JPH06336000A - Production of embossed decorative board - Google Patents

Abstract

PURPOSE:To produce an embossed decorative board having a natural wooden texture excellent in bending processability and having flexibility. CONSTITUTION:A pattern printing layer 2 is formed on a base material 1. Subsequently, a curable resin 3 containing urethane acrylate as a main component is applied to the pattern printing layer 2 and p an embossed sheet having the uneven surface of natural wood texture faithfully transferred to the surface thereof is bonded to the coating layer of the curable resin 3 and, in this bonded state, the whole is irradiated with ionizing radiation 5 to cure the curable resin 3 and, thereafter, the embossed sheet 4 is peeled.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an embossed decorative board, and more particularly to a method of manufacturing a flexible embossed decorative board having a natural wood texture.

[0002]

2. Description of the Related Art Conventionally, various attempts have been made in the veneer industry to make a veneer as close to natural wood as possible.

For example, after a resin layer is formed on the surface of a wood grain pattern printed product, hot pressure embossing is performed using an embossing roll having a wood grain conduit pattern, ink for suppressing curing of an ultraviolet curable resin is used, or a masking film is used. There is known a method of expressing an uneven pattern by using a difference between a cured portion and a non-cured portion of an ultraviolet curable resin.

Further, there is also known a polyester resin decorative board using an embossed sheet in which an uneven surface of natural wood is faithfully modeled (JP-A-56-30858).

[0005]

However, in any of the cases described above and the above methods, it is possible to express a large portion of a conduit or the like, but the expression is artificial in its entirety and natural. It is still insufficient to express the natural feeling of wood.

On the other hand, in the case of the above-mentioned decorative board, it is excellent in expressing the natural feeling of natural wood, but since it is not flexible, it is discolored (whitened) or cracked when bent. Inconvenience occurs. Therefore, it can be used only as an interior door, a storage door, etc. by the flat attachment method, and there is a drawback that the processing method and the shape of the product used are limited.

The present invention has been made in view of the above-mentioned conventional drawbacks, and an object of the present invention is to provide a method for producing a flexible embossed decorative board having a natural wood texture and excellent bending workability.

[0008]

In order to achieve the above object, the present invention provides a desired pattern on a substrate and forms a curable resin layer containing urethane acrylate as a main component on the pattern. Along with that, the curable resin is cured in a state where an embossed sheet having an uneven surface of natural wood is attached to the surface of the curable resin layer, and after the curable resin is cured, the embossed sheet is peeled off. There is.

As the above-mentioned curable resin, an ionizing radiation curable resin such as ultraviolet ray or electron beam can be used.

Further, in the above manufacturing method, finishing processes such as wiping and top coat can be performed as a final step.

The structure of the present invention will be described in detail below.

FIG. 1 is a sectional view showing an embodiment of the manufacturing method of the present invention in the order of steps.

First, in the step shown in FIG. 1A, a desired pattern such as wood grain is printed on the base material 1.

As the substrate 1, any of those generally used as a substrate for decorative boards such as building material paper, non-woven fabric, and resin film can be used, but especially resin-mixed paper, resin-impregnated paper, etc. The use of resin reinforced paper is preferred. Further, when the finished decorative board is subjected to V-cut processing, it is possible to use the base material 1 which is further laminated with thick plywood, particle board or the like. The pattern printing on the base material 1 may be performed by using a known printing method such as gravure printing, but in order to further increase the adhesion strength between the base material 1 and the pattern printing layer 2, a curing agent suitable for the printing ink used. May be added.

Further, in order to form the pattern print layer 2 on the substrate 1, instead of using such a printing method, a desired pattern can be formed on the substrate 1 by a transfer method. That is, it is a method in which a transfer sheet having a release layer and a pattern printing layer formed on a base sheet is stuck on the base material 1, and then the base sheet is peeled off. The use of such a transfer method has an advantage that the selection range of the material of the base material 1 is expanded. Further, when such a transfer method is used, it can be applied to a base material having a curved surface portion such as a peripheral edge, a long pushing frame, a door frame, and the like.

By using a white base material having a fine and smooth surface, such as MDF, as the base material 1, it is possible to suppress variations in color of the design and to provide excellent stability.

Further, the pearl pigment having a high color developability is kneaded into the ink forming the pattern printing layer 2 for printing, or the pearl pigment is kneaded before the pattern is formed on the surface of the substrate 1. By applying the base paint, the natural shine of the famous wood can be expressed, and it is possible to express the design with a higher wood texture.

Next, in the step shown in FIG. 2B, a curable resin 3 containing urethane acrylate as a main component is applied on the pattern printing layer 2 and the uneven surface of natural wood is faithfully modeled. The embossed sheet 4 thus taken is attached to the surface of the coated curable resin layer 3, and the curable resin layer 3 is cured in this state.

