JPH0465237A - Shaping sheet - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

Detailed Description of the Invention [Industrial Application Field] The present invention is an improvement of a shaped sheet for forming an uneven pattern on the surface of thermosetting decorative laminates or wet unsaturated polyester decorative laminates during the production thereof. It is related to.

[Conventional technology]

Conventionally, when manufacturing thermosetting decorative laminates or wet unsaturated polyester decorative laminates, heat-resistant films such as PET (polyethylene terephthalate), When not covered, films of polyvinyl chloride, polypropylene, polyethylene, and hiniron were used. or,
Japanese Patent Publication No. 61-28000 discloses a shaped film in which a polyolefin resin is laminated on paper such as high-quality paper or kraft paper.

[Problem to be solved by the invention]

However, when a heat-resistant film such as PET is used for shaping and binding, it has the advantage that it does not deform even when heat pressure is applied, but its hardness is too high and fine embossing is required. The disadvantage was that it was not possible to apply Furthermore, when polyvinyl chloride, polypropylene, polyethylene, vinylon, or the like is used, embossing is easy, but there is a drawback that the sheet stretches and deforms when hot pressure is applied. Another drawback was that the film was easily cut due to its low strength.

Further, these films have a limited range of use because their release properties are either suitable or unsuitable depending on the type of resin constituting the decorative laminate to be processed.

Further, when a plastic film base material is used, general drawbacks include difficulty in releasing from the mold after molding due to charging, dust attraction, and curling due to lamination with polyolefin.

Conventional paper and polyolefin laminated films have good curling, antistatic, and mold releasability properties, but when used for thermosetting decorative laminates, heat pressure can cause paper formation, traces of fibers, and marks on the decorative laminate. There was also a drawback that it was not possible to faithfully and clearly reproduce the unevenness of the surface or the unevenness of the extruded film.

The present invention was proposed to solve the problems of the prior art described above, and its purpose is to provide a shaped sheet that is capable of fine embossing, is less susceptible to deformation due to heat and pressure, and has a wide range of applications. It's about doing.

[Means to solve the problem]

As a result of repeated studies to achieve the above object, the inventor of the present invention has created a molded product by laminating a base sheet that is less likely to be deformed by heat or various tensions and a thermoplastic film that can be finely embossed. It has been found that by forming a sheet, it is possible to obtain a shaped sheet that takes advantage of the advantages of both methods and has a wide range of applications.

That is, the shaped sheet of the present invention is characterized by the following points.

(]) A sheet is formed by laminating a thermoplastic polyolefin resin layer on a base sheet that is resistant to heat pressure or tension, and the polyolefin resin layer has a depth of 1 to 1 cm.
It has an embossed pattern of 00μ and a thermosetting decorative board with good mold releasability on the surface.

(2) The shaped sheet according to (1) above, wherein the base sheet is a plastic sheet having a higher heat deformation temperature than the polyolefin resin layer, and the shaped sheet is for a thermosetting decorative board.

(3) The excipient sheet according to (1) above, wherein the base sheet is any one of glassine paper, parchment paper, parchment paper, coated paper, and art paper.

As the base sheet used in the present invention, among commonly used plastic films, nylon such as nylon 6 and nylon 66, polyethylene terephthalate, and the like are suitable. Also, plastic films such as polyacrylate, polyimide, polyether ether ketone, triacetyl cellulose, polycarbonate, polyacetal, polytetrafluoroethylene, polyvinyl alcohol, cellophane, unplasticized polyvinyl chloride, polyvinylidene chloride, glassine paper, parchment paper, etc. Paper with a uniform texture and high surface smoothness, such as tracing paper, mimeograph cardboard, parchment paper, coated paper, and art paper, can be used. Moreover, the thickness is preferably 3 to 250μ,
More preferably, it is 12 to 100μ.

In order to control the deformation of the polyolefin resin layer due to heat pressure, especially when used as a thermosetting decorative board, a plastic film with a higher heat deformation temperature than the polyolefin,
For example, polyethylene terephthalate, polyimide, polyacrylate, polyether ether ketone, triacetyl cellulose, glassine paper, parchment paper, etc.
Select paper such as coated paper or art paper. On the other hand, especially when used in wet unsaturated polyester decorative laminates, plastic films with lower oxygen permeability than polyolefin resins, such as nylon 6, nylon 66, cellophane, polyethylene terephthalate, unplasticized polyvinyl chloride, polyvinylidene chloride, Select ethylene and vinyl alcohol copolymer.

Further, as the polyolefin resin layer, polymethylpentene, polypropylene, polyethylene, etc. can be used. Note that the thickness of the resin layer is set depending on the depth of the embossing to be processed.

Furthermore, methods for laminating the base sheet and the polyolefin resin layer as shown in FIGS. 1(A) and 1(B) include commonly used dry lamination, wet lamination, and extrusion coating of polyolefin resin. It is also possible to use so-called doubling embossing, which involves heat-pressing and fusing at the same time as hot-pressure embossing.

Further, as the embossing method applied to the polyolefin resin side of the laminated shaped sheet, a known embossing method can be used.

That is, a hot pressure embossing method using a flat plate or a roll plate, a method of transferring the uneven shape on a cooling roll used during extrusion coating, a method of casting a molten resin, etc. can be used.

The emboss shape to be formed is preferably a precision emboss pattern as shown in FIG. In other words, it is a collection of patterns consisting of a group of unevenness or grooves forming parallel straight lines or curves and a closed boundary line surrounding it, and the parallel straight lines or straight lines of adjacent patterns that share the boundary line. Group direction is different, line depth and spacing are 1~100μ
, preferably 5 to 50μ, and the direction difference between adjacent lines across the boundary is 5° or more. This type of pattern is characterized by the fact that the gloss of each closed area changes depending on the parallax.
Its design is distinctive. To make the directions of adjacent lines all different, we can use the four-color problem theorem J of topology.
Therefore, it is necessary and sufficient that there are four or more types of direction differences.

The thermosetting resin layer that has mold releasability from the olefin layer is based on thermosetting acrylic emulsion, melamine resin-added acrylic emulsion, melamine resin, unsaturated polyester resin, two-component curing type acrylic urethane, polyester urethane, etc. , a colorant such as a pigment or dye, a plasticizer, a stabilizer, a dispersant, a filler, a solvent, a diluent, etc. are added and kneaded. If necessary, metallic pigments such as gold powder, silver powder, or aluminum powder and/or bar pigments such as titanium oxide, mica, or aluminum hydroxide can be used as pigments to create a luxurious metallic tone that cannot be obtained by direct printing on paper. , a pearl-like decorative board can be obtained. A transparent layer that does not use pigments or dyes or a colored transparent layer may be used. The resin layer can be gravure, gravure offset, silk screen, roll coat, reverse roll coat,
Provide using methods such as comma coat. Thickness is 2~100μ
It is possible within the range of After providing the resin layer, a pattern layer may be provided using ink based on the same resin.

In addition, the thermosetting decorative board referred to in the present invention is made of titanium paper mixed with titanium oxide pigment, and if necessary, resin such as melamine, diallyl phthalate, phenol, guanamine, urea resin, polyester, etc. is printed on the surface. Laminate one or more sheets of impregnated paper, overlay paper impregnated with the above resin on transparent paper on the printed side, and core paper on the opposite side to the printed side, and apply the above resin by hot pressure. Created by curing.

At this time, the shaping sheet of the present invention is laminated between the printing paper or the overlay paper and a heating plate or mirror plate, and after molding, the shaping sheet is released from the mold.

Furthermore, the wet unsaturated polyester resin decorative board referred to in the present invention is obtained by pasting decorative paper with a pattern on a base material, and impregnating and curing the paper with an unsaturated polyester resin.

The base material is for providing the thickness and strength necessary as a decorative material, and may be appropriately selected from plywood or particle board, for example.

