JP2021130218A - Foam formation media and production method of foam formation printed matter using the same - Google Patents

Abstract

To provide foam formation media on which an irregular pattern having a large elevation difference, can be acquired, and a production method of a foam formation printed matter using the same media.SOLUTION: There are provided foam formation media which are formed by laminating and forming, as foam formation layers, a first foam formation layer 3 and a second foam formation layer 4 on a substrate 2, in which the first and second foam formation layers 3, 4 have different foam formation mechanism each other, first ink 5 acting to the first foam formation layer is partially adhered to the foam formation layers, and second ink 7 acting to the second foam formation layer is partially adhered to the foam formation layers. By foam formation in a prescribed foam formation, an irregular pattern having at least three stages of heights can be formed, including, a position A to which the first ink is adhered, a position B to which the second ink is adhered, a position C to which the first ink and the second ink are overlapped and adhered, and a position D to which the first ink and the second ink are not adhered.SELECTED DRAWING: Figure 6

Description

The present invention relates to a foamable medium and a method for producing a foamed printed matter using the same.

Sheets with an uneven pattern on the surface of foamed resin sheets are widely used for cushion floors and wallpaper. Mechanical embossing and chemical embossing are known as methods for producing such a sheet.

In mechanical embossing, for example, a foamed resin sheet is embossed with an embossing roll or a press to form concave portions to form an uneven pattern. Mechanical embossing requires mold preparation.

Chemical embossing is performed, for example, by providing a portion having a low foaming temperature by partially applying a foaming accelerator to a foamed resin sheet in which a foaming agent that foams by heat is mixed with a resin, and heating this at a constant temperature. Foam. By adjusting the heating temperature, the portion having a low foaming temperature becomes a highly foamed portion (convex portion), and the portion having a high foaming temperature becomes a low foaming portion (concave portion), and an uneven pattern is formed.

Further, for chemical embossing, for example, a foaming accelerator is blended in the entire foamed resin sheet, and a foaming inhibitor is partially applied to the foamed resin sheet to provide a portion having a low foaming rate, which is constant. Foam by heating at temperature. Since the portion having a low foaming rate becomes a portion having a low foaming rate, the portion becomes a concave portion and an uneven pattern is formed.

Partial application of these foaming accelerators and foaming inhibitors is usually performed by gravure printing, rotary screen printing, flexographic printing and the like.

On the other hand, in order to make the uneven pattern a more advanced design, various studies have been conducted on a method of gradually making the uneven pattern three-dimensional.

For example, Patent Document 1 describes a method using chemical embossing.

In this method, a solid black image and a solid gray image are printed on the surface of the foamed resin layer of the recording medium by changing the density of black printing. By changing the black density between the solid black image and the solid gray image, the heat absorption rate is made different, and when this recording medium is irradiated with heat rays and subjected to heat foaming treatment, the solid black image of the foamed resin layer is applied. The part of is greatly swelled by thermal expansion, and the part of the solid gray image is slightly swelled by thermal expansion, and a two-stage three-stage object can be obtained as a whole. Patent Document 1 also describes that a three-dimensional object having three or more stages can be obtained by setting the black density to three or more stages.

Further, Patent Document 1 describes a method of using a recording medium in which two types of resins containing foaming agents having different foaming temperatures are used and a base material is coated with two foamed resin layers having different coefficients of thermal expansion. There is. For example, a portion of a two-layer recording medium in which a foamed resin layer containing a foaming agent that foams at 180 ° C. or higher is coated with a foamed resin layer containing a foaming agent that foams at 120 ° C. and heated at 120 ° C. is 1. Since only the layer is three-dimensional and the two layers are both three-dimensional in the portion heated at 180 ° C., a two-stage three-dimensional object can be obtained by partially controlling the heating temperature. As the heating device, it is described that a thermal head or a laser irradiation head capable of partially controlling the temperature is used.

Patent Document 2 describes a method in which mechanical embossing and chemical embossing are used in combination.

In this method, a printed pattern is formed on the surface of the resin layer to which the foaming agent and the plasticizer are added with a paint containing a foaming inhibitor having an affinity for the plasticizer, and then heat-foamed to form the printed pattern. A synchronized uneven pattern is formed, and a squeezed pattern is formed on the convex pattern portion by embossing roll on the surface.

Japanese Unexamined Patent Publication No. 2012-171317 Japanese Unexamined Patent Publication No. 8-244060

However, in the former method described in Patent Document 1, although two types of temperature regions, a high temperature region and a low temperature region, are used properly for the solid black image portion and the solid gray image portion, respectively, the heat ray is black toner. It is slightly absorbed even in places where black ink is not printed, and pigments such as carbon are heated to generate heat, which may cause foaming in unintended places.

Further, in the latter method described in Patent Document 1, a heating device capable of partially controlling the temperature is used, and the heating temperature is divided into two types, a low temperature range and a high temperature range. However, the heat transfer of the recording medium is performed. There is a high possibility that the foaming agent will foam in the low temperature region, and foaming may occur at an unintended location.

Further, in the method of mechanically embossing the convex portion formed by chemical embossing as in the method described in Patent Document 2, the pattern that can be put in by mechanical embossing is limited to fine grain or texture that does not crush the chemical embossing. It cannot handle deep embossing.

The present invention has been made in view of the above, and an object of the present invention is to provide an effervescent medium capable of obtaining an uneven pattern having a large height difference, and a method for producing a foamed printed matter using the effervescent media.

As a result of studying the above-mentioned problems, the present inventor prepares a print medium in which two layers that have the same starting conditions for foaming and foam by different mechanisms are laminated, and acts only on the foaming of each mechanism. By printing and foaming each pattern using two types of ink, it was found that an uneven pattern having three or more high and low steps can be obtained. The present inventor has further studied and completed the present invention.

