JPH04276411A - Manufacture of sheet with design property - Google Patents

Abstract

PURPOSE:To provide a method for manufacture of a sheet which is a sheet for a surface decorative member for construction wherein design property is required in such applications as furnitures, wall surfaces and floors and has a pearl-like brilliance, a three dimensional feeling of an not repeated flow pattern and high design property. CONSTITUTION:A method wherein a particle prepd. by coating the surface of a very thin piece-like mica with a thickness of 0.05-2.0mum with titanium oxide at a thickness of 30-500mum is mixed with an amorphous thermoplastic resin and the mixture is calendered and made into a film by means of a calender roll in such a way that the surface roughness of a sheet prepd. by making the temp. of the final calender rolls at 50-120 deg.C higher than Clash-Berg softening temp. of the thermoplastic resin is 2mum or larger in terms of a mean roughness at a central line.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention is a sheet for architectural facing materials that require a design for furniture, walls, floors, etc., and in particular has pearlescent properties and a three-dimensional appearance with a non-reproducible flow pattern. The present invention relates to a method for producing a sheet with high properties.

0002

BACKGROUND OF THE INVENTION In recent years, there has been an increasing demand for surface materials for furniture, wall materials, floor materials, automobiles, and household electrical appliances to have a more luxurious and unique feel. For example, we use high-quality materials such as marble and natural wood, or bring the design and texture closer to those natural woods.
Apart from the design of multi-layered composite materials with increased durability and natural wood, examples include those that express a high level of design by printing geometric patterns. In addition, synthetic wood is coated with a plastic film printed on it, or resin paint is applied to imitate natural materials such as wood or marble, or an abstract pattern is applied in a similar manner for surface decoration. The patterns are elongated, but they all have flat patterns that lack natural depth, or because they are based on printing, they tend to be monotonous because they are repeating patterns, and they lack a sense of luxury. ing. Generally speaking, repetitive identical designs and flat designs, which are common when expressing designs through simple printing, lack a sense of luxury and give only a certain design value.In fact, they lack the sense of non-reproducibility and three-dimensionality found in natural materials. , depth, etc. were given high design value.

However, high-grade precious wood and marble are very expensive, have limited resources, and have problems with mechanical strength and dimensional stability. Items that express reproduction designs are highly sought after. However, the current situation is that it does not have a three-dimensional effect, changes depending on the viewing angle, has depth, or cannot express the brilliance seen in some marbles and precious woods.

0004

[Problems to be Solved by the Invention] The present invention was made as a result of various studies to improve the lack of depth and monotony of conventional resin-coated facing sheets for furniture and housing materials. To provide a highly designed facing sheet having a three-dimensional design and naturalness without repeatability, which are characteristic of natural marble and the like.

[0005]

[Means for Solving the Problems] The present invention provides a method for applying 300 μm on the surface of mica that is in the form of fine flakes and has a thickness of 0.05 to 2.0 μm.
Particles coated with titanium dioxide (hereinafter referred to as titanium mica) with a film thickness in the range of ~500 mμ are mixed with a thermoplastic resin such as transparent amorphous polyvinyl chloride, ABS, polymethyl methacrylate, or amorphous polyethylene terephthalate. When kneading and further forming a film by rolling using a calendar roll having three or more rolls, the temperature of the final calender roll is set to 50 to 120°C higher than the Crushberg flexibility temperature of the thermoplastic resin, and at least one of the formed sheets is The sheet is sheeted so that the surface roughness of one side is 2 μ or more in center line average roughness, and the sheet after calendering is used alone or laminated with a sheet that can be heat-sealed to the sheet. , a method for producing a decorative sheet, which comprises hot pressing with a hot roll or hot plate press at a temperature 50° C. or more higher than the Crashberg flexibility temperature of the thermoplastic resin, and flattening the sheet or thermally laminating the sheet. Preferably, the thermoplastic resin has a Crashberg flexibility temperature of 55 to 70°C, and the sheet that can be heat-sealed to the calendered sheet is a black, white, or gray achromatic sheet, red, blue, or yellow. A printed sheet with a pattern printed on a colored opaque sheet or a transparent sheet, and furthermore, a sheet that can be heat-fused to the calendered sheet is an achromatic sheet of black, white, or gray. This is a method for producing a decorative sheet which is a composite sheet with two or more layers selected from colored sheets such as red, blue, and yellow, colored opaque sheets, or printed sheets with patterns printed on transparent sheets.

