JPS6040400B2 - Transfer sheet and method for manufacturing decorative board using the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing an inorganic decorative laminate mainly used as an interior or exterior material for construction, and a transfer sheet to be used. In addition, by preparing a transfer sheet with a colored pattern using a water-based ink that matches the above, and peeling off the transfer sheet after curing the hydration-curable material in contact with the unevenness and the colored pattern surface, The purpose is to provide the surface of the inorganic decorative board formed by hardening with an uneven pattern and a colored pattern that is synchronized with the uneven pattern and penetrates into the surface layer.

In recent years, in order to meet the increasing demand for non-combustibility or flame-retardant properties of building materials, various non-combustible or flame-retardant materials, mainly inorganic materials, have been developed and proposed.

The surfaces of these materials are painted to enhance their decorative effect and increase their utility value. Conventionally, a simple thermal transfer method, a direct printing method, a kneading method, etc. have been used to decorate such materials. However, it is extremely difficult to apply pictures to hardened inorganic materials using thermal transfer or direct printing methods, and the resulting designs are completely flat, with no depth similar to that of natural materials. I can't get the flavor or taste. Further, in the case of the kneading method, there are drawbacks such as difficulty in predicting the finish and poor reproducibility of the pattern. Therefore, neither method is suitable for industrial production and cannot be said to be a fully satisfactory method. As a result of various studies in order to solve the above-mentioned drawbacks, the present inventors have developed a composition containing as main components a coloring agent and a binder, at least one of which is water-soluble, on one surface of a base sheet. A transfer sheet having an arbitrary pattern layer according to the method is laid down so that the surface of the transfer sheet without the pattern layer is in contact with the inner surface of a mold, and then a hydration-curing material is poured into the mold and cured, We have proposed a method for producing architectural decorative laminates, which involves demolding and peeling off the base sheet (see Japanese Patent Laid-Open No. 52-52965).

When this method is used, the colored pattern on the transfer sheet is water-soluble, so when the hydration-curable material is poured and cured, the colorant penetrates into at least the surface layer of the decorative board formed by curing and is integrated with it, creating a deep layer. It is possible to form colored patterns. The present invention relates to improvements in the manufacturing method of decorative laminates.

That is, although the colored pattern obtained by the above-mentioned method has depth, if the face plates forming the pattern are flat, the fender effect is also limited. The transfer sheet used in the above method is thin and has a certain degree of shape-following ability, so if you give an uneven pattern to the surface of the formwork on which the transfer sheet is laid in advance, you can create a decorative surface consisting of a colored pattern and silk with an uneven pattern. You can give it to the review board. However, the colored pattern and uneven pattern given in this way are given positionally independently, and although they have a certain combined cosmetic effect, the so-called so-called There is no way it can match the design effect of a synchronized embossed pattern. Furthermore, it is almost impossible to reproduce fine uneven patterns. As a method for providing a decorative board consisting of a combination of an uneven pattern and a colored pattern layer, there is also a method disclosed in Japanese Patent Laid-Open No. 53-108115, which was also developed by the present inventors.

In this method, the transfer sheet itself having an aqueous colored pattern is formed into a mold by vacuum forming or pressure forming. Therefore, an uneven pattern can also be provided at this time, and the formed unevenness is transferred to the decorative surface when the cured material is cured. However, even with this method, it is not possible to achieve synchronization between the unevenness and the colored pattern, and it is difficult to form minute and sharp uneven patterns using vacuum forming or pressure forming, and there are also restrictions on the dimensions of the formed transfer sheet. occurs. The present invention provides a method for manufacturing a decorative board having a synchronized embossed pattern, which is different from the method for manufacturing a decorative board described above.

