JP6318963B2 - Method for manufacturing uneven sheet - Google Patents

Description

  The present invention relates to a method for producing an uneven sheet.

  As a decorative board used for interior / exterior building materials, for example, furniture, floor tiles, and wall panels, generally, a decorative sheet printed with a wood grain pattern or the like is bonded to a substrate with an adhesive. High decorativeness is required for decorative sheets and decorative plates used for the above-mentioned applications and the like, and as a means for improving the decorativeness, a method of imparting an uneven shape to the surface has been proposed.

  As means for imparting irregularities to the surfaces of these decorative sheets and decorative plates, an embossing method and a method using a release sheet are widely known. For example, Patent Document 1 discloses that a heated sheet-shaped original fabric is inserted and pressed between an embossing roll and a pressure roll that are provided with a predetermined shaping unevenness pattern, thereby the sheet-shaped original fabric. There has been proposed a method of imparting an uneven shape to the surface. Patent Document 2 proposes a molded sheet having a layer having a concavo-convex pattern on the surface of a base sheet, and a polyester decorative board using the molded sheet.

  Recently, with the diversification of uses of decorative sheets and decorative boards, there is an increasing demand for irregularities provided on the surface to be irregular and natural uneven shapes, that is, random uneven shapes. However, in the method of imparting a concavo-convex shape using an embossed plate or a release sheet as proposed in Patent Documents 1 and 2, the concavo-convex pattern on the surface of the embossed plate or the release sheet is regularly formed. It is only possible to give repeated uneven shapes, and random uneven shapes cannot be given to the surface.

  In addition, when the embossed plate is damaged, it is necessary to recreate the embossed plate having the same uneven pattern as the damaged embossed plate. However, the creation of the embossed plate is expensive, and it is recreated so that the same uneven pattern is obtained. The problem itself is that it is difficult.

JP 2006-272198 A JP 7-164519 A

  This invention is made | formed in view of such a condition, and mainly provides the manufacturing method of the uneven | corrugated sheet | seat which can manufacture the uneven | corrugated sheet | seat with which the random uneven | corrugated shape was provided to the surface by the simple method. Let it be an issue.

  This invention for solving the said subject is a manufacturing method of an uneven sheet, Comprising: The resin sheet by which a resin layer is laminated on the substrate for resin sheets, The preparatory process which prepares a substrate, The above-mentioned resin sheet And a step of overlapping the substrate with the resin layer of the resin sheet and the substrate being in contact with each other, and a stack of the resin sheet and the substrate, a first roll and a second roll Including a laminating step of laminating the resin sheet on the base material by heating the resin layer with one or both of the first roll and the second roll. Contains a thermoplastic resin and a volatile component, and the laminating step is performed in a vacuum chamber, and in the laminating step, the loss tangent of the thermoplastic resin contained in the resin layer is 0.6 to 10 Wherein the heating of the resin layer at a temperature at which the 囲内 is performed.

  Moreover, before performing the said lamination process, the preheating process which preheats the said base material may be included.

  According to the method for producing a concavo-convex sheet of the present invention, a concavo-convex sheet in which a random concavo-convex shape is imparted to the surface of a resin sheet can be produced by a simple method.

It is a figure for demonstrating the manufacturing method of the uneven | corrugated sheet of one Embodiment. It is a figure which shows the state of the resin sheet before and behind passing between between a 1st roll and a 2nd roll. It is a schematic sectional drawing which shows the state which accumulated the resin sheet and the base material. It is a schematic sectional drawing which shows an example of the uneven | corrugated sheet manufactured with the manufacturing method of the uneven | corrugated sheet of one Embodiment.

