KR19980028456A - Formation method of multi-stage decorative pattern and manufacturing method of floor decorative material applying the same - Google Patents

Abstract

The present invention relates to a method of forming a multi-stage decorative pattern and a method of manufacturing a floor decorative material applying the same, and after forming a three-dimensional pattern having a variety of thickness and shape with a plastic sol containing a certain proportion of pearl pigment on the substrate, When the air is injected, the shape and thickness of the three-dimensional pattern is changed, and the density distribution of the pearl pigment particles uniformly distributed in the three-dimensional pattern is changed or rearranged. It is formed, and this pattern forming method is applied to the formation of the pattern layer in the production of the floor decorative material to easily produce a floor decorative material having an excellent multi-stage three-dimensional effect at low cost.

Description

Formation method of multi-stage decorative pattern and manufacturing method of floor decorative material applying the same

The present invention relates to a method of forming a multi-stage decorative pattern and a method of manufacturing a floor decorative material applying the same, and more specifically, to form a three-dimensional pattern having various thicknesses and shapes primarily with a plastic sol containing a certain proportion of pearl pigment on the substrate. After spraying the air by using an air injector, the shape and thickness of the three-dimensional pattern are changed, and mutual interference of the three-dimensional pattern occurs, and the pearl pigment particles uniformly distributed in the three-dimensional pattern are changed or rearranged. The present invention relates to a method of forming a decorative pattern having a natural yet multistage three-dimensional appearance by forming a multistage three-dimensional pattern having a natural flake cloud pattern or a wavy pattern effect and solidifying in this state, and a method of manufacturing a flooring material using the same.

In general, the printing method or the transfer method has been used as a method of forming a decorative pattern on the flooring material, but such a conventional method is more diverse as it cannot be adapted to various demands of consumers by expressing a simple flat pattern. It gives a three-dimensional impression to express a lot of three-dimensional patterns to get a gorgeous decorative effect.

Conventional methods for forming such a three-dimensional pattern include a chemical method and a mechanical method, among which a chemical method coats a plastic sol containing a foaming agent on a substrate and prints it on a printing ink containing a foaming inhibitor thereon. After heating and foaming, it is a method of forming a three-dimensional pattern due to irregularities by partially foaming and suppressing at the same time. By the way, such a chemical method is difficult to create a natural effect and not excellent visual stereoscopic effect, there was a disadvantage that the contamination problem occurs in the irregularities of the surface of the product during use.

And the mechanical method is to heat the substrate made of vinyl chloride resin to a proper temperature (130-150 ℃) to form a concave-convex by using an embossing roll or press having a certain depth of pattern and to give a three-dimensional pattern by cooling will be. This method has been used for a limited purpose because it is productive in terms of energy consumption, complicated process, difficult to produce embossed rolls of multi-stage irregularities, and limited to express three-dimensional patterns of natural texture.

In addition, in the method of forming a three-dimensional pattern by using the air spray, as shown in Figure 7 (a), a predetermined pattern is printed on the predetermined base layer 100 in a conventional manner to form the printed layer 101 Then, the transparent resin sol coating, in which the diffuse reflection chip or pigment 102, such as pearl, is mixed on the printing layer 101 is formed to have a smooth surface.

Subsequently, air is blown from the upper portion of the translucent layer 103 to a predetermined air spray unit to form a three-dimensional pattern in the translucent layer 103, and then the surface of the translucent layer 103 is smoothly treated with transparent resin. Or to add a known chemical or mechanical embossing process described above to express a three-dimensional effect.