As a result of further research, the present inventors found that in the above-mentioned method for manufacturing decorative laminates, a relatively thin transfer sheet is used from the viewpoint of the EO printing characteristics of the transferred pattern and the characteristics of laying it on the formwork. We focused on the fact that it is not necessary for the transfer sheet to be thin from the viewpoint of curing the Japanese-cured material and transferring the colored pattern. Even if the printing characteristics of the colored pattern on the transfer sheet are slightly degraded, the transfer sheet should be thick enough to give the uneven pattern of the desired depth, and a water-based colored pattern that is in sync with the uneven pattern should be applied to the transfer sheet in some way. It was concluded that if the transfer sheet could be formed by this method, a decorative board having a synchronized embossing pattern could be obtained using such a transfer sheet. Thus, the present inventors succeeded in producing a transfer sheet having such characteristics and completed the present invention. Therefore, the transfer sheet for cosmetic production of the present invention is provided on one side of a base sheet with an uneven pattern and a colored pattern layer containing a coloring agent and a binder, at least one of which is water-soluble, in synchronization with the uneven pattern. It is characterized by this. In addition, the method for producing an inorganic decorative board of the present invention includes preparing the above-mentioned transfer sheet, laminating a hydration-curable base material so as to be in contact with the surface of the transfer sheet on which the uneven pattern and the colored pattern layer are provided, and curing it. Thereafter, the transfer sheet is peeled off to impart an uneven pattern to the surface of the cured product that was in contact with the transfer sheet, and a colored pattern that is in sync with the uneven pattern is transferred. Hereinafter, the present invention will be explained in more detail with reference to the drawings as necessary.

FIG. 1 and FIG. 2 are cross-sectional views showing the most basic configuration example of the transfer sheet of the present invention.

The transfer sheet of the present invention has a colored pattern layer 3 on one side of the base sheet 2 that is synchronized with the uneven pattern, but when the colored pattern layer 3 is formed on the convex portions 4 of the base sheet 2 (FIG. 1)
and when it is formed in the recess 5 (FIG. 2). The base sheet 2 may be a known material, such as various papers, synthetic papers, processed papers, synthetic resin sheets, or laminates thereof, which can be embossed by the method described below. .

Among these, foamed resin sheets are preferred. Although the thickness of the base sheet depends on the desired degree of unevenness, it is preferably in the range of 0.5 to 10 Yanagi in the convex portions, taking into account printing characteristics. The colored layer 3 contains a coloring agent and a binder, at least one of which is lagoonal (it does not exclude cases in which it consists only of a colorant and a binder).

These coloring agents and binders are
There is no particular difference from those described in Japanese Patent No. 965 to No. 53-168115.

That is, dyes or pigments can be used as colorants.

Examples of the dye include direct dyes, acid dyes, basic dyes, acidic soot dyes, reactive dyes, and disperse dyes.

For example, Chrysamine G (C.1.22250) * Alizarin Yellow & S (C.1.1055) * Alizarin Skypur-B (C.1.62105) * Palatin Chrome Red RX (C.1.22275) * Anthraquinone Violet ( C.1.61710, 61
800) ※※Alizarin Saphirol (C.1.63
010) ※※ Alizarin Le Nord R (C.1.8
215) ※※ and methylene brake (C.1.520
15) *Can be used [*...Water-soluble:
※※・・・・・・Water-insoluble]. As the pigment, inorganic pigments and organic pigments can be used.

Examples of inorganic pigments include calcium carbonate (C.1.
77220), clay (C.1.77005), talc (C.1.77718), titanium white (C.1.7789)
1), carbon black (C.1.77265), barium sulfate (C.1.77120), yellow lead (C.1.77)
600), cadmium yellow (C.1.7719)
, Chrome Vermilion (C.1.77605), Cadmium Red (C.1.77202), Navy Blue (C.1.7)
7510, 77520), ultramarine (C.1.77007)
, iron oxide (C.1.77491) and alumina white (C.1.77002).

