JPH11198111A - Preparation of decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prepare a decorative sheet wherein recessed parts by embossing can be deeply and stably formed on a wooden fiber board of a base material and the width becomes wider as it approaches to the bottom, i.e., a shape spread out inside is obtd. SOLUTION: Without performing transfer and embossing after preparation of a wooden fiber board is completed, when the wooden fiber board is prepd., the fiber raw material 1 is semi-molded by providing hot pressure to prepare an intermediate body 2 being thicker than that when complete molding is performed afterward and recessed parts 5 are former on this intermediate body by means of an embossing plate 4 and thereafter, the intermediate body is completely molded and compressed by another hot pressure to prepare recessed parts 7. Transfer is performed in such a way that a transfer sheet S is pressed and laminated on the intermediate body before embossing or simultaneously and peeling-off of a releasable substrate of the transfer sheet S is performed before or after embossing or before or after complete molding to prepare a decorative sheet D. A decorative sheet with a protective sheet which is peeled off when it is used may be prepd. by avoiding peeling-off of the releasable substrate.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a decorative board made of a wood fiber board, which is used for building materials such as furniture and fittings, or for interiors of vehicles such as automobiles, aircraft, ships and the like.

[0002]

2. Description of the Related Art Hitherto, as a method of manufacturing a decorative board using a wood fiber board such as MDF (medium density fiber board) as a base material by using transfer, for example, the following method has been known. A method of transferring a transfer layer to a substrate using a transfer sheet. When transferring to a base material with a transfer sheet, as the pattern of the transfer layer, use a pattern with a glossy pattern on the other part of the grain, and a matte and glossy pattern. A method in which a relatively low-gloss conduit part appears to be concave due to the optical illusion. As in Japanese Patent No. 2564231, a method in which MDF of a ready-made product (completion-completed product) is mechanically embossed with a concavo-convex roll to provide concavities and convexities, and then a print pattern is transferred by a transfer sheet. As described in JP-A-8-39920, after transferring a grain pattern to an MDF of a ready-made product (completed product), irregularities are provided by an embossing roller via a coloring transfer sheet, and at the same time, the coloring transfer is performed inside the concave portion. A method of forming a colored layer using a sheet.

[0003]

However, the manufacturing method using the above-mentioned transfer has the following problems. In the manufacturing method in which the decoration is merely transcribed, the decoration surface is flat and has only a flat pattern (picture), which is inferior in design. When the overall gloss is low, there is no difference in gloss, and the duct design is inferior to that of the duct design due to the change in gloss of the duct. In addition, since the irregularities are not actual irregularities due to an illusion, the design of the conduit is inferior. And, in the conduit expression by the actual unevenness formed by embossing, the design feeling is better than the above, but since the embossing target is the finished MDF of the molded product, the embossing is difficult to enter and the embossing depth Is not stable.

[0004]

Therefore, in order to solve the above-mentioned problems, in the method of manufacturing a decorative board according to the present invention, when manufacturing a wood fiber board, the fiber raw material is semi-formed by applying heat pressure, and the fiber board is formed later. After making the intermediate body thicker than at the time of the complete molding to be performed, a recess is formed with an embossed plate having an uneven pattern formed on the intermediate body softer than the completely molded state, and then the intermediate body is again heated and pressed. By compressing and completely molding, a recess depth and a recess shape which could not be obtained in the past were realized. In addition, the transfer sheet including the releasable support and the transfer layer is laminated by pressing against the intermediate body before embossing or simultaneously with embossing. The release of the releasable support of the transfer sheet is performed before or after embossing. That is, at the time of embossing, at least the transfer layer of the transfer sheet is interposed between the embossing plate and the intermediate. In addition to peeling off the release support of the transfer sheet to form a decorative board, there is a case where the support is left as a protective sheet until the decorative board is actually used and is not peeled off until the end of the decorative board manufacturing process.

