JPS6049091B2 - Method for manufacturing decorative material with uneven pattern with protective coating - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a sheet-like decorative material in which an uneven pattern is formed by foaming, and a protective coating is formed on the uneven surface.

Forming such a protective film on the surface is advantageous because it can improve abrasion resistance, heat resistance, stain resistance, and chemical resistance when used, for example, in decorative materials.

As seen in Japanese Patent Publication No. 53-11548, the conventional method uses a die roll with a daily pattern formed thereon, fills the synthetic resin paste containing a foaming agent within the daily pattern, and then covers it with a transparent film. A method is known in which the paste surfaces are overlapped so as to be airtight, the two are thermally bonded and foamed to once produce an intermediate product, and then a protective film is formed separately. This method does not allow continuous continuous operation including the formation of a protective coating, and the die rolls on which the daily pattern is formed are expensive, making it unsuitable for small-volume production of a wide variety of products. An object of the present invention is to provide a method that enables integrated continuous production, including the process of forming a protective film, and is economical enough to accommodate production of a wide variety of products in small quantities.

That is, in the present invention, a foamable synthetic resin paint is printed thickly in a pattern on the surface of a synthetic resin film while the film is being conveyed continuously, and the paint is heated to a temperature at which the foaming agent decomposes. Thereafter, the paint is dried and gelled or semi-gelled and delivered to the packing section, while the non-foaming synthetic resin layer laminated on the base material is heated and softened in advance and fed into the packing section. It is attached so as to be pushed into the non-foaming synthetic resin layer, and then subjected to a foaming heat treatment. The film material to be used as a protective coating is preferably a transparent synthetic resin film such as porous vinyl chloride, polyvinylidene chloride, vinyl fluoride, acrylic resin, or polyester. Depending on the purpose, it may be opaque, colored, or pre-printed with a pattern. It is desirable that this Fukufilm-like material has thermal adhesive properties with the material of the non-foaming synthetic resin layer that will be attached to the packing section later, but if they do not have thermal adhesive properties to each other, a suitable adhesive should be used. For example, by applying it to the surface of a non-foaming synthetic resin layer,
Attach with adhesive.・5 In order to continuously transport the film-like material, use an endless belt in addition to rotating rubber or synthetic resin rolls, or print thick patterns of foaming synthetic resin paint on the surface of the film-like material. A known rotary screen device can be used. This is cheaper than the above-mentioned mold roll with an intaglio pattern formed thereon, and even viscous paint can be easily printed in thick patterns using a squeegee or the like. The foamable synthetic resin paint that is thickly printed on film-like objects is a thermoplastic synthetic resin composition containing a foaming agent that decomposes when heated, and its color depends on the design of the embedded synthetic resin layer. It is desirable that the color be different from the color of .

The applied paint is dried and gelled or semi-gelled using a far-infrared device, for example, and becomes solid or semi-solid, so it can be embedded in the softened non-foamed synthetic resin layer at the next bonding part. . From the side of the non-foaming synthetic resin layer, a sheet-like material as a protective coating is adhered to the surface thereof. The pressure necessary for lamination can be provided by a pressure roll device with a clearance mechanism. By appropriately adjusting this clearance and adjusting the degree of softening of the non-foaming synthetic resin layer, the film-like material covering the surface can be applied flatly or unevenly.
can be done. The foamable synthetic resin paint accumulated in the printing device may dry or gel due to heat transfer from the rotating transport body, resulting in poor printing.

Therefore, after the lamination is completed and the film-like material is peeled off, it is desirable to cool the rotary transfer body portion with a cooling device. The effects of the method of the present invention described above are as follows.

Generally, when a transparent synthetic resin paste is applied to an uneven surface printed with a thick layer, a large amount is filled into the recesses, so even if the paste is foamed later, it is difficult to noticeably create uneven steps.
However, it is extremely difficult to faithfully attach a film to an uneven surface printed with thick embossing. However, as in the present invention, a non-foaming material that is laminated on a base material and softened 3. It is very easy to paste a film-like material on top of the synthetic resin layer, and since the foamable synthetic resin paint that is thickly printed on the film-like material is dry gelled or semi-gelled, this method is very easy to apply. It is also easy to push the material into the softened non-foaming synthetic resin layer. Moreover, if this is subjected to foaming heat treatment, a highly decorative product with noticeable uneven steps can be obtained. This has the advantage that thick printing of foamable synthetic resin paint and coating with a protective film can be performed simultaneously on the same equipment, and thick printing of foamable synthetic resin paint can be performed directly on the film-like material. Because of this, it can be carried out using an inexpensive mechanism without using an expensive die roll with an intaglio pattern, so it can be said that it is an economically efficient method that is suitable for small-lot production of a wide variety of products. Examples are shown below. The equipment used was as shown in Figure 1. First, while a transparent vinylidene chloride film 1 with a thickness of 40 μm is brought into close contact with a rotating rubber roll 3 by a pressure roll 2 and conveyed, a margin color foamable synthetic resin paint 6 having the composition shown in Table 1 is applied using a rotary screen mechanism 4. was extruded with a squeegee 5, and thick printing was carried out on the film 1 to a thickness of about 0.15 mm in an arabesque pattern.

Table 1 PVC10 heel weight part DOP5O〃 Stabilizer 4.5〃 Foaming agent 5〃 , A1 (0H) 350〃 Edge coloring agent 10〃 The thickly printed paint 6 passes through the far infrared device 7 It was dried and gelled.

Separately, a white non-foaming vinyl chloride resin composition 9a having the composition shown in Table 2 was placed on flame retardant paper 9b at 0.2T! The sheet material 9 laminated to a thickness of Rln was softened by a heating device 8 set at about 180° C., and then bonded to the film 1, which was sent in close contact with the rubber roll 3, using a pressure roll 10. As shown in the sectional view of FIG. 2, the edge-colored foamable synthetic resin paint 6 was embedded in the white vinyl chloride resin layer 9a, and the surface was evenly covered with the vinylidene chloride film 1. When this was subsequently passed through a foaming furnace 11 and a cooling furnace 12 set at 230'C, a third
As shown in the figure, a decorative material having a concavo-convex pattern with a protective coating that was expanded approximately six times as much was obtained. Table 2 PV010 weighing part DOP6O Stabilizer 2 CacO33O Titanium oxide 6

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram of an apparatus for carrying out the method of the present invention;
FIG. 2 is a sectional view of the intermediate product after indentation printing, and FIG. 3 is a sectional view of the foamed product. 1... Synthetic resin film, 6... Foaming synthetic resin paint, 9a... Non-foaming vinyl chloride resin composition, 9b... Flame retardant paper, 10...
Pressure roll, 11... Foaming furnace.

Claims (1)

[Claims] 1. While the synthetic resin film material is being continuously transported, a foamable synthetic resin paint is printed thickly in a pattern on the surface of the film material, and the paint is dried and gelled at a temperature below the decomposition temperature of the foaming agent. Alternatively, the paint is semi-gelled, and then the paint is pushed into a non-foaming synthetic resin layer laminated on a base material and softened by heating, and the surface of the non-foaming resin layer is covered with the film-like material. A method for producing a decorative material having an uneven pattern with a protective film, characterized by carrying out foaming heat treatment.