JPH0516308A - Manufacture of decorative material having recessed section in surface - Google Patents

Abstract

PURPOSE:To provide the manufacture of a surface decorative material having a sharp recessed section in a surface and displaying high-grade coating feeling. CONSTITUTION:The title manufacture of a decorative material successively includes a process, in which a first pattern layer 2 is formed onto the surface of a base material for the decorative material, a process, in which the surface of the first pattern layer 2 is coated with a resin liquid containing a coloring material, the resin liquid is solidified and a colored coated layer 3 is formed, a process, in which a second pattern layer 4 by printing ink containing a liquid repellent substance is shaped, and a process, in which the resin liquid is applied onto the surface of the second pattern layer 4 and solidified and a top coat layer 5 is formed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative material, and more particularly to a method for producing a surface decorative material used as an interior material for furniture, wall surfaces, floor surfaces and the like.

[0002]

2. Description of the Related Art As a conventional method for producing a surface decorative material, a method of applying a colored coating to the surface of a plate-like material such as wood, stone or metal is not easy to handle and the construction process is complicated and expensive. . After forming a pattern layer with a printing ink containing a liquid-repellent substance on a cosmetic substrate, form a transparent topcoat layer on the entire surface, and form a concave portion in the portion of the printing ink containing a liquid-repellent substance. In the method of forming, since the top coat layer forming the surface protective layer is transparent and lacks a feeling of painting, a feeling of luxury is lacking. After forming a pattern layer with a printing ink containing a liquid-repellent substance on the base material for makeup, form a topcoat layer containing a colorant on the entire surface and apply it to the printing ink containing the liquid-repellent substance. In the method of forming the concave portion, since the topcoat layer that is repelled contains a colorant, the topcoat layer is difficult to be repelled, and therefore cissing residue is likely to occur in the concave portion, and there is a limit to coloring. There is also the problem that it cannot be dark.

[0003]

As described above, it has been difficult to obtain a decorative material having a sharp concave portion on the surface and exhibiting a high-grade coating feeling by the conventional method for producing a surface decorative material.

[0004]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems of the prior art, in which a resin layer containing a colorant is formed below a pattern layer containing a liquid repellent agent. Thus, the repelling force of the subsequently formed top coat becomes constant, and the concave portion formed in the top coat layer is sharpened and stabilized, and completed.

That is, the method for producing a decorative material having a concave portion on the surface of the present invention comprises a step of forming a first pattern layer on the surface of a base material for a decorative material, and a step of forming the first pattern layer. A step of applying a resin solution containing a colorant on the surface and solidifying the resin solution to form a colored coat layer; a step of forming a second pattern layer with a printing ink containing a liquid repellent substance; The method is characterized by sequentially including a step of applying a resin solution to the surface of the second pattern layer and solidifying the resin solution to form a top coat layer.

In a preferred embodiment of the present invention, the colorant in the resin liquid containing the colorant may be in the range of 10 to 99% by weight based on the solid component of the resin liquid.

In the method of manufacturing a decorative material of the present invention having the above-mentioned constitution, the base material for a decorative material is a general base material for a decorative material which is used when a normal decorative material is obtained, for example, weighing 23 Papers, pulp boards, plastic sheets made of polyethylene, polypropylene, polyester, etc., of about 300 g, various kinds of wood and plywood are used.

The pattern layer applied on the surface of the base material for decorative material, that is, the first pattern pattern layer made of a printing ink containing no liquid-repellent substance is formed on the surface of the base material for decorative material. Generally, they are sequentially formed through a base coat layer that is directly formed. Incidentally, such a base coat layer is, for example, a printing ink or paint containing a vinyl chloride / vinyl acetate copolymer, nitrocellulose or the like as a binder component, and a usual roll coat, gravure coat, bar coat, air knife coat or the like. It is easily formed by applying the coating method.

