JPH01275200A - Decorative material manufacturing method - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for manufacturing a foamed decorative material having a three-dimensional pattern, in particular, which has an extremely conspicuous and sharp uneven shape, and furthermore, by applying a valley staining process. A method for producing a foamed decorative material for interior decoration that has an uneven pattern with excellent design quality rich in clear shading tones because a large amount of colored ink is applied to the concave portions of the shape and a small amount is applied to the white portions. It is related to.

[Conventional technology]

BACKGROUND ART In recent years, as the desire for luxury interior materials for vehicles and buildings has increased, there has been an increasing demand for products with three-dimensional, highly designed patterns.

Conventionally, a method for producing a product having a three-dimensional uneven pattern is as follows: (11) A synthetic resin layer containing a foaming agent is heated and foamed, and immediately after that, a patterned roll having an uneven pattern is used to form an uneven pattern on the surface of the layer. (2) applying a pattern roll to a synthetic resin layer containing a foaming agent before heating and foaming the synthetic resin layer; A method is known in which a concave-convex three-dimensional pattern is formed using an ink, followed by a valley staining process using an ink containing a foaming inhibitor, and then heated and foamed to form a concavo-convex three-dimensional pattern.

[Problems to be solved by the present invention]

However, in the above method (+1), since the pattern pattern is formed after forming the foam layer, the layer is restored and the uneven pattern is deep.
It is not formed into a perfect shape, and the formed irregularities are small and have little change, and even when the valley staining processing method is applied to this, it lacks shading and three-dimensionality, but it gives a pattern with a certain depth and stable shape. It has the disadvantage that it is difficult to

In addition, although the above-mentioned drawbacks can be eliminated in the method (2), it is difficult for the inhibitor to be used to penetrate only below the applied surface, and it tends to diffuse around it as well. The unevenness at the edge of the handle becomes unclear, and therefore, it is not possible to form a three-dimensional sharp uneven pattern that is clear, has a large difference in unevenness, and is delicate at the edge of the handle. In addition, both methods (1) and (2) have the drawbacks that, as mentioned above, expensive rolls are used to form the uneven pattern, which increases the cost of the product, and the pattern is monotonous, making it impossible to form a variety of patterns. It is something.

The present invention was developed as a result of intensive research to solve the above-mentioned conventional problems.The present invention uses a foamed synthetic resin laminate on the base material, and uses a concave-convex pattern on the surface along with a valley staining process to create a sharp and clear pattern. The present invention provides a method for manufacturing a decorative material having an excellent design quality and having a concave-convex three-dimensional shape with a dark and light color tone.

[Means to solve the problem]

In the present invention, after laminating a foaming agent-containing synthetic resin layer on a base material,
A printed pattern is applied to the surface of the layer using a colored paint mixed with a foam suppressor or a crosslinking agent, and then a resin paint containing a foaming agent is applied to the areas where the printed pattern is not applied to thicken the colored convex pattern. The surface is formed to have a thickness of 50 to 400 μm, and then the surface is stained with a colored synthetic resin ink.
This is then heated and foamed to form a decorative material with thick and clear dark and light color tones.

[For production]

The manufacturing method of the present invention will be explained in detail below.

In the present invention, first, a colored or non-colored foaming agent-containing synthetic resin layer is formed on a base material. As the method, any of the calendar method, coach ink method, or extrusion method can be used, but the coating method is particularly preferred.

Using any of the above methods, the sheet thickness is 0.05 to 0.3 m under processing conditions below the decomposition temperature of the foaming agent contained.
I++ is preferably laminated so that the thickness is 0.1 to 0.2. This is because when a printed pattern is applied using a paint mixed with the above-mentioned foam suppressor or crosslinking agent and then heated and foamed to form an uneven shape, if the thickness is less than 0.05 mm, the core layer is too thin and the wall thickness is insufficient. However, if the thickness is 0.3 mm or more, it is possible to form the uneven shape satisfactorily, but it becomes too heavy, so it cannot be used as an interior material. Problems arise in workability, and especially when used as an interior material for wall coverings, it cannot meet the weight restrictions in the fireproofing standards applied to nuclear materials, and the product cost is also undesirable.

In addition, the above-mentioned base material used in the present invention may be paper, flame retardant paper, woven fabric, non-woven fabric, glass cloth, plastic sheet, etc., which are generally used for walls and vehicle interior materials, singly or in combination of these. In addition to the vinyl chloride homopolymer, polyvinyl chloride, polyvinyl acetate, polyethylene, and polyurethane are also used as synthetic resins for the colored or non-colored foaming agent-containing synthetic resin layer laminated on the base material. It is a copolymer of polyvinyl chloride, etc. or a homo-d reamer of vinyl chloride, and a mixture thereof, and a blowing agent, a plasticizer, a stabilizer, a lubricant, a chelator-9 filler, a coloring agent, etc. commonly used in the above resins are added to this. Use by mixing. As the above-mentioned blowing agent, a general-purpose thermally decomposable blowing agent such as azodicarboxylic acid amide, PP'-oxybisbenzenesulfonyl hydrazide, azobisisobutyronitrile, etc. is used in an amount of 1% per 100 parts by weight of the above resin.
~10 parts by weight, preferably 3 to 6 parts by weight, is used. If the amount added is less than 1 part by weight, the foaming suppression or crosslinking effect due to the printed pattern mixed with the foaming agent suppressor or crosslinking agent placed on the foaming agent-containing synthetic resin layer will not be sufficiently applied, and the desired effect will not be achieved. It is not possible to form a three-dimensional uneven shape, and even if 10 parts by weight or more is added, the above effects are not improved any further.

Next, a foaming inhibitor or crosslinking agent is mixed onto the colored or non-colored foaming agent-containing synthetic resin layer using a commonly used printing method such as gravure printing, rotary screen printing, or flexographic printing. A printed pattern is applied using colored paint. The resin used in the paint is polyvinyl chloride or a copolymer of polyvinyl chloride and polyvinyl acetate, or acrylic resin, polyurethane, cellulose acetate, etc. alone or in combination, and a solvent is used to melt the resin. Ketones such as ethylgent, cyclohexanone, and methyl isobutyl ketone, aromatic hydrocarbons such as toluene and xylene, and chlorinated hydrocarbons such as ethylene dichloride and methylene chloride are appropriately selected and mixed according to the type of resin used above. do. Moreover, the above-mentioned coloring is selected from a type having excellent weather resistance and heat resistance. The foaming inhibitors to be mixed into this paint include penzotriazozole, isoacids (e.g., areic acid, fumaric acid, adipic acid, etc.), halogenated organic acids (e.g., galefthaloyl chloride,
(eg, tetrachlorophthalic anhydride) or organic acid anhydrides (eg, maleic anhydride, trimellitic anhydride), etc., but it is particularly preferable to use benzotriazole or trimellitic anhydride. The crosslinking agent to be mixed into the paint is a dithiol-S-triazine derivative (for example, 2-dibutylamino).

S- such as 2-dimethylamino or 2-octylamino
)! Although 2-dibutylamino-5-1-lyazine derivatives can be used, it is particularly preferable to use 2-dibutylamino-5-1-lyazine derivatives.

The amount of the foam suppressor or crosslinking agent mixed into the paint is 2 to 30% by weight, preferably 5 to 20% by weight, based on the total weight of the paint. If the amount of the nucleating agent is less than 2% by weight, the foaming suppression or crosslinking effect of the nucleating agent during heating and foaming of the foaming agent-containing synthetic resin in the printed pattern-applied portion using the paint will be insufficient, which is extremely noticeable as the object of the present invention. It is not possible to obtain concave portions for forming an uneven shape, and even if 30% by weight or more is mixed, the foaming suppression or crosslinking effect is not improved any further.

Next, a colored convex pattern with a thickness of 50 to 400 μm is applied to the areas on the foaming agent-containing synthetic resin layer where the printed pattern is not applied, using a foaming agent-containing resin paint so as not to completely match and overlap.
Form it so that it becomes

A gravure printing method, a loader screen printing method, or a flat screen printing method is used to form the pattern, but when using the above screen printing method, the screen plate has a line count of 20 to 80 lines/inch. The lacquer plate, pierced plate, galvano plate, etc. are selected depending on the pattern pattern to be formed, and when using the gravure printing method, the roll used has a corrosion depth of 200 mm.
A knurled or mesh gravure roll with a thickness of ~600μ and a number of lines of 20 to 60 lines/inch is used. If the thickness of the convex pattern is less than 50 μm, the coloring effect of the light and shade of the colored ink by the valley staining process in the subsequent process will be insufficient, and the protrusions after the heat foaming process will be incomplete and the difference in unevenness will be small. If the thickness exceeds 400 μm, the above-mentioned valley staining effect and upheaval will be satisfied, but the weight will be too much than necessary, causing problems in terms of cost and workability, especially for walls. When used as an interior decoration material, it is not preferable because it cannot meet the flame-retardant standards. Synthetic resins used in the paint include, in addition to homopolymers of vinyl chloride, copolymers of polyvinyl chloride and polyvinyl acetate, polyethylene, polyurethane, etc., or homopolymers of vinyl chloride and mixtures thereof, in addition to a blowing agent. , plasticizers, stabilizers, fillers, 9 colorants or diluents if necessary.

Use with addition of flame retardant etc. As the above-mentioned blowing agent, general-purpose thermally decomposable blowing agents such as azodicarboxylic acid amide, PP'-okinebisbenzenesulfonylhydrazide, and azobisinbutyronitrile can be used. The amount added is 1 to 10 parts by weight per 100 parts by weight of the synthetic resin. If the amount added is less than 1 part by weight, the image area will not be sufficiently foamed and raised during the heat foaming in the post-process described above. ,
It is not possible to form the desired uneven pattern pattern, and even if 10 parts by weight or more is added, the above-mentioned protrusion is satisfactory, but no further improvement in the effect can be expected. As the plasticizer, a general-purpose plasticizer such as phthalate ester, adipate ester, or nistyl phosphate is appropriately selected and used.

Further, a hydrocarbon compound such as mineral spit or quinolol is used as the diluent. The paint is prepared by mixing the above-mentioned materials and adjusting the paint viscosity at room temperature from 1000 to 1 ooooc depending on the amount of the plasticizer and optionally the diluent added.
Ps is preferably adjusted to 2,000 to 8,000 cPS. If the viscosity is less than 1,000 csP, the viscosity is too low, and the shape of the above-mentioned convex pattern is distorted, making it impossible to obtain a clear three-dimensional convex shape.If the viscosity is more than 10,000 csP, the viscosity is too high, so the same purpose cannot be obtained. It is not possible to create a sharp, three-dimensional pattern. After forming the pattern, the paint is dried by heating using a hot air drying oven under heating conditions below the decomposition temperature of the foaming agent in the foaming agent-containing resin layer. Next, the surface on which the uneven pattern is formed is subjected to a valley staining process using a colored synthetic resin ink to further impart clear shading tones to the uneven pattern. As a processing method, a doctor processing method or a roll processing method is used, and in the former, the colored synthetic resin ink is smeared with a doctor knife, and in the latter, the ink is passed between an ink pumping roll and a bank up roll. As a result, a large amount of the colored synthetic resin ink is applied to the convex portions of the concavo-convex pattern and the slightly dented portions. The synthetic resin used for the colored synthetic resin ink includes polyvinyl chloride, a copolymer of polyvinyl chloride and polyvinyl acetate, acrylic resin,
Polyurethane, polyester resin alone or a copolymer or a mixture thereof is used, and methyl ethyl ketone is used.

