JP2019194020A - Method for producing shaped article and heat-expandable sheet - Google Patents

Abstract

To provide a heat-expandable sheet that can suppress a heat-expansion layer from peeling from the substrate when expanding the heat-expansion layer, and to provide a method for producing heat-expandable sheet.SOLUTION: The heat-expandable sheet 10 includes a substrate 11, a first expansion layer 12 provided on the substrate 11, and a second expansion layer 13 provided on the first expansion layer 12. The first heat-expansion layer 12 provided between the substrate 11 and the second expansion layer 13 contains a heat-expandable material at a lower ratio than the second heat expansion layer 13.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a thermally expandable sheet that expands by expansion according to the amount of heat absorbed, and a method for producing the thermally expandable sheet.

  2. Description of the Related Art Conventionally, a thermally expandable sheet is known in which a thermally expandable layer including a thermally expandable material that expands and expands according to the amount of heat absorbed is formed on one surface of a base sheet. By forming a light-to-heat conversion layer that converts light into heat on the thermally expandable sheet and irradiating the light-to-heat conversion layer with light, the heat-expandable layer can be partially or wholly expanded. Moreover, the method of forming a three-dimensional molded item (stereoscopic image) on a thermally expansible sheet | seat by changing the shape of a photothermal conversion layer is also known (for example, refer patent document 1, 2).

JP-A 64-28660 JP 2001-150812 A

  By the way, in a thermally expansible sheet, when a thermal expansion layer is heated, a thermal expansion layer expand | swells in the direction opposite to the surface in which the base material was provided. At this time, the lower surface of the thermal expansion layer may peel from the substrate. When peeling occurs between the base material and the thermal expansion layer, the thermal expansion layer cannot maintain its shape and height at the part where the peeling occurs, and deforms when force is applied. There is.

  For this reason, when a thermal expansion layer is expanded, the thermally expansible sheet which can suppress that a thermal expansion layer peels from a base material is calculated | required.

  The present invention has been made in view of the above circumstances, and manufacture of a thermally expandable sheet and a thermally expandable sheet that can prevent the thermally expandable layer from peeling from the base material when the thermally expandable layer is expanded. It aims to provide a method.

In order to achieve the above object, the thermally expandable sheet according to the present invention is:
A first thermal expansion layer formed on one side of the substrate and comprising a first thermal expansion material in a first ratio to the binder;
A second thermal expansion layer formed on the first thermal expansion layer and including a second thermal expansion material in a second ratio with respect to the binder;
The first thermally expandable material and the second thermally expandable material are the same material,
The first ratio is smaller than the second ratio;
It is characterized by that.

In order to achieve the above object, a method for producing a thermally expandable sheet according to the present invention includes:
Forming on the one surface of the substrate a first thermal expansion layer containing the first thermal expansion material in a first ratio with respect to the binder;
Forming, on the first thermal expansion layer, a second thermal expansion layer containing a second thermal expansion material in a second ratio with respect to the binder,
The first thermally expandable material and the second thermally expandable material are the same material,
Reducing the first proportion compared to the second proportion;
It is characterized by that.

  ADVANTAGE OF THE INVENTION According to this invention, when a thermal expansion layer is expanded, the manufacturing method of the thermal expansion sheet which can suppress that a thermal expansion layer peels from a base material, and a thermal expansion sheet can be provided.

2 is a cross-sectional view schematically showing a thermally expandable sheet according to Embodiment 1. FIG. 3 is a cross-sectional view schematically showing a method for producing a thermally expandable sheet according to Embodiment 1. FIG. 1 is a diagram illustrating an overview of a stereoscopic image forming system according to Embodiment 1. FIG. 3 is a flowchart illustrating a stereoscopic image forming process according to the first embodiment. 3 is a cross-sectional view schematically showing a stereoscopic image forming process according to Embodiment 1. FIG. It is sectional drawing which shows typically the thermally expansible sheet which concerns on Embodiment 2. FIG. It is sectional drawing which shows typically the state which expanded the comparative example and the thermally expansible sheet which concerns on Embodiment 2. FIG. It is sectional drawing which shows typically the thermally expansible sheet which concerns on Embodiment 3. FIG.

  Hereinafter, a thermally expandable sheet and a method for producing a thermally expandable sheet according to an embodiment of the present invention will be described in detail with reference to the drawings.

(Embodiment 1)
As shown in FIG. 1, the thermally expandable sheet 10 according to Embodiment 1 includes a base material 11, a first thermally expandable layer 12, a second thermally expandable layer 13, and an ink receiving layer 14. In the present embodiment, the first thermal expansion layer 12 and the second thermal expansion layer 13 constitute a thermal expansion layer of the thermally expandable sheet 10. In addition, as will be described in detail later, the thermally expandable sheet 10 is a three-dimensional image forming system 50 schematically shown in FIGS. Image) is formed.

  The base material 11 is a sheet-like member that supports the thermal expansion layer. As the substrate 11, paper such as high-quality paper, medium-quality paper, and synthetic paper, or a commonly used plastic film such as polypropylene, polyethylene terephthalate (PET), and polybutylene terephthalate (PBT) can be used. Moreover, the base material 11 is on the opposite side (lower side shown in FIG. 1) of the base material 11 when the first thermal expansion layer 12 and the second thermal expansion layer 13 are expanded entirely or partially by foaming. It does not bulge, and has a strength that does not cause wrinkles or undulations. In addition, it has heat resistance to withstand heating when foaming the thermal expansion layer.

  The first thermal expansion layer 12 is formed on one surface (the upper surface shown in FIG. 1) of the substrate 11. The first thermal expansion layer 12 is a layer that expands to a size corresponding to the heating temperature and the heating time, and a plurality of thermally expandable materials MC1 (thermally expandable microcapsules and microcapsules) are dispersed in the binder B1. Has been placed. Further, as will be described in detail later, in the present embodiment, a photothermal conversion layer is formed on the ink receiving layer 14 provided on the upper surface (front surface) of the base material 11 and / or on the lower surface (back surface) of the base material 11. By irradiating light, the region provided with the photothermal conversion layer is heated. The first thermal expansion layer 12 absorbs heat generated in the photothermal conversion layer on the front surface and / or the back surface and foams and expands, so that only a specific region can be selectively expanded.

  As the binder B1, a thermoplastic resin selected from vinyl acetate polymers, acrylic polymers and the like is used. The thermally expandable microcapsule MC1 is obtained by encapsulating propane, butane, or other low boiling point vaporizable substance in a thermoplastic resin shell. The shell is formed of a thermoplastic resin selected from, for example, polystyrene, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, polyacrylic ester, polyacrylonitrile, polybutadiene, or a copolymer thereof. The average particle size of the thermally expandable microcapsule is about 5 to 50 μm. When this microcapsule is heated to a temperature higher than the thermal expansion start temperature, the polymer shell made of resin is softened, the encapsulated low-boiling vaporizable substance is vaporized, and the capsule expands due to the pressure. Although depending on the characteristics of the microcapsule used, the microcapsule expands to about 5 times the particle size before expansion. In FIG. 1, for convenience, the particle diameters of the microcapsules MC1 are shown to be approximately the same, but actually, the particle diameters of the microcapsules MC1 vary, and all the microcapsules have the same particle diameter. Do not mean.

  The second thermal expansion layer 13 is formed on the first thermal expansion layer 12. Similarly to the first thermal expansion layer 12, the second thermal expansion layer 13 is a layer that expands to a size corresponding to the heating temperature and the heating time, and the thermal expansion material MC2 (thermal expansion) in the binder B2. Microcapsules) are dispersedly arranged. As the binder B2 and the thermally expandable microcapsule MC2, the materials mentioned as the binder B1 and the thermally expandable microcapsule MC1 of the first thermally expandable layer 12 are used. In addition, the binder B2 and the thermally expandable microcapsule MC2 may be made of different materials or the same material as the binder B1 and the thermally expandable microcapsule MC1 of the first thermally expandable layer 12, respectively. It is preferable to use the same material for the first thermal expansion layer 12 and the second thermal expansion layer 13 because the raw materials are made common, the manufacturing process can be simplified, and in addition, the manufacturing cost can be reduced. Similarly to the first thermal expansion layer 12, the second thermal expansion layer 13 absorbs heat generated in the light-to-heat conversion layer formed on the upper surface and / or the lower surface of the thermally expandable sheet 10 and foams. Swell.

  In the present embodiment, in the first thermal expansion layer 12, the ratio (also referred to as content) of the thermally expandable material MC <b> 1 to the binder B <b> 1 is relative to the binder B <b> 2 in the second thermal expansion layer 13. It is made lower than the ratio (also referred to as the content ratio) in which the thermally expandable material MC2 is contained. Here, the ratio of the thermally expandable material to the binder is defined using a volume ratio, a weight ratio, and the like. For example, when the weight ratio is used, the weight ratio (first ratio) of the thermally expandable material MC1 to the binder B1 is smaller than the weight ratio (second ratio) of the thermally expandable material MC2 to the binder B2, Specifically, it is about 1/3 to 1/8. In other words, for example, the thermally expandable material MC1 dispersed in 100 parts by weight of the binder B1 is X1 parts by weight, and the thermally expandable material MC2 dispersed in 100 parts by weight of the binder B2 is X2 parts by weight. X1 / X2 is smaller than 1 and about 1/3 to 1/8. In addition, the ratio in which a thermally expansible material contains with respect to a binder may be defined by the density. In this case, it can be said that the first thermal expansion layer 12 contains a thermally expandable material at a lower density than the second thermal expansion layer 13.

  In addition, since the first thermal expansion layer 12 has a smaller proportion of the thermally expandable material compared to the second thermal expansion layer 13, when the first thermal expansion layer 12 is expanded under the same conditions, the second thermal expansion layer 13. Compared with, the height after expansion becomes lower. For this reason, the first thermal expansion layer 12 is preferably formed thinner than the second thermal expansion layer 13. In addition, it is preferable that the first thermal expansion layer 12 is not formed thicker than necessary. From such a viewpoint, the thickness of the first thermal expansion layer 12 is formed to a thickness corresponding to several thermal expansion materials MC2, for example, 1 to 10, preferably 1 to 5. Is preferred. In other words, it is preferably formed to a thickness of 1 to 10 times, preferably 1 to 5 times the average particle size of the microcapsules.

  The ink receiving layer 14 is formed on the second thermal expansion layer 13 formed on one surface of the substrate 11. The ink receiving layer 14 is a layer that receives and fixes ink used in a printing process, for example, ink of an ink jet printer. The ink receiving layer 14 is formed using a widely used material according to the ink used in the printing process. For example, when water-based ink is used, the ink receiving layer 14 is formed using a material selected from porous silica, polyvinyl alcohol (PVA), and the like. Note that the ink receiving layer 14 may be omitted, for example, when an ultraviolet curable ink is used in an inkjet method. Further, when a material that does not easily accept ink, such as a plastic film, is used as the base material 11 and a photothermal conversion layer is formed on the back side of the base material 11, the other surface of the base material 11 (the lower surface shown in FIG. 1) is used. It is preferable to provide an ink receiving layer.

  The heat-expandable sheet 10 of the present embodiment includes a first material that includes a heat-expandable material at a lower ratio between the base material 11 and the second heat-expandable layer 13 than the second heat-expandable layer 13. By providing the thermal expansion layer 12, it is possible to prevent the thermal expansion layer from peeling from the base material 11 when the thermal expansion sheet 10 is expanded.

(Method for producing thermally expandable sheet)
Next, the manufacturing method of the thermally expansible sheet 10 is demonstrated using Fig.2 (a)-FIG.2 (c).
First, a sheet-like material such as paper is prepared as the base material 11. The base material 11 may be a roll shape or may be cut in advance.

  Next, a binder made of a thermoplastic resin or the like and a thermally expandable material (thermally expandable microcapsule) are mixed to prepare a coating liquid for forming the first thermally expandable layer 12. At this time, the content of the heat-expandable material with respect to the binder is set lower than the content of the heat-expandable material with respect to the binder in the step of forming the second heat-expandable layer 13 performed after this step. The weight ratio is about 1/3 to 1/8.

