JPS6018468B2 - Decorative material manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a three-dimensional decorative material having surface irregularities.

Decorative materials used as materials for interior decoration, furniture, cabinets, etc. have recently become sophisticated and complex, with surface decorations and three-dimensional effects, and there has been a demand for novel aesthetic effects.

In response to this trend, attempts have been made to manufacture three-dimensional decorative materials through various legislations.

For example, there is a method of manufacturing a three-dimensional decorative material by combining embossing and printing to provide an embossed pattern on the surface of a base material that matches the printed pattern. However, in the above method, it is extremely difficult to match the uneven pattern provided by a mold roll or template with any pattern on the decorative base material. Decorative materials were manufactured that were not consistent with the standard, and the quality was extremely unstable.

Furthermore, in the above method, it is extremely difficult to manufacture a mold roll or a template that can provide unevenness of any shape that matches the arbitrary pattern on the decorative base material, and therefore the manufacturing cost is extremely high. It was something. Furthermore, the above-mentioned method has the disadvantage that it is difficult to express molds with minute and complicated shapes and is limited to relatively simple molds, which limits the types of products that can be manufactured. For example, there is a method of manufacturing three-dimensional decorative materials by using silk screen printing to form a synchronized embossed pattern by making the areas without the printing ink layer into concave parts and the areas with the printing ink layer into convex parts. be. However, in the above method, since silk screen printing is used, the printing speed is slow, and there are problems with workability and inline suitability.

Furthermore, a large amount of ink is used, which increases the cost of the product. In addition, gauze may appear on the printed matter or bulges may appear on the edges, deteriorating the empos design. The inventors of the present invention took into account the shortcomings of the conventional methods and conducted intensive research into a method for producing decorative materials with surface irregularities.The inventors of the present invention have conducted intensive research into methods for manufacturing decorative materials with surface irregularities. The present invention was based on the discovery that it is possible to produce a three-dimensional decorative material rich in three-dimensional effect and photorealism by forming recesses in the softened parts by maintaining a softened state in some parts and cooling the other parts by means of a method. completed.

That is, the method for producing a decorative material of the present invention includes a step of applying a paint containing a thermoplastic resin to the surface of a base material.

b. A step of solidifying the resin to form a coating layer.

c. A step of softening the coating layer by heating it to a temperature higher than the softening temperature of the resin.

d A step of selectively heating a part of the softened coating layer to keep it in a softened state, while cooling and solidifying the other part to form a recess in the softened part.

e. A step of solidifying the softened portion of the coating layer to fix the recessed portion.

It is characterized by including.

Hereinafter, the above-described present invention will be described in detail with reference to the drawings as necessary.

First, as the substrate used in the present invention, any base material such as plastic, metal, wood, paper, inorganic material, glass, etc. can be applied, and the selective heating means for the coating layer should be selected according to the base material. do it.

Furthermore, there are no restrictions on the shape of the base material; it may be flat, curved, or multifaceted, and a coating method and selective heating means suitable for the shape may be used. A printed layer can be provided on the surface of the base material prior to providing the coating layer.

The printing layer can be provided by various printing methods using ink appropriately selected depending on the material, shape, etc. of the base material. For example, methods such as gravure, offset, screen, offset gravure, and flexo are applied. In this case, a method of creating a transfer sheet by the same means and performing transfer printing using this can also be applied. Next, a paint is applied to the surface of the substrate with or without the printing layer.

Various types of paints containing thermoplastic resin as a main component can be applied to the paint. In addition to the above-mentioned resin, the above-mentioned paint includes a solvent, and if necessary, a colorant such as a pigment or dye, a plasticizer, a stabilizer, a desiccant, an auxiliary desiccant, a curing agent, a thickener, a dispersant, a filler, etc. Alternatively, a material to which a matting agent, rust preventive, reinforcing agent, etc. are added is applied. For example, alkyd resin paints, vinyl acetate resin paints, vinyl chloride resin paints, acrylic resin paints, and various other emulsion paints.
Examples include various water-soluble paints. The above paint can be applied to the surface of the base material using known methods such as brush coating, air spray coating, airless spray coating, electrostatic coating, powder coating, bar coating, air knife coating, roll coating, curtain floating, or dipping. method can be applied. After applying the above paint, methods for solidifying (hardening) the above resin to form a coating layer include evaporative drying, thermal combination curing, catalytic polymerization curing, catalytic polymerization curing, cooling drying after melting, and swelling gelling drying. , radiation or ultraviolet light polymerization curing, and other known methods can be applied.

The coating layer preferably has a thickness of about 5 to 300 mm. As a heating method for softening the coating layer by heating it to a temperature higher than the softening temperature of the resin, microwave heating or the like can be used in addition to the known heater heating.

Next, a part of the softened coating layer is selectively heated, preferably at a temperature higher than the softening temperature of the resin, to keep it in a softened state, and other parts are cooled and solidified (hardened) to form the softened part. A recess is formed in the area. Methods for cooling and solidifying (hardening) parts other than the selected heating parts mentioned above include natural air cooling,
Known methods such as forced air cooling, cooling body contact, and solvent volatilization curing can be applied. The principle of forming recesses in the coating layer in the present invention is to partially maintain the softened state or partially delay cooling when the softened coating resin is cooled and solidified (hardened). The solidification of the paint (
This can be thought of as creating a difference in curing speed.

As shown in the first diagram, a coating layer 2 is applied to a substrate 1 and formed by a known method such as heating, dissolving and volatilizing, and the coating resin is softened by heating.

Thereafter, a portion 3 of the softened coating layer 2 is selectively heated by a selective heating means to maintain the softened state, and the other portion is cooled and solidified (hardened). , is pulled by the surrounding solidified portion, and the softened portion 3 becomes a recess 4 as shown in the second figure. This depression phenomenon due to shrinkage of the peripheral portion can also be observed, for example, when unsaturated polyester resin is cured by ultraviolet rays. In the present invention, by partially changing the solidification rate of the softened resin using selective heating means, a concave phenomenon is caused by shrinkage of the surrounding area, which is a constant and easy method for forming concave portions, and is applied to Japanese salmon materials. It is something to do. Various means can be applied as selective heating means in the present invention.

For example, first, heat ray irradiation to the patterned heat ray absorber, second, pattern drawing with active energy rays, third, contact heating from the non-coated surface, and fourth, matching the absorption maximum of the color of the pattern. Irradiation with monochromatic light having a peak wavelength of Note that the means for selective heating is not limited to the above-mentioned means, and many other means can be applied. The above four preferred methods will be explained in more detail.

First, in the first method, as shown in FIG. 3a, a desired pattern 5 containing a heat ray absorbing agent is formed on at least part of a printed matter (not shown) on a base material 1 using a known painting method. A part of the coating layer 2 corresponding to the pattern is formed by forming a coating layer 2, softening it, and then irradiating the entire surface with a thermophobic image 6 from above the coating layer 2. By selectively heating, recesses 4 corresponding to the pattern 5 are formed as shown in FIG. 3b. In this case, it is desirable that the paint used be a clear paint, and if pigments are added, the film thickness must be reduced. Moreover, when the base material is a transparent layer, irradiation can be performed from the back surface of the base material. The heat ray absorbers used here include, in addition to black or clear coloring agents such as carbon black, heat ray absorbing vehicles such as polyvinylidene chloride, Phiro 04, Mpu 02, Sn○, Fe○, etc. metal oxide, Mg
Colorless or light-colored heat-absorbing substances such as metal salts such as F2, COTi03, and AgAs03, and organic compounds such as aromatic ketones, aromatics, amines, aromatic amides, and fatty acid amides can be used. Here, as a heat ray source for irradiating heat rays, infrared rays are most preferable, and filament lamps, discharge lamps, arc lamps, flashing light bulbs, etc. are used.

Furthermore, in the present invention, in order to perform selective heat absorption heating by utilizing the difference in heat absorption rate between the pattern formed by the ink containing the heat ray absorber and other areas, it is desirable that the wavelength of the infrared rays is long, and the wavelength of the infrared rays is preferably long. Infrared region (wavelength 0.8-2.
Ideally, a light source has a spectral distribution in the range of 1.0 fd), with a particularly large peak in the spectral distribution around 1.0 fd. Specifically, a tungsten filament lamp, a halogen gas filled lamp, a xenon discharge lamp, etc. can be used. In the second method, as shown in FIG. 4a, a coating layer 2 is formed on the base layer 1 and then softened, and then a desired pattern is drawn using active energy rays 7 from above the coating layer 2. As a result, a part of the coating layer 2 is selectively heated to form a recess 4 as shown in FIG. 4b. In order to form deep recesses, the paint is preferably a clear paint. The active energy rays used here include visible light, infrared rays, ultraviolet rays, laser light, and electron beams.
In particular, a material with a high energy density is desirable, and a focused laser beam, an electron beam, etc. are suitable. Further, as a pattern drawing method, a method of providing a mask pattern on the coating layer can also be used. In the third method, as shown in FIG. 5a, a coating layer 2 is formed using a base material 1 with high thermal conductivity, and then softened, and then a heating element 8 is partially attached to the back surface of the base material 1. Selectively heat a part of the coating layer 2 by contacting it with heat,
A recess 4 is formed as shown in FIG. 5b. According to this method, the recess 4 can be easily formed by simply attaching the heating element 8 to the conveying device for the base material 1. In the fourth method described above, as shown in FIG. 6a, a desired pattern 9 is previously provided on at least a part of the print layer (not shown) on the base layer 1 by a known painting method, and the coating film layer is 2, softened, and then irradiated from above the coating layer 2 using monochromatic light 10 having a peak wavelength that coincides with the absorption maximum of the color of pattern 9, thereby forming a coating film corresponding to pattern 9. A part of the wafer is selectively heated to form a concave portion 4 in conformity with the pattern 9.

In this method, the paint is desirably a clear paint, and if pigments are added, the film thickness must be reduced. In the present invention, when the coating layer is in a soft state,
After selectively heating a part by various means and cooling the other part to form a recess in the heated part, the softened part of the coating layer is solidified to fix the recess. Manufactures decorative materials.

Various known means such as natural air cooling, forced air cooling, and contact with a cooling body can be applied to solidify the softened portion. As is clear from the above description, according to the method of the present invention, a decorative material having surface irregularities and rich in three-dimensional effect and photorealism is bound by extremely simple means. The decorative materials obtained according to the present invention can be used in various applications, for example, as interior materials for buildings, wheels, ships, etc., furniture, tables, and even cabinets and panels for various home appliances. . Hereinafter, the present invention will be explained in more detail with reference to Examples.

Note that "parts" in the following text indicates "parts by weight." Example 1 A cold-rolled steel plate having a thickness of 0.6' and electrogalvanized was used as the base material, and the surface treatment was performed by degreasing, washing with chromic acid, washing with water, and drying.

Next, an adhesive mainly composed of a phenolic vehicle was applied using a roll coater and subjected to a heating treatment at 200 qo for 2 minutes. Next, a brown sol paint consisting of the following composition was applied using a flow coater.
The gel was heated at 0° C. for 2 minutes to form a 25K coating film.

Next, using an ink composed of polyvinyl chloride sol, a wood grain pattern was applied to the entire surface using an offset gravure printing machine. After the fingertips were dry, a conduit pattern was printed on an offset gravure printer using the same ink containing 10% carbon black. After drying to the touch, a clear paint having the following composition was applied using a curtain flow coater.

Gel by heating in a hot air drying oven at 15,000 ℃ for 2 minutes, 3
A coating film of 5 Buddhas was formed. Next, an ultra far infrared heater (
200V-Kitsune W) were heated at a transport speed of 5 m/min to soften the resin, and then immediately heated using 5 tungsten filament lamps (200V-Kitsune W) at a irradiation speed of 5 m/min. When the entire surface was irradiated with infrared rays and simultaneously air-cooled using a blower, recesses that matched the conduit pattern were formed in the clear paint layer.Afterwards, when the recesses were air-cooled, a three-dimensional decorative material was obtained. Example 2 Using a stainless steel plate with a thickness of 0.6 m/skin as the base material,
After pretreatment by degreasing, water washing, and drying, the steel plate was preheated and a mixed powder of polyvinyl chloride/epoxy resin was sprinkled on it.

The resin was melted and softened in a hot air oven (200 oooh - 10 minutes), cooled to form a uniform film, and then further heated to soften the resin, and a conveyor chain with patterned protrusions was brought into contact with it from the back side. .

Since the chain was heated in a hot air oven, contact from the back side kept the patterned part softened and hardening of this part was delayed, while other parts cooled and solidified, forming recesses that matched the protrusion pattern.

When the softened portion was further air-cooled, a decorative material with excellent three-dimensional properties was obtained. Example 3 A transparent polyvinyl chloride film with a skin thickness of 0.1 was used as the substrate.

First, an abstract pattern was gravure printed using ethyl cellulose ink containing a heat ray absorbent MgF2 (magnesium fluoride). After drying, a milky white acrylic resin paint was roll coated and heated at 20,000 for 2 minutes to form a film, which was then softened by reheating at 150q0 for 2 minutes.

When the paint film was in a softened state, we irradiated the entire surface with near-infrared rays from the back side of the film using a tungsten filament lamp, and the abstract pattern remained in a softened state, while other parts were cooled and solidified, so the concave parts that matched the abstract pattern became milky white acrylic. When it was formed on a resin paint layer and the softened portion was further cooled and solidified, a three-dimensional decorative material with an abstract pattern emerging in the recesses and a deep synchronized embossed design was obtained. Example 4 A plywood treated with sealing was used as a base material, and after undercoating with a roll coater, multicolor printing was performed using an offset gravure printing machine.

After that, it was roll coated with acrylic emulsion paint. After forming a film by heating at a low temperature, it is heated further to soften it, and while it remains in a depressed state, C is focused with a lens.
A pattern was drawn with 02 laser light (50W). Horizontal and vertical deflectors were used for drawing, and the drive circuit was controlled by a computer. The pattern part remained in a softened state, and the other parts were naturally cooled and hardened, so that the pattern part formed a recess. Furthermore, when the laser light irradiation was stopped and the softened portion was allowed to cool naturally, a convex snake wood with a rich three-dimensional effect was obtained.

[Brief explanation of the drawing]

FIGS. 1 and 2 are schematic cross-sectional views showing before and after forming the recesses in the coating layer in order to explain the principle of forming the recesses in the coating layer in the present invention, and FIGS. 3 to 6 respectively show the selective heating in the present invention. FIG. 3A is a schematic cross-sectional view conceptually showing an example of the means, with FIG. DESCRIPTION OF SYMBOLS 1... Base material, 2... Coating film layer, 4... Recessed part, 5... Pattern containing a heat ray absorber, 6... Heat ray, 7... Active energy ray, 8... Heating element , 9...pattern, 1
0...Monochromatic light. Figure 1 Figure 2 Figure 3 (0) Figure 3 (b) Figure 4 (o) Figure 4 (b1 Figure 5 (0) Figure 5 (b) Figure 6 (0) Figure 6 (b)

Claims (1)

[Scope of Claims] 1. A method for producing a decorative material, which includes the following steps. a. A process of applying a paint containing a thermoplastic resin to the surface of the base material. b. A step of solidifying the resin to form a coating layer. c. A step of softening the coating layer by heating it to a temperature higher than the softening temperature of the resin. d A step of selectively heating a part of the softened coating layer to keep it in a softened state while cooling and solidifying the other part to form a recess in the softened part. e. A step of solidifying the softened portion of the coating layer to fix the recessed portion. 2. The method for producing a decorative material according to claim 1, wherein a printing layer is provided on the surface of the base material before step a. 3 At least a part of the printing layer contains a heat ray absorber, and in the previous step d, the entire surface of the coating layer is irradiated with heat rays to selectively remove the portion of the coating layer containing the heat ray absorber. A method for producing a decorative material according to claim 2, which involves heating. 4 In step d, the coating layer in the pattern portion is selected by irradiating the coating layer with monochromatic light having a peak wavelength that matches the absorption maximum of the color of the pattern constituting at least a part of the printing layer. 2. A method for producing a decorative material according to claim 2, wherein the decorative material is heated at 5. The method for producing a decorative material according to claim 1 or 2, wherein the selective heating in step d is performed by drawing a desired pattern with active energy rays. 6. The method according to claim 1 or 2, wherein a material with high thermal conductivity is used as the base material, and the selective heating in step d is performed by partially contacting a heating element with the back surface of the base material. A manufacturing method for decorative materials.