JPH03187715A - Manufacture of shaped film - Google Patents

Abstract

PURPOSE:To shape a film from a material such as japanese paper without spoiling the hand and having hand of the material by a method wherein a base is made of a material having weak surface strength, a resin treatment is applied on the base and curing type resin material for templating is applied on the base two times, then, the resin is rolled and deaerated while the coating layer of resin is separated from the base after the resin is cured. CONSTITUTION:A base 1 is made of a material such as japanese paper which is provided with a soft surface and weak surface strength while the base paper 2 for wall paper, particle board 3 or the like is laminated on the opposite surface of a surface to be shaped. Thermosetting resin is impregnated into the base 1 to improve the strength of the base 1 and a strength between the base 1 and the base paper 2 for wall paper. Top coat process is applied to reproduce the hand and feel of the material by coating the thermosetting resin on the surface of the base 1 and resin 12 is formed in a condition that it adheres to the surface of the fibers 11 on the surface of the japanese paper. Curing type resin material for shaping is applied on the surface of the copy 1 more than two times and the resin is rolled. Perfect deaeration is effected by the first applying and rolling while the second applying and rolling is effected to provide the copy 1 with a necessary thickness. Cured coating layers 4', 4'' are separated from the base 1 and a shaped film 4 is obtained.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for producing a molded film, and more specifically, it is possible to mold a material with a soft surface and low surface strength, such as Japanese paper, without impairing its texture. The present invention relates to a method for manufacturing a moldable film that can be removed.

[Conventional technology 1] Conventionally, when making a mold from an original having a fine uneven shape, a method is generally used in which silicone is used as a casting resin, cured and released, and used as a master mold from the original. For example, Japanese Patent Publication No. 51-1139, Japanese Patent Publication No. 56-1987
The technology is disclosed in various publications such as No. 17217 and No. 56-80410.

[Problems to be Solved by the Invention] However, when using the above-mentioned conventional method, it is a prerequisite that the original can be peeled off cleanly without being destroyed when the cured casting resin is released from the mold. The objects that should be used are limited to materials with a somewhat hard surface such as metal, wood, and plastics, and it has been practically impossible to make molds from materials such as Japanese paper, which has a soft surface and poor strength.

The present invention was made in view of such conventional problems,
The object of the present invention is to provide a method for manufacturing a molding film that allows molding from a material such as Japanese paper, which has conventionally been impossible to mold, without impairing the texture of the material.

[Means for Solving the Problems] In order to achieve the above object, the method for manufacturing a molded film according to the present invention uses a material with a soft surface and low surface strength, such as Japanese paper, as a manuscript, and a method for producing a molded film according to the present invention. After impregnation with a thermosetting resin and resin processing with a top coat, a curable resin material for molding is applied and rolled on the surface in at least two times, defoamed, and after the coating layer has hardened. It is designed to be peeled off from the original.

According to the present invention, by applying resin processing to the manuscript using a thermosetting resin, the strength of the manuscript material is improved by impregnation with the resin, and when the imprinting film is peeled off, paper separation does not occur. Even if the original is made of a material with a soft surface such as Japanese paper, it can be molded without damaging the original. Furthermore, by applying a top coat with a resin that matches the shape of the material, it is possible to make molds without damaging the original texture of the material. Furthermore, by applying and rolling the curable resin AI in at least two times during mold making, even if the manuscript is made from a material that tends to produce air bubbles, such as Japanese paper, it will be completely degassed, resulting in completely bubble-free molding. Can produce molded film.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

The manuscript to which the present invention is applied is a material with a soft surface and low surface strength, such as Japanese paper.

Therefore, from the viewpoint of workability and protection of the original, it is desirable to laminate wallpaper base paper, particle board, or the like on the side of the original opposite to the side on which shaping is performed.

In the present invention, such a material is used as a document, and the document is impregnated with a thermosetting resin and processed with a top coat. 1st
The figure is a sectional view showing a state in which the resin processing has been applied to the original. In the figure, 1 represents an original, 2 represents a wallpaper base paper laminated to the original 1, and 3 represents a particle board that is also laminated.

The resin processing consists of two steps: impregnation with a thermosetting resin and top coating.The first step of the impregnation process is to impregnate the original 1 with a thermosetting resin to improve the strength of the material itself and the original 1.
This improves the inter-paper strength of the base paper for wallpaper 2, and prevents separation between the sheets when the finished molded film is peeled off.

Examples of the thermosetting resin used in such an impregnation treatment include melamine resins, and specifically, melamine resins, benzoguanamine resins, and the like are preferably used. Further, the impregnation rate is desirably about 20 to 40%.