However, in the method of forming a pattern layer having a three-dimensional pattern effect using the conventional air spraying method, the translucent layer 103 including the diffuse reflection chip or the pigment 102 on the printing layer 101 is formed on the entire surface in a uniform thickness. After coating, the air is injected from the air inlet 105 by a conventional straight pipe fixed air injector as shown in FIG. 8 to inject air into a plurality of air nozzles 107 installed under the hollow tube 106. As shown in FIG. 7 (b), a predetermined directionality is given to the diffuse reflection chip 102 included in the translucent layer 103, or the density distribution of the diffuse reflection pigment 104 is shown in FIG. While giving a difference to form a pattern layer having a slight cloud pattern effect, that is, a three-dimensional feeling on the surface, such a pattern layer is a substantially non-stereoscopic or very fine three-dimensional pattern is formed, the three-dimensional pattern in the prior art Effect is texture By slightly changing the direction of the density distribution and the diffuse reflection of the diffuse pigment chips by an air jet it is only that of achieving the visual three-dimensional pattern effects.

In addition, a pattern layer having a three-dimensional pattern effect is formed over the entire upper surface of the printing layer, so there is little difference in the shape and size of the cloud pattern and the depth is weak, so that it is impossible to form various three-dimensional cloud patterns, so as to feel monotony overall. There was a limit to that expression.

In addition, products having patterned layers having these three-dimensional effects are used in a plurality of air sprayers because the discontinuities such as the seams of these pieces should not be visually noticeable when used in applications in which several pieces are used successively, such as flooring materials. Although the direction of the pearl pattern was slightly reduced by spraying in the cross direction, when the pattern layer having a three-dimensional effect was formed on the front surface of the product by the conventional air spraying method, the difference in shape and size of the cloud pattern was observed. There is no problem in the construction of these joints because the discontinuous parts such as joints are clearly expressed because there is no constant direction clearly.

Accordingly, an object of the present invention is to provide a method of forming a multistage three-dimensional decorative pattern, which not only easily forms various and multistage three-dimensional decorative patterns, but also has various patterning effects, thereby naturally treating discontinuous joints.

In addition, the present invention has another object to provide a method for producing a multi-stage decorative patterned flooring material using the above-described method.

Method for forming a multi-stage stereoscopic effect decorative pattern according to the present invention for achieving the object as described above, after forming a plastic sol containing a fixed ratio of diffuse reflection pigment on the substrate to form a three-dimensional pattern of various thickness with a rotary screen or engraving roll By spraying air using an air injector, the shape and thickness of the three-dimensional pattern of the plastic sol form are changed to cause the three-dimensional pattern interference and the density distribution of the pearl pigment particles uniformly distributed in the three-dimensional pattern is changed or rearranged. It is characterized by forming a multi-stage three-dimensional pattern having a piece cloud pattern or a wave pattern effect, and solidified in this state.

In forming multi-stage three-dimensional pattern, the air spraying method, namely, the air pressure, the size, shape, number of spraying openings and direction of the injection hole, the height of the fabric and the spraying hole, the angle of the spraying hole, the type and content of the diffuse reflection pigment, and the semi-transparent plastic sol By varying the viscosity, various products can be produced to meet the purpose.

In particular, the air injector is primarily blown into a three-dimensional pattern of plastic sol in a predetermined direction at a predetermined air pressure, and again blown in a different direction at a second changed air pressure to form a multistage three-dimensional decorative pattern. .

And the manufacturing method of the floor decoration material to which the said method is applied is a method of manufacturing a floor decoration material by manufacturing the base material layer of a normal cushion or non-cushion, forming a patterned layer on this base material layer, and performing surface treatment. It characterized in that to form the pattern layer by a method of forming a multi-stage three-dimensional effect decorative pattern.

In addition, a variety of products can be formed by adding an embossing or printing process thereto.

1 is a process chart showing a method of forming a multistage three-dimensional decorative effect pattern in accordance with the present invention;

2 is a line configuration diagram of a process apparatus according to the method of FIG. 1;

Figure 3a is a perspective view showing the separation of the air injector of Figure 2,

Figure 3b is a cross-sectional view showing the air injector of Figure 2,

Figure 4 is a view for explaining a method of forming a multi-stage three-dimensional effect decorative pattern according to the present invention,

5 is a process chart showing a manufacturing method of a flooring material according to the present invention;

6 is a cross-sectional view of the flooring manufactured according to the production method of the present invention,

7 is a view for explaining a method of forming a decorative pattern according to the conventional air injection method,

8 is a perspective view showing a conventional air injector.

Explanation of symbols on the main parts of the drawings

1: base material layer 2: printed pattern layer

3: multistage three-dimensional pattern layer 4: transparent layer

5: surface treatment layer 6: lower foaming layer

10: base material unwinding roll 20: coating coater

30: air injector 31: rotating shaft

32: injection drum 33: air inlet

34 opening opening 35 air leakage shield

36: rotary joint 40: heating oven

50: cooling drum 60: winding roll

L: injection distance

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.

1 is a process flow chart illustrating a method of forming a multistage three-dimensional decoration pattern according to the present invention, and FIG. 2 is a line configuration diagram of the process apparatus according to the present invention. , Plastic sol-like three-dimensional pattern forming process, air spraying process, and solidification process in order.

First, the plastic sol compounding process is a process of preparing a plastic sol by adding and mixing the pearl pigment sufficiently, the sol is preferably translucent, and the blending amount of the pearl pigment is preferably 0.1-30 parts by weight based on 100 parts by weight of the resin. The composition of the plastic sol is shown in Table 1 below.

[Table 1] Compounding ingredients and ratios of plastic sol

ingredient Amount Vinyl chloride resin (paste) 100 parts by weight Plasticizer (dioctylphthalate) 30-40 Secondary plasticizer (dodecylbenzene) 5-10 Epoxy 3-5 Stabilizer (BA-Zn) 3-5 UV absorbers 0.3-1 Pigment 0.1-20

The plastic sol has a viscosity of 3,000 to 10,000 cps (measured at Brookfield's viscometer LVT 4 Rotor 12 RPM), but the limited reason is that when the viscosity is 3,000 cps or less, the three-dimensional pattern effect is insufficient and the coating thickness is very difficult to control. When the viscosity is more than 10,000 cps, the workability is insufficient due to the sliding effect of the pigment when forming a three-dimensional pattern by air pressure, and is limited to 3,000-10,000 cps, and more preferably 4,000-7,000 cps.

Next, the plastic sol-like three-dimensional pattern forming process is performed by using a engraving roll (partly carved into a predetermined shape) or a rotary screen, or the like on the substrate or on the printing surface. It will be applied to have a variety of thickness within the range.

In the air spraying process, the air is sprayed before solidifying the formed plastic sol-like pattern so that the mutual interference of the three-dimensional pattern is generated by the injection pressure, and the pearl is uniformly distributed in the three-dimensional pattern as the shape and thickness of the iris pattern are changed. The density distribution of the pigment particles is changed or rearranged, so that a multistage three-dimensional pattern having a variety of thicknesses and shapes is partially natural to the whole product.

That is, the injection pressure acts differently depending on the thickness and shape of the three-dimensional pattern of each plastic sol to form a pattern having natural and various thicknesses and shapes, and various sizes and shapes according to the height (thickness) and shape of each three-dimensional pattern. As the cloud or wave pattern is formed in multiple stages within each three-dimensional pattern, the multi-stage solid pattern formed on the substrate or the printing surface is like a floating cloud or wave in the calm sea, as if a fragment cloud is floating in the transparent layer formed on the top. We form outstanding three-dimensional pattern which we did not see.

The air injector of the present invention changes the size and shape of the air injection pressure, the air injection opening, the number and direction of the injection, the height of the fabric and the injection port, the angle of the injection port, the moving speed (line speed) of the substrate and the like to meet the purpose. Various multistage three-dimensional patterns can be formed.

Preferably, the injection nozzle air pressure is in the range of 0.1-5kg / ㎠, and when the injection pressure is small, the mutual interference effect between the three-dimensional patterns is small, and the formation of various patterns is difficult, and when the injection pressure is too large, the mutual interference between the three-dimensional patterns is difficult. Excessive, too spread, thick and difficult to form a variety of patterns.

In addition, the number of injections may be performed once or twice or more, and when spraying two or more times, the size and shape of the cloud or the wave pattern in the multistage three-dimensional pattern may be further varied.

At this time, by spraying the spray direction in the cross direction can reduce the constant direction of the formed cloud pattern and reduce the spread of the pattern.

The remaining injection distance (L) is in the range of 5-100mm, the spray angle between the injector and the coating surface is maintained in the range of 10-50 °, the opening is preferably in the range of 1-5mm in diameter.

In particular, the air injector 30 is composed of one pair of the first and second air injectors 30a and 30b to adjust the air nozzles so as to have a mutually staggered injection direction, and further, the primary injection pressure, that is, the first air injector ( Compared to the injection pressure of 30a), the secondary injection pressure, that is, the injection pressure of the second air injector 30b is made relatively low, so that the primary air has a strong air pressure, so that the interaction between the three-dimensional patterns or the shape of the three-dimensional pattern is varied. While naturally changing, multi-stage three-dimensional pattern forms pearl cloud patterns of somewhat smaller size and shape, and secondly, slightly weaker injection pressure, which is primarily affected by injection pressure in the multi-stage three-dimensional pattern (mainly multi-stage three-dimensional pattern). The upper part of the inner part or the part in the direction of the spraying direction) is formed in a rather wide pearl cloud pattern, whereas the smaller ones formed in the primary are formed in the multistage three-dimensional pattern formed by the primary air blowing pressure. The part that is not affected by dead pressure (mainly lower part in the multistage three-dimensional pattern or the back of the spraying direction) has little effect, so that it is possible to form a three-dimensional cloud pattern or a wavy pattern having more various sizes and shapes in the multistage three-dimensional pattern. have.

At this time, each injection pressure is in the range of 0.6-5kg / ㎠, preferably 1.0-1.5kg / ㎠, secondary injection pressure in the range of 0.1-0.8kg / ㎠ and preferably 0.2 -0.5 kg / cm 2.

In addition, the air injector of the present invention can be used in the form of a rotary drum as shown in Figures 3a and 3b, or can be used as a straight tube fixed form as shown in Figure 8, it can be used in a variety of forms . Specifically, in the straight tube fixed type, a plurality of air nozzles 107 are fixed to a cylindrical tube 106 having an air inlet 105 at a side thereof. It is preferable to configure the directions of) to cross each other.

In addition, the cylindrical rotary drum consisting of a rotary shaft 31 and the injection drum 32 is provided with an air inlet 33 at one end of the rotary shaft 31 to inject air into the injection drum 32. In addition, a plurality of openings 34 are formed on the surface of the injection drum 32, and an air leakage prevention shield 35 is provided so as to spray the introduced air in a predetermined direction. At this time, the rotary shaft 31 and the air inlet 33 is connected by a rotary joint 36.

Therefore, as the spraying drum 32 rotates, the arrangement of the openings 34 formed on the drum surface may be changed, and the multistage three-dimensional pattern of various shapes may be formed according to the change of the rotational speed of the spraying drum 32. Will be.

Finally, the solidification process is to stably solidify by heating and drying the multistage three-dimensional pattern formed as described above, preferably 1 minute 30 seconds-3 minutes at a temperature of 190-230 ℃ in a hot air circulation oven Gel or foam and cool.

Each process of the present invention as described above is carried out continuously in the process line as shown in Figure 2, the plastic sol prepared on the substrate (or printing surface) unwound from the substrate take-up roll 10, rotary screen or engraving roll By forming a three-dimensional pattern having a variety of thicknesses by 20, by injecting air into the air injector 30 to form a multi-stage three-dimensional pattern, it is heated and gelled by a heating oven 40 and cooled by a cooling drum 50 The multistage three-dimensional pattern formed is then solidified and wound around the take-up roll 60. The multistage three-dimensional pattern formed in this way may be protected by forming a surface protective layer thereon in various ways depending on the product to be applied.