[These inorganic pigments are water-insoluble]. As an organic pigment, Lake Red 4R (C.1.12120)*
* Fast Yellow G (C.1.13015*, 4
0000*) and Penzidine Yellow G (C.1.
21090) ※※ Azo pigments such as Lake Red C
(C.1.1558) ※※※ Rake Red D (C.
1.15560) ※※※ Brilliant force - let (
C. Azoleki pigments such as Brilliant Carmine (C.1.15800)※※ and Brilliant Carmine (C.1.15850)※※※※: Phthalocyanine Fluor (C.1.74160)
※※ and phthalocyanine green (C.1.742
Phthalocyanine pigments such as 60); Industhrene Violet RH (C.1.73385) ※※Industhrene Direct Black B (C.1.65230) ※
*Indus Rembriant Orange GR (C.1.7
1105) ※※Industhrene Brown BR (C.1.
70800) ※※Industhlen Scarlet RB (C
．． 1.71135) ※※Industhrene Orange RRT
(C.1.59705) ※※Industhrene Orange R
RTP (C.1.59705)** and Alizarin
Strenic pigments such as Lake (C.1.58000)※※; Sinclairsia Red (C.1.46500)※※
Quinacridone pigments such as PV Fast Violet BL (C.1.51319)** Dioxazine pigments such as Green Gold (C.1.12775)*
*Azochelate pigments such as quinoline yellow (C
．． Acidic dye lake pigments such as Auramine Lake Yellow (C.1.47005)*; Basic dye lake pigments such as Auramine Lake Yellow (C.1.41000)*; Naphthol Yellow S (C.
．． Nitro-based pigments such as 1.10316)*; other examples include architectural dye-based pigments, soot-beam dye-based pigments, and nitroso-based pigments.

[※...Water-soluble;※※......Water-insoluble:※※
※...Slightly soluble in water; ※※※※...Soluble in hot water]. Binding agents include dextrin*, pork*, casein**, shellac**, gum arabic**, starch**, protein**, polypinyl alcohol*, polyacrylic acid amide*, sodium polyacrylate*, Polyvinyl methyl ether*, copolymer of methyl vinyl ether and maleic anhydride*, copolymer of vinyl acetate and itaconic acid*, polyvinylpyrrolidone*, or cellulose*
, acetylcellulose※※, acetylbutylcellulose※※, nitrocellulose※※, ethylcellulose※※,
Ruboxymethylcellulose*, Methylcellulose*,
Cellulose derivatives such as hydroxyethylcellulose* and hydroxypropylcellulose can be used alone or in combination. 〔※······Water soluble;※※···
...Water-insoluble). The pattern layer 3 contains at least one of the above-mentioned colorants and binders selected to be water-curable, but in addition to these, known additives such as various plasticizers, Wax/grease, petrolatum, desiccant, auxiliary desiccant, surfactant, filler, etc. can be included. Such a pattern layer 3 is produced by mixing and kneading the above-mentioned coloring agent, binder, and optional additives with water, water-alcohol/alcohol, a solvent such as methyl ethyl ketone, and a diluent, etc. to produce an ink composition. death,
Next, one side of an arbitrary base sheet is coated with the ink composition obtained by the user using a conventional printing method such as gravure printing, offset printing, letterpress printing, or silk screen printing, or by a conventional drawing method. It can be provided by printing or drawing an arbitrary pattern in a single color or in multiple colors. The colored pattern layer 3 has a thickness of, for example, 0.1
~200 parts/day (dry value), of which 10 parts by weight (parts by weight, the same hereinafter) of the binder and 1 part of the colorant.
-500 parts.

When forming the colored pattern layer 3 by printing, if the base sheet 2 is a synthetic resin sheet or synthetic paper,
In order to improve printability, it is preferable to perform a primer treatment on the substrate in advance, such as by applying the water-soluble binder described above in an amount of, for example, 1 to 10 coats/force (dry value).

Next, a method of forming a concavo-convex pattern in synchronization with the colored pattern layer 3 as shown in FIG. 1 or 2 will be explained.

