JP6773176B2 - Manufacturing method of modeled object and heat-expandable sheet - Google Patents

Description

The present invention relates to a manufacturing method and thermal expansion sheet for the shaped object.

Conventionally, a heat-expandable sheet in which a heat-expandable layer containing a heat-expandable material that foams and expands according to the amount of heat absorbed is formed on one surface of the base material sheet is known. By forming a photothermal conversion layer that converts light into heat on the heat-expandable sheet and irradiating the photo-heat conversion layer with light, the heat-expandable layer can be partially or wholly expanded. Further, a method of forming a three-dimensional model (three-dimensional image) on a heat-expandable sheet by changing the shape of the photothermal conversion layer is also known (see, for example, Patent Documents 1 and 2).

Japanese Unexamined Patent Publication No. 64-28660 Japanese Unexamined Patent Publication No. 2001-150812

By the way, in the heat-expandable sheet, when the heat-expandable layer is heated, the heat-expandable layer expands in the direction opposite to the surface on which the base material is provided. At this time, the lower surface of the thermal expansion layer may be peeled off from the base material. When peeling occurs between the base material and the thermal expansion layer, the thermal expansion layer cannot maintain its shape and height at the part where the peeling occurs, and the thermal expansion layer is deformed when a force is applied. There is.

Therefore, there is a demand for a thermally expandable sheet capable of suppressing the thermal expansion layer from peeling off from the base material when the thermal expansion layer is expanded.

The present invention has been made in view of the above situation, when inflated thermal expansion layer, the manufacturing method of inhibiting capable shaped object that thermal expansion layer is peeled from the substrate and thermally expandable sheet The purpose is to provide.

To achieve the above object, a manufacturing method of the engaging Ru granulated form thereof the present invention includes a first step of preparing a medium thermal expansion layer is formed on a substrate to be expanded by heating, the thermal expansion layer is expanded By partially applying heat of a possible temperature to the medium, the surface corresponding to the heat-applied portion of the medium is raised by the expansion of the thermal expansion layer to form irregularities on the surface of the medium. It has a second step and a third step of forming a photothermal conversion layer that converts light into heat on the medium prior to the second step, and the second step is formed on the medium. By irradiating the photothermal conversion layer with light, the thermal expansion layer is expanded, and the thermal expansion layer is formed on the base material, and the first thermal expansion material is subjected to a first ratio with respect to the binder. The first layer including the first layer and the second layer formed on the first layer and containing the second heat-expandable material in a second ratio with respect to the binder. Is set smaller than the second ratio, so that the first layer suppresses the peeling of the thermal expansion layer from the base material when the unevenness is formed in the second step. It is characterized in that it is formed as a peeling suppressing layer for the purpose.

Also, thermally expandable sheet of the first aspect of the present invention is provided on one of the surfaces of the substrate, the thermal expansion layer containing thermally expandable material at a predetermined ratio with respect to the binder, the heat A light heat provided on the thermal expansion layer so as to expose a part of the expansion layer, and when a predetermined light is irradiated, the irradiated light is converted into heat to partially expand the thermal expansion layer. The thermal expansion layer includes a conversion layer, and the ratio is smaller than the second ratio between the second thermal expansion layer and the base material whose ratio is set to the second ratio. as first thermal expansion layer which is set to first rate is interposed, and, between the light-to-heat conversion layer and the first thermal expansion layer, such that the second thermal expansion layer is interposed In addition, it is characterized in that it is provided in multiple layers.
Further, the heat-expandable sheet of the second aspect according to the present invention is provided on one surface of the base material, and includes a heat-expandable layer containing a heat-expandable material in a predetermined ratio with respect to a binder, and the base material. It is provided on the other surface so as to expose a part of the other surface in the above, and when a predetermined light is irradiated, the irradiated light is converted into heat to partially expand the thermal expansion layer. The thermal expansion layer is provided with a photothermal conversion layer, and the ratio is higher than the second ratio between the second thermal expansion layer and the base material whose ratio is set to the second ratio. It is characterized in that it is formed in multiple layers so that a first thermal expansion layer set to a small first ratio is interposed.

According to the present invention, when inflated thermal expansion layer, the thermal expansion layer can be provided a manufacturing method and a thermally expandable sheet for can suppress shaped object to be peeled from the substrate.

It is sectional drawing which shows typically the thermal expansion sheet which concerns on Embodiment 1. FIG. It is sectional drawing which shows typically the manufacturing method of the thermal expansion sheet which concerns on Embodiment 1. FIG. It is a figure which shows the outline of the stereoscopic image formation system which concerns on Embodiment 1. FIG. It is a flowchart which shows the stereoscopic image formation process which concerns on Embodiment 1. It is sectional drawing which shows typically the stereoscopic image formation process which concerns on Embodiment 1. FIG. It is sectional drawing which shows typically the thermal expansion sheet which concerns on Embodiment 2. It is sectional drawing which shows typically the expanded state of the comparative example and the heat-expandable sheet which concerns on Embodiment 2. It is sectional drawing which shows typically the thermal expansion sheet which concerns on Embodiment 3.

Hereinafter, a method for producing a heat-expandable sheet and a heat-expandable sheet according to an embodiment of the present invention will be described in detail with reference to the drawings.

(Embodiment 1)
As shown in FIG. 1, the heat-expandable sheet 10 according to the first embodiment includes a base material 11, a first heat-expansion layer 12, a second heat-expansion layer 13, and an ink receiving layer 14. In the present embodiment, the first thermal expansion layer 12 and the second thermal expansion layer 13 form the thermal expansion layer of the thermal expansion sheet 10. Further, as will be described in detail later, the heat-expandable sheet 10 is a three-dimensional image forming system 50 whose outline is shown in FIGS. 3 (a) to 3 (c), and is printed and has irregularities (three-dimensional shape). Image) is formed.

