JPS6316267B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Conventionally, after applying a polyester resin onto a base material, a forming film having an uneven pattern is superimposed, the polyester resin is cured, and then the forming film having an uneven pattern is peeled off. There is a known method of manufacturing a polyester decorative laminate with an uneven surface by doing this, but conventionally, in order to form an uneven pattern on the surface of a decorative laminate, a molding material such as silicone resin is used to make a mold directly from the original. However, a method for manufacturing a decorative board using this as an embossed board is described in Japanese Patent Publications No. 1739-1984, No. 6484-1984, No. 34750-1974, and the like.

All of the methods described in the above publications are
Since a mold made directly from an original using room-temperature curing silicone resin is used as a mold for manufacturing decorative laminates, the following problems arise.

Since the aim is to cure at room temperature, work processes include mixing the resin such as silicone with the curing agent, degassing under reduced pressure, which is essential for making the mold, uniformly applying it to the document, and integrating it with the backing reinforcing agent. In order to prevent the resin from thickening and gelling, if a silicone resin that cures at room temperature is used, it usually takes about 10 to 20 hours to cure the resin (depending on temperature and humidity). Become. Therefore, if you use natural materials such as natural wood veneers for manuscripts, the manuscripts will not be exactly the same, so for example, it will take about 100 days to create 100 sheets of imprinted film, which will significantly reduce work efficiency. Deteriorate.

As mentioned above, if you use a manuscript such as natural wood that cannot be made the same twice and make impressions many times, the manuscript may become damaged due to repeated molding, and problems such as scratches on the manuscript may occur. There is a high risk of losing the manuscript, and if the manuscript were to be lost, it would be impossible to produce the exact same product ever again. (This is because there is a limit to the number of times the imprinted film can be used.) In the above points, conventional methods are difficult to mass produce, and unlike natural wood, the same product cannot be obtained twice. It is not suitable when using manuscripts.

The present invention provides a novel method for producing a shaped film that eliminates the above-mentioned drawbacks.

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

First, as shown in FIG. 1, a low-temperature thermosetting resin 2 is poured onto a document 1 having an uneven surface in order to prevent thermal deterioration of the document, and a transparent film 4 is placed thereon.

The reason for using low-temperature heat-curing resin is to shorten the curing time of the resin and improve work efficiency.In particular, the low-temperature type of around 40 to 50°C is used because it is not heat-curable. This is because the hardening type requires the original to be placed in a high-temperature atmosphere, resulting in damage to the original. Furthermore, it is preferable to use transparent materials for both the low-temperature heat-curing resin 2 and the film 4. This is because when removing air bubbles in the resin or at the interface of the resin layer, it is necessary to be able to confirm the presence of air bubbles from above.Therefore, it may be semitransparent or colored and transparent as long as the air bubbles can be confirmed.

Next, these are heated at 40 to 50°C to harden the resin 2 and integrate it with the film 4. Silicone resins and others can be used as the transparent low-temperature heat-curing resin 2. Among the silicone resins, there are two-component types that harden through an addition polymerization reaction, and addition-type RTV (Room
Temperature Vulcanizing Silicone Rubber)
Addition-type LTV (Low Temperature
There are two types of Vulcanizing Silicone Rubber: RTV alone or LTV added to RTV for the purpose of extending pot life and adjusting viscosity.
Use RTV, LTV mixture. Curing with LTV alone is slow. The amount of transparent low-temperature heat-curing silicone resin applied varies depending on the uneven shape, etc.
A thickness of about 100 to 500 microns is sufficient since it is supported by the transparent film 4. As the transparent film 4, a transparent film such as a polyester film, a nylon film, a vinylon film, a polyolefin film, etc. can be used as appropriate. Depending on the combination, the transparent film and low-temperature heat-curable silicone resin have poor adhesive properties, so in order to provide adhesive properties, a primer is used to impart adhesive properties to the transparent film 4, as shown in Figure 1. It is desirable to apply 3. As the primer 3, desired materials such as alkyl titanate-modified silicone and alkylsilane-modified silicone can be used.

Then, as shown in FIG. 2, the integrated resin 2 and film 4 are released from the document 1 to form a first mold 5. This first type 5 is 80~
The strength may be increased by post-heating at 100°C.
Next, as shown in FIG. 3, a second mold 8 is created in the same manner as in manufacturing a normal polyester decorative board using the first mold. That is, the first mold 5 is placed on a base material 6 such as plywood, and on a coating layer made of heat-curable, room-temperature-curable, or ultraviolet-curable polyester resin, or silicone that uses the above-mentioned curing methods, and a releasable synthetic resin 7. Place the roller on top of it,
Alternatively, air bubbles in the coating layer are removed by applying pressure with a squeegee, and the surface thereof is brought into complete contact with the first mold 5.

As the resin 7 that can be releasable from the silicone resin, a solvent-free resin such as an unsaturated polyester resin, acrylic resin, epoxy resin, or urethane resin may be used, but the silicone resin is not releasable from the silicone of the first mold 5. This is not desirable because it is difficult to release the mold without the agent. If a mold release agent is used, not only the reproducibility of fine parts of the document is lost, but also a step of applying the mold release agent is required, resulting in disadvantages such as a decrease in work efficiency.

