JPH023691B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a method for manufacturing decorative materials. More specifically, regarding a method for manufacturing a decorative material having a transfer printing pattern, a paste sol made of a foamable thermoplastic resin is applied to the transfer printing surface (transfer ink layer side) using transfer paper, and then heated. This is a method for producing a decorative material, characterized in that the paste sol is gelled and transferred to the gelled sheet at the same time. The main object of the present invention is to provide a method for manufacturing a decorative material having a transfer printing pattern, which does not cause transfer defects (uneven transfer printing).
The purpose of this is to create a clear uneven pattern by using a transfer paper (hereinafter simply referred to as transfer paper for chemical embossing) in which the ink layer of the transfer paper is partially formed with ink containing a foaming suppressor or foaming accelerator. A third object is to provide a method for manufacturing a decorative material that does not require a base material or a carrier sheet. 2. Description of the Related Art Conventionally, a method for manufacturing a decorative material having a transfer printed pattern using transfer paper is known. All of these are manufactured by the following method.
For example, to explain a method for manufacturing a cushion floor, as shown in Figure 1, a paste sol made of a foamable thermoplastic resin is applied onto a base material, and then this is heated at a temperature that does not cause foaming. Then, the ink layer side of the transfer paper is brought into contact with the gel sheet and heated and pressed to transfer the ink layer to the gel sheet surface, and the release paper is peeled off. After removing the
After applying a paste sol made of a transparent or translucent non-foaming thermoplastic resin onto the ink layer, heating is performed to gel the non-foaming paste sol and foam the foamable gelled sheet. That is. In this case, a chemical embossing transfer paper is usually used as the transfer paper, and an uneven pattern is also formed thereon. However, according to the conventional method, transfer printing is performed on a foamable thermoplastic resin gel sheet that does not have any fluidity, so uneven transfer due to uneven pressure etc. is likely to occur, and the transfer paper When using transfer paper for chemical embossing, ink containing a foaming suppressor or foaming accelerator
Due to insufficient adhesion and penetration into the gel sheet, the effect is not fully exhibited in areas where foaming is desired to be suppressed or promoted, and it is therefore difficult to obtain a decorative material with sufficient unevenness. In addition, since it requires a base material or carrier sheet, it not only imposes restrictions on product design and manufacturing equipment, but also requires heating a paste sol made of a foamable thermoplastic resin to form a foamable gel. When forming a sheet, the substrate or carrier sheet, which generally has a large heat capacity, must be heated at the same time, and the heating equipment must be large-sized. The present invention solves the drawbacks of the conventional method of manufacturing decorative materials having a transfer printed pattern using transfer paper as described above, and the present invention will be described in detail below. The present invention provides a transfer paper consisting of a release paper and an ink layer, which is made of a foamable thermoplastic resin on an ink layer.
A paste sol is applied, and then the foamable paste sol is heated at a temperature that does not cause foaming to form a foamable gel sheet. At the same time, the transfer to the gel sheet is completed, and then release paper is removed from the ink layer. The transfer printing pattern is formed by peeling and removing the ink layer, forming a transparent or translucent synthetic resin layer on the transfer paper peeling surface, and then heating the foamable gel sheet to foam it. This is a method for manufacturing a decorative material having the following methods. As described above, the present invention applies a foamable paste sol onto the ink layer of transfer paper and heats it to form an unfoamed foamable gel sheet, and at the same time transfers the foam to the foamable gel sheet. It is something to do. Since the foamable paste sol completely adheres and contacts the ink surface, it can completely prevent transfer printing defects caused by uneven pressure, etc. that were observed in conventional methods, and it has a very good transfer print pattern. Decorative materials can be obtained. Furthermore, if a transfer paper for chemical embossing is used as a transfer paper, the ink layer can be in close contact with and adhere to the foaming paste sol, and the foaming suppressor or foaming accelerator partially contained in the ink layer can be Since it can penetrate into the foamable paste sol very easily, the effect of the inhibitor or accelerator is fully exhibited, and therefore a decorative material having a clear embossed pattern with a large difference in unevenness can be obtained. Furthermore, in the present invention, the transfer paper also plays the role of a carrier sheet, so it is effective when manufacturing decorative materials that do not require a base material.Moreover, since the transfer paper itself has a small heat capacity, it generally has a heat capacity of Compared to the case where the foamable paste sol is applied onto a base material (e.g., asbestos sheet) or carrier sheet (e.g., Teflon sheet, stainless steel sheet, etc.) and heated to gel, the heating capacity is smaller. A single device is sufficient, and it is extremely advantageous in terms of equipment and manufacturing costs. Further, in the present invention, a backing material may be formed on the foam layer side to provide a decorative material with good durability and other performance. In this case, the backing material may be a nonwoven fabric, a woven fabric, a resin-treated fabric thereof, a sheet made of synthetic resin, or the like. In particular, it is preferable to use a glass fiber nonwoven fabric (including one treated with a resin) as the backing material because it improves the dimensional stability of the decorative material, and if a crosslinkable synthetic resin layer is formed, the resulting decorative material can be used. It is even more preferable because it improves dimensional stability, curling resistance, solvent resistance on the back side, and improves the durability of decorative materials, and is suitable as a surface finishing material for walls, floors, etc. In the present invention, foamable thermoplastic resins include polyvinyl chloride-based resins such as polyvinyl chloride, polyvinyl acetate, copolymers thereof, and copolymers of these and other thermoplastic resins, polyethylene, and polypropylene. A chemical blowing agent such as azodicarbonamide and other formulation aids are blended with thermoplastic resins such as olefin resins such as styrene, aromatic vinyl resins such as styrene and α-methylstyrene, and polyurethane resins. You can use the following: In addition, transparent or semi-transparent synthetic resins include
Polyvinyl chloride, polyvinyl acetate, copolymers of these or copolymers of these with other synthetic resins, polyolefin resins such as polyethylene and polypropylene, acrylic resins, polyamide resins, polycarbonates, polyurethane resins, etc. A synthetic resin containing a compounding aid, if desired, can be used. When these are applied to the method of the present invention, they may be in the form of a sheet, paste, or powder. Note that the present invention is not limited to the examples, and the method of implementing the invention can be changed without departing from the spirit of the present invention. Furthermore, in the present invention, a conventionally known method can be applied to the so-called chemical embossing method in which a foaming suppressor or a foaming accelerator is applied to a foamable thermoplastic resin, and a description thereof will be omitted in the present invention. Example 1 The following formulation

[Table] A transparent polyvinyl chloride paste sol and a foamable polyvinyl chloride paste sol were prepared, and as shown in FIG. The vinyl paste sol 4 is coated using a knife coater 8 so that the thickness after foaming becomes 1.3 mm, and this is heated and gelled in an oven 7 to an extent that no foaming or flow occurs, resulting in a foamable gelled sheet 4' And so,
Next, the release paper 3 of the transfer paper 1 is peeled off and removed from the ink layer 2, and a transparent polyvinyl chloride paste sol 5 is applied onto the ink layer 2 using a knife coater 8 so that the thickness after gelation is 0.2 mm. Then, the transparent polyvinyl chloride paste sol was gelled by heating in an oven 7', and the foamable gelled sheet was foamed to obtain a decorative material having chemical embossing and a total thickness of 1.5 mm. Ta. This product has no uneven transfer at all, and the unevenness is clear.
It was suitable as wall material. Example 2 A transparent polyvinyl chloride paste sol and a foamable polyvinyl chloride paste sol having the same formulation as those used in Example 1 were prepared, and as shown in FIG.
On the ink layer 2 of the transfer paper 1 for chemical embossing,
The foamable polyvinyl chloride paste sol 4 is applied using a knife coater 8 so that the thickness after foaming becomes 1.8 mm, and this is heated and gelated in an oven 7 to an extent that no foaming or flow occurs to form a foamable gel. A glass fiber nonwoven fabric (thickness 0.15 mm) 10 impregnated with a separately prepared polyvinyl chloride paste was placed on the foamable gelling sheet 4' as a sheet 4' using hot pressure bonding rolls 13, 13'. Then, the release paper 3 of the transfer paper 1 is peeled off from the ink layer 2, and a transparent polyvinyl chloride paste sol 5 is applied on the ink layer 2 using a knife coater 8.
It is applied so that the thickness after gelation is 0.35 mm, and then heated in an oven 7' to gel the transparent polyvinyl chloride paste sol,
A decorative material with a total thickness of 2.3 mm was obtained by foaming the foamable gel sheet. This item has no transfer defects at all,
Since the embossing was clear and the backing material was made of glass fiber nonwoven fabric, it had good durability and dimensional stability, making it suitable as a floor finishing material.

[Brief explanation of drawings]

Figure 1 is a schematic diagram showing a conventional method of manufacturing decorative materials;
FIGS. 2 and 3 are schematic views for illustrating the method for manufacturing a decorative material according to the present invention. In the figure, 1... transfer paper, 2... ink layer,
3...Release paper, 4,4'...Expansible polyvinyl chloride, 5...Transparent polyvinyl chloride, 6...Base material,
7...Oven for gelling, 7'...Oven for foaming, 8...Knife coater, 9...Roll for transfer,
10...Glass fiber nonwoven fabric, 11...Take-off roll, 12...Guide roll, 13, 13'...
...It is a heated pressure bonding roll.

Claims (1)

[Claims] 1. A paste sol made of a foamable thermoplastic resin is applied onto the ink layer of a transfer paper made of a release paper and an ink layer, and then heated and sintered to an extent that no foaming or flow occurs. A foamable gelatinized sheet is formed, the transfer is completed at the same time, the release paper is peeled off from the ink layer, a transparent or translucent synthetic resin layer is formed on the ink layer, and then heated. A method for producing a decorative material, which comprises foaming the foamable gel sheet. 2. The method for producing a decorative material according to claim 1, wherein the ink layer of the transfer paper partially contains an ink layer containing a foaming inhibitor or a foaming promoter. 3. The method for manufacturing a decorative material according to claim 1, wherein a backing material is formed on the foam layer side. 4. The decorative material according to claim 3, wherein the backing material is one selected from non-woven fabrics, woven fabrics, synthetic resin-treated fabrics thereof, and sheet-like materials made of synthetic resins. manufacturing method.