JPS6045578B2 - Method for manufacturing decorative material with gloss difference in sync with uneven pattern - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative board having a difference in gloss that is synchronized with the uneven pattern, and more specifically, the present invention relates to a method for manufacturing a decorative board having a difference in gloss that is synchronized with the uneven pattern. The present invention relates to a decorative board having on its surface.

Various methods have been proposed in the past for forming an uneven pattern that matches a pattern using a foamable resin composition.

For example, the method using a foaming inhibitor as described in Japanese Patent Publication No. 43-28636, or the method described in Japanese Patent Publication No. 43-15713.
A typical method is a method using a kicker as described in the above publication. However, these conventional methods aim to synchronize the uneven pattern with the pattern formed by printing, etc., and the surface of the resulting product either has a pattern layer exposed or is covered with a surface resin layer having a certain gloss. Therefore, it was not possible to obtain a design effect due to the difference in gloss. The present invention has been made in view of the above points, and it is an object of the present invention to provide a method for manufacturing a decorative board in which an uneven pattern is formed and at the same time a gloss difference that is synchronized with the uneven pattern is imparted. Next, a detailed explanation will be given according to the drawings.

1 and 2 are cross-sectional views showing an example of a decorative board obtained by the method of the present invention.

As a first embodiment of the present invention, a pattern 2 is applied to the surface of a base material 1 as shown in FIG. When applying this pattern, pattern 2-a, which should be a concave part, is applied using ink containing a foaming inhibitor, or pattern 2-b, which should be a convex part.
is applied using an ink containing a foaming accelerator. Next, a transparent foamable resin composition is applied to form a layer with a thickness of O, 3Tn1n or less, and heated and foamed under the conditions described later to form a concavo-convex pattern that matches the pattern, and the concave portions are crossed. The convex portion becomes matte. Next, as a second embodiment, as shown in Fig. 2, the surface of the base material 1 is colored or patterned 2', and a transparent foamable resin composition 3 is applied thereon to a thickness of O, 3 m7.
It is applied in a layer of 7Z or less, and then an embossing plate is brought into contact with or without synchronization with the pattern of the lower layer, and the embossing plate is heated and foamed under the conditions described later.

Then, the composition foams in a shape that conforms to the embossed shape of the embossing/plate, forming an uneven pattern, with the depressions becoming a cross and the protrusions becoming a matte. Base materials include paper, synthetic paper, resin-mixed paper, resin film, asbestos paper, glass vapor, woven fabric, non-woven fabric, knitted fabric, wood materials such as plywood and particle board, and fibers such as hardboard and insulation board. Coating or impregnating synthetic resin on boards, inorganic boards such as asbestos slate boards, gypsum boards, and calcium silicate boards, metal boards such as steel plates and aluminum boards, glass boards, synthetic resin boards, ceramic boards, and the above base materials. and a combination of two or more of the above base materials can be used.

To apply the pattern 2, coloring, or pattern 2'', if an embossing plate is used as described in the second embodiment, normal ink may be used.

In addition, when using the method described in the first embodiment, inks containing trimellitic acid, maleic anhydride, hydroquinone, and other known inhibitors, or zinc hydrofurylate, cadmium hydrofurylate, and phthalic acid are used. It is applied using an ink containing lead or other known accelerators in combination with a conventional ink. An ink containing a mochiromon inhibitor and an ink containing an accelerator may be combined, or a normal ink may be added to combine three types of inks. The transparent foamable resin composition is a mixture of a known thermoplastic polymer material such as polyvinyl chloride resin and a known blowing agent such as azodicarbonamide, and the thickness of the dry film before foaming is 0.
．． 3TIr: Formed to be 1n or less.

Note that if no foaming suppression or foaming promotion method is used, N
Blowing agents such as n'-oxybisbenzenesulfamyl hydrazide can also be used. The conditions for foaming are 180-20
30-90 at a temperature of 0°C.

