JPH1029290A - Manufacture of decorative plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a decorative plate having high design properties and an uneven shape on its surface. SOLUTION: In the case of decorating a protruding part of a base material 11 having a large uneven shape and a fine uneven shape on its surface, a transfer sheet is pressed from a rear surface side of its support sheet toward the base material by a pressure roll having rubber hardness of 60 to 70 deg., then the support sheet is released from the transfer sheet, and thereafter transfer layers 12, 13 containing a decorative layer 13 remaining on the base material are directly pressed by the roll having rubber hardness of 60 to 70 deg.. A desired transfer layer is transferred only to the protruding part of the surface of the material 11 to complete the decorative plate.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a decorative board having a picture on its surface, and more particularly to a method of manufacturing a decorative board having an irregular shape on its surface and having a high design property.

[0002]

2. Description of the Related Art Conventionally, with respect to makeup on a convex portion of a substrate having large irregularities on its surface and fine irregularities on its convex portions, it is either painted with a single color paint or sprinkled with a sand-like material. However, since the decorative plate produced by this method is inferior in design, a printed sheet is pressed with a rubber roller and laminated on the uneven substrate surface to provide a picture. (See Japanese Patent Publication No. 5-2499). However, in this method, fine irregularities are flattened due to the interposition of the sheet therebetween, and it is not possible to express even minute irregularities of the convex portions of the base material.

[0003] Therefore, the transfer sheet is pressed from the back side of the support sheet using a soft roll having a rubber hardness of 60 ° or less, and if necessary, heated so that the pattern is adhered to the base material. A method of peeling and transferring a pattern to a convex portion of an uneven substrate (see Japanese Patent Application Laid-Open No. 6-278400) has been proposed, or a method of using a hard roll having a rubber hardness of 70 ° or more, or a rubber A method has been proposed in which the support sheet is peeled off by pressing with a hard roll having a hardness of 70 ° or more, followed by pressing with a soft roll having a rubber hardness of 60 ° or less (see JP-A-5-270199).

[0004]

However, in the method using a soft roll having a rubber hardness of 60 ° or less, the pattern follows the fine unevenness of the convex portion, but is transferred to the concave portion of the large uneven shape. As a result, a problem arises in that the shape of the base material must be selected. In order to prevent this, the adhesive must be selectively applied only to the convexities of large irregularities,
The work is complicated and a special coating machine is required. When a hard roll having a rubber hardness of 70 ° or more is used in place of the soft rubber roll, the pattern is not transferred to the concave portion having a large concave and convex shape. The problem of not being transferred occurs. In addition, rubber hardness 70
Even with the method of pressing with a hard roll of at least ° and then pressing with a soft roll with a rubber hardness of at most 60 ° and then peeling off the support sheet, the concaves with fine irregularities in the convexes with large irregularities The transfer of the picture to the surface is improved, but it is still incomplete, and an excellent design cannot be obtained.

The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a method of manufacturing a decorative board having a highly decorative decorative board having an uneven surface. To provide.

[0006]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention provides a method for applying a makeup to a convex portion of a substrate having a large irregular shape on the surface and a fine irregular shape on the convex portion. In the method for producing a decorative board by applying a rubber hardness of 60 to 70,
° pressing the transfer sheet toward the substrate from the back side of the support sheet with a pressure roll, and then peeling the support sheet from the transfer sheet, using a pressure roll having a rubber hardness of 60 to 70 °. By directly pressing the transfer layer including the decorative layer remaining on the substrate, the desired transfer layer is transferred only to the convex portions on the surface of the substrate.

[0007] According to the above method, the transfer sheet is first pressed under the support of the support sheet, so that the transfer layer does not come into contact with the concave portion of the large uneven pattern, and the transfer layer has a large uneven shape. By only pressing the transfer layer without interposing the support sheet,
The transfer layer follows and adheres to the concave portions having the fine irregularities on the convex portions having the large irregularities.

[0008]

Embodiments of the present invention will be described below.

The uneven substrate used in the present invention is a ceramic-based board such as a calcium silicate board, a wood chip cement board, an extruded cement board, a lightweight cellular concrete board (ALC), a glass fiber reinforced concrete board (GRC), or a wood-based board. Planks and wood plywood,
Particleboard, glulam, MDF (medium density fiberboard)
And a metal plate such as iron, aluminum, stainless steel, and copper; a ceramic plate such as ceramic and glass; and a resin plate such as polypropylene, PVC, and ABS resin.
The surface of these substrates may be coated in advance with an easy-adhesion primer for assisting the adhesion with the adhesive or a sealer for sealing the fine irregularities and porosity on the surface. A resin such as an isocyanate, a two-part curable urethane resin, an acrylic resin, a vinyl chloride acetate resin, or an epoxy resin is used as an easy-adhesion primer or sealer.

