JP3139010B2 - Decorative sheet and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative sheet having an emboss synchronized with a pattern and a method for producing the same.

[Prior art]

With respect to decorative sheets made of synthetic resin, which are often used for painting interiors of houses and molded articles, those having a variety of designs with embossing synchronized with the pattern are recently preferred. Such a decorative sheet can be manufactured using an embossing plate provided with an embossing pattern corresponding to a picture. However, with this technique, the embossed plate must be raised for each picture, so that the product is expensive unless mass-produced. In addition, it is difficult to register the pattern with the plate and the film shrinks due to heat during embossing, so that it is difficult to obtain a perfectly synchronized decorative sheet. As a method of manufacturing a decorative sheet that solves these problems, a pattern printing layer is provided on a thermoplastic resin sheet with a curable resin ink, and after curing it, embossing is performed, and only a portion without a pattern printing layer is provided. A method consisting of forming an emboss on the floor was proposed (Japanese Patent Publication No. Sho 63-2802).
No. 3). However, inks using a curable resin as a vehicle are generally less suitable for printing delicate patterns than inks using a thermoplastic resin as a vehicle. Therefore, the above method can be used only for producing a decorative sheet having a relatively simple pattern.

[Problems to be solved by the invention]

An object of the present invention is to realize a decorative sheet in which the pattern and the emboss are perfectly synchronized even if the pattern is delicate and complicated, and to provide a manufacturing method thereof.

[Means for Solving the Problems]

The decorative sheet of the present invention will be described first from a basic manufacturing method. As shown in FIG. 1, the same hot-press embossing is performed on a base sheet (1) that does not undergo plastic deformation under hot-press embossing conditions. A pattern is printed with an ink using a thermoplastic resin, which is plastically deformed under the conditions, as a vehicle, and hot-press embossing is performed to emboss (3) only on the surface of the pattern print layer (2).
To form As shown in FIG. 2, the decorative sheet produced in this manner is formed on a heat-resistant base sheet (1) which does not undergo plastic deformation under the conditions of the hot-press embossing, under the same conditions of the hot-press embossing. This is a decorative sheet having a pattern printing layer (2) of ink using a deformable thermoplastic resin as a vehicle, and embossing (3) formed by hot-press embossing only on the surface of the pattern printing layer. The pattern can be arbitrarily selected, such as a wood pattern, a stone pattern, a stripe, a lattice, or an abstract pattern. The ink used for printing a pattern in the present invention contains a thermoplastic resin as a vehicle, for example, a cellulose derivative, a styrene resin, an acrylic resin, or a vinyl resin. Polyvinyl chloride paste is most suitable as a vehicle because it is well dispersed in a solvent and is convenient for preparing ink. Printing on the substrate sheet can be by a known technique,
A gravure printing method is suitable for printing a delicate pattern, and a screen printing method for easily forming a thick film when it is desired to provide a pattern printing layer with deep irregularities. As the base sheet, a sheet of a synthetic resin is preferable because it is easy to handle. Synthetic resins having heat resistance that does not cause plastic deformation under the conditions of normal hot-press embossing are various cured resins, specifically, those obtained by heat-curing urethane resin or epoxy resin, ionizing This is a sheet obtained by curing a radiation-curable acrylic resin with ultraviolet rays or electron beams. Of course, a thermoplastic resin can also be used as the base sheet, in this case, a resin having a softening point 20 ° C. or higher than the softening point of the resin of the ink vehicle is selected.
The hot press embossing is performed at a temperature within the difference between the softening temperatures. A typical thermoplastic resin having a softening point 20 ° C. or more higher than that of a conventional ink vehicle resin is polyester. More specifically, when polyvinyl chloride, a vinyl chloride / vinyl acetate copolymer, an acrylic resin, or the like is used as the ink vehicle, polycarbonate, polyethylene terephthalate, and the like are resins having a softening point higher than 20 ° C. . In addition to synthetic resin sheets, papers such as kraft paper and titanium mixed paper, and metal sheets may be used as the base sheet. A laminated sheet of the above sheets may be used. It is recommended that the base sheet be provided with a metal deposition layer or a colored ink layer on the front surface and / or the back surface in a pattern or on the entire surface so as to make the appearance of the product decorative sheet more beautiful. is there. When the metal deposition layer or the colored ink layer is provided in a pattern, it is preferable to provide the pattern so as to be synchronized with the pattern printing layer. FIG. 2 shows an example in which a patterned metal deposition layer (4) is provided on the surface of a base material sheet (1), a pattern printing layer (2) synchronized with the metal deposition layer is provided, and an emboss (3) is formed on the surface. It is. FIG. 3 shows an example in which a pattern printing layer (5) is provided on the back surface of the base sheet, a picture printing layer (2) synchronized with the pattern printing layer (2) is provided on the front surface, and an emboss (3) is formed on the surface. The coloring ink layer can be provided by a known method such as a gravure coating method and a roll coating method using a normal printing ink. The metal deposition layer uses common metals such as Al, Cr, and Ni,
It may be formed by a vacuum evaporation method or a sputtering method. The formation of the patterned deposition layer may be performed according to a known method, for example, the following method. A) A method of printing a desired pattern on a base sheet with a water-soluble ink, depositing a metal thereon, washing with water, and removing the deposited layer on the water-soluble ink layer together with the ink, b) the entire surface of the base sheet To deposit metal on
A method in which a resist layer having a desired pattern is provided and etched. The embossing plate may use an embossing roll or an embossing plate on which an arbitrary pattern is made by a known plate making technique, for example, an etching method, an electroforming method, or a laser engraving method. To give a preferred example of the emboss pattern,
A set of patterns consisting of a group of parallel straight lines or curves and a closed boundary that surrounds them. The direction of the group of parallel straight lines or curves of adjacent patterns that share a side is different, and the depth of the line Is more than 5μm and less than 100μm, pitch is 0.1μ
m or more and 200 μm or less, and the direction difference between the line groups is 5 ° or more. It goes without saying that embossing is performed by heating and pressing at a temperature at which the vehicle of the picture printing layer undergoes plastic deformation.

