JPH0134151B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative material having a three-dimensional pattern.

This invention forms a thick pattern layer of synthetic resin mixed with granular colored pigments on the surface of a base material, and embosses the surface of this thick pattern layer while it is uncured. The purpose of this method is to produce decorative materials with three-dimensional patterns.

The present invention will be explained below with reference to the drawings.

As the base material 1, plywood with resin-impregnated paper 1b pasted on the surface of the base plate 1a is used, but in addition to the ones shown in the figure, plywood other than the above-mentioned plywood, particle board, hard board, gypsum board, etc. Board materials such as pulp cement boards, calcium silicate boards, calcium carbonate boards, plastic boards, metal plates, etc., or sheets with paper, synthetic resin sheets, cloth, etc. sheets (hereinafter simply referred to as sheets) pasted to the surface of these board materials. itself, etc. can be used.

A colored layer 2 consisting of a pattern of one color or two or more colors is formed on the surface of the base material 1. The colored layer 2 is formed by applying or printing a known synthetic resin paint onto the surface of the base material 1, or by pasting a patterned or colored sheet on the surface of the base material 1. This colored layer 2 is not necessarily necessary, and when the surface of the base material 1 is to be made into a desired color or pattern, for example, when manufacturing a sheet or pulp cement board, the raw material is colored in a desired color. It is unnecessary in some cases.

On the surface of the base material 1, in this example, on the surface of the colored layer 2, a thick pattern layer 3 containing a synthetic resin as a main component, a granular colored pigment, and an opaque powder pigment is formed in a desired planar shape and in a desired arrangement. to form. The thick pattern layer 3 is generally formed by screen printing to form the colored layer 2.
to form. It goes without saying that in the case of the base material 1 without the colored layer 2, the thick pattern layer 3 is directly formed on the surface of the base material 1. As is clear from this description, forming the thick pattern layer 3 on the surface of the base material 1 includes both forming it directly or indirectly on the surface of the base material 1. The thickness of the thick pattern layer 3 is preferably about 100 to 200μ,
The thickness is not limited to this. Synthetic resins include acrylic, epoxy, urethane, and
Transparent synthetic resins such as polyester are suitable. Note that as this synthetic resin, a translucent, or in some cases an opaque one may be used. As the granular colored pigment, a dye or pigment coated with a synthetic resin, a so-called encapsulated pigment, or a granular pigment or dye itself is used. For example, Micro Color (trade name) manufactured by Dainippon Toyo Co., Ltd. and Zolacoat (trade name) manufactured by Kansai Paint Co., Ltd. are suitable. In addition, in the next step, when the granular colored pigment is caused to bleed by a solvent, it goes without saying that a material having the property of bleeding by a predetermined solvent is selected. The particle size of the granular colored pigment is preferably 50 to 300 microns, but it goes without saying that particle sizes other than this can also be used. The amount of the granular colored pigment to be added and the type of color to be added are freely determined in consideration of the design effect. As the opaque powder pigment, clay, titanium oxide, calcium carbonate, etc. are used. The amount of this powder pigment added is freely determined in consideration of the design effect. For example, if the synthetic resin that is the main component of the thick pattern layer 3 is transparent, if the amount of powder pigment added is small, the transparency of the thick pattern layer 3 will increase, allowing the colored layer 2 of the base material 1 and the thick pattern to pass through it. layer 3
If the amount of powder pigment added increases, the transparency of the thick pattern layer 3 will decrease, allowing the granular color pigments in the colored layer 2 and thick pattern layer 3 of the base material 1 to be seen through it. This makes it difficult to see through, or it becomes impossible to see through at all, so the amount of powder pigment to be added (including zero) is determined by taking this into consideration.

After forming the thick pattern layer 3, while it is not cured, the surface of the thick pattern layer 3 is embossed to form a concave membrane 6 having a desired shape. At this time, by applying a solvent that has the effect of causing the granular coloring pigment to bleed onto the convex portion of the embossing mold, either alone or mixed with the paint, the solvent is applied to the inner peripheral surface of the concave membrane 6 at the same time as the embossing process. It can be applied to bleed granular colored pigments. This solvent is applied to the inner circumferential surface of the concave film 6 when the thick pattern layer 3 is uncured.
Not only does it bleed the granular coloring pigment exposed on the inner circumferential surface of the thick pattern layer 3, but it also penetrates into the inside of the thick pattern layer 3 through the inner periphery and bleeds the granular coloring pigment inside. A three-dimensional and deep bleeding pattern can be obtained. As a solvent, for example, if an oil-soluble dye is used as a granular coloring pigment, an organic solvent-type synthetic resin paint or the organic solvent itself may be used, and if a water-based dye is used, a water-based synthetic resin may be used. You can use paint etc.
If you are using encapsulated pigments, you can use a solvent that dissolves the capsules. As this solvent, a synthetic resin paint itself such as an aminoalkyd, acrylic, or epoxy resin paint for coating the inner peripheral surface of the concave membrane 6 may be used.

It is desirable to apply an antifoaming agent such as a surfactant aqueous solution to the surface of the thick pattern layer 3. This antifoaming agent makes it possible to extinguish bubbles in the thick pattern layer 3 and expose the granular colored pigment on the surface of the thick pattern layer 3.

