JPH08309936A - Embossed film and production thereof - Google Patents

Abstract

PURPOSE: To obtain an embossed film having processability necessary for faithfully assuming the shape of the unevenness of a matrix and made hard to receive the deformation by an unsaturated polyester resin soln. by laminating a thermoplastic resin film having excellent resistance against an uncured unsaturated polyester resin on the surface of a polyvinyl chloride film. CONSTITUTION: A thermoplastic resin film 3 consisting of a thermally adhesive resin layer 3b and a polyester resin layer 3a and having excellent resistance against an uncured unsaturated polyester resin is laminated to the surface of the polyvinyl chloride film 2b of a laminated film 2 consisting of a vinylon film 2a and the polyvinyl chloride film 2b. Embossed patterns are formed to the vinylon film 2a. An embossed film 1 is obtained by applying the embossed patterns of a matrix plate to the vinylon film 2a of the laminated film 2 and thermally bonding the thermoplastic resin film 3 having excellent resistance against the uncured unsaturated polyester resin to the surface of the polyvinyl chloride film 2b.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an embossed film for forming an uneven pattern on the surface of a polyester decorative board and a method for producing the embossed film.

[0002]

2. Description of the Related Art Conventionally, after coating an uncured unsaturated polyester resin on a substrate, a shaping film having an uneven pattern is overlaid to cure the unsaturated polyester resin, and thereafter, a shaping having the uneven pattern is applied. A method of producing a polyester decorative board having an uneven surface by peeling off the film is known. As a shaped film having an uneven pattern, which is used to manufacture a polyester decorative board having an uneven surface by such a method, various forms have been conventionally used. Among them, the silicone resin shaped film, which is obtained by applying the room temperature curing type silicone resin to the surface of the original and curing and releasing it as the shaping mold, has extremely good reproducibility of the uneven shape. The silicone resin used for is expensive, and it takes a long time to cure the silicone resin, resulting in poor productivity. As a result, the shaped film becomes expensive. In addition, since the silicone resin is opaque, it has the drawback that it is difficult to synchronize the color pattern and the uneven pattern of the decorative sheet during the manufacturing of the decorative sheet, which makes it unsuitable as a shaping film used in industrial production. there were. As a low-priced, transparent shaped film that replaces it, a vinyl chloride film with excellent transparency and air barrier properties is laminated with a highly processable vinyl chloride film, and the laminated film is heated and pressed to form an uneven pattern on the vinylon surface. It is known that it is shaped. However,
Since the vinyl chloride film is easily swollen by the styrene monomer in the unsaturated polyester resin liquid, the surface that is always in contact with the unsaturated polyester resin liquid is the vinylon film layer, but the vinyl chloride film is directly on the surface. The unsaturated polyester resin scatters during the molding process of the polyester decorative board, adheres to the vinyl chloride film surface and swells the shaped film, tears, and loses the sharpness of the uneven pattern. There was a drawback that it stretched out and the dimensions became longer and it was out of sync with the design.

[0003]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and its object is to:
(EN) An embossed film, which has the workability necessary for faithfully molding the irregularities on a mother die and is less susceptible to deformation by an unsaturated polyester resin liquid, is provided at a low cost.

[0004]

In order to achieve the above-mentioned object, the embossed film according to the present invention is an embossed film for a polyester decorative board having a constitution in which a vinylon film and a vinyl chloride film are laminated. A thermoplastic resin film having excellent resistance to an uncured unsaturated polyester resin is laminated on the vinyl chloride film surface.

The thermoplastic resin film having excellent resistance to the uncured unsaturated polyester resin is a biaxially stretched polyester film obtained by laminating the vinyl chloride film and an adhesive layer having thermal adhesiveness. Is preferable.

In the method for producing an embossed film according to the present invention, a silicone resin is applied to the surface of an original having an uneven pattern surface and cured to prepare a shaped film for a master plate. A thermosetting resin is poured into a shaped film for plate and cured to prepare a master plate, and a concave-convex surface of the master plate has a laminated film of vinylon film and vinyl chloride film and heat adhesion to the vinyl chloride film. It is characterized in that a thermoplastic resin film having excellent resistance to an uncured unsaturated polyester resin having an adhesive layer laminated thereon is sequentially laminated and heated and pressed to laminate a shaped film at the same time as unevenness shaping.

