JPS6117279B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative board, and its purpose is to provide a method for efficiently manufacturing a decorative board having an excellent design without distortion or damage on a highly uneven surface. It is to be.

BACKGROUND ART Decorative boards, which are made mainly of clay, cement, etc., with resins and reinforcing materials mixed in as necessary, have been used as noncombustible materials for wall coverings, flooring materials, and the like. However, the surface of this decorative board is often uneven, making it difficult to obtain a good pattern.

In other words, there are methods of printing directly on this surface,
The transfer printing method, in which an image printed on a support such as paper is transferred to a decorative board, cannot produce a fine and good design on a molded product with a complex surface shape.

Furthermore, when using the kneading method, it is difficult to predict the finish, and the reproducibility of the pattern is poor.
Industrial production is difficult.

In addition, water-soluble ink is printed on a substrate such as paper, and this substrate is molded to create the desired formwork. After that, a hydration hardening material such as cement is poured in and hardened, and the pattern is transferred by the water content of the material. This method is also known, but since the pattern is water-soluble, the pattern may bleed when pouring the hydration-curing material into the mold or before the hydration-curing material hardens. Problems such as blurring, running and distortion of the pattern tend to occur, and it is extremely difficult to obtain desired colors and patterns.

The present invention was developed in view of the above points, and includes a transfer sheet in which each layer is formed in the order of a water-soluble release varnish layer, a porous pattern layer, and a porous resin layer on a base sheet. A decorative board characterized in that it is molded inside or set in a formwork of a desired shape, then a hydration hardening material is poured in and hardened and molded, at the same time a painting is applied, and then the base sheet is peeled off. A manufacturing method is provided.

The present invention will be described in detail below with reference to the drawings.

First, as shown in FIG. 1, a water-soluble release varnish layer 2 is formed on one side of a base sheet 1, and then a porous pattern layer 3 is formed using porous ink containing a filler. Next, a porous resin is applied thereon to form a porous resin layer 4 to form a transfer sheet 5.

Next, as shown in FIG. 2, the transfer sheet is molded into a desired shape with the pattern layer inside to form a mold, or as shown in FIG. Next, set the transfer sheet so that the pattern layer is on the opposite side of the mold.

Next, as shown in FIG. 4, the hydration hardening material 7 is poured into the mold and left to naturally harden. In the process of curing the hydration-curing material, water in the hydration-curing material infiltrates the porous resin layer 4 and the porous pattern layer 3 in order, reaches the water-soluble release varnish layer 2, and forms the release varnish layer. The porous pattern layer and porous resin layer will eventually become part of the surface layer of the cured board.

Next, as shown in FIG. 5, when the base sheet is peeled off, a decorative board having a highly uneven surface with an excellent design without distortion or damage is obtained. Note that the base sheet may be broken and peeled off.

According to the method described above, since the pattern layer is not water-soluble, the pattern does not bleed due to moisture from the hydration-curing material, and the pattern layer is supported by the porous resin layer. Therefore, when the hydration-hardening material is poured and spread, there is no problem of the pattern layer being pulled by the hydration-hardening material and becoming distorted. Therefore, even if the surface of the final molded product is a complex three-dimensional curved surface, a decorative board with excellent design can be manufactured without causing bleeding or distortion of the pattern.

Next, the constituent materials of the present invention will be explained.

The base sheet may be of any material as long as it is flexible and printable, such as plastic sheets such as vinyl chloride, polyethylene, polypropylene, nylon, acrylic, polycarbonate, polystyrene, and polyester, metal foils such as aluminum, etc. be.

The water-soluble release varnish layer is formed of any varnish whose main component is a water-soluble resin such as hydroxypropyl cellulose, polyvinyl alcohol, polyvinyl pyrrolidone, water-soluble acrylic, or hydroxymethyl cellulose.

The porous pattern layer is formed using porous ink containing an inorganic filler, and the amount of the filler added has a great effect on transferability. For example, when salt-vinyl acetate resin is used as the main binder, the amount of filler is required to be at least 100 parts by weight per 100 parts by weight of resin, and when acrylic resin is used as the main binder, at least 300 parts by weight is required. If cellulose resin is used as the main binder, 500 parts by weight or more is required.

As a filler, the average particle size is small (20μ or less)
Suitable materials include calcium carbonate, acid clay, magnesium carbonate, magnesium hydroxide,
Kaolin, diatomaceous earth, barium sulfate, talc,
Calcium silicate, aluminum hydroxide, slate powder, etc. are preferable.

The porous resin layer is formed of a porous resin containing an inorganic filler, and as with the porous ink described above, the amount of the filler added has a great effect on transferability. The specific examples and types of fillers that can be used are the same as in the case of the ink described above.

The hydration-hardening material can be any material that can be poured into a mold and has fluidity and hydration-hardening properties, such as α-type or β-type hemihydrate gypsum, molds, molds,
Various types of gypsum such as molded anhydrite, Portland cement, alumina cement, magnesia cement,
There are cements such as mixed cement, or mixtures of gypsum and cement, and if necessary, hardening accelerators, inhibitors, pulp, glass fibers, metal fibers, synthetic fibers, natural fibers, asbestos, slag fibers, rock wool, etc. Reinforcing agents, methyl methacrylate-butadiene rubber latex, styrene-butadiene rubber latex, acetic acid emulsion, acrylic emulsion, ethylene acetate emulsion, water-based acrylic, urea, phenol, melamine, and other synthetic resins to impart plasticity, hardness, and water resistance. It is possible to use fillers such as fillers, river sand, whitebait balloons, talc, silica, aluminum hydroxide, magnesium carbonate, calcium carbonate, or organic or inorganic coloring agents.

