JPS6320719B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a foamed decorative material using a gravure ink containing foamed vinyl chloride paste as a main component.

Conventionally, various methods for manufacturing decorative materials using foamed ink have been proposed. Among these, decorative materials using inks whose main component is foamed vinyl chloride paste (hereinafter referred to as foamed inks) have a wide range of applications due to their good water resistance and other physical properties, but the viscosity of foamed inks is 4000 to 6000 CPS. It was too large to be printed using a gravure printing machine, so a screen printing machine or the like was used to print patterns. Therefore, screen printing machines have lower productivity than gravure printing machines. If only the non-foamed parts of the pattern are applied by gravure printing, it will be difficult to print in sync with the foamed parts, so the non-foamed parts must also be printed using a screen printer or the like. When using a screen printing machine, it is not possible to create large diameter plates like gravure plates, so
It is limited to small pitch patterns. There were other drawbacks. In addition, since the foaming temperature requires a high temperature of 180°C or higher, it cannot be applied to base materials with low heat resistance.

On the other hand, physical blowing agents (British Patent No. 1044680
However, after being incorporated into the ink vehicle, the foaming effect gradually decreases over time. The ink vehicles that can be used are limited. In particular, it cannot be used with PVC-based inks. It's expensive. In addition, the problem of carcinogenic substances occurred during the manufacturing process of this foaming agent, and the production of this foaming agent was discontinued.

The present invention was made in view of the above points, and uses a foamed ink whose main component is vinyl chloride resin, which has a viscosity of 1500 to 2000 CPS, is capable of gravure printing, and melts and gels at relatively low temperatures. The present invention aims to provide a method for producing a foamed decorative material that can be patterned using a gravure printing machine and then heated and foamed at low temperatures.

Next, the present invention will be explained in detail with reference to the drawings.

A sheet-like base material 1 such as paper, synthetic paper, nonwoven fabric, synthetic resin film, or the like is wound into a roll and set in the unwinding section 2 of a multicolor gravure printing machine. Base material 1
A pattern is applied to the roll in each printing unit 3 of the printing press, and each color is dried in a drying device 4. Each printing unit has 5 foam gravure inks.
Alternatively, normal gravure ink 6 is set, and the pattern applied to the base material 1 is only one color of foamed gravure ink. A combination of multiple colored foam gravure inks. A combination of multiple colors of foamed gravure ink and one color of regular gravure ink. A combination of one color of foamed gravure ink and one color of regular gravure ink. A combination of one color of foamed gravure ink and multiple colors of regular gravure ink.
A combination of multiple colors of foamed gravure ink and multiple colors of regular gravure ink. The printing order is arbitrary.

Although FIG. 1 is a drawing in the case of a four-color machine, it goes without saying that a multi-color machine with five colors or more can also be used.

Further, for the purpose of surface protection, the final unit can be coated with a transparent resin.

Base material 1 patterned and dried in each unit
While passing through the heating device 7, a portion of the foamed gravure ink 5 is foamed and becomes a foamed decorative material 8 having an uneven pattern that matches the pattern, and is wound up in a winding section 9.

Foamed gravure ink 5 has an average degree of polymerization of 900~
1300, particle size less than 1 micron, melting temperature 140~
It is made by adding and kneading a low-viscosity, low-temperature melting resin made of a copolymer of vinyl chloride and vinyl acetate at 150℃ with a blowing agent, plasticizer, stabilizer, colorant, etc. that foams at a temperature below the melting temperature of the resin. This is an ink whose main ingredient is expanded vinyl chloride paste. If a resin with an average degree of polymerization of 900 or less or 1300 or more is used,
When it melts and gels at a low temperature, the surface becomes rough, which is not preferable.

The vinyl chloride resin used in conventional foamed inks is a straight vinyl chloride resin that requires a high temperature of 180°C or higher to completely melt and gel.However, in the present invention, the vinyl chloride resin and vinyl acetate resin are made of vinyl chloride and vinyl acetate. By using a copolymer resin, the melting temperature can be lowered to 140-150℃, thereby completely gelling the vinyl chloride resin without using expensive high-temperature heating equipment, and improving heat resistance. It has become possible to apply it to scarce base materials.

Next, by setting the average degree of polymerization of the resin to 900-1300 and determining the formulation so that the viscosity of the ink after blending would be 1500-2000 CPS, it became possible to print with a normal gravure printing machine. In addition, the particle size of the resin is set to 1 micron or less, so that the resin can enter the cells of the gravure plate well.

In connection with this, the gravure plate used is preferably a mesh plate with a plate depth of 150 to 300 μm and a line count of 30 to 100 l.

The blowing agent completely melts and gels the copolymer resin.
We selected a material that decomposes at temperatures below 140 to 150°C and below the softening point of the resin, enabling in-line printing and foaming and application to substrates with poor heat resistance. Examples of blowing agents that can be used include azo compounds such as azobisisobutyronitrile, diazobenzene, nitroso compounds such as N,N'-dimethyl-N,N' dinitrosoterephthalamide, and paratoluenesulfonyl. Examples include hydrazide, sulfonyl hydrazide compounds such as benzenesulfonyl hydrazide, and the like. However, the decomposition temperature
Even if the blowing agent has a temperature of 150°C or higher, it is possible to lower the decomposition temperature to 150°C or lower by adding urea or the like.

Conventionally known plasticizers can be used, but those with low viscosity are preferred, and from the viewpoint of plasticization rate, compatibility with the resin, etc., dioctyl phthalate, dibutyl phthalate, di-2-ethylhexyl phthalate, di- -2-ethylhexyl adipate and the like are preferred. In addition, ADK cizer 0- made by Adeka Argus (manufactured by Adeka Argus) whose main ingredient is eboxidized soybean oil.
130P also has the effect of acting as a stabilizer, so although the viscosity is a little high at 270CPS, the effect of adding it is large.

As the stabilizer, conventionally known stabilizers such as calcium zinc type, organotin malate, barium zinc type, etc. can be used, but dispersion is better when a liquid type is used. However, compared to conventional PVC paste, the heating temperature is lower and the heating time is shorter, so a high degree of thermal stabilization is not required.

Conventionally known colorants such as organic pigments can be used.

Other additives include volatile diluents such as aliphatic hydrocarbons and fillers such as calcium carbonate and aluminum hydroxide.

By changing the formulation of the foamed gravure ink 5, it is possible to give different heights to the foaming as shown in FIG.

The foamed decorative material of the present invention produced by the method described above is patterned using a gravure printing machine, so it is possible to express a more delicate pattern than that using a conventional screen printing machine. Large patterns can be used. A pattern can be applied using a gravure printing machine, and printing and foaming can be performed in one step. Furthermore, by using a multi-color machine, printing and foaming can be done in one process even when creating a pattern that combines several types (several colors) of foaming ink or a pattern that combines foaming ink and non-foaming regular ink. be able to. Therefore, productivity is significantly improved compared to conventional products. It can also be applied to base materials with poor heat resistance.

Example 1: When applying a four-color wood grain pattern to a rolled base paper weighing 30 g/m ² using a gravure printing machine, three colors are applied with ordinary gravure ink and one color is applied with other colors. is applied with a gravure ink whose main ingredient is expanded vinyl chloride paste of the following composition, and after the four colors have been printed, it is printed in-line using a heating device installed in the final unit of the printing press.
The foamed ink was foamed at 110°C for 50 seconds.

Foaming ink formulation Vinyl chloride-vinyl acetate copolymer resin Zeon 135J (manufactured by Nippon Zeon Co., Ltd.) 100 parts by weight Foaming agent Azobisisobutyronitrile
5 Plasticizer Dioctyl phthalate 50 Stabilizer Calcium zinc based KV-83
3 〃 (manufactured by Kyodo Yakuhin Co., Ltd.) Surfactant Polyethylene glycol 2 〃 Monolaurate ester organic pigment 5 〃 *Viscosity is 2000 CPS (15°C) After foaming, it was continuously rolled up to obtain foamed decorative paper. The foamed decorative paper thus obtained had a foamed pattern and a non-foamed pattern in sync, and the foamed portion did not collapse even under the winding pressure during winding.

Example 2 When applying a three-color abstract pattern to a roll of base paper weighing 30 g/m ² using a gravure printing machine, three types of foamed ink with the following composition were used, and the printing machine's speed was increased every time one color was applied. After semi-gelling in the drying unit and applying the third color, foaming was carried out in-line at 120°C for 40 seconds using a heating device installed in the final unit of the printing press.

Foaming ink formulation 1 Vinyl chloride-vinyl acetate copolymer resin Zeon 135J (manufactured by Nippon Zeon Co., Ltd.) 70 parts by weight Low viscosity polyvinyl chloride resin Zeon-12 (manufactured by Nippon Zeon Co., Ltd.) 30 Foaming agent Para Toluenesulfonyl hydrazide
5 Plasticizer Dioctyl phthalate 50 Dibutyl phthalate 10 Stabilizer Liquid calcium/barium/zinc stabilizer 3 Yellow organic pigment 5 Foaming ink formulation 2 Red organic pigment was used instead of yellow organic pigment The rest was the same as formulation 1. Foamed ink formulation 3 The same as formulation 1 except that a blue organic pigment was used instead of the yellow organic pigment. After foaming, the foamed decorative paper was continuously rolled up.

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram showing an example of the manufacturing process of the decorative material of the present invention, and FIGS. 2 and 3 are cross-sectional views showing examples of the state of the decorative material of the present invention after printing and after foaming, respectively. be. 1... Base material, 2... Unwinding section, 3... Printing unit, 4... Drying device, 5... Foamed gravure ink, 5A... Foamed gravure ink A, 5B... Foamed gravure ink B, 5A' ...Foamed gravure ink A, 5B' after foaming...Foamed gravure ink B, 6...Normal gravure ink, 6A
... Normal gravure ink A, 6B ... Normal gravure ink B, 7 ... Heating device, 8 ... Foamed decorative material, 9 ... Winding section.

Claims (1)

[Claims] 1 After applying a pattern to the base material using ordinary gravure ink, or without applying a pattern, a combination of vinyl chloride and vinyl acetate with an average degree of polymerization of 900 to 1300, a particle size of 1 micron or less, and a melting temperature of 140 to 150°C is used. Gravure whose main component is foamed vinyl chloride paste, which is made by adding and kneading a low-viscosity, low-temperature-melting polymer resin with foaming agents, plasticizers, stabilizers, colorants, etc. that foam at a temperature below the melting temperature of the resin. A gravure ink composition containing foamed vinyl chloride paste as a main component is produced by applying a pattern using an ink composition using a gravure printing machine, and then applying a pattern with ordinary gravure ink or heating without applying the pattern. A method for producing a foamed decorative material comprising foaming.