The first patterned layer formed on the base material for decorative material is a vehicle made of vinyl chloride / vinyl acetate copolymer, nitrocellulose or the like, a coloring agent such as a dye or a pigment, and in some cases, Pearlescent pigments and metal powder pigments, and if necessary, additives such as a plasticizer, a stabilizer, a desiccant, an auxiliary desiccant, a curing agent, a thickener, a dispersant, and a filler,
It is formed by a general printing means such as gravure, offset or offset gravure using an ink or a paint sufficiently kneaded with a solvent to a diluent. Particularly in the case of a wood grain pattern, a pattern layer using a glittering ink such as pearl ink is effective.

A resin liquid containing a colorant for forming a colored coat layer can be applied in a liquid state, and a transparent or semitransparent film can be formed by cooling after application, evaporation of a solvent, crosslinking or the like. A coating agent capable of forming, for example, (a)
Polyethylene, polypropylene, polyvinyl chloride, polyacrylic acid ester, polyvinyl acetate, cellulose, polyamide, polyacrylamide, and these two
Thermoplastic resin made of at least one kind of copolymer, (b) melamine / formaldehyde resin, phenol / formaldehyde resin, urea / formaldehyde resin, allyl resin,
Thermosetting resin such as unsaturated polyester resin, (c)
Acrylic ester polymer, oligomer, monomer, cross-linking acrylic resin with cross-linking aid, or cross-linking modified acrylic resin consisting of urethane modified product thereof,
(D) A resin liquid comprising a component such as a cross-linkable polyurethane resin containing an acrylic polyol or polyester polyol and polyisocyanate, and (e) a cross-linkable resin such as an unsaturated polyester resin containing a vinyl monomer having a functional group is used. .

Considering the adhesiveness to the printing ink containing the liquid repellent substance and the top coat layer in the subsequent step, as the resin liquid,
Thermoplastic resin with a binder such as vinyl chloride / vinyl acetate copolymer or nitrocellulose, or a crosslinkable resin containing acrylic polyol and polyisocyanate (however, O
Regarding the H value and the NCO value, the higher the OH value is, the better.

As the colorant, a colorant used in ordinary printing inks can be used, but those having good solvent resistance, heat resistance, light resistance, dispersibility and the like are preferable. In the coating agent for forming the colored coat layer, the coloring agent is 10 to 99% by weight, preferably 30 to 9% by weight based on the solid component of the resin liquid.
It is in the range of 0% by weight. When the amount of the colorant is less than 10% by weight based on the solid component in the resin liquid, it is difficult to obtain sufficient coloring in the color coat layer, while when it exceeds 99% by weight, the interlayer strength of the resin may be poor. Occurs.

Typical colorants contained in the coating agent are as follows, and the number in parentheses next to the name of the colorant indicates the colorant suitable for the solid component of the resin liquid. It is the content (% by weight). When a plurality of pigments are mixed and used, the total value of the added weights of all pigments is 10 to 9
Try to be 9%. When using a single pigment,
The weight of the pigment alone is adjusted to 10 to 99%. a) White pigment rutile-type and anatase-type titanium white (5 to 99) b) Black pigment carbon black such as channel black and furnace black (5 to 60) c) Yellow pigment disazo yellow (2 to 40), benzidine yellow, Hansaello d) Orange pigment chrome vermillion, benzidine orange e) Red pigment polyazo (2-40), lake red C, brilliant carmine, watching red, resole red, barium resole, rhodamine lake, tannin lake, fanal color, brilliant scarlet G, pyrazolone red, quinacridone red, anthraquinone pigment f) purple pigment methyl violet lake g) blue pigment cyanine blue (2-40), dark blue, Victoria blue lake, fast sky blue, thread Blue, ultramarine blue h) green pigment phthalocyanine green, malachite green lake (tannins rake and FANAL color) i) tea valve handle (2-40)

The printing ink containing a liquid repellent substance for forming the second pattern layer may be transparent, colored transparent or colored opaque, and has solvent resistance, water resistance and abrasion resistance. A stable patterned layer having excellent properties such as resistance, weather resistance, and heat resistance is preferable, and is formed by, for example, a printing ink containing a vehicle made of a curable resin and a liquid repellent substance.

