JPH04246537A - Decorative sheet excellent in peel up properties and its manufacture - Google Patents

Abstract

PURPOSE:To provide the decorative sheet excellent in peel up properties and the manufacture thereof, while even in the case of high foamable object and even in the case of the object to which sharp emboss-working is applied, the defects such as surface-roughness, etc., do not occur. CONSTITUTION:A decorative sheet has the through-hole which exists on the decorative foam layer provided on a base but does not open on the outer surface of the base. Since the adhesive for adhering to the wall surface, etc., of the sheet does not penetrate the through hole and does not permeate the decorative foam-layer, its peel up properties become excellent. The gas due to secondary foaming, etc., diffuses out side through the through-hole, and air-puncture does not occur. At least a decorative foam layer 20 is formed on the base, and the needle emboss working by the needle roll NR provided with a needle N is applied on the decorative layer form its side, and the hole which passes at least the layer and does not reach the base 1 is whereby heating is achieved.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention relates to a decorative sheet with excellent peel-up properties and a method for manufacturing the same. The present invention relates to a decorative sheet that is free from defects and has excellent peel-up properties, and a method for manufacturing the sheet.

0002

[Prior Art] Conventionally, as a decorative sheet used for ceilings, walls, etc., designs such as gravure printing, rotary screen printing, embossing, etc. can be easily applied, and it has excellent durability and is stain-removable. Sheets made of synthetic resins such as vinyl chloride resin are the mainstream because they can be easily processed.

[0003] This synthetic resin decorative sheet has a base coat layer of a synthetic resin such as a vinyl chloride resin on a base material such as a backing paper or a synthetic resin sheet, and a foamable or non-foamable resin is applied on the base coat layer. Generally, a pattern layer (decoration layer) such as the above-mentioned gravure print, rotary screen print, embossing, etc. is formed using a synthetic resin paste such as vinyl chloride resin. , some have a surface treatment layer formed for the purpose of improving water resistance, antifouling properties, etc.

Although the synthetic resin sheets constructed in this way have excellent durability and dirt removal properties as described above, they are used in restaurants that require frequent remodeling, or interior decorations due to changes in ownership, etc. In an office or the like where the interior of the office is being updated, the above-mentioned sheets are replaced quite frequently.

However, the foamed decorative layer formed from the synthetic resin ink described above has low mechanical strength, so when the old sheet is peeled up during the re-covering work, the decorative layer may be torn or torn. Residue remains on the ceiling and walls. This phenomenon can be seen in almost the same way even in products where a surface treatment layer is provided for the purpose of improving surface strength or the like.

[0006] Conventionally, sheets that can be peeled off without leaving any residue have been produced by (1) interposing a layer made of polyolefin resin, which has weak adhesive strength with the glass fiber nonwoven fabric, between glass fiber nonwoven fabrics, etc. as a base material; (Utility Model Publication No. 59-24502), ■ A non-foaming synthetic resin layer is provided between the decorative layer and the backing paper so that it will peel off from the non-foaming synthetic resin layer during peel-up. (Jikkoi No. 1-26433), ■Using two-layer paper that is easy to peel off between layers as the backing paper, ■On the backing paper,
A decorative layer is provided so that a part of the lining paper is exposed, and a through hole is formed in the decorative layer to supply moisture to the lining paper, so that moisture can be supplied to the lining paper during peel-up. (2) Considering the customary peel-up direction during repapering work, a backing paper that is easy to peel up in the paper-making direction and a decorative layer formed in the opposite direction to the paper-making direction has been developed.

[0007] On the other hand, recently, there has been an increasing demand for lighter materials, and in addition to reducing the weight, there has also been a growing demand for designs that have a rich sense of volume or naturalness in the above-mentioned synthetic resin decorative sheets. ing. Light weight and voluminous feel can be achieved by, for example, increasing the foaming ratio of the above-mentioned base coat layer and decorative layer, and natural feel can be achieved by, for example, applying sharp embossing with sharp edges. ing.

[0008]

However, when increasing the foaming ratio of the base coat layer or the decorative layer, there is a problem that so-called air puncture occurs and the surface condition of the decorative layer becomes rough. In addition, when applying embossing with sharp edges, it is necessary to heat the decorative layer prior to embossing to soften the synthetic resin that makes up the layer. Secondary foaming is induced to cause air punctures, and the surface condition of the decorative layer is roughened in the same way as in the case of increasing the foaming ratio described above.

[0009] As a means to eliminate such drawbacks, there is a technique to make the base coat layer or the decorative layer open-celled, or a technique to make the surface treatment layer provided on the open-celled base coat layer or decorative layer also open-celled. have been considered and proposed.

[0010] Furthermore, a method of preventing the above-mentioned air punctures has been considered using needle embossing, which has been used for a long time to make sheets and films breathable. Kosho 60-25262,
No. 60-39544).

However, in the case of this needle embossing technique, the fine needle holes are formed penetrating from the decorative layer to the outer surface of the base material such as backing paper. When pasting such a decorative sheet to a wall, ceiling, etc., the adhesive applied to the back side of the sheet, that is, the outside surface of the base material, is applied to the outside surface of the base material by capillary action through the needle holes that open on the outside surface of the base material. As a result, a large amount of water permeates into the interior of the sheet. The adhesive that has penetrated into the interior of the sheet and solidified contributes to improving the adhesion strength of the sheet due to the anchoring effect, but on the other hand, it extremely inhibits the peel-up properties of the sheet. This peel-up property is due to the above-mentioned ■
The problem cannot be solved by the conventional improvement techniques of ~■.

[0012] The present invention takes the above points into consideration and is lightweight.
Even if it is highly foamed with a rich sense of volume, or has a sharp embossed finish with natural-looking edges, it can be peeled off without defects such as surface roughness. An object of the present invention is to provide a decorative sheet with a high degree of elasticity and a method for manufacturing the same.

[0013]

[Means for Solving the Problems] The sheet of the present invention is a decorative sheet having a decorative layer made of foam on a base material, in which the decorative layer is present at least in the decorative layer portion but is not open on the outer surface of the base material. The ornamental layer is characterized by having a through-hole that does not have a through-hole, and embossing the decorative layer portion having the through-hole.

Furthermore, in the manufacturing method of the present invention, at least a foamable synthetic resin layer is coated on a base material, and after this is foamed, needle embossing is performed from the foamed synthetic resin layer side to at least the foamed synthetic resin layer. It is characterized in that holes are formed that penetrate the synthetic resin layer but do not reach the outer surface of the base material, and then heated and embossed.

Paper, nonwoven fabric, synthetic resin sheet, etc. can be used as the base material in the present invention. Specifically, these papers and nonwoven fabrics include so-called lined paper made of natural pulp paper, synthetic paper, etc., and nonwoven fabrics using one or more types of synthetic fibers, natural pulp, inorganic fibers such as glass fibers, etc. These materials may be made of one layer, or may be obtained by a two-layer papermaking method using these materials alone or in combination. Moreover, the material may be provided with flame retardancy.

In the sheet of the present invention, a decorative layer made of foam is provided on the base material. This foam is made of vinyl chloride resins, vinyl chloride resins such as copolymers of vinyl chloride and vinyl acetate, ethylene, propylene, maleic esters, acrylic esters, methacrylic esters, high vinyl ethers, etc., vinyl acetate resins, etc. , single or mixed resins such as acrylic resins, and mixed resins of these and other polymers, foaming agents, plasticizers, colorants, stabilizers, fillers, flame retardants, etc. as necessary. A foamable paste prepared by blending the above is applied onto the above-mentioned substrate, and then heated and foamed. This foam has a wide range of expansion ratios from 2 to 8 times, from extremely low expansion to high expansion.

[0017] In order to better provide this decorative layer, a base coat layer made of the same synthetic resin as the decorative layer may be provided on the base material in advance.

In the sheet of the present invention, at least the decorative layer provided as described above has through-holes that do not open on the outer surface of the base material, and the decorative layer in which the through-holes are present is embossed. This is what was done. This embossing is preferably performed after heating and softening the decorative layer portion in which the through holes are present, so that the embossed surface has sharp edges and a sharp feel.

Further, in the sheet of the present invention, a surface treatment layer may be formed on the above-mentioned decorative layer for the purpose of improving surface strength, water resistance, antifouling property, etc. This surface treatment layer is
Vinyl chloride-vinyl acetate copolymer, ethylene-vinyl acetate copolymer, vinyl acetate resin, acrylic resin, polyester resin, urethane resin, etc. are commonly used as resins constituting the surface treatment layer of this type of decorative sheet. Constructed from synthetic resin. This surface treatment layer may contain a foaming agent, a matting agent, an antifouling agent, a reinforcing agent, and the like.

The sheet of the present invention described above can be manufactured, for example, by the following manufacturing method of the present invention.

That is, in the manufacturing method of the present invention, the above-mentioned foamable synthetic resin paste for the foam decorative layer is used on the above-mentioned base material, and the rotary screen method, gravure method, offset method, flexo method is used. , Doctor knife method,
Coating is performed by a reverse roll method or other appropriate method, and preheating is performed to gel the resin paste to form a foamable synthetic resin layer. After heating and foaming this foamable synthetic resin layer, needle embossing is performed from the surface side of the foamed synthetic resin layer (foam decoration layer).

