JPH06170943A - Manufacture of decorative plate - Google Patents

Abstract

PURPOSE:To provide a method for manufacturing a decorative plate in which the plate having an embossed shape and a design harmonized with the shape on a surface can be efficiently produced. CONSTITUTION:A method for manufacturing a decorative plate comprises the steps of coating the plate 21 having an embossed shape on a surface with adhesive, and pressing a transfer sheet 22 having a base sheet of thermoplastic resin, a peeling layer and a design layer from a surface of the base sheet of the transfer sheet to the plate by a roll to transfer the design, wherein pressing is conducted by a plurality of soft hot rolls. At least second and the following roll is a roll 34 having a diameter smaller than that of the other roll, and the roll having the small diameter is driven by a backup roll 25 having a diameter larger than that of the roll having the small diameter and being hard.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a decorative board having a pattern, and more particularly to a method for efficiently manufacturing a decorative board having a design which has an embossed shape and a pattern matching the embossed shape.

[0002]

2. Description of the Related Art Conventionally, various decorative boards have been used for interior and exterior of houses, furniture members, etc., but in recent years, products having embossed surfaces have been favored along with the trend toward higher quality and higher design. It's coming. In the case of conventional products with a flat surface, as a method of providing a pattern on the surface, for example, a method of laminating a sheet on which a pattern is printed on the surface, etc. can be used. I had no choice but to rely on a simple manufacturing method such as painting with the above paint or sprinkling sand.

[0003]

SUMMARY OF THE INVENTION The present invention has been made in view of the above conventional problems, and is to efficiently produce a decorative board having an embossed shape on the surface and a pattern matching the embossed shape. The present invention provides a method for enabling transfer to a decorative board having extremely fine embossing, which has become conspicuous under the recent demand for higher quality designs.

[0004]

In order to solve the above-mentioned problems, the present invention applies an adhesive to a decorative board having an embossed shape on the surface thereof, while forming a base sheet made of a thermoplastic resin, a release layer and a pattern layer. A transfer sheet consisting of, a method for producing a decorative plate by pressing a roll from the surface of the base sheet of the transfer sheet on the decorative plate, wherein the pressing is performed by a plurality of flexible heat rolls, At least one roll after the second roll has a smaller diameter than the other rolls,
There is provided a method for manufacturing a decorative plate, characterized in that the roll having the small diameter is driven by a backup roll having a larger diameter and being hard.

The present invention will be described in detail below with reference to the drawings. FIG. 1 schematically shows a cross section of the transfer sheet according to the present invention. In this transfer sheet, a desired pattern layer 2 and a release layer 3 are provided on the surface of a base sheet 1.

As the base sheet 1, a thermoplastic resin capable of following the irregularities on the surface of the decorative plate by heat during transfer is used. Specifically, sheets of polyvinyl chloride, polyethylene, polypropylene, nylon, polyester, etc. can be used. The type and thickness of the resin may be appropriately selected in consideration of the degree of unevenness on the surface of the decorative plate to be transferred and the transfer temperature. For example, 150 ℃ ~ 180 ℃
At the transfer temperature of 1, the vinyl chloride resin having a thickness of 100 μm or less gives the best results.

The method for forming the pattern layer 2 on the base sheet is as follows.
Gravure printing, screen printing, offset printing or the like may be used. The synthetic resin binder used for the printing ink is determined in consideration of the large elongation during heating and the durability of the final product. For example, acrylic resin, styrene resin, alkyd resin, polyamide, polyester, polyvinyl chloride, polyvinyl acetate, or a mixture or copolymer of a combination thereof is used.

The adhesive applied to the decorative board is appropriately determined depending on the material of the decorative board and the material of the ink. Specifically, urethane, polyvinyl alcohol, vinyl acetate emulsion and the like are used. As a coating method, air spray, various coaters or the like may be used.

FIG. 2 shows an example of the manufacturing method of the present invention. After the adhesive is applied to the uneven surface of the decorative plate 21 by air spraying, the transfer sheet 22 shown in FIG. 1 is pressed from the surface of the base sheet with a heat roll 23 to transfer the pattern. The heat roll used at this time is a soft one that follows the unevenness of the plate.

