JPH1080992A - Decorative plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To render specific pattern portions to be coincident with convexo- concave pattern portions so as to improve the brightness of a decorative plate, by forming into recess portions the slightly projected thermal-compressed print portions already formed on a substrate sheet by a printing ink consisting of a polyvinyl chloride resin and a reactive acrylic resin. SOLUTION: A pattern layer 2 and a specific pattern 3 are formed on a substrate sheet 1 by a structural ink which is usually used to produce a thermosetting resin product. Then, slightly projected printing portions 4, made of a printing ink consisting of a polyvinyl chloride resin and a reactive acrylic resin, are formed on certain portions of the substrate sheet 1 corresponding to the specific pattern 3, so as to form a decorative sheet 5. Afterwards, an overlay paper layer 7 impregnated with a melamine resin, is laminated on a printing side of the decorative sheet 5, whilst a core paper 6 impregnated with the same melamine resin is laminated on the other side of the sheet 5, thus producing a laminate which is then thermal-compressed in a conventional high pressure melamine molding process, thereby obtaining a decorative plate 10 containing recess portions 41 forming an identical pattern with the specific pattern 3 in the printing portions 4.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board for a building material having a surface design having an uneven feeling to furniture, a wall surface, a flooring material and the like and having excellent surface protection performance.

[0002]

2. Description of the Related Art Melamine resins, polyesters, diallyl phthalates, phenol resins, epoxy resins and the like have been known as thermosetting resins constituting decorative boards for building materials having excellent surface properties. In order to impart a decorative property to these, a decorative sheet in which a pattern layer is provided on a base sheet having good resin impregnability as described above is used as a constituent element, and is subjected to hot-press molding together with the thermosetting resin to obtain a texture. There was no veneer created. In addition, in order to give a feeling of unevenness, it was used for hot pressing using a press plate in which the pattern layer was molded, but the pattern layer and the uneven pattern did not always match, and the design property was not satisfactory. .

[0003] In order to enhance the design such as polarizing pearl and metallic luster, decorative plates using decorative sheets having a pattern printed with an ink containing pearl pigments and vapor-deposited aluminum powder have been produced. It could not be fully demonstrated.

[0004]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a decorative plate which not only has the pattern portion and the concavo-convex pattern described in the prior art coincide with each other, but also has a glitter.

[0005]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention provides a raised printing portion and a pattern formed on a base sheet with a printing ink comprising at least a polyvinyl chloride resin and a reactive acrylic resin. It is a thermosetting resin decorative board including a decorative sheet having a layer, wherein the hot-pressed portion of the raised printing portion is formed in a concave shape. Further, the raised printing portion is a decorative plate containing a polarizing pearl, a vapor-deposited aluminum powder, and / or a coloring pigment. The decorative sheet is formed by overlaying at least an overlay paper impregnated with a thermosetting resin on the side of the embossed printing section of the decorative sheet and hot-press molding.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION As shown in FIG. 1 (A), a pattern layer 2 and a special pattern 3 are provided on a base sheet 1 with a building material ink used for ordinary thermosetting resin molding, as shown in FIG.
Further, a decorative sheet 5 having a raised printing portion 4 made of a printing ink composed of a polyvinyl chloride resin and a reactive acrylic resin at a portion corresponding to the special pattern 3 is prepared. Then, the decorative sheet is impregnated with the thermosetting resin 11 and heated.
The pressed decorative plate forms the concave portion 41 in the raised printing portion. In addition, the above-mentioned raised printing unit 4 can perform printing with an ink created using polarized pearls, vapor-deposited aluminum powder, and / or coloring pigments. Then, the decorative sheet 5, the overlay paper 7, and if necessary, the unbleached cliff paper or the like are used as the core paper 6, each of which is impregnated with a thermosetting resin 11 and hot-pressed to form a special pattern 3
The decorative board 10 having the concave portion 41 having the same shape as that of the decorative board 10 is formed.

The base sheet of the decorative sheet of the present invention is a thin paper having a basis weight of 23 to 65 g / m ² , a paper-reinforced paper mixed with a resin, a titanium paper having a basis weight of 30 to 200 g / m ² (resin impregnated). Opaque colored paper which has a porous structure having good properties and is mixed with 10 to 30% of a pigment mainly composed of titanium oxide), linter paper, nonwoven fabric or kraft paper. These can be selected from bleached, unbleached and colored ones according to the design.

The pattern layer and the embossed printing section can be applied to any of the usual rotary printing such as gravure printing, flexographic printing, silk screen printing, and sheet-fed printing. A preferred printing method is gravure rotary printing, which has a wide selection range of ink binders and is suitable for the step of impregnating a thermosetting resin. In addition, in order to complete the synchronization between the special pattern and the embossed printing section, it is preferable to perform the same step,
It goes without saying that some lots can be printed on a single sheet.

The ink used for printing the picture layer of the present invention is:
It is for building materials suitable for ordinary thermosetting resin molding.
That is, an ink comprising an inorganic and organic pigment having excellent durability which does not discolor during hot-pressing and a binder mainly composed of a cellulose derivative having good affinity when impregnating and molding a thermosetting resin is used. . For example, there are inorganic pigments such as graphite, cadmium yellow, yellow iron oxide, titanium oxide, dark blue, carbon black, and red pattern, and organic pigments such as disazo pigments, isoindolinone, polyazo pigments, quinacridone, and phthalocyanine blue. Also, there are pigments having a pearl-like luster such as aluminum powder, copper powder, finely cut pieces of a metal-deposited synthetic resin film, titanium dioxide-coated mica, and fish scale foil. In addition, silica, talc, clay and the like can be used.

The polyvinyl chloride resin, which is a binder of the ink used in the raised printing section of the present invention, has a degree of polymerization of 5
Besides polyvinyl chloride of 00 to 1300, a vinyl chloride-vinyl acetate copolymer which is a copolymer with vinyl acetate, maleic anhydride, or the like can be used. The hardness of the plasticizer can be adjusted by the type and amount of the plasticizer, and a compound having a polar portion is used as the plasticizer. A representative example is a dioctyl phthalate (DO)
P). Plasticizers can be used depending on the purpose.For cold-resistance applications, aliphatic dibasic acid esters such as dioctyl adipate and aliphatic esters such as butyl olefin are used. Epoxy type such as soybean oil (ESBO), phosphate type such as tricresyl phosphate (TCP) and chlorine-containing type such as chlorinated paraffin for flame retardant use, and aromatic ester type such as trioctyl trimellitate for heat resistant use Is used. If the migration of the plasticizer is to be prevented, a high molecular weight polyester or nitrile rubber or the like is used.

As a heat stabilizer at the time of molding, the following is used by adding 1 to 5%. For example, there are inorganic acid salts such as basic carbonates, metal soaps such as barium stearate and cadmium stearate, organic tin compounds such as dibutyltin maleate, and organic compounds such as epoxy compounds and amino compounds. These effects are to supplement the acid by the thermal decomposition of polyvinyl chloride, to prevent coloring by photolysis, to prevent decolorization, and to suppress the thermal decomposition itself.

The reactive acrylic resin used as the binder of the ink for forming the raised print portion of the present invention is a monofunctional 2-ethylhexyl acrylate, 2-hydroxyethylhexyl acrylate,
-Hydroxypropylhexyl acrylate, 2-hydroxyethyl acryloyl phosphate, etc., bifunctional 1,3-butanediol diacrylate, 1,4-butanediol diacrylate, 1,6-hexanediol diacrylate, diethylene glycol diacrylate, tripropylene Glycol diacrylate, neoventil glycol diacrylate, polyethylene glycol 400 diacrylate, hydroxypivalic acid ester neoventil glycol diacrylate, etc., trifunctional trimethylolpropane triacrylate, pentaerythritol triacrylate, dipentaerythritol hexaacrylate, etc. Used. Polymerizable oligomers include polyester acrylate, polyurethane acrylate, epoxy acrylate, polyether acrylate, oligoacrylate, alkyd acrylate, polyol acrylate, melamine acrylate,
Silicon acrylate or the like is used.

The reactive acrylic resin is a resin having a polymerizable monomer or a polymerizable oligomer as a main component.
These may be used alone or as a mixture of several types. The above polymerizable monomers and oligomers are of the acrylate type having an acryloyl group as a functional group, but methacrylates may be used instead of acrylates.

The printing viscosity of the binder ink containing a polyvinyl chloride resin and a reactive acrylic resin as main components is 200 to 5000 cps. For adjusting the viscosity, a general organic solvent is used, but a glycol ether solvent having a high polarity is preferable from the viewpoint of promoting the gelation of the printed ink.

The printing method is not particularly limited as long as it can be raised in a pattern, but gravure printing, which can be carried out by winding, is preferred. At this time, the depth of the gravure plate is preferably 45 to 200 μm, and in some cases, it may be screenless. However, generally speaking, when the pattern is relatively delicate and has few irregularities, the transfer amount of the ink can be stabilized by using screens of various shapes of 50 lines / 25 mm. Then, it is desirable to form a raised printing portion of 10 μm or more necessary for obtaining a concave feeling after resin impregnation and molding. The shape of the screen line includes a cell screen shown in FIG. 3A, a stripe line screen shown in FIG. 3B, and a diagonal stripe line screen shown in FIG. 3C. There is. Further, “cell width 25: bank width 26” shown in FIG. 4 is greatly related to the ink used and the transfer amount, but is preferably a ratio of 3 or more. When printing with irregularities, it is better to print at the same time as normal printing when performing winding, but when providing a large difference in irregularities, it is better to perform it in a separate process to adjust the amount of ink transfer. Is also desirable. In addition, the embossed printing having irregularities may be provided on the picture layer 2 using a normal ink as shown in FIG. 1, or may be provided thereunder.
When provided below, only the unevenness is expressed, but it is determined by the design.

The thermosetting resin used for the decorative board of the present invention is not particularly limited as long as it can be used for the decorative board. For example, there are melamine resin, diallyl phthalate resin, guanamine resin, polyester resin, phenol resin and the like. These resin solutions are impregnated into a decorative sheet, a core paper, an overlay paper, etc. and dried by a usual method using a thermosetting resin impregnating machine. And
The resin-impregnated paper is laminated on at least the side of the pattern layer including the embossed printing section, and the metal mirror plate (or satin base plate) provided between the upper and lower heating plates is in contact with the pattern layer side of the resin-impregnated paper. And heat and press with a hot plate from above and below to cure the resin.

The temperature and time of heating and pressurizing can be appropriately selected according to the type of the selected thermosetting resin and the core paper, overlay paper and base material used at the same time. For example, when using melamine resin impregnated paper, 3-4 sheets of phenol-impregnated core paper (porous kraft paper, linter paper),
A melamine resin-impregnated decorative sheet, and furthermore, a melamine resin-impregnated overlay paper of about 35 to 50 g / m ² is laminated on the front surface or the front and back surfaces. Then, it is inserted between two mirror-finished metal plates, and heated and pressed at, for example, 130 ° C. for 20 minutes to cure and mold the resin. The overlay paper provided on the back surface is effective for preventing curling of the decorative board.

The decorative sheet having a raised printing portion formed of a printing ink comprising a polyvinyl chloride resin and a reactive acrylic resin according to the present invention, and a thermoplastic resin are laminated.
By performing heating and pressurization, the embossed printing section initially becomes a uniform plane with other surfaces, but as the reaction progresses further, the embossed printing section shrinks and the curing of the thermosetting resin is almost completed. Therefore, it is considered that the flow does not flow and the concave portion is fixed and formed as a result.

Next, the present invention will be described in more detail with reference to examples.

【Example】

(Example 1) As shown in FIG. 1 (A), a substrate 1 was made of titanium paper having a basis weight of 100 g / m ² (manufactured by Kojin Co., Ltd.), and an ink containing cellulose acetate as a binder was applied by gravure rotary printing. The pattern layer 2 and the printing of the conduit pattern as the special pattern printing section 3 were provided. Further, in the same process, the same pattern as the above-mentioned conduit pattern was placed on the special pattern 3 to a depth of 100 μm.
Using a plate of (cell width / bank width = 3), using a “built-up ink” having the following composition, providing a 10 μm raised print unit 4 and gelling polyvinyl chloride by heat treatment at 200 ° C. for 10 seconds, A decorative sheet 5 of Example 1 was prepared. "Bull-up ink"-Aluminum powder 8 parts by weight-Polyvinyl chloride 50 parts by weight-Trimethylolpropane methacrylate 30 parts by weight-DOP 8 parts by weight-Silica 2 parts by weight-Stabilizer tin-Epoxy type 2 parts by weight-Ethyl Cellosolve (solvent) Suitable amount The overlay surface 7 having a basis weight of 25 g / m ² in which the printing surface of the decorative sheet 5 of Example 1 is impregnated with melamine resin, and the basis weight 40 in which the other surface is impregnated with the same type of melamine resin as the overlay paper
A core paper 8 of 0 g / m ² was laminated and hot-pressed by a normal high-pressure melamine molding method to prepare a high-pressure melamine decorative board 10 shown in FIG. 1 (B).

(Example 2) The decorative sheet 5 prepared in Example 1 was impregnated with a melamine resin, and the non-printed surface thereof and the substrate 9
Was laminated with a plywood having a thickness of 3 mm, and hot-pressed by a normal low-pressure melamine molding method to form a low-pressure melamine decorative board 10 shown in FIG. 1 (C).

Example 3 Similar to FIG. 1 (A), as a substrate 1, a thin paper having a basis weight of 30 g / m ² (manufactured by Sanko Paper Co., Ltd.)
Next, the second embodiment having the configuration shown in FIG.
Was prepared. Then, overlay paper 7 shown in FIG. 2 (A) and melamine resin was impregnated to 120% on the printing surface and the other surface of the decorative sheet 5 of Example 2 as shown in basis weight 25 g / m ^2, the overlay on the other side A core paper 6 made of unbleached kraft paper having a thickness of 0.3 mm and impregnated with 50% of a phenol resin, and the above-mentioned overlay paper 7 were further laminated thereon. And sandwiched between mirror plates, press pressure 200kg /
Heating and pressurizing for 15 minutes under the conditions of m ² and a temperature of 135 ° C., and cooling to room temperature in that state, the thermosetting resin decorative plate 10 of Example 3 shown in FIG. Configured.

The decorative panels of Examples 1, 2 and 3 show the same abrasion resistance, chemical resistance and surface hardness as the cured product of the impregnated resin of the melamine decorative panel constituting the decorative panel. In addition, the pattern portion 3 of the conduit pattern provided with the raised printing portion forms a concave portion 41 synchronized with the conduit, and can constitute the decorative plate 10 having a three-dimensional appearance combined with the unique shine of aluminum-deposited fine powder. Was.

[0023]

The present invention, as described in detail above,
In the process of printing the picture layer, a special pattern portion such as a conduit is provided in the picture layer, and a metallic glossy tone is applied to a binder made of polyvinyl chloride and a reactive acrylic resin in a pattern corresponding to the special pattern. The decorative sheet can be formed by printing with an ink having a raised portion. And the thermosetting resin decorative board molded using the decorative sheet has an effect of forming a decorative board having an excellent three-dimensional appearance by deforming the conduit portion, which is the raised printing section, into a concave shape. It is.

[Brief description of the drawings]

FIG. 1A is a cross-sectional view illustrating a configuration of a decorative sheet of the present invention. (B) It is sectional drawing which shows the structure of the decorative board of this invention. (C) It is sectional drawing which shows the other structures of the decorative board of this invention.

FIG. 2A is a cross-sectional view showing components of another decorative board according to the present invention. (B) It is sectional drawing which shows the structure of the decorative board formed from the said element.

FIG. 3A is an example showing a plane of a normal gravure plate provided with emboss printing. (B) It is the schematic which showed the linear screen plane which provides emboss printing. (C) It is the schematic which showed the diagonal linear screen plane which provides emboss printing.

FIG. 4 is a schematic sectional view of a gravure plate.

[Brief description of reference numerals]

 DESCRIPTION OF SYMBOLS 1 Base sheet 2 Picture layer 3 Special pattern 4 Embossed printing part 5 Decorative sheet 6 Core paper (unbleached kraft paper) 7 Overlay paper 8 Adhesive layer 9 Substrate 10 Decorative board 11 Thermosetting resin 20 Screen line 21 Cellular screen 22 20000 linear screen 23 oblique linear screen 24 cells 25 cell width 26 bank width 41 recess

Claims (3)

[Claims] 1. A thermosetting resin decorative board including a decorative sheet having a raised printing portion and a picture layer formed on a base sheet with a printing ink comprising at least a polyvinyl chloride resin and a reactive acrylic resin. A decorative plate, wherein the hot-pressed portion of the raised printing portion is concave. 2. The decorative plate according to claim 1, wherein the raised printing portion of the decorative sheet contains a polarizing pearl, a vapor-deposited aluminum powder, and / or a coloring pigment. 3. The cosmetic according to claim 1, wherein the decorative sheet is formed by overlaying at least an overlay paper impregnated with a thermosetting resin on the side of the raised printing portion and hot-press molding. Board.