JP2016187945A - Manufacturing method for embossed plate and manufacturing method for decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for an embossed plate, whereby gloss and design matching the design of a housing material such as a decorative sheet can be improved.SOLUTION: A manufacturing method for an embossed plate comprises the following steps (1) to (4): a step (1) in which a surface of a document having a three-dimensional surface is imaged and plate manufacturing data 1 is acquired; a step (2) in which a predetermined area of the plate manufacturing data 1 is selected, and plate manufacturing data 2 for design formed by an aggregation of points is created so as to correspond to the predetermined area; a step (3)in which a projecting and recessed shape is formed on a surface of a metal substrate on the basis of the plate manufacturing data 1 and an embossed plate intermediate body is formed; a step (4) in which an etching process is performed in a predetermined area of the embossed intermediate body on the basis of the plate manufacturing data 2, and an embossed plate is formed.SELECTED DRAWING: None

Description

  The present invention relates to a method for producing an embossed plate and a method for producing a decorative sheet using the embossed plate obtained by the method.

  2. Description of the Related Art Conventionally, a decorative sheet for building materials typified by wallpaper has been provided with a concavo-convex shape imitating a real thing such as wood grain. Such a concavo-convex shape is generally formed using an embossed plate.

  Embossed plates used for the formation of concave and convex shapes such as decorative sheets are subjected to blasting and the like on the concave and convex shapes to improve the gloss and design feeling of the decorative sheet surface. Known (see, for example, Patent Document 1 or Patent Document 2).

  However, in the conventional embossing plate manufacturing method, blasting is uniformly applied to the entire uneven surface area of the embossing plate, so that the embossing plate that improves gloss and design feeling according to the design of the decorative sheet There are significant limitations as to the method.

JP 2010-234513 A JP 2007-268740 A

  The main object of the present invention is to provide a method for producing an embossed plate that can improve the gloss and the design feeling according to the design of a building material such as a decorative sheet. Furthermore, this invention also aims at providing the method of manufacturing a decorative sheet using the embossing plate manufactured using the said method.

The inventors of the present invention have made extensive studies to solve the above problems. As a result, the embossing plate which can improve the glossiness and the design feeling according to the design of the decorative sheet such as wallpaper can be obtained by adopting the method for manufacturing the embossing plate comprising the following steps (1) to (4). I found out.
Step (1): The surface of a document having a three-dimensional surface is imaged, and plate making data 1 is acquired.
Step (2): A predetermined area of the plate making data 1 is selected, and plate making data 2 of a design formed by an aggregate of a plurality of points is created in an area corresponding to the predetermined area.
Step (3): Based on the plate making data 1, an uneven shape is formed on the surface of the metal substrate to form an embossed plate intermediate.
Step (4): Based on the plate-making data 2, an embossed plate is produced by performing an etching process on a predetermined region of the embossed plate intermediate.
That is, this invention provides the manufacturing method of the following embossing plate, and the manufacturing method of a decorative sheet using the embossing plate obtained by the said method.

Item 1. The manufacturing method of an embossing plate provided with following process (1)-(4).
Step (1): The surface of a document having a three-dimensional surface is imaged, and plate making data 1 is acquired.
Step (2): A predetermined area of the plate making data 1 is selected, and plate making data 2 of a design formed by an aggregate of a plurality of points is created in an area corresponding to the predetermined area.
Step (3): Based on the plate making data 1, an uneven shape is formed on the surface of the metal substrate to form an embossed plate intermediate.
Step (4): Based on the plate-making data 2, an embossed plate is produced by performing an etching process on a predetermined region of the embossed plate intermediate.
Item 2. Item 2. The method for manufacturing an embossed plate according to Item 1, wherein the predetermined region in the step (2) is a region mainly recorded as a recess in the plate-making data 1.
Item 3. The predetermined area in the step (2) is substantially the entire area of the plate making data 1, and the plate making data 2 in which the density of the aggregate of the plurality of points, the diameter of the points, and the height difference of the points is changed. The method for producing an embossed plate according to Item 1.
Item 4. In the step (2), using the image processing software, the predetermined area of the plate making data 1 is traced, and the plate making data 2 in which the design of the dark part and / or the bright part of the area is emphasized is created. The manufacturing method of the embossing plate in any one of.
Item 5. Item 5. The embossed plate production according to any one of Items 1 to 4, wherein the metal base is composed of at least one metal selected from the group consisting of copper, brass, zinc, aluminum, iron, and stainless steel. Method.
Item 6. The manufacturing method of the embossing plate in any one of claim | item 1 -5 whose said metal base | substrate is roll shape or plate shape.
Item 7. The manufacturing method of the embossing plate in any one of claim | item 1-6 provided with the process of laminating | stacking a chromium layer on the surface of the said metal base | substrate in which the said uneven | corrugated shape was formed after the said process (4).
Item 8. The embossing according to any one of Items 1 to 7, wherein the step (2) includes the following step (2A) and step (2B), and the step (3) includes the following step (3A). Plate manufacturing method.
Step (2A): A portion for emphasizing the design of the plate-making data 1 obtained in the step (1) is selected, and plate-making data 1A in which the design of the portion is emphasized is created. The plate-making data 1 and the plate-making data 1A is combined with plate making data 1B.
Step (2B): Either one of the predetermined areas of the plate-making data 1 or the plate-making data 1B is selected, and the plate-making data 2 having a design formed by an aggregate of a plurality of points is created in the area corresponding to the predetermined area. .
Step (3A): Based on the plate making data 1B, an uneven shape is formed on the surface of the metal substrate to form an embossed plate intermediate.
Item 9. The manufacturing method of a decorative sheet provided with the process of embossing using the embossing plate obtained by the manufacturing method of the embossing plate in any one of claim | item 1 -8.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the embossing plate which can improve the glossiness and design feeling according to the design of building materials, such as a decorative sheet, can be provided. Furthermore, according to this invention, the method of manufacturing a decorative sheet using the embossed plate manufactured using the said method can also be provided.

