JPH0276735A - Manufacture of sheet-shaped material - Google Patents

Abstract

PURPOSE:To provide recesses and projections on a synthetic resin layer and also provide stereoscopic design properties by expanding micro-capsules transferred onto the synthetic resin layer. CONSTITUTION:A treatment agent coated layer 19 including micro-capsules is formed on thermoplastic synthetic resin 21 and laminated in a manner to cover a plastisol coating material coated layer 20. Resin as a matrix of the micro-capsules is thermoplastic and is softened following to heating the micro- capsules to expand a volatic organic compound included in the capsules and also expand the resin of the softened matrix. When the synthetic resin layer 21 as a base and a layer 20 coated with plastisol coating material and the expansion of micro-capsules in a treating agent coated layer 19 are expanded simultaneously, fine recesses and projections are shown on plastisol coating material coated layers 24 and 29 by the expansion of micro-capsules between synthetic resin layers 25 and 21. The fine recesses and projections and variation of texture can be represented simultaneously as designs.

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a method for manufacturing sheet-like materials such as wall covering materials, flooring materials, leather, wrapping paper, and the like.

<Prior Art and Problems> Initially, designs were expressed on sheet materials such as leather, flooring materials, wall covering materials, etc. by simply printing or coloring them. Therefore, the design of these sheet-like products was expressed only by hue or pattern.

However, the sheet-like products currently manufactured are designed in a variety of ways by adding elements such as changes in the shape of the unevenness and changes in the texture of the material.

The method of embossing is the most widely used method for imparting uneven shape changes to sheet-like materials.

This recipe is a method in which a sheet material softened by heating or the like is pressed with an engraved embossing roll to transfer the shape.

Furthermore, if a plastisol paint containing polyvinyl chloride as a main component is transferred onto a sheet-like material by textile printing or screen printing, the transferred area will bulge, producing a so-called three-dimensional printing effect.

These textile printing and screen printing methods have an extremely large transfer amount compared to general printing methods that transfer ink.

Gravure printing is generally used to print on sheet-like materials mainly composed of synthetic resin layers. As far as the naked eye can see, the ink transferred by gravure printing does not give any unevenness to the sheet-like object.

On the other hand, when transferring plastisol paint containing polyvinyl chloride as the main component by screen printing or textile printing, the paint can be transferred onto a sheet with a thickness of 0.05 to 0.15 s+m, and it is visible to the naked eye. Even when you look at it, you can clearly feel the unevenness. Further, when an azodicarbonylamide foaming agent is blended into the paint, the transferred portion can be made to have a thickness of about 1 to 2 mm by heating.

Furthermore, the texture can be varied due to differences in resin hardness, gloss, surface appearance, etc. between the synthetic resin layer and the plastisol coating layer on the sheet-like article. In other words, if the plasticizer, resin quality, expansion ratio, etc. of the plastisol paint are made different from those of the synthetic resin layer on the sheet-like material, the texture of both layers can be changed.

The cross section of the sheet-like material laminated with plastisol paint is shown in Figure-
1 and Figure 2. Figure 1 shows a state in which plastisol paint of one color is laminated in an arbitrary pattern on a sheet-like object. As shown in Figure 1, when only one color of plastisol paint is laminated, the shape of the unevenness is simple or irregular. On the other hand, as shown in Figure 2, if the first color plastisol paint is laminated with the second color paint so as to partially overlap, the shape of the unevenness can be made slightly more complex.

When plastisol paint, which is widely used in general, is laminated on a sheet-like object, the surface of the laminated part is as shown in Figure 1.
As shown in Figure 2, it has a smooth surface with a resin luster. In particular, when used as a wall covering material, the glossiness described above has tended to be avoided in order to avoid reflections from indoor lighting.

In recent years, resin gloss has been eliminated by introducing formulations such as replacing part of the resin, which is the main component of the paint, with a resin that exhibits a matte effect (generally called a matte resin). .

Furthermore, in Japanese Patent Publication No. 62-28481, by blending microcapsules containing volatile organic compounds into plastisol paint, the coated area has a matte appearance and a suede-like appearance.

The volatile organic compound contained in the microcapsules contained in this paint expands when heated, and the microcapsules themselves expand to about 50 times their volume. After expansion, the microcapsules become soft and elastic spheres,
This gives the coating layer soft, minute irregularities.

Figure 3 shows this paint layered on a sheet-like material. This sheet-like material has fine irregularities, and these fine irregularities give it a suede-like appearance, and also have a good matte state. A sheet-like product made from this formulation has an excellent design and is widely used as a wall covering material.

However, the sheet-like product manufactured using this formulation does not have excellent physical strength because it contains 30 parts of soft microcapsules containing gas.

Furthermore, although this formulation is suitable for expressing suede-like softness, it is not suitable for expressing fine irregularities with an inorganic feel.

Note that the term "fine unevenness with an inorganic texture" as used herein refers to a design that has a hard appearance and touch and gives the impression of minerals or ceramics. In other words,
1. Fine irregularities with an inorganic texture are fine irregularities with the above-mentioned texture. It refers to the so-called sand-grained or concrete-like appearance.

Introducing the above-mentioned embossing may be considered as a method of expressing an appearance with an inorganic feel. With this formulation, it is possible to give an appearance with an inorganic texture, but it is not possible to simultaneously provide the design effect of laminating plastisol paint in an arbitrary pattern to create a change in texture.

Also, it is common practice to synchronize the uneven pattern created by embossing with the pattern created by printing, but this method similarly cannot express changes in texture.

In this way, the sheet-like material has minute irregularities with an inorganic texture,
It is not possible to find a manufacturing method in the prior art that can simultaneously express changes in texture, but this kind of design is actually required when used as wall covering materials. .

There is a method called ``furikake'' (furikake) for laminating completely different materials onto a sheet-like object.

This formulation involves first laminating an adhesive layer on the entire surface or in an arbitrary pattern on a sheet-like material, then sprinkling powder or gravel (hereinafter referred to as "furikake material") from above, and applying it only on the adhesive layer. This is a method of laminating layers.

As materials for furikake materials, generally used are slightly roughly crushed vegetables such as cork, synthetic resins, minerals, eggshells, metals, etc. In some cases, it may be colored or mixed with different materials to be used as a furikake material.

This formulation allows completely different materials to be layered in any desired design. For example, if you sprinkle a sprinkle material such as mica, calcite vermiculite, etc. onto a synthetic resin sheet that is an organic material, it will be possible to create an organic material. Differences in inorganic materials can be expressed as designs.

In this formulation, if an adhesive layer is laminated in an arbitrary pattern on a sheet-like article, a design can be created based on the tone of the laminated portion and the non-laminated portion. Furthermore, if the furikake material is, for example, a mixture of biotite and muscovite, it is possible to give the sheet-like product a so-called "salt-and-pepper" design.

In other words, with this formulation, it is possible to create a design by laminating the adhesive layer in an arbitrary pattern and by making the furikake material a mixture of different ingredients or gravel particles of different particle sizes and colors. It can be done.

However, this formula using furikake material has a narrower range of design expression than the above-mentioned gravure printing, screen printing, etc., and the designs that can be expressed using this formula are limited to special ones.

For example, in gravure printing and screen printing, a pattern with gradation can be expressed by utilizing differences in the amount of ink or paint transferred. However, when Furikake material is used, it is not possible to give a sheet-like product such a gradation design.

For this reason, arbitrary patterns are drawn with adhesive and used as designs, but the patterns that can be expressed are limited to gothic patterns, and it is not possible to create designs with soft patterns, so there are few examples of its use. As shown above, most of them are
A mixture of different properties is used as a furikake material, and this is laminated over the entire surface of the sheet-like material.

