JPS6059880B2 - Decorative board manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative board, and in particular to a method for manufacturing a decorative board using a hydration hardening material slurry.

Conventionally, methods of painting on base materials such as noncombustible materials have been carried out by printing methods such as gravure screen printing or by thermal transfer methods, but in either case, the base materials are limited to flat surfaces.

Furthermore, when the kneading method is used, it is difficult to predict the finish and the reproducibility of the pattern is poor, making industrial production difficult. In addition, a desired mold is created by painting the base with a water-soluble ink that can be transferred with water or an ink of other composition, and a slurry of the hydration hardening material is poured into the mold. Among the methods for producing a cured board by curing, there is a method in which a pattern is transferred to a cured board using moisture in a hydration-cured material.

In this case, it is difficult to completely synchronize the uneven pattern of the formwork and the pattern of the transfer sheet, so it is not possible to obtain a product in which they are completely synchronized. The present invention solves this drawback by synchronizing the pattern with the part of the transfer sheet that should be uneven.In this case, technically speaking, the uneven pattern and the pattern are perfectly formed as a natural result. It is possible to obtain a product that is in tune with the above.

The present invention will be explained in detail step by step with reference to the explanatory diagram of FIG. 1.

(1) indicates the base sheet 1, and the base sheet may be any material that can be printed, such as plastics such as polyvinyl chloride, polyethylene, polypropylene, polybutylene, metal sheets such as aluminum, or paper coated with plastic. .

In (2), superabsorbent resin J is printed in a pattern on the base sheet 1 (printed part 2).

Super absorbent resins are made by partially crosslinking water-soluble polymers to make them insolubilized. Examples of graft polymerization resins include starch, which is obtained by grafting acrylonitrile onto starch, and graft polymerization resins, which are made by grafting acrylonitrile onto starch, and cellulose pulp with acrylonitrile. There are cellulose graft polymerized resins, and crosslinked synthetic resins include acrylic resins, which are made by hydrolyzing methyl methacrylate-vinyl acetate copolymer with alkali and converting it into carboxyl groups and hydroxyl groups, as well as acrylonitrile. Any material that absorbs water and swells significantly, such as synthetic synthetic resin type or nonionic synthetic resin type, can be used. In (3), a water-soluble release varnish layer 3 is further provided on top of the water-soluble release varnish, and the main component of the water-soluble release varnish is a water-soluble resin such as hydroxypropyl cellulose, polyvinyl alcohol, polyvinylpyrrolidone, or water-soluble acrylic hydroxymethyl cellulose. It is fine as long as it is.

In (4), a pattern 4 made of porous ink is further provided on the water-soluble varnish 3 in synchronization with the pattern of the superabsorbent resin.

Porous ink is an ink that contains a high amount of filler, and the filler is added as an extender pigment, and a small average particle size of 20μ or less is suitable.For example, ink containing calcium carbonate, acid clay, magnesium carbonate, water Magnesium oxide, kaolin, diatomaceous earth, barium sulfate,
Talc, calcium silicate, aluminum hydroxide, slate powder, etc. can be used. The amount of resin added is 1 (1)
It is desirable that the amount is 10 parts by weight or more. As the ink binder, any binder commonly used in printing inks such as vinyl resin, alkyd resin, acrylic resin, etc. can be used. (5) Further, an overprint varnish 5 is coated on the porous ink 4 of the sheet of (4) above.

This makes it possible to prevent picture distortion. Transfer sheets are usually made using salt-vinyl acetate, acrylic, or urethane binders. (6) shows a state in which the thus prepared transfer sheet is molded into a formwork or set in a formwork 7 having such a shape. (7) shows a state in which the transfer sheet A is set in the mold 7 and filled with the hydration hardening material slurry 6.

The hydration hardening material may be any material that can form a slurry and has hydraulic properties, such as various types of gypsum such as hemihydrate gypsum and anhydrite gypsum, boltland cement, alumina cement,
Magnesia cement, mixed cement, and other types of cement may be used alone or in combination with an appropriate amount of water to form a slurry, and reinforcing materials such as synthetic resin or glass fiber may be mixed into this slurry. There is also. (8)
After the slurry is filled, the water permeates into the pattern layer 4 before it hardens, and it further dissolves the water-soluble varnish layer (water-soluble release varnish layer) 3, making it easier to peel the pattern from the base sheet. At the same time, on the other hand, water is absorbed into the superabsorbent resin 2, causing the resin to swell significantly.

In (9), as seen in (8), due to the swelling of the water-absorbing resin 2 printed in a pattern, the hydration-curing material corresponding to this area becomes concave, and after curing, the mold is removed and the transfer sheet is The printed pattern and the super absorbent resin pattern are created in sync with the transfer paper from the beginning, so for example, in the case of a wood grain pattern, the conduit part, and in the case of a tile pattern, the part corresponding to the joint is Since they are synchronously recessed and the pattern is transferred to the hardened board while the parts are recessed, the wood grain conduits and tile joints described above give an extremely effective feel.

FIG. 2 is an explanatory diagram showing another embodiment of the present invention, and shows the structure of the transfer sheet according to the steps, 1 indicates the base sheet 1, and 2 shows the pattern of super absorbent resin printed on the base 1. 2 is applied, 3 is provided with a pattern 8 made of water-soluble ink in synchronization with the printed portion 2, and 4 is further coated with an overprint varnish 5 made of porous ink. This is molded into a predetermined uneven shape or set in a predetermined uneven mold as shown in FIG. 1, and cured in the same manner to obtain a decorative board as shown in FIG. 1. Example 1 A 100μ thick unplasticized polyvinyl chloride sheet was used as the base 1, and one side was covered with an acrylonitrile-based super absorbent resin 2 (trade name: Aquaprene, manufactured by Meisei Chemical Industry Co., Ltd.) in the form of tile joints.
was coated in a pattern, then water-soluble release varnish 3 having the composition shown in Table 1 below was coated, and a tile pattern was printed on top of that with porous ink 4 having the composition shown in Table 2 below (note that the tile joint areas were (Includes super absorbent resin).

Finally, transfer sheet A was prepared by coating with overprint varnish 5 shown in Table 3 below. Next, this transfer sheet A was formed with a vacuum forming machine so that the printed surface was the top surface, and then taken out and made to stand on its own. )3 prostitute, water ω
The slurry of the mixture was poured and cured. The mold was removed and the sheet was peeled off. The pattern was integrated into the surface layer of the hardened board, and the parts corresponding to the joints of the tiles were depressed, creating a completely synchronized painted plaster board with depth. Furthermore, this board was top-coated with an acrylic UV-curable clear paint to obtain a tile-like gypsum board.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an explanatory diagram showing the steps of the method for manufacturing a decorative board of the present invention, and FIG. 2 is an explanatory diagram of the steps of another embodiment of the present invention. A...Transfer sheet (Example 1), B...
・Transfer sheet by the process shown in Figure 2, 1...Base sheet, 2...Super water absorbent resin, 3...Water-soluble release varnish layer, 4...Porous Ink pattern, 5
... Overprint varnish layer with porous ink, 6 ... Hydration hardening material slurry, 7 ...
・Formwork, 8... Design made with water-soluble ink.

Claims (1)

[Claims] 1. Make a mold by molding the transfer sheet into a desired shape in advance so that the pattern faces upward, or set it in a mold of the desired shape, and then place the hydration hardening material in the mold. In the method for manufacturing a transfer decorative board, which is produced by filling a slurry of water, curing it, and then removing it from the mold, before printing a pattern on the base sheet that can be transferred by the moisture in the slurry, the base sheet is A method for manufacturing a decorative board characterized by using a transfer sheet having a pattern made of super absorbent resin in a part that matches the pattern.