[0006] Titanium mica is not only normal titanium oxide-coated mica but also one coated with colored oxides such as iron oxide and chromium oxide, and reduced titanium mica with a low-oxidation reduced titanium dioxide layer formed under the titanium oxide. Alternatively, titanium oxide colored with an organic compound may also be included. The ratio of titanium mica to resin may be arbitrary, but is preferably 0.2 to 5 g/m2 per unit area of the sheet.

Examples of thermoplastic resins include rigid polyvinyl chloride, semi-rigid polyvinyl chloride, soft polyvinyl chloride, AB
An amorphous material having transparency such as S, polymethyl methacrylate, or amorphous polyethylene terephthalate having a thickness of 300 μm and a light transmittance of 80% or more is used. For these thermoplastic resins, stabilizers, processing aids, anti-aging agents, lubricants, plasticizers, etc. necessary in processing steps can be optionally used.

Titanium mica and thermoplastic resin are mixed and dispersed in a mixer, kneaded in a kneader, and supplied to a calendar roll in the next step, and the mixed or kneaded titanium mica dispersed resin is rolled into a sheet by the calender roll. . Calendar rolls having 3 to 7 rolls are used, and the temperature of the final calender roll is 50 to 120° C. higher than the Crushberg flexibility temperature of the thermoplastic resin used. The obtained sheet has a surface roughness of at least one side of the sheet having a center line average roughness of 2 μ or more, preferably 5
Adjust the final calender roll temperature so that the surface becomes rougher than μ. The temperature of the rolls other than the final calender roll and the speed of each roll are not particularly specified in the present invention.

[0009] The sheet after calender roll processing (hereinafter referred to as a calender sheet) has a roughened surface and is processed at a final calender roll temperature lower than that of a normal mirror-finished calender sheet, so that the dispersed titanium mica has a complex and non-reproducible dispersion in the roughened calender sheet. In other words, the angle of the axis perpendicular to the scale plane of titanium mica with respect to the calender sheet surface is distributed in synchronization with the disturbance of resin flow, and the reflected interference color of titanium mica appears in an irreproducible pattern on the calender sheet. .

[0010] The obtained calendar sheet is a sheet that can be used alone or heat-sealed to the calendar sheet, for example, a sheet having the same composition as the resin of the calendar sheet, and
One or two of the following: achromatic sheets such as black, white, and gray, colored sheets such as red, blue, and yellow, colored pattern sheets with pattern printing on colored sheets, or transparent pattern sheets with pattern printing on transparent sheets. It is composited with more than one type of sheet and bonded by thermocompression.

[0011] The method involves hot pressing using a hot roll or hot plate press at a temperature of the hot roll or hot plate that is 50°C or more higher than the Crushberg flexibility temperature of the calender sheet, and in the case of a calender sheet alone, the sheet is If it is to be flattened and made into a composite sheet, it is flattened and thermally laminated. In the case of a single sheet, the rough surface of the calender sheet is flattened by flattening heat processing and heat lamination according to the surface processing condition of the heat roll or hot plate press. When forming a composite sheet, the rough surface of the calender sheet is placed on the surface, and when laminated, the calender sheet is flat laminated according to the surface processing conditions of the hot roll or hot plate press, and the calender sheet is placed in the middle of the laminated sheet. If the calender sheet is located at 1, the calender sheet is sandwiched between two types of sheets that can be heat-sealed to form a flat laminate.

Unlike ordinary organic and inorganic pigments, the titanium mica of the sheet layer in which titanium mica is dispersed and flattened by heat fusion, the non-reproducible pattern that appears on the calender sheet remains as it is. emphasized. Furthermore, the slope of the titanium mica scales is maintained as it is even after thermocompression bonding, creating a three-dimensional pattern.

When the titanium mica dispersion sheet layer is used alone
At the same time, the above-mentioned non-reproducible pattern and three-dimensional pattern appear, and at the same time, the reflected color has a pearl-like glitter, and at the same time, the transmitted light reveals a complementary color to the reflected light. When multi-layered, a deep and glittering design is created according to the hue pattern of the combined colored sheets and printed sheets.

[0014]

[Example] <<Example 1>> A blend matter was prepared by blending a stabilizer, a lubricant, etc. with polypinyl chloride (PVC) having an average degree of polymerization of 800. Next, 1 part by weight of titanium mica (Iriodin 235 manufactured by Merck & Co.) was added to 100 parts by weight of PVC, dispersed with a disperser, kneaded with a kneader, and charged onto four inverted calendar rolls. The temperatures of the first, second, third and fourth rolls were set at 180°C, 180°C, 170°C and 140°C, respectively, and a 0.2 mm calender sheet was taken out. Thereafter, it was introduced into a pair of metal rolls set at 160°C and flattened by rolling. The resulting sheet has a bright green color in reflected light and a red color in transmitted light, and the dispersion pattern of titanium mica has a three-dimensional effect and a natural pattern that is not reproducible.It has a high degree of design. A sheet was obtained.

<<Example 2>> A calendar sheet was obtained in the same manner as in Example 1, and a transparent semi-rigid black sheet with a thickness of 0.1 mm and a transparent semi-rigid PVC sheet with a marble pattern printed on it with a thickness of 0.1 mm by four-color gravure printing were separately prepared. Prepare a printing sheet,
A black sheet, a calendar sheet, and a transparent printed sheet were laminated in this order, and laminated under pressure using a hot plate press at a temperature of 160°C. The sheet thus obtained had a bright red color with a blackish reflection, and the surface pattern had a natural marble-like appearance with a three-dimensional effect and was non-reproducible, giving it a high degree of design.

[0016]

[Effects of the Invention] According to the present invention, the flat and depthless reproduced pattern obtained only by printing or painting, which is a general manufacturing method for conventional furniture and building material component facing sheets, is not a clearly recognizable pattern, but a pattern with depth. A decorative sheet with a natural pattern and a bright pearl-like shine was obtained.

Claims (6)

[Claims] Claim 1: Finely flaky with a thickness of 0.05 to 2.5 mm.
Particles coated with titanium dioxide with a film thickness in the range of 30 to 500 mμ on the surface of mica having a diameter of 0 μm are mixed or kneaded with a transparent amorphous thermoplastic resin, and then mixed or kneaded with a calender roll having three or more rolls. When forming a rolling film, the temperature of the final calender roll is set to 50 to 120° C. higher than the Krushberg flexibility temperature of the thermoplastic resin,
The film-formed sheet is sheeted so that the surface roughness of at least one side of the film is 2 μ or more in terms of center line average roughness, and the sheet after calendering is heat-fused alone or together with the sheet. The thermoplastic resin is laminated with a sheet that can be attached to the thermoplastic resin, and then hot pressed using a hot roll or hot plate press at a temperature 50° C. or more higher than the Crushberg flexibility temperature of the thermoplastic resin, and the sheet is flattened or hot laminated. A method for producing a decorative sheet. 2. The method for producing a decorative sheet according to claim 1, wherein the Crushberg flexibility temperature of the thermoplastic resin is 55 to 70°C. [Claim 3] The thermoplastic resin is polyvinyl chloride, AB
The method for producing a decorative sheet according to claim 1, wherein S, polymethyl methacrylate, or amorphous polyethylene terephthalate. 4. The design according to claim 1, 2 or 3, wherein the sheet that can be heat-sealed to the calendered sheet is an achromatic sheet such as black, white, or gray, or a colored sheet such as red, blue, or yellow. Method of manufacturing a sex sheet. 5. The method for producing a decorative sheet according to claim 1, wherein the sheet that can be heat-sealed to the calendered sheet is a colored opaque sheet or a printed sheet in which a pattern is printed on a transparent sheet. 6. The sheet that can be heat-sealed to the calendered sheet is a black, white, or gray achromatic sheet;
Claim 1: It is a composite sheet with two or more layers selected from colored sheets such as red, blue, and yellow, printed sheets with patterns printed on colored opaque sheets, or printed sheets with printed transparent sheets. 2. The method for producing a decorative sheet according to 2 or 3.