JP2000318111A - Manufacturing method of cosmetic material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a decorative material good in abrasion resistance without generating appearance inferiority such as abrasion, a stripe or gloss change on a coating roller or printing plate. SOLUTION: A decorative material D wherein a resin layer 2 having a large number of solid particles P bonded to the surface thereof and/or embedded therein is provided on a base material at least as a decorative layer is produced by sprinkling the solid particles over a resin layer 2A held to a non-flowable and sticky state or a flowable state by a rotary blade type or air nozzle type blast device to bond the solid particles P to the surface of the resin layer 2A or embedding them in the resin layer 2A and solidifying the resin layer 2A to bring the same to a non-sticky or non-flowable state to form the resin layer wherein the solid particles P are fixed. The resin layer 2 may be formed by transfer and a backing substrate may be bonded to the rear surface of the decorative material D.

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 decorative material having a decorative surface used for interiors such as floors, walls and ceilings of buildings, furniture and various cabinets. In particular, the present invention relates to a method for producing a decorative material having excellent surface wear resistance.

[0002]

2. Description of the Related Art Conventionally, decorative materials in which a base material is decorated in various forms, such as a sheet-shaped decorative sheet, a plate-shaped decorative plate, and a three-dimensional object decorative member, have been used for various purposes. I have. Of these decorative materials, the decorative sheet is also called a transfer sheet in the case of a transfer type instead of a laminate type. And a plate-shaped decorative board, a three-dimensional object-like decorative member, etc.
The decorative sheet may be made by directly printing or painting the base material to make it into a decorative sheet. However, a laminate type decorative sheet (laminate sheet) may be adhered or transferred to a transfer type decorative sheet (transfer sheet). In some cases, the transfer layer is transferred to make a decorative plate. In these various decorative materials, when abrasion resistance of the surface is required, a layer that finally becomes a surface in use is formed of a matting agent such as silica or solid particles made of an inorganic powder such as alumina powder. It was formed by coating (or printing) using a coating liquid (or ink) containing the same.

[0003]

However, when a coating liquid (or ink) containing hard solid particles capable of obtaining abrasion resistance is used, a coating roller, a gravure printing plate, and a doctor blade used for coating are used. Wear, etc., easily progressed, and defects such as streaks and appearance defects such as gloss change were likely to occur.
Therefore, an object of the present invention is to improve the abrasion resistance of a roller, a printing plate, and the like used for coating, in spite of being able to have excellent abrasion resistance.
An object of the present invention is to provide a method for producing a cosmetic material in which poor appearance such as streaks and gloss change is unlikely to occur.

[0004]

In order to solve the above-mentioned problems, in the method for producing a decorative material according to the present invention, a plurality of solid particles adhere and / or adhere to a surface of a base material at least as a decorative layer.
Or, in the method of manufacturing a decorative material in which a resin layer embedded in the layer is provided, when the resin of the resin layer is in a non-flowing adhesive state or in a flowing state, rotating toward the resin layer By a blast device of a blade type or an air nozzle type, solid particles are sprayed and solid particles are adhered to the surface of the resin layer, or solid particles are penetrated into the resin layer and embedded therein, and then the resin layer is solidified. The solid particles were fixed to the resin layer in a non-adhesive and non-flowable state. By doing so, even if hard solid particles are used in the resin layer to improve abrasion resistance, after the resin layer is formed on the substrate in a state where the solid particles are adhered or not included, Since the solid particles are attached or included, abrasion by the solid particles of the coating roller or the printing plate can be essentially avoided.

[0005] In the method for producing a decorative material according to the present invention, the resin layer in which a plurality of solid particles are adhered to the surface of the layer and / or embedded in the layer is formed on the releasable support sheet. After forming the transfer layer, the transfer layer was transferred to a base material to form a decorative layer on the base material. As described above, the resin layer on the substrate can be formed by transfer from a transfer sheet formed as a transfer layer on the release support sheet. Transferring the resin layer with solid particles fixed by transfer in this way eliminates the need for solvent drying of the ink or coating liquid required when directly forming the resin layer on the base material by printing or coating, thus reducing the work environment. This is advantageous, and it can be formed even when the forming surface cannot be directly formed by printing or the like due to the uneven surface, and can be formed by one-time transfer with other decorative layers.

[0006] Further, according to a method of manufacturing a decorative material of the present invention, a decorative material obtained by any one of the above-described methods of manufacturing a decorative material is used as a first decorative material, and a back side of the first decorative material is further lined. The base material was adhered and used as the final second decorative material. The first decorative material is, for example, a decorative sheet. As a result, even if it is difficult to directly form a resin layer or a decorative layer formed by printing or the like on the backing substrate, the second decorative material is obtained by sticking the first decorative material on the surface and applying makeup. I can do things. Also,
The backing substrate and the first decorative material to be adhered thereto are separately prepared, and the required number of the first decorative materials are adhered to the backing substrate by a necessary number when necessary. 2 cosmetics can be obtained.

