JPS62267193A - Production of facing having irregularities conforming to pattern - Google Patents

Abstract

PURPOSE:To form an ultraviolet-curing resin layer so that a wall thickness of a portion being in contact with a pattern layer is larger than that of the other portion, by selecting a surface layer of a facing substrate, a printing ink, and a coating material for forming a coating layer of ultraviolet-curing resin. CONSTITUTION:As a facing substrate 4, a paper such as tissue, bleached kraft paper, paper board, and gypsum liner board, a polyethylene film, and a polypropylene film, are used. A thermoplastic resin such as vinyl chloride resin, polyvinyl chloride-acetate, acrylic resin, and the like is used as a vehicle in a printing ink for forming a partial pattern layer on the surface of a thermoplastic resin layer when the surface layer of the facing substrate is made of, for example, vinyl chloride resin. A coating layer 5 of ultraviolet-curing resin is made of a commonly used ultraviolet-curing resin such as acrylic resin, polyester resin, epoxy resin, and polyurethane resin. In this manner, the ultraviolet- curing resin layer in which the portion confirming to the pattern has a wall thickness larger than that of the other portion is formed due to ultraviolet irradiation.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for manufacturing decorative materials used as floor tile sheets, wall panel sheets, etc. The purpose of the present invention is to provide a method for obtaining a synthetic resin decorative material with a high ceramic tile-like design at a low cost without using any special materials.

[Prior Art] As a method for obtaining a synthetic resin decorative material with high design quality that has embossing that matches the pattern, 1) a synthetic resin used for forming a curable synthetic resin layer, which is the surface layer of the decorative material, is A pattern layer is formed using an ink containing a hardening inhibiting substance, and then a transparent synthetic resin layer is formed on the entire surface of the pattern layer so as to cover the pattern layer. 2) A method in which only the transparent synthetic resin layer is made thinner than other parts; 2) An ink containing a substance that has no affinity for the synthetic resin used to form the transparent synthetic resin layer on the surface. A pattern layer is formed, and then on this top surface,
3) A method of forming a transparent synthetic resin layer over the entire surface so as to cover the pattern layer so that the transparent synthetic resin layer is not formed in the portion corresponding to the pattern layer; 3)
There is a method in which a pattern layer is formed using ink on a base sheet, and then embossing is performed using an embossing roll, an embossing template, or the like.

[Problems to be Solved by the Invention] By the way, the method for obtaining a synthetic resin decorative material having an emboss that matches the pattern according to item l) above requires complicated handling of ink containing a hardening inhibitor. In addition, the physical properties of the thin portion of the transparent synthetic resin layer on the surface of the resulting decorative material will deteriorate due to the influence of the hardening inhibitor in the pattern layer that is formed in contact with this portion. It also has the disadvantages of

In addition, in the method according to item 2), the obtained decorative material does not have a transparent synthetic resin layer that functions as a surface protective layer in the four parts of the decorative material, so the physical properties of the pattern layer in the core part It has the disadvantage of poor physical properties.

Furthermore, in the method according to item 3), it is difficult to express fine and complex shapes on the embossing roll or embossing template, so the decorative material obtained tends to have a relatively simple uneven pattern, and it is difficult to match the pattern layer. There are drawbacks such as difficulty in forming a pattern and a tendency to create uneven patterns that are out of alignment.

On the other hand, the method of manufacturing a decorative material having unevenness that matches the pattern of the present invention is a decorative material made of synthetic resin that exhibits an uneven expression similar to flowing glaze in a ceramic-like tile. The present invention provides a method for obtaining a decorative material with high design quality, which is expressed by uneven parts that match the pattern and has the texture of ceramic tiles, at a low cost without using any special additive materials. It is.

[Means for Solving the Problems 1] The method of manufacturing a decorative material having uneven parts that match the pattern of the present invention uses a base material for a decorative material whose surface is a thermoplastic resin layer surface, and After forming a partial pattern layer using printing ink using a thermoplastic resin as a vehicle on the surface of the thermoplastic resin layer of the material base material, a coating layer of an ultraviolet curable resin is applied to the upper surface of the layer to cover the partial pattern layer. and further curing the coating layer of the ultraviolet curable resin by irradiation with ultraviolet rays, wherein the coating layer of the ultraviolet curable resin is formed on the partial pattern layer surface by the printing ink. The surface layer of the base material for decorative materials and the printing ink are bonded together so that the affinity of the coating agent for forming the surface layer of the base material for decorative materials is higher than the affinity for the surface layer of the thermoplastic resin layer that is the surface layer of the base material for decorative materials. A coating agent for forming a coating layer of an ultraviolet curable resin is selected.