The printing ink using the curable resin as a vehicle includes, for example, 1) a two-component curable ink which produces a polyurethane resin by reacting a polyester polyol or polyether polyol with an isocyanate, 2) an epoxy resin and a polyamide, Epoxy curable ink that produces epoxy type resin by reaction with polyamine or acid anhydride, 3) Mixture of unsaturated polyester and styrene monomer with polymerization initiator such as peroxide and polymerization catalyst such as cobalt naphthenate. Thermosetting ink added, 4) Thermosetting ink obtained by adding paratoluenesulfonic acid to melamine resin or urea resin and alkyd resin, 5) Photosensitization of benzophenone and benzoin ether to epoxy acrylate or urethane acrylate To The added electron beam or UV curable ink, etc. are used, and the vehicle component of each resin described above, a plasticizer,
A printing ink comprising a kneading composition such as a stabilizer, a dispersant, a filler, a colorant such as a dye or a pigment, a solvent and a diluent is used. Since the curable ink composition is usually used in a two-pack type, a reaction catalyst, a reaction accelerator and the like are added immediately before using the printing ink.

As the liquid-repellent substance in the printing ink used for forming the second pattern layer, conventionally known liquid-repellent substances such as silicone, wax and fluororesin are used. Silicone used as a liquid repellent substance has, for example, an amino group, a mercapto group, a methyl group, a propyl group, a phenyl group, an alkoxy group, an acetoxy group, a hydroxy group, a halogen atom, a metal, or the like bonded to a silicon atom. A polymer or low-molecular compound having a linear, branched, or cyclic structure is used.

The liquid repellent substance may be premixed in the ink composition or may be added immediately before the use of the printing ink, and the solid content of the ink composition is 5 to 30% by weight. It is preferably added within the range, more preferably 8 to 15% by weight. If it is less than 5% by weight, the effect of addition is small, and if it exceeds 30% by weight, repelling occurs during printing and uneven printing occurs.

The second pattern layer made of a printing ink containing a liquid repellent substance is printed by the same printing method as that for forming the pattern layer made of a normal printing ink, that is, gravure printing, offset printing, letterpress printing and screen printing. And the like. When the vehicle component in the printing ink containing the liquid repellent substance is an electron beam curable or ultraviolet curable resin, the printing layer is cured by irradiation with a predetermined electron beam or ultraviolet light after the printing process. It

For the formation of the topcoat layer, a coating agent which can be applied in a liquid state and which can form a transparent or semitransparent film by cooling after application, volatilization of a solvent, crosslinking or the like, for example, ( A) Polyethylene, polypropylene, polyvinyl chloride, polyacrylic acid ester, polyvinyl acetate, cellulose, polyamide, polyacrylamide, and a thermoplastic resin of a copolymer of two or more of these, (b) melamine / formaldehyde resin,
Thermosetting resin such as phenol / formaldehyde resin, urea / formaldehyde resin, allyl resin, unsaturated polyester resin, (c) acrylic ester polymer, oligomer, monomer, cross-linking acrylic resin by cross-linking aid, or its urethane modification -Type cross-linked modified acrylic resin, (d) cross-linkable polyurethane resin containing acrylic polyol or polyester polyol and polyisocyanate, (e) cross-linkable resin such as unsaturated polyester resin containing vinyl monomer having a functional group, etc. A resin liquid composed of the above components is used.

Further, when a coating agent containing the same liquid-repellent substance as that used for forming the second pattern layer is used as the coating agent for forming the top coat layer Is formed on the surface of the top coat layer because a synergistic action is obtained between the liquid repellency exhibited by the second patterned layer and the liquid repellency exhibited by the coating agent for forming the top coat layer. The appearance of the concave part becomes clearer. Furthermore, in order to adjust the concentration and the consistency of the coating agent, for example, in the coating agent for forming the top coat layer, precipitated barium sulfate, alumina white, gloss white, calcium carbonate, magnesium carbonate, white carbon, etc. Are used as needed.

