JPH0416268A - Manufacture of sheet having real uneven surface - Google Patents

Abstract

PURPOSE:To easily and certainly prepare the title sheet by forming the uneven shape composed of the ionizing radiation-curable resin cured and shape during the filling of a roll intaglio, which is formed by imitating the surface of a natural material, as a sheet base material of resin. CONSTITUTION:A roll intaglio 1 formed by imitating the surface shape of natural matter such as wood, a stone material or a cloth material by either one of an electroforming method, a mill extrusion method, an etching method, a resin casting method or a laser engraving method is used. At least the plate recessed parts 2 of the roll intaglio 1 is filled with an ionizing radiation-curable resin and a sheet base material 4 made of a synthetic resin is brought into contact with the roll intaglio 1. The resin 5 interposed between the base material 4 and the intaglio is cured by the irradiation with the ionizing radiation from an apparatus 6, during the contact period of the base material with the intaglio 1, to be closely bonded to the base material 4 and, subsequently, the base material 4 is peeled off from the intaglio. As a result, a real embossed sheet having the surface uneven shape of the natural matter faithfully and precisely reproduced on the surface thereof can be easily and certainly prepared.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a method for manufacturing a sort having a real uneven surface that reproduces the uneven surface shape of a natural object such as wood or stone with extremely high fidelity and precision.

[Prior Art] Conventionally, sheets of notebooks have been provided with a desired uneven shape on their surfaces in order to obtain an appearance with excellent design. Among these, the so-called real emboss sort is known, which has an uneven shape for rubbing to obtain a design appearance that is closer to the surface appearance (e.g. wood grain, stone grain) of natural objects such as wood and stone. It is being

For example, using a raised printing method such as screen printing, a chemical embossing method, or a mechanical embossing method such as heat embossing, an uneven shape that is close to the surface uneven shape of a natural material is printed on the sorting substrate, or There is something I did.

[Problem to be solved by the invention]

However, when real embossed sheets are produced using the raised printing method or chemical embossing method, the uneven shapes obtained are not as clear as possible, and the reproducibility of details on the surfaces of natural objects is especially lacking. Since it is difficult to reproduce the shape, it has not been possible to obtain a high-quality notebook with a realistic, uneven appearance. Also, when producing by the heat embossing method, there is a limit to the ability to reproduce details particularly. This is because, since thermoplastic resin sort is used as the sheet base material, the grains return to several micrometers to several tens of micrometers after being separated from the nporol during processing. It has been considered to remove the sheet material from the embossing plate after it has completely cooled in order to reduce this grain return, but this creates the problem that peeling from the plate becomes impossible or extremely difficult, and in the end, fine grains It was nearly impossible to reproduce the unevenness. At present, the heat embossing method cannot produce faithful and clear imprinting with fine irregularities of 10 μm or less, which is a guideline for reproducing superior realism. Moreover, since the shaped uneven shape is made of a thermoplastic material, it has no heat resistance and has the disadvantage of being inferior in durability against heat, friction, etc.

Therefore, even with the heat embossing method, it has not been possible to obtain a sort that exhibits a satisfactorily realistic uneven appearance.

The present invention has been made in order to overcome the drawbacks of the above-mentioned prior art, and provides a manufacturing method that can easily and reliably produce a real embossed sheet whose surface has faithfully and precisely reproduced the surface irregularities of natural objects. With the goal.

[Means to solve the problem]

That is, the method of manufacturing a sheet having a real uneven surface according to the present invention involves forming the surface shape of a natural material such as wood, stone, cloth, etc. by electroforming, mill pressing, etching, resin pouring, or laser engraving. A rolled intaglio plate molded by a method is used, at least the concave portions of the rolled intaglio plate are filled with an ionizing radiation curable resin, and a synthetic resin sheet base material is brought into contact with the intaglio plate, and the base material is brought into contact with the intaglio plate. During the process, ionizing radiation is irradiated to harden the resin interposed between the base material and the intaglio plate, so that the resin and the base material are brought into close contact with each other, and after that, the base material is peeled off from the intaglio plate. It is something.

〔Example〕

Embodiments of the present invention will be described below based on the drawings.

FIG. 1 is an explanatory diagram showing an embodiment of the manufacturing method of the present invention. Circular 1 is a roll intaglio plate, 2 is a concave plate molded with the uneven surface shape of a natural object, 3 is a press roll, 4 is a notebook base material, 5
is an ionizing radiation curing resin, 6 is an ionizing radiation irradiation device, and 7 is an ionizing radiation irradiation device.
indicates a real uneven shape.

