JPH02255336A - Shaping sheet - Google Patents

Abstract

PURPOSE:To obtain a shaping sheet wherein the parts different in luster are formed on the surface of a decorative sheet made of thermosetting resin and a foreign matter is prevented from being stuck by static electricity and also a fine unevenness can be excellently reproduced by providing a barrier coat layer, a lusterless pattern layer and a mold release layer in this order on paper having the smooth double sides. CONSTITUTION:Paper 1 becoming the base material sheet of a shaping sheet is good in smoothness of the double sides and uniform in formation in order to make the difference of luster sharp when the patterns different in luster are formed on a decorative sheet. A barrier coat layer 2 prevents infiltration of thermosetting resin into the base material sheet 1 which results from thermocompression at a time for molding the decorative sheet. Smoothness and formation of the base material sheet 1 are compensated thereby and furthermore luster is enhanced and a smooth face is formed. The lusterless pattern layers 3 partially extinguish luster in contrast to the barrier coat layer 2. A mold release layer 4 is formed by applying a mold release agent such as silicone resin and wax. Thereby even when the shaping sheet is allowed to stand, a foreign matter is prevented from being stuck and a fine unevenness can be excellently reproduced.

Description

[Detailed description of the invention] (Industrial application field) The present invention relates to a shaped sheet.

More specifically, the present invention relates to a forming sheet used to form portions of different gloss on the surface of a thermosetting resin decorative board such as a melamine decorative board or a diallyl phthalate decorative board.

(Prior Art) A shaping sheet for forming an uneven shape on the surface of a thermosetting resin decorative board is well known. Examples include: (1) embossed plastic film; and (2) resin that forms convex portions on a base sheet such as paper. However, since thermosetting resin decorative laminates are heated and pressurized during manufacture, the fine irregularities disappear, and it is not possible to express fine details using any of these methods, and irregularities are formed on the decorative laminate. However, it is not possible to change the gloss.

On the other hand, there has also been proposed an imprinted sheet in which a plastic film is printed with a printed pattern using ink of a specific resin, and the gloss is changed depending on the area where the printed pattern is present and the area where the printed pattern is not present.

(Problem to be Solved by the Invention) However, since the base of such a shaped sheet is made of plastic, static electricity is likely to be generated on the opposite side of the surface on which the unevenness is formed, and foreign matter may adhere to it. difficult to reproduce and difficult to handle manually. Alternatively, the forming sheet itself has disadvantages such as being expensive.

(Means for Solving the Problem) In order to solve this problem, the present invention provides a molded sheet in which a barrier coat layer, a matte pattern layer, and a release layer are provided in this order on paper that is smooth on both sides. do.

(Preferred Embodiment of the Invention) Hereinafter, referring to the drawings, FIG. 1 of the drawings for explaining the present invention is a sectional view of a shaped sheet according to the present invention. (1) is a paper that serves as the base material sheet of the imprinting sheet, and when forming patterns with different glosses on the decorative board, in order to highlight the differences in gloss, it has good smoothness on both sides and a uniform texture. It needs to be paper. Further, in order to prevent the generation of static electricity, it is necessary that the material does not contain synthetic 1-fat pulp. In addition, it is desirable that the material be easy to handle manually when forming the decorative board, and the basis weight is preferably 30 to 160 g//rIt.

(2) is a barrier coat layer that prevents the thermosetting resin from penetrating into the base sheet (1) due to heat pressure during decorative board molding, and improves the smoothness and texture of the base sheet (1). It supplements the gloss and creates a smooth surface by increasing the gloss. Examples of the material forming this barrier coat layer (2) include resins such as acrylic resins, vinyl acetate resins, and polyvinyl alcohol resins; 2-20 g/rd, gravure printing, roll coating, etc. All you have to do is apply it by 5 times using the method.

(3) is a matte pattern layer, which partially eliminates gloss in contrast with barrier coat layer (2). The ink used for this pattern layer (3) may include, for example, an ink vehicle such as nitrified cotton thread or urethane, and a gloss modifier containing perilla, calcium carbonate, M
Inks containing extender pigments such as barium monoate can be used. The ink may be printed by a method such as gravure printing, and the picture pattern layer (3) has fine irregularities due to the presence of the extender pigment and becomes matte.

(4) is a release layer. The release layer (4) may be formed by coating 15L of a release agent such as silicone resin or wax. There are two methods of application: one is to dilute the release agent in a solvent, and the other is to add a small amount to a vehicle and apply it together with a solvent.
There is a way to do this. In the method of adding to a vehicle, a vehicle that has good adhesion to the picture pattern layer (3) and is difficult to adhere to the resin on the surface of the thermosetting resin decorative board is used as the vehicle.
Add 0.02 to 2.0 parts by weight of a mold release agent. As the vehicle, thermosetting resins such as aminoalkyd, polyester, and urethane resins can be used, and are sufficiently cured before forming the decorative board to avoid adhesion to the resin on the surface of the decorative board. Note that if the curing is insufficient or if a thermoplastic resin is used, the molded sheet and the decorative board may adhere to each other during decorative board molding and may not be able to be separated. The release layer (4) can be printed by a method such as gravure printing.In order to take advantage of the unevenness of the pattern layer (3), the release layer (4) must be coated at a rate of 5 g/Trt or less. , in order to maintain mold releasability, the coating should be at least 0.5 g/TIt.

