JP2009166400A - Embossing plate for horizontal design embossing, and horizontal design embossed decorative sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an embossing plate for horizontal design embossing capable of forming effectively horizontal design embossing in a sheet structure without causing a problem such as air inclusion. <P>SOLUTION: The embossing plate is used for horizontal design embossing containing continuous horizontal design embossing parts in an almost perpendicular direction relative to a rolling direction of an embossing roller. Slits have a slit width of 40 to 100 μm, a space between the slits of 20 to 500 μm and a depth of not less than 20% of the height of the embossing. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention is an embossing plate used for embossing the surface of a sheet-like material, and in particular, a horizontal handle for providing a horizontal handle embossing, that is, a horizontal handle embossed substantially perpendicular to the longitudinal direction of the sheet-like material. It relates to an embossing plate for embossing.

  One method of providing a concavo-convex pattern on the surface of a sheet-like material is embossing with an embossing roll. In order to improve the reproducibility and productivity of embossing, a method in which a thermoplastic resin is melt-extruded as a sheet and laminated with other sheets, and embossing with an embossing roll is performed at the same time or immediately thereafter is preferably used. Yes.

  As the direction in which the embossing is provided, it is preferable in the manufacturing process to provide a plurality of grooves in the shape of a groove that is perpendicular to the substantially parallel direction along the rotation direction of the embossing roll, and is often used in wood grain conduit patterns. However, in the case of a lattice-like groove or the like, horizontal handle embossing that is continuous in a direction substantially perpendicular to the rotation direction of the embossing roll is required.

However, as the speed of the production line including the embossing roll increases to 50 to 80 m / min, air (air) accumulates on the bank on the near side in the flow direction of the ladle embossing, and the embossing is missing or looks white. There is a problem that a phenomenon called “air biting” occurs.
JP 2005-335336 A Japanese Patent No. 3185590

  The present invention has been made in order to solve such problems, and the problem is that the embossing can be efficiently applied to the sheet-like material without causing problems such as air biting. It is to provide an embossed version for possible horizontal embossing.

  The present invention solves this problem, that is, the invention according to claim 1 is an embossing plate for horizontal pattern embossing having a horizontal pattern embossed portion that is continuous in a direction substantially perpendicular to the rotation direction of the embossing roll, An embossing plate for horizontal pattern embossing, wherein a slit is provided in the rotation direction of the horizontal pattern embossed portion.

  The invention according to claim 2 is the embossed plate for horizontal pattern embossing according to claim 1, wherein the slit has a width of 40 to 100 μm.

  The invention according to claim 3 is the embossed plate for horizontal handle embossing according to any one of claims 1 and 2, wherein an interval between the slits is 20 to 500 m.

  The invention according to claim 4 is the embossing plate for horizontal handle embossing according to any one of claims 1 to 3, wherein the depth of the slit is 20% or more of the height of the embossing. is there.

  The invention according to claim 5 is a decorative sheet having at least a picture layer and a transparent thermoplastic resin layer on a thermoplastic resin base material, and a horizontal pattern emboss having a slit is provided on the transparent thermoplastic resin layer side. The embossed decorative sheet with embossed pattern.

  According to the first aspect of the present invention, it is possible to provide an embossing plate for horizontal pattern embossing in which air efficiently escapes from the slit and the problem of air biting can be reduced.

  Further, according to the inventions according to claim 2, claim 3, and claim 4, it is possible to provide an embossing plate for horizontal handle embossing that allows air to escape from the slit more efficiently and almost eliminates the problem of air biting. It became possible to do.

  According to the invention described in claim 5, it is possible to provide an overlaid embossed decorative sheet in which the embossed portion is not chipped or looks white.

Hereinafter, the present invention will be described in detail based on the drawings.
FIG. 1 shows the structure of the surface of an embodiment of the embossing plate for horizontal handle embossing according to the present invention.
A horizontal handle emboss 2 is provided on the surface of the emboss roll 1, and a slit 3 is provided in the horizontal handle embossed portion 2.

