JPS6123111B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative sheet, and more specifically, a method for manufacturing a decorative sheet having deep and delicate irregularities that match the pattern without using mold rolls or foaming agents. It's about how to do it.

Conventionally, methods for forming uneven patterns on decorative sheets include a method in which the surface of a film or sheet is heated and extruded using a mold roll to deform it, and a method in which a mold plate and a heating plate are used to heat and extrude using a press. In these methods, there is no relationship between the formation of the pattern and the formation of the uneven pattern, so the disadvantage is that the pattern and the uneven pattern are not accurately synchronized, and the mold rolls, templates, etc. are very expensive. The disadvantage is that manufacturing costs are high.

In addition, as a method for forming an uneven pattern without using a mold roll or template, a colored foaming resin containing a foaming agent is printed on a porous base sheet in a pattern, impregnated, and then foamed. There is a method of forming an uneven pattern, but this method is limited in the resin used,
It also has some drawbacks, such as the textured pattern lacks fineness and fineness.

The present invention was completed as a result of research into a method of forming a deep and delicate uneven pattern on a decorative sheet that matches the pattern, in view of the above-mentioned drawbacks of the prior art. That is, in more detail, the method for producing a decorative sheet of the present invention includes a shrinkable porous sheet-like base material,
A laminate obtained by applying a substance that changes the shrinkability of the base material in a pattern and then overlaying a plastic film thereon is subjected to (a) fluid pressure from the surface on which the deformable film is provided; and/or (b) applying suction from a surface opposite to the surface on which the deformable film is provided, thereby imparting a concavo-convex pattern that is synchronized with the pattern on the surface of the laminate on which the deformable film is provided; It is characterized by this. The pressurization and/or suction is preferably carried out under heat by utilizing the thermosoftening or heat shrinkability of the porous base sheet.

The present invention utilizes the property that the pressure shrinkability of the porous base sheet changes depending on the substance contained in the ink applied to give the pattern, and in this way, the pressure shrinkability is partially changed. By applying fluid pressure to different base sheets through the film (including suction from the opposite side to the side where the film is placed), extremely deep and fine particles that are in sync with the pattern can be created. A decorative sheet having an uneven pattern is obtained. Since the unevenness obtained in this way has the pores of the porous sheet-like base material as one unit, it is possible to form unevenness with very good resolution. Further, the film applied to apply fluid pressure serves as a surface protective layer as it is, and there is an advantage that it is not necessary to form a protective layer after forming a difficult uneven pattern.

Hereinafter, the present invention will be explained in more detail with reference to the drawings as necessary.

The porous sheet-like base material used in the present invention includes:
Synthetic fibers such as synthetic resins such as nylon, polyester, polyvinyl chloride, polyvinyl alcohol, polyethylene, polypropylene, and acrylic resin, or semi-synthetic fibers such as rayon and acetate human silk, as well as these fibers and natural fibers such as cotton and linen. A nonwoven fabric, a raised cloth, an artificial flocked sheet made of a mixture of the above and the like; or a porous sheet with open cells prepared by various methods such as an extraction method, etc. are used. These porous sheet-like substrates are used in the present invention in the form of sheets or continuous sheets with an apparent specific gravity of 0.01 to 0.6 and a thickness of 0.5 to 4 mm.

According to the present invention, as shown in FIG. 1, a substance that changes the pressure shrinkability is applied in a pattern on one surface of the porous sheet-like base material 1 as described above, so that the pressure shrinkability is small. A portion 2 and a portion 3 having high compressibility are provided.

Substances that change the pressure shrinkability of the porous sheet-like base material 1 include organic solvents and other softeners that have a softening effect on the synthetic fibers that make up the base material 1. Although a substance that increases the shrinkability of the substrate 1 may also be used, it is preferable to use a substance that reduces the pressure shrinkability of the substrate 1 in the form of an ink. Here, the "pressure shrinkability of the base material" or "change thereof" is determined under the conditions of pressure deformation of the base material, which will be described later.For example, when pressure deformation is performed under heating, the base material There is no need for the material to have pressure-shrinkability at room temperature, nor is it necessary for the pressure-shrinkability at room temperature to change due to the application of the above-mentioned substance.

