JP4672150B2 - Method for producing foam decorative sheet - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
  The present invention relates to a method for producing a foam decorative sheet.To the lawRelated.
[0002]
[Background]
Conventionally, foamed decorative sheets are widely used for building materials such as wallpaper, vehicle members such as door skin materials, furniture such as sofa skin materials, and the like.
As such a foam decoration sheet, there is a demand for a sheet having a three-dimensional pattern in which surface irregularities and a printed pattern are synchronized, and having a printed surface with high wear resistance.
For example, as described in JP-A-54-6064, such a foam decorative sheet is formed by laminating two synthetic resin films with a pattern including a foam layer interposed therebetween, and integrating them. This can be obtained by heating and foaming.
[0003]
[Problems to be solved by the invention]
However, the above-mentioned method is performed by bringing the two synthetic resin films into close contact with the heating drum and, after peeling from the heating drum, cooling with a cooling roll, has the following problems. ing.
(1) Since the film is not cooled at the time of peeling from the heating drum, it is difficult to peel off if the drum temperature is too high, and if it is peeled off forcibly, the product may be stretched or broken.
(2) Considering the ease of peeling, the drum temperature cannot be raised, so the thermal adhesive strength of the two films is weak.
[0004]
(3) Since the adhesive strength of the two films is weak, the films may peel off during foaming or may peel off during use.
(4) Since the temperature cannot be raised during thermocompression bonding, the film surface on the back of the heating drum and the two film surfaces on the side in contact with the pattern containing the foaming agent must be smooth, and the usable film is limited. .
(5) Since the drum temperature cannot be raised, foaming is insufficient and a large amount of foaming agent is required, which is disadvantageous in cost.
[0005]
  Therefore, an object of the present invention is to produce a foam decorative sheet having high adhesive strength between laminated films and a foaming agent sufficiently foamed.The lawIt is to provide.
[0006]
[Means for Solving the Problems]
  The method for producing a foam decorative sheet according to the present invention includes:A foamed decorative sheet manufacturing method using a metal endless belt wound around a plurality of rolls including a heating roll and a cooling roll, wherein a foamable raw sheet containing a pyrolytic foaming agent is included in the metal endless belt. A thermoplastic resin film decorated with foaming ink is laminated on the foamable raw sheet on the non-decorative surface, and another thermoplastic resin film is further laminated on the decorative surface of the thermoplastic resin film. A thermocompression process in which these metal endless belts, sheets and films are integrated by thermocompression bonding at a temperature equal to or higher than the melting point of at least one film, and at the same time or after this thermocompression process, A foaming step for foaming the mold foaming agent and the foamable ink, and after the foaming step, the sheet and the film are cooled, and the metal end Characterized in that it and a peeling step of peeling from Svelte.
[0008]
Here, as the thermoplastic resin used for the thermoplastic resin film, a crystalline resin such as polypropylene, polyethylene, nylon, or a mixture thereof can be used. Furthermore, polystyrene, ethylene-vinyl acetate copolymer, ionomer, various elastomers, etc. may be added to these resins.
The layer structure of the thermoplastic resin film may be either a single layer or a multilayer.
[0009]
The melting point of the film in the present invention refers to the maximum peak temperature in the endothermic exothermic curve obtained by differential scanning calorimetry (DSC).
The melting point of the film in the case of using a multilayer film refers to the melting point of the resin constituting the fused surface, and the melting point of the film in the case of using one film with different resins on both outer layers. The higher melting point of the melting point of the surface in contact with the endless belt and the melting point of the surface on which the pattern is not applied among the both surfaces sandwiching the pattern made of the foamable ink.
[0010]
As the foamable ink, those obtained by adding a foaming agent and an ink component to a thermoplastic resin, or those obtained by dissolving or dispersing a mixture thereof in a solvent can be employed.
Here, as foaming agents, azodicarbonamide, barium azodicarboxylate, azobistetrazoleaminoguanidine, oxybenzenesulfonyl hydrazide, sodium bicarbonate, ammonium bicarbonate, hydrocarbons (pentane, hexane, isobutane, etc.) are microcapsules Or a mixture thereof can be employed.
[0011]
The thermoplastic resin that can be used for the foamable ink is not particularly limited, and examples thereof include polyvinyl chloride, polyvinyl acetate, acrylic resin, polyvinyl alcohol, and mixtures thereof.
Furthermore, as a solvent, cyclohexanone, tetrahydrofuran, methyl ethyl ketone, ethyl acetate, xylene, toluene, water, or a mixture thereof can be employed.