A solvent-type paint is used, which is a general-purpose solvent such as cyclohexanone, methyl isobutyl chloride, ethyl acetate, toluene, etc., and a pigment or dye with excellent weather and heat resistance is mixed in as a coloring agent, but in some cases, a colored emulsion type paint using the above resins is used. You may also use paint. Next, the paint is dried by heating it at a temperature below the decomposition temperature of the blowing agent contained above, and then heated and foamed using a foaming furnace under heating conditions above the decomposition temperature of the blowing agent contained above. In addition, in the areas where printed patterns are printed on the above-mentioned foaming agent-containing synthetic resin layer using a colored paint mixed with a foaming inhibitor or crosslinking agent, most of the foaming occurs because the decomposition of the foaming agent is suppressed. In addition, since a convex pattern is further formed using a foaming agent-containing synthetic resin paint in the area where the printed pattern is not applied, this area is not affected by the foaming of the underlying foaming agent-containing synthetic resin layer. The foaming in the convex pattern portion increases and the synergistic effect results in a convex shape with extremely high protuberance, forming a sharp three-dimensional concavo-convex pattern. The thickness of the convex pattern after foaming is 0.2 to 2.5 mm, preferably 0.5 to 1.5 mm, and if the thickness is less than 0.2 mm, the raisedness will be poor and the volume will not be felt. It lacks sharp three-dimensionality, and although the above points can be satisfied at 2.5 or more, the foamed cell structure becomes rough and uneven due to excessive foaming, and the surface strength becomes weak, and in addition, sharp shapes cannot be formed. This also causes problems and is not desirable.

Thus, by the above-mentioned method, it is possible to obtain a highly designed product that is rich in clear shading tones and has an extremely sharp three-dimensional uneven pattern.

〔Example〕

FIG. 1 and FIG. 2 are explanatory views of one embodiment of the present invention, and the present invention will next be specifically explained with reference to these drawings. As shown in FIG. 1, the present invention involves forming a foaming agent-containing synthetic resin layer 2 on a base material 1, applying a printed pattern 3 containing a foaming inhibitor or a crosslinking agent to the surface, and then applying the printed pattern 3. A foaming agent-containing synthetic resin convex pattern 4 is formed on the part so as not to overlap therewith, and then a valley staining ink layer 5 is applied from the surface thereof.

Next, the formed product shown in FIG. 1 is heated using a foaming furnace to a temperature higher than the decomposition temperature of the foaming agent in the foaming agent-containing synthetic resin layer 2 and the foaming agent-containing synthetic resin convex pattern 4 applied to the surface thereof. When both are foamed, the above-mentioned foaming agent-containing synthetic resin layer 2 is formed.
The 2 portions of the printed pattern containing the foaming inhibitor or crosslinking agent applied to the upper surface hardly rise because the foaming effect is suppressed, forming sharp recesses. The foaming agent-containing synthetic resin convex pattern portion 4 placed on the non-applied area where the printed patterns are not superimposed and combined becomes a highly protruding convex shape due to the synergistic effect of the foaming of both of them, as shown in Figure 2. As shown, in addition to forming a sharp, three-dimensional uneven pattern, by applying the above-mentioned valley staining ink layer 5, a clear shading color tone is imparted, which further emphasizes three-dimensionality, resulting in an advanced design effect. can.

