JP2000334833A - Embossed cosmetic material - Google Patents

Abstract

(57) [Problem] To provide a decorative material having a glossy width, and having stain resistance and scratch resistance. SOLUTION: This decorative material has a fine uneven shape on the surface of a base material, and the uneven shape is composed of a convex portion and a concave portion which are connected to each other with a continuous change in height by a curved surface,
The convex portions are formed by accumulating a plurality of individual convex elements T each having a plurality of different diameters and formed from a randomly densely arranged planar pattern.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an embossed decorative material having an optimum glossy surface, stain resistance and scratch resistance.

[0002]

2. Description of the Related Art For decorative materials such as interior materials and furniture, products in which the gloss of a plastic finished surface is controlled are frequently used in order to enhance texture, luxury, and design. In order to control the final surface gloss of a conventional decorative sheet having a thermoplastic resin layer such as polyvinyl chloride or polyolefin resin on the surface or a decorative material laminated with the same, embossing with fine irregularities is required. It is a common practice to form a concavo-convex shape using a plate. Sand blasting, matte chrome plating, engraving with a gravure printing cylinder engraving machine, matte OP method, etc. have been used to form the concavo-convex shape on this embossing plate, but all have their advantages and disadvantages. Kaihei 10-287
In Japanese Patent No. 099, a convex element is formed by embossing a plurality of times by performing a photoetching method in which a halftone dot pattern having a different size and randomly arranged is baked on a resist film on the surface of an embossed cylinder to perform corrosion, and the pattern is formed. There has been proposed an embossed decorative sheet having an optimum luster formed alone or overlapping, and having excellent stain resistance and scratch resistance, and a decorative material (door) obtained by laminating the embossed decorative sheet.

[0003]

SUMMARY OF THE INVENTION Japanese Patent Application Laid-Open No. H10-2870
The surface of the embossed decorative sheet proposed in Japanese Patent Publication No. 99 can be provided with an appropriate gloss on the whole surface or each part, and is improved as compared with the conventional one in terms of scratch resistance and stain resistance. . However, the convex portion is composed of a single convex element or an aggregate formed by overlapping convex elements, but a flat surface remains between the convex portions, and it has not yet reached a completely matte state. There's a problem. Therefore, there is a problem that the gloss control range is still narrow and the matte expression is not sufficiently performed. Furthermore, a cut-out valley or an intersection line between a horizontal plane and a curved surface remains between the projections, and the concavo-convex cross section is not continuous, so contamination resistance and scratch resistance have not yet been completely solved. There is a problem. The present invention has been made in view of the above problems, and the present invention enhances the design by giving each part of the decorative material an optimal low gloss (matte), and has a more excellent scratch resistance. It is intended to provide a cosmetic material having stain resistance.

[0004]

Means for Solving the Problems The present invention has been made to solve the above problems, and is a decorative material having fine irregularities on the surface of a substrate, wherein the irregularities have a continuous change in height due to a curved surface. A convex portion and a concave portion which are connected to each other with at least a part of the convex portions having a plurality of different diameters, and individually independent convex shapes formed from a randomly densely arranged planar pattern. It is characterized by being formed by an in-plane arrangement of elements.
Further, it is possible to accumulate the convex portions formed from a different planar pattern from the convex elements on the convex portions.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION The embossed decorative material produced by the present invention is a material in which fine irregularities are formed on the surface of a substrate by embossing and the gloss of each part is controlled. As the material of the substrate, usually, polyethylene, polypropylene, polyolefin resin such as olefin thermoplastic elastomer, acrylic resin such as polymethyl methacrylate, polybutyl methacrylate, polyethylene terephthalate, thermoplastic polyester resin such as polybutylene terephthalate, heat Thermoplastic resins such as plastic urethane resin, polyvinyl chloride, ABS, polystyrene, etc., thermosetting resins such as melamine resin, unsaturated (thermosetting) polyester resin, two-pack curing (thermosetting) type urethane resin, radical polymerization type An ionizing radiation curable resin obtained by crosslinking an unsaturated acrylate (or methacrylate) or a cationic polymerization type epoxy resin with ionizing radiation (ultraviolet rays, electron beams, etc.) is used. The substrate is generally a laminate, but may be a single layer.

The present invention will be described in more detail with reference to the drawings. FIG. 1 is an explanatory view of a plane pattern forming a convex element of an embossed decorative material according to the present invention. FIG. 4 is a perspective view of the uneven shape of the embossed decorative material according to the present invention.
As shown in FIG. 4, the uneven shape of the embossed decorative material according to the present invention has a complicated shape including a convex portion and a concave portion connected to each other with a continuous change in height due to a curved surface. The convex elements, which are the minimum units constituting the convex portions, are arranged in a plane. This convex element has a plurality of types of different diameters, and is obtained by embossing a base material with a concave-convex shape of an embossed plate surface obtained by photoetching from a randomly arranged plane pattern. A different plane pattern obtained by shifting the phase of the plane pattern in the plane, or a pattern obtained by repeating photoetching at least twice or more on the embossed plate once obtained using a completely different plane pattern. An embossing plate having a more complicated uneven shape formed by accumulating the shape elements can be obtained. The embossed decorative material according to the present invention is obtained by shaping the surface of a substrate using such an embossing plate. As the planar pattern for forming the above-mentioned convex element, a halftone dot-shaped one is suitably used, and as shown by a solid line in FIG.
At least 2 with a diameter in the range of 0.02-0.6 mm
This is a set halftone dot pattern P in which half or more types of halftone dots are randomly arranged. It is preferable that the individual halftone dots forming the aggregated halftone dot pattern P have a circular shape as shown in the figure in order to obtain the isotropic gloss of the embossed decorative material. , Hexagons and the like. This production can be performed on a display screen of a CRT or the like by a digital image processing method using a computer using software for arranging a plurality of types of halftone dots at intervals with a predetermined tolerance at random. . Further, at the time of calculating the pattern arrangement by the computer, the interval ΔL between the halftone dots may be set each time according to the radius of the halftone dot. In the embossed decorative material according to the present invention, the degree of denseness of individual halftone dots in the aggregate halftone dot pattern P is important. Regarding this density, as shown in FIG. 1B, the interval ΔL between the adjacent halftone dots P1 and P2 and the halftone dot P
It is necessary that there be a relationship of ΔL ≦ F1 + F2 between the side etching widths F1 and F2 of P1 and P2. In other words, it is desirable that a set of halftone dots indicated by dotted lines anticipating up to the width F of the side etching be in a state of fine packing or be dense beyond the state. The distance ΔL between the adjacent halftone dots must be determined in consideration of the halftone dot area, the corrosion depth D, and the corrosion method. that is,
This is because the corrosion depth D increases as the halftone dot area increases, and the width F of the side etching increases as the corrosion depth D increases, and the F / D varies depending on the corrosion method. In the embodiment of the embossed decorative material according to the present invention,
In the case where a halftone dot having a radius of 10 to 50 mμ is corroded to a corrosion depth of 20 mμ, ΔL is set to 10 mμ and a radius of 50 to 100 is set.
ΔL in the case where a halftone dot of mμ is similarly corroded to a corrosion depth of 20 mμ is set to 20 mμ.

FIG. 2 is an explanatory view of the photo-etching for forming the uneven shape of the embossed decorative material according to the present invention. The aggregated halftone dot pattern P having the above-mentioned density is printed on the photosensitive resist film on the embossing plate surface, and after development, the resist pattern R having substantially the same shape as the aggregated pattern P shown in FIG. A non-resist portion (opening) is formed on the plate surface, and then the plate surface in this state is corroded, the corrosion proceeds with side etching, and the corrosion proceeds beyond the resist pattern R indicated by the solid line. , Expanded to the area of the side etching indicated by the dotted line,
Adjacent halftone dots are connected to each other by corrosion. And even after the halftone dots are connected, the corrosion is further continued. Therefore, in the present invention, the bank between the concave portions corresponding to the halftone dots formed by the corrosion is corroded, so that the original embossed plate surface does not remain as it is. This photo-etched pattern is shown in FIG.
This will be described with reference to FIG. Is a plane pattern of three halftone dots P1, P2 and P3 arranged adjacent to each other on a substantially straight line of the set halftone dot pattern P shown in FIG. Hereinafter, these halftone dots are represented by a central cross section virtually cut along the line XX ′. Indicates a resist film 2 of a resist pattern R formed on the plate surface of the embossed plate material 1. The embossing plate 1 is generally made of a metal such as copper or iron, and has a shape of
It is a flat plate or a cylinder (cylindrical). As the resist formed thereon, a negative photosensitive resist such as gelatin dichromate, polyvinyl cinnamate, acrylamide, polyvinyl azidobenzal, or a positive photosensitive resist such as O-quinonediazido novolak resin is used. However, regardless of which type of resist is used, exposure and development are performed so that the portion between the halftone dots becomes the resist as shown in the figure. As a method for applying the photosensitive resist film to the embossing plate material 1, as in a conventional gravure method, a net is formed on a sheet (carbon tissue or the like) in which a photosensitive resist film is previously coated on a release support sheet. After exposing the point pattern, only the exposed resist film on the sheet is transferred onto the plate material, and then developed, and then exposed to light in the case of a negative resist or exposed in the case of a positive resist. A method in which a photosensitive resist film is applied on a plate material in advance, and then a halftone dot pattern is exposed thereon, followed by a development process, as in the method of dissolving and removing the part, or the direct gravure method Either can be adopted. Also, as the exposure method,
A halftone dot pattern is formed in advance as a negative or positive on the surface of a silver halide photosensitive photographic film or the like, and only halftone portions are light-shielding and others are light-transmitting (positive), or only halftone portions are light-transmitting, Otherwise, a light-shielding (negative) film is prepared, and the film is closely adhered to the photosensitive resist film, and the entire surface is exposed with a light source such as a mercury lamp, or the photosensitive resist film is exposed. While scanning two-dimensionally with a light beam such as a laser beam, the light beam is changed to an electric signal corresponding to a halftone dot image (usually a digital signal is used, but an analog signal may be used).
Either N-OFF or a method of intensity modulation can be adopted.

[0008] Next, the etching process indicated by (1) will be described. By the above method, the resist film 2 is formed in a portion other than the halftone dot as shown in FIG. The width of the resist film 2 formed between the adjacent halftone dots is substantially equal to ΔL.
Corrosion starts on the non-resist portion of the plate surface on which such a resist film 2 is formed. Hereinafter, the direction of corrosion is indicated by arrows. The corrosion method includes a method of supplying a corrosive liquid such that a target corrosion depth D and a side etching width F are achieved,
Proceed in consideration of the concentration of the etchant. In general, the spray method is suitable for reducing the side etch and securing the depth, while in order to make the side etching violent,
A Molton roller system is preferred. Corrosion first erodes the non-resist portion in a bowl shape as shown in FIG.
As the corrosion further proceeds, the side etching erodes the lower part of the resist film 2 from both sides as shown in FIG. Further, the corrosion may be temporarily stopped immediately before reaching the state shown in FIG. 1 and further promoted after the resist film 2 is peeled off. If the plate surface without the resist film is further eroded from the state shown in the above, the erosion is particularly violent at the protrusions between the halftone dots, and as a result, a continuous curved cross section with sharp corners as shown in the figure is formed. You. At this point, an embossing plate E 'having an uneven shape having a continuous height change due to the curved surface is obtained for the first time. This embossing plate E 'is an intermediate one. If the embossing plate E' is embossed on a base material, as shown in (1), the convex element T 'corresponding to the initial halftone dots P1, P2, P3
1, T2 and T3 are shaped. FIG. 4 is a perspective view of this state, that is, a state in which the convex elements are randomly arranged in a single layer. The concavo-convex shape is composed of convex portions (convex elements) and concave portions (valleys between convex elements) that are connected to each other with a continuous change in height due to a curved surface. Of course, it may be used as an embossing plate in this state. However, at this stage, if the uneven shape is still too simple to obtain a predetermined gloss width, the embossing plate E in the state shown in FIG. The second photo-etching is performed on the plate surface of '.

FIG. 3 is an explanatory diagram of the second photoetching and embossing steps. Shows a state in which the resist film 2 is formed again on the embossing plate surface obtained in the above.
In this case, the set halftone dot pattern P used for printing
May be used by shifting the phase of the first halftone dot pattern P used in the plane, or may be a different halftone dot pattern having a completely new halftone dot diameter distribution,
The specific embossed pattern may be combined with a linear pattern such as a hairline that is completely different from the halftone dot used for the first time. By doing so, an embossed pattern in which the convex elements formed from the halftone dots and the linear convex portions are connected to each other is produced, and a concave-convex shape having a special design property is obtained. In addition, the linear pattern is not limited to a pattern that provides a simple linear convex portion, and may be a curved pattern or a cross-shaped pattern. As a result of performing the second corrosion on the plate surface in the state shown in FIG. 1, an emboss plate E having a more complicated uneven shape as shown in FIG. In order to form a more complicated shape, the third embossing may be performed on the embossed plate having the shape shown in FIG. In this way, the finally obtained embossing plate E having a predetermined uneven shape may be used as it is in the next embossing step. However, usually, in order to improve abrasion resistance, chrome plating is applied to the entire surface. Apply and use.

