JPH07137186A - Sophisticatedly designed emboss decorative sheet and its manufacture - Google Patents

Abstract

PURPOSE:To provide an embossed decorative sheet with a high surface strength which protects the sheet against deformation by a pressure applied and a sophisticated design and a method of manufacturing the sheet. CONSTITUTION:A polyvinyl chloride film 14 is laminated in such a manner that it fills the surface by applying an adhesive 13 containing a solvent to the surface of an unevenly patterned ionizing radiation curable resin layer 12 formed on the surface of a base film 11. After that, the surface film 14 is deformed by the permeation of the solvent, and further, is deformed so that it has an uneven surface along the uneven profile 12 of the ionizing radiation- curable resin, following the volatization and scattering of the solvent. Thus an embossed decorative sheet is prepared.

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 sheet having an embossed pattern on its surface and an embossed decorative sheet obtained by the method.

[0002]

2. Description of the Related Art Conventionally, various methods have been proposed as means for applying a concavo-convex pattern (embossing) to a decorative surface of a decorative material. For example, a mechanical embossing method using an embossing roll or an embossing plate, A chemical embossing method using a foaming agent, a foaming inhibitor, a curing inhibitor, or the like is known.

[0003]

However, in the above-mentioned method, for example, in the mechanical embossing method, there is a drawback that the decorative pattern and the uneven pattern do not match, and in the chemical embossing method, the resin Foaming, foam suppression,
Alternatively, it is very difficult to control each step such as suppressing curing, it is difficult to reveal a desired uneven pattern, and there is a drawback that a special device is required, which is not preferable. Further, the decorative material obtained by the mechanical embossing method or the chemical embossing method has a problem that the strength of the uneven pattern is insufficient and the uneven pattern disappears due to external pressure. Further, in the mechanical embossing method and the chemical embossing method, it takes a certain amount of time to form an uneven pattern, which is a big problem in terms of productivity. The present invention provides a cosmetic material which solves these problems, has good synchronization accuracy between a printed pattern and an uneven pattern, has a high surface strength, and is excellent in designability capable of revealing a desired uneven pattern, and a manufacturing method thereof. The purpose is to do.

[0004]

Means for Solving the Problems An uneven pattern made of a thermosetting resin or an ionizing radiation-curable resin is formed on the surface of a transparent or semitransparent sheet substrate, and the uneven surface of the sheet is swollen by a solvent or An embossed decorative sheet was formed by laminating shrinkable films via an adhesive containing a solvent so as to form the same uneven pattern on the laminated film surface along the uneven pattern of the sheet. In addition, the surface of the transparent or semi-transparent sheet base material is provided with an uneven pattern of a thermosetting resin or an ionizing radiation-curable resin, and the uneven surface of the sheet contains a solvent that swells or shrinks with a solvent. The method for producing an embossed decorative sheet is the one in which the same uneven pattern is formed on the surface of the laminated film along the uneven pattern of the sheet by laminating with the adhesive.

[0005]

According to the present invention, the production speed is higher than that of the conventional mechanical embossing method or the chemical embossing method, and moreover, the accuracy of synchronization between the printed pattern and the uneven pattern is good, the surface strength is strong, and the desired uneven pattern is formed. It is possible to obtain an embossed decorative sheet having an excellent aesthetic appearance.

[0006]

The present invention will be described in detail below with reference to the drawings based on the embodiments. FIG. 1 is a sectional view showing an example of the embossed decorative sheet of the present invention, and FIG. 2 is an explanatory view showing an example of forming the embossed decorative sheet. Figure 3
FIG. 4 is a schematic diagram for forming a concavo-convex shape on a base film, and FIG. 4 is a schematic diagram showing a method for producing an embossed decorative sheet of the present invention using the film having a concavo-convex pattern formed in FIG. . FIG. 5 is a cross-sectional view of a decorative plywood when the embossed decorative sheet of the present invention is used as a surface for bonding to a plywood, and FIG. 6 is a case where the embossed decorative sheet has an uneven surface to be bonded to a plywood. It is sectional drawing of the makeup plywood.

