JPH1178392A - Embossed decorative material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve scratch resistance by forming an irregular pattern of a base material of an irregular surface having a continuously high and low change, and respectively disposing a highest point at the intersection of a two-dimensional lattice, a lowest point at a central point of a unit lattice for constituting the lattice and a saddle point at the mid-point of a side of the lattice, in the two-dimensional position coordinates of the surface. SOLUTION: A resist pattern P has a resist part 1 and a non-resist part 2. A center of the part 2 is part to become a highest point A of a irregular surface of the embossed decorative material, and arrayed at an intersection of a lattice. And, an intermediate point (intermediate point of one side of a unit lattice) of the adjacent parts 2 is part to become a saddle point B of the angularities. A resist photosensitive layer 4 is formed on a surface of an embossed cylinder 3. Part directly under the part 2 is corroded in a depth d1 with a solution such as ferric chloride or the like. And, further corroding in a depth d3, a bank indicated by B is started to be corroded. Corroded in a depth d4, the bank becomes a smooth hill state. Arriving at this state, maximum point A' in depth and maximum saddle point B' are alternately arranged to provide irregular pattern having irregularities of continuously high and low changes.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to an embossed decorative material having a roughened surface.

[0002]

2. Description of the Related Art For decorative materials such as interior materials and furniture, products which have a roughened plastic finish surface to control gloss and enhance scratch resistance in order to enhance texture, luxury and design are often used. ing. In order to control the final gloss of a conventional decorative material having a thermoplastic resin layer such as polyvinyl chloride or polyolefin resin on the surface, heat and pressure are applied by embossing plates with fine irregularities to form It is generally done. FIG. 6 is an enlarged view showing one embodiment of a cross-sectional shape of a conventional embossed decorative material outermost surface roughened by a sandblast method. As shown in FIG. 6, the uneven shape of the surface of the embossed decorative material 20 is made up of irregular unevenness called a so-called satin finish, which is generally formed by a sand blast method on the surface of the embossed cylinder. Is formed by embossing the surface of the thermoplastic resin by embossing. As shown in FIG. 6, a convex portion shown by a solid line is a portion formed by the first projection formed before the coverage does not exceed 100, and a convex portion shown by a dotted line has a coverage of 100. Is a convex portion formed at the point in time when it exceeds. In some cases, the embossed cylinder is shaped by a concavo-convex shape obtained by applying matte chrome plating to the surface. Further, in the final stage of the decorative sheet processing, the gloss may be controlled by coating the decorative sheet with a matte OP varnish containing fine particles of a light diffusing agent such as silica. Further, in order to enhance the scratch resistance of such a roughened plastic processed surface, a method of providing a relatively hard protective film thinly has been performed.

[0003]

In general, when shaping an uneven shape by heating and press-fitting a plastic surface with an embossing plate, there is a tendency that the shape once shaped tends to slightly return to the original shape. Depends on the type. Therefore, in order to process the outermost surface of the embossed decorative material using various plastics to a predetermined surface roughness,
It is necessary to prepare several embossed plates with different depths of unevenness and use them properly. Generally, a conventional embossing plate is processed by a sand blast method. However, the surface roughness R of the embossed decorative material formed by the embossing plate is used.
_a (center line average roughness) converges to a substantially constant value over coverage 100 (state in which the projected material is projected on all surfaces) as long as the embossed cylinder is processed using the same projected material. I do. Therefore if you try to change the surface roughness R _a of the finished surface, not different mean leave the projection material having a diameter prepared nothing or, if replaced and used according to the surface roughness R _a of interest There is a complicated processing. In addition, since the surface shape of the plate formed by sandblasting has a variation as an established phenomenon, when reprinting the embossed plate, the texture of the outermost surface of the embossed decorative material due to the reprinted embossed plate is slightly different from the previous one There is a problem of sex. Further, the scratch resistance of the outermost surface of the embossed decorative material is greatly affected by the uneven shape. The fine irregularities formed by the sandblasting method have sharp protrusions or bulges, and are easily affected by external force of abrasion and easily broken by the external force. There is a problem that should not be. Furthermore, the sandblasting method is a heterogeneous processing method in view of the embossing plate making process, and has a problem that it is difficult to in-line, takes too much time to complete, and prolongs the delivery date. On the other hand, the method of performing matte chrome plating on the surface of the emboss cylinder has a problem in that it is not possible to form an uneven shape having a high degree of freedom. Further, the method of applying the OP varnish coat to the embossed decorative material has a problem that the reproducibility of gloss tends to be unstable due to uneven dispersion of the light diffusing agent particles, and it is difficult to obtain a delicate finish. The present invention has been made in view of the above-described problems, and has an object of providing an embossed decorative material having scratch resistance, surface roughness _Ra , and good gloss reproducibility controlled to a predetermined value. I do.

