JPH0314684A - Production of synthetic resin leather - Google Patents

Abstract

PURPOSE:To obtain a synthetic resin leather having a printed pattern accurately coinciding with the position of a relief pattern by successively laminating a solid colored layer and a relief-coinciding pattern layer on a releasing paper and laminating a stretchable substrate layer to the reverse face of the solid colored layer. CONSTITUTION:A solid colored layer 20 and a relief-coinciding pattern layer 30 are successively laminated to a releasing paper 10 to form a transfer sheet S. The releasing paper 10 is peeled off from the transfer sheet to expose the reverse face of the solid colored layer. A stretchable substrate layer (or a substrate layer having foamed layer) is laminated to the reverse face of the solid colored layer to obtain a synthetic leather realizing the accurate coincidence of the printed pattern and the relief pattern at a relatively low cost.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention is a synthetic resin leather used as a material for chair surface materials, vehicle seats, shoe covers, bags, bags, etc. This invention relates to a method of manufacturing synthetic resin leather in which a printed pattern on the surface and a three-dimensional uneven pattern are synchronized.

[Conventional technology]

In recent years, it has become common to apply printed patterns to synthetic resin leather, such as the surface material of chairs.

This printed pattern is generally printed on the surface of this synthetic resin layer using a printing method such as gravure printing.
Printing such as this gravure printing method simply prints a low-viscosity liquid ink onto the surface of a synthetic resin layer, so only a simple and flat pattern can be produced.

Therefore, as a means for applying a three-dimensional uneven pattern, for example, a valley printing method or a method using a foaming suppressor or foaming accelerator has been developed. In addition, in order to improve the design of mari synthetic resin leather, these methods not only create an uneven pattern, but also synchronize this uneven pattern with the printed pattern applied to the surface of this synthetic resin layer. Things are being done.

The former valley printing method involves embossing the synthetic resin layer, such as the foam layer and surface layer, using an embossing roll with a coloring agent attached to the surface of the convex parts of the synthetic resin leather. This is a method of attaching a coloring agent to the embossed recesses.

In addition, the latter method of using a foaming suppressor or foaming accelerator involves laminating, for example, a foamable synthetic resin layer before foaming on the base material layer, and then applying an ordinary ink and an ink containing a foaming suppressor to the surface of this layer. Alternatively, by applying a printed pattern using an ink containing a foaming accelerator, and then heating and foaming this foamable synthetic resin layer, the degree of foaming varies depending on the type of ink used to create an uneven pattern. It is a way of showing off.

[Problems to be solved by the present invention]

By the way, in the former valley printing method, although these printed patterns and the uneven pattern are synchronized, there are restrictions on the composition of the pattern, and as the number of types of patterns increases, the need for expensive embossing rolls increases. It had become necessary.

Further, in those having a structure having a foam layer such as a vinyl chloride resin foam layer, secondary foaming occurs during embossing, causing destruction of foam cells and causing defects.

Furthermore, in the latter method of using a foaming inhibitor or foaming accelerator, the ink containing the foaming inhibitor is expensive, resulting in high costs. Foaming and the number of steps were increased.

Furthermore, when a stretchable base material is used, the pattern and uneven pattern are likely to be distorted due to the expansion and contraction of the base material during foaming, resulting in the inconvenience that the desired design cannot be expressed faithfully. there were.

The present invention was made against the background of such conventional technology, and is relatively inexpensive, requires a relatively small number of steps, and can print patterns and prints at precise positions even when using a stretchable base material layer. An object of the present invention is to provide a method for manufacturing synthetic resin leather that can produce an uneven pattern.

[Means to solve the problem]

The present invention forms a transfer sheet by sequentially laminating a colored solid layer and a pattern/concave/convex matching pattern layer on a release paper, and then peels off the release paper from the transfer sheet to expose the back side of the colored solid layer to the outside. The present invention also provides a method for producing synthetic resin leather, characterized in that a base layer is laminated on the back side of the colored solid layer exposed to the outside.

Another object of the present invention is to provide a method for producing synthetic resin leather in which the base layer is a stretchable base layer or has a foam layer depending on the purpose of use of the leather.

[Effect]

In the method for producing synthetic resin leather of the present invention, a colored solid layer and a pattern/concave/convex matching pattern layer are sequentially laminated on a release paper to form a transfer sheet.

Thereafter, the release paper is peeled off from this transfer sheet to expose the back side of the colored solid layer to the outside.

