JPS6330148B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a method for manufacturing polyester decorative laminates, and is particularly characterized by a method for manufacturing a shaped film for imparting irregularities to the surface of polyester decorative laminates. Various forms of embossing plates have been used to manufacture polyester decorative boards. Among these methods, the method of using an embossing roll with an uneven circumferential surface has relatively good productivity, but the embossing roll is expensive, so it is not suitable for small-lot, high-mix production, and the reproducibility of the uneven shape is difficult. It has some disadvantages such as. In addition, the method of applying a room-temperature-curing silicone resin to the surface of the document and removing it from the mold after curing as a practical type has extremely good reproducibility of uneven shapes, but the practical type silicone resin is expensive. ,
Also, since the resistance to polyester resin is not very good, the number of times it can be used is limited to less than 20 times, and as a result, practical types are expensive. In connection with this, the number of times the document is used increases, and the risk of damaging the document also increases. Furthermore, since silicone resin is opaque, it has the disadvantage that it is difficult to defoam during the production of decorative laminates. The present invention eliminates the above-mentioned drawbacks, and provides a method for producing a shaped film that faithfully reproduces the surface shape of an original and can be used repeatedly for producing polyester decorative laminates 100 times or more. The present invention will be explained in detail below with reference to the drawings. First, as shown in Figure 1, cloth, leather,
A silicone resin 2 is coated on the surface of a document 1 having an arbitrary shape such as enamel, a veneer, or the like, and after hardening, the silicone resin 2 is removed from the mold to obtain a first mold 2a as shown in FIG. Next, as shown in FIG. 3, the surface shape is transferred to a solvent-free thermosetting resin 3 using the first mold 2a, and a second mold 3a is produced as shown in FIG. . At this time, a base material 4 that supports the thermosetting resin layer can also be used if necessary. Next, as shown in FIG. 5, in the press machine, on the press surface plate 5, there is a cushion 6, a mirror plate 7, a second mold 3a, and a mold releasable material for polyester resin.
and a transparent film 8, a sheet 9 that can be peeled off from the cushion (this may be omitted), and a cushion 1.
0. Set the mirror plate 11 in this order, heat and pressurize, remove the film from the second mold 3a as shown in FIG. 6, and make a third mold. Using this third mold, as shown in FIG. A polyester decorative board 12 is manufactured as follows. As mentioned above, the original can be made of any material, but if it is flexible, such as cloth, leather, leather, veneer, etc., it may be fixed to plywood, iron plate, plastic plate, etc. with adhesive or the like, if necessary. In addition, for materials that are difficult to mold with silicone, such as cloth or natural wood, it is desirable to apply sealing treatment using a known technique. There are two types of silicone resins: addition type silicone and condensation type silicone, and any commonly used mold-making silicone may be used, but it is preferable to use a low-temperature curing type because it causes less damage to the original. Solvent-free thermosetting resins include unsaturated polyester resins, urethane resins, epoxy resins, etc.
If necessary, add silica to improve dimensional accuracy and strength.
It is also possible to mix fillers such as aluminum hydroxide, calcium carbonate, iron powder, and Al powder, or fibrous substances such as glass strand chips and vinylon strand chips. The required quality is that when molding is made from the first silicone mold, there is adequate workability in terms of degassing, reproducibility, etc., and that it can withstand repeated use under heating and pressurizing conditions in subsequent steps. More specifically, it is necessary that the embossing does not return for 24 hours or more under heating and pressure of at least 5 kg/cm ² at 100°C. The second type made of this resin may be a single layer of resin, but in consideration of workability and cost, the resin layer is placed on a base material such as an aluminum plate, resin-treated plywood, phenol resin or melamine resin laminate. It is also possible to provide A transparent film that has mold releasability to polyester resin and can be used when manufacturing polyester decorative laminates by the film method, specifically, vinylon film, Tetron film, or fluoride film. Refers to fluorine-based films such as vinyl films, and cellulose-based films. polyethylene film, polypropylene film,
Vinyl chloride film and the like are not suitable for making polyester decorative laminates and are therefore undesirable. That is, since polyethylene film, polypropylene film, etc. have the property of permeating oxygen, the polyester resin is difficult to cure, and the film expands due to the styrene monomer in the polyester resin, causing flare in the product. Furthermore, in the case of a film that does not have solvent resistance, such as a vinyl chloride film, the film is attacked by the styrene monomer in the polyester resin, making it difficult to produce a decorative board. The films used in the present invention can be used in a single layer as described above, but since each film has considerable heat resistance, high heat and high pressure are required during pressing. Therefore, depending on the specifications of the press machine and the uneven shape of the second die, the thickness of the film may vary.
It is preferable that the thickness be 50μ or less, and that a film with a low softening point such as a polyvinyl chloride resin film or a polyolefin film is laminated on the back side in advance. For reference, the table below shows the press conditions for embossing a single layer film and a laminated film with a film laminated on the back side. [Test conditions] 2nd type Teak veneer shape press configuration, lower surface plate\cushion\2nd type\
Transparent film＼Peelable film＼Cushion (heat-resistant polyamide non-woven fabric)＼Mirror plate Pressing method: After heating and pressing for 15 minutes, the pressure is kept pressed for 50 minutes.
Cool to ℃ and remove.

[Example 1]

Urethane synthetic leather bonded to the substrate plywood with adhesive is used as the manuscript. Silicone resin (product name: Shin-Etsu Silicon KE-112, Shin-Etsu Chemical Co., Ltd.)
Co., Ltd.), and after curing at room temperature, the mold was released to obtain a first mold. A polyester resin having the following formulation was poured onto the first mold to a thickness of about 5 mm, and to improve strength, a glass nonwoven fabric of 100 g/m ² was placed on it before curing, and the resin was heated at room temperature for 24 hours.
After being left for a period of time to harden, a second mold in which a resin layer and a glass nonwoven fabric are laminated and integrated is produced from the first silicone mold. Polyester resin formulation Polylite FG-283 (Japan Reichhold)
100 parts by weight filler (calcium carbonate) 50〃 Cobalt naphthenate (8% cobalt) 0.5〃 55% methyl ethyl ketone peroxide
1 Next, a laminated film consisting of a pre-laminated vinyl chloride film with a thickness of 300μ and a vinylon film with a thickness of 25μ was stacked on the second mold with the side of the vinylon film facing, and heated to 150°C with the following configuration. Insert into heated press. Configuration: Lower surface plate\Cushion\4 mm thick duralumin plate\2nd type\Laminated film\Nylon release film\Cushion weighing 200 g/ ^m2 \4 mm thick duralumin plate\Upper surface plate Above configuration After heating and pressing at 15Kg/cm ² for 15 minutes at 150℃, cool water was passed through the press while pressurized, and when the press platen reached 50℃, it was removed from the press and the film was removed from the second die. A molded film having a leather surface shape was obtained. When a polyester decorative laminate was produced using the shaped film in the following manner, a decorative laminate that reproduced the surface condition of synthetic leather in great detail was obtained. Base material: 2.7mm thick lauan plywood ＼Titanium paper OKE
-80 (manufactured by Kishu Paper Co., Ltd.) Polyester resin: Polylite KC-34 (Nippon Reichhold Co., Ltd.)
100 parts by weight Colorant EM Color (manufactured by Toyo Ink Manufacturing Co., Ltd.)
10〃 55% Methyl Ethyl Ketone Peroxide
2. Curing conditions: 50°C for 2 hours When a polyester decorative board was manufactured under the same conditions 100 times, no re-embossment or significant change in surface gloss was observed, confirming the suitability for repeated use. According to the method of the present invention as described above, the following effects can be obtained. It is possible to easily produce a molded film for polyester decorative laminates without using expensive embossing rolls.It is possible to faithfully reproduce the surface shape of documents with low strength that are not heat resistant or deform when pressed. The molded film of the present invention has no fear of deterioration due to oxidation compared to silicone molds, etc.
Can be used repeatedly over 100 times. The shaped film of the present invention is extremely easy to handle.

[Brief explanation of drawings]

The drawings are schematic diagrams illustrating an example of the process of the method of the present invention, and FIG. 1 shows a state in which silicone resin is applied to the surface of an original, and FIG. 2 shows a state in which the silicone resin layer is peeled off from the original and the first mold Figures 3 and 4 show the process of manufacturing the second mold using the first mold, and Figures 5 and 6 show the process of manufacturing the third mold, which is a molded film, using the second mold. FIG. 7 is a cross-sectional view showing the steps of manufacturing a polyester decorative board using the shaped film. 1... Manuscript, 2... Silicone resin, 2a...
1st type, 3... thermosetting resin, 3a... 2nd type,
4...Base material, 5...Press surface plate, 6...Cushion, 7...Mirror plate, 8...Film, 9...Sheet that can be peeled from the cushion, 10...Cushion, 11...Mirror plate, 12...Polyester decorative board.

Claims (1)

[Claims] 1. Pour room temperature curing silicone resin onto the surface of an original document having an uneven surface, and after curing, take a mold to create a first mold. A second mold is created by pouring the mold resin and taking the mold after curing. Next, a transparent film having mold releasability for polyester resin is placed on the uneven surface of the second mold, and heated and pressurized to form the second mold. A method for producing a shaped film for polyester decorative laminates, characterized in that a third type of film is formed by forming an uneven surface of the second type.