JPH07144364A - Embossing plate and production thereof - Google Patents

Abstract

PURPOSE:To obtain an embossing plate for producing a decorative material having texture equipped with surface unevenness corresponding to vessels, tracheids and fibers of wood texture and gloss moved and changed in intensity according to a looking direction, reproducing the quality sense of wood as good as possible and hardly damaging the quality sense of wood by surface abrasion. CONSTITUTION:An embossing plate 1 has protruding parts 3 corresponding to vessels, tracheids and fibers of wood texture having numerous-line like fine unvenesses 5 consisting of parallel line groups formed thereto and recessed parts 4 having grained unvenesses formed to the inner surfaces thereof.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is based on sandblasting for matting a convex portion formed with fine line-shaped fine concavities and convexities for forming tracheids, fibers, etc. of a wood structure and a flat portion of a wood surface. The present invention relates to an embossing plate used for producing a decorative material having a good design and having a configuration provided with concave portions having grain-shaped irregularities, and a method for producing the embossing plate.

[0002]

2. Description of the Related Art Conventionally, as a decorative material having fine line-shaped irregularities formed on its surface, for example, Japanese Patent Application Laid-Open No. 4-521 is known.
As described in Japanese Patent Publication No. 81, it comprises a concavo-convex shape that reproduces the original surface shape on the surface of the substrate, and parallel line groups and / or parallel curve groups that reproduce the original surface gloss and its anisotropy. BACKGROUND ART A decorative material having an uneven shape of fine line grooves or an embossed plate for producing the decorative material is known.

In the conventional decorative material or the embossing plate for manufacturing the decorative material as described above, the uneven shape of the fine parallel groove is formed on the entire surface of the decorative material, that is, the convex and concave portions of the surface are formed. Therefore, the unevenness of the fine line grooves formed on the convex portion of the surface is liable to be scratched by abrasion, and as a result, uneven gloss is likely to occur. Also, since the fine line grooves are formed on the entire surface of the decorative material,
Since the difference in the surface gloss between the convex portion and the concave portion is unlikely to occur, the original surface gloss and texture cannot be accurately reproduced.

[0004]

SUMMARY OF THE INVENTION The object of the present invention is to provide a conduit for wood tissue, a temporary conduit, a texture with surface irregularities corresponding to fibers, and a luster, and this luster in particular moves depending on the viewing direction. Another object of the present invention is to provide an embossing plate and a manufacturing method thereof for producing a decorative material that reproduces the texture of wood in which strength and strength change as much as possible and that does not impair the texture of wood due to abrasion of the surface.

[0005]

[Means for Solving the Problems] Having a surface structure provided with a convex portion on which a fine line-shaped irregularity composed of parallel line groups is formed on the top and a concave portion on the inner surface of which grain-like irregularities are formed by sandblasting. Is an embossed version.

[0006] A step of forming parallel fine line irregularities composed of parallel line groups on the surface of the metal base material by etching, and a protective metal layer is formed by plating on the surface of the metal base material on which the parallel fine line texture is formed. And a step of applying a photosensitizer to the surface provided with the protective metal layer, exposing and developing a mask film expressing a temporary passage of wood structure, fibers, etc. to form a resist film, and etching the resist film to form a resist film. A step of removing the protective metal layer of the portion not formed, a step of etching the metal base material of the portion where the protective metal layer is removed to form a recess in the metal base material, and a step of sandblasting the entire surface The step of removing the remaining protective metal layer comprises the step of forming fine parallel lines of parallel lines consisting of parallel lines on the top and the grain-like unevenness formed by sandblasting on the inner surface. And a method for producing embossing plate having a surface configuration having a recess.

