JPH08323950A - Manufacture of harmonious emboss decorative sheet - Google Patents

Abstract

PURPOSE: To provide a manufacturing method for a decorative sheet having a highly accurate harmony with patterns and recessed patterns, feel of quality close to that of a genuine natural material, and superior resistance to wear and resistance to chemical of its surface. CONSTITUTION: A pattern layer 3 is formed on an opaque thremoplastic resin film 2 with a heat-resistant film 1 bonded temporarily on its rear face, and the opaque thermoplastic resin film 2 and a heat transparent thermoplastic resin film 4 are laminated together on the side of the pattern layer 3, and recessed patterns harmonized with the picture patterns of the pattern layer 3 are formed on the transparent thermoplastic film 4 by using an emboss block and heat pressurizing, and then the heat-resistant film 1 is released and removed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing interior materials, decorative materials such as furniture and cabinets.

[0002]

2. Description of the Related Art Regarding a conventionally proposed method for producing a synchronous embossing cosmetic material, Japanese Patent Publication No. 58-14312 discloses a colored thermoplastic sheet provided with a printed pattern layer on which a transparent thermoplastic layer is sandwiched. A decorative sheet in which sheets are laminated, a concave pattern is embossed in the laminated sheet, and the concave portions are filled with a colorant, and a method for producing the same are disclosed. In addition, a solid and pattern pattern is printed on a polyethylene terephthalate film, and this is heat-transferred to a transparent vinyl chloride sheet as a transfer paper, and at the same time synchronous embossing is performed. A method of laminating is also proposed.

[0003]

However, in the manufacturing method disclosed in Japanese Patent Publication No. Sho 58-14312, the colored thermoplastic resin sheet typified by vinyl chloride undergoes thermal deformation at the time of tuning embossing, and further, There is a problem that the pattern pattern and the concave pattern provided in the area do not match each other. Further, the method of heat-transferring a transfer paper based on a polyethylene terephthalate film to a transparent vinyl chloride sheet and at the same time performing synchronous embossing is not sufficient for hiding the color of the base material as a decorative paper only by the density of the solid ink in the back. There is a problem. Further, there is a problem that the solid ink layer reduces the adhesive force with the substrate. As a method of this relief, a colored sheet may be laminated in a later process instead of solid printing, but this causes a problem that the process becomes long and the manufacturing cost becomes high. The present invention has been made in view of the above-mentioned problems, and a doubling embossing method in which laminating and embossing are performed at the same time has a register of a picture pattern and a concave pattern, has a texture, is excellent in design, and is a base substrate. It is an object of the present invention to provide a method for producing a tuned embossing decorative material having sufficient hiding power.

[0004]

The present invention, which has been made to solve the above problems, comprises the first to fourth inventions, and the summary is as follows. A first invention, a pattern layer is provided on an opaque thermoplastic film having a heat-resistant film temporarily adhered to the back surface thereof, and the opaque thermoplastic film and the heated transparent thermoplastic film are laminated on the pattern layer side to form the transparent heat film. A heat-resistant film is peeled off from the plastic film side by forming a concave pattern in synchronism with the pattern pattern of the pattern layer by heating and pressing using an embossing plate. Second invention The embossing plate is a roll-shaped embossing plate, and the heat-resistant film, the opaque thermoplastic film and the transparent thermoplastic film are all long films, and the opaque thermoplastic film is made to run in the longitudinal direction. And a heated transparent thermoplastic film laminated on the picture layer side, and a concave pattern synchronized with the picture pattern of the picture layer from the transparent thermoplastic film side by heat and pressure using the roll-shaped embossing plate After forming, the heat resistant film is peeled off and removed. A third invention, wherein the repeating length in the longitudinal direction of the pattern is smaller than the repeating length in the circumferential direction of the embossed pattern of the roll-shaped embossing plate, and the repeating length in the width direction of the pattern is equal to that of the rolled embossed plate. Be formed larger than the repeated length in the width direction. Fourth invention: A coloring agent is applied to the concave portion of the concave pattern by a wiping process.