  The embossing roll 1 is generally a copper plate having a surface plated with chrome or the like, but is not particularly limited to this and can be used as appropriate. In order to provide the embossing roll 1 with the labyrinth embossing 2, the embossing roll 1 is generally prepared by a commonly used etching method or laser plate-making method. However, the embossing roll 1 is not particularly limited, and various known methods are available. Can be produced.

  The horizontal handle embossed portion 2 is continuous in a direction substantially perpendicular to the rotation direction of the embol roll. Here, the term “substantially vertical” is not limited to vertical, but may be inclined from several degrees to slightly lower than 20 degrees. There is a tendency for the air bite to decrease as the tilt increases. Here, “continuous” means that the convex portion of the emboss is provided longer in the substantially vertical direction. Is provided.

The slit 3 is provided as a narrow concave portion provided along the rotational direction of the embossing roll with respect to the horizontal handle embossed portion 2. Here, the width of the slit 3 is 40 to 100 μm, and the interval between the slits is preferably 20 to 500 μm.
As a result, in the rotation direction of the horizontal handle embossed portion, an efficient flow of air over the horizontal handle embossed portion is completed from the front side of rotation to the back side of rotation, and the occurrence of air biting can be reduced or suppressed. If the slit width is too wide or the interval is too narrow, the embossed expression on the decorative sheet becomes rough, so this range is the most efficient.

  The depth of the slit is preferably 20% or more of the height of the emboss. If it is less than 20%, the air can not escape efficiently.

FIG. 2 shows a cross-sectional structure of an embodiment of the horizontal pattern embossed decorative sheet of the present invention.
On the appropriately colored thermoplastic resin substrate 4, a pattern layer 5 provided with a solid and / or pattern is provided by printing or the like, and a transparent thermoplastic resin layer 7 is appropriately provided with an anchor layer 6 interposed therebetween. Further, a surface protective layer 8 is appropriately provided on the surface, and a horizontal pattern emboss 9 extending over the surface protective layer 8 and the transparent thermoplastic resin layer 7 is provided.

  As the thermoplastic resin substrate 4 in the present invention, an appropriately colored thermoplastic resin is used. There is no restriction | limiting in particular in the kind of thermoplastic resin, The thing similar to what was used for the conventional general decorative sheet can be used fundamentally. Specifically, for example, polyolefin resins such as polyethylene, polypropylene, polymethylpentene, polybutene, ethylene-propylene copolymer, ethylene-α-olefin copolymer, propylene-α-olefin copolymer, and ethylene-vinyl acetate. Olefin-based copolymer resins such as copolymers, ethylene-vinyl alcohol copolymers, ethylene- (meth) acrylic acid (ester) copolymers, ethylene-unsaturated carboxylic acid copolymer metal neutralized products (ionomers) Polyolefin resins such as polyethylene terephthalate, polybutylene terephthalate, polytetramethylene terephthalate, polyethylene naphthalate, polyethylene terephthalate-isophthalate copolymer, 1,4-cyclohexanedimethanol copolymer polyethylene terephthalate Polyester resins such as silicate, polyarylate and polycarbonate, poly (meth) acrylonitrile, polymethyl (meth) acrylate, polyethyl (meth) acrylate, polybutyl (meth) acrylate, polyacrylamide and other acrylic resins, 6-nylon, 6 Polyamide resins such as 1,6-nylon and 6,10-nylon, styrene resins such as polystyrene, AS resin and ABS resin, vinyl resins such as polyvinyl chloride, polyvinyl acetate, polyvinyl alcohol, polyvinyl acetal and polyvinyl butyral , Fluorine resins such as polyvinyl fluoride, polyvinylidene fluoride, polytetrafluoroethylene, ethylene-tetrafluoroethylene copolymer, ethylene-perfluoroalkyl vinyl ether copolymer, or two or more of them Compound, the copolymer can be used complex, a laminate or the like.

