JP3376835B2 - Method of manufacturing three-dimensional pattern decorative sheet - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a three-dimensional decorative sheet for use in surface decoration of building materials such as inner wall surfaces and ceiling surfaces of buildings, furniture fittings, furniture and the like. br />

[0002]

2. Description of the Related Art In recent years, as materials for construction such as inner wall surfaces and ceiling surfaces of buildings, fittings, furniture, fixtures, etc., the price and weight have been reduced as compared with the case of using natural wood or stone materials. For the purpose of obtaining the same or unique designability as those of them, for example, a decorative sheet having a design of a desired pattern on the surface of a base material such as plywood, particle board, medium-density fiberboard, and honeycomb material in advance. The method of sticking is becoming more and more widely used.

The decorative sheet is, for example, a base sheet made of paper, a synthetic resin film or a laminated body thereof, on which a pattern such as a wood grain pattern, a stone grain pattern or an abstract pattern is printed. There is an example in which these are attached to the surface of the base material and used as they are. However, if the pattern layer is exposed on the surface, the pattern may be changed over time due to abrasion during use or the action of various chemical substances such as solvents. The design is lost.

Of course, if the base sheet is a transparent material,
It is also possible to provide a pattern layer on the back surface of the base sheet so that the base sheet has a function of protecting the pattern layer. But,
For example, if an opaque material such as paper, woven cloth, non-woven cloth, veneer, or opaque synthetic resin film is used as the base sheet, it is impossible. For the purpose of imparting surface physical properties such as, a method of applying a transparent or semitransparent coating to the surface is used.

However, in the case of the above-mentioned coating process, for example, in the case of an article having a complicated shape, it is difficult to industrially efficiently perform the coating work, and the spray coating method is usually used. Is scattered and wasteful, and there are many problems in working environment hygiene. In addition, in addition to the above-mentioned problems, it is necessary to manually paint the inner wall surface and ceiling surface of a building, which requires labor costs and requires a period for painting work and drying. As a result, the construction period was prolonged.

Therefore, for the purpose of solving the above-mentioned problems, a top coat layer for imparting surface physical properties such as abrasion resistance and solvent resistance to the surface of the decorative sheet is provided in advance on the decorative layer of the decorative sheet. The method has already been put to practical use. By doing this, it is possible to apply the design property of the pattern and the surface physical properties at the same time without passing through the coating process, simply by sticking the decorative sheet having the top coat layer on the base material. It greatly contributes to the improvement of environment and shortening of construction period.

As described above, the decorative sheet having the top coat layer provided on the entire surface of the pattern layer has a substantially flat surface, and therefore, compared with a natural wood material having irregularities such as annual rings and conduit grooves. However, it is inferior in terms of design. For the purpose of supplementing this, for example, a decorative sheet having a three-dimensional design property close to that of a natural wood-based material has been obtained by imparting unevenness by an embossing method or further applying wiping to color the concave portion. .

However, in the embossing method and the wiping method described above, it is difficult to synchronize the pattern and the unevenness in the manufacturing process, and therefore the design is still inferior to that of the natural wood material. Therefore, on the pattern layer (base pattern layer) provided on the base sheet,
A liquid repellent pattern layer such as a conduit pattern is provided in synchronism with this, and the top coat agent is applied to the entire surface, and then the top coat agent in the portion where the liquid repellent pattern layer is provided is repelled, and the liquid repellent is repelled. A method has been devised to obtain a three-dimensional pattern in synchronism with the underlying pattern layer by selectively providing a top coat layer on the surface excluding the portion where the sex pattern layer is provided (JP-A-59-1).
0371 publication).

By the way, as a printing ink or a topcoat agent used for providing the above-mentioned pattern printing layer or topcoat layer, an organic solvent is conventionally used as a diluting solvent as in other printing fields and coating fields. In most cases, oil-based printing inks and top coat agents were used, but with the increasing awareness of environmental protection in recent years, the use of organic solvents was abolished,
Attempts have already been made in part to manufacture decorative sheets using water-based printing inks and top coat agents that use water as a diluting solvent.

Further, it is possible to manufacture a three-dimensional decorative sheet by using materials such as water-based ink and water-based top coating agent for all of the above-mentioned base pattern layer, liquid repellent pattern layer, and top coat layer. , Already disclosed (Japanese Patent Laid-Open No. 8-3
5199).

However, the water-based printing inks and top coat agents described above pose a serious problem at the manufacturing site. What is important is that water, which is a dilution solvent for water-based printing inks and top coat agents, has a higher evaporation heat and specific heat than organic solvents, which are dilution solvents for conventional oil-based printing inks. This is because the drying speed of the agent is slow and set-off and blocking due to poor drying are likely to occur, so that it cannot be manufactured under the same manufacturing conditions.

