JPS6359364B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a decorative material having a pattern rich in design, more specifically a marble pattern, a stone pattern,
The present invention relates to a method for producing decorative materials capable of creating new three-dimensional deep patterns, whether random or regular patterns.

Conventional methods for applying patterns to interior materials include gravure printing, flat plate pressing, and calendar processing, but in the case of gravure printing, for example, the thickness of the pattern is very thin, so a deep three-dimensional effect cannot be obtained, making it difficult to design. Moreover, since the pattern itself was thin, it was susceptible to abrasion. In addition, the method of agglomerating polyvinyl chloride (sometimes abbreviated as PVC) gel chips and heating them using a flat plate press produces a pattern with a three-dimensional effect, but it does not produce long sheets and has low productivity. Ta.

Furthermore, in the method of rolling PVC pellet pattern material by calendar processing, which has been widely used in the past, that is, the method of spreading and rolling the gelled PVC pellet pattern material on a PVC resin lump that has been heated and mixed to the extent that it can be plasticized. If the pellets are too hard for the PVC lumps mentioned above, the pellets will not deform, and as a result, the pellets will not be completely covered with the low-flowability resin lumps during rolling, and the chips and sheets will not be able to be integrated. The surface smoothness of the obtained sheet was poor. In addition, if the pattern material pellets are too soft, the pellets sprinkled on the resin lump during calendering will be softened, and at the same time as rolling, the high viscosity resin lump will flow and its shear stress will cause it to be stretched beyond the rolling ratio of the pellet itself. In extreme cases, only a meridian pattern is obtained in the flow direction of the calendar sheet, resulting in poor design and lack of appeal as a product. In this way, when a patterned sheet is made using a PVC pellet pattern material that has been gelled during calendar processing, there is a drawback that the range of pellet hardness is limited. Furthermore, it is generally difficult to obtain a deep three-dimensional pattern using gelled PVC pellets.

The inventors of the present invention have conducted intensive research in view of the above-mentioned problems, and have found that the above-mentioned problems can be solved at once by using a deformable soft patterned material and combining this with cold rolling. I found it.

That is, the present invention forms a curable liquid resin layer on one support, applies a deformable soft pattern material to the liquid resin layer, and then connects the support and the other support that runs in the same direction as the support. The present invention relates to a method for manufacturing a decorative material, which comprises deforming the patterned material by cold rolling while holding the liquid resin layer between the decorative material and the body, and then hardening and molding the material.

In the present invention, the above-mentioned cold rolling refers to rolling at a temperature at which the resin does not substantially gel.

According to the present invention, novel random or regular three-dimensional deep patterns can be obtained continuously and with high efficiency. The decorative material obtained by the present invention is widely used for various purposes, and is suitable for, for example, indoor flooring and wall materials that require wear resistance, and is particularly suitable as a soft decorative material that can be rolled up. In the present invention, the pattern material is rolled together with the liquid resin layer while maintaining the vertical relationship, and is cured as it is, so the pattern material can be seen through the sheet, and at this time, a deep decorative material with a sense of depth is obtained. Further, by rolling the liquid resin layer and the soft pattern material, the liquid resin is coated around the pattern material and a desired pattern can be obtained without flowing much. That is, in the present invention, a liquid resin with high fluidity and a soft pattern material with extremely low fluidity are sandwiched between supports and are cold rolled at a temperature at which the liquid resin does not solidify. The pattern material is easily deformed, and at the same time, the liquid resin covers the periphery of the pattern material, and the decorative pattern appears without the pattern material being stretched due to the flow of the liquid resin. This pattern does not elongate and flow due to the shear stress during thermoplastic processing of the base material, unlike the pattern obtained by calender processing, and exhibits a clear shape. Further, in the present invention, since the decorative material is rolled while being held between supports, the surface of the obtained decorative material becomes smooth. Furthermore, compared to decorative materials made by several conventional techniques, a pattern can be obtained over the entire layer of the decorative material with a constant thickness, and sheets with flexibility and a smooth surface can be continuously produced.
Moreover, the pattern has various excellent features such as a clear pattern with a three-dimensional effect and a high design quality.

The present invention will be explained in detail below. In the present invention, the curable liquid resin (hereinafter abbreviated as liquid resin) is
It functions as a so-called matrix resin,
Later, by hardening and molding using heat, light, ultraviolet rays, electron beams, etc., other structures are formed on the pattern material. The liquid resin must remain soft and flexible even after curing and molding. An example of liquid resin is
Examples include PVC plastisol, organosol, thermosetting resin, photocurable resin, moisture-curable resin, and the like. Processing conditions for photocurable resins are set so that the product does not lose its flexibility. In the case of PVC plastisol, vinyl chloride homopolymer as PVC resin,
Any copolymers of vinyl chloride and vinyl acetate, acrylic esters, methacrylic esters, and other monomers can be used. Known plasticizers used in PVC processing are used as plasticizers, such as phthalic acid plasticizers such as di(2-ethylhexyl) phthalate (DOP), diheptyl phthalate (DHP), and butylbenzyl phthalate (BBP). , aliphatic dibasic acid plasticizers such as di(2-ethylhexyl) adipate and diisodecyl adipate, other epoxy plasticizers, and trimellitic acid plasticizers. Plasticizer is usually about 20 parts per 100 parts (by weight, same below) of PVC.
~80 parts, preferably about 25-50 parts.

