JPS6299131A - Manufacturing process of sheet for embossing - Google Patents

Abstract

PURPOSE:To manufacture the sheet easily without using casting resin by putting and pressing the thermoplastic film on the concave and convex faces of the draft for embossing and then releasing the thermoplastic film. CONSTITUTION:The thermoplastic film is put on the concave and convex faces of the draft for embossing, the release face of film being placed exactly on the concaves and convexes, and then heated up and pressurized with the heated press to print the concave and convex forms of the draft for embossing on the release face of thermoplastic film. As the said draft, usually the draft having concaves and convexes on its surface is used, although any type desired is available. The said process shortens the manufacturing period, eliminates casting resin and can manufacture the sheet for processing easily. Upon demand, the duplicate plate can be manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for producing an embossing sheet used in producing polyester decorative plywood.

[Conventional technology]

Methods for manufacturing embossing sheets used in the production of polyester decorative plywood using the film method include: ■ Forming a thermoplastic film using an embossing roll; ■ Embossing using a casting silicone resin. There is a way to make a mold from a mold manuscript.

However, in the above case, although the productivity of the embossing sheet is not bad, it takes time and money to create the embossing roll itself, making it unsuitable for manufacturing a wide variety of small quantities of embossing sheets. . In addition, in the above case, the casting resin takes time to cure, the casting resin is expensive, and the cured resin is not durable during molding, so the molding process is repeated more often than the original for the embossing mold. This may result in damage to the original.

[Problems to be solved by the invention]

Therefore, in the present invention, the above-mentioned drawbacks of the conventional technology are solved, the time from making a mold from a manuscript to embossing on a thermoplastic sheet is short, there is no need to use casting resin, and embossing can be performed easily. The purpose of the present invention is to provide a method for producing a sheet for use in the manufacturing process.

[Means for solving problems]

1 of the manufacturing method of the embossing sheet of the present invention is characterized by ``pressing a thermoplastic film over the uneven surface of an embossing original having an uneven surface, and then peeling off the thermoplastic film.'' In addition, the method 2 for producing an embossing sheet of the present invention is as follows: ``A thermoplastic film is overlaid and pressed on the uneven surface of an embossing original having an uneven surface, and then the thermoplastic film is pressed. peel off the thermoplastic film, mold the irregularities formed on the peeled surface of the thermoplastic film to create a reproduction mold, and further create an embossing sheet using the reproduction mold as the master. be.

[Action/effect of the invention]

According to the present invention, a thermoplastic film is applied directly to an original for an embossing die and a sheet for reemboss processing is produced by pressing, so the time required for production is short and no casting resin is required. An embossing sheet can be easily manufactured, and if necessary, a replication mold can be further created to reproduce a large number of embossing sheets.

[Specific structure of the invention]

You can use whatever you want as the original manuscript, but
For example, materials with uneven surfaces, such as precious wood, veneer, cloth, and leather, are usually used. Among these, flexible ones should be fixed in advance to a rigid support such as plywood, metal plate, or plastic temporary with adhesive, etc. For materials that are difficult to remove, such as natural wood or cloth, it is best to apply sealing treatment in advance using known techniques to the extent that the surface condition is not impaired.

Various thermoplastic films can be used, but when used as an embossing sheet, it is desirable that the thermoplastic film has releasability from the material to be embossed. The embossing sheet used when manufacturing polyester decorative plywood is preferably one that has releasability from the unsaturated polyester resin, and in this case vinylon film, Tetron film, fluorine film, cellulose etc. It is a thermoplastic film such as a type film, and these are used in a single layer or a multilayer. A preferable multilayer thermoplastic film B type is one in which a low softening point film such as a polyvinyl chloride film, a polyethylene film, a polypropylene film, or other olefin film is laminated from the back side to the above-mentioned single layer thermoplastic film, Use of such a multilayer film has the advantage that embossing is easy.

The above-mentioned thermoplastic film is placed on the uneven surface of the above-mentioned embossing original having an uneven surface so that its releasable surface overlaps the uneven surface, and the thermoplastic film is heated and pressed with a force Vl using a heat press. Copy the uneven shape of the embossing original onto the release surface. Heat press conditions cannot be generalized as they vary depending on the heat capacity of the original for the embossing die used and the thermoforming temperature of the thermoplastic film used, but the temperature is 120 to 150°C, and the pressure is 10 to 20°C.
K g/cd. The heat applied by the press can be either hot, hot or hot, but hot press is preferred because it minimizes the return of the emboss.
Cold is preferable.