An example of making the embossed decorative sheet of the present invention is shown below. First, as the base film 11,
After using a heat-resistant and dimensionally stable film such as a polyethylene terephthalate (hereinafter referred to as PET) film and applying a primer solution to this film, as shown in FIG. 3, a drum printing method (nozzle type) is used. The coating device 23 coats the roll intaglio 21 with the ionizing radiation curable resin 12a, and the pressing pressure roll 25 fills the recess 22 of the plate with the ionizing radiation curable resin 12a. At the same time, the base film 11 is rolled. The resin is filled in the intaglio plate, and the resin filled in the recess 22 of the intaglio plate is cured by irradiating the ionizing radiation from the top of the base film 11 with the ionizing radiation irradiation device 24, and the cured resin is adhered to the base film 11.
A method of peeling the base film 11 from the roll intaglio 21 and forming an uneven shape made of an ionizing radiation-curable resin on the base film is referred to as a drum printing method) by ionizing the uneven shape on the base film 11. The radiation curable resin layer 12 is formed.

Next, as shown in FIG. 4, the solvent-containing adhesive 13 is applied by a roll coating method using the winding 31 of the uneven pattern forming film produced as described above,
A polyvinyl chloride (hereinafter referred to as PVC) film, which is a surface film, is unwound from another winding device 32, pressure-bonded by a roll 36 and a roll 37, and laminated to obtain a laminated decorative sheet 1a. The laminated decorative sheet 1a is wound up by the winding device to form a winding 38. When the laminated decorative sheet is stored at room temperature, the solvent penetrates into the PVC film to swell the PVC film, and as shown in FIG. 2, the surface of the laminated decorative sheet 1a is changed from the shape shown in FIG. It deforms to the shape shown in b). Further, when the solvent is volatilized from the PVC film, the solvent finally passes through the shape shown in FIG.
An embossed decorative sheet having a shape as shown in (c) is obtained. The embossed decorative sheet is completed in about 48 hours, depending on the thickness of the PVC film.

The embossed decorative sheet thus obtained is bonded to a wood plate or a metal plate, usually the PET film surface with an adhesive, to obtain a decorative plywood or a decorative steel plate. However, the embossed decorative sheet of the present invention has a P
Even if the VC film surface is attached to a wood board or a metal board, a decorative board showing a three-dimensional design effect with depth can be obtained. Therefore, one kind of embossed decorative sheet makes two kinds of decorative boards showing a design effect. be able to.

The base film used in the present invention is polyethylene terephthalate (PET), polyacrylate,
Any material such as polyetheretherketone or polyimide having strong film strength, having dimensional stability and heat resistance, and transmitting ionizing radiation may be used. When using ultraviolet rays such as a high pressure mercury lamp as ionizing radiation, a transparent PET film is mainly used. A thickness of 10 to 200 μm can be used, but about 50 μm is preferable in consideration of workability, cost, etc. at the time of making a decorative sheet. However, when an electron beam is used as the ionizing radiation, a film that transmits the electron beam may be used and does not necessarily have to be transparent.

The resin for forming the uneven shape on the substrate film is a resin that can transmit the ionizing radiation and cure by the ionizing radiation to form the uneven shape, and the resin does not deform or disappear at room temperature. If Known UV curable resins and electron beam curable resins can be used.

The ionizing radiation curable resin is a polyfunctional prepolymer or oligomer having two or more polymerizable unsaturated groups such as acryloyl group, methacryloyl group, acryloyloxy group, epoxy group, thiol group and the like in the molecule. And / or a liquid composition containing a monomer as a main component is used. Examples of these prepolymers, oligomers or monomers include urethane acrylates, epoxy acrylates, polyester acrylates, acrylates such as silicon acrylates, urethane methacrylates, epoxy methacrylates, polyester methacrylates,
There are methacrylates such as silicon methacrylate, unsaturated polyesters, polythiols, and polyvinylpyrrolidone. It is preferable to use a high crosslink density type such as acrylate, epoxy acrylate, silicon acrylate, and siloxane.

When curing with visible light or ultraviolet light, a photopolymerization initiator such as benzophenones, acetophenones, thioxanthones is added. When using ultraviolet rays such as a high pressure mercury lamp as the ionizing radiation, it is necessary to transmit the ultraviolet rays and cure with the ultraviolet rays, and it is necessary to use a transparent resin. Ultraviolet rays or electron beams are usually used as the ionizing radiation, but other visible light rays, X-rays and the like can also be used.

As a method of forming an uneven shape on a base film with an ionizing radiation curable resin, a roll intaglio having the same uneven shape as the desired uneven pattern formed on the base film but having an opposite uneven shape is used. The drum printing method is used. The roll intaglio plate for forming the uneven shape on the base film is manufactured by engraving, electroforming, sandblasting, or the like. Further, as a method of forming the uneven shape on the base film, a method of forming a thick embossed uneven pattern synchronized with the pattern by a method such as gravure printing or screen printing on the base film on which the pattern is printed may be used. it can.

