JPS6113874B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for forming an uneven pattern, and more specifically, a method for forming a three-dimensional pattern with a clear pattern and an excellent decorative effect.

Conventionally, many methods for forming uneven patterns have been proposed and implemented. One method is to strongly press the base material with a metal roll or metal plate (mold) having an uneven pattern. In order to create a fine uneven pattern using this method, advanced processing technology is required to create a metal roll or metal plate, and in addition, to create a different uneven pattern, a metal roll or metal plate that serves as a mold is required for each one. In addition to requiring a large amount of cost, this uneven pattern forming method has the drawback of damaging the base material, and is disadvantageous for mass production. Furthermore, it was difficult to apply the method to metal substrates on which it is difficult to form irregularities.

Another known method is to chemically form an uneven pattern. For example, a method uses a curable resin and a curing inhibitor, retardant, or curing accelerator, and forms an uneven pattern by utilizing the difference in curing speed depending on the pattern of the curable resin. With this method, it is difficult to obtain a sufficient roughness, and it is also difficult to obtain sufficient resistance as a film.

As a method to improve the drawbacks of the method of forming uneven patterns as described above,
Methods such as Nos. 32694 and 52-28825 have been proposed and implemented. In this method, paint is applied to the surface of the base material, and when the paint is still wet, uneven patterns are formed using a letterpress roll.There is no damage to the base material, and different patterns can be created using a single letterpress roll. It is a method that can be formed and is also excellent in terms of the durability of the film. However, due to the color contrast between the unevenness and the sharpness of the uneven pattern obtained by this method, there was a desire to manufacture decorative materials with an uneven pattern that required even higher contrast and sharpness. .

That is, depending on the coating thickness of the applied undried paint, a concave portion is formed at an appropriate depth using a letterpress roll, and the underlying base material is appropriately exposed. The resulting uneven pattern produces a color contrast between the uneven surfaces and a three-dimensional effect due to the unevenness, and an excellent uneven pattern can be formed by this method. However, depending on the desired pattern, a pattern with even higher contrast and excellent three-dimensional effect is required. For example, in the case of a wood grain pattern, this method provides sufficient contrast and three-dimensional effect for a pattern that resembles a certain kind of wood, but a pattern that resembles another type of wood requires a pattern with even better contrast and three-dimensional effect. Conventional methods have not necessarily been sufficient to meet this demand. Moreover, the same can be said not only for wood grain patterns but also for other patterns.

The present invention is an improvement on the above-mentioned method that does not damage the base material and allows different patterns to be formed using one letterpress roll, and also provides a pattern forming method that reliably provides sufficient color contrast between the unevenness. It is.
That is, this is a method in which a transparent paint is applied to a base material, a colored paint is applied thereon, and an uneven pattern is formed in the undried state of the transparent paint and the colored paint.
According to the present invention, a clear uneven pattern can be reliably formed, and a highly decorative uneven pattern can be obtained.

According to the present invention, since the transparent paint is present under the colored paint, a sharp uneven pattern can be formed without requiring special effort. Moreover, it is easy to obtain a material with sufficient contrast between the unevenness.

The base materials related to the present invention include wood, inorganic board,
The base material is metal, plastic, paper, etc., and if necessary, a base material that has been sealed is applied. Transparent paint can be applied directly to the base material, but to enhance the decorative effect, apply an undercoat paint that has a different tone from the colored paint applied under the transparent paint and apply it to the dry base material. It is preferable. Various paints can be used as the undercoat, and inorganic and/or organic pigments are added to the undercoat. Furthermore, it is also possible to form a printed pattern with or without applying an undercoat paint as an undercoat.
The shape of the base material is generally plate-like, but there is no particular restriction as long as it does not cause any trouble in applying the present invention.

The transparent paint according to the present invention is a paint made by appropriately blending resins such as polyester resins, melamine resins, acrylic resins, epoxy resins, polyurethane resins, polyvinyl chloride, cellulose derivatives, solvents, and various additives. Note that the transparent paint may be a paint containing an extender pigment or a small amount of colored pigment. At least the color of the substrate must be visible through the transparent coating. This transparent paint is applied to the base material by a coating method such as roll coating, doctor coating, gravure coating, or spray coating.

