponding to the light-shielding portion is brought into an uncured state, and then the uncured resin is foamed by heating, the plate-shaped body is removed, and the resin-coated surface of the base material is irradiated with light again.

[0008] Furthermore, the method for producing a patterned laminate of the present invention includes sandwiching a photocurable resin containing a foaming agent between two plate-like materials, at least one of which is light-transmissive. The uncured laminate is made into a laminate, and the uncured laminate is made to face a plate-shaped body with a pattern consisting of a light-transmitting part and a light-shielding part, and light is irradiated onto the uncured laminate from the outside of this plate-shaped body. The resin inside the uncured laminate corresponding to the light transmitting part of the shaped body is cured, and the resin corresponding to the light shielding part is made uncured, and then the uncured resin is foamed by heating to form a plate. The body is removed and the resin-coated surface of the base material is irradiated with light again.

As blowing agents, azodicarbonamide,
Any known blowing agent such as P, P'-oxybis(benzenesulfonyl hydrazide) can be used. Alternatively, thermally expandable microcapsules in which a low boiling point organic substance, an inorganic substance, or a low boiling point organic substance is sealed inside a resin shell can also be used.

As the photocurable resin, one containing a curable resin component and a photopolymerization initiator as essential components is used.

The curable resin component is a resin component that polymerizes and hardens as the photopolymerization initiator is activated by light absorption. This curable resin component includes unsaturated polyester type, acrylic type, thiol/ene type,
Various types such as epoxy type can be used.

[0012] The photopolymerization initiator absorbs light within a specific range of wavelengths to generate active species, thereby initiating the curing reaction of the curable resin component. As this photopolymerization initiator, various kinds such as a radical polymerization type and a cationic polymerization type can be used.

[0013] In addition, various components other than these include stabilizers such as ultraviolet absorbers and antioxidants, leveling agents, thickeners, fillers, non-curing resin components, solvents, and colorants. It may be added as necessary.

[0014] The material of the base material on which the photocurable resin coating is formed is not particularly limited, and may include wood, concrete, metal, painted metal plate, cloth, plastic plate, plastic sheet, glass, and paper. Examples of its uses include building materials, interior and exterior materials, and various parts.

[0015] Furthermore, an indicating or decorative pattern is printed on the base material in advance, or paper, film, etc. printed with an indicating or decorative pattern is pasted or laminated, and a transparent The visual effect can be further enhanced by forming the foamed pattern of photocurable resin in synchronization or non-synchronization. The foamed patterns formed on this base material include wood-like, stone-like, leather-like, floral patterns, letters, numbers, Braille, geometric patterns, decorative patterns, and various functional patterns. It is possible to form foam patterns such as

[0016] A plate-like body having a light-transmitting part and a light-shielding part is formed by shielding a part of the light-transmitting plate-like material with a light-shielding material, so that the light-transmitting part made of the light-transmitting plate-like material has a light-transmitting part. A light shielding portion having a light transmittance of 0% or more and 90% or less of the light transmittance of the light transmitting portion is formed. Then, a pattern is created by the light transmitting portion and the light shielding portion. Furthermore, by providing stages in the light transmittance of the light shielding part, a staged foaming state can be formed.

[0017] The light-transmitting plate-like material may be any plate-like or film-like material that transmits light having a wavelength within a specific range, and examples thereof include glass plates, plastic plates, and films. In particular, Pyrex glass plate (Cor
ning Glass Works (trade name), quartz glass plates, etc., which have high purity silicon oxide, and
A glass plate that has high transmittance to light of a lower wavelength is preferable because it has good light transmittance and allows the curing reaction to proceed efficiently and in a short time.

[0018] As the light-shielding substance, appropriate materials such as paint, ink, sheet-like material, etc. can be used. However, a light transmittance of 0% or more and 90% or less of the light transmittance of the light-transmissive plate-like material by blocking a part of the light-transparent plate-like material, more preferably a light transmittance of 0% or more and 80% or less of the light transmittance of the light-transparent plate-like material. The material must be capable of forming a light shielding part with If the light transmittance of the light-shielding portion exceeds 90%, the difference in curing speed between the light-shielding portion and the light-transmitting portion becomes small, making it impossible to form a foam pattern sufficiently.