As illustrated in FIG. 4 to explain a method of forming a decorative pattern having a multi-stage three-dimensional effect of the present invention, a translucent layer 4 including diffuse reflection pigment on the substrate 1 or the printing surface (layer) 2 is provided. To form a three-dimensional pattern (3) having a variety of thickness, by spraying the air with a relatively strong injection pressure by the first air injector (30a), the three-dimensional pattern included in the translucent layer 4 is combined or unfolded A multistage three-dimensional pattern having various thicknesses and shapes is formed, and is then sprayed by a relatively low injection pressure in the injection direction different from that of the first air injector 30b (mainly in the multistage three-dimensional pattern). The upper part or the front part of the spraying direction) forms a multistage three-dimensional cloud pattern having a layered structure in which the pearl cloud pattern is greatly inflated.

5 is a process flow chart showing a preferred method of manufacturing a flooring material using the method of forming a multi-stage three-dimensional decorative pattern of the present invention as described above, a substrate layer manufacturing process, a printing process, a three-dimensional pattern forming process, a transparent layer ( If necessary, the lower foaming layer is added), and the surface treatment step is performed in order.

First, the base layer manufacturing process is to laminate a plastic sol (usually made of PVC resin) on glass fiber or mineral paper, which is often used for a conventional substrate, and if necessary, a plastic sol containing a foaming agent is about 0.1-1.0 mm. After further coating to a thickness of, and then gelling in a hot air circulation oven of 150-170 ℃ 1 minute 30 seconds to 3 minutes, or a process for producing a non-cushion substrate by seating a plastic sol.

The printing process is a process of giving a basic design and color by printing by a known method such as gravure, offset, rotary screen and transfer printing. In this case, when the foamed plastic sol is additionally coated in the base layer manufacturing process, a foaming inhibitor may be added to allow the three-dimensional pattern effect by the chemical method to be simultaneously expressed, and mechanical embossing is also possible.

And the three-dimensional pattern forming process is to apply the method of forming the multi-stage three-dimensional decorative decoration pattern of the present invention described above, when the foamed plastic sol is further coated in the substrate layer manufacturing process, at the same time the foaming step of the solidification step of the present step, At this time, the preferred foaming conditions are carried out at 190-230 ℃ 1 minutes 30 seconds to 3 minutes.

The transparent layer forming process is a process of applying and gelling a transparent sol in order to protect the three-dimensional pattern formed in the previous step. On the other hand, if necessary to impart additional cushioning properties of the product, the lower foaming layer can be further formed on the back of the substrate, regardless of the order of the present process.

Finally, the surface treatment process is a final process of applying and curing the surface treatment liquid on the transparent layer for pollution prevention, gloss control, and tactile improvement. In this case, the surface treatment liquid uses a lot of urethane acrylate resin.

The flooring material manufactured according to the manufacturing method as described above is shown in cross-sectional view in FIG. 6, as shown, the printed pattern layer 2, the multi-stage three-dimensional pattern layer 3, and the transparent layer on the base layer 1. 4) The surface treatment layer 5 is formed, and the lower foaming layer 6 is formed under the base material layer 1. In this flooring material, the multi-stage three-dimensional pattern layer (3) exerts a three-dimensional effect, but combined with the basic printed pattern layer (2) is to exhibit an excellent appearance effect as if the clouds are floating in the blue sky.

As described in detail above, the method of forming a multi-stage three-dimensional decorative pattern of the present invention, after forming a substantial three-dimensional pattern by blowing a plastic sol containing a pearl pigment using an air spraying machine to the conventional three-dimensional pattern, The process is simple and easy while forming various natural multistage three-dimensional patterns, compared to chemical three-dimensional pattern formation method or by spraying air on the plastic sol including pearl pigment on the entire surface to have a three-dimensional effect, that is, to show a three-dimensional effect. I can do it and the cost becomes low.

In addition, this method is particularly effective when applied to the production of flooring material, the multi-stage three-dimensional pattern layer in the transparent layer as if floating clouds floating in the sky, the appearance of an excellent appearance effect as if the wave ripples in the calm sea By exerting a beautiful multistage three-dimensional effect that could not be produced in the prior art.