That is, the effervescent media according to the first aspect of the present invention is
It has a foaming layer on the base material that foams under predetermined foaming conditions.
It is a foamable medium capable of forming an uneven pattern in which the height of the foamed layer from the base material is different by partially adhering the ink to the foamed layer and foaming the foamed layer under the predetermined foaming conditions. hand,
The foamable media is formed on the base material by overlapping the first foam layer and the second foam layer as the foam layer.
The first foam layer and the second foam layer have different foaming mechanisms.
The ink contains a first ink that acts on the first foam layer and a second ink that acts on the second foam layer when foamed under the predetermined foaming conditions.
The foam layer has a portion A to which the first ink is attached, a portion B to which the second ink is attached, and a portion C to which the first ink and the second ink are adhered in an overlapping manner. The height of at least three steps including the first ink and the second ink not adhered to the foam layer by having at least two of them and foaming under the predetermined foaming conditions. It is possible to form an uneven pattern.

The foamable media having the above structure can obtain an uneven pattern having a large height difference.

The first foam layer and the second foam layer are foam suppression layers having different foaming mechanisms.
In the first foam layer, foaming is suppressed by the first ink and foaming is not suppressed by the second ink.
It is preferable that the second foam layer is suppressed from foaming by the second ink and is not suppressed by the first ink.

With the foamable media having the above structure, it is possible to easily obtain an uneven pattern having a large height difference.

It is preferable that the maximum foam thickness of the first foam layer is different from the maximum foam thickness of the second foam layer.

The effervescent media having the above configuration can obtain an uneven pattern having four levels of height difference.

The first foaming layer is a layer of a first thermoplastic resin having a chemical foaming mechanism and containing a chemical foaming agent.
It is preferable that the second foaming layer is a layer of a second thermoplastic resin having a heat-expandable microcapsule foaming mechanism and containing a heat-expandable foaming agent.

In the foamable media having the above structure, it is easy to control the foaming of each layer independently.

The second foam layer is an adhesion layer of the ink.
The first foaming layer further contains a foaming aid that promotes the foaming of the chemical foaming agent.
The first ink contains a component that chelate with the foaming aid to inactivate the foaming aid, and contains a foaming inhibitor that can penetrate the first thermoplastic resin and the second thermoplastic resin. Contains,
The heat-expandable foaming agent of the second foam layer is a capsule-type foaming agent in which a vaporizing component is filled in a gas-impermeable third thermoplastic resin shell.
The second ink preferably contains a solvent capable of swelling or dissolving the third thermoplastic resin and / or an endothermic agent.

The foamable media having the above configuration can easily control foaming due to adhesion of ink.

It is preferable that the first foaming layer is maximally foamed within the range of the maximum expansion temperature of the capsule-type foaming agent.

Since the foamable media having the above configuration has a range of maximum expansion temperatures of the capsule-type foaming agent, it is easy to adjust with the foaming temperature of the chemical foaming agent, and the foaming of the first foaming layer and the second foaming layer is maximized. Easy to do.

It is preferable that the first thermoplastic resin and the second thermoplastic resin are selected from a combination of resins that can be welded to each other and have good adhesion.

In the foamable media having the above structure, since the first foam layer and the second foam layer are firmly adhered to each other, peeling between layers does not occur, ink easily permeates between layers, and uneven patterns are easily formed.

The foamable medium according to any one of claims 1 to 7, wherein the method of adhering the first ink and the second ink is an on-demand printing method.

The foamable media having the above configuration can be easily produced in small quantities.

The method for producing a foamed printed matter according to the second aspect of the present invention is
A bonding step of partially adhering the first ink and the second ink to the foamable media, respectively.
A foaming step of foaming the foamable media to which the ink is attached under the foaming conditions of the second foaming layer,
including.

In the method for producing a foamed printed matter having the above structure, it is possible to obtain a foamed printed matter having a concavo-convex pattern having a large height difference by a simple operation.

According to the foamable media according to the present invention and the method for producing a foamed printed matter using the same, there are provided a foamable media capable of obtaining an uneven pattern having a large height difference, and a method for producing a foamed printed matter using the same.

A flow for producing a foamed printed matter using an foamable medium according to an embodiment of the present invention. The conceptual diagram of the manufacturing method of the foamed printed matter using the foamable media which concerns on one Embodiment of this invention. The conceptual diagram of the manufacturing method of the foamed printed matter using the foamable media which concerns on one Embodiment of this invention. The conceptual diagram of the manufacturing method of the foamed printed matter using the foamable media which concerns on one Embodiment of this invention. The conceptual diagram of the manufacturing method of the foamed printed matter using the ink which permeates by heat. The conceptual diagram of the manufacturing method of the foamed printed matter using the ink which permeates by heat. The conceptual diagram of the manufacturing method of the effervescent printed matter using the ink which suppresses effervescence and the ink which promotes effervescence. The conceptual diagram of the manufacturing method of the effervescent printed matter using the ink which suppresses effervescence and the ink which promotes effervescence. A manufacturing flow for foamed printed matter that is combined with color ink printing.

The foamable media according to the embodiment of the present invention has a foaming layer that foams under predetermined foaming conditions on a base material, and ink is partially adhered to the foaming layer and foamed under the predetermined foaming conditions. This is an effervescent medium capable of forming an uneven pattern in which the height of the effervescent layer from the base material is different.
Further, the foamable media is formed on the base material by overlapping the first foam layer and the second foam layer as the foam layer, and the first foam layer and the second foam layer have a foaming mechanism. Is different.
Further, the ink contains a first ink that acts on the first foam layer and a second ink that acts on the second foam layer when foamed under the predetermined foaming conditions, and the foam layer contains the first ink that acts on the second foam layer. At least two of the first ink adhering portion A, the second ink adhering portion B, and the first ink and the second ink adhering portion C to be overlapped with each other. By having and foaming under the predetermined foaming conditions, the uneven pattern having at least three steps of height is formed on the foamed layer including the portion D to which the first ink and the second ink are not adhered. It is possible.

The foamable media is formed on the base material by overlapping the first foam layer and the second foam layer as the foam layer. Although the first foam layer and the second foam layer have different foaming mechanisms, both the first foam layer and the second foam layer can be foamed under predetermined foaming conditions. For example, when the predetermined foaming condition is heating at a specific temperature, heating the foamable media at that temperature causes both the first foam layer and the second foam layer to foam.

Ink is attached to the foamable media by printing. The ink is composed of at least two types of ink, a first ink and a second ink, and for example, each ink is separately attached to the foamable media. The first ink acts on the first foam layer when foaming the foam layer under at least predetermined foaming conditions. In addition, the second ink acts on the second foam layer when the foam layer is foamed under at least predetermined foaming conditions.

Here, acting on the foam layer means, for example, promoting or suppressing the foaming of the foam layer. More specifically, promoting foaming when the foaming condition is heating at a specific temperature means that the temperature at which the foamed layer foams is lower than the specific temperature, or the rate at which the foamed layer foams is increased. It is to do. In addition, suppressing foaming when the foaming condition is heating at a specific temperature means that the temperature at which the foamed layer foams is made higher than the specific temperature, or the rate at which the foamed layer foams is slowed down. be.

The effervescent media includes a first effervescent layer and a second effervescent layer having a different effervescent mechanism from the first effervescent layer, so that the first ink and the second ink act on each layer to effervescent. Can be promoted or suppressed. As a result, in the entire foamable media, it is possible to obtain a sharp difference in height of 3 or 4 steps by combining two types of thickness, the thickness of the first foam layer and the thickness of the second foam layer.

That is, since the first ink and the second ink are separately attached to the foamable media, the foamed layer of the foamable media to which the ink has adhered has a portion A to which the first ink has adhered and a second ink. At least two of the portion B to which the ink of No. 1 is adhered and the portion C to which the first ink and the second ink are overlapped and adhered can be formed. Further, in addition to at least two of the points A, B, and C, a place D to which the first ink and the second ink are not adhered can be formed.

At location A, the first ink acts on the first foam layer in the foam layer under predetermined foaming conditions. At location B, the second ink acts on the second foam layer in the foam layer under predetermined foam conditions. At location C, the first ink acts on the first foam layer in the foam layer and the second ink acts on the second foam layer under predetermined foaming conditions. At location D, neither the first ink nor the second ink acts on the foam layer under predetermined foaming conditions.

The conditions under which the first foam layer foams and the conditions under which the second foam layer foams can be adjusted by the respective foaming mechanisms and the first ink and the second ink. By adjusting the foaming of one of the first foaming layer and the second foaming layer so that the other foaming layer foams, the foamable media is set to the foaming condition of one foaming layer. Both the first foam layer and the second foam layer can be foamed in one operation.

Therefore, under predetermined foaming conditions, the portion where the first foamed layer foams, the portion where the first foamed layer does not foam, and the portion where the second foamed layer foams with respect to the height difference of the uneven pattern depending on the portion A, the portion B, the portion C, and the portion D. It is possible to take a total of four combinations of "and non-foaming parts".

When the height at which the first foam layer is foamed and the height at which the second foam layer is foamed are the same, a three-step height uneven pattern can be formed by combining the portion A or the portion B, the portion C, and the portion D. ..

When the height at which the first foam layer is foamed and the height at which the second foam layer is foamed are different, the combination of location A, location B, and location D has three stages, and the combination of location A, location C, and location D has three. A concave-convex pattern having a height of 3 steps can be formed by the combination of the step, the place B, the place C and the place D, and 4 steps by the combination of the place A, the place B, the place C and the place D.

The combination of the first foam layer and the second foam layer is not particularly limited as long as the foaming mechanism is different and both can be foamed under predetermined conditions.

As the foaming mechanism, an azo-based foaming agent is thermally decomposed by heat to generate gas, a baking soda and citric acid are thermally decomposed by heat to generate gas, urethane is reacted with water by heat, etc. Chemical foaming method, mechanical foaming that dissolves supercritical fluid in dissolved resin under high pressure to harden the resin, removal foaming that disperses soluble particles and removes particles through solvent, filling capsules such as nitrile rubber with alkane etc. , Physical foaming such as heat-expandable microcapsule foaming that foams by vaporization.

Examples of the combination of the first foaming layer and the second foaming layer include a foaming layer having a foaming mechanism of chemical foaming and a foaming layer having a foaming mechanism of heat-expandable microcapsule foaming. With this combination, it is easy to match the foaming conditions of the first foaming layer and the second foaming layer.

(Effervescent layer whose foaming mechanism is chemical foaming)
The foamed layer whose foaming mechanism is chemically foamed is, for example, a layer of a first thermoplastic resin containing a chemical foaming agent. In the present specification, a foamed layer whose foaming mechanism is chemically foamed may be referred to as a chemically foamed layer.

When the chemical foaming layer is heated to a specific temperature, for example, the chemical foaming agent is thermally decomposed to generate gas, so that the chemical foaming layer is foamed.

Examples of the chemical foaming agent include an organic pyrolysis foaming agent and an inorganic pyrolysis foaming agent.

Examples of the organic heat-decomposable foaming agent include azodicarboxylic amide (abbreviation: ADCA), 4,4'-oxybis (benzenesulfonyl hydrazide), 1,1'-azobis (1-acetoxy-1-phenylethane), and the like. Dimethyl-2,2'-azobisbutyrate, dimethyl-2,2'-azobisisobutyrate, 2,2'-azobis (2,4,4-trimethylpentane), 1,1'-azobis (cyclohexane) -1-Carbonitrile), 2,2'-azobis [N- (2-carboxyethyl) -2-methyl-propionamidine] and other azo compounds; N, N'-dinitrosopentamethylenetetramine (abbreviation: DPT) And other nitroso compounds; hydrazine derivatives such as 4,4'-oxybis (benzenesulfonyl hydrazide), diphenylsulfone-3,3'-disulfonylhydrazide; semicarbazide compounds such as p-toluenesulfonyl semicarbazide; trihydrazinotriazine and the like. Be done.