In this way, formulations using furikake materials are an excellent means for laminating different materials together into a synthetic resin sheet, but they are not widely used due to the difficulty of designing them.

Means for Solving Problems> As mentioned above, microcapsules containing volatile organic compounds such as butane are thermally expandable. This microcapsule is contained in a synthetic resin layer,
The formulation in which the synthetic resin layer itself swells due to the expansion of the microcapsules is known. Also, special public service 1986-
In No. 28481, the synthetic resin layer containing the microcapsules has a suede-like appearance due to expansion of the microcapsules.

These examples contribute to the expansion of microcapsules formulated with modification of the synthetic resin layer. In other words, the modification of the synthetic resin layer is effected from inside the synthetic resin layer.

In contrast, the present invention is a formulation in which microcapsules are transferred onto a synthetic resin layer and the shape of the synthetic resin layer is changed by expansion of the transferred microcapsules. In other words, the formulation according to the present invention is characterized in that the shape of the synthetic resin layer is changed from the outside rather than from the inside.

The appropriate temperature for expansion of microcapsules varies depending on the components of the base resin.

The expansion of the microcapsules is caused by the expansion of the volatile organic compound contained therein and the softening of the base resin. The resin that forms the base of the microcapsules is thermoplastic, and as the microcapsules are heated, the resin softens. At this time, the encapsulated volatile organic compound expands, causing the softened base resin to swell, thereby expanding the microcapsule.

As mentioned above, the method for producing a sheet-like article according to the present invention is characterized in that the expansion of the microcapsules is applied from outside the thermoplastic synthetic resin to cause the synthetic resin layer to change its shape. In this formulation, the softening temperature at which the synthetic resin layer can be processed must match the appropriate expansion temperature of the microcapsules.

In addition, in order to laminate microcapsules on the thermoplastic synthetic resin layer 5, the inclusion of the microcapsules in a synthetic resin-based treatment agent is as described in claim 1 of the patent claims. The most appropriate! :i! ! The method of wearing is clavia printing.

Gravure printing is so-called intaglio printing, in which a processing agent is held in pockets engraved on the plate and transferred onto a sheet-like object. Therefore, if you enlarge the coating state of the treatment agent, it is shown in Figure 4.
It is transferred while forming a mesh pattern like this. Therefore, on the sheet-like material, a portion where the microcapsules are laminated and a portion where the microcapsules are not laminated are uniformly distributed. In other words, it is possible to provide the thermoplastic synthetic resin layer with portions that exhibit the effect of expansion of the microcapsules and portions that do not.

FIG. 5 shows a cross-sectional view of a state in which a synthetic resin treatment agent containing microcapsules is laminated by gravure printing on a thermoplastic synthetic resin layer according to the formulation according to the present invention. As described above, the treatment agent forms a coated part and a non-coated part. At this time, the microcapsules in the treatment agent coating layer are unexpanded.

After the processing agent is laminated by gravure printing, if the synthetic resin layer is softened and the microcapsules are expanded at the same time, a sheet-like material having fine irregularities as shown in the cross-sectional view of FIG. 6 is obtained.

This unevenness occurs because when the macrocapsule expands, it attracts the softened thermoplastic synthetic resin layer. The area of each mesh (12 in Figure 4) of the applied treatment agent remains the same after expansion, but the volume of the microcapsules present there is approximately 50 times larger. In other words, the volume of a certain area of the area to which the treatment agent is applied expands to about 50 times the volume, causing distortion, which causes the softened synthetic resin layer in the non-applied area to be drawn to it. This phenomenon is clearly not a modification of the shape by components added to the synthetic resin, which has been done in the past, but a modification of the shape from the outside of the synthetic resin layer, and can be said to be an epoch-making formulation.

As stated in the prior art and problems section, when plastisol, which is mainly composed of vinyl chloride, is laminated on a sheet-like object, it is not suitable for expressing fine irregularities with an inorganic texture. be.

