JPH05138846A - Production of plastic laminate having embossed pattern - Google Patents

Abstract

PURPOSE:To inexpensively produce a plastic laminate with high productivity by subjecting a plastic sheet having an arbitrary embossed pattern and a sheet like article composed of other plastic, metal, a nonwoven fabric or ceramic to laminate molding using a usual mirror surface press plate. CONSTITUTION:A plastic laminate is produced by arranging a protective film 4 on a plastic sheet 1 having an embossed pattern and subjecting said sheet to press forming along with a plurality of other sheet like articles 3.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a plastic laminate having an embossed pattern on its surface, which is useful as a building material, a packaging material, an optical material and the like.

[0002]

2. Description of the Related Art Conventionally, for manufacturing a plastic laminate having an embossed pattern, as shown in FIG. 3A, a plastic sheet a and a sheet-like material b are embossed with stainless steel or aluminum alloy. It is sandwiched between the metal plate c and the mirror surface plate d made of the same material, and the embossed pattern is transferred to the surface of the plastic sheet a by press molding to obtain the above laminated body [see FIG. 3 (b)]. Was known. However, in this method, the metal plate with the embossed pattern is expensive, and there is a problem in management such as maintenance against scratches and stains.In actual production, it is necessary to prepare several tens to several hundreds of such metal plates. As a result, the cost has increased and it has not been generalized.

For this reason, a method of using a parchment paper, a sheet of polyethylene terephthalate, polycarbonate or the like instead of the metal plate has been used. This method certainly lowers the cost compared to metal embossed plates, but as press molding is repeated, sheets of parchment paper, polyethylene terephthalate, polycarbonate, etc. deteriorate and the embossed shape collapses and the pattern changes. However, the number of presses that can actually be performed is limited to a few times, and as a result, this method also raises the cost and is not a satisfactory method.

As another method, a known embossing process is applied to the surface of a plastic sheet by an embossing roll, or a sheet having an embossing pattern formed by gravure printing, screen printing or the like is overlaid with another sheet-like material and press-formed. A method of laminating and integrating with is also attempted,
It has not been put to practical use because the embossed pattern is significantly deformed during pressing.

A method of laminating and integrating by using a known doubling machine (hot laminator), instead of the above-mentioned press-forming by laminating and integrating, has been studied.
Also in this case, there is a drawback that the embossed pattern is crushed and deformed when passing through the nip roll. Moreover, the thickness of the plastic sheet available for such a device is about 50 ~.
Since it is 500 μm, there is also a problem that the product shape and use are limited.

[0006] There has also been attempted a method of laminating the above-mentioned embossed plastic sheets by so-called dry laminating (laminating with an adhesive) to integrally laminate them, but this method can maintain the embossed shape. When pasting in sheet form (when using a dry laminator), there is a thickness limitation, and when pasting in cut sheet form, productivity is poor and several days ~
It requires a curing period of 1 week, and there are problems such as deterioration of the plastic sheet due to residual solvent.

[0007]

Therefore, an object of the present invention is to provide a laminate comprising a plastic sheet having an arbitrary embossed pattern and a sheet-like material such as another plastic, metal, non-woven fabric, ceramic, etc. The present invention provides a method for laminating and integrating at low cost and with high productivity by press forming using the brace mirror surface plate.

[0008]

The method for producing a plastic laminate having an embossed pattern according to the present invention comprises providing a protective film on a plastic sheet having an embossed pattern,
It is characterized in that it is press-molded together with other plural sheets.

The details of the present invention will be described below with reference to the accompanying drawings. FIG. 1 relates to a first embodiment of the method of the present invention. FIG. 1A shows the sequence of arrangement of various sheet materials during press lamination molding, and FIG. It is explanatory drawing which respectively shows the state when peeling the protective film from the surface of the coating layer which shows an embossed pattern.

In FIG. 1, 1 is a plastic sheet,
2 is a coating layer provided on the upper surface thereof with an embossed pattern, 3 is a sheet-like material disposed on the lower surface of the plastic sheet 1, 4 is a protective film disposed on the upper surface of the coating layer 5, Reference numeral 5 is a mirror surface plate provided above and below with these sheet materials sandwiched therebetween.

FIG. 2 relates to a second embodiment of the method of the present invention. As with the first embodiment, FIG. 2A shows the arrangement sequence of various sheet materials during press lamination molding, and FIG. 2B. FIG. 3 is an explanatory view showing a state in which the protective film is peeled from the surface of the first plastic sheet having the embossed pattern after the sheet material having this arrangement is laminated and molded.

In FIG. 2, 6 is a plastic sheet having an embossed pattern on its surface by a mechanical means such as an embossing roll, 7 is a sheet-like member provided on the lower surface thereof with an adhesive layer 8, and 9 is plastic. The protective films 10, 10 arranged on the embossed pattern surface of the sheet 6 are mirror surface plates provided above and below with these sheet materials sandwiched therebetween.