Methods for forming the light-shielding portion having a predetermined light transmittance include printing a light-shielding material on a light-transmitting plate, and pasting a sheet-like light-shielding material on a light-transmitting plate. One example is how to wear it. Also, another method is
Examples include a method of printing a light-opaque ink or the like on a light-transparent plate in the form of fine halftone dots or meshes. In this case, the light transmittance of the light shielding portion will have a predetermined light transmittance as a whole due to the light transmitting plate-like material and the light opaque material.

The uncured laminate is formed by sandwiching a photocurable resin containing a foaming agent between two light-transmitting plates. However, it is sufficient that the light-transmitting plate-like material is used at least on the side that is irradiated with light, and a material that does not have light transmittance like the above-mentioned base material may be used on the other side. can.

[0021] With the resin-coated surface of the base material coated with photocurable resin facing the plate-shaped body and with a space between them, the resin-coated surface of the base material is coated from the outside of the plate-shaped body. Examples of the method for irradiating light include a method in which the base material and the plate-shaped body are each independently fixed and left still, and then light is irradiated. Another method is to irradiate light while transporting the base material and the plate-shaped body in an integrated state onto a conveyor. Further, there is a method in which the base material is transferred onto a conveyor, the plate-like body is a continuous film in the form of a belt, and the base material on the conveyor is irradiated with light through the continuous film. The same applies to uncured laminates.

At this time, the light source for curing the photocurable resin may be one that emits light with a wavelength of approximately 250 to 450 nm. For example, high-pressure or ultra-high-pressure mercury lamps, metal halide lamps, fluorescent lamps, xenon lamps, sunlight, etc. can all be used.

Furthermore, the outline of the foamed portion can be adjusted by appropriately adjusting the space between the resin-coated surface of the base material coated with the photocurable resin and the plate-shaped body. That is, by bringing the spaces closer together, the spread of light passing through the light transmitting portion is suppressed, and the outline of the foamed portion becomes clearer. Further, by separating the foamed portions, the spread of light transmitted through the light transmitting portion becomes larger, and the foamed portion has a rounded outline.

When the resin-coated surface is irradiated with light through the plate-shaped body, the resin-coated surface facing the light-transmitting portion of the plate-shaped body progresses in hardening. On the other hand, the resin-coated surface of the plate-shaped body facing the light-shielding portion progresses in hardening at a speed corresponding to the light transmittance of the light-shielding portion.

At this time, the amount of light irradiation is such that the melt viscosity of the resin at the decomposition temperature of the blowing agent progresses until curing progresses to such an extent that foaming is substantially suppressed on the resin coating surface relative to the light transmitting area.
Adjustment is made so that the curing rate of the resin-applied surface facing the light-shielding portion remains at a melt viscosity that allows foaming.

[0026] Thereafter, this resin-coated surface is heated to the decomposition temperature of the foaming agent to selectively cause foaming on the resin-coated surface relative to the light-shielding portion.

At this time, the factors that determine the amount of foaming are the amount of foaming agent added and the melt viscosity of the resin at the decomposition temperature. That is, in order to increase the amount of foaming, it is sufficient to increase the amount of foaming agent added, lower the resin viscosity, and lower the light transmittance of the light shielding part. Furthermore, by grading the light transmittance of the light shielding portion, the curing rate of the resin-coated surface relative to the light shielding portion can be graded, and as a result, it becomes possible to grade the amount of foaming.

After the foaming is completed, the entire surface is irradiated with light again.
Completely cure the photocurable resin. If uncured resin remains,
This is because inconveniences such as bleeding, stickiness, skin irritation, and odor may occur.