Next, a base material layer is laminated on the back side of the colored solid layer exposed to the outside.

Therefore, it is relatively inexpensive and requires a relatively small number of steps.
Moreover, even if a stretchable base material layer is used, the printed pattern and the uneven pattern can be synchronized at precise positions.

〔Example〕

Examples of the present invention will be described below, but the present invention is not limited to these examples.

In describing this embodiment, a method for manufacturing synthetic resin leather having a pattern/concave/convex matching pattern layer consisting of three partial pattern layers each having a different hue will be taken as an example.

The method for manufacturing the Hewei resin leather according to the embodiment of the present invention is as shown in FIG. form. In this embodiment, a transparent solid layer 40 is also laminated on the pattern/irregularity matching pattern layer 3o, but this is not necessarily necessary.

The release paper 10 may be a paper or film whose surface has been subjected to a release treatment, or a material that itself has release properties, and any commonly used paper may be used. In addition,
Since the colored solid layer 20 or the like is laminated in a heated and molten state, it is preferable to use a material having heat resistance.

The colored solid N2o is an opaque layer containing a coloring agent to prevent the background of the base material layer 50, which will be described later, from being seen through the surface of the synthetic resin leather. Although vinyl resin is used, other resins such as urethane resin, cellulose resin, and acrylic resin can also be used.

The vinyl chloride resin used in this example is polyvinyl chloride (vinyl chloride homopolymer), or vinyl chloride and other monomers, such as ethylene, vinyl acetate, vinyl ether, maleic ester, (meth)acrylic acid, etc. In addition to copolymers with , (meth)acrylic acid esters, etc., it also includes metal products of polyvinyl chloride and other polymers.

The average degree of polymerization of this vinyl chloride resin is 800 to 800.
3,500, preferably about 1.000 to 1,500.

Examples of the plasticizer contained in this vinyl chloride resin include dibutyl phthalate, diisobutyl phthalate, dioctyl phthalate, didodecyl phthalate, butylbenzyl phthalate, diisodecyl phthalate, dihexyl phthalate, diisononyl phthalate, dioctyl adipate, diisodecyl adipate, dibutyl Sebacate, dioctyl sebacate, tributyl phosphate, tricresyl phosphate, triphenyl phosphate, trichloroethyl phosphate, trioctyl phosphate, diphenyl cresyl phosphate, etc., as well as trimellitic acid ester plasticizers. , epoxy plasticizer, polyester polymer plasticizer, etc. can be used.

The amount of the plasticizer added is 40 to 150 parts by weight, preferably 50 to 100 parts by weight, per 100 parts by weight of the vinyl chloride resin.
If it is less than 40 parts by weight, adjusting the viscosity or imparting cold resistance will be necessary depending on the application, while if it exceeds 150 parts by weight, it will be difficult to peel off the release paper 10 from the transfer sheet S, and when peeling. There is a risk that the laminated sheet consisting of the colored solid layer 20 and the pattern/concave/convex matching pattern layer 30 will stretch, resulting in insufficient width and distortion of the pattern.

Furthermore, although not used in this example, the vinyl chloride resin may contain a blowing agent; in this case,
If necessary, a foaming inhibitor, a foaming accelerator, etc. may be further included to diversify the design expression.

As the blowing agent to be contained in these cases, usual ones such as azodicarbonamide and dinitrosopentamethylenetetramine can be used, but azodicarbonamide is particularly preferred, and the amount added is determined from vinyl chloride-based foaming agents. 2 to 7 parts by weight, preferably <<
is about 3 to 5 parts by weight.

Furthermore, when using a foaming agent, it is better to use a cell conditioner together in order to uniformly foam the vinyl chloride resin composition by the foaming agent and prevent roughening of the surface of the layer. As the cell conditioner, for example, acrylic resin, ethylene-vinyl acetate copolymer resin, etc. can be used.

The amount of the cell conditioner added is about 1 to 10 parts by weight, preferably about 2 to 8 parts by weight, per 100 parts by weight of the vinyl chloride resin.

In addition, as additives contained in the vinyl chloride resin, for example, usual stabilizers, colorants, fillers, antifungal agents, etc. can be used.

Examples of the stabilizers include tin-based stabilizers such as dibutyltin laurate, metal soaps such as barium stearate, zinc stearate, and calcium stearate, and composite stabilizers such as cadmium barium, barium-zinc, and calcium-zinc. can be mentioned.