After curing the silicone resin and the releasable resin coating film, the mold is released and molded into the second mold 8 as shown in FIG.
shall be.

Next, using this second mold 8 and using this as a document, a molding film 12 made of transparent mold release resin as shown in FIG. 5 is formed in exactly the same manner as in FIGS. 1 and 2. This is used as a molding film for making polyester decorative laminates.

There are silicone resins and others as mold release resins used in this case, and silicone resins are the addition type mentioned above.
Any of RTV, addition-type LTV, and mixtures thereof may be used, but if a heat-resistant resin is used in the second mold, the curing time will be 30 minutes to 1 hour at 80 to 100°C.
It only takes about an hour.

The present invention, which produces a shaped film by the method described above, has the following effects.

(1) The forming film used in the production of decorative laminates is
Since a large number of documents can be manufactured in a short period of time using a mold, there is no need to use the document over and over again as in the past, and accidents that damage the document are drastically reduced.

(2) The silicone resin used to create the first mold is a low-temperature heat-curing type to prevent damage to the manuscript, so it takes 3 to 4 hours to harden.
Although it takes time, it is sufficient to create the first mold once, and the silicone resin constituting a large number of molded films is cured by heating in about 0.5 to 1 hour. Therefore, it was calculated that it would take about 100 days to produce 100 sheets of imprinted film for mass production, but with the present invention, it can be produced satisfactorily within 10 days.

Conventionally, when natural products are used for manuscripts, various artificial modifications are made to improve the design of the manuscript, but the only way to do so is to modify silicone-imprinted film, and due to the characteristics of silicone, it is difficult to make detailed modifications. Moreover, since the same original cannot be obtained twice, it is impossible to make repeated corrections, which is actually difficult, but in the present invention, since a resin other than silicone is used for the second mold, corrections are possible. It is quite possible.

Example Transparent silicone resin, KE-1300T, RTV (manufactured by Shin-Etsu Chemical Co., Ltd.), which is cured by addition polymerization reaction after sanding and finishing painting of natural wood veneer
A mixture of KE-106LTV and KE-106LTV (manufactured by Shin-Etsu Chemical Co., Ltd.) in a 1:1 ratio is poured over the mixture to a thickness of about 400μ, and then primer A (Toray Silicone) is poured over the mixture in advance. Co., Ltd.) was layered with unstretched nylon film, smoothed evenly with a roller over the top of the film, placed in an oven at 50°C for 4 hours to harden the silicone, and then separated from the original. A first mold was created by molding.

After that, unsaturated polyester resin was applied onto the plywood, the first mold was placed on top of the unsaturated polyester resin, and the resin was leveled out uniformly by applying pressure with a roller, and air bubbles were removed at the same time. After heating in an oven for 1 hour to cure the resin, the first mold was released to obtain a second mold. Next, since the conduit portion of the original had the drawback of being too deep when a desired pattern was used, the second mold was corrected by sanding, and this was used as a new second mold.

Next, a transparent silicone KE-106LTV (Shin-Etsu Chemical Co., Ltd.) that is cured by addition polymerization reaction is applied to the second mold.
(manufactured by Toray Silicone Co., Ltd.) was poured to a thickness of approximately 300μ, and then a polyester film that had been treated with Primer A (manufactured by Toray Silicone Co., Ltd.) was layered on top of the film, and the film was smoothed evenly with a roller, and then heated at 100°C. The silicone was cured by placing it in an oven for 40 minutes in an atmosphere of 100 mL, and then it was removed from the oven and released from the second mold to obtain a polyester film-backed transparent silicone-imprinted film.

When a polyester decorative board was manufactured by the film method using the above-mentioned shaped film, a decorative board with an excellent design was obtained which had conduits that were shallower than the conduits of the original but considerably sharper.

[Brief explanation of the drawing]

FIGS. 1 to 5 are explanatory diagrams for explaining each process for manufacturing the shaped film of the present invention, and FIGS. 1 and 2 are the manufacturing steps of the first mold, and FIG. and FIG. 4 is an explanatory diagram of the manufacturing process of the second mold,
FIG. 5 shows an explanatory cross-sectional view of the forming film produced from the second mold. 1... Manuscript, 2... Low temperature heat curing resin, 3...
... Primer, 4 ... Transparent film, 5 ... First mold, 6 ... Base material, 7 ... Resin that can be peeled off from silicone resin, 8 ... Second mold, 9 ... Transparent mold release 10...transparent film, 11...imprinting film.

Claims (1)

[Claims] 1 Additive RTV (Room Temperature
Vulcaning Silicone Rubber) and the addition type LTV (Low
Temperature Vulcanizing Silicone Rubber)
A resin layer consisting of a mixture of Next, a silicone resin and a releasable resin are applied onto the base material, and the first mold is placed on top of the base material, so that the resin surface and the first mold are brought into complete contact. After that, the resin is cured, and then the first mold is released to create a second mold consisting of the base material and the resin layer, and then a transparent resin is placed on top of the second mold.
A layer consisting of addition-type LTV that cures at 50°C to 150°C is formed, and a transparent base film is layered on top of it to integrate it, and then the imprinted film is released from the second mold. A method for producing a shaped film, characterized by the following.