[0004]

According to the present invention, there is provided a decorative material in which the outermost surface of a base material is roughened by an uneven pattern. It is formed from a concavo-convex surface having a continuous height change by a convex portion and a concave portion alternately arranged in a two-dimensional direction, and in a two-dimensional position coordinate within the outermost surface of the base material, the highest point A of the concavo-convex surface is determined. At the intersection of the two-dimensional lattice, the lowest point C is located at the center point of the unit lattice constituting the two-dimensional lattice, and the saddle point B is located at the center of the side of the unit lattice, and the saddle point B is located at the highest point A and In the cross section including the saddle point B, the altitude is the minimum point, and in the cross section including the lowest point C and the saddle point B, the altitude is the maximum point.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION An embossed decorative material is a material in which the surface of a base material is provided with an embossed pattern by a method such as embossing.
The term "emboss" in the present invention is not limited to a method of embossing in a narrow sense, i.e., a method having a pattern having a concavo-convex pattern, in which a substrate is pressed and shaped, and a liquid material is poured into the mold, solidified, and removed from the mold. It is used as a general term for various methods of forming unevenness such as a molding method. The concavo-convex pattern in the present invention is a light-diffusing fine irregularity as described later. The shape of the substrate is typically a sheet or a plate, but may be another shape. Examples of applications of the embossed decorative material according to the present invention include walls, floors, interior materials of buildings such as ceilings, doors, window frames, fittings such as handrails, housings of home appliances, furniture such as chests, containers such as boxes, and the like. An interior material for a vehicle or the like, an interior material for a ship, or the like, and an optional material is further used as a backing if necessary. A typical object to be reproduced with gloss and texture by the uneven pattern (also referred to as an embossed pattern) of the present invention is a wooden surface of a natural wood board surface, but of course, the uneven pattern of the present invention is a wooden surface. In addition to the surface, the surface of the brick array joints and ceilings, granite, marble, etc.
It can also be applied to the reproduction of surface gloss and texture of cloth and squeezed leather.

The present invention will be described in more detail with reference to the drawings. FIG. 1 is an enlarged perspective view of a part of the surface of the embossed decorative material according to the present invention. Embossed decorative material 1 according to the present invention
The uneven surface pattern of the surface 0 is formed by an uneven surface having a continuous change in height due to convex portions and concave portions alternately arranged in a two-dimensional direction in the outermost surface of the base material. FIG.
FIG. 4 is an explanatory view of an arrangement state of convex portions and concave portions on the surface of the embossed decorative material according to the present invention. As shown in FIG. 2, in the two-dimensional position coordinates in the outermost surface of the base material, the points characterizing the concavo-convex pattern of the present invention are the highest point A, the lowest point C, and the saddle point B.
Kind. The highest point A corresponding to the maximum value of the height of the uneven surface (hereinafter also referred to as point A, point B, and point C) is located at the intersection of the two-dimensional lattice. This grid may be a rectangular grid, an oblique grid, or the like in addition to the square grid as shown in FIG. With reference to the lattice point A, the lowest point C is located at the center point of the unit lattice constituting the two-dimensional lattice (the intersection of the diagonal lines of the unit lattice). Of course, the positional relationship between the two may be interchanged. Further, the saddle point B is located at an intermediate point on one side of the unit cell. The saddle point B is a minimum point of altitude when viewed in a cross section including the points A and B in the two-dimensional lattice of FIG. (See FIG. 3 (b).) The saddle point B is
When viewed in a cross section including the point C and the point C, the maximum point is obtained. The relation of the height (high / low) of the height of each point is as follows: point A> point B> point C. The level difference between the highest point A, the lowest point C and the saddle point B portion B is such that the level difference between the saddle point B and the highest point A is larger than the level difference between the saddle point B and the lowest point C. Are formed. In addition, the lattice spacing (lattice constant)
Is determined by the number of lines of a gravure plate making screen used in the production of an embossed decorative material according to the present invention described later, and the number of lines of the screen is preferably in the range of 100 to 400 lines / inch. That is, the length of one side of the unit cell is preferably in the range of 63 to 250 μm.