In addition, when forming the above-mentioned foam decorative layer after forming the base coat layer on the base material, the foamable or non-foamable synthetic resin paste for the base coat layer is
The paste may be coated using the same coating method as the above-mentioned paste for foam decoration layer, and the paste may be gelled by preheating, and then the above paste for foam decoration layer may be applied.

[0023] When a surface treatment layer is formed on the above-mentioned foam decoration layer, the surface treatment layer is added on the gelled foamable synthetic resin layer for the foam decoration layer formed on the base material. After applying a paste, solution, or emulsion of the above-mentioned synthetic resin for the treatment layer and heating and drying it (in the case of a paste, heating and gelling it), or laminating a film made of the synthetic resin. Afterwards, the above-mentioned gelled foamable synthetic resin layer is foamed by heat treatment, and then needle embossing is performed from the above-mentioned surface-treated layer side.

This needle embossing can be carried out using an ordinary needle embossing device consisting of a needle roll and a backup roll. In the method of the present invention, for example, the clearance between the needle roll and the backup roll can be adjusted, By adjusting the length of the needles of the needle roll, through holes are formed that do not reach the outer surface of the base material (that is, do not open on the outer surface side).

After needle embossing is performed as described above, the foam decorative layer and the surface treatment layer are softened by heating again, and then embossing is performed using a suitable embossing device. As a result, a sharp embossed surface with sharp edges can be obtained.

[0026] In the manufacturing method of the present invention, the shape and size (diameter) of the above-mentioned through holes are not particularly limited, but in order to obtain sharp embossing with sharp edges, the foam decorative layer may be softened. In the reheating process when
It is sufficient that the foam decorative layer is sufficient to guide the gas generated by inducing excessive foaming or secondary foaming into the through-holes and diffuse it out of the sheet of the present invention. However, the size (
Regarding the diameter (diameter), if it is too large, the decorative properties of the foam decorative layer will be inhibited, so it is generally preferable to set the diameter to about 20 to 500 μmφ. Further, although it is preferable that the through-holes be formed in a uniform distribution over the entire surface of the decorative layer, there is no problem even if the through-holes are distributed in a non-uniform manner.

[0027]

[Operation] In the present invention, at least the through-holes present in the foam decorative layer portion do not open toward the outer surface of the base material. Therefore, the adhesive used when attaching the sheet of the present invention to a wall surface etc. does not enter into the through hole.
Therefore, it does not penetrate into the interior of the foam decorative layer. The penetration of the sticking adhesive into the foam decorative layer becomes more pronounced as the foaming ratio of the decorative layer increases, but in the present invention, the through holes that guide the adhesive to the inside of the base material are Since there are no openings on the outer surface side (that is, on the surface coated with the adhesive), it is possible to effectively prevent the adhesive from penetrating into the interior even if the foaming ratio of the decorative layer is considerably high. As a result, the present invention provides good peel-up properties even if the decorative layer has a fairly high expansion ratio.

[0028] The through-holes present in at least the foam decorative layer portion are heated during the formation of the foam decorative layer or in the reheating process prior to embossing.
Gas generated when excessive foaming or secondary foaming of the foam decorative layer, base coat layer, etc. is induced is guided to the surface side of the foam decorative layer (opposite side to the base material) and diffused out of the sheet. Therefore, air punctures are prevented and the surface condition of the sheet of the present invention is improved. This excessive foaming and secondary foaming become more pronounced as the foaming ratio of the decorative layer, etc. increases. Therefore, in the present invention, even if the decorative layer has a high foaming ratio, it is possible to maintain a good surface condition without defects such as rupture marks. Realize.

[0029]

EXAMPLE A sheet of the present invention was manufactured by carrying out the manufacturing method of the present invention according to the steps shown in FIG.