First, the simplest method is to emboss the Subaki sheet material that forms the base sheet described above by embossing or selectively promoting or suppressing foaming of a foamable resin sheet to form a base sheet 2 with irregularities. If a colored pattern layer 3 made of the aqueous ink composition is printed on only the convex portions of the transfer sheet, a transfer sheet as shown in FIG. 1 is obtained.

Such selective printing can be performed by any printing method by adjusting the printing pressure to, for example, 0.1 to 10k9/c depending on the degree of unevenness. However, more preferably, a coating-type accelerator or inhibitor that selectively promotes or inhibits foaming of the foamable resin sheet is added to the same surface of the foamable resin sheet together with the aqueous ink composition that provides the colored pattern layer 3 described above. A method of obtaining a transfer sheet as shown in FIG. 1 or 2 by printing on a sheet and then foaming the foamable resin sheet is being explored.
For example, in order to obtain a transfer sheet corresponding to the one shown in FIG. 1, as shown in FIG. As shown in FIG. A foaming accelerator layer 9 is formed on the resin layer 2a at the portion where the convex portion is to be formed.
, If necessary, one layer of Brimmer and the transfer water-based colored pattern layer 3 are sequentially formed on the areas where the convex parts are to be formed; or, as shown in FIG. ,
A method of directly forming an aqueous colored pattern layer 3a containing a foaming accelerator or placing any of the obtained laminates shown in FIGS. In the figure, illustrations of the base sheet 6, foaming inhibitor layer 7, primer layer 8, foaming accelerator layer 9, etc. are omitted).

Furthermore, in order to obtain a transfer sheet corresponding to that shown in FIG.
If necessary, a primer layer 8 and a transferable colored pattern layer 3 are sequentially formed in the areas where the recesses are to be formed (Fig. 6). A agent layer 7, a primer layer 8 if necessary, and a transferable colored pattern layer 3 are formed in the areas where recesses are to be formed (FIG. 7).
Alternatively, a transferable colored pattern layer 3b containing a foaming inhibitor is immediately formed on the portion of the foamable resin layer 2a where the recesses are to be formed (see FIG. 8). A method of subjecting any of the laminates of FIG. 8 to foaming conditions is explored.

To explain the materials of each part, the base material 6 includes woven fabrics such as cotton and hemp; or woven and nonwoven fabrics made of fibers such as nylon, rayon, polyester, and glass; paper, and paper-made paper such as asbelt paper;
Alternatively, a heat-resistant plastic sheet such as polyester or polycarbonate may be used.

Among them, asbelt paper and glass nonwoven fabric are preferably used because they have excellent dimensional stability even under heating. The foamable resin forming the foamable resin layer 2a includes polyethylene,
Thermoplastic resins such as polypropylene, polystyrene, polyvinyl chloride, vinyl chloride-vinyl acetate copolymers, hydrazides such as benzenesulfonyl hydrazide, azos such as azodicarbonamide, nitrosos such as dinitrosobentatetramine, or carbonates. A blowing agent such as an inorganic blowing agent such as sodium hydrogen is added, and if necessary, a plasticizer consisting of a ester of a linear or branched alcohol and a fatty acid, and polymeric inorganic and organic acids such as zinc and lead are added. It means a base-like semi-gelled resin made by adding foaming aids such as salts, colorants, stabilizers, fillers, etc.

In order to form such a foamable resin layer 2a on the base material 6, a film made of the foamable resin as described above is bonded to the base material 6 using heat or an adhesive, or After applying the foamable resin paste as described above, a method such as heating to semi-gelatize the paste is used.
The foaming accelerator may be the same as the foaming aids mentioned above, such as zinc compounds such as zinc caprylate,
Zinc nitrate, zinc fatty acid salts, zinc oxide: lead compounds, such as carbonates, lead phthalates, sulfites, lead phosphites, lead stearate; cadmium compounds, such as cadmium caprylate, cadmium caproate, cadmium laurate, myristin Acid cadmium; other materials such as urea, shelf sand, ethanolamine, etc. that lower the decomposition temperature of the foaming agent when combined with the foaming agent used in the foamable resin layer 2a, and are also included in the foamable resin layer 2a. Blowing agents other than blowing agents can also be used.

