JPH07101027A - Method for manufacturing polyester decorative board by ultraviolet curing method - Google Patents

Abstract

(57) [Summary] [Purpose] To provide a method for producing a polyester decorative board that does not cause mold retention during production by using a sharp shaped film that can be repeatedly used and has an uneven shape. [Structure] After a decorative paper 8 having a pattern 9 is attached to a wood base material 7 such as MDF or plywood, an unsaturated polyester resin 10 containing a thermal polymerization initiator and an ultraviolet initiator is applied to the unsaturated polyester. After covering the patterning film 6 having a concavo-convex pattern formed by laminating a film that is not attacked by a resin and a polyolefin-based film, ultraviolet rays are radiated from the upper part of the film by an ultraviolet lamp 11 to cure the surface layer of the unsaturated polyester resin. Immediately thereafter, the patterning film 6 is peeled off and post-cured to obtain a polyester decorative board 20 having an uneven pattern 12.

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 polyester decorative board having an uneven pattern on its surface, and is particularly used for building interior materials such as kickin doors, doors, stairs and furniture.

[0002]

2. Description of the Related Art Conventionally, as a method of manufacturing a polyester decorative board having an uneven pattern on its surface, a silicone mold obtained by pouring and curing a silicone resin into a mother mold obtained by molding a natural wood has an uneven pattern. Using as a patterning film having, and after curing the patterning film on the unsaturated polyester resin containing only the thermal polymerization initiator applied on the decorative plate and curing by heat, peeling off the patterning film Was created by.

However, in this method, the silicone resin used as the patterning film is attacked by the unsaturated polyester resin, and the number of times of repeated use is as small as about 20 times, which causes a cost increase. Further, since the unsaturated polyester resin is cured only by heat curing, it is necessary to cure the molded film at a temperature of 40 ° C to 50 ° C for 3 to 5 hours while closely contacting it, which may cause the mold to stay. Was becoming.

In order to solve such problems, a film in which a vinylon film having resin resistance and a vinyl chloride film having concavo-convex pattern imparting property are laminated is devised as a patterning film which is not attacked by unsaturated polyester resin. However, this method has a drawback that it is not attacked by the unsaturated polyester resin, but the vinyl chloride is softened by the curing temperature or reaction heat during thermosetting to leave an uneven pattern provided. Further, since the curing method is thermal polymerization, it takes the same time as before until the patterning film can be peeled off, and the problem of mold retention has not been improved at all.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems of the prior art. The object of the present invention is to provide a sharp patterning film which can be repeatedly used and has an uneven shape. An object of the present invention is to provide a method for producing a polyester decorative board which does not cause mold retention during production.

[0006]

In order to solve the above problems, the present invention provides an unsaturated polyester containing a thermal polymerization initiator and an ultraviolet initiator on a decorative paper-coated decorative sheet having a pattern on its surface. A resin was applied, and a patterning film having an uneven pattern was coated on the surface of the resin, and after rolling the resin, the surface of the unsaturated polyester resin was cured by irradiating ultraviolet rays from the patterning film. After that, the patterning film is immediately peeled off and post-cured at a predetermined temperature.

The present invention will be described in detail below with reference to the drawings.

FIG. 1 is a schematic view of the manufacturing process of a pattern-forming film having an uneven pattern according to the present invention.

In this imprinting film 6, a resin mold 2 having an uneven pattern is placed on a base material 1 such as an aluminum plate, and a film 3 which is not attacked by an unsaturated polyester resin and a film 4 which has unevenness imparting property. It can be obtained by coating the two-layered film adhered with and applying pressure while heating by the hot press machine 5.

Here, the material of the base material 1 for the mold is not particularly limited, but an aluminum plate is most suitable in terms of heat conductivity and pressure resistance during hot pressing, and in terms of cost. As a resin used for the resin mold 2 having an uneven pattern, an epoxy resin or a polyester resin used for a normal resin mold is inexpensive and easy to work and is generally used.

As the film 3 on the side of the shaped film 6 having an uneven pattern, which comes into contact with the unsaturated polyester resin, vinylon, tetron, nylon, fluorine, trimethylpentene, etc. are preferable because they are naturally not attacked by the resin. If the thickness is too thin, it is not stiff, and wrinkles easily occur when it is attached to the other film, and if it is too thick, it becomes difficult to impart an uneven pattern.
35 μm is desirable. When these films are used alone, the concavo-convex pattern imparting temperature becomes very high around 200 ° C. However, when a film capable of imparting a concavo-convex pattern at a low temperature is attached to one side of the film, the resin mold 2 is applied by the force of the film. The film is pushed into the inside of the unevenness, and as a result, the unevenness pattern is imparted.