At this time, when transferring to a very fine embossed surface or a linear uneven portion such as an edge portion of a decorative plate, a phenomenon as shown in FIG. 3 may occur. That is, the pattern layer 31 and the decorative plate 32 are not transferred to the lowest point of the concave portion, and only apparently transferred.
A gap 33 is formed between Basically, in order to follow the embossed shape, it has been clarified by the experiments of the present inventors that it is better to soften the roll hardness, but with a very fine embossing, the pressed roll is flexible,
No pressure is applied.

According to the present invention, as shown in FIG. 2, in order to solve this problem, pressing is performed by a plurality of flexible heat rolls, and the second heat roll 24 has a diameter smaller than that of the first heat roll 23. The second heat roll 24, which is a roll, is driven by a backup roll 25 having a larger diameter and being hard.

According to the experiments conducted by the present inventors, the first heat roll 23 has a rubber hardness of 30 °, a wall thickness of 20 mm, and a roll diameter of 220 m, although it depends on the size of the unevenness of the decorative plate.
Good results have been obtained with a silicone rubber roll of m.

The smaller the roll diameter of the second heat roll 24, the better, but any rubber roll having a wall thickness equal to or larger than the thickness of the decorative plate to be transferred may be used.

Since the backup roll 25 drives the second heat roll, it is convenient for the structure of the apparatus to have the same diameter as the first rubber roll. As the material, metal, silicon rubber having high hardness, or the like can be used.

[0015]

As described above, according to the present invention, the pattern layer is transferred to the lowest point of the recess by decreasing the roll diameter and increasing the pressure per unit area. Further, since a high pressure is applied to the roll, a backup roll is used to prevent the roll from being deformed by the pressure, and the backup roll is driven. Also, the use of a large diameter roll for the first heat roll,
This is because when a high pressure is applied suddenly during transfer, wrinkles are likely to occur on the transfer paper, so that the transfer paper and the decorative plate are temporarily tensioned so that wrinkles cannot occur.

[0016]

Example A semi-rigid vinyl chloride sheet having a thickness of 80 μm was used as a base sheet, and a polyvinyl butyral resin was applied as a release layer to the surface by gravure printing, and then a vinyl chloride-vinyl acetate copolymer resin was used as a pattern layer. A brick pattern was formed by gravure printing using the ink as a binder to obtain a transfer sheet. On the other hand, as a decorative board, a fiber-reinforced cement board which was embossed in a brick pattern and provided with an uneven pattern was used, and a urethane adhesive was applied thereto by air spray. The transfer sheet is placed on this, and the surface temperature is 175 ° C. from the surface of the base sheet, the rubber hardness is 30 °, and the wall thickness is 2
0 mm, first hot roll with a roll diameter of 220 mm, and
It was pressed by a second hot roll having a surface temperature of 180 ° C., a rubber hardness of 30 °, a wall thickness of 20 mm, and a roll diameter of 80 mm. Transfer speed is 10 m / min, pressure is 10 kg / cm each
² and 15 kg / cm ² . After the transfer, the base sheet was peeled off, and the obtained decorative plate had a very high design effect in which the brick-like embossing and the transferred brick pattern were in good harmony.

[0017]

As described above, according to the present invention, a beautiful pattern can be provided on the surface of a decorative material having fine irregularities by a simple method.

[0018]

[Brief description of drawings]

FIG. 1 is an explanatory diagram showing a cross-sectional structure of a transfer sheet according to the present invention.

FIG. 2 is an explanatory view schematically showing an example of a method for manufacturing a decorative board according to the present invention.

FIG. 3 is an explanatory diagram schematically showing a transfer failure by a conventional transfer method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Base sheet 2 ... Release layer 3 ... Design layer 21 ... Decorative plate 22 ... Transfer sheet 23 ... First heat roll 24 ... Second heat roll 25 ... Backup roll 31 ... Design layer 32 ... Decorative plate 33 ... Void

Claims (1)

[Claims] 1. A decorative sheet having an embossed surface on which an adhesive is applied, on the other hand, a base sheet made of a thermoplastic resin, a transfer sheet made of a release layer and a pattern layer are placed on the decorative sheet. A method of manufacturing a decorative plate in which a roll is pressed from the surface of the sheet to transfer a pattern, and pressing is performed by a plurality of flexible heat rolls, and at least one roll after the second roll is smaller than other rolls. Is a roll of diameter,
A method for manufacturing a decorative board, characterized in that the roll having the smaller diameter is driven by a harder backup roll having a larger diameter.