JPS6031656B2 - Manufacturing method of polyester decorative material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a polyester decorative material, and relates to a method for producing a polyester decorative material using transfer technology.

Conventionally, various methods for manufacturing polyester decorative materials are known.

A typical method is a method called the film method. In this method, titanium paper printed with a wood grain pattern is placed on a base material such as plywood, coated with an unsaturated polyester resin containing a hardening agent, and then covered with a transparent film such as vinylon film or tetron film. This is a method of obtaining a decorative material by smoothing the surface with a squeegee or the like, allowing the resin to harden naturally or by heating, and then peeling off the film. As other methods, a method called a flow coater method and a method using an ultraviolet curable resin are known.

In the former method, unsaturated polyester resin containing a curing accelerator and unsaturated polyester resin containing a curing agent are coated on a base material such as plywood with a decorative paper made of titanium paper laminated using a flow coater using separate coater heads. coat,
This is a method of curing it and making it into a decorative material. The latter is done by applying an ultraviolet curable unsaturated polyester resin containing a sensitizer onto a base material such as plywood laminated with titanium paper using a gravure coater, roll natural coater, roll reverse coater, etc. This is a method of obtaining a decorative material by irradiating it with ultraviolet rays and curing it.

However, all of these methods use decorative paper printed on titanium paper, and in this case, in order to improve resin impregnation, titanium paper with a low size and poor surface smoothness is used. had to be used.

Therefore, it had a major drawback in that its printing effect was inferior to that of coated paper or plastic films such as vinyl chloride.

In order to eliminate these drawbacks, a polyester resin film layer is provided on the substrate, an ink film is transferred onto it, and an adhesive paint layer is formed as necessary to prevent the film from peeling off on this ink film. A transfer decorative board having a polyester resin film layer provided thereon is known.

However, in this case, the transfer and the surface protection resin layer are performed separately, so the work is complicated.

As a method for solving such complications, a method is also known in which a transfer pattern layer and a surface protective layer are applied at the same time by transfer.

However, in general, such a method requires that the transfer substrate and the transfer sheet be subjected to strong pressure or heating and strong pressure, and the equipment is large-scale and expensive.
Furthermore, since the former is in the form of a plate and the latter is in the form of a film or sheet, the object to be transferred and the surface protective layer are in the form of a film or sheet, so there is a risk of peeling off unless extremely strict control is applied to the adhesive. It has some drawbacks.

The present invention aims to eliminate all of these conventional drawbacks and provide a new method for producing a polyester decorative material by applying a pattern and a surface protection resin by transfer.

In the present invention, it is possible to obtain a polyester decorative material that has further transparency and depth.

In the present invention, Motomura 1 for transfer sheet having mold releasability
A transfer sheet is used, on which a curable resin layer is applied and a desired pattern is applied over the entire surface.

As the transfer sheet substrate 1 having scale-like properties, resin films such as vinylon film, polyester film, polypropylene film, and cellophane film are preferable.

Alternatively, it may be paper, synthetic paper, or a resin film coated with a resin having mold releasability.

However, the resin used in this case may be silicone wax, unsaturated polyester, amino alkyd, etc., or a sheet made by laminating the above-mentioned resin film and paper.
The optimum thickness of the base layer 1 for the transfer sheet is 10 mm to 100 mm.

In the transfer sheet used in the present invention, it is necessary to apply a curable resin layer 2 on the transfer sheet substrate 1. Curable resin layer 2
Examples of resins used include moisture-curing polyurethane resins, thermosetting polyurethane resins, acrylic urethanes, curable acrylic resins such as acrylic melamine, unsaturated polyester resins, and alkyd resins. The curable resin layer 2 must be transparent, and may be colorless and transparent or colored and transparent.

The curable resin layer 2 may be applied to the transfer sheet substrate 1 by any known method, such as gravure coating, roll reverse coating, knife coating, etc.

The thickness of the curable resin layer 2 may be appropriately selected depending on the intended use of the decorative material, its price, the type of resin, etc., but it is generally applied in an amount of about 5 to 5 inches. After the curable resin layer 2 is transferred, it becomes a surface protective layer of the decorative material. A desired pattern is applied over the entire surface of the curable resin layer 2.

This desired pattern is shown as pattern layer 3 in either FIG. 1 or FIG. The desired pattern may be any pattern such as a wood grain pattern, a geometric pattern, a marble pattern, or an abstract pattern. These patterns may be applied by any commonly used method, such as gravure printing, offset printing, letterpress printing, screen printing, transfer printing, hand-printing, and the like. Various types of ink can be used in this case, but ink using ordinary cellulose resin as a binder is common. FIG. 1 shows a sectional view of the transfer sheet used in the present invention obtained as described above.

In the present invention, a curable resin containing polyester resin as a main component is separately prepared on the base material 5 for decorative material.

(8) As the base material 5 for the side material, plywood or wood materials such as particle board, fiberboard such as hardboard or insulation board, inorganic board such as asbestos straight board, calcium silicate board, or gypsum board, etc. It is common to use As the base material 5 for decorative materials, paper, synthetic paper, resin-mixed paper, nonwoven fabric, resin film, etc. may be attached to the above-mentioned plate-like object, or sealer treatment or other pretreatment may be applied as necessary. This can be done in advance. The base material 5 for the Nihonboko material is not limited to the above-mentioned plate-like objects, but may be film-like or sheet-like objects such as paper, synthetic paper, resin-mixed paper, non-woven fabric, resin film or sheet. It's okay.

These plate-like objects, film-like objects, or sheet-like objects may be colored, transparent, or patterned.

In cases where a film or sheet-like material is attached to a plate-like object and it is necessary to hide the surface of the plate-like object, the film or sheet-like material must have opaque concealing properties. Use.

Titanium paper that contains titanium pigments and has good side fat impregnation properties is most suitable as a material that has such hiding properties, but kraft paper, tissue paper, coated paper may also be used, and colored synthetic pulp paper or polyethylene paper may also be used. Plastic films such as can also be applied. In order to attach the film-like or sheet-like material to the plate-like object, conventionally known methods can be used, such as using an adhesive mainly made of vinyl acetate emulsion, which is usually commercially available. good.

A curable resin 4 containing polyester resin as a main component is applied onto such a base material 5 for decorative material. As the curable resin whose main component is polyester resin, unsaturated polyester resin commonly used for polyester decorative boards can be used;
A typical example is a liquid mixture of styrene monomer, methyl ethyl peroxide as a curing agent, and cobalt naphthenate as a curing accelerator. The curing agent and curing accelerator are not limited to those mentioned above, and various combinations are possible depending on the purpose and use.

Organic peroxides are commonly used as curing agents, such as methyl ethyl ketone peroxide, penzoyl peroxide,
Examples include t-butyl perbenzoate, and curing accelerators include cobalt organic salts such as cobalt naphthenate, vanadium-based organic salts, manganese-based organic salts, and tertiary organic salts.
class amines such as dimethylaniline.

Organic salts such as cobalt naphthenate are used in combination with methyl ethyl ketone peroxide, and tertiary amines such as dimethylaniline are used in combination with penzoyl peroxide. The above composition is a thermosetting or room temperature curing polyester resin composition, but it may also be a polyester resin composition that is cured by ultraviolet rays.

Such an ultraviolet curable polyester resin composition is composed of an unsaturated polyester resin, a styrene monomer, a photosensitizer, and the like. As the photosensitizer, generally well-known ones such as penzoin ethyl ether/penzoin methyl ether, benzoin, benzophenone, azobisisobutyronitrile, etc. may be used.

In order to apply the curable resin 4 mainly composed of polyester resin onto the base material 5 for the deck material, a conventionally known method can be used.

The curable resin 4 mainly composed of polyester resin can be opaque, colorless and transparent, or colored and transparent depending on the purpose.

The amount of curable resin 4 mainly composed of polyester resin can be varied depending on various conditions such as the application of the decorative material and the required quality, and is generally between 10 and 50 bits/piece.
Happy.