Foam suppressants include organic acids such as maleic acid, fumaric acid, adipic acid, 1,2-phthalic acid, especially at least
an organic acid having 2 to 12 carbon atoms, containing at least one carboxyl group or at least one carboxyl group and one hydroxyl group; an organic acid halide, especially an acid chloride, having 2 to 20 carbon atoms;
Organic acid anhydrides with 2 to 20 carbon atoms; polyhydric aromatic alcohols and ketones with 2 to 20 carbon atoms having two functional groups; saturated amines with 3 to 12 carbon atoms or unsaturated 6- to 10-membered rings Those having the effect of increasing the foaming temperature in combination with the foaming agent or foaming aid used in the foamable resin layer 2a are selected from amines and the like.

When the above-mentioned foaming accelerator or foaming inhibitor is included in the transferable colored pattern layer 3a or 3b as shown in FIG. 5 or FIG. Water- or alcohol-soluble substances, such as zinc sulfate, can be used by dissolving them in water-alcohol-based solvents or diluents in ink. They can be incorporated into the ink by using a suitable surfactant or by emulsification, encapsulation, or other means.

In order to form the foam suppressor layer 7 or the foam promoter layer 9, for example, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, methyl acetate, ethyl acetate, butyl acetate, toluene, xylene, methyl alcohol, ethyl alcohol, impropyl An ink composition is prepared by dissolving or dispersing a foaming accelerator or a foaming inhibitor together with a binder and a coloring agent as necessary in one or more solvents or dispersion media such as alcohol or water, and is used for gravure, offset, letterpress, etc. Printing is performed on the foamable resin layer 2a by a method such as silk screen, flexography, or drawing.

Generally, the accelerator or inhibitor in the ink composition is between 5 and 75%.
% (weight %; the same applies hereinafter). Further, if at least one of the binder and the colorant used in this ink composition is water-removable, the foaming suppressor layer 7 or the foaming accelerator layer 9 can also be used as the transferable colored pattern layer 3a or 3b.
It also functions as The sheet as shown in FIGS. 3 to 8 obtained in this way has a weight of 150 to 250 q, depending on the resin, foaming agent, etc., for example, in the case of PVC.
o. The transfer sheet of the present invention as shown in FIG. 1 or 2 can be obtained by keeping the foam under foaming conditions for 1 to 5 minutes.

On the colored pattern layer 3 of the transfer sheet 1 thus obtained, a protective film is further applied using a water-soluble binder among the above-mentioned binders in an amount of, for example, 0.5 to 30 min/dry value. This can prevent the colored pattern layer 3 from flowing when pouring the hydration curable material described later.

The method described using FIGS. 3 to 8 has the following advantages compared to the method described above in which the transferable colored pattern layer 3 is formed by printing on the convex portions of the base sheet on which the embossed pattern has already been formed.
It is preferable for various reasons as follows.

In other words, by using an ordinary patterned printing plate, the pattern layers 3, 3a, 7, and 9 can be easily and positionally selectively formed on the foamable resin layer 2a without having to particularly adjust the printing pressure. can do.

{Open} Since both the pattern layer 3 and the pattern layer 7 or 9 are formed by printing, alignment is easy.

Since the colored pattern layer 3 and the pattern layer 7 or 9 for providing unevenness are both formed by printing, it is possible to provide a more precise synchronous embossed pattern with equally precise colored patterns and uneven patterns. 8. The foamable resin layer 2a to be printed is relatively thin before foaming, so printing is easy.

Next, in order to manufacture an inorganic decorative board using the thus obtained transfer sheet as shown in FIG. 1 or 2, as shown in FIG. 3 is placed in a formwork 10 made of any solid material so that the side with 3 faces upward, and the hydration-curable material 11 is poured into the formwork from above and cured, and after removal from the mold, the material is transferred from the cured material. A method of peeling off the sheet 1 is being explored.