The obtained embossing sheet is, for example, a normal /2
In the manufacturing method of polyester decorative plywood using formula polyester molding, unsaturated polyester resin is coated and layered, left to naturally stand at room temperature to harden the resin, and then peeled off to transfer irregularities to the surface of the hardened polyester resin. be able to. In this way, unevenness can be imparted to the surface of the polyester resin decorative plywood.

The embossing sheet obtained by the manufacturing method of the first invention does not have any problem in terms of providing unevenness.When performing surface embossing in large quantities at once, the sheet for embossing obtained by the manufacturing method of the first invention can be It is necessary to create a sheet for embossing,
It's a hassle. Therefore, in the method of the second invention, a reproduction mold is created using the embossing sheet obtained in the first invention as a master, and the reproduction mold is used to emboss, for example, a thermoplastic film by pressing, This is a sheet for embossing.

First, an embossing sheet is prepared by the method of the first invention and used as a prototype in the method of the second invention.

Next, a mold for reproduction is created by molding the unevenness of the original mold. The reproduction mold faithfully reproduces the irregularities of the original.

Any material may be used as long as it can be copied and embossed on the reproduction material, but materials that are easy to handle, have little volume shrinkage during duplication, and are suitable for hot pressing. It is preferable to use a thermosetting resin, particularly a solvent-free thermosetting resin, because of its heat resistance.

Examples of solvent-free thermosetting resins include unsaturated polyester resins, polyurethane resins, and epoxy resins, and these resins may also contain silica, aluminum hydroxide, iron powder, etc. to improve dimensional accuracy and strength. may be mixed as a filler.

Of course, the reproduction mold can be made using the above resin alone, but it may also be lined with resin-treated plywood or hardboard, aluminum plate, phenolic resin laminate, melamine resin laminate, etc. In this way, the self-retainability of the replication mold is improved and the amount of replication material used can be reduced.

Using the obtained replication mold, the surface irregularities of the replication mold are then transferred onto a thermoplastic film to obtain an embossing sheet for final use.

The sheet material used to create the embossing sheet to be finally used is the same as the thermoplastic sheet used in the method of the first invention, and the conditions for hot pressing and the like are also the same.

Here, as a material for creating the final embossing sheet, a material curable with ionizing radiation such as electron beams or ultraviolet rays is used, and if necessary, it may be backed with a suitable substrate.

As materials that can be cured by ionizing radiation such as electron beams or ultraviolet rays, resins such as unsaturated polyester, polyether acrylate, polyester acrylate, epoxy acrylate, urethane acrylate, spiroacecool acrylate, polybutadiene, and polythiol polyene can be used. In addition, in order to further improve the crosslinking density, difunctional heptamer-2 or trimethylolpropane triacrylate such as neopentyl glycol diacrylate, tripropylene glycol diacrylate, diethylene glycol diacrylate, 1,6-hexanediol diacrylate, etc. Trifunctional monomers such as , pentaerythritol triacrylate, dipentaerythritol hexaacrylate, etc., or polyfunctional monomers such as 4.5.6 can be appropriately mixed and used.

When curing the above materials with ultraviolet rays, acetophenones, benzophenone, Michler's ketone, benzoin, pendylmethylkecoel, benzoyl benzoate, α-amyloxime ester, tetramethylthiuram monosulfide, thioxanthone, etc. are used as photoinitiators. Furthermore, as a sensitizer, n-butylamine, triethylamine, tri-n-butylphosphine, etc. can be used.

When using materials that can be cured by ionizing radiation such as electron beams or ultraviolet rays, pour the material onto the uneven surface of the duplication mold.
Usually, a transparent sheet serving as a base is further stacked and defoamed using a roller or the like, and ionizing radiation is irradiated from the side of the transparent sheet to cure it, and the transparent sheets are bonded together.

The amount of material that can be cured with ionizing radiation such as electron beams or ultraviolet rays depends on the size of the unevenness of the duplication mold, but
~1000 μm or so, preferably 100 to 500 μm
If the strength is at a certain level, sufficient strength can be obtained by supporting the base sheet.

