JPS59192531A - Manufacturing method of resin sheet - Google Patents

Abstract

PURPOSE:To make it possible to form a profiled pattern on a resin sheet surface in conformity with a printed pattern, by printing a prescribed pattern on the surface of a thermoplastic resin sheet with an ultraviolet-curing resin ink, exposing the printed sheet to an ultraviolet ray, and heating and stretching the sheet. CONSTITUTION:After the surface of a substrate sheet 1 having a pattern printed with an ultraviolet-curing resin ink 2 is exposed to an ultraviolet ray, another resin sheet for example a vinyl chloride resin sheet 3 is struck to the undersurface of the substrate sheet 1, and the substrate sheet is heated and stretched. Then the sheet 3 is also stretched accordingly to follow the stretching of the part of the substrate sheet 1 where the printed pattern is absent so that a profiled pattern is formed completely in conformity with the printed pattern. If the resin sheet 3 is a colored sheet, the colored sheet will serves as a background of the printed pattern. Since a prescribed pattern is printed on the substrate sheet with an ultraviolet-curing ink, and after the surface having the printed pattern is exposed to an ultraviolet ray to crosslink and cure the printed part, the substrate sheet is heated and stretched, only the part of the sheet having the crosslinked ink is substantially stretched and therefore is raised on the sheet surface so that a profiled pattern is formed completely in conformity with the printed pattern.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a sheet having an uneven pattern that is completely in sync with the printed pattern applied to the surface.

Conventionally, resin decorative sheets with wood grain or geometric uneven patterns on their surfaces have been widely used as exterior panels for furniture, fittings, or electrical equipment, but these sheets are often manufactured by embossing. ing. However, with such mechanical methods, it is difficult to create an uneven pattern that closely matches the pattern of the sheet, and there is also the problem that it requires a large number of large equipment, which increases manufacturing costs. be.

The present invention has been made in order to solve the above-mentioned problems, and an object of the present invention is to provide a simple method for manufacturing a resin sheet having a concavo-convex pattern that is completely in sync with a printed pattern.

The method for manufacturing a resin sheet according to the present invention includes printing a pattern in a desired shape on the surface of a thermoplastic resin sheet using ultraviolet curable resin ink, irradiating it with ultraviolet rays, and then heating and stretching the resin sheet to print the pattern on the surface of the resin sheet. It is characterized by forming a concavo-convex pattern that is synchronized with the .

The present invention will be described below based on drawings showing examples.

FIG. 1 shows a base resin sheet 1 before being heated and stretched. The base sheet is not particularly limited, but includes, for example, polyvinyl chloride resin, polyethylene, polypropylene, ethylene-vinyl acetate copolymer, polyvinyl acetate, saturated polyester, polyvinylidene chloride, acrylic resin, thermoplastic polyurethane resin, etc. is used. The base sheet may contain various necessary additives depending on the resin, such as plasticizers, fillers, colorants, antioxidants, and the like.

The thickness of such a base sheet is such that when the base sheet is heated and stretched, the non-printing part of the sheet is stretched and the printed part is effectively raised to form the desired uneven pattern. Usually 0.05-11I so that
It is preferable that it is about 11.

According to the method of the present invention, a desired pattern is printed on the surface of such a base resin sheet using ultraviolet curable resin ink 2. The thickness of the printed pattern is selected so that when the printing ink is crosslinked and then heated and stretched, the printed pattern portion of the sheet is not substantially stretched.

The ultraviolet curable resin ink used in the method of the present invention usually contains a film-forming component, a reactive diluent, and a photopolymerization initiator, and optionally contains a solvent, dye and pigment, filler, etc. It is an ink made of a resin composition that is crosslinked and cured usually within a few seconds when exposed to ultraviolet rays. As the film-forming component, high molecular weight polymers, oligomers, and polymers having acryloyl groups, methacryloyl groups, or other addition-polymerizable double bonds in the molecule are usually used. In the present invention, polyester (
Meth)acrylateUrethane (meth)acrylate, epoxy (methacrylate, etc.) are preferably used.

The reactive diluent is blended to lower the viscosity of the film-forming component to make it printable, and to crosslink and network the film-forming component when exposed to ultraviolet rays. , 'a wealth, multifunctionality) 1. It is an oligomer or monomer of In the present invention, such reactive diluents include 211Ii1 or more acrylate groups and/or
or methacrylate-1 group, and specific examples thereof include trimethylolpropane tri(meth)acrylate-1-, pentaerythritol tri(meth)acrylate, butanediol di(meth)acrylate, and butanediol di(meth)acrylate. Acrylate, neopentyl glycol di(
Examples include meth)acrylate, 1,6-hexanethiol di(meth)acrylate, diethylene glycol di(meth)acrylate, and the like.

Furthermore, monofunctional monomers such as 2-ethylhexyl (meth)acrylate, 2-hydroxyethyl (meth)acrylate, glycidyl (meth)acrylate, N-vinyl-2-pyrrolidone, and tetrahydrofurfuryl (meth)acrylate are added to these. Can be used together. Further, as the photopolymerization initiator, benzyl, benzophenone, benzoin ether, chlorothioxanthone, jetoxyacetophenone, hensyl dimethyl ketal, etc. are usually used.