In the method of the present invention, first, a roll intaglio plate 1 having plate depressions 2 (plate parts) formed by molding the surface unevenness of a natural object is produced.

In the case of roll intaglio plates made of metal such as copper or iron, the mold is made by electroforming, mill pressing, or etching, and if necessary, the surface is coated with chrome etc. and/or sandblasted. . In addition, unlike hot embossing, the method of the present invention does not require heating during production (when forming unevenness), so it is possible to use a coal intaglio plate in which at least the plate portion is made of synthetic resin, which could not be used due to limitations in physical properties such as heat resistance. can be used. In the case of such a roll intaglio plate, the plate part is molded by a casting method using synthetic resin such as soricone, polyester, or polyacetal, or by laser engraving method on the above synthetic resin film. do. Typical examples of natural objects include wood, stone, cloth, etc., and the surfaces of these materials can be used as original forms for real uneven shapes. Other natural objects include those whose surfaces have been polished, sandblasted, painted, or engraved with the representative natural objects listed above.
Alternatively, it may be a collection of marquetry or the like. In the present invention, the surface irregularities of these natural materials are reproduced and formed on the surface of a sheet base material through a roll intaglio plate shaped as described above.

To explain the above mold-making method in detail, a mold release resin such as silicone resin is poured onto the surface of a natural material that has been subjected to sealing and mold release treatment as necessary, and a resin plate is created by curing and releasing the mold. Alternatively, after sealing and mold release treatment is applied to the surface of the natural object as necessary, conductive treatment is performed by silver mirror reaction, electroless plating, etc., and then a metal layer is formed by electrolytic or electroless plating method. A metal plate can be produced by peeling it off. However, the molding method is not limited to these embodiments.

Next, in the method of the present invention, a sort having a real uneven surface is manufactured using the roll intaglio plate 1 in the following manner.

As shown in FIG. 1, the sheet base material 4 is fed so as to pass between the intaglio roll l and the press roll 3, and the TJIL radiation curing resin 5 is applied so as to fill at least the plate recesses 2 of the intaglio plate 1. While supplying, the base material 4 is brought into contact with the intaglio plate 1,
While the base material 4 is in contact with the intaglio plate 1, ionizing radiation is irradiated from the ionizing radiation irradiation device 6 to harden the resin and at the same time bring it into close contact with the base material side. Thereafter, by peeling the sheet base material 4 from the intaglio plate 1, a real uneven pattern 7 made of an ionizing radiation-curable resin shaped (cured) into a shape corresponding to the shape of the intaglio plate 1 is formed on the surface. In addition, a sheet 8 having a real uneven surface as illustrated in FIG. 2 is obtained.

The ionizing radiation curable resin can be supplied between the intaglio roll and the pressure roll, or on the surface of the sheet base material, by appropriate means such as roll coating or knife coating. As the ionizing radiation curable resin, known ultraviolet or electron beam curable resins can be used. Among them, if a solvent-added type is used, problems such as volume shrinkage, shape deformation, and bubble generation may occur due to curing. This eliminates the need for a pre-drying step for the resin, and it is possible to reliably form a finer uneven shape with good reproducibility. Further, the above resin may be used in a colored manner, if necessary, in order to obtain a realistic appearance. Irradiation of ionizing radiation is performed on the sheet base material 4
If it is transparent to ionizing radiation, it may be carried out from the base material side, or if the intaglio plate 1 is made of a material that hardens with ionizing radiation, it may be carried out from the intaglio side. It may be performed from both directions of the intaglio and the intaglio. The degree of curing by this ionizing radiation irradiation is such that at least the fluidity of the resin is lost, the adhesiveness to the sheet base material is created, and the releasability from the intaglio plate is ensured. Further, after the substrate is peeled off from the intaglio, it is possible to irradiate it with ionizing radiation again to achieve more complete curing.

The material of the sheet base material 1 may be appropriately selected depending on the intended use and is not particularly limited. However, when irradiating ionizing radiation from the base material side, it is necessary to have ionizing radiation transparency. Specific examples include polyvinyl chloride, polyester, polyamide, acrylic, polycarbonate,
Fluorine resin, cellophane, polypropylene, polystyrene, acrylonitrile butadiene styrene (ABS)
Examples include those made of synthetic resins such as.

Further, in the present invention, if necessary, printing or the like may be applied to appropriate locations to enhance the realism of the real uneven surface.

This printing is not limited to the manner in which it is applied to the front side of the sheet substrate as shown in FIG. 2, but may be applied to the back side (numeral 9 in the figure indicates the printed layer).