Now, the decrease in the pressure shrinkability of the porous sheet base material sheet 1 occurs due to various reasons, but typically, the density of the base material increases due to filling of pores, the hardness of the base material increases, or the base material hardness increases. Examples include increasing the heat resistance of the material (when deforming under pressure while heating). Such a partial reduction in the pressure shrinkability of the base material can be obtained by applying ordinary printing ink to one surface of the porous sheet-like base material 1 in a pattern. That is, the vehicle in the ink can be deposited in the pores in the porous sheet-like base material 1, causing an increase in the density, hardness, or heat resistance of the base material. However, in order to actively reduce the pressure shrinkability of the base material 1, it is preferable to add a filler (particularly an inorganic filler), a curing agent, or both to the ink.

Inorganic fillers include calcium carbonate, clay, silicic acid, silicates, asbestos, diatomaceous earth,
Known fillers such as mica powder, glass fiber, glass spheres, graphite, magnesium carbonate, aluminum hydroxide, barium sulfate, and various other metal powders can be used, but the amount added depends on the vehicle.
It is preferably 500 parts or less per 100 parts (parts by weight, same hereinafter). This is because when the amount added is 500 parts or more, the fluidity of the ink decreases and printability deteriorates.

Further, the curing agent may be a heat-curable resin, an ultraviolet ray-curable resin, or an electron beam-curable resin. Heat-curable types include acrylic resins, polyester resins, alkyd resins, silicone resins, melamine resins, vinyl resins, urethane resins, and epoxy resins; ultraviolet or electron beam-curable types include resins with unsaturated groups, vinyl Examples include monomers. Here, the thermosetting resin is preferably a thermosetting resin that takes a crosslinked structure upon curing, but is not limited to this, and thermoplastic resins may also be used. When using a thermoplastic resin, a resin having a higher softening point than the base material constituent material is preferred.

Each component other than the filler and curing agent in the ink is not particularly different from known components. That is, vehicles include oils and fats such as linseed oil, soybean oil, and synthetic drying oil; natural and processed resins such as rosin, copal, dammar, hardened rosin, rosin ester, and polymerized rosin; rosin-modified phenolic resin; and 100% phenol. Synthetic resins such as resins, maleic acid resins, petroleum resins, vinyl resins, acrylic resins, polyamide resins, epoxy resins, aminoalkyd resins; cellulose derivatives such as nitrorsace and ethyl cellulose, chlorinated rubber, cyclized rubber, etc. rubber derivatives, other glues, casein, dextrin, zein, etc. can be used. In addition, colorants such as dyes or pigments having a desired color tone are added to the ink, and furthermore, for example, plasticizers, stabilizers, waxes, greases, desiccants, auxiliary desiccants, thickeners, dispersants, etc. It can be used after being sufficiently kneaded together with a solvent and a diluent.

Porous sheet-like base material 1 obtained in this way
An ink containing a substance that reduces the pressure shrinkage of the material (hereinafter referred to as a "shrinkage inhibiting substance") is usually applied to the substrate 1 by a printing method known per se, followed by drying and curing resin as necessary. After curing, as shown in FIG. 1, a base material 1 having a portion 2 impregnated with a shrinkage-inhibiting substance in at least a portion of its thickness is obtained. The remaining portion 3 may not contain any ink, or may be a portion in which the shrinkage inhibiting substance is removed from the above-mentioned ink or the amount thereof is reduced to apply an ink that is mainly expected to have a coloring effect. As a printing method, known printing methods such as lithography, letterpress, and intaglio can be used, but it is preferable to use a screen printing method using a flatbed screen printer or a rotary screen printer. This is because with the screen printing method, a large amount of ink can be supplied to the inside of the porous sheet-like base material 1, so the difference between the pattern parts 2 and 3, that is, the difference in packing density, hardness, etc., is large. This is because more delicate and deep unevenness is formed.

