JPH07276497A - Production of decorative sheet - Google Patents

Abstract

PURPOSE:To provide an inexpensive decorative sheet excellent in design effect near to natural grain wherein a pattern printing layer and embossed recessed parts are synchronized by using a roll-shaped transfer sheet and a plastic sheet to transfer the pattern printing layer to the plastic sheet and continuously applying embossing synchronized with the pattern printing layer at the same time. CONSTITUTION:In a pattern synchronizing embossing method using a transfer sheet 1 wherein a pattern printing pitch is made smaller than an embossed pattern pitch to transfer a pattern printing layer to the single surface of a transparent plastic sheet 5 while embossing the other surface thereof, a compensator roll 14 is arranged between a feed-out roll 15 and a pressure roll 11 both of which are driven at constant peripheral speed to adjust the tension of the transfer sheet 1 and pattern printing and embossing are accurately synchronized.

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 decorative sheet having an embossed concave portion in conformity with a printed pattern and having an excellent design effect.

[0002]

2. Description of the Related Art As a decorative sheet having a wood grain surface used for interior decoration of buildings, finishing of furniture, and surface decoration of other articles, conventionally, a roll-shaped colored polyvinyl chloride sheet and a roll-shaped transparent polyvinyl chloride sheet have been used. Using a vinyl sheet, provide a wood grain pattern printing layer on one side of the colored polyvinyl chloride sheet, and overlay the transparent polyvinyl chloride sheet on that side for continuous thermal lamination and at the same time the transparent polyvinyl chloride sheet surface. There is used a decorative sheet which is embossed on, and filled with colored ink by wiping in the embossed recesses, and then provided with a gloss adjusting layer on the surface thereof.

In the conventional decorative sheet as described above, a roll-shaped material is used to form a pattern printing layer on the surface of the colored polyvinyl chloride sheet by printing, and the pattern printing layer is provided in a separate step. Since a manufacturing method was adopted in which the colored polyvinyl chloride sheet and the transparent polyvinyl chloride sheet were overlaid and continuously embossed at the same time as thermal lamination, the pattern printing layer and the transparent polyvinyl chloride sheet printed on the colored polyvinyl chloride sheet were used. It was not possible to obtain a decorative sheet excellent in design close to natural wood grain, in which the embossing applied to the vinyl chloride sheet surface could not be synchronized, and the pattern printing layer and the recess of the conduit embossing were synchronized.

As a decorative sheet in which the pattern printing layer and the embossed concave portion are aligned, as described in Japanese Patent Application No. 5-26580, a flat plate press type embossing device is used, and the size is the same as that of the embossing type. Using a sheet-shaped transfer sheet provided with a print pattern, align the embossed die and the print pattern of the transfer sheet, and superimpose a transparent polyvinyl chloride sheet on the surface of the transfer sheet provided with the print pattern. Then, by applying an embossing die from the transparent polyvinyl chloride sheet side and applying pressure, the printed pattern is transferred to one surface of the transparent polyvinyl chloride sheet at the same time as the other surface of the transparent polyvinyl chloride sheet, A method for manufacturing a decorative sheet having an embossing that matches the printed pattern is known.

However, the above-mentioned flat plate press type embossing apparatus is used to manufacture a decorative sheet having an emboss in synchronization with the print pattern by using a sheet-shaped transfer sheet provided with a print pattern having the same size as the emboss type dimension. In the method, a transfer sheet provided with a printed pattern having the same size as that of the embossing mold must be manufactured. In order to manufacture such a transfer sheet, it is necessary to use a thick transfer sheet base material having excellent dimensional stability, which is costly.
There is a problem in that it is technically extremely difficult to provide a printed pattern having the same size as the embossed size by printing. Further, it is necessary to manually align the embossing die and the printed pattern of the transfer sheet and set them in the embossing device. Therefore, the transfer sheet becomes expensive, and the workability is very poor due to the manual production, which is not suitable for mass production.

[0006]

SUMMARY OF THE INVENTION An object of the present invention is to transfer a pattern printing layer onto a plastic sheet by using a roll-shaped transfer sheet and a roll-shaped plastic sheet which have not been conventionally used. At the same time, in a method of continuously performing high-speed embossing in synchronization with the pattern printing layer, by increasing the registration accuracy between the pattern printing layer and the embossing, the design printing layer and the embossed recesses are in synchronization with each other and have excellent design properties close to natural wood grain. It is also possible to manufacture an inexpensive decorative sheet.