As can be seen from these embodiments,
In the method for producing a plastic laminate of the present invention, as a method for imparting an embossed pattern to a plastic sheet, a method for applying an embossed pattern to the surface of the plastic sheet shown in the first embodiment by performing gravure printing, screen printing or the like. In addition to the method of embossing the plastic sheet shown in the second embodiment with an embossing roll having an arbitrary shape, a known inorganic substance such as silica or calcium carbonate, a high degree of polymerization resin, a crosslinked resin, etc. may be added to the plastic sheet. A method of obtaining a continuous embossed matte pattern on the surface by kneading a so-called matting agent, which is not easily melted by heat like the above particles, can be mentioned.

The plastic sheet used here includes, for example, vinyl chloride resin, ABS resin, acrylic resin, ethylene-vinyl acetate copolymer resin, fluororesin,
Thermoplastic resin such as polycarbonate resin, polyethylene resin, polypropylene resin, polyethylene terephthalate resin, polyimide resin, vinyl acetate resin, vinylidene chloride resin, or allyl resin, amino resin, urea resin, melamine resin, epoxy resin, phenol resin, polyurethane resin And the like. These include thermosetting resins such as, and these are used alone or as a mixture of two or more kinds. In addition, if necessary, these resins may include heat stabilizers, lubricants, plasticizers, processing aids, impact modifiers, colorants, fillers, antistatic agents, antioxidants, UV inhibitors, and heat resistance. Additives such as improvers and flame retardants may be added.

The sheet-like materials 3 and 7 to be laminated with these plastic sheets can be laminated by applying an arbitrary adhesive 8 in addition to the plastic sheet which can be heat-sealed with the plastic sheet as it is. All kinds of sheet materials such as plastic, non-woven fabric, metal, glass and ceramic are included.

The protective films 4 and 9 arranged on the plastic sheet having an embossed pattern have a glass transition temperature lower than that of the plastic sheet and are easily deformed by heating and pressing. A sheet-like material of a rubber-like elastic body such as rubber, butadiene rubber, nitrile rubber or the like is used. For example,
When the plastic sheet having an embossed pattern is a hard vinyl chloride sheet, as this protective film,
High density polyethylene, low density polyethylene, polypropylene and the like are used.

If there is a risk that this protective film will be melt-integrated with a plastic sheet having an embossed pattern in the process of lamination and integration by heating and pressurization, the surface in contact with the plastic sheet is preliminarily coated with a silicone resin or a fluororesin. An easy peeling treatment may be performed by providing a film. For example, when the plastic sheet is polypropylene, a polypropylene film coated with a silicone resin can be used as the protective film.

Further, as the press plates 5 and 10 used for the press forming, it is possible to use the generally used mirror surface plates made of stainless steel or aluminum alloy which are generally used. Regarding the pressing conditions at that time, the temperature, pressure and time necessary for laminating and integrating the respective plastic sheets are sufficient, and the embossed pattern is retained by pressing using the ordinary press lamination molding conditions as they are. And it is possible to obtain a laminate with another sheet-like material.

[0019]

According to the method of the present invention, 1) stainless steel or aluminum alloy during press lamination molding is itself expensive and has problems in maintenance such as prevention of scratches and stains. In actual production, Dozens to hundreds of pieces are required, which increases costs and eliminates the need for embossing plates. 2) It is possible to reproduce the embossing roll pattern and the gravure roll printing pattern that have been used in the past.
It is not necessary to prepare a number of press embossing plates for a new embossing pattern or embossing pattern, and only a single embossing roll or a gravure roll is required. 3) During press molding, the convex portion of the embossed pattern is pressed into the protective film, and conversely, the softened protective film fills the concave portion of the embossed pattern, and pressure for lamination is applied. The embossed pattern can be laminated and integrated without being crushed.

[0020]

EXAMPLES Specific embodiments of the present invention will be described below with reference to examples and comparative examples, but the present invention is not limited to the description of these examples. Example 1. A hard vinyl chloride sheet having a thickness of 0.3 mm is used as the plastic sheet 1 in FIG.
As a protective film 4, a hard vinyl chloride sheet having a thickness of 0.05 mm (50 μm), and a mirror plate 5 having a thickness of 2 mm.
A stainless steel laminate was used to make a plastic laminate in the following manner.

Bead-shaped urethane particles 25 having a particle size of 30 μm
To a toluene solution containing 20% by weight of urethane resin and 25% by weight of urethane resin, an isocyanate curing agent was blended at a ratio of urethane resin / curing agent = 10/1, and this was placed on a hard vinyl chloride sheet having a thickness of 0.3 mm. When a gravure coater was applied so that the solid content was 30 μm, a completely matte embossed sheet was obtained.

A thickness of 0.7 mm on the non-coated side of this sheet
Hard vinyl chloride sheet of 0.05 mm (50 μm) in thickness as a protective film on the coating surface side, and these are placed on the upper and lower sides to a thickness of 2 m.
The sheet was sandwiched between stainless steel mirror surface plates of m in diameter, held at a pressure of 150 ° C. for 30 seconds at a pressure of 30 ° C./cm ² , and then cooled to 30 ° C. by another press. When the protective film on the uppermost layer of the obtained laminate was peeled off, FIG.
A completely matte laminate having a thickness of 1.0 mm was obtained, which was similar to that shown in (b). The embossed pattern on this surface was almost unchanged from that before pressing.

Example 2. A hard vinyl chloride sheet having a thickness of 0.2 mm is used as the plastic sheet 6 in FIG.
The sheet-like material 7 is a polypropylene sheet having a thickness of 1.0 mm, the adhesive layer 8 is a urethane adhesive, the protective film 9 is a soft vinyl chloride sheet having a thickness of 0.2 mm, and the mirror surface plate 10 is a thickness of 2 mm. Using the aluminum alloy of No. 3, a plastic laminate was prepared in the following manner.

Immediately after heating a hard vinyl chloride sheet having a thickness of 0.2 mm at 150 ° C. for 20 seconds, it was introduced into the nip between the embossing roll and the rubber roll, the temperature of which was adjusted to 80 ° C., and the pattern of the embossing roll was transferred. The obtained rigid vinyl chloride sheet was obtained.

The anti-embossed side of this sheet was previously coated with a urethane adhesive and dried to a thickness of 1.0 m.
m polypropylene sheet and a 0.2 mm thick soft vinyl chloride sheet as a protective film on the embossed surface side, respectively, which are sandwiched between two upper and lower 2 mm thick aluminum alloy mirror plates, and a temperature of 80 ℃, pressure 30kg /
After performing press lamination molding for 30 seconds under the condition of cm ² ,
Cooled to 30 ° C. When the protective film on the uppermost layer of the obtained laminate was peeled off, a laminate having an embossed pattern with a thickness of 1.2 mm similar to that shown in FIG. 2B was obtained. The embossed pattern on this surface was almost unchanged from that before press molding.

Example 3. Press laminating was carried out in the same manner as in Example 1 except that polyethylene having a thickness of 50 μm was used as the protective film, and a completely matte laminate having a thickness of 1.0 mm was obtained. The matte state of the surface of this laminate before and after lamination was almost unchanged, which was satisfactory.

Example 4. Press lamination was carried out in the same manner as in Example 1 except that a 0.2 mm-thick soft vinyl chloride sheet coated with a silicone resin so that the solid content was 0.3 μm was used as the protective film. A completely matte laminate having a thickness of 1.0 mm was obtained. The matte state of the surface of this laminate before and after lamination was almost unchanged and good.

Example 5. A toluene solution containing 25% by weight of bead-shaped acrylic particles having a particle diameter of 20 μm and 25% by weight of an acrylic resin was applied onto a semi-rigid vinyl chloride sheet having a thickness of 0.2 mm so that the solid content was 30 μm. Partially coated with a gravure coater into a circle with a diameter of 10 cm,
A sheet partially exhibiting a completely matte tone was obtained.

A thickness of 1.0 mm on the non-coated side of this sheet
And a semi-rigid vinyl chloride sheet having a thickness of 0.1 mm with a woodgrain print on the lower side of the hard vinyl chloride sheet, and a thickness of 4 mm as a protective film on the coated surface side.
A 0 μm polypropylene film is placed, and these are sandwiched between two upper and lower 2 mm thick stainless steel mirror plates, and the temperature is set to 1
After holding at 50 ° C. and a pressure of 30 kg / cm ² for 30 seconds,
It was cooled to 30 ° C. as it was. When the protective film on the uppermost layer of the obtained laminate was peeled off, a thickness of partially having a circular completely matte pattern with a diameter of 10 cm was obtained.
A 3 mm laminate was obtained. Almost no change was observed in the matte state of the surface of this laminate before and after press molding.

Example 6. 5 parts by weight of a crosslinked vinyl chloride resin GR-800 (trade name, manufactured by Shin-Etsu Chemical Co., Ltd.) having an average particle size of 4 μm was added to 100 parts by weight of a known compound for molding a calendar sheet, and a known calender molding method was used. A hard vinyl chloride sheet having a thickness of 0.3 mm and a fine matte surface was obtained.

A hard vinyl chloride sheet having a thickness of 0.5 mm is arranged on one surface of this sheet, and a polyethylene film having a thickness of 30 μm is arranged as a protective film on the other surface thereof. It was sandwiched between the aluminum alloy mirror-finished plates of No. 1 and held at a temperature of 150 ° C. and a pressure of 30 kg / cm ² for 30 seconds, and then cooled to 30 ° C. as it was. When the protective film of the obtained laminate was peeled off, a 0.8 mm-thick rigid vinyl chloride laminate having a fine matte surface was obtained. Almost no change was observed in the matte state of the surface of this laminate before and after press molding.

Example 7. After heating a 0.2 mm thick polymethylmethacrylate sheet at 170 ° C. for 20 seconds,
When inserted into the nip between the embossing roll and the rubber roll, the temperature of which was adjusted to 80 ° C., a polymethylmethacrylate sheet having the pattern of the embossing roll transferred was obtained.

A thickness of 0.8 on the side opposite to the embossed surface of this sheet
mm vinyl chloride sheet and a 40 μm thick polypropylene film as a protective film on the embossed surface side, and these are sandwiched between two upper and lower 2 mm thick stainless steel mirror surface plates, temperature 160 ° C., pressure 30 kg / cm ²
After holding for 30 seconds at 30 ° C., it was cooled to 30 ° C. by another press device. When the protective film of the uppermost layer of the obtained laminate was peeled off, the surface having an embossed pattern had a thickness of 1.0 mm.
A laminated body of was obtained. There was almost no change in the embossed pattern on the surface of this laminate before and after press molding.

Example 8. Instead of the polymethylmethacrylate sheet in Example 7, a polycarbonate sheet obtained by heating a 0.2 mm thick polycarbonate sheet at 180 ° C. for 20 seconds and then transferring the pattern of an embossing roll in the same manner was used. Otherwise, when press-lamination molding was performed in the same manner as in Example 7, a 1.0 mm-thick laminate having almost no change in embossed pattern before and after press-molding was obtained.

Comparative Example 1. When press molding was performed in the same manner as in Example 1 except that the protective film was not used, the embossed pattern on the surface of the obtained laminate was significantly crushed and was not suitable for practical use.

Comparative Example 2. When press molding was performed in the same manner as in Example 2 except that the protective film was not used, the embossed pattern on the surface of the obtained laminate was significantly reduced and deformed, which was not suitable for practical use.

Comparative Example 3. When press molding was carried out in the same manner as in Example 6 except that the protective film was not used, the fine matte state disappeared completely and the surface became a mirror-like laminate.

[0038]

EFFECTS OF THE INVENTION According to the method for producing a plastic laminate of the present invention, 1) there is no restriction on the method for providing an embossed pattern, and therefore, ordinary press molding such as expensive metal embossing plate for press, embossed paper, embossed sheet, etc. Since the existing embossing roll, gravure printing, screen printing, etc. can be used without requiring the embossing material used in (1), various embossing patterns can be arbitrarily selected. 2) Since these embossed patterns can be laminated and integrated with other laminating materials by a usual press molding method while sufficiently retaining these embossed patterns, excellent effects can be produced in terms of productivity, cost, and design. 3) The protective film used in the present invention not only protects the embossed pattern, but also serves as a masking film against scratches and stains that easily occur during transportation, cutting, bending, post-form, vacuum forming, pressure forming, etc. To work.

[Brief description of drawings]

1 relates to a first embodiment of the method of the present invention, FIG. 1 (a) shows the sequence of arrangement of various sheet materials during press lamination molding, and FIG. 1 (b) shows lamination of sheet materials with this arrangement. It is explanatory drawing which respectively shows the state after.

FIG. 2 relates to a second embodiment of the method of the present invention, and as in the first embodiment, FIG. 2A shows the arrangement order of various sheet materials during press lamination molding, and FIG. It is explanatory drawing which respectively shows the state after carrying out the lamination molding of the sheet material of arrangement | positioning.

FIG. 3 relates to a method for manufacturing a plastic laminate having an embossed pattern according to a conventional technique, FIG. 3A shows an arrangement order of various sheet materials at the time of press lamination molding, and FIG. 3B shows sheet materials of this arrangement. It is explanatory drawing which respectively shows the state after laminated molding.

[Explanation of symbols]

1, 6 ... Plastic sheet, 2 ... Coating layer,
8 ... Adhesive layer, 3, 7 ... Sheet-like material, 4, 9 ... Protective film, 5, 10 ... Mirror surface plate.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Internal reference number FI Technical display location B29L 9:00 4F

Claims (1)

[Claims] 1. A method for producing a plastic laminate having an embossed pattern, which comprises arranging a protective film on a plastic sheet having an embossed pattern and press-molding it together with a plurality of other sheet-like materials.