JPH01180340A - Preparation of decorative sheet - Google Patents

Abstract

PURPOSE:To flatten the buildup part formed to the peripheral part of a depressed part, by forming a depressed pattern to the surface of a thermoplastic resin sheet by embossing and applying hot pressing treatment to the entire embossed surface of said sheet by a flat embossing plate. CONSTITUTION:A printing pattern layer 2 is formed to either one of a colored thermoplastic resin sheet 3 and a transparent - translucent thermoplastic resin sheet 4. Simultaneously with or after the lamination of the aforementioned both sheets in a sandwich state, a depressed pattern 6 is formed on the surface of the transparent - translucent thermoplastic resin sheet 4. The depressed parts of the depressed pattern 6 on the surface of the obtained laminated sheet are filled with color ink 7 and hot pressing treatment by a flat embossing plate is applied to the embossed surface off the laminated sheet so as not to collapse the depressed pattern 6 of the laminated sheet. The colored thermoplastic resin sheet 3 or transparent - translucent thermoplastic resin sheet 4 is pref. composed, for example, of a plasticizer-containing polyvinyl chloride resin sheet.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention mainly relates to a method for manufacturing decorative sheets used for surface finishing of various building materials and furniture, etc. The present invention provides a method for obtaining a high-quality decorative sheet with a printed pattern that closely resembles the actual product.

[Conventional technology]

Various attempts have been made to make decorative sheets with patterns such as wood grain or stone grain as close to the real thing as possible.
For example, a method for manufacturing a decorative sheet using a combination of a printed pattern and a recessed pattern includes: 1) forming a printed pattern layer with a wood grain pattern on a colored thermoplastic resin sheet, and then providing a top film layer on the printed surface; , furthermore, a method for obtaining a decorative sheet by partially forming recesses on the surface of the top film layer, 2) forming a printed pattern layer with a wood grain pattern on a colored thermoplastic resin sheet, and then applying a top film on the printed surface. A decorative sheet is formed by forming a layer on the top film layer surface using a valley printing method using a conduit embossing plate with ink attached to the convex portions, and forming concave portions in which conduit ink is adhered to the concave portions. 3) A colored thermoplastic resin sheet is embossed to form a concave portion corresponding to a wood grain conduit, and then paint or ink is applied to the entire surface of the colored thermoplastic resin sheet other than the concave portion. A base coat layer is formed using the composition, and then a wood grain pattern printing layer is formed on the base foot layer surface, and a top coat layer consisting of a transparent resin layer is further formed on the entire printed surface of the base coat layer. Method for obtaining a sheet, 4) After forming a printed pattern layer on a colored thermoplastic resin sheet, laminating a transparent to translucent thermoplastic resin sheet on the printed surface of the colored thermoplastic resin sheet having the printed pattern layer, and , forming a concave pattern by embossing on the surface of the transparent to translucent thermoplastic resin sheet to form a laminated sheet having a concave pattern by embossing on the surface, and further, on the obtained laminated sheet, There is a method of obtaining a decorative sheet by filling colored ink into the concave portions of the concave pattern in the laminated sheet.

[Problem that the invention seeks to solve]

Accordingly, in the method of item 1) of the conventional decorative sheet manufacturing method, the position of the conduit portion of the wood grain pattern in the obtained decorative sheet and the position of the recessed portion partially formed on the surface of the top film layer are The disadvantage is that they do not match, and it is not possible to obtain an image that approximates the real thing.

Furthermore, in the method of item 2), the position of the woodgrain-patterned conduit portion in the decorative sheet obtained does not match the position of the recessed portion partially formed on the top film layer surface.
The disadvantage is that it is not possible to obtain an image that approximates the real thing.

Furthermore, in the method described in item 3), the paste coat layer in the resulting decorative sheet is formed as a completely opaque layer, so it has no transparency compared to the actual material, and moreover, it is similar to the conduit of wood grain. Since the concave portion is completely removed, it has the disadvantage that it is impossible to avoid the monotonous situation in which the underlying layer is seen through the core portion.

