JPS6315029B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing decorative materials with three-dimensional patterns, in particular decorative papers or decorative laminates, and relates to a method for producing decorative materials with three-dimensional patterns, particularly a method for producing decorative materials with three-dimensional patterns described in Japanese Patent Application No. 53-38548. It is concerned with the manufacturing method of decorative materials that improve performance.

In other words, the method described in Japanese Patent Application No. 53-38548 is
A colored flat pattern (hereinafter simply referred to as a flat pattern) is printed on a base material, and a raised part that is in sync with the pattern is formed on the required part of the flat pattern by screen printing using colorless or colored transparent or translucent ink. Therefore, there has been no conventional method for producing decorative materials with three-dimensional patterns, particularly decorative paper or decorative boards, which have an excellent three-dimensional effect in which the flat pattern appears to stand out due to the lens effect of the raised pattern portion. It has now become possible to obtain a decorative material with an excellent substantial feel that has never been possible before. In particular, the decorative board obtained by the method described in Japanese Patent Application No. 53-38548 has a thick raised pattern formed by screen printing, so the surface performance of the decorative board is inferior to that of a conventional decorative board with a thin coating film. This is a significant improvement compared to other materials and is suitable for harsh applications such as floor surface materials. The present invention was made for the purpose of further improving the appearance and surface properties of the decorative board and imparting wear resistance that can withstand wearing shoes.
Its feature lies in the addition of transparent, highly hard powder to the screen ink.

Conventionally, methods for improving the abrasion resistance of decorative materials and veneer surfaces include the use of high-hardness abrasion-resistant agents, such as particles with a particle size of 10 to
A method of adding approximately 70 μm of aluminum oxide or silicon carbide powder is used.

However, the method of adding anti-wear agents to paints is difficult due to the suitability of coating machines such as roll coaters and flow coaters, and the settling of anti-wear agents in paints, so it is not possible to use powder with very large particles, and the average diameter is but
It is limited to expensive powders with a particle size of about 100 microns or less, and if powders with too large a particle size are used, there are problems such as the surface of the top coat becomes rough and the appearance becomes very poor.

Therefore, the present invention aims at forming a flat pattern by a printing method selected from gravure, offset, offset gravure, lithography, flexo, convex plate, and screen, with or without surface treatment on the surface of the substrate to be printed. , silicon carbide powder or aluminum oxide powder with a particle size of 30 to 250μ is applied to the desired areas on the pattern by screen printing, either as the printing substrate or after the printing substrate is once attached to the substrate. , silicon oxide powder, aluminum hydroxide powder, silica powder, glass beads, etc., in an amount of 10 to 10% based on the resin content.
By forming a raised pattern part that is in sync with the pattern using a colorless or colored transparent or translucent ink containing 150% weight ratio, the lens effect of the transparent or translucent ink containing high hardness powder can be achieved. Therefore, the present invention relates to a method for producing a decorative material with a three-dimensional pattern, characterized in that the above-mentioned flat pattern stands out and has excellent abrasion resistance.

As the printing substrate used in the present invention, sheet materials such as paper, veneer, synthetic paper, cellophane, cloth, nonwoven fabric, plastic film such as PVC, polyethylene, and Saran, and metal foil are commonly used, and in some cases, It is also possible to print directly onto wood boards, plastic boards, metal boards, etc. In addition, the above-mentioned sheet-like material with the first level of normal flat colored printing can be used to print wood boards such as plywood, particle board, hardboard, asbestos slate, pulp cement board, minerals such as glass fiber, etc. The subsequent screen printing process can also be carried out after being attached to a substrate selected from quality fiberboard, gypsum board, silicate lime board, metal plate, and other architectural boards. When the sheet-like material is paper or the like that is easily expanded and contracted by printing, painting, etc., it is preferable to once adhere it to the substrate and then carry out the subsequent process. The most commonly used printing substrate for the present invention is paper;
It can be used as a decorative paper made by applying the method of the present invention to paper as it is, or by applying the general printing of the present invention to paper to the above-mentioned substrate, especially plywood, and then subjected to subsequent steps after the screen printing process. The most common practice is to produce decorative laminates.

The manufacturing method of the present invention will be explained by taking as an example a case where paper is used as the printing substrate. The paper used in this invention is
In addition to thin paper of about 25 to 40 g/ ^m2 , titanium paper of about 35 to 200 g/ ^m2 , synthetic paper or the like is used, and if necessary, surface treatment such as impregnation with synthetic resin or coating with sealer is used.