[0007]

The above embossing shaped film of the present invention has a vinylon film whose surface in contact with the uncured unsaturated polyester resin has an irregular pattern, and the vinyl chloride film surface of the laminated film. Since a thermoplastic resin film with excellent resistance to is provided,
Even when the styrene monomer in the uncured unsaturated polyester resin turns to the surface during molding of the polyester decorative board, the shaped film swells and can be used without deterioration. Also, by using a biaxially stretched polyester film in which a thermo-adhesive resin layer is laminated as a thermoplastic resin film having excellent resistance to an uncured unsaturated polyester resin, it can be laminated on the vinyl chloride film surface at the same time as embossing and processing. The number of man-hours for producing a shaped film can be shortened. Therefore, a shaped film for molding a polyester decorative board can be easily provided at low cost.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to the drawings. FIG. 1 is a cross-sectional view showing an embossing-shaped film of the present invention, FIG. 2 is a cross-sectional view illustrating a manufacturing process of the embossing-shaped film of the present invention, 1 is an embossing-shaped film, and 2 is
Is a laminated film, 2a is a vinylon film, 2b is a vinyl chloride film, 3 is a thermoplastic resin film having excellent resistance to an uncured unsaturated polyester resin, 3a is a polyester resin layer, 3b is a heat-adhesive resin layer, and 4 is an original. 5a is a silicone resin, 5b is a shaping film for a master plate, 6 is a master plate, 6a is a thermosetting resin layer, 6b is a base material, 11 is a heating plate,
12 is a cushion paper and 13 is a backing plate.

As shown in FIG. 1, the embossing film 1 of the present invention has a heat-adhesive resin layer 3b on the vinyl chloride film 2b side of a laminated film 2 in which a vinylon film 2a and a vinyl chloride film 2b are laminated. The thermoplastic resin film 3 having excellent resistance to the uncured unsaturated polyester resin composed of the polyester resin layer 3a is laminated,
The uneven pattern is formed on the vinylon film 2a side.

Next, a method of manufacturing the embossed film 1 having the above structure will be described. First, in the present invention, FIG.
As shown in (a), the silicon resin 5a is applied to the surface of the original 4 by a method such as pouring or coating, and then cured, and then the silicon resin film is peeled off from the original 4 to remove the silicon resin 5a. Fine shapes such as fine irregularities on the surface are finely exposed on the surface of the silicon resin film to produce a mother resin shaping film 5b made of silicon resin having a shape opposite to the original 4.

Next, in the present invention, as shown in FIG. 2 (B), the mold film 5b made of the silicone resin obtained above is placed on the thermosetting resin surface 6a and then cured. After that, the shaping film 5b for master plate is peeled off, and a mold material having a shape opposite to that of the shaping film 5 for master plate, that is, the same shape as the regular original 4 is produced, and this is used as a master plate. 6

Next, as shown in FIG. 2C, the surface of the vinylon film 2a of the laminated film 2 consisting of the vinylon film 2a and the vinyl chloride film 2b laminated in advance on the master plate 6 obtained above. On the vinyl chloride film 2b side of the laminated film 2 and then the thermoadhesive resin layer 3b of the thermoplastic resin film 3 having excellent resistance to the uncured unsaturated polyester resin is laminated, The backing plate 13 and the cushion paper 12 are sequentially sandwiched and sandwiched, and this is inserted between the heated heating plates 11 and heated under pressure, and the mother plate 6 of the master plate 6 is placed on the vinylon film 2a surface of the laminated film 2. An embossed shaped film in which an uneven pattern is formed and a thermoplastic resin film 3 having excellent resistance to unsaturated polyester resin liquid is heat-bonded to the vinyl chloride film 2b surface. To obtain a beam 1 [2 (d)].

