JPH07276570A - Shaping sheet for thermosetting resin decorative panel - Google Patents

Abstract

PURPOSE:To provide a shaping sheet capable of being utilized without contaminating a mirror surface metal panel at the time of press processing when a thermosetting resin decorative panel having an embossed pattern on the surface thereof is produced. CONSTITUTION:After a primer layer 3 is formed on the surface of a base material film 2, an ionizing radiation curable resin layer 4 having an uneven shape is formed on the primer layer from an ionizing radiation curable resin using a roll intaglio and a metal membrane layer 5 is further formed on the rear surface of the base material film to form a shaping sheet 1. Next, melamine resin impregnated core paper 21, decorative paper M surface paper 24 and the shaping sheet 1 are successively superposed on a base panel 26 and the whole is held between mirror surface processed metal panels to be heated and pressed by a press to form a laminated sheet. After the laminated sheet is cooled, the shaping sheet 1 is peeled to obtain a melamine decorative panel 20 having an embossed pattern layer 25 on the surface thereof. The shaping sheet 1 can be reutilized without contaminating the metal panel at the time of press processing.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement of a shaping sheet used for imparting an uneven pattern to a thermosetting resin decorative material such as a melamine decorative board.

[0002]

2. Description of the Related Art Conventionally, as such a shaped sheet, for example, a film of a thermoplastic resin is used as a substrate film, and a pattern is formed on the surface of the film by a method such as heat embossing (Japanese Patent Laid-Open No. No. 7341, etc.), ink was cured after screen-printing, gravure printing, etc. was used to make swelling printing on the surface of a substrate film using ink that used a thermosetting resin or an ultraviolet-curing resin as a vehicle. (Japanese Patent Application Laid-Open No. 60-9740, etc.), polyethylene terephthalate (hereinafter referred to as PET) film, etc., as a base material, a rotary type cylindrical mold is coated with an ionizing radiation curable resin liquid to form a film. The resin liquid is cured by ionizing radiation while the base material is in close contact with it,
After that, it is peeled off to form an uneven shape (Japanese Patent Laid-Open No. 5-2
No. 38196, etc.), etc. are known.

[0003]

SUMMARY OF THE INVENTION To form an uneven pattern on the surface of a thermosetting resin decorative board such as a melamine decorative board, a decorative paper impregnated with a thermosetting resin is imprinted on the decorative board during production. The sheets were stacked and pressed to form an uneven pattern on the surface of the decorative paper. In the conventional shaping sheet, the thermosetting resin decorative plate, which is pressed under the conditions of high temperature and high pressure, is usually pressed at a heating temperature of 100 to 150 ° C. and a pressure of 5.
Since it is carried out under the conditions of ~ 100 Kg / cm ² and heating / pressurizing time of 5-30 minutes, when pressed under the above conditions, PET
In the case of a shaped sheet that uses a resin commonly used as a base material film, oligomers in the base material, fluid low molecular weight components such as plasticizers elute or bleed, and adhere to the metal plate of the press. As a result, the metal plate was contaminated and the shaped sheet could not be reused. The present invention solves these problems, the uneven shape is well reproduced, in order to produce a thermosetting resin decorative board having an excellent uneven feeling, an object of the present invention is to provide a reusable shaped sheet To do.

[0004]

Means for Solving the Problems An uneven shape is provided on the surface of a resin film substrate having a component that bleeds when heated and pressed, and a metal thin film layer that prevents the bleeding component is provided on the back surface of the film. It was a mold sheet. The shape-imparting sheet can be used repeatedly without soiling the mirror-finished metal plate.

[0005]

According to the present invention, when the thermosetting resin decorative sheet is pressed, it is possible to prevent the oligomer and the like in the film base material of the shaping sheet from bleeding due to the heating temperature and pressure of the metal plate of the press. The thin film prevents the metal plate from becoming dirty.

[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 patterning sheet of the present invention. FIG. 2 is an explanatory view showing an example (drum printing method) of a method for manufacturing a shaped sheet. FIG. 3 is a cross-sectional view showing an example of a melamine decorative board produced using the shaped sheet of the present invention.