[0007]

Embodiments of the present invention will be described below with reference to the accompanying drawings. FIG. 1 is a conceptual view conceptually illustrating a method of manufacturing a decorative material of the present invention in one form, and FIG. 2 is a conceptual view conceptually illustrating an embodiment using transfer as a method of manufacturing a decorative material of the present invention. FIG. 3 is a conceptual diagram illustrating a rotary blade type blast device for spraying solid particles, FIG. 4 is a conceptual diagram illustrating an air nozzle type blast device for spraying solid particles,
FIG. 5 is a cross-sectional view showing an example of a laminate type decorative sheet as a decorative material obtained in the present invention, FIG. 6 is a cross-sectional view showing an example of a transfer sheet obtained or usable in the present invention, and FIG. It is sectional drawing which shows an example of the decorative material which laminated | stacked the 1st decorative material on the backing base material as a decorative material obtained.

[Outline] First, a method of manufacturing a decorative material according to the present invention will be described with reference to the conceptual diagram of FIG. Here, the method described with reference to FIG. 1 is a method according to the first aspect of the present invention. FIG.
(A) shows a state in which the resin layer 2A on which the solid particles P are not yet adhered or embedded on the base material 1 is formed by coating or printing. Then, as shown in FIG. 1B, the resin layer 2A
Is appropriately heated and melted as necessary to obtain a resin layer 2
After the resin A is brought into a non-flowing adhesive state or a flowing state, a large number of solid particles P are directed toward the resin layer 2A by a rotary blade type or air nozzle type blasting device.
Spray. Then, a large number of solid particles P are formed in the resin layer 2A.
Is in a non-flowing adhesive state, the resin layer 2A
When the resin layer 2A is in a fluid state, the solid particles P adhere to the surface of the resin layer 2A depending on the speed at which the solid particles P collide with the resin layer 2A and the degree of the fluid state of the resin layer 2A. However, depending on the speed of the solid particles colliding with the resin layer 2A and the fluidity of the resin layer 2A, the resin layer 2A
It penetrates to the inside and is buried. When the solid particles are buried, some of the solid particles that have collided with the resin layer 2A may not enter the inside but remain attached to the surface.
Thereafter, the resin layer 2A on which the solid particles are adhered and / or embedded is solidified by cooling, solvent drying, chemical reaction, or the like, to form the resin layer 2. As a result, the resin layer 2 in which the plurality of solid particles P adhere to the surface of the resin layer 2A (the solid particles are not yet fixed) and / or are embedded in the layer is formed on the substrate 1. This is a method in which the formed decorative material D as shown in FIG. 1 (C) is obtained.

As will be described in detail later, the base material 1 is a sheet, a plate, a three-dimensional object, or the like. When the base material 1 is a sheet, the base material 1 is separated from the base material 1 so that the resin layer 2 is peeled off from the base material 1. Is a mold releasing property, that is, if the base material 1 is a mold releasing support sheet, the obtained decorative material becomes a transfer sheet. When the substrate 1 is a sheet having no release property, the obtained decorative material is a laminate sheet.

As a method using a transfer sheet, the resin layer 2 may be formed by transfer as shown in the conceptual diagram of FIG. FIG. 2 shows the method according to the second aspect of the present invention.
The form in which the obtained decorative material becomes a transfer sheet is also shown. That is, the resin layer 2 is formed on the transfer layer 1 on the release support sheet 11.
Using the transfer sheet 10 formed as 2, the transfer sheet 10 is formed on the substrate 1 by transfer from the transfer sheet 10. This transfer sheet 10 corresponds to a mode in which the substrate 1 is a release sheet (release sheet 11) by the method shown in FIG.

That is, first, as shown in FIG. 2A, a resin layer 2A (with no solid particles fixed thereon) is formed as an (unfinished) transfer layer 12 on a release support sheet 11. Then, as shown in FIG. 2 (B), the resin layer 2A formed on the releasable support sheet 11 is heated and melted as needed as necessary in the same manner as described above, so that the resin layer 2A becomes non-flowable. After the adhesive state or the flowing state of the resin layer 2A, a large number of solid particles P are sprayed toward the resin layer 2A to form a resin layer 2A.
A is solidified as before. Then, as shown in FIG. 2C, the resin layer 2 in which the plurality of solid particles P are adhered to the surface of the resin layer 2 and / or embedded in the layer is formed as a transfer layer 12 on the releasable support sheet 11. The formed transfer sheet 10 can be prepared. Up to this point, this corresponds to the method for producing a decorative material in the case where the base material 1 is the release support sheet 11 in the method shown in FIG. Then, using the transfer sheet 10,
As shown in FIG. 2 (D), when the transfer layer 12 including the resin layer 2 is transferred from the transfer sheet 10 onto the base material 1, a decorative material D is obtained.

Incidentally, in the embodiment shown in FIG.
An adhesive layer 14 is provided between the resin layer 2 and the adhesive layer 14. The adhesive layer 14 is preliminarily formed before the transfer in order to adhere and transfer the transfer layer 12 made of the resin layer 2 to the substrate 1. This is a layer formed on the material 1 side. However, the adhesive layer 14 may be provided on the transfer sheet 10 as a part of the transfer layer 12 (see FIG. 6). When the resin layer 2 alone can be transferred to the substrate 1 by bonding, the adhesive layer 14 may be omitted.

Although the resin layer 2 is a kind of decorative layer, usually, the resin layer 2 is formed on another layer such as another decorative layer on the substrate 1 or on the release support sheet 11. It is laminated with. The other layer is, for example, a picture layer formed by printing or the like for representing a picture pattern (see reference numeral 3 in FIGS. 5 and 6). On the release support sheet 11 of the transfer sheet 10, the other layers are, for example, as shown in FIG. 6, a pattern layer 3 or a release layer 13, and a transfer layer adhered to a base material. An adhesive layer 14 or the like for transfer. In addition,
As the picture pattern layer 3, usually, a full solid layer 3A and a pattern pattern layer 3B expressing a pattern pattern are formed.

When the transfer layer 10 is used to transfer and form the resin layer 2, other layers other than the resin layer 2 are simultaneously transferred together with the resin layer 2 by the transfer sheet 10, as in the transfer sheet 10 illustrated in FIG. Transcription is efficient. However, it is not necessary to simultaneously form the resin layer 2 on the base material by transferring and forming only the resin layer 2 on the base material, and forming other layers such as a picture layer directly on the base material (usually by printing). good.

As described above, when the base material is, for example, a resin sheet, the decorative material is usually a decorative sheet. If the base material is a release sheet (release support sheet) in addition to the laminate sheet, the decorative sheet can also be a transfer sheet.

The obtained decorative material is a decorative plate when the base material is, for example, a wooden board. When the base material is a three-dimensional object such as a resin molded product, the decorative material is usually a decorative member or a decorative product. If a decorative material capable of such various forms is used as a first decorative material and a backing base material is laminated on the back side of the first decorative material, a (second) backing base material is provided.
Becomes a cosmetic material. For example, as one form of cosmetic material,
When a decorative sheet of the type is laminated on a wooden board as a backing substrate (laminate), a decorative board can be obtained.

Hereinafter, the method for producing a decorative material of the present invention will be further described.

[Substrate] The shape and material of the substrate 1 are not particularly limited. For example, the shape may be any of a sheet, a plate, and a three-dimensional object. In addition, the material is wood-based, metal-based, inorganic non-metal-based (ceramic-based, non-ceramic ceramic-based, etc.), plastic-based, paper, and the like. Specifically, in the wood system, for example, there are a veneer made of cedar, cypress, oak, lauan, teak, and the like, a plywood, a particle board, a fiber board, a laminated wood, and the like. Further, in the metal system, for example, there are metal materials such as iron, aluminum, and copper. In the case of inorganic non-metals,
For example, extruded cement, slag cement, ALC
(Lightweight cellular concrete), GRC (glass fiber reinforced concrete), pulp cement, wood chip cement, asbestos cement, calcium silicate, gypsum, gypsum slag, etc., non-ceramic ceramic materials, earthenware, pottery, porcelain, setware, glass, There are ceramic materials such as enamel. In the case of plastics, for example, polyolefin resins such as polyethylene, polypropylene, and olefin thermoplastic elastomers, polyester resins such as polyethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalephthalate, polymethyl (meth) acrylate, and polybutyl (meth) acrylate [(Meth) acrylate means methacrylate or acrylate], vinyl chloride resin, polycarbonate resin, ABS (acrylonitrile-butadiene-
There is a resin material such as a styrene copolymer) resin. Examples of the paper include high-quality paper, thin paper, linter paper, kraft paper, resin-impregnated paper, titanium paper, and coated paper.

As described above, when the base material 1 is a sheet, if the base material 1 is the release support sheet 11, the obtained decorative material D is the transfer sheet 10. Examples of the material of the sheet-shaped base include resin (resin sheet), paper, metal (metal foil), and the like. The thickness of the release support sheet is usually 20 to
A typical example of the releasable support sheet 11 is a polyethylene terephthalate film or the like. In addition, the base material 1 is made to be releasable from at least the transfer layer 12 having the resin layer 2, and the releasable support sheet 11
In some cases, release properties between the base material and the transfer layer may be obtained by providing a release layer between the resin layer and the base material. A sheet-shaped substrate is used as a material sheet, and a release layer is provided on the transfer layer side of the material sheet.
The substrate to be a release support sheet is composed of a material sheet and a release layer, and the release layer is peeled off integrally with the material sheet when the substrate is peeled from the transfer layer. The release layer may be, for example, coated or printed by a known method using a coating liquid or ink using a simple substance such as a silicone resin, a melamine resin, a polyamide resin, a urethane resin, a polyolefin resin, or a mixture containing these. Formed.

[Resin Layer] The resin layer 2 is not only a layer providing abrasion resistance but also a kind of a decorative layer. The resin used for the resin layer 2 may be a non-flowing adhesive state or a temporary flowing state. Basically, there is no particular limitation as long as the resin is a resin which can be formed by a chemical reaction (curing reaction), cooling, or dissolving and drying. Normally, a pattern layer is also laminated below the resin layer 2 on the base material 1 (when observing the decorative material in the final use form), so that the pattern by the pattern layer can be seen through. Use a resin that can secure transparency to a certain degree or more. Since the purpose of fixing the solid particles to the resin layer is to improve the wear resistance, the resin itself of the resin layer 2 is preferably a resin suitable for the wear resistance.

