JPS5930525B2 - Manufacturing method for three-dimensional decorative board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a three-dimensional decorative board having an uneven pattern, in particular, a decorative surface coated with a cross-linked curable resin for forming a decorative layer and a plate-like material transparent to active energy rays. Active energy is applied from outside of the negative plate while facing a plate-like object (hereinafter abbreviated as negative plate) made of an impermeable material and with a space between the negative plate and the decorative surface. The present invention relates to a method for manufacturing a three-dimensional decorative board by irradiating lines to form a decorative surface with a pattern of a negative board.

In recent years, the development of decorative laminates using synthetic resins has progressed rapidly, and they are now being used as extremely convenient materials in many fields.

The demand for high-quality finishes for decorative laminates continues to grow, and the demand for decorative laminates that have the same feel as decorative laminates made from natural wood continues to grow due to their excellent characteristics as decorative laminates. The development of a manufacturing method for so-called three-dimensional decorative boards is underway. Conventionally, various methods of manufacturing decorative laminates having such a structure have been studied.

For example, a method of applying a polymerization inhibitor of a crosslinked curable resin to form a decorative layer on a decorative surface where concave portions are required, or a method of promoting crosslinking of the crosslinked curable resin on a decorative board surface where convex portions are required to be formed. Some methods have been proposed, such as applying a coating agent, but the decorative boards made by these methods have a difference in crosslinking density between the concave and convex parts of the decorative surface, so it is difficult to obtain a coated surface with uniform characteristics. The difficulty is that it is difficult to create decorative laminates with . Another method is to closely adhere a negative plate with a wood conduit pattern to the decorative surface coated with the cross-linked curable resin, irradiate ultraviolet rays from the top surface of the negative plate, and then peel off the negative plate. A method has been proposed in which the surface is cleaned with an alkaline aqueous solution or an alcohol solution to dissolve and remove the uncured resin portion of the decorative surface, but this method has the disadvantage of being an extremely complicated process. It's summery. Therefore, the inventors of the present invention are currently investigating the purpose of obtaining a three-dimensional decorative board with fewer defects as described above, by placing a negative plate with a space on the decorative surface coated with uncured resin, and applying active energy from the outside of the negative plate. The present invention was completed by discovering that a three-dimensional decorative board having an uneven pattern with extremely uniform characteristics can be produced by irradiating the surface with a line.

The present invention will be specifically explained with reference to illustrative drawings.

Figure 1 shows the manufacturing situation of a three-dimensional decorative board, in which a cross-linked curable resin 2 such as unsaturated polyester resin is applied to the surface of a base material 1 such as plywood, stone, plaster board, or particle board to an arbitrary thickness. Apply evenly. An active energy ray transparent plate (negative plate) 5 such as a polyester film or a glass plate, which has a pattern made of an active energy ray opaque material, is placed on top of the crosslinked curable resin 2 in a space 3 as shown in the figure. Create and install. During this installation, the distance of the space 3 between the cross-linked curable resin 2 and the negative plate 5 can be adjusted using the frame 6.
This can be done by Active energy rays such as electron beams or ultraviolet rays capable of curing the crosslinked curable resin may be irradiated from above the negative plate 5 placed on the decorative layer as described above. When carrying out the above-described method of the present invention, the area where the pattern 4 formed of the substance opaque to active energy rays is not attached has a large amount of active energy rays passing through it, so the cross-linked curable resin directly below it is As the crosslinking and curing progresses, a slight curing shrinkage behavior is exhibited and convex portions are formed.

On the other hand, the active energy rays irradiated onto the patterned area 4 of the negative plate are prevented from passing through by this patterned area, so the curable resin layer directly below is not cured and is pulled toward the hardened decorative area. This causes the portion to cave in and form a recess. Fig. 2 is a cross-sectional view of the three-dimensional decorative board formed in this way, and part B is the resin part on the decorative layer corresponding to the pattern attachment part of the negative board; This becomes a recess in the board.

In addition, part A indicates a resin part on the decorative layer corresponding to the part of the negative plate to which the pattern is not attached, and in this part, crosslinking and curing of the resin and curing shrinkage occur to form convex parts. In the method for manufacturing three-dimensional decorative boards, it is extremely important to provide a space between the negative board and the decorative coating layer.

When irradiating active energy rays from the upper surface of the negative plate with no space between the negative plate and the decorative coating layer as in the conventional technology, a crosslinked curing shrinkage phenomenon of the crosslinked part occurs when the resin is crosslinked and cured. The formation of convex portions in the decorative layer and the formation of concave portions in the uncrosslinked portions are not performed at all, and it is necessary to take new means to form concave portions in the decorative layer.However, the method of the present invention Because it has a specific space as described above, it is possible to easily create a three-dimensional decorative board without taking such new measures. FIG. 3 shows a process diagram for continuously manufacturing the three-dimensional decorative board as described above.

In this method, as shown in 5 in Fig. 3, the negative plate is a continuous film or sheet-like material, or a plate-shaped negative plate is placed under an active energy ray irradiation source for making a decorative board. It is preferable to use a device that can be moved while being integrated with the base material. In this method, it is necessary to synchronize the moving speeds of the negative plate and the decorative substrate, and if the moving speeds are not synchronized in this way, it will be difficult to create a decorative board with an aesthetically pleasing uneven pattern. It is necessary to keep this in mind.

In addition, the resin in the concave parts of the decorative board created by this method does not harden, causing a difference in performance between it and the convex parts, so after removing the negative board on the decorative layer, active energy is applied to the decorative surface again. It is necessary to irradiate the wire to harden the recessed portion.

Plywood is most often used as the decorative base material 1 used in carrying out the present invention, but other thin base materials such as particle board, asbestos, concrete, plaster, metal, cloth, film, and sheet can also be used. The uneven pattern formed on these base materials can include not only a conduit pattern of wood but also a stone pattern, a floral pattern, and other geometric patterns.

Figure 3 shows a process diagram suitable for the continuous production of three-dimensional decorative laminates using continuous film-like or sheet-like materials as the base material, and Figure 4 shows a process diagram suitable for continuous production of three-dimensional decorative laminates using continuous film-like or sheet-like materials as the base material. This paper describes a method for continuous production of three-dimensional decorative laminates using such plate-like materials as decorative substrates.

Further, when carrying out the method of the present invention, it is possible to use a decorative base material with a printed paper on which a wood grain pattern or a stone pattern has been printed in advance, and which is adhered to the decorative substrate. By synchronizing the applied pattern with the printed pattern applied to the decorative base material, it is possible to produce plywood with the three-dimensional feel of natural wood, natural stone, etc.

Specific examples of the crosslinked curable resin used in carrying out the present invention include acids such as dicarboxylic acids represented by maleic acid, itaconic acid, and fumaric acid as unsaturated carboxylic acid components, or their anhydrides as main components, and polyol components. Examples include unsaturated polyesters, polyester di(meth)acrylates, and unsaturated vinyl resins obtained by condensing with polyol poly( Polyfunctional compounds such as meth)acrylates, diluents such as styrene, vinyl acetate, and (meth)acrylates may be used in combination as appropriate.

Further, as the negative material, a glass plate, a polyester film, a polypropylene film, etc. can usually be used, but when radiation is used as the active energy source, a radiation-transparent film of aluminum, titanium, etc. can be used. Although it is most convenient to use ordinary photographic development to create patterns on negative plates, other methods such as printing can also be used. When creating a three-dimensional decorative board using the method of the present invention, there is no need to perform complicated processes such as diversification of printing processes and removal of unnecessary resin as in conventional methods, and the resulting cross-linked and cured surface can be partially cured. It is possible to produce a three-dimensional decorative board with extremely excellent properties without any disadvantages such as non-uniform coating properties.

An embodiment of the present invention is shown below.

Using 31u thick veneer plywood as the base material, this base material 1
A decorative paper with a wood grain pattern printed on it using regular ink is adhered with adhesive (vinyl acetate resin: urea resin: 4:1).
A crosslinked curable resin layer 2 is formed by applying an ultraviolet curable polyester resin onto the decorative paper at a coating amount of 150 t/y.

A negative plate 5 having a woodgrain pattern negative is placed on the top of the cross-linked curable resin layer 2 by a frame 6 between the cross-linked curable resin layer 2 and the negative plate 5.
The distance between the two is 2m7F! Set it up so that Next, ultraviolet rays with a main wavelength of 3650λ can be emitted from this negative plate.
When a 0W ultraviolet lamp was installed at a distance of 150 m above the coating surface and irradiated with ultraviolet light for 3 minutes, a three-dimensional decorative board having an uneven pattern as shown in FIG. 2 was obtained.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view explaining the manufacturing situation of the three-dimensional decorative board of the present invention, FIG. 2 is a cross-sectional view explaining the three-dimensional decorative board formed by the method of the present invention, and FIG. A process diagram for continuously manufacturing a three-dimensional decorative board using a sheet-like material as a base material is shown. FIG. 4 shows a process diagram for continuously manufacturing a three-dimensional decorative board using a plate-like material as a base material. 1...Base material, 2...
...Crosslinked curable resin, 3... Space, 4...
...Pattern, 5...Negative board, 6...
Frame, 7... Active energy ray, 8...
Coating device, 9...belt conveyor.

Claims (1)

[Claims] 1. The resin-coated surface of the decorative substrate coated with a cross-linked curable resin and the plate-shaped article that is transparent to active energy rays and has a pattern made of a substance that is opaque to active energy rays are made to face each other, and a space is left between them. A method for manufacturing a three-dimensional decorative board, comprising irradiating active energy rays from the outside of the board while the board is in a suspended state.