JP2000225665A - Unevenly patterned electron beam curing resin decortive sheet and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To simplify a production process and, at the same time, improve the surface hardness, wearability, scratch resistance, pollution resistance or the like by a method wherein a surface protective layer is made of an electron beam curing resin and, at the same time, an uneven pattern is provided on a thermoplastic resin layer surface to be laminated to one side of a paper-based base material sheet so as to transferringly form with a shaping sheet. SOLUTION: A shaping sheet 7, in which an uneven patterned surface 7c is provided on the surface of a thermoplastic resin layer 7b to be laminated onto one side of a paper-based base material sheet 7a, is prepared. An electron beam curing resin 5 is coated on a decorative sheet 4 pasted through an adhesive layer 3 on the top surface of a base material 2 for a decorative sheet. In succession, an electron beam EB is applied from the paper-based base material sheet 7a surface under the sate that the uneven patterned surface 7c of the shaping sheet 7 is placed upon the electron beam curing resin 5 surface so as to cure the electron beam curing resin 5 in order to produce a surface protective layer 5. Next, by peeling off the shaping sheet 7, the electron beam curing resin decorative sheet, on the top surface of the surface protective layer 5 of which an uneven patterned layer 6 is formed, can be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electron beam-curable resin decorative board having an uneven pattern on its surface, which is suitable for various furniture surface materials and building material interior materials, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, decorative boards having a high surface hardness, being hardly damaged and having excellent stain resistance include, for example, wood-based base materials such as plywood, MDF, particle board, calcium silicate board, and asbestos slate board. A method of attaching a decorative paper having a printed pattern formed thereon to a base material such as an inorganic base material such as a cement slate plate, a method of printing a pattern pattern directly on the base material,
Or after providing a pattern by a method of transferring the pattern to the substrate surface using a transfer sheet or the like, and then coating and curing an ionizing radiation-curable resin paint from the top of the pattern pattern layer, as a surface protective layer. It is known, but has the drawback that the surface is smooth and poor in design.

[0003] In order to solve the above-mentioned drawbacks, an ionizing radiation-transmitting release substrate having a releasable surface is provided with an ionizing radiation shielding pattern layer, and the release substrate is interposed through an ionizing radiation-curable resin layer. Laminate, irradiate ionizing radiation from the side of the peelable substrate and cure the ionizing radiation-curable resin layer corresponding to the portion without the ionizing radiation shielding pattern, then peel off the peelable substrate, and cure with ionizing radiation. A method of forming a concave-convex pattern by attaching a part of the resin in the uncured portion of the conductive resin layer to a peelable substrate and removing the resin is used. However, in these methods, the step of removing the uncured resin after peeling the releasable substrate, such that the edge portion of the concavo-convex pattern swells and the design is inferior,
Alternatively, there is a problem that the number of production steps is large, such as a step of irradiating ionizing radiation again to cure the uncured resin, and the cost is complicated and the cost is increased.

[0004] Further, as a base material of a shaped film,
When a heat-resistant film such as polyethylene terephthalate is used, the cost is high, the film is easily curled when the film is thinned, and it is difficult to manufacture a decorative board. There were drawbacks such as difficulty in working, suction of dust, and curling due to lamination with a polyolefin resin.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and has as its object to improve surface properties such as surface hardness, abrasion resistance, scratch resistance, and stain resistance. An object of the present invention is to provide a decorative board excellent in design such as a three-dimensional appearance with good productivity and low cost, that is, to provide an electron beam-curable resin decorative board having an uneven pattern and a method for producing the same.

[0006]

In order to achieve the above-mentioned object, the present invention provides a method for manufacturing a decorative board comprising an adhesive layer, a decorative sheet, and a surface protective layer which are sequentially laminated on the upper surface of a decorative board substrate. In a decorative plate having an uneven pattern layer formed on the upper surface side of the layer, the surface protective layer is made of an electron beam curable resin, and the uneven pattern layer is formed by laminating a thermoplastic resin on one surface of a paper-based base sheet. An electron beam-curable resin decorative board having an uneven pattern, which is formed by transfer using a shaped sheet having an uneven pattern on the surface of the thermoplastic resin layer. By adopting such a configuration, since the uneven pattern on the surface is transferred and formed by the shaping sheet, the production process is simplified, the yield is improved, and an electron beam-curable resin decorative plate having an inexpensive uneven pattern is provided. In addition, since the surface protective layer of the decorative board is formed of an electron beam curable resin, the decorative board has excellent surface physical properties such as surface hardness, abrasion resistance, scratch resistance, and stain resistance. Furthermore, since the base material of the shaped sheet is made of a paper-type base material sheet having a lower specific gravity than a thermoplastic resin film such as a polyester film, the electron beam permeability is high, and it reaches deeper in the depth direction.
An uneven pattern having an excellent three-dimensional effect can be formed, and curling prevention and antistatic properties are improved, and the product can be manufactured with high efficiency.

