JPH05208478A - Production of decorative laminate - Google Patents

Abstract

PURPOSE:To improve handleability of a transfer sheet per se and prevent the contamination of a pattern or the like caused by a transfer sheet having an uncured pattern layer by using a transfer sheet in which a pattern layer is partially cured by being irradiated with ultraviolet light. CONSTITUTION:A pattern layer 2 made of an uncured ultraviolet-curing composition in a transfer sheet 3 is superposed on a coating layer 5 made of an uncured ultraviolet-curing composition formed as one surface layer of a decorative laminate substrate 4. Namely, the pattern layer 2 of the transfer sheet 3 and the coating layer 5 of the decorative laminate substrate 4 are superposed on each other in wet states. This is irradiated with ultraviolet light, whereby the pattern layer 2 and the coating layer 5 turn to a cured pattern layer 2a and a cured coating layer 5a and, simultaneously, the transfer sheet 3 and the decorative laminate substrate 4 are integrated by curing. After that, a substrate sheet 1 is released from the laminate integrated by curing, whereby a decorative laminate is obtained.

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 board having a transfer pattern by a transfer sheet, which comprises transferring a layer of an ultraviolet curable composition onto the surface of a base material for a decorative board to transfer the composition. Provided is a method for easily and surely obtaining a decorative board having a large adhesive strength between a pattern and a base material for a decorative board and having a transferred pattern having excellent properties such as solvent resistance and chemical resistance. Is.

[0002]

2. Description of the Related Art A surface coating with an ultraviolet curable composition,
As a specific manufacturing method of various building materials having a colored pattern layer, plywood, gypsum board, a method of directly applying an ultraviolet-curable composition containing a colorant to a substrate such as a metal plate, and curing by irradiating with ultraviolet rays, Directly print with a standard ink on the base material, apply the UV-curable composition to the printed surface and irradiate it with ultraviolet light to cure it, or attach a decorative sheet to the base material and apply UV light to the surface. A method of applying a curable composition and irradiating the composition with ultraviolet rays to cure the composition, laminating a decorative sheet after applying the ultraviolet curable composition to a substrate, and further applying the ultraviolet curable composition to the surface of the decorative sheet. There is a method of irradiating the composition with ultraviolet rays to cure and integrate the two layers of the ultraviolet curable composition.

[0003]

However, the former two methods of forming a pattern layer by applying ink directly or to the base material are limited to the surface condition and shape of the base material used.
It is not a versatile method. In addition, the latter two methods of using a decorative sheet are not only the method of using irradiation of ultraviolet rays, which is originally intended to obtain a high quality pattern layer, in which the obtained cured substance has a decrease in physical properties, and There are drawbacks such as poor adhesion between the sheet and the UV curable substance of the paper and delamination of the decorative sheet itself.

Further, as a method of manufacturing various building materials having a pattern layer using a colorant, there is a method of molding a transfer pattern by a transfer sheet, and specifically, a so-called hot stamp or film method performed through a thermoplastic synthetic resin. There is a method that is widely used in the production of polyester resin decorative boards, etc.
If the pattern layer formed on the transfer sheet is composed of normal ink, the transfer pattern obtained has the drawback of being inferior in solvent resistance and chemical resistance. There is a need. In addition, when the pattern layer formed on the transfer sheet is composed of a curable ink, there is a problem in the adhesion between the curable ink and the polyester resin, and both are easy and high quality transfer. In terms of getting the pattern, it is not satisfactory.

[0005]

In view of the above-mentioned object, the present invention constitutes the scope of the claims, and a method for manufacturing a decorative sheet having a transfer pattern by a conventional transfer sheet, or laminating decorative sheets, ultraviolet rays After applying the curable composition paint,
It is possible to provide a method for easily and surely obtaining a decorative board having a high-quality colored pattern layer, which could not be obtained by the method of producing a decorative board having a colored pattern layer by irradiating ultraviolet irradiation energy. ..

[0006]

The method for manufacturing a decorative board of the present invention will be described below with reference to the process charts of the illustrated embodiments. In the method for manufacturing a decorative sheet of the present invention, the transfer sheet indicated by reference numeral 3 in FIG. 1, that is, the ultraviolet curability obtained by partially curing one surface of the base sheet 1 in a touch-free state containing a coloring agent. As shown in FIG. 2, a transfer sheet 3 provided with arbitrary pattern layers 2, 2, ... Made of a composition and a base material 4 for a decorative sheet having a coating layer 5 made of an ultraviolet curable composition are provided. , Transfer sheet 3
By laminating so that the surface of the pattern layer 2 and the surface of the decorative plate base material 5 are in contact with each other, a laminate 6 of the transfer sheet 3 and the decorative plate base material 4 is obtained. Next, ultraviolet rays are irradiated from the transfer sheet 3 side of the laminate 6 of the transfer sheet 3 and the decorative plate substrate 4 obtained in the above step, that is, the arrow (A) side in FIG.
At the same time as curing the pattern layer 2 in the transfer sheet 3 and the coating layer 5 in the base material 4 for decorative plate to form the pattern layer 2a and the cured coating layer 5a in FIG. The transfer sheet 3 and the base material 4 for decorative plate are integrated, and subsequently, as shown in FIG. 3, the transfer sheet 3 is formed from the laminated body 6a that is cured and integrated by the irradiation of the ultraviolet rays. Peeling off only the base sheet 1 which is present,
It is to obtain a decorative plate having a structure as indicated by reference numeral 7.