The adhesive resin for laminating the base film having the uneven shape and the PVC film of the surface film may be any resin that can bond the base film and the surface film with a resin that dissolves in a solvent. For example, urethane type,
Known resins such as epoxy resins and acrylic resins can be used. The solvent is selected according to the adhesive resin and the surface film, but ethyl acetate, methyl ethyl ketone (hereinafter MEK), toluene, isopropyl alcohol (hereinafter IPA), etc. are used. The solvent content may be 3 to 60% by weight, but 10 to 30
Weight percent is preferred.

The surface film to be laminated on the base film having an uneven pattern may be one having a property of swelling and shrinking by a solvent and a property of rapidly volatilizing the solvent. As the film having such properties, there are PVC, vinyl acetate, ethylene-vinyl acetate copolymer and the like, and the PVC film is suitable for the present invention. The thickness of the film can be up to about 200 μm, but the range of 50 to 100 μm is preferable. In the case of polyvinyl chloride resin, the average degree of polymerization is 1000 to 20.
00, a soft polyvinyl chloride containing a plasticizer in an amount of 10 to 70 parts by weight, preferably 10 to 35 parts by weight in terms of dioctyl phthalate (DOP) is suitable. Alternatively, it may have a physicochemical property equivalent to this. A pigment and a pearl pigment may be kneaded into a PVC film. As the pigment, a pigment having a metallic luster such as metal powder of aluminum, copper, brass or the like, gold foil powder, a fine piece of a metal vapor deposition synthetic film or the like is used. Further, pigments having pearl luster or interference luster such as titanium oxide-coated mica, fish scale foil, and bismuth trioxide are used. If necessary, a pattern may be printed on a PVC film or a PET film as a base material to provide the pattern on any interface of the laminated decorative sheet.

A first embodiment for producing the embossed decorative sheet of the present invention will be shown below. First, as a base film, biaxially stretched PET film (manufactured by Teijin Ltd.) 50 μm
The surface of the film is coated with a primer solution by a gravure printing method and dried at 100 ° C. for 30 seconds to form a primer layer.

Next, as shown in FIG. 3, the nozzle type coating apparatus 2 is used by using the roll intaglio 21 with an abstract pattern having a plate depth of 50 μm.
3. Urethane acrylate UV curable resin 12a
(“P-EX-808-1” manufactured by Dainichiseika Kogyo Co., Ltd.) is applied, and the concave portion 22 of the intaglio plate 21 is filled with the ultraviolet curable resin 12a by the pressing roll 25, and the PET film 11 is formed thereon. And is irradiated with a high pressure mercury lamp 24 (160 W / cm, 2 lamps) for 2 seconds from above the PET film 11 to cure the ultraviolet curable resin and adhere the cured resin to the PET film. After the UV curable resin is cured, P
The ET film 11 is peeled off from the roll intaglio 21,
As shown in FIG. 1, an ultraviolet curable resin layer 1 having an uneven shape is formed.
An embossed film having No. 2 formed is produced. The roll intaglio with the abstract pattern is manufactured by electroforming at a plate depth of 50.

Next, as shown in FIG. 4, the solvent-containing adhesive 13 made of urethane resin is used by using the winding 31 of the PET film having the uneven shape produced as described above.
(Showa Ink Co., Ltd. "Kaware X Medium MD": solvent (MEK) content 20% by weight) by roll coating method 3
0 g / m ^{2 was} applied, and a colored PVC film (BHST manufactured by Band Co., Ltd.) having a thickness of 50 μm was fed out from another winding 32, and pressure-bonded with a roll 36 and a roll 37 to laminate the laminated decorative sheet 1a. obtain. The laminated decorative sheet 1a is wound up by the winding device to form a winding 38. When the laminated decorative sheet is stored at room temperature, the solvent penetrates into the PVC film and P
When the PVC film is deformed by swelling the VC sheet and the solvent is further volatilized from the PVC film, FIG.
Finally, an embossed decorative sheet having a shape as shown in FIG. 2C is obtained through such a shape. The embossed decorative sheet 1 is completed in about 48 hours, depending on the thickness of the PVC film. The obtained embossed decorative sheet 1 is bonded to the plywood 15 with the PET film 11 surface through the adhesive 16 to obtain a decorative plywood 2 as shown in FIG. Since the decorative plywood faithfully reproduces the uneven pattern of the plate, it becomes a decorative plywood with a high design effect.