Next, after drying for a predetermined time, the thick pattern layer 3
Polish the surface using a sander or the like. This polishing operation allows the particulate colored pigment to be exposed and clearly visible on the surface.

The surfaces of the thick pattern layer 3 and the colored layer 2 are coated with a sealer layer 4 of synthetic resin such as urethane, epoxy, acrylic, etc., if necessary.

The surface of the sealer layer 4 is coated with aminoalkyd-based
An upper transparent coating layer 5 made of a transparent synthetic resin paint such as urethane, unsaturated polyester, epoxy, or acrylic is formed.

Next, embodiments of this invention will be described.

Example 1 Urethane enamel mixed with one or more pigments such as red iron oxide, iron oxide yellow, and phthalocyanine blue was applied to the surface of a phenol resin-impregnated paper-attached plywood [solid content excluding pigments and other contaminants (hereinafter simply referred to as solid content)] ) is 52% by weight (hereinafter simply referred to as %)]
A colored layer was formed by applying 90 g/m ² of the colored layer, and a thick pattern layer with a thickness of 200 μm was formed on this surface by screen printing using a paint having the composition shown below.

Paint composition modified acrylic emulsion (solid content 68%)
100 parts by weight (hereinafter simply referred to as parts) Encapsulated pigment (30-250 μ) Red 12 parts Yellow 12 parts Blue 12 parts Then, on the convex part of the rubber letterpress of the flexo printing machine as an embossing machine, 30 g/m of a specified synthetic resin paint (20% solid content, containing organic or inorganic pigment) such as aminoalkyd, acrylic, epoxy, or urethane paint that has the effect of blurring encapsulated pigments. ² coated and using this flexo printing machine, when the thick pattern layer is uncured,
A concave pattern is formed on its surface. Along with this work, the painting of the inner peripheral surface and the work of bleeding the encapsulated pigment are completed at the same time. Then 60
After drying at ℃ for 60 minutes, the surface of the thick pattern layer is sanded with a sander, and then a urethane-based synthetic resin sealer (solid content 38%) is applied to the plywood surface including the thick pattern layer.
40g/ ^{m2 of} the sealer layer was applied and dried at 50℃ for 12 minutes, and then 180g/ ^m2 of urethane-based synthetic resin paint (solid content 45%) containing iron oxide yellow was applied as a top coat to the surface of the sealer layer. The desired decorative board was obtained by drying at ℃ for 90 minutes.

Example 2 The desired makeup was created through the same steps as in Example 1, except that a paint with the following composition was used to form the thick pattern layer instead of the paint for the thick pattern layer used in Example 1. Got the board.

Paint composition: Epoxy-modified acrylic emulsion (solid content
71%) 100 parts Encapsulated pigment (30-150 μ) Red 10 parts Yellow 10 parts Blue 10 parts Titanium oxide (opaque powder pigment) 20 parts Example 3 Concave film-like material used in Example 1 Instead of internal paint, use synthetic resin paints such as acrylic or urethane paints (20% solids, containing organic or inorganic pigments) that do not have the effect of causing encapsulated pigments to bleed. Except for this, all the steps were the same as in Example 1 to obtain a desired decorative board.

Example 4 In place of the paint for the thick pattern layer used in Example 1, a paint with the following composition was used, and in place of the paint for concave film-like inner surface coating, a paint that had the effect of causing the encapsulated pigment to bleed was used. Acrylic type that does not
A desired decorative board was obtained through the same steps as in Example 1, except for using a synthetic resin paint such as urethane (solid content: 20%, containing organic or inorganic pigment).

Paint composition: Epoxy-modified acrylic emulsion (solid content
71%) 100 parts Encapsulated pigment (50-100 μ) Red 7 parts Yellow 7 parts Blue 7 parts Calcium carbonate (opaque powder pigment) 14 parts According to the invention, the substrate surface Since it forms a thick pattern layer on the surface, it is possible not only to make the decorative material three-dimensional, but also to emboss the surface of the thick pattern layer when it is uncured. Since it is possible to extremely easily form a beautiful uneven pattern rich in variation on the surface of a thick pattern layer, a three-dimensional and deep decorative material can be obtained. Furthermore, since the granular colored pigment is mixed in the thick pattern layer, by making it possible to see through the granular colored pigment freely dispersed in the plane direction and the thickness direction through the thick pattern layer, it is possible to combine with the uneven pattern. This makes it possible to obtain decorative materials with even greater variety and superior design.

[Brief explanation of drawings]

The drawing is a longitudinal sectional view showing an example of a decorative material manufactured by the method of this invention. 1...Base material, 2...Colored layer, 3...Thick pattern layer, 6...
Concave membranous.

Claims (1)

[Claims] 1. A thick pattern layer of synthetic resin mixed with granular colored pigment is formed on the surface of a base material, and when this thick pattern layer is uncured, the surface is embossed, and then A method for producing a decorative material, comprising forming a thick pattern layer and a top coat layer on the surface of a base material. 2. The method for producing a decorative material according to claim 1, wherein the particulate coloring pigment has a bleed property, and embossing is performed by applying a solvent that causes the granular coloring pigment to bleed onto an embossing mold.