As is apparent from the above description, in the method for manufacturing a decorative sheet of the present invention, the pattern layer 2 made of the uncured ultraviolet-curable composition in the transfer sheet 3 is replaced with the surface layer on one side of the decorative sheet substrate 4. Is superposed on the coating layer 5 made of the uncured ultraviolet curable composition, that is, the pattern layer 2 of the transfer sheet 3 and the coating layer 5 of the base material 4 for decorative plate are superposed in a wet state. Makeup by a transfer method using a method of irradiating ultraviolet rays to form the coating layer 5 of the pattern layer 2 into the cured pattern layer 2a and the coating layer 5a and at the same time integrating the transfer sheet 3 and the base material 4 for decorative plate. In the plate manufacturing method, if the transfer sheet in which the pattern layer 2 in the transfer sheet 3 is partially cured by ultraviolet irradiation is used, the transfer sheet 3 itself can be easily handled, and the uncured pattern layer 2 can be easily handled. Have Problems such as dirt pattern due to copy sheet 3 is solved.

In the method for manufacturing a decorative board of the present invention, the transfer sheet 3 constituting the laminate 6 which is irradiated with ultraviolet rays is formed of an ultraviolet curable composition containing a colorant as described above. The base sheet 1 having the patterned layer 2 is used, that is, the base sheet 1 having the patterned layer 2 which is formed of an ultraviolet curable composition and is partially cured to a touch-free state by irradiation with ultraviolet rays is used. However, even if a known transfer sheet having a pattern layer made of a completely uncured UV-curable composition or a conventional pattern layer using a normal ink is used, the physical properties aimed at by the present invention can be obtained to some extent. Although it is possible to obtain a decorative board having the above, there is a drawback in that the fastness of the obtained pattern layer is not sufficiently satisfied by such a method.

The transfer sheet 3 used in the method for producing a decorative sheet of the present invention comprises an optional pattern layer 2 made of an ultraviolet curable composition containing a colorant on one surface of the base sheet 1.
.. are provided, and as the base sheet 1, a synthetic resin film or sheet known as a base sheet of a transfer sheet, or a composite sheet of these is used. In particular, the base sheet 1 is peeled off from the laminate when obtaining the decorative sheet as the final product, and is embodied as the gloss of the surface of the decorative sheet 7 which gives the gloss of the base sheet 1 surface. A base sheet 1 having a gloss matching the above is used.

An optional pattern layer 2 on the substrate sheet 3,
2, ... are composed of a UV-curable composition containing a colorant, and a prepolymer or oligomer having a colorant and an ethylenically unsaturated bond in the molecule or an ethylenically unsaturated bond in the molecule. A composition containing as a main component the monomer or a mixture thereof is used.

Examples of the prepolymer or oligomer having an ethylenically unsaturated bond in the molecule used in the ultraviolet curable composition include unsaturated polyesters,
Various acrylates such as polyester acrylate, epoxy acrylate, urethane acrylate, polyol acrylate, and melamine acrylate, various methacrylates such as polyester methacrylate, epoxy methacrylate, urethane methacrylate, polyol methacrylate, melamine methacrylate, etc. Examples of the monomer having a bond include styrene, styrene-based monomers such as α-methylstyrene, methyl acrylate, 2-ethylhexyl acrylate, methoxyethyl acrylate, butoxyethyl acrylate, butyl acrylate, methoxybutyl acrylate, and acrylic acid. Acrylic esters such as phenyl, methyl methacrylate, ethyl methacrylate, propyl methacrylate, etc. Methacrylic acid esters, acrylamides, unsaturated carboxylic acid amides, such as methacrylamide, acrylic acid 2- (N, N-dibenzylamino)
Substituted amino alcohol esters of unsaturated acids such as ethyl, (N, N-dimethylamino) methyl methacrylate, 2- (N, N-diethylamino) propyl acrylate,
Ethylene glycol diacrylate, propylene glycol diacrylate, neopentyl glycol diacrylate, 1,6-hexanediol diacrylate, diethylene glycol diacrylate, triethylene glycol diacrylate, dipropylene glycol diacrylate, ethylene glycol dimethacrylate, propylene glycol dimethacrylate , Polyfunctional compounds such as diethylene glycol methacrylate, and / or polythiol compounds having two or more thiol groups in the molecule, such as trimethylolpropane trithioglycolate, trimethylolpropane trithiopropionate, pentaerythritol tetrathioglycol. Rate etc.