An example of producing the shaped sheet of the present invention will be shown below. First, as shown in FIG. 1, as a base film 2, a film having heat resistance and good dimensional stability, such as a biaxially stretched polyethylene terephthalate film (hereinafter referred to as PET film), is used, and a primer is applied thereto. The solution is gravure coated and dried to form the primer layer 3. Next, a drum printing method using a roll intaglio (disclosed in JP-A-5-238196)
Then, the uneven ionizing radiation curable resin layer 4 is formed on the PET film. Further, a metal thin film layer 5 is provided on the surface of the PET film opposite to the surface on which the concavo-convex shape is formed by a vacuum deposition method, a sputtering method, or the like to obtain the patterning sheet 1 for a thermosetting resin decorative plate.

In the drum printing method, as shown in FIG. 2, an ionizing radiation-curable resin liquid 4a is coated on a roll intaglio 12 rotating around an axis by a nozzle type coating device 11, and ionized by a nip roll 14a. Radiation curable resin liquid 4
a is filled in at least the recess 13 of the roll intaglio, and at the same time, the base film 2 is brought into close contact with the surface of the roll intaglio via the resin liquid, and the ionizing radiation irradiation device 1 is placed on the film.
5 is used to irradiate ionizing radiation to cure the resin liquid filled in the concave portions 13 of the roll intaglio plate, and at the same time to bond the cured ionizing radiation curable resin 4 to the base film 2, It is a method of peeling the base film 2 from 12 through the roll 14b to form an uneven shape made of the cured ionizing radiation curable resin on the base film 2.

In order to form an uneven shape on the base film,
Various methods other than the drum printing method can be used. For example, it is also possible to form an uneven shape by ink-jet printing using a thermoplastic resin, a thermosetting resin, or the like, using gravure printing or screen-printing method. As the ink composition, in addition to these resins, a colorant such as a dye or a pigment, a filler, a plasticizer, a stabilizer, or the like is appropriately added depending on the purpose of the uneven shape. Also,
An ultraviolet curable resin or an electron beam curable resin can also be used as the ink resin. Alternatively, the concavo-convex shape can be formed directly on the film base material 2 itself by a method such as pressing or sandblasting. Furthermore, in order to improve physical properties such as solvent resistance, chemical resistance, and abrasion resistance of the uneven shape, the topcoat layer may be provided with a resin suitable for the purpose.

The film substrate used for the shaped sheet is preferably one having heat resistance and good dimensional stability, but the present invention is particularly applicable to 100 to 150 at the time of hot pressing. It is a film made of a resin into which a fluid component such as an oligomer, a monomer, a plasticizer and a stabilizer is leached out or eluted under a condition of heating and pressurizing at a temperature of 5 to 100 kg / cm ² . For example, polyester resins such as polyethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalate are typical, but depending on the compounding, such as methyl polymethacrylate, methyl polyacrylate, ethyl polymethacrylate, and ethyl polyacrylate. Acrylic resins, polyolefin resins such as polyethylene, polypropylene and polymethylpentene, acrylonitrile-butadiene-styrene copolymer (ABS), cellulose triacetate, cellophane, polycarbonate and other films or sheets can be used. If necessary, the surface of the film substrate is subjected to easy adhesion treatment such as corona discharge treatment and easy adhesion primer coating.

As the ionizing radiation curable resin used for forming the uneven shape, a (meth) acryloyl group and a (meth) acryloyloxy group ((meth) acryloyl) are used in the molecule to mean acryloyl or methacryloyl.
A composition in which a prepolymer, an oligomer, and / or a monomer having a polymerizable unsaturated bond such as (meta) has the same meaning) or an epoxy group is appropriately mixed is used. As these prepolymers and oligomers, urethane (meth) acrylate, polyester (meth) acrylate, acrylate such as epoxy (meth) acrylate, silicon resin such as siloxane, unsaturated polyester,
Examples thereof include epoxy.

Examples of the monomer include styrene, styrene-based monomers such as α-methylstyrene, methyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, dipentaerythritol hexa (meth) acrylate, and dimethacrylate. Pentaerythritol penta (meth) acrylate, trimethylolpropane tri (meth) acrylate, and / or a polyol compound having two or more thiol groups in the molecule, for example, trimethylolpropane trithioglycolate, trimethylolpropane trithio Examples include propylate and pentaerythritol tetrathioglycol. The above compounds may be used alone or in admixture of two or more, if necessary, but in order to impart ordinary coating suitability to the resin composition, the above prepolymer or oligomer may be used in an amount of 5% or less.
95% by weight or more of the monomer and / or polythiol
It is preferable to set the content to be not more than weight%.