That is, a first embodiment of the method for producing a decorative board of the present invention comprises the following steps. (A) a step of applying heat pressure to produce a fibrous raw material in a semi-forming manner during the production of a wood fiber board to form a thicker intermediate than in the following complete molding.
(B) a step of pressing a transfer sheet composed of a releasable support and a transfer layer against the intermediate, peeling the releasable support, and transferring the transfer layer to the intermediate. (C) a step of forming a recess in the intermediate with an embossing plate on which an uneven pattern is formed via a transfer layer. (D) a step of completely forming the intermediate by the re-heating pressure;

A second embodiment of the method for manufacturing a decorative board according to the present invention comprises the following steps. (A) a step of applying heat pressure to produce a fibrous raw material in a semi-forming manner during the production of a wood fiber board to form a thicker intermediate than in the following complete molding.
(B) a transfer sheet comprising a release support and a transfer layer,
A step of laminating on an intermediate. (C) a step of forming a recess in the intermediate body with an embossing plate on which a concavo-convex pattern is formed via a transfer sheet. (D) a step of peeling the releasable support simultaneously with or after embossing to complete the transfer.
(E) a step of completely forming the intermediate by the re-heating pressure;

A third embodiment of the method for manufacturing a decorative board according to the present invention comprises the following steps. (A) a step of applying heat pressure to produce a fibrous raw material in a semi-forming manner during the production of a wood fiber board to form a thicker intermediate than in the following complete molding.
(B) a transfer sheet comprising a release support and a transfer layer,
A step of laminating on an intermediate. (C) a step of forming a recess in the intermediate body with an embossing plate on which a concavo-convex pattern is formed via a transfer sheet. (D) While the transfer sheet is laminated,
A step of completely molding the intermediate by re-heating pressure. (E) a step of peeling the release support to complete the transfer.

[0008] A fourth embodiment of the method for manufacturing a decorative board according to the present invention comprises the following steps. (A) a step of applying heat pressure to produce a fibrous raw material in a semi-forming manner during the production of a wood fiber board to form a thicker intermediate than in the following complete molding.
(B) a transfer sheet comprising a release support and a transfer layer,
A step of laminating on an intermediate. (C) a step of forming a recess in the intermediate body with an embossing plate on which a concavo-convex pattern is formed via a transfer sheet. (D) While the transfer sheet is laminated,
A step of completely forming the intermediate body again by applying heat and pressure, and forming a decorative plate in which the releasable support is left as a protective sheet to be peeled off before use.

A fifth aspect of the method for manufacturing a decorative board according to the present invention comprises the following steps. (A) a step of applying heat pressure to produce a fibrous raw material in a semi-forming manner during the production of a wood fiber board to form a thicker intermediate than in the following complete molding.
(B) a step of forming a concave portion in the intermediate body and simultaneously laminating the transfer sheet with an embossing plate having a concavo-convex pattern via a transfer sheet composed of a release support and a transfer layer. (C) a step of peeling the releasable support simultaneously with or after embossing to complete the transfer. (D) a step of completely forming the intermediate by the re-heating pressure;

A sixth aspect of the method for manufacturing a decorative board according to the present invention comprises the following steps. (A) a step of applying heat pressure to produce a fibrous raw material in a semi-forming manner during the production of a wood fiber board to form a thicker intermediate than in the following complete molding.
(B) a transfer sheet comprising a release support and a transfer layer,
A step of forming a concave portion in the intermediate body with an embossing plate having a concavo-convex pattern formed therebetween and simultaneously laminating the transfer sheet with the transfer sheet therebetween. (C) A step of completely forming the intermediate by re-heating under the condition that the transfer sheets are laminated. (D) a step of peeling the releasable support to complete the transfer.

A seventh embodiment of the method for manufacturing a decorative board according to the present invention comprises the following steps. (A) a step of applying heat pressure to produce a fibrous raw material in a semi-forming manner during the production of a wood fiber board to form a thicker intermediate than in the following complete molding.
(B) a transfer sheet comprising a release support and a transfer layer,
A step of forming a concave portion in the intermediate body with an embossing plate having a concavo-convex pattern formed therebetween and simultaneously laminating the transfer sheet with the transfer sheet therebetween. (C) A step of completely forming the intermediate body again by applying heat and pressure while keeping the transfer sheet laminated, and forming a decorative plate in which the releasable support is left as a protective sheet to be peeled off before use.

Further, in an eighth aspect of the method for producing a decorative board according to the present invention, the first, the second, the third, the fifth or the sixth or the above-mentioned decorative board from which the releasable support is peeled off. For the form
After the process, the following process is further performed. (A) A step of filling a concave portion formed by the embossing plate with a coloring ink. (B) a step of solidifying the filled coloring ink;

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an embodiment of a method for manufacturing a decorative board according to the present invention will be described.