[0007] The invention is characterized in that the thermoplastic resin is made of a polyethylene resin. By doing so, it is possible to easily form a fine uneven pattern, and to adhere relatively well to the paper-based substrate sheet, and to be inexpensive.

[0008] A decorative sheet having a pattern printing layer provided on the upper surface thereof is laminated on a base material for a decorative plate via an adhesive layer, an electron beam curable resin is applied on the upper surface, and a paper material is further applied on the upper surface. A shaping sheet composed of a base material sheet and a thermoplastic resin layer having a concavo-convex pattern on the surface is placed so that the concavo-convex pattern surface is in contact with the electron beam curable resin, and a paper-based base material of the shaping sheet. Irradiate an electron beam from the sheet side, cure the electron beam curable resin to form a surface protective layer, and then
By making the method of manufacturing an electron beam-curable resin decorative board having an uneven pattern characterized by peeling the shaping sheet, an electron beam-curable decorative sheet having an uneven pattern having the above-described effects can be easily obtained. It can be reliably manufactured.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, specific embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a laminated cross-sectional view showing an embodiment of an electron beam-curable resin decorative board having an uneven pattern according to the present invention, and FIG. FIG. 1 is a cross-sectional view of a laminate to be described, wherein 1 is an electron beam-curable resin decorative plate having an uneven pattern, 2 is a decorative plate base, 3 is an adhesive layer, 4 is a decorative sheet, 4a is a decorative sheet base, 4b Is a pattern printing layer, 5 is a surface protective layer, 5 'is an electron beam curable resin layer, 6 is an uneven pattern, 7 is a shaping sheet, 7a is a paper base sheet, 7b is a thermoplastic resin layer, and 7c is uneven. And EB represent an electron beam, respectively.

As shown in FIG. 1, a decorative board 1 for an electron beam-curable resin having a concavo-convex pattern according to the present invention has a substrate 2 for a decorative board.
A decorative sheet 4 is provided on the upper surface of the sheet with an adhesive layer 3 interposed therebetween, and a surface protective layer 5 is further laminated on the upper surface of the decorative sheet 4, and an uneven pattern 6 is formed on the upper surface. A shaping sheet in which the surface protective layer 5 is made of an electron beam-curable resin, and a thermoplastic resin 7b having an uneven pattern 7c provided on one surface of a paper-based substrate sheet 7a described later on the surface thereof is laminated. 7 is irradiated with an electron beam EB and cured, and thereafter, the shaping sheet 7 is peeled off from the surface protective layer 5, and an uneven pattern layer 6 is provided on the surface of the surface protective layer 5. I do.

Next, a method of manufacturing the decorative veneer 1 having an uneven pattern according to the present invention will be described with reference to the drawings. First, as shown in FIG. 2A, a thermoplastic resin layer 7b is laminated on one surface of a paper base sheet 7a, and a shaped sheet 7 having an uneven pattern 7c provided on the surface thereof is prepared.
Next, as shown in FIG. 2 (b), a decorative sheet 4 is adhered to the upper surface of the decorative board base material 2 via an adhesive layer 3, and then, as shown in FIG. Electron beam curable resin 5 'is applied to decorative sheet 4 on the upper surface of decorative board base material 2, and then, as shown in FIG.
As shown in (d), the uneven pattern surface 7c of the shaping sheet 7
Is superimposed on the surface of the electron beam-curable resin 5 ′ provided on the surface of the decorative sheet substrate 2, and the electron beam EB is irradiated from the surface of the paper-based substrate sheet 7 a of the shaping sheet 7, The conductive resin 5 ′ is cured to form the surface protective layer 5. Then, FIG.
As shown in (e), the shaping sheet 7 was peeled off to form the concavo-convex pattern layer 6 on the upper surface of the surface protective layer 5, that is, the electron beam curability having the concavo-convex pattern as shown in FIG. The resin decorative board 1 is obtained.