As the original 4, natural wood, veneer, woven cloth,
Any material such as glass fiber, net, mat, and leather can be used. If desired, the original 4 may be coated with releasable silicone or wax, or may be impregnated with a synthetic resin solution and dried to improve the releasability of the silicon resin film. The silicone resin used for preparing the shaped film 5 for the master plate may be one that is cured by a condensation reaction, one that is cured by an addition polymerization reaction, or the like.

The laminated film 2 is a laminate in which a thermoplastic film excellent in transparency and air barrier property and a thermoplastic film excellent in processability are laminated by dry lamination, and has excellent transparency and air barrier property. Vinylon film 2a is most suitable as an excellent thermoplastic film. In addition to these, Tetron film, vinyl fluoride film, cellophane, etc. can also be used. The thickness is 10 to 100 μm, preferably 20 to 50 μm. The vinyl chloride film 2b is most suitable as the thermoplastic film having excellent processability, and other films such as polyethylene film and polypropylene film can be used. Thickness is 200 ~
It is 500 μm, preferably 250 to 350 μm.

In the present invention, the thermoplastic resin film 3 having excellent resistance to the uncured unsaturated polyester resin used in the embossed film 1 has a laminated structure of a thermoadhesive resin layer 3b and a polyester resin layer 3a. 2 consisting of a body
It is an axially stretched polyester laminated film. By laminating the heat-adhesive resin layer 3b having excellent heat-adhesiveness with the vinyl chloride film and the polyester resin layer 3a having excellent strength, heat resistance, dimensional stability, solvent resistance and the like, excellent physical properties of both layers can be obtained. Polyester resin 3
The heat-adhesive resin 3b is applied to the surface of the non-oriented polyester film immediately after melt-extruding a, and then stretched in the machine direction and the transverse direction.

Examples of the polyester resin excellent in strength, heat resistance, dimensional stability, solvent resistance and the like are ethylene terephthalate, ethylene-α, β-bis (2-chlorophenoxy) ethane-4,4-dicarboxylate, Ethylene
Examples of the polyester include 2,6 naphthalene dicarboxylate as a polymerized unit, and among these, polyethylene terephthalate is particularly preferable. The thickness is 5 to 200 μm, preferably about 25 to 50 μm.

As the resin which can be used as the heat-adhesive resin 3b having excellent heat-adhesiveness with the vinyl chloride film, a resin having excellent adhesiveness with the vinyl chloride-based resin and also excellent adhesiveness with the polyester resin can be used. Acrylic resin, polyurethane resin, and polyester resin are preferable. Thermal adhesive resin layer 3b made of such a resin composition
In order to form the above on the polyester resin layer 3a which is the base film, each of the above thermoadhesive resins is dissolved in an appropriate solvent, and the obtained solution is used as a coating agent. The coating agent obtained as described above is melt-extruded and then preferably applied to the surface of an unoriented polyester film immediately after casting or a low-oriented polyester film having a low degree of stretching. The coating of the coating agent is a film having a low degree of crystallinity which is not stretched as it is melt-extruded as described above, or a low degree of crystallinity which is uniaxially stretched mildly in the longitudinal direction or the transverse direction. When the film is low in film thickness, the adhesion of the coating film to the base polyester film 3a is enhanced, and at the same time when the physical properties of the base polyester film 3a are enhanced by the subsequent transverse and longitudinal stretching, the coating film is also coated. It is possible to obtain the biaxially stretched polyester film 3 to which the ultrathin film is firmly adhered by being stretched to be thin.

Example 1 A natural oak veneer was pasted on a medium fiberboard having a thickness of 9 mm to prepare a document. A silicon resin with a thickness of 0.5 is placed on the original.
It was poured into the film so as to have a size of 10 mm, left to cure at room temperature for 24 hours, and then released from the original to obtain a shaped film for a master plate.
Next, a black titanium paper with a weight of 80 g / m ² was attached to a medium fiber board having a thickness of 3 mm with a vinyl acetate adhesive, and an unsaturated polyester resin was applied thereon at a coating amount of 300 g / m ² to obtain the above. The shaped film for the master plate was coated from above and evened using a roller. After being left at room temperature for 1 hour to cure the unsaturated polyester resin, the shaping film for a mother die was peeled off to obtain a mother die which is a polyester fiber board having a conduit shape. Next, pre-laminated thickness 300μ
m vinyl chloride film and 25 μm thick vinylon film are laminated on the master plate so that the vinylon film side faces, and the vinyl chloride film surface of the laminated film has a thickness of 30 μm and has thermal adhesiveness. The heat-bonded surfaces of biaxially stretched polyethylene terephthalate film are overlaid and inserted into a press machine heated to 135 ° C.
° C., 50 kg / cm ^2, 5 min heating clamping after pressurized while the press through the cooling water, taken out of the cooling after press, embossed with the surface shape of the natural oak and demolded film from mold plate A shaped film was obtained.

