JPS5923262B2 - Decorative material manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative material intended for three-dimensional design effects for wall materials, floor materials, etc.

Conventionally, the base material of this type of decorative material is polyvinyl chloride (PVC).
) were dispersed and mixed with decorative pieces, which were colored fine pieces of thermoplastic synthetic resin such as PVC, and a transparent protective layer made of thermoplastic synthetic resin such as PVC was laminated thereon.

In order to manufacture a transparent protective layer in which such decorative pieces are dispersed and mixed, there is a method in which the transparent protective layer is calender-sheeted while supplying decorative pieces to the calendar top roll, or a method in which materials for the transparent protective layer and decorations are applied. Calendar sheeting is used after mixing the decorative pieces, but in both cases, calendar sheeting is performed while the transparent protective layer and the decorative pieces coexist, so the decorative pieces may be deformed and their outlines may become unclear, or the decorative pieces may be distorted. is kneaded into the transparent protective layer and tends to be oriented in the flow direction of the transparent protective layer material, resulting in a decorative material with a three-dimensional and vivid feel in which decorative pieces with clear outlines are randomly dispersed. It was difficult to obtain. Therefore, a method can be considered in which only the transparent protective layer is first manufactured by calender sheeting, and the decorative pieces are grown between the base material and the transparent protective layer, or between the transparent protective layers when manufacturing the decorative material. According to this method, decorative pieces are sprinkled on the base material or the transparent protective layer soil layered on the base material, and a transparent protective layer is further laminated on top of the decorative pieces. The sprayed surface is heated to soften the sprayed surface and the decorative piece, and a transparent protective layer is laminated thereon and pressed. In this method, if interlayer adhesion is to be improved, the surface on which the decorative pieces are sprayed must be heated to a high temperature to sufficiently soften the base material surface and the decorative pieces. If heated to high temperatures in this way, the decorative pieces will be thermally deformed and their outlines will become unclear, and the pressing force when laminating the transparent protective layer will cause the decorative pieces to become oriented, resulting in directionality in the pattern. Therefore, the drawbacks of the prior art described above cannot be improved at all. In particular, when a foamable, unfoamed thermoplastic synthetic resin is used as the base material, the base material may start foaming due to heating and trap gas between the layers.
This causes the printing on the base material surface to run, causing a big problem. However, if the heating temperature is lowered in order to eliminate the above-mentioned drawbacks, the interlayer adhesive strength will decrease and air will become more likely to be trapped around the decorative piece. In order to increase the interlayer adhesive strength even if the heating temperature is low, it is possible to increase the pressing force during lamination, but such pressing force may damage or deform the printed surface of the base material. . The present invention improves the above-mentioned drawbacks of the prior art, thereby preventing the printed surface of the base material from being damaged by decorative pieces. Decorative pieces made of fine pieces of colored thermoplastic synthetic resin are scattered on the transparent protective layer, and another transparent protective layer is then laminated thereon. The invention will be explained in detail below.

The base materials used in the present invention include asbestos sheets, inorganic sheets such as glass fiber boards, fiber sheets, synthetic boards, wooden boards such as hard boards, and particle boards, polyvinyl chloride, polystyrene, polymethacrylmethyl, polyurethane, Various materials are used, such as plastic sheets such as polyamide, polyester, polyethylene, and polypropylene, metal sheets, and sheets laminated with each other. In order to obtain a decorative board with uneven texture, for example, unfoamed sheets mixed with a foaming agent are used. A sheet on which a desired pattern is printed on the surface of a thermoplastic synthetic resin sheet with an ink partially or completely containing a foaming inhibitor, or another base material as exemplified above is applied to the sheet. Use backed laminate.

When such a sheet is heated, the sheet foams and irregularities are formed on the surface while suppressing foaming in the areas printed with the ink containing the foaming suppressant. The decorative pieces used in the present invention include polyvinyl chloride, polymethacrylmethyl, polystyrene, polyvinylidene chloride, polyethylene,
Thermoplastic synthetic resin such as polypropylene is colored with pigments, dyes, etc., a plasticizer is added if desired, and the sheet is formed by calendar sheeting or T-die extrusion, and then crushed or cut into fine pieces. Or,
Alternatively, well-known micronization methods can be used, such as forming the colored thermoplastic synthetic resin into fine pellets by extrusion molding or granulating it with a high-speed stirrer.