In addition, barrier coat M (2>, pattern layer (3)
The release layer (4) can be applied or stamped in-line using a gravure printing plate.

In the present invention, a thermosetting decorative board refers to a decorative board whose surface is made of a thermosetting resin. Figure 2 shows the molding process for producing a melamine decorative board, which is a typical example of a thermosetting decorative board. FIG. That is, the following items are stacked in order from the top between the upper and lower heating plates (10). (11) is a heat-resistant cushion, (13) is a mirror plate, and a molding sheet (5) is arranged below this. . (8) is an overlay paper, which is a transparent impregnated paper obtained by impregnating rayon pulp or nonwoven fabric with a basis weight of 25 to 45 g/rrt with 40 to 100% melamine resin and drying it, which may be removed depending on the case. (
7) is a paper impregnated with melamine resin, and has a basis weight of 55 to 1609
/m titanium paper, optionally with a pattern printed on it, impregnated with 40 to 100% melamine resin, and dried. The core paper (6) determines the thickness of the melamine resin decorative board, and approximately 4 to 5 sheets are stacked and used. ku) is backer paper, which is a titanium paper with a basis weight of 55 to 15 Qg/n impregnated with 40 to 100% melamine resin and dried.
It balances the melamine resin-impregnated paper (7) and overlay paper (8) that form the surface of the decorative board, and plays a role in preventing the decorative board from warping.

(12) is a release sheet that prevents the melamine resin from adhering to the lower heat-resistant cushion sheet (11). Second
Laminated in the state shown in the figure, heated and pressure molded at a maximum temperature of 140 to 150°C, pressure of 80 to 100 kg/cti, time of 15 to 30 minutes, and cooled with cold water for 15 to 60 minutes while pressurized (6 ) to (9) can be cured to obtain an integrated melamine resin decorative board.

(Example) As shown in Fig. 1, 4 g/'ni of acrylic emulsion resin was applied using a gravure printing machine to paper with good smoothness on both sides and good texture, and a basis weight of 65 g/m. After drying to form a barrier coat layer, a matte picture pattern layer was formed in-line using a gradated stone grain pattern board, and a release layer was formed on the entire surface using a solid plate. The pattern layer is urethane resin 1
00 parts by weight mixed with 20 parts by weight of silica with an average particle size of 2.5 μ as a gloss adjuster.
For the mold release layer, an ink containing 100 parts by weight of epoxy melamine resin, 0.5 parts by weight of silicone resin as a mold release agent, and 9 parts by weight of para-toluenesulfonic acid as a curing catalyst was used to form a mold release layer of 3.09/m. Printed. Finally 160℃,
The mold release layer was completely cured by heating for 10 seconds. The resulting imprinted sheet has a very high gloss in the part where the stone grain pattern was not printed, and the part where the stone grain pattern was printed was matte, and because it was printed with a gradation plate, the stone grain was There were also differences in gloss among the patterns.

Next, as shown in Figure 2, between the upper and lower heating plates (10), from top to
), overlay paper (8), the above-mentioned imprinting sheet (5>, 60% melamine resin on white titanium paper with a basis weight of 100q/rd)
Impregnated and dried melamine resin impregnated paper (7), 4 pieces of core paper (6), backer paper (9), release sheet (13)
After laminating the heat-resistant cushion sheets (11), they were heated and pressed at a maximum temperature of 145°C and a pressure of 80 kg/CIi for 25 minutes, and then cooled with water for 20 minutes while being pressurized to harden and integrate the melamine resin and phenolic resin. A melamine decorative board was molded.

After molding, when the imprinted sheet was peeled off, a melamine decorative board with a stone grain pattern with different gloss on the surface and a stone grain pattern printed in three colors on the base, with subtle differences in gloss and closely resembling natural stone, was obtained. Obtained.

In addition, the shaped sheet did not attract foreign matter even when left unattended, was easy to handle, and even subtle irregularities could be reproduced satisfactorily.

(Effects) As described above, according to the present invention, parts with different gloss can be formed on the surface of a thermosetting resin decorative board, and there is no adhesion of foreign matter due to static electricity, and subtle unevenness can be reproduced well. 1q of sheets are taken. It is also easy to handle,
Obtained at a low price.

Fig. 1: A cross-sectional view of the imprinting sheet.

Fig. 2: Cross-sectional view during molding of the melamine decorative board.

1) Base sheet 2)...Barrier coat layer 3)...Picture pattern layer 4)...Release layer 5)...imprinting sheet

Claims (1)

[Claims] (1) A molded sheet consisting of paper with smooth surfaces on which a barrier coat layer, a matte pattern layer, and a release layer are provided in this order.