FIG. 3 is an explanatory view showing an example of the principle of forming an embossed pattern on an embossed decorative material according to the present invention. FIG.
(A) is a resist pattern P formed on the surface of the embossed cylinder, which is composed of a resist portion 1 and a non-resist portion 2, and the center of the non-resist portion 2 is located at the highest point A of the uneven surface of the embossed decorative material. And are arranged so as to be located at the intersections of the lattice. Also, the midpoint between adjacent non-resist portions 2, that is, 1 of the unit cell
The midpoint of the side is the portion that becomes the saddle point B on the uneven surface. Such a resist pattern P is substantially the same as a resist pattern formed by a plain halftone net in gravure printing. Therefore, the resist pattern P can be formed on the embossed cylinder surface by the same method as the conventional gravure printing plate making method, and the resist photosensitive layer is formed by coating the embossed cylinder having a copper plating layer on the surface in advance. Exposure and printing of halftone solid halftone dots formed on the film, or
Such halftone image data may be once input to a computer, and may be directly output to the emboss cylinder surface using a direct exposure device by laser beam scanning modulated with the image data and printed.

FIG. 3 (b) shows the x-
It is explanatory drawing of the uneven | corrugated pattern formation principle of the embossed decorative material by this invention by x 'cross section. FIG. 3 is a view showing a state in which the resist photosensitive layer 4 is formed on the surface of the emboss cylinder 3.
When the non-resist portion 2 is corroded under a corrosive condition in which side etching occurs violently using a solution of ferric chloride or the like under the non-resist portion 2, the corroded portion is corroded by a depth d1 as shown in FIG. What is close to a halftone cell in a plate is obtained. In the present invention, the corrosion is further promoted, and after the depth reaches the state of d2 from the initial level to the state of d3, the bank indicated by B is eroded for the first time, and reaches the depth d4. As shown, the bank becomes gentle hills. The depth d4 at this stage has reached about three times d1. In this state, the maximum point A 'of the plate depth and the saddle point B' (however, the maximum and the minimum are opposite to the saddle point of the decorative material) are alternately arranged, and the height of the uneven shape changes continuously. An embossing plate E having a roughened pattern is obtained. Lastly, chrome plating is applied to extend the life of the embossing plate E and finished. As shown in FIG. 3 (b), the corrosion depth d4 of the embossing plate E of the present invention is about 30 μm of halftone halftone dots in the case of ordinary gravure plate making with a screen ruling of 150 lines / inch. It reaches 90 to 100 μm which is three times as large as that.

FIG. 4 is also an explanatory view of one example of the principle of forming an embossed pattern on the embossed decorative material according to the present invention. FIG.
FIG. 4A shows a resist pattern P formed on the surface of an embossed cylinder similar to that shown in FIG.
FIG. 4 is an explanatory view of a principle of forming an embossed pattern of an embossed decorative material according to the present invention by using a yy ′ cross section of a resist pattern P. Non-resist portions 2 arranged as shown in FIG.
The shape change of the yy 'cross section obliquely passing through occurs simultaneously with the change of the xx' cross section, but the center point of the non-resist portion 2 corresponding to the highest point A of the uneven shape of the decorative material and its The concave shape due to corrosion of the portion corresponding to the lowest point C of the uneven shape of the decorative material located in the middle is different from the above-mentioned xx 'cross section, and the point C' portion corresponding to the lowest point C as shown in FIG. It has a slightly pointed shape. The reason is that the corrosion of the bank at the point C 'is delayed more than that of the bank at the point B' corresponding to the saddle point B. Is farther from the edge of the non-resist part where the side etching starts than the point B ′. Therefore, the point C ′ at the shallowest part of the yy ′ cross-sectional shape of the embossing plate E shown in FIG.
It is at a higher level than the point B ′ corresponding to the saddle point B in the x ′ cross-sectional shape. The difference between the two levels converges to the same level as the corrosion progresses further. However, excessive corrosion not only eliminates the difference in elevation of the uneven surface, but also necessitates a thick copper plating layer. Therefore, it is desirable to stop the corrosion in the state shown in FIGS. As can be seen from FIGS. 3 and 4, the concavity and convexity of the embossed plate E and the concavity and convexity of the embossed decorative material 10 are reversed, and points A ′ and B ′ on the embossed plate are reversed.
Correspond to points A and B on the embossed decorative material. According to the method for producing an embossing plate by the above-described corrosion, the same resist pattern P can be formed on the surface of the embossed cylinder every time. An embossing plate having the same concavo-convex shape is obtained. Also, by controlling the corrosion conditions, mainly the corrosion time, it is possible to easily prepare an embossing plate having several kinds of desired depths, and it is possible to use differently according to the difference in the moldability of the plastic of the surface base sheet. is there.

Finally, as shown in FIGS. 3 (b) and 4 (b), using the above-described embossing plate E, the heat forming the outermost surface layer of the base material of the two-layer laminate constituting the embossed decorative material. At the same time as embossing the base material 5 made of a plastic resin sheet by embossing, or laminating the colored sheet 6 off-line, and finally, a transparent protective layer 7 is thinly coated on the entire surface to improve the scratch resistance. If necessary, a backing material (not shown) according to the purpose of use may be attached. For example, when the embossed decorative material 10 is a door, a core material of a door having a honeycomb structure may be bonded with a strong adhesive.

In the above example, an example of embossing in a narrow sense is described in which an embossing plate is used to press and shape a heat-softened thermoplastic resin surface. However, the method for producing the embossed decorative material according to the present invention is not limited to this, and it can be produced by other methods. For example, an uncured liquid composition such as an unsaturated acrylate oligomer is applied to the surface of an embossing plate made by the above method, and the liquid composition is filled into at least the concave portions of the concavo-convex pattern. The resin layer is cured (solidified) by irradiating ultraviolet rays or an electron beam from the sheet side in a state where the sheets are stacked and adhered to each other, and the resin layer is adhered to the sheet and the surface thereof, and the concavo-convex pattern of the emboss plate is formed. Of releasing the cured product layer from the embossing plate (Japanese Patent Laid-Open No. 2-1117)
No. 5 publication) can also be used. Further, in the present invention, the substrate for forming the uneven pattern is polyethylene,
Polyolefin resins such as polypropylene and olefin-based thermoplastic elastomers, thermoplastic resins such as polyvinyl chloride, acrylic resin and polyester resin, thermosetting resins such as melamine resin, and ultraviolet rays made of unsaturated acrylate or the like, or electron beam curing A material such as a cured resin is used, and it may be a single layer or a laminate of two or more layers. As needed,
A pattern layer such as a grain pattern or a stone pattern may be provided at a position visible from the surface.

FIG. 5 is a comparative explanatory diagram of scratch resistance. FIG. 5A shows x of the embossed decorative material 10 according to the present invention.
FIG. 5B shows one mode of the cross-sectional shape in the case of the conventional surface processing by sandblasting. In both figures, the protective layer 7
Have been omitted for clarity. As apparent from a comparison between FIG. 5A and FIG. 5B, the scar 8 caused by the rubbing of the surface with a hard material has a relatively large area in the case of the embossed decorative material 20 by the conventional sandblast. On the other hand, in the case of the embossed decorative material 10 according to the present invention, it falls within a narrow range. that is,
In the case of the embossed decorative material 10 according to the present invention, the embossed decorative material 10 has a rounded uneven shape that continuously changes in height at a relatively large pitch, and only the highest portion A is rubbed, and the other portions are hardly affected. is there. Further, when the surface is in such a gentle hill state, the surface is less likely to be contaminated, and even if it is contaminated, it is easy to return to the original clean state.