1. Embossing plate manufacturing method The embossing plate manufacturing method of the present invention includes the following steps (1) to (4).
Step (1): The surface of a document having a three-dimensional surface is imaged, and plate making data 1 (image data 1) is acquired.
Step (2): A predetermined area of the plate making data 1 is selected, and plate making data 2 (image data 2) having a design formed by an aggregate of a plurality of points is created in an area corresponding to the predetermined area.
Step (3): Based on the plate making data 1, an uneven shape is formed on the surface of the metal substrate to form an embossed plate intermediate.
Step (4): Based on the plate-making data 2, an embossed plate is produced by performing an etching process on a predetermined region of the embossed plate intermediate.
Hereinafter, the manufacturing method of the embossing plate of this invention is explained in full detail.

Process (1)
In step (1), the surface of the document having a three-dimensional surface is imaged and plate making data 1 is acquired. The original having a three-dimensional surface is not particularly limited, and an original having a design desired to be expressed on the surface of a building material such as a decorative sheet is used. Specific examples of the manuscript include wood, woven fabric, plaster, stone board, painted board, plastered wall, and the like. These originals are preferably used as the manuscript.

  The method for imaging the surface of the document is not particularly limited, and for example, the surface of the document may be scanned using a three-dimensional scanner or the like, and the three-dimensional data of the document surface may be stored in a storage device such as a computer.

  The plate-making data 1 may be data obtained by performing seamless processing on three-dimensional data obtained by imaging the document surface. That is, step (1) may be a step of acquiring plate making data 1 by imaging the surface of a document having a three-dimensional surface and further performing seamless processing. By performing seamless processing, originals larger than the size of a 3D scanner are divided into a plurality of images and then stitched together naturally, or when a roll-shaped embossed plate is manufactured, the seams at each cycle are made natural. It is possible to make the joint between the decorative sheets inconspicuous when the decorative sheets are arranged side by side. The seamless processing can be performed using commercially available image processing software. As the image processing software, the same one as in step (2) described later can be used.

Step (2)
In step (2), a predetermined area of plate making data 1 acquired in step (1) is selected, and plate making data 2 of a design formed by an aggregate of a plurality of points is created in an area corresponding to the predetermined area. . That is, the plate making data 2 is a design formed by an aggregate of a plurality of points, and the area of the design corresponds to a predetermined region selected by the plate making data 1.

  In the design of the plate-making data 2, an aggregate of a plurality of points is a design in which each point is a minute recess and the minute recess is gathered. What is necessary is just to set the diameter of each point suitably according to the design etc. of a decorative sheet, for example, about 50-250 micrometers is mentioned. Moreover, what is necessary is just to set suitably about the depth of a recessed part according to the design etc. of a decorative sheet, for example, about 10-100 micrometers is mentioned.

  For example, a designer can select a predetermined area and set a design in the plate-making data 1. The predetermined region forming the design can be appropriately selected depending on the design (uneven shape) to be applied to the decorative sheet or the like. From the viewpoint of manufacturing an embossed plate that can give a design that expresses a high three-dimensional effect to building materials such as a decorative sheet, the predetermined region forming the design is a region that emphasizes the three-dimensional effect of the decorative sheet, in particular. It is preferable to select.

  The predetermined area in the step (2) may be a partial area of the plate making data 1 or substantially the entire area. The predetermined area in the step (2) is preferably an area recorded mainly as a recess in the plate making data 1. That is, by forming the design of the plate-making data 2 (a set of a plurality of points) in an area corresponding to the area recorded mainly as the concave portion of the plate-making data 1, it is formed on a decorative sheet or the like by the embossed plate. The three-dimensional effect of the uneven shape can be further enhanced.

  In addition, when the predetermined area in the step (2) is substantially the entire area of the plate making data 1, the density of the aggregate of a plurality of points, the diameter of the points, and the entire area of the plate making data 1; The plate-making data 2 in which the height difference of the points is changed can be obtained. That is, when the predetermined area in the step (2) is substantially the entire area of the plate making data 1, by changing the density, diameter, and height difference of the aggregate of a plurality of points in the entire area, The design can be expressed using gradation that cannot be formed by conventional sandblasting. It is also possible to set a plurality of predetermined regions in the step (2), and to specify a plurality of points having different density, diameter, height difference, etc., for each of the points. Thereby, gloss changes according to the position of a pattern, and design nature can be improved.

  Step (2) is preferably performed using image processing software. The image processing software is not particularly limited, and a commercially available product can be used. By using image processing software, it is possible to trace the predetermined area of the plate making data 1 and create the plate making data 2 in which the design of the dark part and / or the bright part of the area is emphasized. By emphasizing the design of the dark part and / or the bright part of the predetermined region, an embossed plate that can further improve the gloss and the design feeling of the decorative sheet can be manufactured.

From the viewpoint of making an embossed plate capable of imparting a design that expresses a particularly high three-dimensional feeling to a building material such as a decorative sheet, step (2) includes the following step (2A) and step (2B). Preferably it is.
Step (2A): A portion for emphasizing the design of the plate making data 1 obtained in step (1) is selected, plate making data 1A is created with the design of the portion emphasized, and the plate making data 1 and the plate making data 1A are selected. Combining and creating plate making data 1B.
Step (2B): Either one of the predetermined areas of the plate-making data 1 or the plate-making data 1B is selected, and the plate-making data 2 having a design formed by an aggregate of a plurality of points is created in the area corresponding to the predetermined area. .

  In the step (2A), first, the plate making data 1 acquired in the step (1) is used to select a portion of the plate making data 1 to emphasize the design, and the plate making data 1A in which the design of the portion is emphasized is created. To do. The plate making data 1A is data that emphasizes the design of the portion of the plate making data 1 where the design is to be emphasized, and is different from the plate making data 1.

  For example, a designer can perform selection of a part that emphasizes the design in the plate-making data 1 and setting of the design. The part that emphasizes the design can be appropriately selected depending on the design to be applied to the decorative sheet or the like. From the viewpoint of manufacturing an embossed plate that can give a design that expresses a high three-dimensional effect to a building material such as a decorative sheet, the part that emphasizes the design is particularly selected as the part that emphasizes the three-dimensional effect of the uneven shape. It is preferable.

  The step (2A) is preferably performed using image processing software. The image processing software is not particularly limited, and a commercially available product can be used. By using the image processing software, it is possible to trace the part that emphasizes the design of the plate making data 1 and create the plate making data 1A having a pattern that emphasizes the design of the part.

  Next, in the step (2A), the plate making data 1 and the plate making data 1A are synthesized to create plate making data 1B. The plate making data 1B is uneven shape data formed on the embossed plate intermediate in the step (3A) described later. By synthesizing the plate making data 1 and the plate making data 1A in the step (2A) to make the plate making data 1B, the design (particularly the three-dimensional effect of the uneven shape) is partially emphasized in the step (3A) described later. The resulting embossed intermediate is obtained.

  The composition of the plate-making data 1 and the plate-making data 1A is not particularly limited as long as the plate-making data 1B can be used, and can be performed using commercially available image processing software or the like.

  In the step (2B), either one of the plate making data 1 or the plate making data 1B is selected, and the plate making data 2 of a design formed by an aggregate of a plurality of points is created in the region corresponding to the predetermined region. To do. That is, in the step (2B), the plate making data 2 may be created from the plate making data 1 or the plate making data 2 may be created from the plate making data 1B.

  In addition, in the manufacturing method of the embossing plate of this invention, when a process (2) is provided with the process (2A) and the process (2B), the below-mentioned process (3) becomes a process (3A).

  In the method for producing an embossed plate of the present invention, when the step (2) includes the step (2A) and the step (2B), the maximum height difference of the surface of the original having a three-dimensional surface is 1 mm or more, and further 3 mm What is super can also be used. The height difference of the concavo-convex shape that can be formed on the surface of the decorative sheet using the embossed plate is at most about several hundreds μm even when the decorative sheet is a foamed laminated sheet having a foamed resin layer, but the process (2A) And the embossed plate manufactured by the manufacturing method of the present invention including (2B), the three-dimensional design feeling of the original with a large difference in height is suitably reflected on the building material such as a decorative sheet. be able to.

Step (3)
In step (3), based on plate making data 1 created in step (1) (if step (2) includes step (2A) and step (2B), plate making data 1B), the metal substrate An embossed plate intermediate is formed by forming a concavo-convex shape on the surface. A method for forming an embossed plate intermediate by forming a concavo-convex shape on the surface of the metal substrate based on the plate making data 1 is not particularly limited, and a conventionally known method can be adopted.

  The metal constituting the metal substrate is not particularly limited and includes at least one metal selected from the group consisting of copper, brass, zinc, aluminum, iron, and stainless steel. Among these, when the concave and convex shape of the metal substrate is formed by the later-described corrosion method, the concave and convex shape can be suitably formed, and from the viewpoint of excellent stability of the concave and convex shape, iron, aluminum alloy, Copper is preferred.

  The shape of the metal substrate is not particularly limited, and examples thereof include a roll shape (columnar or cylindrical shape), a plate shape, and the like. Also, the size of the metal substrate is not particularly limited. For example, when a roll-shaped metal substrate used for an embossing plate for wallpaper is used, the roll circumference is about 600 to 1300 mm, and the width is 500 to 1400 mm. Degree.

  The method for forming the concavo-convex shape on the surface of the metal substrate is not particularly limited, and examples thereof include known methods such as a corrosion method, NC (numerical control) engraving method, and laser engraving method.

  For example, if the uneven shape is formed on the surface of the metal substrate by a corrosion method, the uneven shape can be formed as follows. First, a resist solution is applied to the surface of the metal substrate. Next, using a commercially available laser printing apparatus, plate making data 1 is output to form a pattern on the coating film of the resist solution. Next, by performing corrosion (etching) and resist stripping, an uneven shape corresponding to the plate making data 1 can be formed on the surface of the metal substrate. If the steps from application of the resist solution to resist stripping are repeated by matching the position of the pattern, a more complicated three-dimensional shape can be created.

  Further, for example, when forming a concavo-convex shape on the surface of the metal substrate by engraving, the plate making data 1 is input to a commercially available engraving machine, and the surface of the metal body is engraved using the engraving machine based on the plate making data 1. To do. Also by such a conventional NC engraving method, the uneven shape corresponding to the plate making data 1 can be formed on the surface of the metal substrate. In recent technology, embossing plate making by laser engraving has been put into practical use, and a desired embossing roll can be made in a shorter time than NC engraving.

  In the step (3), the height difference of the concavo-convex shape formed on the surface of the metal substrate is not particularly limited, but is usually 1000 μm or less, preferably about 200 to 800 μm, more preferably about 300 to 600 μm.

As described above, when the step (2) includes the step (2A) and the step (2B), the step (3) becomes the following step (3A).
Step (3A): Based on the plate making data 1B, an uneven shape is formed on the surface of the metal substrate to form an embossed plate intermediate.

  The step (3A) is the same as the step (3) except that the plate making data 1B is used instead of the plate making data 1.

  Note that either step (2) or step (3) may be performed first or in parallel. Further, when the plate making data 1B is used in the step (2B), the step (3A) can be performed before, after or in parallel with the step (2B).

Step (4)
In step (4), based on the plate making data 2 created in step (2), a predetermined region of the embossed plate intermediate is etched to produce an embossed plate. The design formed in the predetermined area based on the plate making data 2 is an aggregate of a plurality of points as described above. That is, in the embossed plate intermediate, the design formed by the etching process is a design in which point-like fine recesses are gathered. The diameter of each point and the depth of the recess are as described above.

  The embossed intermediate obtained by the above-mentioned step (3) is formed in a concavo-convex shape to such an extent that it can be used as a completed embossed plate in the conventional manufacturing method. And an etching process based on the plate making data 2 is performed on a predetermined region of the embossed plate intermediate, thereby obtaining an embossed plate that can improve the gloss and the design feeling according to the design of the building material such as a decorative sheet.

