JPH01242176A - Method for manufacturing decorative board with unevenness - Google Patents

Abstract

PURPOSE:To reduce cost by selecting base paint applied to the surface of a base material and specifying pressing and heating conditions. CONSTITUTION:Base paint (acrylic resin paint) 2 is applied to the surface of a base material with a flow coater F. Transfer paper P printed with transfer paint 3 is put on the base material having the base paint and they are pressed and heated through a cushion 4. The paper P is then stripped. A decorative sheet can be efficiently produced by transfer at a low cost.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to an improved method for applying makeup only to the convex surface of a substrate having an uneven surface. To explain this in more detail, in the past, as a means of beautifully applying colors and patterns only to the convex parts of a base material with an uneven surface, a decorative board with a good finish was created by applying several layers of various paints. However, the present invention eliminates these steps and allows the process to be performed immediately using transfer paper by simply applying the base paint to the surface of the substrate to be processed, drying it, and forming a thin base paint layer. This is a decorative board manufacturing method that transfers beautiful colors, patterns, etc. only to the convex surfaces of the processed base material, and obtains a product whose finish is comparable to that produced by the conventional method, which requires multiple steps. .

(Prior art) Conventionally, in order to create patterns only on the convex surfaces of board materials and other base materials with uneven surfaces, after applying a base paint to the surface of the base material, pre-painting is applied only to the convex portions of the base material. Apply the hot adhesive and place the transfer ink side of the transfer paper on top of it.
The transfer ink is transferred to the convex surface by applying pressure and heating.

For example, Japanese Patent Laid-Open No. 56-48271 discloses a method of forming a base coat layer on the entire surface of the substrate, and then printing a pattern or the like on only the convex surface by means of gravure offset printing or the like. .

(Problems to be Solved by the Invention) In the conventional method of gravure offset printing on the convex surface of a member after forming a base paint layer, the flatness of the convex surface is is required to be extremely accurate.

Otherwise, the print will be faded and a good finish will not be obtained. Furthermore, in the method of forming a heat-sensitive adhesive layer on the base paint layer, extra materials are used and one step is added, which inevitably increases costs.

Therefore, even if it can be adopted for expensive products, it cannot be adopted for inexpensive products. Furthermore, since the transfer ink is only transferred to the convex surface of the workpiece, it is necessary to apply too much pressure (applying pressure will cause the ink to reach the concave parts, resulting in a defective product, so in order to achieve a transfer effect with light pressure) , an adhesive layer with good adhesiveness is required, and in this case, sufficient consideration must be given to the selection of adhesive, which is another factor that increases costs.

(Means for Solving the Problems) The present invention has been completed as a result of various studies in order to solve the above-mentioned problems, and its basic technology can be said to consist of two main points. One of the key points is that the convex surface of the base material is quite uneven when viewed minutely, and even with conventional methods, the base paint layer (B) (Fig. 1) is coated using a paint such as synthetic resin. The purpose of forming this base paint layer is to fill in these irregularities and flatten the surface as much as possible.The paint is applied to this base paint layer using a coating method such as blow coating, but after application, When we examine the surface of the layer in detail, we find that there are unavoidable irregularities that correspond to the irregularities on the surface of the base material.
This is generally well known. Therefore, in the present invention, it has been found that by repairing these minute irregularities, highly accurate flatness can be obtained and the transfer effect can be enhanced. This concerns the materials and physical properties of the base paint, which will be explained in detail later. The second point is the discovery of special conditions for the transfer means of the transfer paper, that is, pressure and heating, that is, the physical properties of the base paint and the appropriate conditions for obtaining a good finish. To describe this more specifically, in Fig. 1, (T) is the base material to be processed, with a convex portion (1) and a concave portion (1°).
A base paint layer (B) is formed by applying a base paint (2) to the entire surface of the base paint by a coating method such as flow coating. This base paint (2) is a paint based on acrylic resin, such as acrylic ester (methyl acrylate, ethyl acrylate, etc.), methacrylic ester (methyl methacrylate, ethyl methacrylate, etc.), or styrene resin. Sufficient adhesion, fluidity and smoothness can be obtained with a paint having a standard viscosity of 25 to 50 seconds/NK 2 cups and a very thin film thickness of 0.05 to 0.1 mm. Furthermore, the coating has a standard viscosity of 25 to 50 seconds/NKN12 cup and a glass transition temperature of 40 to 95 degrees Celsius, leaving the concave portion (1 degree) of the base material intact without being buried.

The glass transition temperature is set at 40°C to 95°C because if it is below 40°C, the temperature resistance will decrease and the range of use of the product will be limited, for example, it cannot be used in bathrooms, kitchens, etc. This is because, if the temperature exceeds this level, transfer of the transferable ink will occur (＼), and the softening of the resin will decrease.

Materials that have adhesiveness and smoothness are preferred; materials that form a rough surface are not suitable. The composition of the base paint is:
Resin 20-30%, Colorant 40-50%, Solvent 20-4
Usually, a plasticizer or the like is added to this in the range of 0%, but the present invention is not limited thereto.