The base material 11 is a sheet-like member that supports the thermal expansion layer. As the base material 11, paper such as high-quality paper, medium-quality paper, or synthetic paper, or a commonly used plastic film such as polypropylene, polyethylene terephthalate (PET), or polybutylene terephthalate (PBT) can be used. Further, the base material 11 is placed on the opposite side (lower side shown in FIG. 1) of the base material 11 when the first thermal expansion layer 12 and the second thermal expansion layer 13 are expanded by foaming in whole or in part. It is strong enough not to be raised, wrinkled, or wavy. In addition, it has heat resistance to withstand heating when the thermal expansion layer is foamed.

The first thermal expansion layer 12 is formed on one surface (upper surface shown in FIG. 1) of the base material 11. The first thermal expansion layer 12 is a layer that expands to a size corresponding to the heating temperature and heating time, and a plurality of thermal expansion materials MC1 (thermally expandable microcapsules, microcapsules) are dispersed in the binder B1. Have been placed. Further, as will be described in detail later, in the present embodiment, a photothermal conversion layer is formed on the ink receiving layer 14 provided on the upper surface (front surface) of the base material 11 and / or on the lower surface (back surface) of the base material 11. By irradiating with light, the region provided with the photothermal conversion layer is heated. Since the first thermal expansion layer 12 absorbs the heat generated in the photothermal conversion layer on the front surface and / or the back surface to foam and expand, only a specific region can be selectively expanded.

As the binder B1, a thermoplastic resin selected from vinyl acetate-based polymers, acrylic-based polymers and the like is used. Further, the heat-expandable microcapsule MC1 is obtained by encapsulating propane, butane, and other low-boiling vaporizable substances in a shell of a thermoplastic resin. The shell is formed from, for example, a thermoplastic resin selected from polystyrene, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, polyacrylic acid ester, polyacrylonitrile, polybutadiene, and copolymers thereof. The average particle size of the heat-expandable microcapsules is about 5 to 50 μm. When the microcapsules are heated above the thermal expansion start temperature, the polymer shell made of resin softens, the low boiling point vaporizable substance contained therein evaporates, and the capsule expands due to the pressure. Although it depends on the characteristics of the microcapsules used, the microcapsules expand to about 5 times the particle size before expansion. In FIG. 1, for convenience, the particle size of the microcapsules MC1 is shown to be substantially the same, but in reality, the particle size of the microcapsules MC1 varies, and all the microcapsules have the same particle size. Do not mean.

The second thermal expansion layer 13 is formed on the first thermal expansion layer 12. Like the first thermal expansion layer 12, the second thermal expansion layer 13 is also a layer that expands to a size corresponding to the heating temperature and the heating time, and the thermal expansion material MC2 (thermal expansion) is contained in the binder B2. Sex microcapsules) are dispersed. As the binder B2 and the heat-expandable microcapsule MC2, the materials listed as the binder B1 of the first heat-expanding layer 12 and the heat-expandable microcapsule MC1 are used. Further, the binder B2 and the heat-expandable microcapsule MC2 may use different materials from the binder B1 and the heat-expandable microcapsule MC1 of the first heat expansion layer 12, respectively, or the same material may be used. When the same material is used for the first thermal expansion layer 12 and the second thermal expansion layer 13, the raw materials are standardized, the manufacturing process can be simplified, and in addition, it is possible to contribute to the reduction of manufacturing cost, which is preferable. Further, the second thermal expansion layer 13 absorbs the heat generated in the photothermal conversion layer formed on the upper surface and / or the lower surface of the thermal expansion sheet 10 and foams like the first thermal expansion layer 12. , Inflate.

In the present embodiment, the ratio (also referred to as the content rate) of the heat-expandable material MC1 to the binder B1 in the first thermal expansion layer 12 is the ratio of the thermal expansion material MC1 to the binder B2 in the second thermal expansion layer 13. It is made lower than the ratio (also referred to as the content) in which the heat-expandable material MC2 is contained. Here, the ratio of the heat-expandable material to the binder is defined by using a volume ratio, a weight ratio, or the like. For example, when the weight ratio is used, the weight ratio of the heat-expandable material MC1 to the binder B1 (first ratio) is smaller than the weight ratio of the heat-expandable material MC2 to the binder B2 (second ratio). Specifically, it is about 1/3 to 1/8. In other words, for example, the heat-expandable material MC1 dispersed with respect to 100 parts by weight of the binder B1 is X1 parts by weight, and the heat-expandable material MC2 dispersed with respect to 100 parts by weight of the binder B2 is X2 weight. As a part, X1 / X2 is smaller than 1, and is about 1/3 to 1/8. The ratio of the heat-expandable material to the binder may be defined by the density. In this case, it can be said that the first thermal expansion layer 12 contains the thermal expansion material at a lower density than the second thermal expansion layer 13.

Further, since the first thermal expansion layer 12 contains a smaller proportion of the thermal expansion material than the second thermal expansion layer 13, when expanded under the same conditions, the second thermal expansion layer 13 The height after expansion is lower than that of. Therefore, it is preferable that the first thermal expansion layer 12 is formed thinner than the second thermal expansion layer 13. In addition, it is preferable that the first thermal expansion layer 12 is not formed thicker than necessary. From this point of view, the thickness of the first thermal expansion layer 12 is formed to be a thickness corresponding to several thermal expansion materials MC2, for example, 1 to 10 thick, preferably 1 to 5 thick. Is preferable. In other words, it is preferably formed to have a thickness of 1 to 10 times, preferably 1 to 5 times, the average particle size of the microcapsules.