A film of polyester, nylon, vinylon, polyolefin or the like can be used as the transparent base sheet, and preferably has a thickness of about 50 to 100 μm. When the adhesion between the base sheet and a material that can be cured by ionizing radiation such as electron beams or ultraviolet rays is poor, it is desirable to apply a primer to the base sheet side. Examples of the brimers include two-component curing types such as urethane-based and alkyl titanate-based brimers, which can be applied by an appropriate coating method.

Examples of ionizing radiation include ultraviolet rays emitted from light sources such as ultra-high-pressure mercury lamps, high-pressure mercury lamps, low-pressure mercury lamps, carbon arcs, xenon arcs, metal halide lamps, etc.; Emitted from various electron beam accelerators such as linear type, dynamidron type or high frequency type, 50 to 10
An electron beam or the like having an energy in the range of 0 KeV, preferably 100 to 300 KeV is used.

Using a material that can be cured by ionizing radiation such as electron beams or ultraviolet rays makes it easy to create embossing sheets, which can be done in a short time and at low cost, making it suitable for producing a wide variety of products in small lots.

〔Example〕

One large "L turn" - A veneer was pasted onto a 9 mm thick hardboard with adhesive, the surface of the veneer was sanded, and a finishing coat was applied to create a manuscript for embossing.

Separately, a 25μm thick vinylon film and a 200μm thick
A laminated film was prepared by laminating a polyvinyl chloride film of 1.0 m, and the vinylon side of the laminated film was placed against the surface of a veneer and hot pressed.

The hot press temperature was 130°C and the pressure was 20Kg/M, and after pressing for 10 minutes under these conditions, it was cooled to 30°C.

When wet polyester molding was performed using the obtained embossing sheet, the surface irregularities of the veneer original could be reproduced extremely faithfully, and a polyester decorative plywood with a natural feel was obtained.

Using the sheet for embossing mold obtained in Example 1 as a prototype, it was made as follows.

9mm thick medium density fiberboard (MDF) (made by Hokushin Plywood ■)
Starwood) is pasted with black titanium paper using adhesive, and a polyester resin of the following composition is poured over it, the uneven surfaces of the above model are overlapped, and after being left to harden at room temperature for 12 hours, the model is peeled off and duplicated. A mold was created.

Part 1: 100 parts of unsaturated polyester resin (manufactured by Mitsui Toatsu, Nistar D-117B) Curing catalyst 1
(manufactured by NOF Corporation, Permec N) Separately, a vinylon film with a thickness of 25 μm and a thickness of 200 μm.
Prepare a laminated film laminated with a polyvinyl chloride film of 500 m, apply the vinylon side to one side of a duplication mold, heat and pressurize at 120'C515K g/m for 10 minutes, then cool to 30 ° C. Peeled off.

Even when the embossed sheet obtained in this way was used, it was possible to obtain a polyester decorative plywood with a natural feel, similar to when the embossed sheet obtained in Example 1 was used.

lll↓ Attach the fabric to aluminum using adhesive,
The same procedure as in Example 1 was carried out except that the surface of the cloth was sealed and used as a manuscript.

When the obtained embossing sheet was used, a polyester decorative plywood whose texture was faithfully reproduced was obtained.

The same procedure as in Example 3 was carried out until the mold for replicating Sensenkodo was prepared.

Next, an ultraviolet curable resin (FP-70, manufactured by Asahi Kasei Kogyo Co., Ltd.) was poured onto the duplicating mold at a rate of 150/Jm, and a polyethylene terephthalate film (Toshiba Co., Ltd. (manufactured by F-60, thickness 75 μm) were stacked on top of each other, and defoamed from the film side using a roller. After defoaming, ultraviolet rays were irradiated from the film side for 1 second using a high-pressure mercury lamp with an output of 160 W/cm to harden the resin and integrate it with the film.Then, the film was peeled off and the embossing sheet was made. Obtained.

Even when using the embossing sheet obtained in this way, it was possible to obtain a polyester decorative plywood with a natural feel, as in Examples 1 to 3.

Claims (2)

[Claims] (1) A method for manufacturing an embossing sheet, which comprises pressing a thermoplastic film over the uneven surface of an embossing original having an uneven surface, and then peeling off the thermoplastic film. (2) A thermoplastic film is layered and pressed on the uneven surface of an embossing original that has an uneven surface, and then the thermoplastic film is peeled off, and the unevenness formed on the peeled surface of the thermoplastic film is molded. 1. A method for manufacturing an embossing sheet, comprising: creating a duplication mold, and further creating an embossing sheet using the duplication mold as a master model.