JPH09109303A - Foamed embossed decorative sheet and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve surface hardness, stain resistance, chemical resistance, and processability by a method in which an expandable resin layer is installed on a substrate, a printing layer is formed optionally, and an ultraviolet curable resin layer is laminated on a surface. SOLUTION: In a foamed embossed decorative sheet, an expandable resin layer 2 is laminated on a substrate 1 and adjusted not to be expanded by heating. Next, a printing layer is installed optionally using oil ink or water-color ink, and an ultraviolet curable resin layer 4 is laminated on a surface for constitution. The expandable resin layer 2 can be laminated on the substrate 1 by application using a knife coater, a gravure coater, etc. The ultraviolet curable resin layer 4 is laminated on the expandable resin layer 2 by a method similar to that in which the expandable resin layer 2 was laminated on the substrate 1. Drying is done in a similar method. The laminate, after being expanded by heating to a foaming temperature, is embossed by a embossing roll. The surface of the ultraviolet curable resin of the sheet is irradiated with ultraviolet rays to be cured completely.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foamed embossed decorative sheet used as an interior material for buildings, and more particularly, a foamed embossed decorative sheet used for wallpaper having excellent surface strength, stain resistance, chemical resistance and workability. The present invention relates to a sheet and a method for manufacturing the sheet.

[0002]

2. Description of the Related Art The basic construction of wallpaper, which has been used in large quantities as an interior material for construction, is to apply a resin paste on a base material, print various prints, patterns, etc., and foam it. , The surface of which is provided with an uneven pattern by embossing. However, since vinyl chloride wallpaper, which is mainly used in wallpaper, contains a large amount of plasticizer, there is a problem that bleeding of the plasticizer on the surface of the wallpaper causes dust and tars of cigarettes to adhere and stain easily over time. It was

On the other hand, non-plastisol wallpaper is being developed (JP-A-6-33380 and JP-A-6-33).
No. 399, etc.), an organic solvent such as a plasticizer is not used, so that there is no fear of stains due to bleeding. But,
Water-based emulsions and other water-based resins are the main resins used for non-plastisol wallpaper, and they lack the excellent elasticity and toughness of vinyl chloride, so when high foaming is required, for example, the surface strength is weak. There is a problem of becoming.

Therefore, various proposals have been made to solve these problems. For example, olefin-based copolymer resin film, fluorine-based copolymer resin film, acrylic-based copolymer resin film, etc. are aligned with the resin surface of the foamed vinyl chloride wallpaper, and pressure-bonded with an adhesive or hot embossing roll, and at the same time embossed Or a method of blocking the bleeding of the plasticizer and providing a stain preventing function by simply laminating them (Japanese Patent Publication No. 5-3381, Japanese Patent Application Laid-Open No. 2-139484, Japanese Utility Model Application Laid-Open No. 4-263).
No. 0 gazette, actual Kaihei 6-10400 gazette, actual Kaihei 6-2
2396).

However, since the embossing is performed through the film, if the film is too soft, it may be taken by the embossing roll and the stain resistance is deteriorated. On the contrary, if it is too hard, a sharp embossed shape cannot be obtained. , There is a problem.

On the surface of the vinyl chloride resin layer coated on the substrate, ethylene-vinyl alcohol copolymer resin (JP-A-6-57692) and fluorine copolymer resin (JP-A-2-300388). However, since a film is formed on the foamed resin surface, it is difficult to foam and only low foamed products can be produced.

[0007] Further, in order to give the wallpaper strength and hardness,
A method in which a transparent UV-curable resin layer is coated on the resin surface of a vinyl chloride wallpaper, semi-cured and then attached to a wall surface, and the entire surface of the wallpaper is irradiated with UV rays to complete the curing (Japanese Patent Laid-Open No. 3-161600) However, similarly, there are problems that the expansion ratio cannot be obtained and that it is not realistic to bring an ultraviolet irradiation device to the site of implementation.

