JPS6246356B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a metal decorative sheet, and its purpose is to provide a method for manufacturing a decorative sheet that has a metallic appearance and excellent performance at a low cost. This is what I am trying to do.

Various methods for manufacturing decorative sheets with a metallic appearance have been proposed in the past. For example, a metal sheet is laminated on a base sheet, a photosensitive resin layer is formed on the metal sheet, and then a patterned film is closely attached. There is a step of forming a resist that matches the pattern through exposure and development steps, and obtaining a decorative sheet through the steps of corroding the metal and peeling off the resist. However, this method has the disadvantage that the manufacturing cost is high and that the color tone cannot be freely selected because the pattern is formed by corrosion of the metal. Another known method is to provide a metal vapor deposition layer on the back side of a patterned resin film and then laminate it with a base material such as paper, nonwoven fabric, or plastic film. There is a risk of damaging the pattern, and furthermore, deep embossing will cut the vapor deposited layer, which limits embossing. Furthermore, since the metal layer is thin, it also has the disadvantage of being susceptible to chemicals such as alkalis.

The present invention solves the above-mentioned drawbacks and makes it possible to inexpensively produce a metal decorative sheet that has a metallic appearance, has any desired printed pattern, and has excellent chemical resistance and flexibility. The aim is to provide a method to do so.

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

First, as shown in FIG. 1, the metal decorative sheet produced by the method of the present invention has four layers: a metal foil 1, a pattern layer 2, a transparent film layer 3, and a resin film layer 4. If necessary, a backing layer 5 is also added. may be provided.

As the metal foil, aluminum foil, body foil, brass foil, nickel foil, chrome foil, etc. can be arbitrarily used, and one suitable for the purpose is selected in consideration of the degree of metallic luster, workability, cost, etc.

The resin film layer includes polyvinyl chloride resin, polyurethane resin, polystyrene resin, polyacrylate resin, polyvinyl acetate resin, polyolefin resin, melamine resin, alkyd resin, etc.
Resins such as polyacetate cellulose resin, nitrocellulose resin, polychlorinated rubber resin, polyester resin, maleic acid resin, etc. can be used, and these resins can be applied by conventionally known methods, or a film made of the above resin can be appropriately bonded. The layer may be laminated using an agent.

The pattern layer can be formed by using polyvinyl chloride resin, polyvinyl acetate resin, maleic acid resin, chlorinated rubber resin, polyol isocyanate resin, etc. as the main ingredients on the surface of the metal foil, and mixing coloring pigments, solvents, etc. with this. Either ink is printed using a conventional printing method, or the surface of the metal foil is coated with the above-mentioned resins containing no pigment, and then printed with a conventional ink. At this time, the surface of the metal foil may be subjected to an undercoat treatment in order to improve the adhesion of the ink or resin to the surface of the metal foil.

Moreover, as a method for providing a pattern layer, in addition to printing on the surface of the metal foil as described above, a pattern can also be provided on the back surface of the transparent film layer. In this case, as described below, a transparent film made of various resins is used as the transparent film layer, an arbitrary pattern layer is provided on the back side of the film, and then the pattern layer surface and the metal foil surface are bonded together using an adhesive. .

The transparent film layer is made of polyvinyl chloride resin, polyurethane resin, polystyrene resin, polyacrylic ester resin, polyvinyl acetate resin, polyolefin resin, melamine resin, alkyd resin, polyacetate cellulose resin, nitrocellulose resin, polychlorinated rubber resin, polyester A transparent resin such as a resin or a maleic acid resin may be applied by a conventionally known method, or a transparent film made of the resin may be laminated using an appropriate adhesive.

The backing layer may be paper with a basis weight of 30 to 160 g/m ² , cloth such as cheesecloth or plain weave, various nonwoven fabrics, or a composite thereof, which is bonded to the back side of the resin film layer 4 via an adhesive. .

Next, as shown in Figure 2, the sheet configured as described above is embossed using a continuous embossing method such as paper embossing or heat embossing, or a flat embossing method, so that unevenness that may or may not be in sync with the pattern is applied. Grant. Note that the thickness of the metal foil, the thickness and hardness of the resin film layer, the transparent film layer, etc. are adjusted in advance according to the shape, depth, sharpness, etc. of the unevenness.

Next, as shown in FIG. 3, a colored resin layer 7 is provided in the embossed recesses.

The colored resin may be applied only to the concave portions using a valley dyeing method at the same time as embossing, using an ink or paint made by mixing a colored pigment, a solvent, etc. with any resin that can be used for the transparent film layer, or After embossing, the ink or paint is applied to the entire surface, and the ink or paint is removed from the convex portions using a doctor or roll, leaving only the concave portions.

The method of the present invention for manufacturing a metal decorative sheet by the method described above has the following effects.

