JPH04189140A - Interior material and manufacture thereof - Google Patents

Abstract

PURPOSE:To obtain an interior material having a three-dimensional feeling and showing excellent design effect by providing lower patterns to a base material and intermittently providing upper patterns on the lower patterns and filling upper pattern non-forming parts with transparent resin decorative pieces so as to be capable of seeing through the lower patterns. CONSTITUTION:Lower patterns 22 composed of thin ink layers are formed to a pasty resin base material 21 composed of PVC or urethane by a transfer method and transparent resin layers 29 are formed on the lower patterns 22 and a low density fiber sheet 26 such as a glass fiber nonwoven fabric 26 is laminated to the base material 21 to intermittently form pattern parts 25 on the glass fiber nonwoven fabric. The pattern parts 25 are constituted of ink layers 23 and transparent resin layers 24. Pattern non-forming parts (intermittent parts) are filled with a transparent resin and transparent decorative pieces 29 are formed. As a result, excellent three-dimensional effect is obtained and it is prevented that dust is accumulated in the vicinity of the pattern pieces to contaminate said pattern pieces. Since the transparent resin decorative pieces themselves are synchronized with patterns to form patterns, high design effect is obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application) The present invention relates to interior materials such as floor materials and wall materials, and more specifically, to provide interior materials with excellent three-dimensional appearance and design.

(Problems with the prior art) Conventional methods for manufacturing interior materials include printing using methods such as gravure and screens, methods that provide a difference in gloss in appearance, and these methods include chemical embossing and mechanical embossing. There is a method of using both methods together, but the depth and three-dimensionality of the interior materials obtained by either method are insufficient, and interior materials with even higher designability have been desired.

(Means for solving the problems) The present invention is an invention that solves the above problems, has a three-dimensional effect and is excellent in design, and the manufacturing method of the present invention includes: (a) Step of providing a lower pattern on a base material .

(b) A step of creating a makeup base in which an upper pattern is intermittently formed on a fiber material sheet with a sparse density; (c) A transparent resin is applied on the lower pattern.

a step of placing a makeup base on the transparent resin, (d) permeating the transparent resin through the fiber gaps of the miscellaneous material sheet, coating the upper pattern-free portion with the resin, and then heating and curing;
The gist thereof is a method for producing an interior material, characterized by including a step of forming a transparent resin decorative piece.

Hereinafter, one manufacturing example of the present invention will be explained based on the drawings.

FIG. 6 is a manufacturing process diagram of the decorative material of the present invention, in which polyvinyl chloride (PVC
) Apply the paste lower layer 2 with a doctor blade 3 and pregel it with a heater 4.

The lower pattern 6 may be formed on this pregel layer by printing with a transfer roll 5 or the like, or by applying a relatively thin ink of 3 to 50 μm by rotary or gravure printing, or by a non-printing method.

On the obtained lower pattern 6, M5 of transparent liquid resin 7 such as PVC paste is applied with a doctor blade 8, and while it is in an ungelled state, a makeup base 9 is taken out from the original fabric and a paste is made in an ungelled state. It is placed on top and pressed onto the paste layer by means of rolls 10, 10'. Upper patterns 11 are intermittently formed in advance on the makeup base.

The obtained sheet was heated and cured at 150 to 220°C in an oven 12, and then coated with an ultraviolet ray (hereinafter abbreviated as UV) curable resin [in 13, a layer of U curable resin 14 was applied to a thickness of 20 to 200 μm.
After coating the resin 14 thickly, the resin 14 was cured using a UV irradiation device W15.

The obtained sheet was wound up to obtain an interior material of the present invention.

FIG. 2 is a cross-sectional view of the makeup base used in the present invention,
30 to 60 g/m of ink N18 such as a nonwoven fabric 17 such as glass or a coarse fiber sheet material (exemplified as a nonwoven fabric) having a mesh density is formed, and a transparent resin layer 9 is further formed thereon. A pattern 11 is formed.

At this time, a pattern-free area 20 is obtained, and as a result, the pattern of this pattern-free area is also in sync.

Incidentally, the entire upper pattern 11 may be formed by printing a thick ink layer, and preferably has a thickness of 0.3 to 0.0 mm. In this way, the makeup base 9 is obtained.

