JPH05200927A - Decorative sheet for interior building material and production thereof - Google Patents

Abstract

PURPOSE:To form a design having depth wherein printing patterns synchronize to surface unevenness by bonding a printing sheet wherein built-up printing layers of curable resin ink are formed on the rear surface of a base sheet to a backing material through a thermoplastic resin foam layer and making the surface of the base sheet uneven by the intensities of the foaming synchronizing to the built-up printing layers of the resin foam layer. CONSTITUTION:A thermoplastic resin layer 2A containing a foaming agent foamed by heating is formed on a backing material 1 and desired patterns are formed on the surface of a base sheet 31 by build-up printing using ink containing a curable resin as vehicle to form a printing layer 32. The ink is subsequently cured to form a printing sheet 3. The printed surface of the printing sheet 3 is laminated to the layer 2A of the foaming agent-containing thermoplastic resin on the backing material 1. The obtained laminate is heated to form resin foam layers 2 wherein the parts 32 where the building-up printing of the curable resin ink is present are foamed at a lower level and parts free from said build-up printing are highly foamed to form uneveness synchronizing to the printing patterns on the surface of the base sheet 31.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative sheet for interior building materials such as flooring materials and wallpaper of buildings, and a method for producing the same.

[0002]

2. Description of the Related Art Among flooring materials used for houses, stores and other buildings, there are those which are not so-called heavy walking types and those which use polyvinyl chloride as decorative sheets for interior building materials such as wallpaper. .. This is usually manufactured by laminating a decorative plastic sheet on a backing material, applying a polyvinyl chloride (PVC) paste on the backing material, heating it for gelation and embossing.

Conventional flooring materials of this type are either plain or have a continuous pattern even if they have a pattern, because it is difficult to manufacture them by synchronizing the printed pattern inside and the embossing on the surface. .

Recently, a cushioning floor material, which gives a soft touch by adding a foaming agent to a PVC paste and foaming it, has been preferred, but it is conventional because of its poor design change. It has the same limitations as floor materials.

As described in JP-B-43-28636, an ink containing a foaming inhibitor is printed on a foamable resin layer to form irregularities by suppressing foaming in that portion. Although there is a technology called “chemical embossing”, the flooring material with a deep design cannot be obtained because the printing layer is not thick. Foaming inhibitors (typically trimellitic anhydride) also have the drawback that the inhibition curing generally decreases over time due to atmospheric humidity.

[0006]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a flooring material having a deep design in which a printed layer of a pattern and surface irregularities are synchronized with each other, and a manufacturing method thereof.

[0007]

As shown in FIG. 1, the flooring material of the present invention comprises a printing sheet (2) in which a foam layer (2) of a thermoplastic resin such as polyvinyl chloride is sandwiched on a backing material (1). The printed sheet (3) is obtained by adhering 3) with an adhesive (33).
Is a plastic substrate sheet (31) having a cured resin ink swell print layer (32) formed on the lower surface thereof. The resin foam layer (2) is synchronized with the swell print and the swell print layer (32) is formed. The part with is the part where foaming is suppressed (22), and the part without is the part with high foaming (2).
In 1), the surface is made uneven by the strength of foaming.

The material of the backing material is arbitrary, but in consideration of dimensional stability and heat resistance, paper having a basis weight of about 50 to 120 g / m ² , polyvinyl chloride (which may be an inexpensive recycled product) or bitumen is used. It is preferable to add calcium carbonate as a filler. If a material having particularly high dimensional stability is required, a material to which glass fiber is added may be used. Nonwoven fabric, glass cloth, or other woven fabric may be used directly, or may be used by laminating the above layers.

The base sheet is made of PVC, polystyrene,
Various plastic sheets can be used, including polyester and polyolefin sheets. The suitable thickness of the base sheet is 25 to 500 μm, particularly about 300 μm.

The adhesive is selected from known ones such as vinyl chloride-vinyl acetate copolymer type and acrylic type.