As the resin, thermoplastic resin such as acrylic resin, saturated (thermoplastic) polyester resin, polyolefin resin, vinyl chloride-vinyl acetate copolymer, nitrocellulose, etc. is used, and softening by heating (or melting), solvent The adhesive may be in a non-fluid state or a fluid state by dissolving (or swelling) in a dispersion medium, or the like. However, in terms of abrasion resistance, thermosetting resins, ultraviolet rays, electron beams, etc. A curable resin such as an ionizing radiation-curable resin that cures with the above is more preferable. In the case of a curable resin, if solid particles are fixed at the stage before curing is completed, a non-flowable adhesive state or a flowing state can be utilized, and if finally cured, a hard coating film of the resin itself will be used. Is obtained, and the wear resistance can be further improved by the solid particles fixed to the resin layer.

As the thermosetting resin, for example, a two-component curable urethane resin, a one-component curable urethane resin, an epoxy resin, an unsaturated polyester resin, or the like can be used. In addition,
As the two-component curable urethane resin, an acrylic polyol, a polyester polyol, a polyether polyol, or the like is used as a main component polyol, and 2,4-tolylene diisocyanate, 1,1, is used as a crosslinking agent (curing agent) isocyanate.
It may be appropriately selected from known urethane resins using polyvalent isocyanates such as 6-hexamethylene diisocyanate and isophorone diisocyanate. The one-component curable urethane resin or the like may be appropriately selected from known moisture-curable urethane resins made of a prepolymer having an isocyanate group at the molecular terminal. The curable urethane resin can be used in the form of a blocked isocyanate obtained by blocking the isocyanate with a blocking agent.

The above-mentioned ionizing radiation-curable resin is a composition curable by ionizing radiation such as ultraviolet rays and electron beams. Specifically, the resin has a radical polymerizable unsaturated bond,
Alternatively, it is a composition in which a prepolymer (including a so-called oligomer) having a cationically polymerizable functional group and / or a monomer are appropriately mixed. Such an ionizing radiation-curable resin may be appropriately selected and used from known ones. For example, in the case of a composition having a radically polymerizable unsaturated bond, a polyester acrylate-based, urethane acrylate-based, epoxy acrylate-based In the case of a composition having a cationic polymerizable functional group, such as an ionizing radiation curable resin such as melamine acrylate or triazine acrylate, an epoxy ionizing radiation curable resin may be used. Here, the acrylate type includes a methacrylate type.

When the resin layer 2 is formed as the transfer layer 12 on the releasable support sheet 11, apart from the fixing of the solid particles to the resin layer 2 (A), in the state of the transfer sheet, From the viewpoint of ease of handling, a resin that is preferably in a non-flowable state is selected for the resin layer 2.

[Solid Particles] As the solid particles P, organic particles and inorganic particles can be used. The average particle size of the solid particles is such that particles having an average particle size of about 5 to 50 μm conceal the abrasion resistance and, further, the pattern expression formed by a pattern layer normally formed below the resin layer 2 (at the time of observation). It is preferable in that it does not adversely affect. When the average particle size exceeds 50 μm, when embedding the solid particles in the resin layer, the thickness of the necessary resin layer increases,
The cost increases accordingly. The shape of the solid particles may be, for example, a true sphere, an ellipsoid, a scale, an irregular shape, a polygonal shape, or the like. The material of the solid particles is preferably inorganic particles such as alumina, silica, diamond and glass when used solely as a lubricating agent, and calcium carbonate, barium sulfate, silica and kaolinite when used as a matting agent. Inorganic particles are preferred, and when used for the purpose of imparting a soft touch, organic particles (resin beads) such as urethane resin, silicone resin, urea resin, fluororesin, polycarbonate resin, melamine resin, and nylon (polyamide resin) Is preferred.

[Method of Spraying Solid Particles] As a method of spraying the solid particles onto the resin layer, it is possible to spontaneously drop or sprinkle by hand, but it is not practical in mass production due to difficulty in workability. Therefore, in the present invention, as a method for dispersing the solid particles, a rotary blade type or air nozzle type blasting device used in the blasting field such as sand blasting, shot blasting and shot peening is used. The rotating blade type blast device blows off solid particles poured into a rotating impeller by centrifugal force of the impeller, and is a device called a centrifugal blast device. An air nozzle type blasting device is a device that blows solid particles from an air nozzle together with compressed air, and there are a pressurized blasting device and a suction blasting device depending on the type of mixing of solid particles and compressed air. In pressurized blasting equipment, solid particles are mixed with compressed air,
Spouts out of the air nozzle with the air. On the other hand, in the suction type blast device, solid particles are sucked into a negative pressure part generated by a high-speed flow of compressed air, and are ejected from an air nozzle together with air.

When only solid particles are adhered to the surface of the resin layer, it is possible to use a natural fall or a sprinkle by hand if the workability is not considered a problem. In order to penetrate and bury particles, it is necessary that solid particles collide vigorously with the resin layer and be able to enter the interior.
Solid particles having such good momentum (high collision velocity) cannot be obtained. Also, a spraying method using an electrostatic force such as an electrostatic coating method cannot similarly obtain solid particles having good momentum. In addition, when solid particles are fixed to the resin layer, the solid particles can be fixed more securely by embedding them inside the resin layer than by fixing them to the surface of the resin layer. Since more solid particles can be fixed by the thickness, it is more preferable in terms of abrasion resistance.

Here, the blast device of the rotary blade type and the air nozzle type will be described in further detail with reference to FIGS. 3 and 4 which conceptually explain the principle of scattering solid particles.

First, FIG. 3 is a conceptual view showing an impeller for applying a centrifugal force to solid particles in a rotary blade type blasting apparatus. FIG. 3 (A) is a perspective view of the entire impeller, and FIG. 3 (B). FIG. 2 is a side view for explaining the inside. The impeller 812 includes a plurality of blades 813 fixed on both sides thereof by two side plates 814, and a rotation center at a hollow portion 815 having no blades 813.
It has become. Further, a direction controller 816 is provided inside the hollow portion 815 (see FIG. 3B). Direction controller 81
Numeral 6 is a hollow cylinder having an opening 817 that is partially open in the circumferential direction and has the same rotation axis as the rotation axis of the impeller 812, and is rotatable independently of the impeller. ing. When using the impeller, the opening of the direction controller is fixed so as to face an appropriate direction, and the ejection direction of the solid particles is adjusted. Further, inside the directional controller, another impeller having a hollow inside and the same rotation axis as the rotation axis of the impeller 812 is provided.
[See FIG. 3 (B)]. The spreader 818 rotates with the outer impeller 812. A rotating shaft 819 is fixed to the center of rotation of the side plate 814. The rotating shaft 819 is rotatably supported by a bearing 820, and is driven and rotated by a rotating power source (not shown) such as an electric motor.
12 rotates. Further, the rotating shaft 819 does not penetrate between the two side plates 814 having the blades 813 therebetween, and forms a space without a shaft. Then, the solid particles P are supplied into the inside of the sprayer 818 from a hopper or the like through a transport pipe. Usually, the solid particles are supplied from above (directly above or obliquely above) the impeller. The solid particles supplied into the sprayer are scattered outward by the impeller of the sprayer. The scattered solid particles are emitted only in the direction allowed by the opening 817 of the direction controller 816, and the blades 813 of the outer impeller 812 are discharged.
And between the blades 813. And the feather 813
, And is accelerated by the rotational force of the impeller 812 and squirts from the impeller.

Next, FIG. 4 is a conceptual view showing a suction type blasting device of the air nozzle type blasting device and an air nozzle for mixing and blowing off solid particles with compressed air. The air nozzle 840 shown in the figure includes an induction chamber 841 for mixing the solid particles P and the compressed air F, an internal nozzle 842 for jetting the compressed air into the induction chamber, and a blowing nozzle for jetting the solid particles and the compressed air from the nozzle opening 843. 844. When compressed air F in a pressurized state from a compressor or the like is ejected from the internal nozzle 842 and is ejected from the nozzle opening 843 of the nozzle 844 via the induction chamber 841, the compressed air F is guided at high speed by the induction chamber 841 in the ejector. A negative pressure is created by the action of the flowing compressed air flow, the solid particles are guided into the compressed air flow by this negative pressure and mixed, and the solid particles are accelerated by the compressed air flow,
It is conveyed and ejected from the nozzle opening 843 of the nozzle 844 together with the compressed air flow.

In the rotary impeller blast apparatus, in addition to the impeller described above, a cover that covers the periphery of the impeller and has an open solid particle ejection port, an electric motor for rotating the impeller, a hopper for supplying solid particles, and the like are provided. Usually equipped. In addition, the air nozzle type blast apparatus usually includes, in addition to the above air nozzle, a compressor for producing compressed air, a pressurized tank, a hopper for supplying solid particles, and the like. Further, when the solid particles are sprayed on the resin layer, it is preferable to perform the spraying in a chamber separated from the surrounding space so that the solid particles are not scattered in the surrounding atmosphere.

[Picture layer] The resin layer 2 alone can express its surface gloss (with gloss, matte, etc.) and paint feeling, and the resin layer 2 itself has a decorative function and is a kind of decorative layer. Therefore, a decorative material comprising only the base material 1 and the resin layer 2 is also possible. However, the resin layer 2 is usually a layer formed on the entire surface, and therefore, in order to express a pattern-like pattern, a pattern layer can be separately provided as a decorative layer.

Such a pattern layer 3 may be formed by a conventionally known forming method and material such as gravure printing, silk screen printing, offset printing, electrophotographic copying, and hand drawing (for example, brush drawing). . The pattern represented by the pattern layer is arbitrary, and according to the use, for example, a grain pattern, a stone pattern,
The texture pattern, tile pattern, brick pattern, leather pattern, character, geometric pattern, solid color, etc. The solid pattern layer on the entire surface can be formed of a paint by a known coating method such as gravure coating or roll coating. The ink (or paint) for forming the picture layer is made up of a vehicle such as a binder, a colorant such as a pigment or a dye, and various additives appropriately added thereto, similarly to a general ink (or paint).
As the resin used for the binder, for example, an acrylic resin, a vinyl chloride-vinyl acetate copolymer, a polyester resin, a cellulose resin, a polyurethane resin, or the like, or a mixture containing these, is used. Examples of the coloring agent include inorganic pigments such as titanium white, zinc white, red iron oxide, vermilion, ultramarine, cobalt blue, titanium yellow, graphite, carbon black, isoindolinone, Hansa Yellow A, quinacridone, and permanent red 4R. Pearlescent (pearl) made of organic pigments (or dyes) such as phthalocyanine blue, indathrene blue RS, and aniline black, metal pigments such as aluminum and brass, titanium dioxide-coated mica, and foil powder such as basic lead carbonate Pigments and the like. These are added and dispersed as powder or flaky foil pieces.