Among the above-mentioned various thermoplastic resins, in view of the increasing social interest in environmental problems in recent years, it is not desirable to use a resin containing chlorine (halogen) such as polyvinyl chloride resin. It is desirable to employ a halogen-based thermoplastic resin. Among these, from the viewpoints of various physical properties, processability, versatility, economy, etc., it is most desirable to use polyolefin resin or polyester resin (amorphous or biaxial stretching). Of these, polyolefin resins have been pointed out to be conspicuously poor in machinability, although they have been used as decorative sheet materials to replace polyvinyl chloride resin. It is possible to remarkably improve the sex, and it is a material that exhibits the effects of the present invention most remarkably.

  As the above-mentioned polyolefin-based resin, many types are known as already listed, and may be appropriately selected from those according to the purpose of use of the decorative sheet. The most suitable for use is a polypropylene-based resin, that is, a single or copolymer mainly composed of propylene. Specifically, for example, a homopolypropylene resin, a random polypropylene resin, a block polypropylene resin or the like may be blended alone or appropriately. Further, a resin or the like in which atactic polypropylene is appropriately blended with them can be used. Further, it may be a copolymer containing an olefin monomer other than propylene, for example, an α-olefin having a polypropylene crystal part and having 2 to 20 carbon atoms other than propylene, preferably ethylene, butene- Examples thereof include a propylene-α-olefin copolymer containing 15 mol% or more of one or more comonomers of 1,4-methylpentene-1, hexene-1 or octene-1. In addition, low density polyethylene, ethylene-α-olefin copolymer, ethylene-propylene copolymer rubber, ethylene-propylene-nonconjugated diene copolymer rubber, styrene-butadiene copolymer, which are usually used for softening polypropylene resins. A modifier such as a coalescence or a hydrogenated product thereof can be appropriately added.

  For the thermoplastic resin base material 4, for example, a colorant, a filler (silica, talc, titanium oxide, barium sulfate, etc.), an ultraviolet absorber, a light stabilizer, a heat stabilizer, an antioxidant, an antistatic agent, if necessary. 1 or more selected from various additives such as lubricants (stearic acid, metal soap, etc.), flame retardants, antibacterial agents, antifungal agents, antifriction agents, light scattering agents, gloss adjusting agents, etc. good.

  As the pattern layer 5 in the present invention, it is provided as necessary in order to give the decorative sheet of the present invention design characteristics by a pattern, and when the colored thermoplastic resin base material 4 itself can be substituted, etc. Can be omitted. This pattern layer 5 uses a printing ink or paint obtained by dissolving or dispersing a colorant such as a dye or a pigment in a suitable diluent solvent together with a suitable binder resin, for example, a gravure printing method or an offset printing method. These are generally formed by various printing methods, and various coating methods such as a gravure coating method or a roll coating method. As the binder resin, for example, urethane resin, acrylic resin, vinyl chloroacetate resin, polyimide resin, nitrified cotton, or a mixture thereof is often used, but it is not limited thereto. The type of the pattern is arbitrary as desired, for example, a wood grain pattern, a stone pattern, a cloth pattern, an abstract pattern, a geometric pattern, a character or a symbol, a combination thereof, etc., and may be a solid color. Moreover, in order to improve the concealing property of the decorative sheet, a concealing layer made of an opaque printing ink or paint containing a large amount of an opaque pigment such as titanium dioxide or iron oxide may be provided on the back side of the pattern layer 5 in some cases.

  The anchor layer 6 provided as appropriate is provided as necessary to adhere the thermoplastic resin substrate 4 and the transparent thermoplastic resin layer 7 described later, and the adhesiveness of other layers can be used. In this case, it can be omitted. Although there is no restriction | limiting in particular in the kind of adhesive agent used for the anchor layer 6, It is most desirable to use the 2 liquid curing type urethane adhesive which uses an isocyanate type hardening | curing agent. Specifically, for example, polyester polyol or polyether polyol can be used as the main agent, and tolylene diisocyanate, diphenylmethane diisocyanate, xylylene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, or the like can be used as the curing agent.

  In the example shown in FIG. 2, the pattern layer 5 and the anchor layer 6 are arranged in this order from the thermoplastic resin base material 4 side to the transparent thermoplastic resin layer 7 side. It is not limited to the manufacturing method provided, and it can be set as arbitrary arrangements in random order according to the procedure. The example shown in FIG. 2 mainly assumes a manufacturing procedure in which a pattern layer 5 is sequentially formed on a thermoplastic resin substrate 4 and then laminated with a transparent thermoplastic resin layer 7 to be described later via an anchor layer 6. However, for example, the pattern layer 5 is sequentially formed on the back surface of the transparent thermoplastic resin layer 7 and is laminated on the thermoplastic resin substrate 4 via the anchor layer 6, or the transparent thermoplastic resin layer. A manufacturing procedure such as laminating the pattern ink layer 4 on the back surface of 7 and laminating these with the thermoplastic resin substrate 4 and the anchor layer 6 is applicable.

  As the transparent thermoplastic resin layer 7 in the present invention, the same thermoplastic resin as the thermoplastic resin substrate 4 can be used, and the same additive as the thermoplastic resin substrate 4 is added as necessary. May be. The transparent thermoplastic resin layer 7 is usually transparent or translucent. On the other hand, the colored thermoplastic resin 2 is often used in order to conceal color variations, defects, etc. on the surface of the base material for decorative material, and is opaque and colored, but the base material for cosmetic material is used. In order to make use of the surface texture of the material, a transparent or translucent material may be used. Moreover, the material of the thermoplastic resin base material 4 and the transparent thermoplastic resin layer 7 may be the same, and may differ. A plurality of thermoplastic resins may be mixed.

  The surface protective layer 8 provided as appropriate is provided on the surface of the transparent thermoplastic resin layer 7 which is the outermost surface of the decorative sheet in order to further improve the cutting workability of the decorative sheet of the present invention. A liquid curable acrylic urethane resin or ionizing radiation curable resin is preferably used. This surface protective layer 8 suppresses the elongation on the surface side of the transparent thermoplastic resin layer 7 and facilitates the breakage when the elongation rate reaches a certain level or more. It becomes effective for suppression.

  As the two-component curable urethane resin, a two-component curable polyol and isocyanate can be used. Examples of the ionizing radiation curable resin include prepolymers, oligomers and / or monomers having a polymerizable unsaturated bond such as a (meth) acryloyl group having a property of crosslinking reaction upon irradiation with ionizing radiation such as an electron beam or ultraviolet rays. A composition comprising the main component and, if necessary, an additive such as a polymerization initiator or a sensitizer can be used. The ionizing radiation here includes not only ionizing α-rays, β-rays, γ-rays (electron beams), radiation, short wavelength ultraviolet rays, etc., but also ultraviolet rays having no ionizing action.

  The horizontal pattern embossing 9 in the present invention is provided as necessary to give a decorative sheet a three-dimensional design feeling. The shape of the embossing is arbitrary as desired, for example, wood grain conduit, stone, cloth, abstract pattern, Japanese paper, suede, leather, satin, sand, hairline, parallel straight lines or parallel A geometric pattern such as a curve group or a combination thereof can be exemplified. The embossing may be performed before or after the transparent thermoplastic resin layer 7 is laminated on the thermoplastic resin substrate 4, or may be formed simultaneously with the lamination by a doubling embossing method or an extrusion lamination simultaneous embossing method. In the present invention, a high-speed extrusion laminate simultaneous embossing method is desirable. By using the embossed plate for horizontal pattern embossing according to the present invention, it is possible to obtain a decorative pattern embossed sheet having slits that are not problematic in design and in which the embossed part is not chipped or looks white. It becomes.