As shown in FIG. 2, preferably an adhesive 4 is applied to the surface of the printed base material 1 thus obtained, and a deformable film 5 is overlaid thereon. Here, as the adhesive 4, any hardening type or non-hardening type can be used as long as it has an adhesive effect between the film 5 and the printed base material 1, and its form can also be an emulsion type, Regardless of the type, such as solution type or sol type. Furthermore, any known coating means such as a doctor knife coater, a bar coater, a flow coater, a roll coater, a reverse roll coater, a gravure coater, etc. may be used for coating the adhesive.

The film 5 may be made of any known film material as long as it can be deformed following the contraction and deformation of the base material 1. Particularly preferred are thermosetting materials, such as soft polyvinyl chloride film, hard polyvinyl chloride film, cellulose acetate film, polyethylene film, polystyrene film, polycarbonate film, polyacrylic resin film, polypropylene film, polyamide film, and polyester. Films, polyvinylidene chloride films, polyvinyl alcohol films, films made of various individual or copolymer resins, ultraviolet curable films, and electron beam curable films can be used. In the present invention,
The thickness of the deformable film does not need to be particularly limited, but if the film is extremely thick, the unevenness effect will be reduced, so it is preferably 500 μm or less. Further, the film 5 needs to have a certain degree of airtightness or fluid blocking ability in order to apply fluid pressure to the base material 1 through it, and for this reason, a thickness of 10 μm or more is desirable. In the present invention, an arbitrary pattern may be formed on the surface of the film preferably in contact with the porous sheet-like base material by printing or other means. Thereby, a decorative sheet having a more complex and beautiful pattern can be created.

Although the adhesive 4 is not essential in the present invention, the adhesive 4 is not required for the base material 1 obtained as shown in FIG.
In a laminate of the film 5 and the film 5, it is preferable to use it to improve the adhesion between the two and the deformation followability of the film 5 to the base material 1. However, after printing the base material as shown in Figure 1,
If you stack the films without drying the ink,
Since the Birkle solvent, plasticizer, etc. in the ink have an adhesive effect, the same effect can be obtained without using adhesive again. Adhesion to the base material 1 can be obtained by heating the adhesive after applying the agent.

Next, fluid pressure is applied to the laminate as shown in FIG. 2 from the side on which the film 5 is provided to cause the base material 1 to contract and deform. The voltage is preferably applied to the upper molding chamber and the lower vacuum chamber 7 through the ventilation hole 8, as shown in FIG.
This is carried out using an apparatus 10 having a structure partitioned by a forming plate 9 having a molding plate 9. As shown in FIG. 3, after the stack of FIG. 2 is placed in the upper molding chamber so that there is no gap, a vacuum pump (see FIG. (not shown) to reduce the pressure in the vacuum chamber 7 and suction the laminate, or apply a pressurized fluid, preferably pressurized air, to the upper molding chamber that houses the laminate, or both. . As a result, the portion 3 of the base material 1 that does not contain or contains less shrinkage inhibiting substance.
shrinks preferentially, and a convex portion corresponding to the pattern portion 2 containing the shrinkage-inhibiting substance given by printing is formed. The laminate after molding becomes a decorative sheet according to the present invention.