[0007]

Operation: Parallel line group (A parallel line group means a line group made up of a plurality of parallel lines or a line group made up of a plurality of lines that do not intersect each other although the interval between two adjacent lines is not constant) The embossing plate having a structure having a fine line-shaped fine unevenness and a recess having a grain-like unevenness formed on the inner surface thereof, and a decorative material produced using the embossing plate. Has a rough surface with a roughened surface, and a concave shape that corresponds to the temporary conduit, texture, etc. of wood grain has a fine line-shaped uneven surface. It is possible to obtain a cosmetic material that is excellent in physical properties and design, in which the surface gloss and texture of the wood, which changes in texture, are faithfully reproduced, and the texture of the wood is not easily damaged by abrasion of the surface. In addition, the embossed plate can be easily sand-blasted only in the concave portions by sandblasting the entire surface in the state where the hard protective metal layer is provided only in the convex portions where the fine line-shaped irregularities are formed. Therefore, it is possible to manufacture an embossing plate having a convex portion formed with parallel fine lines formed of parallel line groups and a concave portion formed with sand-blasted unevenness on the inner surface by sandblasting.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to the drawings. FIG. 1 is a cross-sectional view of the embossing plate of the present invention, and FIG. 2 is a diagram showing a manufacturing process of the embossing plate of the present invention. (A) shows a state in which linear fine irregularities are formed on the surface of a metal substrate, (b) ) Is a state in which a protective metal layer is formed on the surface of a metal base material on which line-shaped fine irregularities are formed, and (c) a convex portion corresponding to a wood grain temporary conduit or texture is formed by etching on the protective metal layer surface. A state where a resist film for forming is formed, (d) is a state in which the protective metal layer in the part without the resist film is removed by etching and a concave portion is further formed in the metal substrate, and (e) is a sand blast on the entire surface. A state in which eye-shaped irregularities are formed, (f) is an embossed plate completed by removing the protective metal layer remaining on the surface,
(G) is a state in which chrome plating is applied to the completed embossed plate, FIG. 3 is a cross-sectional view of a decorative material manufactured using the embossed plate of the present invention, and FIGS. 4 (A) to 4 (E) are used in the present invention. FIG. 6 is a diagram showing a specific example of a linear fine uneven pattern to be formed,
1 is an embossed plate, 2 is a metal substrate, 3 is a convex portion, 4 is a concave portion,
Reference numeral 5 is a line-shaped fine unevenness, 6 is a grainy unevenness, 7 is a protective metal layer, 8 is a resist film, 9 is a decorative material, 10 is a surface base material layer, 11
Is a printing ink layer, 12 is a backside substrate layer, and 13 is a protective layer.

The cross-sectional shape of the embossing plate 1 of the present invention is, as shown in FIG. 1, a convex portion 3 on a surface of a metal base material 2 in which parallel fine line-shaped irregularities 5 composed of parallel line groups are formed on the top. It has a structure in which the concave portion 4 in which the grain-shaped irregularities 6 are formed is formed on the inner surface. When the embossing plate 1 is used to emboss the surface base material 10 of the decorative material, the convex portion 3 in which the fine linear unevenness 5 composed of parallel lines is formed on the top of the embossing plate 1 forms the surface of the decorative material. Material
In FIG. 10, a concave portion having fine line-shaped irregularities 5 formed on the inner surface corresponding to a temporary conduit of a wood structure, fibers, etc., and a concave portion 4 having a grain-like unevenness 6 formed on the inner surface of the embossing plate 1 are used as a decorative material. Front substrate
A flat portion having the grain-shaped irregularities 6 is formed on the surface 10.

As shown in FIG. 4, the pattern of the parallel fine line unevenness 5 consisting of parallel line groups is composed of a corrugated parallel curve group as shown in (a) and a composite sine curve as shown in (b). , A combination of parallel straight line groups with different directions depending on the section such as (C), a combination of parallel curve groups with different shapes depending on the section such as (D), and a closed loop like (E) A combination of parallel curved line groups can be used. It is possible to reproduce the movement effect of surface luster and texture by combining the fine linear irregularities 5 in an arbitrary pattern suitable for each grain depending on the type of wood.

The fine line-shaped irregularities 5 are for reproducing the surface luster of wood grain and the anisotropy in which the luster moves depending on the viewing direction. The depth of the unevenness 5 can be arbitrarily set within the range of 1 to 100 μm. Depth is 1 to 30, depending on the type of wood grain
Line-shaped fine irregularities 5 having a size of micron and a spacing of 20 to 100 micron are generally used.

As the metal base material 2 constituting the embossing plate 1, metals such as zinc, copper, brass, iron and aluminum can be used, but copper is most suitable. The embossing plate 1 may have any shape such as a flat plate shape and a cylindrical shape, but it is generally used as a cylindrical embossing plate. In the case of a cylindrical embossing plate, the metal base 2 made of copper having a thickness of 0.2 to 1.0 mm is formed on the surface of a cylindrical iron core by plating, and the surface of the metal base 2 is formed. It has a shape in which unevenness is formed.

The embossing plate 1 of the present invention is manufactured by the process shown in FIG. First, a photosensitive solution is applied to the surface of the metal base material 2 that constitutes the embossing plate 1, exposed using a mask film composed of a pattern of fine line-shaped fine irregularities 5, and developed, and then (a) by direct etching. As shown in (1), the linear fine irregularities 5 are formed on the surface of the metal substrate 2. Since copper is generally used as the metal base material 2, etching is performed using a ferric chloride solution.

As shown in (b), a protective metal layer 7 is formed by plating on the entire surface of the metal base material 2 on which the fine line-shaped irregularities 5 are formed. Chrome as the protective metal layer 7,
Aluminum, nickel, zinc or the like can be used, but chromium is usually used. The thickness of the protective metal layer 7 is not particularly limited, but it is required to completely cover the surface of the fine line-shaped fine concavities and convexities 5 and not to be peeled or worn by a sand blasting process in a subsequent step. Is preferred.

Next, a photosensitizer is applied to the surface on which the above-mentioned protective metal layer 7 is formed, and exposure / development is carried out using a mask film which expresses a conduit of a wood grain structure, a temporary conduit, fibers, etc. As shown in FIG. 4A), a resist film 8 is provided on the surface of the protective metal layer 7 for providing the convex portions 3 corresponding to the conduit of the wood grain structure, the temporary conduit, the fibers and the like.

The protective metal layer 7 having the resist film 8 formed on the surface is etched to remove the protective metal layer 7 in the portion where the resist film 8 is not present. When the protective metal layer 7 is chromium, hydrochloric acid is used as the etching liquid. Next, the portion of the metal base material 2 from which the protective metal layer 7 has been removed is etched to form a recess 4 on the surface of the metal base material 2 as shown in (d). When the metal substrate 2 is copper, a ferric chloride solution is used as the etching liquid. The depth of the recess is 30-80
Micron is suitable.

Sandblasting is performed on the entire surface of the metal substrate 2 having the recesses 4 formed in the portion where the resist film 8 is not formed, and as shown in FIG. The sandblasting is performed by using inorganic particles such as iron, silicon carbide, alumina, chromium oxide, and iron oxide having a particle size of about 1 to 100 microns and spraying the surface of the metal base material 2 from the tip of the nozzle with the force of compressed air or the like. Be seen. The sandblast treatment may be performed with the resist film 8 left or after the resist film 8 is removed. By sandblasting, grain-like irregularities are formed on the inner surface of the concave portion 4 on the surface and the entire surface of the remaining protective metal layer 7.

Finally, the protective metal layer 7 remaining on the surface of the sandblasted metal substrate 2 is completely removed, and as shown in FIG. An embossing plate in which the fine linear irregularities 5 are formed on the surface of the convex portion 3 is completed. To remove the remaining protective metal layer 7, hydrochloric acid is used when the protective metal layer 7 is chromium. Even in the state shown in (f), it can be used as an embossed plate, but in order to improve durability, it is used by applying chrome plating to the surface as shown in (g).

As shown in FIG. 3, the decorative material 9 manufactured by using the embossing plate 1 of the present invention comprises a front surface base material layer 10, a printing ink layer 11 and a back surface base material layer 12 which are laminated. A convex portion and a concave portion are formed on the surface of the surface base material layer 10, fine linear irregularities 5 are formed on the inner surface of the concave portion, and grain-like irregularities 6 are formed on the convex portion by sandblasting. . The protective layer 13 is provided so as to cover the entire surface of the concave portion having the fine line-shaped irregularities 5 formed on the inner surface and the convex portion having the grain-like irregularities 6 formed by sandblasting.

The laminated constitution of the decorative material 9 of the present invention is not shown in FIG. 3, except that the surface base material layer 10, the printing ink layer 11 and the back surface base material layer 12 are used. Surface base material layer
It may be composed of 10 and the printing ink layer 11.

In the constitution of the decorative material 9 of the present invention shown in FIG. 3,
Although the printing ink layer 11 is provided between the front surface base material layer 10 and the back surface base material layer 12, the printing ink layer 11 is provided between the front surface base material layer 10 and the back surface base material layer 12 as in the above configuration. Instead of providing
The printing ink layer 11 may be provided on the surface of the surface base material layer 10, that is, on the surface to be embossed.

As a material for forming the surface base material layer 10 of the decorative material 9 of the present invention, a thermoplastic resin such as polyvinyl chloride resin, polyester resin, acrylic resin or polyolefin resin can be used. Resin is the most suitable. As the material forming the back surface base material layer 13, the same material as the material forming the front surface base material layer 10 can be used, and a colored thermoplastic resin is mainly used. The thickness of the front surface base material layer 10 and the back surface base material layer 12 is 70 to 15 respectively.
0 micron is suitable, and when the backing material layer 12 is not used and the decorative material 9 is composed only of the backing material layer 10, the surface material layer is
A suitable thickness for 10 is 120 to 250 microns.

Printing ink layer constituting the decorative material 9 of the present invention
11 is composed of a pattern layer and a solid coloring layer provided by gravure printing or the like. In order to reproduce the gloss more effectively, the solid colored layer can be printed with an ink containing a bright pigment. If desired, the pattern layer may also be printed with an ink containing a bright pigment. As the luster pigment, a metallic luster pigment made of metal powder such as aluminum or copper or a piece of metal foil, a pearl luster pigment such as mica, fish scale foil and the like can be used. When the decorative material 9 is composed only of the front surface base material layer 10 without using the back surface base material layer 12, a material obtained by coloring the front surface base material layer 10 with a bright pigment is used instead of providing a solid colored layer by printing. It can also be implemented using.

The protective layer improves the surface properties of the decorative material 9 and adjusts the surface gloss, and as the resin used as the protective layer, a urethane thermosetting resin, an ultraviolet curable resin or the like is suitable. There is. In order to adjust the surface gloss, it is possible to add inorganic fine powders such as calcium carbonate, barium sulfate, silica, and alumina to the above thermosetting resin and ultraviolet curable resin, and it is possible to color them with a transparent pigment if necessary. it can.

In the manufacturing method of the decorative material 9, a colored back substrate layer 12 is used and a printing ink layer 11 composed of a solid ink layer and a pattern ink layer is provided on the surface by printing. An ordinary embossing machine in which the transparent surface base material layer 10 is superposed on the surface of the printing ink layer 11 of the back surface base material layer 12 provided with the printing ink layer 11 and the embossing plate 1 having the shape shown in FIG. 1 is attached is used. Using, at the same time to emboss the surface of the transparent surface base material layer 10, after adhesively laminating the back surface base material layer 12 provided with the printing ink layer 11 and the transparent surface base material layer 10, the embossed surface The decorative material 9 is completed by providing the transparent protective layer 13 on the entire surface of the.

Example 1 Fine line unevenness having a line width of 30 microns, a spacing of 30 microns, and a depth of 5 microns is formed by direct etching on the entire surface of a roll having a copper plating of 200 microns in thickness around an iron core. . A protective metal layer made of chrome plating having a thickness of 10 μm is formed on the fine line-shaped fine irregular surface, a photosensitive resin is applied to the protective metal layer surface to a thickness of 5 μm, and a convex portion is formed with an embossing plate. The part is transparent,
A mask film whose black portion is to be formed with a black portion is overlaid on the photosensitive resin surface, exposed and developed to form a resist film. Then, the protective metal layer in the portion without the resist film is removed by etching with hydrochloric acid, and the copper base material surface in the portion where the protective metal layer is removed is further etched with a ferric chloride solution to a thickness of 50 μm. Form a recess of depth. Sandblasting is performed using # 150 particles on the entire surface on which the concave portions are formed to form grain-like irregularities on the surface. The remaining protective metal layer made of chromium was dissolved and removed with hydrochloric acid, and chromium plating was applied to the entire surface to provide a metal protective layer to prepare an embossed plate. By imprinting on a polyvinyl chloride sheet provided with a printing ink layer using the embossing plate, the surface luster of wood, the movement effect of luster, texture such as texture can be faithfully reproduced, and the wood is worn due to abrasion of the surface. As a result, it was possible to obtain a decorative material that was excellent in physical properties and design and was not easily damaged.

[0027]

EFFECTS OF THE INVENTION An embossing plate having a surface structure in which parallel fine line irregularities composed of parallel lines are formed on the surface of a convex portion and grain-like irregularities are formed on the inner surface of the concave portion By the method of removing the protective metal layer after sandblasting the entire surface in the state where the protective metal layer was formed only on the convex portion where the fine irregularities were formed, the grain-like irregularities were easily formed only on the inner surface of the concave portion. The above embossed version is obtained. By using the embossing plate, it has a structure in which grain-like irregularities are formed on the flat portion of the surface, and fine line irregularities are formed on the concave portions corresponding to the wood temporary duct, texture, etc. It is possible to obtain a decorative material that has a surface gloss and texture that move depending on the direction and that changes in strength, reproduces the texture of wood very faithfully, and that does not easily damage the texture of wood due to abrasion of the surface.

[Brief description of drawings]

FIG. 1 is a sectional view of an embossing plate of the present invention.

FIG. 2 is a diagram showing a manufacturing process of the embossing plate of the present invention, in which (a) shows a state in which fine linear irregularities are formed on the surface of the metal substrate, and (b) shows fine linear irregularities in the linear form. A state in which a protective metal layer is formed on the surface of the formed metal substrate, and (c) A state in which a resist film is formed on the surface of the protective metal layer by etching for forming convex portions corresponding to wood grain conduits, tissues, etc. ,
(D) is a state in which the protective metal layer in the portion without the resist film is removed by etching and a concave portion is further formed in the metal substrate,
(E) is a state where grain-like irregularities are formed on the entire surface by sandblasting, (f) is an embossed plate completed by removing the protective metal layer remaining on the surface, and (g) is a finished embossed plate with chrome plating. The state of doing.

FIG. 3 is a cross-sectional view of a decorative material manufactured using the embossing plate of the present invention.

FIG. 4A to FIG. 4E are diagrams showing specific examples of the linear fine uneven pattern used in the present invention.

[Explanation of symbols]

 1 Embossed Plate 2 Metal Substrate 3 Convex 4 Concave 50,000 Fine Micro Asperity 6 Grainy Asperity 7 Protective Metal Layer 8 Resist Film 9 Decorative Material 10 Surface Base Layer 11 Printing Ink Layer 12 Backside Base Layer 13 Protective Layer

Claims (2)

[Claims] 1. A surface structure comprising a convex portion having parallel line fine irregularities formed of parallel line groups on the top portion and a concave portion having a sandblasted irregularity formed by sandblasting on the inner surface. Embossed version. 2. A step of forming parallel fine line irregularities composed of parallel line groups on the surface of a metal base material by etching, and a protective metal layer formed on the entire surface of the metal base body on which the fine parallel line fine roughness is formed. The process of forming with a mask, the process of applying a photosensitizer to the surface provided with the protective metal layer, exposing the mask film expressing the temporary passage of the wood structure, fibers, etc. and developing to form a resist film, and etching. A step of removing the protective metal layer in the portion where the resist film is not formed, a step of etching the metal base material in the portion where the protective metal layer is removed to form a concave portion in the metal base material, and sandblasting the entire surface. A convex portion having parallel fine line irregularities formed of parallel line groups on the top and a grain-like irregularity by sandblasting on the inner surface, which comprises a step of applying and a step of removing the remaining protective metal layer. Shape A method for manufacturing an embossing plate having a surface structure having a recess formed therein.