It is best to heat for 2 seconds. Foaming temperature is 180°C
If the temperature is below 200℃, the softening of the resin and the generation of gas from the foaming agent will become uneven, resulting in irregular size and shape of the foam cells.If it is above 200℃, the softening of the resin and the generation of gas will proceed rapidly, resulting in rapid foaming. This is undesirable because it causes the foam cells to become irregular in size and shape. When heating and foaming is carried out under the above conditions, foam cells are formed between areas with a low expansion ratio, that is, concave parts, and areas with a high expansion ratio, that is, convex parts, as shown in Figures 1 and 2. Foam layers with different sizes and densities are generated.

In other words, the dense concave portions have small foam cells, so there is little diffusion and high transparency, so the coloring and patterns of the underlying layer can be seen in detail, resulting in the layer as a whole having a high gloss, that is, a cloth state.

In addition, the convex portions with low density have large foam cells, which causes a large diffusion of light and reduces transparency, which reduces the transparency effect of the coloring and pattern of the underlying layer, and therefore the layer as a whole has a low gloss, that is, a matte state. becomes. Also, in the present invention, the thickness of the transparent foamable resin composition layer is 0.3T! It is limited to Un or below, but is this 70.3? In this case, even if the recesses have a high density, the thickness of the layer increases and the transparency decreases, making it impossible to obtain the see-through effect and the gloss level above a certain value, which is the objective of the present invention. That's because there isn't. This also applies to convex portions, and it is possible that the perspective effect may be completely lost as the thickness of the layer increases. The foaming ratio of the foam layer of ordinary foam decorative materials is usually 4 or 5 times or more, but even if the resin can be used for the surface protective layer, the physical performance of the foam layer In general, this tends to decrease; for example, if the foaming ratio is increased to 5 times, the surface abrasion resistance will decrease to 113, so a new surface protective layer must be provided on top of it. Nakatsuta, but
Since the foaming ratio of the foamed layer of the present invention is suppressed to 3 times or less, the physical performance is only reduced to 11'2J before foaming, even if the foaming layer is severely damaged. Since it has the above strength, it can be fully expected to be effective as a surface protective layer. In addition, the conventional method of making the surface matte is to use a resin mixed with a matting agent, but a resin layer containing a matting agent has the disadvantage that various physical properties such as abrasion resistance deteriorate. It was hot.

However, the method of obtaining the matte effect in the method of the present invention does not use a matting agent as in the conventional method, but is based on the difference in density obtained by the difference in foaming ratio, so it does not have the disadvantages of the conventional method. None. The decorative material obtained by the method of the present invention as described above has an effect due to the uneven pattern that matches the pattern of the lower layer, an effect due to the difference in gloss that matches the unevenness,
It has a unique expressive effect due to the synergistic effect of three types of effects, including the effect due to the transparency of the foam layer, and it has been impossible to achieve these effects simultaneously using conventional techniques.

In addition, the perspective effect makes it possible to express soft light color tones in terms of design.

Example An abstract pattern was printed on the surface of resin-mixed paper with a basis weight of 40 y/d using normal ink and a suppression ink containing trimellitic anhydride, and then a transparent resin of the following composition was printed on the surface to a thickness of 0.
．． 3? Apply it so that it looks like this.

The resin layer was foamed by mixing the transparent resin and heating it at 190° C. for 18 hours to obtain a decorative material in which the concave portions were crossed and the convex portions were matte.

[Brief explanation of the drawing]

The drawings are cross-sectional views showing one example of the decorative material obtained by the method of the present invention. Figure 1 shows the case where a foam suppressor or foam accelerator is used, and Figure 2 shows the case where an embossing plate is used. Each shows a cross-sectional view. 1... Base material, 2... Pattern, 2-a...
...Picture of the part that should be a recess, 2-b...
Pattern of the portion to be made into a convex portion, 2″... Coloring or pattern, 3... Foamable resin composition.

Claims (1)

[Claims] 1. A transparent foamable resin composition layer with a thickness of 0.3 mm or less is formed on a colored or patterned base material, and then a method such as chemical foaming suppression or foaming promotion or pressure application using an embossing plate is used. , and by heating and foaming at a temperature of 180 to 200°C to form a foamed layer with a density of 0.3 to 1.2, a concave portion with high density, high transparency, and high gloss,
A method for producing a decorative material having a difference in gloss synchronized with an uneven pattern, characterized by providing convex portions with low density, low transparency, and low gloss compared to concave portions.