It is highly preferred to carry out the above shaping operation under heat. As a result, if the base material 1 has heat-softening or heat-shrinkability and the film 5 has heat-softenability, the partial shrinkability of the base material 1, the follow-on deformability of the film 5, and the heat-shrinkability of the base material 1. Adhesion and fixation properties are also improved, and a decorative sheet with extremely sharp and deep unevenness is formed. Heating is performed by embedding a hot wire in the forming plate 9 or by blowing hot air 12 from the top surface of the film 5 to perform a compressed air operation. The appropriate heating temperature is generally 100 to 400°C, but it is a temperature higher than the secondary transition point of the heat-softening film 5 to be laminated to the base material 1, and the temperature is higher than the second-order transition point of the heat-softening film 5 to be laminated to the base material 1, and the temperature of the film, the porous sheet-like base material, and the adhesive. Other temperature ranges can also be suitably used as long as the temperature is lower than the temperature at which the ink deteriorates or melts. Note that when the adhesive 4 used between the base material 1 and the film 5 is heated and suctioned, it penetrates into the gap between the shrunk base material 1 and is further solidified by heating. It has the effect of preventing recovery.

In addition, as another effect of heating, for example, as shown in FIG. 5, if the heating conditions are severe, such as by raising the temperature of the hot air 12 or increasing the blowing time, the heat softening film can be heated. No. 5 undergoes significant thermal deformation, forming many fine wrinkle-like irregularities. As a result, in combination with relatively large irregularities caused by partial shrinkage deformation of the base material 1,
It is also possible to produce a decorative sheet with an extremely unique and beautiful surface design.

The thus obtained decorative sheet has a beautiful design and, of course, has commercial value as it is, but it can be further subjected to post-treatment if necessary. As an example, a reinforced sheet can be obtained by impregnating the base material with a liquid or paste resin from the surface of the obtained decorative sheet that does not have the film 5, and heating it to solidify the resin. can. As a resin for impregnation,
Resins among the materials listed above as ink vehicles, adhesives, or hardeners can be used. These resins can be prepared using suitable solvents, oil plasticizers,
It can be applied as a solution, emulsion or liquid or paste mixture in a liquid medium such as water, or as a liquid itself. The liquid medium used is preferably selected from those that do not dissolve the ink vehicle described above. Otherwise, the pattern will inevitably become disordered during impregnation with the resin. The liquid or paste resin preferably has a viscosity suitable for impregnation in the range of 1000 to 10000 cps. The liquid or paste resin is applied to the decorative sheet one to several times using a knife coater, a roll coater, etc., depending on the thickness of the porous sheet-like base material used. The heating temperature required to solidify the impregnated resin and the solidification mechanism depend on the type of the impregnated resin. That is, in the case of thermoplastic resin solutions or emulsions, it is the evaporation of the liquid medium and the paste (plastisol).
In the case of , it is gelling, and in the case of thermosetting resin, it is curing. In order to enhance the impregnating effect and provide a finely detailed decorative sheet, it is preferable to use a thermoplastic resin paste or a thermosetting resin.

In this way, the decorative sheet according to the present invention is obtained, but in consideration of its construction, in order to improve the adhesion effect with the surface to which it is applied when it is applied to walls, floors, ceilings, etc., it is shown in Fig. 6. As shown, the lining is made of asbestos paper, cotton cloth, nonwoven fabric, glass paper, etc. with a thickness of about 0.5 to 1 mm 1
3 may be attached.

As described above, according to the present invention, a decorative sheet having extremely deep and delicate irregularities that match the pattern can be obtained without using mold rolls or foaming agents, and the film used to form the irregularities can be directly applied to the surface. It can also be used as a protective layer.

Hereinafter, the present invention will be explained in more detail with reference to Examples.

Example A polyester nonwoven fabric (Zu-6701 manufactured by Nippon Vilene Co., Ltd.) with a thickness of 2 mm and an apparent specific gravity of 0.04 was used as a porous sheet-like base material, and a water-based emulsion type acrylic resin ink (Moroboshi Ink) was applied to this base material. Made by Co., Ltd.
Print part 3 shown in Figure 1 with RSN), and print part 2 with vinyl chloride ink (Moroboshi Ink Co., Ltd. RSP).
and aluminum hydroxide (H31 manufactured by Showa Denko Co., Ltd.) with the following composition, 1050g/
Printing was carried out at a ratio of m ² to obtain a patterned sheet as shown in FIG.