[Explanation in One Embodiment] First, FIG. 1 is a conceptual diagram conceptually illustrating a method of manufacturing a decorative plate according to the present invention in one embodiment, and FIG. 1 corresponds to the third embodiment. I do. FIG.
As shown in the above, in the present invention, embossing and transfer using a transfer sheet are performed during the process of forming a wood fiber board by hot pressing. FIG. 1A shows a fiber raw material 1 which is a raw material of a wood fiber board. The fiber raw material is obtained by mixing a wood fiber with a binder such as an adhesive. Then, this fiber raw material 1 is used as shown in FIG.
In the present invention, the hot pressing is performed under the hot pressing conditions under which the intermediate is thicker than the final wood fiber board obtained by the complete pressing.
Normally, the thickness is controlled by the magnitude of the pressure, but the thickness may be controlled by the constant pressure and the temperature. For example, the obtained intermediate 2
Is set to a pressure lower than the pressure at the time of complete molding so that the thickness is about 2 to 5 times the thickness of the finally obtained wood fiber board. The heat and time for the semi-molding are, of course, such that the curable adhesive is not used when the curable adhesive is used as the binder in the fiber material. Then, as shown in FIG.
The transfer sheet S is pressed against the intermediate 2 by using a pressing roller 3 or the like as appropriate, and is stacked. The pressing roller may be appropriately heated so that the transfer sheet adheres to the intermediate. Although not shown, the transfer sheet S is composed of a releasable support and a transfer layer. The transfer sheet is supplied to the intermediate so that the transfer layer faces the intermediate, and is laminated on the intermediate.

Then, as shown in FIG. 1 (D), the embossing plate 4 on which the uneven pattern is formed is embossed from above the transfer sheet of the intermediate body 2 on which the transfer sheet S is laminated, and immediately after embossing on the intermediate body 2 The intermediate concave portion 5 obtained as described above is formed. Since the intermediate is softer than at the time of complete molding, the recess can be formed deeply and stably. In addition, the depth of the recess formed with respect to the intermediate body can be set to a depth greater than that required to compensate for the compression and shallowness during the subsequent complete molding. Therefore, the depth of the concave portion after the complete molding can be made deeper than in the case of directly embossing the conventional molded wood fiber board.

Then, as shown in FIG. 1 (F), a final heat pressure is applied under a heat pressure condition such as a larger pressure than in the semi-molding so that the intermediate 2 becomes thinner. ,again,
Intermediate 2 (where transfer sheet S is laminated and irregularities 5 are formed)
Is completely molded. Then, as shown in FIG. 1 (G),
The transfer is completed if the transfer sheet S (the releasable support) is appropriately peeled off using the peeling roller 6 or the like. Then, on the surface exposed by peeling the releasable support, the intermediate recess 5 (see FIG. 3A) is compressed and deformed by complete molding.
The decorative plate D having the inwardly extending concave portion 7 (see FIG. 3B) is obtained.

[Explanation of Various Forms] In the method of manufacturing a decorative board of the present invention, various types of semi-molding and complete molding are performed by combining the respective timings of transfer sheet lamination, embossing, and release of the releasable support. Divided into forms. Therefore, various embodiments of the present invention will be described with reference to the conceptual diagram of FIG. 2 illustrating the relationship with these timings. FIG. 2 (A)
FIGS. 4A to 4C are conceptual diagrams of first to fourth embodiments in which a transfer sheet is laminated on an intermediate before embossing. FIG. 2 (B)
It is a conceptual diagram of the 5th-7th form of the form which laminates a transfer sheet to an intermediate body simultaneously with embossing with an embossing plate. In the figure, the symbols [1] to [7] (attached to the place where the release support of the transfer sheet is peeled) are the first embodiment to [7], respectively.
Means the seventh mode. In the present invention, the transfer is performed on the intermediate, which means that the object when pressing and laminating the transfer sheet is the intermediate, and the timing of peeling the release support of the transfer sheet depends on the timing after lamination. It may be stage.
In other words, the release of the releasable support is performed before embossing (first mode), after embossing before complete molding (second and fifth modes), after complete molding (third and sixth modes), and peeling. It may be left when the decorative board is used (fourth and seventh embodiments). The reason for peeling off when using the decorative board is to leave it without peeling, because the releasable support is used as a protective sheet, it is stored and transported in that state, and before and after assembly of the decorative board, or installation on site This is how to use a decorative board that peels off before and after. In this case, the decorative plate obtained is a decorative plate with a protective sheet, and the transfer is completed when the protective sheet is peeled off. Also, as shown in FIG. 2B, the step of pressing the transfer sheet against the intermediate body, bonding and stacking it (FIG. 1C) may be integrated with the next embossing step (FIG. 1D). (5th
Seventh form). That is, in FIG. 1, the transfer sheet S is laminated on the intermediate body 2 using an emboss roller (emboss plate) 4 instead of the pressing roller 3. When an embossing roller is used for the embossing plate, it may be used as a peeling roller to peel off the releasable support simultaneously with embossing. Therefore, in the second and fifth embodiments in which the releasable support is peeled after the embossing and before the complete molding, the timing for peeling the releasable support is the same as in [2] and [5] shown in FIG. As in the case of embossing, it may be simultaneous.