The above-mentioned curable resin is a resin which is cured by ionizing radiation such as ultraviolet rays or electron beams, and has urethane acrylate as a main component as described above. Specifically, one kind of urethane acrylate oligomer is used alone or a plurality of kinds of urethane acrylate oligomers are arbitrarily mixed, and a low cross-linking bifunctional monomer (for example, hexanediol diene Acrylate (such as HDDA) is used as a diluent.
Urethane acrylate oligomer is diisocyanate,
It is formed by a reaction between a diisocyanate semi-adduct and a long-chain glycol as a soft segment (for example, polyethylene glycol, propylene glycol, caprolactone diol, etc.) and forms a flexible film after curing. Also,
In addition to these, various additives such as surfactants, antistatic agents, stabilizers, and slip agents can be optionally used.

In the case of the ultraviolet curing type, the above resin is further mixed with acetophenones and benzophenones as photopolymerization initiators and n-butylamine and triethylamine as photosensitizers. The content of the initiator is about 0.1 to 10 parts by weight based on the resin.

Further, by mixing a compound such as tolylene diisocyanate (TDI) as a curing agent into the above resin, a thermosetting resin which is cured in an atmosphere of about 60 ° C. to 100 ° C. can be obtained. I can.

As the method for applying the curable resin 3 onto the pattern printing layer 2, any known method such as roll coating, flow coating, knife coating, and gravure coating can be adopted. But are not limited to the coating amount is specifically from the viewpoint of flexibility after ^{curing, 20g / m 2 ~100g / m} 2 about desirable. In addition, in order to further increase the adhesion strength between the curable resin layer 3 and the pattern printing layer 2, a transparent intermediate layer made of urethane resin or the like may be provided between these layers.

The embossed sheet 4 is attached to the surface of the curable resin layer 3 applied on the pattern printing layer 2 in this manner, and the curable resin is cured in a wet state in contact with the embossed sheet 4. As a result, the uneven pattern of the embossed sheet 4 is formed on the surface of the curable resin layer 3.

The embossed sheet 4 is formed by faithfully molding a concave and convex surface of natural wood. Specifically, a natural wood material is used as a manuscript and a synthetic resin (for example, vinylon resin, silicone resin, etc.) for molding is used. ), And then peeling the synthetic resin from the natural wood material.

The embossed sheet 4 can also be made by printing the conduit shape of wood grain thickly on the surface of the synthetic resin sheet by silk screen printing or the like.

Further, as the embossed sheet 4, a synthetic resin plate or a metal plate prepared by photolithography using a natural wood material as an original may be used.

The method of curing the curable resin layer 3 is to irradiate the so-called ionizing radiation 5 such as ultraviolet rays or electron beams from the side of the embossed sheet 4 when the curable resin is an ultraviolet ray or electron beam curing type. Further, when the curable resin is of the thermosetting type, it is allowed to stand in a high temperature atmosphere. Needless to say, when the ionizing radiation 5 is used, a material that can transmit the ionizing radiation 5 is selected as the material of the embossed sheet 4.

As shown in FIG. 1C, after the curable resin layer 3 is cured, the embossed sheet 4 is peeled off, and the embossed decorative plate 6 as shown in FIG. 1D is completed.

The finished embossed decorative plate 6 may be further subjected to finishing such as wiping and top coating for the purpose of improving the design and protecting the surface.
FIG. 2 shows an embossed decorative plate 6 that is produced by finally applying such wiping and top coat.

An example of a wiping method will be described. First, a colored paint is applied to the entire surface of the embossed decorative plate 6,
Before the colored coating material solidifies, the colored coating material on the convex portions on the surface is removed with a squeegee, a barrel, or a dry cloth, and the remaining colored coating material 7 in the concave portions is dried and solidified.

On the other hand, it is desirable to use urethane resin or the like for the top coat layer 8.

FIG. 3 shows the case where a base material having a curved surface is used. As shown in FIG. 3A, a release layer (not shown) and a pattern printing layer are formed on the base sheet 10. The transfer sheet on which 11 is formed is attached to the surface of the base material 9 with the adhesive 12 interposed therebetween, and then the base sheet 10 is peeled off to transfer the pattern printing layer 11 to the surface of the base material 9. Next, as shown in FIG. 3B, the curable resin 3 is applied onto the uneven surface of the embossed sheet 4, and the surface of the curable resin 3 is attached to the surface of the pattern printing layer 11 of the base material 9. After the curable resin 3 is cured, the embossed sheet 4 is peeled off, whereby a curved embossed decorative plate is completed.

[0033]

As described above, according to the present invention, since the embossed sheet faithfully has the uneven surface of natural wood is used for shaping, the natural feeling of natural wood can be sufficiently expressed, and urethane acrylate is mainly used. Since the curable resin contained as a component is used, a flexible resin layer is formed after curing, and an embossed decorative board excellent in bending workability is completed.

[0034]

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

Example 1 HPA-30 resin-reinforced paper manufactured by Tenma Special Paper Co., Ltd.
g / m ²⁾ on, by gravure printing machine, using Toyo Ink Mfg. Co., Ltd. PC ink (nitrocellulose ink), Toyo Ink Mfg the grain pattern printing and at the same time its surface by solid printing and handle three colors A urethane paper UR-139 manufactured by Co., Ltd. was solidly printed (coating amount: 3 to 5 g / m ² ) to prepare a decorative paper. In addition,
In order to increase the adhesive strength between the base paper and the ink layer, an appropriate amount of an isocyanate-based curing agent was added to the bottom solid ink.

The obtained decorative paper was laminated on a 2.5 m / m-thick lauan plywood using a vinyl chloride vinyl acetate adhesive to prepare a decorative plywood.

On the pattern-printed layer side of the obtained decorative plywood, a UV coater Ubi 70 manufactured by Nippon Paint Co., Ltd. was uniformly applied at a coating amount of 50 g / m ² using a flow coater, and at the same time, a real wood grain was obtained. A 25 μm thick vinylon resin embossed sheet obtained by copying the shape of the conduit from the original was stuck on the surface, and in this state, an ultraviolet lamp was irradiated from the embossed sheet side. When the UV curable resin was completely cured and then the embossed sheet was peeled off, an embossed decorative board having a natural wood texture was obtained.

In order to further enhance the design effect, the obtained embossed decorative board is wiped with urethane 1-component curing type ink manufactured by Toyo Ink Mfg. Co., Ltd. to further protect the surface and to adjust the gloss of the surface. Therefore, the urethane two-component curing type top coat URSP manufactured by Toyo Ink Mfg. Co., Ltd. was used for the top coat to obtain a finished embossed decorative board.

Even if a V-cut is applied to the lauan plywood side of the back surface of the embossed decorative plate thus obtained and the decorative plate is bent at a right angle,
There is no such thing as discoloration or cracking,
It had excellent bending workability.

Example-2 Using the decorative plywood prepared in Example-1, a flow coater was used on the decorative printed layer side of this decorative plywood using acrylic urethane resin with 3 tolylene diisocyanate as a curing agent.
The same amount of ~ 5% was applied at a coating amount of 50 g / m ² , and at the same time, the embossed sheet used in Example-1 was attached to the surface, and in this state, it was placed in a curing chamber (temperature 60 ° C to 80 ° C). I left it. When the embossed sheet was peeled off after the acrylic urethane resin was completely cured, an embossed decorative board having a natural wood texture was obtained as in Example 1.

Example 1 was further added to the obtained embossed decorative board.
Wiping and top coating were performed in the same manner as in.

The embossed decorative board thus obtained is also used in the Example-
Like No. 1, it was excellent in bending workability.

Example 3 Polypropylene film having a thickness of 20 μm and wood free paper (basis weight 5
3.2 g / m ² ) of the base sheet (made by Goyo Paper Co., Ltd.), which is laminated with (3 g / m ² ), is printed on the entire surface by a gravure printing machine with a varnish made by Toyo Ink Mfg. After that, a wood grain pattern is printed using a vinyl chloride ink VCGTK manufactured by Toyo Ink Mfg. Co., Ltd.
A transfer sheet was prepared.

On the other hand, using a continuous laminating machine, a roll coater manufactured by Konishi Co., Ltd. on a white substrate with a finely smooth surface such as Starwood NS type manufactured by Hokushin Co., Ltd. or Nelson Pine manufactured by Sumitomo Forestry Co., Ltd. Adhesive CVC
Immediately after uniformly applying -36 at a coating amount of 7 g / m ² , the above-mentioned transfer sheet was attached, and after the adhesive was cured, the above-mentioned base sheet was peeled off to prepare a transfer decorative board.

On the surface of a vinylon film having a thickness of 25 to 40 μm (manufactured by Tokyo Cellophane Paper Co., Ltd.), silk screen ink manufactured by Toyo Ink Mfg. Co., Ltd. was used. An embossed sheet having a raised shape with a thickness of about 15 μm was produced.

Next, on the pattern printing layer side of the transfer decorative board,
Using a flow coater, Nippon Paint Co., Ltd. UV curable resin Ubi 70 was uniformly applied at a coating amount of 50 g / m ² , and at the same time, the above embossed sheet was attached to the surface and irradiated with an ultraviolet lamp in this state. When the UV-curable resin was cured and the embossed sheet was peeled off, an embossed decorative board having a natural wood texture was obtained as in Example 1.

Example 1 was applied to the embossed decorative board thus obtained.
Wiping and top coat were applied in the same manner as in.

The embossed decorative plate thus obtained was also excellent in bending workability as in Example-1.

Example 4 PET film G-PET having a thickness of 25 μm manufactured by Toray Industries, Inc.
Use a gravure printing machine to print the release varnish made by Toyo Ink Mfg. Co., Ltd. on the entire surface with a solid plate, and then print a wood grain pattern with the vinyl chloride ink VCGTK made by Toyo Ink Mfg. Co., Ltd. Then, a transfer sheet was prepared.

On the other hand, on the surface of the PET film having a thickness of 25 μm, a silk screen plate (a urethane two-component curing type) made by Toyo Ink Mfg. Co., Ltd. was used to form a silk screen plate with a pattern only on the conduit portion. 150-200
An embossed sheet having a conduit pattern of about 25 to 40 μm was produced by a silk screen printing machine using a (mesh).

Next, using a wrapping machine, the above-mentioned transfer sheet (slit-processed to a required width) was set, and a knife coater was used on the back surface of this transfer sheet to bond it to a product manufactured by Sumitomo Chemical Co., Ltd. Agent UX-10 100
After being uniformly applied to a thickness of up to 150 μm, the solvent is removed by passing through a drying line at about 60 ° C., while MD
F, laminated wood of coniferous trees Using a C router machine, a rod-shaped base material processed into a required shape is introduced, and the transfer sheet coated with the adhesive is attached to the required surface using a plurality of pressing rollers. After the adhesive was cured, only the PET film, which is the substrate of the transfer sheet, was peeled off to prepare a transfer substrate.

Then, using the same wrapping machine, the embossed sheet (those slittered to the required width) is set, and the surface of the embossed sheet (the surface having irregularities) is knife-coated. A UV-curable resin Ubicoat manufactured by Nippon Paint Co., Ltd., which has high adhesion to vinyl chloride-based ink, is uniformly applied to the entire surface with a thickness of about 30 to 50 μm (more than the thickness of the conduit ink), and multiple pressers A roller is used to bond the transfer substrate. In this state, the ultraviolet ray lamp is irradiated to completely cure the ultraviolet ray curable resin, and at the same time, firmly adhere the ultraviolet ray curable resin and the lower wood grain pattern printing layer. Then, when the embossed sheet was peeled off,
An embossed decorative board having a natural wood texture (a curved surface shaped member) was obtained.

Example 1 was further added to the obtained embossed decorative board.
Wiping and top coating were performed in the same manner as in.

[0054]

As described in detail above, according to the method for producing an embossed decorative board of the present invention, a curable resin layer containing urethane acrylate as a main component is formed on a base material having a pattern on its surface. At the same time, the curable resin is cured in a state where an embossed sheet having a natural uneven surface of natural wood is adhered to the surface, and after the curing, the embossed sheet is peeled off. Since it is possible to fully express a natural feeling, and the curable resin forms a flexible resin layer after curing,
Even if it is bent, it does not cause any inconvenience such as discoloration or cracking. Therefore, since it has a natural wood texture, and is flexible and has excellent bending workability, the processing method and the shape of the product to be used are not limited, and an embossed decorative board that can be used in a wide range can be manufactured. It has an excellent effect.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an embodiment of a manufacturing method of the present invention in the order of steps.

FIG. 2 is a cross-sectional view showing another embodiment of the manufacturing method of the present invention.

FIG. 3 is a cross-sectional view showing another embodiment of the manufacturing method of the present invention.

[Explanation of symbols]

 1 Base Material 2 Pattern Printing Layer 3 Curable Resin (Layer) 4 Embossing Sheet 5 Ionizing Radiation 6 Embossing Decorative Board 7 Coloring Paint 8 Top Coat Layer 9 Base Material 10 Base Sheet 11 Pattern Printing Layer 12 Adhesive

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Office reference number FI technical display location B32B 33/00 7148-4F

Claims (3)

[Claims] 1. A desired pattern is formed on a base material, a curable resin layer containing urethane acrylate as a main component is formed on the pattern, and an embossed sheet having an uneven surface of natural wood is used as the curable resin. A method for producing an embossed decorative board, characterized in that a curable resin is cured in a state of being attached to the surface of a resin layer, and after the curable resin is cured, the embossed sheet is peeled off. 2. The method for manufacturing an embossed decorative board according to claim 1, wherein the curable resin is an ionizing radiation curable resin such as an ultraviolet ray or an electron beam. 3. The method for manufacturing an embossed decorative board according to claim 1, wherein a finishing process such as wiping or top coat is applied as a final step.