JPH0699696A - Method for producing hydrothermally cured product having pattern and embossed shape - Google Patents

Abstract

(57) [Abstract] [Purpose] A hydrothermal synthetic cured product having a desired pattern and embossed shape on the surface and having an extremely high design property can be easily produced and efficiently produced. [Structure] A transfer sheet 22 in which a base material sheet, a release layer, a pattern layer, and an adhesive layer are sequentially provided is emboss-molded by pressing a mold material 21 having a desired embossing in advance with a flexible heating roll 23. Is placed on the bottom of the mold so that the embossed shape does not collapse, the hydrothermal synthetic cured product is put on this, and the base material sheet is peeled off after curing.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a hydrothermally synthetic hardened decorative sheet used for exterior or interior of a house or as a furniture member, and more particularly to a decorative sheet having a pattern and an embossed surface.

[0002]

2. Description of the Related Art Conventionally, various decorative boards have been used for exterior or interior of houses or as furniture members, but in recent years, products having embossed surfaces have been favored along with the tendency toward higher quality and higher design. Has become. On the other hand, in terms of materials, the demand for decorative boards called inorganic materials is rapidly increasing due to their excellent physical properties.

Hydrothermal synthetic hardened products (precast concrete, in-situ concrete, ALC, etc.) are also typical inorganic ones, and the method for producing them is as follows.

(1) An inorganic raw material forming a hydrothermal synthetic cured product (precast concrete, cast-in-place concrete, ALC) is poured into a desired mold in the form of an aqueous slurry, reacted and cured, and then demolded. In the case of precast concrete and ALC, autoclave curing is required on the way.

(2) Hydrothermally synthetic cured product (wooden cement board,
Inorganic raw materials that form ceramic boards such as calcium silicate board, magnesium carbonate board, fiber reinforced cement board) are extruded in the form of aqueous slurry or formed into a certain shape by papermaking method, and then pressed (roll press or flat press). It is dehydrated and molded into a desired shape by pressing. After that, it is cured by autoclave curing.

As a decoration method, a three-dimensional uneven pattern is formed on the surfaces of the mold, press roll and press plate,
There is a method in which the pattern is transferred to the surface of a molded product that is obtained, a coloring pigment is mixed in the aqueous slurry raw material, the resulting molded product is colored, and the surface of the obtained molded product is painted.

However, the design effect obtained by these methods was not so remarkable. In addition, in order to make an embossed product using a mold, the mold itself must first be embossed, which requires a complicated work such as cutting or casting. It was

[0008]

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and it is an object of the present invention to have a desired design and embossed shape on the surface, which is of extremely good design. An object of the present invention is to provide a method for easily producing a highly hydrothermal synthetic cured product and efficiently producing it.

[0009]

In order to solve this problem, the present invention uses a transfer sheet in which a base sheet, a release layer, a pattern layer, and an adhesive layer are sequentially provided on a mold material that has been embossed in a desired manner. It is embossed by pressing it with a soft heat roll, and it is placed on the bottom of the mold with the adhesive layer on top so that the embossed shape does not collapse. The present invention provides a method for producing a hydrothermal synthetic cured product having a pattern and an embossed shape characterized by peeling a material sheet, and using an embossing roll as the desired embossed mold material. To do.

The present invention will be described in detail below with reference to the drawings. FIG. 1 shows the structure of the transfer sheet used in the present invention.
On the surface of the base material sheet 1, a release layer 2, a pattern layer 3, an adhesive layer 4
Are sequentially provided.

As the base material sheet 1, a thermoplastic resin film which can follow the irregularities on the surface of the base material by the heat at the time of molding is used. Specifically, films of vinyl chloride, polyethylene, polypropylene, nylon, polyester, etc. can be used. The type and thickness of the resin may be appropriately selected in consideration of the degree of surface irregularities and the transfer temperature. For example, at a molding temperature of 150 ° C. to 180 ° C., a vinyl chloride resin film having a thickness of 100 μm or less is most suitable. .

As a method of forming the following layers on this base material, gravure printing, screen printing, offset printing or the like may be used.

The material of the release layer 2 is any varnish or the like, and an appropriate one is selected according to the material of the base sheet. For example, when the substrate sheet is a vinyl chloride resin film, polyvinyl butyral is suitable.

The printing ink used for the printing layer 3 may be weather resistant, such as a pigment-based coloring material. The synthetic resin binder used in the printing ink is determined in consideration of its large elongation during heating and its influence on the durability of the final product. For example, acrylic resin, styrene resin, alkyd resin, polyamide, polyester, polyvinyl chloride, polyvinyl acetate,
Alternatively, a mixture of these combinations or a copolymer can be used.

As the adhesive used for the adhesive layer 4, a water-soluble resin having good adhesion to an aqueous slurry of a raw material such as hydroxypropyl cellulose, polyvinyl alcohol, polyvinyl pyrrolidone, water-soluble acrylic, hydroxymethyl cellulose can be used. Is.

FIG. 2 schematically shows one of the transfer sheet molding methods. The adhesive layer surface of the transfer sheet 22 shown in FIG. 1 is installed on the uneven surface of the mold material 21 on which the desired embossing has been performed in advance, and the surface is pressed by the heat roll 23 to form the desired embossing. As the material of the mold material, it is sufficient that it is smooth so as not to scratch the transfer paper and that it has heat resistance, and plastic, metal or the like can be used. The heat roll used at this time is a soft one that follows the unevenness of the plate. Silicon rubber having a rubber hardness of 30 ° and a wall thickness of 20 mm or more is suitable, depending on the size of the unevenness of the plate.