The transfer sheet to be supplied to the intermediate may be supplied in a single sheet or in a continuous band. In the case of a continuous strip, for example, the sheet may be cut into individual sheets for each intermediate before the next embossing step or the like, or may be formed as a continuous strip until the step of separating the releasable support. Further, each of the pressurization at the time of manufacturing the intermediate, the pressurization (pressing) at the time of laminating the transfer sheet, the pressing at the time of embossing, and the pressing at the final manufacturing of the decorative board is performed by a flat press, respectively. Either flat pressure, circular pressure by a roller, or pressure by a belt press (a belt-shaped embossing plate in the case of an embossing plate) may be used. Also, in FIG. 1, each step is illustrated as if it were performed in a batch system, but in practice, it may be either a batch system or a continuous system. In the case of the continuous type, for example, the fiber raw material is placed on a belt conveyor or the like, and is sequentially conveyed to a zone where each process is performed, and each process is continuously performed online.

[Concave Shape] According to the present invention, the concave portion formed on the decorative board can have a shape which cannot be obtained by the conventional method.
The shape of the concave portion formed by the conventional embossing is such that the width increases as the side surface of the concave portion approaches the opening portion, or a vertical U-shape having a constant width from the bottom surface to the opening portion like the concave portion 5 in FIG. At best, it had an "extended shape." This is also the shape of the concave portion at the stage of forming the intermediate in the present invention.
However, the concave shape obtained by the present invention can have an “inwardly expanding shape” in which the width becomes narrower as the distance from the bottom surface to the opening increases, as in the concave portion 7 shown in FIG. It is shown in Fig. 3 (A)
In the process in which the embossing depth becomes shallow because the concave portion 5 having a particularly vertical or near-vertical side surface of the outer expansion shape is compressed in the thickness direction by the pressure at the time of complete molding, the side surface near the opening is inward. This is because they are deformed so as to slightly collapse. The inwardly extending concave portion 7 has a shape very similar to the shape of a conduit groove of a natural wooden board in particular (because the conduit groove is a longitudinal section of a cylindrical or elliptical column-shaped conduit). The result is a cosmetic material that is realistic and has an excellent design feeling.
In addition, the recess 7 having the inwardly expanding shape cannot be expressed by embossing the conventional (completely) molded MDF of the existing product. That is, the embossing plate cannot be released from the MDF with such an inwardly extending shape. The depth of the recess by embossing is, for example, 20 to 500 μm at the stage of the intermediate in the case of a conduit. At the stage of the decorative board after the complete molding, it is about 1/5 to 1/2, depending on the degree of compression at the time of complete molding. Moreover, the pattern by the unevenness is suitable as a concave and convex pattern, particularly for reproducing a conduit groove of a natural wooden board, and can also be used as another uneven pattern.

[Filling and solidification of colored ink] For the concave portion 7 exposed after the complete molding and the release of the releasable support,
Further, it may be filled with coloring ink and solidified (in addition,
Of course, this is only possible for configurations where the releasable support is not left as a protective sheet). In particular, if a colored ink is filled in a concave portion serving as a wood grain conduit or the like and solidified, a decorative board having a concave portion such as a wood grain conduit or the like which is richer in design can be obtained. For this purpose, a conventionally known wiping method can be used. In the wiping method, for example, by applying a coloring ink to the entire surface including the concave portion 7 by a doctor blade coating method, a knife coating method, or the like, the coloring ink is removed only from the inside of the concave portion by removing the coloring ink from the surface other than the concave portion. Fill.
After filling, the colored ink in the recess is solidified. The solidification is performed by drying when there is a volatile component such as a solvent, and by using a non-solvent having no volatile component, the resin is cured by a curing reaction using ionizing radiation such as heat or ultraviolet rays, and is performed by both drying and curing. Note that the filling does not have to be performed in the entire recess. Also,
As the coloring ink, an acrylic resin as a vehicle binder, a thermoplastic resin such as a vinyl chloride-vinyl acetate copolymer, a cellulose resin, a two-part curable urethane resin,
Thermosetting resins such as epoxy resins, unsaturated acrylates, conventionally known resins such as epoxy-based ionizing radiation-curable resins, quinacridone as a coloring agent, organic pigments such as isoindolinone, carbon black, An ink in which an inorganic pigment such as a red petal, a bright pigment such as mica coated with titanium dioxide, and the like, and other additives as necessary, or an emulsion type water-based ink is used. When the concave portion 7 has a wood grain conduit groove shape, it is generally dark brown,
Use brown-colored ink.

