JPH06142603A - Manufacture of rugged decorative material with ionization radiant ray irradiation - Google Patents

Abstract

PURPOSE:To provide the manufacturing method of a rugged decorative material executed by ionization radiant ray irradiation, by which a peeling-off (demolding) property from a rugged type roll plate for forming a rugged pattern is satisfactory, and fine rugged patterns can be formed with high reproducibility. CONSTITUTION:An ionization radiant ray hardening type resin 2 is applied onto a base material 1, thereafter, by allowing its resin layer side to bring it into contact with a rugged type roll plate 3, rugged patterns are formed on the surface, thereafter, at the time of peeling off the base material 1 from the rugged type roll plate 3 together with the resin layer, the resin layer immediately before and immediately after its peeling-off is irradiated with an ionization radiant ray by an irradiating device 6.

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 concavo-convex decorative material by irradiating ionizing radiation such as ultraviolet rays and electron beams, and more specifically, peeling (demolding) from a concavo-convex roll plate for forming a concavo-convex pattern. The present invention relates to a method for producing a concavo-convex decorative material by irradiating with ionizing radiation, which is capable of forming fine concavo-convex patterns with good reproducibility.

[0002]

2. Description of the Related Art Conventionally, various methods for producing a decorative material having an uneven pattern on its surface have been known, and in particular, a mechanical embossing method using an uneven roll plate is now widely practiced.

As a conventional technique by the mechanical embossing method, for example, an electron beam curable liquid material is applied onto a base material, brought into contact with an uneven roll in a wet state, and an electron beam is irradiated from the base material side during the contact. A method of curing the above liquid material and finally releasing the cured uneven material from the uneven roll (Japanese Patent Publication Sho 63
-50066) is known.

Further, a method of forming an ionizing radiation-curable resin layer on a substrate, embossing it, and then irradiating it with ionizing radiation to sufficiently cure the surface of the resin layer to form irregularities (Japanese Patent Laid-Open No. 2000-242242). (Sho 59-227413) is known.

[0005]

However, in the method of Japanese Patent Publication No. 63-50066, the electron beam curable liquid material is cured during contact with the concavo-convex roll. Therefore, depending on the shape of the concavo-convex pattern, demolding after curing may occur. There is a problem that it may be difficult to remove.

On the other hand, in the method of the above-mentioned JP-A-59-227413, since there is a time between the embossing and the curing by the irradiation of ionizing radiation, the shape of the resin layer embossed during that time is slightly recovered. However, there is a problem that it is not possible to accurately reproduce the uneven pattern of the embossed plate, and it is particularly difficult to form a fine uneven pattern.

The present invention has been made in view of the above-mentioned conventional problems, and it is excellent in peeling (demolding) from an uneven roll plate for forming an uneven pattern and capable of forming a fine uneven pattern with good reproducibility. It is an object of the present invention to provide a method for producing an uneven decorative material by irradiation.

[0008]

In order to solve the above-mentioned problems, according to the present invention, after coating an ionizing radiation-curable resin on a substrate, the resin layer side thereof is brought into contact with a concavo-convex roll plate, and then the substrate is When the material is peeled together with the resin layer from the concavo-convex roll plate, the resin layer immediately before and immediately after the peeling is irradiated with ionizing radiation.

Further, according to the present invention, while at least the concave portion of the concavo-convex roll plate is filled with the ionizing radiation curable resin, a base material is pressure-bonded to the roll plate and the filled resin. When peeled from the roll plate, the resin existing between the roll plate and the substrate immediately before and immediately after the peeling is irradiated with ionizing radiation.

The present invention will be described in detail below.

FIG. 1 is a schematic diagram showing the outline of an apparatus for carrying out the method of the present invention.

First, a liquid ionizing radiation curable resin 2 having a viscosity adjusted to an appropriate level so that good coating properties can be obtained on a substrate 1.
Is applied and the resin layer side is brought into contact with the concavo-convex roll plate 3 in a wet state by the roll 4 to form a concavo-convex pattern on the surface of the resin layer, and then the substrate 1 is concavo-convex with the resin layer. When peeling from the mold roll plate 3, the resin layer immediately before and immediately after the peeling is irradiated with ionizing radiation by the irradiation device 6 to cure the resin layer and remove the mold.

Here, the base material 1 is a building material paper,
Can be used with mixed sandpaper, non-woven fabric, resin film, etc.
It is preferably about g / m ² to 150 g / m ² . Further, a desired pattern may be printed on the surface of the base material 1.

The ionizing radiation curable resin 2 which can be used in the present invention is a resin which is cured by ionizing radiation such as ultraviolet rays and electron beams. This ionizing radiation curable resin has an ethylenically unsaturated bond in the molecule. A prepolymer or oligomer having, for example, unsaturated polyesters,
Polyester acrylate, epoxy acrylate, various acrylates such as urethane acrylate, polyester methacrylate, one or more kinds of various methacrylates such as polyether methacrylate, etc., if necessary, a monomer having an ethylenically unsaturated bond in the molecule, for example, , Styrene-based monomers such as styrene and α-methylstyrene, acrylic acid esters such as methyl acrylate and 2-ethylhexyl acrylate,
Methacrylic acid esters such as methyl methacrylate and ethyl methacrylate, unsaturated carboxylic acid amides such as acrylamide and methacrylamide, acrylic acid-2-
(N, N-diethylamino) ethyl, methacrylic acid-2
Polyfunctional compounds such as substituted amino alcohol esters of unsaturated acids such as-(N, N-dimethylamino) ethyl, ethylene glycol diacrylate, 1,6-hexanediol diacrylate, diethylene glycol diacrylate and triethylene glycol diacrylate Compound,
And / or a polythiol compound having two or more thiol groups in the molecule, such as trimethylolpropane trithioglycolate.

The above compounds may be used in any mixture, but the above prepolymer or oligomer is used as a diluent in order to provide suitable coating suitability. In addition to these, various additives such as a surfactant, an antistatic agent, a stabilizer, and a slip agent can be optionally used.

In the case of the ultraviolet curing type, acetylphenones, benzophenones and the like as photopolymerization initiators and n-butylamine, triethylamine and the like as photosensitizers are further mixed and used in the above resin. The content of the initiator is about 0.1 to 10 parts by weight with respect to the resin.

The ionizing radiation curable resin 2 can be obtained as a commercial product.

As a method for applying the ionizing radiation-curable resin 2 on the substrate 1, any known method such as roll coating, knife coating and gravure coating can be adopted. The coating amount is not particularly limited, but is preferably about 3 g / m ² to 120 g / m ^{2 in} order to obtain a constant thickness.

The ionizing radiation-curable resin 2 thus coated on the base material 1 comes into contact with the concavo-convex roll plate 3 in a wet state, where the concavo-convex pattern is formed on the surface. A desired uneven pattern such as a wood grain conduit pattern or an abstract pattern is formed on the peripheral surface of the uneven roll plate 3, and the plate depth is generally 0.1 μm to 100 μm.
It is about m. The concave-convex roll plate 3 can usually be made of a metal material, but it is naturally preferable to select a material that does not cause any trouble even when exposed to ionizing radiation.

The ionizing radiation-curable resin 2 which is in contact with the concavo-convex roll plate 3 and has the concavo-convex pattern formed thereon is then peeled off from the concavo-convex roll plate 3. In the present invention, the resin layer immediately before and immediately after the peeling is irradiated with the ionizing radiation from the irradiation device 6. By this irradiation, at least the surface layer of the resin layer immediately before being peeled from the concavo-convex roll plate 3 is instantaneously cured, so that the concavo-convex pattern of the concavo-convex roll plate 3 can be accurately reproduced, and peeling from the concavo-convex roll plate 3 is performed. Will also be easier. Moreover, since the resin is irradiated immediately after it is peeled from the concavo-convex roll plate 3, the resin is sufficiently cured at this stage.

The irradiation position of the ionizing radiation is almost as shown in FIG. 1, but in particular, as shown in FIG. 2, the tangential direction m when the resin layer is peeled from the concavo-convex roll plate 3 and the irradiation direction n of the ionizing radiation. The angle α (irradiation angle) formed with is 1 to 90
It is desirable that the irradiation position be at a degree, preferably about 10 to 70 degrees. When the ionizing radiation is applied from such an irradiation position, the resin layer immediately before and immediately after being peeled from the concavo-convex roll plate 3 can be efficiently irradiated. Further, the distance A between the peeling position of the resin layer and the irradiation position of the ionizing radiation in FIG.
When electron beam irradiation is performed with V and an output of several mA to several tens of mA, A is preferably about 5 mm.

The dose of ionizing radiation is, for example, 4 Mrad to 10 Mrad in the case of electron beam irradiation and 3 in the case of ultraviolet irradiation.
00mJ / cm ^{2 to} 1000mJ / cm ² is preferable.

It is also possible to dispose the ionizing radiation not at the irradiation position shown in FIG. 1 but inside the concavo-convex roll plate 3 and irradiate it to the peeled portion of the resin layer. In this case, the concavo-convex roll plate 3 is made of a material that is transparent to electron beams or ultraviolet rays. As another method, it is possible to arrange an irradiation device inside or in the vicinity of the roll 5 to irradiate ionizing radiation from the back surface side of the base material 1 to the peeled portion of the resin layer. In this case, the base material 1 needs to be formed of a material that is transparent to electron beams or ultraviolet rays.

Although not shown in FIG. 1, after coating the substrate 1 with the ionizing radiation curable resin 2, before contacting it with the concavo-convex roll plate 3 or after peeling it from the concavo-convex roll plate 3. If necessary, preheating or postheating with a heater may be performed.