First, as shown in FIG. 1, a base paint 2 is applied to the entire surface of a printing substrate, paper 1, using a normal coating device such as a roll coater or a flow coater, and then dried or baked. This pretreatment is not necessarily required.

Next, as shown in Figure 2, by normal printing,
A pattern printing 3 is applied to the base 2 by a flat colored printing means. The flat pattern printing method used here may be any of the commonly used methods such as gravure, offset, offset gravure, lithography, flexo, convex plate, and screen, and is suitable for printing dense patterns. Any method that can express the image can be used, and depending on the degree of coloring, printing in multiple colors can be performed. The paints and inks used for this purpose are determined by the type of substrate to be printed, the product, and the properties of the base material, but common materials can be used.

Next, as shown in FIG. 3, silicon carbide powder, aluminum oxide powder, silicon oxide powder with a particle size of 30 to 250 μm are added to the desired portions of the printed pattern by screen printing in synchronization with the printed pattern. A raised pattern is created using a colorless or colored transparent or translucent ink containing one or more of the above 9, such as aluminum hydroxide powder, silica powder, and glass beads, in an actual weight ratio of 10 to 150% based on the resin content. By shaping the portion 6, the decorative board of the present invention is obtained. or as the case may be, the fourth
As shown in the figure, a transparent layer 7 of a conventional transparent top coat may be applied to the surface using a conventional coating device for surface protection and cosmetic effect, followed by drying or baking.

For screen printing, in addition to the usual flat type, a rotary screen printing machine with an endless screen plate is used, and a screen made of wire mesh or synthetic fibers such as nylon or Tetron is used. However, as a screen printing ink vehicle that becomes transparent or translucent upon curing, which is an important feature of the present invention,
For example, acrylic resins, vinyl acetate resin emulsions, epoxy resins, urethane resins, vinyl chloride resins, ethyl cellulose resins, etc. are used, and water-soluble vehicles are preferred because they do not clog the screen. When adding extender pigments, it is preferable to use transparent pigments such as silica or zinc stearate or glass beads with a particle size of 30μ or less, and when using colorants, it is preferable to use ordinary transparent dyes. . This raised part needs to be transparent, and even if it is semi-transparent, it needs to be so transparent that at least the flat pattern underneath can be seen through.

In addition, in order to further increase the effect of the present invention by increasing the amount of transfer, it is necessary to use a material with a high solid content, for example, non-volatile content of 50% or more, and a viscosity of, for example, 30,000 to 50,000 centipoise, or even higher depending on the case. A high-priced one is used. Furthermore, although the ink used in the present invention causes leveling upon application, the leveling occurs only to the extent that the corners of the raised portions are removed, and the viscosity and thixotropy, which cause the pattern to flow outward and become disordered, are undesirable. Particle size is 30~ compared to the resin content of screen ink
Contain one or more of 250μ silicon carbide powder, aluminum oxide powder, silicon oxide powder, aluminum hydroxide powder, silica powder, glass beads, etc. at a weight ratio of 10 to 150% based on the resin content of the screen ink. If the particle size is 250μ or more, it will impede the transparency of the screen ink and will easily damage wire mesh or synthetic fiber screens, significantly reducing the number of times the screen can be used. If it is less than 30μ, it is difficult to obtain the desired wear resistance performance. On the other hand, if the amount added is more than 150% by weight based on the resin content of the screen ink, the transparency of the screen ink layer will decrease and the flat pattern will appear faded, and if the amount added is less than 10% by weight, the desired abrasion resistance performance will not be achieved. This is because it cannot be obtained.

The above powders may be used alone or
They can also be mixed and used at the same time.

As mentioned above, in the present invention, there is less risk of pattern incongruity even if the physical properties are not adjusted as strictly as required for conventional screen printing. In order to increase the actual transfer amount of ink and improve the durability of the screen plate, for example, if the mesh size is 30 to 40 and the mesh spacing is 0.2 to 0.8 mm, there will be less clogging of ink and scratches on the screen. It is preferable that the thickness of the raised pattern 6 after drying is about 100 to 500 μm, so that an ink layer with excellent three-dimensional effect can be obtained with appropriate ink flow after printing.

