JPH07186155A - Manufacture of mold for decorative laminated sheet - Google Patents

Abstract

PURPOSE:To provide a method for preparing a mold for decorative sheet with an anastatic part which approximates natural vessels consisting of deep parts and shallow parts. CONSTITUTION:This method for preparation consists of the first and the second exposure processes and the first and the second etching processes. A mask film 2 used in the first exposure process has a vessel transparent part 2d corresponding to the whole natural vessels and a mask film 2' used in the second exposure process has a vessel transparent part 2d' corresponding to the deep parts 1a of the natural vessels. A mold with a two-step anastatic part is obtd. by two times exposure-etching processes. A decorative sheet with vessels which approximate natural vessels having gradation can be farmed.

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 die for a decorative board, and more particularly to a decorative board which is artificially shaped with wood grain and is made of a material such as paper or synthetic resin. The present invention relates to a method for manufacturing a shaping mold used in a pressing process.

[0002]

2. Description of the Related Art Conventionally, for example, in the case of a decorative board having a wood grain pattern, the pattern of conduits forming the wood grain, that is, a number of concave line patterns is generally formed. Therefore, an infinite number of concave line patterns corresponding to the wood grain (conduit) is formed on the shaping die for forming such a decorative board. Conventionally,
As a method for forming such a shaped mold, a natural wood grain (conduit 1) shown in FIG. 1 is photographed on a photographic film, and the photographic film is used as an original plate to form a photosensitive resin on a substrate. A method is known in which the film is baked and then a portion corresponding to the conduit is formed as a convex portion by using a chemical etching method.

In the conventional manufacturing method, an uneven pattern is thus formed corresponding to the desired pattern of wood grain or the like. However, depending on the conventional method, a decorative plate having gradation such as photographic gradation is provided. It was not possible to realize a shaped mold for making.

As for the shaping mold for producing such a decorative board having gradation such as photographic gradation, the best solution is to shape the decorative board with an uneven pattern which is almost the same as a natural conduit. Needless to say. That is, the natural wood conduit has a shallow portion and a deep portion as shown in FIGS. 2 and 3, and it is necessary to form a relief plate portion corresponding to such a shape in a shaping mold. .

Referring to FIGS. 2 and 3, FIG. 2 shows a natural wood, and innumerable triangular conduits 1 schematically shown on the surface of the wood. In the figure, AB and CD indicate that cutting is performed on a plane including each line segment. This cross-sectional state is shown in FIG. The conduit acts as a passage for water in the tree and is a long pipe.
The cut end of the conduit appears on the surface of the cut wood as shown in FIG. In FIG. 3 (I), the cutting line A
In -B, it is clear that the conduit 1 is cut obliquely. Further, as shown in (II) and (III), in the section C-D, a state in which the upper part or the upper half of the conduit 1 is cut is shown. in this way,
Since the conduit itself is essentially pipe-shaped, the cut portion of the conduit appearing on the surface of the wood is formed by the peripheral shallow portion 1a and the central deep portion 1b. And the depth change is gradually changing.

The gradation corresponding to the depth of the conduit cannot be obtained in the photographic film as the original plate used in the conventional shaping manufacturing method, and the entire conduit is photographed as a shaded area on the film. Because of this (in the case of a positive film), the shaped mold produced using the mask film did not necessarily correspond exactly to the shape of the natural wood conduit.

[0007]

Therefore, the technical problem to be solved by the present invention is to provide a manufacturing method of a shaping mold capable of manufacturing a decorative plate having gradation similar to photographic gradation, that is, a deep portion. It is an object of the present invention to provide a method of manufacturing a shaping mold having a relief portion that approximates a natural conduit formed by a shallow portion.

[0008]

Means, Actions and Effects for Solving the Problems In order to solve the above technical problems, the present invention provides a manufacturing method having the following configuration.

FIG. 4 (I) shows a cross section of the conduit portion of natural wood corresponding to FIG. 3, and (II) shows two stages of the depth of the conduit 1 shown in FIG. The cross section represented by
II) shows respective cross sections representing it in three stages. That is, in (II), the conduit 1 has the deep portion 1a.
And (1), the conduit 1 is composed of a deep portion 1a, a shallow portion 1b and an intermediate portion 1c therebetween. In this way, the depth of the continuous and gradually changing conduit of natural wood can be approximated by multi-tiering it.

Based on the above-mentioned observation, the present invention has an object to multi-stage the relief plate portion of the shaping mold for shaping the conduit, and in order to achieve this object, the following steps 1) to 6) are carried out.
A method of manufacturing a shaped mold having

That is, this manufacturing method includes the following steps.

1) The photocurable layer laminated on the metal substrate is exposed through a first mask film having a transparent conduit portion corresponding to the whole of the natural conduit and a ground portion other than the transparent conduit portion is shaded, A first exposure step of uniformly photo-curing a portion corresponding to the transparent portion of the conduit to form a photo-curing portion.

2) Next, a first developing step of removing the uncured portion adjacent to the photocured portion of the exposed photocured layer.