Next, a colored paint is applied when the applied transparent paint is in an undried state, that is, when it has dried to the extent that it is possible to form an uneven pattern immediately after or after application. This colored paint is a paint made by appropriately blending resins, pigments, solvents, and various additives.The resin used may be the same as or different from the transparent paint, but due to the drying or baking process, the same resin may be used. It is preferable to use As the pigment, a pigment having a hue different from that of the base material is generally used, but they may be of the same type. Furthermore, the transparent paint and the colored paint can be selected as appropriate, such as by using the same type of solvent for both, by using different solvents, or by using one of them as a solvent-free paint.

A base material coated with a transparent paint and a colored paint is passed between a letterpress roll and a feed roll, in which concave portions of a desired pattern are formed into convex portions, and a feed roll such that the coated surface of the substrate is in contact with the letterpress roll. The distance or pressure between the letterpress roll and the feed roll is such that the tips of the convex portions of the letterpress roll are in contact with the undried paint surface. Usually, the tip of the convex portion touches the transparent paint. The letterpress roll is generally a roll wound with an abrasion-resistant rubber elastic material having an uneven pattern on the surface. The letterpress roll is rotated in the same direction as the feed roll and at different speeds, either faster or slower, which reduces the fluidity of the transparent paint and colored paint applied to the substrate, causing the paint to be applied by the letterpress roll. Appropriate light printing pressure is applied to the paint film where the uneven pattern has flowed and the unevenness has not disappeared, and the convex part of the letterpress roll slides and cuts through the paint film to create a very clear pattern. Shape the unevenness of the shape. Note that the feed roll is not limited to only cylindrical rolls,
It may also be a belt type or other type of transport means.

Next, it is dried and solidified in a dryer. This drying may be carried out naturally depending on the type of paint, etc.

Various patterns such as wood grain patterns and abstract patterns can be used as the pattern of the letterpress roll, and when the paint applied to the base material is in an undried state, an uneven pattern is formed by the letterpress roll. The pattern can be changed by changing the speed of the letterpress roll; for example, in the case of a woodgrain pattern, reducing the speed of the letterpress roll makes it elongated, and conversely increasing it makes it shrink. Furthermore, if it is necessary to perform synchronized printing following the formation of the uneven pattern of the present invention, for example, when the circumferential speed of the feed roll and the circumferential speed of the letterpress roll are set to 1:1/2, the uneven pattern will be printed on the letterpress roll. Since it has been stretched twice in the vertical direction relative to its original size, the plate for synchronized printing must be synchronized to the twice stretched pattern. Note that the direction of movement of the base material coated with the paint and the direction of rotation of the letterpress roll may be different.

By forming the above-described uneven pattern, the base material or the undercoat applied to the base material can be exposed reliably and easily in the concave portions, and a pattern rich in color can be obtained. Note that after forming the pattern of the present invention, it is also possible to print or paint on the pattern to improve durability, wearing effect, etc.

In the present invention, the uneven pattern is formed using the method detailed above in an undried coating film, so the base material is not damaged or deformed, and can be pressed with a metal embossing roll using a conventional embossing machine. This is a method that allows the formation of an uneven pattern easily and with inexpensive equipment, even on metal substrates for which it has been difficult to form an uneven pattern. Furthermore, the color of the base material can be expressed without transferring or pushing ink or paint into the recesses, and the effect of coloring the recesses can also be expressed at the same time. Furthermore, in the present invention, the formation of this uneven pattern allows the base material to be exposed in the recessed portions, and the contrast between the uneven areas is large, and a clear pattern can be formed, and a pattern with a very high decorative effect can be formed.

With the method of the present invention, the composition of the paint can be selected to be a coating film with excellent weather resistance, corrosion resistance, flame retardance, etc., without any special restrictions, and can be used as an exterior material,
Patterns with excellent decorative effects can be formed for noncombustible materials and other uses that require special resistance, interior materials, furniture materials, etc.

Next, the present invention will be explained with reference to examples. "Parts" indicate parts by weight.