In addition to the above, the manufacturing method of the present invention is modified in that, as shown in FIG. Alternatively, there is a case where a normal transparent top coat 7 is applied on top of it (FIG. 5 shows this case), thereby obtaining a decorative material with a pattern that has an even more three-dimensional effect and excellent abrasion resistance. Can be done.

The decorative material thus produced by the method of the present invention, in this case the decorative paper, can be used as it is as a decorative paper with a three-dimensional pattern, or it can be used as a decorative paper with a three-dimensional pattern, or it can be used as a decorative paper with a three-dimensional pattern. Used as a decorative board attached to substrates such as plastic board, particle board, hardboard, asbestos slate, pulp cement board, mineral fiber board, gypsum board, silicate lime board, metal board, or other architectural boards. It will be done. In this case, a strongly alkaline substrate such as a pulp cement board or asbestos slate should be pretreated with an alkaline sealer.

In addition, when using, for example, paper or other easily stretchable material as the printing substrate of the present invention, the forming of the raised layer by normal flat pattern and screen printing is performed in the paper state as described above. It is used as a decorative paper or as a decorative board by pasting it on a substrate, but another method is to print the flat pattern in the previous process to make a printed patterned paper or plastic sheet, and then apply it to one of the substrates mentioned above. It is better to carry out the above-mentioned screen printing process after pasting the paper to the paper (most commonly plywood) to prevent changes due to expansion and contraction of the paper, and to ensure accurate synchronization between the flat pattern and the raised pattern. Therefore, it is better to perform the steps after screen printing after attaching it to the substrate. The pattern is shown in the explanatory diagrams of FIGS. 6 to 8. In the figure, 4 is a substrate, and 5 is an adhesive layer between the printing material and the substrate.

As described above, according to the method of the present invention, a colorless or colored transparent or translucent raised layer is printed on the required portions of a gradated flat colored pattern, and the screen ink layer itself forms a wear-resistant three-dimensional pattern. It not only works as a convex lens (in this invention, this is referred to as a lens effect), visually making the flat printed pattern stand out and further emphasizing the three-dimensional effect, giving it an excellent sense of substance that was completely unimaginable in the past. It has now become possible to obtain decorative materials such as decorative papers or decorative laminates.

Furthermore, it is actually impossible to perfectly synchronize two types of printed patterns using different printing methods on a material with a large degree of expansion and contraction, such as paper, and in the prior art, pattern misalignment was unavoidable. ,
Due to the manufacturing method of the present invention, even if the pattern is slightly misaligned, it does not cause any discomfort, but rather gives a soft feel. It has become possible to industrially manufacture sheets or decorative laminates with almost no loss in yield. Furthermore, compared to the conventional method of adding high-hardness powder to the top coat to improve the wear resistance of the decorative surface, the method of the present invention, which adds high-hardness powder only to the convex portions of the decorative surface, improves the wear resistance of the decorative surface. The amount added can be reduced and is effective.

Furthermore, in the conventional method of adding high-hardness powder to top coat paint and applying it using a roll coater, etc., when the particle size of the high-hardness powder exceeds about 100μ, the viscosity and fluidity of the paint deteriorates, making it difficult to paint. sex becomes very bad. However, according to the method of the present invention, since high-hardness powder is added to the screen printing ink for printing, even if the particle size of the high-hardness powder is about 250 mm, it can pass through the screen mesh without any problem and print easily. This makes it possible to improve the abrasion resistance of decorative surfaces at low cost and with easy work. In addition, even if a high-hardness powder with a large particle size is used, in the case of the present invention, the particles are not directly exposed to the decorative surface, so the surface of the decorative material does not become rough, and a beautiful decorative surface can be obtained.

Next, examples of the present invention will be shown.

Example 1 After printing a solid plate with nitrocellulose ink using a gravure printing machine on the entire surface of 55g/ ^m2 titanium paper,
A two-color floral pattern was printed on printed paper. The printed paper was then attached to the surface of a 12 mm thick plywood board using a hot press using a vinyl acetate resin adhesive. Next, a convex pattern was formed using a screen printing machine using a colored transparent screen ink having the following composition in accordance with the pattern part that would become the convex part on the printing paper.
Dry for 10 minutes to adjust the thickness of the screen ink layer.
It was set to 400μ.