[Fiber raw material] The fiber raw material 1 is the MD to be produced.
Depending on the wood fiber board such as F, a conventionally known material obtained by mixing wood fibers and an adhesive serving as a binder for the fibers may be used. For example, the wood fiber is not particularly limited as long as it is a wood fiber made of waste wood, softwood, hardwood, and the like, and a wood fiber suitable for use is used. In addition, as a residual waste material, paper, waste paper, etc. may be used other than wood waste material. As the adhesive, a curable adhesive such as a urea resin, a phenol resin or a urethane resin is used.

[Transfer Sheet] The transfer sheet comprises a releasable support and a transfer layer which transfers and transfers. The transfer layer usually includes a decorative layer, and a release layer, an adhesive layer and the like as appropriate. Incidentally, the transfer sheet S illustrated in FIG.
1, a release layer 23, a decoration layer 24, and an adhesive layer 25 are laminated as a transfer layer 22. Such a conventionally known transfer sheet may be used. However, in the form in which the transfer sheet is completely formed while being laminated, the releasable support is made of a heat-resistant material that does not melt or shrink under the heat and pressure at the time of complete formation (for example, polyethylene terephthalate film,
Paper).

(Releaseable Support) As the releasable support,
A material having good releasability from the transfer layer is used. For example, polyethylene terephthalate, polybutylene terephthalate, ethylene terephthalate-isophthalate copolymer, polyester resin such as polyarylate, polyethylene, polypropylene, polymethylpentene, polyolefin resin such as olefin-based thermoplastic elastomer, nylon 6,
Polyamides such as nylon 66, polyvinyl chloride, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, vinyl polymers such as polyvinyl alcohol and vinylon, cellulose resins such as cellulose triacetate and cellophane, polymethacrylic acid Monolayer body of synthetic resin film (sheet) such as acrylic resin such as methyl, polyethyl methacrylate, polyethyl acrylate, polybutyl acrylate, etc., or paper such as high quality paper, thin paper, glassine paper, sulfuric acid paper, etc. Alternatively, a plurality of laminates is used. The thickness of the releasable support is usually from 5 to 200 μm. The releasable support may have a structure in which a release layer is provided on the transfer layer side, if necessary, in order to promote releasability from the transfer layer. As the release layer, a coating film of a paint in which a release agent such as a fluorine-based resin, various waxes and silicone is added to a known vehicle, for example, an acrylic resin, a cellulose-based resin, a vinyl-based resin, or the like, Release resin, for example, fluorine resin,
A film formed by coating a resin such as silicone, melamine resin, polyolefin resin, ionizing radiation crosslinkable polyfunctional acrylate, polyester, epoxy or the like and forming the film by extrusion coating or the like is used.

(Decoration layer) The decoration layer may be formed by a conventionally known method such as gravure printing, silk screen printing, offset printing, etc., a picture layer printed with a picture or the like by a material, a mere colored layer, a transparent resin layer, aluminum, chromium, etc. A metal thin film layer or the like in which the above metal is partially or entirely formed by a known vapor deposition method or the like. The pattern is a wood grain pattern, a stone pattern such as marble or granite,
Tile patterns, brick patterns, cloth patterns, characters, geometric patterns, etc. are optional. In particular, in the present invention, the characteristic concave shape is suitable for expression of a conduit, and is suitable for design expression of a wood grain pattern. The picture layer ink comprises a vehicle such as a binder, a coloring agent such as a pigment or a dye, and various additives appropriately added thereto. For the binder, for example, acrylic resin,
Room temperature or thermosetting resins such as chlorinated polyolefin resins, chlorinated polypropylene, vinyl acetate, butyral resins, thermoplastic resins such as vinyl chloride-vinyl acetate copolymers, cellulose resins, polyurethane resins, epoxy resins, etc. It is used in the form of a resin alone or a mixture. Examples of the colorant pigment include inorganic pigments such as titanium white, carbon black, red iron oxide, graphite, and ultramarine blue; organic pigments such as aniline black, quinacridone, isoindolinone, and phthalocyanine blue; metal pigments such as aluminum foil powder; Titanium-coated mica, pearlescent (pearl) pigments and the like are used.

(Release Layer) As the release layer, a resin composition having releasability from the releasable support and having desired physical properties as a surface protective layer of the transfer layer after transfer is selected. A thermoplastic resin, a thermosetting resin, or the like is used. In particular, when the surface requires scratch resistance, chemical resistance, and stain resistance, a thermosetting resin,
Alternatively, an ionizing radiation-curable resin is usually often used. or,
The thickness is also selected depending on the desired physical properties and the like.
0 μm. In addition, as the thermoplastic resin, for example, ethyl cellulose, cellulose nitrate, cellulose acetate, ethyl hydroxyethyl cellulose, cellulose derivatives such as cellulose acetate propionate, polystyrene, styrene resin such as poly α-methylstyrene or styrene copolymer, polymethacrylic Acrylic resins such as methyl acrylate, polyethyl methacrylate, polyethyl acrylate, and polybutyl acrylate; vinyl polymers such as polyvinyl acetate, vinyl chloride-vinyl acetate copolymer and polyvinyl butyral; rosin; rosin-modified maleic resin Rosin ester resins such as rosin-modified phenolic resins and polymerized rosins, and natural or synthetic resins such as polyamide resins. Further, as the thermosetting resin, phenol resin, urea resin, diallyl phthalate resin, melamine resin, guanamine resin, unsaturated polyester resin, polyurethane resin, epoxy resin, amino alkyd resin, melamine-urea co-condensation resin, Silicon resin, polysiloxane resin, or the like is used. As the ionizing radiation-curable resin, an unsaturated acrylate resin, an epoxy resin, or the like is used. The release layer is formed by a known method such as a printing method such as gravure printing, offset printing, or silk screen printing, or a coating method such as roll coating or the like, using an ink or paint made of these resins.

(Adhesive Layer) The adhesive layer is a layer for transferring and adhering the transfer layer to an intermediate serving as a base material of a decorative plate, and is a heat-sensitive adhesive, a solvent-activated adhesive, an ionizing radiation-curable adhesive. Select from the agents etc. according to the application. In addition, when the transfer layer other than the adhesive layer such as the pattern layer and the release layer has sufficient adhesiveness, the adhesive layer may be omitted. For example, polystyrene, styrene resin such as poly-α-methylstyrene or styrene copolymer, acrylic resin such as polymethyl methacrylate, polyethyl methacrylate, polyethyl acrylate, polybutyl acrylate, polyvinyl acetate, vinyl chloride- Vinyl acetate copolymer, vinyl polymer such as polyvinyl butyral, rosin, rosin-modified maleic acid resin, rosin-modified phenol resin, rosin ester resin such as polymerized rosin, polyisoprene rubber, polyisobutyl rubber, styrene butadiene rubber, butadiene acrylonitrile rubber Or a mixture of two or more resins selected from natural or synthetic resins such as a rubber resin such as a dimer acid and a condensate of ethylenediamine, a urethane resin and an epoxy resin. The adhesive layer is formed by a known method such as a printing method such as gravure printing, offset printing, or silk screen printing, or a coating method such as roll coating, using an adhesive made of these resins. The adhesive may be applied to the transfer sheet when the transfer sheet is laminated. Usually, the thickness of the adhesive layer is about 5 to 100 μm. Further, the adhesive layer can be provided not on the transfer sheet side but on the intermediate body side.

[Pretreatment of Wood Fiber Stencil to Intermediate] Prior to lamination of the transfer sheet, the intermediate of the wood fiber stencil may be subjected to a known sealing treatment and a coloring paint treatment, if necessary. . Further, as described above, the adhesive layer can be formed on the intermediate body side.

[Use of decorative board] The use of the decorative board obtained in the present invention is not particularly limited. For example, interior materials for buildings such as wall surfaces, ceilings and floors, outer walls, fences, roofs, gates, etc. Exterior materials such as gable boards, window frames, doors, handrails, sills, surface decorations for fittings such as lintels, furniture such as chests of drawers, and weak electricity such as television receivers.
It is used as a surface decorative material for cabinets of OA equipment, vehicle interior materials such as automobiles and trains, and interior materials such as ships.