The blending amount of each component in the above-mentioned ultraviolet curable resin ink is usually about 20 to 90% by weight of the film-forming component.
, preferably from 40 to 70% by weight, with about 10% reactive diluent
The amount is 80% by weight, preferably 30% to 60% by weight, the photopolymerization initiator is about 0.5% to 10% by weight, and the above-mentioned components are further added as necessary.

Next, according to the present invention, ultraviolet rays are irradiated from the printed pattern surface of the sheet to crosslink and cure the printed pattern. The method for crosslinking and curing the ink may be any conventionally known method, for example, using an ultraviolet source such as a xenon lamp, a low pressure, medium pressure, high pressure, or ultra-high pressure mercury lamp. The amount of ultraviolet rays to be irradiated is sufficient to fully cure the ultraviolet curable resin ink, and is appropriately selected depending on the ink.
In the case of a 0W/■ mercury lamp, irradiation may be performed for one to several seconds.

When the sheet is then heated and stretched, as shown in FIG. Because it is cross-linked and cured, it is not substantially stretched, and thus the sheet portion having the printed pattern rises from the sheet surface, forming an uneven pattern that is completely in sync with the printed pattern. The heating temperature of the above sheet is usually
A suitable temperature range is 100 to 200°C, and a suitable stretching ratio is 5 to 40% in both length and width. Note that it is desirable that the film be stretched at approximately the same stretching rate in both length and width.

By controlling the heating temperature and stretching rate, it is possible to control the stretching of the sheet portion that does not have a printed pattern on its surface, and to control the height of the protrusion of the sheet portion that has a printed pattern.

FIG. 3 shows a laminated base sheet prior to heating in another embodiment of the method of the invention. That is, after irradiating the surface of the base sheet 1 with a printed pattern with the ultraviolet curable resin ink 2 with ultraviolet rays in the same manner as described above, another resin sheet, for example, a vinyl chloride resin sheet 3, is laminated on the back surface. By adhering and laminating the sheets by a method such as the above, and then heating and stretching the sheets, as shown in FIG. It is stretched, thus forming a textured pattern in perfect conformity to the printed pattern. When a colored sheet is used as the resin sheet 3, this sheet can be used as a background of a printed pattern.

According to the method of the present invention, a desired pattern is printed on a stretchable base sheet using ultraviolet curable resin ink, and the printed pattern surface is cross-linked and cured by irradiating ultraviolet rays. After that, the base sheet is heated and stretched, so that only the portion of the sheet that does not have a crosslinked ink pattern on its surface is substantially stretched, while the portion that has a printed pattern on its surface is not substantially stretched. As a result, this portion is raised on the surface of the sheet, forming an uneven pattern that perfectly matches the printed pattern.

The present invention will be explained below with reference to Examples, but the present invention is not limited to these Examples in any way.

Example 1 A resin composition containing 100 parts by weight of a hinyl chloride resin with an average degree of polymerization of 1100, 12 parts by weight of a conventional plasticizer, and appropriate amounts of stabilizers and pigments was prepared by a calendering method to a thickness of 0.0.
75i+i+ sheet.

A wood grain pattern is printed on the surface of this base sheet using ultraviolet curable resin inks A to C having the compositions shown in the table, respectively.
After irradiating ultraviolet rays for 1 second using a mercury lamp with a main wavelength of 365 mμ and an output of 80 W/cm, the printed pattern was stretched at a temperature of 170°C with a stretching ratio of 15% in both length and width. It was possible to obtain a sheet in which a convex pattern was formed in sync with the area.

Example 2 The printed sheet 1- obtained in Example 1 was similarly irradiated with ultraviolet rays. Separately, vinyl chloride resin with an average degree of polymerization of 1100
0 parts by weight, a resin composition containing 17 parts by weight of a conventional plasticizer and appropriate amounts of stabilizers, pigments, and fillers was molded into a sheet with a thickness of 0° and 11 cm by a calendar method, and this was molded into a sheet with a thickness of 0° and 11 cm. Laminated on the back side of the material sheet. Next, this laminated sheet was stretched at a temperature of 170°C with a stretching ratio of 15% in both length and width, and when using any ink,
It was possible to obtain a sheet in which a convex pattern was formed in synchronization with the printed pattern portion.

[Brief explanation of the drawing]

The drawings show an embodiment of the method according to the present invention; FIG. 1 is a cross-sectional view of a main part of a base sheet having a pattern printed with ultraviolet curable resin ink on its surface, and FIG. 3 is a sectional view of a main part of a sheet having an uneven pattern according to the invention, FIG. 3 is a sectional view of a base sheet laminated with, for example, colored resin sheets, and FIG. FIG. 1...Base material sheet, 2...UV curable resin ink, 3...Resin sheet. 1 Figure 1

Claims (1)

[Claims] (1) Print a pattern in the desired shape on the surface of the thermoplastic resin sheet using ultraviolet curable resin ink, irradiate it with ultraviolet rays, and then heat and stretch it to form an uneven pattern on the surface of the resin sheet that matches the printed pattern. A method for manufacturing a resin sheet characterized by: