JPS6132157B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a transfer sheet and a method for manufacturing a textured decorative material using the same.

Conventionally, the method of painting designs on the surface of decorative materials is to use a transfer sheet, which has an ink layer to be transferred on one side of a temporary base sheet, and then transfer this to the desired base material, usually under heating. It is used. This method is suitable for painting beautiful printed patterns on the surface of decorative materials, but
The drawback was that it only produced a two-dimensional painting effect, and it was not possible to obtain a decorative surface with three-dimensional expressiveness.

As a method to compensate for this defect and give a three-dimensional effect,
There is a known method of applying mechanical or chemical embossing to the surface of a decorative material after applying a painting by transfer, but mechanical embossing requires expensive embossing rolls and is a complicated process. Chemical embossing methods have drawbacks such as poor workability and the fact that the printed pattern and embossed pattern are not synchronized.Additionally, chemical embossing methods have many limitations on the patterns and materials that can be used, and can only be used for limited purposes. be.

In addition, as another method for producing a decorative material having an uneven surface, a thick ink layer is deposited on one side of a temporary base sheet, and a release layer and a pattern layer to be transferred are provided on top of the ink layer to form a transfer sheet. A method has also been proposed in which most of the thickened ink layer is left behind and transferred to a desired base material. According to this method, an uneven pattern that is in sync with the pattern can be obtained at the same time as the transfer, but the degree of unevenness obtained depends on the thickness of the ink layer, so the three-dimensional expressiveness is poor, and it is especially difficult to maintain the surface properties. When a protective layer is provided, there is a drawback that the unevenness may be reduced by half or even disappear.

An object of the present invention is to provide a transfer sheet that can provide a decorative material having a richly expressive uneven pattern that is in sync with the pattern, and a method for easily manufacturing the above-mentioned decorative material using the transfer sheet. purpose.

As a result of intensive research for the above-mentioned purpose, the present inventors found that it is very effective to use a transfer sheet in which the transfer ink pattern layer is formed from an ink containing a water-absorbing and swelling resin.

That is, the transfer sheet for producing a textured decorative material of the present invention is characterized in that an ink pattern layer containing a water-absorbing and swelling resin is formed on one surface of a temporary base sheet.

In addition, the method for producing the uneven decorative material of the present invention includes transferring the ink pattern layer of the transfer sheet to a desired base material, and then applying a resin-containing aqueous liquid to the transferred ink pattern layer to swell the ink pattern layer by absorbing water. It is characterized by further drying by heating.

Hereinafter, the present invention will be explained in more detail with reference to the drawings as necessary.

FIG. 1 is a schematic cross-sectional view of one embodiment of the transfer sheet of the present invention.

That is, the transfer sheet of this example includes, on a temporary base sheet 1, a release layer 2, an ink pattern layer 3 containing a water-absorbing and swelling resin, a normal printing ink layer 4, and an adhesive layer 5.
are stacked in this order.

As the temporary base sheet 1, materials commonly used for this type of transfer sheet can be used as they are, such as various papers and processed papers, synthetic resin films or sheet materials, metal foils such as aluminum foil, or laminate films thereof.

The peeling layer 2 is provided as necessary to promote peeling between the ink pattern layers 3 and 4 and the temporary base sheet 1, and is preferably made of a resin that melts with heat and has the effect of promoting peelability. is used. Specifically, for example, rosin, copal,
Natural resins and processed resins such as dammar, silica, hardened rosin, and rosin esters; polyvinyl acetate resins, polyvinyl chloride resins, polyvinyl alcohol, polyvinyl butyral, polystyrene resins, acrylic resins, phenolic resins, and their modifications. Synthetic resins such as resins, unsaturated polyester resins, alkyd resins, polyamide resins, epoxy resins, polyurethane resins, aminoplast resins, petroleum resins; nitrocellulose, methyl-, ethyl-, carboxymethyl- or a cellulose derivative such as acetyl butyryl-cellulose; one or a mixture of two or more of chlorinated rubber, rubber derivatives, glue, casein, dextrin, etc., which has good releasability to the binder of the ink pattern layers 3 and 4; Things are chosen.

The water-absorbing and swelling resin (hereinafter simply referred to as "water-absorbing resin") contained in the ink pattern layer 3 is a known hydrophilic resin that can absorb water and swell. (1978)
As described on pages 25 to 29 (November issue), it is a polymer compound that contains a hydrophilic group such as a carboxyl group or a hydroxyl group in its molecule, and is usually moderately crosslinked. This resin absorbs water at room temperature or in a heated state and expands to several hundred times its own weight, but it does not dissolve in water and is able to maintain its elastic shape even when it absorbs water. . Since such water-absorbing resins are stable and do not dissolve in organic solvents, any organic solvent can be used as a medium in preparing the printing ink.

In the present invention, the following water-absorbing resins can be used, for example: As described in Japanese Patent Publication No. 13495/1983,
Saponified product of copolymer of vinyl ester and ethylenically unsaturated carboxylic acid or its derivative; Japanese Patent Publication No. 53-46199 and Japanese Patent Publication No. 53-46200
A copolymer of starch or cellulose and an unsaturated carboxylic acid or its derivative as described in Japanese Patent Publication No. 55-4462; A copolymer of starch or cellulose and an unsaturated carboxylic acid or its derivative as described in Japanese Patent Publication No. A mixture of a copolymer of and an insolubilized carboxymethyl cellulose salt;
Self-crosslinking type acrylic acid alkali metal salt polymer; as described in JP-A No. 53-50290,
A saponified product of a copolymer of vinyl ester and an acrylic ester or a methacrylic ester; a crosslinked product of a lower olefin-maleic anhydride copolymer and an ethylene- Mixtures with vinyl acetate copolymers or polybutadiene; and as described in JP-A-55-40749,
Copolymer of acrylic acid alkali metal salt or ammonium salt and acrylic acid.

Commercially available water-absorbing resins that can be used in the present invention include, for example, Hydrogel-S (Sumitomo Chemicals), Sunwet IM-300 (Sanyo Chemicals), Aqua Keep 4S (Steel Chemicals), SGP Absorbent Bolior (a product of General Chemicals) and the like can be mentioned.

The above water-absorbing resin is usually a fine powder with a maximum particle size of 35μ and a minimum of about 0.1μ, but 100μ
Those having a particle size of ~1μ are usually used.

Water-absorbing resins such as those mentioned above are used in printing ink.
The content is usually 5 to 70%, preferably 10 to 30%.
If the resin content is too low, the water absorption and swelling effect will be insufficient; on the other hand, if it is too high, the water absorption and swelling effect will be good, but the adhesion of the ink to the base material will decrease and the ink will not stick to the base material. This is not preferable because the printed layer 3 easily falls off due to friction.

As mentioned above, the water-absorbing resin used in the present invention is stable against organic solvents, so when preparing the ink, aliphatic hydrocarbons, aromatic Organic solvents such as group hydrocarbons, alcohols, ketones, esters, alcohol ethers, chlorine-containing hydrocarbons, and nitrogen-containing hydrocarbons can be used as desired.

The printing ink further contains a binder for bonding the water-absorbing resin to the substrate, and various binders that are contained in conventional printing ink vehicles can be used as such a binder. Such binders include, for example, the following: natural or synthetic drying oils such as linseed oil, linseed oil, soybean oil, dehydrated castor oil, styrenated oils, vinyltoluenated oils, maleated oils, rosins,
Kobal, Dammar, Sierra Tsuk, hardened rosin,
Natural resins such as rosin esters or their processed resins, polyvinyl acetate resins, polyvinyl chloride resins, polyvinyl alcohol, polyvinyl butyral, polystyrene resins, acrylic resins, phenolic resins or their modified resins, unsaturated polyester resins , synthetic resins such as alkyd resins, polyamide resins, epoxy resins, polyurethane resins, aminoplast resins, petroleum resins,
Cellulose derivatives such as nitrocellulose, methyl, ethyl, carboxymethyl or acetylbutyryl cellulose, rubber derivatives such as chlorinated rubber and cyclized rubber, and one or more types of glue, casein, dextrin, etc. blend. These binders are included in the ink in a proportion of 3 to 50% in order to give the ink a viscosity suitable for printing and adhesion on the substrate.

In addition to the components described above, the printing ink may further contain colorants such as dyes or pigments.
Such dyes or pigments include those used in conventional printing ink compositions, such as azo, anthraquinone, and diephenylamine disperse dyes, oil-soluble dyes, or basic dyes, or yellow and chromium. Inorganic pigments such as vermilion, navy blue, Bengara, cadmium pigments, ultramarine, carbon black, or insoluble mono- or polyazo pigments,
Use organic pigments such as azo lake pigments, phthalocyanine pigments, thioindigo or anthraquinone pigments, quinacridone pigments, dioxazine pigments, irgazine pigments, dyed lake pigments, nitro and nitrone pigments, etc. I can do it.

The ink further includes known auxiliary agents that are contained in ordinary printing inks, such as plasticizers, stabilizers, waxes, greases, desiccants, auxiliary desiccants, dispersants,
Thickeners, fillers, ultraviolet absorbers, etc. may also be included.

