JPH0220347Y2 - - Google Patents

Description

[Detailed description of the invention] (Technical field) The present invention is a method of forming uneven patterns on the surface of plastic materials, such as plastering materials, by press-bonding them to the surface of materials that can be embossed before hardening. The present invention relates to an embossing sheet that can be embossed.

(Prior Art) As for embossing methods used in the field of architecture, especially in the field of plastering, traditional methods include engraving on cement and plaster, which are newer than these. Patterned roller construction method and cut-out sheet construction method are relatively efficient methods. For example, the patterned roller application method uses a patterned roller that has porous or semi-hard patterned irregularities on the coated surface of a cement mixture containing a synthetic resin emulsion while the coated surface is still in a semi-hardened state. Embosses are formed by rolling the material onto the coated surface. Although this method does create unevenness, since the width of the roller is limited, there is a discontinuity between the areas where the roller is applied to the coated surface and the areas where it is not, due to the limited width of the roller. It spoils the beauty of the finished product,
Moreover, it requires skill to improve this. Furthermore, materials from the coated surface tend to adhere to the roller, and to prevent this, it is necessary to constantly supply water to the roller using a separate water supply roller or a water supply sponge, or to make the roller itself breathable. It requires some ingenuity. Furthermore, due to the suitability of this construction method for forming irregularities, there are material constraints such as the use of special plastering materials such as elastic acrylic, and in general, the patterns are abstract with inconspicuous seams. I have no choice but to.

On the other hand, the cut-out sheet construction method has a thickness of 2~
Use a 3 mm styrene sheet cut out in a pattern, for example, after surface treatment, the thickness is 2 to 3 mm.
Apply the coating material and press the sheet with a roller etc., then apply the coating material on top of the sheet, fill the cut-out part of the sheet with the coating material, and remove the sheet after it dries and hardens (about 10 to 15 hours later). It is something. Even in this method, it takes time and effort to correct the seams of the sheets, and, like the above method, there is little freedom in terms of design.

(Purpose of the invention) Therefore, the invention solves the problem of seams,
Another object of the present invention is to provide an embossing sheet that has a high degree of freedom in design and can provide an embossed surface with few defects.

(Structure of the invention) The present invention is characterized in that a convex pattern is formed on a transparent base sheet, leaving a part of the base sheet, and at least in a portion where the convex pattern is not formed. The gist of the invention is an embossing sheet characterized by having microscopic holes penetrating through the front and back sides.

Hereinafter, the present invention will be explained in more detail with reference to the drawings.

FIG. 1 is a sectional view showing a first embodiment of the present invention, in which a convex pattern 3 is laminated on a base sheet 2, and a portion of the base sheet without the convex pattern 3 is laminated on a base sheet 2. A fine hole 4 is formed through the front and back sides. Here, as the base sheet 2, transparent paper or transparent plastic film is used. or,
The convex pattern 3 is formed by printing, especially thick printing, or by cutting out a pattern and laminating suitable materials such as plastic, rubber, wooden plates, metal plates, etc. may have been done. The micropores 4 usually have a diameter of about 0.01 mm to 5 mm, and are provided at a rate of 0.1 to 100/cm ² .

FIG. 2 is a sectional view showing a second embodiment of the present invention, which differs from the one shown in the first embodiment in that the pattern 3' is formed by foaming using a foamable composition. . In this example, a thick pattern 3' can be obtained by foaming using a relatively small (or thin) material.

In the examples shown in FIGS. 1 and 2 above, the convex pattern is formed on the base sheet 2 as a layer separate from the base sheet.

FIG. 3 is a sectional view showing a third embodiment of the present invention, in which the convex pattern 3'' is formed by deforming the base sheet 2.

The embossing sheet of the present invention is characterized in that its base sheet is transparent, and that through holes are formed in the base sheet in areas without convex patterns. Because the through holes are formed here, air easily escapes when pasting the embossing sheet onto a coated surface such as plastering material, and because the base sheet is transparent, air bubbles that occur during pasting can be prevented. This has the advantage that the position can be easily confirmed and measures such as removing air bubbles can be easily taken.