  In FIG. 3, the photograph of the surface of one Example of the horizontal pattern embossing decorative sheet of this invention is shown. The horizontal embossing 9 is provided from the left to the right in the center of the photograph, and the slit 2 is provided at the indicated location. Although it can be confirmed that there is a slit in this way, it is not a problem in terms of design visually.

(Preparation of embossed plate for horizontal pattern embossing)
The copper embossing roll was corroded three times by a laser plate making method and subjected to chrome plating, and the embossing plate for horizontal pattern embossing according to the present invention in which a horizontal pattern embossing portion having slits as shown in FIG. 1 was provided was produced.

(Production of decorative sheet)
A pattern was printed with urethane printing ink on the surface of a colored polyethylene resin sheet having a thickness of 80 μm (“Rivest TPO” manufactured by Riken Technos Co., Ltd.).
On this printed surface, the two-component curable polyester urethane adhesive was applied so that the coating amount after drying was 5 g / m ² .
On this adhesive-coated surface, a transparent polypropylene resin sheet having a thickness of 80 μm was extruded and laminated at 230 ° C. at a line speed of 70 m / min, and the surface was embossed with the embossing plate for horizontal embossing.
Further, an acrylic urethane resin (“UC Clear” manufactured by Dainippon Ink & Chemicals, Inc.) is applied to the embossed surface so that the coating amount after drying is 5 g / m ^2. Formed.
Furthermore, on the back surface of the colored polyethylene resin sheet, a urethane resin to which silica powder was added was applied so that the coating amount after drying was 1 g / m ² to form a primer layer, thereby preparing a decorative sheet.

(Production of decorative board)
30cm square, the surface density fiberboard in a thickness of 20 mm, a two-component aqueous emulsion adhesive of the coating prior to drying. The coating is 90 g / m ^2, and this primer layer side of the decorative sheet Then, pressure was applied to room temperature and 50 N / 30 cm square to bond, and a decorative board was produced.

  Except for changing the slit width, the slit interval, and the slit depth, in the same manner as in Example 1, horizontal pattern embossed decorative boards serving as Examples 2 and later and Comparative Examples were produced. The evaluation results are shown in Table 1.

  According to the present invention, it is possible to more efficiently manufacture a sheet-like material having a labyrinth emboss.

It is explanatory drawing which shows the outline of one Example of the embossing plate for horizontal pattern embossing of this invention. It is explanatory drawing which shows the structure of the cross section of one Example of the horizontal pattern embossing decorative sheet of this invention. It is a photograph of the surface of one Example of the horizontal pattern embossing decorative sheet of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Roll embossing 2 ... Horizontal pattern embossing part 3 ... Slit 4 ... Thermoplastic resin base material 5 ... Picture layer 6 ... Anchor layer 7 ... Transparent thermoplastic resin layer 8 ... Surface protection layer 9 ... Horizontal pattern embossing

Claims (5)

  An embossing plate for horizontal pattern embossing having a horizontal pattern embossing portion which is continuous in a direction substantially perpendicular to the rotation direction of the embossing roll, wherein a slit is provided in the rotation direction of the horizontal pattern embossing portion. .   The embossed plate for horizontal handle embossing according to claim 1, wherein the slit has a width of 40 to 100 µm.   The embossed plate for horizontal pattern embossing according to any one of claims 1 and 2, wherein a distance between the slits is 20 to 500 µm.   The embossed plate for horizontal pattern embossing according to any one of claims 1 to 3, wherein a depth of the slit is 20% or more of an embossed height.   A decorative sheet having at least a pattern layer and a transparent thermoplastic resin layer on a thermoplastic resin substrate, wherein a horizontal pattern embossing having a slit is provided on the transparent thermoplastic resin layer side, the horizontal pattern embossing decorative sheet characterized by .