[Operation]

When a hot-press embossing is performed from the top of the pattern printing layer of the thermoplastic resin, as shown in FIG. 1, the emboss is formed on the surface of the pattern printing layer, while the exposed surface of the base sheet is Remains without plastic deformation. Therefore, it is possible to manufacture a decorative sheet in which a picture and an embossed pattern are seen to be perfectly synchronized by using an embossed plate in which embossing is made on the entire surface. In the present invention, unlike the conventional method, since an ink using a thermoplastic resin as a vehicle is used for printing a pattern, a decorative sheet having a delicate and complicated pattern can be easily realized. In particular, when a sheet of a thermoplastic resin is used as the base sheet, the suitability for printing is good, so that the above-mentioned effects are further enhanced. In the conventional method, it is possible to perform pattern embossing with an entire embossing plate, but the emboss effect is reduced because there is a layer of a cured resin that is not deformed on a thermoplastic resin that is deformed by hot pressure. On the other hand, in the present invention, since the embossed plate contacts the layer printed on the undeformed base sheet,
High emboss effect and sharp unevenness can be obtained. If there is a metal vapor deposition layer or a colored ink layer synchronized with the pattern printing layer on the front or back surface of the base sheet, the decorative effect of the decorative sheet is further enhanced.

Example 1 A 50 μm thick polyethylene terephthalate sheet “HP
-7 "(manufactured by Teijin) was used as a substrate sheet, and a stripe pattern was silk-screen printed thereon with an ink having the following composition. Vehicle: Polyvinyl chloride “121” (manufactured by Zeon Corporation) 100 parts by weight Plasticizer: DOP 60 parts by weight Stabilizer: “FL-41” (manufactured by Adeka Argus) 3 parts by weight “O-130” (same as above) 2 parts by weight Using a roll embossing plate with a hairline tone on the entire surface, the above-mentioned pattern printing layer is provided on the base sheet, and then the sheet temperature is 110 ° C, the sheet supply speed is 20m / min, and the embossing roll temperature
Hot and pressure embossing was performed at 200 ° C. and a pressure of 1 kg / cm ² . The obtained decorative sheet had a hairline-like emboss only in the striped pattern print layer.

Example 2 A 50 μm-thick polyethylene terephthalate film “T-60” (manufactured by Toray Industries, Inc.) was used as a base sheet, and the surface thereof was activated by corona treatment. It was applied so as to be 0.3 g / m ² (at the time of drying). The same ink as in Example 1 except that the content of the plasticizer (DOP) is 45 parts by weight, and the thickness is 30 μm.
m, the stripe pattern was silk-screen printed. An embossed pattern plate was prepared which is a set of patterns consisting of a parallel line group having a depth of 10 μm and a pitch of 50 μm and a closed boundary line surrounding the group, wherein the directions of the adjacent parallel line groups are different. Using this embossing plate, hot press embossing was performed in the same manner as in Example 1. The back surface of the base sheet was roll-coated with an adhesive "Olivine" (manufactured by Toyo Ink), and silicone release paper was applied to obtain a decorative sheet.

Example 3 A transparent polyethylene terephthalate film “diafoil 0 type” (manufactured by Mitsubishi Plastics) having a thickness of 50 μm was used as a base sheet, and a 100-mm-thick aluminum vapor-deposited layer was provided on one side of the base sheet, and on the other side. A polyvinyl chloride-based primer was applied so that the coating amount when dried was 0.3 g / m ² . On the primer layer, the same vehicle, plasticizer and stabilizer as those of Example 1 were used, and a grid pattern was silk-screen printed with an ink of the following composition in which mar powder was dispersed so that the thickness became 30 μm. Vehicle 100 parts by weight Plasticizer 50 parts by weight Stabilizer 5 parts by weight Mar powder 5 parts by weight As in Example 2, hot-press embossing is performed on the printing surface, and a pressure-sensitive adhesive layer and release paper are provided on the evaporation surface to prepare a decorative sheet. Obtained.

Example 4 A white polyethylene terephthalate film “E-20” (manufactured by Toray) having a thickness of 50 μm was used as a base sheet, and 5 parts by weight of aluminum powder was used on the ink used in Example 3 instead of Marl powder. Dispersed ink, thickness 30
A polka dot pattern was silk-screen printed to a thickness of μm. In the same manner as in Example 2, hot decorative embossing and lamination of the pressure-sensitive adhesive layer and release paper were performed to obtain a decorative sheet.

Example 5 A 50 μm thick polyethylene terephthalate sheet “HP
-7 "(manufactured by Teijin) was used as a base material sheet, and Al was vacuum-deposited thereon so as to have a thickness of 600 mm, and an etching treatment was performed thereon to form a striped vapor deposition layer. On the deposition surface of the base sheet, with the same ink as in Example 1,
As shown in FIG. 2, a stripe pattern synchronized with the stripe pattern of the vapor-deposited layer was subjected to silk-screen printing, and then subjected to hot-press embossing in the same manner as in Example 1.

【The invention's effect】

ADVANTAGE OF THE INVENTION According to the method of this invention, even if a pattern is delicate and complicated, a decorative sheet in which the pattern and the emboss are perfectly synchronized can be manufactured.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a conceptual cross-sectional view for explaining a method for manufacturing a basic aspect of a decorative sheet according to the present invention. 2 and 3 are cross-sectional views each showing another embodiment of the decorative sheet of the present invention. DESCRIPTION OF SYMBOLS 1 ... Base sheet 2 ... Picture printing layer 3 ... Emboss 4 ... Metal deposition layer 5 ... Pattern printing layer

──────────────────────────────────────────────────の Continuation of the front page (51) Int.Cl. ⁷ identification code FI B32B 33/00 B32B 33/00 (58) Field surveyed (Int.Cl. ⁷ , DB name) B41M 1/00-3/06 B29C 59/02 B32B 7/02 103 B32B 15/08 B32B 27/00 B32B 33/00

Claims (7)

(57) [Claims] 1. A pattern printing layer of an ink using, as a vehicle, a thermoplastic resin which is plastically deformed under the same hot-press embossing condition is provided on a heat-resistant base sheet which does not plastically deform under hot-press embossing conditions. A decorative sheet in which an emboss is formed only on the surface of the pattern printing layer by hot-press embossing. 2. The method according to claim 1, wherein the base sheet has a surface and / or
2. A metal layer or a colored ink layer on the back surface.
Decorative sheet. 3. The decorative sheet according to claim 2, wherein the metal deposition layer or the colored ink layer is provided in a pattern synchronized with the picture printing layer. 4. The decorative sheet according to any one of claims 1 to 3, wherein the emboss is a pattern comprising a group of parallel lines having a depth of more than 5 μm and 100 μm or less and a pitch of 0.1 μm or more and 200 μm or less. 5. A pattern is printed on a heat-resistant base sheet that does not plastically deform under the conditions of hot-press embossing with an ink using a thermoplastic resin as a vehicle that plastically deforms under the same conditions of hot-press embossing, A method for producing a decorative sheet, comprising forming an emboss only on the surface of a picture print layer by performing hot-press embossing. 6. A sheet according to claim 5, wherein a sheet of a cured resin or a sheet of a thermoplastic resin having a softening point higher than that of a thermoplastic resin used for an ink vehicle by 20 ° C. or more is used as the base sheet. Production method. 7. The method according to claim 5, further comprising the step of providing a metal deposition layer or a colored ink layer on the base sheet.