The decorative board substrate 2 used for the electron beam curable resin decorative board 1 having an uneven pattern according to the present invention includes wood,
Plywood, particle board, wood base material such as MDF, calcium silicate board, asbestos slate board, lightweight foam concrete board, cement board such as hollow extruded cement board, gypsum board such as gypsum board, gypsum slag board, pulp cement board An inorganic base material such as a fiber cement board such as an asbestos cement board or a wood chip cement board can be used, as long as it provides the thickness and strength required as a decorative board, for example,
By using an inorganic base material, a decorative plate having nonflammability can be obtained, which is used for a wide range of applications.

The base material 4a for a decorative sheet used in the present invention may be a normal one such as a printing paper for building materials weighing 23 to 65 g / m ² , pure white paper, bleached or unbleached kraft paper, titanium paper, and the like. Mixed paper mixed with so-called synthetic resin, etc.
The paper is impregnated with latex or the like, and is subjected to calender roll processing to control the density and thickness so that the electron beam curable resin as the surface protective layer 5 can penetrate, and to make the surface smooth and smooth. Are preferred.

The pattern printing layer 4b is composed of a pattern ink layer formed by printing an arbitrary pattern such as a wood pattern, an abstract pattern, and a stone pattern, or a solid ink layer entirely printed.
As the vehicle, a general-purpose resin composed of an alkyd-based resin, a urethane-based resin, a vinyl chloride-based resin, or the like is used as a vehicle, and further, if necessary, other additives such as an organic or inorganic pigment. , A coloring agent such as a dye and a brilliant pigment, an extender pigment, a stabilizer, a plasticizer, a solvent and the like are appropriately mixed.

In order to give a more three-dimensional appearance to the design, the solid ink layer contains only a coloring pigment in the structure of the pattern printing layer 4b, and a coloring ink layer of a coloring pigment and a glitter pigment are added as the pattern ink layer. It is also possible to form a picture by a glitter ink layer, and it is also possible to include a glitter pigment in the solid ink layer together with a coloring pigment. And when the solid ink layer and the pattern ink layer contain a brilliant pigment, the solid ink layer and the pattern ink layer differ in the color tone of the brilliant pigment and are associated with each other's pattern,
Special visual effects and three-dimensional effects can be created.

As shown in FIG. 2A, the shaping sheet 7 for forming the concavo-convex pattern layer 6 on the decorative sheet according to the present invention includes a thermoplastic resin layer on one side of a paper base sheet 7a. 7b are laminated, and the irregular pattern 7c is formed on the surface of the thermoplastic resin layer 7b.
It is characterized by laminating a thermoplastic resin made of polyethylene resin or the like capable of forming a fine uneven pattern on one side of a paper-based base sheet 7a such as thin paper, By using a paper base sheet as the base material, the electron beam permeability is increased, so that the electron beam curable resin can be cured with high efficiency, and since the electron beam penetration is deep, the thermoplastic resin is used. Since the layers are stacked thickly and a deep uneven pattern can be formed, a three-dimensional appearance can be obtained. Further, it is preferable that the paper base sheet 7a is as thin as possible. However, when the paper base sheet 7a is too thin, the base material is easily stretched and curled easily during shaping of the concavo-convex pattern. Paper-based base sheet 7a from the viewpoint of workability
The thickness of the paper is desirably 23 to 65 g / m ^2, and 20 to 1 g / m ² for thin paper having a weight of 23 to 65 g / m ^2.
The one coated with a thermoplastic resin of 00 μm is optimal.

Further, as the thermoplastic resin layer 7b, a polyolefin-based resin excellent in shaping moldability is preferable.
For example, polymethylpentene, polypropylene, polyethylene and the like can be used, and among them, a polyethylene resin having a low cost is most preferable. The thickness of the thermoplastic resin layer 7b is set according to the depth of the emboss to be processed. Further, on the surface of this resin layer, a paint (including silicon, wax, fluorine-based resin, etc.) having releasability from an electron beam-curable decorative plate to be processed is included.
May be applied. Further, the paper base sheet 7a
And the thermoplastic resin layer 7b can be laminated by a commonly used dry lamination, wet lamination,
Extrusion coating of polyethylene resin, so-called doubling embossing which is fused simultaneously with heat and pressure at the same time as heat and pressure embossing can be used. In addition, as an embossing method applied to the thermoplastic resin 7b side of the shaped sheet 7 formed by lamination, a known embossing method can be used. That is, a hot-press embossing method using a flat plate or a roll plate, or a method of transferring irregularities on a cooling roll used during extrusion coating, or
A method of casting a resin in a molten state can be used.