FIG. 3 schematically shows another method for molding the transfer sheet. The transfer sheet 33 shown in FIG. 1 is passed between the embossing roll 31 having the desired embossing and the flexible rubber roll 32, and pressed to form the desired embossing. The installation direction of the transfer sheet is determined depending on whether the embossing roll used is a male type or a female type. Silicon rubber having a rubber hardness of 30 ° and a wall thickness of 20 mm or more is suitable for the rubber roll.

FIG. 4 schematically shows a transfer molding method for a hydrothermal synthetic cured body. The transfer sheet 42 molded on the mold 41 is
Place the adhesive layer facing up. At this time, in order to prevent the transfer paper from being deformed due to the weight of the raw material aqueous slurry, sand or wood chips, etc.
Spread 3 After pouring the raw material aqueous slurry 44 into this and curing and curing, the base material sheet is peeled off as shown in FIG. 5 to obtain a decorative plate having a desired picture pattern and a desired concavo-convex pattern.

[0019]

According to the present invention, desired irregularities can be easily formed on a transfer sheet having a desired pattern by printing, and a desired pattern and a desired emboss can be obtained by simply installing the pattern on a formwork having a flat bottom surface. Since it is possible to efficiently produce the hydrothermally-synthesized cured product, there is no complicated work such as making a mold with an embossed bottom surface. Further, when the embossing of the transfer sheet is performed, it is possible to continuously form the embossing on the transfer sheet by using the embossing roll, which further improves the productivity.

[0020]

【Example】

<Example 1> A semi-rigid vinyl chloride sheet having a thickness of 50 µm was used as a substrate sheet, and a release layer made of polyvinyl butyral, a coloring pigment (alamide yellow, phthalocyanine blue, dianthraki) was formed on the sheet by gravure printing. A printing ink layer (brick pattern) made of nonidryl red) and polyvinyl chloride and vinyl chloride, and an adhesive layer made of polyvinyl butyral were sequentially provided to form a transfer sheet.

With the adhesive layer of the obtained transfer sheet facing down,
Installed on a fiber-reinforced cement board that has been embossed in a brick pattern and has an uneven pattern.
It was pressed with a hot roll having a rubber hardness of 30 ° at 60 ° C. The pressure was 10 kg / cm and the speed was 5 m / min.

This molded transfer sheet was placed on the bottom surface of a mold spread with sand, with the adhesive layer facing upward. An aqueous slurry, which is a raw material for cement, was put on this, vibrated, clamped, and cured. After the curing was completed, the mold was removed, and the base sheet was peeled and removed. The obtained product had a very high designability with the embossing of the transfer sheet and the pattern being imparted.

<Example 2> A substrate sheet having a thickness of 50 μm
m using a semi-rigid vinyl chloride sheet, and using gravure printing on this, a release layer made of polyvinyl butyral,
A printing ink layer (wood grain pattern) made of a coloring pigment (alamide yellow, phthalocyanine blue, dianthraquinonidryl red) and poly (vinyl chloride) and an adhesive layer made of polyvinyl butyral were sequentially provided to form a transfer sheet.

With the adhesive layer of the obtained transfer sheet facing down,
It was pressed with an embossing roll having a wood grain embossing in advance and a silicone rubber roll having a rubber hardness of 30 ° and a thickness of 20 mm. Since the embossing roll used was a male type, it was installed so that the adhesive layer was on the embossing roll side. The pressure was 10 kg / cm and the speed was 5 m / min.

This molded transfer sheet was placed on the bottom surface of a mold spread with sand, with the adhesive layer facing upward. An aqueous slurry, which is a raw material for cement, was put on this, vibrated, clamped, and cured. After the curing was completed, the mold was removed, and the base sheet was peeled and removed. The obtained product had a very high designability with the embossing of the transfer sheet and the pattern being imparted.

[0026]

As described above, the constitution of the transfer sheet according to the present invention, the formation of the emboss by the soft rubber roll,
By transfer to the hydrothermal synthetic cured product, a decorative plate made of the hydrothermal synthetic cured product having a beautiful pattern and emboss can be obtained by a simple method. In addition, by using a roll as a mold material that gives embossing, it becomes possible to continuously form embossing on the transfer sheet, which further improves productivity.

[0027]

[Brief description of drawings]

FIG. 1 is a sectional view showing an embodiment of a transfer sheet according to the present invention.

FIG. 2 is a schematic view showing an example of a transfer sheet molding method according to the present invention.

FIG. 3 is a schematic view showing another example of the transfer sheet molding method according to the present invention.

FIG. 4 is a schematic view showing transfer molding according to the present invention.

FIG. 5 is a schematic view showing a state in which a base sheet is peeled from a decorative board according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Base material sheet 2 ... Release layer 3 ... Design layer 4 ... Adhesive layer 21 ... Mold material 22 ... Transfer sheet 23 ... Thermal roll 31 ... Embossing roll 32 ... Rubber roll 33 ... Transfer sheet 41 ... Form 42 ... Transfer sheet 43 ... Sand 44 ... Raw material aqueous slurry

Claims (2)

[Claims] 1. A transfer sheet on which a base sheet, a release layer, a pattern layer, and an adhesive layer are sequentially provided is emboss-molded by pressing a transfer material having a desired emboss in advance with a soft heat roll. Place the embossed shape on the bottom of the mold with the adhesive layer facing up so that the embossed shape does not collapse, put the hydrothermally cured product on this, and peel off the base material sheet after curing to create a pattern and embossed shape. A method for producing a hydrothermal synthetic cured product having. 2. A mold material having the desired embossing,
A method for producing a hydrothermally cured product having a pattern and an embossed shape, characterized by using an embossing roll.