Furthermore, all of the decorative sheets obtained by the above-described decorative sheet manufacturing method have recesses formed on the surface of the synthetic resin layer, so as shown by the symbol m in FIG. Since the peripheral area of the recess is slightly raised, the unnaturalness caused by the uneven reflection of light rays caused by this raised part is a factor that impairs the high-quality paint feel. O On the other hand, in the decorative sheet obtained by the method for manufacturing a decorative sheet of the present invention, the recessed portion formed on the surface of the synthetic resin layer does not have a raised portion around the recessed portion. Therefore, the present invention can provide a method for obtaining a decorative sheet that is similar to the actual product and is coated with a high-grade coating of good quality.

[Means for solving problems]

The method for producing a decorative sheet of the present invention includes a first step of forming a printed pattern layer on either a colored thermoplastic resin sheet or a transparent to translucent thermoplastic resin sheet; While sandwiching a thermoplastic resin sheet and a transparent to translucent thermoplastic resin sheet, both sheets are laminated, and at the same time, a concave pattern is formed by embossing on the surface of the transparent to translucent thermoplastic resin sheet. Alternatively, after laminating both sheets in a state in which the printed pattern layer is sandwiched between the colored thermoplastic resin sheet and the transparent to translucent thermoplastic resin sheet, the transparent to semitransparent thermoplastic resin a second step of forming a concave pattern by embossing on the surface of the sheet to obtain a laminated sheet having a concave pattern by embossing on the surface; Filling the concave portions of the concave pattern on the surface of the sheet with colored ink, and also applying heat and pressure treatment to the surface of the laminated sheet using a flat embossing plate to an extent that does not crush the concave portions of the concave pattern in the laminated sheet. This process consists of a step of performing the process as a first step, and a third step of performing the process.

The colored thermoplastic resin sheet and the transparent to translucent thermoplastic resin sheet used in the first step in the method for manufacturing a decorative sheet of the present invention having the above-mentioned structure are, for example, cellophane or acetate.

Polyethylene, polypropylene, polyester, polyvinyl chloride, polyvinylidene chloride.

A thermoplastic resin sheet with a thickness of about 50 to 500 μm made of polystyrene, polycarbonate, polyvinyl alcohol, polyamide, etc., especially tributyl phosphate, triphenyl phosphate, dimethyl phthalate, diethyl phthalate, dibutyl phthalate, octyl phthalate. , butyl adipate, n-hexyl adipate, dibutyl sebacate,
A polyvinyl chloride resin sheet containing a plasticizer such as chlorinated diphenyl is preferred.

In addition, when the printed pattern layer has a wood grain pattern, the coloring on the colored resin sheet is applied to a tone that approximates the bright part of the wood surface, and when the printed pattern layer is a stone pattern, the color tone is similar to the bright part of the stone surface. It is preferable that the thermoplastic resin sheet is colored in a tone similar to that of the transparent to translucent thermoplastic resin sheet.
It may be colorless or colored.

The printed pattern layer formed on either the colored thermoplastic resin sheet or the transparent to translucent thermoplastic resin sheet can be formed by gravure printing, flexographic printing, silk printing, etc. using a plate usually called a blur plate. It is formed using printing means.

The ink used to form this printed pattern layer is a known one, for example, a vehicle, a coloring agent such as a dye or a pigment, etc.
Adding extender pigments and further melding, plasticizers, stabilizers,
Known additives such as wax, grease, desiccant, auxiliary desiccant, curing agent, thickener, dispersant, filler, etc. are optionally added, and this is thoroughly kneaded with a solvent, diluent, etc. This is a printing ink that utilizes an ink composition.

The vehicle in the ink composition includes, for example, various oils and fats such as linseed oil, soybean oil, and synthetic drying oil, natural resins and processed resins such as rosin, copal dammar, hardened gin, gin ester, and polymerized rosin. Synthetic resins such as rosin-modified phenolic resins, 100% phenolic resins, maleic acid resins, alkyd resins, petroleum resins, vinyl resins, acrylic resins, polyamide resins, epoxy resins, amino alkyd resins, nitrocellulose , cellulose derivatives such as ethyl cellulose, chlorinated rubber, cyclized rubber derivatives, and other known vehicles comprising a solid binder such as glue, casein, dextrin, zein, etc., and a solvent are used.