  Subsequently, the coating liquid is applied onto the substrate 11 using a known coating apparatus such as a bar coater, a roller coater, or a spray coater. Subsequently, the coating film is dried to form the first thermal expansion layer 12 as shown in FIG. In addition, in order to obtain the target thickness of the first thermal expansion layer 12, the coating liquid may be applied and dried a plurality of times. In addition, the first thermal expansion layer 12 is formed thinner than the second thermal expansion layer 13. The thickness of the first thermal expansion layer 12 is preferably formed to a thickness corresponding to several thermal expansion materials MC1, for example, 1 to 10, preferably 1 to 5.

  Next, a coating liquid for forming the second thermal expansion layer 13 is prepared by mixing the binder and the thermal expansion material. The binder and the thermally expandable material may be different from the coating liquid for forming the first thermally expanded layer 12, but it is preferable to use the same material.

  Then, the coating liquid for forming the 2nd thermal expansion layer 13 is apply | coated on the 1st thermal expansion layer 12 using the well-known coating device by systems, such as a bar coater, a roller coater, and a spray coater. Next, the coating film is dried to form a second thermal expansion layer 13 as shown in FIG. In addition, in order to obtain the target thickness of the second thermal expansion layer 13, coating and drying may be performed a plurality of times.

  Next, a material constituting the ink receiving layer 14, for example, a material selected from porous silica, PVA, or the like is dispersed in a solvent to prepare a coating liquid for forming the ink receiving layer 14. Subsequently, this coating solution is applied onto the second thermal expansion layer 13 by using a known coating apparatus such as a bar coater, a roller coater, or a spray coater. Subsequently, the coating film is dried to form an ink receiving layer 14 as shown in FIG. When the roll-shaped base material 11 is used, it is cut into a size suitable for the stereoscopic image forming system 50.

  The thermally expandable sheet 10 is manufactured by the above process.

(3D image forming system)
Next, the three-dimensional image forming system 50 that forms a three-dimensional image on the thermally expandable sheet 10 of the present embodiment will be described. As shown in FIGS. 3A to 3C, the stereoscopic image forming system 50 includes a control unit 51, a printing unit 52, an expansion unit 53, a display unit 54, a top plate 55, and a frame 60. And comprising. 3A is a front view of the stereoscopic image forming system 50, FIG. 3B is a plan view of the stereoscopic image forming system 50 in a state where the top plate 55 is closed, and FIG. FIG. 3 is a plan view of the stereoscopic image forming system 50 in a state where a top plate 55 is opened. 3A to 3C, the X direction is the same as the horizontal direction, the Y direction is the same as the conveyance direction D in which the sheet is conveyed, and the Z direction is the same as the vertical direction. is there. The X direction, the Y direction, and the Z direction are orthogonal to each other.

  The control unit 51, the printing unit 52, and the expansion unit 53 are placed in the frame 60 as shown in FIG. Specifically, the frame 60 includes a pair of substantially rectangular side plates 61 and a connecting beam 62 provided between the side plates 61, and a top plate 55 is passed above the side plates 61. Further, the printing unit 52 and the expansion unit 53 are installed side by side in the X direction on the connection beam 62 passed between the side plates 61, and the control unit 51 is fixed under the connection beam 62. The display unit 54 is embedded in the top plate 55 so that the height coincides with the top surface of the top plate 55.

  The control unit 51 includes a central processing unit (CPU), a read only memory (ROM), a random access memory (RAM), and the like, and controls the printing unit 52, the expansion unit 53, and the display unit 54.

  The printing unit 52 is an ink jet printing apparatus. As shown in FIG. 3C, the printing unit 52 includes a carry-in unit 52 a for carrying in the thermally expandable sheet 10 and a discharge unit 52 b for discharging the thermally expandable sheet 10. The printing unit 52 prints the designated image on the front or back surface of the thermally expandable sheet 10 carried in from the carry-in section 52a, and discharges the thermally expandable sheet 10 on which the image has been printed from the discharge section 52b. The printing unit 52 includes color inks (cyan (C), magenta (M), yellow (Y)) for forming a color ink layer 42, which will be described later, and a front side photothermal conversion layer 41 and a back side photothermal conversion layer. And black ink (including carbon black). In order to form a black or gray color in the color ink layer 42, a black color ink not containing carbon black may be further provided as the color ink.

  The printing unit 52 acquires color image data indicating a color image (color ink layer 42) to be printed on the surface of the thermally expandable sheet 10 from the control unit, and based on the color image data, color ink (cyan, magenta, yellow). ) Is used to print a color image (color ink layer 42). The black or gray color of the color ink layer is formed by mixing three colors of CMY, or is formed by further using black color ink not containing carbon black.

  Moreover, the printing unit 52 prints the front side photothermal conversion layer 41 using black ink based on the surface foaming data which is data indicating the portion to be foamed and expanded on the surface of the thermally expandable sheet 10. Similarly, the back side photothermal conversion layer 43 is printed using black ink based on back surface foaming data, which is data indicating a portion to be foamed and expanded on the back surface of the thermally expandable sheet 10. Black ink containing carbon black is an example of a material that converts light into heat. The higher the density of the black ink, the higher the expansion height of the thermal expansion layer. For this reason, the density of the black ink is determined so as to correspond to the target height.

  The expansion unit 53 is an expansion device that applies heat to the thermally expandable sheet 10 to expand it. As shown in FIG. 3C, the expansion unit 53 includes a carry-in portion 53 a for carrying in the thermally expandable sheet 10 and a discharge portion 53 b for discharging the thermally expandable sheet 10. The expansion unit 53 applies heat to the thermally expandable sheet 10 carried in from the carry-in part 53a to expand it, and discharges the expanded thermally expandable sheet 10 from the discharge part 53b. The expansion unit 53 includes an irradiation unit (not shown) inside. An irradiation part is a halogen lamp, for example, and is a near infrared region (wavelength 750-1400 nm), visible light region (wavelength 380-750 nm), or mid-infrared region (wavelength 1400-4000 nm) with respect to the thermally expandable sheet 10. ). When light is applied to the heat-expandable sheet 10 on which black ink containing carbon black is printed, light is converted into heat more efficiently in the portion where the black ink is printed than in the portion where the black ink is not printed. Is done. Therefore, in the thermal expansion layer (the first thermal expansion layer and the second thermal expansion layer), the area where the black ink is printed is mainly heated. As a result, the thermal expansion layer is printed with the black ink. The area is expanded.