  The method for etching the predetermined region of the embossed plate intermediate is not particularly limited, and examples thereof include the above-described corrosion method. That is, first, a resist solution is applied to the surface of the embossed plate intermediate. Next, using a commercially available laser printing apparatus, plate making data 2 (that is, a design formed by an aggregate of a plurality of points in a region corresponding to a predetermined region of plate making data 1) is output, and the resist solution is applied. Bake the film. Next, by performing corrosion (etching) and resist peeling, a design corresponding to the plate-making data 2 can be formed on the surface of the embossed plate intermediate.

Lamination of chrome layer In the method for producing an embossed plate of the present invention, for the purpose of controlling gloss and providing a function as a protective layer, the uneven shape is formed after the step (4). A chromium layer may be laminated on the surface of the metal substrate. A known method can be adopted for the lamination of the chromium layer in the embossed plate.

  The kind of chromium used for the lamination of the chromium layer is not particularly limited. Since there are many types of chromium such as glossy and completely matte, it may be appropriately selected according to the design to be applied to the decorative sheet or the like. Further, the thickness of the chromium layer is not particularly limited, but preferably about 5 to 40 μm.

2. Manufacturing method of decorative sheet The manufacturing method of the decorative sheet of the present invention is characterized by including a step of embossing using the embossed plate obtained by the above-described method of manufacturing an embossed plate. The embossed plate to be used is as described above. Hereinafter, the manufacturing method of the decorative sheet of this invention is explained in full detail.

  In the method for producing a decorative sheet of the present invention, an object to be embossed is a decorative sheet before being embossed. The decorative sheet is not particularly limited, but is preferably a foamed laminated sheet having at least a foamed resin layer on a substrate. The foamed laminated sheet is suitable for applications such as wallpaper and ceiling materials because it has a good formability of the concavo-convex shape by embossing and is excellent in the concealability of the shape of the foundation to be constructed. Hereinafter, the preferable structure of the foaming lamination sheet used as the object which performs embossing is demonstrated.

The foamed laminated sheet to be subjected to the embossing of the laminated structure of the foamed laminated sheet is composed of a laminate in which at least a foamed resin layer is laminated on a substrate. A non-foamed resin layer A may be laminated on the foamed resin layer as necessary. Moreover, the non-foamed resin layer B may be laminated | stacked between the base material and the foamed resin layer as needed. Further, a pattern layer may be laminated on the non-foamed resin layer A as necessary. In addition, a matte layer may be laminated on the non-foamed resin layer A (on the design pattern layer if it has a design pattern layer) as necessary. Furthermore, a surface protective layer may be laminated on the outermost surface (surface opposite to the substrate) of the foamed laminated sheet, if necessary.

Composition of each layer that constitutes the foamed laminated sheet (base material)
The material of the base material is not particularly limited as long as it has mechanical strength, heat resistance and the like suitable for a base material such as a decorative sheet, and a fibrous sheet can be generally used.

  Specifically, among fiber sheets, general paper for wallpaper (pulp-based sheets sized with a known sizing agent); flame-retardant paper (pulp-based sheets such as guanidine sulfamate and guanidine phosphate) Treated with flame retardant); inorganic paper containing inorganic additives such as aluminum hydroxide and magnesium hydroxide; fine paper; thin paper; fiber mixed paper (paper made by mixing pulp and synthetic fiber) Can be mentioned. In addition, what corresponds to a nonwoven fabric is included in the fibrous sheet used for this invention on classification.

Although the basis weight of the substrate is not critical, preferably about 50 to 300 g / m ^2, about 50~130g / m ² is more preferable.

(Non-foamed resin layer B)
In the present invention, the non-foamed resin layer B may be formed between the base material and the foamed resin layer as necessary. In particular, when the non-foamed resin layer B is formed as an adhesive layer, excellent adhesion can be obtained. As the non-foamed resin layer B, for example, ethylene-vinyl acetate copolymer resin (EVA) or the like can be suitably used. The non-foamed resin layer B may contain known additives in addition to the resin component, but is preferably blended so that the content of the resin component is 70 to 100% by mass.

  The thickness of the non-foamed resin layer B is not limited, but is preferably about 3 to 50 μm, and more preferably about 5 to 20 μm.

(Foamed resin layer)
The foamed resin layer is a layer formed by foaming the foaming agent-containing resin layer. As the resin component contained in the foaming agent-containing resin layer, vinyl chloride resins and olefin resins conventionally used for wall covering materials can be widely used. However, the vinyl chloride resin may cause the plasticizer to bleed over time. Therefore, an olefin resin is preferable to a vinyl chloride resin from the viewpoint of increasing the durability of the laminated sheet. Also, from the viewpoint of easy embossing, an olefin resin is preferable to a vinyl chloride resin, and an ethylene resin is particularly preferable.

  The ethylene-based resin contains at least one kind of ethylene copolymer (hereinafter, abbreviated as “ethylene copolymer”) having, in particular, 1) polyethylene and 2) ethylene and components other than ethylene as monomers. preferable.

  As the polyethylene, low-density polyethylene (LDPE), medium-density polyethylene (MDPE), high-density polyethylene (HDPE), linear low-density polyethylene (LLDPE), and the like can be widely used. Among these, low-density polyethylene is preferable.

  The ethylene copolymer is suitable for extrusion film formation from the viewpoint of the melting point and MFR (melt flow rate). Examples of the ethylene copolymer include an ethylene-vinyl acetate copolymer (EVA), an ethylene-methyl methacrylate copolymer (EMMA), an ethylene-ethyl acrylate copolymer (EEA), and an ethylene-methyl acrylate copolymer ( EMA), ethylene-methacrylic acid copolymer (EMAA), ethylene-α olefin copolymer, and the like.

  These ethylene copolymers can be used alone or in admixture of two or more. Among these ethylene copolymers, at least one of ethylene-vinyl acetate copolymer, ethylene-methyl methacrylate copolymer and ethylene-methacrylic acid copolymer is preferable, and when these are used in combination with other resins. The content of at least one of ethylene-vinyl acetate copolymer, ethylene-methyl methacrylate copolymer and ethylene-methacrylic acid copolymer is preferably 70% by mass or more, and more preferably 80% by mass or more.

