JPH10175363A - Embossed sheet and embossed decorative material with the sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a continuous embossed sheet which can form a recessed and projected pattern on the resin surface of a DAP (diallyl phthalate) resin decorative sheet or the like and adjust glass such as matting on its recessed sections so that the design feeling demonstrating natural grains and natural rifts is provided, and also provide an emboss decorative material using the above-referred embossed sheet. SOLUTION: A raised printing pattern layer 11 is formed on a film base 10 by using two-pack curing resin ink to which a matting agent is added to manufacture an embossed sheet, and a pattern layer 13 is formed on one face of a paper base 12, and then impregnated with DAP (diallyl phthalate) resin to manufacture a resin impregnated decorative sheet. Then a raised pattern face of the embossed sheet is overlapped on the pattern face, and hot pressing is applied, and then the continuous embossed sheet is released, and a recessed and projected pattern is formed on a DAP (diallyl phthalate) resin layer 14 on the resin impregnated decorative sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thermosetting resin decorative board used for surface decoration and surface protection of architectural interiors, partitions, storage furniture, and the like. The present invention relates to an embossed sheet used for embossing and an embossed decorative material manufactured using the embossed sheet.

[0002]

2. Description of the Related Art Conventionally, thermosetting resin decorative boards have been widely used for desks, storage furniture, building interiors, etc. because of their excellent abrasion resistance, heat resistance, water resistance and the like.

[0003] The decorative board is firstly made of titanium paper, which has a weak paper-to-paper strength but contains a large amount of inorganic fillers. Impregnated to make a resin impregnated decorative sheet, then MDF,
It is manufactured by laminating with a wood substrate such as particle board and hot pressing, but the resin impregnated decorative sheet used here is generally hard and can not be continuously wound on reels, Not only during storage and transportation, but also in laminating in the production of thermosetting resin decorative boards, it is necessary to carry out sheet by sheet, handling is troublesome, production efficiency is low,
Therefore, this is one factor in reducing production costs.

In order to improve the design of the surface of the decorative board, in the process of manufacturing the decorative board, an embossed sheet for providing irregularities on a resin-impregnated decorative sheet at the time of hot pressing is superposed on the surface. Although it is common to provide an uneven pattern, the concave and convex portions on the surface after molding have the same gloss, and thus lack the expressive power of the uneven feeling, and the effect of the precious unevenness is reduced.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems of the prior art, and is intended to improve the glossiness of the uneven portion of the surface in the production of a thermosetting resin decorative board having an uneven pattern on the surface. Can be continuously wound on a reel with an embossed sheet that forms a sharp uneven pattern that gives a difference to
Provided is an embossed decorative board which is bonded to a wood-based base material of a thermosetting resin decorative board, the surface of which is provided with irregularities by the embossed sheet, which is effective for improving the production efficiency of the decorative board, and which is hot-press molded. The purpose is to:

[0006]

The embossed sheet of the present invention is an embossed sheet comprising a film substrate and a raised printing pattern layer formed of a two-component curable resin ink.
The present invention is characterized in that a matting agent is added to the two-component curable resin ink. Further, the embossed decorative material of the present invention,
After providing a pattern layer on one side of the paper substrate, on the pattern layer side of the resin-impregnated decorative sheet impregnated with diallyl phthalate resin,
The embossed sheet of the embossed sheet is overlapped with the embossed printed pattern layer, and after hot-press molding, the embossed sheet is peeled off, and a concavo-convex pattern corresponding to the embossed printed pattern is formed on the pattern layer surface of the resin-impregnated decorative sheet. Things.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described based on embodiments. The embossed sheet (FIG. 1) of the present invention has a structure in which a raised printing pattern layer (11) made of a two-part curable resin ink to which a matting agent is added is provided on a film substrate (10).

Further, the embossed decorative material of the present invention (FIG. 3)
Is provided with a pattern layer (13) on one side of a paper base material (12) and then impregnated with a diallyl phthalate resin (dap resin) (14) on the pattern layer side of a resin-impregnated decorative sheet (FIG. 2). Overlay the embossed printing pattern layer surface of the embossed sheet,
After the hot-press molding, the embossed sheet is peeled off, and a concavo-convex pattern corresponding to a raised printing pattern is formed on the pattern layer surface of the resin-impregnated decorative sheet.