The ink composition is approximately as follows. Ink for part 2 in Figure 1 Polyvinyl chloride 100 parts by weight Dioctyl phthalate 85 Calcium-subacute stabilizer 4 Pigment 25 Aluminum hydroxide 390 Antimony oxide 2 Part 3 in Figure 1 Ink acrylic resin 9 Weight water-dispersed pigment 3 Dispersant 2 Thickener 1 Water 35 Mineral spirits 50 The surface of the patterned sheet obtained was dried at 200°C for 20 seconds, and then adhesive 4 A vinyl chloride resin sol was applied to the sheet surface at a rate of 330 g/m ² using a knife coater. Next, a polyvinyl chloride film (manufactured by Band Kagaku Co., Ltd.) with a thickness of 150 μm is superimposed as the heat-softening film 5 as shown in FIG. It was placed on a molding plate 9. After that, as shown in Figure 4, hot air at 200°C was blown from the top of the film while suctioning at a vacuum level of -500mmHg.
It was sprayed for 10 seconds and then dried and solidified at 200° C. for 5 minutes to obtain a decorative sheet having irregularities. lastly,
Glass paper (GS30, manufactured by Mitsubishi Paper Mills Co., Ltd.) was pasted on the back side of the decorative sheet thus obtained to obtain a desired chemical name sheet as shown in FIG.

[Brief explanation of the drawing]

The drawings show an outline of an example of the method for manufacturing a decorative sheet of the present invention, and FIG. 1 is a cross-sectional view of a patterned porous sheet-like base material, and FIG. A sectional view of the combined laminate, FIG. 3 is a sectional view when the laminate is placed on a molding device, and deformation of the laminate caused by vacuum and compressed air operations from the state shown in FIGS. 4 and 5. A cross-sectional view showing the situation, FIG. 6, is a cross-sectional view of a decorative sheet according to the present invention with a backing material attached thereto. 1...Porous sheet-like base material, 2...Patterned portion with low pressure shrinkability, 3...Patterned portion with large pressure shrinkage, 4
... adhesive, 5 ... deformable film, 6 ... vacuum conduit, 7 ... vacuum chamber, 8 ... ventilation hole, 9 ... molding plate, 10
...Forming device, 13...Backing material.

Claims (1)

[Scope of Claims] 1. A laminate obtained by applying a substance that changes the pressure shrinkability of the base material in a pattern to a porous sheet-like base material, and then overlaying a deformable film on top of the material. By applying (a) fluid pressure from the surface on which the deformable film is provided, and/or (b) suction from the surface opposite to the surface on which the deformable film is provided, the pattern is formed. A method for producing a decorative sheet, characterized in that a synchronized convex pattern is provided on the surface of the laminate on which the deformable film is provided. 2. The method of item 1 above, wherein the substance that changes the shrinkage of the base material is a substance that reduces the shrinkage of the base material. 3. The method of item 2 above, wherein the substance that reduces the shrinkage of the base material includes a curable resin. 4. The method of item 2 or 3 above, wherein the substance that reduces the shrinkage of the base material includes an inorganic filler. 5. Items 1 to 4 above, wherein the porous sheet-like base material has heat softening or heat shrinking properties, and the pressure and/or suction for imparting the uneven pattern is performed under heating. Either way. 6. The method according to any one of items 1 to 5 above, wherein the deformable film is heat softenable and the pressure and/or suction for imparting the uneven pattern is performed under heating. 7. The method according to any one of items 1 to 6 above, wherein a deformable film is applied to the porous sheet-like base material via an adhesive. 8. The method according to any one of items 1 to 7 above, wherein a substance that changes the shrinkage of the porous sheet-like base material is applied in the form of ink to the porous sheet-like base material by a screen printing method. 9 Further step of reinforcing the decorative sheet by impregnating the obtained decorative sheet with a liquid or paste-like resin from the side opposite to the side to which the deformable film is applied and solidifying the decorative sheet. The method according to any one of the above items 1 to 8, comprising: