JPH1071668A - Inorganic decorative panel and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain an inorg. decorative panel excellent in depth feeling and three-dimensional feeling by forming a gentle uneven shape having a specific uneven cycle and uneven height on the surface of a topcoat layer. SOLUTION: An inorg. decorative panel 1 is obtained by laminating a pattern printing layer 4 and a topcoat layer 5 formed from an ionizing radiation curable resin through the base coat layer 3 provided to the surface of an inorg. base material having an uneven shape. The surface uneven shape is applied by a method forming uneven parts to the surface of the inorg. base material before curing by a roll press or a flat plate press. The uneven shape has a gentle shape wherein an unevenness cycle is at least 1mm, and the height of unevenness is 1/10 the cycle or less.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a building interior material, and more particularly, to an inorganic decorative board used around a kitchen such as a sink or a gas stove.

[0002]

2. Description of the Related Art Conventionally, as inorganic decorative boards used around kitchens such as sinks and gas stoves, for example, (1) printed patterns on inorganic base materials such as calcium silicate boards, asbestos slate boards and cement slate boards; (2) A pattern is provided by, for example, a method of directly printing a pattern on an inorganic base material, and then applying a transparent paint over the pattern to protect the surface. Layers are known, but the case (1) is good in terms of design, but when used around kitchens such as sinks and gas stoves, for example, around a sink, it is poorly water-resistant and has a decorative paper surface There is a problem of more peeling, and there is a problem that abnormalities occur in the heat resistance and fire resistance around the gas stove. In the case of (2), the printability is poor, and the appearance of a fine picture pattern appears. Difficult There is a disadvantage that it is inferior to Takumi property.

In order to solve the above-mentioned drawbacks, after a pattern is provided on the surface of an inorganic base material by a method of transferring the pattern, etc., a transparent paint is applied over the pattern to form a surface protective layer. Is used, and as a transparent paint,
A material using an ionizing radiation-curable resin is used as a material having excellent surface properties such as stain resistance and scratch resistance.

However, those using the above ionizing radiation-curable resin have a smooth surface finish and conspicuous defects such as fine foreign matter and bubbles, resulting in poor product yield and an increase in cost. Further, as a method for smoothing the surface and preventing adhesion of foreign matter, after applying an ionizing radiation-curable resin liquid, the surface is covered with a transparent ionizing radiation-permeable sheet, and ionizing radiation is irradiated from the ionizing radiation-permeable sheet side. Although the method of curing the ionizing radiation curable resin is used,
There is a problem that the production efficiency is poor and the cost is high because the number of processes is increased.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and has as its object to be used even around kitchens such as sinks and gas stoves.
Extremely little peeling, heat resistance, fire resistance, contamination resistance, excellent surface properties such as scratch resistance, and in terms of design, excellent depth and three-dimensional appearance. An object of the present invention is to provide an inorganic decorative board having a high product yield at the time of manufacturing and a method for manufacturing the same.

[0006]

Means for Solving the Problems To achieve the above object, a solution of the present invention is to provide an inorganic type base material having a pattern printing layer and a top coat layer sequentially laminated on a surface of a base material via a base coat layer. An inorganic decorative plate, wherein a smooth uneven shape having an uneven period of 1 mm or more and an uneven height of 1/10 or less of the period is formed on the surface of the top coat layer. . With this configuration, defects such as minute foreign matter and air bubbles are not conspicuous due to irregular reflection at the projections of the uneven shape on the surface of the top coat layer. Also, due to the flow of the resin at the time of coating the resin for the top coat layer, there is a high probability that the fine foreign matter or the like is hardened while moving to the concave portion of the top coat layer, and becomes less noticeable.

[0007] The present invention is characterized in that a smooth uneven shape having an average of the uneven period of 5 to 10 mm and an average of the uneven height of 10 to 100 µm is formed. With this configuration, defects such as fine foreign matter and bubbles on the surface of the top coat layer become less noticeable.

[0008] The present invention is characterized in that an irregular shape having the same irregular period is formed on the surface of the inorganic base material. By doing so, there is a high possibility that foreign matter or air bubbles are present in the concave portions of the base material, and the defects become less noticeable. Also, in terms of design, it has an excellent effect of producing a deep feeling and a three-dimensional feeling.

In the transfer sheet having the pattern printing layer provided with a pattern printing layer formed on one surface of the transfer sheet substrate, the transfer sheet having the pattern printing layer is in contact with the base coat layer surface of the inorganic base material. After being placed on and heated and pressurized, the transfer base sheet of the transfer sheet is formed by peeling the transfer base sheet, and the top coat layer is formed by applying and curing an ionizing radiation-curable resin. It is characterized by the following. By doing so, there is no decrease in adhesion when used around a sink or the like, and there is no concern about heat resistance and fire resistance even when used around a gas stove, and surface properties such as stain resistance and scratch resistance In addition, it is possible to obtain an excellent inorganic decorative board.

[0010] The invention is characterized in that the ink for forming the picture printing layer is obtained by mixing a pigment having glitter. By doing so, it is possible to make the adhesion of fine foreign matter and air bubbles more inconspicuous, exhibit an excellent effect of expressing a three-dimensional effect, and to provide an inorganic decorative board having more excellent design.

A step of preparing a transfer sheet in which a pattern printing layer is laminated on one surface of the transfer sheet substrate; a step of coating a base coat layer on the uneven surface of an inorganic base material having an uneven shape; A step of placing the printing layer in contact with the base coat layer of the inorganic base material having the uneven shape and heating and pressing the same, and peeling the transfer sheet base material of the transfer sheet to form the inorganic base material having the uneven shape. A process for forming a pattern layer on the uneven surface, a method for producing an inorganic decorative board, comprising a step of forming a top coat layer by coating and curing an ionizing radiation-curable resin on the surface of the pattern layer. By doing so, an inorganic decorative board having the above-described effects can be easily and reliably manufactured.

[0012]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a laminated sectional view showing an embodiment of the inorganic decorative board of the present invention, FIG. 2 is a laminated sectional view showing another embodiment of the inorganic decorative board of the present invention, and FIG. 3 is an inorganic decorative board of the present invention. FIG. 4 is a partial cross-sectional view showing an uneven shape of the top coat layer surface of the inorganic decorative board of the present invention, wherein 1 and 1 ′ are inorganic decorative boards and 2 is an inorganic decorative board. Base material, 3 is a base coat layer,
3a is a sealer layer, 3b is a primer layer, 4 is a pattern printing layer, 4a is a solid ink layer, 4b is a pattern ink layer, 4c is a glitter ink layer, 5 is a top coat layer, 6 is a transfer sheet, and 7 is a transfer sheet base. Each represents a material.

As shown in FIG. 1, the structure of the inorganic decorative board 1 of the present invention is such that the pattern printing layer 4 and the ionizing radiation-curable material are cured via a base coat layer 3 provided on the surface of an inorganic base material 2 having an uneven shape. It has a configuration in which a top coat layer 5 formed of a conductive resin is laminated. The pattern printing layer 4 is composed of a solid ink layer 4a and a pattern ink layer 4b, and a base coat layer 3 composed of a sealer layer 3a and a primer layer 3b provided on the uneven surface of the inorganic base material 2 having the uneven shape.
And a top coat layer 5 having an irregular shape made of an ionizing radiation curable resin is provided on the upper surface of the pattern printing layer 4.

Next, an example of a method for producing the inorganic decorative board 1 of the present invention will be described with reference to the drawings. First, FIG.
As shown in (a), a pattern printing layer 4 composed of a pattern ink layer 4b and a solid ink layer 4a is formed on the surface of the polyolefin resin layer 7b of the transfer sheet substrate 7 having the polyolefin resin layer 7b provided on the surface of the thin paper 7a. The transfer sheet 6 provided is prepared. Next, as shown in FIG. 3B, the sealer layer 3a and the primer layer 3 are formed on the uneven surface of the inorganic base material 2.
The base coat layer 3 made of b was provided. Next, FIG.
As shown in (c), the pattern printing layer 4 of the transfer sheet 6 is overlapped so as to face the base coat layer 3 provided on the surface of the inorganic base material 2, and heated and pressed from the surface of the transfer sheet 7. . Next, as shown in FIG. 3D, the transfer sheet base material 7 of the transfer sheet 7 is peeled off, and the pattern printing layer 4 is provided on the uneven surface of the inorganic base material 2. Further, FIG.
As shown in (e), a top coat layer 5 having an uneven shape is formed by applying and curing an ionizing radiation curable resin on the upper surface of the inorganic base material 2 including the picture print layer 4, The inorganic decorative board 1 is obtained.

The inorganic base material 2 used for the inorganic decorative board 1 of the present invention is generally a calcium silicate board,
Asbestos slate board, lightweight foam concrete board, cement board such as hollow extruded cement board, gypsum board, gypsum-based board such as gypsum slag board, pulp cement board, asbestos cement board, fiber cement board such as wood chip cement board, As a method for imparting a surface unevenness, before the inorganic base material is cured,
A method of forming an uneven portion on the surface by a roll press, a flat plate press, or the like can be given. As the size of the uneven shape, a smooth shape having an uneven period of 1 mm or more and a height of the unevenness of 1/10 or less of the period is preferable.

The base coat layer 3 is formed to prevent elution of alkali components from the inorganic base material 2 and to improve the adhesion between the inorganic base material 2 and the picture print layer 4 and the transfer property of the picture print layer 4. It is provided for the purpose of the appearance of a design feeling, the configuration is optional, and it is a matter of course that it may be a single layer configuration of a resin composition having both of the above physical properties, but as a method of improving quality performance, To prevent elution of alkali components, a sealer layer 3a made of a curable resin such as a polyisocyanate-based resin, a moisture-curable urethane-based resin, and a styrene-acrylate copolymer resin, and a pattern printing on the surface of the inorganic base material 2. A primer layer 3b made of an acrylic urethane-based resin, a methacrylate-based resin paint or the like for the purpose of improving the adhesion and transferability of the layer 4;
It is desirable to have a layer configuration. Furthermore, by making the primer layer 3b colored and opaque, it is possible to impart concealing properties and to prevent the pattern printing layer 4 formed on the substrate from being affected by the color of the substrate to be bonded. .

As shown in FIG. 3A, the transfer sheet 7 for forming the pattern printing layer 4 on the inorganic decorative board 1 is made of polyolefin as a release layer on one side of a thin paper 8a. An arbitrary pattern printing layer 4 is laminated on the surface of the polyolefin resin layer 8b of the transfer sheet base material 8 on which the entire resin layer 8b is formed. As the transfer sheet base material 8, a plastic film such as a polyethylene film, a polypropylene film, or a polyester film, a thin paper, a paper such as a pure white paper, or a composite film thereof, which is used as a base material of a normal transfer sheet, is used. What laminated | stacked the polyolefin resin layer 8b of polyethylene, polypropylene, etc. on the upper surface of the thin paper 8a is used preferably. In order to improve the thermal conductivity at the time of transfer, it is preferable that the transfer sheet base material 8 be as thin as possible. It is desirable to line the thin paper 8a or the like from the viewpoint of printability.
It is most preferable that the substrate is coated with a polyolefin resin of 10 to 30 μm. Further, by using a polyolefin-based resin such as polyethylene or polypropylene, the transfer can be facilitated by utilizing the thermal flexibility even in the uneven shape of the surface of the inorganic base material 2.

The pattern printing layer 4 includes a solid ink layer 4a of full-surface printing and a pattern ink layer 4b expressing, for example, a stone pattern, a cloth pattern, a surface pattern of natural leather, an abstract pattern, and the like. As a vehicle of the ink for forming 4, a general-purpose resin such as an alkyd-based resin, a urethane-based resin, or a vinyl chloride-based resin is used, and if necessary, other additives such as an organic or inorganic pigment. A suitable mixture of a coloring agent such as a dye, an extender pigment, a stabilizer, a plasticizer, a solvent and the like can be used.

As the transparent resin for forming the top coat layer 5, it is desirable to form a film having excellent surface properties such as stain resistance, scratch resistance and solvent resistance. Suitable are thermosetting resins such as urethane-based resins, ionizing radiation-curable resins such as polyester acrylate and urethane acrylate, and also exhibit a sense of depth and three-dimensionality in synergy with the unevenness of the surface of the inorganic base material. Is preferably a transparent resin layer of 50 μm or more.
The ionizing radiation-curable resin is most suitable for easily forming a coating thickness of m or more on the inorganic base material. Further, as a coating method for forming a gentle uneven shape on the surface of the decorative plate, coating means such as curtain flow coating and spray coating can be used, and the coating thickness is 50 to 100 μm.
m is preferred.

As shown in FIG. 4, the unevenness of the top coat layer surface of the inorganic decorative plate 1 of the present invention is such that the unevenness period P of the unevenness is 1 mm or more and the unevenness height h is the unevenness period P. It is necessary to have a smooth uneven shape of 1/10 or less, and by doing so, due to irregular reflection of light on the uneven portion of the surface of the decorative sheet, fine foreign matter or fine foreign matter adhered to the top coat layer. The defects such as air bubbles are less noticeable, and contribute to the improvement of the yield rate of the product. That is, when the unevenness period P of the uneven shape is 1 mm or less, irregular reflection of the uneven shape convex portion is weak, defects on the surface of the top coat layer are conspicuous, and the unevenness height h is 1 / (1/3) of the unevenness period P.
When it is as large as 10 or more, the transfer of the picture print layer cannot be performed favorably and is not suitable. Further, the average of the uneven period P is 5 to 10 m.
By forming a top coat layer having a smooth uneven shape having an average height h of 10 to 100 μm with m, the above effect can be more easily obtained.

FIG. 2 shows another embodiment of the inorganic decorative board 1 'of the present invention. The ink forming the design ink layer 4b of the inorganic decorative board 1 of the present invention shown in FIG. Brilliant ink layer 4 using ink mixed with pigment
This is a configuration in which c is provided, so that a three-dimensional effect is more apparent. That is, as shown in FIG. 2, the solid ink layer 4 a contains only the coloring pigment in the configuration of the pattern printing layer 4, and the pattern ink layer 4 b made of the coloring pigment and the glittering ink layer 4 c added with the glittering pigment as the pattern layer. It is also possible to form a picture, and although not shown, it is also possible to include a glitter pigment together with the color pigment in the solid ink layer 4a. When the solid ink layer 4a and the pattern ink layer 4b contain a brilliant pigment (the brilliant ink layer 4c), the brilliant pigments of the solid ink layer 4a and the brilliant ink layer 4c can have different color tones. In addition, a special visual effect and a three-dimensional effect can be created by making the color tone of the brilliant pigment different and relating them to each other's pattern.

The brilliant pigments include, for example, pearl pigments, specifically, those obtained by crushing the inside of a shell or pearls, those obtained by baking titanium oxide or iron oxide on mica fine particles, metal powders (for example, Fine particles of preferably 1 to 120 μm of copper, aluminum, brass, bronze, gold, silver, etc., and pieces of deposited plastic, for example, polyethylene terephthalate film, and the above metal (usually aluminum) were deposited and pulverized. Stuff (silver powder),
After the vapor deposition, a transparent yellow paint is applied and pulverized (golden powder).

[0023]

【Example】

Example 1 20 μm of polyethylene resin was applied to thin paper having a weight of 40 g / m ^2.
A desired pattern was printed on the polyethylene resin layer surface of the transfer sheet base material coated to a thickness of m using an alkyd resin-based ink with a gravure rotary printing machine to prepare a transfer sheet. Separately, press-molding the surface to make the surface uneven
A 30 g / m ² moisture-curable urethane-based resin coating is applied as a sealer layer to a calcium silicate plate having a thickness of 10 m.
It was coated at 0 g / m ² and dried at 80 ° C. for 20 minutes. Then placed as picture-printed surface of the transfer sheet to the coating film surface is opposed, heating platen temperature 135 ° C., at a pressure 15 kg / cm ² 5
The transfer was performed by heating and pressing under the condition of minutes. After the transfer sheet base material of the transfer sheet is peeled off, a urethane acrylate-based ultraviolet curable resin paint is applied on the pattern transfer surface with a coating thickness of 50 to 60 μm
(Dry) is applied with a curtain flow coater, passed through an irradiation device equipped with two 80 w / cm ozoneless ultraviolet lamps at a speed of 20 m / min, irradiated with ultraviolet light, cured, and gently applied to the surface. An inorganic decorative plate having an uneven shape was obtained.

[0024]

As described above, according to the present invention, the unevenness of the top coat layer formed on the surface of the inorganic base material is 1 mm or more and the height of the unevenness is 1/10 or less of the period. By using an inorganic decorative panel with a gentle uneven shape, light is irregularly reflected on the decorative panel surface, and defects such as fine foreign substances and bubbles attached during manufacturing are less noticeable.
The product yield rate is improved, and an inorganic decorative board excellent in three-dimensional appearance can be obtained at low cost.

Further, a pattern printing layer is provided on the uneven surface of the inorganic base material having the uneven shape, and a top coat layer made of a transparent ionizing radiation-curable resin is provided on the surface of the pattern printing layer. It is possible to obtain an inorganic decorative board excellent in the sense of depth and three-dimensionality in terms of properties, and excellent in stain resistance, scratch resistance and the like in terms of surface physical properties.

By using an ink obtained by mixing a glittering pigment in the ink for forming the pattern printing layer, an inorganic decorative plate having a very realistic design can be produced in synergy with the uneven surface of the inorganic substrate. Can be obtained.

Further, since the pattern printing layer is directly provided on the surface of the base coat layer provided on the surface of the inorganic base material without using printing paper by transfer, the adhesiveness can be maintained even when used around a water flow such as a sink. It can be used as a decorative panel without any reduction and without heat resistance and fire resistance even when used around a gas stove, and can be used as a kitchen back panel.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an embodiment of an inorganic decorative board according to the present invention.

FIG. 2 is a laminated sectional view showing another embodiment of the inorganic decorative board of the present invention.

FIG. 3 is a cross-sectional view illustrating an example of the method for producing an inorganic decorative board according to the present invention.

FIG. 4 is a partial view showing an uneven shape of a top coat layer surface of the inorganic decorative board of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1, 1 'Inorganic decorative board 2 Inorganic base material 3 Base coat layer 3a Sealer layer 3b Primer layer 4 Picture printing layer 4a Solid ink layer 4b Picture ink layer 4c Bright ink layer 5 Top coat layer 6 Transfer sheet 7 Transfer sheet base P Period of irregularities h Height of irregularities

Claims (6)

[Claims] 1. An inorganic decorative board in which a pattern printing layer and a top coat layer are sequentially laminated on a surface of an inorganic base material via a base coat layer, wherein the top coat layer surface has an irregularity period of 1 mm or more, Asperity height is 1/10 of cycle
An inorganic decorative plate characterized by having the following smooth uneven shape. 2. The method according to claim 1, wherein an average of the period of the unevenness is 5 to 10 mm, and a smooth uneven shape having an average of the height of the unevenness is 10 to 100 μm.
The inorganic decorative board as described in the above. 3. The inorganic decorative board according to claim 1, wherein the surface of the inorganic base material is formed with an uneven shape having the same uneven period. 4. The transfer sheet according to claim 1, wherein the pattern print layer has a pattern print layer formed on one surface of a transfer sheet substrate, and the transfer sheet having the pattern print layer has a surface having the pattern print layer and a base coat layer surface of the inorganic base material. After being placed so as to be in contact with and heated and pressed, the transfer base sheet of the transfer sheet is formed by peeling, and the top coat layer is formed by applying and curing an ionizing radiation-curable resin. The inorganic decorative plate according to claim 1, wherein 5. The inorganic decorative plate according to claim 1, wherein the ink for forming the pattern printing layer is obtained by mixing a glitter pigment. 6. A step of preparing a transfer sheet in which a pattern printing layer is laminated on one surface of a transfer sheet substrate, a step of coating a base coat layer on an uneven surface of an inorganic base material having an uneven shape, and the transfer sheet. Placing the pattern printing layer so as to be in contact with the base coat layer of the inorganic base material having the concavo-convex shape, and heat-pressing the inorganic base material having the concavo-convex shape by peeling off the transfer sheet base material of the transfer sheet A step of forming a pattern layer on the uneven surface of the material, and a step of forming a top coat layer by coating and curing an ionizing radiation-curable resin on the surface of the pattern layer, thereby producing an inorganic decorative board. Method.