As shown in the lower part of FIG. 2, the method of the present invention for producing a cosmetic sheet as described above comprises a layer of a thermoplastic resin containing a foaming agent which is foamed by heating on the backing material (1). To form. As a specific example, a polyvinyl chloride paste (2A) is applied and heated to a temperature below the foaming temperature to cause gelation. On the other hand, as shown in the upper part of FIG. 2, a desired pattern is piled up and printed on the surface of a plastic base sheet (31) with an ink containing a curable resin as a vehicle, and then the ink is cured to form a printing sheet. As shown in FIG. 3, the printing surface of the printing sheet was laminated on the coating film of the above-mentioned expandable polyvinyl chloride paste with an adhesive (33), and the obtained laminate was heated to form a cured resin ink. By forming a resin foam layer (2) that causes a low degree of foaming in the areas with raised printing and a high degree of foaming in the areas that do not, forming unevenness in synchronization with the printing pattern on the surface, as shown in FIG. Consists of obtaining flooring.

Needless to say, the paste used in the present invention is made of PVC plastisol and dioctyl phthalate (DO).
It is preferable to add an appropriate amount of a plasticizer represented by P), a foaming agent, a foaming accelerator if necessary, and various additives.

The foaming agent is one which foams when heated.
There are thermal decomposition type and heat expansion type. Examples of the former include inorganic foaming agents such as sodium bicarbonate and ammonium carbonate, and organic foaming agents such as azodicarbonamide, 4,4-oxybisbenzenesulfonyl hydrazide, and paratoluenesulfohydrazide. There are resin microcapsules encapsulating low-boiling substances. Any known one may be used. The foaming accelerator, if necessary,
It is appropriately selected and used according to the foaming agent used. For example, when azodicarbonamide is used as a foaming agent, lead sulfate, lead maleate, lead phthalate, lead stearate, zinc white, urea, oxalic acid, ethanolamine and the like are suitable.

Application of the foamable resin paste to the backing material is
A usual method such as a comma coat method, a gravure coat method, a screen printing method, a roll coat method or a knife coat method may be used.

The thermoplastic resin layer is formed by PV in advance by the sol-coating method or the calendering method.
It may be formed by attaching a C sheet to the backing material with an adhesive. As the thermoplastic resin, in addition to PVC, a vinyl chloride-vinyl acetate copolymer, an acrylic resin, a polyolefin such as polyethylene, or rubber may be used.

The ink for pattern printing on the substrate sheet is
It is an ink that uses a curable resin such as an ionizing radiation curable resin or a thermosetting resin as a vehicle. In particular, it is preferable to use an ink having a vehicle made of an ionizing radiation curable resin because the curing step is completed in a short time.

As the ionizing radiation curable resin, for example, epoxy acrylate, urethane acrylate, acrylic acid-modified alkyd, acrylic-modified polyester or the like is used as an oligomer, and a neopentyl glycol-containing resin is used for the purpose of adjusting a cross-linking structure or viscosity. A mixture of monomers such as diacrylate, pentaerythritol-triacrylate, trimethylolpropane-triacrylate, and trimethylolpropane-trimethacrylate is used. These can be sufficiently cured with an electron beam, but in the case of curing with ultraviolet irradiation, it is common to add a photopolymerization initiator such as a benzoin-based, acetophenone-based, benzyl ketal-based, or ketone / amine-based photopolymerization initiator. is there.

Electron beams and ultraviolet rays are typical examples of ionizing radiation. The former is emitted from various electron beam accelerators,
An electron beam having an energy in the range of 50 to 1000 KeV, preferably 100 to 300 KeV is used, and the latter uses a high pressure mercury lamp or another ultraviolet ray source.

Printing on the substrate sheet may be carried out according to a known method such as a screen method. When using an ionizing radiation curable ink, a method called a drum printing method, in which a pattern is printed and the ink is cured at the same time, is suitable. The raised printing layer is preferably formed so as to have a thickness of 50 μm or more, particularly 100 μm or more.

Lamination may be performed according to known means.

[0021]

In the decorative sheet for interior building materials of the present invention, the foaming of the foaming resin is suppressed by the presence of the raised printing of the cured resin ink, so that the foaming is weak in the portion where the raised printing occurs.
As a result of the non-existent portion becoming stronger, unevenness is formed in synchronism with the print pattern. This unevenness, combined with the fact that the printed layer is thick, realizes a deep design.

[0022]

EXAMPLE A transparent semi-rigid PVC sheet "R type" (manufactured by Riken) having a thickness of 0.3 mm is used as a base sheet, and an ultraviolet curable ink "EXD-1216-3" (Dainichi Seika Kogyo Co., Ltd.) Was manufactured by gravure printing and then irradiated with ultraviolet rays to cure the ink. An adhesive "V-12 medium" (manufactured by Dainichiseika Kogyo Co., Ltd.) was applied to the printing surface of this printing sheet.

On a 0.3 mm thick glass fiber-containing PVC backing material, a PVC paste having the following composition was applied so that the total thickness of the backing material was 1.8 mm, and the temperature was 200 ° C.
The gel was heated by heating to the temperature of 1 minute for 1 minute. On top of this PVC layer, stack the above print sheet with the print side down, 1
It laminated using the impression cylinder roll heated to the temperature of 20 degreeC.

PVC paste PVC “G121” (manufactured by Zeon Corporation) 100 parts by weight Plasticizer (DOP) 65 parts by weight Calcium carbonate “Whiten P30” (manufactured by Toyo Fine Chemical) 5 parts by weight Titanium white “JRNC” (manufactured by Teika) 16 .25 parts by weight Other additives "AZS" (manufactured by Otsuka Chemical) 2.5 parts by weight "O-110" (manufactured by Asahi Denka) 1 part by weight "EC-14" (manufactured by Asahi Denka) 0.5 parts by weight KF-838 "(manufactured by Kyodo Chemical Co., Ltd.) 0.5 parts by weight The above laminate is put in an oven at a temperature of 210 ° C for 2 minutes to foam a PVC layer, and the decorative building material for interior building material of the present invention shown in Fig. 1 is obtained. -A floor material that is

[0025]

EFFECTS OF THE INVENTION The decorative sheet for interior building materials of the present invention has a deep design in which the internal printing pattern and the surface irregularities are synchronized.

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view for explaining the configuration of a flooring material, which is an example of a decorative sheet for interior building materials of the present invention.

FIG. 2 is a view for explaining the method for manufacturing the flooring material of FIG. 1, and is similar to FIG. 1, showing the step of laminating the printing sheet on the expandable polyvinyl chloride layer on the backing material. .

FIG. 3 is a view showing a state of being laminated after FIG.
The same figure as FIG.

[Explanation of symbols]

1 Backing Material 2 Thermoplastic Resin Foaming Layer 21 Highly Foamed Part 22 Foam Suppressed Part 2A Foaming Resin Layer 3 Printing Sheet 31 Base Material Sheet 32 Printing Layer
33 adhesive

Claims (2)

[Claims] 1. A printing sheet is formed by adhering a thermoplastic resin foam layer on a backing material, the printing sheet having a raised printing layer of cured resin ink formed on the lower surface of a plastic base sheet. The resin foam layer is in synchronization with the raised printing, the portion with the raised printed layer is the portion where foaming is suppressed, the non-exposed portion is the highly foamed portion,
A decorative sheet for interior building materials, characterized in that the surface is made uneven by the strength of foaming. 2. An ink containing a curable resin as a vehicle on the surface of a plastic base sheet, which is formed by applying a paste of a thermoplastic resin containing a foaming agent that foams when heated on a backing material A desired pattern is raised and printed, and then the ink is cured to form a printing sheet, and the printing surface of this printing sheet is laminated on the coating film of the foamable polyvinyl chloride paste with an adhesive to obtain a laminate. By heating, hardened resin ink has a low degree of foaming on the printed part and a high degree of foamed resin on the non-printed part to form a resin foam layer, which forms irregularities in synchronization with the printing pattern on the surface. Floor material manufacturing method.