[Post-processing] In the decorative plate in the form after the transfer without leaving the releasable support as a protective sheet, the surface after the transfer (regardless of the filling and solidification of the colored ink)
In order to impart design feeling such as durability and coating feeling, a transparent protective layer made of an ionizing radiation-curable resin such as an acrylic resin, a urethane resin, or an acrylate may be further applied. An ultraviolet absorber such as benzotriazole and ultrafine cerium oxide, and a light stabilizer such as a hindered amine radical scavenger may be added to the transparent protective layer. Coating is performed by a known coating method such as roll coating or spray coating. The thickness of the transparent protective layer is about 1 to 100 μm.

[0030]

The present invention will now be described by way of Examples and Comparative Examples.
This will be described more specifically.

(Embodiment) Transfer sheet S having the structure shown in FIG.
As a transfer layer 22, a release ink made of a binder of a nitrocellulose-based resin is applied to a matte surface of a release support 21 made of a matte polyethylene terephthalate film (manufactured by Diafoil Co., Ltd.) having a thickness of 26 μm to a thickness of 2 μm. After the gravure printing of the release layer 23, a decorative layer 24 of an oak pattern with a pattern ink obtained by adding a pigment mainly composed of a red stalk to a binder of a nitrocellulose resin, and a polyamide comprising a condensate of dimer acid and ethylenediamine An adhesive layer 25 having a thickness of 30 μm made of a system resin was prepared by gravure printing. On the other hand, as a fiber raw material, a wood fiber for MDF obtained by disintegrating a wood chip and a melamine resin-based adhesive added as a binder was applied at a pressure of 5 kg / c.
An intermediate was obtained by half-molding at m ² , a temperature of 70 ° C. and a press time of 10 seconds. The intermediate was embossed at a pressure of 10 kg / cm ² with a (plate-shaped) embossing plate formed with an oak pipe pattern and an uneven pattern (the unevenness is reversely uneven) through the transfer sheet. A U-shaped recess as shown in FIG. 3A was formed in the portion. Further, a transfer sheet was laminated on the intermediate at the same time as the embossing. After embossing, the intermediate body was completely formed with the transfer sheet in a laminated state at a pressure of 20 kg / cm ² , a temperature of 130 ° C., and a press time of 10 minutes, thereby reducing the thickness of the intermediate body to 10 mm. Next, the release support of the transfer sheet was peeled off to obtain a decorative plate composed of an MDF substrate. In the obtained decorative board, the conduit shape consisting of the concave part formed by embossing, by complete molding after embossing,
As shown in FIG. 3 (B), the shape of the inner pipe is inwardly expanded and is close to a natural tree.

(Comparative Example) 10 mm of a completely formed ready-made product
Using a thick MDF (the material is the same as that in the example) as a substrate to be transferred, the transfer sheet used in the example was transferred at a transfer pressure of 20 kg.
/ Cm ² , a temperature of 90 ° C., and a time of 10 seconds for flat pressing for lamination. After pressing, the transfer sheet was embossed from above the transfer sheet under the same conditions as in the example while the laminate was kept as it was. In the obtained decorative board, the conduit shape formed of the concave portion formed by embossing has a U-shaped outwardly expanding shape as shown in FIG. 3 (A), and is embossed with respect to the MDF which has already been completely formed. Therefore, embossing was difficult to enter, and it was shallower than the concave portion which became shallow by complete molding after embossing in the example. As a result, the design expression of the conduit was inferior to the embodiment.

[0033]

According to the method for producing a decorative board of the present invention, embossing is performed in a half-molding stage before completely forming a wood fiber board such as MDF from a fiber raw material. enter. In addition, since the concave portion formed by embossing is completely deformed at the time of complete molding to completely mold after embossing, a concave portion having an inwardly expanding shape which cannot be expressed conventionally can be obtained. This concave shape is closer to the conduit shape of natural wood,
By faithfully reproducing the appearance of the conduit, it is possible to give the decorative plate an excellent design feeling that could not be obtained conventionally. In addition, if the embossed concave portions are filled with coloring ink and solidified, only embossed concave portions are distinguished from the others to obtain a colored decorative pattern. Is obtained.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram illustrating a method for manufacturing a decorative board according to the present invention in one embodiment.

FIG. 2 is a conceptual diagram illustrating various embodiments of a method for manufacturing a decorative board according to the present invention.

FIG. 3 is a conceptual diagram illustrating a change in the shape of a concave portion due to embossing, obtained by the method for manufacturing a decorative board of the present invention. (A) is an outer expanding shape, and (B) is an inner expanding shape.