In the case of an organosol, it is preferable to use naphtha, mineral spirits, etc. as a diluent. Known stabilizers used in PVC processing can be used as stabilizers, such as metal soap, organic tin,
Composite stabilizers and the like are suitable.

In the present invention, the soft pattern material can be a material that is easily deformed during rolling in ordinary plastic processing, and specific examples include non-gelled PVC granules and soft polyurethane granules. When the soft pattern material is, for example, PVC non-gelled granules, the above PVC for paste, suspension polymerized PVC and plasticizer are used as the PVC resin and plasticizer, and the plasticizer is about 10 to 60 parts per 100 parts of PVC. It is preferable to mix them.

The liquid resin and soft pattern material in the present invention may include fillers, pigments, ultraviolet absorbers, flame retardants,
Antifungal agents, crosslinking agents, thixotropic agents, surfactants, etc. can be added. Further, the pattern material may further contain fine particles, fiber materials, mica, metal foils such as aluminum and gold, glass beads, coloring agent-containing microcapsules, and the like.

Specific methods for producing PVC non-gelled pattern materials include, for example, adding a small amount of plasticizer to a PVC composition excluding plasticizer and dispersing it, and pre-obtained PVC
An example is a method of obtaining granules by mixing and dispersing a granular composition such as PVC powder or filler in a paste, and in either case, the granules are simply obtained by means such as stirring without heating. These PVC
Ungelled granules are extremely soft because they have not been heated to gel, and can be crushed even by finger pressure, and can be easily deformed under normal plastic sheet processing, rolling, and lamination conditions.

In the present invention, the pattern material can be applied by spraying the pattern material onto a liquid resin layer on a horizontally running support (see Figure 1), or by spraying the pattern material onto a liquid resin layer that is caught between the nip of a pair of rolls. Examples include a method of dispersing the pattern material (see FIG. 2), and a method of attaching the pattern material from below to a liquid resin layer on a support rotating from above and picking it up. Examples of the rolling method include roll press, Ohmer press, funnel press, etc., but any known method may be used for continuous rolling.

Next, the present invention will be explained with reference to the drawings. FIG. 1 is a manufacturing process diagram of the decorative material of the present invention, in which 1 is one support, 2 is a liquid resin, and 3 is a doctor blade. Supply liquid resin, e.g. PVC paste, onto the support 1 and use a doctor blade to spread it approximately 0.1 to 2 mm.
Control thickness. On the obtained PVC paste layer of uniform thickness, a soft pattern material, such as PVC ungelled granules 4, which has fallen onto the belt from a hopper, is sprinkled. PVC paste resin 6 is applied on the other support 5 to a thickness of about 0.1 to 2 mm, and patterned roll 7 is applied.
PVC non-gelled pattern material once accumulated on the surface of
is sprinkled onto the paste resin layer 6. Both PVC
Paste layers 2 and 6 are merged and cold-rolled with rolling rolls 9 and 9' while the PVC paste layer is sandwiched between support 1 and support 5. Supports 1 and 5
run in the same direction via rolling rolls. By cold rolling, the pattern materials 4 and 8 are deformed while being overlapped and guided to the oven 10. In the oven, approx.
The sheet is heated and cured at 150 to 250°C, and the decorative material 11 of the product is obtained without peeling or peeling off the support.

Figure 2 shows a method in which a pattern material is spread on the nip portion of the roll and rolled. The rolls 12, 12' are arranged horizontally. The supports 1 on the one hand and the supports 5 on the other hand are fed vertically to the rolling rolls from above. Uniform liquid resin layers 2 and 6 are formed on the supports 1 and 5. Support 1
and 5 is a part that is rotatably stretched around the rolling rolls 12, 12' and where the liquid resin layer joins and comes into close contact;
That is, the pattern material 4 is spread over the nip portion of the rolling rolls. In FIG. 2, the pattern material may of course be sprinkled on any part of the liquid resin layer other than the nip portion of the roll.

In the present invention, the support is a cloth that has been subjected to mold release treatment,
Materials with good removability such as metal belts, asbestos,
Backing materials for flooring materials such as rock wool, cellulose paper, and glass matte, transparent films, synthetic resin sheets, etc. are used, and when winding up, various combinations of supports are possible depending on the form of the product, but at least one side is It must be transparent and the pattern must be visible. Depending on the form of the product, the support may become part of the product or may be separated from it.
In the present invention, the liquid resin layer may be formed on one support or both supports. In the latter case, the surface of the decorative material will be smoother. As a method of curing liquid resin,
In the case of PVC resin, thermosetting is suitable, and photocurable resins can be cured by UV rays under conditions that do not lose their flexibility.
Curing by electron beam is suitable.

The decorative material obtained by the method of the present invention is punched, cut, or crushed by an appropriate method to form pattern pieces of an appropriate size, and then glued to the floor.
It may be adhered to a wall or the like, or furthermore, the pattern pieces obtained by the above method may be adhered to various supports to create new pattern sheets for use.

As described above, the present invention enables a clear pattern to be obtained without the pattern being significantly stretched due to shear stress as in conventional calendering, and also provides new and highly designed patterns with various three-dimensional effects. This is a method for producing a decorative material with a smooth surface, flexibility, and excellent abrasion resistance.

Examples of the present invention are given below. Hereinafter, parts simply refer to parts by weight.

Example 1 Blend A PVC paste resin (=1700) 70 parts PVC blend resin (=1000) 30 parts Plasticizer (DOP) 50 parts Plasticizer (epoxidized soybean oil) 2 parts Stabilizer (Ba-Zn system) 2 Part: Prepare PVC plastisol of the above formulation A and perform vacuum defoaming.

Formulation B PVC paste resin 50 parts PVC blend resin 50 parts Plasticizer (DOP) 15 parts Stabilizer (Ba-Zn system) 2 parts Pigment Appropriate amount Mix the parts of the above Formulation B excluding the plasticizer at room temperature, Next, a plasticizer was added and dispersed to obtain non-gelled PVC granules. Suspension polymerization was carried out to prevent blocking of the obtained granules.
It was coated with PVC powder and used as a pattern material.

The asbestos sheet was used as one support and the release sheet was used as the other support, and the supports were rotatably stretched around a pair of horizontally installed rolls. 0.6mm thick on asbestos sheet, 0.5mm on release sheet
A thick layer of the above PVC paste was applied. The above-mentioned pattern material was sprinkled onto the nip where the paste layers on the supports running in the same direction were joined by a pair of rotating rolls, and the material was held between both supports and cold-rolled with the rolls at room temperature. Both supports were then passed into an oven to gel the paste layer at approximately 200°C. The release sheet was removed from the gelled sheet to obtain a 2 mm thick decorative material of the present invention. The obtained sheet had a smooth surface, and a highly designed pattern with three-dimensional depth was obtained over the entire surface.

Example 2 Compound C PVC paste resin 70 parts PVC blend resin 30 parts Plasticizer (DOP) 70 parts Filler (calcium carbonate) 150 parts Stabilizer (Sn-based stabilizer) 15 parts Pigment Appropriate amount PVC made of the above formulation C After applying the paste sol to a thickness of 0.5 mm on the surface of release paper 1, a glass mat (50 g/m ² ) was impregnated thereon and gelatinized with an infrared heater to obtain a support. After coating the defoamed PVC paste sol of Formulation D on this support to a thickness of 0.4 mm using a knife coater, equal amounts of mixed granules of Formulation E and Formulation B were sprinkled on top of this.

Blend D PVC paste resin 60 parts PVC blend resin 40 parts Plasticizer (DOP) 35 parts Surfactant 0.5 parts Blend E PVC paste resin 40 parts PVC blend resin 60 parts Plasticizer (DOP) 25 parts Pigment Appropriate amount For sprinkling Powdered PVC suspension resin 10 parts On the other hand, PVC paste gel consisting of formulation C was applied to release paper 5 to a thickness of 0.35 mm. Both of these sheets were cold-rolled with two rolls and then introduced into a heating furnace (200° C. hot air) to gel. The sheet that came out of the heating furnace was then cooled, and the release papers 1 and 5 were peeled off. The obtained sheet had a deep (three-dimensional appearance) in which the particulate matter had penetrated into the sheet, and a decorative sheet with excellent abrasion resistance that was rich in design without the particulate matter being stretched significantly was obtained. .

Example 3 A case similar to Example 2 except that the PVC paste sol (Formulation C) was applied onto the release paper 5, and then PVC non-gelled granules of Formulation F were further sprinkled. Also, a decorative sheet with even better design was obtained.

Mixture F PVC suspension resin 100 parts Plasticizer (DOP) 20 parts Stabilizer (Sn-based stabilizer) 1.5 parts Pigment appropriate amount

[Brief explanation of the drawing]

FIG. 1 is a manufacturing process diagram of the decorative material of the present invention, and FIG. 2 is a partial diagram showing the case where the pattern material is sprinkled on the nip portion of the roll. 1, 5...Support, 2,6...Liquid resin, 4...
...Soft pattern material, 9, 12... Roll, 10...
…oven.

Claims (1)

[Claims] 1. After forming a curable liquid resin layer on one support and applying a deformable soft pattern material to the liquid resin layer, the above support is run in the same direction as the above support. 1. A method for producing a decorative material, which comprises cold rolling the liquid resin layer while sandwiching it with another support to deform the patterned material, and then hardening and molding. 2. The manufacturing method according to claim 1, wherein the curable liquid resin is polyvinyl chloride plastisol or organosol. 3. The manufacturing method according to claim 1, wherein the soft pattern material is polyvinyl chloride non-gelled granules. 4. The manufacturing method according to claim 1, wherein a curable liquid resin layer is provided on the other support. 5 Claim 4 which provides a deformable soft pattern material to the liquid resin layer provided on the other support
Manufacturing method described in section.