[0010] The irregularities of the substrate are composed of a large irregular shape and fine irregularities on the convex portions. The large uneven shape is composed of one having a step of 1 to 10 mm, a width of a concave portion of 1 to 10 mm, and a width of a convex portion of 5 mm or more. It is smaller than the shape, specifically, the step is about 0.1 to 5 mm, the width of the concave portion and the width of the convex portion are 1 mm or more, and is about less than 1/2 of the width of the convex portion of the large uneven shape.

If the substrate to be used has a so-called two-dimensional uneven surface having unevenness only in one direction, such as a plate having a plurality of parallel grooves arranged side by side, a siding-free siding, etc. ,
The transfer sheet may be made of a material having no extensibility, but the present invention provides a so-called three-dimensional structure having irregularities in two directions like tiles or bricks two-dimensionally arranged through joint grooves that exhibit their true value. In order to adapt to a substrate having a typical uneven surface, it is preferable to use a transfer sheet having stretchability (either elastic deformation or plastic deformation) at least at the time of transfer.

The transfer sheet comprises a support sheet and a transfer layer. The transfer layer may be composed of at least a decorative layer, and may have a configuration in which an adhesive layer and a release layer are further laminated. The stretchability of the transfer sheet is mainly governed by the stretchability of the support sheet. Therefore, if a rubber film is used as the support sheet, the transfer sheet can be transferred to the fine uneven surface of the base projection without heating the transfer sheet at the time of transfer, due to the properties of the rubber which is stretched at room temperature. In addition, if a thermoplastic resin film is used as the support sheet, there is almost no stretchability at the time of forming the decorative layer, and the registration accuracy of printing is good.
At the time of transfer, the transfer sheet is plastically deformed by heating and becomes a transfer sheet having a sufficient stretchability even to a concave portion having a fine uneven shape.

Examples of the support sheet include polyester films such as biaxially stretched polyethylene terephthalate film and polybutylene terephthalate, polyolefin films such as polypropylene film, polyethylene film and polymethylpentene film, polyvinyl chloride resin films, nylon films and the like. Low-stretched or non-stretched film, natural rubber, butadiene rubber, urethane-based elastomer, olefin-based elastomer and the like. Thickness is 25μm or more and 100μm
The following is preferred. If it is less than 25 μm, it tends to break when transferred to a large pattern, and if it is more than 100 μm, the ability to follow fine irregularities tends to be insufficient.

The decorative layer includes a pattern layer on which a pattern is printed by a known printing method and material such as gravure printing, silk screen printing, offset printing, etc., aluminum, chrome, gold,
It is a metal thin film or the like in which a metal such as silver is partially or entirely formed by a known vapor deposition method or the like. Examples of the pattern include woodgrain, stonegrain, tile, brick, abstract pattern, and solid color. Further, providing a layer such as a release layer between the support sheet and the decorative layer in order to adjust the releasability of the decorative layer is the same as a known transfer sheet. As the resin (or binder) forming the release layer or the picture layer, acrylic resin, vinyl chloride-vinyl acetate copolymer resin, polyvinyl butyral resin,
1 of polyester resin, fluorine resin, cellulose resin, etc.
A species or a mixture of two or more species is used. As pigments constituting the picture layer, carbon black, titanium white, red pattern,
Graphite, titanium yellow, cadmium red, cobalt blue,
Known ones such as ultramarine, aniline black, quinacridone red, isoindolinone, and phthalocyanine blue can be used. The adhesive layer is also a rubber-based adhesive type adhesive,
Hot melt adhesives such as polyvinyl acetate, acrylic resin, polyamide resin, thermoplastic polyester resin, thermoplastic polyurethane resin, ionomer, etc., thermosetting adhesives such as block isocyanate curable polyurethane resin, diallyl phthalate resin, phenol resin etc. Conventionally known ones are used. Note that the adhesive layer of the transfer sheet can be omitted when the decorative layer itself has adhesiveness or when the adhesive layer is provided on the transfer-receiving substrate side.

As the method of providing the adhesive layer, a method of providing the adhesive layer on a transfer sheet in advance may be adopted. Any form, such as a method of providing in advance or immediately before the material side, may be used. The method in which the adhesive layer is provided in advance only on the transfer sheet side has an advantage that it can be formed by printing or the like at the same time as the decoration layer, and that the time and labor required for the transfer and the device for the transfer can be omitted. When the adhesive is applied to one or both of the transfer sheet and the substrate immediately before, an adhesive such as a pressure-sensitive adhesive or a water-based adhesive may be used. If necessary, a small hole may be formed over the entire surface of the transfer sheet so that air remaining between the transfer sheet and the substrate to be transferred at the time of transfer is released.

