JPH05270199A - Manufacture of decorative sheet - Google Patents

Abstract

PURPOSE:To improve efficiency by pushing, transferring and forcibly cooling a rigid heated roll having specified rubber hardness, peeling the base body sheet of a transfer sheet and transferring a pattern only on the projecting surface of embossed irregularities in the manufacture of a decorative sheet having embossed irregularities and the pattern. CONSTITUTION:A transfer sheet 22 is composed of a semirigid polyvinyl chloride sheet 1 in specified thickness, a peel varnish ply 2, a pattern layer 3 and a polyester-resin adhesive layer 4. The transfer sheet 22 is placed onto a decorative sheet substrate 21 made of a fiber-reinforced cement board, to which specified embossing work is conducted, and pushed by a heated roll 23 from a rear, thus transferring a pattern. The heated roll 23 is organized as a rigid roll having rubber hardness of 70 deg. or more. The decorative sheet 21 is cooled forcibly, the basic sheet 1 is peeled, and the pattern is formed onto the embossed projecting surface of the decorative sheet 21. Two kinds of hard and soft rolls are prepared at that time, the boundary of a transfer section and a non-transfer section is divided by the hard roll, and fine irregularities are followed up by the flexible roll, thus improving the finishing of the pattern.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a decorative sheet having a pattern on its surface, and particularly to efficiently producing a decorative sheet having a pattern having embossed irregularities on the surface and having a pattern in harmony therewith. On how to do.

[0002]

2. Description of the Related Art Conventionally, various decorative boards have been used for exterior and interior of houses and as furniture members, but in recent years, products with embossed surfaces have become popular along with the tendency toward higher quality and higher design. It has become popular. In the case of a conventional product with a flat surface, as a method of providing a pattern on the surface, for example, a sheet on which a pattern is printed can be laminated on the surface, but when the surface has embossing Inevitably, they had no choice but to rely on a simple decoration method such as painting a single color paint or sprinkling sand.

[0003]

DISCLOSURE OF THE INVENTION The present invention provides a method for efficiently manufacturing a decorative board having an embossed shape and a pattern matching the embossed shape on the surface thereof, by compensating for the above-mentioned drawbacks of the prior art. Is. In particular, the present invention provides a method capable of efficiently providing a decorative pattern only on the convex surface of a decorative plate having a brick or tile-like embossed pattern.

[0004]

[Means for Solving the Problems] That is, according to the present invention, the adhesive layer surface of a transfer sheet having a pattern layer to be transferred is installed toward a decorative board substrate having a large embossed uneven surface on the surface, and the transfer sheet is formed. Is a method for manufacturing a decorative plate in which a desired pattern layer is transferred to a decorative plate base material by pressing with a hot roll from the back surface of, and pressing with a hard hot roll having a rubber hardness of 70 ° or more,
After the transfer, the base sheet of the transfer sheet is peeled off after the step of forcibly cooling the decorative sheet, whereby the desired pattern is transferred only to the convex surface of the large embossed uneven surface of the decorative sheet. It is a manufacturing method.

When the decorative plate base material to which the pattern layer is to be transferred has not only a large embossed uneven surface on the surface but also a fine uneven surface on the convex surface, a hard heat roll having a rubber hardness of 70 ° or more is used. A two-step pressing method is used in which after pressing with a soft hot roll having a rubber hardness of 60 ° or less.

In applying a desired decorative pattern to a decorative board having an embossed surface, a transfer sheet having a thermoplastic resin film as a base sheet and a release varnish layer, a pattern layer and an adhesive layer provided on the surface thereof at least sequentially is used. By placing the decorative board on a decorative board base material and pressing from the back surface of the base sheet with a hot roll to transfer a desired pattern, a decorative board with a high design in which the embossing and the pattern are in harmony can be obtained.

A detailed description will be given below with reference to the drawings. Figure 1
FIG. 3 is a configuration diagram of a transfer sheet used in the present invention. On the surface of the base sheet (1), a release varnish layer (2), a pattern layer (3), and an adhesive layer (4) are sequentially provided.
As the base sheet (1), a thermoplastic resin film capable of following the irregularities on the surface of the decorative plate base material by heat during transfer is used. Specifically, films of vinyl chloride, polyethylene, polypropylene, nylon, polyester, etc. can be used. The type and thickness of the resin may be appropriately selected depending on the degree of unevenness on the surface and the transfer temperature, but according to the experiments conducted by the present inventors, 150 ° C. to 180 ° C.
At the transfer temperature of ° C, the best results are obtained with a vinyl chloride resin film having a thickness of 100 µm or less.

The release varnish layer (2) may be appropriately selected depending on the type of the base sheet (1). When vinyl chloride is used as the base sheet (1), polyvinyl butyral gives good results. Was given. The pattern layer (3) is usually printed by a method such as gravure printing or screen printing. The binder of the ink is determined in consideration of the large elongation upon heating and the durability of the final product.

As the adhesive layer (4), polyvinyl alcohol, acrylic, hydroxymethyl cellulose, polyester, polyamide or the like is used.

FIG. 2 is an explanatory view showing an example of the method for manufacturing a decorative board of the present invention. Decorative board base material to be decorated (21)
The transfer sheet (22) shown in FIG. 1 is placed on the uneven surface of and the desired pattern is transferred by pressing it from the back side with a heat roll (23). At this time, the pattern is transferred only to the convex surface of the decorative board having a brick-like or tile-like embossed pattern,
At the time of peeling, the printed pattern and the film of the adhesive layer may be peeled from the base sheet (1) even if the film does not have to be actually transferred, and a defect generally called a burr may occur.

The present inventor has, in order to improve this,
The means as shown in FIG. 3 is proposed. That is, after transfer, the transfer sheet and the decorative board are integrated,
The unit (31) for forced cooling is provided. When the base sheet (1) is peeled off after passing through this cooling unit and being sufficiently cooled, since the peeling layer, the pattern layer, and the adhesive layer have no flexibility, respectively, a portion to be transferred and a portion not to be transferred. It will be divided neatly at the boundary between and, and burr will not occur.

Further, there is a decorative board having a brick-like and tile-like embossed pattern and having fine projections and depressions formed on its convex surface to improve the design. The present invention is applied to such a decorative board. When used, it proposes the following method. It has been clarified by experiments by the present inventor that it is better to soften the roll hardness in order to basically follow the embossed shape, and actually proposed.

However, as in the present invention, when it is not desired to perform the transfer on the concave surface of large unevenness, when the hardness of the roll becomes soft, burrs tend to occur easily. Therefore, the present invention proposes a transfer device in which a plurality of rolls are installed. That is, at least one roll (32) having a high hardness and at least one roll (33) having a low hardness are installed, and the first hard roll divides the boundary between the transfer portion and the non-transfer portion to transfer. This is a method in which the portion of the film other than the base sheet is cut, and the second soft roll follows the fine irregularities formed on the large convex surface.
The number and combination of the rolls may be appropriately considered according to the actual shape.

[0014]

The present invention is a manufacturing method capable of imparting a beautiful pattern to the surface of various decorative boards having an embossed uneven surface and obtaining a decorative board having a high designability in which the embossed unevenness and the pattern are in harmony. In particular, the boundary between the transferred portion and the non-transferred portion is neatly divided, and by using the second soft roll, it is possible to follow the fine irregularities formed on the convex surface of the large pattern.

[0015]

【Example】

Example 1 A polyvinyl butyral resin is applied as a release varnish layer on the surface of a semi-rigid vinyl chloride sheet having a thickness of 75 μm, and then a marble pattern is formed by a gravure printing method using an ink having a vinyl chloride resin as a binder. Was printed, and a polyester resin was applied as an adhesive layer to prepare a transfer sheet.

This transfer sheet was placed on a fiber-reinforced cement board that had been embossed in a brick pattern and had an uneven pattern in advance, and was pressed from the back side with a hot roll having a surface temperature of 170 ° C. and a rubber hardness of 90 °. Yes (pressure is linear pressure 10
kg / cm, speed is 15 m / min). After the transfer, the integrated decorative plate was cooled to a surface temperature of 10 ° C. by air cooling, and then the base sheet was peeled off.

The fiber-reinforced cement board thus obtained is
The brick-like embossing and the transferred marble pattern on the convex surface were in good harmony with each other, and the design effect was extremely high.