The same section also states that even if a sheet-like material is embossed, it is not possible to simultaneously impart a change in texture.

However, according to the formulation according to the present invention (the formulation described in claim 2), it is possible to simultaneously express fine unevenness with an inorganic texture and a change in texture due to plastisol paint.

Figure 7 shows that a treatment agent containing microcapsules is applied onto a thermoplastic synthetic resin according to the formulation according to the present invention, and then a plastisol paint is applied to the I! ! FIG. 3 is a cross-sectional view of sheet-like materials laminated to cover the processing agent.

The synthetic resin layer 2 that is the base! When the softening of the coating layer 20 of the plastisol paint and the expansion of the microcapsules in the treatment agent coating layer 19 proceed simultaneously, the result is as shown in FIG. The plastisol paint coating layer 24 is the synthetic resin layer 2
5. Due to the expansion of the microcapsules between the 5 and 5, the microcapsules have minute irregularities. Moreover, the texture changes between the areas where the plastisol paint is applied and the areas where the plastisol paint is not applied.

Furthermore, when this plastisol paint is made non-foaming or low-foaming, the transferred portion becomes somewhat hard and becomes fine irregularities with a so-called inorganic texture. In other words, by following the prescription of the present invention, it has become possible to simultaneously express minute irregularities and changes in texture as a design.

Regarding conventional technology and problems, it was stated that sheet-like products using furikake materials are not widely used due to limitations in design expression. Although it is an excellent means of achieving this, it is difficult to create designs with delicate patterns. This is due to the inability to introduce gradation into design expression.

On the other hand, according to the formulation according to the present invention (the formulation described in claim 3), it is possible to obtain a sheet-like article having an appearance as if sprinkled with furikake material. A feature of this formulation is that the thermoplastic synthetic resin layer to which the microencapsulated treatment agent is applied is a foamed material.

This thermoplastic synthetic resin foam has a cross section as shown in Figure 9.The foam has air bubbles filled in the layer, and the partition walls are concave and thin, so the foam When the body is softened, it becomes susceptible to being scratched and deformed by physical external forces.

When this foam is coated with the treatment agent containing microcapsules by gravure printing and heated, the attracting action of the microcapsules is more effective than with non-foamed resin, and the fine irregularities grow larger. do. At this time, the convex portions of the sheet-like material have an appearance as if furikake material has been sprinkled from above. In this formulation, the state of the sheet-like material at this time is shown in a cross-sectional view in FIG. 9, in which the processing agent is applied by gravure printing. Therefore, the processing agent can be applied with varying shades like gradation.

The size of the unevenness caused by the action of the processing agent is approximately proportional to the transfer type of the microcapsule. If there are many transfer molds of microcapsules, the attraction of the synthetic resin layer will be more effective, but if there are fewer transfer molds, the effect will be less. If the treatment agent containing microcapsules is printed in a gradation tone using the transfer mold, it will be possible to form a sheet. This makes it possible to vary the amount of microcapsules transferred onto an object. As a result, it has become possible to create a furikake-like sheet-like product with a delicate gradation design.

Furthermore, as mentioned above, the synthetic resin foam has thin partition walls, but these partition walls are ruptured by heating and the air bubbles in the foam are interconnected.For this reason, the foam is a breathable sheet-like material. Turn into nothing.

By using the formulation described in claim 3 and using a foam as the thermoplastic synthetic resin layer, it is possible to obtain an air-permeable sheet-like article having fine irregularities similar to furikake.

Currently, wall covering materials are a field that requires the function of breathability.

With the spread of air conditioning equipment, there are more and more cases of rooms being closed off. For this reason, there has been a demand for a wall covering material with breathability for some time, and the sheet-like material produced according to the formulation of the present invention can meet these demands.

<Examples> Example 1 A wall covering material produced according to the recipe set forth in claim 2 will be described as an example.

A plastisol having the composition shown in Table 1 was coated on a base material of flame-retardant paper to a thickness of 0.15 mm, and the plastisol was turned into a semi-gel by heating to produce a sheet-like product. A white pigment (Tie,
) was added.

Table-1 Resin: PVC 100 parts Plasticizer:
...DOP 60 parts filler...
CaCO 5100 parts Foaming agent...ADCA type 2 parts Stabilizer...Zn type 3 parts Pigment...Ti0z 20 parts Meanwhile, manufactured by Dainichiseika Co., Ltd. Five parts of microcapsules (appropriate expansion temperature: 160 to +7 [1° C. type)] were dispersed in an acrylic-vinyl chloride organic solvent solution, and this was prepared as a processing agent.

This treatment agent was applied onto a sheet material in an arbitrary pattern. The treatment agent was applied by gravure printing, and the pattern-applied area had a fine mesh pattern between the transferred area and the non-transferred area, as shown in Figure 4. Although hot air was used to dry this treatment agent, no expansion of the microcapsules was observed.

Immediately after drying, a plastisol paint colored light gray and having the composition shown in Table 2 was applied onto the area to which the treatment agent had been applied, and was gelled. During this gelation, the sheet-like material required heating to approximately 140°C, but no expansion of the microcapsules was observed. The cross section of the sheet material at this time was as shown in Figure 7.

Table-2 Resin...PVC 100 parts oJ plasticizer...
...DOP 5 [1 part filler...
・・・380 parts of CaCO Foaming agent・・・・・・・・・ADC
A type 2-part stabilizer・・・・・・Zn type
385B Vehicle weight ・・ ・ ・ ・ ・
loil then about 225
When the sheet-like material was heated in a hot air oven whose temperature was controlled to ℃, the microcapsules expanded and the sheet-like material had a cross section as shown in Figure 8. This sheet-like product had a grain-like fine unevenness portion 24 and a flat portion to express an arbitrary design. The part of the sheet with fine irregularities is a part where the synthetic resin is laminated thickly, so it is higher than the flat part, and only this part has a grainy appearance. In addition, the plastisol paint coating layer 23 and the synthetic resin layer 25 had different textures due to the difference in color and softness because the color of the pigment and the number of added parts of the blowing agent were different.

In the past, there was no sheet-like product whose design was expressed using multiple elements like this. Therefore, the sheet-like material produced according to the formulation of the present invention was a wall covering material rich in novelty.

Example 2 A wall covering material produced according to the recipe set forth in claim 3 will be described as an example.

Plastisol having the composition shown in Table 1 of Example 1 was coated on flame-retardant paper to a thickness of 0.17 m, and this was semi-gelled by heating to produce a sheet-like material.

Next, this sheet-like material was passed through a foaming furnace maintained at about 225° C. to foam the coated synthetic resin layer.

When the cross section and surface of this foam were enlarged, it was confirmed that the fine cells were collapsed and formed by thin resin partition walls. Further, the foamed sheet-like material had a smooth surface and had good printing suitability.

On the other hand, acrylic-
Dispersed in a salt and organic solvent solution and used as a treatment agent.
Next, this treatment agent was colored in two colors: light gray and dark gray.

A processing agent colored light gray was applied onto a sheet-like material using gravure printing in a desired pattern in a gradation pattern. Furthermore, a processing agent colored in a second dark gray color was applied using the same recipe so as to overlap the color printing. Although warm air was used to dry the treatment agent, no expansion of the microcapsules was observed.

After applying the treatment agent, the sheet-like material was heated in a hot air oven at a temperature of about 225° C., and the microcapsules expanded, resulting in a sheet-like material having an appearance similar to furikake. As shown in the cross-sectional view of FIG. 11, this sheet-like material had a regular design of sprinkle-like irregularities that woven a gradation.

Furthermore, since the area to which the two-color treatment agent was applied overlapped with the first-color treatment agent, the amount of microcapsules applied was particularly large. For this reason, the expansion of the microcapsules in this area had a large effect on pulling the foam together, and the furikake-like irregularities in particular became large. The shape of this part was as if a furikake material with large particle size had been sprinkled on it.

Furthermore, the synthetic resin foam layer 34 had air permeability because the partition walls forming this layer were cleaved by heating. For that reason,
This sheet-like material not only has a unique design, but also has excellent breathability, making it an excellent wall covering material.

BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1 and 2 are cross-sectional views of a sheet-like product in which plastisol paint is laminated by screen printing. Figure 3 shows a cross-sectional view of a sheet-like product produced according to the recipe of Japanese Patent Publication No. 62-28481. Figures 4 and 5 show microcapsule-containing processing agents applied to a sheet using gravure printing in the formulation of the present invention. !
! This shows how it arrived. Furthermore, FIG. 6 shows a cross-sectional view of the finished state manufactured using this recipe. Figures 7 and 8 are explanatory views of the prescription and Example 1 described in claim 2, with Figure 7 showing an intermediate stage and Figure 8 showing a completed state as a sectional view. It is. . Figure 9 shows a cross-sectional view of the synthetic resin foam. FIG. 10 is a cross-sectional view of a sheet-like product produced using the prescription described in claim 3. Further, a cross-sectional view of a sheet-like material (wall covering material) produced according to the recipe described in Example 2 according to this recipe is shown in Figure 5-11. l...plastisol paint r! ! Adhesive layer, 2... Synthetic resin layer, 3... Base material, 4... Plastisol paint coating layer (-color), 5... Plastisol paint receiving layer (two-color). , 6...Synthetic resin layer, 7...Base material, 8...Microcapsule-containing plastisol paint coating layer, 9...Synthetic resin layer, lid 0...Base material, II
...Synthetic resin layer, 12...Microcapsule-containing processing agent! ! ! Adhesive layer, 13... Microcapsule-containing treatment agent coating layer, 14... Synthetic resin layer, 15...
- Base material 16... Microcapsule-containing treatment agent coating layer, 17... Synthetic resin layer, 18... Base material, 19...
...Microcapsule-containing treatment agent coating layer, 20...
- Plastisol paint coating layer, 21... Synthetic seal coat layer, 22... Base material, 23... Microcapsule-containing treatment agent layer 24... Plastisol paint I! ! Viewing layer, 25...Synthetic resin coat layer, 26...Flame retardant paper, 27...Synthetic resin foam layer, 28...Base material,
29...Microcapsule treatment agent r4! layering,
30...Synthetic resin foam layer, 31...Base material (flame retardant paper), 32...Microcapsule-containing treatment agent coating layer (-color), 33...Microcapsule-containing treatment Agent coating layer (two-color mouth), 34...Synthetic resin foam layer, 35
...Flame retardant paper. Patent Applicant Kanto Leather Co., Ltd. Representative Director Akinori SekiΦ = Figure-5 Figure-6 Figure-8 [4-9 Figure-1O Figure-11

Claims (1)

[Claims] 1. A synthetic resin-based treatment agent containing microcapsules containing volatile organic compounds such as butane is applied over the entire surface or optionally onto a sheet-like material whose main component is a thermoplastic synthetic resin. The synthetic resin layer is laminated in a pattern, and then the expansion of the microcapsules contained in the processing agent and the softening of the thermoplastic synthetic resin are made to have minute irregularities. A method for manufacturing a sheet-like product. 2. In the manufacturing method described in claim 1, a synthetic resin layer containing vinyl chloride as a main component is laminated on the entire surface or in an arbitrary pattern on the treatment agent-applied area, thereby producing a grain-like pattern. A method for manufacturing a sheet-like product characterized by having an external appearance. 3. A method of manufacturing a sheet-like article according to claim 1, which has air permeability and fine irregularities by using a foam as the thermoplastic synthetic resin layer.