JPH05269955A - Patterned film and manufacture thereof - Google Patents

Abstract

PURPOSE:To eliminate complexity in manufacturing process of a decorative sheet by a method wherein recesses on a mold releasing face of a mold releasing sheet having irregularity on its mold releasing face are colored by wiping, coated with resin material so as to bury the recesses, and the mold releasing sheet is peeled and removed. CONSTITUTION:For a mold releasing sheet 2 having a mold releasing face, a thermoplastic resin sheet easy for processing irregularity is used and the surface thereof is treated with coating agent containing mold releasing agent. On the surface of the mold releasing sheet 2, a plain or patterned layer 1 is formed by using a resin which can be peeled easily from the sheet face and can be used as a coating again, and irregularity is produced by thermocompression embossing. On the whole irregular surface made by the irregular processing is coated with coloring ink and the surface is wiped off so as to remove the ink in the recesses. Next, it is coated with a resin material whose adhesion to the ink 3 in the recesses is comparatively hard to be kept and cured by an appropriate way. In order to strengthen a patterned film, a base material film 4 is further arranged on a resin material layer 5 and the mold releasing sheet 2 is peeled off.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a patterning film for forming a concavo-convex pattern on the surface of a decorative plate and a method for producing the same, and in particular, it is possible to color only the inside of the concavity simultaneously with the concavo-convex patterning. TECHNICAL FIELD The present invention relates to a shaped film and a manufacturing method thereof.

[0002]

2. Description of the Related Art Conventionally, as a method of forming a concavo-convex pattern on the surface of a decorative plate or the like at the time of manufacturing it, a metal plate is provided with a desired concavo-convex pattern by etching or the like, and this is used as an embossed plate on the surface of the melamine decorative plate or the like. There is known a method of giving unevenness to the surface, or a method of making unevenness on a surface of a decorative plate or the like by making unevenness on a film of polyethylene terephthalate, polyvinyl chloride, polypropylene or the like.

[0003]

However, all of the above-mentioned shape-imparting films are intended only to make the surface of the molding plate uneven, and therefore, when coloring the recesses of the decorative plate. , A coloring operation such as wiping must be performed in a separate process. However, performing the coloring operation in a separate step is complicated, and there is a problem that the coloring agent is difficult to adhere to the concave portion of the surface of the curable resin, and thus wiping is difficult.

The first object of the present invention is to solve the inconvenience of the conventional patterning film, and specifically,
By simultaneously performing unevenness shaping on the surface of the decorative plate and coloring inside the recessed portion, it is possible to eliminate the complexity of operations in the manufacturing process of the decorative plate and to obtain a decorative plate with excellent colorability. Is. A second object of the present invention is to make it possible to repaint the surface of the decorative plate after shaping, and to improve the design of the decorative plate.

[0005]

In order to achieve the above-mentioned object, the present invention provides a releasable sheet having a transferable and repaintable plain or pattern layer, which is desired after the releasable surface. The unevenness is further applied, the concave portion is colored by wiping, and then a resin material is applied so as to also fill the concave portion, and then the release sheet is peeled off and removed.
A method of manufacturing a shaped film is disclosed. Note that the wiping and the formation of the pattern layer can be performed after the concavo-convex imprinting.

The present invention will be described in detail below. As the releasable sheet having the surface as the releasable surface, it is preferable to use a thermoplastic resin sheet such as soft vinyl chloride so as to facilitate the uneven processing. Further, in addition to the sheet having releasability, a sheet having no releasability whose surface is treated with a coating agent containing a release agent can be used.
As such a coating agent, those which are usually used may be used. For example, a releasing agent such as a fluororesin, various waxes and silicones may be a known vehicle such as an acrylic resin, a fibrin resin and a vinyl resin. What was added to can be used.

The plain or pattern layer provided on the surface of the releasable sheet is preferably one that can be easily peeled off from the sheet surface. Specifically, vinyl resin such as acrylic resin, vinyl chloride / vinyl acetate copolymer, alkyd, etc. Resin, fibrin resin, urethane resin, butyral resin, melamine resin, etc. can be used. Further, these are preferably resins having repaintability.