  The display unit 54 includes a touch panel or the like. For example, as shown in FIG. 3B, the display unit 54 displays an image (star shown in FIG. 3B) printed on the thermally expandable sheet 10 by the printing unit 52. The display unit 54 displays an operation guide or the like, and the user can operate the stereoscopic image forming system 50 by touching the display unit 54.

(Stereoscopic image formation processing)
Next, with reference to the flowchart shown in FIG. 4 and the cross-sectional views of the thermally expandable sheet 10 shown in FIGS. 5A to 5E, the stereoscopic image forming system 50 applies a stereoscopic image to the thermally expandable sheet 10. A flow of processing to be formed will be described.

  First, the user prepares the thermally expandable sheet 10 before the stereoscopic image is formed, and designates color image data, front surface foam data, and back surface foam data via the display unit 54. Then, the thermally expandable sheet 10 is inserted into the printing unit 52 with the surface thereof facing upward. The printing unit 52 prints the photothermal conversion layer (front side photothermal conversion layer 41) on the surface of the inserted thermally expandable sheet 10 (step S1). The front side photothermal conversion layer 41 is a layer formed of a material that converts light into heat, specifically, black ink containing carbon black. The printing unit 52 ejects black ink containing carbon black onto the surface of the thermally expandable sheet 10 in accordance with the designated surface foaming data. As a result, a front side photothermal conversion layer 41 is formed on the ink receiving layer 14 as shown in FIG. For ease of understanding, the front-side photothermal conversion layer 41 is illustrated as being formed on the ink receiving layer 14, but more accurately black ink is received in the ink receiving layer 14. Therefore, a photothermal conversion layer is formed in the ink receiving layer 14.

  Secondly, the user inserts the thermally expandable sheet 10 on which the front side photothermal conversion layer 41 is printed into the expansion unit 53 with the surface thereof facing upward. The expansion unit 53 heats the inserted thermally expandable sheet 10 from the surface. If demonstrating it concretely, the expansion | swelling unit 53 will irradiate light to the surface of the thermally expansible sheet 10 by an irradiation part (step S2). The front side photothermal conversion layer 41 printed on the surface of the thermally expandable sheet 10 generates heat by absorbing the irradiated light. As a result, as shown in FIG. 5B, the region where the photothermal conversion layer 41 of the thermally expandable sheet 10 is printed rises and expands. Further, in FIG. 5B, when the density of the black ink of the photothermal conversion layer 41 shown on the right is made higher than that of the photothermal conversion layer 41 shown on the left, as shown in the drawing, the darkly printed region becomes higher. It can be inflated.

  Third, the user inserts the thermally expandable sheet 10 whose surface has been heated and expanded into the printing unit 52 with the surface facing upward. The printing unit 52 prints a color image (color ink layer 42) on the surface of the inserted thermally expandable sheet 10 (step S3). Specifically, the printing unit 52 ejects cyan C, magenta M, and yellow Y ink onto the surface of the thermally expandable sheet 10 in accordance with the designated color image data. As a result, a color ink layer 42 is formed on the ink receiving layer 14 and the photothermal conversion layer 41 as shown in FIG.

  Fourth, the user inserts the thermally expandable sheet 10 on which the color ink layer 42 is printed into the expansion unit 53 with the back surface thereof facing upward. The expansion unit 53 heats the inserted thermally expandable sheet 10 from the back surface, and dries the color ink layer 42 formed on the surface of the thermally expandable sheet 10 (step S4). Specifically, the expansion unit 53 causes the irradiation unit to irradiate the back surface of the thermally expandable sheet 10 with light, heats the color ink layer 42, and volatilizes the solvent contained in the color ink layer 42.

  Fifth, the user inserts the thermally expandable sheet 10 on which the color ink layer 42 is printed into the printing unit 52 with the back surface thereof facing up. The printing unit 52 prints the photothermal conversion layer (back side photothermal conversion layer 43) on the back side of the inserted thermally expandable sheet 10 (step S5). Similar to the front side photothermal conversion layer 41 printed on the surface of the thermally expandable sheet 10, the back side photothermal conversion layer 43 is a layer formed of a material that converts light into heat, specifically black ink containing carbon black. It is. The printing unit 52 ejects black ink containing carbon black on the back surface of the thermally expandable sheet 10 in accordance with the designated back surface foaming data. As a result, a photothermal conversion layer 43 is formed on the back surface of the base material 11 as shown in FIG. Also for the backside photothermal conversion layer 43, when the density of the black ink of the photothermal conversion layer 43 shown on the left is made higher than that of the photothermal conversion layer 43 shown on the right, the darkly printed region is expanded higher as shown in the figure. It becomes possible.

  Sixth, the user inserts the thermally expandable sheet 10 on which the back side light-to-heat conversion layer 43 is printed into the expansion unit 53 with its back surface facing upward. The expansion unit 53 heats the inserted thermally expandable sheet 10 from the back surface. If it demonstrates concretely, the expansion | swelling unit 53 will irradiate light to the back surface of the thermally expansible sheet 10 by an irradiation part (not shown) (step S6). The photothermal conversion layer 43 printed on the back surface of the thermally expandable sheet 10 generates heat by absorbing the irradiated light. As a result, as shown in FIG.5 (e), the area | region in which the photothermal conversion layer 43 of the thermally expansible sheet 10 was printed rises and expand | swells.

  A three-dimensional image is formed on the thermally expandable sheet 10 by the procedure as described above.

  In general, in a thermally expandable sheet, a thermal expansion layer provided on a base material expands in a direction opposite to the surface on which the base material is provided (for example, an upward direction shown in FIG. 1). Due to this expansion, peeling may occur between the base material and the thermal expansion layer provided immediately above the base material. In general, the higher the content of the heat-expandable material, the easier it is to peel off from the substrate. On the other hand, in the thermally expandable sheet 10 of the present embodiment, the content of the thermally expandable material is lower than that of the second thermally expandable layer 13 between the base material 11 and the second thermally expandable layer 13. The thermal expansion layer 12 is interposed. Since the degree of foaming and expansion of the first thermal expansion layer 12 is suppressed as compared with the second thermal expansion layer 13, the thermal expansion layer can be prevented from peeling off from the base material 11. In addition, since the first thermal expansion layer 12 itself also expands, the first thermal expansion layer 12 has an effect of contributing to an increase in the height of the entire thermal expansion layer.

  As described above, according to the thermally expandable sheet and the method for producing a thermally expandable sheet of the present embodiment, when the thermally expandable layer is expanded, it is possible to suppress the thermally expandable layer from being peeled off from the base material. The manufacturing method of a sheet | seat and a thermally expansible sheet can be provided.

(Embodiment 2)
A thermally expandable sheet 20 according to Embodiment 2 will be described with reference to the drawings. The thermal expansion sheet 20 according to the second embodiment is different from the thermal expansion sheet according to the first embodiment in that a third thermal expansion layer 26 is further provided on the second thermal expansion layer 13. Parts having the same configurations as those of the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  As shown in FIG. 6, the thermally expandable sheet 20 according to Embodiment 2 includes a base material 11, a first thermally expanded layer 12, a second thermally expanded layer 13, an ink receiving layer 14, and a third layer. And a thermal expansion layer 26. In addition, the first thermal expansion layer 12, the second thermal expansion layer 13, and the third thermal expansion layer 26 constitute a thermal expansion layer of the thermally expandable sheet 20. In this embodiment, the ink receiving layer 14 is formed on the third thermal expansion layer 26 provided on the second thermal expansion layer 13.

  The third thermal expansion layer 26 is formed between the second thermal expansion layer 13 and the ink receiving layer 14. In the third thermal expansion layer 26, similarly to the first thermal expansion layer 12, the thermal expansion material MC3 (thermal expansion microcapsule) is dispersedly arranged in the binder B3. The third thermal expansion layer 26, like the first thermal expansion layer 12, absorbs heat generated in the light-to-heat conversion layer formed on the upper surface and / or lower surface of the thermally expandable sheet 20, expands, and expands. To do. In addition, as the binder B3 and the thermally expandable microcapsule MC3, the materials mentioned as the binder B1 and the thermally expandable microcapsule MC1 of the first thermally expandable layer 12 are used. The thermal expansion material MC3 of the third thermal expansion layer 26 is made of a material different from the thermal expansion material MC1 of the first thermal expansion layer 12 and the thermal expansion material MC2 of the second thermal expansion layer 15. Alternatively, the same material as either or both may be used. It is preferable to use the same material as the first thermal expansion layer 12 and / or the second thermal expansion layer 13 as the third thermal expansion layer 26 because the raw materials are shared. Similarly, the binder B3 may be different from the binder B1 and the binder B2, but it is preferable to use the same material as either or both.

  Further, in the third thermal expansion layer 26, the proportion of the thermally expandable material MC3 contained in the binder B3 is such that the thermally expandable material MC2 is contained in the binder B2 in the second thermally expanded layer 13. Low compared to proportion. Similar to the first embodiment, the proportion of the thermally expandable material MC3 contained in the binder B3 is defined using a volume ratio, a weight ratio, or the like. For example, when the weight ratio is used, the weight ratio of the thermally expandable material MC3 to the binder B3 is smaller than the weight ratio of the thermally expandable material MC2 to the binder B2, specifically, 1/3 to 1/8. Degree. In other words, if MC3 dispersed with respect to 100 parts by weight of binder B3 is X3 parts by weight and MC2 dispersed with respect to 100 parts by weight of binder B2 is X2 parts by weight, X3 / X2 is 1 It is smaller, about 1/3 to 1/8. Note that the ratio of the thermally expandable material to the binder may be defined by the density. In this case, the third thermally expanded layer 26 has a lower density than the second thermally expanded layer 13. It can also be said that it contains a thermally expandable material.

  The third thermal expansion layer 26 has a lower content of the thermally expandable material than the second thermal expansion layer 13 and is difficult to obtain a height when expanded. It is preferably formed thinner than the layer 13. The third thermal expansion layer 26 is preferably not formed to be thicker than necessary, and has a thickness corresponding to several thermal expansion materials MC3, for example, 1 to 10, preferably 1 to 5. Is preferably formed. In other words, it is preferably formed to a thickness of 1 to 10 times, preferably 1 to 5 times the average particle size of the microcapsules.

Next, a method for manufacturing the thermally expandable sheet 20 according to Embodiment 2 will be described.
First, the base material 11 is prepared, and the first thermal expansion layer 12 and the second thermal expansion layer 13 are formed on the base material 11 as in the first embodiment.

  Next, a coating solution for forming the third thermal expansion layer 26 is prepared. A thermal expansion material is dispersed in a binder using a known dispersion device or the like to prepare a coating solution for forming the third thermal expansion layer 26. The binder and the thermally expandable material may be the same material as the coating liquid for forming the second thermally expanded layer 13. At this time, the content of the thermally expandable material with respect to the binder is set lower than the content of the thermally expandable material with respect to the binder in the second thermally expanded layer 13. For example, the weight ratio is about 1/3 to 1/8. Subsequently, using a known coating apparatus such as a bar coater, a roller coater, or a spray coater, the coating solution is applied onto the substrate to form a coating film. Next, the coating film is dried. Application and drying may be performed in a plurality of times, and the third thermal expansion layer 26 having a target thickness is formed on the second thermal expansion layer 13.

Subsequently, the ink receiving layer 14 is formed on the third thermal expansion layer 26 in the same manner as in the first embodiment, and cutting or the like is performed as necessary.
Thereby, the thermally expansible sheet 20 of Embodiment 2 is manufactured.

  According to the thermally expandable sheet and the method for producing the thermally expandable sheet of the present embodiment, the thermally expandable material is further formed on the second thermally expandable layer 13 at a lower content than the second thermally expandable layer 13. By forming the third thermal expansion layer 26 including, the occurrence of unevenness generated on the surface of the thermally expandable sheet when the thermally expanded layer is expanded is alleviated, and the surface of the thermally expandable sheet is smoothly smoothed. It is possible to have good scratch resistance.

  For example, as a comparative example, FIG. 7A schematically shows a sheet surface when a thermally expandable sheet having a configuration not including the third thermally expanded layer is expanded. In this configuration, as shown in FIG. 7A, the microcapsules aggregate on the surface of the thermal expansion layer, and the unevenness of the step d1 occurs on the surface. As shown in the figure, the microcapsules located on the surface of the thermal expansion layer are easily peeled off and have poor scratch resistance. On the other hand, in the thermally expandable sheet shown in FIG. 7B that has the same configuration as that of the present embodiment, the step d2 generated on the surface of the third thermal expansion layer is suppressed to be smaller than the step d1. Since the third thermal expansion layer expands not only in the upward direction but also in the downward direction, it is possible to fill the unevenness generated in the second thermal expansion layer by the expansion of the third thermal expansion layer. In addition, since the amount of microcapsules contained in the third thermal expansion layer is small, aggregation of macrocapsules on the surface of the third thermal expansion layer can be suppressed. In addition, in particular, since the third thermal expansion layer 26 of the present embodiment includes a thermally expandable material, the third thermal expansion layer itself also expands, contributing to an increase in the overall height of the thermal expansion layer. There is also. The ink receiving layer 14 is a layer for receiving and fixing ink on the surface of the thermally expandable sheet 20. By providing this layer on the third thermally expandable layer 26, the thermally expandable sheet 20 is provided. The surface of the film is smoothed better, and the scratch resistance is further improved.

(Embodiment 3)
A thermally expandable sheet 30 according to Embodiment 3 will be described with reference to the drawings. The heat-expandable sheet 30 according to the third embodiment is different from the heat-expandable sheet 10 or 20 according to the above-described embodiment in that it includes a third heat-expandable layer 36 as shown in FIG. The layer 36 is in that it contains a white pigment W. In the present embodiment, the first thermal expansion layer 12, the second thermal expansion layer 13, and the third thermal expansion layer 36 constitute a thermal expansion layer. Parts having the same configuration as those of the other embodiments are denoted by the same reference numerals, and detailed description thereof is omitted.

  As shown in FIG. 8, the thermally expandable sheet 30 according to the third embodiment includes a base material 11, a first thermally expandable layer 12, a second thermally expandable layer 13, an ink receiving layer 14, and a third layer. And a thermal expansion layer 36. Further, the first thermal expansion layer 12, the second thermal expansion layer 13, and the third thermal expansion layer 36 constitute a thermal expansion layer of the thermally expandable sheet 20. In this embodiment, the ink receiving layer 14 is formed on the third thermal expansion layer 36 provided on the second thermal expansion layer 13.

  The third thermal expansion layer 36 is formed on the second thermal expansion layer 13 provided on one surface of the substrate 11. In the third thermal expansion layer 36, as in the second embodiment, the thermal expansion material MC3 (thermal expansion microcapsules) is dispersedly arranged in the binder B3. The third thermal expansion layer 36 is characterized in that it further includes a white pigment W. As the white pigment W, a material selected from titanium oxide, barium sulfate, zinc oxide and the like can be used, and titanium oxide is particularly preferable. Moreover, the content rate of the thermally expansible material MC3 with respect to binder B3 is set low compared with the content rate of the thermally expansible material MC2 with respect to binder B2 in the 2nd thermal expansion layer 13 similarly to Embodiment 2. .

  In this embodiment, when a white material such as porous silica is used as the ink receiving layer 14, the whiteness of the ink receiving layer 14 is also improved. Therefore, the ink receiving layer 14 is also preferable because the whiteness of the surface of the thermally expandable sheet 30 is improved.

  In the heat-expandable sheet 30 of this embodiment, the second heat-expandable layer further includes a white pigment, whereby the whiteness of the surface of the heat-expandable sheet can be increased, and the color provided on the heat-expandable sheet. The ink color can be improved.

Next, a method for manufacturing the thermally expandable sheet 30 of Embodiment 3 will be described.
As in the first embodiment, the base material 11 is prepared, and the first thermal expansion layer 12 and the first thermal expansion layer 13 are formed on the base material 11.

  Next, a thermal expansion material and a white pigment are dispersed in the binder using a known dispersion device to prepare a coating liquid for forming a third thermal expansion layer. At this time, the weight of the thermally expansible material mixed into the binder in the coating liquid is 1/3 to 1 as compared with the coating liquid for forming the second thermal expansion layer as in the second embodiment. The amount is about / 8. Subsequently, using a known coating apparatus such as a bar coater, a roller coater, or a spray coater, the coating solution is coated on the substrate to form a coating film. Next, the coating film is dried. In order to form the third thermal expansion layer 36 having a target thickness, application and drying may be performed in a plurality of times.

Subsequently, the ink receiving layer 14 is formed in the same manner as in the first embodiment, and cutting is performed as necessary.
Thereby, the thermally expansible sheet 30 which concerns on Embodiment 3 is manufactured.

  In the thermally expandable sheet of this embodiment, the third thermally expandable layer 36 further includes a white pigment, whereby the whiteness of the thermally expandable layer can be improved, and the color ink provided on the thermally expandable sheet 30. The shine of the color can be improved. Furthermore, it is preferable to form the ink receiving layer 14 using a white material such as porous silica because the whiteness of the thermally expandable sheet 30 is improved by the ink receiving layer 14. In addition, in the present embodiment, the white pigment W is included in the third thermal expansion layer 36 instead of the first expansion layer 12, the second expansion layer 13, and the ink receiving layer 14. For this reason, it is not necessary to mix a white pigment in the 1st expansion layer 12 and the 2nd expansion layer 13, and it avoids reducing the expandable height of the 1st expansion layer 12 and the 2nd expansion layer 13. It is done. Further, since the white pigment is not mixed into the ink receiving layer 14, the ink receiving layer 14 has an excellent effect that the performance of receiving ink can be avoided.