The picture layer 3 may be a metal thin film layer or the like.
The metal thin film layer is formed of aluminum, chromium, gold, silver,
Using a metal such as copper, a film is formed by a method such as vacuum deposition or sputtering. Alternatively, a combination of these may be used. The metal thin film layer may be provided on the entire surface or partially in a pattern.

The transfer sheet 10 may be a transfer layer 12 including the picture layer 3 together with the resin layer 2.

FIG. 6 shows such a transfer sheet 1.
0 is an example. The transfer sheet 10 in FIG. 6 has a release layer 13, a resin layer 2 (with solid particles fixed), and a pattern layer as a transfer layer 12 on the release support sheet 11 in this order from the release support sheet 11 side. 3. A configuration in which the adhesive layer 14 is laminated.

[Release Layer] The release layer 13 is a part of the transfer layer 12. When the release support sheet 11 is released, the release layer 13 separates from the release support sheet to form a base material as an object to be transferred. It is a layer that remains on the side. For the release layer 13, a resin or the like used as a binder in the above-described ink for forming a picture layer or a coating liquid can be used. The release layer is formed of an ink (or coating liquid) using the resin,
It may be formed by a known printing method such as gravure printing or roll coating or a coating method.

[Adhesive Layer] The adhesive layer 14 is used when the resin layer 2 is transferred and formed on a substrate and the resin layer 2 alone does not adhere to the substrate. When using the adhesive layer 14,
The adhesive layer is formed as a part of the transfer layer 12 as shown in FIG. 6, or is formed in advance on the substrate side before the transfer [FIG.
(D)] or a combination of both. As the adhesive layer 14, the materials of the resin layer 2 and the base material 1,
A known suitable adhesive may be used according to the required physical properties and the like. For example, for the adhesive layer, a thermoplastic resin such as a vinyl acetate resin, a vinyl chloride-vinyl acetate copolymer, or a polyamide resin, a two-component curable urethane resin, or a curable resin such as an epoxy resin may be used. The adhesive layer 14 may be formed of an adhesive made of these resins by a known coating method such as roll coating or gravure printing or a printing method. In addition, when forming on the uneven | corrugated surface of a base material, what is necessary is just to form by coating methods, such as a spray coat.

[Overcoat Layer] The overcoat layer 4 is a transparent layer provided as the outermost surface layer on the front side (observer side) of the resin layer 2 in a laminate material which is not a transfer sheet or a decorative material having a backing substrate. It is a resin layer (top clear layer) (see FIG. 5). The overcoat layer is a layer provided for reinforcing solid particles adhering to the surface of the resin layer 2, adjusting the surface gloss, and the like. The overcoat layer is also a kind of decorative layer. Overcoat layer 4 is resin layer 2
By providing the solid particles on the solid particles, the solid particles which are fixed to the surface of the resin layer 2 by adhesion and are partially exposed can be completely buried by the overcoat layer. Therefore, it is possible to prevent the solid particles from falling off from the surface of the decorative material and reducing the wear resistance. For the purpose of gloss control, when the gloss is reduced by the solid particles attached to the resin layer surface, the gloss can be improved by filling the solid particles with the overcoat layer. Further, if a known matting agent such as silica is added to the overcoat layer, gloss can be eliminated. The matting agent can be added to the resin layer when the resin layer is exposed on the surface without forming the overcoat layer. In this case, the matting agent is applied to the resin layer (2
It is good to add at the time of A).

The overcoat layer may be formed by a known coating method such as gravure coating or roll coating, or a known printing method such as gravure printing, using an appropriate resin paint or ink. As the resin of the overcoat layer, ionizing radiation curable resins such as urethane acrylate and polyester acrylate, curable resins such as epoxy resin, urethane resin and silicone resin, and fluorine resins such as polyvinyl fluoride and polyvinylidene fluoride are wear-resistant. It is preferable in terms of surface physical properties such as properties.

[Primer Layer] If it is necessary to improve the interlayer adhesion, a primer layer may be formed between the layers. For example, in the laminate type decorative material D shown in FIG. 5, when the resin layer 2 is formed on the pattern layer 3, the pattern layer 3
This is an example in which a resin layer 2 is formed after a primer layer 5 is formed on the substrate. As the primer layer 5, a known appropriate primer may be used according to the material of both the front and back layers in contact with the layer. For example, a two-component curable urethane resin may be used. The primer layer may be formed by a known coating method such as roll coating or gravure printing or a printing method.

[Adhesion of First Cosmetic Material and Backing Substrate] In the method of manufacturing a cosmetic material of the present invention, as shown in FIG. The backing base material B may be adhered to the back surface of the first decorative material Da to produce the second decorative material D.

[Backing Substrate] As the backing substrate B, those listed for the substrate 1 described above can be used. That is, the backing base material B is not particularly limited in shape, material, and the like. For example, the shape may be any of a sheet, a plate, and a three-dimensional object. Also,
The material is wood-based, metal-based, inorganic non-metal-based (ceramic-based, non-ceramic ceramic-based, etc.), plastic-based, paper, and the like. Therefore, further description is omitted here.

[Affixing Method of First Cosmetic Material and Backing Substrate] In order to adhere the first decorative material and the backing substrate, the first decorative material or the backing substrate itself is subjected to, for example, heat fusion. As long as there is adhesiveness due to attachment or the like, it may be directly attached without intervening anything. Further, the adhesive layer may be used for bonding with an adhesive layer interposed therebetween. The adhesive layer may be applied to a decorative material, a backing substrate, or both, and then attached. In addition, you may use the decorative material of the structure which the adhesive layer was previously formed in the back surface as a decorative material.
As the adhesive layer to be attached, a known appropriate adhesive may be used according to the material of the back side of the decorative material, the material of the backing substrate, required physical properties, and the like. For example, for the adhesive layer, a thermoplastic resin such as a vinyl acetate resin, a vinyl chloride-vinyl acetate copolymer, or a polyamide resin, a two-component curable urethane resin, or a curable resin such as an epoxy resin may be used. The adhesive layer may be formed of an adhesive made of these resins by a known coating method such as roll coating or gravure printing or a printing method. In addition, when it is formed on the uneven surface of the backing substrate, it may be formed by a coating method such as spray coating.

As the sticking method, a known appropriate sticking method may be used depending on the form of the decorative material. For example, when the decorative material is in the form of a decorative sheet, pressure is applied by a pressing roller, and when the decorative material is a decorative sheet or a three-dimensional object, a pressing method of pressing with a flat press, the first decorative material is in the form of a decorative sheet, JP-B-50-19132, JP-B-43-27488
As described in Japanese Unexamined Patent Application Publication No. H10-75, after placing a decorative sheet between the male and female molds for injection molding, the resin in a fluid state by heat melting or the like is injection-filled into the mold, and a backing base as a resin molded product is formed. A so-called simultaneous injection molding laminating method in which a decorative sheet is bonded and laminated on the surface of the material at the same time as the material is formed.
No. 8, Japanese Patent Publication No. 60-58014, etc., a decorative sheet is placed on the surface of a three-dimensional backing substrate, facing or placed with an adhesive therebetween, from the backing substrate side. A so-called vacuum press laminating method in which a decorative sheet is laminated and adhered to the surface of a backing substrate by a pressure difference caused by vacuum suction of the first decorative material in the form of a decorative sheet.
No. 5, JP-B-3-2666, etc., in the major axis direction of a columnar backing substrate such as a cylinder and a polygonal pillar,
While supplying the decorative sheet through an adhesive, the decorative sheet is sequentially pressure-bonded to a plurality of side surfaces constituting the column-shaped backing base material by a plurality of rollers having different directions, laminated and adhered. A so-called lapping method can be adopted.

[0046]

EXAMPLES Hereinafter, the method for producing a decorative material of the present invention will be further described with reference to examples.

Example 1 A laminate type decorative sheet as shown in FIG. 5 was used as a decorative material D (provided that there was no overcoat layer 4 shown in FIG. 5), and the following was produced. A thin paper having a basis weight of 50 g / m ² was used as the sheet-shaped substrate 1. One side of the substrate 1 was a mixture of nitrocellulose and an acrylic resin as binder resin, titanium white as a colorant, and a valve. Using a pattern, carbon black, and an ink containing benzidine yellow as main components, a pattern layer 3 composed of the whole solid layer 3A and the wood pattern pattern layer 3B was formed by multicolor gravure printing. Further, a primer layer 5 of a two-component curable urethane resin composed of acrylic polyol and 1,6-hexamethylene diisocyanate was formed on the entire surface of the pattern layer 3 by gravure coating.

Next, on the entire surface of the primer layer 5, ionizing radiation comprising 60 parts by weight of a prepolymer of trifunctional polyester acrylate, 10 parts by weight of trimethylolpropane triacrylate, and 30 parts by weight of 1,6-hexanediol diacrylate. (Electron beam) A coating liquid composed of a curable resin is gravure coated (before solid particles are fixed) so as to have a coating amount of 5 g / m ² (solid content basis).
A) was formed. The uncured resin layer (2
The surface of A) was tacky at room temperature without heating.

The solid particles P have an average particle size of 6 μm.
The spherical α-alumina particles were uniformly spread on the surface of the resin layer (2A) by a rotary blade type blast device as shown in FIG. Next, an electron beam was irradiated at an intensity of 100 mJ / cm ² to cure the resin of the resin layer 2A, fix the solid particles P to the resin layer 2, and obtain a decorative material D as a decorative sheet. In addition, the surface of the resin layer 2 after curing had lost its tackiness.

The abrasion resistance of the obtained decorative material was 600 times (J
AS special plywood standard wear test A), and the appearance was also excellent.

Example 2 As the decorative material D, a transfer sheet 10 as shown in FIG. 6 was produced as follows. First, a biaxially stretched polyethylene terephthalate film having a thickness of 26 μm was prepared as a releasable support sheet 11 which is a sheet-shaped releasable base material. Then, on one surface of the release support sheet 11, as a transfer layer 12, first, a coating liquid made of an acrylic resin was gravure-coated on the entire surface to form a release layer 13 having a thickness of 1 μm. Next, an uncured resin layer (2A) having a thickness of 5 μm (before solid particles were fixed) was formed by gravure coating with a coating solution composed of a two-component curable urethane resin.
The surface of the uncured resin layer 2A was tacky at room temperature without heating.