[0013]

According to the present invention, the concave and convex pattern of the outermost substrate of the embossed decorative material is continuously formed by the convex and concave portions arranged alternately as described above. In the two-dimensional position coordinates of the uneven surface, the highest point A is at the intersection of the two-dimensional grid, the lowest point C is at the center point of the unit grid constituting the grid, and the saddle point B is at the side of the grid. By positioning each at the midpoint, there is little unevenness and unevenness of gloss, and excellent in scratch resistance and stain resistance,
Further, by forming an uneven surface from the same resist pattern P by a corrosion method, it is possible to stably manufacture an embossing plate and to provide an embossed decorative material having excellent reproducibility in a reprinting plate.

[Brief description of the drawings]

FIG. 1 is an enlarged perspective view of a part of the surface of an embossed makeup according to the present invention.

FIG. 2 is an explanatory view of an arrangement state of convex portions and concave portions on the surface of an embossed decorative material according to the present invention.

FIG. 3 is an explanatory view showing an example of a principle of forming an uneven pattern of an embossed decorative material according to the present invention.

FIG. 4 is an explanatory view showing an example of a principle of forming an uneven pattern of an embossed decorative material according to the present invention.

FIG. 5 is a comparative explanatory diagram of scratch resistance.

DESCRIPTION OF SYMBOLS 1 Resist part 2 Non-resist part 3 Emboss cylinder 4 Resist layer 5 Substrate made of transparent thermoplastic resin sheet 6 Substrate made of colored sheet 7 Protective layer 8 Scar 10 Embossed decorative material according to the present invention 20 Conventional Embossed cosmetic material A Highest point B Saddle point C Lowest point E Embossed version

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[Procedure amendment]

[Submission date] November 18, 1997

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Brief description of drawings

[Correction method] Change

[Correction contents]

[Brief description of the drawings]

FIG. 1 is an enlarged perspective view of a part of the surface of an embossed makeup according to the present invention.

FIG. 2 is an explanatory view of an arrangement state of convex portions and concave portions on the surface of an embossed decorative material according to the present invention.

FIG. 3 is an explanatory view showing an example of a principle of forming an uneven pattern of an embossed decorative material according to the present invention.

FIG. 4 is an explanatory view showing an example of a principle of forming an uneven pattern of an embossed decorative material according to the present invention.

FIG. 5 is a comparative explanatory diagram of scratch resistance.

FIG. 6 is an enlarged view showing one embodiment of a cross-sectional shape of a conventional embossed decorative material outermost surface roughened by a sandblast method.

DESCRIPTION OF SYMBOLS 1 Resist part 2 Non-resist part 3 Emboss cylinder 4 Resist layer 5 Substrate made of transparent thermoplastic resin sheet 6 Substrate made of colored sheet 7 Protective layer 8 Scar 10 Embossed decorative material according to the present invention 20 Conventional Embossed cosmetic material A Highest point B Saddle point C Lowest point E Embossed version

Claims (1)

[Claims] 1. A decorative material in which the outermost surface of a base material is roughened by an uneven pattern, wherein the uneven pattern has a convex portion and a concave portion alternately arranged in a two-dimensional direction in the outermost surface of the base material. In the two-dimensional position coordinates within the outermost surface of the base material, the highest point A of the uneven surface is located at the intersection of the two-dimensional grid, and the lowest point C is located at the intersection of the two-dimensional grid. The saddle point B is located at the center point of the unit cell to be configured, at the center of the side of the unit lattice, and the saddle point B is
An embossed decorative material characterized in that it is an extremely minimal point in a cross section including the highest point A and the saddle point B, and is an extremely maximal point in a cross section including the lowest point C and the saddle point B.