As the film 4 to be bonded to the film 3, it is easy to give an uneven pattern so that the unevenness is not sagged by the radiant heat of an ultraviolet lamp during the subsequent curing of the unsaturated polyester resin and is not deteriorated by ultraviolet rays. Considering this, a polyolefin film is effective. Here, if the thickness of the film is less than 100 μm, an uneven pattern can be imparted, but it is too thin and the film is weak and the workability deteriorates. If it is thicker than 300 μm, it is too thick and problems such as bending whitening occur. Therefore, the thickness of 100 μm to 300 μm is optimal.

Next, the conditions for imparting the uneven pattern by the hot press 5 may be any conditions as long as the polyolefin film is partially melted to provide the uneven pattern, and in the present invention, for example, 13
Pressure of 10 kg / cm ^{2 to} 60 k at a temperature of 0 ° C. to 160 ° C.
It takes about 10 minutes to reach g / cm ² . The imprinted film 6 having an uneven pattern obtained in this manner faithfully reproduced the unevenness of the mold.

Next, the process of making an unsaturated polyester decorative board using the above-mentioned shape-imparting film 6 will be described.

FIG. 2 is a schematic view of the manufacturing process of the unsaturated polyester decorative board.

After a decorative paper 8 having a pattern 9 is attached to a wood base material 7 such as MDF or plywood (the same figure (a)), an unsaturated polyester resin 10 is applied (the same figure (b)). , After coating the patterning film 6 having the uneven pattern created above,
After irradiating ultraviolet rays from the upper part of the film with an ultraviolet lamp 11 to cure the surface layer of the unsaturated polyester resin ((c) in the same figure), the imprinting film 6 is immediately peeled off and post-cured to form an uneven pattern 12. A polyester decorative board 20 having the same is obtained ((d) of the same figure).

The unsaturated polyester resin 10 to be cured here is not particularly limited as to the type of unsaturated polyester resin as long as both a thermal polymerization initiator and an ultraviolet initiator are added. Any type of thermal polymerization initiator may be used as long as it is usually used for curing the polyester resin. For example, peroxide is used, and methyl ethyl ketone peroxide and the like show particularly good results. Further, if the addition amount is less than 0.5 part with respect to 100 parts of the resin, curing failure will occur, and if it exceeds 2.5 parts, the curing rate will be too fast, and gelation will start during the rolling operation of the resin, so it is desirable Addition of 0.5 to 2.5 parts is preferable. On the other hand, the ultraviolet initiator is also preferably a benzophenone type or acetophenone type, which is usually used for curing a polyester resin, and the addition amount thereof is 1.0 with respect to 100 parts of the resin.
If the amount is less than 1.0 part, the curing rate is slow, and if it exceeds 3.0 parts, the effect due to excessive addition is not exerted.

Next, the irradiation conditions of the ultraviolet rays for curing the unsaturated polyester resin 10 are not particularly specified as long as the surface is cured so that the patterning film 6 can be peeled off immediately after the irradiation. In the present invention, 80 W /
Line speed 5m / min with 6 to 10 cm-120W / cm metal halide or high-pressure mercury lamp
The irradiation was performed at an irradiation condition of 10 m / min. The curing after the surface curing of the unsaturated polyester resin 10 is performed by the action of the thermal polymerization initiator, and finally the resin inside the paper layer of the decorative paper 8 is also cured, but at room temperature 1 The final physical properties are sufficiently reached by leaving it in the sun. In order to further increase the curing speed, it is sufficient to leave it at about 40 ° C. for 1 hour.

[0019]

[Function] An unsaturated polyester resin containing a thermal polymerization initiator and an ultraviolet initiator is applied on a decorative paper-coated decorative sheet with a pattern on the surface as described above, and an uneven pattern is formed on the surface. After coating the applied patterning film and rolling the resin, ultraviolet rays are radiated from above the film to cure the unsaturated polyester resin surface layer, and then the patterning film is immediately peeled off and left at a predetermined temperature. By curing, it became possible to greatly reduce the time until the release of the patterning film.

Further, by using a polyolefin film as the film having a concavo-convex pattern-imparting property of the shape-imparting film, it has become possible to obtain a film which is sufficiently resistant to ultraviolet curing and whose concavo-convex shape does not change even after repeated use.

[0021]

EXAMPLES The present invention will be described in more detail with reference to specific examples.

