JPH08267687A - Manufacture of polyester decorative sheet - Google Patents

Abstract

PURPOSE: To manufacture a highly aesthetically designed polyester decorative laminated sheet by laminating a decorative laminated sheet formed by using a print original plate with color patterns of natural lumber or a fancy board of natural lumber enlarged and corrected into desired dimensions, on the decorative laminated base material via an adhesive layer. CONSTITUTION: A polyester decorative laminated sheet 1 is manufactured with use of a decorative laminated sheet 4 and formed film 7. That is, when lauan plywood is used as a decorative laminated sheet base material 2, a decorative sheet printed using a printed layer plate is adhered, and when decorative laminated sheet base material 2 with its smooth surface such as MDE is used, a decorative lamented sheet 4 printed using another print original plate is adhered on the decorative laminated sheet base material 2 respectively via an adhesive 3. Then, unsaturated polyester resin 6 is poured thereon so as to match the uneven patterns 8 of the formed film 7 with the color patterns of the decorative laminated sheet 5 and transfer the unevennesses on the formed film surface onto the resin surface. After curing the unsaturated polyester resin, the formed film 7 is separated therefrom to complete the polyester decorative laminated sheet 1.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is a decorative board used for various furnitures, interior materials for building materials, etc. The present invention relates to a method for manufacturing a polyester decorative board.

[0002]

2. Description of the Related Art Conventionally, an unsaturated polyester resin is coated on a base material for a decorative board, a shaped film having an uneven pattern is superposed on the substrate, and the unsaturated polyester resin is cured. A method for producing a polyester decorative board having an uneven surface by peeling off the shaped film is widely known as having high reproducibility of the texture of the material. As the print pattern of the decorative sheet used on the plate base material, a method of using an arbitrary print pattern similar to the original in which the shaped film having an uneven pattern is used, or a color pattern of the original from the same original is used. There is a method of preparing and using the decorative sheet and the shaped film having an uneven pattern.

However, in the case of the above method, in the former case, the printed pattern and the uneven pattern are taken from different originals, so that the design is uncomfortable, and in the latter case, the makeup is different. When the sheet is attached to the base material for decorative sheet, the decorative sheet shrinks and the pattern size of the printed pattern shortens.On the other hand, the uneven pattern on one side is made during molding due to the use of silicone resin as the material for the shaped film. There is a problem that the shaped film expands due to the heat of, and the pattern size increases especially in the width direction. Therefore, the pattern positions of the color pattern and the concave-convex pattern cannot be perfectly matched, and there is a problem that a highly designed wood grain polyester decorative board cannot be obtained.

That is, at the time of printing, tension is applied in the flow direction of the pattern so that the base sheet for a decorative sheet is stretched and printed in a state of being contracted in the width direction. Then, when the sheet is cut to a predetermined size, the stress is released and the decorative sheet becomes Since it shrinks in the pattern flow direction and expands in the width direction, the pattern size is reduced in the pattern flow direction and expanded in the pattern width direction as compared with the plate surface size of the printing original plate. Furthermore, when it is attached to a base material for a decorative plate, and if it has a rough surface such as Lauan plywood with unevenness on the surface, the decorative sheet is difficult to recess and the pattern size in the width direction becomes small, so As described above, in the case of a base material having a smooth surface, there is almost no reduction in the size of the pattern in the width direction, and the difference in pattern between the color pattern and the concave-convex pattern of the decorative sheet differs depending on the smoothness of the surface of the base material for a decorative sheet. Therefore, there is a problem in that it is not possible to produce a clear decorative plate without a pattern deviation by synchronizing the color pattern of the decorative sheet and the concave-convex pattern of the shaping mold with one type of printing original plate so as to match each other.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and its object is to:
A method for producing a polyester decorative board of high design in which the color pattern of the wood grain pattern and the concavo-convex pattern match well depending on the type of base material for the decorative board, in the case of a polyester decorative board using a natural wood board or a veneer of a natural wood as a manuscript Is provided.