Decorative paper is usually mixed with opaque pigments such as titanium oxide and weighs 50~tsog/rr? The material used is ``titanium paper'' and filter paper with a pattern printed using known techniques such as gravure printing, offset printing, or silk screen printing.

The base material and decorative paper are attached with adhesive in the same way as in the past. As the adhesive, a vinyl acetate emulsion type adhesive is suitable.

[For production]

According to the present invention, by using a base sheet that is less likely to be deformed by heat or various tensions, deformation of the shaping film during press molding of a thermosetting decorative board is prevented,
In addition, by using a thermoplastic film that can be subjected to fine embossing on the embossed surface side, it is possible to perform embossing that has a three-dimensional effect and is excellent in design.

In addition, by using glassine paper or other paper with a fine texture and good flat surface smoothness for the base sheet, there is no curling of the excipient sheet, difficulty in releasing from the mold due to electrification, and there is no suction of dust. Excellent embossing can be performed on thermosetting decorative boards, such as faithful embossed patterns that can be reproduced without forming formation or fiber traces on the decorative board.

The specific contents of the present invention will be explained in detail below using Examples.

[Example 1] Polypropylene (PP) film (
Two-phase chemical FHK-20μ) was dry laminated (using urethane adhesive manufactured by Kanebo NSC), heat was applied to the PP side (50°C), and a precision emboss pattern (parallel line spacing shown in Figure 2) was applied using a flat plate press. or 20μm, depth 10μm
m, the angle of the parallel line is 0° (standard), 30°, 600.9
4 types of 0°) Form an emboss.

A transparent resin layer with a thickness of 50 μm is provided on the embossed surface by roll coating using a thermosetting ink made of a two-component curable urethane resin (■Showa Ink Kogyo Separation "U Type"). Alternatively, a thermosetting ink containing a mixed resin of melamine and epoxy as a vehicle and a golden pigment as a coloring agent (IME-T Cold manufactured by Showa Ink Industries) may be gravure coated to a thickness of 10 μm.

Using the shaped sheet obtained in this way, the pressure was 100k.
When a high-pressure melamine resin decorative board was molded under conditions of g/ad and heating at 130°CCl2O, very fine embossing could be formed, and no deformation occurred even when heat or tension was applied during molding of the decorative board. Furthermore, the releasability of the shaped sheet was also good.

[Example 2] A sheet was prepared by extruding 20μ of PP resin (manufactured by Mitsui Petrochemical) onto a base sheet of PET (Toyobo E-510050μ), and the same procedure as in Example 1 was performed by applying heat to the PP side (150°C). An emboss is formed on the surface, and a transparent resin layer is provided on the surface.

Also in the shaped sheet obtained in this way, Example 1
A similar effect was obtained.

[Example 3] The shaped sheet used in Example 1 was used to create a thermosetting decorative board as shown in FIG.

That is, PET (Banjin G350μ)/PP (Two-Phase Kagaku FHK-2020μ) was dry laminated, and a finely embossed surface and a transparent resin layer were provided in the same manner as in Example 1 on the PP side to create a shaped sheet.

In addition, black titanium paper (80 g/rr? manufactured by Kenjin ■) was impregnated with diacryl phthalate resin, dried and placed on a particle board, stacked so that the embossed side of the above-mentioned excipient sheet was in contact with the impregnated paper side, A mirror plate was placed on top of it and pressed at 130°C, 10kg/cnf, and 10 minutes.

As a result, when the shaped sheet was peeled off, a decorative board with a three-dimensional effect and an excellent design was obtained.

[Example 4] The shaped sheets used in Examples 1 and 3 were used to create a thermosetting decorative board as shown in FIG. 4.

That is, the balance sheet, core paper, melamine resin-impregnated titanium paper (made by Kuro Kenjin ■), melamine resin-impregnated overlay paper (made by Daifuku Paper Co., Ltd.), and the excipient sheet (the enphos surface should be in contact with the overlay) are sequentially prepared. Stack them together, put a mirror plate on top of them, 150°C, 180kg/co? , Pressing was performed for 30 minutes.

