JPH06155487A - Manufacture of decorative laminated sheet having indentation and picture pattern - Google Patents

Abstract

(57) [Summary] [Structure] A transparent synthetic resin film on which a pattern is printed is placed on an endless belt with the printing surface facing upward and moved. A shaping sheet is moved at a synchronized speed while keeping a small gap above it, and a monomer or a prepolymer of a cast-polymerizable synthetic resin such as an acrylic resin is cast in the gap. Polymerization proceeds to form a polymer integrated with the film, and a decorative board having a pattern inside one surface and unevenness on the other surface is obtained. [Effect] A synthetic resin decorative plate having precise irregularities and a highly sophisticated design can be manufactured in an arbitrary length, and the cost is low.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a decorative plate made of acrylic resin, which has irregularities on one surface and a pattern on the other surface.

[0002]

2. Description of the Related Art For example, a synthetic resin decorative plate used for partitioning in a room is favorably used with an acrylic resin as a material having good moldability and a high-grade feeling.

In the manufacture of this type of decorative board, generally, a pattern is printed on a transparent acrylic resin plate directly or by transfer,
If desired, a transparent resin plate may be stacked on it, or an embossing plate may be hot pressed to form irregularities on the surface.

[0004] Such a method has the drawback that the size of the product obtained is limited because the embossing plate is used, and that the heating press has a limit in the precision of the irregularities that can be formed. In addition, there is a drawback that the process to reach a product is long and therefore costly.

[0005]

SUMMARY OF THE INVENTION It is an object of the present invention to overcome the above-mentioned problems and to provide a method for producing a product having a precise concavo-convex pattern of an arbitrary length in a short process, thereby providing a pattern. The objective is to make the design of the transparent synthetic resin veneer with unevenness more sophisticated than before, and to reduce the manufacturing cost.

[0006]

As shown in FIG. 1, a method for manufacturing a decorative board having irregularities and a pattern according to the present invention is such that a pattern is printed (2) on a transparent plastic long film (1). Of the upper support (4) provided substantially horizontally above the lower support (3) provided in a substantially horizontal direction with the surface of the pattern facing upward at a predetermined speed. The lower part is moved in synchronism with the film (1) so that a cast-polymerizable synthetic resin monomer or prepolymer (6) can be cast between the film and the shape-imparting sheet.
Is heated by casting, and polymerization is promoted while the film is moved while controlling the distance between the film and the shaping sheet by the upper and lower supports, and the surface of the polymer of the acrylic resin formed integrally with the film by polymerization (7 (1) having a pattern protected by a plastic film on one surface and a pattern protected by a transparent plastic film on the other surface (1).
0) is a manufacturing method.

The details of the step of peeling off the shape-imparting film are shown in FIG.

As the upper and lower supports, it is preferable to use an endless belt as shown in FIG. 1, particularly one made of stainless steel.

Acrylic resin is most suitable as the cast-polymerizable resin. Specific examples of the monomer include the following compounds, and it is needless to say that a mixture thereof can also be used. Acrylic esters such as methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, methoxyethyl acrylate, butoxyethyl acrylate, phenyl acrylate, and methyl methacrylate, ethyl methacrylate, methacrylic acid Methacrylic acid esters such as propyl, methoxyethyl methacrylate, ethoxymethyl methacrylate, phenyl methacrylate, and lauryl methacrylate.

It is easy to handle these monomers as a prepolymer by preliminarily preliminarily polymerizing several percent to several dozen percent of the complete degree of polymerization so as to have a viscosity suitable for casting.

Polymerization can be initiated by adding an appropriate amount of a radical polymerization initiator such as benzoyl peroxide and heating.

The shape-imparting sheet is preferably one manufactured by the drum printing method using a plate having a desired unevenness. FIG. 3 shows an enlarged structure of such a shaping sheet. Reference numeral (51) is the base sheet of the shaping sheet, and (52) is the unevenness formed on it. The resin forming the irregularities is an ultraviolet curable resin, and a resin having a degree of polymerization of about 200 to 250 is suitable.
To add silicone resin or Teflon resin prior to application to the drum, or to apply these resins to the surface after shaping sheet molding so that they can be easily peeled from the synthetic resin formed by cast polymerization. Is preferred.

When an acrylic resin is used as the cast-polymerizable synthetic resin, it is preferable to use the acrylic resin film also as the transparent plastic film. Needless to say, this is to obtain high adhesion with the synthetic resin formed by polymerization on the film.
A suitable thickness is in the range of 10 to 200 μm.

For the same reason as above, it is preferable to use a vinyl chloride-acrylic ink as an ink for printing a picture.

The pattern to be printed is arbitrary, such as stone, grain, wood, and abstract pattern. The gravure method is suitable for printing.

[0016]

[Function] The synthetic resin monomer or prepolymer (6) cast on the transparent synthetic resin film (1) on which the pattern is printed (2) is polymerized by heating to be integrated with the film. Form a resin plate. Since the polymerization involves some volume contraction, it is desirable to adjust the interval between the upper and lower supports by taking measures such as shortening the interval between the rolls supporting the endless belt to cope with the contraction. A usual decorative board has a thickness of 1 to 10 mm, and as described above, a product having any exact thickness can be obtained in this range.

