JPS6030540B2 - foam decorative sheet - Google Patents

Description

[Detailed description of the invention] The present invention relates to a foam decorative sheet.

More specifically, the present invention relates to a decorative foam sheet that has pattern-like irregularities on the surface, has a smooth back surface, and is free from patterns and unintentional expansion and contraction of the sheet due to heat foaming. Decorative sheets with irregularities on the surface are well known. For example, a paste-like material is poured into the recesses of a roll or metal plate with an irregular pattern engraved on the surface, heated to gel, and then There is a method of transferring the paste to a sheet, or a method of applying a paste-like material in a pattern to a synthetic resin sheet by a method such as screen printing, and heating it to gel it.

However, the decorative sheets obtained by these methods are easily scratched because the patterns are visible on the surface, and the patterns are easily damaged by wear. To compensate for this drawback, there is a method of laminating a film on the patterned surface, but since the pattern already has a convex shape, the pattern may be crushed during lamination, or air bubbles may get mixed in between the film and the sheet. Accidents such as Moreover, in any of these methods, it is impossible to obtain a decorative sheet having a multicolored uneven pattern or an uneven pattern as well as other designs that are in harmony with this pattern. One object of the present invention is to provide a decorative sheet having an uneven pattern that does not have the above-mentioned drawbacks.

Other purposes will become apparent from the following description. That is, the present invention is characterized in that it consists of two synthetic resin films pasted together with a pattern containing a foaming agent in between, the front surface has irregularities corresponding to the pattern, and the back surface is mirror-like and smooth. It is a foam decorative sheet.

The sheet of the present invention is produced by a method of manufacturing a foam decorative sheet by bonding two synthetic resin films with a pattern containing a foaming agent interposed between them, and heating and foaming them after they are integrated or simultaneously with the bonding. It can be manufactured by placing two synthetic resin films in close contact with each other on a mirror-finished heating drum so that the smooth surfaces of the synthetic resin films are in contact with each other, and heating and foaming the film.

The two synthetic resin films according to the present invention may be any synthetic resin films such as PVC, EVA, PP, and PE.

Further, in order to increase the flexibility of the films, it is preferable that the two films contain a plasticizer. Preferably, the surface in contact with the heating drum is mirror-like and smooth.

Further, it is preferable that the surfaces of the two synthetic resin films that come into contact with the foaming agent are both substantially smooth.

Here, approximately smooth means that the two synthetic resin films are preheated and pressed by a pressure roll before being bonded together, which will be described later.
It refers to the degree of smoothness that allows the two films to be closely integrated without air being mixed in between them, and this includes, for example, a surface with a satin pattern. More preferably, both surfaces are smooth, especially mirror-like smooth. When the surface is mirror-like and smooth, preheating before bonding is not necessarily necessary. When the surface has irregularities, it is desirable to preheat one film to the extent that the preheated film bites into the other film by applying pressure to make it flexible. The pattern containing the foaming agent is sandwiched between the two sides of the two synthetic resin films. The pattern is preferably composed of a composition containing a synthetic resin, and may be printed in advance on the substantially smooth surface of one of the two synthetic resin films by gravure printing, screen printing, etc. good. Further, this pattern may be colored or uncolored, and if desired, a pattern using ink that does not contain a foaming agent may be applied on the same surface at the same time. The present invention will be described in detail below with reference to embodiments shown in the drawings.

Fig. 1 is a schematic sectional view showing the device used in the present invention, Fig. 2 is a schematic sectional view showing the device used in the present invention;
The figures are enlarged partial cross-sectional views of the foamed decorative sheet ``a'' before foaming and ``b'' after foaming. In the present invention, two synthetic resin films are used, but for convenience of explanation, the two will be distinguished and hereinafter referred to as the first film 1 and the second film 2, respectively. In the embodiment shown in FIGS. 1 and 2, the pattern 3 containing the foaming agent is formed in advance on the substantially smooth surface 1-
It is applied on 2. The second film 2 is a synthetic resin film whose one surface 2-1 is mirror-like and smooth, and the other surface 2-2 may or may not be smooth.

Particularly when this surface is matte, special effects can be obtained as described later. These two synthetic resin films 1 and 2 are placed between their substantially smooth surfaces 1-2 and 2-1 after one of the films is heated with a heating roll 4 or the like as necessary. The pattern 3 is sandwiched between the first film 1 and the heating drum 6 and between the first film 1 and the second film 2 by a pressure roll 6 or the like. Closely adhered to prevent air bubbles from forming.

The first point to be noted is that the heating should not be done to the extent that the blowing agent foams.

When the foaming agent foams due to preheating, this foaming agent is pressurized. −
The film is crushed by the foaming agent 5 and cannot maintain a good shape, and air may enter between the films from the sides of the raised foaming agent. Air mixed between the films expands when heated by the heating drum 6, damaging the decoration. For this reason, it is preferable to preheat the film that does not have a pattern containing a blowing agent. The second point to be noted is that the surface 1-1 of the first film in contact with the heating drum 6 must be smooth.

The surface 1 - 1 of the first film does not necessarily have to be mirror-like and smooth, but must be smooth enough to come into close contact with the heating drum 6 when pressed by the child heat or the pressure roll 5 . For example, when the surface is not smooth, such as a satin pattern, the adhesion is insufficient; (1) heating by the heating drum causes the air between the film and the drum to expand, causing the film to shrink;

■ During foaming, the force of foaming causes the film to shrink. (2) Foaming also occurs in the direction of the heating drum (back side), resulting in foamed patterns appearing on both the front and back sides, resulting in poor bulge in the pattern on the front side.

This may cause defects such as

On the other hand, when the close contact is sufficient, the heating drum 6 and the first
The film behaves as if it were integrated, and no shrinkage or flaring occurs during foaming, and no foaming occurs in the direction of the heating drum. The third point to be noted is that the first film and the second film 2 should be well-adhered and integrated without any air being mixed in between them.

If the adhesion is not sufficient, shrinkage will occur due to the force applied during foaming. The child heat generated by the heating roll 4 and the like described above also serves to further improve the adhesion between the films. The heating for bonding the first film 1 and the second film 2 or the heating for foaming the pattern 3 may be performed using only the heating drum 6, or if necessary, additional heating may be performed using a heater 7 or other means. It's okay.

Particularly when the surface 2-2 of the second film 2 that is not in contact with the pattern 3 containing the foaming agent is matte, the heating drum 6 does not heat the second film from the side using the heater 7 or the like. Special effects can be obtained by heating only from one side of the film. That is, by heating only from the heating drum 6, the first film 1 and
The part of the second film 2 where the pattern 3 is not applied becomes soft and the surface 2-2 of the second sheet 2 becomes glossy, but the part with the pattern 3 is foamed by the foaming agent in the pattern 3. As a result, the surface of the second sheet 2 swells to form convex portions, and the film 2 for the heat insulation effect of the foamed portions (patterns) 3 does not soften, making it possible to maintain a matte surface. In other words, the foamed decorative sheet obtained in this way consists of two synthetic resin films 1 pasted together with a pattern 3 containing a foamed foaming agent in between.
and 2, the front surface 2-2 has unevenness corresponding to the pattern 3, and the back surface 1-1 is a mirror-like smooth surface without unevenness because it is attached to the heating drum 6 during foaming, and The convex portions of the surface 2-2 are matte, and the concave portions are glossy.

Further, by igniting the material, it is possible to obtain a decorative sheet having gloss in both the convex and concave portions. The first film and the second film 2 are placed on the heating drum 6 while being closely polymerized on the heating drum 6.
After being heated for an appropriate time, it is peeled off from the heating drum 6 and cooled by a cooling roll 8.

The cooling by the cooling roll 8 is preferably performed immediately after heating in order to prevent the sheet from shrinking and softening. This method is particularly effective when the film in contact with the heating drum has a thickness of 40 microns or less.

When using a film with a thickness greater than this, shrinkage of the film is less likely to occur, so close contact with a mirror-like drum is not necessarily required. Since the present invention has the above-described structure, the obtained decorative foam sheet has a strong surface and
It is long-lasting, and the convex parts are soft and have cushioning properties.
Furthermore, by using gravure printing, etc., it is possible to obtain a product with a three-dimensional effect that matches the photographic pattern.

In addition, you can freely change the gloss condition or gloss difference between concave and convex parts, so you can obtain special decorative effects, such as tablecloths, accordion doors, underlays of exhibits, etc.
It can be used in a wide range of applications that are difficult to use with conventional products, such as overlays for cabinets, wall hangings, or for one-point decoration such as pencil cases, boxes, and album covers, furniture fittings such as curtains and wall hangings, and interior decoration items. can.

[Brief explanation of the drawing]

The drawings show an embodiment of the present invention, and FIG. 1 is a schematic cross-sectional view of the apparatus, and FIG. 2 is an enlarged partial cross-sectional view of the foam decorative sheet before foaming (a) and after foaming (b). 1... Synthetic resin film (first film) with mirror-like smoothness on both sides, 2... Synthetic resin film (second film) with mirror-like smoothness on at least one side, 3...
...Pattern containing a foaming agent, 4...Heating roll,
5... Pressure roll, 6... Heating drum, 7... Heater, 8... Cooling roll. Figure 2 Figure 1

Claims (1)

[Scope of Claims] 1. A first synthetic resin film that is smooth on one side and a second synthetic resin film that is smooth on both sides, with their smooth surfaces facing each other, and a foamed foaming agent is placed between them. The other surface of the first synthetic resin film has an unevenness corresponding to the pattern, and the other surface of the second synthetic resin film has a mirror-like smooth surface. A foam decorative sheet characterized by: 2. The foam decorative sheet according to claim 1, wherein the convex portions on the surface are matte-like and the concave portions are glossy.