[0006]

In order to achieve the above object, a method for producing a polyester decorative board of the present invention is a decorative material in which a natural wood board or a veneer of a natural wood is used as an original and a color pattern of the original is formed. On the above, an unsaturated polyester resin liquid is applied, and after curing in a state where the unsaturated polyester resin liquid surface is placed so as to contact the uneven surface of the shaping film in which the uneven pattern of the original is shaped, In the method for producing a polyester decorative board by peeling off the shaped film, a decorative sheet formed by using, as the decorative material, a printing original plate in which the color pattern of the natural wood board or the natural wood veneer is enlarged and corrected to a desired dimension. Is laminated on the base material for decorative board via an adhesive layer, so that the color pattern and the uneven pattern of the natural wood board or the veneer of the natural wood are matched with each other. .

Then, using a printing original plate prepared by using a photographic original plate in which the color pattern of the natural wood board or the natural wood veneer is enlarged and corrected by 0.22 to 0.27% in the pattern flow direction and the width direction in the photoengraving process. It is characterized by using a decorative sheet on which a color pattern is formed.

In addition, the color pattern of the natural wood board or the natural wood veneer is set to 0.
A decorative sheet on which a color pattern is formed by using a printing original plate prepared by using a photographic original plate having an expansion correction of 22 to 0.27% and further reducing and correcting the pattern width direction by 0.13 to 0.17% in a printing plate process. It is characterized by using.

[0009]

According to the method for producing a polyester decorative board of the present invention described above, the color pattern of the decorative sheet is a color pattern taken from an original such as a natural wood board or a veneer of natural wood. A photographic master plate that has been uniformly enlarged and corrected in the same direction is formed, and since it is formed using a printing master plate that is manufactured by changing the reduction ratio in the width direction of the pattern corresponding to the substrate for the decorative plate in the printing plate process, it has a color pattern. It is easy to perfectly match the uneven pattern, and it is also possible to easily deal with base materials for decorative boards having different surface smoothness.

[0010]

Embodiments of the present invention will be described below with reference to the drawings. 1 is a laminated sectional view of a polyester decorative board of the present invention, FIG. 2 is a process system diagram showing steps according to the implementation of the method of the present invention, and FIG. 3 is a laminated sectional view showing a method of manufacturing a polyester decorative board of the present invention. And 1 is a polyester veneer, 2
Is a base material for decorative plate, 3 is an adhesive layer, 4 is a decorative sheet, 41
Is a base sheet for decorative sheet, 5 is a color pattern, 6 is an unsaturated polyester resin, 7 is a shaped film, and 8 is an uneven pattern.

The structure of the polyester decorative board 1 of the present invention is as follows.
As shown in FIG. 1, the adhesive layer 3, on the base material 2 for decorative plate,
Decorative sheet 4, color pattern 5, unsaturated polyester resin 6
Are laminated in order, and the color pattern 5 and the concavo-convex pattern 8 are completely in tune with each other.

The manufacturing process of the polyester decorative board 1 of the present invention will be described with reference to FIG. A natural wood board or a veneer of natural wood is commonly used as a manuscript for manufacturing the decorative sheet 4 and the shaped film 7.

First, the manufacturing method of the shaped film 7 will be described. As shown in FIG. 2, the shaping film 7 is formed by pouring or applying a silicone resin as a molding material on the surface of a natural wood board or a veneer of a natural wood. Then, after curing, it is peeled off to obtain a shaped film (first type). At this time, it is preferable to use, as the reinforcing material, a cloth, a screen mesh, or the like stretched in advance on an aluminum frame, an iron frame, a wooden frame, or the like. There are silicone resins that can be cured by a condensation reaction and those that can be cured by an addition polymerization reaction, but any silicone resin that is commonly used for molding can be used. Desirably, a low temperature curing type is the original. It is good that there is little damage. A transparent or semitransparent silicone resin is preferable in consideration of deaeration during molding of the polyester decorative board.

Next, titanium paper is placed on MDF, plywood, etc., and an air-drying type unsaturated polyester resin is flown on it, and the first mold is pressed to extend the resin while defoaming it. The mold is peeled off to make an uneven replica plate (second mold). On the other hand, a titanium paper is laminated on an MDF board, an unsaturated polyester resin is applied and cured to prepare a polyester fiber board, an adhesive is applied to the back surface of the polyester fiber board, and a second die cut to a predetermined size is used as a photo master. Two pieces are placed side by side so as to be synchronized with C, and a laminated copy (third type) is made with a press machine.
The connection may be straight or curved.