The coating agent for forming the top coat layer can be applied to a base material for a cosmetic material by a known coating means such as roll coating, gravure coating, bar coating, air knife coating, flow coating, dip coating or spray coating. The first pattern layer and the second pattern layer are applied so as to cover the entire surfaces of the printing surfaces, and subsequently, they are solidified by a predetermined means. The means for solidifying the coating layer of the coating agent is selected according to the type of resin in the coating agent. For example, in the case of a thermoplastic resin topcoat layer, cooling, in the case of a thermosetting resin topcoat layer, heating, further, in the case of a crosslinkable resin topcoat layer, if necessary, ultraviolet rays or electron beam Is irradiated.

In the top coat layer obtained by the above-mentioned step, the coating agent applied in contact with the pattern pattern layer made of the printing ink containing the liquid repellent substance is repelled by the liquid repellency of the pattern layer. Therefore, the surface of the portion corresponding to the pattern pattern layer becomes concave. The concave shape of the surface of the top coat layer corresponding to the pattern layer may be formed by exposing a part or all of the surface of the pattern layer to the surface of the decorative material.

In the method for producing a decorative material of the present invention having the above-mentioned structure, a curable resin is used as a vehicle when forming the first pattern layer, the second pattern layer, the top coat layer and the like. Or when using a printing ink or coating agent contained as a film-forming component,
Using a so-called blocked curing agent or catalyst in which the curing action of the curing agent or the catalytic action of the polymerization catalyst is blocked, the curing action of the curing agent or the polymerization catalyst after the printing process or coating process with the printing ink or coating agent By removing the blocking of the catalytic action of, the plate clogging of the printing machine and the coating device, the abrasion of the doctor and the plate, the corrosion, etc. due to the action of the curing agent or the catalyst in the printing ink or coating agent can be prevented. . Therefore, even if the curing agent or catalyst has an activating effect that adversely affects the printing machine or coating device, a high-quality cosmetic material can be stably manufactured over a long period of time. It

An example of a combination of a curable resin, a blocked curing agent or catalyst in a state where its action is blocked, and a method of releasing the blocking of these blocked curing agents or catalysts is as follows. Is. Curable resin Blocking curing agent For blocking Or catalyst release method Melamine resin Sulfonic acid heating Urea resin Amine salt (* 1) Alkyd resin Urethane resin Blocking agent and heating (in some cases, use of dissociation catalyst with isocyanate) Addition compound (* 2) Epoxy resin microcapsule Destructed amine compound of capsule (pressurization, heating, etc.) (* 3) (* 1) dinonylnaphthalene sulfonic acid, dinonyln
aphthalene disulfonic acid, p-toluensulfonic acid
, Dodecylbenzene sulfonic acid (* 2) Addition dissociation reaction RNCO + R'HCO = RNHCOR 'between a blocking agent (R'H) and an isocyanate compound (RNCO) is used. When the dissociation reaction is performed without a catalyst, 18
Although heating at 0 to 200 ° C. or higher is necessary, for example, when a dissociation catalyst composed of amines, organic compounds, metal soaps, etc. is used, the dissociation can be performed at a temperature of 160 ° C. or lower. An example of the compound of the blocking agent (R'H) with respect to the isocyanate compound (RNCO) is as follows.

[0025] Phenol type Phenol, cresol, xylenol, p-ethylphenol, o-isopropylphenol, p-tert-butylphenol, p-tert-octylphenol, thymol, p-naphthol, p-nitrophenol, p-chlorophenol alcohol type Methanol, ethanol, propanol, butanol, ethylene glycol, methyl cellosolve, butyl cellosolve, methyl carbitol, benzyl alcohol, phenyl cellosolve, furfuryl alcohol, cyclohexanol active methylene dimethyl malonate, diethyl malonate, ethyl acetoacetate Mercaptan type butyl mercaptan, thiophenol, tert-dodecyl mercaptan acid amide type acetanilide, acetaniside, acetic acid amide, benzamide imimi Succinimide, maleic imide amine diphenylamine, phenylnaphthylamine, aniline, carbazole imidazole imidazole, 2-ethylimidazole urinary urea, thiourea, ethylene urea carbamic acid phenyl phenylcarbamate, 2-oxazolidone salt Imine-based ethyleneimine oxime-based formaldoxime, acetoaldoxime, methylethylketoxime, heclohexanone oxime sulfite-based sodium bisulfite, potassium bisulfite (* 3) gelatin, cellulose-based substances, electrolyte polymers, and other encapsulating materials are used. To be done.