Explaining more concretely, in the case of toluene, which is one of the typical diluents for conventional oil-based printing inks, the heat of evaporation is 0.364 kJ / g and the specific heat is 1.76.
J / K · g, whereas water has a heat of vaporization of 2.26 kJ /
g, specific heat 4.19 J / Kg (boiling point is 1
10.6 ° C and 100 ° C). Therefore, in order to evaporate the dilute solvent of the same weight, it is necessary to calculate the amount of heat required for water to be several times that of toluene.

Therefore, when an attempt is made to produce a decorative sheet by using a water-based printing ink and a top coating agent, the operating conditions of the dryer are the same as when an oil-based printing ink and a top coating agent are used. In that case, it is necessary to reduce the printing speed to a fraction, while in order to manufacture at the same printing speed, the drying capacity of the dryer must be increased several times.

However, none of these methods is very realistic. This is because the method of reducing the printing speed naturally lowers the production amount per unit time, which leads to an increase in manufacturing cost. On the other hand, in order to increase the drying capacity of the dryer, the printing device becomes large and expensive, and if you try to use the conventional printing device for oil-based ink, it requires a considerably large-scale remodeling. This leads to an increase in manufacturing costs.

Further, where either method is adopted, a large increase in energy required for operating the dryer is inevitable. Therefore, if the organic solvent was successfully reduced by such a method, and the energy consumption increased significantly, there was a problem that it could not be said that it contributes to environmental protection as a whole. .

[0016]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems in the conventional method for producing a three-dimensional pattern decorative sheet , and reduces productivity and energy consumption required for production. Without significantly increasing
A three-dimensional decorative makeup sheet that can contribute to environmental protection by reducing the amount of organic solvent used and that is excellent in three-dimensional design.
The present invention aims to provide a method for manufacturing a gut .

[0017]

The method for producing a three-dimensional decorative sheet according to the present invention comprises a substrate sheet and a liquid-repellent pattern layer provided on the substrate sheet.
After coating, apply a top coat to the entire surface and
Bounce the top coat agent on the part where the handle layer is provided,
Selectively on the surface except for the serial lyophobic pattern layer is provided partially
In the method <br/> the three-dimensional pattern decorative sheet providing a topcoat layer, using the oily liquid repellency ink in the liquid repellent pattern layer
The solvent contained in the oil-based liquid-repellent ink is non-polar.
Higher evaporation rate than organic solvent and non-polar organic solvent
Mainly a polar organic solvent, as the top coat agent
Using aqueous top coating agent, and the liquid-repellent pattern
On the base sheet provided with a layer, the water-based top coat
At the time of applying the agent, the liquid repellent pattern layer is
Mainly composed of the non-polar organic solvent to the extent that it becomes free.
It is characterized by containing a residual solvent .

Further, in particular, the evaporation rate of the non-polar organic solvent
Is 50 or more and 200 or less (assuming 100% of pure butyl acetate)
And the evaporation rate of the polar organic solvent is 20
It is characterized by being 0 or more and 1000 or less .

Further, in particular, the liquid-repellent pattern layer and the topography
After-drying zone is used for printing and coating
Using the multi-color printing device provided, the liquid repellent pattern layer is the final
Print with a printing unit other than the printing unit, and
The top coat agent is applied in the final printing unit.
It is characterized by integrated production in-line .

Further, in particular, the base sheet and the liquid repellent property
A mark used for printing the liquid-repellent pattern layer between the pattern layer
Use the printing unit on the paper feed side of the printing unit,
It is characterized in that a base pattern layer is printed with an oil-based ink .

[0021]

[0022]

[0023]

[0024]

[0025]

[0026]

[0027]

[0028]

[0029]

DETAILED DESCRIPTION OF THE INVENTION The present invention will be described in detail below with reference to the drawings. FIG. 1 is a side sectional view showing an example of a three-dimensional pattern decorative sheet manufactured by the method of the present invention.
FIG. 3 is an overall side view showing an example of a printing apparatus used in the method for producing a three-dimensional decorative sheet according to the present invention.

As shown in FIG. 1, the three-dimensional patterned decorative sheet produced by the method of the present invention has a liquid repellent pattern layer 3 and a liquid repellent pattern on a base sheet 1 such as paper. A top coat layer 4 provided on the surface excluding a portion where the layer 3 is provided, and if necessary, between the liquid repellent pattern layer 3 or the top coat layer 4 and the base sheet 1, A base pattern layer 2 is provided.

As the base sheet 1, various sheet-like or film-like materials can be used as conventionally known, depending on the intended use. Specifically, for example, thin paper, titanium paper, resin-impregnated paper, flame-retardant paper, paper such as inorganic paper, woven or non-woven fabric made of natural fibers or synthetic fibers, veneer, etc., or polyolefin resin, polyester resin, Acrylic resin, styrene resin, polyamide resin, fibrin resin, polycarbonate resin, polyvinyl chloride resin, polyvinylidene chloride resin, transparent resin composed of a mixture of synthetic resins such as fluororesin, copolymers, etc., Any conventionally known material such as a semitransparent or opaque synthetic resin film, a composite body or a laminated body thereof can be used.