The solid particles P have an average particle size of 6 μm.
Was sprayed uniformly on the surface of the resin layer (2A) with an air nozzle blast device.

Next, the binder resin is a mixture of an acrylic resin and nitrocellulose, the colorant is titanium white,
The pattern layer 3 composed of the wood pattern pattern layer 3B and the entire solid layer 3A was formed by multi-color gravure printing using an ink mainly composed of a red pattern, benzidine yellow, and carbon black. Finally, an acrylic resin-based adhesive layer 14 was formed on the entire surface of the picture layer 3 by gravure coating to obtain a transfer sheet 10 as a decorative material D.

The obtained transfer sheet was transferred to a resin plate made of polystyrene to obtain a decorative material as a transfer. The decorative material as the transcript had excellent abrasion resistance of 400 times (according to JAS special plywood standard abrasion test A), and also had excellent appearance and design.

[0055]

According to the method for producing a decorative material of the present invention,
Even if hard solid particles are used in the resin layer to improve the abrasion resistance, the resin layer is formed on the substrate in a state where the solid particles are not adhered or contained, and then the solid particles are adhered or contained. Therefore, abrasion by the solid particles of the coating roller and the printing plate can be essentially avoided. In addition, if the resin layer is transferred and formed, there is no need to spray the solid particles after forming the resin layer on the base material. Therefore, the ink necessary for directly forming the resin layer on the base material by printing or coating is not required. It is also possible to omit the solvent drying of the coating liquid and it is advantageous in working environment, and it can be formed even when the forming surface is not directly formed by printing etc. on the uneven surface, and it can be formed once with other layers such as the pattern layer It can also be formed by transfer. Also, a backing substrate is stuck on the back side of the first decorative material,
If this is used as the final second decorative material, even if it is difficult to directly form a resin layer or a pattern layer by printing or the like, the surface of the backing substrate can be decoratively decorated. Alternatively, the backing base material and the first decorative material to be adhered to the backing material may be separately prepared, and the necessary number of decorative materials may be obtained when necessary.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram conceptually illustrating a method for producing a cosmetic material of the present invention in one form thereof.

FIG. 2 is a conceptual diagram conceptually illustrating a case where transfer is used as an embodiment of the method for manufacturing a decorative material according to the present invention.

FIG. 3 is a conceptual diagram illustrating the principle of a rotary blade type blasting device for scattering solid particles.

FIG. 4 is a conceptual diagram illustrating the principle of an air nozzle type blasting device for scattering solid particles.

FIG. 5 is a sectional view showing an example of a laminate type decorative sheet as a decorative material obtained in the present invention.

FIG. 6 is a sectional view showing an example of a transfer sheet obtained or usable in the present invention.

FIG. 7 is a cross-sectional view showing an example of a decorative material obtained by laminating a first decorative material on a backing substrate as a decorative material obtained in the present invention.

[Explanation of symbols]

 Reference Signs List 1 base material 2 resin layer 2A (solid particles not yet fixed) resin layer 3 pattern layer 3A solid layer 3B pattern pattern layer 4 overcoat layer 5 primer layer 10 transfer sheet 11 releasable support sheet 12 transfer layer 13 Release layer 14 Adhesive layer 812 Impeller 813 Blade 814 Side plate 815 Hollow portion 816 Direction controller 817 Opening 818 Sprayer 819 Rotation shaft 820 Bearing 840 Air nozzle 841 Induction chamber 842 Internal nozzle 843 Nozzle opening 844 Nozzle B D Cosmetic material Da First cosmetic material to be adhered F Compressed air P Solid particles

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4F100 AA19 AJ06G AK01B AK25 AK25G AK41 AL01 AT00A AT00C BA02 BA03 BA07 BA10B BA10C CB00 DE01B DG10A EA061 EC182 EG002 EH612 EH762 EJ082 EJ522 GB08 GB81 HB00J

Claims (3)

[Claims] 1. A method for producing a decorative material, wherein a resin layer in which a plurality of solid particles are adhered to a layer surface and / or embedded in a layer is provided at least as a decoration layer on a base material. When the resin is in a non-flowing adhesive state or in a flowing state, the solid particles are sprayed toward the resin layer by a rotating blade type or air nozzle type blast device, and the solid particles adhere to the resin layer surface. Or a method of manufacturing a cosmetic material in which solid particles enter the resin layer and are buried therein, and then the resin layer is solidified to be in a non-adhesive and non-flowing state to fix the solid particles to the resin layer. 2. A resin layer in which a plurality of solid particles are adhered to a layer surface and / or embedded in a layer is formed as a transfer layer on a release support sheet, and then the transfer layer is transferred to a substrate. The method for manufacturing a decorative material according to claim 1, wherein the decorative material is formed as a decorative layer on the base material. 3. A decorative material obtained by the method for producing a decorative material according to claim 1 or 2 as a first decorative material, wherein a backing substrate is stuck on a back surface of the first decorative material. And a method of manufacturing a decorative material, which is used as a second decorative material.