Example 1 A two-layer film obtained by laminating a vinylon film having a thickness of 25 μm and a polypropylene film having a thickness of 200 μm was coated on a resin mold provided with an uneven pattern with an epoxy resin placed on an aluminum plate, ℃, 20kg / cm
^A shaped film was obtained by hot pressing under the conditions of ² for 10 minutes. Next, a thin paper having a thickness of 30 g / m ² with a wood grain pattern was laminated on the MDF substrate, and 1.0 part of methyl ethyl ketone peroxide as a thermal polymerization initiator and 2 ethoxy-2 as an ultraviolet initiator were laminated thereon. Unsaturated polyester resin 100 containing 2.0 parts of phenylacetophenone
120 W after applying a part of the coating, coating the above-mentioned shape-imparting film on this, rolling with a rubber roll to remove air in the resin,
/ Cm high pressure mercury lamp was irradiated with 7 lamps, the patterning film was immediately peeled off, and the polyester decorative board was obtained by curing at room temperature for 24 hours.

Comparative Example 1 Using the shaped film of Example 1, only 1.0 part of methyl ethyl ketone peroxide as a thermal polymerization initiator was added to 100 parts of the unsaturated polyester resin.
The resin was cured only by heat under the condition of 3 ° C. for 3 hours to obtain a polyester decorative board.

Comparative Example 2 A vinylon film having a thickness of 25 μm and a vinyl chloride film having a thickness of 200 μm were bonded together as an imprinting film 2
A layered film was prepared, and the unsaturated polyester resin was cured by UV irradiation under the same conditions as in Example 1 except that this shaped film was used to obtain a polyester decorative board.

Comparative Example 3 A polyester decorative board was obtained by using the shaped film of Comparative Example 2 and curing the resin only by heat under the conditions of Comparative Example 1.

Comparative Example 4 A patterning film was obtained by pouring a thermosetting type silicone resin onto a mold having an uneven pattern made of epoxy resin, and curing and releasing the mold. Using this film, the resin was cured by ultraviolet rays under the conditions of Example 1 to obtain a polyester decorative board.

Comparative Example 5 Using the silicon mold of Comparative Example 4, the resin was cured only by heat under the same conditions as in Comparative Example 1 to obtain a polyester decorative board.

Table 1 below shows the time until peeling of the shaped film and the number of times the shaped film can be repeatedly used under the conditions of Example 1 and Comparative Examples 1 to 5 above.

[0029]

[Table 1]

[0030]

As described in detail above, according to the method for producing a polyester decorative board of the present invention, as shown in the results shown in Table 1 above, the time until peeling of the shape-imparting film is increased as compared with the conventional method. It can be shortened significantly, and the number of times the shaped film can be used repeatedly can be semi-permanent.

[Brief description of drawings]

FIG. 1 is a schematic view of a manufacturing process of a pattern-forming film having an uneven pattern according to the present invention.

FIG. 2 is a schematic view of a manufacturing process of the polyester decorative board of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base material 2 Resin type | mold which has uneven | corrugated pattern 3 Film which is not attacked by unsaturated polyester resin 4 Film with uneven | corrugation-imparting property 5 Heat press machine 6 Imprinting film 7 Wood base material 8 Paper base material 9 Picture 10 Unsaturated polyester resin 11 UV irradiation lamp 12 Concavo-convex pattern 20 Polyester decorative board having concavo-convex pattern

Claims (3)

[Claims] 1. An unsaturated polyester resin containing a thermal polymerization initiator and an ultraviolet initiator is applied on a decorative paper-coated decorative sheet having a pattern on its surface, and an uneven pattern is provided on the surface of the unsaturated polyester resin. After coating the shape-imparting film and rolling the resin, ultraviolet rays are radiated from above the shape-imparting film to cure the unsaturated polyester resin surface layer, and then the shape-imparting film is immediately peeled off and left at a predetermined temperature. A method for producing a polyester decorative board by an ultraviolet curing method, which is characterized by curing. 2. A thickness of 15 μm on a side of the shape-imparting shaped film contacting the unsaturated polyester resin.
The UV curing method according to claim 1, which has a two-layer structure of a vinylon, tetron, fluorine, nylon, trimethylpentene film having a thickness of 35 μm and a polyolefin film having a thickness of 100 μm to 300 μm on the other side. Method for manufacturing polyester decorative board. 3. The amount of the thermal polymerization initiator added to the unsaturated polyester resin is 0.5 part to 100 parts of the resin.
The method for producing a polyester decorative board by the ultraviolet curing method according to claim 1, wherein the amount is 2.5 parts and the amount of the ultraviolet initiator is 1 to 3 parts.