The fine pieces usually have a size of 12 to 42 meshes.
The transparent protective layer in the present invention uses a thermoplastic synthetic resin similar to that used for decorative pieces, and can be directly calendered or T-die extruded, or the thermoplastic synthetic resin can be kneaded with a plasticizer to form a paste sol. A sheet can be used which has been prepared by applying it to an easily peelable sheet, heating and solidifying it, and then peeling off the peelable sheet, or by any other suitable method.

In particular, the lowermost transparent protective layer, that is, the transparent protective layer that protects the surface of the base material, has better fluidity near the processing temperature than other transparent protective layers because it contains a synthetic resin with a lower degree of polymerization and/or has a higher polymerization degree. It is preferable to use one. A decorative piece is produced by laminating the transparent protective layer on the base material, then scattering the decorative pieces on the sprayed surface of the transparent protective layer, and then laminating another transparent protective layer thereon. In this case, the decorative piece may be sandwiched between the transparent protective layers and then the transparent protective layer may be laminated on the base material.

In order to laminate a transparent protective layer on a base material, both or one of the base material and the transparent protective layer may be heated, laminated, and pressed.

Well-known means such as hot air, high frequency, and far infrared rays are used for heating. When a low polymerization degree synthetic resin compound and/or a highly plasticized compound is applied to the lowermost transparent protective layer, the sheet has good fluidity, so the heating temperature can be lowered, and the printing surface of the base material can be prevented from blistering due to heating. , can prevent discoloration, etc., and also blends well with the printed surface. The decorative pieces may be spread onto the spraying surface of the transparent protective layer by hand or mechanically using a vibrating sieve or the like. The amount of sieving pieces to be sprayed is desirably in the range of 40 to 180, more preferably in the range of 60 to 140, assuming that the amount of decorative pieces to completely cover the sprayed surface is 100. The spraying surface is heated, and the transparent protective layer bonded to the spraying surface is also preheated and laminated onto the spraying surface and pressed. In order to produce a decorative material that maintains the shape of the decorative piece and maintains sufficient interlayer adhesion, the heating temperature should be kept as low as possible and the pressing force should be increased. At this time, the transparent protective layer coated on the surface of the base material may cause the decorative pieces to damage the printed layer of the base material, wash away the printed layer, or allow the decorative pieces to penetrate through the printed layer of the base material. is prevented. In particular, if a transparent protective layer containing a low degree of polymerization synthetic resin and/or a highly plasticized compound is used, not only the interlayer adhesion strength will be improved, but also the pressing force, especially the pressing force through the thickness of the decorative material, will be mostly reduced by the transparent protective layer. The surface smoothness of the resulting decorative phase is improved. In this way, a laminated material with a decorative layer sandwiched between the layers is obtained.Finally, the base material is a foamable unfoamed thermoplastic synthetic resin sheet with an ink containing part or all of the foaming inhibitor on the surface of the foamable unfoamed thermoplastic synthetic resin sheet. When using a sheet with a pattern printed on it or a laminated material of the sheet and a backing material, if the decorative material is heated to the foaming temperature of the sheet and foamed, the ink containing the foaming inhibitor can be used. Since foaming is suppressed in the printed sheet portion, unevenness is formed on the surface of the sheet in synchronization with the printed pattern, resulting in a decorative material that has cushioning, heat insulation, and soundproofing properties as well as an extremely three-dimensional appearance. .

As described above, in the present invention, decorative pieces made of fine pieces of colored thermoplastic synthetic resin are scattered on the transparent protective layer soil laminated on the surface of the base material, and then when another transparent protective layer is laminated from the soil, the decorative pieces are This method preheats both the sprayed surface and the other transparent protective layer, thus softening the sprayed surface at a low temperature that prevents thermal deformation of the decorative pieces and orientation due to pressing force, and improving interlayer adhesion. Even if the pressing force is increased to increase the pressure, the printed surface of the base material will not be damaged by the decorative pieces, and a product with high interlayer adhesion can be obtained.

The decorative material of the present invention is used for architectural interior materials such as wall materials and floor materials.

Examples will be given below to further specifically explain the present invention. Example 1 The following composition was mixed and a sheet with a thickness of 1 mm was obtained by calender sheeting.

A hesher cloth 2 is applied to the sheet 1 thus obtained, and a pattern 3 is printed on the surface to obtain a base material B shown in FIG.

As shown in FIG. 2, pull out the base material B from the roll 4 of the base material B in the direction of the arrow, and first heat the base material B using the far infrared heater 5AVC.
Therefore, the transparent protective layer 6, which was also preheated to a surface temperature of about 150°C by the far-infrared heater 5B, was laminated on the surface of the heated base material B to a surface temperature of about 150°C. Twist and press. The transparent protective layer is obtained by mixing the following composition and calender-sheeting it to a thickness of 0.51II. Next, decorative pieces 8 are sprayed from a spraying device 9 onto the surface of the transparent protective layer 6 laminated on the base material B.

Here, the decorative piece 8 was prepared by mixing the following three types of compositions and calender sheeting to obtain three types of colored PVC sheets with a thickness of 0.2mm, each sheet was crushed and sieved to obtain fine pieces that passed through 12 meshes, # 140%, #240%, #32
Mix at a ratio of 0%. The spray surface is then heated by the far infrared heater 10A.

The surface temperature of the sprayed surface during heating is approximately 150°C. A transparent protective layer 11, which is also preheated by a far-infrared heater 10B, is laminated on the heated spraying surface, and the roll 12
Pressed by. The surface temperature of the transparent protective layer 11 during heating is approximately 150°C. The transparent protective layer 11 is obtained in the same manner as the transparent protective layer 6. Thus, as shown in FIG. 3, a transparent protective layer 6 is laminated on the surface of the base material B consisting of a sheet 1 on which a pattern 3 is printed and lined with a hessier cloth 2, and a decoration is applied on the surface of the transparent protective layer 6. A decorative material is obtained in which the decorative pieces 8 are sprayed and a transparent protective layer 11 is further laminated on the sprayed surface, but since both the sprayed surface of the decorative pieces 8 and the transparent protective layer 11 are heated in advance before lamination, the decorative pieces are The adhesion between the sprayed surface and the transparent protective layer 11 becomes strong even when heated at a temperature that does not cause the thermal deformation in step 8.

Therefore, a decorative material with a clear and three-dimensional appearance can be obtained. Example 2 The following Q compositions are mixed to obtain a PVC paste sol.

The paste sol having the above composition was spread and coated on asbestos paper soil having a thickness of 0.8 mm using a roll coater to a thickness of 0.4 mm.

Immediately after application, the paste sol was heated at 170° C. for 2 minutes to solidify it into a semi-gel state. A pattern layer is formed by printing on this surface soil with one color of ink containing a foaming inhibitor and the other colors of ink containing no foaming inhibitor. Thus, as shown in FIG. 4, a base material B' is obtained, in which the PVC semi-gel layer 21 is lined with aspest paper 22 and a pattern layer 23 is provided on the surface. Using the base material B', a decorative material is produced in the same manner as in Example 1, but finally, it is heated to a foaming temperature to foam the base material B'. Thus, as shown in FIG. 5, the PvC semi-gel layer 21 of the base material B' becomes a foam layer 21', but the portions printed with 4-ink containing a foaming inhibitor are inhibited from foaming and form recesses 24. In this way, a decorative material is obtained which has a clear and extremely rich three-dimensional effect and at the same time has cushioning, heat-insulating, and sound-insulating properties.

[Brief explanation of drawings]

FIG. 1 is a partial side view of an embodiment of the base material used in the present invention;
FIG. 2 is a system diagram of an embodiment of manufacturing the decorative material of the present invention;
Fig. 3 is a partial side view of one embodiment of the decorative material thus produced, Fig. 4 is a perspective view of another embodiment of the base material, and Fig. 5 is a decorative material in which the base material is foamed and provided with projections and depressions. FIG. 3 is a partial side cross-sectional view of one embodiment.

Claims (1)

[Scope of Claims] 1. A transparent protective layer made of a thermoplastic synthetic resin is laminated on the surface of a printed substrate, and decorative pieces made of colored fine pieces of a thermoplastic synthetic resin are scattered on the transparent protective layer, A method for producing a decorative material, which comprises heating the surface of a transparent protective layer on which the decorative pieces have been sprinkled, and preheating and laminating another transparent protective layer thereon. 2. A transparent protective layer made of thermoplastic synthetic resin was laminated on the surface of the printed substrate, and decorative pieces made of colored fine pieces of thermoplastic synthetic resin were sprinkled on the transparent protective layer. In a method for manufacturing a decorative material in which the surface of a transparent protective layer is heated and another transparent protective layer is preheated and then laminated on top of the transparent protective layer, the base material includes a foaming inhibitor on the surface of a foamable unfoamed thermoplastic synthetic resin sheet. A sheet on which a desired pattern is printed with ink containing part or all of 1. A method for producing a decorative material, which comprises forming irregularities by foaming a base material while suppressing foaming in a portion printed with an ink containing a foaming inhibitor.