When flexibility of the cured product is required when selecting the monomer, the amount of the monomer may be reduced or the monofunctional or difunctional acrylate may be used in a range that does not hinder the coating suitability. A structure with a relatively low cross-linking density is used using a polymer. Also,
When heat resistance, hardness, solvent resistance, etc. of the cured product are required, increase the amount of the monomer or use a trifunctional or higher functional acrylate-based monomer within a range that does not hinder the coating suitability. A structure having a high crosslink density is preferable. Monofunctional and bifunctional monomers and 3
It is also possible to mix monomers having a functionality or higher to adjust coating suitability and physical properties of the cured product.

Examples of the monofunctional acrylate type monomer as described above include 2-hydroxy acrylate, 2-hexyl acrylate and phenoxyethyl acrylate. Examples of the bifunctional acrylate-based monomer include ethylene glycol diacrylate and 1,6-hexanediol diacrylate, and examples of the trifunctional acrylate-based monomer include trimethylolpropane triacrylate, pentaerythritol hexaacrylate, and dipentaerythritol hexaacrylate. Acrylate etc. are mentioned.

In order to control the physical properties such as flexibility and surface hardness of the cured product, the prepolymer, oligomer,
The following ionizing radiation non-curable resin is used in an amount of 1 to 70% by weight, preferably 5 to 5 with respect to at least one of the monomers.
It can be used by mixing 0% by weight.

As the ionizing radiation non-curable resin, thermoplastic resins such as urethane type, fibrin type, polyester type, acrylic type, butyral, polyvinyl chloride and polyvinyl acetate can be used, which are particularly flexible. From the point of fibrin,
Urethane type and butyral are preferable.

When the ionizing radiation curable resin is cured with ultraviolet rays, acetophenones, benzophenones, Michler benzoyl benzoate, α-amyloxime ester, tetramethyl are used as photopolymerization initiators in the ionizing radiation curable resin composition. Meuram monosulfide, thioxanthone, and / or as a photosensitizer, n-butylamine, triethylamine, tri-n-butylphosphine, etc. may be mixed and used.

The ionizing radiation as used herein means an electromagnetic wave or a charged particle beam having an energy quantum capable of polymerizing and cross-linking a molecule. Usually, ultraviolet rays and electron beams are used, but visible rays, γ Lines, X-rays, etc. can also be used. As the ultraviolet ray, a light source such as an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc, a black light and a metal halide lamp is used. As the electron beam source, various electron beam accelerators such as Cockloft Wald type, Van de Graaff type, resonance transformer type, insulating core transformer type or linear type, dynamitron type and high frequency type are used, and 100 to 1000K are used.
Irradiation with electrons having an energy of eV, preferably 100 to 300 KeV. The irradiation dose is usually 0.5
It is about 30 Mrad.

As a method for forming a metal thin film on a film or sheet, known vacuum deposition, sputtering, electroless plating, thermal spray plating, CVD (chemical vapor depos
ition) is used. As the metal of the metal thin film, one that can block fluid low-molecular components such as oligomers, plasticizers, monomers, etc. that bleed out under predetermined heat pressing conditions from the metals usually used in the thin film forming method. To use. For example, it can be selected from aluminum, chromium, nickel, cobalt, copper, gold, silver, tin, zinc, brass, stainless steel and the like. Aluminum is good for the bleed component of the polyester film. As the metal, in addition to the metal element simple substance, a metal compound such as an oxide or a salt of the metal can be used. Although the thickness of the metal thin film is selected depending on the use, it is usually about 40 to 10000Å, and preferably 300 to 500Å. Examples of the thermosetting resin decorative board that is the object of the present invention include known melamine resin decorative boards (high pressure method or low pressure method) diallyl phthalate resin decorative boards, guanamine resin decorative boards, and the like.

Specific examples will be described below. As shown in FIG. 2, a 50 μm-thick biaxially stretched PET film (“HP-7” manufactured by Teijin Ltd.) was used as the base material 2, and a primer liquid 3a (The Inktech Co., Ltd.) was used.
"Chemical Matt Medium" made by gravure coating,
The primer layer 3 is formed on the PET film by drying at 100 ° C. for 30 seconds.