Examples of the inorganic heat-decomposable foaming agent include bicarbonates such as sodium hydrogen carbonate and ammonium hydrogen carbonate, carbonates such as sodium carbonate and ammonium carbonate; nitrites such as ammonium nitrite, and hydrogen compounds.

Among these, ADCA is preferable as the chemical foaming agent from the viewpoint of being less susceptible to the influence of moisture.

The chemical foaming layer can disperse or dissolve the above-mentioned chemical foaming agent in the first thermoplastic resin. As the first thermoplastic resin, it is preferable to use a resin that softens or melts at a temperature at which the above-mentioned chemical foaming agent is thermally decomposed to generate gas. If the first thermoplastic resin is softened or melted when the foaming agent is foamed, the foamed layer can be foamed and expanded by the gas, and the foamed state can be maintained when cooled.

Examples of such a first thermoplastic resin include vinyl chloride, polyethylene, polypropylene, ethylene-vinyl acetate copolymer, polyurethane, and polyacrylic. Of these, polyvinyl chloride and polyolefin resins are preferable in terms of flexibility.

The chemically foamed layer preferably further contains a foaming aid. The foaming aid is a compound that lowers the foaming temperature of the chemical foaming agent.

Examples of the foaming aid include an inorganic metal compound capable of forming a chelate with a foaming inhibitor described later. Specific examples thereof include zinc compounds such as zinc oxide and zinc, organometallic compounds such as barium compounds, and inorganic metal compounds. Of these, zinc compounds and barium compounds are preferable.

The chemically foamed layer may contain other components as long as the effects of the present invention are not impaired. Examples of other components include fillers such as talc and calcium carbonate, white pigments such as titanium oxide, and flame retardants such as aluminum hydroxide, magnesium hydroxide, antimony trioxide, and triphenyl phosphate.

The method for producing the chemical foaming layer is not particularly limited, but for example, a method of adhering a coating liquid of a thermoplastic resin containing a chemical foaming agent to a base material to form a film, melt laminating in advance, or forming a sheet by a calendar roll. Examples thereof include a method of laminating a thermoplastic resin film containing a chemical foaming agent on a base material.

Examples of the base material include high-quality paper, water-resistant paper, and non-woven fabric.

The thickness of the first foamed layer such as the chemically foamed layer is not particularly limited, but is preferably 100 μm or more and 300 μm or less, and more preferably 100 μm or more and 200 μm or less in the unfoamed state.

The thickness of the first foam layer at the time of maximum foaming is not particularly limited, but is preferably 200 μm or more and 1000 μm or less, and more preferably 300 μm or more and 500 μm or less.

The foaming temperature of the first foaming layer is not particularly limited as long as it does not foam during the production of the foamable media or when the ink is adhered, but it is preferably 120 ° C. or higher and 250 ° C. or lower, and 150 ° C. or higher and 230 ° C. or lower. And more preferable.

When the first foaming layer is a chemical foaming layer, the foaming temperature can be adjusted by the foaming agent used, the foaming aid, and the first ink. By containing the foaming aid, the foaming temperature of the chemical foaming layer can be lowered. Here, the foaming temperature of the chemically foamed layer is a temperature at which foaming is observed when heated over time while observing the chemically foamed layer.

(First ink)
When the first foaming layer is a chemical foaming layer, the first ink acts on the first foaming layer to promote or suppress the foaming of the chemical foaming agent.

In order for the first ink to promote the foaming of the chemical foaming agent, the first ink contains a foaming aid that lowers the foaming temperature of the chemical foaming agent.

Further, in order for the first ink to suppress the foaming of the chemical foaming agent, the chemical foaming layer contains the chemical foaming agent and the foaming aid, and the first ink foams to reduce the effect of the foaming aid. Contains an inhibitor.

Examples of the foaming inhibitor contained in the first ink that reduce the effect of the foaming aid include a chelating agent that can be chelated with the foaming aid.

The chelating agent can chelate (coordinate) the catalyst metal, for example, when the foaming aid contains a catalyst metal.

Examples of the chelating agent capable of chelating (coordinating) the catalyst metal include oxycarboxylic acid, aminocarboxylic acid, phosphonic acid and triazole compounds, and salts thereof.

Examples of the oxycarboxylic acid include glycolic acid, lactic acid, malic acid, tartaric acid, citric acid and the like.

Examples of the aminocarboxylic acid include ethylenediaminetetraacetic acid (abbreviation: EDTA), nitrilotriacetic acid (abbreviation: NTA), diethylenetriaminepentaacetic acid (abbreviation: DTPA), hydroxyethylenediaminetriacetic acid (abbreviation: HEDTA), glycol etherdiaminetetraacetic acid (abbreviation: abbreviation). : GEDTA), triethylenetetraminehexacetic acid (abbreviation: TTHA), hydroxyethyliminonic acid (abbreviation: HIDA), dihydroxyethylglycine (abbreviation: DHEG) and the like.

Examples of the phosphonic acid include 2-aminoethylphosphonic acid, 1-hydroxyethylidene-1,1-diphosphonic acid, aminotri (methylenephosphonic acid), ethylenediaminetetrax (methylenephosphonic acid), diethylenetriaminepenta (methylenephosphonic acid), and ethane-1. , 1-diphosphonic acid, ethane-1,1,2-triphosphonic acid, ethane-1-hydroxy-1,1-diphosphonic acid, ethane-1-hydroxy-1,1,2-triphosphonic acid, ethane-1,2 -Dicarboxy-1,2-diphosphonic acid, methanehydroxyphosphonic acid, 2-phosphonobutane-1,2-dicarboxylic acid, 1-phosphonobutane-2,3,4-tricarboxylic acid, α-methylphosphonosuccinic acid and the like. Be done.

Examples of triazole compounds include 5-methyl-1H-benzotriazole (also known as tolyltriazole), benzotriazole, 1- [N, N-bis (2-ethylhexyl) aminomethyl] benzotriazole, 1- [N, N- Examples thereof include bis (2-ethylhexyl) aminomethyl] methylbenzotriazole and 2,2'-[[(methyl-1H-benzotriazole-1-yl) methyl] imino] bisethanol.

Among these chelating agents, a chelating agent that does not corrode the members of the printing apparatus such as an inkjet head and does not dissolve the water-repellent layer thereof is preferable.

Further, among these chelating agents, triazole-based compounds are preferable, and triltriazole is more preferable, because they have a high ability to suppress foaming.

The first ink can contain other components such as a medium. For example, when a solvent ink such as ecosolvent is used in inkjet printing, the same solvent as the solvent ink can be contained as another component. When water-based ink such as latex is used, water and a water-soluble solvent can be used as other components.

Examples of the solvent for the solvent ink include diethylene glycol methyl ethyl ether and gamma-butyrolactone. Examples of the solvent for the water-based ink include a mixed solution of water and glycerin, propylene glycol, or the like.

The content of the chelating agent in the first ink is not particularly limited, but is preferably 1% by mass or more and 40% by mass or less.

Adhesion of the first ink and the second ink described later is preferably an on-demand printing method in which printing is performed based on digital data using an inkjet printer or the like. If the adhesion of the first ink and the second ink is an on-demand printing method, it is easy to cope with small-quantity production.

(Effervescent layer whose foaming mechanism is thermally expandable microcapsule foam)
The foaming layer in which the foaming mechanism is heat-expandable microcapsule foam is, for example, a layer of a second thermoplastic resin containing a heat-expandable foaming agent. In the present specification, a foamed layer in which the foaming mechanism is heat-expandable microcapsule foam may be referred to as a heat-expandable foamed layer.

Examples of the heat-expandable foaming agent include capsule-type foaming agents in which a vaporizing component such as volatile organic carbon is filled in a gas-impermeable third thermoplastic resin shell (outer shell).
When the microcapsules are heated to a specific temperature, the vaporized components begin to vaporize and the microcapsules begin to swell. When the temperature is further increased, the microcapsules expand further, but when the vaporizing component permeates the shell, the microcapsules begin to contract. Therefore, capsule-type foaming agents have a range of maximum expansion temperatures, which are the maximum expansion temperatures of microcapsules.

Examples of the third thermoplastic resin that can be used for the shell include vinylidene chloride-acrylonitrile copolymer and acrylonitrile-based copolymer.

Examples of the vaporizing component include organic solvents generally used as volatile solvents such as petrochemicals, hydrocarbons (isobutane, pentane, hexane, heptane, etc.), low boiling halogenated hydrocarbons, and methylsilane.

The heat-expandable foam layer may contain other components as long as the effects of the invention are not impaired. Other components include fillers such as talc and calcium carbonate, white pigments such as titanium oxide, and flame retardants such as aluminum hydroxide, magnesium hydroxide, antimony trioxide, and triphenyl phosphate.

Examples of the second thermoplastic resin include vinyl chloride, polyethylene, polyprovylene, ethylene-vinyl acetate copolymer, polyurethane, and polyacrylic. Of these, polyvinyl chloride and polyolefin resins are preferable in terms of flexibility.

The first thermoplastic resin and the second thermoplastic resin are preferably selected from resins that can be melt-bonded. When the first thermoplastic resin and the second thermoplastic resin are selected from the resins that can be melt-bonded, the first foam layer and the second foam layer are firmly bonded to each other, so that the layers do not peel off and the ink is ink. Is easy to penetrate between layers, and uneven patterns are easy to form.

As a combination of resins that can be welded to each other and have good adhesion, it is difficult to use the same resin or a resin that is easily heat-welded on one side (for example, vinyl acetate, ethylene vinyl acetate, acrylic, urethane). Examples include combinations that do not contain adhesive resins (eg polypropylene, polyethylene, polyester).

The thickness of the second foam layer such as the thermal expansion type foam layer is not particularly limited, but is preferably different from the thickness of the first foam layer, and more preferably thinner than the thickness of the first foam layer.

For example, the thickness of the second foam layer is preferably 30 μm or more and 150 μm or less, and more preferably 50 μm or more and 100 μm or less in the unfoamed state.

The thickness of the second foam layer at the time of maximum foaming is not particularly limited, but is preferably 200 μm or more and 1000 μm or less, and more preferably 300 μm or more and 500 μm or less.

Further, it is preferable that the thickness of the second foam layer at the time of maximum foaming is different from the thickness of the first foam layer at the time of maximum foaming. When the thickness of the second foam layer at the time of maximum foaming and the thickness of the first foam layer at the time of maximum foaming are different, the unfoamed region and the maximum foamed region of the second foamed layer and the unfoamed region and the maximum foamed region of the first foamed layer are different. By combining the regions, a four-step uneven pattern can be formed.

When the second foam layer is a heat-expandable foam layer, the heat-expandable microcapsules soften the outer shell of the microcapsules at a specific temperature as the temperature is raised over time, and also volatile organic carbon. As it begins to volatilize, it begins to swell and the swelling of the foaming agent is maximized at a particular temperature. When the temperature is further increased, the volatile organic carbon that has volatilized permeates from the outer shell, and the microcapsules shrink to become smaller than the original microcapsules. When the heating is stopped at a temperature near the maximum expansion of the foaming agent, the outer shell of the microcapsules and the constituent resin of the second foaming layer are cured, and the foamed state is maintained.

When the second foam layer is a heat-expandable foam layer, the above-mentioned foam temperature is in the temperature range before and after the expansion of the foaming agent is maximized. For example, it is a temperature range in which the magnification is 90% or more of the maximum foaming magnification.

When the second foam layer is a heat-expandable foam layer, the foaming temperature can be adjusted by the thermoplastic resin used for the outer shell and the volatile organic carbon contained in the outer shell. By using a thermoplastic resin that softens near the foaming temperature and volatile organic carbon that volatilizes near the foaming temperature, the heat-expandable microcapsules foam at the foaming temperature.

When the second foam layer is a heat-expandable foam layer, the foaming temperature can be adjusted by the foaming agent used.

