JP3230293B2 - Method for producing hydrothermally synthesized cured product having pattern and embossed shape - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board made of a hydrothermally cured material used for exterior or interior of a house or as a furniture member, and more particularly to a decorative board provided with a picture and an embossed surface.

[0002]

2. Description of the Related Art Conventionally, various decorative panels have been used for exterior and interior of a house or as a furniture member. In recent years, products having embossed surfaces have been favored along with the trend toward higher quality and higher design. It has become On the other hand, in terms of materials, the demand for decorative boards, which are called inorganic, is rapidly increasing due to their excellent physical properties.

[0003] Hydrothermally synthesized hardened products (precast concrete, cast-in-place concrete, ALC, etc.) are also representative inorganic materials, and their production methods are as follows.

[0004] (1) An inorganic raw material for forming a hydrothermally cured synthetic body (precast concrete, cast-in-place concrete, ALC) is poured into a desired mold in the form of an aqueous slurry, reacted and hardened, and then demolded. In the case of precast concrete and ALC, autoclave curing is required on the way.

(2) Hydrothermally synthesized hardened products (wood chip cement board,
An inorganic raw material for forming a ceramic board such as a calcium silicate board, a magnesium carbonate board, and a fiber reinforced cement board) is extruded in the form of an aqueous slurry or formed into a predetermined shape by a papermaking method, and then pressed (roll press or flat press). Press) to form a desired shape by dehydration. Thereafter, the reaction is cured by autocure curing.

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

[0007] However, the design effects obtained by these methods have not been so outstanding. In addition, in order to produce an embossed product using a mold, it is necessary to first emboss the mold itself, which requires a complicated operation such as cutting and casting. Was.

[0008]

SUMMARY OF THE INVENTION The present invention has been made to solve such a problem, and it is an object of the present invention to provide a design having a desired pattern and an embossed shape on its surface. It is an object of the present invention to provide a method for easily producing and efficiently producing a high hydrothermally cured product.

[0009]

In order to solve this problem, the present invention provides a transfer sheet having a base sheet, a release layer, a picture layer, and an adhesive layer sequentially formed on a mold material which has been embossed in advance. transfer Sea by pressing a flexible heat roll
The embossed shape of the irregularities exceeding the thickness of the mold is embossed , and the embossed shape is placed on the bottom of the mold frame with the adhesive layer facing up so that the embossed shape does not collapse. It is intended to provide a method for producing a hydrothermally cured product having a pattern and an embossed shape characterized by peeling a base sheet, and using an embossing roll as the desired embossed mold material. It is assumed that.

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

As the substrate sheet 1, a thermoplastic resin film capable of following irregularities on the surface of the substrate by heat during molding is used. Specifically, films of vinyl chloride, polyethylene, polypropylene, nylon, polyester and the like can be used. The degree of surface irregularities, the type and thickness of the resin may be appropriately selected from the balance with 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 preferable. .

As a method for forming the following layers on the substrate, gravure printing, screen printing, offset printing, or the like may be used.

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

The printing ink used for the printing layer 3 may be a weather-resistant printing ink such as a pigment-based coloring material. The synthetic resin binder used in the printing ink is determined in consideration of a large elongation at the time of heating, an influence on durability to a final product, and the like. For example, acrylic resin, styrene resin, alkyd resin, polyamide, polyester, polyvinyl chloride, polyvinyl acetate,
Alternatively, a mixture or a copolymer of these combinations 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 hydroxypropylcellulose, polyvinyl alcohol, polyvinylvirolidone, water-soluble acryl, and hydroxymethylcellulose can be used. It is.

FIG. 2 schematically shows one method of forming a transfer sheet. The adhesive layer surface of the transfer sheet 22 shown in FIG. 1 is placed on the concave and convex surface of the mold material 21 which has been subjected to a desired embossing in advance, and is pressed from the surface with the hot roll 23 to form the desired emboss. The material of the mold material may be any material that is smooth so as not to damage the transfer paper and has heat resistance, and plastic and metal can be used. The heat roll used at this time is a soft roll 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, though depending on the size of the unevenness of the plate.

FIG. 3 schematically shows another method of forming a transfer sheet. The transfer sheet 33 shown in FIG. 1 is passed between an embossing roll 31 having a desired embossing and a flexible rubber roll 32 and pressed to form a 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. The rubber roll is preferably made of silicon rubber having a rubber hardness of 30 ° and a thickness of 20 mm or more, as described above.