Incidentally, when the intended molded product has a reverse tapered shape in a portion thereof, it is desirable that the transfer sheet 5 be made to stand on its own. The self-supporting transfer sheet 5 is made of polyester, polystyrene, polyvinyl chloride, polypropylene, polyethylene, nylon,
It uses a base material made of acrylic resin, polycarbonate, silicone, etc. film, and its thickness should be determined by taking into account the thickness of the molded product, in order to ensure that it can stand on its own after molding. For example, vertically and horizontally
For a plate-shaped decorative board of 200 mm and depth of 10 mm, a film with a thickness of 200 μ or more is preferable, and for a plate-shaped decorative board of 1000 mm in length and width and 20 mm in depth, a film with a thickness of 300 μ or more is preferable.
From the viewpoint of moldability, vinyl chloride, styrene film, unstretched polypropylene, polyethylene, etc. are preferable.

The present invention has the above-described structure, and since the pattern layer is supported by a porous resin layer and is not water-soluble, the pattern layer is There is no distortion due to tension or bleeding of the pattern layer due to moisture in the hydration-cured material, and a fine and good pattern can be transferred at the same time as molding.

The present invention will be explained in more detail below using examples.

Example 1 An unplasticized vinyl chloride sheet with a thickness of 200 μm was used as a base sheet, and one side thereof was coated with a varnish having the following formulation using a gravure printing machine to form a release varnish layer.

Varnish formulation hydroxypropyl cellulose (20% solids)
50 parts by weight Isopropyl alcohol 50 Total 100 Next, print a marble pattern on the release varnish layer using an ink with the following formulation using a gravure printing machine.

Ink formulation Acrylic varnish (solid content 30%) 50 parts by weight Pigment 5 Barium sulfate 45 Total 100 Next, a porous resin with the following formulation was gravure coated on top to form a porous resin layer. It was made into a transfer sheet.

Porous resin formulated acrylic varnish (solid content 10%) 75 parts by weight Barium sulfate 25 Total 100 This transfer sheet was molded into the shape of a tile board using a vacuum forming machine with the printed side facing up, and then removed from the mold. The container was made to stand on its own, and a hydration curing mixture having the following formulation was poured into it and allowed to harden naturally.

Hydrated hardening mixture formulation β gypsum 100 parts by weight Vinyl acetate emulsion (solid content 50%) 30 Water 55 Total 185 When the base sheet was peeled off after curing, the pattern on the transfer sheet was transferred to the surface layer of the hardened plate. A decorative plaster board with integrated depth was obtained.

Furthermore, 100 g/m ² (dry) of acrylic ultraviolet curable clear paint is applied on top of it to form a surface protection layer.
A tile-like plaster board with a marble pattern was obtained.

Example 2 A polyethylene film with a thickness of 50 μm was used as a base material sheet, and after being made into a transfer sheet, vacuum forming was performed on the inner surface of a mold having the shape of a tile plate, and without removing the mold, a hydration-curing mixture was poured as it was and allowed to harden. A tile-like gypsum board similar to that in Example 1 was obtained in the same manner as in Example 1 except that the mold was demolded after curing.

Comparative Example Using a transfer sheet that does not have a porous resin layer formed of a porous resin having the formulation described in Example 1, plaster was applied in the same steps as those described in Examples 1 and 2. Boards were manufactured, but in each case the design was significantly distorted when pouring the hydration curing mixture or while the mixture was curing.
A gypsum board with the desired pattern could not be obtained.

[Brief explanation of the drawing]

1 to 5 are cross-sectional views showing one embodiment of the method of the present invention, and FIG. 1 is a cross-sectional view of a transfer sheet;
Figure 2 is a cross-sectional view of the transfer sheet molded to stand on its own; Figure 3 is a cross-sectional view of the transfer sheet vacuum-formed on the inner surface of the mold; and Figure 4 is a cross-sectional view of the transfer sheet that has been vacuum-formed on the inside of the mold. FIG. 5 shows a cross-sectional view of the state in which the hydration-cured material has been poured, and FIG. 5 shows a sectional view of the state in which the base sheet is peeled off after the hydration-cured material has been cured. 1... Base sheet, 2... Peeling varnish layer, 3...
Porous pattern layer, 4... Porous resin layer, 5...
Transfer sheet, 6... Formwork, 7... Hydration hardening material.

Claims (1)

[Claims] 1. A transfer sheet in which each layer is formed in the order of a water-soluble release varnish layer, a porous pattern layer, and a porous resin layer on a base sheet is molded with the pattern layer inside, or a mold of the desired shape is formed. A method for manufacturing a decorative board, which is characterized by setting the inside of the board, then pouring a hydration hardening material, hardening and molding the board, and painting at the same time, and then peeling off the base sheet.