JPH07148878A - Decorative sheet - Google Patents

Abstract

PURPOSE:To provide a decorative sheet which is rich in a three-dimensional feel, an integral feel between a design layer and the underlayer, and has a suede appearance. CONSTITUTION:A pattern layer 2 consisting of synthetic resin containing a heat decomposable foaming agent is formed on a base material 1, and a coating layer 3 consisting of synthetic resin containing micro-capsules 4, 4', or the micro- capsule and the heat decomposable foaming agent is formed on the pattern layer. Further, the pattern layer consisting of the synthetic resin containing the heat decomposable foaming agent is formed on the base material, and a coating layer consisting of synthetic resin wherein the micro-capsule and/or the heat decomposable foaming agent are contained, and its average polymerization degree is larger than that of the synthetic resin of the pattern layer, is formed on the pattern layer. The synthetic resin of the pattern layer and the coating layer is peferably polyvinyl chloride, a difference in the average plymerization degree of polyvinyl chloride between the pattern layer and the coating layer is at least 400, the abverage polymerization degree of polyvinyl chloride of the pattern layer is 700-1400, and the average polymerization degree of polyvinyl chloride of the coating layer is 1100-1800.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative sheet,
In particular, the present invention relates to a decorative sheet having a three-dimensional effect and a unity feeling, or a decorative sheet having a suede tone in addition to these.

[0002]

2. Description of the Related Art Walls and ceilings of various buildings, furniture,
So-called decorative sheets used for the purpose of decorating the surface of furniture, electric appliances, bags, etc. have hitherto been (1) foamed or non-foamed synthetic resin ink on a base material such as paper or plastic sheet. The coating layer is formed by, and various pattern layers are also formed by the foaming or non-foaming synthetic resin ink, and the foaming layer is foamed, or (2) this (1) is embossed. It is generally applied.

Further, in order to enhance the decorative effect, a technique for obtaining a decorative sheet exhibiting a suede tone by using a synthetic resin ink containing microcapsules which expand at an appropriate temperature is also described in the following (3) to. Various items listed as an example in (5) have been conventionally developed and partially put into practical use.

(3) The above-mentioned ink containing microcapsules is coated on the entire surface or a part of the above-mentioned substrate, and the ink containing microcapsules is also used thereon to perform a rotary screen method, a gravure printing method, an intaglio printing method. After forming various pattern layers by various printing techniques such as method,
A method in which a microcapsule is expanded by heating to obtain a sheet having extremely fine protrusions by the microcapsule, that is, a suede-like sheet.

(4) A method of producing a suede-like sheet with an uneven pattern by performing embossing after the thermal expansion of the above (3).

(5) After coating the above-mentioned ink containing microcapsules on a base material, printing is carried out on a portion to be formed as a recess with a solvent capable of dissolving the coating film (shell) (made of synthetic resin) of the microcapsules. Destroy the microcapsule,
Then, the microcapsules are expanded by heating to form a sheet in which only the convex portions have a suede tone and the concave portions are flat.

[0007]

[Problems to be Solved by the Invention]
Even in the technique of obtaining a general decorative sheet of (2),
Also, in the technique of obtaining a suede-like decorative sheet of (3) to (5), a sheet having a large number of irregularities can be obtained.

However, in the above-mentioned technique for obtaining a general decorative sheet (1) and the technique for obtaining a suede-like decorative sheet (3), the pattern layer and the coat layer existing below this layer are combined. It lacks a sense of unity, and causes problems such as poor durability or poor luxury depending on the material of both layers and the type of pattern.

On the other hand, with the technique of obtaining the decorative sheet of (2), (4), and (5), it is possible to obtain a sense of unity, but there are the following problems. That is, (2) and (4)
Then, due to the pressure applied during embossing, and in (5) the solvent, the foamed cells and microcapsules may be destroyed or crushed not only in the concave portions but also in the convex portions, and the suede feeling becomes poor and the high-grade feeling disappears. I have something to do.

Various measures have been conventionally proposed as a measure against the three-dimensional effect. One of them is to increase the amount of synthetic resin ink deposited to increase the thickness of the coat layer and the pattern layer. However, this method limits the use because of the increased weight of the sheet. As another one,
There is a method of increasing the expansion (expansion) ratio, but with this method, there is a concern that the strength of the foam layer will decrease in addition to the cost increase due to the increase in the amount of the foaming agent and microcapsules used.
After all, it is subject to application restrictions.

As a measure against the three-dimensional effect without such a defect, a pattern layer made of a synthetic resin containing a decomposable foaming agent is formed on a substrate, and a decomposition layer having a decomposition temperature higher than that of the foaming agent is formed thereon. A technique has also been proposed in which a coating layer is formed from a synthetic resin containing a hydrophilic foaming agent, and foam molding is performed (see Japanese Patent Publication Nos. 59-1580 and 60-36389).

The present invention uses a technique whose technical idea is different from that of the previously proposed one, and is a decorative sheet which is rich in three-dimensional effect and also has a sense of unity without accompanying defects such as increase in weight and decrease in strength of the foam layer. Or, in addition to these, an object is to provide a decorative sheet having a suede tone.

[0013]

Means for Solving the Problems The inventors of the present invention have conducted extensive studies to achieve the above object, and as a result, (a) an uneven pattern layer is provided on a substrate, and a layer covering the pattern layer is formed on the uneven pattern layer. By providing a (that is, a coating layer) and being able to detect the uneven pattern provided on the pattern layer through this coating layer, it is possible to obtain a decorative sheet having a rich three-dimensional effect and a sense of unity. b) If the coating layer contains microcapsules, a decorative sheet exhibiting a suede tone in addition to a three-dimensional effect and a one-dimensional effect can be obtained, and (c) a synthetic resin as a base material of the uneven pattern layer. The inventors have found that a decorative sheet having a more uneven feeling or a three-dimensional effect can be obtained by varying the average degree of polymerization of the synthetic resin that is the base material of the coating layer.

The present invention has been made based on these findings, and a pattern layer made of a synthetic resin containing a thermally decomposable foaming agent is formed on a substrate, and microcapsules or microcapsules are formed on the pattern layer. A gist is a decorative sheet (hereinafter, referred to as a "first invention") characterized by comprising a coating layer made of a synthetic resin containing microcapsules and a thermally decomposable foaming agent.

Further, according to the present invention, a pattern layer made of a synthetic resin containing a thermally decomposable foaming agent is formed on a substrate, and microcapsules and / or a thermally decomposable foaming agent are contained on the pattern layer, and A decorative sheet (hereinafter, referred to as "second invention") characterized in that a covering layer made of a synthetic resin having an average polymerization degree higher than that of the synthetic resin forming the pattern layer is formed. And

In the second invention, the synthetic resin of the pattern layer and the coating layer is polyvinyl chloride, and the difference between the average degree of polymerization of polyvinyl chloride of the pattern layer and the average degree of polymerization of polyvinyl chloride of the coating layer is different. The average degree of polymerization of polyvinyl chloride in the pattern layer is 700 to 1400, and the average degree of polymerization of polyvinyl chloride in the coating layer is 1100.
It is also characterized by being ~ 1800.

In the first and second inventions, the base material is
Paper, plastic sheets, woven fabrics, non-woven fabrics, knitted fabrics, composite materials of these, or those that have been subjected to treatments such as flame retardancy, magnetic shielding, and electrical conductivity, and other materials used as the base material for this type of sheet. Anything can be used if it exists.

In the first and second inventions, the synthetic resin constituting the pattern layer and the coating layer is polyvinyl chloride, a vinyl chloride resin such as a copolymer of vinyl chloride and acetic acid or acrylic acid. , Acrylic resin, etc. can be used.

In these synthetic resins, the pattern layer and the coating layer are generally the same kind of resin, but it goes without saying that different resins may be used. However, in the latter case, a resin in which the resin of the pattern layer and the resin of the coating layer have good adhesiveness is selected and used.

In the second aspect of the invention, the average degree of polymerization of the synthetic resin of the coating layer is larger than the average degree of polymerization of the synthetic resin of the pattern layer. This difference is set to at least 400 when polyvinyl chloride is used for both the pattern layer and the coating layer as the synthetic resin. In the case of polyvinyl chloride, the average degree of polymerization of the pattern layer is 700 to 1
And the average degree of polymerization of the coating layer is 1100 to 1800.
And Even when a resin other than polyvinyl chloride is used, or when the types of synthetic resin used for the pattern layer and the coating layer are different, an appropriate average degree of polymerization is selected using this difference and the range of the average degree of polymerization as a guide. You can use it.

As the heat-decomposable foaming agent to be mixed with the above synthetic resin, the heat-decomposable foaming agent of this type of sheet may be used as long as it decomposes by heating to generate gas. Both an organic foaming agent and an inorganic foaming agent which are usually used as a foaming agent can be used. The decomposition temperature of the foaming agent is not particularly limited as long as it decomposes at about the melting temperature of the synthetic resin of the pattern layer and the coating layer.

The types of foaming agents to be mixed in the synthetic resin for the pattern layer and the coating layer may be the same or different, and the decomposition temperatures may be the same or different.

Further, as the microcapsules to be blended with the synthetic resin of the coating layer in place of the above decomposable foaming agent or together with the decomposable foaming agent, both the first and second inventions,
Any material can be used as long as the volatile solvent or the like enclosed in the synthetic resin shell (coating) is vaporized by heating to expand the shell.

The expansion temperature of the microcapsules is not particularly limited as long as it expands at about the melting temperature of the synthetic resin of the coating layer, and it may be the same as or different from the decomposition temperature of the above-mentioned thermally decomposable foaming agent. May be.

In each of the first and second inventions, the synthetic resin for the pattern layer and the coating layer may include, in addition to the above-mentioned thermally decomposable foaming agent and microcapsules, a plasticizer, a filler, and a flame retardant, if necessary. ,
Antifungal agents, stabilizers, viscosity reducing agents, coloring agents and the like are added.
At this time, if the amount of the stabilizer (particularly, the zinc-based stabilizer) blended in the pattern layer is made larger than the amount blended in the coating layer, foaming of the pattern layer is promoted more than foaming of the coating layer, and It is possible to obtain a product having a more three-dimensional effect.

Further, in the first and second inventions, a pattern layer (hereinafter referred to as "surface pattern layer") can be further formed on the coating layer. However, the thickness of the surface pattern layer is such that the effect of the microcapsules mixed in the coating layer is not lost, that is, about several μm. Further, a thermal decomposable foaming agent or microcapsules can also be added to this surface pattern layer.

Next, a method for producing the decorative sheet of the first and second inventions will be described. 1 (A) and 1 (B)
The process which manufactures an example of the 1st invention is shown, (A) shows the state before heating, and (B) shows the state after heating, respectively.

In FIG. 1A, first, on the base material 1,
Using a synthetic resin ink containing a thermally decomposable foaming agent and other additives as necessary, various patterns are printed by the rotary screen method, gravure printing method, intaglio printing method, doctor knife method, etc. Then, the synthetic resin ink is heated to gel, and the pattern layer 2 is formed.

When the above-mentioned pattern layer 2 is formed by using a synthetic resin ink containing a heat-decomposable foaming agent and microcapsules on the pattern layer 2 and optionally mixed with other various additives. The coating layer is printed by a printing technique similar to the above so as to have a predetermined thickness, and the synthetic resin ink is gelated by heating to form the pattern layer 3. Note that FIG. 1 (A)
Inside, 4 shows the microcapsule before expansion.

After the pattern layer 2 and the coating layer 3 are formed as described above, the above-mentioned surface pattern layer (not shown) is printed by various printing techniques as described above, if necessary, and heat-gelled. To do.

Next, the whole is heated to decompose the thermally decomposable foaming agent in the pattern layer 2 and the coating layer 3, and the microcapsules 4 in the coating layer 3 are expanded to form these layers 2, 3
Are foamed and expanded as shown in FIG. That is, in FIG. 1 (B), the pattern layer 2 is in a state of being foamed by the thermally decomposable foaming agent, and the coating layer 3 is in a state of being foamed by the thermally decomposable foaming agent and expanded by the microcapsules. Become. In addition, 4'in FIG. 1 (B)
Indicates a microcapsule after expansion, and 5 indicates a foam cell.

2A and 2B show a process of manufacturing another example of the first invention, in which (A) shows a state before heating,
(B) shows the state after heating. The example of FIG. 2 is exactly the same as the example of FIG. 1 except that the synthetic resin ink forming the coating layer 3 contains the microcapsules 4 but does not contain the thermally decomposable foaming agent. is there. Therefore, as compared with the example of FIG. 1, the volume of the coating layer 3 is slightly smaller, and the others are exactly the same as the example of FIG.

The example of the second invention is as a synthetic resin ink for the coating layer 3 of FIGS. 1 and 2, (1) a synthetic resin having an average degree of polymerization larger than that of the synthetic resin of the pattern layer 2 (in the case of polyvinyl chloride, Has a difference of 400 or more), or (3) the average degree of polymerization has a pattern as shown in FIG. 3 (A) (state before heating) and (B) (state after heating). A synthetic resin larger than the synthetic resin of layer 2 (in the case of polyvinyl chloride, having a difference of 400 or more), and further containing a thermally decomposable foaming agent but not microcapsules Except for this, it is exactly the same as the example of the first invention shown in FIGS.

In the above manufacturing steps, the heating temperature for gelling the synthetic resin ink of the pattern layer 2, the coating layer 3 and the surface pattern layer is selected according to the kind of synthetic resin ink used or the heat decomposable foaming agent to be blended. In the case of polyvinyl chloride, the temperature is usually about 130 to 160 ° C. at a temperature at which decomposition of the thermally decomposable foaming agent and expansion of the microcapsules do not occur, although it depends on the type of the microcapsules. Further, the temperature at which these layers 2 and 3 and the surface pattern layer are foamed / expanded also differs depending on the types of the synthetic resin ink, the thermally decomposable foaming agent and the microcapsules. The decomposition of the foaming agent and the expansion of the microcapsules are sufficiently performed, but the shell of the microcapsules is at a temperature at which it does not excessively soften, and is usually about 180 to 210 ° C.

[0035]

In the decorative sheet according to the first aspect of the invention, the pattern layer formed on the base material is foamed by the pyrolyzable foaming agent blended into the base material to form an uneven state, and the coating layer formed on the pattern layer. Through this, this unevenness is visually recognized as a three-dimensional pattern, so that a three-dimensional effect and a one-dimensional effect are realized together.

At this time, since the coating layer contains microcapsules, the entire surface of the layer, that is, the decorative sheet of the first aspect of the present invention, has a beautiful suede tone. If the coating layer also contains a pyrolyzable foaming agent, the coating layer also foams, so that the decorative sheet of the first aspect of the invention has an excellent volume feeling.

In the second aspect of the invention, since the average degree of polymerization of the synthetic resin of the coating layer is larger than the average degree of polymerization of the synthetic resin of the pattern layer, both layers are heated together for foaming and expansion. In addition, the degree of melting of the synthetic resin in each layer is different. First, the pattern layer is melted to cause foaming of the layer, and then the coating layer is melted to cause foaming / expansion of the layer. Moreover,
The melting and foaming of the pattern layer continues for a while even after the melting and foaming / expansion of the coating layer is started.
Along with foaming and expansion, more sufficient melting and foaming are performed. From the above, the three-dimensional effect of the pattern layer, and by extension, the decorative sheet of the second invention is sufficient.

In the case where polyvinyl chloride is used as the synthetic resin, the difference in the average degree of polymerization at this time is set to be 400 or more, and when it is less than 400, the above-mentioned action is not sufficiently exhibited, Therefore, a sufficient three-dimensional effect cannot be obtained. In this case, the average degree of polymerization ranges from 700 to 1400 for the pattern layer and 1100 to 1800 for the coating layer.
In the case of polyvinyl chloride, the higher the average degree of polymerization, the better the physical properties and the lack of gloss, which is preferable, but if it exceeds the upper limit, the processability decreases, and if it is less than the lower limit, the processability is good. However, there are drawbacks such as deterioration of physical properties and increased gloss.

Also in the second invention, as in the first invention, since the pattern layer is covered with the covering layer, a sufficient sense of unity can be secured. Since the coating layer contains the microcapsules, a beautiful suede tone can be exhibited on the entire surface of the sheet as in the case of the first invention. If a thermal decomposable foaming agent is also added to this coating layer, the coating layer also foams, resulting in an excellent volume feeling.

[0040]

【Example】

Example 1 As shown in FIG. 1 (A), a base material (on a backing paper) 1 was provided with a table 1
Using a synthetic resin (polyvinyl chloride) ink with the composition shown in, print a pattern by the rotary screen method, and
The pattern layer 2 was formed by heating at 0 ° C. to cause gelation.

A synthetic resin (polyvinyl chloride) ink having the composition shown in Table 2 was used to print the entire surface of the pattern layer 2 by a rotary screen method, and the coating layer 3 was heated to 140 ° C. for gelation. Was formed.

After that, when foamed and expanded in an oven kept at 185 ° C., a three-dimensional effect (unevenness) as shown in FIG. It was possible to obtain a decorative sheet having the above-mentioned characteristics and having a beautiful suede tone in both the concave portion and the convex portion.

[0043]

[Table 1]

[0044]

[Table 2]

Example 2 Except for the fact that the foaming agent (azodicarbonamide) was omitted from the formulation shown in Table 2, the same procedure as in Example 1 was carried out, and as shown in FIG. Forming a pattern layer 2 on the
When the coating layer 3 is formed on this and expanded and expanded in an oven, the state as shown in FIG. 2B is rich in a three-dimensional effect and also has a sense of unity. It was possible to obtain a beautiful suede-like decorative sheet.

Examples 3 to 6 In the formulations shown in Tables 1 and 2, an average degree of polymerization of 130
As shown in FIG. 1 (A), the substrate (on the backing paper 1), a pattern layer 2 is formed, and a coating layer 3 is formed on the pattern layer 2 and foamed / expanded in an oven. In any combination of Table 3, the state as shown in FIG. It is possible to obtain a decorative sheet which has a rich three-dimensional effect and also has a sense of unity, and in which recesses and protrusions have a beautiful suede tone.

[0047]

[Table 3]

Examples 7 to 10 Exactly the same as Example 1 except that the microcapsules were excluded from the formulations shown in Table 2 and the average degree of polymerization of polyvinyl chloride shown in Tables 1 and 2 was changed to the combination shown in Table 3. And then
As shown in FIG. 3 (A), a pattern layer 2 was formed on a base material (on the backing paper) 1, a coating layer 3 was formed on this, and foaming was performed in an oven. In any combination,
As shown in FIG. 3 (B), it was possible to obtain a decorative sheet which was rich in three-dimensionality and had a sense of unity, and in which the recesses and protrusions had a beautiful suede tone.

[0049]

As described above in detail, according to the first and second inventions, the decorative sheet which has a rich three-dimensional effect and also has a sufficient sense of unity between the pattern layer and the covering layer can be obtained. And can be provided at low cost. In addition, the suede tone due to the microcapsules blended in the coating layer does not occur because the microcapsules are destroyed or crushed in the concave portions, and disappears, and even in the concave portions, as beautiful as the convex portions, and It expresses clearly. Moreover, according to the decorative sheet of the first and second inventions, since the pattern layer is covered with the covering layer, the pattern layer peels off during use of the sheet. Without it, it becomes a sheet with excellent durability, and if you combine it with the above-mentioned three-dimensional feeling and unity,
The use of this type of sheet can be further expanded.

[Brief description of drawings]

FIG. 1 is a diagram showing an embodiment of a decorative sheet of the first invention, (A) showing a state before heat foaming (expansion), (B).
Shows the state after heat foaming (expansion).

FIG. 2 is a view showing another embodiment of the decorative sheet of the first invention, (A) showing a state before heat foaming (expansion), and (B).
Shows the state after heat foaming (expansion).

FIG. 3 is a view showing an embodiment of a decorative sheet of the second invention, (A) showing a state before heat foaming (expansion), (B).
Shows the state after heat foaming (expansion).

[Explanation of symbols]

 1 base material 2 pattern layer 3 coating layer 4 microcapsules before expansion 4'microcapsules after expansion 5 foam cells

Claims (4)

[Claims] 1. A pattern layer made of a synthetic resin containing a thermally decomposable foaming agent is formed on a substrate, and the pattern layer is coated with a synthetic resin containing microcapsules or microcapsules and a thermally decomposable foaming agent. A decorative sheet comprising a layer. 2. A pattern layer made of a synthetic resin containing a heat-decomposable foaming agent is formed on a substrate, and microcapsules and / or a heat-decomposable foaming agent are contained on the pattern layer, and the pattern layer is formed. A decorative sheet comprising a coating layer made of a synthetic resin having an average degree of polymerization higher than that of the constituent synthetic resin. 3. The synthetic resin of the pattern layer and the coating layer is polyvinyl chloride, and the difference between the average degree of polymerization of the polyvinyl chloride resin of the pattern layer and the average degree of polymerization of the polyvinyl chloride of the coating layer is 4
The decorative sheet according to claim 2, wherein the decorative sheet is 00 or more. 4. The polyvinyl chloride in the pattern layer has an average degree of polymerization of 700 to 1400, and the polyvinyl chloride in the coating layer has an average degree of polymerization of 1100 to 1800. Decorative sheet.