[0007]

[MEANS FOR SOLVING THE PROBLEMS] Using a transfer sheet provided with a pattern printing layer with a pattern printing pitch smaller than an embossing pitch, a constant tension is maintained by adjusting peripheral speeds of a driven feeding roll and a pressure roll. The transfer sheet is stretched, the embossing and the pattern printing layer are synchronized, and the pattern printing layer is transferred to one surface of the transparent plastic sheet and the other surface is embossed.In the method, a compensator roll is provided between the delivery roll and the embossing roll, A method for producing a decorative sheet, wherein embossing is performed in synchronization with the pattern printing layer by changing the path length of the transfer sheet when the pattern printing layer and the embossing are misaligned.

[0008]

[Operation] A transfer sheet is manufactured so that the pattern print layer of the pattern print layer provided on the transfer sheet substrate is slightly smaller than the embossed pattern pitch, and the pattern print layer is transferred to the transparent plastic sheet at the same time as embossing. In doing so, the tension is adjusted by changing the path length of the transfer sheet by the compensator roll provided between the delivery roll and the pressure roll of the embossing section, and the size of the transfer sheet is changed to change the pattern printing pitch. The pattern print layer transferred to the transparent plastic sheet and the emboss can be synchronized with each other in accordance with the emboss pattern pitch.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to the drawings. FIG. 1 is a schematic view of an apparatus used in the method for producing a decorative sheet of the present invention, FIG. 2 is a diagram for explaining a compensator roll in the apparatus for producing a decorative sheet of the present invention, and FIG. 3 is a method of producing the decorative sheet of the present invention. Sectional view of the transfer sheet used in
4A and 4B are views showing the constitution of the decorative sheet of the present invention, in which FIG. 4A is a sectional view in a state where transfer and embossing are completed, and FIG. 4B is a sectional view in a completed state. Is a transfer sheet substrate, 3 is a pattern printing layer, 4 is a colored resin layer, 5 is a transparent plastic sheet, 6 is an embossed recess, 7 is a gloss adjusting layer, 8 is a wiping ink, 11 is a pressure roll, and 12 is an emboss roll. , 13 is a nickel roll, 14 is a compensator roll, 15 is a delivery roll, 16 is a pitch mark detection device, 17
Is a heating drum, 18 is a heater, 19 is a cooling roll, 20
Is a transfer sheet feeding unit, 21 is a transparent plastic sheet feeding unit, 22 is a transfer sheet base material winding unit, and 23 is a processed sheet winding unit.

The apparatus used in the method for manufacturing a decorative sheet of the present invention is as shown in FIG. 1, and the transfer sheet 1 fed from the transfer sheet feeding section 20 is driven by a feeding roll 15 at a constant peripheral speed. Delivered compensator roll 14
Sent to the embossing section. On the other hand, the transparent plastic sheet 5 exits from the transparent plastic sheet feeding section 21, passes through the heating drum 17 and the preheater 18, and is sent to the embossing section. The pressure roller 11 and the embossing roll 11 are driven so that the transparent plastic sheet 5 is superposed on the pattern printing layer 3 provided on the transfer sheet 1 so that the transparent plastic sheet 5 is in contact with the embossing roll 12.
By passing between the two, the pattern printing layer 3 is transferred to one surface of the transparent plastic sheet 5, and at the same time, the other surface of the transparent plastic sheet 5 is embossed. Pressure roll
After the transfer sheet base material 2 is pressed between the embossing roll 11 and the embossing roll 12, the pitch mark detecting device 16
After being cooled by a cooling roll 19, the transfer sheet base material 2 is peeled off from the transparent plastic sheet 5 and wound up in the processed sheet winding section 23 or transfer sheet base material winding section 22, respectively, to obtain a transparent plastic sheet. Transfer of the pattern print layer 3 to 5 and embossing synchronized with the pattern print layer 3 are completed. The number of delivery rolls 15 driven in the above apparatus is two.
Although it is composed of book rolls, it may be three rolls.