The foaming temperature of the second foaming layer such as the heat-expandable foaming layer does not foam when the foamable media is manufactured or when ink is adhered, and the foaming temperature is different from that of the first foaming layer by 50 ° C. or more. Although not particularly limited, the foaming temperature is preferably 120 ° C. or higher and 250 ° C. or lower, and more preferably 150 ° C. or higher and 230 ° C. or lower. When an endothermic agent is used for the foam control ink, it is preferable that the foam temperature is 20 ° C. or higher higher than that of the first foam layer.

Examples of the endothermic agent include materials having a phase transition temperature such as a melting point or a boiling point below the temperature at which the foamed layer is foamed.

Here, the foaming temperature of the heat-expandable foam layer is a temperature at which the microcapsules swell and harden, and the film thickness of the foam layer greatly increases.

The foaming temperature of the thermal expansion type foam layer is preferably closer to the foaming temperature of the chemical foam layer. For example, it is preferable that the foaming temperature of the thermal expansion type foaming layer and the foaming temperature of the chemical foaming layer are within ± 20 ° C. Since the heat-expandable foaming agent shrinks when the heating temperature is high, it is possible to prevent the heat-expandable foam layer from shrinking when the difference in foaming temperature is within this range.

When there is a range in the maximum expansion temperature of the capsule-type foaming agent of the heat-expandable foam layer, if the first foam layer is maximally foamed within that range, the difference in thickness due to foaming and non-foaming of each foam layer is large. Therefore, it is preferable because an uneven pattern having a large height difference can be formed.

The method for producing the foamable media is not particularly limited, but when the foamable media is a medium for printing on the first foam layer side, for example, a second foam layer is laminated on a base material, and the second foam layer is laminated. It is obtained by laminating the first foam layer on the foam layer.

When the second foamed layer is a heat-expandable foam layer, for example, the heat-expandable foam layer can be formed by dispersing it in a resin dispersion liquid or a resin solution and applying it to a base material.

The method for producing the heat-expandable foam layer is not particularly limited. For example, a method of applying a coating liquid of a thermoplastic resin containing a chemical foaming agent to a base material to form a film, a melt laminating in advance, or a calendar roll to form a sheet. Examples thereof include a method of laminating a thermoplastic resin film containing a chemical foaming agent on a substrate.

When the first foam layer is a chemically foamed layer and the second foam layer is a heat-expandable foam layer, it is preferable that the heat-expandable foam layer is an ink adhesion layer. The first ink can permeate the second foam layer and reach the second foam layer without affecting the outer shell of the heat-expandable foaming agent. Further, it is preferable to use the heat-expandable foam layer of the second foam layer, which is less likely to cause surface roughness due to the generation of air bubbles on the surface, as the surface layer because surface roughness can be easily suppressed.

It is preferable that the layers of the foamable media are laminated in the order of the chemical foam layer and the heat-expandable foam layer from the base material side, and the heat-expandable foam layer is the ink adhesion layer from the viewpoint of ink transmission.

The effervescent media can further include other layers. Examples of the other layer include an ink receiving layer. In the case where the ink receiving layer is included, when a soft vinyl chloride resin is used as the first thermoplastic resin and / or the second thermoplastic resin, in order to prevent the plasticizer in the soft vinyl chloride resin from migrating to the ink receiving layer. , It is preferable to provide the plasticizer migration prevention layer between the ink receiving layer and the surface layers of the first foam layer and the second foam layer.

(Second ink)
When the second foam layer is a heat-expandable foam layer, it acts on the second foam layer, and the second ink promotes or suppresses the foaming of the heat-expandable microcapsules.
For example, in order for the second ink to suppress foaming, the second ink contains a solvent that dissolves and / or swells the outer shell of the microcapsules to break the microcapsules, or the microcapsules are heated by heating in the foaming step. It contains an endothermic material that absorbs heat so that it does not expand, or both.

Examples of the solvent for dissolving and / or swelling the outer shell of the microcapsules include polar compounds capable of dissolving and / or swelling the resin material constituting the outer shell, specifically, acetone, methyl ethyl ketone, and ethyl butyl. Examples include ketones, methanol, ethanol, ethyl acetate, gamma butyrolactone, epsilon caprolactent, dimethylformamide and the like. Of these, gamma-butyrolactone is preferable.

Examples of the endothermic material include a solvent having a large specific heat capacity and a solid.
Examples of the solvent having a high specific heat include 2-pyrrolidone, N-formylmorpholine, gamma-butyrolactone, epsilon caprolactone, and propylene carbonate. Among these solvents, 2-pyrrolidone is preferable because it has the highest effect of suppressing foaming.
Examples of the solid having a large specific heat capacity include aluminum hydroxide, calcium hydroxide, magnesium sulfate heptahydrate and the like.

When an endothermic material is used, it is preferable that the heating time in the foaming step is shortened so that the endothermic material has an amount of heat that can be absorbed. Further, since the endothermic material may affect the foaming of the first foam layer, it is preferable to use only a solvent that dissolves and / or swells the outer shell.

The method for producing a foamed printed matter using the foamable media according to the present embodiment will be described below with reference to the drawings.

FIG. 1 shows a manufacturing flow of a foamed printed matter using the foamable media according to the present embodiment. In the production flow of the foamed printed matter (foam) according to the present embodiment, as shown in FIG. 1, in the preparatory step (S1) for preparing the foamable media, the ink acting on the foamed layer is attached to the foamable media. The adhesion step (S2) includes a foaming step (S3) of foaming the foamable media to which the ink is adhered.

Next, each step will be described with reference to FIGS. 2 to 4. 2 to 4 are conceptual diagrams of a method for producing a foamed printed matter using the foamable media according to the present embodiment.

First, in the preparation step (S1), the foamable media 1 is prepared (FIG. 2A). In the foamable media 1, the base material 2, the first foam layer 3, and the second foam layer 4 are laminated in this order. The first foam layer 3 is a chemical foam layer, and the second foam layer 4 is a thermal expansion type foam layer using microcapsules. The first foam layer 3 and the second foam layer 4 are welded and bonded.