As a result, an uneven pattern corresponding to the colored pattern transferred from the colored pattern layer 3 and the uneven surface of the transfer sheet is formed on the surface layer of the surface of the inorganic decorative board made of the cured product that was in contact with the transfer sheet. . The decorative laminate according to the present invention can also be obtained by pouring the curable material 11 into the formwork 10 and then pressing the curable material with the surface of the transfer sheet 1 having the colored pattern layer 3 before curing. However, the decorative surface of the decorative board obtained in this case has the disadvantage that it becomes rough due to the inclusion of air bubbles. However, this surface roughness can be considerably improved by skillfully degassing the cured material. The hydration-curable material used in the present invention has fluidity and hydraulic properties that allow it to be poured into a mold.
For example, various types of gypsum such as hemihydrate gypsum and anhydrite, various cements such as boltland cement, alumina cement, magnesia cement, mixed cement, etc. are used singly or in combination with an appropriate amount of water to form a slurry. . Bulbs, synthetic fibers, glass fibers, metal fibers, carbon fibers, synthetic resins, etc. may be mixed into this slurry for reinforcement, and various additives may also be added. In particular, by adding an amino resin to the slurry, it is possible not only to improve the surface gloss and surface hardness, but also to completely prevent the pattern on the transfer sheet from collapsing during casting.

The architectural decorative laminate obtained by the manufacturing method of the present invention described above can be fully used as is, but by performing the following post-processing, properties such as durability, gloss, and design can be further improved. can be increased.

For example, a transparent resin layer may be coated on the surface of the architectural decorative board by a conventional method such as roll coating, gravure coating, percoat, or spray coating.

Examples of the above resin include urethane resin, vinyl chloride resin, vinylidene chloride resin, vinyl acetate resin,
Polyolefin resins such as polyethylene or polypropylene, polystyrene resins, acrylic resins, polyvinyl alcohol, polypynylacetal, copolymers of styrene and acrylonitrile, ABC resins, polyamide resins, unsaturated polyester resins, epoxy resins , phenolic resins, amino resins, etc.
In addition, if the cured board of the architectural decorative board is a material that hardens to form a porous material, such as gypsum, the cured board may be impregnated with a monomer or prepolymer, then polymerized and dried, or Alternatively, by impregnating the above-mentioned cured plate with a polymer solution and then drying it, the strength of the cured plate can be increased, and the integrated pattern can penetrate into the surface area of the cured plate and further penetrate into the porous interior. It can add even more depth and flavor.

After this post-processing, a transparent resin layer can be provided on the surface in the same manner as above. As described above, according to the transfer sheet of the present invention and the method for manufacturing an inorganic decorative board using the same,
Since at least one of the binder and the coloring agent that make up the colored pattern layer is water-soluble, the colored pattern transferred to the resulting decorative board penetrates into the surface area of the decorative board, giving it a deep and tasteful pattern. Moreover, the concavo-convex pattern that is in sync with the overall pattern is formed with the same fineness and sharpness as that of the colored pattern.

Therefore, the decorative board obtained by the present invention has extremely excellent design effects. Furthermore, the resulting colored and uneven patterns have good reproducibility, and decorative boards having desired patterns can be stably and industrially produced. Since the inorganic decorative board produced by the method of the present invention is inherently heat-resistant and fire-resistant, it can be used in general architectural applications such as floor panels, wall panels, and ceiling materials, and can also be used for its excellent design effects. It can also be used as a covering material for various articles. below,
The present invention will be explained more effectively by Examples.

In the examples, "parts" and "%" are based on weight. Example 1 Expandable plastisol made of the following formulation was applied to the surface of a felt sheet with a skin thickness of 1.14 cm to a thickness of 0.2 ribs, and
The mixture was gelled in 0.002 minutes to obtain a foamable resin layer.

