JPH11254898A - Embossed decorative material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an embossed decorative material wherein there is a feel of material having a gloss variation in a conduit as well, and the design property is high. SOLUTION: This decorative material has a plurality of recesses on the surface, following an embossed picture pattern. In this case, on the bottom surfaces of the recesses D1, D2, at least two kinds of fine uneven shapes having gloss differences, are formed, and a gloss variation is partially imparted. In this case, the embossed decorative material is obtained, e.g. in such a manner that an original plate film having an embossed picture (it is called an uneven pattern as well) pattern is baked to the surface of a metal cylinder such as copper, on the surface of which a photo-sensitive resist is applied, and the original plate film is developed, and a resist is formed, and after applying an embossing treatment (the shaping of the uneven pattern) on a base material sheet by using an embossing plate which is manufactured by a so-called photo- etching method wherein a corrosion, resist separation is performed, and on the rear surface of the base material sheet, a backing material is affixed when necessary.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an embossed decorative material having concave portions on its surface, and in which the gloss of each concave portion is different depending on the location and which enables a high degree of design expression.

[0002]

2. Description of the Related Art An embossed decorative material which is partially embossed in accordance with an embossed picture pattern to form a concave portion to enhance texture, luxury and design is used for building interior materials, furniture and home appliances. It is frequently used for cabinet surface materials. The embossed picture pattern includes a wood type, a stone type, an abstract pattern and the like, and a typical example is a wood grain conduit cross-sectional pattern of natural wood. The embossed decorative material based on the wood grain conduit cross-section pattern has a concave portion formed by embossing a portion corresponding to the wood grain conduit cross section. According to the invention disclosed in Japanese Patent Publication No. 58-14312 or the like, a high density ink such as black or brown is filled into the recessed portion by wiping in order to reproduce the image realistically. In addition, in order to control the gloss of the non-embossed surface, generally, fine irregularities such as grain are shaped by an embossing plate, or a matte (matte, low gloss) OP coat is applied.

[0003]

However, according to the wiping in which the embossed recesses are filled with ink, it is possible to reproduce the depth and rough feeling of the cross section of the wood grain conduit, and the wiping ink used has a low level. By using a glossy material, the gloss of the concave portion can be made lower than that of the convex portion (non-recessed portion), but each concave portion has substantially the same gloss, and the design is monotonous in terms of gloss. There is a problem that it has to be an expression. In addition, wiping has a problem in that ink costs are high, and the number of steps increases, which is troublesome, leading to an increase in manufacturing costs and an increase in delivery time. The present invention has been made in view of the above-described problems, and has as its object to provide an embossed decorative material that enables a high-level design expression in which the gloss in a concave portion is partially different.

[0004]

According to the present invention, there is provided an embossed decorative material having a plurality of recesses on a surface of a base material, wherein the bottom surface of each of the recesses has a fine uneven shape. And the fine irregularities have at least two or more different gloss differences from each other.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION An embossed decorative material is a sheet or plate having an uneven pattern formed on its surface by embossing or the like. As the material of the base material, usually, polyethylene, polypropylene, polyolefin resin such as olefin thermoplastic elastomer, polyvinyl chloride, acrylic resin, thermoplastic polyester resin, thermoplastic urethane resin, ABS, thermoplastic resin such as polystyrene, Thermosetting resins such as melamine resins, unsaturated (thermosetting) polyester resins, two-pack curing (thermosetting) urethane resins, radical polymerizable unsaturated acrylates, and cationic polymerizable epoxy resins are used for ionizing radiation (ultraviolet rays, electron beams). Etc.), and an ionizing radiation-curable resin or the like cross-linked is used. In addition, applications include building interior materials such as walls, floors, and ceilings, doors, window frames, door frames, surface materials for fittings such as handrails, surface materials for housings for home appliances, and surfaces for furniture such as chests of drawers. Materials, surface materials for containers such as boxes, interior materials for vehicles and the like, interior materials for ships, and the like. The embossed decorative material according to the present invention is typically, for example, baked and developed on an original film having an embossed pattern (also referred to as a concavo-convex pattern) on the surface of a metal cylinder such as copper coated with a photosensitive resist. Form resist, corrode,
Embossing (molding of uneven pattern) is performed on the substrate sheet using an embossing plate created by a so-called photo-etching method for removing the resist, and then a backing material is attached to the back surface of the substrate sheet as necessary. It is something that can be done. In addition, the embossed pattern targeted by the present invention includes a wood grain pattern reproducing a natural wood board having a wood grain pipe cross-sectional pattern (wood grain groove), a wood grain pattern processed in a floating style, a surface irregularity of a travertine marble board, and an unevenness. Although a standard independent pattern includes an abstract pattern arranged adjacent to each other, among others, a wood grain pattern in which a wood grain conduit cross-sectional pattern is an important motif, the present invention can be applied effectively, so A case of a wood grain pattern having a wood grain pipe cross-sectional pattern (hereinafter, referred to as a pipe pattern) will be described.

FIG. 1 shows an example of a conduit pattern in which only a conduit portion is extracted from a natural wood pattern. As shown in FIG. 1, each conduit pattern looks irregular at first glance, but is a modification of a long ellipse extending in substantially the same direction. I will show it by shape. Note that the depth of the natural wood in the conduit portion continuously changes in the longitudinal direction in any conduit portion.

FIG. 2 is an explanatory view of a conduit pattern processed for an embossed decorative material according to the present invention. The conduit pattern DP processed for the embossed decorative material according to the present invention is one in which individual conduit patterns are randomly arranged in a natural wood style as shown in the lower part of FIG. At least two or more kinds of fine uneven patterns A1 and A2 ----- which reduce gloss are assigned and mapped. In the state of being formed on the base sheet, the fine uneven patterns A1 and A2 have different shapes, dimensions, and the like so as to have different gloss.
On the left and right in the upper part of FIG. 2, two groups of conduit patterns MP1 and MP2 in which conduit portions are arranged in separate areas are shown. These are images extracted from a natural wood board as a binarized image and divided into two groups, and this binarized image can also be used as a mask pattern. The divided conduit patterns (mask patterns) MP1 and MP2 divided into two groups in this manner and the concave / convex shape patterns A1 and A2 shown in the middle part of FIG.
The conduit pattern DP used for the embossed decorative material according to the present invention is obtained by fitting the fine uneven patterns A1 and A2 into each of the conduit patterns P1 and MP by mapping. The mapping method will be described later.

FIG. 3 is an explanatory plan view of a fine concavo-convex pattern mapped inside the conduit pattern of the embossed decorative material according to the present invention. The fine uneven pattern is
It is provided for roughening the bottom surface of the recess formed by embossing or the like to give a specific gloss (matte), and an extremely wide range of patterns can be used. For example, when the irregularities are regularly arranged, see FIG.
The cell array pattern of gravure printing as shown in FIG. 3 or the halftone dot array pattern of offset printing as shown in FIG. 3B is also preferable, as shown in the middle part of FIG. Applicable to Further, an irregular arrangement pattern may be used. For example, a pattern of a grain screen as shown in FIG.
An irregular pattern created by computer graphic as shown in (d) may be used. At the bottom of the recess formed by the conduit pattern DP of the embossed decorative material according to the present invention, a fine uneven shape that clearly generates a gloss difference is formed. These fine concavo-convex shapes can be controlled by the shape and dimensions of the fine concavo-convex shape pattern, and if the fine concavo-convex shape pattern is periodic, changing parameters such as the period, the area ratio between concave portions and convex portions, and the like. Express different gloss. It is preferable that the depth of the embossment in the conduit portion is generally in the range of 100 to 140 μm, while the amplitude of the uneven shape formed on the bottom is generally in the range of 20 to 30 μm. In forming this uneven shape, it is necessary to select at least two or more types of fine uneven shape patterns A1, A2, --- and appropriately assign them to each conduit pattern and combine them. This combination may be one in which the roughness of the same type of concavo-convex shape pattern is appropriately changed, or a combination of different types of concavo-convex shape patterns as shown in the middle part of FIG.

In general, a rougher concave / convex shape has an effect of suppressing gloss in roughening a concave portion. However, if it is too coarse, it becomes undesirably large enough to visually confirm the uneven shape, and the sense of incongruity becomes strong. In addition, the base sheet of the embossed decorative material according to the present invention usually uses a thermoplastic resin layer such as a polyolefin-based resin or polyvinyl chloride in many cases. It is necessary to reduce the gloss to a predetermined level, and at the same time, the concave portion of the conduit portion is formed by the embossing plate, and at the same time, a fine uneven shape is formed in the non-conduit portion (non-embossed portion). In general, the surface of the embossing plate roughness R _a (J
When the center line average roughness of IS B0601 is increased, the gloss of the embossed decorative sheet surface decreases. When the embossing plate is roughened by the sandblasting method to reduce the gloss, it is effective to use a projection material having a large particle size of 3 μm or more in _Ra , but the roughness of the surface becomes conspicuous and the fineness increases. There is a problem that the finish with a high quality texture is impaired. Therefore, in the case of a wood grain pattern, there is naturally a limit in roughening the non-conduit portion (non-embossed portion). Further, instead of processing the non-conduit portion as described above, an OP coat (overcoating) that gives a mat-like feeling may be applied to the entire surface. Generally, in the embossed decorative material, the gloss of the conduit portion must be suppressed to be smaller than the gloss of the non-conduit portion, even if any surface roughening means is used. The greater the difference in gloss between the two, the more the depth of the conduit is perceived to be greater than the actual depth, and substantially the same effect as when the matting ink is filled by wiping is obtained. Also, by forming a gradation in the gloss due to the uneven shape of the conduit portion, it is possible to make it seem as if there is a change in the depth of the conduit portion. In the case of the embossed decorative material according to the present invention,
The difference in gloss that is visually perceived is further added to the bottom surface of the recessed portion, and it is possible to provide a three-dimensional and high-level design that is not seen in the conventional embossed decorative material. Further, the elimination of the wiping process shortens the process, thereby reducing the manufacturing cost and the delivery time.

