JPH0364582A - Production of synthetic resin sheet - Google Patents

Abstract

PURPOSE:To obtain a synthetic resin sheet having varied decorative pattern free from distortion and shear in printing by adjusting the thickness of a plane layer formed on a releasing sheet having uneven surface to replicate the unevenness to the plane layer and laminating a patterned layer on the plane layer. CONSTITUTION:A plane layer 2 made of e.g. a polyvinyl chloride resin is formed on a releasing sheet 1 having uneven surface in such a manner as to replicate the surface unevenness of the sheet to the surface of the layer by adjusting the thickness of the layer. Patterned layers 3, 3' are laminated to the obtained laminate to form a transfer sheet 4. The releasing sheet is peeled off and the laminate is pasted with an adhesive to a substrate layer 5 produced by mixing a resin to a knit fabric. The product ia hot-pressed to extremely easily obtain the objective synthetic resin sheet having varied excellent decorative pattern.

Description

[Detailed Description of the Invention] [Industrial Application Branch] The present invention is a synthetic resin sheet suitable for furniture covering materials such as bags, bags, and chairs, vehicle seats, shoe covers, etc. This invention relates to a method for producing synthetic resin sheets that can express uneven designs, matte effects, etc. on parts, and can also add unique decorative effects that have never been seen before.

[Prior Art] Conventionally, it has been known that it is difficult to apply raised patterns by printing such as screen printing. It had been. This means that in order to form a raised pattern on a sheet by printing, you must print while the sheet is stretched.
The raised pattern formed on the sheet will be distorted, making it impossible to form a beautiful raised pattern.Also, when forming multicolored or overlapping patterns, the sheet tension must always be the same or the pattern may shift. It was not possible to form a raised pattern that matched the texture and color tone, or a raised pattern that harmonized with the unevenness.

To solve this problem, it has been proposed to use a transcription method. The use of such a transfer method involves printing on a flat sheet with little elasticity and releasability, forming a solid layer and a raised pattern on top of the solid layer, and then peeling this off.
The elastic base fabric and the synthetic resin layer are laminated on the synthetic resin layer of a laminated sheet.

[Problem to be solved by the invention]

However, applying a raised pattern by direct printing on the synthetic resin layer of a laminated sheet in which the synthetic resin layer is laminated on a stretchable base fabric has the disadvantages mentioned above, and the transfer method also has the disadvantages of printing a raised pattern on the synthetic resin layer, which is a decorative element. If the layer is to be further decorated with matte or irregularities, it has the disadvantage that a gloss modifier or the like must be added to the constituent materials or it must be processed with an embossing roll.

In practice, processing with an embossing roll not only complicates the manufacturing process, but also involves the risk of the solid layer peeling off from the release sheet during embossing, and the risk of damaging the release sheet. It has not been implemented. Moreover, the unevenness processing using an embossing roll cannot fully express even the minute unevenness.

[Means to solve the problem]

The method of the present invention provides a method for manufacturing a synthetic resin sheet in which a solid layer can be decorated with matting or irregularities without adding such gloss modifiers or adding means such as embossing.

That is, the gist of the method of the present invention is to form a transfer sheet by sequentially laminating a solid layer and a pattern layer so that a part of the solid layer is exposed on a releasable sheet. In a method for manufacturing a synthetic resin sheet, the release sheet is peeled off from the transfer sheet to expose the back side of the solid layer to the outside, and then a base material layer is laminated on the back side of the solid layer exposed to the outside. A moldable sheet with an uneven surface is used, and the surface of the solid layer formed on the moldable sheet has irregularities formed under the influence of the unevenness of the underlying moldable sheet. A method for producing a synthetic resin sheet, characterized by adjusting the thickness of the solid layer so that the thickness of the solid layer increases.

It is in.

The releasable sheet used in the present invention must first have irregularities at least on its surface. Such release sheets are typically used in the field of synthetic leather production, such as release paper with textured texture similar to natural leather on the surface, but other types include polyester films,
A releasable film such as a sheet, and a sheet with irregularities formed thereon can also be used.