<< Method for manufacturing uneven sheet >>
The manufacturing method of the uneven | corrugated sheet 100 of one Embodiment of this invention prepares the resin sheet 10 by which the resin layer 2 is laminated | stacked on the base material 1 for resin sheets, and the base material 20, as shown in FIG. A preparation step, a step of overlapping the resin sheet 10 and the base material 20 so that the resin layer 2 of the resin sheet 10 and the base material 20 are in contact with each other, and a resin sheet 10 and a base as shown in FIGS. The material 20 stacked is passed between the first roll 50 and the second roll 51, and the resin layer 2 is heated while being heated by one or both of the first roll 50 and the second roll 51. Thus, a laminating step of laminating the resin sheet 10 on the substrate 20 is included. And the manufacturing method of the uneven | corrugated sheet | seat 100 of this invention is the resin layer 2 of the resin sheet 10 prepared at the said preparatory process contains the thermoplastic resin and a volatile component, and the said lamination process is in a decompression chamber. In the laminating step, the resin layer 2 is heated at a temperature at which the loss tangent (tan δ) of the thermoplastic resin contained in the resin layer 2 is in the range of 0.6 to 10. Yes. That is, the manufacturing method of the uneven | corrugated sheet 100 of one Embodiment of this invention has the following (feature 1)-(feature 3).

  In addition, FIG. 1 is a figure for demonstrating the manufacturing method of the uneven | corrugated sheet of one Embodiment, FIG. 2 shows the state of the resin sheet before and behind passing between the 1st roll 50 and the 2nd roll 51. FIG. FIG. 3 is a schematic cross-sectional view showing a state in which a resin sheet and a base material are stacked.

(Characteristic 1): The resin sheet 10 has a resin layer 2 laminated on a resin sheet substrate 1, and the resin layer 2 contains a thermoplastic resin and a volatile component.
(Characteristic 2): The laminating process of laminating the resin sheet 10 on the substrate 20 is performed in a vacuum chamber.
(Feature 3): In the laminating step, the temperature at which the resin layer is heated is such that the loss tangent (tan δ) of the thermoplastic resin contained in the resin layer 2 is in the range of 0.6 to 10.

  The loss tangent (tan δ) of the thermoplastic resin referred to in the present specification is the ratio between the loss elastic modulus (G ″) and the storage elastic modulus (G ′), and the loss elastic modulus (G ″) is expressed as the storage elastic modulus. The value divided by the rate (G ′). A large loss tangent (tan δ) indicates that the ratio of loss energy is large. Specifically, it means that the thermoplastic resin has a strong tendency to be viscous at that temperature. In other words, it means close to the liquid state. Further, when the loss tangent (tan δ) is small, it indicates that the ratio of stored energy is large. Specifically, it means that the thermoplastic resin has a strong tendency to be elastic at that temperature. In other words, it means close to a solid state. The temperature at which the loss tangent (tan δ) of the thermoplastic resin is in the range of 0.6 to 10 is the temperature at which the thermoplastic resin is in the solid-liquid transition region (mixed).

  According to the manufacturing method of the concavo-convex sheet 100 of the present invention having the above (feature 1) to (feature 3), a random concavo-convex shape is formed on the surface as shown in FIG. 4 without using an embossed plate or a release sheet. Can be produced. FIG. 4 is a schematic cross-sectional view illustrating an example of the concavo-convex sheet manufactured by the method for manufacturing the concavo-convex sheet according to the embodiment of the present invention. Hereinafter, each step will be described.

<Preparation process>
A preparation process is a process of preparing the resin sheet 10 by which the resin layer 2 is laminated | stacked on the base material 1 for resin sheets, and the base material 20. As shown in FIG.

(Resin sheet)
As shown in FIG. 3, the resin sheet 10 includes a resin sheet substrate 1 and a resin layer 2 provided on the resin sheet substrate 1. The resin sheet 10 has the resin sheet substrate 1 as an essential component, and this is a resin sheet formed by either one or both of the first roll 50 and the second roll 51 in the laminating process described later. This is to prevent the first roll 50 and the resin sheet 10 from being heat-sealed when 10 is heated. Specifically, in the laminating process, the resin layer 2 of the resin sheet is heated at a temperature satisfying the above (feature 3) by one or both of the first roll 50 and the second roll 51, and the substrate 20 This is because the resin sheet 10 is laminated thereon, but the resin layer 2 is heat-sealed with the first roll 50 when the resin sheet 10 does not include the resin sheet substrate 1.

"Base material for resin sheet"
The material for the resin sheet substrate 1 is such that the resin layer 2 is not thermally fused to the first roll 50 at the temperature when the resin layer 2 is heated, specifically, at the upper limit of the temperature that satisfies the above (feature 3). What is necessary is just to use the material which has heat resistance, and the material of the base material 1 for resin sheets is the temperature (above-mentioned (the above-mentioned) when the resin layer 2 is heated in relation to the thermoplastic resin which the resin layer 2 contains. What is necessary is just to determine suitably according to the temperature) of the characteristic 3). General materials having heat resistance include polyesters such as polyethylene terephthalate, polyarylate, polycarbonate, polyurethane, polyimide, polyetherimide, cellulose derivatives, polyethylene, ethylene / vinyl acetate copolymer, polypropylene, polystyrene, acrylic, poly Vinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyvinyl butyral, nylon, polyether ether ketone, polysulfone, polyether sulfone, tetrafluoroethylene / perfluoroalkyl vinyl ether, polyvinyl fluoride, tetrafluoroethylene / ethylene, tetrafluoroethylene / Various plastics such as hexafluoropropylene, polychlorotrifluoroethylene, and polyvinylidene fluoride Irumu or sheets, or can include or aluminum foil, a metal foil such as a copper foil or the like.

  Although there is no limitation in particular about the thickness of the base material 1 for resin sheets, when the thickness exceeds 400 micrometers, even if it is a case where an unevenness | corrugation is provided to the surface of the resin layer 2 in the lamination process mentioned later, the surface of the said resin layer 2 It tends to be difficult to cause the unevenness imparted to the surface to follow the surface of the resin sheet substrate 1. Therefore, the thickness of the resin sheet substrate 1 is preferably 400 μm or less, and more preferably 50 μm or less. An example of the lower limit is about 10 μm.

"Resin layer"
The resin layer 2 provided on the resin sheet substrate 1 contains a thermoplastic resin and a volatile component.

  There is no limitation in particular about the thermoplastic resin which the resin layer 2 contains, A conventionally well-known thing can be selected suitably, and can be used. For example, thermoplastic resin materials include polyester resins, polyacrylate resins, polyvinyl acetate resins, styrene acrylate resins, polyurethane resins, polyethylene resins, polypropylene resins and other polyolefin resins, polystyrene Resins, polyvinyl chloride resins, polyether resins, polyamide resins, polyimide resins, polyamideimide resins, polycarbonate resins, polyacrylamide resins, polyvinyl chloride resins, polyvinyl butyral resins, polyvinyl acetoacetal resins, etc. An acetal resin etc. can be mentioned. Other thermoplastic resins may be used.

  The resin layer 2 may contain one kind of thermoplastic resin alone, or may contain two or more kinds of thermoplastic resins. In the laminating process described later, heating is performed at a temperature at which the loss tangent (tan δ) of the thermoplastic resin contained in the resin layer 2 is in the range of 0.6 to 10. In the case where the resin layer 2 contains two or more types of thermoplastic resins, the thermoplastic resin that serves as a reference for determining the temperature at which the resin layer 2 is heated is, among the two or more types of thermoplastic resins, The thermoplastic resin with the highest content may be used as a reference. Further, when the resin layer 2 is heated at a temperature at which the loss tangent (tan δ) of the reference thermoplastic resin is in the range of 0.6 to 10, the other thermoplastic resins other than the reference thermoplastic resin The loss tangent (tan δ) may be within the range of 0.6 to 10, or may be outside the range.

  The content of the thermoplastic resin contained in the resin layer 2 is not particularly limited, but the resin layer 2 has a loss tangent (tan δ) within a range of 0.6 to 10 at a temperature when the resin layer 2 is heated. It is preferable that 50 mass% or more of the resulting thermoplastic resin is contained with respect to the total solid content of the resin layer 2. For example, when the resin layer 2 contains two or more kinds of thermoplastic resins, the reference thermoplastic resin is selected from the content, and the loss tangent (tan δ) of the reference thermoplastic resin is 0. The heating temperature of the resin layer 2 within the range of 6 to 10 is determined. When the loss tangent (tan δ) of the thermoplastic resin other than the reference thermoplastic resin at the determined temperature is out of the range of 0.6 to 10, the resin layer 2 has the above reference heat. The plastic resin is preferably contained in an amount of 50% by mass or more based on the total solid content of the resin layer 2. On the other hand, when the loss tangent (tan δ) of the other thermoplastic resin is within the range of 0.6 to 10 at the determined temperature, the resin layer 2 has the above-mentioned standard with respect to the total solid content of the resin layer 2. Containing the above-mentioned reference thermoplastic resin and other thermoplastic resins so that the total mass of the thermoplastic resin and the other thermoplastic resin within the range becomes 50% by mass or more. Preferably it is.

  The resin layer 2 contains a volatile component together with the thermoplastic resin. There is no limitation in particular about a volatile component, Solvents, such as water, an organic solvent, etc. can be mentioned. Moreover, a volatile component is the concept containing gas, such as air. Moreover, the resin layer 2 contains a volatile component not only that a volatile component is contained inside the resin layer 2 but also in a step of stacking a resin sheet 10 and a substrate 20 described later in a resin. Among the surfaces of the layer 2, those that adhere to the surface on the side in contact with the substrate 20 are included. In other words, when the resin sheet 10 and the base material 20 are stacked, a volatile component may be present at the interface between the resin layer 2 and the base material 20.

  Whether or not the resin layer 2 contains a volatile component can be specified using, for example, a gas chromatography method.

  In general, when the resin layer 2 is formed using various coating methods, or when formed using extrusion molding or the like, a gas such as air, a solvent, a solvent, or the like is formed in the resin layer 2. Volatile components remain. Therefore, the resin layer 2 usually contains a volatile component, and the resin layer that has not been subjected to degassing treatment or defoaming treatment satisfies the condition that it contains a thermoplastic resin. If it is a thing, it shall be contained in the resin layer 2 said by this invention. Moreover, although the resin layer 2 does not contain a volatile component positively, according to the uneven | corrugated shape provided, the resin layer 2 can also be made to contain a volatile component positively. For example, in the case where the resin layer 2 is formed by a coating method, the viscosity of the coating liquid for forming the resin layer 2 is appropriately adjusted, so that the coating liquid can be actively added during coating. Air can be contained, and a large amount of air can be contained in the formed resin layer 2. Further, the resin layer 2 can contain a large amount of a solvent or a solvent by lowering the temperature at which the coating liquid is dried.

  The resin layer 2 may contain arbitrary components such as a plasticizer, a heat stabilizer, and an antistatic agent together with the thermoplastic resin and the volatile component.

  The method for forming the resin layer is not particularly limited. For example, a resin layer coating solution prepared by dissolving or dispersing a thermoplastic resin in an appropriate solvent is prepared, and this is applied to the gravure printing method, screen printing method or gravure plate. It can be formed by coating and drying on the resin sheet substrate 1 by means such as a reverse coating method using.

  In addition, the extruded resin layer 2 may be bonded onto the resin sheet substrate 1. Moreover, the base material 1 for resin sheets and the resin layer 2 can also be formed by coextrusion molding.

  Although there is no limitation in particular about the thickness of the resin layer 2, when the thickness of the resin layer 2 exceeds 500 micrometers, sufficient unevenness | corrugation on the surface of the said resin layer 2 depending on content of the volatile component which the resin layer 2 contains In some cases, the shape cannot be imparted. Therefore, considering this point, the thickness of the resin layer 2 is preferably 500 μm or less. Although there is no limitation in particular about a lower limit, Preferably it is 10 micrometers or more.

(Base material)
Although there is no limitation in particular about the base material 20 prepared at this process, for the same reason as the reason demonstrated with the said base material 1 for resin sheets, the base material 20 also has heat resistance in the temperature when heating the resin layer 2. FIG. It is preferable that it is comprised from the material which has. As such a base material 20, what was demonstrated with the said base material 1 for resin sheets can be selected suitably, and description here is abbreviate | omitted. The resin sheet substrate 1 and the substrate 20 may be the same or different.

<Process of stacking resin sheet and substrate>
The step of stacking the resin sheet and the base material is a step of stacking the resin sheet 10 and the base material 20 prepared in the preparation step so that the resin layer 2 of the resin sheet 10 and the base material 20 are in contact with each other. In the method for manufacturing an uneven sheet according to an embodiment, the substrate 20 is supplied from the substrate supply roll 54, and the resin sheet 10 is supplied from the resin sheet supply roll 55. And in the stage where the base material 20 supplied from the base material supply roll 54 and the resin sheet 10 supplied from the resin sheet supply roll 55 pass between the first roll 50 and the second roll 51, The resin layer 2 of the resin sheet 10 and the base material 20 are stacked so as to contact each other. FIG. 3 is a schematic cross-sectional view showing a state in which the resin layer 2 of the resin sheet 10 and the base material 20 are overlapped with each other.

  This invention is not limited to said form, You may supply what overlapped the resin sheet 10 and the base material 20 previously from one supply roll (not shown).

  In the form shown in FIG. 1, the base material 20 supplied from the base material supply roll 54 has a pair of upper and lower preheating rolls 56 before passing between the first roll 50 and the second roll 51. The substrate 20 has been preliminarily heated in advance. The preheating will be described later.

<Lamination process>
In the laminating step, a laminate of the resin sheet 10 and the substrate 20 is passed between the first roll 50 and the second roll 51, and either or both of the first roll 50 and the second roll 51 are used. This is a step of laminating the resin sheet 10 on the base material 20 by heating and pressurizing the resin layer 2.

  In this step, the resin layer 2 is heated in the decompression chamber 60 in order to obtain a concavo-convex sheet 100 having a random concavo-convex shape on the surface without using an embossed plate or a release sheet (described above). Feature 2) In addition, the heating of the resin layer 2 is performed at a temperature at which the loss tangent (tan δ) of the thermoplastic resin contained in the resin layer 2 is in the range of 0.6 to 10 (the above feature 3). It is a feature.

  According to this step satisfying the above feature (feature 3), the volatile component as the above (feature 1) can be vaporized to generate bubbles in the resin layer 2, and further satisfy the above (feature 2). Thus, it is possible to grow the bubbles and generate an uneven shape on the surface of the resin layer 2. And this uneven | corrugated shape pushes up the base material 1 for resin sheets, The uneven | corrugated shape corresponding to the uneven | corrugated shape produced | generated on the surface of the resin layer 2 is provided also to the surface of the base material 1 for resin sheets, FIG. As a result, a concavo-convex sheet 100 having a random concavo-convex shape on the surface is obtained as a result.

  Heating of the resin layer 2 may be performed by the first roll 50 located on the resin sheet base material side 1 or by the second roll 51 located on the base material 20 side. Further, the resin layer 2 may be heated by both the first roll 50 and the second roll 51. In particular, when the resin layer 2 is heated by both the first roll 50 and the second roll 51, the heat energy when the resin layer 2 is heated is on the resin sheet substrate 1 side or the substrate 20 side. Escape can be suppressed, and the resin layer 2 can be heated in a stable state. Moreover, the resin layer 2 can be raised to the temperature satisfying the above-mentioned feature 3 in a short time, and the laminating speed can be increased.

  The heating method of the resin layer 2 by the first roll 50 is not particularly limited. For example, the first roll 50 is heated and heated by passing steam through the vent of the first roll 50 made of metal or the like. The resin layer 2 can be heated using the first roll 50. In the case where the resin layer 2 is heated by the first roll 50, the temperature of the surface of the first roll 50 may be the same as the temperature when the resin layer 2 is heated, or higher. May be. In any case, as a result, the temperature when heating the resin layer 2 is such that the loss tangent (tan δ) of the thermoplastic resin contained in the resin layer 2 is in the range of 0.6 to 10. It only has to be temperature. The same applies to the case where the resin layer 2 is heated by the second roll 51. As an example, a form using a conventionally known laminate roll as the first roll 50 and a receiving roll having no heating mechanism can be used as the second roll. That is, any one of the first roll 50 and the second roll 51 only needs to have a heating mechanism for heating the resin layer 2.

  As a method of measuring the heating temperature of the resin layer 2, for example, a method of measuring the heating temperature by installing a contact thermometer on the substrate 1 for the resin sheet or the substrate 20, or the substrate 1 for the resin sheet Or the method of installing a radiation thermometer in the vicinity of the base material 20 and measuring heating temperature can be mentioned.

  FIG. 2 is a schematic cross-sectional view showing the state of the resin sheet 10 before and after passing between the first roll 50 and the second roll 51, exaggerating the shape of the air bubbles and the surface of the resin sheet 10. Yes. As shown in FIG. 2, since the resin layer 2 is not heated in the state before passing between the first roll 50 and the second roll 51 (zone I in the figure), the resin layer 2 The volatile component contained in is not vaporized, and no bubbles are generated in the resin layer. The resin layer 2 is subjected to a temperature at which the loss tangent (tan δ) of the thermoplastic resin contained in the resin layer 2 is within the range of 0.6 to 10 by the first roll 50 or the second roll 51, The resin sheet 10 is laminated on the base material 20 by being pressurized by the first roll 50 and the second roll 51 (zone II in the figure). Further, from the stage immediately after the resin sheet 10 is laminated on the base material 20, the volatile component contained in the resin layer 2 is vaporized, and bubbles are generated in the resin layer 2. Then, as the bubbles grow in the decompression chamber, the bubbles push up the surface of the resin layer 2, and an uneven shape is imparted to the surface of the resin layer 2. Furthermore, the uneven | corrugated shape provided to the surface of the resin layer 2 pushes up the surface of the base material 1 for resin sheets and the base material 20, in other words, the bubble grown in the resin layer 2 is for resin sheets. By pushing up the base material 1 and the base material 20, the surface of the resin sheet base material 1 and the surface of the base material 20 are also provided with a concavo-convex shape (zone III in the figure). Thereafter, as the temperature of the resin layer 2 is lowered, the bubbles generated in the resin layer 2 are reduced, and the thermoplastic resin is cured, so that the provided uneven shape is fixed. Then, the concavo-convex sheet 100 having a concavo-convex shape on the surface is obtained (see zone IV in the figure, FIG. 4). Further, since the generation of bubbles occurs at random positions, the uneven shape imparted to the surface of the uneven sheet 100 is a random shape. In the form shown in FIG. 1, the manufactured concavo-convex sheet 100 is wound up by a winding roll 57.

  In FIG. 2, the concavo-convex shape is given to both the surface of the resin sheet substrate 1 and the surface of the substrate 20, but the concavo-convex shape is given only to the surface of the resin sheet substrate 1. If the thickness of the base material 20 is desired, the surface of the base material 20 may be prevented from exhibiting an uneven shape by using a method such as increasing the thickness of the base material 20 or using a hard material as the material of the base material 20. .

  In the laminating step, the method for producing a concavo-convex sheet according to the present invention is provided on the condition that the above (Feature 2) and (Feature 3) are satisfied, but the resin layer 2 contains a volatile component ( Even in the case of (Feature 1)), when either one of the features (Feature 2) or (Feature 3) is not satisfied, the surface of the resin layer 2 cannot be provided with an uneven shape. Specifically, when the laminating process is performed in the atmosphere, the volatile component contained in the resin layer 2 cannot be vaporized, or bubbles generated by vaporizing the volatile component are removed. It cannot be grown sufficiently, and an uneven shape cannot be imparted to the surface of the resin layer. Further, when laminating, the temperature at which the resin layer 2 is heated is such that the loss tangent (tan δ) of the thermoplastic resin contained in the resin layer 2 is not in the range of 0.6 to 10. However, the surface of the resin layer cannot be provided with an uneven shape.

  By setting the temperature at which the resin layer 2 is heated to a loss tangent (tan δ) of the thermoplastic resin contained in the resin layer 2 within a range of 0.6 to 10 (above (Feature 3)), the uneven shape The mechanism capable of imparting is not clear at present, but as explained above, the temperature is the temperature at which the thermoplastic resin is in the solid-liquid transition region (mixed), and the laminate It is presumed that by setting the temperature of the time to a temperature at which the thermoplastic resin is in the solid-liquid transition region, it is possible to generate bubbles capable of imparting an uneven shape in the resin layer 2. In addition, even if it does not depend on this inference, it is clear also from the result of the Example and comparative example which are mentioned later that an uneven | corrugated shape can be provided by the synergistic effect of said (feature 1)-(feature 3). It has become.

  In the form shown in FIG. 2, as the temperature of the resin layer 2 decreases, the thickness of the resin layer 2 decreases (zone IV in the figure), but the conveyance speed of the resin sheet 10 (lamination speed). Alternatively, the thickness of the resin layer 2 can be controlled by appropriately setting the cooling time of the resin layer 2 of the resin sheet.

  Furthermore, it is preferable that the manufacturing method of the uneven | corrugated sheet | seat of this invention includes the preheating process which preheats the base material 20 before performing a lamination process. In the form shown in FIG. 1, the base material 20 is preliminarily heated by passing through a preheating roll 56. By preheating the base material 20, the heat energy applied from the first roll 50 or the second roll 51 is sufficiently applied to the resin layer 2 when the base material 20 and the resin sheet 10 are laminated and laminated. Even when the laminating speed is increased, a good uneven shape can be imparted. Although there is no limitation in particular about preheating temperature, it is preferable that it is the range of +/- 10 degreeC with respect to the temperature when the resin layer 2 is heated in the said lamination process. Further, the substrate 20 can be preheated using means other than the preheating roll 56, such as a heater.

The decompression chamber 60 referred to in the specification of the present application means a chamber 60 having a degree of vacuum lower than the standard atmospheric pressure (1 atm (1.01325 × 10 ⁵ Pa)). The degree of vacuum in the decompression chamber only needs to satisfy the condition that it is less than the standard pressure. However, if the degree of vacuum in the decompression chamber exceeds 10,000 Pa, bubbles generated in the resin layer 2 There is a tendency for the growth of Therefore, considering this point, the degree of vacuum in the decompression chamber 60 is preferably 10000 Pa or less, and more preferably 1000 Pa or less. There is no particular limitation on the lower limit value of the degree of vacuum, and the lower limit value can be set as appropriate according to the growth property of the bubbles and the height of the convex portion having the desired concave and convex shape (depth of the concave portion).

  The laminating speed is not particularly limited, but when the laminating speed is too high, for example, when the speed exceeds 2.0 m / min, the resin sheet 10 cannot be sufficiently laminated on the substrate 20. In addition, the heating of the resin layer 2 of the resin sheet 10 becomes insufficient, and the vaporization rate of the volatile resin and the bubble growth rate tend to decrease. Therefore, in consideration of this point, the laminating speed is preferably 2.0 m / min or less, and more preferably 1.0 m / min or less.

  By passing through the laminating process, as shown in FIG. 4, a concavo-convex sheet having a random concavo-convex shape on its surface is manufactured. The method for producing a concavo-convex sheet of the present invention can produce the concavo-convex sheet 100 by a simple method without using an embossed plate or a release sheet, and the concavo-convex shape imparted to the surface is a random shape. The design property different from the embossed plate or the concavo-convex sheet formed using the release sheet can be imparted. In the above description, the decorative sheet is mainly described as the concavo-convex sheet, but any sheet may be used as long as the concavo-convex sheet is provided on the surface. For example, it can also be used as a film or the like for giving a glass-like texture to a window glass.

  Moreover, the base material 1 for resin sheets, the resin layer 2, or the base material 20 which comprises the resin sheet 10 can also be colored.

  Moreover, the manufacturing method of the uneven | corrugated sheet | seat of this invention is not limited at all to the form shown in figure. For example, in the form shown in FIG. 1, the resin sheet supply roll is disposed in the decompression chamber 60, but may be disposed outside the decompression chamber 60. Further, all the rolls may be arranged in the decompression chamber 60. In addition, it is an essential condition that the first roll 50 and the second roll 51 are arranged in the decompression chamber 60. As long as this condition is satisfied, the arrangement positions of various other rolls are not limited in any way.

  Next, the present invention will be described more specifically with reference to examples and comparative examples. Hereinafter, unless otherwise specified, parts or% is based on mass.

(Preparation of base material)
A polyethylene terephthalate film (Lumirror S10 manufactured by Toray Industries, Inc.) having a thickness of 50 μm was prepared as a base material.

(Preparation of resin sheet 1)
On a polyethylene terephthalate film with a thickness of 50 μm, an acrylic resin layer is formed by applying a coating solution obtained by dissolving an acrylic resin (WB2000 manufactured by DNP Fine Chemical Co., Ltd.) in a solvent to a thickness of 50 μm. Resin sheet 1 was obtained.

Example 1
Using a vacuum laminating apparatus (HLM-V530 Hitachi Chemical Electronics Co., Ltd.) and combining the base material prepared above and the resin sheet 1, the laminating speed is 1.0 m / min, and the temperature of the resin layer is 75 ° C. By heating the laminating roll as described above, the resin sheet 1 was laminated on the substrate, and the laminate sheet of Example 1 was obtained. The temperature of the resin layer was measured using a contact thermometer (HD-1000 U type sensor manufactured by Anritsu). The loss tangent (tan δ) at 75 ° C. of the thermoplastic resin (acrylic resin) contained in the resin layer of the resin sheet 1 is 0.6, and the loss tangent (tan δ) is a rheometer (solid mode Anton pearl of MCR301). It is a value when measured using a company). Hereinafter, the same applies to the temperature of the resin layer and the measurement of tan δ of each example and comparative example.

(Example 2)
A laminate sheet of Example 2 was obtained in the same manner as Example 1 except that the laminate roll was heated so that the temperature of the resin layer was 80 ° C. The loss tangent (tan δ) at 80 ° C. of the thermoplastic resin (acrylic resin) contained in the resin layer of the resin sheet 1 is 1.0.

(Example 3)
Example 1 except that the laminate roll was heated so that the temperature of the resin layer was 90 ° C.
In the same manner, a laminate sheet of Example 3 was obtained. The loss tangent (tan δ) at 90 ° C. of the thermoplastic resin (acrylic resin) contained in the resin layer of the resin sheet 1 is 10.

Example 4
A laminate sheet of Example 4 was obtained in the same manner as Example 1 except that the laminating speed was 0.5 m / min.

(Example 5)
A laminate sheet of Example 5 was obtained in the same manner as Example 2 except that the laminating speed was 1.2 m / min.

(Example 6)
A laminate sheet of Example 6 was obtained in the same manner as Example 3 except that the laminating speed was 1.2 m / min.

(Comparative Example 1)
A laminate sheet of Comparative Example 1 was obtained in the same manner as in Example 1 except that the laminate roll was heated so that the temperature of the resin layer was 70 ° C. The loss tangent (tan δ) at 70 ° C. of the thermoplastic resin (acrylic resin) contained in the resin layer of the resin sheet 1 is 0.3.

(Comparative Example 2)
A laminate sheet of Comparative Example 2 was obtained in the same manner as Example 1 except that the laminate roll was heated so that the temperature of the resin layer was 100 ° C. The tan δ at 100 ° C. of the thermoplastic resin (acrylic resin) contained in the resin layer of the resin sheet 1 is 11.4.

(Confirmation of surface irregularities)
The surface on the resin layer base material side of the laminate sheets of each Example and Comparative Example obtained above was visually confirmed, and it was confirmed whether or not the surface was provided with an uneven shape. As a result, it was confirmed that random uneven shapes were given to the surfaces of the laminate sheets of Examples 1 to 6, and the uneven sheets were obtained. On the other hand, it was confirmed that the surface of the laminate sheets of Comparative Examples 1 and 2 was not provided with an uneven shape. From the above results, the superiority of the manufacturing method of the concavo-convex sheet of the present invention is clarified.

DESCRIPTION OF SYMBOLS 10 ... Resin sheet 1 ... Resin sheet base material 2 ... Resin layer 20 ... Base material 50 ... 1st roll 51 ... 2nd roll 54 ... Base material supply roll 55 ... Resin sheet supply roll 56 ... Preheating roll 57 ... Winding up Roll 60 ... Depressurized chamber 100 ... Uneven sheet

Claims (2)

A method for producing a concavo-convex sheet,
A resin sheet in which a resin layer is laminated on a resin sheet substrate, and a preparation step of preparing the substrate;
A step of stacking the resin sheet and the base material so that the resin layer of the resin sheet and the base material are in contact with each other;
A layer in which the resin sheet and the base material are stacked is passed between a first roll and a second roll, and the resin layer is heated by one or both of the first roll and the second roll. Thus, including a laminating step of laminating the resin sheet on the base material,
The resin layer contains a thermoplastic resin and a volatile component,
The laminating step is performed in a vacuum chamber,
In the laminating step, the resin layer is heated at a temperature at which the loss tangent of the thermoplastic resin contained in the resin layer is in a range of 0.6 to 10.   The method for producing a concavo-convex sheet according to claim 1, further comprising a preheating step of preheating the base material before performing the laminating step.