The sheet obtained by the method of the present invention can be used for various purposes, including decorative sheets that can utilize the realistic design appearance of the realistic uneven surface. for example,
It can be laminated and used on decorative plywood, PVC sol steel sheets, decorative steel sheets, plastic parts, glass adhesive sheets, etc. In addition, the notes obtained by the present invention can be laminated by heating and/or pressurizing in plus-think molding such as injection molding, extrusion molding, and vacuum forming, or the notes obtained by the present invention can be placed on the surface of a ready-made molded product. They can also be used by laminating them in a vacuum, under pressure, or by heating and/or pressurizing such as a vacuum-pressure method or a wrapping method.

Next, the present invention will be explained in more detail by giving specific examples.

Example 1 A wood grain pattern is printed on one side of a transparent polyvinyl chloride film (manufactured by Riken Vinyl Co., Ltd.: W-50023P) with a thickness of 0.1o using an ink containing a vinyl chloride-vinyl acetate copolymer as a vehicle.

A roll intaglio plate was prepared by winding a 1-round-thick film-like plate part, which was formed by molding the surface shape of a natural wood board using silicone resin, around a metal roll.

Next, this rolled intaglio plate was used in the manufacturing form as illustrated in FIG. , viscosity 3000cρS) was supplied using an applicator roll coating method, and ultraviolet rays were applied from the film side using an ozone-containing high-pressure mercury lamp (120W/C1
1) Sheet feed speed is 30 using an irradiation device equipped with two lights.
The film was irradiated under m/win conditions, and then the film was peeled off to obtain a sheet having a real uneven surface.

The obtained sheet faithfully and clearly reproduced the uneven pattern corresponding to the surface shape of the natural wood molded on the roll intaglio plate, and most notably, the uneven shape of 0.1 μm or less was reproduced. . In addition, uneven shapes with continuous gradation were also reproduced. This uneven pattern, combined with the printed wood grain pattern, created a realistic woodgrain appearance that closely resembled the grain of natural wood.

[Effects of the Invention] As explained above, the method of the present invention uses a roll intaglio plate formed by molding the surface of a natural material such as wood or stone, and while filling the roll intaglio plate as described above. Because the uneven shape made of an ionizing radiation-curable resin that has been cured and molded is formed on the sheet base, the surface shape of natural objects is faithfully and clearly reproduced, which cannot be obtained with conventional real embossed sheet manufacturing methods. Therefore, it is possible to obtain a sort that exhibits an appearance of a highly realistic uneven pattern.

Moreover, the formation of a real uneven surface can be done efficiently and easily using a roll intaglio plate by curing the resin by irradiation with ionizing radiation within the intaglio plate, and the formation work can be carried out at any time without the need for a heating process. It is possible to easily and reliably produce high-quality sheets with a realistic appearance. In particular, according to the method of the present invention, the 10 μm required to reproduce realistic uneven shapes of natural objects, etc., which was nearly impossible with conventional methods.
The following fine unevenness can be sufficiently formed, and there is a remarkable effect that even the fine details of the surface of a natural object can be reliably and clearly reproduced. In fact, it has been confirmed that it is possible to reproduce ultrafine irregularities of 0.1 μm or less.

Moreover, since the real uneven pattern is formed from a cured tH radiation-curable resin, there is no risk of inferiority in durability as in the uneven shape formed by heat embossing, and the pattern is advantageous in terms of maintaining the uneven shape.

[Brief explanation of drawings]

FIG. 1 is an explanatory diagram showing one embodiment of the manufacturing method of the present invention, and FIG.
The figure is a sectional view showing an example of a sheet obtained by the method of the present invention. l... Roll intaglio 2... Plate recess 4...
Sheet base material 5... Ionizing radiation curing resin 7... Real uneven pattern 8... Sheet with real uneven surface Patent applicant Dai Nippon Printing Co., Ltd.

Claims (1)

[Claims] We use a roll intaglio plate made by molding the surface shape of natural materials such as wood, stone, cloth, etc. by electroforming, mill pressing, etching, resin pouring, or laser engraving. At least the concave portions of the rolled intaglio plate are filled with an ionizing radiation-curable resin, and a synthetic resin sheet base material is brought into contact with the intaglio plate, and while the base material is in contact with the intaglio plate, ionizing radiation is irradiated to create a gap between the base material and the intaglio plate. A method for manufacturing a sheet having a realistic uneven surface, characterized in that the resin interposed in the intaglio is cured to bring the resin into close contact with the base material, and then the base material is peeled off from the intaglio.