In the present invention, the base material 5 for decorative material coated with the curable resin 4 mainly composed of polyester resin and the above-mentioned transfer sheet are laminated together.

In this case, it is necessary to overlap the transfer sheet so that it is in contact with the curable resin 4 whose main component is polyester resin, and furthermore, to overlap the transfer sheet while the curable resin whose main component is polyester resin is not yet cured. There must be. In this manner, the curable resin 4 containing polyester resin as a main component is cured while the curable resin 4 containing polyester resin as the main component is brought into sufficient contact with the transfer sheet.

For curing, use a means suitable for the curable resin 4 used. If a thermosetting resin is used as the curable resin 4, it may be cured by leaving it at room temperature or by heating. In the case of using a synthetic material, it is sufficient to irradiate it with ultraviolet rays.

In this case, if the resin is to be cured by irradiation with ultraviolet rays, the transfer sheet substrate 1 needs to be transparent, for example, through which ultraviolet rays can pass. After curing the curable resin 4, only the transfer sheet base material 1 is peeled off, thereby obtaining a polyester IQ fender material.

The pattern layer 3 and the curable resin layer 2 become part of the product.

If the curable resin layer 2 and the curable resin 4 are bonded by reaction, the adhesion between the resins will be improved, and the physical properties of the surface coating film will also be improved.

In this way, the resins can be bonded to each other by reaction in the following manner. Either excess polyisocyanate or prepolymer is added to the curable resin layer 2, and a polyol such as polyester polyol or acrylic polyol is added to the curable resin 4, or vice versa. Alternatively, a polyol such as acrylic polyol is added, and a polyisocyanate prepolymer is added to the curable resin 4. In the former case, the curable resin layer 2 may be a two-part type of polyol and polyisocyanate prepolymer, but may also be made of polyisocyanate alone. Also in the latter case, the curable resin layer 2 is
A two-component type of polyol and a polyisocyanate prepolymer or a polyol alone may be used. Typical polyisocyanate prepolymers that can be used for this purpose include trirediisocyanate (TDI), hexamethylene diisocyanate (
HMDI), xylylene diisocyanate (XDI), etc.

Since the present invention has the above configuration, it has the following effects.

That is, since there is no need to print on titanium paper with poor surface smoothness, a decorative material having an extremely good printed pattern can be obtained.

It is also possible to use titanium paper with a pattern on it, which has poor surface smoothness, as a base material for decorative materials.
The combination of this rough pattern and the delicate pattern created by the transfer makes it possible to obtain decorative materials that are complex and rich in three-dimensionality.

In addition, since the transfer is performed while the curable resin, whose main component is polyester resin, is not yet cured, the transferred pattern will penetrate into the inside of the cured resin, whose main component is polyester resin, depending on the amount of ink applied. Therefore, it is possible to provide a more three-dimensional effect, and there is no need to apply too much pressure during transfer. The pressure may be enough to even out the curable resin whose main component is a resin. In addition, in the present invention, in order to protect the desired pattern, a transparent curable resin layer is applied by transfer, so workability is extremely good, and the resulting decorative material is coated with a curable resin. Because of this, it has excellent abrasion resistance, scratch resistance, chemical resistance, stain resistance, etc.

The decorative material obtained by the present invention can be used as a high-grade surface for interior building materials, furniture materials, cabinet materials, etc., or for decorative interior decoration using asbestos slate boards and calcium silicate boards, which are noncombustible or semi-noncombustible materials. By changing the type of base material and other conditions, the application can be applied to a very wide range, such as being applicable as a decorative material around bathrooms and kitchens as a tile.Examples of the present invention will now be described.

<Example 1> A vinylon film with a thickness of 50 cm was gravure coated with acrylic urethane resin in a ratio of 1/2, then multicolor gravure printing was performed using gravure ink mainly composed of nitrocellulose resin, and a transfer sheet was applied. Created.

In this case, acrylic urethane resin and gravure printing were performed continuously using the same printing machine. Separately, 8 sheets/piece of colored titanium paper was laminated to a 3-thick plywood board using an adhesive mainly made of polyvinyl acetate, and then a resin composition of the following composition was applied on top of the 40 sheets/piece of colored titanium paper.
After applying the final coat and pasting the transfer sheet to the frame while the resin composition is uncured, the resin composition surface is evenly coated after being overlaid so that the printed surface and the uncured resin composition are in contact with each other. After the resin composition was allowed to harden for 30 minutes, the vinylon film was peeled off to obtain a decorative board to which the printed pattern and acrylic urethane resin had been transferred.

This decorative board passed the JAS special plywood FW type standard with excellent thinner resistance, abrasion resistance, and scratch resistance.

Resin composition Unsaturated polyester resin 10 parts by weight Styrene monomer 10'' methyl ethyl ketone peroxide 2 Cobalt naphthenate
1 <Example 2> Example 1 was applied to a transparent polyester film with a thickness of 25 cm.
Apply urethane alkyd resin to the drum/eye in the same manner as above.
Then, of the wood grain pattern, only the conduit portion was printed with opaque ink, and the other portions were printed with transparent ink to prepare a transfer sheet.

Paste this transfer sheet in a frame. Furthermore, 55 g of colored titanium paper was adhered onto the plywood substrate using an adhesive, and a resin composition having the composition shown below was applied thereon in 20 coats.

Resin composition Unsaturated polyester resin 10 parts by weight Methyl ethyl ketone/gu oxide 1 Cobalt naphthenate 0.5'' penzoin ethyl ether (photosensitizer) 3 While this resin composition is uncured A transfer sheet was placed on top of this using the same method as in Example 1, and after making the resin composition surface uniform, it was irradiated with ultraviolet rays for 3 hours using a high-pressure mercury lamp of 80 W/2 to make the resin composition. After curing, the polyester film was peeled off to obtain a decorative board.

This product had the same performance as the decorative board of Example 1, and had a surface in which the conduit portion of the wood grain was sunken.

<Example 3> A colored hard vinyl chloride film containing 8 parts by weight of a plasticizer was adhered onto a particle board having a thickness of 1 inch using an acrylic emulsion adhesive.

On top of this, an ultraviolet curable acrylic resin was applied in five coats. While this resin was hardening, a transfer sheet similar to that used in Example 1 was used to overlap the resin surface in the same manner as in Example 1, and then the same transfer sheet as that used in Example 2 was used. After the ultraviolet curable resin was cured by irradiation using the same high-pressure mercury lamp as described above, the acrylic urethane resin used as the base material for the transfer sheet was peeled off to obtain a sun-dried plate. In this case, the polyisocyanate prepolymer in the resin composition on the transfer sheet and the acrylic polyol in the acrylic urethane resin used on the base material react, increasing the adhesive strength and durability of the surface resin film on the surface of the key slope. It satisfied the physical properties of the surface coating film, such as abrasion resistance, scratch resistance, and solvent resistance, and also had V-cut suitability, so it could be used as a decorative board for cabinets.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view of a transfer sheet used in the present invention, and FIG. 2 is a cross-sectional view showing a state in which the base material for the transfer sheet is peeled off after curing the resin. DESCRIPTION OF SYMBOLS 1...Motomura for transfer sheet, 2...Curable resin layer, 3...Pattern layer, 4...Curable resin, 5... ...Base material for cosmetic materials. Figure 1 Figure 2

Claims (1)

[Claims] 1. A curable resin layer 2 is provided on a transfer sheet base material 1 having mold releasability, and a desired ink having permeability to an uncured curable resin containing a polyester resin as a main component is applied on the curable resin layer 2. A transfer sheet having a pattern layer 3 of Apply the curable resin 4 to the pattern layer 3 of the transfer sheet.
The curable resin layer 2 and the curable resin 4 are reacted and bonded to each other through the pattern layer 3, and then subjected to a desired curing treatment, and then only the base material 1 for the transfer sheet is formed. A method for producing a polyester decorative material, which comprises peeling off.