[0012]
The method for printing the foamable ink thus configured on the thermoplastic resin film is not particularly limited, and gravure printing, silk printing, flexographic printing, roll coating, brush coating, and the like can be employed.
When printing, a pattern component containing a foaming agent and a pattern component not containing a foaming agent can be applied in an appropriate manner depending on the pattern required.
[0013]
As the material of the metal endless belt in the present invention, stainless steel, nickel spring steel or the like can be employed. Furthermore, it is also possible to adjust the peelability of the foamed sheet by coating the surface of these belts with polyimide, fluororesin or the like.
[0014]
  In this manufacturing method, when thermocompression bonding is not performed at a temperature equal to or higher than the melting point of at least one of the films, the adhesive strength between the films is weakened, so that the foamable ink expands and tension is applied to the film. The foamed part of the film is easily peeled off. further, DBy partial peeling of the film on the beltless belt sideTheUneven foaming is likely to occur due to insufficient heat transfer from the belt.
[0015]
  According to the present invention, the foamed decorative sheet has a high adhesive strength of each film and is sufficiently foamed with foamable ink, since it is heated at a temperature equal to or higher than the melting point of at least one film in the thermocompression bonding process. Can be obtained.
  Moreover, since the sheet | seat after a foaming process is fully cooled by the cooling process, while being able to peel easily from metal endless belts etc., the fracture | rupture of the sheet | seat at the time of peeling, etc. can be prevented. In addition, by peeling from the endless belt after cooling, the thermocompression bonding temperature and the foaming heating temperature can be raised to the melting point of the film or higher without causing a decrease in peelability even at a high temperature, resulting in a result. The adhesive strength of the foamed decorative sheet can be increased.
  Moreover, since peeling can be performed easily, the production speed can be increased and the production efficiency can be improved.
  In addition, by raising the temperature above the melting point of the film, between each film and film-Between sheets and sheets-Since the adhesive strength between the belts is improved, between the films when foaming ink is foamed,Between film and sheet, sheet-Peeling between belts hardly occurs.
[0018]
  Here, as the resin constituting the foamable raw sheet, polyvinyl chloride resin, polyolefin resin (polyethylene, polypropylene, etc.), polystyrene resin, and the like can be employed.
  As the pyrolytic foaming agent, azodicarbonamide, barium azodicarboxylate, azobistetrazoleaminoguanidine, oxybenzenesulfonyl hydrazide, sodium bicarbonate, ammonium bicarbonate and the like can be employed.
  The foamable raw sheet can be molded by kneading a resin and a foaming agent at a temperature below the decomposition temperature of the foaming agent, and kneading the molten resin by a calender roll, T-die extrusion molding, or the like. In addition, it is also possible to supply the melt web from the extruder directly to the metal endless belt for thermocompression bonding..
[0019]
According to the present invention, the foamable raw sheet and the thermoplastic resin film decorated with the foamable ink are laminated by the thermocompression bonding process. The sheet can be foamed simultaneously, which is efficient.
Moreover, since the obtained foam decoration sheet | seat has additional functions, such as cushioning properties and heat insulation, the use can be expanded.
[0020]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[First Embodiment]
[1] Foam decorative sheet
FIG. 1 shows a foamed decorative sheet 1 according to the first embodiment of the present invention.
The foam decoration sheet 1 includes a first polypropylene film (hereinafter referred to as a PP film) 11 as a thermoplastic resin film having a decoration layer 11A formed by foaming of foamable ink on the surface, and another on the decoration layer 11A. And a second PP film 12 as a thermoplastic resin.
[0021]
[2] Foam decorative sheet manufacturing equipment
FIG. 2 shows a manufacturing apparatus 2 for the foam decorative sheet 1.
The manufacturing apparatus 2 includes first to third rolls 21, 22, and 23 </ b> A arranged so as to be positioned at the apexes of a substantially triangular shape, and an endless wound between these three rolls 21, 22, and 23 </ b> A. For the belt 24, the pressure roll 25 provided to press the first PP film 11 and the second PP film 12 decorated with foamable ink on the first roll 21, and the third roll 23A. The peeling roll 26 provided so as to press the foam decorative sheet 1, the take-up roll 27 for winding the peeled foam decorative sheet 1, and supply rolls 29A and 29B for supplying the first PP film 11 and the second PP film 12 And is configured.
[0022]
Here, the 1st roll 21 and the 2nd roll 22 are heating rolls in which heating means, such as an electric heater, was built, and polyimide resin was applied and coated on the surface. The surface temperature of the first roll 21 is equal to or higher than the melting point of each PP film 11, 12, which is a temperature at which the first PP film 11 can be crimped to the endless belt 24 and the first PP film 11 and the second PP film 12 can be thermally laminated. The temperature is set to be lower than the foaming start temperature of the foamable ink. Thereby, the surface temperature of the endless belt 24 positioned on the first roll 21 is also heated to the temperature.
[0023]
Moreover, the surface temperature of the 2nd roll 22 is set to the temperature more than melting | fusing point of each PP film 11 and 12, and more than the foaming start temperature of foamable ink. Thereby, the surface temperature of the endless belt 24 positioned on the second roll 22 is also heated to the temperature.
On the other hand, the third roll 23A is a metal cooling roll having a built-in cooling means such as a water cooling type.
At least one of the rolls 21, 22, 23A is connected to a rotation driving means such as a motor so as to be rotatable.
[0024]
The endless belt 24 is made of stainless steel having a mirror-finished surface.
Moreover, the press roll 25 is a metal roll, and can be cooled by a water cooling type cooling means or the like as necessary. A surface material 28 made of silicone rubber is mounted on the outer peripheral surface. Here, the thickness of the surface material 28 can be appropriately set according to the thickness of each of the PP films 11 and 12.
On the other hand, the peeling roll 26 is a metal roll. Here, the pressure-bonding roll 25 and the peeling roll 26 are adjusted so as to urge the first roll 21 and the third roll 23 with an appropriate force. The urging force can be set as appropriate according to the thickness of the foam decorative sheet 1 and the like.
[0025]
[3] Method for producing foam decorative sheet
The manufacturing method of the foam decoration sheet 1 using the manufacturing apparatus 2 comprised as mentioned above is demonstrated.
First, the first PP film 11 and the second PP film 12 are supplied from the supply rolls 29A and 29B with the non-decorative surface of the first PP film 11 positioned on the endless belt 24 side. The first PP film 11 is brought into contact with the endless belt 24 while the supplied PP films 11 and 12 are pressed by the press roll 25, and the PP films 11 and 12 are placed between the press roll 25 and the first roll 21. Clamp at a predetermined pressure.
[0026]
In this state, the pressure-bonding roll 25 and the heated first roll 21 pressure-bond the first PP sheet 11 to the endless belt 24 and perform thermal lamination of the PP films 11 and 12 (thermo-compression process).
At this time, the first roll 21 is heated to a temperature higher than the melting point of the PP films 11 and 12 and lower than the foaming start temperature of the foamable ink, that is, a predetermined temperature of 140 to 250 ° C. as described above.
The heat of the first roll 21 is transmitted to each of the PP films 11 and 12 through the endless belt 24 so that the temperature can be thermocompression-bonded and heat-laminated.
[0027]
Subsequently, the PP films 11 and 12 that are thermocompression bonded to the endless belt 24 are moved onto the second roll 22 as the endless belt 24 rotates.
Here, the PP film 11, 12 has a melting point or higher and a foaming ink temperature equal to or higher than the foaming start temperature of the foamable ink, that is, the second roll 22 heated to a predetermined temperature of 140 to 240 ° C. The foam is heated to a temperature of (no foaming process).
Thereafter, the foamed decorative sheet 1 is moved onto the third roll 23A and cooled (cooling process), peeled off from the endless belt 24 by the peeling roll 26 (peeling process), wound up by the winding roll 27, and foamed ink. A foamed decorative sheet 1 decorated by foaming is obtained.
[0028]
According to the first embodiment as described above, the following effects can be obtained.
(1) Since the heating is performed at a temperature equal to or higher than the melting point of the PP films 11 and 12 by the thermocompression bonding process, the adhesive strength between the PP films 11 and 12 is high, and the foaming ink is sufficiently foamed. A foamed decorative sheet 1 having no decorative layer 11A can be obtained.
(2) In the peeling process, the foamed decorative sheet 1 after the foaming process is adhered to the metal endless belt 24 and cooled and then peeled off, so that it can be easily peeled off and foamed at the time of peeling. Breakage of the decorative sheet 1 can be prevented.
In addition, since peeling is performed after cooling, even when the temperature is increased, the peelability is not deteriorated, and the thermocompression bonding temperature and the foaming heating temperature can be increased to the melting point of the PP films 11 and 12 or higher. The adhesive strength of the foamed decorative sheet 1 obtained can be increased.
Moreover, since peeling can be performed quickly, the production speed can be increased and the production efficiency can be improved.
[0029]
(3) By raising the temperature above the melting point of each PP film 11, 12, the adhesive strength between each PP film 11, 12 and between the first PP film 11 and endless belt 24 is improved. The delamination between the PP films 11 and 12, the first PP film 11 and the endless belt 24 is difficult to occur.
(4) Since the foaming step is performed at a temperature higher than the melting point of each PP film 11, 12 and higher than the foaming start temperature of the foamable ink, compared with the case where heating is performed at a temperature higher than the foaming start temperature and lower than the melting point, The adhesive strength of the laminated PP films 11 and 12 can be further increased, and the foaming agent in the foamable ink can be completely foamed.
[0030]
(5) The manufacturing apparatus 2 using the endless belt 24 can continuously perform the thermocompression bonding process, the foaming process, the cooling process, and the peeling process, and the manufacturing apparatus 2 can be simplified and made compact. it can.
(6) Since the endless belt 24 and the PP films 11 and 12 are integrated by the thermocompression bonding process, the shape is maintained by the endless belt 24 even when a film made of a material that is easily heat-shrinkable is used. Can be prevented. Also, the adhesion strength between each layer is increased, and the peeling can be prevented.
[0031]
(7) Since cooling is performed in a state where the foamed decorative sheet 1 is pressure-bonded to the endless belt 24, a product having a high cooling rate and maintaining the form after foaming can be obtained.
(8) Since the surface of the endless belt 24 is mirror-finished, the foamed laminated sheet 1 can be more easily peeled off, and a skin layer is formed on the contact surface of the first PP film 11 with the endless belt 24. be able to.
[0032]
(9) When the PP films 11 and 12 are pressure-bonded to the first roll 21, they are urged at a predetermined pressure or higher using the pressure-bonding roll 25. Therefore, when the PP films 11 and 12 are supplied onto the endless belt 24, air can be prevented from being caught between the endless belt 24 and the first PP film 11 and between the PP films 11 and 12. .
(10) Since the surface material 28 made of silicone rubber is mounted on the surface of the pressure-bonding roll 25, the second PP film 12 can be prevented from slipping.
[0033]
[Second Embodiment]
In the following description, only the parts different from the first embodiment will be described in detail, and the same reference numerals will be given to the other same members and the same structure, and the detailed description thereof will be omitted or simplified.
[1] Foamed decorative sheet manufacturing equipment
FIG. 3 shows a manufacturing apparatus 3 used in the method for manufacturing the foam decorative sheet 1 according to the second embodiment of the present invention.
The manufacturing apparatus 3 includes a second roll 22 and a third roll 23A that are arranged at a predetermined interval, an endless belt 24 wound around the second and third rolls 22 and 23A, and the second roll 22. A pressure roll 25 provided so as to press the PP films 11 and 12 on top of each other, a peeling roll 26 for peeling the foam decorative sheet 1 from the endless belt 24, and a winding roll for winding the peeled foam decorative sheet 1 27, and supply rolls 29 </ b> A and 29 </ b> B for supplying the first PP film 11 and the second PP film 12.
[0034]
[2] Method for producing foam decorative sheet
The manufacturing method of the foam decoration sheet 1 using the manufacturing apparatus 3 comprised as mentioned above is demonstrated.
First, the first PP film 11 and the second PP film 12 are supplied from the supply rolls 29A and 29B with the non-decorative surface of the first PP film 11 positioned on the endless belt 24 side. The first PP film 11 is brought into contact with the endless belt 24 while the supplied PP films 11 and 12 are pressed by the press roll 25, and the PP films 11 and 12 are placed between the press roll 25 and the second roll 22. Is sandwiched at a predetermined pressure.
[0035]
In this state, the pressure-bonding roll 25 and the heated second roll 22 simultaneously press-bond the first PP film 11 to the endless belt 24, thermally laminate the PP films 11 and 12, and foam the foamable ink at the same time. Is performed (thermocompression bonding process, foaming process).
At this time, as described above, the second roll 22 is heated to a temperature equal to or higher than the melting point of each PP film 11 and 12 and equal to or higher than the foaming start temperature of the foamable ink.
Since the peeling process is the same as that in the first embodiment, the description thereof is omitted.
[0036]
According to the second embodiment as described above, in addition to the same effects as (1) to (10) in the first embodiment, the following effects are also obtained.
(11) Since the thermocompression bonding of the PP films 11 and 12 and the endless belt 24, thermal lamination of the PP films 11 and 12 and foaming of the foamable ink are simultaneously performed on the second roll 22, the manufacturing apparatus 3 is It can be made compact and the installation space can be reduced.
[0037]
[Third Embodiment]
In the following description, only the parts different from the first embodiment will be described in detail, and the same reference numerals will be given to the other same members and the same structure, and the detailed description thereof will be omitted or simplified.
[1] Foamed decorative sheet manufacturing equipment
FIG. 4 shows a manufacturing apparatus 4 used in the method for manufacturing the foam decorative sheet 1 according to the third embodiment of the present invention.
Since the manufacturing apparatus 4 is the same as that of the first embodiment except that the manufacturing apparatus 4 includes two cooling rolls, that is, a third roll 23A and a fourth roll 23B, detailed description thereof is omitted.
[0038]
[2] Method for producing foam decorative sheet
The manufacturing method of the foam decoration sheet 1 using the manufacturing apparatus 4 comprised as mentioned above is demonstrated.
In the same manner as in the first embodiment, the PP films 11 and 12 are supplied and a thermocompression bonding process is performed.
Then, each PP film 11 and 12 united with the endless belt 24 by the thermocompression bonding process is transferred to the second roll 22 side together with the endless belt 24. Similarly to the first embodiment, the foamable ink is foamed on the second roll 22 to obtain the foamed decorative sheet 1.
Thereafter, the foam decoration sheet 1 is cooled stepwise by the two cooling rolls of the third roll 23A and the fourth roll 23B as the endless belt 24 rotates.
In addition, since the peeling process is the same as that of the said 1st Embodiment, the description is abbreviate | omitted.
[0039]
According to the third embodiment as described above, in addition to the same effects as (1) to (10) in the first embodiment, the following effects can also be obtained.
(12) Since the foamed decorative sheet 1 is cooled stepwise by the two cooling rolls of the third roll 23A and the fourth roll 23B, the cooling efficiency can be improved and the obtained foamed decorative sheet 1 is obtained. Is more easily peeled from the endless belt 24.
[0040]
[Fourth Embodiment]
In the following description, only the parts different from the first embodiment will be described in detail, and the same reference numerals will be given to the other same members and the same structure, and the detailed description thereof will be omitted or simplified.
[1] Foam decorative sheet
FIG. 5 shows a foamed decorative sheet 5 according to the fourth embodiment of the present invention.
The foam decoration sheet 5 is configured by laminating a foam layer 13 made of LLDPE on the surface of the first PP film 11 of the foam decoration sheet (see FIG. 1) of the first embodiment where the decoration layer 11A is not formed. Yes.
[0041]
[2] Foam decorative sheet manufacturing equipment
FIG. 6 shows a manufacturing apparatus 6 used in the method for manufacturing the foam decorative sheet 5 according to the fourth embodiment of the present invention.
The manufacturing apparatus 6 includes a supply roll 29C that supplies the LLDPE foamable raw sheet 13A, and the surface temperature of the second roll 22 is set to be equal to or higher than the foaming ink and the foaming start temperature of the raw sheet 13A. Since this is the same as the manufacturing apparatus of the first embodiment (see FIG. 2), description thereof is omitted.
[0042]
[3] Method for producing foam decorative sheet
The manufacturing method of the foam decoration sheet 5 using the manufacturing apparatus 6 comprised as mentioned above is demonstrated.
First, in a state where the foamable raw sheet 13A is positioned on the endless belt 24 side and the non-decorative surface of the first PP film 11 is laminated on the raw sheet 13A, the first rolls are supplied from the supply rolls 29A, 29B, and 29C. A 1PP film 11, a second PP film 12, and a foamable raw sheet (hereinafter referred to as a raw sheet) 13A are supplied. While pressing the supplied PP films 11 and 12 and the original sheet 13A with the pressing roll 25, the original sheet 13A is brought into contact with the endless belt 24 and the PP films 11 and 12 and the original sheet 13A are pressed. It is sandwiched between the roll 25 and the first roll 21 with a predetermined pressure.
[0043]
In this state, the pressure-bonding roll 25 and the heated first roll 21 pressure-bond the original sheet 13A to the endless belt 24 and perform thermal lamination of the original sheet 13A and the PP films 11 and 12 (thermo-compression bonding). Process).
At this time, the first roll 21 is heated to a temperature higher than the melting point of the PP films 11 and 12 and lower than the foaming start temperature of the foamable ink, that is, a predetermined temperature of 140 to 250 ° C. as described above.
The heat of the first roll 21 is transmitted to the original fabric sheet 13A and each of the PP films 11 and 12 through the endless belt 24 so that the temperature can be thermocompression-bonded and heat-laminated.
[0044]
Subsequently, the original fabric sheet 13 </ b> A and the PP films 11 and 12 thermally bonded to the endless belt 24 are moved onto the second roll 22 as the endless belt 24 rotates.
Here, the foamable ink is heated by the second roll 22 heated to a predetermined temperature of 150 to 240 ° C. above the melting point of each of the PP films 11 and 12 and above the foaming start temperature of the foamable ink and the raw sheet 13A. The raw fabric sheet 13A is heated to a temperature equal to or higher than the foaming start temperature and foamed almost simultaneously (foaming step).
Thereafter, the foamed decorative sheet 5 is moved onto the third roll 23A, cooled, peeled off from the endless belt 24 by the peeling roll 26 (peeling step), wound up by the winding roll 27, and decorated by foaming of the foamable ink. A foamed decorative sheet 5 having a foamed layer 13 to which is applied is obtained.
[0045]
According to the fourth embodiment as described above, in addition to the same effects as (1) to (10) in the first embodiment, the following effects are also obtained.
(13) Since the foamable original sheet 13A and the first PP film 11 decorated with the foamable ink are laminated by the thermocompression bonding process, the foamable ink and the foamable original sheet 13A are formed by the subsequent foaming process. And the foamed decorative sheet 5 having the foamed layer 13 can be efficiently produced.
[0046]
It should be noted that the present invention is not limited to the above-described embodiments, and modifications and improvements as long as the object of the present invention can be achieved are included in the present invention. For example, in each of the above-described embodiments, a PP film is used as the thermoplastic resin film. However, the present invention is not limited to this, and crystalline resins such as polyethylene and nylon, or a mixture thereof, polystyrene, ethylene-acetic acid are used. A vinyl copolymer, an ionomer, a material added with various elastomers, or the like can be used.
Moreover, although the single layer thing was used as a thermoplastic resin film, you may use a multilayer thing.
Furthermore, the first PP film was only decorated with foaming ink, but is not limited to this, and depending on the pattern required, a pattern component and foaming agent with foaming ink containing a foaming agent are included. The pattern component by the ink which is not included can also be applied in an appropriate manner.
[0047]
In each of the above embodiments, a stainless steel belt having a mirror-finished surface is used as the endless belt 24. However, the present invention is not limited thereto, and a nickel belt, a metal belt coated with polyimide or the like on the surface, or the like is used. It may be used.
In the said 1st, 3rd-4th embodiment, although the temperature of the thermocompression bonding process was performed at the temperature more than melting | fusing point of each PP film 11 and 12, it is not limited to this, It is more than melting | fusing point of at least one film Any temperature is acceptable.
[0048]
In the said 1st-4th embodiment, although the foaming process was performed above melting | fusing point of each PP film 11 and 12, and more than the foaming start temperature of foamable ink, it is not limited to this, Foaming of foamable ink If it is more than start temperature, it can carry out at arbitrary temperature.
In each of the above embodiments, the heating is performed directly from the endless belt 24 wound around the heating roll. However, the present invention is not limited to this, and the heating efficiency can be improved by combining an external heater such as an electric heater and electromagnetic induction heating. You can also plan.
[0049]
In the fourth embodiment, the LLDPE sheet is used as the foamable sheet 13A. However, the present invention is not limited to this, and other polyolefin resins, polyvinyl chloride resins, polystyrene resins and the like are employed. You can also.
In addition, the specific structure, shape, and the like when carrying out the present invention may be other structures and the like as long as the object of the present invention can be achieved.
[0050]
【Example】
Hereinafter, the present invention will be described more specifically with reference to examples and comparative examples.
[Example 1]
[1] Thermoplastic resin film
Polypropylene (F-744NP, manufactured by Idemitsu Petrochemical Co., Ltd., melting point 138 ° C.) was molded by a casting method using a T die to obtain a film having a thickness of 200 μm.
[2] Application of foamable ink to thermoplastic resin film
A foamable ink (New Daifoam EX-12523, manufactured by Dainichi Seika Kogyo Co., Ltd.) is dispersed in an ethylene-vinyl acetate copolymer and water, and a roll is formed on one of the PP films obtained in [1] above. A floral pattern was applied by a coating method.
The PP film decorated with foamable ink after coating was dried in a hot air oven at 90 ° C. for 1 minute to obtain a first PP film.
[0051]
[3] Manufacture of foam decorative sheet
Using the manufacturing apparatus 2 of the first embodiment, the foaming decorative sheet 1 was manufactured by setting the manufacturing conditions as follows.
Endless belt 24 circumference: 2500 mm
Endless belt 24 peripheral speed: 1m / min
Surface temperature of the first roll 21: 140 ° C.
Temperature of the endless belt 24 on the first roll 21: 140 ° C.
Surface temperature of second roll 22: 155 ° C
Temperature of the endless belt 24 on the second roll 22: 155 ° C.
Surface temperature of the third roll 23A: 40 ° C
Diameter of each roll 21, 22, 23A: 250mm
[0052]
The foamed decorative sheet 1 obtained was firmly bonded between the PP films 11 and 12 and the interface between the decorative layer 11A and the PP films 11 and 12, and did not peel off at these interfaces.
Further, in the decorative layer 11A, the ink pattern and the three-dimensional pattern were synchronized, and the surface of the first PP film 11 that was in contact with the endless belt 24 had a good mirror surface.
[0053]
[Example 2]
[1] Thermoplastic resin film
Using the same raw materials as in Example 1, the same method was used.
[2] Application of foamable ink to thermoplastic resin film
In the same manner as in Example 1, after applying a floral pattern with a foaming ink to a PP film, and further applying an ink not containing a foaming agent on the entire floral pattern, under the same conditions as in Example 1. It dried and the 1st PP film 11 was obtained.
[0054]
[3] Manufacture of foam decorative sheet
Using the manufacturing apparatus 2 of the first embodiment, the foaming decorative sheet 1 was manufactured by setting the manufacturing conditions as follows.
Endless belt 24 circumference: 2500 mm
Endless belt 24 peripheral speed: 1m / min
Surface temperature of the first roll 21: 145 ° C
Temperature of the endless belt 24 on the first roll 21: 145 ° C
Surface temperature of second roll 22: 160 ° C.
Temperature of the endless belt 24 on the second roll 22: 160 ° C.
Surface temperature of the third roll 23A: 40 ° C
Diameter of each roll 21, 22, 23A: 250mm
[0055]
The foamed decorative sheet 1 thus obtained has a strong adhesion between the PP films 11 and 12 and the interface between the decorative layer 11A and the PP films 11 and 12, and when peeled forcibly, the entire printed surface and the second PP film The interface with No. 12 was not peeled off, but was peeled off in the form of material destruction in the decorative layer 11A or the entire surface-printed paint.
Moreover, the external appearance of the foam decoration sheet 1 was the same as that of Example 1, and quality was favorable.
[0056]
[Example 3]
[1] Thermoplastic resin film
Using the same raw materials as in Example 1, the same method was used.
[2] Application of foamable ink to thermoplastic resin film
In the same manner as in Example 1, a first PP film 11 was obtained.
[0057]
[3] Manufacture of foamable raw sheet
(1) Density 0.92g / cm^Three(Measured in accordance with JIS-K7112, the same shall apply hereinafter), Melt Flow Index (hereinafter referred to as MI) 1.2 g / 10 min (measured in accordance with JIS-K7210, the same shall apply hereinafter) linear low density polyethylene (LLDPE) (trade name Moretech 0134N, manufactured by Idemitsu Petrochemical Co., Ltd.): 80 kg
(2) Ethylene propylene rubber (trade name: P0680, Mitsui Petrochemical Co., Ltd.) having a density of 0.89 and MI = 0.7 g / 10 min: 20 kg
(3) Azodicarbonamide (ADCA) having a decomposition temperature of 208 ° C. (trade name: VINYHALL AC # 3, manufactured by Eiwa Kasei Co., Ltd.): 3 kg
(4) Zinc aliphatic monocarboxylate (trade name: SP-100Z, manufactured by Eishin Kasei Co., Ltd.): 1kg
[0058]
Each raw material of (1) to (4) was kneaded at 180 ° C. using a mixing roll and filled into a calender molding apparatus via a warming roll. The calendar forming apparatus used here is a four roll type, and the set temperature of the first roll was 140 ° C. With this molding apparatus, a polyolefin foamable raw sheet 13A having a thickness of 0.2 mm and a width of 1020 mm was finally obtained.
[0059]
[4] Manufacture of foam decorative sheet
Using the manufacturing apparatus 6 of the fourth embodiment, the foaming decorative sheet 1 was manufactured by setting the manufacturing conditions as follows.
Endless belt 24 circumference: 2500 mm
Endless belt 24 peripheral speed: 1m / min
Surface temperature of the first roll 21: 150 ° C.
Temperature of the endless belt 24 on the first roll 21: 150 ° C.
Surface temperature of second roll 22: 190 ° C.
Temperature of the endless belt 24 on the second roll 22: 190 ° C.
Surface temperature of the third roll 23A: 40 ° C
Diameter of each roll 21, 22, 23A: 250mm
[0060]
The foamed decorative sheet 5 obtained was sufficiently strong that the foamable raw sheet 13A was sufficiently foamed and did not peel off between the PP films 11 and 12 and at the interface between the first PP film 11 and the foamed layer 13.
In addition, the foamed decorative sheet 5 was a sheet 5 having high cushioning properties with the unevenness synchronized with the decorative layer 11A.
[0061]
[Comparative Example 1]
A foam decorative sheet was produced in the same manner as in Example 1 except that the temperature of the endless belt 24 on the first roll 21 was set to 135 ° C. below the melting point of the PP film.
The obtained foamed decorative sheet had a weak adhesive strength between the two films, and when peeled off forcibly, it peeled off at the lamination surface.
Further, it was partially peeled off from the surface of the endless belt 24 during the production, and the unevenness due to the peeling was present on the sheet surface, which was of poor quality.
[0062]
[Comparative Example 2]
A foamed decorative sheet was produced in the same manner as in Example 2 except that the temperature of the endless belt 24 on the second roll 23A was 125 ° C.
The foamed decorative sheet thus obtained had a sufficient foam pattern, but the interface strength between the entire printed surface and the unprinted film was weak.
[0063]
【The invention's effect】
According to the present invention, the foamed decorative sheet has a high adhesive strength of each film and is sufficiently foamed with foamable ink, since it is heated at a temperature equal to or higher than the melting point of at least one film in the thermocompression bonding process. Can be obtained.
Furthermore, since the adhesive strength between each film improves by raising the temperature above the melting point of the film, peeling between the films hardly occurs when the foamable ink is foamed.
[Brief description of the drawings]
FIG. 1 is a partial cross-sectional view showing a foam decorative sheet according to a first embodiment of the present invention.
FIG. 2 is a schematic configuration diagram showing a manufacturing apparatus used in the method for manufacturing a foam decorative sheet in the embodiment of FIG.
FIG. 3 is a schematic configuration diagram showing a manufacturing apparatus used in a method for manufacturing a foam decorative sheet according to a second embodiment of the present invention.
FIG. 4 is a schematic configuration diagram showing a manufacturing apparatus used in a method for manufacturing a foam decorative sheet according to a third embodiment of the present invention.
FIG. 5 is a partial cross-sectional view showing a foam decorative sheet according to a fourth embodiment of the present invention.
6 is a schematic configuration diagram showing a manufacturing apparatus used in the method for manufacturing a foam decorative sheet in the embodiment of FIG.
[Explanation of symbols]
1, 5 Foamed decorative sheet
11 1st PP film (thermoplastic resin film)
12 2nd PP film (other thermoplastic resin film)
13A foamable raw sheet
21 First roll (heating roll)
22 Second roll (heating roll)
23A 3rd roll (cooling roll)
23B 4th roll (cooling roll)
24 Endless Belt

Claims (1)

A method for producing a foam decorative sheet using a metal endless belt wound around a plurality of rolls including a heating roll and a cooling roll,
A foamable raw sheet containing a pyrolytic foaming agent is brought into contact with the metal endless belt, and a thermoplastic resin film decorated with foamable ink is placed on the non-decorative surface on the foamable raw sheet. Then, another thermoplastic resin film is laminated on the decorative surface of this thermoplastic resin film, and these metal endless belts, sheets and films are integrated by thermocompression bonding at a temperature equal to or higher than the melting point of at least one of the films. A thermocompression bonding process;
Simultaneously with or after this thermocompression bonding step, a foaming step of foaming the pyrolyzable foaming agent and foamable ink,
After the foaming step, the sheet and the film are cooled, and a peeling step of peeling from the metal endless belt is provided.

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