(Plastisol) Polyvinyl chloride 10 parts dioctyl phthalate 3 parts tricresyl phosphate 1 part azodicarbonamide 5 parts zinc oxide
3 parts titanium dioxide
3 copies Next, in order to print a tile pattern on the surface of this foamable resin layer, an inhibitor ink having the following composition was gravure printed on areas other than the tile joints.

(Inhibitor ink) Vinyl chloride-vinyl acetate copolymer 8.5 parts Methyl ethyl ketone 54. Part: Titanium dioxide 25. 12.5 parts of trimellitic anhydride A, B, C consisting of the following composition on the joint area and the entire surface other than the joint area
Multicolor tile wall patterns were printed using three types of ink compositions.

(Ink A) Permanent Yellow HR (C.1. Pigment Yellow-83) 1 part certified polypynyl alcohol 5 parts polyvinylpyrrolidone 3 parts ethyl alcohol
42 parts water
4 recognition (ink B) PV carmine HF
4C (C.1. Pigment Red 185) 1 part polyvinyl alcohol 5 parts polyvinylpyrrolidone 3 parts ethyl alcohol
42 parts water
4 Ankaribe (Ink C) Mikesrunflu RS
N (C.1.6 Group 00) 1
Boho polyvinyl alcohol 5 parts polypynylpyrrolidone 3 parts ethyl alcohol
42 parts water
4 anchors 20 pieces of the printed sheet obtained above
A heat foaming treatment was performed at 0° C. for 3 minutes to obtain a transfer sheet with a tile wall pattern in which the joints became convex portions and the areas other than the joint portions became concave portions.

After that, the transfer sheet obtained above was placed in a large mold of 60 skins x 60 skins with the pattern layer facing up, and on top of that, 10 parts of plaster, 43 parts of water, and 0 parts of glass fiber were applied.
．． A hydration curable material having a blending ratio of 5 parts and 3 parts of urea resin was poured into the mold, and was left to stand for 3 hours with nitrogen stripes to fully harden.

Next, the cured product was demolded, and the base sheet was peeled off to obtain a decorative gypsum board with a tile wall pattern in which the joints were concave and the areas other than the joints were convex. Approximately 30% of the acrylic ultraviolet curable paint is applied to the pattern transfer surface of the decorative gypsum board obtained above.
After spray coating at an amount of 0 m/force (dry value), it was cured by irradiating ultraviolet light (240-60 m) for 7 minutes.

This further improved the heat resistance and appearance of the decorative gypsum board. Example 2 A foamable plastisol of the following composition was evenly applied to a thickness of about 0.3 ribs on the surface of a polyester nonwoven fabric with a thickness of 1.2 ribs, and heated at about 150 qo for 1 minute to gel the plastisol and make it foamable. It was made into a resin layer.

(Expansible plastisol) Polyvinyl chloride 10 base alkylaryl modified phthalate ester
55 parts Dibasic lead phosphite 1.5 parts Titanium dioxide 5 parts Azodicarbonamide 2.5 parts Next, an inhibitor ink having the following composition was gravure printed on the surface of the foamable resin layer in a relief pattern.

(Inhibitor ink) Vinyl chloride-vinyl acetate copolymer
8.5 parts methyl ethyl ketone
54 parts titanium dioxide 2
5 parts maleic anhydride 12.5
The printed sheet above was subjected to a heating foaming treatment for 200 minutes and 0.3 minutes to obtain a foamed sheet in which the suppressor ink printed areas were concave portions (difference between concave and convex portions was approximately 2 rows).