After applying a mold-releasing silicone oil onto the third mold, a molding film 7 (fourth mold) was obtained by molding with a silicone resin or the like by the same method as the first mold. . The shaped film 7 thus finished may be used as it is as an embossing plate, but from the viewpoint of mass production of the shaped film 7 and stability of quality, the shaped film 7 is used as a mother mold, and a seamless return type is taken from this. The shaped film 7 to be used may be manufactured.

Next, a method of manufacturing the decorative sheet 4 of the present invention will be described. As shown in FIG. 2, a photographic original plate A is prepared by taking a photograph of a color pattern on the surface of an original of a natural wood board or a veneer of a natural wood. . The original photo A is enlarged and corrected to produce an original photo B. The two photo masters B are horizontally connected to prepare a photo master C having a desired size. At this time, the photographic original plate B may be connected in a straight line or a curved line. As for this connecting portion, it is as if it is a continuous pattern by increasing the image density by means of dyeing or the like to reduce the density difference or discontinuity of the pattern, or by physically or chemically decreasing the image density. Fix it.

Then, using the above-mentioned photo master C, a printing master is produced on a printing cylinder by a known electronic engraving gravure plate making apparatus. As shown in FIG. 2, a photographic master C is used to perform a printing plate in a usual manner to obtain a printing master B.
Printing is performed using the printing original plate a to produce a decorative sheet 4a. Further, when a printing plate is made using the photographic master C, the printing plate is obtained by reducing and correcting only the widthwise direction of the pattern to obtain a printing master plate B having a reduced pattern size in the widthwise direction, and a decorative sheet using the printing master plate B. Make 4b. The printing method at this time is gravure printing.

Using the decorative sheet 4 and the shaped film 7 printed by the above-mentioned method, a polyester decorative board 1 is manufactured by a conventionally known method as shown in FIG. That is, when lauan plywood is used as the base material 2 for decorative plate, the decorative sheet 4a printed by using the printing original plate a is used, and in the case of the base material 2 for decorative plate having a smooth surface such as MDF, the printing original plate is used. The decorative sheet 4b printed by using B is attached to each base material 2 for decorative plate via the adhesive 3. Unsaturated polyester resin 6 is poured on this, and the uneven pattern 8 of the shaping film 7 is formed.
And the color pattern 5 of the decorative sheet 4 are synchronized with each other to transfer the irregularities on the surface of the shaped film to the resin surface. After the unsaturated polyester resin 6 is cured, the shaped film 7 is peeled off to complete the polyester decorative board 1.

As the base material 2 for the decorative plate used in the present invention, for example, a wood base material such as lauan plywood, particle board and MDF is appropriately selected and used, and laminated on the base material 2 for the decorative plate. The decorative sheet 4 to be used is weighed 30 to 6
5 g / m ² of building material printing paper, pure white paper, or synthetic paper base paper 41 such as thin paper with enhanced interlaminar strength is used, and a color pattern 5 such as a wood pattern is gravure on the surface. A material provided by a known method such as printing can be used, and as the ink material for the color pattern 5, a cellulose acetate-based ink is preferably used.

In the manufacturing method of the present invention, the pattern print size of the color pattern 5 on the decorative sheet 4 needs to be formed larger than the color pattern of the original of the natural wood or the veneer of the natural wood. The reason is that these base papers 41 for decorative sheets are
When the color pattern 5 is printed, the color pattern is applied in a stretched state by applying tension in the flow direction of the pattern, and the stress is released when the color pattern 5 is cut to a predetermined size when it is attached to the base material 2 for decorative plate. Since the decorative sheet shrinks in the flow direction and expands in the width direction, the pattern size is reduced in the pattern flow direction and expanded in the pattern width direction as compared with the plate surface size of the printing original plate. Further, on the other hand, the uneven pattern on one side causes the shape-imparting film to expand due to the heat at the time of molding, so that the pattern size is expanded particularly in the width direction.

Further, it is necessary to adjust and form the enlargement ratio of the size of the color pattern in accordance with the smoothness of the surface of the base material 2 for decorative plate used. The reason for this is that the decorative sheet bites into the concave portion of the surface when it is attached via an adhesive, and the paper width becomes shorter.

Therefore, in the present invention, for example, when a substrate such as a Lauan plywood having an uneven surface such as a conduit is used as a substrate, 0.22 to 0.22 in both the pattern length direction and the width direction are used.
The original plate C, which had been enlarged and corrected by 0.27%, was used as a printing original plate which was printed by a usual electronic engraving gravure plate making method.

Alternatively, when a substrate having a smooth base material surface such as MDF is used as the substrate, a photographic master C that has been enlarged and corrected by 0.22 to 0.27% in both the pattern length direction and the width direction is used. Engraving gravure plate making machine 0.13 ~ in width direction
A printing original plate was prepared by reducing 0.17%.

Example 1 [Preparation of shaped film (type 4)] A veneered veneer single plate (thickness 0.35 mm × width 1000 mm × length 2100 mm) having a wood grain conduit was vinegared on a 9 mm thick plywood. The original shall be the one that is pasted with a hot press using Bi adhesive. After correcting defects such as dents and scratches on the original and smoothing the original surface with sandpaper, the original is released with Vaseline, and a room temperature curable silicone resin is applied 1.0 mm on the original. It was coated to a thickness, cured, and peeled off to obtain a shaped film (first type). Next, 80 g / m ² of titanium paper is attached to a 3 mm thick MDF, 500 g / m ² of air-drying unsaturated polyester resin is applied onto this, and a shaping film (first type) is covered,
After curing, it was peeled off to obtain a concave-convex replica plate (second type). Meanwhile, 3 mm
Prepare a poly-plate with a flat surface of MDF base material with a thickness, apply 6 g / m ² of vinyl acetate adhesive on the back side, and cut ^two 615 mm wide × 2100 mm long concave-convex replica plates (type 2). Laminated duplicated plate (third type) by cold pressing with an array press
I got Next, apply mold release silicone oil on the replica plate (third mold), and apply room temperature curing type silicone resin to 1.0 mm.
A thick film was coated, and after curing, peeled off to obtain a shaped film (fourth type). [Preparation of Printing Master Plate and Decorative Sheet] A photo master plate A is prepared by taking a photograph of the above document. Photo original A 0.25
%, And a photographic original plate B was prepared. Two photographic original plates B were horizontally connected to obtain a photographic original plate C. Using original photo C,
An electronic engraving gravure plate making device was used to engrave a cylinder plated with copper having a circumference of 2100 mm to prepare a gravure printing plate. A zelkova pattern was printed on the inter-paper reinforced paper having a basis weight of 30 g / m ² using the above gravure printing plate using an ink containing cellulose acetate as a vehicle to obtain a decorative sheet. [Preparation of Polyester Decorative Board] Then, a vinyl acetate adhesive was applied to a 9 mm thick plywood in an amount of 60 to 65 g / m ^2, and the above decorative sheet was press-bonded with a hot press. Subsequently, 400 g / m ^{2 of} unsaturated polyester resin was applied to the entire upper surface of the decorative sheet having the above-mentioned pattern layer, and the shaping film (fourth type) was coated from above, and then visually from the back surface of the shaping film. The uneven pattern of the shaped film and the wood grain color pattern corresponding thereto were matched, defoamed using a roller, smoothed, and then left to stand in a drying oven at 80 ° C. for 3.5 minutes to cure the unsaturated polyester resin. After that, the shaped film was peeled off to obtain a tuned polyester decorative board having a zelkova pattern in which the wood grain color pattern and the concave and convex pattern were beautifully matched.

Example 2 [Preparation of shaped film (fourth mold)] Same as in Example 1 [Preparation of printing original plate and decorative sheet] A photographic original plate A is prepared by photographing the above original. Photo original A 0.25
%, And a photographic original plate B was prepared. Two photographic original plates B were horizontally connected to obtain a photographic original plate C. Using original photo C,
A gravure printing plate was prepared by engraving a copper-plated cylinder having a circumference of 2100 mm with 0.15% reduction engraving in the pattern width direction using an electronic engraving gravure plate making apparatus. A zelkova pattern was printed on the inter-paper reinforced paper having a basis weight of 30 g / m ² using the above gravure printing plate using an ink containing cellulose acetate as a vehicle to obtain a decorative sheet. [Production of polyester veneer] Next, MD with 9 mm thickness
A vinyl acetate adhesive was applied to F at 60 to 65 g / m ^2, and the above decorative sheet was press-bonded with a hot press. Subsequently, 400 g / m ^{2 of} unsaturated polyester resin was applied to the entire upper surface of the decorative sheet having the above-mentioned pattern layer, and the shaping film (fourth type) was coated from above, and then visually from the back surface of the shaping film. The uneven pattern of the shaped film and the opposite wood grain color pattern were matched, defoamed and smoothed by using a roller, and then the mixture was left standing in a drying oven at 80 ° C. for 3.5 minutes to cure the unsaturated polyester resin. After that, the shaped film was peeled off to obtain a tuned polyester decorative board having a zelkova pattern in which the wood grain color pattern and the concave and convex pattern were beautifully matched.

Comparative Example 1 [Preparation of shaped film (fourth mold)] Same as in Example 1 [Preparation of printing original plate and decorative sheet] A photographic original plate A is prepared by photographing the above original. Two photo masters A were connected side by side to obtain a photo master C. A gravure printing plate was prepared by engraving a copper plate having a circumference of 2100 mm with an electronic engraving gravure plate making apparatus using the photo master C. A zelkova pattern was printed on the inter-paper reinforced paper having a basis weight of 30 g / m ² using the above gravure printing plate using an ink containing cellulose acetate as a vehicle to obtain a decorative sheet. [Production of polyester decorative board] Same as in Example 1

Comparative Example 2 [Preparation of shaped film (type 4)] Same as Example 1 [Preparation of printing original plate and decorative sheet] Same as Comparative Example 1 [Preparation of polyester decorative board] Same as Example 2

Then, the deviation of the pattern between the wood grain color pattern and the concavo-convex pattern on the obtained decorative board was measured. As a result, Table 1 shows the difference in the grain pattern size with respect to the uneven pattern size.

[0029]

From these results, it can be seen that the decorative boards of Examples 1 and 2 according to the present invention can provide a polyester decorative board having a very matching pattern as compared with the conventional method.

[0031]

According to the present invention, it is possible to easily manufacture a decorative board having a substantive feel in which a fine and delicate color pattern of natural wood and an uneven pattern, which cannot be obtained by a conventional decorative board, are matched. A high-quality decorative board can be obtained.

[Brief description of drawings]

FIG. 1 is a laminated sectional view of a polyester decorative board of the present invention.

FIG. 2 is a process flow chart showing steps according to the implementation of the method of the present invention.

FIG. 3 is a laminated cross-sectional view showing a method for manufacturing a polyester decorative board of the present invention.

[Explanation of symbols]

 1 polyester decorative board 2 base material for decorative board 3 adhesive 4 decorative sheet 41 base paper for decorative sheet 5 color pattern 6 unsaturated polyester resin 7 imprinted film 8 uneven pattern

Claims (3)

[Claims] 1. A natural wood board or a natural wood veneer is used as a manuscript,
The unsaturated polyester resin liquid is applied onto the decorative material on which the color pattern of the original is formed, and the uneven surface of the shaping film on which the uneven pattern of the original is formed is brought into contact with the unsaturated polyester resin liquid surface. In the method for producing a polyester decorative board, which is obtained by peeling off the shaped film after being cured in a state of being placed on, the color pattern of the natural wood board or the natural wood veneer is expanded to a desired dimension as the decorative material. A decorative sheet formed by using the corrected printing original plate is laminated on a base material for a decorative plate via an adhesive layer, so that the color pattern and the uneven pattern of the natural wood board or the natural wood veneer are synchronized. A method for producing a polyester decorative board, which is characterized by the above. 2. The color pattern of the natural wood board or the natural wood veneer is 0.22 in the pattern flow direction and the width direction in the photoengraving process.
2. The method for producing a polyester decorative board according to claim 1, wherein a decorative sheet having a color pattern formed by using a printing original plate produced by using a photographic original plate having an expansion correction of 0.27% is used. 3. The color pattern of the natural wood board or the natural wood veneer is 0.22 in the pattern flow direction and width direction in a photoengraving process.
A decorative sheet having a color pattern formed by using a photographic original plate that has been enlarged and corrected to ~ 0.27%, and further using a printing original plate that is produced by reducing and correcting the pattern width direction by 0.13 to 0.17% in the printing plate process. The method for producing a polyester decorative board according to claim 1, wherein: