JPS6027584B2 - Decorative sheet manufacturing method - Google Patents

Description

[Detailed description of the invention] The present invention relates to a method for manufacturing a decorative sheet.

Conventional Japanese sheets use a porous material such as paper or synthetic paper as the base material, a pattern is printed on the surface, and after printing, an uncured thermosetting resin layer is applied on one or both sides. It is often manufactured by a method of then curing a Hishiwashi thermosetting resin layer.

When using a porous material such as paper or synthetic paper as the base material,
It has excellent pattern printing, is easily impregnated with thermosetting resin, and has excellent mechanical strength such as tensile strength and tear strength because the thermosetting resin layer is not simply formed in a thin layer on the surface. is obtained. However, when the base material is paper, synthetic paper, etc., its dimensions expand and contract due to the influence of moisture and heat in the air until it is used as a base material after the manufacturing process.
For example, paper expands and contracts by about 0.5 to 3% compared to the dimensions of the actual pot. Due to the size expansion and contraction of the main village of the Q-board sheet, the printed pattern will also expand and contract, and when it is pasted on surfaces such as walls, ceilings, furniture, etc., the continuity of the pattern will not be achieved at the seams of the decorative sheet, resulting in an aesthetically pleasing appearance. There was a risk of damage. The present invention has been made with the aim of solving the above-mentioned drawbacks, and the printed pattern does not expand or contract, and therefore, it is possible to obtain continuity of the pattern at the seam part of the IQ salmon sheet. The purpose of the present invention is to provide a method for manufacturing an IQ-hoko sheet that can be produced easily.

The gist of the present invention is to provide an uncured thermosetting resin layer on at least one side of a porous substrate, and to print a background color or a background pattern before the thermosetting resin layer is completely cured. The present invention provides a method for producing a Y-containing sheet, characterized in that after the thermosetting resin layer is completely cured, a decorative pattern is printed on the surface of the thermosetting resin layer. Next, a method for manufacturing the Ikhoko sheet of the present invention will be explained with reference to the drawings.
1 is a porous base material such as paper, synthetic paper, woven fabric, nonwoven fabric, etc.
2 is an uncured thermosetting resin layer provided on at least one side of the base material 1.

Examples of thermosetting resins include unsaturated polyester resins,
Melamine resins, urea resins, diallyl phthalate resins, urethane resins, etc. are suitable, and are applied in liquid form to at least one side of the substrate 1. Porous base materials such as paper, synthetic paper, woven fabrics, and non-woven fabrics have excellent impregnating properties with thermosetting resins, and some of them are impregnated into the base material 1, becoming integrated with the base material 1 and strengthening the base material 1. It is made into something. The thermosetting resin layer 2 provides the base material 1 with mechanical strength such as tensile strength and tear strength, provides surface hardness, provides dimensional stability, and plays the role of surface protection. In the present invention, the background color or background pattern printing 3 is applied before the thermosetting resin forming the uncured thermosetting resin layer 2 is partially cured but not completely cured.

The ground color is a base color applied to make the decorative pattern print 4 stand out, and the ground pattern is a pattern applied for the same purpose. The reason why the background color or background pattern printing 3 is performed when the thermosetting resin is partially cured but not completely cured is to avoid the adverse effect that the fluidity of the thermosetting resin has on printing, and to avoid the negative effect on the printing, and to perform the background color or background pattern printing. If step 3 is carried out after the thermosetting resin has completely cured, the adhesion of the printing ink will not be sufficient, so it is carried out before the thermosetting resin is partially cured but not completely cured. As the printing ink for applying the background color or background pattern printing 3, one containing a thermoplastic resin is used. As the thermoplastic resin, amide resin, vinyl chloride resin, vinyl acetate resin, styrene resin, nitrile resin, acrylate resin, etc. are suitable, and the thermoplastic resin may be dissolved or dispersed. Since this printing ink contains a thermoplastic resin, even if the decorative pattern printing 4 is applied after the thermosetting resin layer 2 is completely cured, the printing ink for applying the decorative pattern printing 4 is Excellent adhesion. For this purpose, it is preferable that the background color or background pattern printing 3 be applied over as wide a range as possible. Apply background color or background pattern printing 3,
The thermosetting resin layer 2 is completely cured.

In this case, complete curing may be accomplished by leaving the material to stand naturally, or by subjecting it to heat treatment. - When the thermosetting resin layer 2 is completely cured, the base material 1 has excellent dimensional stability,
No expansion or contraction occurs. In the present invention, by completely curing the thermosetting resin layer 2 and stabilizing its dimensions before printing the decorative pattern 4, there is no expansion or contraction of the decorative pattern, and the continuity of the pattern at the joints of the decorative sheet is good. This is what you get.

The decorative pattern printing 4 is applied on the thermosetting resin layer 2 after it is completely cured, and the thermosetting resin layer 2 is printed with a ground color or pond pattern printing 3 using printing ink containing a thermoplastic resin.
By adhering this thermoplastic resin, the printing ink for printing the decorative pattern 4 adheres well, and peeling of the printing ink does not occur.

Note that the printing ink for applying the decorative pattern printing 4 may be of the same type as the background color or background pattern printing 3, or may be of a different type, and therefore does not contain a thermoplastic resin. It's okay. In the present invention, since the background color or background pattern printing 3 and the decorative pattern printing 4 are performed on the surface of the thermosetting resin layer 2, in order to protect this, the thermosetting resin layer 2 is further coated with thermoplastic resin. The printed surface protective layer 5 can be formed of resin or thermosetting resin. The printed surface protective layer 5 is made of, for example, a thermoplastic resin such as an olefin resin, a styrene resin, a vinyl chloride resin, an acrylate resin, or a vinyl acetate resin, an unsaturated polyester resin,
It is formed into a thin layer by applying a liquid thermosetting resin such as melamine resin, urea resin, diallyl phthalate resin, etc. In the present invention, by providing an uncured thermosetting resin layer on at least one side of the porous substrate, a portion of the thermosetting resin is impregnated into the substrate and imparts mechanical strength to the paper.

Furthermore, the thermosetting resin layer is cured and has excellent dimensional stability. Background color or background pattern printing is done before the thermosetting resin is partially cured but not completely cured, so the adhesion of the printing ink is good. Although the decorative pattern is printed after the plastic resin layer is completely cured, the adhesion of the printing ink is improved. Decorative pattern printing is applied after the thermosetting resin layer is completely cured and its dimensions are stabilized, so the decorative pattern printing does not expand or contract, and the pattern continuity at the joints of the resulting decorative sheet is maintained. This sheet is not damaged by expansion and contraction and has an excellent facial appearance. Example 180 days / Using a roll coater, a mixture of uncured unsaturated polyester resin and urethane resin is applied to both sides of the paper 1 having a uniform thickness. It was impregnated with 1.

Naturally hardening the resin layer 2 formed as described above,
Before the resin forming the layer 2 is partially cured but not completely cured, a printing ink containing a polyamide resin is used every 5 days to print a spotted background pattern over the entire surface, Next, the resin layer 2 was heated with hot air to completely cure it. A pattern was printed on the surface of this completely cured resin layer 2 to obtain a decorative sheet. The thus obtained decorative sheet shows almost no dimensional expansion or contraction, either immediately after pattern printing or after a number of days, and dimensional expansion and contraction of 0.25% or less in the vertical and horizontal directions. It was just enough to be recognized.

[Brief explanation of drawings]

Figure 1 is a cross-sectional view showing a state in which an uncured thermoplastic resin layer is provided on one side of paper, Figure 2 is a cross-sectional view showing a state in which background color or background pattern printing is applied, and Figure 3 is a background pattern printing. FIG. 4 is a cross-sectional view showing a state in which a decorative sheet with a printed surface protective layer formed thereon is layered horizontally on a base, and FIG. 5 is a perspective view of the decorative sheet. Explanation of symbols 1... Porous base material, 2... Thermosetting resin layer, 3... Ground pattern printing, 4... Decorative pattern printing, 5...
・Printed surface protection layer. Figure 1 Figure 2 Figure 3 Figure 4 Figure 5

Claims (1)

[Claims] 1. An uncured thermosetting resin layer is provided on at least one side of a porous substrate, and a thermoplastic resin is applied to the thermosetting resin layer until the thermosetting resin layer is partially cured but not completely cured. It is characterized by performing ground color or background pattern printing with the containing printing ink, and after completely curing the thermosetting resin layer, printing a decorative pattern on the surface of the thermosetting resin layer. A method for manufacturing decorative sheets. 2. The method for producing a decorative sheet according to claim 1, which comprises forming a printed surface protective layer made of a thermoplastic resin on the surface printed with a decorative pattern. 3. The method for manufacturing a decorative sheet according to claim 1, which comprises forming a printed surface protective layer made of a thermosetting resin on the surface printed with a decorative pattern.