JPH0825783A - Manufacture of embossing plate, the plate and decorative sheet shaped by using the same - Google Patents

Abstract

PURPOSE:To provide an embossing plate for manufacturing a decorative sheet having texture similar to that of natural tree and high design properties. CONSTITUTION:A gravure screen for gravure engraving is printed on a gelatin film 10 in which photosensitivity is imparted. Then, a negative film 12 of a woodgrain vessel pattern of continuous density gradation is printed, the printed film 10 is transferred to an embossing plate material 13, then developed and the unphotosensed part of the film is removed. Thereafter, the plate 13 is corroded with corrosive liquid to form an uneven part on the material 13, thereby obtaining an embossing plate.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an embossing plate for producing a decorative sheet having a texture close to that of natural wood and having a high design property, a method for producing the embossing plate, and a decorative sheet having irregularities formed using the embossing plate. It is about.

[0002]

2. Description of the Related Art Decorative sheets having an uneven pattern with a grain pattern have been widely used in the fields of building materials for homes, furniture, electric appliances and the like. Such a decorative sheet has been manufactured by forming irregularities on the surface of the decorative sheet using a so-called embossing plate. In order to manufacture a highly decorative decorative sheet that has a texture close to that of natural wood, an embossed plate that can faithfully reproduce the grain pattern of natural wood is required.

Conventionally, as a method for manufacturing an embossed plate, a method by the Porschel method in gravure plate making is known. In this method, as shown in FIG. 4, a photosensitive resin (such as TPR manufactured by Tokyo Ohka Kogyo Co., Ltd.) is evenly applied onto a cylinder (embossed plate material, generally a copper-plated cylinder) 1 to form a lith film. The negative film of the wood grain conduit pattern photographed at is printed and developed. Then, the photosensitive resin in the unexposed area is dissolved and removed, and the photosensitive resin in the exposed area is cured and remains to form the resist layer 2. Since the Poschel method expresses lightness and darkness depending on the size of halftone dots, the negative film uses a black and white lith type as described above. That is,
By baking and developing a negative film on the photosensitive resin, as shown in FIG. 4, a resist layer 2 having a uniform thickness is formed on the cylinder 1, and a portion where the surface of the cylinder 1 is completely exposed. Is formed. Then, by corroding this with a ferric chloride solution, the portion of the surface of the cylinder 1 where the resist layer 2 is not formed is corroded and an embossed plate is completed.

[0004]

However, in the Poschel method, the exposed portion of the surface of the cylinder 1 where the resist layer 2 is not formed is uniformly corroded, and a flat recess is formed at a uniform depth. Since the surface of the convex portion is also flat, if the surface of the decorative sheet is impressed with such an embossed plate, a flat conduit shape with a square cross section is impressed, so that the texture of natural wood is not obtained, There was a problem that a product with a high design quality could not be obtained.

The present invention has been made in view of the above conventional problems, and an object of the present invention is to provide an embossing plate and a embossing plate for manufacturing a decorative sheet having a texture close to that of natural wood and having high designability. It is intended to provide a manufacturing method and a decorative sheet in which unevenness is formed by using the embossing plate.

[0006]

In order to achieve the above object, the method for producing an embossed plate of the present invention comprises the steps of baking a white line screen for gravure plate making on a gelatin film having photosensitivity, and then producing a continuous density gradation wood grain. A negative film with a conduit pattern is baked, and the photosensitive gelatin film after baking is transferred onto the embossed plate material, and then developed to remove the unexposed portion of the gelatin film, and then the above embossed plate material is corroded with a corrosive liquid. It is characterized by forming irregularities on the embossed plate material.

Further, the method for manufacturing an embossing plate of the present invention is
A negative film of continuous density gradation wood grain pattern is baked on the gelatin film to which photosensitivity is given, and the photosensitive gelatin film after baking is transferred onto the embossed plate material, and then developed to remove the unexposed part of the gelatin film. It is characterized in that the embossed plate material is removed, and then the embossed plate material is corroded with a corrosive liquid to form irregularities on the embossed plate material.

The embossing plate of the present invention is characterized by being manufactured by the above method.

Further, the decorative sheet of the present invention is characterized in that the embossing plate is used to form irregularities.

The present invention will be described in more detail below.

FIG. 1 is a sectional view for explaining a method for manufacturing an embossing plate according to the present invention.

The method for producing an embossed plate of the present invention is roughly divided into the steps of baking a white line screen for gravure plate making on a gelatin film having photosensitivity, and then baking a negative film of continuous density gradation wood grain conduit pattern ( (Hereinafter referred to as a baking step), a step of transferring the photosensitive gelatin film after baking onto an embossed plate material, and then developing it to remove an unexposed portion of the gelatin film (hereinafter referred to as a transfer / developing step), and then A step of corroding the embossed plate material with a corrosive liquid to form irregularities on the embossed plate material (hereinafter referred to as a corrosive step). Hereinafter, description will be given according to these steps.

(1) Baking step Photosensitive gelatin film 1 as shown in FIG. 1 (a)
Step 0 is a step of printing a white line screen for gravure plate making (see FIG. 2B), and then a negative film 12 having a continuous density gradation (hereinafter referred to as continuous tone) with a wood grain conduit pattern (see FIG. 2C). Is.

As the gelatin film, a so-called carbon tissue, which is generally used for gravure plate making, can be used. This carbon tissue is obtained by dispersing a pigment (such as iron oxide), glycerin, and other additives in a gelatin solution, coating the dispersion on baryta paper, and drying the dispersion. Carbon Tissue is not photosensitive by itself,
It is soaked in a photosensitive solution to impart photosensitivity. A dichromate aqueous solution is usually used as a photosensitive liquid for imparting photosensitivity. When the photosensitized carbon fish is exposed to light, it undergoes a chemical change to cure and become insoluble in water. Since the degree of insolubility differs depending on the amount of light, it is possible to connect the light and shade of the film to be printed to the depth of the plate.

A carbon line screen for gravure plate making is brought into close contact with the carbon fish thus imparted with the photosensitivity, that is, the gelatin film 10 and baked. The white line screen for gravure plate making is a transparent glass or film in which black squares are regularly arranged, and the fineness thereof is expressed by the number of lines per inch, and generally 150 to 250 lines. When the white line screen is baked, the gelatin film 10 (the part indicated by 11 in the figure) in the part corresponding to the white line of the screen is exposed and hardened to become insoluble. In the production of the embossed plate of the present invention, unlike the case of the usual gravure plate making, it is desirable that the embossed plate material of the part corresponding to the white line is almost disappeared by the side etching in the subsequent corrosion step, which point It is necessary to determine the number of lines of the white line screen in consideration of the above.

Then, the negative film 12 having the wood grain conduit pattern is closely adhered to the gelatin film 10 having the white line screen printed thereon and baked. Negative film 1 with this wood grain conduit pattern
Reference numeral 2 indicates, for example, a natural wood oak material used as a manuscript, the surface of which is wiped with ink such as black ink as a pigment, or coated with black pigment fine particles, and then a continuous tone film is formed. It was taken in. Note that, in FIG. 1C, the negative film 12 is
For the sake of clarity, 12a is shown as a portion having a low concentration (corresponding to a deep conduit portion), 12c is shown as a portion having a high concentration (corresponding to a shallow conduit portion), and 12b is shown as an intermediate portion therebetween. This negative film 12 is replaced with a gelatin film 10
When baked on, an image of a wood grain conduit pattern having a different degree of curing depending on the density of the negative is formed (the gelatin films 14a, 14b and 14c shown in FIG. , 12c are shown respectively corresponding to the exposed portions.

The above white line screen and negative film 1
As the light source for the second baking, an arc lamp, an ultra-high pressure mercury lamp, a xenon lamp, or another light source with a large amount of ultraviolet rays is used.

(2) Transfer / Development Step As shown in FIG. 1 (d), the gelatin film 10 after baking is transferred onto an embossing plate material 13 and then developed to remove the uncured gelatin film 10. , A step of forming a relief pattern of gelatin having different thicknesses according to the density of the baked negative (see (e) in the same figure).

As the embossing plate material 13, a metal plate obtained by plating an iron plate with copper or a metal plate formed on a cylinder is usually used.

After the surface of the embossed plate material 13 is cleansed, the gelatin film 10 that has been baked is pressurized and brought into close contact with the surface of the embossed plate material 13 while applying water.

The embossed plate material 13 to which the gelatin film 10 has been transferred in this manner is then immersed in hot water of about 40 to 45 ° C. for development. Then, the uncured gelatin is dissolved, and a relief pattern of gelatin having a different thickness depending on the shade of the printing negative is formed on the embossed plate material 13. That is, the relief pattern 14 according to the shade of the wood grain conduit pattern.
a, 14b, 14c and the relief pattern 11 corresponding to the white line screen are formed.

(3) Corrosion step A step of corroding the embossed plate material 13 on which a relief pattern of gelatin is formed with a corrosive solution to form irregularities on the embossed plate material 13 as shown in FIG. 1 (f). Is.

In this case, a ferric chloride solution is generally used as the corrosive liquid. The relief pattern of gelatin becomes a resist film against the corrosive liquid, and corrosion starts when the corrosive liquid reaches the surface of the embossed plate material 13 through the gelatin film swollen by absorbing the corrosive liquid. Therefore, the depth of corrosion differs depending on the permeability of the corrosive liquid depending on the thickness of the relief pattern of gelatin, and finally the plate depth differs depending on the shade of the wood grain conduit pattern, that is, the gradation of the wood grain conduit pattern. 1
The embossed plate represented by the plate depth as shown by 13a, 13b, 13c in (f) is completed.

As a method of corrosion, several kinds of corrosive liquids having different concentrations are prepared, and a liquid having a high concentration (having a small penetrating power to the relief pattern) to a liquid having a low concentration (having a large penetrating power to the relief pattern) are sequentially placed. There are a method of using it and a method of using one concentration of the corrosive liquid (in some cases, a thick liquid is first used while diluting this). In the present invention, either method may be used.

In this way, the embossing plate of the present invention as shown in FIG. 1 (f) is completed. In the embossed plate of the present invention, the gradation of the wood grain conduit pattern is expressed by the plate depth, the tone of a genuine conduit can be reproduced, and the texture of natural wood can be obtained.

When the relief pattern 11 corresponding to the white line screen is formed, the relief patterns 14a, 14b, 14 corresponding to the shade of the wood grain conduit pattern at the time of corrosion.
It is possible to make c difficult to sag and enhance the unevenness of the finished embossed plate. Further, although the embossed plate material 13 in the portion corresponding to the relief pattern 11 is almost disappeared by side etching at the time of corrosion, some convex portions (for example, as shown by 13d in FIG. 1 (f)) may remain. However, it does not significantly deteriorate the design.

Next, a decorative sheet having irregularities is formed using the embossing plate of the present invention. That is, as shown in FIG. 2, the embossing plate of the present invention is used to form irregularities on a decorative sheet 15 on which a pattern such as wood grain is printed by a hot pressing method. As a result, a decorative sheet having an uneven pattern 16 on the surface as shown in the figure is obtained. As the material of the decorative sheet for imprinting unevenness, that is, the material to be embossed,
Materials that can be hot-pressed include paper, thermoplastics, wood, plywood, wood fiberboard, metal plates, and ceramic cement plates.

The decorative sheet produced by using the embossing plate of the present invention is provided with a conduit shape as rich in change as the tone of a genuine conduit. Therefore, it is possible to faithfully reproduce the state of the wood grain pattern of natural wood, and to obtain a decorative sheet with a highly-designed texture that has a texture that is very close to the real thing.

FIG. 3 shows another example of the method for manufacturing an embossing plate according to the present invention. The same parts as those in FIG. 1 are designated by the same reference numerals.

The process shown in FIG. 3 is exactly the same as the process shown in FIG. 1 except that the step of baking the white line screen on the gelatin film 10 having photosensitivity is omitted. Therefore, as shown in FIG. 3 (c), the gelatin relief pattern corresponding to the white line screen is not formed, so that the relief patterns 14a, 14b, 14c corresponding to the shade of the wood grain conduit pattern flow to some extent during corrosion,
Although the unevenness of the finished embossed plate may be impaired to some extent, for example, 13 in FIG.
Since the convex portion as shown by d does not remain on the embossing plate, a decorative sheet having a texture of natural wood and high design can be obtained by using the embossing plate manufactured according to the process shown in FIG.

[0031]

According to the present invention, a white line screen for gravure plate making is baked on a gelatin film having photosensitivity, and then,
Baking a negative film of continuous density gradation wood grain conduit pattern,
Alternatively, only the negative film of the wood grain conduit pattern is baked onto the gelatin film, the photosensitive gelatin film after baking is transferred onto an embossed plate material, and then developed to remove the unexposed portion of the gelatin film, and then the corrosive solution. Since the above embossed plate material is corroded to form irregularities on the embossed plate material, the gradation of the light and shade of the wood grain conduit pattern is expressed by the plate depth, so the tone of the real conduit is reproduced and the texture of the wood is reproduced. An embossed version that can be expressed is obtained.

Further, by shaping the decorative sheet using the embossing plate as described above, a conduit shape that is as varied as the tone of a real conduit tube is imparted, and the texture of wood is expressed. Therefore, it is possible to obtain a decorative sheet with a highly-designed appearance that is extremely close to the real appearance.

[0033]

EXAMPLES The present invention will be described more specifically by showing examples. Example 1 A white line screen (175 lines) for gravure plate making was brought into close contact with a carbon tissue sensitized by immersing it in a potassium dichromate solution, and exposed by a high pressure mercury lamp. The exposure time at this time was 3 minutes and 30 seconds.

Next, exposure was carried out by bringing a negative film having a continuous grain pattern of wood grain into close contact with the same carbon fish. The exposure time at this time was 7 minutes. As a negative film with a wood grain conduit pattern, a film obtained by applying a wiping coating to the surface of an oak material with black ink using carbon black as a pigment, and then taking a film of a continuous tone film was used.

Next, a plate cylinder with a copper plate on the steel pipe was
The carbon fish, which had been baked as described above, was passed through pressure rollers to be brought into close contact with the plate cylinder while water was applied by a transfer machine.

The plate cylinder to which the carbon tissue was transferred was transferred to a developing tank, and development was carried out for 10 minutes with hot water at 43 to 45 ° C. while rotating the plate cylinder to completely dissolve the uncured gelatin.

After the completion of development, the entire plate cylinder was cooled to room temperature and alcohol was applied to the plate surface to uniformly dry it.

Then, the plate cylinder was corroded by using a ferric chloride solution having a liquid temperature of 23 ° C. and a Baume degree of 40 ° C. While observing the progress of corrosion, a new solution was appropriately replenished and the final corrosion time was set to 50 minutes.

The plate cylinder after completion of the corrosion removed the remaining gelatin with dilute sulfuric acid to obtain an embossed plate.

Using the embossing plate thus obtained, a vinyl chloride decorative sheet having a thickness of 0.2 mm and having a wood grain print on the surface was press-molded at a temperature of 150 ° C. and a pressure of 5 kg / cm ^{2 for} 10 minutes to obtain the above-mentioned makeup. Unevenness was applied to the sheet.
This shaped decorative sheet was given a variegated conduit shape similar to a real conduit, and the texture of wood was expressed, and the appearance was very close to the real thing. Example-2 An embossed plate was produced in the same manner as in Example-1 except that the step of baking the white wire screen for gravure plate making on carbon tissue in Example-1 above was omitted. However, the corrosion time was 20 minutes.

The embossed plate thus produced was used to form irregularities on a vinyl chloride decorative sheet in the same manner as in Example-1. As a result, a conduit shape similar to a real conduit was imparted, and the texture of wood was expressed. Thus, a decorative sheet having an appearance very close to that of the real product was obtained.

[0042]

As described in detail above, according to the present invention, a white line screen for gravure plate making is baked on a gelatin film to which photosensitivity is imparted, and then a negative film of continuous density gradation wood grain conduit pattern is baked. Or, only the negative film of the wood grain conduit pattern is baked onto the gelatin film,
After transferring the photosensitive gelatin film after baking onto the embossed plate material, develop it to remove the unexposed part of the gelatin film, and then corrode the embossed plate material with a corrosive solution to form irregularities on the embossed plate material. Therefore, since the gradation of light and shade of the wood grain conduit pattern is expressed by the plate depth, the excellent effect that the tone of the real conduit is reproduced and the embossed plate that can express the texture of the tree is obtained. Play.

Further, according to the present invention, the embossing plate is used to shape the decorative sheet to have irregularities.
A decorative sheet having a highly-designed appearance is obtained, which is provided with a conduit shape that is as varied as the condition of a genuine conduit and expresses the texture of wood.

[Brief description of drawings]

FIG. 1 is a sectional view for explaining a method for manufacturing an embossing plate of the present invention.

FIG. 2 is a cross-sectional view of a decorative sheet shaped using the embossing plate.

FIG. 3 is a cross-sectional view for explaining another example of the embossing plate manufacturing method of the present invention.

FIG. 4 is a cross-sectional view for explaining a conventional embossing plate manufacturing method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 cylinder 2 resist layer 10 gelatin film 11 white line screen exposed area 12 negative grain film negative film 13 embossed plate material 15 decorative sheet 16 uneven pattern

Claims (4)

[Claims] 1. A white line screen for gravure plate making is baked on a gelatin film to which photosensitization is applied, and then a negative film of continuous density gradation wood grain conduit pattern is baked, and the photosensitive gelatin film after baking is printed on an embossed plate material. A method for producing an embossed plate, comprising the steps of transferring and developing to remove the unexposed portion of the gelatin film, and then corroding the embossed plate member with a corrosive solution to form irregularities on the embossed plate member. 2. A gelatin film formed by baking a negative film of continuous density gradation wood grain pattern on a gelatin film to which photosensitization is applied, transferring the baked photosensitive gelatin film onto an embossing plate material, and then developing. The method for producing an embossed plate, which comprises removing the unexposed portion of, and then corroding the embossed plate material with a corrosive liquid to form irregularities on the embossed plate material. 3. An embossing plate produced by the method according to claim 1. 4. A decorative sheet, characterized in that unevenness is formed using the embossing plate according to claim 3.