  Moreover, 5-25 mass% is preferable as content of monomers other than ethylene, and, as for ethylene copolymer, 9-20 mass% is more preferable. By adopting such a copolymerization ratio, the extrusion film forming property is further enhanced. As a specific example, the ethylene-vinyl acetate copolymer has a vinyl acetate copolymerization ratio (VA amount) of preferably 9 to 25% by mass, more preferably 9 to 20% by mass. The ethylene-methyl methacrylate copolymer preferably has a methyl methacrylate copolymerization ratio (MMA amount) of 5 to 25% by mass, more preferably 5 to 15% by mass. Moreover, 2-15 mass% is preferable as a copolymerization ratio (MAA amount) of methacrylic acid, and, as for an ethylene-methacrylic acid copolymer, 5-11 mass% is more preferable.

  The resin component contained in the foaming agent-containing resin layer preferably has an MFR measured at 190 ° C. and a load of 21.18 N described in JIS K 6922 of 10 to 25 g / 10 minutes. When the MFR is within the above range, the temperature rise when forming the foaming agent-containing resin layer by extrusion film formation is small, and since the film can be formed in a non-foamed state, a smooth surface can be formed when a pattern layer is formed later. Can be printed easily and there is little pattern loss. If the MFR is too large, the resin is too soft, and the formed foamed resin layer may have insufficient scratch resistance.

  Preferable examples of the foaming agent contained in the foaming agent-containing resin layer include a pyrolytic foaming agent. Examples of the thermally decomposable foaming agent include azo series such as azodicarbonamide (ADCA) and azobisformamide; hydrazide series such as oxybenzenesulfonyl hydrazide (OBSH) and paratoluenesulfonyl hydrazide. The content of the pyrolytic foaming agent can be appropriately set according to the type of foaming agent, the expansion ratio, and the like. From the viewpoint of the expansion ratio, it is 3 times or more, preferably about 7 to 10 times, and the pyrolytic foaming agent is preferably about 1 to 20 parts by mass with respect to 100 parts by mass of the resin component.

  As the resin composition for forming the foaming agent-containing resin layer, for example, a resin composition containing the above resin component, wax, inorganic filler, pigment, crosslinking aid and the like can be suitably used. In addition, stabilizers, lubricants and the like can be used as additives.

  It does not specifically limit as a wax, A conventionally well-known wax can be used. As such a wax, for example, paraffin wax, polyethylene wax, polypropylene wax and the like can be used, and among them, polyethylene wax is preferable.

  The weight average molecular weight (Mw) of the wax is preferably 1,000 to 10,000, and more preferably 1,500 to 5,000. The wax is distinguished from the resin used as the resin component by MFR and weight average molecular weight. That is, the wax has a very low molecular weight, and the fluidity is so high that MFR cannot be measured. For this reason, the resin used as the resin component is different from the wax.

  About 0.1-10 mass parts is preferable with respect to 100 mass parts of resin components, and, as for content of wax, about 0.5-5 mass parts is more preferable.

  Examples of the inorganic filler include calcium carbonate, aluminum hydroxide, magnesium hydroxide, antimony trioxide, zinc borate, and a molybdenum compound. By including an inorganic filler, an effect of suppressing see-through, an effect of improving surface characteristics, and the like are obtained. About 0-100 mass parts is preferable with respect to 100 mass parts of resin components, and, as for content of an inorganic filler, about 20-70 mass parts is more preferable.

  For pigments, for example, titanium oxide, zinc white, carbon black, black iron oxide, yellow iron oxide, yellow lead, molybdate orange, cadmium yellow, nickel titanium yellow, chrome titanium yellow, iron oxide (valve) ), Cadmium red, ultramarine, bitumen, cobalt blue, chromium oxide, cobalt green, aluminum powder, bronze powder, titanium mica, and zinc sulfide. Examples of organic pigments include aniline black, perylene black, azo (azo lake, insoluble azo, condensed azo), polycyclic (isoindolinone, isoindoline, quinophthalone, perinone, flavantron, anthrapyrimidine, anthraquinone, quinacridone. Perylene, diketopyrrolopyrrole, dibromoanthanthrone, dioxazine, thioindigo, phthalocyanine, indanthrone, halogenated phthalocyanine). About 10-50 mass parts is preferable with respect to 100 mass parts of resin components, and, as for content of a pigment, about 15-30 mass parts is more preferable.

  Although the thickness of a foaming agent containing resin layer is not limited, About 40-100 micrometers is preferable. Further, the thickness of the foamed resin layer after foaming is preferably about 300 to 700 μm.

  What is necessary is just to implement according to the method described in the below-mentioned manufacturing method as a method of foaming a foaming agent containing resin layer.

(Non-foamed resin layer A)
It is preferable that the non-foamed resin layer A is formed on the foamed resin layer. The non-foamed resin layer A mainly protects the foamed resin layer. In the present invention, a layer formed of a resin composition containing, as a resin component, a polymer obtained using at least one of acrylic acid (CH ₂ ═CHCOOH) and methacrylic acid (CH ₂ ═C (CH ₃ ) COOH) as a monomer. Is preferably the non-foamed resin layer A.

  As the resin component, for example, a copolymer obtained by a combination of at least one monomer of acrylic acid and methacrylic acid and ethylene can be suitably used as the resin component. More specifically, it is desirable to use at least one of ethylene-methacrylic acid copolymer (EMAA), ethylene-acrylic acid copolymer, and ionomer resin. As the ionomer resin, a resin having a structure in which the molecules of ethylene-methacrylic acid copolymer and / or ethylene-acrylic acid copolymer are intermolecularly bonded with metal ions such as sodium and zinc can be used. When such a resin component is used, it is possible to form a strong layer particularly due to hydrogen bonds in the resin, so that excellent scratch resistance, abrasion resistance, and the like can be obtained. These may be known or commercially available.

  The content of acrylic acid or methacrylic acid in the copolymer is preferably about 4 to 15% by mass. Such a resin can also use a commercial item. A known additive can also be blended in the resin composition.