2 shows an embossing process using the embossing plate E. As a typical method of forming a concave-convex shape on the base material 3 on the substrate 3 using the embossing plate E to obtain a decorative material, the embossing plate is pressed on the surface of the thermoplastic resin substrate that has been softened by heating. There is an embossing in a narrow sense of cooling, solidifying and shaping. However, the method for producing the embossed decorative material according to the present invention is not limited to this, and it can be produced by other methods. For example, an unsaturated acrylate prepolymer, an uncured liquid composition such as a monomer is applied to the surface of the embossed plate made by the above method, and the liquid composition is filled into at least the concave portions of the uneven shape,
Next, in a state where a sheet-like base material such as a resin is overlaid on and adhered to the liquid composition, ultraviolet rays or an electron beam is irradiated from the sheet side to cure (solidify) the liquid composition and adhere to the sheet surface. And a method of releasing a cured product layer on which the embossed plate has been formed from the embossed plate (Japanese Patent Laid-Open No. 2-131).
175, etc.). Of course,
The uneven shape on the embossing plate and the uneven shape on the decorative material are reversed as shown in FIG. The form of the substrate 3 is a sheet (or a film), a plate, or the like. Substrate 3 with irregularities formed on the surface as required
Forming a pattern layer such as a wood pattern, a stone pattern, a cloth pattern, a geometric pattern, and a solid pattern on the front surface, the back surface (when the base material is transparent), or the front and back surfaces using a known ink and printing method. Alternatively, a decoration process may be performed by forming a metal thin film on the entire surface or a part, or kneading a known coloring material such as a pigment or dye into the base material itself. Examples of the use of the embossed decorative material according to the present invention include walls, floors, interior materials of buildings such as ceilings, doors, window frames,
Door frames, surface materials of fittings such as handrails, surface materials of housings of home appliances such as television receivers, surface materials of furniture such as chests, surface materials of containers such as boxes, interior materials of vehicles, interiors of ships A material, etc., which is optionally backed and used as needed. FIG. 3 shows a state in which the embossed base material 3 is backed with a backing material 4.

[0011]

According to the present invention, there is no flat portion on the surface of the base material, and a complex uneven shape composed of a convex portion and a concave portion connected to each other with a continuous change in height due to a curved surface is formed. The glossy expression range can be expanded especially in the low glossy region, so-called glossy patterns can be created that can express patterns with a high range of gloss change, and gloss matching printing patterns such as wood grain patterns can be given. Therefore, it is possible to create an unprecedented realistic texture and advanced design expression. In addition, the stain resistance is greatly improved, dirt is less likely to accumulate, and even if the surface is dirty, it is easy to wipe off. Further, the scratch resistance is greatly improved, and a cosmetic material which is hardly scratched can be provided.

[Brief description of the drawings]

FIG. 1 is an explanatory view of a plane pattern forming a convex element of an embossed decorative material according to the present invention.

FIG. 2 is an explanatory view of photo-etching for forming an uneven shape of the embossed decorative material according to the present invention.

FIG. 3 is an explanatory diagram of a second photoetching and embossing process.

FIG. 4 is a perspective view of the uneven shape of the embossed decorative material according to the present invention.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 embossed plate material 2 resist film 3 embossed base material 4 backing material 10 decorative material according to the present invention P aggregate dot pattern R resist pattern E embossed plate T convex element

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 2H113 AA06 BA28 BB07 CA05 DA47 DA57 DA62 FA05 FA28 FA29 FA43 FA45 4F209 AA03 AA04 AA11 AA13 AA15 AA21 AA25 AA31 AA39 AA45 AG01 AG05 AH26 AH48 AH51 PA03 PB02 PC05 P03

Claims (2)

[Claims] 1. A decorative material having fine irregularities on the surface of a base material, the irregularities comprising a convex portion and a concave portion connected to each other with a continuous change in height due to a curved surface, and at least a part of the convex portion and the concave portion. An embossed makeup characterized in that the projections are formed by an in-plane arrangement of individually independent convex elements formed from a plurality of types of different diameter and randomly arranged densely arranged planar patterns. Wood. 2. The embossed decorative material according to claim 1, wherein the convex portions are formed by accumulating convex portions formed from a different planar pattern from the convex elements.