Next, an example of the method for producing the conduit pattern DP of the embossed decorative sheet according to the present invention will be described.
First, a natural wood board manuscript is once photographed on a photosensitive film by silver halide photography and the like, then scanned by a plate making scanner, photoelectrically converted, converted into a digital signal, and read.
It is stored in the hard disk of CEPS (COLOR ELECTRONIC PREPRESS SYSTEM). Alternatively, digital image data captured using a digital camera may be directly input to CEPS. Next, from the image data, only the conduit pattern is taken out as a binarized image on a display screen.
The endless correction according to the circumference of the embossing plate is performed, and this image is further divided into two as shown in FIG. 2 (and further divided into three and four as necessary), and the divided conduit patterns MP1 and MP2 are divided. Create an image file. This 2
The quantified conduit pattern can also be used as a mask pattern. Next, as described above, two types (and three or four types, if necessary) of the fine concavo-convex shape patterns A1 and A2 are selected from the fine concavo-convex shape patterns previously input as image data, and the above-mentioned divided conduits are selected. Pattern MP
1, MP2 and, for example, as shown in FIG.
Mapping is performed using a combination such as P2 and A2, and MP
By fitting the fine concavo-convex shape pattern A1 in each conduit pattern 1 and the fine concavo-convex shape pattern A2 in each conduit pattern MP2 and combining them into one image, as shown in the lower part of FIG. A conduit pattern DP in which two types of uneven patterns A1 and A2 are mapped.
Is formed, and the image file is created. The above processing is performed as image processing of a computer using an image processing apparatus for plate making, a layout scanner, or the like.

FIG. 4 is an explanatory view showing an example of a process for producing an embossed decorative material according to the present invention. The digital image data of the conduit pattern DP is output from the above-mentioned image file by a direct exposure apparatus using laser beam scanning onto the copper plating layer of the emboss cylinder 1 on which the resist photosensitive film 2 has been formed in advance, and is printed and developed. The two kinds of uneven patterns A1 and A2 shown in FIG. In this state, when the first corrosion is performed using ferric chloride or cupric chloride, fine irregularities are formed on the surface of the emboss cylinder 1 as shown in FIG. Then, using the binarized conduit pattern (combined MP1 and MP2) before division as a mask pattern, a resist photosensitive film 2 is formed again on the uneven surface, that is, the conduit portion as shown in FIG. Then, when the second corrosion is performed, as shown in FIG. 4, the convex portions 3 corresponding to each conduit pattern are obtained. Next, a separately prepared grain image is printed on the entire surface of the non-conduit portion 4, and after development, the third corrosion is performed or sandblasting is performed to roughen the non-conduit portion 4. Then, the embossing plate 10 used in the present invention as shown in FIG. 4 is obtained by stripping the resist film having an uneven surface and plating the entire surface with chromium. In addition, the embossing plate 10 may be cylindrical (cylindrical) or flat.

The embossing plate 1 produced by the above manufacturing method
As a typical method for forming an embossed decorative material using the embossing plate 10 made of a thermoplastic resin such as a polyolefin-based resin or polyvinyl chloride.
There is a method of pressing. When this method is further classified, the single-layer sheet (top base sheet) 11 is heated and softened, and the embossing plate 10 is pressed or the top base sheet 11 is embossed.
2 to make a two-layer laminate decorative sheet,
Alternatively, the top base sheet 11 and the base base sheet 12 are heat-fused with the heat pressure at the time of pressing the embossing plate to form a two-layer laminate by doubling embossing for simultaneously embossing and laminating. The base sheet 11 is melt-extruded from the T-die and is brought into contact with an embossing plate cylinder also serving as a cooling roll to be embossed, and is also thermally fused with the base base sheet 12 inserted on the back surface of the top sheet to form a doubling emboss in-line. There is a method of forming a two-layer laminate by performing the method. Further, as another method, JP-A-57-87318, JP-A-7-32
As disclosed in Japanese Patent No. 476, 476 and the like, an uncured liquid material of an ionizing radiation-curable resin is applied to the embossing plate 10, and the liquid material is irradiated by irradiating with ionizing radiation in a state where a base material is further superposed thereon. A method may be used in which the top substrate is cured and bonded to the base substrate sheet, then released from the embossing plate, and the top substrate sheet is formed with irregularities on the plate. Further, the embossed decorative material 20 according to the present invention can be obtained by a method such as bonding a backing material 13, for example, a honeycomb board or the like when processing into a door according to the final use.

[0013]

EXAMPLE An embossed decorative material according to the present invention was prototyped for a door using an oak wood grain pattern as a document. First, the oak plate is photographed using a silver halide photographic film, and the resulting film is input by a plate making scanner, converted into digital image data, and extracted as a binary image by computer image processing. To form a conduit pattern, which is randomly divided into divided conduit patterns MP1, M as shown in the upper part of FIG.
It was set to P2. Further, two types of fine uneven patterns A1 and A2 having a screen line number of 100 lines / inch and a roughness of 150 lines / inch are arranged in a cell array of gravure printing as shown in FIG. Is different from the figure of FIG. 1), these are mapped to the divided conduit patterns MP1 and MP2 by digital image processing, and the fine irregular pattern A1 is formed in the conduit of MP1 and the fine irregular pattern is formed in each conduit of MP2. A2 is inserted and emboss cylinder (width direction 420mm, circumferential direction 930m)
m) An image file that was subjected to endless correction according to the above was created. The digital data of this image file is output to a copper embossing cylinder coated with a negative resist photosensitive solution in advance using a laser stream plate making device (manufactured by Synch Laboratories), and exposure printing is performed. Unexposed parts are removed (Fig. 4),
Corrosion was caused by an aqueous ferric chloride solution, and treatment was performed in the order of resist stripping to form two types of fine irregularities having different roughnesses on the conduit portion as shown in FIG. Next, the resist photosensitive solution is applied again to the emboss cylinder, and the binarized conduit pattern (MP
1 + MP2) was output as a mask pattern, baked and developed, and a resist layer as shown in FIG. 4 was provided immediately above the conduit portion, and a second corrosion was performed with a ferric chloride aqueous solution to obtain a high emboss depth. Thus, a convex portion 3 was formed. Next, the resist provided on the convex portion 3 is left as it is, and a resist photosensitive liquid is applied to the entire surface to obtain a particle diameter of 20 to 1.
A grain image composed of a sand pattern of 00 μm is exposed and baked on the non-conduit portion 4 around the convex portion 3, similarly developed, corroded, and stripped of all the resist, and finally chromium plated on the entire surface, An embossing plate 10 used in the present invention as shown in FIG. 4 was prepared. The embossing plate 10 was pressed against a 160 μm-thick base sheet made of a semi-cured brown brown polyvinyl chloride resin softened by heating and embossed. As a result, the emboss depth of the conduit portions D1 and D2 was 11
0 μm, and _Ra is approximately 30 μm and 2
Fine irregularities having two kinds of depths of 0 μm were formed. Lastly, the embossed decorative sheet was bonded to both surfaces of a core material having a honeycomb structure using a two-component curable urethane resin adhesive to produce a door. When the embossed decorative material according to the present invention thus produced is visually observed, two kinds of gloss differences are generated in the conduit portions D1 and D2, which deviate from the conventional monotony, and have a texture and a high degree of design. Oak wood patterns could be created.

[0014]

According to the present invention, by providing at least two types of fine irregularities on the bottom surface of the recess formed by embossing, a difference in gloss occurs in the recess, and there is a difference in depth in the recess. It is possible to produce embossed decorative materials that look and feel high in quality and have a high degree of design. Further, by eliminating the wiping, it is possible to reduce the manufacturing cost and the delivery time.

[Brief description of the drawings]

FIG. 1 is an example of a conduit pattern in which only a conduit portion is extracted from a natural wood pattern.

FIG. 2 is an illustration of a conduit pattern processed for embossed decorative material according to the present invention.

FIG. 3 is an explanatory plan view of a fine concavo-convex pattern mapped inside the conduit pattern of the embossed decorative material according to the present invention.

FIG. 4 is an explanatory diagram of an example of a process for producing an embossed decorative material according to the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Emboss cylinder (emboss plate) 2 Resist 3 Convex part 4 Non-conduit part, non-emboss part 10 Emboss plate used in the present invention 11 Top base sheet 12 Base base sheet 13 Backing material 20 Emboss decorative material according to the present invention A1 , A2 Fine irregularities MP1, MP2 Divided conduit pattern (mask pattern) D1, D2 Conduit portion (recessed portion) DP Conduit pattern according to the present invention

Claims (1)

[Claims] 1. An embossed decorative material having a plurality of recesses on the surface of a base material, the bottom surface of each of the recesses has a fine uneven shape, and the fine uneven shape has at least two or more different gloss differences. An embossed decorative material characterized by having.