[0008] As a method for forming the unevenness, a hot press embossing method which is usually used may be used, and various known presses and embossing machines such as a flat plate press and a roll embossing machine can be used. The wiping method may be a commonly used method, for example, a colored ink is applied to the entire uneven surface generated by uneven processing, and then the surface is an in-blade, an air knife, or a roller having a sponge, cloth or the like as a surface material. It can be carried out by wiping with, and removing the ink on the convex portion. The ink used for wiping is preferably selected according to the final specifications of the decorative board.For example, in the case of a melamine resin decorative board, melamine-based, acrylic-based,
Cellulose-based and cellulose acetate-based inks are preferable,
In the case of a DAP (diallyl phthalate) resin decorative plate or a polyester resin decorative plate, butyral-based or cellulose-based ink is preferable. As will be described later, the ink in the recess is transferred to the resin material applied on top of it, but regarding the transfer of the ink, it is sufficient to use the releasability of the applied resin, and a special ink is used. You don't have to use
A release agent such as a silicone resin may be added to improve the releasability of the ink.

The resin material to be applied is not particularly limited, and a material such as polyethylene, polypropylene, nylon, polyvinyl alcohol or the like, which is relatively hard to maintain close contact with general ink, may be used. To apply such a resin material on a wiped film, if it is a thermoplastic resin, it can be coated using, for example, an extrusion method, and if it is a curable resin,
For example, it may be coated by a method such as comma coating or roll coating, and then cured by an appropriate method.

In order to reinforce the shaped film of the present invention, a base material film such as polyester resin or a paper of 30 to 80 g / m ² may be placed on the resin material layer as a support. The shape-imparting film of the present invention is, after carrying out operations such as embossing by embossing as described above, coloring by wiping, and pattern layer formation, etc., applying a resin agent on the sheet, and then releasing the releasable sheet. It can be manufactured by peeling. Here, the order of performing operations such as unevenness shaping, wiping, and pattern layer formation can be arbitrarily selected. For example, as shown in Example 2, after providing a pattern layer and then performing unevenness shaping and wiping in this order, as shown in FIG. 4, first, unevenness is applied to a sheet, and then the concave portions are colored by wiping. After that, a method for providing a pattern layer or as shown in FIG.
It is also possible to adopt a method of performing wiping after that.
When the pattern layer is provided after wiping, the pattern layer should be transparent enough to allow the wapping ink to be seen.

The transfer pattern and the base film have similar SP values (solubility parameters), preferably the same resin. The shaped film of the present invention is a melamine decorative board, a thermosetting resin decorative board such as a DAP decorative board, a decorative board such as a polyester resin decorative board, or an electron beam curable resin applied on a substrate, It can be widely used, for example, for shaping an ultraviolet curable resin. However, when an ultraviolet curable resin is used, it is necessary to use a film and an ink having a property of transmitting ultraviolet rays.

[0012]

The shape-imparting film of the present invention comprises a resin layer 5 having irregularities as shown in FIG. 1 (e) and a pattern layer 1 having recoatability and transferability. Has wiping ink 3 attached thereto. When this shaped film is applied to, for example, a melamine decorative board, it is as follows. As shown in FIG. 2, the melamine decorative board is composed of a phenol resin-impregnated core paper 8, a melamine resin-impregnated printed titanium paper 7, and a melamine resin-impregnated overlay paper 6, which are laminated in this order. Then, the shaped film A of the present invention is placed on this, and thermocompression molding is performed. When pressure is applied, the convex portion of the shape-imparting film immerses in the overlay paper, forming a depression on the surface of the decorative sheet as shown in FIG. At the same time, the pattern layer 1 is transferred to the surface of the decorative plate by pressure. Further, the wiping ink attached to the convex portion of the resin layer 5 is transferred to the concave portion of the decorative plate.

[0013]

EXAMPLES The present invention will be described below with reference to examples.

[0014]

Example 1 DOP (dioctyl phthalate) as a plasticizer
A vinyl chloride sheet 2 (thickness: 0.1 mm) containing 8 parts by weight of 100 parts by weight of a resin was provided with a release layer with a vinyl chloride ink containing a silicone release agent. The pattern layer 1 was provided on the release layer side with an acrylic resin containing a carboxyl group and a hydroxyl group (FIG. 1A). After that, the embossing roll having a convex portion having a wood grain tube pattern was provided with a concave portion on the releasable surface of the sheet and the pattern 1 (FIG. 1B), and the concave portion was wiped with a melamine-based ink (brown) 3. (Fig. 1C).

Next, a melted polypropylene resin 5 is extruded by a T-die method between a PET (polyethylene terephthalate) film 4 having a thickness of 25 μ and the wiped vinyl chloride sheet 2 (thickness 60 μ) of PET / PP / PVC. A laminate was obtained (Fig. 1D). Here, the vinyl chloride sheet 2 provided with the release layer was peeled off to obtain a shaped film A (FIG. 1E) in which only the convex portions of the wood grain conduit were colored.