In the present invention, a coarse fiber sheet with a density of 30 to 60 g/m is interposed between the upper pattern and the lower pattern, which constitutes a makeup base, and after this fiber sheet is impregnated with a transparent resin, it is cured to become transparent. A pattern piece is obtained, and thus,
The transparent pattern piece allows the lower pattern to be seen through.

The interior material of the present invention includes: (a) a lower pattern is provided on the base material, (b) an upper pattern is intermittently provided on the lower pattern, and (c) a transparent resin decorative piece is provided on the lower part in the area where the upper pattern is not formed. The gist thereof is an interior material characterized by being filled with a pattern that can be seen through.

FIG. 3 is a sectional view of the decorative material of the present invention.

21 is a paste-like resin base material such as PVC or urethane, and the base material preferably has a thickness of 0.5 to 1.5 mm.

A base pattern 22 consisting of a transfer method or a thin ink layer with a thickness of 3 to 50 μm is formed on the base material, and a transparent resin layer 29 is formed on the base pattern 22. Rough fiber material sheets 26 are laminated, and pattern portions 25 having a thickness of 0.3 to 1.0 mm are intermittently formed on the glass fiber nonwoven fabric.

The pattern portion 25 preferably includes the ink layer 23 and the transparent resin 124.
However, the entire pattern layer may be thickly coated with an ink layer.

The non-formed portions (intermittent portions) of the pattern are filled with transparent resin to form transparent decorative pieces 29.

In the present invention, the non-patterned area is also obtained in synchronization with the pattern, and since the transparent decorative piece is formed in this non-formed area, the decorative piece itself also forms the pattern in synchronization with the pattern.

On the other hand, even though there is a textile sheet through the transparent decorative piece, the lower pattern can be seen through.

In the present invention, the surface of the pattern 25 and the decorative piece are coated with transparent resin 28, 28'. The transparent resin may be a PVC paste or a UV curable resin.

In this way, the decorative material 30 of the present invention is obtained.

FIG. 4 is a perspective view of the interior material of the present invention, where 23 is an upper pattern, 29 is a transparent resin decorative piece, 22 is a lower pattern, and 30 is an interior material.

The transparent resin decorative piece 29 allows the lower pattern 22 to be seen through.

Therefore, an interior material with a three-dimensional effect and excellent design can be obtained.

Other manufacturing methods in this application.

(a) Step of providing a lower pattern on the base material; (b) Step of intermittently forming a shielding layer on the lower pattern; re) Providing an upper pattern intermittently on the shielding layer in synchronization with the shielding layer. (d) Filling and forming transparent resin decorative pieces in the intermittent portions to make the lower pattern transparent.

The gist is:

Hereinafter, one manufacturing example of the present invention will be explained based on the drawings.

FIG. 5 is a manufacturing process diagram of the decorative material of the present invention.

A polyvinyl chloride (PVC) paste lower layer 2 is applied onto a base material 1 such as a removable base material or a glass nonwoven fabric using a doctor blade 3 and pregelled using a heater 4 .

A lower pattern 6 is provided on the pre-gelled 176 layer. The lower pattern may be printed by the transfer roll 5, or by printing from 3 to 3.
The lower pattern 6 may be formed using a relatively thin ink of 50 μm using rotary printing, gravure printing, or a non-printing method.

A shielding layer 32 with intermittent portions 33 is formed by a printing layer [31] on the lower pattern.

The shielding layer 32 may be an ink layer of PVC paste or the like having a thickness of 0.1 to 0.31, a soft resin sheet or film, a metal foil, or any other material as long as it is thin and has flexibility and shielding properties.

An upper pattern 35 is provided on the shielding layer by a printing device 34 . The upper pattern 35 may be a transfer print similar to the lower pattern, a thin printed layer, or a 0.3 to 1.0 m thick printed pattern.

A transparent resin layer 36 is formed on the upper pattern obtained above, if desired, and dried with a heater.

Furthermore, a filling device [37, PVC paste,
A transparent resin 38 such as PvC tri-blend powder or acrylic resin is filled, and the obtained sheet is passed through an oven 39 and cured by heating at PVC1,50-220°C, and then UV hardening is applied to the entire surface. After applying a 20 to 200 μm thickness of the transparent vinyl resin, the resin is cured by UV irradiation, and the interior material of the present invention is rolled up.

As a result, the transparent resin 38 is cured and a transparent resin decorative piece is formed.

If desired, after curing the paste layer by heating in an oven,
The release base material may be removed at any position.

In the present application, other interior materials include: (a) a lower pattern is provided on the base material, (b) a shielding layer is intermittently formed on the lower pattern, and (c)
An interior material characterized in that an upper pattern is intermittently provided on the shielding layer in synchronization with the shielding layer, and (d) transparent resin decorative pieces are filled in the intermittent portions so that the lower pattern can be seen through; The gist is:

FIG. 6 is a sectional view of the interior material of the present invention.

21 is a paste-like resin base material such as PVC or urethane, and the base material preferably has a thickness of 0.5 to 1.5I. A base pattern 22 preferably having a relatively thin thickness is formed on the base material by a transfer method or other method. A shielding layer 40 is formed on the base pattern to prevent the base pattern from being seen through from above except through the two gaps provided intermittently.

The shielding layer 40 is a 0.1-0.3I thick soft pvc sheet or film, other soft resin, or metal foil.

The lower pattern of the shielding layer is not seen through except for the intermittent portions 4.

A top pattern 23 is formed on the shielding layer. The pattern layer is 0.3 by transfer method, thin printing layer, or thick printing layer.
Form to a thickness of ~1.0 mm. Furthermore, a transparent resin layer may be formed on the printing layer if desired. The intermittent portion 41 is filled and fixed with transparent resin. The transparent resin is PVCV-st.

PvC triblend, acrylic resin, etc. are suitable, and after filling the intermittent portions with these resins, they are heated and melted to obtain the transparent resin decorative piece 42.

The lower pattern 22 can be seen through the transparent resin decorative piece, and an interior material 43 with a three-dimensional effect and a high design quality can be obtained.

Transparent powder such as PvC tri-blend, PVCV-St38, or other transparent resin may be applied from above the main pattern, and liquid resin such as the uncured paste may be applied to the pattern on the top of the makeup base. The part that has oozed out into the forming part is fixed, and the transparent resin is filled in the same manner as the non-forming part of the upper pattern.

The obtained sheet was passed through an oven as in FIG.
After the VCV-st layer is heat-cured at 150-220°C, a UV-curable resin is coated on the entire surface to a thickness of 50-200 μm using a UV-curable resin coating means, and the resin is cured using a UV irradiation device. Wind up the decorative material.

If desired, after curing the paste layer by heating in an oven,
The release base material may be removed at any position.

As a result, the transparent resin is cured to form the transparent resin decorative piece r'J- in the present invention.

(Effects of the invention) ■ The lower pattern could be seen through the transparent decorative piece, and an excellent three-dimensional effect was obtained.

■ Maintenance was easy because dust did not accumulate near the pattern piece and it did not get dirty.

(2) In the decorative material of the present invention, a high degree of design was achieved because the transparent resin decorative piece itself synchronized with the pattern and also served as a pattern.

(Example) The present invention will be described below with reference to Examples.

Example 1 A 0.2 inch thick ink layer was intermittently formed using PVCV-stylus ink on a 50 g/rrr glass fiber nonwoven fabric, and a 0.2 inch thick transparent resin layer was formed on the ink layer to form an intermittent upper layer. A makeup base having a pattern was created.

PVC paste lower layer and P of the following composition on the peelable base layer
After coating the upper layer of VC paste and pregelling the upper layer of PVC paste, the lower pattern was formed by transfer printing, and then a PVC transparent paste was applied on the transfer printing surface, and while this paste was in an uncured state. The above makeup base was placed on the holder, and the P■C paste was allowed to penetrate into the non-patterned areas.

After filling the non-patterned area, the PVC paste layer was heated to gel.

Next, apply 100μ of acrylic-urethane ultraviolet curable resin.
The interior material of the present invention was obtained by applying ultraviolet rays.

Example 2 A lower layer of PVC paste and an upper layer of PvC paste having the same formulation as in Example 1 were coated on the removable substrate to pregel, and a lower pattern was immediately transfer-printed thereon.

Furthermore, on the base pattern, a PVC paste with the same composition as above was applied and a soft PVC shielding sheet with one intermittent part was laminated,
An upper pattern that matched the intermittent portions of the shielding sheet was transfer printed.

The uncured PvC paste penetrated into the intermittent portions to fill the intermittent portions, and the laminate was heated to gel at 220°C.

Furthermore, an ultraviolet curable resin layer similar to that in Example 1 was formed to obtain an interior material of the present invention.

The interior materials of Examples 1 and 2 are a combination of an upper pattern and a lower pattern with a three-dimensional effect, and the lower pattern can be seen through the transparent resin decorative piece.

High design quality was achieved.

[Brief explanation of the drawing]

Figures 1 and 5 are manufacturing process diagrams for the interior material of the present invention, Figure 2 is a cross-sectional view of the makeup base used in the present invention, Figures 3 and 6 are cross-sectional views of the interior material, and Figure 4 is the interior material. FIG. 1 is a base material, 6 and 22 are lower patterns, 11, 18, and 23 are upper patterns, 9 is a makeup base, and 29.42 is a transparent decorative piece. Figure 2 Figure 3 Figure 4 Procedural amendment written above) December 1990, 5-125-4 Higashiarioka, Tahi Itami City, date of amendment order Voluntary action 5, number of inventions increased by amendment and "drawings" Amendment Content 1: "Interior material and method for manufacturing the same" in the title of the invention on page 1 of the specification is amended to "Interior material and method for manufacturing the same." 2. "Figure 6" on page 4, line 15 of the specification is changed to "Figure 1"
I will correct it. 3. "Layer 5 of 7" on page 5, line 6 of the specification is "layer 7"
I will correct it. 4. Correct "Interior material" in the third line from the bottom of page 5 of the specification to "Interior material 16." 5. Correct "transparent resin layer 29 was formed" on page 7, line 15 of the specification to "impregnated with transparent resin." 6. Correct "Intermittent part 4" on page 12, line 12 of the specification to "Intermittent part 41." 7. Correct "Formulation" in the second line of page 15 of the specification to "Formulation A" and correct "on the printing surface" and rPVcJO in the fifth line of the same page.
Insert "Formulation B below" in between. 8. Insert the following table between lines 10 and 11 on page 15 of the Meirensho. To compounding Part by weight pvc <
(to zero strike scene)
70P V C()-Ln)-C scene)
30DOP
70 stabilizer (Ba-Zn type)
3 Calcium carbonate 150 Titanium oxide 3 combination B
Weight part pvc <to 0-stroke scene) 100DOP
50 stabilizer (Ba-Zn type)
3 Stabilizer (Sn-based) 1
9. Correct the drawing “Figure 6” as shown in the attached sheet. Figure 6 above

Claims (1)

[Claims] 1. (a) a lower pattern is provided on the base material, (b) an upper pattern is intermittently provided on the lower pattern, and (c) a transparent resin decorative piece is provided in the area where the upper pattern is not formed. An interior material characterized by being filled with a pattern at the bottom that can be seen through. 2. The interior material according to claim 1, wherein a fibrous sheet with a coarse density is interposed between the upper pattern and the lower pattern. 3. (a) Step of providing a lower pattern on the base material, (b) Step of creating a makeup base in which an upper pattern is intermittently formed on a fiber material sheet with a sparse density, (c) A step of forming a transparent base on the lower pattern. (d) After permeating the transparent resin through the fiber gaps of the fiber material sheet and coating the upper pattern-free portion with the resin; A method for producing an interior material, comprising the step of heating and curing to form a transparent resin decorative piece. 4. (a) A lower pattern is provided on the base material, (b) a shielding layer is intermittently formed on the lower pattern, and (c) an upper pattern is intermittently formed on the shielding layer in synchronization with the shielding layer. (d) The intermittent portions are filled with transparent resin decorative pieces so that the lower pattern can be seen through. 5. (a) Step of providing a lower pattern on the base material, (b) Step of intermittently forming a shielding layer on the lower pattern, (c) Intermittently forming an upper part on the shielding layer in synchronization with the shielding layer. A method for producing an interior material, comprising the steps of: providing a pattern; (d) filling and forming transparent resin decorative pieces in the intermittent portions to make the lower pattern transparent.