In terms of the above-mentioned bubble escape and bubble position confirmation, the convex patterns 3 and 3' should be transparent like the base material, and the through holes should be made all over including the convex patterns 3, 3' and 3''. However, when you actually use the embossing sheet,
Since the convex pattern is the first to touch the coated surface, air bubbles tend to scatter in the direction of the surface.In fact, air bubbles tend to move to areas without convex patterns, so through-holes are formed intensively in this area. If this is done, no bubbles will be generated to the extent that they actually cause problems. For the same reason, the convex patterns 3, 3' do not necessarily need to be made of a transparent material.

The materials constituting the embossing sheet of the present invention and the method for manufacturing the embossing sheet will be described below.

Transparent base sheet The transparent base sheet 2 is made of polyethylene,
Polypropylene, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyethylene terephthalate, polycarbonate, nylon (polyamide), polystyrene, ethylene/vinyl acetate copolymer, ethylene/vinyl alcohol copolymer, ionomer, cellulose diacetate, cellulose triacetate, A transparent film or sheet of plastic such as polysulfone or polyimide can be used. Alternatively, paper that is highly transparent or made transparent by impregnation with synthetic resin or the like can also be used, such as thin paper, parchment paper, moisture-proof paper, and glassine paper.

The above materials may be used alone or in combination.

Convex Pattern The convex pattern 3 is typically formed by printing. Ink vehicles used for printing include cellulose derivatives such as ethylcellulose, ethylhydroxyethylcellulose, cellulose acetate propionate, nitrocellulose, and cellulose acetate, polystyrene, styrene resins and styrene copolymer resins such as polyα-methylstyrene, and polymethacrylate. Acrylic or methacrylic resins alone or copolymerized, such as methyl acid, polyethyl methacrylate, polyethyl acrylate, and polybutyl acrylate; rosin; rosin esters, such as rosin-modified maleic acid resin, rosin-modified phenolic resin, and polymerized rosin; Resin, polyvinyl acetate resin, coumaron resin, vinyltoluene resin, vinyl chloride resin, polyester resin, polyurethane resin, butyral resin, polyamide resin, vinyl chloride-vinyl acetate copolymer resin, polyvinylidene chloride resin, melamine resin, silicone resin. An ink prepared by using one type or two or more types and appropriately adding a plasticizer, stabilizer, dispersant, extender pigment, dye, pigment colorant, solvent, and diluent to the above vehicle is used. Note that the convex pattern 3' is typically formed using the above-mentioned ink further containing a foaming agent,
Foaming agents include inorganic foaming agents such as sodium bicarbonate, ammonium carbonate, sodium boron hydride, silicon oxyhydride, azodicarbonamide, azobisisobutyronitrile, dinitrosopentamethylenetetramine, paratoluenesulfonylhydrazide, etc. , 4'-oxybisbenzenesulfonyl hydrazide, microballoons (or microspheres) containing gas or a low-boiling organic solvent, etc. vehicle 100
1 to 10 parts by weight, preferably 2 to 8 parts by weight
Add part by weight and knead to form a foamable ink.

Method for forming a convex pattern A convex pattern can be formed using the above-mentioned ink or foaming ink by any known printing method, such as gravure printing, gravure offset printing, lithographic offset printing, dilitho printing, Examples of printing methods include letterpress printing, intaglio printing, jet printing, silk screen printing, and electrostatic printing. Among these, when non-foaming ink is used, gravure printing, which has a relatively large amount of ink transfer,
Silk screen printing is preferred. In addition, when using foaming ink, the pattern portion protrudes due to foaming of the foaming pattern, so there is no need to increase the amount of transfer compared to normal printing, and in gravure printing, the plate depth of the gravure plate is is 100~250μm,
Preferably it is 200 to 220 μm, and in silk screen printing, the number of screen lines is 100 to 20 lines/
inch, preferably 40 to 20 lines/inch. In addition,
When a convex pattern is formed by a lamination method such as printing, the transparent base sheet may be subjected to a primer treatment, if necessary, in order to increase the adhesion strength of the ink.