[0029]

[Function] According to the method for producing a patterned sheet of the present invention, the resin-coated surface facing the light-transmitting part of the plate-like body progresses in curing by light irradiation, while the resin-coated surface facing the light-blocking part of the plate-like body progresses in hardening. may be completely uncured or remain at a partially cured stage. Then, by heating, foaming in the hardened portion is suppressed, and the completely unhardened or partially hardened portion foams, and this foamed portion becomes convex, and bubbles are formed within this foamed portion. It will be formed. As a result, a decorative pattern is formed by the portions that have been cured by photocuring and the portions that have been foamed and cured by heating. At this time, even if an uncured part is formed in the part covered by the plate-like material and used as a light-shielding part, the light is irradiated after the plate-like material is removed, so that it will definitely be in a hardened state. can.

Further, according to the method for manufacturing a patterned laminate of the present invention, the resin inside the plate-like object facing the light-transmitting part of the plate-like object progresses in hardening due to light irradiation, while the light-shielding part of the plate-like object progresses in hardening. The resin inside the plate-like object facing the surface remains completely uncured or only partially cured. Then, by heating, the foaming of the hardened portion is suppressed, and the completely unhardened or partially hardened portion foams, and foamed cells are formed within this foamed portion. As a result, a decorative pattern is formed by the portions that have been cured by photocuring and the portions that have been foamed and cured by heating. At this time, even if an uncured part is formed in the part covered by the plate-like material and used as a light-shielding part, the light is irradiated after the plate-like material is removed, so that it will definitely be in a hardened state. can.

[0031]

[Examples] Examples according to the present invention will be described below.

[0032]

[Example 1] Urethane acrylate (manufactured by Negami Kogyo Co., Ltd., Art Resin UV-125) as a photocurable resin
5), 40 g of ethyl acetate, 1.8 g of methylphenylglyoxylate (photopolymerization initiator), and 3 g of azodicarbonamide as a blowing agent were mixed and used.

[0033] As a base material, the thickness is 3 mm and the length and width are 100 mm.
A white polystyrene plate was used.

[0034] Then, the photocurable resin was cast on the surface of this base material, and the ethyl acetate was volatilized by heating and drying.
A resin-coated surface with a thickness of 0.5 mm was formed.

On the other hand, as a light-transmitting plate-like material, a thickness of 4 mm is used.
Pyrex glass plate (Corning Glass)
As shown in FIG. 1, an S-shaped red polyester film 10 is pasted with adhesive on the surface of the glass plate as a light-shielding material, and the area around this S-shape is A green oil-based ink 11 was printed on the plate to form a plate-shaped body 1.

This plate-shaped body 1 has an average light transmittance of 90% in the light transmitting part 12 in the range of 300 to 450 nm, an average light transmittance of the light shielding part by the red polyester film 10 of 5%, and a light shielding part by the green oil-based ink 11. The average light transmittance of the sample was 30%.

Then, as shown in FIG. 2, the base material 2 is placed on the support plate 5, and the plate-shaped body 1 is installed horizontally and integrally around the periphery of the base material 2 via the support frame 4. This was designated as test piece 6. At this time, the distance between the resin-coated surface 3 on the surface of the base material 2 and the plate-shaped body 1 is 2
mm.

[0038] This test piece 6 was conveyed 10m/10m on a belt conveyor.
It transfers at a speed of min.
4cm metal halide lamp from the belt conveyor
Irradiation was performed from a position 0 cm apart.

Thereafter, the plate 1 was removed from the test piece 6 and heated in an oven at 160°C for 5 minutes.
As shown, the resin surface 3 facing the green oil-based ink 11
A patterned sheet 7 was obtained in which 1 had a trapezoidal shape and the resin surface 30 facing the red polyester film 10 had a clearly convex shape. Note that no foaming was observed on the resin surface 32 facing the light transmitting portion 12.

Further, when the patterned sheet 7 was transported at a speed of 1 m/min by a belt conveyor and irradiated with a metal halide lamp again, the entire resin-coated surface 3 was completely cured and became convex in a trapezoidal and S-shape. A beautiful cured coating film was obtained.

[0041]

[Example 2] A resin-coated surface was formed in the same manner as in Example 1 on the surface of a float plate glass having a thickness of 2 mm and a length and width of 10 mm. A float glass plate of the same size was laminated on top of this resin surface while preventing air bubbles from entering to form an uncured laminate.

[0042] Contrary to the above Example 1, as for the plate-shaped body,
Using a red polyester film with an S-shape cut out,
It has an S-shaped light transmitting part. In addition, the structure, positional relationship, etc. of the test piece were the same as in Example 1 above.

Then, this test piece was placed on a belt conveyor vertically below a metal halide lamp, and irradiated with the metal halide lamp for 5 seconds.

After that, the plate was removed and heated in an oven at 160° C. for 5 minutes. As shown in FIGS. 4 and 5, only the resin surface 33 in the float glass plate 8 facing the light-shielding portion was foamed. A laminate 9 was obtained in which the resin surface 34 in the float glass plate 8 facing the light transmitting portion was not foamed.

[0045] Also, the laminate 9 is conveyed by a belt conveyor at a rate of 1 m/
When the mixture was transported at a speed of 10 min and irradiated with a metal halide lamp again, a beautiful foam pattern was obtained in which the S-shaped portion was transparent and the entire surface other than the S-shaped portion had a foamed pattern.

[0046]

[Effects of the Invention] As described above, according to the method for manufacturing a patterned sheet and the method for manufacturing a patterned laminate of the present invention,
Even if an uncured part is formed in the area covered by the plate-like material and used as a light-shielding part, the appearance due to bleed can be avoided because the plate-like material is removed and then irradiated with light to ensure a cured state. It can prevent deterioration, stickiness, skin irritation, odor, etc.

[Brief explanation of the drawing]

FIG. 1 is a plan view showing a plate-like body.

FIG. 2 is a cross-sectional view showing the test piece taken along line A-A in FIG. 1 when irradiated with light.

FIG. 3 is a cross-sectional view showing a foam pattern formed on a patterned sheet according to Example 1.

FIG. 4 is a cross-sectional view showing a foam pattern formed on a laminate according to Example 2.

FIG. 5 is a plan view showing a foam pattern formed on a laminate according to Example 2.

[Explanation of symbols]

1 Plate-shaped body 10 Red polyethylene film (light shielding part) 11
Green oil-based ink (light-shielding part) 12 Light-transmitting part 2 Base material 3 Resin-coated surface 7 Patterned sheet 8 Plate-shaped object 9 Patterned laminate

Claims (2)

[Claims] 1. A resin-coated surface of a base material coated with a photocurable resin containing a foaming agent is made to face a plate-shaped body having a pattern consisting of a light-transmitting part and a light-blocking part, and this plate-shaped body is made to face each other. Light is irradiated onto the resin-coated surface of the base material from the outside to harden the resin on the base material that corresponds to the light-transmitting part of the plate, and uncured the resin that corresponds to the light-shielding part. A method for producing a patterned sheet, which comprises foaming an uncured resin by heating, removing the plate-like body, and irradiating the resin-coated surface of the base material with light again. Claim 2: 2 at least one of which has optical transparency;
A photocurable resin containing a foaming agent is sandwiched between two plate-like materials to form an uncured laminate, and a plate-like material with a pattern consisting of the uncured laminate, a light-transmitting part and a light-blocking part. The uncured laminate is irradiated with light from the outside of the plate-shaped body, and the resin inside the uncured laminate corresponding to the light-transmitting part of the plate-shaped body is cured, and the resin in the uncured laminate is cured in the light-shielding part. A patterned laminate characterized in that the corresponding resin is brought into an uncured state, the uncured resin is then foamed by heating, the plate-shaped body is removed, and the resin-coated surface of the base material is irradiated with light again. Production method.