Next, in the adhesion step (S2), the ink acting on the foam layer is partially adhered to the foamable media 1. Adhesion of ink is, for example, coating. In FIGS. 2 to 4, the first ink 5 is first adhered, and then the second ink 7 is adhered. The first ink 5 is an ink that suppresses the foaming of the first foaming layer 3, and contains a component that inhibits the catalytic action of the chemical foaming of the first foaming layer 3.

As shown in FIG. 2B, the first ink 5 is partially adhered to the foamable media 1. FIG. 2B is a diagram showing the moment when the first ink 5 is attached. After that, as shown in FIG. 2C, the first ink 5 permeates the second foam layer 4 and further penetrates to the first foam layer 3 to form the first ink penetrating portion 6. .. The first ink 5 does not affect the foaming of the heat-expandable foaming agent in the second foam layer 4.

Next, as shown in FIG. 3D, the second ink 7 is partially adhered to the foamable media 1. FIG. 2D is a diagram showing the moment when the second ink 7 is attached. After that, as shown in FIG. 3E, the second ink 7 permeates the second foam layer 4 to form the second ink penetrating portion 8. The second ink is an ink that suppresses the foaming of the second foaming layer 4, and is, for example, a solvent that destroys the outer shell of the microcapsules by melting or the like. The second ink may penetrate the first foam layer 3, but does not affect the chemical foaming of the first foam layer 3.

As shown in FIG. 3E, the foamable media 1 has a portion A to which the first ink 5 adheres, a portion B to which the second ink 7 adheres, and the first ink 5 and the second ink 5. A portion C to which the inks 7 overlap and adhere to a portion C and a portion D to which the first ink 5 and the second ink 7 do not adhere are formed.

Next, in the foaming step (S3), as shown in FIG. 4, the foamable media 1 is heated. The heating conditions are within the range of the maximum expansion temperature of the capsule-type foaming agent in the second foam layer 4 and the foaming temperature of the first foam layer 3. By heating, bubbles 14 are generated and foamed in the portion other than the first ink penetrating portion 6 in the first foaming layer 3, and microcapsules are generated in the portion other than the second ink penetrating portion 8 in the second foaming layer 4. 15 expands and foams (FIG. 4 (f)). The region (I) 10 in which the first foam layer 3 and the second foam layer 4 are foamed corresponding to the portion D to which the first ink 5 and the second ink 7 are not adhered to the foam 9 (foam printed matter). , The region (II) 11 in which only the first foam layer 3 was foamed corresponding to the portion B to which the second ink 7 was adhered, and the region A to which the first ink 5 was adhered, and only the second foam layer 4 was foamed. Region (III) 12, the region (IV) in which neither the first foam layer 3 nor the second foam layer 4 is foamed corresponding to the portion C where the first ink 5 and the second ink 7 are overlapped and adhered. An uneven pattern having four levels of height difference is formed in the order of 13.

As described above, according to the present embodiment, a foamed printed matter having a concavo-convex pattern having a large height difference can be obtained.

(Other Embodiment 1)
Although FIGS. The same effect can be obtained by lowering the foaming temperature of the chemical foaming agent to be lower than the foaming temperature of the microcapsules.

(Other Embodiment 2)
The ink adhered to the foamable media 1 may permeate into the foam layer by heating when it is heated in the foaming step (S3). That is, as shown in FIG. 5, in the adhesion step (S2), the first ink 5 is partially adhered to the foamable media 1 (FIG. 5 (b)), and the second ink 7 is partially adhered. Attach (Fig. 5 (c)).

Next, when the foamable media 1 is heated in the foaming step (S3), as shown in FIG. 6D, the first ink 5 permeates the second foaming layer 4, and further reaches the first foaming layer 3. It permeates to form the first ink penetrating portion 6, and the second ink 7 permeates into the second foam layer 4 to form the second ink penetrating portion 8.

When further heating is performed, bubbles 14 are generated in the portion other than the first ink penetrating portion 6 in the first foaming layer 3 to foam, and the portion other than the second ink penetrating portion 6 in the second foaming layer 4 is generated. The microcapsules 15 expand and foam at (FIG. 6 (e)). In the foam 9 (foamed printed matter), the region (I) 10 in which the first foam layer 3 and the second foam layer 4 were foamed, the region (II) 11 in which only the first foam layer 3 was foamed, and the second foam layer 4 An uneven pattern having four levels of height difference is formed in the order of the region (III) 12 in which only the foam is formed, the region (IV) 13 in which none of the first foam layer 3 and the second foam layer 4 is foamed.

(Other Embodiment 3)
7 and 8 show a method for producing a foamed printed matter using an ink that promotes the foaming of the first foam layer as the first ink 5 and an ink that suppresses the foaming of the second foam layer 4 as the second ink 7. It is a conceptual diagram of. The ink that promotes the foaming of the first foam layer 3 is an ink containing a heat generating agent such as carbon, and acts on the first foam layer 3 to foam under predetermined foaming conditions.

First, in the preparation step (S1), the foamable media 1 is prepared (FIG. 7A). In the foamable media 1, the base material 2, the first foam layer 3, and the second foam layer 4 are laminated in this order.

In the adhesion step (S2), as shown in FIG. 7B, first, the first ink 5 is partially adhered to the foamable media 1. The first ink 5 does not penetrate into the second foam layer 4 but adheres to the second foam layer 4.

Next, as shown in FIG. 7C, the second ink 7 is partially adhered to the foamable media 1. FIG. 7C is a diagram showing the moment when the second ink 7 is attached. After that, the second ink 7 permeates the layer of the first ink 5 and the second foam layer 4 as shown in FIG. 8D to form the second ink penetrating portion 8.

As shown in FIG. 8D, the foamable media 1 has a portion A to which the first ink 5 is attached, a portion B to which the second ink 7 is attached, the first ink 5, and the first ink 5. A portion C to which the ink 7 of 2 is overlapped and adhered, and a portion D to which the first ink 5 and the second ink 7 are not adhered are formed.