Example 1 25 parts of polyester resin, 15 parts of melamine resin, 10 parts of carbon black and xylene were placed on a galvanized iron plate.
An undercoat consisting of 100 parts of a mixed solvent of butyl cellosolve and butanol was applied with a roll coater to a dry film thickness of 13 g/m ² and baked at 260°C for 1 minute to obtain a black iron plate with polyester resin.
A transparent paint consisting of 100 parts of melamine resin, 20 parts of precipitated barium sulfate, and 100 parts of the same mixed solvent was applied with a roll coater to a weight of 18 g/m ² , and the transparent paint was coated in an undried state. A brown paint consisting of 100 parts of polyester resin, 20 parts of melamine resin, 50 parts of iron oxide pigment, and 100 parts of the same mixed solvent was applied to the steel plate, which was coated while still wet, and had convex parts with a wood grain conduit groove pattern. An uneven pattern was formed by passing between the urethane rubber letterpress roll and the feed roll. Next, it was baked at 260°C for 1 minute. The obtained decorative galvanized iron plate had an uneven feel, and a wood grain pattern with a large contrast between the unevenness could be formed. By the way, different wood grain patterns were obtained by changing the circumferential speeds of the letterpress roll and the feed roll.

Comparative Example 1 In Example 1, an uneven pattern was formed under the same conditions as Example 1 without applying a transparent paint. There wasn't enough contrast between them.

Example 2 Instead of the brown paint of Example 1, a silver paint consisting of 25 parts of polyester resin, 20 parts of titanium white, 5 parts of aluminum paste, and 50 parts of mixed solvent was applied, and the wood grain of Example 1 was applied without drying. When an uneven pattern was formed using a letterpress roll with a satin pattern instead of a pattern, a clear uneven pattern could be formed.

Example 3 30g/ ^m2 of cream-colored alkyd resin filler was applied to a 3.5mm thick slate board, dried to smooth the surface, and coated with 15 parts of alkyd resin, 1.5 parts of nitrocellulose lacquer, and iron oxide. An undercoat consisting of 20 parts of pigment, 4.5 parts of carbon black, 14 parts of talc, 0.15 parts of metal dryer, and 44.8 parts of solvent was applied at 50 g/m ² using a roll coater, and heated at 100°C.
After drying for 10 minutes, add 17 parts of alkyd resin, 14 parts of precipitated barium sulfate, 14 parts of talc, and a metal dryer.
40g/ ^m2 of transparent paint consisting of 0.15 parts and 50 parts of solvent.
14.5 parts of alkyd resin, 7.5 parts of iron oxide pigment, 14 parts of precipitated barium sulfate, 14 parts of talc, and a metal dryer are applied on top of this without drying.
70 parts of light brown paint consisting of 0.15 parts and 47.8 parts of solvent.
It was coated with a roll coater at a ratio of g/m ² , and an uneven pattern was formed in the same manner as in Example 1 using an abstract-patterned letterpress roll while undried, and dried at 100° C. for 10 minutes. Furthermore, an abstract pattern was gravure offset printed on top of the uneven pattern in synchronization with the uneven pattern. The decorative slate board obtained had an extremely high decorative effect.

Example 4 A pale yellow aqueous sealant was applied at 100 g/m ² onto a 3.5 mm thick veneer plywood, and after drying, it was sanded to make the surface smooth. The same undercoat paint as in Example 3 was applied thereon and dried at 80°C for 5 minutes.
Further, the same transparent paint and light brown paint as in Example 3 were applied thereon, and an uneven pattern was formed using a letterpress roll with a wood grain pattern in the same manner as in Example 1.
After drying for a minute, a two-color wood grain pattern was printed using an alkyd resin wood grain ink using a gravure offset printing machine. Next, apply a transparent top coat of 30g/m ² consisting of 21.5 parts of alkyd resin, 21.5 parts of amino resin, 2.7 parts of para-toluenesulfonic acid, and 5.5 parts of solvent.
It was applied at a ratio of 100° C. and dried for 5 minutes at 100°C to obtain wood-grained plywood for interior decoration with a three-dimensional effect similar to that of natural precious wood.

Claims (1)

[Claims] 1. Apply a paint to a base material, and when the paint is not dry, place the coated base material on the coated surface between a convex plate roll and a feed roll, which have convex parts that are supposed to be concave parts of the desired pattern. In the pattern forming method, a transparent paint is applied to a base material, a colored paint is applied on top of this, and the transparent paint and the colored paint are A method characterized by forming an uneven pattern in an undried state.