In addition, among the methods for producing vinyl chloride wallpaper, there is currently a wallpaper that is made by a method using a suppressive ink (chemical embossing) or a foaming ink, and it is widely adopted because of its excellent design. There is. However, if the above-mentioned conventional techniques are applied in order to improve the stain resistance, strength, etc. of the surface of the wallpaper made by these methods, they are both tough depending on whether they are coated on the surface of the wallpaper or laminated with a film. Since the surface film is formed and the foaming of the resin layer is suppressed, neither the suppressing ink nor the foaming ink exerts its effect.

[0009]

SUMMARY OF THE INVENTION The present invention has been made to solve such problems, and its problems are surface strength, stain resistance, chemical resistance, workability, etc. To provide an excellent foamed embossed decorative sheet and a method for producing the same.

[0010]

Means for Solving the Problems In order to solve the above-mentioned problems, the present invention provides a foamed embossed decorative sheet having a foamable resin layer on a substrate and optionally a printed layer, To provide a foamed embossed decorative sheet, characterized in that it is provided with an ultraviolet curable resin layer, as a manufacturing method thereof, the foamable resin is applied on a substrate, dried, and a printing layer is optionally provided by printing, It is characterized by applying UV-curable resin on it, drying it, foaming the foamable resin by heating, embossing the surface, and then irradiating the surface with UV light to completely cure the UV-curable resin. The present invention provides a method for producing a foamed embossed decorative sheet.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the drawings. The substrate 1 of the present invention is not particularly limited. For example, a pulp paper-based flame-retardant paper impregnated with a water-soluble flame-retardant such as guanazine sulfanylate or guanazine phosphate is possible, and an inorganic substance obtained by mixing an inorganic agent such as calcium carbonate, aluminum hydroxide or magnesium hydroxide. In addition to paper, woven and non-woven fabrics can be used.

The resin of the expandable resin layer 2 of the present invention comprises the following resins, foaming agents, inorganic fillers and other additives. Examples of the resin include (1) a plastisol-based vinyl chloride resin and an acrylic resin or a copolymer resin thereof; (2) an aqueous emulsion-based acrylic aqueous emulsion, an aqueous urethane-based resin, a polyolefin-based resin, and vinyl chloride. Type, vinylidene chloride type, SBR type, vinyl acetate type, ethylene vinyl acetate copolymer, silicon,
It is possible to use at least one kind of an aqueous emulsion of polyurethane, polybutene or the like, or a mixture of two or more kinds of resins.

Examples of the foaming agent added to the foamable resin layer 2 of the present invention include (1) azo compounds such as azodicarbonamide and azobisisobutylnitrile, which are thermally decomposable chemical foaming agents;
(2) A thermal expansion type microcapsule foaming agent formed of a vinylidene chloride-acrylonitrile copolymer containing a low boiling point hydrocarbon or a polymer mainly composed of an acrylonitrile-acrylic copolymer can be used.

Calcium carbonate, which is generally used as an inorganic filler added to the expandable resin layer 2 of the present invention,
Inorganic agents such as aluminum hydroxide and magnesium hydroxide can be used.

Other additives to be added to the foamable resin layer 2 of the present invention include titanium pigments, and in the case of plastisols, plasticizers such as DOP, stabilizers, and diluents can be added. If desired, dispersants, defoamers, wetting agents, antiblocking agents and thickeners can be added.

As a method of mixing the additives with the plastisol and the aqueous emulsion, a Henschel mixer, a dissolver, a homomixer or the like can be used.

As a method for laminating the foamable resin layer 2 on the substrate, there are conventional knife coaters, nozzle coaters,
It can be applied by a gravure coater, a rotary screen coater, a reverse coat coater, or the like. As a drying method after coating, a method of irradiating with hot air or infrared rays or a method of mixing these is used. However, it is adjusted to such an extent that foaming does not occur by heating.

As the ink of the printing layer 3 which is optionally provided, an oil-based or water-based ink can be used. Further, in order to increase the variety of products, a foam-suppressing ink and a foaming ink can be used. As a printing method, a gravure printing method, a rotary screen printing method, or the like can be used. As a method for drying the printed layer 3, the same method as for the foamable resin layer can be used.

The foaming-suppressing ink is an ink containing a chemical agent that changes the decomposition temperature of an azo type thermal decomposition type chemical foaming agent. As this agent, one that normally raises the temperature of the foaming agent (foaming inhibitor) is used, and, for example, trimellitic acid, benzotriazole or the like is added.

As the foaming ink, the same one as the plastisol mixture or the aqueous emulsion resin mixture of the foaming resin layer can be used. However, since fluidity suitable for various printing methods is required, it is important to add a diluent or thickener appropriately in order to obtain good transferability. You may color if needed.

As the ultraviolet curable resin of the ultraviolet curable resin layer 4 in the present invention, a polyfunctional acrylate polymer such as polyester acrylate, epoxy acrylate, polyether acrylate, urethane acrylate, and silicon acrylate can be used. In the case of water-based resin,
Blending with an acrylic aqueous emulsion resin is also possible. By adjusting the Tg suitable for these resins, a film obtained by heat-drying these resins can be prepared with almost no stickiness at room temperature.

The UV curable resin layer 4 is applied to the foamable resin layer 2.
As a method of laminating, the foamable resin layer 2 is laminated on the base material 1.
A method similar to that can be used. Application amount is 1 to 20g
/ M ^TwoIs preferred. 1g / m^TwoLess chemical resistance, etc.
20g / m^TwoWhen more
It is inconvenient for the strike.

When the ultraviolet curable resin layer 4 of the present invention is made of a transparent resin, the foamed embossed decorative sheet obtained is glossy and glossy. If you want to have a matte feel, you can use titanium, calcium carbonate,
A matting agent such as aluminum hydroxide or magnesium hydroxide is preferably added.

The method for drying the ultraviolet curable resin layer 4 of the present invention can be the same as the above. The dried sheet is heated to a foaming temperature, foamed and then embossed, and then the ultraviolet curable resin surface of the sheet is irradiated with ultraviolet rays to be completely cured.

As a method for embossing the surface after foaming, mechanical embossing with a normal embossing roll or the like is possible.

Known methods can be used as the method and apparatus for curing the ultraviolet curable resin layer 4 of the present invention. For example, Japanese Patent Application Laid-Open No. Sho 60-235793,
It is possible to use the curing method and the curing device described in JP-A-158451.

[0027]

【Example】

<Example 1> 70 g / m ² flame-retardant paper was used as a substrate,
A vinyl chloride paste having the composition shown in Table 1 below was coated thereon with a comma coater to 150 g / m ² and dried at 150 ° C. Subsequently, the texture pattern was printed by guavia printing and dried. Subsequently, an ultraviolet curable resin having the composition shown in Table 2 below was coated with a gravure plate at 5 g / m ² and dried at 90 ° C.

[0028]

[Table 1]

[0029]

[Table 2]

After that, foaming was performed in a foaming furnace at 200 ° C. for 40 seconds, embossed with a cooling embossing roll, and then the surface was irradiated with ultraviolet rays of 300 mJ / cm ² . The finished foamed embossed decorative sheet had a sharp embossed shape and was excellent in stain resistance, chemical resistance and surface hardness.

Example 2 A flame-retardant paper of 70 g / m ² was used as a base material, and a vinyl chloride paste having the composition shown in the following Table 1 was coated thereon with a comma coater at 150 g / m ² to obtain 150 It was dried at ° C. Subsequently, the pattern of the cloth was printed by gravure printing and dried. Subsequently, an ultraviolet curable resin having the composition shown in Table 3 below was coated with a gravure plate at 5 g / m ² and dried at 90 ° C.

[0032]

[Table 3]

Then, after foaming in a foaming furnace at 200 ° C. for 40 seconds and embossing with a cooling embossing roll, the surface was irradiated with ultraviolet rays of 300 mJ / cm ² . The finished foamed embossed decorative sheet had a sharp embossed shape and was excellent in stain resistance, chemical resistance and surface hardness.

Example 3 100 g / m ² of inorganic paper was used as a base material, and an aqueous emulsion paste having the composition shown in Table 4 below was used in a comma coater at 130 g / m 2.
² was coated and dried at 90 ° C. Subsequently, the stone pattern was printed by gravure printing and dried. Subsequently, the UV curable resin having the composition shown in Table 2 was applied to the gravure plate at 5 g / m ²
And was dried at 90 ° C.

[0035]

[Table 4]

Then, after foaming for 50 seconds in a foaming furnace at 150 ° C. and embossing with a cooling embossing roll, the surface was irradiated with ultraviolet rays of 300 mJ / cm ² . The finished foamed embossed decorative sheet had a sharp embossed shape and was excellent in stain resistance, chemical resistance and surface hardness.

<Example 4> 70 g / m ² flame-retardant paper was used as a base material, and a vinyl chloride resin paste having the composition shown in Table 1 was coated thereon with a comma coater to 150 g / m ² at 150 ° C. Dried in. Subsequently, the tile pattern was printed by gravure printing using the foaming suppression ink to which trimellitic acid was added. Subsequently, the UV-curable resin shown in Table 2 was coated with a gravure plate at 5 g / m ² to 90
Dried at ° C.

Then, foaming was carried out for 40 seconds in a foaming furnace at 200 ° C., and the surface was irradiated with ultraviolet rays of 300 mJ / cm ² . The finished foamed embossed decorative sheet had an embossed shape that was in tune with the design, and was excellent in stain resistance, chemical resistance, and surface hardness.

Example 5 A flame-retardant paper of 70 g / m ² was used as a substrate, and a vinyl chloride paste having the composition shown in Table 1 was coated on the comma coater to 120 g / m ² and dried at 150 ° C. did. Subsequently, a pattern of cloth was printed by gravure printing using the foaming ink shown in the formulation of Table 5 below and dried. Further, the UV curable resin shown in Table 2 was coated with a gravure plate at 5 g / m ² and dried at 90 ° C.

[0040]

[Table 5]

Then, after foaming for 40 seconds in a foaming furnace at 200 ° C., the surface was irradiated with ultraviolet rays of 300 mJ / cm ² . The finished foamed embossed decorative sheet had a sharp embossed shape and was excellent in stain resistance, chemical resistance and surface hardness.

Comparative Example 1 70 g / m ² of flame-retardant paper was used as a base material, and a vinyl chloride paste having the composition shown in Table 1 was coated thereon with a comma coater at 150 g / m ² and at 150 ° C. Dried. Subsequently, the pattern of the texture was printed by gravure printing and dried. No ultraviolet curable resin layer was provided.

Then, after foaming for 40 seconds in a foaming furnace at 200 ° C., embossing was performed with a cooling embossing roll. The finished foamed embossed decorative sheet had a weak surface strength.

Comparative Example 2 100 g / m ² of inorganic paper was used as a substrate, and the aqueous emulsion paste shown in Table ² was coated thereon with a comma coater to 130 g / m ² and dried at 90 ° C. Subsequently, the stone pattern was printed by gravure printing and dried.

Then, after foaming for 40 seconds in a foaming furnace at 150 ° C., embossing was performed with a cooling embossing roll. The finished foamed embossed decorative sheet had a weak surface strength.

Table 6 shows the above results.

[0047]

[Table 6]

[0048]

As described above, according to the present invention, the ultraviolet curable resin coated on the surface of the base material is sufficiently dried by heat without curing, and has no influence on the subsequent foaming. After the embossing, the method of completely curing by irradiating with ultraviolet rays makes it possible to obtain a foamed embossed decorative sheet having excellent surface strength and stain resistance while having sharp embossing.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a cross-sectional structure of a foamed embossed decorative sheet according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Substrate 2 ... Foaming resin layer 3 ... Printing layer 4 ... UV curable resin layer 5 ... Embossing

Continuation of front page (51) Int.Cl. ⁶ Identification number Office reference number FI Technical display location C08J 7/04 C08J 7/04 L // B29K 105: 04 105: 24 B29L 9:00

Claims (2)

[Claims] 1. A foamed embossed decorative sheet having a foamable resin layer on a substrate and optionally having a printed layer, wherein an ultraviolet curable resin layer is provided on the surface of the foamed embossed decorative sheet. Sheet. 2. A base material is coated with a foamable resin, dried, and optionally printed to form a printed layer, and an ultraviolet curable resin is applied and dried thereon, and the foamable resin is foamed by heating to obtain a surface. A method for producing a foamed embossed decorative sheet, characterized in that the surface of the sheet is subjected to embossing, and then the surface is irradiated with ultraviolet rays to completely cure the ultraviolet curable resin.