Method for forming micropores Any known method can be applied to form micropores penetrating the transparent base sheet from both sides, such as pressing using a roll with needles or a veneer with needles. Examples include a cutting method and a method using a heated needle, and the size, shape, number, and position of the micropores should be determined appropriately, such as by determining experimentally so that air bubbles can be easily removed when used as an embossing sheet. Bye.

Further, the formation of the micropores may be performed before or after the formation of the convex pattern.

Note that it is sufficient to provide the micropores in the portion of the embossing sheet excluding the convex pattern portion, but for convenience of forming the micropores, they may be provided over the entire surface of the embossing sheet. It is easy to manufacture by previously opening micropores on the entire surface of a transparent base sheet and then forming a convex pattern thereon.

How to use the embossing sheet The method of using the embossing sheet of the present invention will be described below.

First, a moldable plastic material such as a plastering material is coated on a suitable base material to be decorated. The base material to be decorated is, for example, the concrete surface of a building, or the surface of a base plate to which a lath sheet is attached. The plastering material used is cement mixture, plaster, gypsum, plaster, etc., or a mixture of these with resin added if necessary, mixed with water etc., and applied to the base material to be decorated using a trowel etc. Work it, level it, and keep it flat.

Next, the convex pattern side of the embossing sheet is applied to the coated surface, and the embossing sheet contacts the coated surface in the areas where the embossing sheet does not have the convex pattern, and the embossing sheet touches the coated surface in the areas with the convex pattern. Press the embossing sheet from the back with a trowel or a smooth rubber roll so that it is pushed into the coated surface. In this step, it is sufficient to apply the embossing sheet to the coating surface so that the back surface of the embossing sheet is flat. In order to equalize the level of each convex portion on the finished surface, it is better that the embossing sheet, especially its base sheet, has high rigidity. However, with this method, rather than applying the plastering material and smoothing it with a trowel, it is smoothed through the base sheet, so even if there are some unevenness when first applying the material, once you apply the embossing sheet, it will be smoother. Since a flat surface can be easily formed, construction can be carried out even if one is not a skilled plasterer.

(Effects of the invention) Since the embossing sheet of the present invention has the above-mentioned structure, when applied to a coated surface such as plastering material, air bubbles are likely to disappear through the fine pores, and even if air bubbles are Even if air bubbles occur, they are easy to detect because the area other than the convex pattern on the embossing sheet is transparent, and as soon as they are discovered, the air bubbles can be removed using a trowel or roller, making it difficult for defects to occur on the embossed surface. It also has the advantage that it is easy to obtain overall flatness because the coated surface of plastering material, etc. is smoothed through the embossing sheet.

Example Vent holes with a diameter of 0.5 mm and a pitch of 5 mm were formed on one side of a polyethylene terephthalate film (manufactured by Toray Industries, Ltd., Lumirror #100, T type) using a roll equipped with needles.

A pattern is printed on the perforated film using a silk screen plate (100 lines/inch) using ink with the following composition. After printing, the film is heated at a temperature of 200°C for 6 minutes to foam the pattern and create a bubble in the patterned area. An embossing sheet consisting of a convex portion and a flat portion without a pattern was prepared.

Ink composition Polyvinyl chloride resin 100 parts by weight (Nippon Zeon, Geon121) Dioctyl phthalate 65 Calcium carbonate 25 Acarbonamide 5 Ba/Zn stabilizer 3 On the other hand, the vertical surface of the external wall of the building (concrete surface)
An acrylic emulsion was applied using a sponge roll and dried for 30 minutes to form a primer layer, and mortar with the following composition was troweled onto the primer layer to a thickness of 10 mm.

Mortar composition Portland cement 100 parts Sand 100〃 Water 50〃 Apply the previously prepared embossing sheet to the coated surface, press it with a rubber roller and remove the air between the coated surface and the embossing sheet. was brought into close contact with the coated surface to level out the surface.

When the embossed sheet was peeled off 12 hours after the mortar application, the coated surface had hardened and the concave pattern created by the convex pattern of the embossed sheet was reproduced on the surface.

Example 2 Release paper for vinyl leather having a basis weight of 153 g/m ² was applied to a paper embossing machine to give it an embossed finish. A transparent PVC sol having the following composition was applied to the release surface of the release paper having an embossed surface in an amount of 150 g/m ² by a knife coating method, and was heated at 200° C. for 3 minutes to form a gel.

Transparent PVC sol composition: PVC 100 parts DOP 60〃 Ba-Zn stabilizer 5〃 On the surface of the thus obtained transparent PVC, a stone wall joint pattern was silk-printed twice using silk ink having the composition shown below, and the pattern was thickly plated.

Silk ink composition Extender pigment (calcium carbonate) 50 parts Acrylic resin 20〃 Solvent 25〃 Plasticity 5〃 After this, ventilation holes were formed all over using a needle roll with needles of 1 m/m diameter and 7 m/m pitch. The release paper was removed and an embossed sheet with stone wall joints was created.

Hereinafter, the same procedure as in Example 1 was followed except that the mortar composition was changed as shown below, and the same results were obtained.

Mortar composition Portland cement 100 parts Silica 30〃 Water 50〃 Example 3 Polyvinyl chloride sheet (0.2mm thickness, 20PHR)
Extrusion consists of a polyvinyl chloride sheet with a diameter of 0.5 m/m and ventilation holes formed all over it using needle rolls with a pitch of 5 mm, and high-quality paper with a thickness of 50 g/ ^m2 , and a polyethylene resin layer with a thickness of 30 μm as an adhesive layer. It was laminated and lined using the Yon-laminate method. The adhesive strength between the polyvinyl chloride sheet and the polyethylene resin layer of the laminated sheet obtained with this lining is 50
g/30 mm (180°C peeling, speed 0.2 m/min), so it could be easily peeled off. Silk printing was performed on the polyvinyl chloride sheet surface of this laminated sheet using the same foaming ink as in Example 1,
After heating and foaming, the backing material (high-quality paper) was peeled off to create an embossing sheet.

Example 1 is shown below, except that a gypsum-based plaster made of gypsum, lime, and water is used instead of mortar.
The same procedure was carried out and the same results were obtained.

Example 4 A 0.2 m/m thick polystyrene sheet was vacuum-formed so that the 50 mm square tile joints were convex. This was pressed using a veneer plate with a diameter of 0.5 m/m and needles of 5 m/m pitch so as not to break the convex molding described above to form ventilation holes, thereby producing an embossed sheet.

Separately, a slurry having the following composition was poured into a 90 cm square mold, and the embossing sheet obtained above was pasted on the surface of the slurry with a roll while defoaming, and the slurry was allowed to harden naturally. The mold was then demolded and the base sheet was peeled off to obtain a tiled panel with a thickness of 32 mm and a square size of 90 cm. The method of this example could also be applied to the production of conventional precast concrete plates.

Slurry composition White cement 100 parts Silica sand 15〃 Water 40〃 Alkali-resistant glass fiber 8 Water reducing agent (manufactured by Kao Soap Co., Ltd., Mighty 150) 1

[Brief explanation of the drawing]

1 to 3 are cross-sectional views showing embodiments of the embossing sheet of the present invention. 1... Embossing sheet, 2... Base material sheet,
3...Convex pattern, 4...Minute pores.

Claims (1)

[Claims for Utility Model Registration] (1) A transparent base sheet in which a convex pattern is formed on a portion of the base sheet, and at least a portion where the convex pattern is not formed. An embossing sheet characterized by having minute holes penetrating the front and back sides. (2) The embossing sheet according to claim (1) of the utility model registration, wherein the convex pattern is formed by printing. (3) The embossed sheet according to claim 1, wherein the convex pattern is printed using foaming ink and foamed. (4) The embossing sheet according to claim (1) of the utility model registration, wherein the convex pattern is formed by molding a transparent base sheet.