The electron beam-curable resin 5 'used to form the surface protective layer 6 provided on the upper surface of the picture printing layer 5 includes a (meth) acryloyl group, a (meth) acryloyloxy group and the like in the molecule. A monomer having a radically polymerizable unsaturated group, or a cationically polymerizable functional group such as an epoxy group,
It consists of a prepolymer or a polymer, and these monomers, prepolymers and polymers are used alone or as a mixture of two or more. In this specification, (meth) acrylate is used to mean acrylate or methacrylate.

Examples of the prepolymer having a radical polymerizable unsaturated group include polyester (meth) acrylate, urethane (meth) acrylate, polyether (meth) acrylate, silicon (meth) acrylate, epoxy (meth) acrylate, and fluorine (meth) acrylate. ) Acrylate,
Melamine (meth) acrylate, triazine (meth) acrylate, polyvinylpyrrolidone and the like can be mentioned. This prepolymer usually has a molecular weight of about 10,000 or less. If the molecular weight exceeds 10,000, the cured resin layer has insufficient surface properties such as scratch resistance, abrasion resistance, chemical resistance, and heat resistance. Although the above acrylate and methacrylate can be used in common, acrylate is faster than acrylate in terms of the rate of crosslinking and curing with an electron beam. Therefore, acrylate is more advantageous for the purpose of curing efficiently at high speed in a short time.

Examples of the prepolymer having a cationically polymerizable functional group include epoxy resins such as bisphenol type epoxy resin, novolak type epoxy resin and alicyclic type epoxy resin, aliphatic vinyl ether, aromatic vinyl ether, urethane vinyl ether, and the like. Vinyl ether resins such as ester vinyl ethers, cyclic ether compounds,
Prepolymers such as spiro compounds are exemplified.

The electron beam source used in the present invention includes:
Using a Cockloft-Walton type, Van degraft type, Resonant transformer type, Insulated core transformer type, or various electron beam accelerators of linear type, dynamitron type, high frequency type lamp, 100
Irradiation with electrons having an energy of １０００1000 KeV, preferably 100-300 KeV can be used. Upon irradiation with an electron beam, the electron beam-curable resin undergoes a cross-linking polymerization reaction and changes to a three-dimensional polymer structure.

The coating method of the electron beam curable resin layer includes gravure coat, gravure reverse coat, gravure offset coat, spinner coat, roll coat, reverse roll coat, kiss coat, wheeler coat, solid coat by silk screen, flow coat, spray Known coating means such as a coat can be used, and the thickness of the coating film is preferably 30 to 100 μm. Also,
If necessary, coloring may be carried out by adding a pigment or a dye.

Example 1 A pure white paper weighing 40 g / m ² was coated with a polyethylene resin to a thickness of 50 μm by an extrusion coating method, embossed on the polyethylene resin side by a hot roll press, and a shaped sheet having an uneven pattern on the surface. Was prepared. Separately, a solid ink layer and a desired pattern were printed on thin paper having a basis weight of 50 g / m ² using a nitrocellulose-based resin ink using a gravure rotary printing machine to prepare a decorative sheet. Next, the obtained decorative sheet was laminated on a 2.7 mm thick MDF plate using a vinyl acetate-based adhesive to prepare a decorative plate.
Next, a urethane acrylate-based electron beam-curable resin paint was applied to the pattern printing layer side of the decorative plate having a coating thickness of 100 μm.
(Wet) by an overflow coater, immediately placed on the surface of the urethane acrylate-based electron beam-curable resin paint such that the uneven pattern surface of the shaped sheet is opposed, and accelerated from the pure white paper side of the shaped sheet Voltage 200 Ke
A V electron beam was irradiated at 5 Mrad to cure the urethane acrylate-based electron beam-curable resin paint. The shaped sheet was peeled off to obtain an electron beam-curable resin decorative board having an uneven pattern on the surface.

[0024]

As described above, according to the present invention, an adhesive layer, a decorative sheet, and a surface protective layer are sequentially laminated on the upper surface of a decorative board substrate, and an uneven pattern layer is formed on the upper surface side of the surface protective layer. In the decorative board provided, the surface protective layer is made of an electron beam curable resin, the uneven pattern layer is formed by laminating a thermoplastic resin on one surface of a paper-based base sheet, and the uneven pattern is formed on the thermoplastic resin layer surface. An electron beam-curable resin decorative plate having a concavo-convex pattern characterized by being formed by a shaping sheet provided with. By doing so, since the uneven pattern on the surface is formed by the shaped sheet, the production process is simplified, the yield is improved, and an electron beam-curable resin decorative plate having an inexpensive uneven pattern can be obtained. In addition, since the surface protective layer of the decorative plate is formed of an electron beam curable resin,
Excellent surface properties such as surface hardness, abrasion resistance, scratch resistance, and stain resistance. Furthermore, since the base material of the shaped sheet is made of a paper-based material sheet, the electron beam has high transparency and can be manufactured with high efficiency.

A decorative sheet having a pattern printing layer provided on the upper surface thereof is laminated on a decorative plate base material with an adhesive layer interposed therebetween, and an electron beam curable resin is further applied on the upper surface thereof, and a paper material is further applied on the upper surface. A shaping sheet composed of a base material sheet and a thermoplastic resin layer having a concavo-convex pattern on the surface is placed so that the concavo-convex pattern surface is in contact with the electron beam curable resin, and a paper-based base material of the shaping sheet. Irradiate an electron beam from the sheet side, cure the electron beam curable resin to form a surface protective layer, and then
By making the method of manufacturing an electron beam-curable resin decorative board having an uneven pattern characterized by peeling the shaping sheet, an electron beam-curable decorative sheet having an uneven pattern having the above-described effects can be easily obtained. It can be reliably manufactured.

[Brief description of the drawings]

FIG. 1 is a laminated cross-sectional view of an embodiment of an electron beam curable resin decorative plate having a concavo-convex pattern of the present invention.

FIG. 2 is a cross-sectional view for explaining a method of manufacturing an electron beam-curable resin decorative plate having an uneven pattern according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Decorative board of electron beam curable resin having a concavo-convex pattern 2 Decorative board base material 3 Adhesive layer 4 Decorative sheet 4a Decorative sheet base 4b Picture printing layer 5 Surface protection layer 6 Concavo-convex pattern layer 7 Shaped sheet 7a Paper type Base sheet 7b Thermoplastic resin layer (polyethylene resin layer) 7c Uneven pattern surface EB electron beam

 ──────────────────────────────────────────────────続 き Continuing on the front page F term (reference) 4F100 AC01 AK01C AK01D AK04D AK22G AK25 AK51 AS00C AT00A BA04 BA07 CB00 DD01 DG10D EC042 EC182 EH012 EH171 EH462 EJ082 EJ401 EJ532 EJ91C EJ933 H21B16H12J12H12B12H12B12H12B12

Claims (3)

[Claims] 1. A decorative board in which an adhesive layer, a decorative sheet, and a surface protective layer are sequentially laminated on an upper surface of a decorative board base material, and an uneven pattern layer is provided on an upper surface side of the surface protective layer. The protective layer is made of an electron beam curable resin, and the uneven pattern layer is formed of a shaped sheet in which a thermoplastic resin is laminated on one surface of a paper-based base sheet and an uneven pattern is provided on the thermoplastic resin layer surface. An electron beam-curable resin decorative plate having a concavo-convex pattern. 2. The decorative board according to claim 1, wherein the thermoplastic resin is made of a polyethylene resin. 3. A decorative sheet having a pattern printing layer provided on an upper surface thereof is laminated on a decorative plate base material via an adhesive layer, and an electron beam curable resin is applied on the upper surface thereof. A shaping sheet composed of a paper-based substrate sheet and a thermoplastic resin layer having an uneven pattern on the surface thereof is placed on the surface so that the uneven pattern surface is in contact with the electron beam-curable resin, and the paper quality of the shaped sheet is Irradiating an electron beam from the substrate sheet side, curing the electron beam-curable resin to form a surface protective layer, and then peeling off the shaped sheet, the electron beam-curable resin having a concavo-convex pattern Manufacturing method of decorative board.