JP4033924B2 - Manufacturing method of plastic decorative sheet - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention is a plastic decorative sheet that is used by laminating on the wall surface and fittings of a house, or the surface of furniture, furniture, etc., in particular, having a glitter or light reflective pattern in whole or in part and forming embossing, The present invention relates to a plastic decorative sheet aiming at a synergistic decorative effect of a glitter pattern and an embossed uneven pattern and a method for producing the same.
[0002]
[Prior art]
Conventionally, an uneven pattern by embossing formed on a plastic decorative sheet having a laminated structure has been formed on the surface of the sheet. Some were embossed from the back side, but the sheet thickness was 1 mm or more.
[0003]
[Problems to be solved by the invention]
However, when the technique for embossing from the back side is used for a thin plastic decorative sheet, there is a problem that the embossing is affected to the surface and a plastic decorative sheet having a good surface state cannot be obtained.
[0004]
The present invention has been made in view of the above points, and the synergistic decorative effect of the glitter pattern and the embossed uneven pattern is more highly exhibited, and the smoothness of the surface is not impaired. An object of the present invention is to provide an easy-to-handle plastic decorative sheet and a method for producing the same.
[0005]
[Means for Solving the Problems]
Next, means for solving the above problems will be described with reference to the embodiment shown in the drawings.
That is, the plastic decorative sheet 1 (FIG. 1) or 101 (FIG. 4) according to the invention of claim 1 has a plastic pattern having a pattern layer 2 on the surface at least partially having a glittering (light reflecting) pattern portion. A plastic decorative sheet in which a transparent or translucent plastic overlay sheet 4 and a resin transfer coating layer formed by transfer using a polyester film as a transfer substrate are laminated on the surface side of the sheet 3 by thermal lamination. A back emboss 5 is formed from the back side, and an intermediate emboss 6 along the back emboss 5 is formed on the pattern layer 2 by the back emboss 5.
[0006]
Furthermore, in the plastic decorative sheet 1 (FIG. 1) according to the invention of claim 1, the resin transfer coat layer 7 is coated with a smooth polyester film 11 so that the surface is smooth and has a high hardness. It is a feature.
[0007]
The polyester films 11 and 111 are peeled off from the surface of the plastic decorative sheet produced by the above production method.
[0008]
The pattern sheet 3 and the overlay sheet 4 may be made of vinyl chloride resin, olefin resin, or acrylic resin.
[0009]
As the resin transfer coating layers 7 and 8, a normal resin transfer coating layer mainly composed of polymethyl methacrylate can be used, and other resin layers having a high surface hardness such as an ultraviolet curable resin and an electrocurable resin. Can be used.
[0010]
Polyester terephthalate film (PET film) is usually used for the polyester films 11 and 111 as transfer substrates.
[0011]
The overlay sheet 4 includes colored transparent or translucent.
[0012]
The plastic pattern sheet 3 can be formed by using a printing sheet that is printed using a material that reflects light, such as a luster pigment, on the surface thereof, a material that reflects light on the surface, or a metal thin film. The pattern sheet 3 can also be formed by bonding a metal foil to the surface of the sheet or by metal deposition.
[0013]
In the above-described plastic decorative sheets 1 (FIG. 1) and 101 (FIG. 4) according to the present invention, although the surface is a smooth surface or a matte surface, there is an intermediate emboss 6 inside, and inside the layer, Depending on the viewing angle, the glitter pattern portion 2a in the pattern layer 2 appears to shine by reflected light, and the glitter pattern portion 2a in the pattern layer 2 has an irregular shape along the irregularities by the intermediate emboss 6. The reflected light changes. Moreover, although it is the structure using an embossing effect | action, since the surface is smooth or substantially smooth, there is little contamination and cleaning is also easy.
[0014]
Invention of Claim 3 concerns on the manufacturing method of the said plastic decorative sheet 1 (FIG. 1), 101 (FIG. 4). FIG. 2 is an end view showing each layer of the sheet in the manufacturing process of the plastic decorative sheet, and FIG. 3 is a view showing a manufacturing method. The manufacturing method according to the invention of claim 4 with reference to FIGS. Will be explained.