The method of applying a shaping film to a liquid monomer or prepolymer to polymerize it is far more precise than the method of heat-pressing an embossing plate on a polymer which has already been molded into a plate. Unevenness can be realized. Since the monomer or prepolymer is a liquid, it spreads to every corner of the unevenness of the shape-imparting film and becomes a polymer as it is, so that the shape of the shape-imparting film can be accurately copied. This profit is
The finer the uneven pattern is, the more prominent it is.

Since the pattern printed on the transparent film is inside the decorative plate and is protected by the film, there is an advantage that the design has a depth and is not damaged by scratches that may occur on the surface. .

When the shaped sheet is manufactured by the drum printing method, it is easy to obtain a long shaped sheet, and it is easy to form a continuous sheet having no irregularities and a seamless shape. And can be arbitrarily set within the restriction of handling.

[0020]

Example First, a shaped sheet was manufactured by the drum printing method. UV curable resin "DA-501
S "(Asai Bussan Co., Ltd.) was applied to the relief plate on the drum, and the surface was covered with a transparent polyester film" A-4100 "75 μm (Toyobo Co., Ltd.) which had been subjected to an easy-adhesion treatment. Irradiate ultraviolet rays through the film (two 120 W high-pressure mercury lamps, drum rotation peripheral speed 20 m / min) to cure the resin,
By peeling the film from the plate, a shaped sheet having irregularities that faithfully follows the shape of the plate was obtained.

Next, a transparent acrylic resin film "HB
S-001 ”75 μm (Mitsubishi Rayon) was printed with a printing ink“ VMC ”(The Inktech Co., Ltd.) to provide a stone pattern by gravure printing. The film was placed on an endless belt made of stainless steel, with the surface provided with this pattern facing upward, and the film was run, and a prepolymer of methyl methacrylate was flown from thereover. The prepolymer is obtained by adding 1% by weight of benzoyl peroxide to a methyl methacrylate monomer, heating the mixture, and polymerizing it for about 15%.

An endless belt made of stainless steel is also used above the prepolymer, and the above-described shape-imparting sheet is placed along the endless belt as shown in FIG. 1, and is synchronized with the acrylic resin film running on the endless belt below. The prepolymer of methyl methacrylate was filled between the pattern of the film and the shaping sheet. The polymerization of the prepolymer heated between the two stainless endless belts proceeded and was cured.

The shaped sheet was peeled off from the resin plate thus formed to obtain the decorative plate of the present invention.

[0024]

EFFECTS OF THE INVENTION According to the method of the present invention, a decorative board having a pattern inside a transparent synthetic resin and having irregularities on one surface, the irregularities being precise according to the irregularities of the pattern forming sheet Therefore, a product that realizes a high degree of design can be manufactured in an arbitrary length.

The manufacturing process is simpler than the conventional manufacturing technique, since it is only one step of printing and molding on the transparent synthetic resin film and simultaneously performing cast polymerization. Therefore, the cost is low. can do.

[Brief description of drawings]

FIG. 1 is a vertical cross-sectional view of the main part of the apparatus for explaining the steps of the method for manufacturing a decorative plate of the present invention.

FIG. 2 is an enlarged cross-sectional view of a part of FIG.

FIG. 3 is an enlarged cross-sectional view showing the configuration of the shaping sheet used in FIG.

[Explanation of symbols]

 1 Long film of transparent plastic 2 Printing of patterns 3 Upper support 4 Lower support 5 Imprinting sheet 6 Prepolymer 7 Polymer surface 10 Decorative plate

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Office reference number FI technical display location B44C 3/02 A 9134-3K // B29K 33:00

Claims (4)

[Claims] 1. A transparent plastic long film on which a pattern is printed is moved at a predetermined speed over a lower support provided in a substantially horizontal direction with the surface of the pattern facing upward, Under the upper support provided in the substantially horizontal direction above, the shaping sheet is moved in synchronism with the film, and a castable synthetic resin monomer or prepolymer between the film and the shaping sheet is used. Casting and heating, polymerization is advanced while moving while controlling the distance between the film and the shaping sheet by the upper and lower supports, and shaping is performed from the surface of the polymer of the acrylic resin integrally formed with the film by the polymerization. Makeup that consists of peeling off the film, and has a pattern protected by a plastic film on one side and a pattern protected by a transparent plastic film on the other side. Method of manufacturing a plate. 2. The manufacturing method according to claim 1, wherein an endless belt is used as the upper and lower supports. 3. The manufacturing method according to claim 1, wherein the patterning sheet is manufactured by a drum printing method using a plate having a desired unevenness. 4. The cast-polymerizable synthetic resin is an acrylic resin, an acrylic resin film is used as a transparent plastic film, and a vinyl chloride-acrylic ink is used as an ink for printing a pattern. Production method.