Next, in the foaming step (S3), the foamable media 1 is foamed under predetermined foaming conditions. As for the foaming conditions, the first foaming layer 3 in which foaming is not promoted does not foam, the first foaming layer 3 in which foaming is promoted by the first ink 5 foams, and the foaming is not suppressed. Reference numeral 4 denotes a condition in which the second foam layer 4 that foams and the foaming is suppressed by the second ink 7 does not foam (FIG. 8 (d)).

When the foamable media 1 is placed under foaming conditions, the first foam layer 3, the portion A and the portion C to which the first ink 5 is attached, are foamed because the first ink 5 promotes foaming. However, the portion B and the portion D to which the first ink 5 is not adhered do not foam. Further, the portions B and C of the second foam layer 4 to which the second ink 7 adheres do not foam because the second ink 7 suppresses foaming, and the second ink 7 does not adhere. The ink spots A and D are foamed (FIGS. 8 (d) and 8 (e)).

As a result, as shown in FIG. 8 (e), in the foam 9 (foamed printed matter), the region (I) 10, the first foam layer 3, and the first foam layer 3 and the second foam layer 4 in which the first foam layer 3 and the second foam layer 4 were foamed were formed. 2 Region (I) 10 where the foamed layer 4 is foamed, region (II) 11 where only the first foamed layer 3 is foamed, region (III) 12, where only the second foamed layer 4 is foamed, the first foamed layer 3 and the first An uneven pattern having four levels of height difference is formed in the order of the non-foamed region (IV) 13 of the two foam layers 4.

(Other Embodiment 4)
FIG. 9 shows a manufacturing flow of a foamed printed matter according to another embodiment using the foamable media. As shown in FIG. 9, the production flow of the foamed printed matter according to the present embodiment includes a preparation step (S1) for preparing the foamable media, an adhesion step (S2) for adhering the foaming control ink to the foamable media, and foaming. The process includes a color ink printing step (S4) of printing the colored ink on the foamable media to which the control ink is attached, and a foaming step (S3) of foaming the foamable media to which the foaming control ink is attached and the colored ink is printed. According to this aspect, it is possible to add color corresponding to the uneven pattern of the foamed printed matter.

The present invention allows for various embodiments and modifications without departing from the broad spirit and scope of the present invention. Moreover, the above-described embodiment is for explaining the present invention, and does not limit the scope of the present invention. That is, the scope of the present invention is indicated not by the embodiment but by the claims. Then, various modifications made within the scope of the claims and the equivalent meaning of the invention are considered to be within the scope of the present invention.

1 Foamable media 2 Base material 3 1st foam layer 4 2nd foam layer 5 1st ink 6 1st ink penetrating part 7 2nd ink 8 2nd ink penetrating part 9 Foam 10 region (I)
11 regions (II)
12 regions (III)
13 regions (IV)
14 bubbles 15 microcapsules

Claims (9)

It has a foaming layer on the base material that foams under predetermined foaming conditions.
It is a foamable medium capable of forming an uneven pattern in which the height of the foamed layer from the base material is different by partially adhering the ink to the foamed layer and foaming the foamed layer under the predetermined foaming conditions. hand,
The foamable media is formed on the base material by overlapping the first foam layer and the second foam layer as the foam layer.
The first foam layer and the second foam layer have different foaming mechanisms.
The ink contains a first ink that acts on the first foam layer and a second ink that acts on the second foam layer when foamed under the predetermined foaming conditions.
The foam layer has a portion A to which the first ink is attached, a portion B to which the second ink is attached, and a portion C to which the first ink and the second ink are adhered in an overlapping manner. The height of at least three steps including the first ink and the second ink not adhered to the foam layer by having at least two of them and foaming under the predetermined foaming conditions. An effervescent medium that can form an uneven pattern. The first foam layer and the second foam layer are foam suppression layers having different foaming mechanisms.
In the first foam layer, foaming is suppressed by the first ink and foaming is not suppressed by the second ink.
The foamable medium according to claim 1, wherein the second foam layer is suppressed from foaming by the second ink and is not suppressed from foaming by the first ink. The foamable media according to claim 1 or 2, wherein the maximum foam thickness of the first foam layer is different from the maximum foam thickness of the second foam layer. The first foaming layer is a layer of a first thermoplastic resin having a chemical foaming mechanism and containing a chemical foaming agent.
The foaming according to any one of claims 1 to 3, wherein the second foaming layer is a layer of a second thermoplastic resin having a heat-expandable microcapsule foaming mechanism and containing a heat-expandable foaming agent. Sex media. The second foam layer is an adhesion layer of the ink.
The first foaming layer further contains a foaming aid that promotes the foaming of the chemical foaming agent.
The first ink contains a component that chelate with the foaming aid to inactivate the foaming aid, and contains a foaming inhibitor that can penetrate the first thermoplastic resin and the second thermoplastic resin. Contains,
The heat-expandable foaming agent of the second foam layer is a capsule-type foaming agent in which a vaporizing component is filled in a gas-impermeable third thermoplastic resin shell.
The foamable medium according to claim 4, wherein the second ink contains a solvent capable of swelling or dissolving the third thermoplastic resin and / or an endothermic agent. The foamable media according to claim 5, wherein the first foaming layer foams maximum within the range of the maximum expansion temperature of the capsule-type foaming agent. The foamable medium according to any one of claims 4 to 6, wherein the first thermoplastic resin and the second thermoplastic resin are selected from a combination of resins that can be welded to each other and have good adhesion. The foamable media according to any one of claims 1 to 7, wherein the method of adhering the first ink and the second ink is an on-demand printing method. A bonding step of partially adhering the first ink and the second ink to the foamable media according to any one of claims 1 to 8.
A foaming step of foaming the foamable media to which the ink is attached under the foaming conditions of the second foaming layer,
A method for producing foamed printed matter including.

Images