JPH0214175B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative material that has a smooth surface and has a three-dimensional effect and a complex and beautiful pattern.

Conventionally, in order to give a decorative material a three-dimensional effect, there is a method of chemically or mechanically creating embossing on the decorative material to give it an uneven pattern, but such decorative materials with embossed surfaces cannot be used for a long time. If you do so, dust will accumulate in the dented area, making it unsightly.

In addition, the surface of the pattern material is made of polyvinyl chloride (PVC).
A method is known in which a liquid material such as a paste is applied and heated to gel, but the viscosity of the paste usually increases over time and the production efficiency decreases. For this reason, the paste sol usually has to be used up within a certain period of time. When using a paste sol in this manner, viscosity control is required, and this viscosity control has complicated process control and has been an obstacle to improving production efficiency.

In addition, the paste resin undergoes large dimensional changes due to moisture absorption, and the difference in expansion and contraction with parts other than the paste resin layer is large, resulting in large warpage. Additionally, if PVC paste is applied as is, air bubbles will enter the resulting decorative material, so defoaming is required.

Furthermore, when using other liquid resins, such as reaction-curing resins such as polyester, polyurethane, and epoxy resins, a solvent is required to adjust the viscosity, which causes the molded decorative board to warp, which is not good for the working environment, and is expensive. Since various devices are required, the product price also increases and it is not economical.

The present invention relates to a manufacturing method that solves the above-mentioned problems and has a smooth surface and a three-dimensional effect. A method for producing a decorative material with a three-dimensional effect, characterized in that the transparent powder is filled into at least the concave portions of the patterned material, and then heated and pressed to form the surface into a smooth state. This is the summary.

1 to 3 are manufacturing process diagrams of the present invention, where 1 is a press table, 2 is a base material, and 3 is a pattern material. Base material 2 is polyolefin resin, PVC, polystyrene resin,
Any soft or hard synthetic resin can be used, such as urea-formaldehyde resin. The base material 2 is preferably colored darker than the pattern material 3, and its thickness is preferably 0.1 to 5 mm.

The pattern material 3 is a sheet having a three-dimensional design, and may be, for example, a lace fabric made of cloth, PVC, PP, etc., or a thin sheet with an appropriate embossed pattern, preferably having a thickness of 0.2 to 2 mm. The pattern material 3 may have any elaborate three-dimensional structural design obtained by a known method. The pattern material is
PVC resin, acrylic resin, ethylene-vinyl acetate copolymer, ABS resin, SBR resin, NBR resin, organic fiber or inorganic fiber material, etc. can be used.

4 is a colored layer formed on the pattern layer 3, and the colored layer may be arbitrarily colored on the surface of the pattern layer. Furthermore, the decorative effect can be further improved by using ink containing pigments such as gold powder, silver powder, other metal powder, pearl essence, etc. in the colored layer. Note that it is also possible in the present invention to color the bottoms of the recesses in the pattern layer (not shown) or to uniformly color the entire pattern layer.

Furthermore, methods for obtaining the patterned material of the present invention include a method in which a foamable layer is printed with an ink containing a foaming inhibitor and foamed by heating (chemical embossing), a method in which the ink is layered using a screen to create a bulge, and a method in which foaming ink is applied as appropriate. How to use: Apply adhesive to the base material surface, and then apply granular materials such as plastics and minerals on top of it.
It is also possible to form a design with a three-dimensional structure using a fibrous material, or to simply adhere a knitted fabric with a three-dimensional structure to a base material. In FIG. 2, 1 is a press table, 2 is a base material, 3 is a pattern material, 4 is a colored layer, 5 is a thermoplastic resin transparent powder, and 6 is a transparent film.

Transparent thermoplastic resin powder (hereinafter abbreviated as powder) 5 is supplied from above the pattern material 3 so as to at least completely fill the concave portions of the pattern material 3. Powder material 5 is
PVC homopolymer or vinyl chloride and ethylene,
Compositions prepared by adding plasticizers and stabilizers to copolymers of vinyl acetate, (meth)acrylic acid, and their esters, or materials such as acrylic resins and thermoplastic urethanes can be used, preferably 10 to 42 meshes, and heated. This makes it transparent.

If the material of the powder or granule material is appropriately selected, heat fusion properties with the pattern material 3 can be obtained.

The granular material 5 can be supplied to every corner of the three-dimensional design by known methods such as knife coating, plain screen, roll coating, and dispersion using a vibrator.

Note that the powder or granular material 5 may be colored as appropriate within the range where it becomes transparent upon heating.

The granular material 5 may be supplied to the extent that it completely fills the concave portion of the pattern material, but may be supplied to such an extent that it slightly covers the entire pattern material. The transparent powder used in the present invention is filled into the fine details of the pattern material.

A flexible transparent film 6 is placed on the powder 5. The film 6 improves the protection and abrasion resistance of the decorative material surface.

The transparent film is preferably made of a soft resin such as PVC, acrylic resin, polyolefin, polyester, or polyurethane, and has a thickness of 0.05 to 0.3 mm.

Note that the transparent film 6 may be replaced with a transparent resin such as epoxy resin, polyurethane resin, acrylic resin, polyester resin, or UV curable resin.

In FIG. 3, the aforementioned components are shown in press table 1-
The decorative material of the present invention is obtained by heating and pressure molding between press top plates 7 at 130 to 200°C.

As a heating and pressurizing means, a far infrared heater, a stubbunk heater, a steam heater, a press roll, an Ohmer device, etc. may be used in appropriate combination to melt the powder and obtain a smooth surface.

The manufacturing method of the present invention provides the following effects.

The obtained decorative material exhibits excellent surface smoothness and can maintain its beautiful appearance for a long time with easy maintenance and no dust buildup.

As shown in FIG. 5, the three-dimensionally designed pattern material 3 can be seen through.

Since the transparent powder fills even the details of the pattern of the pattern material having a three-dimensional design, the pattern material 3 and the transparent resin 8 are completely integrated, and no air bubbles are generated.

Transparent layer 8 obtained by heating and pressing powder material
In this case, the decorative material does not warp, and the shape of the patterned material 3 can be maintained without any damage during heating and pressure molding.

By using a dark color such as black for the base material and a light color for the pattern material, the three-dimensional effect of the pattern material becomes even more remarkable.

By using an ink containing pearl essence in the colored layer 4, a decorative material with a mother-of-pearl inlaid look can be obtained.

In the present invention, it is also possible to laminate a foamed sheet, a non-foamed sheet, a glass fiber mat, cold paper, asbestos paper, a pulp sheet, a wood board, a mineral fiber board, etc. as a backing material on the decorative material. The decorative board of the present invention can be used as wall materials, floor materials, interior decorations, home appliances/containers, book covers, and various other decorative materials.

Example 1 The following composition was stirred and mixed in a super mixer, and when the composition temperature reached 88°C, the above composition was cooled to room temperature to obtain 32 meshes of PVC transparent powder A.

PVC (=800) 100 parts by weight Tin-based stabilizer 1 〃 Plasticizer (DOP) 35 〃 0.5% of powder A was applied to the embossed 0.3 mm PVC leather sheet pattern material so that the surface was evenly covered. Spread uniformly to a thickness of mm using a vibrator,
The surface of the patterned material is heated to 160℃ using a far-infrared heater,
Pressure molding was carried out using a press roll to fuse the granular material A and the granular material and the pattern material to obtain a wall covering material with a transparent and smooth surface.

Example 2 Thickness made of PVC paste resin whose surface is colored with metal powder ink on a black rigid PVC sheet
A 0.5 mm lace pattern material was placed, and the powder was uniformly dispersed using a vibrator until the concavities of the pattern material were sufficiently filled.A soft PVC film was placed on top of the powder, and the same process as in Example 1 was carried out. A decorative material was created by heating and pressing under the same conditions.

The obtained decorative material was beautiful and suitable for wall panels.

Example 3 Instead of Example 2, a lace fabric whose surface was colored with ink containing pearl essence was used. When the obtained decorative material was attached to the outside of the container, a container with an elegant mother-of-pearl inlaid pattern was obtained.

Example 4 When acrylic resin powder was used in place of PVC in Example 3, even better transparency was obtained.

Example 5 A paste containing a foaming agent is applied onto a glass mat substrate and pregelled at a temperature below the decomposition temperature of the foaming agent, followed by printing in a pattern with an ink containing a foaming inhibitor and foaming by heating to form a chemical embossed pattern. I got the material. A decorative material was produced in the same manner as in Example 1.
The obtained decorative material had a three-dimensional appearance as a cushion flooring material and was an excellent flooring material that did not collect dust.

Example 6 A UV-curable polyurethane transparent resin was applied to the surface of the floor material obtained in Example 5 and irradiated with ultraviolet rays.
A more durable cushioning flooring material that does not require wax was obtained.

The obtained decorative materials of Examples 1 to 6 have a three-dimensional effect without distorting the design of the pattern material when pressurized, have a smooth surface, do not contain air bubbles, and meet JIS standards.
A5705 showed excellent performance with no warping at all in the warping test.

[Brief explanation of drawings]

1 to 3 are manufacturing process diagrams of the present invention, and FIGS. 4 and 5 are sectional views and plan views of the decorative material of the present invention. 2 is a base material, 3 is a pattern material, 4 is a colored layer, 5 is a thermoplastic resin transparent powder, and 6 is a transparent film.

Claims (1)

[Claims] 1 From the top of the patterned material, which has a three-dimensional structure design,
Supplying a thermoplastic resin transparent powder having a fusion property with the pattern material, filling at least the concave portions of the pattern material with the transparent powder, and then heating and pressurizing the material to form a smooth surface. A method for producing a decorative material with a three-dimensional effect.