[0005]

According to the present invention, the colored thermoplastic film is temporarily adhered to the heat-resistant film and then the doubling embossing is performed to suppress the deformation of the colored thermoplastic film due to heat, and the pattern and the concave pattern are formed in advance. By adjusting the pitch difference between and, the tension at the time of doubling embossing is controlled to enhance the synchronization between the picture pattern and the concave pattern, that is, registration accuracy, and the concave portion is colored by wiping, giving it an excellent texture and high design. Enables the production of synchronous embossing cosmetics.

[0006]

The present invention will be described in detail below with reference to the drawings.
The first invention is according to the basic concept of the invention and is illustrated by FIG. First, the heat-resistant and dimensionally stable heat-resistant film 1 which is heat-resistant and dimensional-stable is temporarily adhered to the back surface of the opaque thermoplastic film 2 serving as a substrate. Next, as shown in FIG. 1 (a), a pattern is printed on the opaque thermoplastic film 2 of the temporarily laminated film to form a pattern layer 3. Next, as shown in FIG. 1B, the opaque thermoplastic film 2
The heated transparent thermoplastic film 4 is pressure-bonded and laminated on the side where the pattern layer 3 is present, and at the same time, a concave pattern synchronized with the pattern pattern of the pattern layer 3 is heated from the transparent thermoplastic film 2 side by using an embossing plate. Form by pressure. The above is a method generally called doubling embossing, and the point of the first invention is that the heat resistant film 1 is temporarily adhered and lined during the process of printing a pattern and doubling embossing. Finally, as shown in FIG. 1 (d), the heat-resistant film 1 that has been temporarily adhered is peeled off and removed, whereby the tuning embossing decorative material 10 according to the present invention is obtained.

The opaque thermoplastic film 2 and the transparent thermoplastic film 4 are made of polyolefin resin, polyester, polyvinyl chloride, polyvinylidene chloride, polystyrene, polycarbonate, polyvinyl alcohol,
A thermoplastic film such as polyamide can be used, and the opaque thermoplastic film 2 is colored vinyl chloride (PVC) 30 to 30 by calendering, casting or extrusion film formation.
80 μm is preferably used. As the heat resistant film 1, polyester, nylon polyphenylene oxide,
Polymethylpentene, polycarbonate and the like can be used, but among them, biaxially stretched polyethylene terephthalate film (PET) 25 to 50 μm is preferably used.
Further, any of the following methods may be adopted as a method for temporarily peelably temporarily adhering the heat resistant film to the opaque thermoplastic film. The above-mentioned two films are vacuum-contacted. Casting coating method in which vinyl chloride resin is dissolved in a solvent such as ketone or tetrahydrofuran in the form of paper or heat resistant film and dried. The heat-resistant film is coated with a natural rubber-based, synthetic rubber-based, acrylic emulsion-based, urethane elastomer-based or other pressure-sensitive adhesive, dried, and then pressure-bonded with the thermoplastic film. A thermoplastic resin such as a vinyl chloride resin is extrusion coated onto the heat resistant film. A thermoplastic resin formed into a film by calendering is thermocompression-bonded to a heat-resistant film.

The design pattern is not limited to a wood grain pattern with conduits and may be a stone pattern pattern, an abstract pattern or the like as long as it is effective for reproducibility of the pattern by embossing. The design pattern can be formed on the opaque thermoplastic film 2 by using a known printing method such as gravure printing or silk screen printing. The pattern layer 3 is composed of a printing ink layer, and is used as a printing ink in which known binders such as colorants such as pigments and dyes, extender pigments, solvents, stabilizers, plasticizers, catalysts, curing agents and the like are appropriately mixed. Can be formed by printing. As the binder, an acrylic resin such as polymethylmethacrylate, a vinyl chloride vinyl acetate copolymer, an isocyanate compound and a polyol compound, a room temperature curable or thermosetting resin such as an unsaturated polyester resin, a monomer having an acryloyl group or a methacryloyl group, An ionizing radiation curable resin or the like made of a prepolymer can be used. As the diluting solvent, a binder resin, a colorant such as a pigment, and the like, which has the ability to dissolve and disperse other additives and which has an appropriate drying property, are generally used, but generally, the solubility parameter is a liquid similar to that of the binder. It is preferable to select a solvent from the viewpoint of solubility. As the pigment, a commonly used organic or inorganic pigment can be used. Further, as the pigment, those having a glittering property such as aluminum powder and titanium oxide-coated mica may be used, and in this case, a glittering pattern pattern is obtained.

A second aspect of the present invention is a doubling embossing shown in FIG.
The heat-resistant film 1, the opaque thermoplastic film 2, and the transparent thermoplastic film 4 are all long films, and a roll-shaped embossing plate is used. In the second invention, as shown in FIG. 2, a roll-shaped embossing plate 11 is installed so as to face a backup roll 12 having a silicone rubber wound on the surface thereof, and is supplied from an unwinder 14 between the two rolls. Laminated film, that is, the long opaque thermoplastic film 2 lined with the long heat-resistant film 1 and the unwinder 1 heated by the heating roll 13 to a temperature not lower than the softening temperature of the resin
The long thermoplastic resin film 4 supplied from 5 is guided so that the transparent thermoplastic film 4 is on the embossing roll side, and the film is heated and pressure bonded together to perform embossing at the same time as the lamination. After forming the recessed portion 5 as shown in (1), it is cooled by the cooling roll 16 and wound up.

A third invention is a method used in the second invention for improving the registration accuracy of the picture pattern and the concave pattern. The long opaque thermoplastic film 2 which is the base material of the decorative paper produced by the present invention is the long heat resistant film 1.
It is lined with and has improved dimensional stability. However, due to the heat and tension applied during pattern printing and doubling embossing, the repeating length (pitch) of the pattern is in the longitudinal direction of the long film, that is, in the flow direction and the direction crossing the flow. It is difficult to match the pitch in the circumferential direction and the pitch in the width direction of the concave pattern. Therefore, in the present invention, the pitch in the flow direction of the design pattern is smaller than the pitch in the circumferential direction of the embossed pattern of the roll-shaped embossing plate, and the pitch in the cross direction is intentionally larger than the pitch in the width direction of the roll-shaped embossed plate. Largely formed, apply tension to the laminated film with a picture pattern supplied at the time of performing doubling embossing, and extend the pitch dimension in the flow direction,
The pitch dimension is reduced in the cross direction, and the pitch of the picture pattern is adjusted to the pitch of the recessed pattern. As a result, the pitch error is eliminated and a highly accurate tuning embossing is possible. That is, the point of the third aspect of the invention is to anticipate the registration error between the picture pattern and the concave pattern that may occur at the time of printing and doubling embossing, and pre-design the picture pattern at the printing plate stage within a range in which the laminated film can be tensioned and registered. Is to set the pitch of. The improvement of the accuracy of tuning embossing by this method shows the effect of sharply reproducing the three-dimensional deep texture of the original picture pattern. Note that the registering operation performed during the actual doubling embossing may be performed by visually measuring the register error between the picture pattern and the concave pattern and manually controlling the tension, or by adjusting the pitch marks of the picture pattern and the concave pattern. The tension may be automatically controlled while monitoring by the color-con scanning head 17 that detects the relative deviation amount. The color-con scanning head 17 is operated by a sync signal from a pre-sensor 18 which detects a sync mark.

A fourth aspect of the present invention is a method of coloring a valley portion of a recess 5 formed by doubling embossing with a colored paint or ink, as shown in FIG. 1 (d). This method is for faithful color reproduction of the conduit in the case of a wood grain pattern and the cracks in the case of a stone pattern, and after coating the concave portion with a color coating by roll coating or knife coating, it is scratched with a doctor blade or wiping paper. By taking this, it is possible to give coloring only to the concave portions, and at the same time, it is possible to improve the abrasion resistance and solvent resistance of the product itself.

(Embodiment 1) Next, an embodiment of the method for producing a tuned embossing decorative material according to the present invention will be specifically described. The thickness of the biaxially stretched polyethylene terephthalate film having a thickness of 38 μm was 5
A laminated film was formed by forming a 0 μm colored vinyl chloride film. On the vinyl chloride film surface of this laminated film, a wood grain pattern layer was formed by gravure printing in which the conduit portion of the oak material was removed by gravure printing ink.
Next, a transparent vinyl chloride film (23P
HR) is passed through the film heating section of the doubling embossing machine to raise the temperature of the transparent vinyl chloride film to 160 to 25.
Immediately after heating to about 0 ° C., the laminated film and the pattern layer surface are overlapped and embossed by an embossing roll,
The transparent vinyl chloride film surface was passed through a cooling roll to form a conduit-shaped recess. The concave pattern of the embossing roll in this case is the same as the above-mentioned oak material, and is produced by etching only the conduit portion. The circumferential length of the pattern of the gravure printing plate in the circumferential direction is about 10% smaller than the circumferential length of the concave pattern, and the width of the pattern is repeated in the width direction of the embossed pattern. It is 5% larger than the length. Next, the concave portion of the concave pattern on the surface of the transparent vinyl chloride film obtained by doubling embossing was colored by wiping. Finally, the temporarily adhered polyethylene terephthalate film was peeled off and removed. In the decorative material obtained by the above method, the wood grain and the conduit were well aligned, and the three-dimensional deep texture of natural oak was well reproduced.

[0013]

EFFECTS OF THE INVENTION According to the present invention, it is possible to achieve a very good synchronization between a picture pattern and a concave pattern, and sharply reproduce the three-dimensional deep texture of natural wood, such as wood grain and stone grain, and to improve designability. It is possible to manufacture a high-quality decorative material, and to impart abrasion resistance, chemical resistance, etc. to the outermost surface of the decorative material. Therefore, it is possible to manufacture a high-value-added decorative material.

[Brief description of drawings]

FIG. 1 is a basic conceptual diagram according to the present invention.

FIG. 2 is an explanatory diagram of a doubling embossing method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Heat resistant film 2 Opaque thermoplastic film 3 Picture layer 4 Transparent thermoplastic film 5 Recessed part 6 Coloring material layer 10 Decorative material according to the present invention 11 Embossing roll 12 Backup roll 13 Heating roll 14 Unwinder for laminated film 15 Transparent thermoplastic film Unwinder 16 Cooling roll 17 Color-con scanning head 18 Pre-sensor

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display location B32B 31/18 7148-4F B32B 31/18 31/20 7148-4F 31/20 // B29K 101: 10 B29L 9:00

Claims (4)

[Claims] 1. A pattern layer is provided on an opaque thermoplastic film having a heat-resistant film temporarily adhered to its back surface, and the opaque thermoplastic film and the heated transparent thermoplastic film are laminated on the pattern layer side, and A heat-resistant film is peeled off from a transparent thermoplastic film side to form a concave pattern in synchronization with the pattern of the pattern layer by heating and pressing using an embossing plate, and then the heat-resistant film is peeled and removed. Manufacturing method. 2. The embossing plate according to claim 1 is a roll-like embossing plate, and the heat-resistant film, the opaque thermoplastic film and the transparent thermoplastic film are all long films, and they are run in the longitudinal direction. The opaque thermoplastic film and the heated transparent thermoplastic film are laminated on the pattern layer side, and the roll-shaped embossing plate is used to heat and pressurize the transparent thermoplastic film side of the pattern layer. A method for producing a tuned embossing decorative material, comprising forming a concave pattern in synchronization with a picture pattern and then peeling and removing the heat resistant film. 3. The repeating length in the longitudinal direction of the pattern according to claim 2 is smaller than the repeating length in the circumferential direction of the embossed pattern of the roll-shaped embossing plate, and the repeated length in the width direction of the pattern. Is formed to be larger than the repeated length in the width direction of the roll-shaped embossing plate. 4. The method for producing a tuned embossing cosmetic material according to claim 1, 2, or 3, wherein a colorant is applied to the concave portion of the concave pattern by a wiping process. Production method.