FIG. 4 is a sectional view showing an example of a transfer sheet that can be used in the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Textile raw material 2 Intermediate body 3 Press roller 4 Emboss roller 5 Intermediate concave part (immediately after embossing) 6 Peeling roller 7 Final concave part (after complete molding) 21 Releasable support 22 Transfer layer 23 Peeling layer 24 Decoration Layer 25 adhesive layer D decorative board S transfer sheet

Claims (8)

[Claims] 1. A method for producing a decorative board comprising the following steps: (a) In producing a wood fiber board, a fiber material is semi-formed by applying heat pressure to obtain a thicker intermediate than in the following complete molding. Process. (B) a step of laminating a transfer sheet comprising a release support and a transfer layer on an intermediate, peeling the release support and transferring the transfer layer to the intermediate; (C) a step of forming a recess in the intermediate with an embossing plate on which an uneven pattern is formed via a transfer layer. (D) a step of completely forming the intermediate by the re-heating pressure; 2. A method for producing a decorative board comprising the following steps: (a) In the production of a wood fiber board, a fiber material is semi-formed by applying heat pressure to obtain a thicker intermediate than in the following complete molding. Process. (B) a transfer sheet comprising a release support and a transfer layer,
A step of laminating on an intermediate. (C) a step of forming a recess in the intermediate body with an embossing plate on which a concavo-convex pattern is formed via a transfer sheet. (D) a step of peeling the releasable support simultaneously with or after embossing to complete the transfer. (E) a step of completely forming the intermediate by the re-heating pressure; 3. A method for producing a decorative board comprising the following steps: (a) In producing a wood fiber board, a fiber material is semi-molded by applying heat pressure to obtain a thicker intermediate than in the following complete molding. Process. (B) a transfer sheet comprising a release support and a transfer layer,
A step of laminating on an intermediate. (C) a step of forming a recess in the intermediate body with an embossing plate on which a concavo-convex pattern is formed via a transfer sheet. (D) a step of completely forming the intermediate by re-heating under the condition that the transfer sheets are laminated. (E) a step of peeling the release support to complete the transfer. 4. A method for producing a decorative board comprising the following steps: (a) In producing a wood fiber board, a fiber material is semi-molded by applying heat pressure to obtain a thicker intermediate than in the following complete molding. Process. (B) a transfer sheet comprising a release support and a transfer layer,
A step of laminating on an intermediate. (C) a step of forming a recess in the intermediate body with an embossing plate on which a concavo-convex pattern is formed via a transfer sheet. (D) A step of completely forming the intermediate body again by applying heat and pressure while keeping the transfer sheet laminated, and forming a decorative plate in which the releasable support is left as a protective sheet to be peeled off before use. 5. A method for producing a decorative board comprising the following steps: (a) In producing a wood fiber board, a fiber material is semi-formed by applying heat pressure to obtain a thicker intermediate than in the following complete molding. Process. (B) a step of forming a concave portion in the intermediate body and simultaneously laminating the transfer sheet with an embossing plate having a concavo-convex pattern via a transfer sheet composed of a release support and a transfer layer. (C) a step of peeling the releasable support simultaneously with or after embossing to complete the transfer. (D) a step of completely forming the intermediate by the re-heating pressure; 6. A method for producing a decorative board comprising the following steps: (a) In producing a wood fiber board, a fiber material is semi-molded by applying heat pressure to obtain a thicker intermediate than in the following complete molding. Process. (B) a transfer sheet comprising a release support and a transfer layer,
A step of forming a concave portion in the intermediate body with an embossing plate having a concavo-convex pattern formed therebetween and simultaneously laminating the transfer sheet with the transfer sheet therebetween. (C) A step of completely forming the intermediate by re-heating under the condition that the transfer sheets are laminated. (D) a step of peeling the releasable support to complete the transfer. 7. A method for producing a decorative board comprising the following steps: (a) In the production of a wood fiber board, a fiber material is semi-formed by applying heat and pressure to obtain a thicker intermediate than in the following complete molding. Process. (B) a transfer sheet comprising a release support and a transfer layer,
A step of forming a concave portion in the intermediate body with an embossing plate having a concavo-convex pattern formed therebetween and simultaneously laminating the transfer sheet with the transfer sheet therebetween. (C) A step of completely forming the intermediate body again by applying heat and pressure while keeping the transfer sheet laminated, and forming a decorative plate in which the releasable support is left as a protective sheet to be peeled off before use. 8. The method according to claim 1, further comprising the following steps:
The method for producing a decorative board according to any one of 2, 3, 5, and 6. (A) A step of filling a concave portion formed by the embossing plate with a coloring ink. (B) a step of solidifying the filled coloring ink;