FIG. 3 shows another embodiment of the present invention.
At least the concave portions of the concavo-convex roll plate 3 are pressure-bonded to the base material 1 while being filled with the ionizing radiation curable resin 2, and then, when the base material 1 is peeled from the concavo-convex roll plate 3, immediately before and immediately after the peeling. This shows a method for producing an uneven decorative material by curing the resin 2 interposed between the roll plate 3 and the base material 1 by irradiating it with ionizing radiation in the same manner as described above. As a specific method for press-bonding the base material 1 while filling the ionizing radiation curable resin 2 into at least the recesses of the concavo-convex roll plate 3, as shown in FIG. The ionizing radiation curable resin 2 is applied to the contact portion between the concavo-convex roll plate 3 and the roll 4 by a different coating means, and the ionizing radiation curable resin 2 is applied to the base material 1. Instead of coating, it is possible to employ a method in which the concavo-convex roll plate 3 and the roll 4 are stored in the upper part of the contact part and supplied to the corresponding contact part.

According to the method of the present invention as described above, approximately 60
It is possible to manufacture a stable uneven decorative material at a speed of about m / min to 150 m / min.

[0027]

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

Example 1 The following composition (viscosity 200 cps) was applied on a building material paper (TP-30 manufactured by Tenma Special Paper Co., Ltd.) having a basis weight of 30 g / m ^{2 on} the surface of which a wood grain pattern was printed using a roll coater. Was uniformly applied at a coating amount of 20 g / m ² .・ Urethane acrylate (EB-4883, manufactured by Daicel UCP Ltd.) 100 parts by weight ・ 1,6-hexanediol diacrylate 10 parts by weight As shown in FIG. 4Mra at 200KV, 14.9mA when contacting the mold roll plate and then peeling from the roll plate.
By irradiating with an electron beam of d at a position where the irradiation angle was 10 degrees to cure, a wood grain pattern uneven decorative material having a wood grain conduit pattern on the surface was obtained. In addition, all manufacturing is 100m / in-line.
It was done at the speed of a minute.

Example-2 A wood grain pattern uneven decorative material was obtained in exactly the same manner as in Example-1, except that the electron beam irradiation angle in Example-1 was 70 degrees.

Example-3 A wood grain pattern uneven decorative material was obtained in exactly the same manner as in Example-1, except that the electron beam irradiation angle in Example-1 was 90 degrees.

Example 4 A wood grain pattern uneven decorative material was obtained in exactly the same manner as in Example 1 except that the electron beam irradiation angle in Example 1 was 5 degrees.

Example 5 20 g / m ^{2 of the following} composition (viscosity 200 cps) was applied on a building material paper having the wood grain pattern printing used in Example 1 by a roll coater.
A uniform coating amount was applied. -Urethane acrylate (the same as in Example-1) 100 parts by weight-1, 6-hexanediol diacrylate 10 parts by weight-Reaction initiator (DAROCURE 1173 manufactured by Merck & Co., Inc.) 0.1 parts by weight In the same manner as in 1, contact with a concave-convex roll plate having a wood grain conduit pattern, and then, when peeling from the roll plate, by irradiating with an ultraviolet ray of 500 mJ / cm ² at a position of an irradiation angle of 20 degrees to cure, A wood grain pattern uneven decorative material having a wood grain conduit pattern on the surface was obtained. The manufacturing is 40m
/ Min.

Example-6 A wood grain pattern uneven decorative material was obtained in exactly the same manner as in Example-5 except that the ultraviolet irradiation angle in Example-5 was changed to 90 degrees.

The reproducibility of the relief pattern and the releasability from the relief roll plate of each of the obtained decorative materials in Examples 1 to 6 were evaluated according to the following criteria.
The results shown in Table 1 were obtained. ○: Good △: Somewhat bad, but usable ×: Poor

[0035]

[Table 1] From the results of Table 1, the irradiation angle of the electron beam or ultraviolet rays is 10
It has been found that particularly good results can be obtained by setting the range to 70 degrees.

[0036]

As described in detail above, according to the present invention, ionizing radiation is applied to the ionizing radiation-curable resin layer immediately before and immediately after it is peeled from the uneven roll plate for forming the uneven pattern on the resin layer surface. By irradiating and curing, the peelability from the concavo-convex roll plate is good, and the concavo-convex pattern of the roll plate can be accurately reproduced, and even a fine concavo-convex pattern can be formed with good reproducibility. It has an excellent effect.

[Brief description of drawings]

FIG. 1 is a schematic diagram showing an outline of an apparatus for carrying out the method of the present invention.

FIG. 2 is a configuration diagram for explaining an irradiation angle of ionizing radiation.

FIG. 3 is a schematic diagram showing another device for carrying out the method of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base material 2 Ionizing radiation curable resin 3 Concavo-convex roll plate 4,5 rolls 6 Irradiator

Claims (2)

[Claims] 1. A method of coating an ionizing radiation curable resin on a substrate, contacting the resin layer side thereof with an uneven roll plate, and then peeling the substrate together with the resin layer from the uneven roll plate. A method for producing a concavo-convex decorative material by irradiation with ionizing radiation, which comprises irradiating the resin layer immediately before and after peeling with ionizing radiation. 2. A base material is pressure-bonded to the roll plate and the filled resin while filling at least the concave portion of the concavo-convex roll plate with an ionizing radiation curable resin, and then the base material is peeled from the roll plate. In the process, the resin existing between the roll plate and the substrate immediately before and after the peeling is irradiated with ionizing radiation.