JPS5976978A - Production of decorative sheet - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a new method for producing decorative sheets having marble patterns, etc., and more specifically, the present invention relates to a method for producing a decorative sheet having a marble pattern or the like. The purpose of this invention is to produce decorative sheets for use in floor finishing materials and upholstery materials that have a marble pattern or a polished terrazzo-like pattern.

BACKGROUND OF THE INVENTION Floor pillar top materials, particularly floor finishing materials made of synthetic resins typified by vinyl chloride resin, have been used for a variety of purposes due to their flexibility in coloring and variety of decorations.

The fact that decorative effects can be imparted to these synthetic floor finishing materials is simply u? It is not only necessary to arouse the desire to purchase, but also has extremely important meaning in terms of livability and psychological effects brought about by decorative effects.

Accordingly, research has been actively conducted into methods and means for imparting an irritating Rib effect to synthetic resin floor finishing materials, and many inventions and ideas have been proposed. However, looking at these inventions and ideas, as well as the synthetic resin floor covering materials currently in use, it has been found that floor covering materials with high decorative effects similarly lack durability or wear resistance. Floor coverings with good wear resistance often have poor decorative effects and are rare. For example, Tokuko Sho 43-2863
What is described in Publication No. 6 is a famous invention of Convolium Co., Ltd., and is an invention that can be said to be the original invention of a cushion floor by the so-called chemical embossing method, but the floor finishing material obtained by this invention is , exhibits a very good decorative effect, but since this decorative effect is only brought about under special conditions such as the printing method and the presence of the foam layer, once the printing layer wears out, it can no longer be used as a floor covering material. It is a floor finishing material with extremely poor durability. In addition, the invention described in Publication No. 81:142-5430 uses a suction roll to suck synthetic resin tile strips onto the roll surface, and onto a base sheet on which adhesive has been applied in advance.
This method involves rolling the strips on a suction roll, and the floor finishing material obtained by this method is
Although the synthetic resin tile strips are the structural unit of the floor finishing material and have excellent durability, there are problems with uneven adsorption of the strips to the suction roll and the spacing between the strips.
That is, since the arrangement of the strips is rough, it cannot be said to be very good in terms of decorative effect. Furthermore, as a method for producing floor finish I using synthetic resin strips in this way, there is a method described in ``Tit'' (Publication No. 53-8569).
In this method, instead of the suction roll method, a pattern is created by dropping strips into a predetermined position in a pattern using a screen similar to that used in textile printing, and the entire material is compacted to strengthen it. However, the materials that make up these patterns, i.e., the synthetic resin particles or crushed pieces, are poorly manufactured, and the patterns, especially the joints between patterns, are unclear. In addition, when suppressing, the synthetic resin pieces may flow, or if the suppression is insufficient, there may be nests, or in some cases, the synthetic resin pieces may fall unevenly, resulting in a uniform and homogeneous floor finish. It has drawbacks such as difficulty in obtaining material.

The present invention is a method of manufacturing a decorative sheet for use as a floor finish or wall decoration, which has an excellent decorative effect, by a method completely different from that of conventionally known floor finishing materials.

Hereinafter, the method for producing a decorative sheet according to the present invention will be explained with reference to the figure.The colored synthetic resin paste is blown out onto a release paper (B) using the dyed synthetic method, and the colored synthetic resin paste is blown out or shaped into a string. The first step is to let the pattern layer fall to form a pattern layer (A), and then heat it to form a kelp, and the third step is to
(Fig.), the pattern layer (4) is made of paste (1, 1'), (1)... on the uneven surface of the gelatinized layer, and an intermediate paste layer is used to smooth the uneven surface. The step of applying (2) is the second step, and the step of laminating the odor ladle material (3) on the intermediate base 1 (2) when the intermediate paste layer (2) is not gelled is the third step. The second and third steps are shown in Figure 4), and either the whole is heated or
) The step of heating and gelling the intermediate paste layer (2) by heating with an electric heater or the like from above is the fourth step (not shown), and after cooling the whole, the Pli# pattern paper (B
) is characterized in that the fifth step (Fig. 5) is the step of peeling off the resin. F9'rHM paste grade resins made of vinyl thread copolymers, polymerized by emulsion method or microsuspension method are suitable; in addition to these vinyl chloride thread resins, ethylene-vinyl acetate emulsion resins and hyacrylic resins are preferred. Emulsions can be used. In addition, when the colored synthetic resin paste in the first step (1 bar 15 σ 1... Colored synthetic resin paste in multiple colors.

You can also use In the case of a single color, by coloring the intermediate paste layer (2) in a different color from the colored synthetic resin paste of the pattern layer (4), the gap between the dropped colored synthetic resin paste (1) are filled with intermediate paste layers (2) of different colors, so that the resulting decorative sheet exhibits a two-color effect.

In addition, in the case of several colors of rice, two or three colors may be applied at the same time. (1
) is sprayed in its original color, and some parts are sprayed with a mixture of these colors, so the resulting pattern is extremely intricate and beautiful, and is not a natural or traditional color. This is a decorative sheet that has a very unique decorative effect that cannot be seen anywhere else.

Release paper (B): Any release paper such as smooth glossy paper or smooth matte paper is used, and usually the pattern layer (4) is sprayed directly onto the release paper (B), but it has abrasion resistance, Alternatively, if special performance such as cigarette resistance is required, a surface transparent layer (not shown) having such characteristics is coated on the release paper in advance, and then a paste (pattern layer) is sprayed. Also good.

Spray gun (C) & In normal cases, a wide-spraying gun such as a 5-89 caliber Rishin gun is suitable, and the paint reservoir is partitioned off with partition walls a depending on the number of colors.

In the case of Figure 3, three colored synthetic resin pastes 1) (1 bar 1)
(C1) (C2) (C
3) Divide into three paint reservoirs, fill each with a different colored synthetic resin paste (1),
Blow out the paste by blowing in compressed air (smell).

In this case, it is necessary to spray the colored paste horizontally in a direction parallel to the sieve pattern (B).

This colored paste has a viscosity of 2000 to 5000 cp.
This is because if a material with a relatively high viscosity is used, if it is sprayed directly toward the ν and IE pattern paper, the MAL will be insufficient due to the colored paste and the pattern will be partially biased. By using the horizontal blowing method, most of the blown paste falls onto the release paper in a cylindrical shape due to its surface tension, and a part of it falls in the form of a string, that is, a string. Therefore, a plurality of colors are uniformly dispersed in the colored paste, and a uniform pattern can be obtained. The coating thickness of the colored paste can be adjusted anywhere from 0.2 to 2.0 mm depending on the purpose and use. For mass production or when making wide decorative sheets, it is better to spray with a single sprayer, but rather with a multi-head sprayer, that is, one spray gun with one spray gun.
It would be preferable to fill in the colored pastes and prepare a spray gun for each color depending on the number of colors, and spray at the same time or separately.

Colored synthetic resin base) (IXI Bali...
After forming the pattern layer (~), place it in a heating furnace to gel the pattern 74, and the surface will still have unevenness caused by the dripping of the sprayed colored paste, leaving no imperfections. The surface is on land.Therefore, a second step is required to smooth the surface.

In the second step, the intermediate paste layer (2) is coated onto the uneven surface of the pattern layer (4) using a P9r ftM fixed blade such as a doctor blade or a doctor roll. The intermediate paste layer (2) is used for two purposes.The first purpose is to adjust the surface unevenness of the layer (4) as described above. When the decorative sheet is attached to the floor surface, the unevenness of the pattern layer (A) appears as unevenness on the side surface of the sheet, resulting in a very ugly finish. A) The unconformity, that is, the smoothing, is extremely simulating the M loss force.Second
The purpose of this layer is to serve as an adhesive layer for laminating the Dake batting material (3). When pasting this decorative sheet on a wall or floor surface, the backing material is necessary to facilitate the pasting, and at the same time, the backing material is necessary for the pattern layer (A) and the intermediate paste layer (2).
Since the material is entirely made of synthetic resin paste, the support is weak, and excessive abrasive elongation is applied during the pasting process, but these drawbacks can be covered by laminating the base material. This backing material can be bonded to the decorative sheet by the lamination method when the intermediate paste is not gelled, so it can be done in one line, which is not only extremely economical, but also very economical in terms of process. It becomes easy.

The backing I (3) used in the present invention is made of a woven fabric such as linen cloth or Kanayama vinylon, a non-woven fabric such as glass or polyester, or paper such as asbestos paper. In the case of dog-sized carpet IJ with openings such as linen cloth,
After laminating on the intermediate paste layer (2), the intermediate paste layer (2) is heated from the upper surface with an electric heater or the like.
) can be gelled, or after laminating a thick backing I (3) such as non-woven fabric or asbestos paper, the whole thing must be placed in a heating furnace and heated to a certain gelling temperature. Become.

After heating and gelling the intermediate base 1id (2) in this way, the laminated sheet is cooled while remaining attached to the release paper (B), and then the release paper (B) is peeled off and the product is formed. A certain H medium sheet is obtained.

Next, specific embodiments of the present invention will be described by way of implementation.

Example (Coating of surface transparent layer I5 Self-coating 1 year old Zeo 7121" 100DOP
30T
XIB*2 10 Epoxidized soybean oil 3 Stabilizer
3 Viscosity conditioning agent Yuke*l
Vinyl chloride resin for paste made by Nippon Zeon *2 A mixture of texanol inbutyrate formulation 1 was mixed with a vacuum suction kneader,
A Qingming paste with a viscosity of 10,000 c'ps is prepared. Next, the transparent paste is applied to a thickness of 0.2 mm on a release paper.

(2) Pattern layer (N spraying is blend 2 Zeon 121 60 blending resin 40DOP
40T, 1 (IB
10 stabilizer 3
Filler 3° viscosity modifier
Masutan eyebrow coloring agent toner
Color-fastening pastes in three colors, dark brown, light brown, and white, were prepared as the citrus colorant toner in the same manner as in the formulation 1 using the basic formulation 2 as the basic formulation. The blending resin in Formulation 2 is effective in 1) preventing stringiness during spraying, and if the blending resin is not used for a period of time, there will be a lot of stringiness. do not become. As the blending resin, Nanaon 103z (manufactured by Nippon Zeon) is suitable. The pastes according to Formulation 2 were each adjusted to a viscosity of 3500 cpsFjJ with a viscosity modifier. In this case, if there is a difference in viscosity between the pastes, it is important to adjust the viscosity so that they have approximately the same viscosity, since the pastes will be blown out at the same time as a soufflé.

Three colored pastes were injected into Ccl) (c2) and (ca) of the partition wall spray gun shown in Figure 3, respectively, and the non-gelled paste previously applied on the release paper according to (1) above was applied under the following conditions. It was sprayed onto the transparent paste layer using a bucket sprayer.

For spraying, use the Eiken spray gun caliber for ricin.
6% Air nozzle diameter 2.0) Air pressure
2 Kg/ctl The diameter of a spray gun is large, and the size of the window drop or string is not large, and the diameter of a gun with a small diameter is small. In the case of a small diameter gun such as 2-3%, the discharge amount is small and the pattern is too fine, which is not preferable.

The coating thickness of pattern IfjI (4) is 1.0 to 1.0 for floor finishing.
It is assumed to be about 1.5 days ahead.

After spraying the pattern (4), the pattern layer (4) is immediately introduced into a heating furnace heated to a temperature of 150° C. to heat and gel the pattern layer (4).

(3) Application of intermediate paste layer and lamination composition of backing material 3 Zeon 121, 100DOP
40TXIB
10 Epoxidized soybean oil
3 Stabilizer 3 Filler 30 White M material
Appropriate amount of viscosity regulator
Following a method similar to the notified formulation, the viscosity [5ooo cps
A white paste was prepared and applied to the upper surface of the pattern layer using a doctor blade by the blade pulling method. The applied paste surface was smooth. Next, a glass nonwoven fabric (SO T/L?) mixed with 20% pulp was laminated on the surface of the paste, and then the whole was heated in a heating furnace heated to 170°C. Out of the furnace! ') After pressing the entire sheet with a pressure roll, it is cooled through a cooling roll.
When the Pi1F pattern paper was peeled off, a decorative sheet was found on the floor covering the extremely granite-like front pattern with a transparent layer on the surface.

The decorative sheet obtained in this way can be used in its samurai state, but after peeling off the release paper, it may be embossed on the surface j1-1, or it may be used without a base on the front surface. In some cases, a pattern may be embossed on the surface of the pattern layer. Alternatively, the embossed pattern may be formed using a release paper that has been embossed in advance.

As described above, according to the present invention, marble Tm &? Alternatively, a decorative sheet with a decorative effect having a polished leaflet-like pattern etc. can be obtained, and a decorative sheet with excellent durability and abrasion resistance can be obtained easily and quickly, thus achieving the intended purpose. be.

[Brief explanation of drawings]

The drawings show an embodiment of the method for manufacturing a decorative sheet of the present invention, and FIG. 1 is a partially cutaway perspective view of the manufactured decorative sheet. Figure 2 is a cross-sectional view, and Figures 3 to 5 are process diagrams, in which (A) is the pattern layer, (1'3) is the release paper,
(a) is a spray gun, (1) (1)... is a layer color paste, (2) is an intermediate base material, and (3) is a base material.

Claims (1)

[Claims] (The first step is to spray a colored synthetic resin paste onto the release paper in a horizontal blowing direction with a spray gun, and cause the colored synthetic resin paste to fall in the form of drops or strings to form a pattern layer. The second step is to heat and gel it. The third step is to apply an intermediate paste layer to smooth the surface, and the third step is to apply a ladle on the intermediate paste layer when the intermediate paste layer is not gelled. The fifth step is to heat and gel the intermediate paste layer by heating the entire layer, or by heating it with an electric heater or the like to improve the coating material.The fifth step is to cool the entire layer. (2) The medium 10'' paste layer is a synthetic resin colored in a different color from the color-resistant synthetic resin paste of the pattern layer. (3) The method for producing a decorative sheet as described in Paragraph 1 of the Patent Encyclopedia, which is a paste. (3) The decorative sheet as described in Paragraph 2, wherein the color-matching synthetic resin paste of the pattern layer is monochromatic. Manufacturing method. (4) The decorative sheet according to item 1 above, wherein the pattern layer is made of colored synthetic resin paste or two or more colors, and these colors are sprayed in an appropriate mixed state. Production method.