In addition, when the printed pattern layer has a wood grain pattern,
Of course, in the case of a stone grain pattern, the pattern and color tone are similar to the surface of the wood, and the pattern and color tone are similar to the ground color of the stone.

The second step in the method for producing a decorative sheet of the present invention comprises using the colored thermoplastic resin sheet obtained in the first step and transparent to
Using a translucent thermoplastic resin sheet and both sheets, one of which has a printed pattern layer formed on it,
The printed pattern layer is sandwiched between the colored thermoplastic resin sheet and the transparent to translucent thermoplastic resin sheet, and at the same time, the printed pattern layer is laminated, and at the same time, the surface of the transparent to semitransparent thermoplastic resin sheet is embossed. Alternatively, after the printed pattern layer is sandwiched between the colored thermoplastic resin sheet and the transparent to semi-transparent thermoplastic resin sheet, the printed pattern layer is laminated with the colored thermoplastic resin sheet and the transparent to semi-transparent thermoplastic resin sheet. A laminated sheet having an embossed concave pattern on the surface is obtained by forming an embossed concave pattern on the surface of a transparent thermoplastic resin sheet.

Note that at the same time as laminating both of the former sheets, the transparent ~
A method of forming a concave pattern by embossing on the surface of a translucent thermoplastic resin sheet to obtain a laminated sheet having a concave pattern by embossing on the surface is achieved by doubling embossing in the lamination process,
When the colored thermoplastic resin sheet and the transparent to translucent thermoplastic resin sheet are polyvinyl chloride resin sheets, the method of applying doubling embossing in this lamination process can be carried out stably. The two steps can be carried out efficiently.

In addition, the embossing plate used when forming the concave pattern on the surface of the transparent to translucent thermoplastic resin sheet in the second step includes, for example, the unevenness of the surface of the wood or the cracks of the stone. An embossed plate is made by copying the condition, etc. on the unevenness of the surface by electroforming and forming these unevenness, or photolithography is used to transfer the condition, etc. on the unevenness of the surface of the wood, including the cracks of the stone. This is an embossed plate that uses an original plate that has been copied using the photo-etching method, and has an uneven state formed using the photo-etching method.

Furthermore, the third step of the method of the present invention includes a step of filling colored ink into the concave portions of the concave pattern in the laminated sheet obtained in the second step, and also filling the surface of the laminated sheet with colored ink. and a step of performing heat pressure treatment using a flat embossing plate to an extent that does not crush the concave shape of the concave pattern in the laminated sheet, and a step of filling the colored ink and a heat pressure treatment using the flat embossing plate. Although either step may be carried out first, it is generally preferable to carry out the hot-pressure treatment step using a flat embossing plate after the colored ink filling step.

The colored ink to be filled into the concave portions of the concave pattern in the laminated sheet is a paint or ink that uses pigments or dyes as a coloring agent, such as natural resins such as shellac, copal, tantalum, rosin, and rosin ester, or natural resins such as shellac, copal, tanmal, rosin, and rosin ester. Modified resins, cellulose derivatives such as nitrocellulose, acetylcellulose, ethylcellulose, benzylcellulose, phenolic resins, urea resins, phthalic acid resins, maleic resins, melamine resins, polyvinyl acetate resins, polychloride Synthetic resins such as vinyl resins, acrylic resins, polyvinyl alcohol, polyvinyl butyral, epoxy resins, silicone resins, polyester resins, polyamide resins, polyurethane resins, and others; other chlorinated rubbers, cyclized rubbers, and synthetic rubbers. A paint or ink obtained by using a rubber derivative or the like as a vehicle material and adding a colorant, an extender pigment such as precipitated barium sulfate, a plasticizer, etc. to the vehicle is used. In addition, when using a colored ink whose vehicle material is a curable resin such as phenol resin, urea resin, melamine resin, epoxy resin, polyester resin, or polyurethane resin among the resins mentioned above, A colored filled layer having extremely excellent properties such as abrasion resistance and solvent resistance can be obtained in the concave portions of the concave pattern. Furthermore, when a colored filled layer is formed by mixing an ultraviolet curing agent or the like into the paint or ink and using an ultraviolet curing system, the quality of the obtained colored filled layer is stabilized and production efficiency is improved. can be measured.

A specific method for filling the concave portions of the concave pattern with colored ink is, for example, by coating the surface of the laminated sheet with a roll foot or knife coat, and then scraping it off with a doctor blade or wiping paper to fill the convex portions of the laminated sheet with colored ink. It is preferable to remove the coated colored ink and fill it so that the colored ink remains only in the recessed portions.In this step, the coloring used is adjusted so that the colored ink remains only in the recessed portions of the surface of the laminated sheet. It is necessary to adjust the ink viscosity, roll rotation speed, doctor angle, thickness, sheet speed, wiping paper speed, rubber roll hardness, etc. Also, fill in the concave parts of the concave pattern on the surface of the laminated sheet. If the printed pattern formed in the first step is, for example, a wood grain pattern, the colored ink is applied to a color tone that approximates the conduit part of the wood grain, and if it is a stone grain pattern, the colored ink is applied to a color that approximates the cracks of the stone grain. It goes without saying that the color tone has been adjusted to suit the desired color tone.

Further, a matting agent such as calcium carbonate, precipitated barium carbonate, silica, talc, clay, shirasu paroon, etc. may be added to the coloring ink or ink as desired.

Further, the flat embossing plate used in the third step of the method of the present invention has a surface roughness of about 0.5 to 20 μm.

In addition, in this third step, when performing the heat-pressure treatment step using a 7-rat embossing plate after the colored ink filling step, the recessed pattern of the laminated sheet is formed between these two steps. A step of forming a top coat layer made of a transparent to semi-transparent curable resin layer can be provided on the entire surface of the curable resin. The curing treatment is preferably performed after the heat-pressure treatment step using the flat embossing plate, but it can also be performed before the heat treatment step. Also,
After performing the third step of filling colored ink into the concave portions of the concave pattern on the surface of the laminated sheet, the surface of the laminated sheet is filled with a coloring ink to an extent that does not crush the concave portions of the concave pattern on the surface of the laminated sheet. When carrying out a process of heat-pressure treatment using a flat embossing plate, a top coat layer consisting of a transparent to semi-transparent curable resin layer is optionally applied to the treated surface after the heat-pressure treatment. It goes without saying that a forming process can be provided.

Furthermore, in the third step, if the colored ink filling step is performed after the heat-pressure treatment using the flat embossing plate, the top layer consisting of the curable resin layer is A coating step for the coating layer can be provided, and the curing treatment is preferably carried out after the colored ink filling step, but before the heat pressure treatment with the flat embossing plate, or after the heat pressure treatment with the flat embossing plate and the colored ink. It can also be carried out during the filling process.

Furthermore, the top coat layer consisting of a transparent to semi-transparent curable resin layer formed as necessary may be formed by applying a coating agent such as polyvinyl chloride resin, acrylic resin, epoxy resin, etc. using gravure foot or roll coating. , Knife Coat It is easily formed by coating with an air knife coat, etc., and provides the resulting decorative sheet with excellent properties such as abrasion resistance and chemical resistance. The top foot layer may be a matte top coat obtained by adding a matting agent such as calcium carbonate, precipitated barium carbonate, silica, talc, clay, or shirasu balloon to the curable resin. It can also be made into layers.

〔Example〕

Hereinafter, the specific structure of the method for manufacturing a decorative sheet of the present invention will be explained based on Examples.

Example 1 A colored opaque polyvinyl chloride sheet, which is colored in a yellowish brownish color that approximates the lightest color of the wood surface of whole nut wood, was printed using a gravure printing method to match the slightly darker color of the wood surface. A similar blackish brown wood grain pattern layer,
Printing was performed using a blurred plate (line count 150/inch, plate depth approximately 25 μm).

Printing conditions = (a) Printing pressure Linear pressure 1 or less, (b) Hardness of center roll 80 degrees Ink used: Vinyl chloride resin gravure ink Next, a colored opaque polyvinyl chloride sheet having the above-mentioned wood grain pattern layer and , a transparent polyvinyl chloride sheet is stacked on top of the other with the wood grain pattern layer on the inside, and at the same time, a walnut wood board is placed on the transparent polyvinyl chloride sheet. Doubling embossing with an embossing plate (temperature 150℃ linear pressure 1t1 speed Low) /win
, ) to obtain a laminated sheet having a concave pattern corresponding to a conduit formed on its surface.

Furthermore, the entire surface of the laminated sheet in which the concave pattern is formed is coated with a black wiping ink similar to the color tone of the conduit portion of the painted walnut material using a roll coating method, and then the concave pattern is formed. Removes wiping ink that adheres to the convex parts of the pattern other than the concave parts.
Almost complete removal was achieved by using both a doctor blade and wiping paper.

The wiping ink used in the above step was an ultraviolet curing type acrylic paint with a viscosity of 5000 cps and a matting agent and carbon added thereto.

Further, the thickness of the doctor blade used to remove the adhered ink from unnecessary portions was approximately 3su+, and the angle between the doctor blade and the sheet was maintained at 90 degrees.

After that, the wiping ink filled in the concave portions of the concave pattern of the laminated sheet is cured, and further,
A urethane-based ultraviolet curing type coating material (viscosity 2500 cps) was applied to the surface by reverse roll coating to form a coating layer with a thickness of about 10 μm.

Subsequently, the surface of the coating layer was subjected to heat-pressure treatment using a flat embossing plate with a surface roughness of 5 μm at a roll temperature of 150°C.
A decorative sheet having a laminated structure indicated by reference numeral 1 in FIG. I got it.

The decorative sheet 1 has a laminated structure of a colored opaque polyvinyl chloride sheet layer 3 having a printed pattern layer 2, a transparent polyvinyl chloride sheet layer 4, and a top foot layer 5 made of a urethane resin layer. There is a concave pattern 6.6.6 on the surface of the transparent polyvinyl chloride sheet layer 40.・
... is formed, and the recessed pattern 6,6°6,
Filling layers 7, 7, 7, . . . . is formed, and the top coat layer 5 made of the above-mentioned urethane resin layer
are filled layers 7.7, 7. with the colored ink.・・・・・・
... in the concave portion 6.6, 6.・・・・・・
. . , are formed on the entire surface of the transparent polyvinyl chloride sheet layer 40, and furthermore, on the entire surface of the top coat layer 5, a group of fine irregularities 8° 8.8. It has...

Example 2 A laminated sheet in which a concave pattern corresponding to a conduit is formed on the surface by a doubling embossing method using an embossing plate having an embossing pattern corresponding to the concave part of a conduit formed by an etching method from the surface of a walnut board. was obtained by the same procedure as the laminated sheet in which a concave pattern corresponding to the conduit in Example 1 was formed on the surface.

Next, a two-component wiping ink made of urethane resin is applied to the entire surface of the laminated sheet on which the concave pattern is formed, using a knife foot method, and then the concave pattern is removed using a doctor blade. The ink adhering to the convex parts other than the parts was removed, and then a coating agent made of two-component curable urethane resin was applied to the entire surface using the gravure coating method to form a coating layer with a thickness of about 10 μm. Formed.

Further, the surface of the coating layer was subjected to heat-pressure treatment under the same conditions as the heat-pressure treatment using the flat embossing plate in Example 1 to obtain a decorative sheet, which is the object product of the present invention.

[Action and effect of the invention]

The method for producing a decorative sheet of the present invention includes a first step of forming a printed pattern layer on either a colored thermoplastic resin sheet or a transparent to translucent thermoplastic resin sheet; While sandwiching a thermoplastic resin sheet and a transparent to translucent thermoplastic resin sheet, both sheets are laminated, and at the same time, a concave pattern is formed by embossing on the surface of the transparent to translucent thermoplastic resin sheet. Alternatively, after laminating both sheets in a state in which the printed pattern layer is sandwiched between the colored thermoplastic resin sheet and the transparent to translucent thermoplastic resin sheet, the transparent to semitransparent thermoplastic resin A second step of forming an embossed concave pattern on the surface of the sheet to obtain a laminated sheet having an embossed concave pattern on the surface; In addition to the step of filling colored ink into the concave portions of the concave pattern, the surface of the laminated sheet is also subjected to heat-pressure treatment using a flat embossing plate to an extent that does not crush the concave portions of the concave pattern in the laminated sheet. and a third step of performing the steps.

In the method for manufacturing a decorative sheet of the present invention, after forming a concave pattern by embossing on the surface of a thermoplastic resin sheet, the entire surface having the concave pattern by embossing is subjected to heat pressure treatment using a flat embossing plate. The heat-pressure treatment using this flat embossing plate flattens the bulges around the concave portions. Therefore, in the decorative sheet manufacturing method of the present invention, the thermoplastic resin sheet is There is no unevenness in the reflection of light due to the raised areas around the concave pattern formed on the surface, and it has a high design characteristic that gives an appearance that closely resembles that of a high-grade painted board or natural stone. This has the effect of providing a decorative sheet.

[Brief explanation of the drawing]

FIG. 1 is a schematic cross-sectional view illustrating the laminated structure of a decorative sheet obtained in an example of the method of the present invention, and FIG. FIG. 2 is a schematic cross-sectional view illustrating the state of swelling around the periphery of the portion. 1: Decorative sheet, 2: Printed pattern layer, 3: Colored opaque polyvinyl chloride sheet layer, 4: Transparent polyvinyl chloride sheet layer, 5: Top foot layer consisting of urethane resin layer, 6
,6. : Concave pattern, 7, 7. : Filled layer with colored ink, 8°8, : Fine unevenness group. Patent applicant: Dai Nippon Printing Co., Ltd.

Claims (4)

[Claims] (1) After forming a printed pattern layer on either one of a colored thermoplastic resin sheet and a transparent to translucent thermoplastic resin sheet, the printed pattern layer is formed on either the colored thermoplastic resin sheet and a transparent to semitransparent At the same time, while sandwiching the sheets with a thermoplastic resin sheet, by forming a concave pattern by embossing on the surface of the transparent to semitransparent thermoplastic resin sheet, or by forming a concave pattern by embossing the printed pattern layer. After the colored thermoplastic resin sheet and the transparent to translucent thermoplastic resin sheet are sandwiched together and the two sheets are laminated, a concave pattern is embossed on the surface of the transparent to translucent thermoplastic resin sheet. By forming, a laminated sheet having a concave pattern by embossing is formed on the surface, and further, colored ink is applied to the concave portions of the concave pattern formed on the surface of the laminated sheet with respect to the obtained laminated sheet. and a step of subjecting the surface of the laminated sheet to heat-pressure treatment using a flat embossing plate to an extent that does not crush the concave shape of the concave pattern in the laminated sheet. A method for manufacturing decorative sheets. (2) The laminated sheet to be subjected to heat-pressure treatment using a flat embossing plate is a laminated sheet of a colored thermoplastic resin sheet having a printed pattern layer on either side and a transparent to translucent thermoplastic resin sheet; The transparent layer in the laminated sheet
a filled layer of colored ink filled in the concave portions of the concave pattern formed on the surface of the translucent thermoplastic resin sheet;
and a transparent to semitransparent curable resin layer formed on the entire surface of the transparent to semitransparent thermoplastic resin sheet on which the concave pattern is applied, the laminated sheet having the above structure. With respect to the curable resin layer surface in
The method for producing a decorative sheet according to claim 1, wherein the decorative sheet is subjected to heat-pressure treatment using a flat embossing plate. (3) The method for producing a decorative sheet according to claim 2, wherein the curable resin layer in the laminated sheet subjected to heat-pressure treatment using a flat embossing plate is a polyurethane resin layer. (4) Production of a decorative sheet according to claim 1, 2, or 3, wherein the colored ink filled in the concave portions of the concave pattern in the laminated sheet is an ink containing a matting agent. Method.