The coloring agent contained in the ultraviolet curable composition is calcium carbonate, clay,
Inorganic pigments such as titanium white, carbon black, yellow lead, chrome vermilion, cadmium red, navy blue, ultramarine blue, iron oxide, and alumina white, and organic such as azo pigments, azo lake pigments, slene pigments, and quinacridone pigments Based pigments are used.

The UV-curable composition containing a colorant for forming the pattern layer 2 in the transfer sheet 3 is based on 100 parts by weight of a prepolymer or oligomer having an ethylenically unsaturated bond in the molecule and a monomer. It is preferable that the content of the pigment as the colorant is about 1 to 20 parts by weight, and especially when the amount of the pigment as the colorant exceeds 20 parts by weight,
The solvent and chemical resistance of the pattern layer in the obtained decorative board are deteriorated.

Further, when utilizing the irradiation of ultraviolet rays for partially curing the pattern layer 2 of the transfer paper 3, as the UV curable composition for forming the pattern layer 2 of the transfer paper 3, ethylenically unsaturated in the molecule. 5-10 with respect to 100 parts by weight of prepolymer or oligomer having a bond and monomer
About parts by weight of a photopolymerization initiator, for example, benzoin methyl ether, benzoin propyl ether, benzoin n
-Various benzoin ethers such as butyl ether and benzoin butyl ether, benzophenones,
The photopolymerization initiator that generates radicals by ultraviolet irradiation such as halogenated acetophenones and biatyls, and the pattern layer 2 on the transfer paper 3 form a secondary layer on the laminate 6 of the transfer paper 3 and the decorative plate base material 4. In order to prevent the resin from being completely cured before being irradiated with ultraviolet rays, it is preferable to mix 10 parts by weight or less of a polymerization inhibiting stabilizer such as hydroquinone, hydroquinone monomethyl ether, benzoquinone and the like.

The pattern layer 2 on the transfer paper 3 is obtained by subjecting the above-mentioned ultraviolet curable composition to various printing methods such as gravure printing, offset printing and screen printing.
It can be easily formed by printing on.

Next, in the method for manufacturing a decorative board of the present invention, the decorative board substrate 4 having the coating layer 5 of the ultraviolet curable composition laminated on the transfer sheet 3 is, for example, plywood, particle board, or the like. Wood-based base materials such as fiberboard, ceramic base materials such as calcium silicate board, gypsum board, asbestos slate board and pulp cement board, metal-based base materials such as zinc iron plate, aluminum plate and stainless steel plate, hard vinyl chloride plate, In the same manner as the UV curable composition constituting the pattern layer 2 in the transfer sheet 3, the ethylenically unsaturated bond is added to the molecule in the base material 4 for a decorative plate made of a plastic base material such as an acrylic plate. A composition containing a prepolymer or oligomer having a monomer having an ethylenically unsaturated bond in the molecule as a main component, or a coloring agent added to this composition The ultraviolet-curable composition comprising forming material, for example, reverse roll coating, gravure roll coating, air knife coating, curtain coating, by coating methods such as Mayer bar coating, but which is easily obtained by applying on one surface.

The decorative board manufacturing method of the present invention comprises the transfer sheet 3 and the decorative board substrate 4 having the coating layer 5 each having the above-mentioned structure, the surface of the pattern layer 2 of the transfer sheet 3 and the decorative board. The base material 4 is laminated so that the surface of the coating layer 5 is in contact with the base material 4, and ultraviolet rays are radiated from the transfer sheet 3 side (A) of the obtained laminate 6 to obtain the pattern layer 2 and the coating layer 5 in the laminate 6. And 2 are completely cured, and the cured pattern layers 2a
And the coating layer 5a.

Prior to the second UV irradiation, the laminate 6 is
Is applied to the surface of the transfer sheet 3 of the laminate 6 with a flexible roll so that the air present between the transfer sheet 3 and the decorative plate base material 4 is removed. It is preferable in that the effect of oxygen that adversely affects the hardening effect due to the irradiation with can be prevented.

The irradiation amount of the ultraviolet rays applied to the laminated body 6 needs energy enough to completely cure the pattern layer 2 on the transfer sheet 3 and the coating layer 5 on the decorative plate base material 4.

The specific structure of the method for manufacturing a decorative board of the present invention will be described below with reference to examples.

[0021]

EXAMPLE 1 45 parts by weight of oligoester acrylate, 40 parts by weight of 1,6-hexanediol diacrylate, 10 parts by weight of pigment, and 4.5 parts of benzophenone were formed on one surface of a base sheet made of a polyester film having a thickness of 25 μm.
Parts by weight. Printing with a silk screen using 0.5 part by weight of hydroquinone and then irradiating the printed surface with ultraviolet rays from an ultraviolet lamp, the printed pattern layer is cured to a touch-free state (partially cured). A transfer sheet was obtained. Next, from a glass fiber reinforced gypsum board having a coating layer in which a coating consisting of 50 parts by weight of oligoester acrylate, 50 parts by weight of 1,6 hexanediol diacrylate and 4.5 parts by weight of benzophenone is applied at a rate of 100 g / m ^2. The decorative sheet substrate is laminated so that the pattern layer surface of the transfer sheet and the coating layer surface of the decorative sheet substrate are in contact with each other, and a strong and large amount of ultraviolet ray is irradiated from the transfer sheet side of the laminated sheet. Then, the pattern layer in the transfer sheet and the coating layer in the base material for decorative plate are completely cured, and the transfer sheet and the base material for decorative plate are cured and integrated, and thereafter, the base sheet in the transfer sheet is transferred from the laminate. The barrel polyester film was peeled off to obtain a target product, a plaster decorative board. The surface of the obtained gypsum decorative board including the colored pattern layer was excellent in solvent resistance and chemical resistance and had high hardness.

[0022]

EFFECT OF THE INVENTION The method for producing a decorative board of the present invention is constructed as described above, and the surface including the colored pattern layer has a high hardness and is excellent in solvent resistance and chemical resistance. It is possible to easily and surely obtain a decorative board for building materials for various purposes such as a flooring agent, a wall material, a ceiling material and the like having the properties, and an effect. In addition, in the method for manufacturing a decorative sheet of the present invention, since the gloss of the transfer sheet can be stably reproduced as the gloss of the surface of the decorative sheet, by selecting the base sheet in the transfer sheet, the makeup that achieves the desired gloss can be obtained. The action that the seat is surely obtained,
Have an effect. Further, in the method for manufacturing a decorative sheet of the present invention, ultraviolet rays are generated in a state in which the pattern layer in the transfer sheet and the coating layer in the decorative sheet substrate are both sandwiched between the base sheet and the decorative sheet substrate in the transfer sheet. Since the pattern layer and the coating layer, which are cured by the irradiation of ultraviolet rays, are shielded from oxygen due to the irradiation, an action and an effect that an extremely high quality pattern layer and the coating layer can be obtained by the irradiation of ultraviolet rays are also exhibited.

Further, since the pattern layer on the transfer sheet is once partially cured to the touch-free state by irradiation with ultraviolet rays, the transfer sheet can be temporarily wound and stored, or handled. It has excellent workability without the risk of ink sticking to other parts and getting dirty. At that time, the polymerization-inhibiting stabilizer in the pattern layer can prevent the pattern layer in a partially cured state from proceeding with reaction over time and completely curing before the transfer, so that the process between the production of the transfer sheet and the transfer step can be prevented. Regardless of variations in time, storage location of transfer sheet (temperature, etc.),
It is possible to always obtain stable adhesion between the pattern layer and the coating layer.

[Brief description of drawings]

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

FIG. 2 is a cross-sectional view of a laminate of a transfer sheet and a decorative board substrate.

FIG. 3 is a cross-sectional view showing a state in which a base sheet is peeled off from a laminated body after being irradiated with ultraviolet rays.

FIG. 4 is a cross-sectional view of a decorative plate obtained by the above steps.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Base sheet 2 Pattern layer 3 Transfer sheet 4 Base material for decorative board 5 Coating layer 6 Laminated body of transfer sheet and base material for decorative board 7 Decorative board A Transfer sheet side in laminated body 2a Cured by UV irradiation Patterned layer 5a coating layer cured by irradiation of ultraviolet rays 6a laminated body of a transfer sheet and a base material for decorative plate which are cured and integrated

Claims (1)

[Claims] 1. A pattern layer of an ultraviolet-curable composition containing a colorant, a photopolymerization initiator, and a polymerization inhibition stabilizer is provided on one surface of a base sheet, and the pattern layer is irradiated with ultraviolet rays to form a finger. A transfer sheet that is partially cured to a touch-dry state and a base material for a decorative sheet having an uncured UV-curable composition coating layer, the pattern layer of the transfer sheet and the coating layer surface of the base material for a decorative sheet. The transfer sheet and the base material for a decorative sheet are cured and integrated by irradiating ultraviolet rays from the transfer sheet side of the laminate obtained by contacting with each other, and then the base sheet is formed from the cured and integrated laminate. A method for manufacturing a decorative board, which comprises peeling.