As the film substrate (10) used for the embossed sheet of the present invention, polyester, polypropylene, polypropylene ruder lami paper, ethylene-tetrafluoroethylene copolymer, vinylon film and the like can be used. Since the film has high heat resistance and good releasability from the curable resin layer, it can be desirably used. Further, when the releasability of the film substrate and the curable resin layer is insufficient, a releasable silicone oil is provided on the film substrate surface and on the raised ink,
Wax or the like can be coated or sprayed. Further, in order to delay the softening of the film substrate due to the high heat generated by the hot press, a silicone resin layer or the like may be provided on the back surface of the film substrate (the surface without the raised ink) to supplement the heat resistance.

The raised print pattern layer (11) provided on the film substrate (10) is an ink using a two-component curable resin as a binder, and withstands the heat and pressure during hot pressing to maintain a convex shape. It is necessary to be able to, as the two-part curable resin, a melamine resin, a urea resin, a thermosetting resin such as a phenolic resin, an acrylic polyol, a polyester polyol, a polyol prepolymer such as a polyether polyol and an isocyanate compound. Mixed resin, modified (acrylic resin, epoxy resin, alkyd resin, etc.) silicone resin, ultraviolet curable resin, electron beam curable resin, etc. can be used. Also, a modified silicone resin is added to the raised ink in an amount of from 1 to 20.
% Blending can be preferably used because it can be easily released from the resin-impregnated decorative sheet (FIG. 2) even if it is repeatedly pressed several times.

Further, in order to adjust the gloss of the concave portions of the diallyl phthalate resin (dup resin) layer (14), a matting agent (matting agent) is added to the embossing ink (11). Inorganic fillers such as magnesium carbonate, barium sulfate, talc, silica, titanium oxide, etc. can be used, and the amount of addition to the priming ink can be adjusted by matting or semi-glossy concave portions of the diallyl phthalate resin (dap resin) layer (14). The matting agent can be used as an adjusting agent for matte gloss, etc. The addition amount of the matting agent is preferably 3 to 40% by weight with respect to the curable resin. If it is less than 3%, the matting effect becomes insufficient, and %, The adhesiveness of the ink to the base film is reduced, and the number of times of repeated use as an embossed sheet is reduced. And thus causing a decrease in capacity.

Further, a small amount of a coloring agent such as a pigment may be added to the embossing ink in addition to the curable resin and the matting agent so that the printing state of the embossed pattern on the embossed sheet can be grasped. Further, as a printing method of the embossed ink, any method can be used as long as it can be printed on a continuous substrate by a gravure method, a screen method, a rotary screen method, or the like. It is desirable in design to provide a raised ink having a height of 5 to 50 μm.

[0013] The resin-impregnated decorative sheet used in the present invention.
(FIG. 2) has a picture layer (13) on one side of a paper substrate (12).
After being provided, it is impregnated with a curable resin (14).
And the paper base material (12) is 23 to 65 g / m2.^Two
Single-sided thin paper, printed paper for building materials with high whiteness, 23
~ 65g / m^TwoHigh quality paper, and 50-200g / m ^Two
Titanium paper, etc. can be used.
Titanium paper which is excellent in soaking amount and the like can be preferably used.

Further, as the ink for forming the picture layer (13), an ink comprising a urethane resin, an acrylic resin, a melamine resin or the like which has excellent adhesion to the impregnated resin and does not inhibit the curing of the impregnated resin can be used. But,
In order to reduce the inhibition of resin impregnation, an appropriate amount of an inorganic filler such as calcium carbonate, magnesium carbonate, barium sulfate, talc, silica, or titanium oxide may be kneaded and used in the ink.