In the above method, the pattern printing pitch in the pattern printing layer 3 of the transfer sheet 1 to be used is printed smaller than the embossed pitch so that the transfer sheet 1 is transferred at the time of transfer.
It is a method of synchronizing the pattern printing layer 3 and the embossing by transferring the pattern printing layer 3 and embossing the pattern printing pitch by stretching it with the tension applied to the embossing pitch. Therefore, the pattern printing pitch in the pattern printing layer 3 is set smaller than the embossing pitch within the range of 0 to 0.5%. Regarding the relationship between the pattern print width and the emboss width, the pattern print width naturally shrinks when the transfer sheet 1 is stretched by tensioning it. Therefore, it is necessary to set the width of the pattern print layer 3 larger than the emboss width. The width of the pattern printing layer 3 is 0 to 0.2% of the width of the embossed pattern.
Largely set. Pattern print layer 3 provided on the transfer sheet 1
It is necessary to appropriately set the numerical values of the pattern printing pitch and the pattern printing width depending on the type and thickness of the transfer sheet substrate, the transfer and embossing conditions.

The pattern printing pitch of the pattern printing layer 3 provided on the transfer sheet 1 is naturally varied when the pattern printing layer 3 is printed on the transfer sheet base material 2. Therefore, the variation is reduced as much as possible, and the pattern printing pitch is reduced. The average value of is preferably in the range of 0 to 0.5% smaller than the embossed pattern pitch as described above. When the pattern print layer 3 is provided on the transfer sheet 1, pattern print pitch marks are provided on both edges of the transfer sheet base material 2 where the pattern print layer 3 is not present, and the emboss roll 12
Should be provided with embossed stitch marks on both flat parts without embossed pattern.

With respect to the relative positional relationship between the pattern print pitch mark and the embossed pitch mark, when the emboss is perfectly aligned with the pattern print layer 3, the two are completely overlapped, the two are adjacent to each other, and both are at a constant distance. Although it may be arranged at any position, it is generally preferable that both are completely overlapped at the same position in a state where the emboss is perfectly aligned with the pattern printing layer 3. In a state where the embossing is not in tune with the pattern print layer 3, the relative positions of both the pattern print pitch mark and the embossed pitch mark are misaligned, so that both the pattern print pitch mark and the embossed pitch mark are optically detected by the pitch mark detection device 16. Accurately detects the position deviation and transmits the information to the compensator roll 14.

The compensator roll 14 is moved in a direction for correcting the deviation between the pattern print pitch mark and the embossed pitch mark based on the information from the pitch mark detection device 16. The operation of the compensator roll 14 will be described with reference to FIG. 2. When the pattern print pitch mark transferred to the transparent plastic sheet 5 is displaced to a position preceding the embossed pitch mark, the compensator roll 14 is moved upward. By increasing the path length of the transfer sheet 1 between the feeding roll 15 and the pressure roll 11 which are driven at a constant peripheral speed, the tension is increased and the deviation is corrected in the direction in which the pattern printing pitch is extended. On the contrary, when the pattern print pitch mark transferred to the transparent plastic sheet 5 is displaced to the position retracted from the embossed pitch mark, the compensator roll 14 is moved downward and driven at a constant peripheral speed. By shortening the path length of the transfer sheet 1 between the delivery roll 15 and the pressure roll 11, the tension is reduced and the pattern printing pitch is shortened to correct the deviation.

When the compensator roll 14 reaches the upper limit U position or the lower limit L position in FIG. 2, it ceases to function, and therefore the upper limit U position or the lower limit L position.
When the position reaches a position U ′ or L ′, which is slightly before this position, a signal is sent to the sending roll 15 to change the peripheral speed of the sending roll 15 to return the compensator roll 14 to the central position C, and the central position C When it reaches, the signal is output again and the peripheral speed of the delivery roll 15 is returned to the original value. That is, when the compensator roll 14 reaches the position of U'close to the upper limit, the peripheral speed of the delivery roll 15 is slowed to move the compensator roll 14 downward, and when the central position C is reached, the peripheral speed of the delivery roll 15 is reached. When the compensator roll 14 reaches the position of L ', which is close to the lower limit, the peripheral speed of the delivery roll 15 is increased to move the compensator roll 14 upward, and when it reaches the central position C, the delivery is performed. Restore the circumferential speed of roll 15.

In the method for producing a decorative sheet of the present invention,
The embossing and the pattern printing layer 3 are perfectly synchronized with each other. When the positions of the pattern printing pitch mark and the embossing pitch mark are displaced, the displacement is detected by the pitch mark detection device 16, and the information is detected by the compensator roll 14. By transmitting, when the compensator roll 14 moves to correct the deviation, and when the compensator roll 14 comes to the position of U'or L'close to the upper limit or the lower limit, the signal is transmitted to the transmission roll 15 and is transmitted. This is performed by changing the peripheral speed of the roll 15 and returning the compensator roll 14 to the central position C.

As shown in FIG. 3, the transfer sheet 1 used for producing the decorative sheet of the present invention generally has a colored resin layer 4 provided on a transfer sheet substrate 2 and a pattern printing layer formed thereon. 3 is formed, however, the pattern printing layer 3 may be directly formed on the transfer sheet substrate 2 without the colored resin layer 4. The colored resin layer 4 provided on the transfer sheet substrate 2 serves as a solid colored layer or a protective layer that covers the entire surface of the pattern printing layer 3 in a state where the pattern printing layer 3 is transferred to the transparent plastic sheet 5. The thickness of the colored resin layer 4 can be arbitrarily set within a range in which it can be applied by printing or coating, but a thickness of 5 to 20 μm is preferable.

As the transfer sheet substrate 2, a plastic film having excellent heat resistance and dimensional stability is suitable, and a polyethylene terephthalate film, a biaxially oriented polypropylene film or the like can be used. Is the best.
The resin used for the pattern printing layer 3 to the colored resin layer 4 may be a resin having good adhesiveness to the transparent plastic sheet 5,
When a transparent polyvinyl chloride sheet is used as the transparent plastic sheet 5, a printing ink made of a vinyl chloride resin or a coating liquid made of a vinyl chloride resin is used. The coloring density of the colored resin layer 4 can be arbitrarily set in relation to the thickness of the colored resin layer 4 so as to be a density necessary for reproducing the grain design in the case of wood grain.

According to the method of the present invention, the pattern printing layer 3 and the colored resin layer 4 are transferred to one surface of the transparent plastic sheet, and the other surface is embossed.
As shown in FIG. 4 (a), the pattern printing layer 3 surface of the sheet in the state of FIG. 4 (a) is wiped, and a protective layer is further provided thereon to provide the pattern printing layer shown in FIG. 4 (b). A decorative sheet in which 3 and emboss are synchronized is obtained.

[0020]

[Effects of the Invention] Using a transfer sheet having a pattern printing layer having a pattern printing pitch smaller than that of the embossed pitch, the transfer sheet is stretched by stretching and one of the transparent plastic sheets is aligned with the pattern printing pitch aligned with the embossed pitch. When the pattern printing layer is transferred to the surface and the embossing is performed in synchronization with the pattern printing layer on the other surface, if a misalignment between the pattern printing layer and the emboss occurs, the misalignment is detected by the pitch mark detection device. Then, by transmitting the information to the compensator roll, it is a manufacturing method of a decorative sheet that adjusts the tension of the transfer sheet to perfectly synchronize the pattern printing layer and the embossing, and by the above method,
The design printing layer transferred to the transparent plastic sheet and the embossing are perfectly in tune with each other, and the design is close to that of natural wood grain.
An inexpensive decorative sheet can be obtained.

[Brief description of drawings]

FIG. 1 is a schematic view of an apparatus used in the method for producing a decorative sheet of the present invention.

FIG. 2 is a diagram for explaining a compensator roll in the decorative sheet manufacturing apparatus of the present invention.

FIG. 3 is a cross-sectional view of a transfer sheet used in manufacturing the decorative sheet of the present invention.

FIG. 4 is a sectional view showing a structure of a decorative sheet of the present invention, where (a) is a sectional view in a state where transfer and embossing are completed, and (b) is a sectional view in a completed state.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Transfer sheet 2 Transfer sheet base material 3 Pattern printing layer 4 Colored resin layer 5 Transparent plastic sheet 6 Embossing concave portion 7 Gloss adjusting layer 8 Wiping ink 11 Pressure roll 12 Embossing roll 13 Nipro roll 14 Compensator roll 15 Sending roll 16 Pitch mark detecting device 17 Heating drum 18 Heating heater 19 Cooling roll 20 Transfer sheet feeding section 21 Transparent plastic sheet feeding section 22 Transfer sheet substrate winding section 23 Processed sheet winding section

Claims (1)

[Claims] 1. A transfer sheet provided with a pattern printing layer with a pattern printing pitch smaller than an embossing pitch is used, and the transfer sheet is kept at a constant tension by adjusting peripheral speeds of a driven feeding roll and a pressure roll. In the method of stretching, transferring the pattern printing layer to one side of the transparent plastic sheet by synchronizing the embossing and the pattern printing layer and embossing on the other side, a compensator roll is provided between the sending roll and the embossing roll, and the pattern printing layer A method for manufacturing a decorative sheet, wherein embossing is performed in synchronization with the pattern printing layer by changing the path length of the transfer sheet when the embossing shift occurs.