In this case, the color is usually used as the ground color.

Traditionally, transfer paper consists of a thin film with a transferable ink layer of about 1 to 5 microns at most, and is made by coating a synthetic resin such as silicone or polyamide on a conventionally used material, such as a paper synthetic resin sheet. A thermally adhesive ink layer having a thickness of about 1 to 5 μm is printed thereon, and most commonly used thermally adhesive inks can be used.

That is, it is made by using various oils and fats, rosin, rosin modified resin, rubber derivatives, etc. as a vehicle, mixing pigments and dyes into the vehicle, and then adding a solvent.

Next, regarding the transfer means, the ink side of the transfer paper is placed on the substrate to be processed using the usual method (Fig. 2), and if necessary, the cushioning material (4) is placed on top of it, and the entire surface is It is heat pressed, and the pressure is 10 to 25 kg/
ca+2, heating temperature is 70-120℃, time is 3-5
A minute is enough. In this way, a clear pattern or the like is transferred onto the convex surface of the processed substrate after the transfer process is completed. In order to protect the ink thus transferred, various top coats (5) are further applied to the entire surface of the base material using a flow coater.
Finish it as a complete product.

(Fig. 4) (Function) To explain the function of the method of the present invention described above, since it has a function, a transfer paper is placed, pressure is applied under the above-mentioned moderate heating, and the method is heated for 3 to 5 minutes. After a few minutes have passed, the convex surface of the base material is close to the heated surface, so it softens a little first, and a so-called recovery phenomenon of adhesiveness occurs, and the surface becomes significantly flat due to pressure. In addition, the ink on the transfer paper is transferred well due to its adhesive properties, and the finish, that is, the transfer, is very clear. When the transfer is completed and the heating is stopped, the base paint solidifies again.

Furthermore, by applying a top coat (5) on top of the ink, the ink is protected and its commercial value is increased.

There is a deep reason why the base paint layer (B) is made to be a thin film layer of 0.05 to 0.1 mm.As a result of experiments, when the core layer is thick, the unevenness that occurs during the coating process is added to it. Amplify new irregularities. If it is thin, the paint film will have the effect of repairing minute irregularities on the surface of the base material, and even if the irregularities remain, they will be minimal.

The slight irregularities are repaired using a heat press. Also, the thinness of the coating film has the advantage of being able to be repaired in a short period of time.

When the unevenness reaches approximately 0.2 mm, repair is extremely difficult and remains as a flaw.

In addition to the above-mentioned acrylic resin paint, styrene resin paint is also effective.

(Example) Examples of the present invention will be described below. In Figure 1 (T)
is a base material (tile) with a convex part (1) and a concave part (1) on its surface.
゛). Using a flow coater (F), coat the entire surface with an acrylic resin base paint (2) with a glass transition point of 80°C.
Apply an amount of 120g/+'' using a paint.At this time, be careful not to bury the recess (1゛).Next, apply an appropriate transfer paint (ink) (3) on the base material having this base paint. Place the transfer paper (P) printed on it to a thickness of about 3 μm with the ink side facing down as shown in Figure 3, and if necessary, add a cushioning material, such as a silicone resin sheet, on top of the transfer paper (P). (4) is placed, and when the preparation is completed, heat and pressure is applied from above the transfer paper (P) or the cushion material (4) on it.The pressure is applied only to transfer the beautiful pattern to (1). Ta.

(Effects of the Invention) As described above, the present invention enables the provision of a layer of heat-sensitive adhesive or the formation of a surface to be transferred by selecting the base paint to be applied to the surface of the substrate and specifying the pressure and heating conditions. It is an extremely effective means for efficiently transfer-producing decorative materials at low cost, without requiring any preparation process for flattening, or special printing means such as offset printing.

[Brief explanation of the drawing]

Fig. 1 is an explanatory diagram showing a partially cut-out end surface showing the unevenness of the base material, Fig. 2 is an explanatory diagram showing the transfer paper and cushion material, Fig. 3 is an explanatory diagram showing the transfer state, and Fig. 4 is an explanatory diagram showing the top coating. It is an explanatory diagram showing a state. Description of symbols (1)... Convex portion, (1')... Concave portion,
(2)・・・Base paint, (3)・・・・・・
Transfer ink, (4)...Cushion material, (5)
...Top coat paint, (B) ...Base paint layer, (T) ...Base material, (1') ...
Flow coater, (P)...Transfer paper.

Claims (1)

[Claims] Mainly uses acrylic resin paint on the uneven base material surface,
A base paint made by mixing colorants, solvents, plasticizers, etc. and having a glass transition temperature of 40°C to 95°C is coated to a thickness of about 0.05 to 0.1 mm, and then any desired coating is applied. Place a transfer paper with an appropriate picture printed with thermal adhesive ink on the sheet material with the ink side facing down, and apply pressure of 10~
A method for manufacturing a decorative board having an uneven surface, characterized by carrying out pressure and heat treatment at a pressure of 25 kg/cm^2 and a temperature of 70°C to 120°C.