The amount of the stabilizer added is preferably 2 to 7 parts by weight, particularly preferably 2.5 to 5 parts by weight, per 100 parts by weight of the vinyl chloride resin. Thermal stability deteriorates, and on the other hand, if it exceeds 7 parts by weight, it not only tends to cause quality problems such as bloom and bleed, but also increases the price, which is undesirable.

The coloring agent may be appropriately selected from, for example, phthalocyanine green, chrome yellow, titanium oxide, color carbon black, and the like.

The filler may be any filler as long as it does not undergo physical or chemical changes such as melting or decomposition at the processing temperature, including calcium carbonate, magnesium carbonate, clay, talc, silica, and diatomaceous earth. , silica sand, pumice powder, mica powder, abestos, aluminum ξnium hydroxide, aluminum oxide, aluminum sulfate, barium sulfate, calcium sulfate,
Inorganic fillers such as glass bulbs, foamed glass bulbs, fly ash bulbs, volcanic glass hollow bodies (shirasu balloons), powdered fibers (cellulose powder), polyvinyl alcohol fibers, cork powder, wood powder, thermosetting resin powder, heat Organic fillers such as curable resin hollow bodies can be used. Among them, calcium carbonate, silica, and the like are preferable because they have a matting effect on the colored solid layer 20.

The amount of the filler added is preferably 0 to 70 parts by weight, particularly preferably 0 to 30 parts by weight, per 100 parts by weight of the vinyl chloride resin.If it exceeds 70 parts by weight, the strength may decrease. This is not preferable because it makes the cell structure of the foam rough.

The anti-mold agent may discolor vinyl chloride resin,
10,to'-oxybisphenoxyarsine, which does not inhibit the foaming promoting effect of the foaming promoter;
N-(fluorodimethylthio)monophthalimide,
N-}lichloromethylmercabuto-4-cyclohexane-1,2-dicarpoximide, 2,4,5,6-tetrachlorisophthanitrile and other organic fungicides were added to 100 parts by weight of a vinyl chloride resin. On the other hand, it is preferable to use 1 to 5 parts by weight of an inorganic antifungal agent such as barium metaborate in a case where a sustained effect is required.

In addition, this antifungal agent can be used alone or in combination of two or more kinds.

The vinyl chloride resin composite used for this colored solid layer 20 is similar to conventional vinyl chloride resin composites.
Mixed, kneaded and used.

The vinyl chloride resin compound used for the colored solid layer 20 is used in the form of a paste by adding the plasticizer.

Further, as a method for laminating the colored solid layer 20 on the mold release layer 10, for example, a rotary screen method using a squeegee blade, a doctor method, etc. can be used, and the rotary screen method is particularly preferred because it allows thick coating. . Note that this rotary screen method uses a vinyl chloride resin composition (synthetic resin material), which is the raw material for the colored solid layer 20 shown in FIG. A resin composite material) is extruded through a squeegee blade (not shown) onto the mold release plate 10 shown in FIG.

Next, the pattern/unevenness synchronized pattern layer 30 is a pattern layer in which a printed pattern consisting of an uneven part containing a coloring agent and an uneven pattern are in sync with each other, as shown in FIG.
Materials similar to 0 can be used.

In addition, this pattern/unevenness matching pattern layer 30 is similar to the colored solid layer 20.
It is used in a paste state with the same plasticizer as , and furthermore, the method of laminating this pattern/irregularity matching pattern layer 30 on the colored solid N20 uses the rotary screen method, but it can also be used in combination with printing technology such as gravure printing method. Design expression can be further expanded.

Furthermore, the pattern/unevenness matching pattern layer 30 in this embodiment has a first partial pattern layer 31, a second partial pattern layer 32, and a third portion having different hues such as white, blue, and red, as shown in FIG. The pattern layer 33 is formed by partially overlapping each other, but it is not limited to this, and a colored solid layer is formed by placing an arbitrary number of different color pattern/concave/convex synchronized pattern layers 30 in parallel or partially overlapping each other. It can also be laminated on top of 20.

Next, the transparent solid layer 40 is a surface layer of the synthetic resin leather, as shown in FIG. 1, and is made of a transparent vinyl chloride resin composition (synthetic resin composition t7. material). .

As the material used for this transparent solid layer 40, the same material as the colored solid layer 20 and the pattern/unevenness matching pattern layer 30 can be used, but at least the colored solid layer 20 and the pattern/unevenness matching pattern layer 30 can be seen through. Care must be taken when selecting the type and amount of colorant to be added.

In addition, this transparent solid layer 40 includes a pattern/concave/convex matching pattern layer 30.
The transparent solid layer 40 is used in a paste state by adding the same plasticizer as the colored solid layer 20, and the method of laminating the transparent solid layer 40 on the pattern/irregularity matching pattern layer 30 and/or the colored solid layer 20 is also similar, for example. The rotary screen method can be preferably used. Further, as described above, these release paper 10, colored solid layer 20, pattern/concave/convex matching pattern layer 30, and transparent solid layer 40
The transfer sheet S is formed by sequentially laminating these layers, but this transfer sheet S does not necessarily have to be formed only from these layers, and any other layers may be laminated at any position of these layers. This also includes things that have happened. The specific manufacturing method is as shown in FIG. 2. First, a release paper IO in the form of a raw material is pulled out, and this release paper IO is passed through a rotary screen R1 for colored solid layers and a gelling chamber 01 for colored solid layers. As shown in Figure 1, this release paper l
A colored solid layer 20 is laminated on O. Thereafter, as shown in FIG. 2, this colored solid J! ! A first partial pattern layer 31 is laminated on top of the pattern layer 20, and then, as shown in FIG. As shown in FIG. 2, a second partial pattern layer 32 is laminated on top of the colored solid layer 20 and partially overlaps the first partial pattern layer 31, and then, as shown in FIG. Through the layer rotary screen R4 and the gelling chamber 04 for the third partial pattern layer, as shown in FIG. A three-part pattern layer 33 is laminated. Next, a transparent solid layer 40 is applied to the transparent solid layer rotary screen R5 on the pattern/concave/convex matching pattern layer 30 consisting of the first partial pattern layer 3l, the second partial pattern li32, and the third partial pattern layer 33. The transfer sheet S shown in FIG. 1 is manufactured by laminating the layers through a transparent solid layer gelling chamber G5.

Thereafter, as shown in FIG. 1, the release paper 10 is peeled off from this transfer sheet S to expose the back surface 20a of the colored solid layer 20, and then as shown in FIG. A base material layer 50 is laminated on the back surface 20a of the colored solid layer 20.

The base material layer 50 is a layer that is laminated on the transfer sheet S and serves as a base material of synthetic resin leather.In this embodiment, the material is a material having elasticity, such as sponge or knitted material. However, other fabrics such as woven fabrics, knitted fabrics, and non-woven fabrics can also be used, and the materials include cotton, cotton, polyester fibers, polyamide fibers, vinylon fibers, etc. It can be any type of fiber, such as natural fibers or synthetic fibers,
In order to obtain the effect of the base material layer having elasticity, which is a feature of the present invention, it is suitable to use elastic materials such as knitted fabric and spandex.

Further, as the base material layer 50, a composite material in which a synthetic resin foam layer such as foamed vinyl chloride resin is laminated on these materials can also be used. When the base material layer 50 having such a foam layer is used, it is preferable because sufficient lamination and adhesion can be achieved without using a special pressure bonding rubber, which will be described later.

In this embodiment, the base material layer 50 is laminated onto the transfer sheet by an adhesive method using an adhesive 60 shown in FIG. 4 and a pack-up roller B shown in FIG. Pressure/crimping methods can also be used. Note that if the colored solid layer 20 is hard or the unevenness difference in the pattern/concave/convex matching pattern layer 30 is large, or if the base material layer 50
If it is not sponge, the pressure on the concave portion of the pattern/concave/convex matching pattern layer 30 will be weak, so a soft pressure bonding rubber (usually Shore hardness 70 to 90, preferably less than 70) is used as the backup roller B to improve the adhesion. It is desirable to improve this.

As the adhesive 60 shown in FIG. 4 used in this adhesive method, a urethane adhesive such as a two-part reaction type is used in this embodiment, but other adhesives include polyester adhesive, vinyl chloride-acrylic adhesive, etc. Adhesives, acrylic adhesives, vinyl acetate adhesives, etc. can also be used.

Note that when bonding, if the base material layer 50 is made of a material that is not heat resistant or is made of a material that expands and contracts when heated, care must be taken not to reach a high temperature during the heating operation. Similarly, in the case of the base material layer 50 having a foam layer, high-temperature work should be avoided.

Specifically, when the foam layer 50 is made of vinyl chloride resin,
Desirable temperature conditions are 150°C or less, and 130°C or less when attempting to suppress thickness reduction due to foam cell collapse due to secondary foaming as much as possible.

To ensure adhesive strength at temperatures below 130"C, it is preferable to use a two-component reactive polyurethane adhesive. In this case, the drying temperature of the two-component reactive polyurethane adhesive should be as low as possible (80" below C, preferably below 50°C)
It's good to do.

A specific method of laminating these transfer sheets S and the base material layer 50 is as shown in FIG. adhesive 60
The base material N50 coated with is sandwiched between the heat drum D and the backup roller B shown in FIG. 3, and primary pressure bonding is performed.
Furthermore, if it is necessary to increase the adhesive strength depending on the application, the transfer sheet S side is heated to, for example, 100 to 150°C with a heater H, and then this is subjected to secondary pressure bonding with a pressure roller P, and then this secondary pressure bonded again. The material is cooled by cooling rollers C to produce synthetic resin leather.

In addition, in the case of products with a foam layer with a high expansion ratio or soft products, sufficient heating may not be possible during lamination, and in such cases, the product may be heated for 50 to 60 minutes in a heating room.
C. It is also an effective means to age the adhesive for 24 hours or more to accelerate the reaction of the adhesive.

In the present invention, the colored solid layer 20 and the pattern/concave/convex matching pattern layer 30 are sequentially laminated on the release paper 10 to form the transfer sheet S, and then the release paper is formed from the transfer sheet S. 10
is peeled off to expose the back surface 20a of the colored solid layer 20 to the outside,
Next, the back side 20 of this colored solid layer 20 exposed to the outside
Since the base material layer 50 is laminated on the base material layer 50, it is relatively inexpensive and requires a relatively small number of steps.Moreover, even if a stretchable base material layer is used, printed patterns and uneven patterns can be printed at precise positions. Can appear.

In addition, in the embodiment, the pattern/irregularity matching pattern layer 30 is composed of a first partial pattern layer 31, a second partial pattern layer 32, and a third partial pattern layer 33 that have different hues and are partially overlapped. The design of the manufactured synthetic resin leather can be further improved.

Although the embodiments of the present invention have been described above, the present invention does not need to be limited thereto, and any changes in structure and operation within the scope of the invention are included in the present invention.

For example, in the example, the transfer sheet and the base material layer are sandwiched between a backup roller and a heat drum, and are first pressed together, then the first press bonded material is heated with a heater, and then this is second press bonded with a pressure roller. Although this method is not necessarily limited to this method, any lamination method may be used.

In addition, by mixing a matting agent into the colored solid layer and the pattern/concave/convex matching pattern layer and adjusting the blending ratio of this matting agent, the contrast of the luster of the resin leather can also be matched.

〔Effect of the invention〕

According to the method of the present invention, the synthetic resin is relatively inexpensive, requires a relatively small number of steps, and can produce printed patterns and uneven patterns at accurate positions even when using a stretchable base material layer. The effect of being able to provide leather can be obtained.

Furthermore, when a foamed layer is used as the base material layer, sufficient lamination adhesion can be achieved without using a soft pressure bonding rubber or the like during lamination.

[Brief explanation of drawings]

FIG. 1 is an enlarged sectional view of a transfer sheet in the method for producing synthetic resin leather of the present invention, FIG. 2 is a schematic diagram showing the manufacturing process of the transfer sheet in the method for producing synthetic resin leather of the present invention, and FIG. FIG. 4 is a schematic view showing the process of laminating the transfer sheet and the base material layer in the invention, and is an enlarged sectional view of the synthetic resin leather manufactured by the synthetic resin leather manufacturing method of the invention. S: Transfer sheet IO; Release paper 20: Colored solid layer 20a; Back side 30; Pattern/unevenness matching pattern layer 50; Base material layer

Claims (3)

[Claims] (1) Form a transfer sheet by sequentially laminating a colored solid layer and a pattern/concave/convex matching pattern layer on a release paper, and then peel off the release paper from this transfer sheet to expose the back side of the colored solid layer to the outside, Next, a method for producing synthetic resin leather is characterized in that a base material layer is laminated on the back side of the colored solid layer exposed to the outside. (2) Claim 1, wherein the base material layer is a stretchable base material layer.
The method for manufacturing the synthetic resin leather described. (3) Claim 1, wherein the base material layer has a foam layer.
Or the method for producing synthetic resin leather according to 2.