That is, the method for producing a plastic decorative sheet according to the invention of claim 3 is transparent or semi-finished on the surface side of the plastic pattern sheet 3 having at least a pattern layer 2 having a glitter or reflection pattern part on the surface. A transparent plastic overlay sheet 4 is heat-laminated and a transfer film 10 is heat-laminated on the surface side of the overlay sheet 4, and then the pattern sheet 3, the overlay sheet 4, and the transfer film 10 are laminated sheets from the back side of the pattern sheet 3. The embossing roll F is applied to form the back embossing 5 on the back surface of the pattern sheet 3 and at the same time the intermediate embossing 6 is formed on the pattern layer 2.
[0015]
In the embodiment shown in FIG. 2 (3), the transfer film 10 comprises a polyester film 11 (111) as a transfer substrate and a resin transfer coat layer 7 having a smooth surface or a resin transfer coat layer 8 having a matte surface. The hard coat layer is laminated through the release layer 12, and the adhesive layer 14 is provided on the back surface of the hard coat layer.
[0016]
The polyester films 11 and 111 of the transfer film 10 are peeled off from the plastic decorative sheets 1 and 101 as final products. During storage, transportation, or pasting, the polyester films 11 and 111 are preferably laminated in order to protect the surface of the plastic decorative sheet. Therefore, the polyester films 11 and 111 are usually provided on the surfaces of the plastic decorative sheets 1 and 101 when shipped from the factory. In order to manufacture the plastic decorative sheet 101 (FIG. 4) having the matte resin transfer coating layer 8, the transfer film 10 using the polyester film 111 in which fine irregularities are formed on the back surface in advance is used.
[0017]
As a method for producing the polyester film 111 having fine irregularities, there are a method of applying fine embossment with a depth of about 1 to 5 μm in advance, or a method of kneading inorganic particles with a particle size of 10 μm or less, preferably 1 to 8 μm. is there.
[0018]
According to the above manufacturing method, when the embossing roll F is applied to the back surface of the laminated sheet as the main body of the plastic decorative sheet to form the back embossing 5 and at the same time the intermediate embossing 6 is formed, the surface side of the laminated sheet is the transfer film 10. Therefore, the smoothness on the surface side of the laminated sheet or the matte state by the matte process is not impaired.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail based on the illustrated embodiments. 1 is an end view of a plastic decorative sheet 1 according to Embodiment 1. FIG. This plastic decorative sheet 1 is formed by laminating a transparent or translucent plastic overlay sheet 4 on the surface side of a plastic pattern sheet 3 having a pattern layer 2 having a glittering (light reflecting) pattern portion 2a on at least a part thereof. In the plastic decorative sheet, a back emboss 5 is formed from the back side of the pattern sheet 3, and an intermediate emboss 6 along the back emboss 5 is formed on the pattern layer 2 by the back emboss 5. Further, a resin transfer coating layer 7 having a smooth surface and high hardness is transferred and formed on the surface of the overlay sheet 4 by thermal lamination via an adhesive layer.
[0020]
The pattern sheet 3 and the overlay sheet 4 are formed of a vinyl chloride resin, and the resin transfer coat layer 7 is formed of a normal resin transfer coat layer mainly composed of polymethyl metal acrylate. As the pattern sheet 3, a printing sheet is used in which the pattern layer 2 is printed on the surface with a pigment using at least part of a glitter pigment.
[0021]
Next, a method for manufacturing the plastic decorative sheet 1 according to Embodiment 1 will be described with reference to FIGS.
The manufacturing method according to this embodiment uses a lamination method called doubling embossing also shown in the above Japanese Patent Publication No. 7-39170.
In this manufacturing method, as shown in FIG. 3, a roll B of a plastic pattern sheet 3 as a printing sheet on which a glittering (light reflecting) pattern layer 2 is printed, a roll C of an overlay sheet 4, and a transfer film Ten rolls D are prepared and prepared in advance. The preheated pattern sheet 3 is pressure-bonded onto the heating drum A, the preheated overlay sheet 4 is pressure-bonded thereon, and the transfer film 10 is further pressure-bonded thereon.