The present invention is not limited to the above-described embodiments, and various modifications and applications are possible.
For example, the above-described embodiments can be appropriately combined.

  In the above-described embodiment, the configuration in which printing is performed in the process illustrated in FIG. 4 has been described as an example, but the present invention is not limited thereto. For example, the order in which processes are performed can be changed as appropriate. For example, after forming a photothermal conversion layer on both sides of the substrate and forming a color ink layer, it is also possible to irradiate light from the front side and the back side of the substrate to expand the thermal expansion layer.

  Further, in each of the above-described embodiments, the configuration in which the photothermal conversion layer is formed on both the front surface and the back surface is described as an example, but the present invention is not limited to this. The photothermal conversion layer may be formed only on the front surface or only on the back surface according to the use of the printed matter and the printing method. In addition, when printing only on the surface, the ink receiving layer should just be formed in the surface at least.

  Moreover, you may provide an adhesive agent and a release paper in the back surface of a base material according to the use of printed matter, for example using it as a seal | sticker. In this case, a layer made of an adhesive is formed on the back surface of the substrate, and a release paper is provided thereon. The ink receiving layer may be provided on the release paper.

  Although several embodiments of the present invention have been described, the present invention is included in the invention described in the claims and the equivalents thereof. Hereinafter, the invention described in the scope of claims of the present application will be appended.

[Appendix 1]
A first thermal expansion layer formed on one side of the substrate and comprising a first thermal expansion material in a first ratio to the binder;
A second thermal expansion layer formed on the first thermal expansion layer and including a second thermal expansion material in a second ratio with respect to the binder;
The first ratio is smaller than the second ratio;
A thermally expandable sheet characterized by that.
[Appendix 2]
The thickness of the first thermal expansion layer is formed thinner than the thickness of the second thermal expansion layer.
The heat-expandable sheet according to Supplementary Note 1, wherein
[Appendix 3]
The first thermally expandable material and the second thermally expandable material are the same material.
The heat-expandable sheet according to supplementary note 1 or 2, characterized in that.
[Appendix 4]
The first thermally expandable material and the second thermally expandable material are microcapsules containing a vaporizable substance in a shell,
The thickness of the first thermal expansion layer is a thickness corresponding to several of the microcapsules,
The heat-expandable sheet according to any one of appendices 1 to 3, characterized in that:
[Appendix 5]
A third thermal expansion layer provided on the second thermal expansion layer and further including a third thermal expansion material in a third ratio with respect to the binder;
The third ratio is smaller than the second ratio;
The heat-expandable sheet according to any one of appendices 1 to 4, characterized in that:
[Appendix 6]
The third thermal expansion layer further includes a white pigment.
The thermally expandable sheet according to Supplementary Note 5, wherein
[Appendix 7]
An ink receiving layer for receiving ink is further provided on the third thermal expansion layer.
The heat-expandable sheet according to appendix 5 or 6, wherein:
[Appendix 8]
Forming on the one surface of the substrate a first thermal expansion layer containing the first thermal expansion material in a first ratio with respect to the binder;
Forming, on the first thermal expansion layer, a second thermal expansion layer containing a second thermal expansion material in a second ratio with respect to the binder,
Reducing the first proportion compared to the second proportion;
A method for producing a thermally expandable sheet, characterized in that
[Appendix 9]
Forming a thickness of the first thermal expansion layer thinner than a thickness of the second thermal expansion layer;
The method for producing a thermally expandable sheet according to Supplementary Note 8, wherein:
[Appendix 10]
The first thermally expandable material and the second thermally expandable material are the same material.
The method for producing a thermally expandable sheet according to Supplementary Note 8 or 9, wherein:
[Appendix 11]
The first thermally expandable material and the second thermally expandable material are microcapsules containing a vaporizable substance in a shell,
The thickness of the first thermal expansion layer is a thickness corresponding to several of the microcapsules,
The method for producing a thermally expandable sheet according to any one of appendices 8 to 10, wherein:
[Appendix 12]
Forming a third thermal expansion layer containing a third thermal expansion material in a third ratio with respect to the binder on the second thermal expansion layer;
Reducing the third proportion compared to the second proportion;
The method for producing a thermally expandable sheet according to any one of appendices 8 to 11, characterized in that:

  INDUSTRIAL APPLICABILITY The present invention can be used for a thermally expandable sheet that expands according to the amount of heat absorbed and a method for producing the thermally expandable sheet.

10, 20, 30 ... thermally expandable sheet, 11 ... base material, 12 ... first thermal expansion layer, 13 ... second thermal expansion layer, 14 ... ink receiving layer, 26, 36 ... third thermal expansion layer, 41 ... front side photothermal conversion layer, 42 ... color ink layer, 43 ... back side photothermal conversion layer, 50 ... stereoscopic image forming system, 51. ..Control unit, 52... Printing unit, 52 a, 53 a .. carry-in part, 52 b, 53 b .. discharge part, 53... Expansion unit, 54 .. display unit, 55. , 60 ... Frame, 61 ... Side plate, 62 ... Connection beam, B1, B2, B3 ... Binder, MC1, MC2, MC3 ... Thermally expandable material

The present invention relates to a manufacturing method and thermal expansion sheet for the shaped object.

The present invention has been made in view of the above situation, when inflated thermal expansion layer, the manufacturing method of inhibiting capable shaped object that thermal expansion layer is peeled from the substrate and thermally expandable sheet The purpose is to provide.

