JPS59178251A - Manufacture of decorative board - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a decorative laminate having a transferred pattern using a transfer agent, which has high adhesion strength between the transferred pattern and the base material for the decorative laminate, and is resistant to solvents and chemicals. The present invention provides a method for easily and reliably obtaining a decorative board having a transferred pattern that has excellent properties such as physical properties.

In recent years, in the manufacture of various construction materials including decorative boards,
As a method for producing a coating having a pattern layer using a coloring agent, a method is used in which a high-quality colored pattern layer is obtained by irradiating a paint made of an ionizing radiation-curable composition with ionizing radiation energy. As a specific method for producing various building materials having a colored pattern layer by such a method, an ionizing radiation-curable composition containing a coloring agent is directly applied to a base material such as a metal plate, a metal plate, etc., and an ionizing radiation-curable composition is applied. A method of curing by irradiating with radiation, printing directly on the base material with ordinary paint,
A method of applying an ionizing radiation-curable composition to the printed surface and curing it by irradiating it with ionizing radiation, or a method of laminating a decorative sheet to the base material and then applying an ionizing radiation-curable composition to the surface of the decorative sheet. After applying the ionizing radiation-curable composition to the base material, a decorative sheet is laminated, and the ionizing radiation-curable composition is further applied to the surface of the decorative sheet. However, there is a method of curing and integrating two layers of the ionizing radiation-curable composition by irradiating this with ionizing radiation.

However, the first two methods of forming a pattern layer by directly applying paint to the base material are limited by the surface condition and shape of the base material used, and are not versatile methods and are cumbersome. The latter two methods, which utilize gold, are the same as the fT4 method, which uses one shot of ionizing radiation for the purpose of obtaining a high-quality pattern layer. In addition to poor performance, disadvantages include poor adhesion between the decorative sheet and the radiation-curable material, delamination of the decorative sheet itself, and poor hardening of the ionizing radiation-curable composition. There is.

On the other hand, as a manufacturing method for various building materials having a pattern layer using a coloring agent, there is a method for forming a transferred pattern using a transfer sheet (Mather = T-plastic synthetic resin, so-called honotostan or Widely used in the production of polyester matte plates, etc. by the film method.
However, if the pattern layer formed on the transfer sheet is made of ordinary ink, the pattern layer formed on the transfer sheet may not be resistant to solvents. There is a lack of 7% in durability and chemical resistance, and the surface of the transferred pattern needs to be painted again, and the pattern layer formed on the transfer sheet is still made of hardening ink. There is a problem with the adhesion between the curable ink and the polyester resin.
I am satisfied with the fact that it is easy to obtain a high-quality transferred pattern.

The present invention provides a method for manufacturing a decorative board having a transfer pattern using a conventional transfer sheet, and a method for forming a colored pattern layer by irradiating a paint made of an ionizing radiation-curable composition with ionizing radiation energy. The present invention provides a method for easily and reliably producing a decorative board having a high-quality colored pattern layer, which could not be obtained by the Buchi method.

Hereinafter, the method for manufacturing a decorative laminate of the present invention will be explained according to a process diagram of a first embodiment.

In the method for producing a decorative laminate of the present invention, an ionizing radiation-curable composition containing a coloring agent is applied to one surface of the transfer sheet indicated by reference numeral 3 in FIG. A transfer sheet 3 provided with an arbitrary pattern layer 2.2., and a coating layer 5 made of an ionizing radiation-curable composition.
As shown in FIG. 2, the base material 4 for decorative laminates having the following properties is laminated in such a way that two surfaces of the pattern layer of the transfer sheet 3 are in contact with the surface 5 of the coating layer of the base material 4 for decorative laminate, and the transfer is performed. A laminate 6 of the sheet 3 and the decorative board base material 4 is obtained.

Next, the transfer sheet 3 in the laminate 6 is applied to the laminate 6 of the transfer sheet 3 obtained in the above step and the base material 4 for decorative laminate.
The pattern layer 2 in the transfer sheet 3 and the coating layer 5 in the base material 4 for decorative laminate are cured by irradiating ionizing radiation from the side indicated by the arrow (A) in FIG. At the same time, the transfer sheet 3 and the decorative board base 4 are integrated into a pattern layer indicated by 2' and a coating layer indicated by 5', and subsequently, as shown in FIG. Then, only the base sheet 1 constituting the transfer sheet 3 was peeled off from the laminate 6' which had been cured and integrated by the irradiation with the ionizing radiation. A structural decorative board is obtained.

As is clear from the above explanation, in the method for manufacturing a decorative laminate of the present invention, the pattern layer 2 made of the uncured ionizing radiation curable composition in the transfer sheet 3 is used as one surface layer of the base material 4 for decorative laminate. The pattern layer 2 of the transfer plate 3 and the coating layer 5 of the decorative board base material 4 are superimposed on the coating layer 5 of the uncured ionizing radiation curable composition, that is, the pattern layer 2 of the transfer plate 3 and the coating layer 5 of the decorative board base material 4 are superimposed in a wet state. At the same time, the pattern layer 2 and the coating layer 5 are cured by irradiating them with ionizing radiation to form the pattern layer 2' and the coating layer 5', and at the same time, the transfer sheet 3 and the decorative board base material 4 are integrated. In particular, as described in the second claim, a transfer sheet in which the pattern layer 2 in the transfer sheet 3 is partially cured by irradiation treatment with ionizing radiation. If you use ", the transfer sheet 3 itself will be easy to handle.
Problems such as 7r and scratches in the pattern caused by the transfer sheet 3 having the uncured pattern layer 2 are solved.

In addition, in the method for manufacturing a decorative board of the present invention, as the transfer sheet 3 constituting the laminate 6 to which ionizing radiation is irradiated, an ionizing radiation-curable composition containing a colorant is used. Using a base notebook 1 having a pattern layer 2 formed thereon, that is, an entirely uncured pattern layer 2 formed of an ionizing radiation curable composition, or a completely uncured pattern layer 2 formed of an ionizing radiation curable composition,
Although the base sheet 1 having a pattern layer 2 which has been partially cured by irradiation with ionizing radiation is used, it is also possible to use a known transfer sheet having a conventional pattern layer, which is applied to ordinary ink. Although it is possible to obtain a decorative board having the desired physical properties according to the present invention, this method has the drawback that the fastness of the patterned layer obtained is not fully satisfactory.

The transfer notebook 3 used in the method for manufacturing a decorative board of the present invention includes an arbitrary pattern layer 2, 2.・
The base sheet 1 is a material known as a base notebook in a transfer sheet, such as various processed paper 1 synthetic resin film or sheet!・.

7)b Metal foil such as minilum foil, or a composite sheet of these materials is used. In particular, the base sheet 1 is peeled off from the laminate when obtaining the final product, the decorative laminate.
Since the gloss on the surface of the base sheet 11 is realized as the gloss on the surface of the decorative board 7, a base sheet 1 having a gloss that matches the intended gloss of the decorative board 7 is used.

The optional pattern layers 2 and 2° in the transfer sheet 3 are formed from an ionizing radiation-curable composition containing a colorant, and are composed of a prepolymer or oligomer having an ethylenically unsaturated bond in the molecule. Alternatively, a composition containing as a main component a monomer having an ethylenically unsaturated bond in the molecule or a mixture thereof is used.

Examples of the prepolymer or oligomer having an ethylenically unsaturated bond in the molecule used in the ionizing radiation-curable composition include unsaturated polyesters, polyester acrylate, epoxy acrylate, urethane acrylate, and polyol acrylate. 1. Various acrylates such as melamine acrylate, polyester methacrylate, and epoxy acrylate.

Urethane 7 methacrylate, polyol methacrylate-1
・Various methacrylates such as polyol methacrylate 1・and melamine methacrylate 1・. Examples of methacrylates having an ethylenically unsaturated bond in the molecule include styrene, α-methylstyrene, etc. Styrenic monomers, acrylic acid esters such as methyl acrylate, 2-ethylhexyl acrylate, methoxyethyl acrylate, butyethyl acrylate, butyl acrylate, methquin butyl acrylate, phenyl acrylate,
Methacrylic acid esters such as methyl methacrylate, ethyl methacrylate, and zolobyl methacrylate, and acrylamide.

Unsaturated carboxylic acid amides such as methacrylamide, 2-(N,N-dibenzylamino)ethyl acrylate, (N,N-methylamino)methyl methacrylate, 2-(N,N-diethylamine)propyl acrylate, etc. Substituted amino alcohol esters of unsaturated acids, ethylene glycol diacrylate-1-, 7'ropylene glycol diacrylate, neopentyl glycol cyacrylate,
1,6-hexanethiol diacrylate, diethylene glycol diacrylate.

Polyfunctional compounds such as triethylene glycol diacrylate, sulfo-ropylene glycol diacrylate, ethylene glycol dimecacrylate, sulfo-ropylene glycol dimethacrylate, sulfo-ropylene glycol dimethacrylate, and/or polyfunctional compounds containing 2 in the molecule. These include polythiol compounds having more than one thiol group, such as trinotyolpropane trithioglycolate, trimethylo-schiff 0 loban lithiopropione-1, pentaerythritol tetrathioglycolate, and the like.

1. As the coloring agent contained in the ionizing radiation curable composition, calcium carbonate, clay, titanium white, carbon branov, yellow lead, cadmi yellow, chrome vermilion, catomilent, silk night, gun kidney, Inorganic pigments such as iron oxide and alumina white, anno-based pigments,
Organic pigments such as azo lake pigments, phthalonanine pigments, styrene pigments, and quinac pigments are used.

The ionizing radiation-curable composition containing the coloring agent forming the pattern layer 2 in the transfer sheet 3 is based on 100 parts by weight of the prepolymer or oligomer or heptadol having ethylenically unsaturated bonds in the molecule. It is preferable that the amount of the pigment as a coloring agent is about 1 to 20 parts by weight.In particular, if the amount of the pigment as a coloring agent exceeds 20 parts by weight, the solvent resistance and chemical resistance of the pattern layer in the resulting decorative board will decrease. Harmful effects occur.

Furthermore, in the method for manufacturing a decorative board having the configuration described in the second claim, particularly when ultraviolet irradiation is used as the ionizing radiation irradiation method for partially curing the pattern layer 2 of the transfer paper 3, As the ionizing radiation-curable composition forming the pattern layer 2 of the transfer paper 3, about 5 to 10 parts by weight of Q-no. Photopolymerization initiators, such as various benzine ethers such as benzine methyl ether, penzoinfuropyl ether, benzine n-butyl ether, and benzine methyl ether, benzophenones, halogenated acetate/enones, and biacyl. A photopolymerization initiator that generates radicals when irradiated with ultraviolet rays such as
The pattern layer 2 becomes the transfer paper 3. ]: 10 parts by weight or less of polymerization inhibitor 1 is added in order to completely cure the laminate 6 with the board 4 before irradiating it with ionizing radiation.
- Stabilizers such as hydroquinone, hydroquinone methyl ether, benzoquinone, etc. are preferably incorporated.

Note that the pattern layer 2 of the transfer paper 3 is formed by gravure printing the above-mentioned ionizing radiation-curable composition.

It can be easily formed by printing on the base sheet 1 using various printing methods such as offset printing and screen printing.

Next, in the method for producing a decorative laminate of the present invention, the decorative laminate base material 4 having the coating layer 5 made of an ionizing radiation-curable composition and laminated with the transfer sheet 3 may be, for example, plywood, particle board, fiber board, etc. Wood base materials such as calcium silicate board 7 gypsum board 2 asbestos slate board, ceramic base material such as Nornolp cement board, metal profiteering such as galvanized iron plate, aluminum plate, stainless steel plate, hard vinyl chloride board,
The base material 4 for a decorative board made of a Zorastic-Tsuku co-phase such as an acrylic board is coated with ethylenic elements in the molecule in the same manner as described for the ionizing radiation-curable composition constituting the pattern layer 2 in the transfer sheet 3. An ionizing radiation-curable composition consisting of a prepolymer or oligomer having an unsaturated bond, a composition whose main component is a monomer having one ethylenically unsaturated bond in the molecule, or a composition in which a coloring agent is added to this composition. It can be easily obtained by applying a material to the negative side using a coating method such as reverse roll coating, gravure roll coating, air knife coating, curtain coating, or myobar coating.

The method for manufacturing a decorative laminate of the present invention involves transferring the transfer sheet 3 having the above-described configuration and the decorative laminate base material 4 having the coating layer 5 to the pattern layer 21Jjj, 11 of the decorative laminate substrate 4 in the transfer sheet 3. The resulting laminate 6 is subjected to ionizing radiation such as X-rays, γ-rays, electron beams, ultraviolet rays, etc. from the transfer notebook 3 side (A) of the laminate 6. The pattern layer 2 and the coating layer 5 in the laminate 6 are irradiated with radiation to completely cure, forming the pattern layer 2' and the coating layer 5', respectively. Then, the laminate 6 was subjected to pressure treatment from the transfer notebook 3 side of the laminate 6 using a flexible roll to remove air interposed between the transfer sheet 3 and the base material 4 for decorative laminate. It is preferable to leave the resin in place for a long time in order to prevent the effect of oxygen that adversely affects the curing effect due to irradiation with ionizing radiation.

The amount of ionizing radiation irradiated to the laminate 6 requires enough energy to completely cure the pattern layer 2 on the transfer sheet 3 and the coating layer 5 on the base material 4 for decorative laminate. 150-500 Ke for irradiation
An electron beam with an energy of about 5 to 15 Mra
It is preferable to irradiate at a dose of about d.

The specific structure of the method for manufacturing a decorative board of the present invention will be described below with reference to Examples.

Example I Polyester film with a thickness of 25 μm (Nilmirror, manufactured by Toshi Corporation) was coated with oligoesteno fragment acrylate (manufactured by Toagosei Corporation: Aroninox M 80) on one side of the base sheet.
30) 5 (1 ton), 40ffi! parts of 1°6-hexanediol diacrylate, and 10 parts by weight of pigment were used for printing with a silk screen plate to obtain a transfer sheet having a pattern layer.

Next, 50 parts by weight of oligoester acrylate,
] , ] 6-Hexanediol diacrylate 50% by weight paint is applied at a ratio of 100 f7/m2 to the coated layer surface of a base material for a decorative board made of a glass fiber reinforced gypsum board, and The base material for decorative board and the transfer sheet are laminated so that the pattern layer surfaces are in contact with each other to obtain a laminate of the two.

After that, the laminate e is irradiated with a scanning electron beam [OMrad] of 300 Key and 30 mA from the transfer sheet side of the laminate,
The pattern layer on the transfer sheet and the coating layer on the decorative laminate substrate are cured, and the transfer sheet and the decorative laminate material are cured and integrated, and then the polyester film, which is the base sheet of the transfer sheet, is peeled off from the laminate. The desired product, a gypsum decorative board, was obtained.

The colored pattern layer in the obtained gypsum decorative board and the surface of the gypsum decorative board had excellent solvent resistance and chemical resistance, and high surface hardness.

Example 2 45 parts by weight of oligoester acrylate, 40 parts by weight of 1,6-hexene diol diacrylate, and 10 parts by weight of pigment were placed on one surface of a base sheet made of a polyester film having a thickness of 25 μm.

An ink consisting of 4.5 parts by weight of benzophenone and 05 parts by weight of hydroquinone was used to print on a silk screen plate, and then 80 w/cm of UV Lanzo [manufactured by Ushio Inc.: Unicure System] 1 was applied to the printed surface. The transfer sheet was irradiated with ultraviolet light using a lamp to obtain a transfer sheet that had been cured (partially cured) to a pattern layer strength of 1: dryness to touch by printing.

Thereafter, the transfer sheet and a base material for decorative laminate having the same structure as the base material for decorative laminate made of glass fiber reinforced gypsum board having the coating layer used in Example 1 were connected to the pattern layer surface of the transfer sheet and the decorative laminate. The laminate that was laminated so that the coating layer surface of the substrate for use was in contact with the surface of the coating layer was irradiated with an electron beam from the transfer sheet side of the laminate under the same conditions as the electron beam irradiation in Example 1 to form a pattern on the transfer sheet. The layer and the coating layer for use in decorative laminates were completely cured, and the transfer sheet and the base material for decorative laminates were cured and integrated.

Next, the polyester film serving as the base sheet of the transfer sheet was peeled off from the laminate to obtain a gypsum decorative board as the desired product.

The surface of the obtained gypsum decorative board containing the colored pattern layer had excellent solvent resistance and chemical resistance, and high hardness.

Example 3 Epoxy acrylic resin 1 was applied to the polypropylene resin layer surface of a base sheet such as a composite sheet in which a polyzolopylene resin layer with a thickness of 15 μm was laminated on one surface of double-quality paper.
・[Showa Kobunshi ■: Epoxy VR-60] 60 parts by weight, 25 fLt parts of methoxyethyl acrylate + 4.5 parts by weight of benzophenone, 0.5 parts by weight of hydroquinone, M
Multicolor printing was performed using an offset plate using an ink containing 1.0 parts by weight of the dye, and then the printed surface was irradiated with ultraviolet rays under the same conditions as the ultraviolet irradiation treatment during the production of the transfer sheet in Example 2. A transfer sheet was obtained in which the pattern layer formed by color printing was partially cured to the extent that it was dry to the touch.

Thereafter, the transfer sheet and a decorative laminate having the same structure as the decorative laminate made of glass fiber-reinforced gypsum board having a coating layer used in Example 1 were applied to the pattern layer surface of the transfer sheet and the decorative laminate substrate. The laminate, which has been laminated so that the coating layer surface of the material is in contact with the pattern layer on the transfer sheet, is irradiated with an electron beam under the same conditions as the electron beam irradiation in Example 1 from the transfer sheet side of the laminate, and the pattern layer on the transfer sheet and The coating layer on the base material for decorative laminate was completely cured, and the transfer sheet and the base material for decorative laminate were cured and integrated. The desired product, a gypsum decorative board, was obtained.

The surface of the obtained gypsum decorative board including the colored pattern layer is
It had excellent solvent resistance and chemical resistance, and high hardness.

The method for producing a decorative laminate of the present invention consists of the following two configurations, and it is a floor that has high hardness on the surface including a colored pattern layer and has excellent properties such as solvent resistance and chemical resistance. This has the advantage of being able to obtain decorative boards for building materials for various purposes, including building materials, wall materials, and ceiling materials 1, in a compact and reliable manner.

′! In addition, in the method for manufacturing a decorative laminate of the present invention (= the gloss of the transfer sheet can be stably reproduced as the gloss of the surface of the decorative laminate), by selecting the Z base sheet in the transfer sheet, the desired gloss can be achieved. It has the function and effect that a decorative sheet that embodies the above is reliably obtained.

Furthermore, in the method for producing a decorative laminate of the present invention, the pattern layer in the transfer note and the coating layer in the base material for decorative laminate are both sandwiched together by the base sheet in the transfer sheet and the material for decorative laminate, and then exposed to ionizing radiation. Since the pattern layer and coating layer that are hardened by irradiation with ionizing radiation are shielded from oxygen, extremely high quality pattern layer and coating layer can be obtained by irradiation with ionizing radiation. 5 effects and effects.

et al., 4. A brief description of the drawing.

Figures 1 to 4 are schematic sectional views showing an example of the method for manufacturing a decorative laminate according to the present invention according to the steps; Figures 11 and 4 are sectional views of a transfer sheet; FIG. 3 is a sectional view showing how the base sheet is peeled from the laminate after irradiation with ionizing radiation;
FIG. 4 is a cross-sectional view of the decorative board obtained through the above steps.

1: Base sheet, 2: Pattern layer, 3: Transfer sheet, 4: Decorative board exploitation, 5: Coating layer, 6: Laminated body of transfer sheet and decorative board base material, 1: Decorative board, (N: Transfer sheet side in the laminate 6, 2': pattern layer that has been cured by irradiation with ionizing radiation, 5': coating layer that has been cured by irradiation with ionizing radiation, 6': transfer that has been cured and integrated A laminate of a sheet and a base material for decorative laminate.

Claims (2)

[Claims] (1) A base material for a decorative board having a transfer sheet provided with a pattern layer made of an ionizing radiation-curable composition containing a colorant on one surface of the base sheet, and a coating layer made of the ionizing radiation-curable composition. and the pattern layer opening of the transfer sheet.
The transfer sheet and the decorative laminate substrate (A A method for manufacturing a decorative laminate, comprising: curing and integrating the laminate, and then peeling off the base sheet in the transfer belt from the cured and integrated laminate. (2) In the method for manufacturing a decorative laminate according to claim 1, the transfer sheet to be laminated with the base material for a decorative laminate,
Ionizing radiation containing a colorant on one surface of the substrate
A method for producing a decorative board, which is a transfer sheet provided with a pattern layer made of a curable composition, and in which the pattern layer is partially cured by irradiation with ionizing radiation.