  The thickness of the non-foamed resin layer A is not limited, but is preferably about 2 to 50 μm, and more preferably about 5 to 20 μm.

  Moreover, although content of the said resin component in a resin composition is not limited, Usually, it is preferable to set suitably in the range of 70-100 mass%.

(Matte layer)
A matte layer may be laminated on the non-foamed resin layer A as necessary. The matte layer is provided to reduce the gloss of the surface of the foam wallpaper.

  The matte layer contains 2 to 10% by mass (preferably 3 to 6% by mass) of acrylic particles having an average particle size of 3 to 20 μm (preferably 3 to 10 μm). Here, the acrylic particles are acrylic resin particles. The average particle diameter of the acrylic particles is an average value when the acrylic particles are observed with a scanning electron microscope and the particle diameters of 100 or more particles are measured. By having such a matte layer, the gloss of the surface of the foam wallpaper can be suppressed sufficiently low.

  Moreover, if it is the said content, even when it further has a pattern pattern layer between the non-foaming resin layer A and a matte layer, the visibility of a pattern pattern layer is not inhibited.

  The matte layer can be formed, for example, by applying a coating agent containing the acrylic particles on the non-foamed resin layer A and then drying it. Examples of the coating agent include compositions containing the above acrylic particles, resin components other than acrylic particles, liquid components, and the like. More specifically, there is a composition containing the acrylic particles, aqueous urethane resin, water and / or alcohol. Silicone particles may be further added for the purpose of adjusting the surface smoothness of the matte layer. By adding the silicone particles, the surface of the matte layer is reduced in scratches and friction, so that the scratch resistance of the surface can be improved.

  The thickness of the matte layer is not limited, but it is preferable that some of the acrylic particles protrude from the surface of the matte layer. That is, it is preferable that the thickness by components other than acrylic particles is about 2 to 10 μm (particularly about 2 to 5 μm).

(Pattern pattern layer)
In the present invention, a pattern layer may be further provided between the non-foamed resin layer A and the matte layer as necessary.

  The pattern layer imparts design properties to the foamed wallpaper. Examples of the design pattern include a wood grain pattern, a stone pattern, a grain pattern, a tiled pattern, a brickwork pattern, a cloth pattern, a leather pattern, a geometric figure, a character, a symbol, and an abstract pattern. The pattern can be selected according to the type of foam wallpaper.

  The pattern pattern layer can be formed, for example, by printing a pattern pattern on the non-foamed resin layer. In addition, when forming a pattern layer, you may form a primer layer previously as needed. Examples of printing methods include gravure printing, flexographic printing, silk screen printing, and offset printing. As the printing ink, a printing ink containing a colorant, a binder resin, and a solvent (or a dispersion medium) can be used. These inks may be known or commercially available.

  As the colorant, for example, a pigment used in a foaming agent-containing resin layer can be appropriately used.

  The binder resin is, for example, an acrylic resin, a styrene resin, a polyester resin, a urethane resin, a chlorinated polyolefin resin, a vinyl chloride-vinyl acetate copolymer resin, a polyvinyl butyral resin, an alkyd resin, or a petroleum resin. Examples include resins, ketone resins, epoxy resins, melamine resins, fluorine resins, silicone resins, fiber derivatives, rubber resins, and the like.

  Examples of the solvent (or dispersion medium) include petroleum organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and acetic acid-2 -Ester-based organic solvents such as ethoxyethyl; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, propylene glycol; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone Organic solvents; ether organic solvents such as diethyl ether, dioxane, tetrahydrofuran; dichloromethane, carbon tetrachloride, trichloroethylene, tetrachloroethylene Chlorinated organic solvents; and water.

  The thickness of the design pattern layer is different from the type of design pattern, but is generally preferably about 0.1 to 10 μm.

(Surface protective layer)
The foamed wallpaper may form a surface protective layer on the outermost surface (surface opposite to the base material). The kind of surface protective layer is not limited. If it is a surface protective layer aiming at gloss adjustment, there exists a surface protective layer containing known fillers, such as a silica, for example. As a method for forming the surface protective layer, a known method such as gravure printing can be employed. In addition, when adhesion between the layer (for example, the pattern layer) located under the surface protective layer and the surface protective layer is not sufficiently obtained, the surface of the pattern layer was subjected to easy adhesion treatment (primer treatment). A surface protective layer can also be provided later.

  When forming a surface protective layer for the purpose of surface strength (such as scratch resistance) of foamed wallpaper, stain resistance, protection of the pattern layer, etc., those containing ionizing radiation curable resins as resin components are suitable. is there. The ionizing radiation curable resin is preferably one that undergoes radical polymerization (curing) by electron beam irradiation.

  When a surface protective layer containing an ionizing radiation curable resin is formed, the surface protective layer can be cured by electron beam irradiation. Such electron beam irradiation can be performed simultaneously (same processing) as electron beam irradiation performed to crosslink the resin contained in the foaming agent-containing resin layer. That is, after forming a foaming agent-containing resin layer, a pattern layer and a surface protective layer containing an ionizing radiation curable resin in order, electron beam irradiation is performed to crosslink the resin contained in the foaming agent-containing resin layer and protect the surface. The resin contained in the layer can be cured.

  The thickness of the surface protective layer can be appropriately set, and is preferably about 0.1 to 15 μm.

(Embossing)
As described above, in the wallpaper manufacturing method of the present invention, the foamed wallpaper is embossed to give the surface an uneven shape. In this case, embossing may be performed from the outermost surface side (the side opposite to the base material). In embossing, the above-mentioned embossing plate is used. Conventionally known conditions may be appropriately adopted as conditions such as pressing of the embossed plate. For example, a desired uneven shape can be imparted by pressing the embossed plate after heat-softening the surface of the foam wallpaper. Examples of the concavo-convex shape imparted by embossing include the patterns such as woven fabric, plaster, stone plate, painted plate, plastered wall, etc. described above.