The printing pressure was adjusted to lk9/low so that the ink did not adhere to the concave portions of this foam sheet, and a relief pattern was gravure printed using the three inks A, B, and C of Example 1 only on the convex portions. A foamed transfer sheet with unevenness was manufactured. Thereafter, the transfer sheet was placed in a formwork capable of manufacturing a decorative board of any size with the pattern layer facing upward, and a mixture of 10 parts of plaster, 20 parts of acrylic emulsion, and 35 parts of water was applied. A hydration-curable material was poured into the mold, left to harden at room temperature for 3 hours, and then removed from the mold. Further, the transfer sheet was peeled off to obtain a decorative board made of a gypsum-plastic composite with a pattern applied to the recesses. Furthermore, by applying dipping coating to the surface of this decorative board with an acrylic-urethane resin, a decorative board with further improved durability and feel was obtained. Example 3 A foamable resin composition having the following composition was applied onto paper with a skin thickness of 0.1 using a doctor knife at a rate of 320 mm/cm, and then placed in a drying oven and dried at approximately 15,000 ℃ for 2 minutes. The mixture was passed through a foaming furnace for 3 minutes to obtain a foamed material about 3 times the size.

(Foamable resin layer composition) Emulsion polymerized polyvinyl chloride 10 parts dioctyl phthalate 7 parts titanium dioxide 1 part dibasic lead phthalate 3 parts azodicarbonamide
5 parts Then, the above foam sheet was heated to about 20,000 ℃ to gel the resin content, and in that state, an embossed metal roll with a relief pattern engraved (with an uneven size of 1
．． 2 side) to obtain a foamed sheet having an uneven surface.

This foam sheet was printed with the three types of inks A, B, and C of Example 1 by gravure printing at a printing pressure of lk 9/2 so that the ink adhered only to the convex portions, thereby forming a colored pattern layer on the convex portions. A foamed transfer sheet having the following properties was obtained.

Next, this transfer sheet was laid in a formwork, and 100 parts of white cement, 15 parts of cinnabar sand, 4 parts of water, and 8 parts of alkali-resistant glass were added.
A hydration-curable base material was obtained by mixing 1 part of a water reducing agent (Mighty-150 manufactured by Kao Soap Co., Ltd.) with a water-reducing agent (Mighty-150, manufactured by Kao Soap Co., Ltd.), and this was poured onto a transfer sheet and cured, allowing demolding and peeling of the transfer sheet. By doing so, a decorative cement board with a pattern applied to the concave portions was obtained.

[Brief explanation of the drawing]

Figures 1 and 2 are schematic cross-sectional views of a transfer sheet showing the simplest structure of the transfer sheet of the present invention, and Figures 3 to 8 illustrate the foamability of the transfer sheet of the present invention by foaming, respectively. FIG. 9 is a schematic cross-sectional view of a sheet, and FIG. 9 is a schematic cross-sectional view of a formwork for explaining the manufacturing process of a decorative board according to the present invention. 1... Transfer sheet, 2... Base sheet (2a... foamable resin layer), 3... Transferable colored pattern layer (3a... ...Contains a foaming accelerator,
3b... Contains a foaming inhibitor), 4... Base sheet convex portion, 5... Base sheet concave portion, 6... Base sheet, 7... Foaming. Inhibitor layer, 8...
・Primer layer, 9... Foaming accelerator layer, 10.
...Formwork, 11...Hydration curable material. Tsutomu

Claims (1)

[Scope of Claims] 1. A base sheet is characterized by being provided on one side thereof with an uneven pattern and a colored pattern layer containing a coloring agent and a binder, at least one of which is water-soluble, and which matches the uneven pattern. A transfer sheet for manufacturing decorative laminates. 2. A transfer sheet is prepared which has an uneven pattern on one side of a base sheet, and a colored pattern layer containing a water-soluble colorant and a binder, at least one of which is water-soluble, and is in sync with the uneven pattern, and the transfer sheet has an uneven pattern. After laminating and curing a hydration-curable material so as to be in contact with the surface on which the pattern and colored pattern layer are provided, the transfer sheet is peeled off to impart an uneven pattern to the surface of the cured product that was in contact with the transfer sheet. A method for manufacturing an inorganic decorative board, comprising transferring a colored pattern layer that is in sync with the uneven pattern.