JPH03169613A - Manufacture of decorative sheet - Google Patents

Abstract

PURPOSE:To obtain excellent design by which precise image or pattern is easily provided by a method in which an embossed plate is applied onto the rear side of the film for a decorative sheet made of thermoplastic resin and a pressure barrel is applied onto its front side, thereby achieving emboss working. CONSTITUTION:The film for a decorative sheet is mainly made of thermoplastic resin, and for instance, styrene resin and acryl resin, etc., are used. The preferable materials in said resins are vinylchloride resin and the mixture of vinylchloride resin with acryl resin. The thickness of said film is preferably 30-250mum. The embossed plate having a large print depth i.e., the depth of unevenness shows its effect remarkably, and it is preferably at least 100mum. The embossed plate is applied with pushing onto the rear side of the decorative sheet, and the protrusion of the embossed plate is pushed out, as it is, on the front side of the decorative sheet, and the surface protrusion of the decorative sheet is made, whereby the same shape as the shape to be reproduced, i.e., the same unevenness as its manuscript is obtained. When the opposite embossed plate is a roll, a pressure barrel is preferably a roll naturally. The pressure barrel has preferably the flexibility of some degree and the hardness of at most 80 deg..

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method for manufacturing a decorative sheet, and more particularly to a method for manufacturing a decorative sheet on which precise patterns are clearly applied.

[Prior Art] In the production of conventional decorative sheets, embossing was usually performed by pressing an embossing plate onto the surface of a resin layer provided on a base material.

According to the above method, the concave portions of the embossed decorative sheet are formed in direct contact with the convex portions of the embossing plate, so by forming the desired picture or pattern on the embossing plate in advance, the decorative sheet There is an advantage that a fine pattern can be provided on the bottom or side surface of the recess.

[Problem to be solved by the invention]

However, with the above conventional method, especially when attempting to create deep irregularities on the decorative sheet by embossing, the concave portions of the embossing plate often cannot come into contact with the surface of the resin layer, and the convex portions of the decorative sheet are imprinted with the pattern of the embossing plate. The surface shape of the uncoated resin layer is maintained as it is without being coated, and good design is not imparted to the most conspicuous portion of the decorative sheet. Therefore, a solution to this problem was desired.

Therefore, an object of the present invention is to provide a method for producing a decorative sheet that can easily be provided with precise designs or patterns and that has a good design.

[Means to solve the problem]

As a result of intensive study on the above-mentioned problem, the present inventor found that the object of the present invention can be achieved by the following means.

That is, the present invention relates to a method for producing a decorative sheet, which is characterized in that embossing is performed by applying an embossing plate from the back side of a decorative sheet film made of a thermoplastic resin and applying an impression cylinder from the front side.

The present invention will be explained in detail below.

The decorative sheet film used in the present invention is mainly made of thermoplastic resin. For example, styrene resins, vinyl polymers, acrylic resins, cellulose derivatives, polyester resins, rubber resins, etc. are used. Among them, vinyl chloride resin and a mixture of vinyl chloride resin and acrylic resin are preferred. Thickness is preferably 30-250
It is μm.

The above-mentioned film may be colored, or may have a picture, pattern, etc. printed on its surface.

The embossing plate is preferably made of metal, but other materials such as rubber, plastic, ceramic, etc. can also be used. The embossing plate is preferably in roll form. The surface is engraved with irregularities by etching, electroforming, laser engraving, etc., preferably in the form of a picture or pattern. The effect of the present invention is more clearly exhibited when the plate depth, that is, the depth of the unevenness, is larger. Preferably it is 100 μm or more. The formed unevenness can be obtained by pressing the embossing plate from the back side of the decorative sheet and extruding the convex portion of the embossing plate as it is to the front side of the decorative sheet to form the surface convexity, so that the shape to be reproduced is obtained. It has the same unevenness as the original, that is, the same unevenness as the original. The unevenness formed on a conventional embossing plate is usually the opposite of the unevenness that should be reproduced, since the surface is made into a convex part by pressing the embossing plate from the surface of the decorative sheet and pushing the decorative sheet into the recessed part of the embossing plate. It is important to note that the An impression cylinder is pressed against the surface of the thermoplastic resin layer, facing the embossing plate.

When the facing embossing plate is a roll, the above-mentioned impression cylinder is
Naturally, a roll is preferable. Further, it is preferable that the impression cylinder has a certain degree of flexibility and a hardness of 80° or less.

Preferred materials used include silicone and NBR resin.

The above impression cylinder has fine grains of about 50 μm or less, parallel lines,
It is particularly preferable that unevenness having a shape such as a satin hairline is formed.

In the present invention, embossing can be performed by adjusting temperature and pressure according to a commonly used method.

〔Example] Examples of the present invention are shown below. Example 1 FIG. 1 is a schematic diagram of the apparatus used in this example.

Thickness 5 with pattern 2 printed on the surface by gravure printing
A semi-rigid white polyvinyl chloride sheet 1 containing 8 parts of 0 μm plasticizer was placed on an embossing plate 3 (etching plate plated with chrome, plate depth 500 μm) and a rubber roll 4 in contact with it.
(an NBR resin plate with a hardness of 50', with grain-like unevenness of 5 μm on the surface) was passed through with the pattern 2 on the rubber roll 4 side under pressure to perform embossing.

As a result, the decorative sheet obtained has convex portions of 4 to 8 μm.
It had a matte shape with fine irregularities of m, and exhibited excellent design.

For comparison, a decorative sheet was produced in the same manner as above, with the picture side of the sheet placed against an embossing plate, but the entire surface became glossy and the design was much inferior.

Note that FIG. 3 shows how unevenness is imparted to the decorative sheet in the embossing step. The sheet 1 is passed between the embossing plate 3 and the rubber roll 4 (FIG. 2A). Then,
Pressure is applied in the direction of the arrow, and the sheet 1 is pressed against the embossing plate 3 and the rubber roll 4 (FIG. 2B). With this operation, sheet 1 has large irregularities due to the embossing plate.
Further, fine irregularities are provided by the rubber roll.

Example 2 As shown in the outline of the apparatus used in FIG. 2, a transparent polyvinyl chloride sheet 1' with a pattern printed on both sides 2' was used as an embossing plate (same as in Example 1) and 4 ~8μm
A decorative sheet was obtained in the same manner as in Example 1 by passing it between rubber rolls 4' whose surfaces had somewhat fine patterns.

As a result, a decorative sheet having an excellent design as in Example 1 was obtained.

In particular, it was found that different embossing processes were applied to both sides of the transparent sheet at the same time, creating a design that varied greatly depending on the light rays.

〔Effect of the invention〕

According to the method of the present invention, even when deep irregularities are provided, the convex portions on the surface of the decorative sheet are formed by being dug into the impression cylinder, so that the convex portions have fine and precise concave and convex shapes and a glossy decorative sheet. is obtained. When deep unevenness is created using conventional manufacturing methods, the convexities on the surface of the decorative sheet are pushed into the concave portions of the embossed plate. In many cases, the shape remains and gives an unnatural appearance, so the present invention provides a significantly superior method for improving the design of decorative sheets.

Furthermore, according to the present invention, embossing of different depths can be simultaneously applied to both sides of the decorative sheet, thereby providing a decorative sheet with a wide range of design variations.

[Brief explanation of the drawing]

1 and 2 are schematic diagrams of apparatus used in embodiments of the invention. FIG. 3 is a sectional view showing how the decorative sheet is embossed.

Claims (1)

[Claims] 1. A method for producing a decorative sheet, which is characterized by applying an embossing plate from the back side of a decorative sheet film made of thermoplastic resin and applying an impression cylinder from the front side to perform embossing. 2. The method for manufacturing a decorative sheet according to claim 1, wherein fine irregularities are formed on the surface of the impression cylinder.