(1) Since metal foil is used as the material that imparts metallic luster, there are no restrictions on the pattern or hue of the pattern layer, and any pattern can be selected, and by adjusting the thickness of the metal foil. The shape and depth of the unevenness,
You can freely choose the sharpness.

(2) Since a rust-preventing resin film layer is provided on the back side of the metal foil, it has good resistance to chemicals such as alkalis that come from the back side of the sheet, and it is highly resistant to solvents that seep in from adhesives and substrates such as slate during construction. It will not be corroded by alkaline solutions, etc.

(3) By combining the hue of the metal foil with the design and hue of the pattern layer, it is possible to produce decorative sheets in large quantities and at low cost that have an excellent appearance in terms of design.

(4) Since the transparent film layer is provided on the surface of the pattern layer, it is possible to give depth to the pattern and improve the design effect.

(5) Metal foil alone causes wrinkles during construction and the adhesive used is limited, but the decorative sheet produced by the method of the present invention has flexibility in the resin used to form the resin film layer and the transparent film layer. By selecting a resin that has properties, such problems can be solved, and the substrate during construction can also be arbitrarily selected.

(6) Since the embossed recesses are colored, the design effect can be further improved.

(7) By selecting the resin used for the transparent film layer and pattern layer, it is also possible to produce a decorative sheet that can be used for exterior purposes.

Example 1 3 g of vinyl chloride maleic acid resin was applied to the surface of a 100μ thick soft aluminum foil using a gravure plate.
After applying ^m2 , an abstract pattern was printed using a salt-vinyl acetate ink, and an acrylic urethane transparent material was applied thereon at 10g/ ^m2 to form a transparent film layer.
Next, a semi-rigid vinyl chloride film with a thickness of 70 μm was laminated on the back side of the aluminum foil via a rubber adhesive, and a heat embosser was used to impart irregularities that matched the pattern. Next, a black vinyl chloride paint was applied with a gravure coater, and the paint on the convex portions was scraped off with a resin doctor, thereby obtaining a decorative sheet with metallic luster in which the concave portions were colored black.

Example 2 A mosaic tile pattern was applied to the back side of a 70μ thick transparent semi-rigid vinyl chloride film with a plasticizer content of 20% using vinyl chloride vinyl acetate ink, and then a mosaic tile pattern was applied to the surface of a 100μ thick aluminum foil. The patterned film was attached to the aluminum foil using a polyol isocyanate adhesive, with the patterned surface facing the aluminum foil. Next, 5g/ ^m2 of PVC acrylic resin for rust prevention was applied to the back side of the aluminum foil, and the basis weight was 100g/ ^m2.
The cardboard was pasted together using a vinyl acetate emulsion adhesive. Thereafter, a heat embosser was used to provide irregularities that matched the pattern. Next, a black vinyl chloride paint was applied with a gravure coater, and the paint on the convex portions was scraped off with a resin doctor, thereby obtaining a decorative sheet with metallic luster in which the concave portions were colored black.

Example 3 A soft vinyl chloride film with a thickness of 75 μm and a plasticizer content of 30% and cheesecloth made of 20 No. 40 threads per inch were bonded together via a vinyl acetate emulsion type adhesive, and then the A 100μ thick aluminum foil was attached to the surface of the vinyl chloride film using a polyol isocyanate adhesive. Next, a film with an abstract pattern printed on the back side of a transparent semi-rigid vinyl chloride film with a thickness of 75μ and a plasticizer content of 15% was attached to the aluminum foil surface of the laminated sheet via a vinyl chloride vinyl acetate adhesive. After bonding them together with their printed surfaces facing, a paper embosser was used to provide irregularities that did not match the pattern.
Next, a black vinyl chloride paint was applied with a gravure coater, and the paint on the convex portions was scraped off with a resin doctor, thereby obtaining a decorative sheet with metallic luster in which the concave portions were colored black.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view showing an example of a metal decorative sheet produced by the method of the present invention, FIG. 2 is a cross-sectional view of the metal decorative sheet with unevenness provided, and FIG. 3 is a cross-sectional view of the metal decorative sheet with the recesses colored. DESCRIPTION OF SYMBOLS 1... Metal foil, 2... Pattern layer, 3... Transparent film layer, 4... Resin film layer, 5... Backing layer, 6... Embossed recessed part, 7... Colored resin layer.

Claims (1)

[Claims] 1. After providing a desired pattern layer and a transparent film layer on the surface of a metal foil having an arbitrary hue and thickness, a resin film layer for protecting the metal foil is provided on the back side of the metal foil. 1. A method for producing a metal decorative sheet, which comprises embossing a laminated sheet made of a laminate with or without matching the pattern, and then coloring the embossed recesses. 2. The method for producing a metal decorative sheet according to claim 1, characterized in that a backing layer of paper, cloth, nonwoven fabric, or other material is provided on the back side of the resin film layer.