Next, using a roll intaglio, as shown in FIG. 2, the following UV curable resin liquid composition (manufactured by Asai Bussan Co., Ltd.) was coated by a drum printing method to obtain a roll intaglio plate. UV curable resin liquid composition 4 in the concave portion 13 of
a, the PET film 2 is brought into contact therewith, and the high pressure mercury lamp 15 (160 W
/ Cm, 2 lights) for 2 seconds to cure the ultraviolet curable resin liquid and to bond the cured resin to the PET film. After the UV curable resin liquid is sufficiently cured, the PET film is peeled off from the roll intaglio
The uneven UV-curable resin layer 4 is formed on the film. The roll intaglio plate is a conduit plate having a plate depth of 50 to 150 μm, is made of metal by electroforming, and faithfully reproduces the actual grain.

Composition of UV curable resin composition (acryloyl group content 4.2 mole / Kg) Urethane acrylate prepolymer 58 parts by weight 2-hydroxyethyl acrylate 17 parts by weight Tripropylene glycol diacrylate 5 parts by weight Dipentaerythritol hexaacrylate 10 parts by weight Reactive silicone 10 parts by weight Sensitizer 4 parts by weight

Further, on the opposite side of the uneven surface of the PET film having the uneven ionizing radiation curable resin layer,
An aluminum vapor-deposited film 400Å was formed by a vacuum vapor-deposition method to prepare a patterning sheet 1 having an uneven ionizing radiation curable resin layer 4 and a metal thin film layer 5 as shown in FIG.

Next, a melamine decorative board as shown in FIG. 3 was produced using the above-mentioned shaping sheet. First, the substrate 26
4 sheets of core paper 21 impregnated with melamine resin are stacked on top of this, melamine resin-impregnated decorative paper 22 having a pattern 23 printed thereon and melamine resin-impregnated surface paper 24 are successively laminated, and then the above-mentioned treatment Mold sheet 1 with uneven surface 4
As shown in FIG. 3, the front surface paper 24 is brought into contact with and superposed. This is sandwiched between two mirror-finished metal plates, heated and pressed by a press at 135 ° C., 100 Kg / cm ² for 20 minutes to prepare a laminated plate, and further cooled to prepare a melamine decorative plate. By pressing, a melamine resin layer leached from the surface paper and the decorative paper and cured is formed on the surface of the laminated plate, and an uneven pattern is formed on the melamine resin layer by the shaping sheet 1. After the press working, the laminate is taken out from the press after cooling to room temperature, and the patterning sheet 1 is peeled off to obtain the melamine decorative board 20 having the uneven pattern layer 25 on the surface. Since the shape-imparting sheet has a vapor-deposited thin film layer of aluminum on the surface in contact with the metal plate, the mirror-like metal plate was not contaminated during press working, and the shape-imparting sheet could be reused.

[0025]

As described above, according to the present invention,
By using a shaped sheet that can faithfully reproduce the shape of the plate, it is possible to obtain a thermosetting resin decorative board to which a fine and realistic uneven pattern such as a wood grain pattern or an abstract pattern is provided. In particular,
When a shaped sheet is manufactured, a metal thin film such as an amminium vapor deposition film is provided on the surface opposite to the surface on which the uneven shape is formed, so that the mirror-finished metal plate for press working does not get dirty during the manufacturing of the decorative sheet, Can be used repeatedly, and work efficiency can be improved.

[Brief description of drawings]

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

FIG. 2 is an explanatory view when a shaped sheet is made by a drum printing method.

FIG. 3 is a cross-sectional view of a melamine decorative board produced using the shaped sheet of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Shaped sheet of this invention 2 Substrate film (PET film) 3 Primer coat layer 4 Irregular ionizing radiation curable resin layer (after hardening) 4a Ionizing radiation curable resin liquid (before hardening) 5 Metal thin film layer 11 Nozzle Type coating device 12 roll intaglio 13 roll intaglio recess 14a nip roll 14b roll 15 ionizing radiation irradiation device (ultraviolet irradiation device) 16 ink pan 20 melamine decorative plate with uneven pattern 21 core paper 22 decorative paper 23 pattern 24 surface paper 25 uneven pattern Layer 26 Substrate

Claims (1)

[Claims] 1. A resin film substrate having a component that bleeds when heated and pressed is provided with an uneven shape, and a metal thin film layer that prevents the bleeding component is provided on the back surface of the film. Shaped sheet.