In this case, as in Example 3, a decorative board with a three-dimensional effect and an excellent design was obtained.

[Example 5] PET film (Toyobo E-50QQ 25μ) was coated with polyethylene resin (manufactured by Mitsui Polychemicals) to a thickness of 20μ by extrusion coating [or PE film (20μ manufactured by Mitsui Polychemicals) was dry laminated]
The same fine embossing and transparent resin layer as in Example] were provided on the PE side using a hot roll press to form a shaped sheet.

C Example 6] ○PP (Nimura Chemical Membrane F
OR20μ) was dry-laminated, and the same enhancer as in Example 1 was applied to the OPP side. Next, balance sheet, modified phenol core paper (manufactured by Ohta Sangyo), melamine resin impregnated titanium paper, melamine resin impregnated overlay (manufactured by Ohta Sangyo)
L-25) The above shaped sheets (embossed surfaces are in contact with the overlay) are laminated one after another, and hot press (80 kg
/al, 135°C for 115 minutes) As the sheet itself did not curl and did not generate static electricity, it was easy to work when releasing from the mold, and there was no suction of dust, so a clean molded product could be obtained. In addition, there is no uneven formation of the paper during press molding, no fiber traces transferred to the molded product, and because the paper is backed, there is no stretching or distortion of the embossed uneven pattern caused by hot pressing during press molding, making it faithful. The unevenness of the imprinting sheet was able to be imprinted on the high-pressure melamine decorative board.

[Example 7] SK coated paper (manufactured by Yamaba Kokusaku Pulp Co., Ltd.) 104.7 g/
B) Dry laminate OPP (FOR20μ manufactured by Niphasical Chemical Co., Ltd.) to the OPP side, and apply the same Enphos and transparent resin layer as in Example 1 to the OPP side. Next, balance sheet, modified phenol core paper (manufactured by Ohta Sangyo), melamine resin impregnated titanium paper, melamine resin impregnated overlay (manufactured by Ohta Sangyo 0L-2)
5) The above-mentioned shaped sheets (embossed surface or overlay are in contact with each other) are laminated one after another, and hot press (80kg/a+f
, 135°C, 15 minutes), the sheet itself did not curl and did not generate static electricity, so it was easy to work when releasing from the mold, and there was no suction of dust, so a clean molded product could be obtained. In addition, there is no uneven formation or fiber traces of paper that is transferred to the molded product due to the heat and pressure during press molding, and since the paper is used as a backing, there is no stretching or distortion of the embossed uneven pattern due to the heat and pressure during press molding. The unevenness of the imprinting sheet was able to be imprinted on the high-pressure melamine decorative board.

〔Effect of the invention〕

Since the present invention is constructed as described above, it is resistant to heat and tension, and can be used when molding various decorative laminates, and faithfully maintains the shape, color, and gloss of the fine embossing provided on the olefin layer. A shaped sheet that can be reproduced as a thermosetting decorative board will be provided, which will be of industrial benefit.

[Brief explanation of the drawing]

FIG. 1 is a sectional view showing an embodiment of the shaped sheet of the present invention;
FIG. 2 is a plan view showing an example of a precision embossed pattern formed on the shaped sheet of the present invention, and FIGS. 3 and 4 show the case where the shaped sheet of the present invention is used when molding a thermosetting decorative board. FIG. Figure 3

Claims (1)

[Claims] 1. A sheet is formed by laminating a thermoplastic polyolefin resin layer on a base sheet that is resistant to heat and pressure or tension, and the polyolefin resin layer has a depth of 1 to 10 mm.
1. A shaped sheet comprising a fine embossed pattern of 0 μm and a thermosetting resin layer having release properties from an olefin on the embossed surface. 2. The shaped sheet according to claim 1, wherein the base sheet is a plastic sheet having a higher heat deformation temperature than the polyolefin resin layer, and the shaped sheet is for a thermosetting decorative board. 3. The excipient sheet according to claim 1, wherein the base sheet is any one of glassine paper, parchment paper, parchment paper, coated paper, and art paper.