JPH10157045A - Decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative sheet using an aqueous emulsion, wherein the decorative sheet has a sharp ink pattern without a decrease in ink density and has good stain resistance. SOLUTION: An intermediate coat layer in which an aqueous emulsion paint containing an unfoamed capsule foaming agent is provided on a base sheet 11, and an aqueous emulsion paint containing no capsule foaming agent is coated thereon. After providing the pattern printing layer 13 thereon, heat-foaming and embossing are performed to obtain a decorative sheet.
It is also possible to obtain a decorative sheet by performing stencil printing with an aqueous emulsion paint containing an unfoamed capsule foaming agent from the top of the pattern printing layer 13 and then heating and foaming. Since the picture printing layer 13 is not directly affected by foaming, the ink density does not decrease and the picture becomes sharp. Stain resistance is also good.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to interior materials for houses and the like,
In particular, the present invention relates to a decorative sheet suitably used as a wall covering material such as wallpaper.

[0002]

Heretofore, as this type of decorative sheet, a so-called PVC wallpaper having a vinyl chloride resin layer formed on a paper base material has been widely used. Sheets are considered, for example,
There is a wallpaper using an aqueous emulsion. However, in this type of decorative sheet, when a pattern print layer is provided on a non-foamed aqueous emulsion coat layer and subjected to heating embossing, sharp emboss does not appear without a sense of volume. Therefore, there is a type in which a pattern printed on an aqueous emulsion coat layer containing an unfoamed capsule foaming agent is heated and foamed and embossed.
When the capsule foaming agent foams, there is a problem that the capsule is exposed on the surface of the ink layer and the ink concentration is reduced, and furthermore, there is a disadvantage that the stain resistance is poor. Also, there is a method in which a pattern is printed on an aqueous emulsion coat layer containing an unfoamed capsule foaming agent, and a layer formed with an aqueous emulsion paint containing a capsule foaming agent and printed thereon is heated and foamed. However, even with this, the drawbacks such as the lack of ink density and poor stain resistance are not eliminated, and since both the base coat layer and the raised printing layer are foamed, the overall matte shape and the gloss difference between the two There is a disadvantage that the design is poor because it does not come out.

[0003] The present invention has been made in view of the above problems, and an object of the present invention is to provide a decorative sheet which does not decrease the ink density, has a sharp pattern, and has good stain resistance. To provide.

[0004]

In order to achieve the above object, a first decorative sheet according to the present invention is a base coat comprising a base sheet coated with an aqueous emulsion paint containing an unfoamed capsule foaming agent. Layer, an intermediate coat layer coated with an aqueous emulsion paint not containing a capsule foaming agent is provided thereon, and a pattern printing layer is further provided thereon, and then heated and foamed to perform embossing. Features.

In order to achieve the same object, a second decorative sheet according to the present invention is provided with a base coat layer coated with an aqueous emulsion paint containing an unfoamed capsule foaming agent on a base sheet, An aqueous emulsion paint containing an aqueous emulsion paint that does not contain a capsule foaming agent is provided thereon, and a picture printing layer is further provided thereon, and an unfoamed capsule foaming agent is further provided on the picture printing layer. , And then by heating and foaming.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION The base sheet is a flame-retardant paper for wallpaper, aluminum hydroxide paper, inorganic paper or general paper, having a basis weight of 50 to 300 g / m ² , preferably 70 to 150 g.
/ M ² . When the expansion and contraction due to the influence of water at the time of the emulsion coating is taken into consideration, at least the surface of the base sheet may be provided with a coat layer for increasing the water resistance and decreasing the moisture permeability.

As the aqueous emulsion resin, various non-vinyl chloride emulsions can be used, but general ethylene-vinyl acetate, acrylic resin alone, blend or copolymer is preferable. The same resin can be commonly used for the base coat layer, the intermediate coat layer and the raised print layer. Each resin contains an inorganic filler, pigment, capsule foaming agent (excluding the intermediate coat layer), various defoamers, thickeners, dispersants, drying retarders, flame retardants, preservatives, and fungicides Etc. to make a paint.

[0008] Wallpaper must have fireproofing properties, and PVC wallpaper has flame retardancy, but the emulsion burns, so it is necessary to use a flame retardant inorganic filler or a general inorganic filler such as calcium carbonate in combination. There is. Examples of the inorganic filler having a flame retardant effect include aluminum hydroxide, magnesium hydroxide, calcium hydroxide, zinc borate, and barium metaborate. Examples of general inorganic fillers include calcium carbonate, barium sulfate, talc, carion, and clay. The base coat layer and intermediate coat layer are made of resin 1
About 50 to 200 parts of a filler is added to 00. Since printing requires smoothness, the average particle size is 1
It must be 0 μm or less, preferably 5 μm or less.
The raised printing layer is also added in the same manner, but it is necessary to consider the transferability, and the particle size and the amount added are adjusted.