Method for producing foam wallpaper The method for producing the foam wallpaper is not particularly limited. For example, in order to produce a foam wallpaper having a foamed resin layer and a non-foamed resin layer A in order on a base material, two layers of a foaming agent-containing resin layer and a non-foamed resin layer A are simultaneously extruded by a T-die extruder. Is preferred. A multi-manifold type T-die capable of simultaneously forming two layers by simultaneously extruding molten resin corresponding to two layers can be used. In this case, the resin composition for forming the foaming agent-containing resin layer and the resin composition for forming the non-foamed resin layer A are placed in separate cylinders, and two types and two layers are simultaneously extruded to form and laminate. do it. In this method, the coextruded laminate is simultaneously laminated (film formation) on the substrate. Since the resin layer laminated simultaneously with extrusion on the base material has adhesiveness by heat melting, it is bonded to the base material.

  In addition, a laminate in which two types and two layers are simultaneously formed in advance may be prepared, placed on the substrate, and bonded to the substrate by thermal lamination.

  In addition, when an inorganic filler is contained in the resin composition forming the foaming agent-containing resin layer, and the foaming agent-containing resin layer is formed by extrusion molding, an extrusion port (so-called die) of an extrusion molding machine is used. Inorganic filler residues (so-called eyes and eyes) are likely to occur, and this tends to be a foreign matter on the sheet surface. Therefore, when the inorganic filler is contained in the resin composition forming the foaming agent-containing resin layer, the non-foaming resin layer A and the non-foaming resin layer B can be coextruded together with the foaming agent-containing resin layer. preferable. In this manner, the co-extrusion molding in a mode in which the foaming agent-containing resin layer is sandwiched between the non-foamed resin layers can suppress the occurrence of the above-mentioned eye corners.

  Next, the foamed resin layer is formed by heating the foaming agent-containing resin layer. The heating conditions are not limited as long as the foamed resin layer is formed by the decomposition of the pyrolytic foaming agent. The heating temperature is preferably about 210 to 240 ° C., and the heating time is preferably about 20 to 80 seconds.

  Electron beam irradiation may be performed before the heat treatment. Thereby, since the resin component can be crosslinked, the surface strength of the foamed wallpaper, the degree of foaming, and the like can be controlled. The energy of the electron beam is preferably about 150 to 250 kV. The irradiation amount is preferably about 1 to 7 Mrad. A known electron beam irradiation apparatus can be used as the electron beam source. Crosslinking can also be performed using a chemical crosslinking agent (also referred to as a crosslinking agent or a crosslinking aid).

  In the case of performing electron beam irradiation, the composition may contain a crosslinking agent. Any crosslinking agent that promotes crosslinking by electron beam irradiation may be used. Examples thereof include polyfunctional monomers such as neopentyl glycol dimethacrylate and trimethylolpropane trimethacrylate, oligomers, and the like. The cross-linking agent is preferably about 0 to 10 parts by mass, more preferably 1 to 4 parts by mass with respect to 100 parts by mass of the resin component.

  When producing a foam wallpaper having a pattern layer, it is preferable to form a pattern layer on the surface of the non-foamed resin layer A before the heat treatment. The pattern pattern layer may be formed as described above.

  EXAMPLES Next, although an Example demonstrates this invention further in detail, this invention is not limited at all by these examples.

Example 1 Production of Embossed Plate An embossed plate was produced by the following steps. A plasterer applied a plaster iron to the base material (gypsum board) to form a concavo-convex pattern with the sensitivity of the craftsman. The surface roughness of the finished plaster panel exceeded 3 mm at the maximum. The unevenness of the surface unevenness was varied over a wide range with the pitch of the arm of the plasterer as the pitch. Next, the plaster panel was cut to a size that can be set on an XY table of a commercially available three-dimensional input machine. Next, the input resolution of the three-dimensional input machine was set to 635 dpi, and a plurality of previously cut documents were input. A plurality of inputted images were connected with image processing software (Photoshop made by Adobe) to create a seamless image A (plate making data 1).

  Next, the image A was divided into five levels using the posterization function of the image processing software on the seamless image A. Of the five stages, the region of the most concave portion (the most convex portion of the plate) was set as the target region. On the other hand, a white image having a resolution of 342 dpi in the same gray scale mode and vertical and horizontal sizes as the image A was produced. The density of the white image was changed to 17%, and an image B (plate making data 2) of a set of a plurality of points was further obtained with two monochrome gradations (error diffusion method). The diameter of one of the points was about 75 μm, and the area ratio of black spots in the white field was generated at 16 to 18%.

  Next, a seamless image A was engraved with a maximum depth of 700 μm on a hollow cylindrical iron base having a surface length of 1100 mm using a commercially available laser engraving machine. The embossing roll was further engraved at a depth of 70 μm using the binary image B. Image A and image B were aligned. After engraving, surface finishing was performed with sandblast (alumina # 220), and chrome plating was further applied to a thickness of 10 μm to obtain an embossed plate of Example 1.

Comparative Example 1 Production of Embossed Plate An embossed plate was produced by the following steps. A plasterer applied a plaster iron to the base material (gypsum board) to form a concavo-convex pattern with the sensitivity of the craftsman. The surface roughness of the finished plaster panel exceeded 3 mm at the maximum. The unevenness of the surface unevenness was varied over a wide range with the pitch of the arm of the plasterer as the pitch. Next, the plaster panel was cut to a size that can be set on an XY table of a commercially available three-dimensional input machine. Next, the input resolution of the three-dimensional input machine was set to 635 dpi, and a plurality of previously cut documents were input. A plurality of inputted images were connected with image processing software (Photoshop made by Adobe) to create a seamless image A (plate making data 1).

  Next, a seamless image A was engraved with a maximum depth of 700 μm on a hollow cylindrical iron base having a surface length of 1100 mm using a commercially available laser engraving machine. After engraving, surface finishing was performed with sandblasting (alumina # 220), and chrome plating was applied to a thickness of 10 μm to obtain an embossed plate of Comparative Example 1.