Using four pieces of separately prepared phenol resin-impregnated core paper, melamine resin-impregnated wood grain printed titanium paper 7 and overlay paper 6, as shown in FIG. Stacked in order,
The shape-imparting film obtained above was placed on the uppermost overlay paper, and hot pressed under normal melamine molding conditions.

After completion of the molding, the shaped film A was peeled off to obtain a wiping-like melamine decorative board B having a pattern transferred as shown in FIG.
By further coating this with urethane, a paint-like wiping melamine plate which was not found in conventional melamine decorative plates was obtained.

[0018]

Example 2 On the surface of a vinyl chloride sheet having a releasing layer similar to that of Example 1, a transferable pattern layer made of nitrocellulose alkyd and a transparent solid layer were sequentially provided. After that, a concave portion was provided on the sheet releasable surface with an embossing roll having a convex portion having a wood grain pattern, and the concave portion was wiped with urethane ink. Then, a polypropylene resin melted between a 25 μPET film and the wiped vinyl chloride sheet was extruded by a T-die method to obtain a PET / PP / PVC laminate. Here, the vinyl chloride sheet provided with the release layer was peeled off to obtain a shaped film having colored convex portions of the wood grain conduit.

On a separately prepared 2.5 m / m plywood, 80 g / m ² titanium paper was pasted with a wood grain print using a vinyl acetate adhesive. About 30 g / unsaturated polyester resin (cobalt naphthenate catalyst, containing MEK peroxide initiator) on this surface
After coating with the amount of scale ² , the above-mentioned shaped film was laminated while defoaming so that the colored surface was in contact with the unsaturated polyester resin. After the unsaturated polyester resin was cured, the embossed film was peeled off to obtain a decorative board having the conduit embossed portion wiped. By further coating the surface of this decorative board with urethane, a high-grade polyester decorative board with a feeling of painting was obtained.

[0020]

EFFECTS OF THE INVENTION According to the present invention, by performing unevenness shaping and coloring the inside of the concave portion at the same time, the complexity of the operation in the manufacturing process of the decorative plate and the like is eliminated, and the thermosetting resin surface which has been difficult in the past. It is possible to favorably color the inside of the concave portion of the unevenness formed in the above. Further, since the re-paintable pattern layer or the like is transferred to the surface of the decorative plate, it is possible to re-coat after the imprinting, and the design of the decorative plate can be improved in combination with the original pattern.

[Brief description of drawings]

FIG. 1 is a diagram showing a process for producing a shaped film of the present invention.

FIG. 2 is a diagram showing a manufacturing process of a melamine resin decorative board.

FIG. 3 is a view showing a melamine decorative board after uneven shaping.

FIG. 4 is a diagram showing a process for producing a shaped film of the present invention.

FIG. 5 is a diagram showing a process for producing a shaped film of the present invention.

[Explanation of symbols]

1-design, 2-embossing film, 3-wiping ink, 4-base film, 5-resin resin layer, 6-overlay paper, 7-printed titanium paper, 8-core paper, A-shaped film, B --Melamine resin decorative board

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Internal reference number FI Technical display location B44C 1/165 F 9134-3K 3/02 A 9134-3K

Claims (5)

[Claims] 1. A mold release sheet having a mold release surface having a desired unevenness is colored by wiping the concave part of the mold release surface, and then a resin material is applied so as to fill the concave part. A method for producing a shaped film, which comprises peeling and removing the formable sheet. 2. A mold release sheet is provided with a transferable and repaintable plain or pattern layer on the mold release surface, and then the desired unevenness is formed, and the recesses are colored by wiping. Characterized in that a resin material is applied so as to also fill the recesses, and then the release sheet is peeled off and removed.
Shaped film manufacturing method. 3. A mold release sheet is provided with a desired unevenness on its release surface, the recesses are colored by wiping, and a plain or pattern layer having transferability and repaintability is further provided thereon. Next, a resin film is applied so as to fill the recesses, and then the release sheet is peeled off and removed. 4. The release surface of the release sheet is provided with desired unevenness, and a plain or pattern layer having transferability and repaintability is provided thereon, and the recess is colored by wiping. Next, a resin film is applied so as to fill the recesses, and then the release sheet is peeled off and removed. 5. A shaped film produced by the method according to any one of claims 1 to 4.