3) Next, a corrosive liquid is caused to flow from above the photo-curing layer to corrode and remove the peripheral portion of the upper layer of the metal substrate other than the photo-curing portion, so that the relief plate portion corresponding to the photo-curing portion is removed. A first etching step for forming.

4) Next, a second mask film having a transparent conduit portion corresponding to the deep portion of the natural conduit and having a ground portion other than the transparent conduit portion shaded is aligned with the metal substrate after the first etching process. After overlapping, the metal substrate and the photo-curing layer after the first etching process are exposed through the second mask film to uniformly photo-cure the portion corresponding to the transparent portion of the conduit to form the photo-curing portion. Exposure process.

5) Next, a second developing step of removing the uncured portion adjacent to the photocured portion of the photocured layer after the second exposure step.

6) Next, a corrosive liquid is caused to flow from above the photo-curing layer to corrode the upper layer of the relief plate portion located around the photo-curing portion of the upper layer of the metal substrate and the periphery of the relief plate portion. A second etching step of forming a letterpress portion having a two-stage structure by removing.

The above method includes two exposure steps, a development step and an etching step, but this means the minimum number of times, and the number of times may be increased according to the desired number of stages. The higher this number, the more closely the letterpress portion is to the natural conduit.

According to the above process, the shaped relief plate is multi-staged, that is, the portion corresponding to the deepest part of the conduit is made to protrude most, while the protruding amount of the portion corresponding to the shallowest part of the conduit is minimized. By making the amount of the protrusion stepwise in the middle thereof, it is possible to form a relief plate portion capable of obtaining a decorative sheet with a conduit similar to a natural conduit in a shaped mold.

[0020]

EXAMPLES Examples will be described below in detail with reference to FIGS.

FIG. 5 (I) shows an exemplary conduit 1 intended to be shaped into a veneer (same as II in FIG. 4). This conduit 1 comprises a deep portion 1a and a shallow portion 1b. In order to form this two-staged conduit, the two mask films 2 and 2'shown in (II) and (III) are used in the manufacturing method of the shaping mold.

The first mask film 2 has a transparent conduit portion 2d corresponding to the entire natural conduit 1, that is, the entire natural conduit extending in the width and width, and the transparent conduit portion 2d.
The background portion or the ground portion 2c other than the above is shaded. on the other hand,
The second mask film 2'has a part of the natural conduit 1, that is, a transparent conduit portion 2d 'corresponding to the deep portion 1a of the natural conduit, and the ground portion 2c other than the transparent conduit portion 2d' is shaded. There is. These mask films can be produced by a known photographic technique for photographing natural wood as an original plate. For example, it can be created by taking a picture from an oblique direction, or by taking a picture after applying ink to a part of the original conduit,
A mask film having a different conduit expression can be produced by changing the exposure time and the exposure angle.

Now, as shown in FIG. 6, in the first step, the photocurable layer 3 is coated on the upper surface of the metal substrate 4, that is, the shaping base material of the shaping mold, usually a copper plate, and
The first mask film 2 is laminated thereon. Then, the photocurable layer 3 is exposed to the light L through the first mask film 2. Then, in the photo-cured layer 3, the portion corresponding to the transparent conduit portion 2d of the first mask film 2 becomes the photo-cured portion 3f, while the portion corresponding to the base portion 2c becomes the uncured portion 3g. The photo-cured portion 3f is shown by diagonal lines + dotted lines in the figure.

Then, in the next developing step, the uncured portion 3
g are washed away. Therefore, as shown in FIG.
Only the photo-cured portion 3f is in a state of being laminated on the metal substrate 4.

FIG. 7 shows the next step, that is, the first etching step. In this step, the corrosive liquid Q is caused to flow from above the photo-curing layer 3 so that it penetrates into the metal substrate 4. The infiltrated portion of the corrosive liquid is shown by stippling. The corrosive liquid Q hardly penetrates into the portion of the photo-cured portion 3f, but permeates deeply into the upper layer of the metal substrate 4 around it in proportion to time. That is, this first
By the etching process, as shown in FIG. 7 (II), the relief plate portion 4c corresponding to the conduit 1 can be formed on the upper layer of the metal substrate 4. Note that (II) shows a state in which the photo-cured portion 3f has already been removed.

FIG. 8 shows the next step, that is, the second exposure step. In this step, the upper surface of the metal substrate 4 of FIG. 7 (II) is coated with the photocurable layer 3 ′ again,
Further, a second mask film 2'is laminated on the metal substrate 4 which has been subjected to the first etching process. Then, the light curing layer 3 ′ is exposed to the light L through the second mask film 2 ′. Then, in the photo-curing layer 3 ', the portion corresponding to the transparent conduit portion 2d' of the second mask film 2 becomes the photo-curing portion 3f ', while the portion corresponding to the base portion 2c' becomes the uncured portion 3g '. Become.

Then, in the next developing step, the uncured portion 3
g'is washed away. Therefore, as shown in FIG. 9 (I), only the photo-cured portion 3f 'is laminated on the metal substrate 4.