As the material of the rubber roll, known materials such as natural rubber, silicon rubber, neoprene rubber, styrene butadiene rubber, and fluororesin rubber are used. However, heat resistance, durability, surface releasability (particularly, (In the case of a roll used when pressing). Further, a plastic body can also be used. Among them, the silicone rubber roll was good in the present invention. In the present invention, a rubber having a hardness of 60 ° or more and 70 ° or less is used. Rubber hardness is 7
When it is harder than 0 °, the transfer sheet does not easily follow the fine irregularities in the convexities of the large irregularities of the irregular substrate at the first pressing, or the transfer layer follows the fine irregularities at the second pressing. Transfer easily occurs. On the other hand, when the rubber hardness is softer than 60 °, the rubber roll is pressed down to the large concave and convex shape of the concave and convex base material at the time of the first pressing, and a desired design cannot be obtained. Especially rubber hardness 65 °
Good results were obtained with the silicone rubber roll.

Since the rubber roll is easily deformed only by rubber, a rubber roll having a configuration in which rubber is coated on the outer periphery of a metal core such as iron is used. When a thermosetting or hot melt adhesive is used as the adhesive or a thermoplastic resin is used as the support sheet, the surface of the rubber roll is heated.
As a heating method, for example, an infrared heater or the like is used. The surface temperature is equal to or higher than the softening temperature of the support sheet or equal to or higher than the adhesive force developing temperature of the adhesive, and is lower than the melting point of the support sheet or lower than the thermal deformation temperature of the substrate to be transferred. When the above various materials are used, the temperature is typically about 100 to 200 ° C.

In the first pressing step and the second pressing step,
The same rubber roller may be used, or separate rubber rollers may be used. When separate rollers are used for both steps, it is preferable that the rollers for the first pressing step have higher hardness and the rollers for the second pressing step have lower hardness. The optimum value of the diameter of the roller varies depending on the shape and material of the transfer object and the material and thickness of the transfer sheet, but is usually about 50 to 100 mm. In the pressurization method, usually, both ends of the roller are pressed by a hydraulic cylinder or the like.However, in order to correct the deflection of the rubber roller or to strengthen the pressure, the side opposite to the transfer substrate of the rubber roller is used. May be pressed by a backup roller made of a rigid body such as metal. If necessary, one or both of the substrate to be transferred and the transfer sheet may be preheated prior to pressing. This preheating uses an infrared heater or the like.

The first pressing step has a minimum purpose of adhering the transfer layer of the transfer sheet only to the convex portions having large irregularities on the surface of the substrate to be transferred, and the transfer layer is interposed via the support sheet. Pressure is applied to the transfer object. If there are no fine irregularities on the large convexities, only the first step is sufficient. In the subsequent second pressing step, the purpose is to adhere the transfer layer completely to the uneven surface of the fine unevenness in the large unevenness. After the support sheet is peeled and removed, the transfer layer is directly pressed against the base material to be transferred by using a rubber roll, so that pressure can be applied to fine recesses as compared with the first step, and heat conduction is also better. Then, the transfer layer follows the fine concave portion.

The following are specific examples of the large irregularities. One-dimensional or two-dimensional arrangement of bricks, ceramic tiles and joints between them. Wood paneling or siding and joints and grooves between them. Pattern-like irregularities in which the metal plate surface is partially corroded.

The following are specific examples of the fine irregularities. Bricks, carved patterns on the tile surface, stamps or grain,
Fine irregularities such as satin and hair lines. Tree rings and sculptures on wood boards. Hairline, grain, satin, sculpture pattern on metal plate surface.

The following are specific examples of the decorative layer formed on the transfer sheet. Coloring of bricks, ceramic tiles, solid colors, and patterns painted on ceramics (flowers, Qinghai waves, arabesques). A picture and a grain pattern representing the color pattern of the annual rings of wood (autumn wood) and other parts (spring wood). Colored solid on metal plate surface, metal thin film, picture pattern, etc. Stone patterns such as marble and granite.

After transferring a desired transfer layer along the fine irregularities of the convex portions on the surface of the base material, a coating film is formed on the surface of the transfer layer as necessary, and the abrasion resistance, water resistance and weather resistance of the transfer layer are formed. The properties may be reinforced. Examples of the paint include one or a mixture of two or more of a fluorine resin such as a polyvinylidene fluoride resin, a two-component curable urethane resin, an acrylic resin, a polyester resin, and an epoxy resin. If necessary, one or both of an ultraviolet absorber such as benzotriazole and fine particle cerium oxide and a light stabilizer such as a hindered amine radical scavenger are added to the coating film.

The decorative board obtained by the present invention is used for a surface material such as an inner wall, an outer wall, a ceiling and a floor of a building.

[0025]

【Example】

(Example) FIG. 1 is a cross-sectional view showing an example of a decorative plate manufactured by the manufacturing method of the present invention. This decorative plate 10 has a large irregular shape and a base material 11 having a fine irregular shape in its convex portion. The decorative layer 13 is transferred to the convex portion together with the adhesive layer 12, and then the transparent protective layer 14 is formed so as to cover the whole. The manufacturing procedure is described below.

First, a joint 70 having a width of 5 mm and a depth (step) of 2.5 mm as a large uneven shape forms a recess 70.
A calcium silicate panel having a two-dimensional array pattern of ceramic tiles of × 70 mm and a flower pattern engraving pattern of 1 mm in depth and 2 mm in width as fine irregularities on the tile surface was prepared as the base material 11. Then, a two-component curable urethane resin composed of acrylic polyol and hexamethylene diisocyanate was applied to the surface of the base material 11 and subjected to a sealer treatment.

Next, a 50 μm thick polypropylene film was used as a support sheet, and carbon black,
Iron oxide, titanium white, quinacridone, pigment consisting of isoindolidone, and an ink consisting of a binder binder of acrylic resin and vinyl chloride-vinyl acetate copolymer resin,
A colored solid and a floral pattern-like pattern were printed as the decorative layer 13 and an acrylic resin was applied as the adhesive layer 12 to prepare a transfer sheet as a transfer layer.

This transfer sheet was placed with the surface of the adhesive layer 12 floating above the substrate, and pressed against the substrate 11 from the back side of the support sheet by a heated pressure roll. The pressure roll used had a silicon rubber layer having a rubber hardness of 65 ° on an iron core, and the surface temperature of the silicon rubber was 130 ° C. The pressing force was 10 kg / cm in linear pressure, and the feeding speed of the transfer sheet was 15 m / min. After the transfer sheet was cooled at room temperature, the support sheet was peeled off.

Next, the decorative layer 13 remaining on the substrate 11
Was directly pressed with a heated pressure roll from the top of the transfer layer containing, and cooled to room temperature. The pressure roll used had a silicon rubber layer with a rubber hardness of 61 ° on the iron core,
The surface temperature of the silicon rubber is 120 ° C. The pressing force is 10 kg / cm in linear pressure, and the transfer speed of the transfer sheet is 15 m / m.
in. As a result, a decorative board having a pattern transferred only to the convex portions of the tile pattern was obtained. No pattern was transcribed in the joint. Further, the pattern followed and adhered to the inside of the concave portion of the engraved pattern on the tile surface and even to the tile surface. The pattern did not come off at all even when the surface was wiped off with a cloth.

Further, a polyvinylidene fluoride coating material having a thickness of 1
The transparent protective layer 14 is formed by coating and curing at 0 μm.
Was formed to complete the decorative plate 10 shown in FIG.

Comparative Example 1 Both pressure rolls had a rubber hardness of 9
A 0 ° silicone rubber layer was used, and other conditions were the same as in the example. As a result, the pattern was not transferred to the joints, but the pattern was not transferred in the concave portion of the sculpture pattern, and the pattern was lost. It became bad.

Comparative Example 2 Both pressure rolls had a rubber hardness of 3
Using a silicone rubber layer of 0 °, the other conditions were the same as in the example. As a result, the pattern was bonded and transferred to the inside of the concave portion of the sculpture pattern, but the pattern was also transferred to the inside of the joint. It became bad.

(Comparative Example 3) In the example, the manufacturing process was completed up to the first pressing process. As a result, there was no picture transfer to the joint. On the other hand, the sculpture pattern on the tile, although the pattern remains, does not adhere to the recess of the sculpture pattern and partially floats. It fell and became bad.

[0034]

As described above, according to the present invention,
Because the pattern can be transferred only to the convex part of the base material having a large irregular shape on the surface, and it can completely follow and transfer to the fine concave part of the large convex part. In addition, it is possible to manufacture a decorative plate having a highly designed surface having an uneven shape on the surface.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing an example of a decorative board manufactured by the manufacturing method of the present invention.

[Explanation of symbols]

 Reference Signs List 10 decorative board 11 base material 12 adhesive layer 13 decorative layer 14 transparent protective layer

Claims (1)

[Claims] 1. A method for producing a decorative board by applying a makeup to said convex portion of a base material having a large irregular shape on its surface and a fine irregular shape on its convex portion, wherein the rubber hardness is 60 to 70.
° pressing the transfer sheet toward the substrate from the back side of the support sheet with a pressure roll, and then peeling the support sheet from the transfer sheet, using a pressure roll having a rubber hardness of 60 to 70 °. A method for manufacturing a decorative board, wherein a desired transfer layer is transferred only to a convex portion of a base material surface by directly pressing a transfer layer including a decorative layer remaining on the base material.