[0022]
As described above, the transfer film 10 is coated with the polyester film 11 as the transfer substrate and the resin transfer coat layer 7 as the hard coat layer via the release layer 12, and an adhesive layer is formed on the back surface of the resin transfer coat layer 7. 14 is a laminated structure. The polyester film 11 is a member that finally peels off and imparts smoothness to the surface of the plastic decorative sheet 1.
[0023]
The three-layer laminated sheet thus pressure-bonded is fed out from the heating drum A and back embossed from the back side of the pattern sheet 3 by the rubber roll E and the embossing roll F. At the same time, the intermediate emboss 6 is formed on the pattern layer 2.
[0024]
At this time, the surface side of the laminated sheet is backed up by a polyester film 11 as a transfer substrate of the transfer film 10, so that it is hardly affected by back embossing, and surface smoothness and high glossiness are imparted. Will be.
[0025]
FIG. 4 is a cross-sectional view of the plastic decorative sheet 101 according to the second embodiment. This plastic decorative sheet 101 has a resin transfer coating layer in which a matte surface 9 that is finer than the intermediate emboss 6 is provided on the surface of the overlay sheet 4 by thermal transfer of a polyester film 111 having fine unevenness. The other structure is the same as that of the plastic decorative sheet according to the first embodiment.
The manufacturing method of the second embodiment is the same as the above manufacturing method except that the surface side of the resin transfer coat layer 8 as the hard coat layer of the transfer film 10 is subjected to matting.
[0026]
【Example】
Examples of the present invention will be given below.
Example 1 (corresponding to Example 1 of the plastic decorative sheet of Embodiment 1 (FIG. 1))
(1) To a 90 μm semi-rigid PVC film colored in gray with a lightness of 7.0, first use a PVC ink to make a medium (transparent ink): silver ink (aluminum pigmented ink) = 50: 50, a grainy negative plate Print with white sand (similar to printing on the black paper part that appears when the white sand is sprinkled on the black paper), and increase the reflective part when embossed on the back.
(2) Next, using a grain-tone positive plate (inverted negative plate of (1)), medium: black ink: red ink: yellow ink = 94.5: 0.4: 1.7 : Print with beige ink consisting of 3.4.
For both (1) and (2), a plate made by gravure halftone gravure was used.
(3) Further, a solid is printed with a gravure roll having a depth of 150 μm and a depth of 150 μm from above to obtain a depth. The ink is medium: black ink: red ink: yellow ink = 98.7: 0.2: 0.7: 0.4 (2) A lighter beige one is used, and a semi-rigid PVC printing film ( Pattern sheet 3) was produced.
(4) Next, with a three-layer laminator, a 60 μm semi-rigid transparent PVC film (overlay sheet 4) on the printing surface of the semi-rigid PVC printing film (pattern sheet 3) produced in (1) to (3), thickness After laminating in order of a hard coat transfer foil (transfer film 10) using a PET film transfer substrate (transfer substrate 11) having a thickness of 12 μm, a cross-tone made by etching from the back side of the printed film (pattern sheet 3) Emboss with embossing roll (depth 50μMAX).
(5) By peeling the PET film transfer substrate (transfer substrate 11), a three-dimensional plastic decorative sheet having a smooth and glossy hard coat transfer foil layer was obtained.
[0027]
Example 2 (equivalent to Example 2 of the plastic decorative sheet of Embodiment 1 (FIG. 1))
(1) A 100μ semi-rigid PVC printing film (Munsell symbol: 5YR 6/10) close to the birch grid pressure coating finish. Printing with 20:80 ink.
(2) Next, the medium: black ink: red ink: yellow ink, 90: 1: 2: 7 for the first color, and 73: 3 for the second color, respectively, were used, using the plates in which the birch cells were separated into three colors. 4:20, the third color was printed at 77: 6: 7: 10, and a semi-rigid PVC printing film (pattern sheet 3) was produced. Both plates were made by electronic engraving.
(3) Next, on the printing surface (pattern layer 2) of the semi-rigid PVC printing film (pattern sheet 3) printed in (1) to (3) using a three-layer laminator, a 200 μm semi-rigid PVC film (overlay) After laminating the sheet 4) and a hard coat transfer foil (transfer film 10) using a PET film transfer substrate (polyester film 11) having a thickness of 50 μm in this order, etching is performed from the back side of the printing film (pattern sheet 3). Emboss with the hairline embossing roll (depth 50μMAX).
(4) By removing the PET film transfer substrate (transfer substrate 11), a three-dimensional plastic decorative sheet having a smooth and glossy hard coat transfer foil layer (smooth surface coat layer 7) is obtained. It was.
[0028]
As described above, the surface glossy and flatness required requires a PET film transfer substrate (polyester film 11) to be thick, but the hardness of the rubber roll used in opposition to the embossing roll is 80 in JIS hardness. Of sand (usually around 70 degrees), the sand particles mixed in the rubber are about 500 mesh finer than the usual 320 mesh, and the amount of mixing is 50 parts (usually about 60 parts) with respect to the rubber content. )
That is, the depth of the embossing roll is 10 μm to 150 μm, preferably 15 μm to 100 μm.
Moreover, the roughness of the particle | grains used for a rubber roll shall be 280 mesh or more, Preferably you may be 300-800 mesh.
The thickness of the plastic decorative sheet is 100 to 450 μm, the thickness of the transparent film (overlay sheet 4) is 50 to 300 μm, and the thickness of the printing film (pattern sheet 3) is 50 to 150 μm.
The thickness of the PET film transfer substrate (transfer substrate 11) of the hard coat transfer foil (transfer film 10) is 10 to 80 μm, preferably 12 to 60 μm.
[0029]
Example 3 (Example 1 of plastic decorative sheet of Embodiment 2 (FIG. 4): equivalent to matte (matte) hard coat transfer foil)
(1) A bright 90μ semi-rigid PVC film (Munsell symbol: 2.5Y 9/2) close to a spruce square board, first a gravure roll of 150 mesh and 40μ depth, pearl white: pearl gold = 70 : Solid print with 30 inks.
(2) Next, it is a plate that expresses the texture of the bark of the spruce grid, and is printed with ink of medium: black ink: red ink: yellow ink = 96.3: 1: 1.2: 1.5.
(3) A plate with emphasis on spruce cells, medium: black ink: red ink: yellow ink = 93.4: 0.6: 1.5: 4.5, semi-rigid PVC printing film (Pattern sheet 3) was produced.
The plates (2) and (3) were both made by electronic engraving.
(4) Next, a 100 μm semi-rigid transparent PVC printing film is applied to the printing surface (pattern layer 2) of the semi-rigid PVC printing film (pattern sheet 3) printed in (1) to (3) using a three-layer laminator. (Overlay sheet 4) After laminating in order of mat-like hard-coded transfer foil (transfer film 10) using a PET film transfer base (transfer base 11) having a thickness of 12 μ pre-embossed to a depth of about 4 μ, Embossed with a hairline embossing roll (depth: 100 μMAX) made by a mill method from the back side of the printed film (pattern sheet 3).
(5) By removing the PET film transfer substrate (polyester film 11), the surface has a matte-like (matte surface) hard coat transfer foil layer (resin transfer coat layer 8) and a realistic three-dimensional effect. A plastic decorative sheet with a spruce pattern was obtained.
[0030]
【The invention's effect】
According to the plastic decorative sheet according to the invention of claim 1 or 2 of the present application, although the surface is a smooth surface or a matte surface, there is an intermediate emboss 6 in the interior of the pattern layer 2 in the layer. Since the glitter pattern portion 2a appears to be shining with reflected light, and the glitter pattern portion 2a in the pattern layer 2 is uneven along the unevenness by the intermediate emboss 6, the reflected light changes depending on the viewing angle. In other words, the synergistic decorative effect of the glitter pattern and the embossed uneven pattern is exhibited to a higher degree, and an excellent decorative effect is obtained. Moreover, although it is the structure using an embossing effect | action, since the surface is smooth or substantially smooth, there is little contamination and cleaning is also easy.
Furthermore, the brightness due to the embossing from the intermediate layer is compared with the glossy surface or the matte surface, so that a further brightness effect is obtained.
[0031]
Further, since the glitter pattern is covered and protected by the overlay sheet 4 and the intermediate embossing imparted to the intermediate glitter pattern is also applied from the back side of the pattern, printing of the glitter pattern by embossing, etc. Will not be damaged.
[0032]
Furthermore, since a resin transfer coat layer having a hard, glossy smooth surface or a resin transfer coat layer having a hard matte surface is formed on the surface, there is little contamination, scratches are prevented, and cleaning is also possible. Not only is it easy, but the glitter from the inside of the sheet due to the intermediate embossing 6 is contrasted with the high gloss or matte surface of the surface, giving a strong impression, and an even better decorative effect. Further, the back embossing does not affect the smooth surface, the high gloss surface or the matte surface due to the back-up action by the hard resin transfer coating layer.
[0033]
According to the manufacturing method of the third or fourth aspect of the present invention, when the back embossing 5 is formed by applying the embossing roll F to the back surface of the laminated sheet serving as the main body of the plastic decorative sheet, the intermediate embossing 6 is simultaneously formed. Since the surface side of the sheet is firmly covered and backed up by the transfer film 10, there is an excellent effect that the smoothness on the surface side of the laminated sheet or the matte state by the matte embossing is not impaired.
[Brief description of the drawings]
FIG. 1 is an end view of a plastic decorative sheet according to Embodiment 1 of the present invention.
FIG. 2 is an end view of a sheet layer showing a process of manufacturing a plastic decorative sheet according to the present invention.
FIG. 3 is a diagram showing a method of manufacturing a plastic decorative sheet according to the present invention.
FIG. 4 is an end view of a plastic decorative sheet according to Embodiment 2 of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1,101 Plastic decorative sheet, 2 pattern layer, 3 pattern sheet, 4 overlay sheet, 5 back embossing, 6 middle embossing, 7, 8 resin transfer coating layer, 9 matte embossing, 10 transfer film, 11, 111 polyester film, 12 peeling layer, 14 adhesive layer, A heating drum, B roll of plastic pattern sheet 3, C roll of overlay sheet 4, D roll of transfer film 10, E rubber roll, F embossing roll

Claims (2)

A transparent or translucent plastic overlay sheet is thermally laminated on the surface side of a plastic pattern sheet having a pattern layer having a glittering or reflective pattern part on the surface, and transferred to the surface side of the overlay sheet. After a transfer film comprising a polyester film as a substrate and a resin transfer coating layer transferred by the polyester film is laminated by thermal lamination, the pattern sheet, overlay sheet, resin transfer coating layer, and pattern of the laminated sheet by the polyester film An embossing roll is applied from the back side of the sheet to form back embossing on the back side of the pattern sheet, and at the same time, intermediate embossing is formed on the pattern layer, and the resin transfer coating layer is coated on the smooth surface of the polyester film. By table Plastic decorative sheet manufacturing method of which is characterized in that is smooth and highly sophisticated layers. A transparent or translucent plastic overlay sheet is thermally laminated on the surface side of a plastic pattern sheet having a pattern layer having a glittering or reflective pattern part on the surface, and transferred to the surface side of the overlay sheet. After a transfer film comprising a polyester film as a substrate and a resin transfer coating layer transferred by the polyester film is laminated by thermal lamination, the pattern sheet, overlay sheet, resin transfer coating layer, and pattern of the laminated sheet by the polyester film An embossing roll is applied from the back side of the sheet to form a back emboss on the back side of the pattern sheet, and at the same time an intermediate emboss is formed on the pattern layer, and the resin transfer coating layer is coated on the fine uneven surface of the polyester film. To be done Plastic decorative sheet manufacturing method of, wherein the surface is an altitude higher layer with a fine matte.

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