On the other hand, the latter top coat treatment is a process in which a thermosetting resin that matches the gloss of the Japanese paper material is applied to the surface of the original 1 to reproduce the texture of the material.As shown in Figure 1, the surface of the Japanese paper The resin 12 is formed so as to be entangled around the fibers 11 of the fibers 11.

Examples of thermosetting resins used in such top coat treatment include acrylic urethane resins and diallyl phthalate resins that match the gloss of the Japanese paper material.

Also, the amount of application in this case is 7 to 14! Approximately II/l' is preferable.

After performing such resin processing, a hardening mold 4!4WB material for molding is applied and rolled on the surface of the original 1.

In the present invention, this coating and rolling step is carried out in two or more steps, but from the viewpoint of workability, it is preferable to carry out the step in two steps. Rolling can be carried out, for example, by placing a film member or the like on the coated resin material using a rubber roll or the like. The original washi paper is a material that tends to generate bubbles, so the first coating and rolling process completely removes the bubbles, and a second coating and rolling process is performed to obtain the necessary thickness for the shaped film. The state after this coating rolling is shown in Fig. 2, in which 4' is the result of the first coating rolling, and 4'' is the 2nd
The layers are formed by each coating and rolling process, and ultimately form an integral cured film layer. As a curable resin material for mold-making, any material that can reproduce the fine irregularities and gloss differences on the surface of the original can be used, and materials that are flexible are most suitable for mold-making and mold release, such as silicone resin. can be preferably used, but
A flexible curable epoxy resin or the like can also be used.

In addition, if the application amount is divided into two times, the first time is 40%
0Q/f~500Mf, second time 500Q/t"~
Approximately 6GGM1 is preferable. If the first application amount is too small, defoaming will be incomplete, and if it is too large, defoaming will be difficult.

Finally, when the cured integral coating layers 4', 4'' are peeled off from the original 1, a forming film 4 that reproduces the texture of the original surface is completed as shown in FIG.

The finished imprinting film 4 may be used as it is as an embossing plate, or the finished imprinting film 4 may be used as a matrix and a return mold is taken from it to produce an imprinting film to be used. good.

By using the forming film produced using the present invention, a decorative material having the texture of Japanese paper can be produced.

[Example J] The present invention will be described in more detail with reference to Examples below.

Wallpaper base paper (80o/V) was wet-laminated onto continuous Japanese paper, and the composite sheet was impregnated with melamine resin at an impregnation rate of 40%.

The above-mentioned sheet was laminated onto a particle board having a thickness of 10 m/m, and an acrylic urethane resin corresponding to the length of the Japanese paper was coated with a coating amount of 109/f using a roll coater to obtain a resin-treated manuscript. Furthermore, by the melamine resin impregnation treatment, the interpaper strength between the wallpaper base paper and the Japanese paper was improved from 50 g/inch to 120111/inch before the impregnation treatment.

Next, a silicone resin of 40012/f is applied onto the processed original, and a nylon film attached to the frame is placed on top of the silicone resin and rolled with a rubber roll.

Leave it for about 20 minutes, and after confirming that the air bubbles have disappeared, remove the nylon film attached to the frame.

Next, 600 Mf of silicone resin is applied onto the document again, and the nylon film attached to the frame is again placed and rolled in the same manner.

The original was placed in an oven at 60° C. for about 3 hours to be cured, and then the silicone resin layer was peeled off from the original to obtain a molded film similar to the surface of the Japanese paper.

On the other hand, the above-obtained imprinting film was closely placed on the photocurable unsaturated polyester resin coated on the wallpaper base paper.
After degassing, UV irradiation was performed and the imprinting film was peeled off, yielding a decorative material with the texture of Japanese paper.

[Effects of the Invention] As explained in detail above, according to the method for producing a molded film of the present invention, it is possible to make a mold from a material with a soft surface and poor strength, such as Japanese paper, and still maintain the original texture of the material. It has the excellent effect of being able to take a mold without damaging it. In addition, even if the material is prone to air bubbles, such as Japanese paper,
According to the production method of the present invention, it is also possible to produce a shaped film completely free of bubbles.

[Brief explanation of drawings]

Fig. 1 is a cross-sectional view showing a manuscript processed with thermosetting resin, Fig. 2 is a cross-sectional view showing a manuscript coated with molding material and rolled, and Fig. 13 is a cross-sectional view showing a manuscript manufactured by the present invention. FIG. 1... Manuscript 2... Base paper for wallpaper 3... Particle board 4... Imprinting film Figure 1 Figure 2 Figure 3

Claims (1)

[Claims] A material with a soft surface and low surface strength, such as Japanese paper, is used as a manuscript, and after the manuscript is impregnated with a thermosetting resin and treated with a top coat, a hardening resin material for molding is applied to the surface. Coating and rolling in at least two times,
A method for producing a molded film, which comprises degassing and peeling the coated layer from the original after it has hardened.