Acrylic resin emulsion 98.99 parts by weight Extender pigment (silica) 1 〃 Dye (CI Acid Red 184) 0.01 〃 Aluminum oxide powder (100-150μ) 60.00 〃 Additive 1 〃 Next, apply amino alkyd resin transparent paint to the entire surface
After applying a topcoat of 100g/ ^m2 , dry at 70-80℃ for 30 minutes,
A three-dimensional patterned decorative plywood with excellent abrasion resistance in which the flower pattern is convex and the printed flat pattern stands out is obtained.

The screen plate was made on Tetron 250μ wire (Mesh 30 opening 50μ), and the plate thickness was 450μ.
It was a finished product.

For a comparative test, a three-dimensional patterned decorative plywood was created using the screen ink composition of Example 1 except that aluminum oxide powder (100 to 150μ) was removed. When we compared the abrasion resistance performance of both using an abrasion tester specified by JIS-K6902, we found that although the floral pattern on the surface of the decorative paper began to disappear, the one of this example passed the abrasion test 2,500 times. On the other hand, the comparative example
It only passed 600 wear tests.

Example 2 After solid printing on the entire surface of 80 g/m ² synthetic paper with vinyl chloride resin ink using a gravure printing machine, a tile pattern was printed in three colors to obtain printed paper.

Next, the printed paper was adhered to the surface of a 6 mm thick asbestos cement board using an acrylic resin adhesive using a roll press. Next, a convex pattern is formed using a screen printing machine using a transparent screen ink made of the following crude composition in accordance with the patterned areas that will become convex parts on the printing paper, and dried at 80°C for 20 minutes to form a screen ink layer. The tile pattern is convex with a thickness of 300μ and epoxy resin 97 parts by weight Extender pigment (zinc stearate) 1 Thickener (methylcellulose) 1 Glass beads (150-200μ) 90 Additives 1 At the same time, a three-dimensional patterned decorative board with excellent abrasion resistance in which the printed flat pattern stands out was obtained.

The screen plate was manufactured using the same plate making process as in Example 1 to a thickness of 350 μm. For a comparative test, a three-dimensional patterned decorative plywood was created using the screen ink composition of Example 2 except that the glass beads (150 to 200μ) were removed. Both of these are JIS-
When comparing the abrasion resistance performance using an abrasion tester specified by K6902, it was found that although the tile pattern on the surface of the decorative paper began to disappear, the one of this example passed the abrasion test 1800 times, while the one of the comparative example It passed only 500 wear tests.

[Brief explanation of the drawing]

1 to 8 are schematic enlarged sectional explanatory views for explaining the outline of each process of the present invention, and FIGS. 1 to 3 show a decorative material having a three-dimensional pattern without adhering a printing material to a substrate. In this case, FIGS. 4 and 5 are explanatory diagrams illustrating the process of manufacturing paper (paper), and FIGS. 4 and 5 are explanatory diagrams of a modified method thereof. FIGS. 6 and 7 are explanatory diagrams illustrating the process of manufacturing a decorative board having a three-dimensional pattern by printing a flat colored pattern on a printing material, pasting it onto a substrate, and performing the steps after screen printing. FIG. 8 shows an explanatory diagram of the modified method. In the figure, 1: Printing substrate (paper in this case), 2:
Base color paint, 3: Flat colored pattern printing layer, 4: Substrate (in this case, plywood), 5: Adhesive layer, 6: Transparent or colored transparent screen ink layer, 7: Transparent top coat layer, 8: Flat colored layer. Pattern printing layer, 9: High hardness powder.

Claims (1)

[Claims] 1 After forming a flat pattern by a printing method selected from gravure, offset, offset gravure, lithography, flexo, convex plate, and screen with or without surface treatment on the surface of the printing substrate, the printing substrate is Silicon carbide powder with a particle size of 30 to 250μ is applied to the desired areas on the pattern by screen printing, either as is or after the printed base material is once attached to the base material.
Colorless or colored transparent or translucent ink containing one or more of aluminum oxide powder, silicon oxide powder, aluminum hydroxide powder, silica powder, glass beads, etc. at a weight ratio of 10 to 150% based on the resin content. A three-dimensional object characterized in that a raised pattern portion that is in sync with the pattern is created using the ink layer, and the flat pattern appears to stand out due to the lens effect of the transparent or semi-transparent ink layer, and also has excellent wear resistance. A method for producing patterned decorative materials.