As the curable resin (14) for impregnation, a high-pressure melamine resin, a low-pressure melamine resin, an unsaturated polyester resin, or the like is too hard to be used in the curing step, and is not suitable for use. Dap resin (diallyl phthalate resin) is not only excellent in flexibility, but also can be cured by heating under low pressure, low temperature and short time, and is particularly excellent in continuous processability and low cost. Can be preferably used.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIG. 3, a description will be given of an embodiment of a decorative veneer having an uneven surface according to the present invention. Basis weight 80g /
m ² of the base paper (12) (Kojin Co., Ltd.: PM over 27P) on one side of the wood grain pattern (13) and gravure printing with alkyd-melamine resin inks, DAP resins (14) (diallyl phthalate resin) Was impregnated to form an impregnated resin decorative paper, and then a 25 μm-thick polyester film (1
0) A continuous embossed sheet was prepared by performing rotary screen printing with a screen embossing ink (11) in which a polyester modified silicone resin and a melamine resin were kneaded in a ratio of 1: 5 (manufactured by Toray Industries, Inc .: Lumirror F65). Next, the raised ink pattern surface of the continuous embossed sheet was superimposed on the wood pattern surface of the impregnated resin decorative paper.
After pressing under the condition of 0 second, the continuous embossed sheet was peeled off, and a dipped resin decorative sheet having an irregular pattern on the surface of the dipped resin on the grain surface of the impregnated resin decorative paper was prepared. The back of the decorative sheet (the side without wood grain pattern)
The plywood was bonded with a vinyl acetate adhesive to obtain a three-dimensional decorative veneer reminiscent of natural wood.

[0017]

According to the embossed sheet of the present invention, it is possible to impart a concavo-convex pattern to the resin surface of a curable resin impregnated decorative paper such as a dap (diallyl phthalate resin) resin, and to provide a matte concave portion and the like. It is also possible to adjust the glossiness of the natural wood, so that a design feeling reminiscent of natural wood grain can be expressed. Therefore, the design of the conventional melamine veneer and the surface of the dap (diallyl phthalate resin) veneer are flat, and there is no difference in the surface gloss. However, it is possible to improve a point that has been greatly separated.

The base film of the embossed sheet of the present invention is a polyester film or the like having a high heat resistance, and can be wound up sufficiently continuously after printing the raised ink. Resin) Resin-impregnated decorative paper impregnated with resin is also flexible and can be wound continuously (note that high-pressure melamine resin,
Low-pressure melamine resin, unsaturated polyester, etc. cannot be continuously wound because the cured resin is very hard. Therefore, the embossed sheet of the embossed sheet and the resin-impregnated decorative paper Are superposed on each other to achieve an effect of enabling continuous embossing.

Further, the decorative sheet impregnated with the embossed sheet of the present invention having a concavo-convex pattern is made of a wood base material (plywood, particle board, medium density fiberboard (MD)
F), hardboard), etc., becomes a dup decorative material, and is also bonded to a metal plate (iron, aluminum, copper, etc.) or ceramic inorganic plate (gypsum board, concrete plate, calcium silicate plate, etc.) This has the effect that it can be used as an embossed decorative material having excellent design properties and physical properties (scratch resistance, heat resistance, etc.) in a wide range of various wall decorative materials, partition materials, partition materials, and the like. .

[Brief description of the drawings]

FIG. 1 is a sectional view of an embossed sheet of the present invention.

FIG. 2 is a cross-sectional view of a resin-impregnated decorative sheet on which an embossed pattern is formed by the embossed sheet of the present invention.

FIG. 3 is an explanatory diagram showing a cross section when an embossed sheet of the present invention is superimposed on a resin-impregnated decorative sheet, an embossed pattern is formed, the embossed sheet is peeled off, and an embossed decorative material is produced.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 ... Film base material 11 ... Emboss print pattern layer 12 ... Paper base material 13 ... Picture layer 14 ... Diallyl phthalate resin layer

Claims (2)

[Claims] 1. An embossed sheet comprising a two-part curable resin ink and a raised printing pattern layer provided on a film substrate, wherein a matting agent is added to the two-part curable resin ink. Sheet. 2. A pattern layer is provided on one side of a paper base material, and a raised printing pattern layer surface of the embossed sheet is superimposed on a pattern layer side of a resin-impregnated decorative sheet impregnated with a diallyl phthalate resin. After embossing, the embossed sheet is peeled off, and an embossed pattern is formed on the pattern layer surface of the resin-impregnated decorative sheet according to a raised printing pattern.