A printing ink containing this water-absorbing resin can be easily prepared by mixing the various components described above and then kneading the mixture in a suitable device. However, by adding and mixing the water-absorbing resin into various known printing inks containing the above-mentioned various components other than the water-absorbing resin, such as offset, gravure, letterpress or silk screen inks, desired results can be obtained. It is convenient to prepare an ink of.

The ink containing the water-absorbing resin obtained in this way is printed onto the release layer 2 by a known printing method such as screen printing, gravure printing, offset printing, letterpress printing, or inkjet printing. m ² (dry weight) to form an ink layer 3. Among the printing methods, screen printing method or gravure printing method is preferable.

The printing layer 4 is usually provided as necessary to provide an additional cosmetic effect, and conventional printing inks and printing methods are used for this purpose.

For the adhesive layer 5, a thermoplastic resin that adheres to the base material of the decorative material described later, preferably by heat, is optionally used. Although the adhesive layer 5 is normally used during transfer, it is not an essential element of the transfer sheet of the present invention, and it may be formed just before transfer, and it can also be applied to the decorative material base material side during transfer. be. In such a case, the adhesive is not limited to a heat-sensitive adhesive, but may be a pressure-sensitive adhesive or a reaction-curing type.

Next, one embodiment of the method for manufacturing a decorative material of the present invention using the above-described transfer sheet shown in FIG. 1 will be described.

That is, as shown in FIG. 2, the base material 6 is overlapped so as to be in close contact with the adhesive layer 5 of the transfer sheet shown in FIG. After heat-pressing the plate or heat roll at a surface temperature of 80 to 250°C for 1 to 2 seconds, the base material 1 is peeled off to form the base material 6.
A structure as shown in FIG. 3 with the ink patterns 3 and 4 transferred thereto is obtained.

Various materials can be used as the base material 6 depending on the end use, such as paper, plastic film, woven fabric, non-woven fabric, synthetic paper, plywood, wood veneer, other wood boards, metal plates, particle boards, and hard materials. Boards, cement boards, and other inorganic boards can be used alone or in combination of two or more types.

Next, a resin-containing aqueous solution 7 is sprayed onto the transferred ink pattern layers 3 and 4 of the structure shown in FIG.
It is applied at a rate of, for example, 1 to 30 g/m ² (resin content) by brush coating, gravure method, knife coater, roll coater, or reverse roll coater method. Here, the resin-containing aqueous liquid includes, for example, acrylic resin, styrene/acrylic acid copolymer resin, styrene/maleic acid/acrylic acid copolymer resin, polyvinyl alcohol, melamine resin,
Aqueous varnishes containing water-soluble resins such as polyacrylic acid amide, casein, glue, dextrin, methylcellulose, carboxymethylcellulose, or self-crosslinking acrylic resin emulsions;
Reactive acrylic resin emulsion containing a crosslinking agent,
It includes aqueous emulsions of synthetic resins such as epoxy resin emulsions and urethane resin emulsions. Dyes or pigments can be added to the aqueous liquid.

Another method for applying aqueous liquids is
It is also possible to immerse the illustrated structure in an aqueous liquid.

3a in FIG. 4 by applying aqueous liquid 7.
As shown in the figure, the ink layer containing the water-absorbing resin expands, and water is retained here.

Next, when the structure shown in FIG. 4 is heated as a whole in a heating furnace or the like, the resin-containing aqueous liquid forms a coating 7a, and some water is removed from the water-containing ink layer 3a, as shown in FIG. evaporates and the height of the convex portion decreases to some extent, but the convex portion remains due to the shape retention and moisture permeation prevention ability of the resin coating formed by heating. Also, due to water evaporation, the coating 7
A matte texture is imparted to the convex portion a.

In order to strengthen the shape retention and moisture permeation prevention ability of the coating 7a, or to protect the surface of the decorative material, an overcoat varnish dissolved in an organic solvent may be further applied thereon. The overcoat varnish may be applied either before or after heating and drying. Examples of the solvent-based resin varnish include thermosetting resins such as unsaturated polyester resins, polyurethane resins, alkyd resins, epoxy resins, diallyl phthalate resins, and melamine resins; polyvinyl acetate resins, polyvinyl chloride resins, Thermoplastic resins such as polyvinyl alcohol, polyvinyl butyral, polystyrene resins, and acrylic resins are used.

As described above, according to the present invention, by using a transfer sheet on which an ink pattern layer containing a water-absorbing resin is formed, an arbitrary uneven pattern that is in sync with the pattern can be created by a simple method that slightly modifies the normal transfer method. It is possible to easily produce a decorative material having the following properties.

The present invention will be explained below using more specific examples.

Example 1 A water-absorbing resin-containing ink containing the following components was prepared.

Red pigment 8 parts Polyethyl methacrylate 10 Hydrogel S (water absorbent resin manufactured by Sumitomo Chemical Co., Ltd.) 30 Methyl ethyl ketone 27 Methyl isobutyl ketone 4 Ethyl acetate 13 Toluene 13 (Total) 108 23g/m ² A release layer was formed by applying a varnish containing dissolved polyamide resin to the entire surface of thin paper using a gravure printing machine. Next, a floral pattern was printed at a rate of 2 g/m ² (ink amount) using the water-absorbing resin-containing ink to form a foamable printed layer, and then a normal ink layer was formed using normal vinyl chloride ink. Next, a varnish made of vinyl chloride resin and acrylic resin was applied to the entire surface to form an adhesive layer, and a transfer sheet was manufactured.

The transfer sheet was placed on an ABS resin plate with a thickness of 5 m/m, and a transfer image was applied using a hot roll at 150°C, 5 kg/cm ² pressure, and a speed of 20 m/min.

A self-crosslinking acrylic emulsion (resin content: 30%) is applied to the surface of the ABS resin plate with the transferred image at a rate of 15 g/m ² (wet) using a roll coater, and then a two-component urethane resin is applied on top using a roll coater. The solution was applied at a rate of 5 g/m ² and then dried at 100° C. for 5 minutes to obtain a decorative material with a rich three-dimensional effect in which a flower pattern stood out.

Example 2 A water-absorbing resin-containing ink containing the following components was prepared.

Butyral resin 5 parts Aqua Keep 4S (water absorbent resin manufactured by Seitetsu Kagaku Kogyo Co., Ltd.) 20〃 Permanent Carmine HF-4C 5〃 Cyclohexanone 6〃 Xylene 55〃Isobutanol 9〃 (Total) 100〃 Printed on 25μ polyester film by silk screen printing machine The above-mentioned water-absorbing ink was printed at a rate of 5 g/m ² to form a foamable printing layer, and then a varnish made of polyester resin was applied to the entire surface to form an adhesive layer to produce a transfer sheet.

The above transfer sheet was superimposed on a cement board with a thickness of 20 m/m, and transfer painting was applied in the same manner as in Example 1.

Next, apply 5 g/m ² of urethane emulsion (resin content 30%) to the transferred surface using a doctor coater.
A cement decorative material having an uneven pattern was obtained by drying at 60°C for 10 minutes.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view in the thickness direction of an embodiment of the transfer sheet of the present invention, and FIGS. 2 to 5 illustrate intermediate steps in an embodiment of the method for producing a decorative material of the present invention using the transfer sheet. FIG. 1... Temporary base sheet, 2... Release agent layer, 3...
Ink pattern layer containing water-absorbing and swelling resin (3a... after water-absorbing expansion), 4... Normal printed pattern layer, 5... Adhesive layer, 6... Decorative material base material, 7... Resin-containing aqueous resin liquid layer (7a...coating after heating).

Claims (1)

[Scope of Claims] 1. A transfer sheet for producing an uneven decorative material, characterized in that an ink pattern layer containing a water-absorbing and swelling resin is formed on one surface of a temporary base sheet. 2. The transfer sheet according to item 1 above, wherein an ink pattern layer containing a water-absorbing swellable resin and an ink pattern layer not containing a water-absorbing swellable resin are formed on one surface of a temporary base sheet. 3. After transferring the ink pattern layer of a transfer sheet formed by forming a pattern layer of ink containing a water-absorbing and swelling resin on one surface of a temporary base sheet to a desired base material, a resin-containing aqueous liquid is applied to the transferred ink pattern layer. 1. A method for producing an uneven decorative material, which comprises coating the ink pattern layer, expanding the ink pattern layer by absorbing water, and further heating and drying. 4. The transfer sheet has a pattern layer made of ink containing a water-absorbing and swelling resin on one side of the temporary base sheet, and a pattern layer made of ink that does not contain the water-swelling resin, and both of these ink pattern layers are transferred to a desired base material. The method of item 3 above. 5. The method of item 3 or 4 above, in which a solvent-based resin varnish is applied on the ink pattern layer after heating and drying. 6 After absorbing water and expanding the transferred ink pattern layer,
The method according to item 3 or 4 above, further comprising applying a solvent-based resin varnish and then heating and drying it.