(Example 2) Production of foamed wallpaper Using a three-type three-layer multi-manifold T-die extruder, the thickness becomes 10 μm / 100 μm / 10 μm in the order of non-foamed resin layer A / foaming agent-containing resin layer / non-foamed resin layer B. Thus, a film was extruded onto the backing paper. Thereby, the laminated body which consists of non-foaming resin layer A / foaming agent containing resin layer / non-foaming resin layer B / backing paper was obtained. As the backing paper, “NI-65A (manufactured by Nippon Paper Industries Co., Ltd.)” was prepared, heated to 90 ° C., and then the above three layers were extruded to form a film. As for the extrusion conditions, the cylinder temperature containing the resin for forming the non-foamed resin layer A was 115 ° C., the cylinder temperature containing the resin composition for forming the foaming agent-containing resin layer was 110 ° C., and non-foamed The cylinder temperature in which the resin for forming the resin layer B was accommodated was 100 ° C. The die temperature was 110 ° C. for all.

The laminate was irradiated with an electron beam (200 KV, 3 Mrad) from the non-foamed resin layer A side, and the non-foamed resin layer A was particularly resin-crosslinked. Further, a corona discharge treatment was performed on the non-foamed resin layer A. Next, an EVA-based aqueous emulsion was applied on the non-foamed resin layer A (2 g / m ² ) to form a primer layer, and a fabric pattern was printed with an aqueous ink “Hydric” (manufactured by Dainichi Seika Kogyo). . Next, the laminate on which the fabric pattern was printed was heated in a furnace (250 ° C. × about 30 seconds) to foam the foaming agent-containing resin layer. Finally, an uneven shape was imparted to the foam using the embossed plate produced in Example 1 to obtain a foam wallpaper.

Each layer of the foam wallpaper was formed using the following components.
The non-foamed resin layer A was formed by EMAA “Nucleel N1560 (MAA content: 15 wt%, MFR: 60 g / 10 min), manufactured by Mitsui DuPont Polychemicals”.
-The foaming agent-containing resin layer consists of EVA "Evaate H4011 (VA content: 20 wt%), manufactured by Sumitomo Chemical" 90 parts by weight, hydrogenated petroleum resin "Alcon P-100, manufactured by Arakawa Chemical" 10 parts by weight, calcium carbonate 40 parts by weight of “Whiteon H, manufactured by Toyo Fine Chemical”, 20 parts by weight of titanium dioxide “R-108, manufactured by DuPont”, 4 parts by weight of ADCA foaming agent “Vinihole AC # 3, manufactured by Eiwa Kasei Kogyo”, stabilizer “ADK STAB CPL -19, manufactured by ADEKA ”and a resin composition consisting of 3.3 parts by weight of a foaming aid“ zinc stearate ”.
The non-foamed resin layer B was formed by EVA “Evaflex EV150 (VA content: 33% by weight), manufactured by Mitsui DuPont Polychemical”.

Comparative Example 2 Production of Foamed Wallpaper A foamed wallpaper was produced in the same manner as in Example 2 except that the embossed plate produced in Comparative Example 1 was used instead of the embossed plate produced in Example 1.

<Evaluation of design feeling>
The design feeling of the decorative sheets obtained in Example 2 and Comparative Example 2 was evaluated according to the following criteria. The wallpaper of Example 2 was applied to one surface of a living room wall width of about 3600 mm and a ceiling height of 2400 mm from a floor. Moreover, the wallpaper of the comparative example 2 was constructed in the living room of the same floor plan (the direction of the window is the same). Next, we asked 50 men and women in their 30s to 50s who were randomly selected from the public about which wall they would like to construct in their homes. As a result, 92% of people chose the foamed wallpaper obtained in Example 2.

Claims (9)

The manufacturing method of an embossing plate provided with following process (1)-(4).
Step (1): The surface of a document having a three-dimensional surface is imaged, and plate making data 1 is acquired.
Step (2): A predetermined area of the plate making data 1 is selected, and plate making data 2 of a design formed by an aggregate of a plurality of points is created in an area corresponding to the predetermined area.
Step (3): Based on the plate making data 1, an uneven shape is formed on the surface of the metal substrate to form an embossed plate intermediate.
Step (4): Based on the plate-making data 2, an embossed plate is produced by performing an etching process on a predetermined region of the embossed plate intermediate.   The method for manufacturing an embossed plate according to claim 1, wherein the predetermined region in the step (2) is a region recorded mainly as a concave portion in the plate making data 1.   The predetermined area in the step (2) is substantially the entire area of the plate making data 1, and the plate making data 2 in which the density of the aggregate of the plurality of points, the diameter of the points, and the height difference of the points is changed. The method for producing an embossed plate according to claim 1.   In the step (2), using the image processing software, the predetermined area of the plate making data 1 is traced, and the plate making data 2 in which the design of the dark part and / or the bright part of the area is emphasized is created. 4. A method for producing an embossed plate according to any one of 3 above.   The embossing plate according to any one of claims 1 to 4, wherein the metal substrate is made of at least one metal selected from the group consisting of copper, brass, zinc, aluminum, iron, and stainless steel. Production method.   The manufacturing method of the embossing plate in any one of Claims 1-5 whose said metal base | substrate is roll shape or plate shape.   The manufacturing method of the embossing plate in any one of Claims 1-6 provided with the process of laminating | stacking a chromium layer on the surface of the said metal base | substrate in which the said uneven | corrugated shape was formed after the said process (4). The said process (2) is equipped with the following processes (2A) and the process (2B), and the process (3) is equipped with the following processes (3A) in any one of Claims 1-7. Embossed plate manufacturing method.
Step (2A): A portion for emphasizing the design of the plate-making data 1 obtained in the step (1) is selected, and plate-making data 1A in which the design of the portion is emphasized is created. The plate-making data 1 and the plate-making data 1A is combined with plate making data 1B.
Step (2B): Either one of the predetermined areas of the plate-making data 1 or the plate-making data 1B is selected, and the plate-making data 2 having a design formed by an aggregate of a plurality of points is created in the area corresponding to the predetermined area. .
Step (3A): Based on the plate making data 1B, an uneven shape is formed on the surface of the metal substrate to form an embossed plate intermediate.   The manufacturing method of a decorative sheet provided with the process of embossing using the embossing plate obtained by the manufacturing method of the embossing plate in any one of Claims 1-8.