The ink receiving layer 14 is formed on a second thermal expansion layer 13 formed on one surface of the base material 11. The ink receiving layer 14 is a layer that receives and fixes ink used in the printing process, for example, ink of an inkjet printer. The ink receiving layer 14 is formed by using a material that is widely used depending on the ink used in the printing process. For example, when water-based ink is used, the ink receiving layer 14 is formed by using a material selected from porous silica, polyvinyl alcohol (PVA), and the like. The ink receiving layer 14 can be omitted when an ultraviolet curable type ink is used in the inkjet method. When a material that does not easily accept ink such as a plastic film is used as the base material 11 and a photothermal conversion layer is further formed on the back side of the base material 11, the other surface of the base material 11 (lower surface shown in FIG. 1) is used. It is also preferable to provide an ink receiving layer.

The heat-expandable sheet 10 of the present embodiment contains a first heat-expandable material between the base material 11 and the second heat-expandable layer 13 at a lower ratio than that of the second heat-expandable layer 13. By providing the thermal expansion layer 12, it is possible to prevent the thermal expansion layer from peeling off from the base material 11 when the thermal expansion sheet 10 is expanded.

(Manufacturing method of thermally expandable sheet)
Next, a method for manufacturing the heat-expandable sheet 10 will be described with reference to FIGS. 2 (a) and 2 (c).
First, a sheet-like material, for example, paper is prepared as the base material 11. The base material 11 may be in the form of a roll or may be pre-cut.

Next, a binder made of a thermoplastic resin or the like and a heat-expandable material (heat-expandable microcapsules) are mixed to prepare a coating liquid for forming the first heat-expandable layer 12. At this time, the content of the heat-expandable material with respect to the binder is lower than the content of the heat-expandable material with respect to the binder in the step of forming the second heat-expandable layer 13 performed after this step. The weight ratio is about 1/3 to 1/8.

Subsequently, the coating liquid is applied onto the base material 11 using a known coating device such as a bar coater, a roller coater, or a spray coater. Subsequently, the coating film is dried to form the first thermal expansion layer 12 as shown in FIG. 2A. In addition, in order to obtain the target thickness of the first thermal expansion layer 12, the coating liquid may be applied and dried a plurality of times. Further, the first thermal expansion layer 12 is formed thinner than the second thermal expansion layer 13. The thickness of the first thermal expansion layer 12 is preferably formed to be a thickness corresponding to several thermal expansion materials MC1, for example, 1 to 10 thick, preferably 1 to 5 thick.

Next, the binder and the heat-expandable material are mixed to prepare a coating liquid for forming the second heat-expandable layer 13. The binder and the heat-expandable material may be different from the coating liquid for forming the first heat-expandable layer 12, but it is preferable to use the same material.

Subsequently, a coating liquid for forming the second thermal expansion layer 13 is applied onto the first thermal expansion layer 12 by using a known coating device such as a bar coater, a roller coater, or a spray coater. Next, the coating film is dried to form a second thermal expansion layer 13 as shown in FIG. 2 (b). In addition, in order to obtain the target thickness of the second thermal expansion layer 13, coating and drying may be performed a plurality of times.

Next, a material that constitutes the ink receiving layer 14, for example, a material selected from porous silica, PVA, and the like is dispersed in a solvent to prepare a coating liquid for forming the ink receiving layer 14. Subsequently, this coating liquid is applied onto the second thermal expansion layer 13 using a known coating device such as a bar coater, a roller coater, or a spray coater. Subsequently, the coating film is dried to form the ink receiving layer 14 as shown in FIG. 2 (c). Further, when the roll-shaped base material 11 is used, it is cut into a size suitable for the stereoscopic image forming system 50.

The heat-expandable sheet 10 is manufactured by the above steps.

(3D image formation system)
Next, the stereoscopic image forming system 50 that forms a stereoscopic image on the heat-expandable sheet 10 of the present embodiment will be described. As shown in FIGS. 3A to 3C, the stereoscopic image forming system 50 includes a control unit 51, a printing unit 52, an expansion unit 53, a display unit 54, a top plate 55, and a frame 60. And. FIG. 3A is a front view of the stereoscopic image forming system 50, FIG. 3B is a plan view of the stereoscopic image forming system 50 with the top plate 55 closed, and FIG. 3C is a plan view of the stereoscopic image forming system 50. , Is a plan view of the stereoscopic image forming system 50 in a state where the top plate 55 is opened. In FIGS. 3 (a) to 3 (c), the X direction is the same as the horizontal direction, the Y direction is the same as the transport direction D in which the sheet is transported, and the Z direction is the same as the vertical direction. is there. The X, Y and Z directions are orthogonal to each other.

The control unit 51, the printing unit 52, and the expansion unit 53 are respectively placed in the frame 60 as shown in FIG. 3A. Specifically, the frame 60 includes a pair of substantially rectangular side plates 61 and a connecting beam 62 provided between the side plates 61, and a top plate 55 is passed above the side plates 61. Further, the printing unit 52 and the expansion unit 53 are installed side by side in the X direction on the connecting beam 62 passed between the side plates 61, and the control unit 51 is fixed under the connecting beam 62. The display unit 54 is embedded in the top plate 55 so that the height coincides with the upper surface of the top plate 55.

The control unit 51 includes a CPU (Central Processing Unit), a ROM (Read Only Memory), a RAM (Random Access Memory), and the like, and controls the printing unit 52, the expansion unit 53, and the display unit 54.

The printing unit 52 is an inkjet printing device. As shown in FIG. 3C, the printing unit 52 includes a carry-in unit 52a for carrying in the heat-expandable sheet 10 and a discharge part 52b for discharging the heat-expandable sheet 10. The printing unit 52 prints the designated image on the front surface or the back surface of the heat-expandable sheet 10 carried in from the carry-in unit 52a, and discharges the heat-expandable sheet 10 on which the image is printed from the discharge unit 52b. Further, the printing unit 52 includes color inks (cyan (C), magenta (M), yellow (Y)) for forming the color ink layer 42, which will be described later, and a front side photothermal conversion layer 41 and a back side photothermal conversion layer. A black ink (including carbon black) for forming with 43 is provided. In addition, in order to form a black or gray color in the color ink layer 42, a black color ink that does not contain carbon black may be further provided as the color ink.

The printing unit 52 acquires color image data indicating a color image (color ink layer 42) to be printed on the surface of the heat-expandable sheet 10 from the control unit, and based on the color image data, color ink (cyan, magenta, yellow). ) Is used to print a color image (color ink layer 42). The black or gray color of the color ink layer is formed by mixing the three colors of CMY, or is formed by further using a black color ink that does not contain carbon black.

Further, the printing unit 52 prints the front side photothermal conversion layer 41 using black ink based on the surface expansion data which is the data indicating the portion to be expanded and expanded on the surface of the heat-expandable sheet 10. Similarly, the back side photothermal conversion layer 43 is printed using black ink based on the back surface foaming data which is the data indicating the portion to be expanded and expanded on the back surface of the heat expandable sheet 10. The black ink containing carbon black is an example of a material that converts light into heat. The higher the density of the black ink is formed, the higher the expansion height of the thermal expansion layer. Therefore, the density of the black ink is determined so as to correspond to the target height.

The expansion unit 53 is an expansion device that expands the heat-expandable sheet 10 by applying heat. As shown in FIG. 3C, the expansion unit 53 includes a carry-in unit 53a for carrying in the heat-expandable sheet 10 and a discharge part 53b for discharging the heat-expandable sheet 10. The expansion unit 53 applies heat to the heat-expandable sheet 10 carried in from the carry-in portion 53a to expand it, and discharges the expanded heat-expandable sheet 10 from the discharge unit 53b. The expansion unit 53 includes an irradiation unit (not shown) inside. The irradiation unit is, for example, a halogen lamp, and the heat-expandable sheet 10 has a near-infrared region (wavelength 750 to 1400 nm), a visible light region (wavelength 380 to 750 nm), or a mid-infrared region (wavelength 140 to 4000 nm). ) Is irradiated. When the heat-expandable sheet 10 on which the black ink containing carbon black is printed is irradiated with light, the light is converted into heat more efficiently in the portion where the black ink is printed than in the portion where the black ink is not printed. Will be done. Therefore, in the thermal expansion layer (the first thermal expansion layer and the second thermal expansion layer), the region on which the black ink is printed is mainly heated, and as a result, the black ink is printed on the thermal expansion layer. The area expands.

The display unit 54 is composed of a touch panel or the like. The display unit 54 displays an image (stars shown in FIG. 3B) printed on the heat-expandable sheet 10 by the printing unit 52, for example, as shown in FIG. 3B. Further, the display unit 54 displays an operation guide or the like, and the user can operate the stereoscopic image forming system 50 by touching the display unit 54.

(Three-dimensional image formation processing)
Next, referring to the flowchart shown in FIG. 4 and the cross-sectional view of the heat-expandable sheet 10 shown in FIGS. 5A to 5E, the stereoscopic image forming system 50 creates a stereoscopic image on the heat-expandable sheet 10. The flow of the processing to be formed will be described.

First, the user prepares the heat-expandable sheet 10 before the stereoscopic image is formed, and designates the color image data, the front surface foaming data, and the back surface foaming data via the display unit 54. Then, the heat-expandable sheet 10 is inserted into the printing unit 52 with its surface facing upward. The printing unit 52 prints a photothermal conversion layer (front side photothermal conversion layer 41) on the surface of the inserted heat-expandable sheet 10 (step S1). The front side photothermal conversion layer 41 is a layer formed of a material that converts light into heat, specifically, black ink containing carbon black. The printing unit 52 ejects black ink containing carbon black onto the surface of the heat-expandable sheet 10 according to the designated surface foaming data. As a result, as shown in FIG. 5A, the front photothermal conversion layer 41 is formed on the ink receiving layer 14. For ease of understanding, the front photothermal conversion layer 41 is shown to be formed on the ink receiving layer 14, but more accurately, the black ink is received in the ink receiving layer 14. Therefore, a photothermal conversion layer is formed in the ink receiving layer 14.

Second, the user inserts the heat-expandable sheet 10 on which the front-side photothermal conversion layer 41 is printed into the expansion unit 53 with its surface facing upward. The expansion unit 53 heats the inserted heat-expandable sheet 10 from the surface. Specifically, the expansion unit 53 irradiates the surface of the heat-expandable sheet 10 with light by the irradiation unit (step S2). The front side photothermal conversion layer 41 printed on the surface of the heat-expandable sheet 10 generates heat by absorbing the irradiated light. As a result, as shown in FIG. 5B, the area of the heat-expandable sheet 10 on which the photothermal conversion layer 41 is printed rises and expands. Further, in FIG. 5B, when the density of the black ink in the photothermal conversion layer 41 shown on the right is darker than that in the photothermal conversion layer 41 shown on the left, as shown in the figure, the darkly printed area is higher. It can be inflated.

Third, the user inserts the heat-expandable sheet 10 whose surface is heated and expanded into the printing unit 52 with its surface facing upward. The printing unit 52 prints a color image (color ink layer 42) on the surface of the inserted heat-expandable sheet 10 (step S3). Specifically, the printing unit 52 ejects cyan C, magenta M, and yellow Y inks onto the surface of the heat-expandable sheet 10 according to the designated color image data. As a result, as shown in FIG. 5C, a color ink layer 42 is formed on the ink receiving layer 14 and the photothermal conversion layer 41.

Fourth, the user inserts the heat-expandable sheet 10 on which the color ink layer 42 is printed into the expansion unit 53 with its back surface facing upward. The expansion unit 53 heats the inserted heat-expandable sheet 10 from the back surface to dry the color ink layer 42 formed on the front surface of the heat-expandable sheet 10 (step S4). Specifically, the expansion unit 53 irradiates the back surface of the heat-expandable sheet 10 with light by the irradiation unit to heat the color ink layer 42 and volatilize the solvent contained in the color ink layer 42.

Fifth, the user inserts the heat-expandable sheet 10 on which the color ink layer 42 is printed into the printing unit 52 with the back surface facing upward. The printing unit 52 prints a photothermal conversion layer (back side photothermal conversion layer 43) on the back surface of the inserted heat-expandable sheet 10 (step S5). The back side photothermal conversion layer 43 is a layer formed of a material that converts light into heat, specifically black ink containing carbon black, similarly to the front side photothermal conversion layer 41 printed on the surface of the heat-expandable sheet 10. Is. The printing unit 52 ejects black ink containing carbon black to the back surface of the heat-expandable sheet 10 according to the designated back surface foaming data. As a result, as shown in FIG. 5D, a photothermal conversion layer 43 is formed on the back surface of the base material 11. As for the back side photothermal conversion layer 43, when the density of the black ink in the photothermal conversion layer 43 shown on the left is darker than that in the photothermal conversion layer 43 shown on the right, the darkly printed area is expanded higher as shown in the figure. It becomes possible.

Sixth, the user inserts the heat-expandable sheet 10 on which the back side photothermal conversion layer 43 is printed into the expansion unit 53 with the back side facing upward. The expansion unit 53 heats the inserted heat-expandable sheet 10 from the back surface. Specifically, the expansion unit 53 irradiates the back surface of the heat-expandable sheet 10 with light by an irradiation unit (not shown) (step S6). The photothermal conversion layer 43 printed on the back surface of the heat-expandable sheet 10 generates heat by absorbing the irradiated light. As a result, as shown in FIG. 5 (e), the area of the heat-expandable sheet 10 on which the photothermal conversion layer 43 is printed rises and expands.

A stereoscopic image is formed on the heat-expandable sheet 10 by the above procedure.

Generally, in a heat-expandable sheet, the heat-expanding layer provided on the base material expands in the direction opposite to the surface on which the base material is provided (for example, the upward direction shown in FIG. 1). Due to this expansion, peeling may occur between the base material and the thermal expansion layer provided immediately above the base material. Further, in general, the higher the content of the heat-expandable material, the more likely it is that peeling from the base material will occur. On the other hand, in the heat-expandable sheet 10 of the present embodiment, the content of the heat-expandable material between the base material 11 and the second heat-expandable layer 13 is lower than that of the second heat-expandable layer 13. The thermal expansion layer 12 of the above is interposed. Since the degree of expansion and expansion of the first thermal expansion layer 12 is suppressed as compared with the second thermal expansion layer 13, it is possible to prevent the thermal expansion layer from peeling off from the base material 11. In addition, since the first thermal expansion layer 12 itself expands, the first thermal expansion layer 12 also has an effect of contributing to an increase in the height of the entire thermal expansion layer.

As described above, according to the method for producing a heat-expandable sheet and a heat-expandable sheet of the present embodiment, when the heat-expandable layer is expanded, the heat-expandable layer can be prevented from peeling from the base material. A method for producing a sheet and a heat-expandable sheet can be provided.

(Embodiment 2)
The heat-expandable sheet 20 according to the second embodiment will be described with reference to the drawings. The thermal expansion sheet 20 according to the second embodiment is different from the thermal expansion sheet according to the first embodiment in that a third thermal expansion layer 26 is further provided on the second thermal expansion layer 13. The parts having the same configuration as that of the first embodiment are numbered the same, and detailed description thereof will be omitted.

As shown in FIG. 6, the heat-expandable sheet 20 according to the second embodiment includes a base material 11, a first heat-expansion layer 12, a second heat-expansion layer 13, an ink receiving layer 14, and a third. The thermal expansion layer 26 of the above is provided. Further, the first thermal expansion layer 12, the second thermal expansion layer 13, and the third thermal expansion layer 26 form the thermal expansion layer of the thermal expansion sheet 20. Further, in the present embodiment, the ink receiving layer 14 is formed on the third thermal expansion layer 26 provided on the second thermal expansion layer 13.

The third thermal expansion layer 26 is formed between the second thermal expansion layer 13 and the ink receiving layer 14. In the third thermal expansion layer 26, similarly to the first thermal expansion layer 12, the thermal expansion material MC3 (thermally expandable microcapsules) is dispersedly arranged in the binder B3. Similar to the first thermal expansion layer 12, the third thermal expansion layer 26 absorbs heat generated in the photothermal conversion layer formed on the upper surface and / or the lower surface of the thermal expansion sheet 20 and foams to expand. To do. Further, as the binder B3 and the heat-expandable microcapsule MC3, the materials listed as the binder B1 of the first heat-expanding layer 12 and the heat-expandable microcapsule MC1 are used. The thermal expansion material MC3 of the third thermal expansion layer 26 uses a material different from the thermal expansion material MC1 of the first thermal expansion layer 12 and the thermal expansion material MC2 of the second thermal expansion layer 15. May use the same material as either or both. It is preferable to use the same material as the first thermal expansion layer 12 and / or the second thermal expansion layer 13 as the third thermal expansion layer 26 because the raw materials are shared. Similarly, the binder B3 may be different from the binder B1 and the binder B2, but it is preferable to use the same material as either or both.

Further, in the third thermal expansion layer 26, the ratio of the thermal expansion material MC3 to the binder B3 is such that the thermal expansion material MC2 is contained in the binder B2 in the second thermal expansion layer 13. Low compared to the percentage. Similar to the first embodiment, the ratio of the heat-expandable material MC3 to the binder B3 is defined by using a volume ratio, a weight ratio, and the like. For example, when the weight ratio is used, the weight ratio of the heat-expandable material MC3 to the binder B3 is smaller than the weight ratio of the heat-expandable material MC2 to the binder B2, specifically, 1/3 to 1/8. Degree. In other words, assuming that the MC3 dispersed with respect to 100 parts by weight of the binder B3 is X3 parts by weight and the MC2 dispersed with respect to 100 parts by weight of the binder B2 is X2 parts by weight, X3 / X2 is 1 It is smaller, about 1/3 to 1/8. The ratio of the thermally expandable material to the binder may be defined by the density. In this case, the third thermal expansion layer 26 has a lower density than the second thermal expansion layer 13. Therefore, it can be said that it contains a heat-expandable material.

The third thermal expansion layer 26 has a lower coefficient of thermal expansion material than the second thermal expansion layer 13, and it is difficult to obtain a height when expanded. Therefore, the second thermal expansion layer 26 has a second thermal expansion. It is preferably formed thinner than the layer 13. Further, the third thermal expansion layer 26 is preferably not formed thicker than necessary, and has a thickness corresponding to several thermal expansion materials MC3, for example, a thickness of 1 to 10, preferably 1 to 5. It is preferably formed in. In other words, it is preferably formed to have a thickness of 1 to 10 times, preferably 1 to 5 times, the average particle size of the microcapsules.

Next, a method of manufacturing the heat-expandable sheet 20 according to the second embodiment will be described.
First, the base material 11 is prepared, and the first thermal expansion layer 12 and the second thermal expansion layer 13 are formed on the base material 11 in the same manner as in the first embodiment.

Next, a coating liquid for forming the third thermal expansion layer 26 is prepared. The heat-expandable material is dispersed in the binder using a known dispersion device or the like to prepare a coating liquid for forming the third heat-expandable layer 26. As the binder and the heat-expandable material, it is preferable to use the same material as the coating liquid for forming the second heat-expandable layer 13. At this time, the content of the heat-expandable material with respect to the binder is lower than the content of the heat-expandable material with respect to the binder in the second heat-expandable layer 13. For example, the weight ratio is about 1/3 to 1/8. Subsequently, the coating liquid is applied onto the base material using a known coating device such as a bar coater, a roller coater, or a spray coater to form a coating film. The coating is then dried. The coating and drying may be performed in a plurality of times, and a third thermal expansion layer 26 having a target thickness is formed on the second thermal expansion layer 13.

Subsequently, the ink receiving layer 14 is formed on the third thermal expansion layer 26 in the same manner as in the first embodiment, and cutting or the like is performed as necessary.
As a result, the heat-expandable sheet 20 of the second embodiment is manufactured.

According to the method for producing a heat-expandable sheet and a heat-expandable sheet of the present embodiment, a heat-expandable material is further placed on the second heat-expandable layer 13 at a content rate lower than that of the second heat-expandable layer 13. By forming the third thermal expansion layer 26 including the thermal expansion layer 26, the occurrence of irregularities on the surface of the thermal expansion sheet when the thermal expansion layer is expanded is alleviated, and the surface of the thermal expansion sheet is satisfactorily smoothed. , It is possible to have good scratch resistance.

For example, as a comparative example, FIG. 7A schematically shows the sheet surface when a heat-expandable sheet having a configuration without a third thermal expansion layer is expanded. In this configuration, as shown in FIG. 7A, the microcapsules aggregate on the surface of the thermal expansion layer, and unevenness of the step d1 is generated on the surface. As shown in the figure, the microcapsules located on the surface of the thermal expansion layer are easily peeled off and have poor scratch resistance. On the other hand, in the heat-expandable sheet shown in FIG. 7B having the same configuration as that of the present embodiment, the step d2 generated on the surface of the third heat-expandable layer is suppressed to be smaller than the step d1. Since the third thermal expansion layer expands not only in the upward direction but also in the downward direction, it is possible to fill the unevenness generated in the second thermal expansion layer by the expansion of the third thermal expansion layer. Further, since the amount of microcapsules contained in the third thermal expansion layer is small, aggregation of macrocapsules on the surface of the third thermal expansion layer can be suppressed. In addition, since the third thermal expansion layer 26 of the present embodiment contains a thermal expansion material, the third thermal expansion layer itself also expands, which has the effect of contributing to an increase in the height of the entire thermal expansion layer. There is also. Further, the ink receiving layer 14 is a layer for receiving and fixing ink on the surface of the heat-expandable sheet 20, and by providing this layer on the third heat-expandable layer 26, the heat-expandable sheet 20 The surface of the ink is smoothed even better, and the scratch resistance is also improved.

(Embodiment 3)
The heat-expandable sheet 30 according to the third embodiment will be described with reference to the drawings. The difference between the heat-expandable sheet 30 according to the third embodiment and the heat-expandable sheet 10 or 20 of the above-described embodiment is that the heat-expandable sheet 30 includes a third heat-expandable layer 36 as shown in FIG. The layer 36 is at a point containing the white pigment W. In the present embodiment, the first thermal expansion layer 12, the second thermal expansion layer 13, and the third thermal expansion layer 36 form the thermal expansion layer. The parts having the same configuration as those of the other embodiments are numbered the same, and detailed description thereof will be omitted.

As shown in FIG. 8, the heat-expandable sheet 30 according to the third embodiment includes a base material 11, a first heat-expansion layer 12, a second heat-expansion layer 13, an ink receiving layer 14, and a third. The thermal expansion layer 36 of the above is provided. Further, the first thermal expansion layer 12, the second thermal expansion layer 13, and the third thermal expansion layer 36 form the thermal expansion layer of the thermal expansion sheet 20. Further, in the present embodiment, the ink receiving layer 14 is formed on the third thermal expansion layer 36 provided on the second thermal expansion layer 13.

The third thermal expansion layer 36 is formed on the second thermal expansion layer 13 provided on one surface of the base material 11. In the third thermal expansion layer 36, the thermal expansion material MC3 (thermally expandable microcapsules) is dispersedly arranged in the binder B3 as in the second embodiment. The third thermal expansion layer 36 is characterized in that it further contains the white pigment W. As the white pigment W, a material selected from titanium oxide, barium sulfate, zinc oxide and the like can be used, and titanium oxide is particularly preferable. Further, the content of the heat-expandable material MC3 with respect to the binder B3 is set lower than the content of the heat-expandable material MC2 with respect to the binder B2 in the second heat-expandable layer 13, as in the second embodiment. ..

Further, in the present embodiment, when a white material such as porous silica is used as the ink receiving layer 14, the whiteness of the ink receiving layer 14 is also improved. Therefore, the ink receiving layer 14 also improves the whiteness of the surface of the heat-expandable sheet 30, which is preferable.

In the heat-expandable sheet 30 of the present embodiment, the whiteness of the surface of the heat-expandable sheet can be increased by further containing the white pigment in the second heat-expandable layer, and the collar provided on the heat-expandable sheet. The color appearance of the ink can be improved.

Next, a method of manufacturing the heat-expandable sheet 30 of the third embodiment will be described.
Similar to the first embodiment, the base material 11 is prepared, and the first thermal expansion layer 12 and the first thermal expansion layer 13 are formed on the base material 11.

Next, the thermal expansion material and the white pigment are dispersed in the binder using a known dispersion device to prepare a coating liquid for forming the third thermal expansion layer. At this time, in the coating liquid, the weight of the heat-expandable material mixed with the binder is 1/3 to 1/3 as compared with the coating liquid for forming the second thermal expansion layer as in the second embodiment. The amount should be about / 8. Subsequently, a coating liquid is applied onto the substrate using a known coating device such as a bar coater, a roller coater, or a spray coater to form a coating film. The coating is then dried. In order to form the third thermal expansion layer 36 of the target thickness, the coating and drying may be performed in a plurality of times.

Subsequently, the ink receiving layer 14 is formed in the same manner as in the first embodiment, and cutting is performed if necessary.
As a result, the heat-expandable sheet 30 according to the third embodiment is manufactured.

In the heat-expandable sheet of the present embodiment, the whiteness of the heat-expandable layer can be improved by further containing the white pigment in the third heat-expandable layer 36, and the color ink provided on the heat-expandable sheet 30 can be improved. It is possible to improve the appearance of the color of. Further, when the ink receiving layer 14 is formed by using a white material such as porous silica, the whiteness of the heat-expandable sheet 30 is also improved by the ink receiving layer 14, which is preferable. In addition, in the present embodiment, the white pigment W is contained in the third thermal expansion layer 36 instead of the first expansion layer 12, the second expansion layer 13, and the ink receiving layer 14. Therefore, it is not necessary to mix the white pigment in the first expansion layer 12 and the second expansion layer 13, and it is possible to avoid reducing the expandable height of the first expansion layer 12 and the second expansion layer 13. Be done. Further, since the white pigment is not mixed in the ink receiving layer 14, it also has an excellent effect that it is possible to avoid lowering the performance of the ink receiving layer 14 for receiving ink.

The present invention is not limited to the above-described embodiment, and various modifications and applications are possible.
For example, the above-described embodiments can be combined as appropriate.

Further, in the above-described embodiment, the configuration in which printing is performed in the process shown in FIG. 4 has been described as an example, but the present invention is not limited to this. For example, the order in which the processes are performed can be changed as appropriate. For example, it is also possible to form a photothermal conversion layer on both surfaces of the base material, form a color ink layer, and then irradiate light from the front side and the back side of the base material to expand the heat expansion layer.

Further, in each of the above-described embodiments, the configuration in which the photothermal conversion layer is formed on both the front surface and the back surface has been described as an example, but the present invention is not limited to this. Depending on the intended use and printing method of the printed matter, the photothermal conversion layer may be formed only on the front surface or only the back surface. When printing is performed only on the surface, the ink receiving layer may be formed at least on the surface.

Further, an adhesive and a release paper may be provided on the back surface of the base material depending on the intended use of the printed matter, for example, when used as a sticker. In this case, a layer made of an adhesive is formed on the back surface of the base material, and a release paper is provided on the layer. The ink receiving layer may be provided on the release paper.

Although some embodiments of the present invention have been described, the present invention is included in the scope of claims and the equivalent scope thereof. The inventions described in the claims of the original application of the present application are described below.

[Appendix 1]
A first thermal expansion layer formed on one surface of the substrate and containing the first thermal expansion material in a first ratio with respect to the binder.
A second thermal expansion layer formed on the first thermal expansion layer and containing a second thermal expansion material in a second ratio with respect to the binder is provided.
The first ratio is smaller than the second ratio.
A heat-expandable sheet characterized by that.
[Appendix 2]
The thickness of the first thermal expansion layer is formed thinner than the thickness of the second thermal expansion layer.
The heat-expandable sheet according to Appendix 1, wherein the sheet is characterized by the above.
[Appendix 3]
The first heat-expandable material and the second heat-expandable material are the same material.
The heat-expandable sheet according to Appendix 1 or 2, characterized in that.
[Appendix 4]
The first heat-expandable material and the second heat-expandable material are microcapsules containing a vaporizable substance in a shell.
The thickness of the first thermal expansion layer is a thickness corresponding to several microcapsules.
The heat-expandable sheet according to any one of Supplementary note 1 to 3, wherein the heat-expandable sheet is characterized by the above.
[Appendix 5]
A third thermal expansion layer provided on the second thermal expansion layer and containing a third thermal expansion material in a third ratio with respect to the binder is further provided.
The third ratio is smaller than the second ratio.
The heat-expandable sheet according to any one of Supplementary Provisions 1 to 4, wherein the heat-expandable sheet is described.
[Appendix 6]
The third thermal expansion layer further contains a white pigment.
The heat-expandable sheet according to Appendix 5, characterized in that.
[Appendix 7]
An ink receiving layer that receives ink is further provided on the third thermal expansion layer.
The heat-expandable sheet according to Appendix 5 or 6, characterized in that.
[Appendix 8]
A step of forming a first thermal expansion layer containing the first thermal expansion material at a ratio of a first ratio to a binder on one surface of the base material.
A step of forming a second thermal expansion layer containing the second thermal expansion material in a second ratio with respect to the binder is provided on the first thermal expansion layer.
The first ratio is made smaller than the second ratio.
A method for producing a heat-expandable sheet.
[Appendix 9]
The thickness of the first thermal expansion layer is formed thinner than the thickness of the second thermal expansion layer.
The method for producing a heat-expandable sheet according to Appendix 8, wherein the heat-expandable sheet is produced.
[Appendix 10]
The first heat-expandable material and the second heat-expandable material are the same material.
The method for producing a heat-expandable sheet according to Appendix 8 or 9, wherein the heat-expandable sheet is produced.
[Appendix 11]
The first heat-expandable material and the second heat-expandable material are microcapsules containing a vaporizable substance in a shell.
The thickness of the first thermal expansion layer is set to a thickness corresponding to several microcapsules.
The method for producing a heat-expandable sheet according to any one of Appendix 8 to 10, wherein the heat-expandable sheet is produced.
[Appendix 12]
A step of forming a third thermal expansion layer containing the third thermal expansion material in a third ratio with respect to the binder is further provided on the second thermal expansion layer.
The third ratio is made smaller than the second ratio.
The method for producing a heat-expandable sheet according to any one of Appendix 8 to 11, wherein the heat-expandable sheet is produced.

The present invention can be used in a method for producing a heat-expandable sheet and a heat-expandable sheet that expands according to the amount of heat absorbed.

10, 20, 30 ... Thermal expansion sheet, 11 ... Substrate, 12 ... First thermal expansion layer, 13 ... Second thermal expansion layer, 14 ... Ink receiving layer, 26, 36 ... 3rd thermal expansion layer, 41 ... front side photothermal conversion layer, 42 ... color ink layer, 43 ... back side photothermal conversion layer, 50 ... stereoscopic image forming system, 51.・ ・ Control unit, 52 ・ ・ ・ Printing unit, 52a, 53a ・ ・ ・ Import part, 52b, 53b ・ ・ ・ Discharge part, 53 ・ ・ ・ Expansion unit, 54 ・ ・ ・ Display unit, 55 ・ ・ ・ Top plate , 60 ... frame, 61 ... side plate, 62 ... connecting beam, B1, B2, B3 ... binder, MC1, MC2, MC3 ... thermally expandable material

Claims (10)

The first step of preparing a medium in which a thermal expansion layer that expands by heating is formed on a base material, and
By partially applying heat at a temperature at which the thermal expansion layer can expand to the medium, the surface of the medium corresponding to the heated portion is raised by the expansion of the thermal expansion layer, and the medium is subjected to. The second step of forming irregularities on the surface and
A third step of forming a photothermal conversion layer that converts light into heat on the medium prior to the second step,
Have,
In the second step, the photothermal conversion layer formed on the medium is irradiated with light to expand the thermal expansion layer.
The thermal expansion layer is
A first layer formed on the substrate and containing the first thermally expandable material in a first ratio with respect to the binder.
A second layer formed on the first layer and containing a second thermally expandable material in a second ratio with respect to the binder.
With
By setting the first ratio to be smaller than the second ratio, the first layer is derived from the base material of the thermal expansion layer when the unevenness is formed in the second step. It is formed as a peeling suppression layer for suppressing peeling.
A method for manufacturing a modeled object, which is characterized in that. The first heat-expandable material and the second heat-expandable material are microcapsules containing a vaporizable substance in a shell.
The method for manufacturing a modeled object according to claim 1 . The first heat-expandable material and the second heat-expandable material have the same expansion principle at the time of thermal expansion.
The method for manufacturing a modeled object according to claim 1 or 2 , wherein the modeled object is manufactured. A thermal expansion layer provided on one surface of the base material and containing a thermal expansion material in a predetermined ratio with respect to the binder.
It is provided on the thermal expansion layer so as to expose a part of the thermal expansion layer, and when a predetermined light is irradiated, the irradiated light is converted into heat to partially expand the thermal expansion layer. The photothermal conversion layer and
With
The thermal expansion layer is set to a first ratio in which the ratio is smaller than the second ratio between the second thermal expansion layer in which the ratio is set to the second ratio and the base material. It is provided in multiple layers so that the first thermal expansion layer is interposed and the second thermal expansion layer is interposed between the first thermal expansion layer and the photothermal conversion layer. Yes,
A heat-expandable sheet characterized by that. A thermal expansion layer provided on one surface of the base material and containing a thermal expansion material in a predetermined ratio with respect to the binder.
It is provided on the other surface so as to expose a part of the other surface of the base material, and when a predetermined light is irradiated, the irradiated light is converted into heat to form a portion of the thermal expansion layer. With a photothermal conversion layer that expands
With
The thermal expansion layer is set to a first ratio in which the ratio is smaller than the second ratio between the second thermal expansion layer in which the ratio is set to the second ratio and the base material. It is formed in multiple layers so that the first thermal expansion layer is interposed.
A heat-expandable sheet characterized by that. The first thermal expansion layer is located at the lowest layer among the thermal expansion layers formed in the multilayer.
The heat-expandable sheet according to claim 4 or 5 . The second thermal expansion layer is located in the layer directly above the lowest layer among the thermal expansion layers formed in the multilayer.
The heat-expandable sheet according to claim 6 . The thickness of the first thermal expansion layer is thinner than the thickness of the second thermal expansion layer.
The heat-expandable sheet according to any one of claims 4 to 7 , characterized in that. The heat-expandable material is a microcapsule containing a vaporizable substance in the shell.
The heat-expandable sheet according to any one of claims 4 to 8 , characterized in that. The first thermal expansion layer is formed as a peeling suppression layer for suppressing peeling of the thermal expansion layer from the base material when the thermal expansion layer expands.
The heat-expandable sheet according to any one of claims 4 to 9 , characterized in that.

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