FIG. 1 is a schematic explanatory view for explaining the layer structure of a decorative material produced by the method of the present invention, in which a first pattern layer 2 and a colored layer are sequentially formed on a base material 1 for a decorative material. The manner in which the coat layer 3, the liquid-repellent ink (second pattern layer) 4, and the top coat layer 5 are laminated is shown. Top coat layer 5
The concave portion 6 is formed in the portion where the liquid repellent ink is present.

[0027]

The following examples serve to explain the present invention more specifically. The scope of the present invention is not limited by the following examples. 30 g / m basis weight of paper made from pulp with a cationic acrylic resin adsorbed
After forming a base coat layer with a gravure printing ink containing a vehicle made of a urethane resin and a titanium oxide pigment and a coloring pigment as solid components on the surface of a base material for a decorative material made of thin paper of ² , and a vehicle made of a nitrocellulose resin, A wood grain pattern layer was formed with a printing ink containing a color pigment as a solid component.

Then, a colored coat layer having the following composition was applied to the entire surface of the wood grain printing paper, dried and solidified. = Ink for gravure printing [I] = Acrylic polyol 30 parts by weight Hexamethylene diisocyanate 2 Rouge 10 Toluene / Butyl acetate 58

Then, a portion corresponding to the conductive length of the wood grain printing paper was heated with a gravure printing ink [II] having the following composition at 150 ° C. for 20 seconds to obtain a gravure printing ink [II]. It was cured by utilizing the curing action of paratoluene sulfonic acid. = Gravure printing ink [II] = Aminoalkyd resin 40 parts by weight Silicone 10 Blocked paratoluenesulfonic acid 10 Butyl acetate / xylene / isobutane = 3/3/4 40

Thereafter, a coating agent [III] for forming a top coat layer having the following composition was formed on the entire surface of the printing paper.
The coating material was applied at a rate of 6 g / m ² , heated and dried at 150 ° C. for 30 seconds to obtain a decorative material as the target product of the present invention. = Coating agent [III] = Acrylic polyol 50 parts by weight Micro silica 5 Silicone 3 Tolylene diisocyanate 25 Methyl ethyl ketone (MEK) 17

[0031]

In the cosmetic material produced by the production method of the present invention, since it is not necessary to substantially contain the coloring agent in the top coat layer which is repelled, the top coat layer is easily repelled, and the top coat layer is repelled in the concave portion. It is possible to form a stable and sharp concave portion without leaving a residue. In addition, since the colored coat layer containing the colorant is formed under the pattern layer containing the liquid repellent, the coloring can be dark without limit. Therefore, according to the manufacturing method of the present invention, it is possible to obtain a decorative material having a sharp concave portion and exhibiting a high-grade coating feeling.

[Brief description of drawings]

FIG. 1 is a schematic explanatory view for explaining a state of a layer structure of a decorative material manufactured by the method of the present invention.

[Explanation of symbols]

1 Base material for cosmetics 2 First patterned layer 3 Colored coat layer 4 Liquid-repellent ink (second pattern layer) 5 Top coat layer 6 concave part

Claims (2)

[Claims] 1. A step of forming a first pattern layer on the surface of a base material for a decorative material, and a step of applying a resin liquid containing a colorant on the surface of the first pattern layer, Solidifying to form a colored coat layer; forming a second pattern layer with a printing ink containing a liquid repellent substance; and coating a resin solution onto the surface of the second pattern layer. A method for producing a decorative material having a concave portion on the surface, which comprises sequentially processing and solidifying to form a top coat layer. 2. The method according to claim 1, wherein the colorant in the resin liquid containing the colorant is 10 to 99% by weight with respect to the solid component of the resin liquid.