FIG. 4 schematically shows a transfer molding method for a hydrothermally synthesized cured product. The transfer sheet 42 formed on the mold 41 is
Place the adhesive layer 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 4
Spread 3 The raw material aqueous slurry 44 is poured therein, cured and cured, and then the base sheet is peeled off as shown in FIG. 5 to obtain a decorative plate having a desired pattern and a desired uneven 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 formed simply by installing the mold on a flat bottom. Since it is possible to efficiently produce a hydrothermally cured product having the same, there is no need for complicated work such as forming a mold having an embossed bottom surface. Further, by using an emboss roll in forming the emboss of the transfer sheet, it is possible to form the emboss continuously on the transfer sheet, and the productivity is further improved.

[0020]

【Example】

<Example 1> A semi-rigid vinyl chloride sheet having a thickness of 50 µm was used as a base sheet, and a release layer made of polyvinyl butyral was formed thereon by using gravure printing, and a coloring pigment (alamide yellow, phthalocyanine blue, dianthraceki) was used. Nonidyl red), a printing ink layer (brick pattern) made of polyvinyl chloride and polyvinyl 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 is installed on a fiber-reinforced cement board with a brick-like embossed and uneven pattern, and a surface temperature of 1
It was pressed with a hot roll at 60 ° C. and a rubber hardness of 30 °. The pressure was 10 kg / cm, and the speed was 5 m / min.

The formed transfer sheet was placed on the bottom surface of a mold frame laid with sand so that the adhesive layer faced upward. On top of this, an aqueous slurry as a cement raw material was charged, vibrated, clamped, and hardened. After the curing was completed, the mold was released, and the substrate sheet was peeled off. The resulting product had a very high design with embossing and a picture on the transfer sheet.

Example 2 50 μm thick base sheet
m, using a semi-rigid vinyl chloride sheet, and using gravure printing thereon, a release layer made of polyvinyl butyral,
A printing ink layer (wood pattern) composed of a coloring pigment (alamide yellow, phthalocyanine blue, diansuraquinonidyl red) and polyvinyl chloride, and an adhesive layer composed 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 previously embossed in woodgrain 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 set so that the adhesive layer was on the embossing roll side. The pressure was 10 kg / cm, and the speed was 5 m / min.

The formed transfer sheet was placed on the bottom surface of a formwork covered with sand, with the adhesive layer facing upward. On top of this, an aqueous slurry as a cement raw material was charged, vibrated, clamped, and hardened. After the curing was completed, the mold was released, and the substrate sheet was peeled off. The resulting product had a very high design with embossing and a picture on the transfer sheet.

[0026]

As described above, the structure of the transfer sheet according to the present invention, the formation of emboss by a soft rubber roll,
By the transfer to the hydrothermally cured product, a decorative plate made of a hydrothermally cured product having a beautiful pattern and emboss can be obtained by a simple method. Further, by using a roll as the embossing mold material, embossing can be continuously formed on the transfer sheet, and the productivity is further improved.

[0027]

[Brief description of the drawings]

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

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

FIG. 3 is a schematic view showing another example of a transfer sheet forming 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 ... Picture layer 4 ... Adhesive layer 21 ... Mold material 22 ... Transfer sheet 23 ... Heat roll 31 ... Emboss roll 32 ... Rubber roll 33 ... Transfer sheet 41 ... Mold frame 42 ... Transfer sheet 43 ... Sand 44 ... Aqueous slurry of raw material

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-4-135891 (JP, A) JP-A-4-239700 (JP, A) JP-A-58-31705 (JP, A) JP-A-2- 160576 (JP, A) JP-A-4-135799 (JP, A) JP-A-1-120399 (JP, A) JP-A-60-92810 (JP, A) (58) Fields investigated (Int. ⁷ , DB name) B44C 1/165-1/17

Claims (2)

(57) [Claims] 1. A substrate sheet, a release layer, picture layer, and transferring sea transfer sheet provided with an adhesive layer sequentially by pressing a flexible heat roll type material which previously subjected to desired embossing
The embossed shape of the irregularities exceeding the thickness of the mold is embossed , and the embossed shape is placed on the bottom of the mold frame with the adhesive layer facing up so that the embossed shape does not collapse. A method for producing a hydrothermally synthesized cured product having a pattern and an embossed shape, comprising peeling a base sheet. 2. The molding material having the desired embossing,
2. The method according to claim 1, wherein an embossing roll is used.
A method for producing a hydrothermally cured product having the picture and embossed shape described in the above .