In order to achieve the above object, the method for producing a shaped article according to the first aspect of the present invention includes a first step of preparing a medium in which a thermal expansion layer that is expanded by heating is formed on a substrate, and a predetermined energy. A second step of forming a pattern layer with a predetermined material on the medium so that the thermal expansion layer partially expands, and the predetermined medium is formed on the medium on which the pattern layer is formed. A third step of partially expanding the thermal expansion layer by applying energy to form irregularities on the surface of the medium, and the thermal expansion layer is formed on the substrate, A first layer containing one thermally expandable material in a first ratio with respect to the binder; and a second layer formed on the first layer, the second thermally expandable material in a second ratio with respect to the binder. A second layer comprising, wherein the first proportion is compared to the second proportion By being set in advance, the first layer is formed as a delamination suppressing layer for suppressing delamination of the thermal expansion layer from the substrate when forming the irregularities in the third step. , characterized in that.
Moreover, the manufacturing method of the molded article of the 2nd aspect which concerns on this invention is the 1st process of preparing the medium in which the thermal expansion layer expanded by heating was formed on the base material, and the said thermal expansion layer is expandable. Secondly, the surface of the medium is bulged by expansion of the thermal expansion layer by partially applying heat at a temperature to the medium so that the surface corresponding to the portion of the medium to which the heat is applied is formed. The thermal expansion layer is formed on the substrate, and includes a first layer containing the first thermal expansion material in a first ratio with respect to the binder, and the first layer. And a second layer containing a second thermally expandable material in a second ratio with respect to the binder, wherein the first ratio is set smaller than the second ratio. The first layer is formed in front of the thermal expansion layer when the irregularities are formed in the second step. Is formed as a separation preventing layer for suppressing peeling from the substrate, wherein the.

Also, thermally expandable sheet of the first aspect of the present invention is provided on one of the surfaces of the substrate, the thermal expansion layer containing thermally expandable material at a predetermined ratio with respect to the binder, a given A pattern layer provided on the thermal expansion layer so that the thermal expansion layer partially expands when energy is applied, and the thermal expansion layer has the ratio of the second ratio. Between the set second thermal expansion layer and the pattern layer, the first thermal expansion layer set to the first ratio smaller than the second ratio is interposed, and The multilayer structure is provided such that the first thermal expansion layer is interposed between the second thermal expansion layer and the base material .
The thermally expandable sheet according to the second aspect of the present invention is provided on one surface of a substrate, and includes a thermally expandable layer containing a thermally expandable material in a predetermined ratio with respect to the binder, and the thermally expandable sheet. Photothermal conversion is provided on the thermal expansion layer so as to expose a part of the layer, and when irradiated with predetermined light, the irradiated light is converted into heat to partially expand the thermal expansion layer And the thermal expansion layer is smaller than the second ratio between the second thermal expansion layer set to the second ratio and the photothermal conversion layer. The first thermal expansion layer set to the first ratio is interposed, and the first thermal expansion layer is interposed between the second thermal expansion layer and the base material. , Provided in multiple layers.
Moreover, the thermal expansion sheet according to the third aspect of the present invention is provided on one surface of a base material, and includes a thermal expansion layer containing a thermal expansion material in a predetermined ratio with respect to the binder, and the base material Is provided on the other surface so that a part of the other surface is exposed, and when the predetermined light is irradiated, the irradiated light is converted into heat to partially expand the thermal expansion layer. The thermal expansion layer, and the thermal expansion layer has a ratio between the second thermal expansion layer and the base material, the ratio of which is set to the second ratio, than the second ratio. The first thermal expansion layer set at a small first ratio is formed in multiple layers so as to be interposed.

According to the present invention, when inflated thermal expansion layer, the thermal expansion layer can be provided a manufacturing method and a thermally expandable sheet for can suppress shaped object to be peeled from the substrate.

Claims (10)

A first thermal expansion layer formed on one side of the substrate and comprising a first thermal expansion material in a first ratio to the binder;
A second thermal expansion layer formed on the first thermal expansion layer and including a second thermal expansion material in a second ratio with respect to the binder;
The first thermally expandable material and the second thermally expandable material are the same material,
The first ratio is smaller than the second ratio;
A thermally expandable sheet characterized by that. The thickness of the first thermal expansion layer is formed thinner than the thickness of the second thermal expansion layer.
The thermally expandable sheet according to claim 1. The first thermally expandable material and the second thermally expandable material are microcapsules containing a vaporizable substance in a shell,
The thickness of the first thermal expansion layer is a thickness corresponding to 1 to 10 microcapsules,
The thermally expandable sheet according to claim 1, wherein the sheet is thermally expandable. A third thermal expansion layer provided on the second thermal expansion layer and further including a third thermal expansion material in a third ratio with respect to the binder;
The third ratio is smaller than the second ratio;
The thermally expandable sheet according to any one of claims 1 to 3, wherein the sheet is thermally expandable. The third thermal expansion layer further includes a white pigment.
The thermally expandable sheet according to claim 4. An ink receiving layer for receiving ink is further provided on the third thermal expansion layer.
The thermally expandable sheet according to claim 4, wherein the sheet is thermally expandable. Forming on the one surface of the substrate a first thermal expansion layer containing the first thermal expansion material in a first ratio with respect to the binder;
Forming, on the first thermal expansion layer, a second thermal expansion layer containing a second thermal expansion material in a second ratio with respect to the binder,
The first thermally expandable material and the second thermally expandable material are the same material,
Reducing the first proportion compared to the second proportion;
A method for producing a thermally expandable sheet, characterized in that Forming a thickness of the first thermal expansion layer thinner than a thickness of the second thermal expansion layer;
The method for producing a thermally expandable sheet according to claim 7. The first thermally expandable material and the second thermally expandable material are microcapsules containing a vaporizable substance in a shell,
The thickness of the first thermal expansion layer is a thickness corresponding to 1 to 10 microcapsules,
The method for producing a thermally expandable sheet according to claim 7 or 8, wherein: Forming a third thermal expansion layer containing a third thermal expansion material in a third ratio with respect to the binder on the second thermal expansion layer;
Reducing the third proportion compared to the second proportion;
The method for producing a thermally expandable sheet according to any one of claims 7 to 9.

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