^On a titanium paper having a weight of 80 g / m ^2, a wood grain pattern was printed by gravure printing using an ink containing cellulose acetate as a vehicle to obtain a decorative base paper. Then 2.
After roll-coating a vinyl acetate adhesive on a 5 mm plywood, the decorative base paper obtained above is laminated, and 200 g / unsaturated polyester resin is applied to the entire upper surface of the decorative base paper having the pattern layer.
After coating with the coating amount of m ² and covering the embossed film obtained above from above, defoaming and smoothing with a roller, and leaving it in a drying oven at 50 ° C. for 3.5 minutes to heat. To cure the unsaturated polyester resin. Then, after taking out and cooling, the embossed film was peeled off to obtain a polyester decorative board on which the natural oak conduit unevenness pattern was reproduced in very detail. In addition, when a polyester decorative board was manufactured 50 times under the same conditions, no sagging of embossed uneven pattern, deviation from the pattern due to stretching of the shaped film, tearing of the film, etc. were observed, and it had repeatability. Was confirmed.

[0020]

According to the present invention, since the biaxially stretched polyester film having excellent resistance to the uncured unsaturated polyester resin is provided on the vinyl chloride surface of the vinylon / vinyl chloride film laminated film, the unsaturated polyester Since there is no concern about swelling due to the styrene monomer in the resin liquid, it can be used repeatedly 100 times or more.

Furthermore, by using a biaxially stretched polyester film provided with a heat-adhesive layer, the film can be attached to a vinylon / vinyl chloride film laminated film at the same time as embossing, so that the number of steps does not increase and workability is improved. And the embossed film can be manufactured at low cost.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an embossed film of the present invention.

FIG. 2 is a cross-sectional view illustrating a manufacturing process of the embossed film of the present invention.

[Explanation of symbols]

1 Embossed Film 2 Laminated Film 2a Vinylon Film 2b Vinyl Chloride Film 3 Thermoplastic Resin Film 3a Excellent in Resistance to Uncured Unsaturated Polyester Resin 3a Polyester Resin Layer 3b Thermal Adhesive Resin Layer 4 Original 5a Silicone Resin 5b Mother Shaped film for mold plate 6 Master plate 6a Thermosetting resin layer 6b Base material 11 Hot platen 12 Cushion paper 13 Patch plate

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical display location B32B 27/36 B32B 27/36 // B29K 67:00 B29L 7:00

Claims (3)

[Claims] 1. A thermoplastic resin having excellent resistance to an uncured unsaturated polyester resin on the vinyl chloride film surface of an embossed film for a polyester decorative board having a structure in which a vinylon film and a vinyl chloride film are laminated. An embossed shaped film characterized in that the films are laminated. 2. A thermoplastic resin film having excellent resistance to the uncured unsaturated polyester resin is a biaxially stretched polyester film obtained by laminating the vinyl chloride film and an adhesive layer having thermal adhesiveness. The embossed shaped film according to claim 1. 3. An original surface having an uneven surface is coated with a silicone resin and cured to prepare a shaping film for a master plate, and a thermosetting resin is further applied to the shaping film for a master plate. An uncured unsaturated polyester resin in which a master plate is prepared by casting and curing, and a laminated film of vinylon film and vinyl chloride film and an adhesive layer having thermal adhesiveness with the vinyl chloride film are laminated on the uneven surface of the master plate. A method for producing an embossed shaped film, which comprises laminating a shaped film at the same time as unevenness shaping by stacking thermoplastic resin films having excellent resistance against one another in order and heating and pressing.