[0009] The capsule foaming agent has a particle diameter of 10 to 30 in which a low boiling point solvent is wrapped in a film or shell of a thermoplastic polymer material.
μm microspheres. As the shell material, acrylonitrile / vinylidene chloride copolymer or acrylonitrile / vinylidene
Acrylic copolymers, nitrile copolymers and the like are used, and the included gas includes pentane, isopentane, isobutane, butane and the like. As the capsule foaming agent, a high-temperature foaming agent which is heated at 140 (160) to 190 ° C. for 1 minute to obtain the highest magnification, wherein the shell material is a nitrile copolymer and the inclusion gas is pentane is preferable. is there. It is preferable that the foaming timing of the base coat layer and that of the raised printing layer be the same or that the raised printing be foamed first.

The base coat layer is an aqueous emulsion coat layer containing a capsule foaming agent, and various methods such as a comma coat, a doctor coat, and a roll coat can be applied to the emulsion paint. After being applied on the base sheet, for example, drying is performed at 120 ° C. for about 1 minute by a hot-air oven dryer to produce an unfoamed base coat material. The amount of the aqueous emulsion applied to the base coat layer is 5
0 to 250 g / m ² (when dried), preferably 80 to ² g / m ²
00 g / m ² (at the time of drying).

The intermediate coat layer is a coat layer in which the capsule foaming agent is not added. In order to obtain a volume as a whole, it is better to apply a small amount of the coating. Affected. The application amount is at least 10 g / m ² and at most 50 g / m ² . The coating method of the intermediate coat layer is the same as that of the base coat layer, except that the base coat layer is a dried film,
In addition to performing coating thereon, two base coat layers and an intermediate coat layer can be dried in a wet state and then dried.

As the printing ink for forming the pattern printing layer, various printing inks can be used irrespective of solvent type or aqueous type. Examples of the main resin include non-vinyl chloride-based resins such as acrylic, urethane, polyester, cellulose, and casein. Various pigments can be used regardless of organic or inorganic pigments. Luminous pigments such as aluminum, brass, vapor-deposited powder, and pearl pigments (white, gold, etc.) lose their brightness when printed directly on the base coat layer due to the effect of the capsule foaming agent. The effect is greatly improved by the provision. Various printing methods such as gravure, offset, flexo, and silk can be used as the printing method.

A transparent coat layer may be provided on the picture printing layer for gloss control, and various types of paints can be used irrespective of solvent type or aqueous type. Matting agents include silica, alumina, calcium carbonate and the like.

Various non-vinyl chloride emulsions can be used as the aqueous emulsion resin for forming the embossed print layer.
A, an acrylic resin is desirable. Besides, inorganic fillers,
Pigments, defoamers, thickeners, dispersants, drying retarders, flame retardants,
Add preservatives and the like. As a method of embossing printing, gravure embossing, rotor silk printing, or the like can be used. In order to increase the transferability, a fluidity and tackifier for the paint may be added. The coating amount is about 10 to 50 g / m ² , and in addition to one-color printing,
Multicolor printing may be performed. Multi-color printing is 1
Dry by color and repeat printing. The foaming agent for stencil printing is
Foaming at the same timing as the base coat layer or at a lower temperature than the base coat layer is more voluminous and has better design.

In the case of manufacturing the first decorative sheet, for example, as shown in FIG. 1, the printed sheet 1 is fed out, passed through a foaming furnace 2 and heated at 140 to 200 ° C. for about 1 minute. After being foamed, the sheet is passed between the embossing roll 4 and the impression cylinder 5 for embossing while the surface is heated by the infrared heater 3 so that the sheet temperature does not drop. Then, as soon as the emboss is put, it is cooled by the cooling roll 6 so as to obtain a sharp emboss product without drawing.

When the second decorative sheet is manufactured, the product is obtained by heating the printed sheet in a foaming furnace at 140 to 200 ° C. for about 1 minute.

[0017]

【Example】

Example 1 A first decorative sheet (foamed embossed type) according to the present invention was evaluated for performance by producing a conventional product, a product of the present invention, and a comparative product.

[Conventional product] A backing paper "TT-120CW" (made by special paper making) which has been subjected to a water-resistant treatment coating on both sides is used as a base sheet, and as shown in FIG. A base coat layer 12 was formed by coating a paint “RCE (H)” having a composition A shown below (manufactured by The Inktec) with a comma coat at 150 g / m ² (dry).