[Example 1] Flame retardant paper for wallpaper lining (80A manufactured by Sanyo Kokusaku Pulp Co., Ltd.)
F-10) After coating the following composition containing a blowing agent on the surface using a comma coater to a thickness of approximately 0.12 mm, use a hot air drying oven to determine the decomposition temperature of the blowing agent. This is gelled and dried by heating at the following temperature of about 150"C for about 2 minutes to form a foaming agent-containing synthetic resin layer colored white. Then, a gravure printing machine is applied to the surface of the foaming agent-containing synthetic resin layer.
・A printed pattern with a line pattern colored brown using ink mixed with the foaming inhibitor of the following formulation B is applied, and approximately 120
After hot air drying for about 30 seconds at a temperature of °C, the corrosion depth is about 4
Using a gravure printing machine with a handle roll of 00 μm and a line count of 30 lines/inch, the above-mentioned foam suppressant-containing printing was carried out using a paint with the following formulation whose viscosity at 25°C was adjusted to about 3500 cPS. The thickness is about 0 to prevent overlapping and compounding on other parts of the above foaming agent-containing synthetic resin layer that is not patterned.
．． A foaming agent-containing synthetic resin convex pattern of 2 mm in the form of a line pattern colored white is formed, and then this is heated for about 1 minute at a temperature of about 150° C. below the decomposition temperature of the blowing agent using a heating furnace. After gelling by heating, the ink was then passed between an ink pumping roll and a backup roll, and the ink was colored black using ink of the following formulation E. The applied convex portions were subjected to a valley staining process so that they became very thin and pale in color, and dried for about 1 minute using a hot air oven at a temperature of about 120'C below the decomposition temperature of the above-mentioned blowing agent.

Next, this is heated at a temperature of about 200″C for about 2 hours using a foaming furnace.
When the foaming agent-containing synthetic resin layer and the foaming agent-containing synthetic resin convex pattern pattern portion placed on the foaming agent-containing synthetic resin layer and the foaming agent-containing synthetic resin convex pattern pattern portion placed on the foaming agent-containing synthetic resin layer were foamed by heating for a minute, the foaming agent contained in the foaming agent was decomposed. The foaming was added and increased, and the synergistic effect formed a convex shape with extremely high protrusions, resulting in a product with a sharp three-dimensional uneven pattern. The product thus obtained was an excellent decorative material for building interiors, with clear shading, a remarkable three-dimensional effect, and a variety of high design qualities.

[Formulation A]

[Formulation B] [Formulation D] [Formulation E] [Example 2] A polyester fiber nonwoven fabric with a basis weight of 909/rl was used as a base material, and foaming crosslinking was performed by changing it to In-FB mixed with the foaming inhibitor of Example 1. A decorative material was obtained by using the same processing method and the same blended materials as in Example 1, except for using the ink of the following formulation C mixed with the agent. The obtained product was a product with a variety of high design qualities and had the same color tone effect and three-dimensional effect as in the example.

[Formulation C]

[Effects] As described above, the present invention laminates a colored or non-colored foam-containing resin layer on a base material, and then applies a printed pattern to the surface of the layer with a colored paint containing a foam suppressor or a crosslinking agent. A colored convex pattern is formed using a foaming agent-containing resin paint on the other unapplied areas where the above printed pattern is not applied, and then the surface is stained with valleys using colored ink, and then this is By heating and foaming, the foaming of the foam-containing resin layer and the foaming agent-containing synthetic resin convex portion placed on the layer is increased, and the synergistic effect forms a convex portion that is noticeably raised. At the same time, the foaming of the printed pattern-imparted areas impregnated with the above-mentioned foaming suppressor or crosslinking agent is suppressed, so that an extremely sharp three-dimensional uneven pattern is formed. By applying it very lightly to the convex portions, it is possible to obtain a decorative material for interiors that has an excellent high design quality and also has clear shading tones.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view of an embodiment of the present invention before foaming, and FIG. 2 is a cross-sectional view after foaming. 1: Base material, 2: Foaming agent-containing synthetic resin layer, 3: Foaming inhibitor or crosslinking agent mixed printed pattern, 4: Foaming agent-containing synthetic resin convex pattern, 5: Valley staining ink layer. Patent applicant Kyowa Leather Co., Ltd.

Claims (1)

[Claims] After laminating a foaming agent-containing synthetic resin layer on a base material, a printed pattern is applied to the surface of the layer using a colored paint containing a foaming inhibitor or a crosslinking agent, and then the above printed pattern is not applied to the upper surface. A colored convex pattern with a thickness of 50 to 400 μm is formed on the part using a foaming agent-containing resin paint, and then the surface is subjected to a valley staining process using a colored synthetic resin ink. A method for producing a decorative material, which is characterized by forming an uneven shape with sharp and clear shading tones by heating and foaming the material.