In the method for producing a decorative material having uneven parts that match a pattern according to the present invention having the above-mentioned structure, an ultraviolet curable resin is applied to the entire surface of a base material for a decorative material on which a partial pattern layer formed by printing ink is formed. When forming the coating layer, based on the difference in the degree of affinity between the partial pattern layer and the portion other than the partial pattern layer on the surface of the base material for cosmetics with respect to the coating layer of the ultraviolet curable resin, By taking advantage of the fact that the coating layer of the ultraviolet curable resin in the areas in contact with the partial pattern layer is thicker than in other areas, and irradiating it with ultraviolet rays in such a state,
The ultraviolet-cured resin layer is thicker only in the parts that match the pattern.

Therefore, the degree of surface unevenness of the obtained decorative material is
Of course, it is related to the degree of difference between the affinity of the thermoplastic resin layer forming the surface layer of the decorative material base material with respect to the coating layer of the ultraviolet curable resin and the affinity of the partial pattern layer formed by the printing ink. However, the viscosity of the coating agent when forming the coating layer of the ultraviolet curable resin, the thickness of the coating layer, and the standing time after forming the coating layer of the ultraviolet curable resin before irradiating the ultraviolet rays. The height of the convex portion of the resulting decorative material can be appropriately selected by appropriately selecting each of the above-mentioned conditions.

In addition, the affinity of the coating agent for forming the coating layer of the ultraviolet curable resin with respect to the thermoplastic resin layer forming the surface layer of the base material for cosmetic materials, and the said coating agent with respect to the partial pattern layer surface formed by printing ink. The difference in degree of affinity can be determined, for example, by dropping 0.04±0.002 g of the coating agent onto each predetermined surface with a dropper, and measuring the diameter of the dot of the coating agent 5 minutes after dropping. In this case, if a difference occurs to the extent that dots with a diameter of at least 1.05 times the diameter of the dots in the surface layer of the decorative material base material are obtained on the surface of the partial pattern layer, the surface of the resulting ultraviolet curable resin layer It has been confirmed that a sufficient unevenness effect is exhibited.

Examples of the base material for the decorative material in the method for manufacturing a decorative material having uneven parts that match the pattern of the present invention include, for example, plastic-based, wood-based, and metal-based.

Inorganic base materials, specifically papers such as tissue paper, bleached kraft paper, titanium paper, linter paper, paperboard, gypsum board paper, polyethylene film, polypropylene film, polyvinyl chloride film, polyvinylidene chloride film,
Plastic films such as polyvinyl alcohol film, polyethylene terephthalate film, polycarbonate film, nylon film, polystyrene film, ethylene vinyl acetate copolymer film, ethylene vinyl alcohol copolymer film, ionomer, wood substrates such as plywood, particle board, etc. LA of gypsum board, gypsum board slag board, etc., pulp cement board, asbestos cement board, wood chip cement board, etc.
M1 cement board, GRC and concrete, metal foil or sheet of iron, aluminum, copper, etc.
A composite of each of the base materials described in 2 is used, and the surface thereof is the thermoplastic resin layer surface, but it is necessary that the surface is the thermoplastic resin layer surface. In the case of materials other than the base material, a predetermined thermoplastic resin layer can be constructed by, for example, laminating vinyl chloride films or forming a coating layer of vinyl chloride resin. The thermoplastic resin layer, which is the surface layer of the base material for decorative materials, may be a thermoplastic resin layer rich in extender pigments, such as a vinyl chloride resin tile backer.

The thermoplastic resin used as a vehicle in the printing ink for forming a partial pattern layer on the surface of the thermoplastic resin layer of the base material for decorative materials constitutes the thermoplastic resin layer that is the surface layer of the base material for decorative materials. For example, if the surface layer of the base material for a cosmetic material is a doyl chloride resin layer, vinyl chloride resin, salt/vinyl acetate resin, acrylic resin may be used. etc. are used.