Claims (15)

After forming the plastic sol containing the diffuse reflection pigment on the substrate into a three-dimensional pattern having various thicknesses and shapes, the shape and thickness of the three-dimensional pattern in the three-dimensional pattern of the plastic sol on the plastic sol under a predetermined injection pressure using an air spraying machine A method of forming a multistage three-dimensional decorative pattern in which the density distribution of pearl pigment particles uniformly distributed in the pattern is changed or rearranged to form a multistage three-dimensional pattern, and solidified in this state. The method of claim 1, wherein the content of the diffuse reflection pigment in the plastic sol is 0.1-30 parts by weight based on 100 parts by weight of the resin. The method according to claim 1, wherein the plastic sol is made transparent or translucent and has a viscosity of 3,000 to 10,000 cps. The method of claim 1, wherein the plastic sol is applied in a thickness of 0.05-1.0 mm. The method of claim 1, wherein the three-dimensional pattern is formed by a rotary screen or a engraving roll. According to claim 1, wherein the air injector, a rotary drum consisting of a rotary shaft 31 and the air injection drum 32, it is possible to inject air into the injection drum 32 to one end of the rotary shaft (31) The air inlet 33 is formed so that, the surface of the injection drum 32 is formed with a plurality of openings 34 is multistage three-dimensional decorative pattern, characterized in that the injected air can be injected to the outside Formation method. The method of claim 1, wherein the injection opening tool of the air injector is made into various sizes of 1-5mm in diameter, and the spraying distance between the air injector and the coating surface is 5-100mm and the spraying angle is 10-50 °. Method of forming a multi-stage three-dimensional decorative pattern, characterized in that. The method of claim 1, wherein the air pressure of the air injector is 0.1-5 kg / cm ² . According to claim 1, wherein the air injector 30 is composed of a pair arranged before and after the first and second air injectors (30a, 30b), compared to the injection pressure of the first air injector (30a) the second air injector ( Method for forming a multi-stage decorative pattern, characterized in that to lower the injection pressure of 30b). 10. The injection pressure of the first air injector 30a is in the range of 0.6-5 kg / cm2, and the injection pressure of the second air injector 30b is in the range of 0.1-0.8 kg / cm2. Method of forming a multistage three-dimensional decorative pattern characterized in that. The method of claim 1, wherein the solidification of the plastic sol is formed by heating the gel in a hot air circulation oven at a temperature of 150-170 ℃ for 1 minute 30 seconds to 3 minutes to form a multi-layered decorative pattern Way. A method of manufacturing a flooring material by forming a patterned layer on a base material layer of a conventional flooring material of a cushion or a non-cushion, and manufacturing a flooring material, wherein the plastic sol containing a diffused reflection pigment on the base material has various thicknesses and shapes. After the three-dimensional pattern was formed, the shape and thickness of the three-dimensional pattern were changed in the three-dimensional pattern of the plastic sol at a predetermined injection pressure by using an air sprayer, and the density distribution of the diffusely diffused pigment particles uniformly distributed in the three-dimensional pattern was changed. Forming a multi-stage three-dimensional pattern, and solidified in this state to form a multi-stage three-dimensional pattern layer, the method for producing a floor decorative material, characterized in that to form the pattern layer. 13. The method of claim 12, wherein a printed pattern layer is further formed on the base layer before forming the multistage three-dimensional pattern layer. The method according to claim 13, wherein the plastic sol containing a foaming agent in the manufacturing of the base layer is further coated with a thickness of 0.1-1.0mm, and when the printed pattern layer is formed, a foam inhibitor is added to the printing ink, and the multi-stage solid pattern layer is formed. Method of manufacturing a flooring material characterized in that to form a three-dimensional pattern by a chemical method by allowing the foam at the same time during the process. The method of claim 12, wherein the transparent sol is applied to the multi-stage three-dimensional pattern layer and gelated to form a smooth transparent layer.