The base pattern layer 2 may not be provided at all if not necessary, but for the purpose of obtaining an excellent design effect in which a three-dimensional pattern is added to a two-dimensional pattern, the liquid-repellent pattern layer 3 is provided. In general, the undercoat pattern layer 2 is also provided on the top coat layer 4. When the base sheet 1 is made of a transparent or translucent material, it may be provided on the back side of the base sheet 1 or may be provided on both sides. However, in consideration of convenience for in-line integrated production using a multicolor printing device, it is preferable that the base pattern layer 2 is provided between the liquid-repellent pattern layer 3 or the top coat layer 4 and the base sheet 1.

As the material used for the base pattern layer 2, any conventionally known printing ink, coating agent or the like can be used, and it may be oily or aqueous. In recent years, examples of using water-based ink are gradually increasing in consideration of environmental problems. However, in the three-dimensional decorative sheet of the present invention, in consideration of in-line integrated production using a multi-color printing device, it is preferable to use a conventional oil-based ink, which is more advantageous in terms of drying speed than an aqueous ink.

The above-mentioned oil-based ink is formed by dissolving or dispersing a colorant such as a dye or a pigment together with an appropriate binder resin in an organic solvent. Examples of the colorant include inorganic pigments such as carbon black, titanium white, zinc white, red peony, yellow lead, navy blue, and cadmium red, azo pigments, lake pigments, anthraquinone pigments, phthalocyanine pigments, isoindolinone pigments, and dioxazine. It is possible to use organic pigments such as pigments, or the like, or a mixture of two or more thereof.

Examples of the binder resin include acrylic resin, styrene resin, polyester resin,
Urethane resin, polyvinyl resin, alkyd resin, petroleum resin, ketone resin, epoxy resin, melamine resin, fluorine resin, silicone resin, fiber resin,
Various synthetic resins such as rubber-based resins, mixtures thereof, copolymers and the like can be used.

As the organic solvent, for example, toluene, xylene, cyclohexane, ethyl acetate, butyl acetate, methyl alcohol, ethyl alcohol, isopropyl alcohol, acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, or a mixture thereof is used. Can be used.

In addition, if necessary, extender pigments and plasticizers,
Dispersant, surfactant, tackifier, adhesion aid, desiccant,
Various additives such as a curing agent, a curing accelerator or a curing retarder are used as appropriate.

The undercoat pattern layer 2 may be of one color, but is usually subjected to multicolor printing of two or several colors for the purpose of designing natural colors. For an abstract pattern or the like, there are cases where three colors of yellow, crimson, indigo or four colors obtained by adding black ink to these are used as in the case of a normal commercial multicolor printed matter. On the other hand, as is well known, in the case of a wood grain pattern, it is usual to separate into a solid background, a wood grain pattern, a conduit pattern, etc. Among them, the conduit pattern is generally used as a liquid repellent pattern layer 3 described later. It is provided. Further, when the base sheet 1 is transparent or translucent, for the purpose of imparting the hiding property,
It is common to provide a white or colored opaque solid printing layer on the bottom layer. Although the coating amount of the pattern print layer 2 depends on the type of the pattern, it is usually 1 to 3 g / m in total of all colors.
It is about ² (after drying).

As the liquid-repellent pattern layer 3, at least a liquid-repellent agent, that is, more specifically, a liquid-repellent substance such as a fluorine-based resin, a silicone-based resin, or a wax is added. Ink is used. The added amount of the liquid repellent is usually about 5 to 70% by weight based on the solid content. In the present invention, an oil-based liquid-repellent ink using an organic solvent as a diluting solvent is particularly used. As the coloring agent, the binder resin, and the solvent, the same materials as in the case of the base pattern layer 2 described above can be used. However, since the liquid-repellent pattern layer 3 is exposed on the surface in the completed state of the three-dimensional pattern decorative sheet, in consideration of abrasion resistance, solvent resistance and the like, as a binder resin, It is preferable to use a curable resin.

Specific examples of the curable resin include urethane resin, melamine resin, epoxy resin, alkyd resin, acrylic resin, polyester resin,
Thermosetting resin such as silicone resin or room temperature curable resin, acrylic resin, urethane acrylate resin,
Ionizing radiation curable resins such as ester acrylate resins, epoxy acrylate resins, and silicone resins can be preferably used.

The solvent contained in the oil-based liquid-repellent ink used for forming the liquid-repellent pattern layer 3 is preferably composed mainly of a strong hydrophobic non-polar organic solvent. The use of the non-polar organic solvent has high solubility in a hydrophobic binder resin and a liquid repellent which are highly repellent to water, and the liquid repellent pattern layer 3
If it remains in a small amount, it also has the effect of enhancing its water repellency, so it enhances the repulsive force against the water-based topcoat agent and repels the water-based topcoat agent coated on the liquid-repellent pattern layer 3 quickly and surely. In addition, it is effective in improving the printing speed and preventing the occurrence of defects such as unremoved parts.

Specific examples of the nonpolar organic solvent include aliphatic hydrocarbon solvents such as hexane, octane, isooctane and trimethylhexane, cyclopentane,
Alicyclic hydrocarbon solvents such as cyclohexane, methylcyclohexane, and ethylcyclohexane, aromatic hydrocarbon solvents such as benzene, toluene, xylene, and ethylbenzene, petroleum solvents such as ligroin, petroleum benzine, and mineral spirits, or the like. It is preferable to mainly use a mixed solvent of two or more kinds.

However, the above-mentioned non-polar organic solvent often does not always have sufficient solubility in the binder resin.
In particular, when a curable resin is used as the binder resin, the curable resin often contains a polar group such as an isocyanate group, an epoxy group, or a (meth) acryloyl group, and therefore only a non-polar organic solvent is used. I used
In many cases, sufficient printability cannot be obtained due to poor dissolution. In such a case, a method of using a nonpolar organic solvent and a polar organic solvent in combination is widely adopted for the purpose of ensuring the solubility.

Specific examples of the polar organic solvent include alcohols such as methanol, ethanol, isopropyl alcohol and isobutyl alcohol, ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone and cyclohexanone, methyl acetate, ethyl acetate, Esters such as pure butyl acetate and isobutyl acetate, ethers such as diethyl ether, dioxane, tetrahydrofuran and the like, or a mixed solvent of two or more kinds thereof are generally used.

However, in that case, if a polar organic solvent having a smaller evaporation rate than the nonpolar organic solvent is used in combination, the nonpolar organic solvent evaporates first in the drying step, and a large amount of the polar organic solvent is likely to remain. There is a possibility that the repulsive force against the water-based topcoat agent to be processed will be reduced. Therefore, when the non-polar organic solvent and the polar organic solvent are used in combination, it is preferable to mainly use a combination of the non-polar organic solvent having a low evaporation rate and the polar organic solvent having a high evaporation rate.

As a measure of the evaporation rate of these solvents, the evaporation rate of non-polar organic solvents (assuming 100% of normal butyl acetate)
Is about 50 or more and 200 or less, and the evaporation rate of the polar organic solvent is preferably about 200 or more and 1000 or less. If the evaporation rate of the non-polar organic solvent is less than 50, the ink will dry too slowly in the printing process, which may easily cause blocking or dripping. On the other hand, if it exceeds 200, the time until the coating of the top coat agent is completed. In some cases, it may evaporate and dry sufficiently, and the effect of improving liquid repellency may not be obtained. Further, when the evaporation rate of the polar organic solvent is less than 200, it may not be possible to sufficiently evaporate and dry it by the time of applying the top coat agent, and the liquid repellency may be lowered. If it exceeds, the on-press stability of the ink is deteriorated because the evaporation and drying are too fast, which may adversely affect the printing workability and the printing quality.

Specifically, the nonpolar organic solvent is, for example, octane, trimethylhexane, ethylcyclohexane, mineral spirit, toluene, xylene, ethylbenzene, etc., and the polar organic solvent is, for example, methanol, ethanol, isopropyl alcohol, Methyl ethyl ketone, ethyl acetate, propyl acetate,
It is preferable to use mainly one selected from isopropyl acetate, propyl formate and the like, or a combination of two or more selected appropriately.

With this structure, the polar organic solvent having a high evaporation rate is preferentially selected from the nonpolar organic solvent and the polar organic solvent contained in the oily liquid repellent ink when the liquid repellent pattern layer 3 is printed. Since a large amount of non-polar organic solvent having a low evaporation rate tends to remain, it is possible to sufficiently exert the effect of improving the repulsion force with respect to the water-based top coat agent to be subsequently coated thereon. However, according to the present invention, a small amount of a slow-drying polar organic solvent having a relatively small hydrophilicity is added for the purpose of preventing whitening or powdering of the liquid-repellent pattern layer 3 as has been widely performed. Does not prevent

When the base pattern layer 2 is provided, the liquid-repellent pattern layer 3 may or may not be synchronized with the pattern of the base pattern layer 2 depending on the intended design property. good. However, for example, in the design of a wood grain pattern, when the underlying pattern layer 2 having a wood grain pattern and the liquid-repellent pattern layer 3 having a conduit pattern are synchronized, it is extremely comparable to a natural wood material. It is very suitable because it can be designed.

The topcoat layer 4 is provided for the purpose of imparting surface physical properties such as abrasion resistance, scratch resistance, solvent resistance and stain resistance to the surface of the decorative sheet, and at least the pattern printing layer. A transparent, colored transparent or semi-transparent resin layer having a transparency capable of seeing through 2 is provided. Further, in the present invention, since the top coat layer 4 is selectively provided on the surface excluding the portion where the liquid-repellent pattern layer 3 is provided, due to the difference in film thickness from the liquid-repellent pattern layer 3, It gives the surface a three-dimensional effect.

In particular, in the case of a three-dimensional decorative sheet having a wood grain pattern, generally, by making the thickness of the top coat layer 4 thicker than that of the colored liquid-repellent pattern layer 3, a repellency corresponding to a conduit pattern is obtained. The concave portion 5 can be formed in the liquid pattern layer 3 to give a three-dimensional conduit pattern similar to that of a natural wood-based material.

In addition to this, one or both of the liquid-repellent pattern layer 3 and the top coat layer 4 may be appropriately added with a luster modifier such as silica, alumina, calcium carbonate, barium sulfate or the like to form the liquid-repellent pattern layer. It is also possible to impart a glossy change pattern in synchronism with the picture pattern or the unevenness by making the surfaces of 3 and the top coat layer 4 different in glossy state.

The top coat layer 4 is a liquid repellent pattern layer 3
After the top coat agent is applied to the entire surface including the portion where the liquid-repellent pattern layer 3 is applied, the liquid-repellent pattern layer 3 repels the top-coat agent applied thereon to form a liquid-repellent pattern layer. It is selectively formed on the surface excluding the portion where 3 is provided. As such a topcoat agent, an oily topcoat agent having an organic solvent as a diluent solvent has been conventionally used, but in the present invention, an aqueous topcoat agent having water as a main diluent solvent is particularly used.

As described above, the first reason is the improvement of the liquid-repellent effect by the combination with the oil-based liquid-repellent picture layer 3, and the second reason is that the recent awareness of environmental protection. In view of the increase, reduction of the amount of organic solvent used can be mentioned.

To explain the situation in detail, the top coat layer 4
The coating amount depends on conditions such as the desired design and required abrasion resistance, but usually reaches about 5 to 10 g / m ² (after drying), so the content of the diluting solvent is inevitable. The amount is much larger than that of the base pattern layer 2 or the liquid-repellent pattern layer 3. The three-dimensional decorative sheet of the present invention achieves a large reduction in the amount of organic solvent used by using an aqueous topcoat agent having water as a main diluting solvent as the topcoat agent used in the topcoat layer 4. To do.

In addition to the above, as an advantage of using an aqueous topcoat agent, since a hydrophilic resin having good water solubility or water dispersibility is generally used as a constituent resin, the topcoat layer 4 obtained by curing this is obtained. Can also be mentioned as being excellent in solvent resistance to organic solvents.

Examples of the above-mentioned water-based top coat agent include an aqueous solution of a water-soluble curable resin such as a water-soluble melamine resin, a vinyl acetate resin water-based emulsion, a urethane resin water-based emulsion, an acrylic resin water-based emulsion, and a polyolefin. It is possible to use any conventionally known aqueous topcoat agent such as an emulsion type topcoat agent in which fine particles of a water-insoluble resin such as a resin-based aqueous emulsion are dispersed in water by the action of an appropriate dispersant. it can.

Of course, in order to obtain the required surface physical properties, it is preferable to use a curable topcoat agent to which melamines, epoxy compounds, aziridine and the like are added as a curing agent. In addition, in the aqueous topcoat agent, solubility,
For the purpose of improving dispersibility or coating suitability, there is also an example in which a solution prepared by adding a small amount of a water-soluble organic solvent such as alcohol to water is used as a diluting solvent, but the present invention excludes these. is not.

Of the method for producing a three-dimensional decorative sheet according to the present invention
In practice , as a method for printing / coating the base pattern layer 2, the liquid-repellent pattern layer 3, and the top coat layer 4, for example, an offset printing method, a screen printing method, a flexo printing method, etc. may be possible. Multi-color continuous high-speed printing is possible on a sheet-shaped printing material, rich gradation and excellent tone stability, easy to make endless pattern of arbitrary circumference, and excellent printing durability of printing plate It is well known that the gravure printing method is most suitable for the production of such a decorative sheet, and that most of the decorative sheets have been conventionally produced by the gravure printing method.

As described above, when the aqueous topcoat agent is used for the topcoat layer 4, the drying property is naturally lowered as compared with the case where the conventional oily topcoat agent is used.
Problems such as blocking and trawling easily occur. In order to avoid this problem, a method of increasing the drying capacity of the dryer 23 of each printing unit may be considered, but this requires new capital investment. On the other hand, when it is attempted to manufacture a decorative sheet using a water-based topcoat agent using the existing printing device used to manufacture conventional oil-based decorative sheets, it is necessary to reduce the printing speed. Of course, it can occur.

However, in the conventional printing apparatus for manufacturing a decorative sheet, after drying by the dryer of the final printing unit, a large-capacity dryer (after-drying zone) provided separately from the dryer of the printing unit. A printing device equipped with
There are many. Therefore, if a multicolor printing apparatus having the above-mentioned after-drying zone is used as a printing apparatus used for producing the three-dimensional pattern decorative sheet of the present invention and the top coat layer is applied in the final printing unit, an aqueous top is obtained. Even if the dryer of the printing unit that applies the coating agent does not have sufficient drying capacity, it can be sufficiently dried in the after-drying zone after that, so it does not cause defects such as blocking and trawling, and at high speed. It can be manufactured by printing.

Of course, since the oil-based ink having a better drying property than the water-based ink is used for the base pattern layer 2 and the liquid-repellent pattern layer 3, the same conditions as those of the conventional all-oil type decorative sheet are used. Even if the printing is carried out by (1), since it can be sufficiently dried by the dryer of the printing unit, the problem of poor drying does not occur.

FIG. 2 shows an example of a multicolor printing apparatus including the after-drying zone 60 described above.
4 with 4 printing units 20, 30, 40, 50
This is a color gravure rotary printing device.

In the method for manufacturing a three-dimensional pattern decorative sheet of the present invention, for example, the first printing unit 20 is used as a solid base, the second printing unit 30 is used as a wood grain pattern, and oily ink is used in this order from the paper feed unit 10 side. The base pattern layer 2 is printed to provide the liquid-repellent pattern layer 3 on the third printing unit 40 with the oil-based liquid-repellent ink, and finally the fourth printing unit 50, which is the final printing unit, has an aqueous top. Apply the coating agent on the entire surface.

Then, by utilizing the liquid repellency of the surface of the liquid-repellent pattern layer 3, the aqueous topcoat agent on the liquid-repellent pattern layer 3 is repelled to form the liquid-repellent pattern layer 3. The top coat layer 4 is selectively formed on the surface excluding the portion. Thus, due to the difference in the coating amount between the liquid-repellent pattern layer 3 and the top coat layer 4, the concave portion 5 appears at the portion where the liquid-repellent pattern layer 3 is provided, and a three-dimensional pattern design feeling can be obtained. is there.

Of course, the method for producing a three-dimensional pattern decorative sheet of the present invention is not limited to the above, and for example, a printing apparatus of three colors or less is used and the base pattern layer 2 is not provided or only one color is provided. It is also possible to use the printing device of 5 colors or more to print the base pattern layer 2 in 3 colors or more and the liquid-repellent pattern layer 3 in 2 colors or more. is there. The printing method is not limited to the gravure method, and any printing method such as an offset printing method, a screen printing method, a letterpress printing method, a flexographic printing method, a dry offset printing method can be applied.

As a method for forming the solid underlayer and the top coat layer 4, particularly, for example, a gravure coating method,
It is also possible to apply any coating method such as a micro gravure coating method, a roll coating method, a lip coating method, a knife coating method, an air knife coating method, a kiss coating method, a spray coating method and a dip coating method.

In the method for producing a three-dimensional decorative sheet of the present invention, the liquid-repellent picture layer 3 made of an oil-based liquid-repellent ink.
By the time of application of the water-based topcoat agent, on the contrary, it contains a residual solvent to the extent that it becomes a tack-free state that does not cause blocking or traverse, rather than drying it sufficiently, The liquid-repellent effect of the liquid-repellent agent is added to the liquid-repellent effect of the residual solvent to increase the repulsive force against the water-based topcoat agent, and to repel quickly and reliably, improving the printing speed,
It is very effective in preventing the occurrence of defects such as unplayed parts.

As described above, as a method for leaving the solvent content in the liquid-repellent pattern layer 3, for example, the air volume and the drying temperature of the dryer of the printing unit for printing the liquid-repellent pattern layer 3 are set to be weak. Appropriate methods such as a method and a method of adding an organic solvent slower drying than the solvent used in a normal oil-based printing ink to the oil-based liquid-repellent ink can be used.

If the solvent remains in the liquid-repellent pattern layer 3 even after the top coat layer 4 is formed, blocking, set-off, odor, etc. may occur, which is not preferable. However, after the aqueous topcoat agent is applied in the final unit, the printed sheet is sufficiently dried by the dryer 23 in the final unit and the large-capacity after-drying zone 60, so that the problem of residual solvent usually occurs. There is no.

The solvent remaining in the liquid repellent pattern layer 3 at the time of applying the water-based top coat agent is preferably a solvent having a high repulsive force against water, and among them, a nonpolar organic solvent having a low surface tension is mainly used. It is preferable that
Therefore, it is, of course, most preferable that the solvent contained in the oil-based liquid-repellent ink used for the liquid-repellent pattern layer 3 is mainly composed of a nonpolar organic solvent.

However, as described above, the nonpolar organic solvent generally does not always have sufficient solubility in various binder resins. Therefore, when a diluting solvent mainly composed of the nonpolar organic solvent is used, the printability is excellent. It is often difficult to obtain good ink. Therefore, in order to obtain an oil-based liquid-repellent ink having excellent printability and excellent repulsion against an aqueous topcoat agent while using a polar organic solvent having excellent solubility in various binder resins, At the time of applying the water-based top coat agent, the residual solvent contained in the liquid repellent pattern layer 3 is mainly composed of a non-polar organic solvent, so that the diluting solvent for the oil-based liquid repellent ink is a non-polar organic solvent. However, it is preferable to mainly use a combination with a polar organic solvent having a higher evaporation rate than that.

By doing so, in the drying step immediately after the printing of the liquid-repellent pattern layer 3, the polar organic solvent having a high evaporation rate is preferentially given to the non-polar organic solvent having a low evaporation rate. As a result of evaporation and drying, as a result, the nonpolar organic solvent is likely to remain selectively and contributes to the improvement of the repulsion force.

In order to achieve the above object, as described above, the evaporation rate of the above-mentioned non-polar organic solvent (assuming 100% of positive butyl acetate) is 50 or more and 200 or less,
On the other hand, the evaporation rate of the polar organic solvent used in combination with this is preferably 200 or more and 1000 or less.

In addition to this, due to the structure of a normal printing apparatus, the time between application of the water-based topcoat agent and the application of the coating portion in the dryer is extremely short, so that the temperature may be increased immediately after coating. If dried, the water-based topcoat agent is forcibly dried and thickened by a dryer before being completely repelled by the liquid-repellent pattern layer 3, so that a defective remnant is likely to occur. Also, depending on the conditions, boiling of water occurs inside the water-based top coating agent, and bubbles generated by this are not discharged to the outside air due to the thickening of the water-based top coating agent, May be dried and solidified, and defective foaming may occur.

Therefore, as described in JP-A-8-35199, the drying temperature after coating the aqueous topcoat agent is
When drying is performed while gradually changing from the low temperature side to the high temperature side, rapid thickening in the initial stage of drying is suppressed, so that it is possible to secure time for the water-based topcoat agent to be sufficiently repelled, and the boiling phenomenon. That is suppressed,
Since the time for discharging the air bubbles is secured, it is effective in preventing defects such as unspilled residue and foaming.

Using a conventional gravure five-color printing machine for producing a decorative sheet equipped with an after-drying zone, the basis weight is 30 g.
/ M ² thin paper, using nitrified cotton-based oil-based printing ink with toluene and ethyl acetate as the main solvent, one color solid base layer that provides both ground coloring and hiding power, and two colors excluding conduit pattern And a wood grain pattern layer are sequentially printed using the first to third printing units to provide a base pattern layer having a total coating amount after drying of about 2 g / m ² , and then the fourth composition unit has the following composition. After providing a liquid repellent pattern layer of a conduit pattern in synchronism with the wood grain pattern using the oil repellent ink of No. 1, further using an aqueous top coat agent having the following composition in the fifth printing unit, and drying. A top-coat layer having a coating amount of about 6 g / m ² was provided to produce a three-dimensional decorative sheet.

Oil-based liquid-repellent ink composition Acrylic resin 20 parts by weight 20 parts by weight of silica gel powder Color pigment 5 parts by weight Isocyanate curing agent 20 parts by weight Silicone liquid repellent 3 parts by weight Toluene 30 parts by weight Methyl ethyl ketone 15 parts by weight 15 parts by weight of ethyl acetate

Aqueous topcoat composition Acrylic resin 75 parts by weight Epoxy curing agent 10 parts by weight Silicone release agent 0.5 part by weight 24.5 parts by weight of water

In the above printing process, the printing speed is 100
m / min, and the drying condition is 1 for the first to third printing units.
Although the temperature was set to 00 ° C. and sufficiently dried, the fourth printing unit was set to a low temperature of 80 ° C., and the solvent content was left to the extent that the liquid-repellent pattern layer was tack-free. After the application of the water-based top coat agent, the after-drying zone is divided into 3 zones of 5 m each, and the temperature is 80 ° C., 120 ° C. and 18 ° C., respectively.
It was dried by setting the temperature in three stages of 0 ° C.

In this way, a three-dimensional design having excellent embossing of a conduit pattern in synchronism with the pattern of wood grain was obtained without causing problems such as blocking / trailing due to poor drying, remnants of remnants, and bubbles. It was possible to manufacture a three-dimensional decorative sheet.

[0082]

The method for producing a three-dimensional decorative sheet according to the present invention has a conventional structure including a combination of a liquid repellent pattern layer made of an oily liquid repellent ink and a top coat agent made of an aqueous top coat agent. Compared with the all-oil type decorative sheet of three-dimensional pattern, the amount of organic solvent used can be greatly reduced, which can contribute to environmental protection, and the working environment can be greatly improved. No equipment is required, and the energy consumption required for drying is not significantly increased as in the case of completely aqueous solution.

Further, since the liquid-repellent pattern layer is made of an oil-based ink, it is excellent in repulsive force with respect to the water-based top coat agent and can be swiftly and surely swung. It is possible to manufacture by printing, and it is possible to easily manufacture a three-dimensional decorative sheet having a sharp repulsion at the end of the conduit and excellent three-dimensional design.

In addition, among the printing devices that have been widely used for the production of conventional oil-based decorative sheets, a multicolor printing device equipped with an after-drying zone is used to perform in-line integrated production. It is possible to manufacture with good productivity under almost the same conditions as the conventional one, without the need for additional equipment or reduction of printing speed.

Further, at the time of applying the water-based topcoat agent, since the residual solvent is contained to such an extent that the liquid-repellent pattern layer becomes tack-free, the oil-based residual solvent prevents the liquid-repellent pattern layer from repelling. It is possible to improve the liquidity and contribute to the productivity and the quality improvement of the three-dimensional design feeling.

[0086] Also, the solvent contained in the oily liquid repellency ink used in the liquid-repellent pattern layer is a non-polar organic solvent and than mainly a large polar organic solvent evaporation rate, and,
At the time of applying the water-based topcoat agent, the residual solvent contained in the liquid-repellent pattern layer to the extent of being tack-free is mainly composed of a hydrophobic non-polar organic solvent ,
It is possible to improve the liquid repellency of the liquid repellent pattern layer and contribute to the improvement of productivity and the quality of three-dimensional design.

In particular, when the solvent contained in the oil-based liquid-repellent ink used for the liquid-repellent pattern layer is mainly composed of a non-polar solvent and a polar organic solvent having a higher evaporation rate than that, a non-polar organic solvent is used. The evaporation rate of the solvent is 50 or more and 200 or less,
By setting the evaporation rate of the polar organic solvent to 200 or more and 1000 or less, it is possible to prevent the polar organic solvent from remaining at the time of applying the aqueous topcoat and to easily allow the nonpolar organic solvent to selectively remain. It is possible to improve the liquid repellency of the liquid repellent pattern layer and contribute to the improvement of productivity and the quality of three-dimensional design.

As described in detail above, the three-dimensional model of the present invention is used.
Such a method of manufacturing a decorative sheet does not reduce productivity or significantly increase the energy consumption required for manufacturing,
This has an excellent advantage that the amount of the organic solvent used can be reduced to contribute to environmental protection and that a three-dimensional decorative sheet having excellent three-dimensional design can be easily obtained.

[Brief description of drawings]

FIG. 1 is a side sectional view showing an example of a three-dimensional pattern decorative sheet manufactured by the method of the present invention.

FIG. 2 is an overall schematic side view showing an example of a printing apparatus used in the method for manufacturing a three-dimensional pattern decorative sheet of the present invention.

[Explanation of symbols]

1. Base sheet 2 ... Base layer 3 ... Liquid repellent pattern layer 4 Topcoat layer 5 ... Recessed part 10 ... Paper feeder 11 ... Printing material 20 First printing unit 21 ... plate cylinder 22 ... impression cylinder 23 ... Dryer 30 ... Second printing unit 40th third printing unit 50 ... 4th printing unit 60 ... After-drying zone 70 ... Inspection Department 80 ... Paper output section

─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Masaru Takahashi 1-5-1, Taito, Taito-ku, Tokyo Toppan Printing Co., Ltd. (56) Reference JP-A-60-132680 (JP, A) JP-A-53 -55217 (JP, A) JP-A-56-81163 (JP, A) JP-A-8-117903 (JP, A) (58) Fields investigated (Int.Cl. ⁷ , DB name) B05D 5/06 104 B05D 7/00 B32B 33/00

Claims (4)

(57) [Claims] 1. A liquid-repellent pattern layer is provided on a base sheet .
After that, apply a top coat agent on the entire surface to form the liquid repellent pattern layer.
Thereby play the top coating agent of the portion provided with selectively top on the surface except for the portion in which the liquid repellent pattern layer is provided
In the method of manufacturing a three-dimensional decorative sheet having a coating layer , an oil- and liquid-repellent ink is used for the liquid-repellent pattern layer.
However, the solvent contained in the oil-based liquid-repellent ink has a non-polar property.
Machine solvent and a pole with a higher evaporation rate than the non-polar organic solvent
Water-based topcoat agent as the topcoat agent , and a liquid repellent pattern layer.
The water-based topcoat agent on the base sheet provided with
At the time of applying, the liquid-repellent pattern layer is
Mainly composed of the non-polar organic solvent to the extent that it becomes free
A method for producing a three-dimensional decorative sheet, comprising a residual solvent . 2. The evaporation rate of the non-polar organic solvent (acetic acid positive solvent).
Chill is 100) is 50 or more and 200 or less,
In addition, the evaporation rate of the polar organic solvent is 200 or more and 10
It is 00 or less, The manufacturing method of the three-dimensional decorative sheet of Claim 1 characterized by the above-mentioned . 3. The liquid-repellent pattern layer and the topcoat agent
Multi-color printing and coating with an after-drying zone
Using a printing device, the liquid-repellent pattern layer is printed on the final printing unit.
Printed with a printing unit other than
The agent is applied in the final printing unit,
The method for producing a three-dimensional pattern decorative sheet according to claim 1 or 2, wherein the three-dimensional decorative sheet is manufactured through integrated production . 4. The base sheet and the liquid-repellent pattern layer
In between, a printing unit used for printing the liquid-repellent pattern layer
Use the printing unit on the paper feed side rather than the oil-based ink
Claim 3, characterized in that to print the underlying pattern layer by
The method for producing a three-dimensional pattern decorative sheet according to.