<Composition A> Resin: EVA 100 parts by weight Filler: Aluminum hydroxide 120 parts by weight Capsule foaming agent: "F-85" (Matsumoto Yushi) 12 parts by weight Titanium oxide 10 parts by weight Defoamer 2 parts by weight Other 2 parts by weight

Then, as shown in FIG. 2B, two-color gravure printing is performed on the base coat layer 12 with an acrylic ink "UE" (manufactured by Showa Ink Industries Co., Ltd.) to form a pattern printing layer 13. did. Then, at 170 ° C x 1 in a foaming furnace
After heating and foaming in minutes, the surface temperature is set to 2 with an infrared heater.
After embossing at 00 ° C and cooling, Fig. 2 (c)
Was obtained.

[Product of the present invention] A base sheet 11 similar to the conventional product is used, and a base coat layer 12 similar to that of the conventional base sheet is provided. 20g / m by Comma Coat
² (at the time of drying) to form an intermediate coat layer 14 as shown in FIG.

<Composition B> Resin: EVA 100 parts by weight Aluminum hydroxide 120 parts by weight Titanium oxide 10 parts by weight Defoamer 2 parts by weight Others 2 parts by weight

Subsequently, the same gravure printing as in the case of the conventional product was performed to form a picture print layer 13 as shown in FIG. 3 (b). Then, as in the case of the conventional product, 17
After foaming by heating at 0 ° C. × 1 minute, embossing was performed at a surface temperature of 200 ° C. with an infrared heater, followed by cooling to obtain a decorative sheet shown in FIG.

[Comparative product] A paint “RCE (G)” (manufactured by The Inktec Co., Ltd.) of the composition B used in the intermediate coat layer of the product of the present invention was applied on the same base sheet as the conventional product by comma coating FIG. 4 after coating with 150 g / m ² (when dried)
A coat layer 15 was formed as shown in FIG. Gravure printing was performed on the coat layer 15 in the same manner as in the case of the conventional product to form a picture print layer 13 as shown in FIG. Then, as in the case of the conventional product, 170 ° C in a foaming furnace.
After heating and foaming in × 1 minute, the surface temperature was set to 200 ° C. with an infrared heater, embossed, cooled, and cooled.
A decorative sheet shown in (c) was obtained.

-Performance evaluation- The evaluation results of each decorative sheet obtained in Example 1 are as shown in Table 1.

[0026]

[Table 1]

(Example 2) Conventional products and products 1 to 3 of the present invention were prepared for the second decorative sheet (print-up type) according to the present invention, and the performance was evaluated.

[Conventional product] Flame-resistant backing paper "E-140S"
RS ”(made by Kishu Paper) as a base sheet
As shown in (a), a paint “RCE (E)” (manufactured by The Inktec) having the following composition C was coated on the base sheet 21 with a comma coat at 80 g / m ² (when dried). Thus, a base coat layer 22 was formed.

<Composition C> Resin: EVA 100 parts by weight Filler: Aluminum hydroxide 120 parts by weight Capsule foaming agent: "F-85" (manufactured by Matsumoto Yushi) 8 parts by weight Titanium oxide 10 parts by weight Defoaming agent 2 parts by weight Other 2 parts by weight

Next, as shown in FIG. 5B, two-color gravure printing of a pattern is performed on the base coat layer 22 with an acrylic ink "UE" (manufactured by Showa Ink Industries, Ltd.) to form a pattern printing layer 23. After that, an embossed printing layer 24 was formed by a gravure intaglio (printing depth: 200 μm) using an aqueous embossing ink “SEF” (manufactured by Showa Ink Industries, Ltd.) having the following composition D.

<Composition D> Resin: acrylic 100 parts by weight Filler: aluminum hydroxide 40 parts by weight Capsule foaming agent: "F-50" (Matsumoto Yushi) 12 parts by weight Titanium oxide 10 parts by weight Defoamer 2 parts by weight Parts Other 2 parts by weight

After forming the raised print layer 24 in this manner, the foam is formed in a foaming furnace at 170 ° C. for 1 minute to form a foam as shown in FIG.
Was obtained.

[Product 1 of the Present Invention] A base sheet 21 similar to the conventional product was used, and a base coat layer 22 similar to the above-described composition C was formed thereon.
EC (G) ”(manufactured by The Inktec) is coated on the base coat layer 22 with a comma coat at 20 g / m ² (when dried) to form an intermediate coat layer 25 as shown in FIG. did.

<Composition E> Resin: EVA 100 parts by weight Filler: Aluminum hydroxide 120 parts by weight Titanium oxide 10 parts by weight Defoamer 2 parts by weight Others 2 parts by weight

Subsequently, as shown in FIG. 6 (b), after performing the same gravure printing as in the case of the conventional product to form the picture print layer 23, the aqueous build-up of the composition D is performed in the same manner as in the case of the conventional product. An embossed printing layer 24 was formed by gravure embossing printing using the ink “SEF”. And 1 in the foaming furnace
Foaming was performed at 70 ° C. for 1 minute to prepare a decorative sheet shown in FIG. 6C.

[Product 2 of the Present Invention] In the same manner as in the case of Product 1 of the present invention, a base coat layer 22 and an intermediate coat layer 25 were formed on a base sheet 21 to prepare a raw material. Next, acrylic ink "VW Silver" using aluminum flakes as pigment
After printing the first color with (Showa Ink Kogyo) and the second color with the acrylic ink "UE" (from Showa Ink Kogyo) to form the pattern printing layer 23, the same as in the case of the conventional product. The embossed printing layer 24 was formed by gravure embossing printing using the aqueous embossing ink “SEF” (manufactured by Showa Ink Industries, Ltd.) having the composition D. After forming the embossed print layer 24, the foam was similarly foamed at 170 ° C. for 1 minute in a foaming furnace to obtain a decorative sheet.

[Product 3 of the Present Invention] As shown in FIG. 7A, a base coat layer 22 and an intermediate coat layer 25 were formed on a base sheet 21 in the same manner as in the case of the product 1 of the present invention to prepare a raw material. . Then, as shown in FIG. 7B, after the first color and the second color are printed to form the pattern printing layer 23 in the same manner as in the case of the product 2 of the present invention, the “flat mat O” is formed thereon.
P "(manufactured by Showa Ink Co., Ltd.) is coated with a solid to form a transparent coat layer 26 for gloss control, and then the aqueous embossing ink" SEF "(manufactured by Showa Ink Co., Ltd.) having the composition D is used. An embossed printing layer 24 was formed by gravure embossing printing. After forming the raised print layer 24 as described above, the foam was similarly foamed at 170 ° C. for 1 minute in a foaming furnace to obtain a decorative sheet shown in FIG. 7C.

-Performance Evaluation- The evaluation results of each decorative sheet obtained in Example 2 are as shown in Table 2.

[0039]

[Table 2]

[0040]

As described above, according to the present invention,
By providing an intermediate coat layer containing no capsule foaming agent on the base coat layer containing the capsule foaming agent, and by providing a picture printing layer thereon, the picture printing layer is not directly affected by foaming, A decorative sheet having a sharp ink pattern without a drop in ink density and excellent stain resistance can be obtained. In particular, in the raised printing type, there is a gloss difference between the base coat layer and the raised printing layer, and a decorative sheet having a more uneven feeling can be obtained.

[Brief description of the drawings]

FIG. 1 is a schematic view of an apparatus for embossing by heating and foaming a printed sheet.

FIG. 2 is a process chart showing a manufacturing procedure of a conventional product of a foamed emboss type.

FIG. 3 is a process chart showing a production procedure of a foamed embossed type product of the present invention.

FIG. 4 is a process chart showing a production procedure of a foamed emboss type comparative product.

FIG. 5 is a process chart showing a manufacturing procedure of a conventional product of a printing type.

FIG. 6 is a process diagram showing a production procedure of a product of the present invention of a stencil printing type.

FIG. 7 is a process diagram showing another manufacturing procedure of the product of the present invention of the print-in-print type.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 Sheet after printing 2 Foaming furnace 3 Infrared heater 4 Emboss roll 5 Impression cylinder 6 Cooling roll 11 Base sheet 12 Base coat layer 13 Picture print layer 14 Intermediate coat layer 15 Coat layer 21 Base sheet 22 Base coat layer 23 Picture print layer 24 Raised print layer 25 Intermediate coat layer 26 Transparent coat layer

Claims (6)

[Claims] 1. A base coat layer coated with an aqueous emulsion paint containing an unfoamed capsule foaming agent is provided on a base sheet, and an intermediate coat layer coated with an aqueous emulsion paint containing no capsule foaming agent is provided thereon. Provided,
Further, a decorative sheet obtained by providing a pattern printing layer thereon, and then performing heating and foaming to perform embossing. 2. The decorative sheet according to claim 1, wherein a transparent coat layer for gloss control is provided on the picture printing layer. 3. The decorative sheet according to claim 2, wherein a brilliant ink is used as the ink for forming the picture print layer. 4. A base coat layer coated with an aqueous emulsion paint containing an unfoamed capsule foaming agent is provided on a base sheet, and an intermediate coat layer coated with an aqueous emulsion paint containing no capsule foaming agent is provided thereon. Provided,
Further, a pattern printing layer is further provided thereon, and a makeup print obtained by performing a stencil printing with an aqueous emulsion paint containing an unfoamed capsule foaming agent on the pattern printing layer, followed by heating and foaming. Sheet. 5. The decorative sheet according to claim 4, wherein a transparent coat layer for gloss control is provided on the picture printing layer. 6. The decorative sheet according to claim 4, wherein a brilliant ink is used as the ink for forming the picture print layer.