Examples of means for forming a partial pattern layer on the surface of the base material for decorative materials include gravure and offset.

General printing means such as flexo and screen can be used.

Furthermore, after forming the partial pattern layer, the coating layer of the ultraviolet curable resin can be formed using a general ultraviolet curable resin, such as acrylic resin, polyester resin, epoxy resin, polyurethane resin, polyamide resin, etc. Usually, a coating agent is prepared by adding a known sensitizer to a prepolymer or oligomer having an ethylenic saturated bond in the molecule as detailed below, or a coating agent having a known sensitizer as necessary.
g, preferably about 100 g.

Polyester (meth)acrylate, epoxy (meth)acrylate, urethane (
meth)acrylate, polyether (meth)acrylate, polyol (meth)acrylate, etc.

2) Methyl (meth)acrylate, ethyl (meth)acrylate, propyl (meth)acrylate, and butyl (meth)acrylate as molecules having an ethylenically unsaturated bond in the molecule.

2-ethylhexyl (meth)acrylate, methoxyethyl (meth)acrylate, ethoxymethyl (meth)acrylate, methoxybutyl (meth)acrylate, butoxyethyl (meth)acrylate, lauryl (meth)acrylate.

(meth)acrylic acid esters such as phenyl (meth)acrylate, unsaturated carboxylic acid amides such as (meth)acrylic acid amide, (meth)acrylic acid 2-(N,N-
dimethylamino)ethyl, (meth)acrylic acid 2-(N
.

N-dimethylamino)methyl, (meth)acrylic acid 2-
Substituted amino alcohol esters of unsaturated carboxylic acids such as (N,N-diethylamino)propyl, as well as
Ethylene glycol di(meth)acrylate, propylene glycol di(meth)acrylate, neopentyl glycol di(meth)acrylate, 1,6-hexanediol diacrylate, diethylene glycol di(meth)acrylate, triethylene glycol di(meth)acrylate, Diprobylene glycol di(meth)acrylate, trimethylolpropane tri(meth)acrylate, melamine(meth)acrylate, etc.

Incidentally, known sensitizers can be used, and specific examples include benzophenone-based and benzoin ether-based sensitizers.

Further, the coating agent is applied to the surface of the above-mentioned base material for cosmetic materials by a coating method such as a roll coating method, a flow coating method, a knife coating method, etc., to form a coating layer of the ultraviolet curable resin. It is something.

After forming the coating layer of the ultraviolet curable resin, it is generally sufficient to leave it for 5 to 20 minutes at room temperature before irradiating it with ultraviolet rays (setting conditions) to cure it with ultraviolet rays. By leaving it in an atmosphere heated to a temperature of 80° C. or less, this leaving time can be arbitrarily shortened.

[Example] Hereinafter, a specific configuration of the method for manufacturing a decorative material having an uneven portion matching a pattern of the present invention will be described based on an example.

Example 1 Thickness obtained by extrusion molding a mixed composition of 100 parts by weight of vinyl chloride resin, 30 parts by weight of DOP, 200 parts by weight of calcium carbonate, 3 parts by weight of tin-based stabilizer, and 2 parts by weight of epoxidized soybean oil; On three 0.5 mm base sheets, a partial pattern layer consisting of a gravure printing pattern with gradation expression using printing ink of the following composition was applied to a 0.1 mm thick white vinyl chloride film containing 30% by weight of plasticizer. The attached printed films were stacked one on top of the other with the printed pattern side facing outward, and heated at 150°C and 30 Kg/am''.
This was subjected to pressure molding for 3 minutes to obtain a base material for a decorative material having a partial pattern layer made of printing ink.

[PVC/PVC acetate=90/10T)=750] Methacrylic acid ester resin solution...5 parts by weight [solid content 40% by weight, p=400] Pigment...... 3 parts by weight solvent ・・・・・・・・・6
4 parts by weight of the ultraviolet curable resin [Seirybeam Patto] was then applied to the surface of the base material for decorative material having the partial pattern layer so as to coat the partial pattern layer.

(TR), manufactured by Dainichiseika Co., Ltd.] and 3 parts by weight of ethyl acetate was coated with a coating agent of 110 g (wet)/rn'' (thickness approximately 0, 1) using a flow coater method.
mm), and then placed in an oven at 60°C.
By leaving it for a minute, the part of the gravure printing pattern layer that is in contact with the part with a large amount of ink will swell up high.
The part that touches the part without the pattern layer is the lowest,
That is, a coating layer of an ultraviolet curable resin was formed which had unevenness that matched with the pattern layer. In addition, the coating agent 0.04
The diameter of the dot 5 minutes after dropping ±0.002g onto the surface of the decorative material base material with a dropper was 8.8mm, and the diameter of a similar dot on the pattern layer surface was 9.5mm, the latter being about 1.5mm of the former. It has been confirmed that it is 0.8 times as large.

Subsequently, when the UV curable resin layer was cured by UV irradiation treatment at 120 W/cm and 5 m/sin, gentle unevenness that matched the pattern as shown in the drawing was introduced on its surface. A decorative material l was obtained.

In the decorative material 1 shown in the drawing, reference numeral 2 indicates a base portion of a base material for a decorative material composed of three base sheets, reference numeral 3 indicates a white vinyl chloride film, reference numeral 4 indicates a base member for a decorative material, Reference numerals m49m2 and 5 respectively represent a picture pattern layer formed by gravure printing and an ultraviolet curable resin layer.

The obtained decorative material 1 had a gently uneven surface that matched the pattern layer, and had a high-quality appearance similar to that of a ceramic tile with a rich luster.

[Operations and Effects of the Invention] The present invention provides an ultraviolet curable resin so as to cover a partial pattern layer formed on the thermoplastic resin layer surface of a decorative material base material whose surface is a thermoplastic resin layer surface. When forming the coating layer of the above-mentioned printing ink, the affinity of the coating agent for forming the coating layer of the ultraviolet curable resin with respect to the surface of the partial pattern layer formed by the printing ink is determined by the affinity of the coating agent for forming the coating layer of the base material for decorative material. By selecting the surface layer of the base material for decorative material, the printing ink, and the coating agent for forming the coating layer of the ultraviolet curable resin so that the affinity for the surface of the thermoplastic resin layer is higher than that of the surface of the thermoplastic resin layer. The thickness of the ultraviolet curable resin layer before curing is such that the thickness of the portion in contact with the pattern layer is greater than the thickness of other portions, and then the ultraviolet curable resin layer is cured.

Therefore, in the method of the present invention, a decorative material made of synthetic resin exhibits the unevenness of a flowing glaze in a ceramic-like tile, and the unevenness is expressed by unevenness that matches the pattern. , a highly decorative decorative material having the texture of a ceramic tile can be obtained at low cost without using any special additive materials.

[Brief explanation of the drawing]

The figure is a cross-sectional view schematically showing a decorative material obtained by an example of the method of manufacturing a decorative material having uneven parts that match a pattern according to the present invention. l: decorative material, 4: base material for decorative material, m2m2: pattern layer,
5: Resin layer cured by ultraviolet rays.

Claims (3)

[Claims] (1) A partial pattern layer is formed using printing ink using a thermoplastic resin as a vehicle on the thermoplastic resin layer surface of a base material for decorative material whose surface is a thermoplastic resin layer surface, and then a UV-curable layer is formed on the entire surface. In the method for producing a decorative material, the method comprises forming a coating layer of resin to cover the partial pattern layer, and then further irradiating the coating layer with ultraviolet rays to cure the coating layer of the ultraviolet curable resin. The affinity of the coating agent for forming the coating layer of the ultraviolet curable resin with respect to the surface of the partial pattern layer formed by ink is higher than the affinity with the surface of the thermoplastic resin layer which is the surface layer of the base material for decorative material. A cosmetic having irregularities that match a pattern, characterized in that the surface layer of the base material for cosmetic materials, printing ink, and a coating agent for forming a coating layer of an ultraviolet ray curable resin are selected. Method of manufacturing wood. (2) Manufacture of a decorative material having irregularities that match the pattern as set forth in claim 1, which involves forming a coating layer of an ultraviolet curable resin, leaving it at room temperature for 5 minutes or more, and then irradiating it with ultraviolet rays. Method. (3) The thickness of the coating layer of ultraviolet curable resin is 20 to 300 mm.
A method for manufacturing a decorative material having concavities and convexities that are in tune with the pattern according to claim 1 or 2, which is μm.