First, a foamable synthetic resin paste (foamed synthetic resin paste of the composition shown in Table 1) was applied to a base material of 80 g/m2 (backing paper used for ordinary wallpaper, thickness 0.12 mm) 1 using a doctor knife D. Body decoration layer paste) 2 applied in an amount of 250g/
After coating in m2, the paste 2 was heated in a heating furnace H1 at 150° C. for 2 minutes to gelatinize the paste 2. The thickness of the gelled foamable synthetic resin layer was 0.18 mm. Next, a synthetic resin solution (synthetic resin solution for surface treatment layer) 3 having the composition shown in Table 2 was coated with a gravure roll G at a coating amount of 15 g/m2, and then heated to 140°C in a heating furnace H2 to form the synthetic resin. Solution 3 was dried. Next, this was heated in a heating furnace H3 for 20
The gelled foamable synthetic resin layer was foamed by heating to 0° C. for 70 seconds to obtain a foam decorative layer. The thickness of this foam decorative layer was 0.9 mm. Thereafter, a needle embossing device consisting of a needle roll NR and a backup roll BR1 is used to move the needle roll NR and the backup roll BR1 from the side on which the dried synthetic resin layer for the surface treatment layer is laminated to the base material 1 side. The clearance was adjusted to 0.9 mm, and a through hole with a diameter of 400 μm was bored.

Details of this needle embossing are shown in FIG. As shown in the figure, 1 is a base material, and a foam decorative layer 2 is placed on this base material.
0 and a dry synthetic resin layer 30 for the surface treatment layer, and the needle N provided in the needle roll NR passes from the layer 30 side through the foam decoration layer 20 to form the layer 20. Although it reaches slightly above the interface between the base material 1 and the base material 1, it does not penetrate through the base material 1. Therefore, the needle hole does not open on the outer surface side of the base material 1.

After needle embossing as described above, FIG.
As shown in Figure 2, the surface treatment layer is heated to 140°C in a heating furnace H4, and embossing is performed from the surface treatment layer side using an embossing device consisting of an embossing roll ER and a backup roll BR2, which have a predetermined uneven pattern on the surface. The sheets of the present invention were produced by embossing the layers and the foam decorative layer with sharp edges. The expansion ratio of the foam decorative layer of this sheet was 5 times, and no rupture marks were observed on the surface, indicating that the surface condition was extremely good.

[0033]

[Table 1]

[0034]

[Table 2] The above-described sheet of the present invention was adhered to a gypsum board using an ordinary wallpaper adhesive. When the sheet of the present invention was peeled up one week later, it was possible to peel up easily and beautifully, leaving the base material 1 on the gypsum board surface.

Comparative Example Using the needle embossing device in which the clearance between the needle roll NR and the backup roll BR of Example 1 was adjusted to 0, needle embossing was performed so that all the through holes were opened on the outer surface side of the base material 1. A comparative sheet was manufactured in the same manner as in Example 1, except that the following steps were performed. When this sheet was attached to a plasterboard in the same manner as in Example 1 and peeled off after one week, a considerable amount of force was required to peel it off. In addition, remnants of the foam decorative layer and surface treatment layer remained.

[0036]

[Effects of the Invention] As detailed above, according to the present invention,
Since the adhesive for adhesion to a wall surface or the like does not penetrate into the interior of the foam decorative layer of the sheet of the present invention, the peel-up properties of the sheet of the present invention can be improved. Therefore, the peel-up surface of the sheet of the present invention becomes extremely beautiful, and a new sheet can be applied immediately after peel-up.

According to the present invention, not only the heating process when forming a foam decorative layer, base coat layer, or surface treatment layer, but also the reheating process when performing sharp embossing with sharp edges. Even if these layers induce excessive foaming or secondary foaming, it is possible to prevent the occurrence of air punctures that would ruin the surface condition, so that the surface condition can be made beautiful.

In particular, according to the present invention, the foaming ratio of the foam decorative layer, base coat layer, etc. can be greatly increased compared to conventional sheets of this type, and the sheet is lightweight and has a rich sense of volume and naturalness. It is possible to easily put the decorative sheet into practical use.

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram showing an example of the process of the manufacturing method of the present invention.

FIG. 2 is an explanatory diagram showing details of needle embossing during the process of FIG. 1;

[Explanation of symbols]

1 Base material 2 Synthetic resin paste for foam decorative layer 3
Synthetic resin solution for surface treatment layer 20 Foam decoration layer 30 Dried synthetic resin solution for surface treatment layer NR Needle roll BR Backup roll N Needle of needle roll NR

Claims (2)

[Claims] [Claim 1] A decorative sheet having a decorative layer made of foam on a base material, the decorative sheet having through holes that are present in at least the decorative layer portion but are not open on the outer surface of the base material. ,
A decorative sheet with excellent peel-up properties, characterized in that the decorative layer portion having the through holes is embossed. 2. After coating at least a foamable synthetic resin layer on a base material and foaming it by heating, needle embossing is performed from the foamed synthetic resin layer side to penetrate at least the foamed synthetic resin layer. 1. A method for producing a decorative sheet with excellent peel-up properties, which comprises punching holes that do not reach the outer surface of a base material, followed by heating and embossing.