FIG. 9I shows the next step, that is, the second etching step. In this step, the corrosive liquid Q is made to flow again from above the photo-curable layer 3 ′ so that it penetrates into the metal substrate 4. The corrosive liquid Q hardly penetrates into the portion of the photo-cured portion 3f, but permeates deeply into the upper layer of the metal substrate 4 around it in proportion to time. That is, as a result of this second etching step, as shown in FIG. 9 (II), a part of the relief printing portion 4c already formed on the metal substrate 4 remains as the relief printing portion 4c-1 corresponding to the deep portion 1a of the conduit 1. , The other portion of the letterpress portion 4c is eroded to a certain depth, and the letterpress portion 4 is one step lower than the letterpress portion 4c-1.
formed as c-2. The periphery of the letterpress portion 4c is further eroded and becomes the lowest. Note that (II) shows a state in which the photo-cured portion 3f has already been removed. In this way, a shaping mold having a two-stage letterpress portion 4c of the letterpress portion 4c-1 corresponding to the deep portion 1a of the conduit 1 and the letterpress portion 4c-2 corresponding to the shallow portion 1b of the conduit 1 is formed. Can be manufactured.

By using this shaping mold to shape (emboss) a decorative sheet made of, for example, a polyvinyl chloride sheet, a decorative plate having a conduit 1 as shown in FIG. 10 can be obtained. When the wiping ink N is applied to the conduit 1 of this decorative plate, the ink layer becomes thicker in the deep portion 1a and becomes thinner in the shallow portion 1b. As a result, the deep portion 1a becomes thicker and a deep conduit can be formed.

[Brief description of drawings]

FIG. 1 is a plan view showing a surface of natural wood having a conduit pattern.

2 is a diagram schematically showing the natural wood conduit of FIG. 1. FIG.

FIG. 3 is an explanatory view showing a cross section of the natural conduit of FIGS.

FIG. 4 is an explanatory sectional view showing a multi-staged conduit to be shaped on a decorative plate in the present invention.

FIG. 5 is a cross-sectional view showing two mask films used in an example of the present invention.

FIG. 6 is a cross-sectional view showing a first exposure process of the example. .

FIG. 7 (I) is a sectional view showing the first etching step of the embodiment, and (II) is a sectional view of the metal substrate obtained as a result.

FIG. 8 is a cross-sectional view showing a second exposure process of the example.

FIG. 9 (I) is a sectional view showing the second etching step of the embodiment, and (II) is a sectional view of the resulting shaping mold.

FIG. 10 is a cross-sectional view showing a decorative plate shaped by using the shaping mold obtained by the method of the example.

[Explanation of symbols]

1 conduit 1a
Shallow 1b Deep 1c
Middle part 2,2 First and second mask film 2
c, 2c 'base 2d, 2d' transparent conduit 3,
3'photocurable layer 3f, 3f 'photocurable layer 3
g, 3g 'Base paper 4 Metal board (copper plate) 4c
Letterpress L Light Q
Corrosion liquid N Wiping ink

Claims (1)

[Claims] 1. A ground portion (2c) having a transparent conduit portion (2d) corresponding to the entire natural conduit (1) and other than the transparent conduit portion (2d).
Through the first mask film (2) which is shaded, the photo-curing layer (3) laminated on the metal substrate (4) is exposed to uniformly photo-cure the portion corresponding to the transparent section (2d) of the conduit. Light curing part
A first exposure step of forming (3f), then a first development step of removing the uncured portion (3g) adjacent to the photocured portion (3f) of the exposed photocured layer (3), and A corrosive liquid (Q) is caused to flow from above the photo-curing layer (3) to corrode and remove the peripheral portion of the upper layer of the metal substrate (4) other than the photo-curing part (3f) to remove the photo-curing part. A first etching step for forming a relief plate portion (4c) corresponding to (3f), and then a conduit transparent portion (2d ') corresponding to the deep portion (1b) of the natural conduit (1) and a transparent conduit portion ( Other than 2d ')
After the second mask film (2 ′) whose shade is c ′) is aligned with the metal substrate (4) which has been subjected to the first etching process, the second mask film (2 ′) is passed through the first etching film (2 ′). A second step of exposing the processed metal substrate (4) and the photo-curing layer (3) to uniformly photo-cure the portion corresponding to the transparent conduit part (2d ') to form the photo-curing part (3f'). Exposure step and then the photo-cured part of the photo-cured layer (3) after the second exposure step
The second developing step of removing the uncured portion (3g ') adjacent to (3f'), and then flowing the corrosive liquid (Q) from above the photocurable layer (3f ') to remove the metal substrate (below). 4) Photocuring part (3f ') on the upper layer
Second etching step for forming a two-stage letterpress portion (4c-1, 4c-2) by corroding and removing the upper layer of the letterpress portion (4c) located in the periphery other than The manufacturing method of the shaping | molding die for decorative boards characterized by including the following.