Example 2 A polyvinyl butyral resin was applied as a release varnish layer to the surface of a semi-rigid vinyl chloride sheet having a thickness of 75 μm, and then gravure was performed using an ink containing a vinyl chloride-vinyl acetate copolymer resin as a binder. A marble pattern was printed by a printing method, and a polyester resin was applied as an adhesive layer to prepare a transfer sheet.

This transfer sheet is placed on a fiber-reinforced cement board, which has been embossed in a brick pattern and finely embossed in a split stone pattern on its convex surface to give an uneven pattern. It was pressed with a hot roll of 170 ° C and rubber hardness of 90 ° (pressure is linear pressure of 10 kg / cm,
The speed is 15m / min). Next, it was pressed with a hot roll having a surface temperature of 160 ° C. and a rubber hardness of 50 ° (the pressure was 10 k in linear pressure).
g / cm, speed 15 m / min). After the transfer, the integrated decorative plate was cooled by air to a surface temperature of 10 ° C., and the post-base sheet was peeled off.

The fiber-reinforced cement board thus obtained is
The brick-like embossing, the split stone-like embossing pattern applied to the convex surface, and the marble pattern by transfer were in good harmony, and the design effect was extremely high.

[0021]

EFFECTS OF THE INVENTION According to the present invention, it is possible to provide a beautiful decorative pattern on a surface of various decorative plates having an uneven surface, and to obtain a decorative plate having a high design property in which embossing and patterns are harmonized. is there. In particular, it can be neatly divided at the boundary between the part to be transferred and the part not to be transferred, and if a second soft roll is used, it is possible to follow the fine irregularities made on the convex surface of a large pattern. While higher quality is demanded, the present invention is extremely excellent in practical use because it can be suitably transferred to a decorative plate that is conspicuous and has a larger unevenness difference.

[0022]

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an example of a transfer sheet used in the method for manufacturing a decorative board of the present invention.

FIG. 2 is an explanatory view showing a transfer method used in the method for manufacturing a decorative board of the present invention.

FIG. 3 is an explanatory diagram showing an example of a transfer device used in the present invention.

[Explanation of symbols]

(1) Base sheet (2) Release varnish layer (3) Pattern layer (4) Adhesive layer (21) Decorative plate (22) Transfer sheet (23) Heat roll (31) Cooling unit (32) High hardness heat roll (33 ) Low hardness hot roll

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁵ Identification code Office reference number FI technical display location B44C 3/02 A 9134-3K

Claims (3)

[Claims] 1. An adhesive layer surface of a transfer sheet having a pattern layer to be transferred is placed toward a decorative board substrate having a large embossed uneven surface on the surface, and pressed from the back surface of the transfer sheet with a heat roll, A method for manufacturing a decorative sheet, comprising transferring a desired pattern layer to a decorative sheet substrate, comprising a step of pressing with a hard heat roll having a rubber hardness of 70 ° or more, forcibly cooling the decorative sheet, and then a transfer sheet. A method for producing a decorative board, characterized in that the desired pattern is transferred only to the convex surface of the large embossed concavo-convex surface by peeling off the base sheet. 2. The adhesive layer surface of a transfer sheet having a pattern layer to be transferred is installed so as to face a decorative board substrate having a large embossed uneven surface and a fine uneven surface on the large embossed uneven surface. A method for manufacturing a decorative board, in which a desired pattern layer is transferred from a back surface of a transfer sheet to a decorative board base material by pressing with a hot roll, the method comprising pressing with a hard hot roller having a rubber hardness of 70 ° or more. By pressing with a soft heat roll with a rubber hardness of 60 ° or less, and after transferring, the decorative sheet is forcibly cooled, and the base sheet of the transfer sheet is peeled off, so that only the convex surface of the large embossed uneven surface is formed. A method for manufacturing a decorative board, which comprises transferring a desired pattern. 3. A transfer sheet comprising, as a transfer sheet, a thermoplastic resin film as a base sheet, and a release varnish layer, a pattern layer and an adhesive layer at least sequentially provided on the surface of the base sheet. Item 2. A method for producing a decorative board according to item 2.