The second embodiment is a case where a PVC film containing a pearl pigment is used as the surface film. Similar to the first embodiment, an uneven UV-curable resin layer 12 is formed on the PET film 11 with a UV-curable resin, and then a solvent-containing adhesive 13 is applied to contain a pearl pigment having a thickness of 100 μm. PVC film ("F from Nikko Vix Co., Ltd."
C10167M ”: Plasticizer content is 12 parts by weight with respect to 100 parts by weight of resin) and is stored at room temperature for PV
The C film is deformed to obtain the embossed decorative sheet 1 as shown in FIG. The embossed decorative sheet 1 is attached to the embossed surface of the PVC film 14 with the adhesive 16 interposed therebetween.
5 is attached to obtain a decorative plywood 2 as shown in FIG.
In the decorative plywood thus obtained, since the uneven pattern is seen through the PET film, the uneven pattern has a depth,
The three-dimensional design effect is high.

[0021]

As described above, according to the present invention,
Compared with conventional mechanical embossing method and chemical embossing method,
The production speed can be increased and the work efficiency can be improved. In addition, since the pattern to be printed and the concavo-convex pattern are synchronized with high accuracy and a desired concavo-convex pattern can be revealed, an embossed decorative sheet having high surface strength and excellent design can be obtained. When the embossed decorative sheet is used for a wooden decorative plate or a metal decorative plate, the PET film surface is usually attached to the wooden plate or the metal plate, but the uneven PVC film surface is used for the wooden plate or the metal plate. Even when they are laminated, a deep three-dimensional design effect can be obtained, and one type of embossed decorative sheet can provide a decorative plate exhibiting two types of design effects. Furthermore, since the embossed decorative sheet of the present invention is a laminated sheet of a film having good dimensional stability and a film having flexibility, when used for a wooden decorative board or a metal decorative board, it has excellent processability of the decorative board, A quality cosmetic product can be obtained.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an example of an embossed decorative sheet of the present invention.

FIG. 2 is an explanatory view showing an example in which an embossed decorative sheet is formed, and (a) is a cross-sectional view of a laminated sheet in which a surface film is bonded to a film having an uneven shape with a solvent-containing adhesive. (B) A cross-sectional view of the laminated sheet in which the surface film of the laminated sheet of FIG. (C) Sectional drawing of the embossed decorative sheet which the solvent volatilized from the surface film of the laminated sheet of the said FIG. (B), and the surface film deform | transformed along the uneven | corrugated shape.

FIG. 3 is a schematic diagram showing a method for forming a concavo-convex shape on a base film using an ionizing radiation curable resin.

FIG. 4 is a schematic diagram showing a method for producing an embossed decorative sheet of the present invention using the unevenness-forming film produced in FIG.

FIG. 5 is a cross-sectional view of a decorative plywood made of the embossed decorative sheet according to the first example.

FIG. 6 is a cross-sectional view of a decorative plywood made of an embossed decorative sheet according to a second example.

[Explanation of symbols]

 1 Embossed Decorative Sheet 1a Laminated Decorative Sheet 1b Laminated Decorative Sheet with Deformed Surface Film 2 Decorative Plywood 11 Base Film (PET Film) 12 Irregular Ionizing Radiation Curable Resin Layer (After Curing) 12a Ionizing Radiation Curable Resin (Curing) Previous) 13 Adhesive containing solvent 14 Surface film (polyvinyl chloride film) 15 Plywood 16 Adhesive (for laminating plywood) 21 Roll intaglio 22 Recessed plate 23 Nozzle type coating device 24 Ionizing radiation irradiation device (UV irradiation device) 25 Pressing Roll 31 Winding of Concavo-convex Pattern Forming Film 32 Winding of Surface Film (Polyvinyl Chloride Film) 33 Ink Pan 34 Attaching Roll 35 Coating Roll 36 Heating Roll 37 Impression Cylinder 38 Winding of Laminated Decorative Sheet

Claims (2)

[Claims] 1. A transparent or semi-transparent sheet base material having an uneven pattern formed of a thermosetting resin or an ionizing radiation-curable resin on the surface thereof, and a film swelling or shrinking with a solvent is formed on the uneven pattern surface of the sheet. An embossed decorative sheet, characterized by forming the same uneven pattern on the laminated film surface along the uneven pattern of the sheet by laminating with an adhesive containing a solvent. 2. A transparent or semi-transparent sheet base material having an uneven pattern formed of a thermosetting resin or an ionizing radiation-curable resin on the surface thereof, and a film swelling or shrinking with a solvent on the uneven pattern surface of the sheet. A method for producing an embossed decorative sheet, characterized in that the same embossed pattern is formed on the surface of the laminated film along the embossed pattern of the sheet by laminating with an adhesive containing a solvent.