The solid layer and pattern layer formed on such a release sheet can be made of any material used in this type of synthetic resin sheet, specifically polyvinyl chloride resin, urethane resin, acrylic resin, etc. It is mainly made of synthetic resin such as resin.

The solid layer and pattern layer are formed on the release sheet by coating the above-mentioned resin material in the form of a sol or solution.
The layers are sequentially formed by printing or the like.

For example, for this coating and printing, known methods such as a doctor knife coater, squeeze roll coater/reverse roll coater, gravure printing, screen printing, etc. can be employed.

The pattern layer is preferably formed by printing multiple times using gravure printing, screen printing, or the like to form a pattern that is rich in unevenness and synchronized.

In this case, the pattern layer should not cover the entire surface of the solid layer, but a portion of the solid layer should be exposed and visible so that the solid layer also becomes part of the decorative element.

In addition, sol formation for forming solid layers and pattern layers,
Coloring agents, foaming agents, foaming inhibitors, foaming accelerators, crosslinking agents, fillers, stabilizers, matting agents, polishing agents, anti-mold agents, etc. are added to the resin material in the form of a solution, etc., as necessary. Can be added.

In forming the solid layer, it is necessary to adjust its thickness so that the surface of the core layer is uneven, under the influence of the unevenness of the release sheet located below.

If the thickness of the solid layer is large, the effect of the unevenness of the release sheet is suppressed, and as a result, the effect of the unevenness does not appear on the surface of the solid layer, resulting in a flat surface and no decorative effect can be expected.

The thickness of this solid layer is mainly adjusted by taking into account the irregularities of the release sheet, but if it is a release paper used in the field of ordinary synthetic leather production, the thickness of the solid layer is 300 μm or less, preferably 150 μm or less. Adjusted within range. Depending on the degree of unevenness of the release sheet, the grain pattern, etc., the unevenness on the surface of the layer can have various decorative effects.

In this way, a transfer sheet is formed in which a solid layer and a pattern layer are sequentially laminated on a releasable sheet.

Next, the release sheet is peeled off from this transfer sheet to expose the back surface of the solid layer to the outside.

On the other hand, in the present invention, a base layer is prepared, and this base layer is laminated on the back surface of the solid layer of the laminate consisting of the solid layer and the pattern layer.

Preferred materials that can be used as this base layer include stretchable knitted fabric, spandex, etc.
The material is not limited thereto, and general fabrics such as woven fabrics, nonwoven fabrics, and knitted fabrics made of natural fibers such as cotton, cotton, polyester fibers, polyamide fibers, vinylon fibers, and synthetic fibers can be used.

Furthermore, a composite material in which a synthetic resin layer such as non-foamed or foamed vinyl chloride resin is laminated on these materials can also be used as the base layer.

The method of laminating this base material layer onto a laminate consisting of a solid layer and a pattern layer is the simplest and most reliable method using an adhesive.

As for adhesives, urethane adhesives such as typical two-component adhesives can be used, such as acrylic, vinyl acetate, PVA, and SBR.
, NBR, CR, NR, and other synthetic resin-based and synthetic rubber-based solvent-based and emulsion-based adhesives can be used.

Note that if heating is required to bring out the adhesive strength of the adhesive during this bonding, consideration must be given to materials that are not heat resistant or materials that expand and contract when heated.

Specifically, for example, in the case of a base material layer that is a composite material in which a foam layer of vinyl chloride resin is laminated on a knitted cloth, 150
℃ or less, and in the case of suppressing as much as possible the decrease in thickness due to the collapse of foam cells due to secondary foaming, a desirable temperature condition is 130°C or less.

In order to ensure adhesive strength at temperatures below 130°C, it is preferable to use a two-component reactive urethane adhesive, and in this case, the drying temperature of this adhesive is below 80°C, preferably at 50°C. It is best to do it below, and if you need more, 50~
It is preferable to age the adhesive at 60°C for 24 hours or more to accelerate the reaction of the adhesive.

(Example) Examples will be described below based on the drawings.

A polyvinyl chloride resin paste made of the ink formulation A shown below was printed on a releasable sheet (1) with a fine grain texture with a difference of 10 μm to 15 μm using a rotary screen, and gelatinized in a heating oven. , thickness 100μm
A solid N (2) was formed.

On the surface of the solid layer (2), there is a release sheet (1)
The unevenness (20) influenced by the unevenness (10) was formed.

Ink formulation A Unit: parts by weight Polyvinyl chloride resin 100 DOP 75Ba-Zn composite stabilizer 3 Pigment Appropriate amount Then, apply the polyvinyl chloride resin paste of the ink formulation in which only the pigment in ink formulation A was replaced with another hue to the rotary screen in the same way. to remove the previously printed solid layer (
The pattern layer (3) is printed in a raised pattern so that about 50% of 2) is exposed, gelled in a heated oven, and after curing, the pattern layer (3) is formed.
Then, on a rotary screen, a polyvinyl chloride resin paste with an ink formulation in which only the pigment in ink formulation A was changed to another hue was applied.
Build-up printing was performed in synchronization with the previous embossed printing pattern to shape the part that would become the pattern layer (3') after curing, and then introduced into a heating oven to harden all of the polyvinyl chloride resin paste ink.

In this way, the releasable sheet (1), the solid layer (2),
A transfer sheet (4) consisting of the pattern N (3), (3') is prepared, and then, while peeling off the release sheet (1), the solid layer (2), pattern layer (3), (3') are transferred. A laminated sheet consisting of was wound up. Next, stretch knitted fabric (
50), polyvinyl chloride #M resin 100 weight DOP 80 parts by weight, abdicarbonamide 3゜5
A foamable polyvinyl chloride resin compound consisting of parts by weight and an appropriate amount of pigment is kneaded, put into an inverted calendar, a resin sheet with a thickness of 0.2 mm is dispensed, and the resin sheet is dumped onto the knitted cloth. Then, the resin (51) was introduced into a foaming furnace heated to 200° C. to foam the resin (51), and the resin (51) was wound up to form a sheet that would become the base layer (5).

Next, toluene/methyl ethyl ketone = 50150 with a resin solid content of 25% containing a crosslinking agent is added to this base layer (5).
A urethane adhesive (6) consisting of a mixed solution of 20 g/m2 was applied using a gravure roll printer, and the coated surface was dried at 50°C for 1 minute to remove the previous solid layer (2).
, pattern layers (3) and (3') were laminated to the back surface of the solid layer (2) of the laminated sheet 1-, and then passed between a heated drum at 120° C. and a pressure-bonding rubber roll to produce a synthetic resin sheet.

The resulting synthetic resin sheet has no distortion or misalignment of the pattern,
What's more, the solid layer, which is the background, has fine irregularities, making it a highly decorative sheet that creates a dignified and calm atmosphere.

[Effects of the Invention] As described above, according to the method of the present invention, a release sheet with unevenness is used, and the thickness of the solid layer formed thereon is adjusted to actively improve the unevenness of the release sheet. Since the surface of the solid layer is made to appear uneven, there is no need for additional materials or methods such as adding a matting agent or processing with an embossing roll. This means that only the thickness of the solid layer can be adjusted when producing the transfer sheet, which is beyond the scope of existing equipment for synthetic resin sheets using the transfer method, and it is possible to impart a wide variety of decorative properties to the solid layer very easily. There are advantages.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view showing an example of a transfer sheet in the synthetic resin sheet manufacturing method of the present invention, and FIG. 2 is a cross-sectional view showing an example of a synthetic resin sheet manufactured by the synthetic resin sheet manufacturing method of the present invention. It is a diagram. (1) ... Release sheet (2) ... Solid layer 1 (3), (3') ... Pattern layer (4) ... Transfer sheet!・(5)...Base material layer 2

Claims (1)

[Claims] (1) Form a transfer sheet by sequentially laminating a solid layer and a pattern layer so that a part of the solid layer is exposed on a release sheet, and then peel the release sheet from this transfer sheet. In the method for manufacturing a synthetic resin sheet, the back surface of the solid layer is exposed to the outside, and then a base material layer is laminated on the back surface of the exposed solid layer. The thickness of the solid layer is adjusted so that unevenness is formed on the surface of the solid layer formed on the release sheet under the influence of the unevenness of the release sheet located below. A method for producing a synthetic resin sheet, characterized by: