KR20180091505A - The manufacturing method of decoration sheet in which pattern and embo conincide and the manufacturing appartus thereof - Google Patents

Abstract

The present invention relates to a method for manufacturing a decorative sheet, comprising: a step for preparing a substrate; a step for mixing an ink with a foaming agent to prepare a puff ink; a first printing step for printing a first color on a front side of the substrate; a second printing step for printing the puff ink on the front side of the substrate with the first color printed thereon to form a second printed layer in the shape of a printing pattern; and a step for drying the substrate printed with the puff ink in a drying oven, and at the same time, expanding the puff ink to form an emboss. In addition, the present invention relates to an apparatus for manufacturing a decorative sheet, comprising: a first printing means for printing a first color on a substrate to form a first printed layer; a second printing means for printing a puff ink on the substrate in the shape of a printing pattern to form a second printed layer; and a drying oven for drying the first printed layer and the second printed layer printed on the substrate and expanding the second printed layer to form an emboss.

Description

(EN) METHOD FOR MANUFACTURING ORGANIZATION SHEET CONTAINING PRINTED PATTERN AND EMO. {THE MANUFACTURING METHOD OF DECORATION SHEET IN WHICH PATTERN AND EMBO CONNECTION AND THE MANUFACTURING APPARTUS THEREOF}

The present invention relates to a method for manufacturing a decorative sheet in which a printed pattern and an emboss match, and an apparatus for manufacturing the same.

As the public's interest in the interior has increased in recent years, the demand for decorative seats is increasing. In particular, a decorative sheet in which fine patterns capable of expressing various textures are formed is widely used in home appliances and automobiles as well as in interior decorations.

Among the decorative sheets, decorative sheets with embossed are used in many fields because they can show various textures. For example, decorative sheets of PVC material can be used as flooring or as a surface finish for plywood furniture, in which case the decorative sheet can provide a real wood-like appearance to the floor or furniture. An actual tree-like appearance includes not only a tree-like pattern, but also ruggedness such as a wooden result. Therefore, it is important to provide a rug (emboss) that matches the wood pattern to provide a real wood-like appearance. However, the decorative sheet of PVC material is subject to shrinkage due to expansion and cooling due to heating in the pattern printing and drying process, so that the width and length may be different from the first. The variation of the width and length of the decorative sheet may result in discrepancies between the embroidery pattern on the decorative sheet. It is practically impossible to print a pattern by predicting a change in the width and length of the decorative sheet.

In the prior art, there is a method of attaching a supporting layer such as glass fiber or paper to a decorative sheet in order to prevent the variation of the width and the length of the decorative sheet. However, there is a problem in that the possibility of utilization of the decorative sheet may be significantly deteriorated in the above method.

Another conventional method is to form a tuned emboss using corrosion. However, such a method is suitable for a metal decorative sheet and is difficult to apply to a polymer decorative sheet such as PVC.

An object of the present invention is to provide a method of manufacturing a decorative sheet in which a printed pattern and an emboss match each other even when a substrate is deformed by heat in a decorative sheet manufacturing process and a manufacturing apparatus thereof.

According to another aspect of the present invention, there is provided a method of manufacturing a decorative sheet, Mixing the ink and the foaming agent to prepare a foaming ink; A first printing step of printing a first color on the front surface of the substrate; A second printing step of printing the foamed ink on the entire surface of the substrate on which the first color is printed to form a second printed layer in the form of a printed pattern; And drying the substrate on which the foamed ink is printed in a drying oven and foaming the foamed ink to form an embossment corresponding to the printed pattern.

According to another aspect of the present invention, there is provided an apparatus for manufacturing a decorative sheet, comprising: a first printing apparatus for printing a first color on a substrate to form a first printing layer; A second printing apparatus for printing a foamed ink on a substrate in a printed pattern to form a second printed layer; And a drying oven for drying the first printed layer and the second printed layer printed on the substrate and foaming the second printed layer to form an emboss.

According to the method for manufacturing a decorative sheet according to the present invention, even when the substrate is deformed by heat in the process of manufacturing the decorative sheet, the decorative sheet in which the embossed pattern and emboss match is provided.

In addition, since the method and apparatus for manufacturing a decorative sheet according to the present invention can dry and foam the ink simultaneously in one drying oven, the process cost is reduced and the process efficiency is greatly increased.

1 is a flowchart illustrating a method for manufacturing a decorative sheet according to an embodiment of the present invention.
2 is a flowchart illustrating a method of manufacturing a decorative sheet according to another embodiment of the present invention.
3 schematically shows a cross-section of a decorative sheet manufactured according to another embodiment of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS The advantages and features of the present invention and the manner of achieving them will become apparent with reference to the embodiments described in detail below with reference to the accompanying drawings. It should be understood, however, that the invention is not limited to the disclosed embodiments, but is capable of many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, To fully disclose the scope of the invention to those skilled in the art, and the invention is only defined by the scope of the claims. Like reference numerals refer to like elements throughout the specification.

How to make decorative sheet

Hereinafter, a method of manufacturing a decorative sheet according to the present invention will be described in detail. Referring to FIG. 1, a method of manufacturing a decorative sheet according to an embodiment of the present invention includes preparing a substrate (S100); Foam ink preparing step S200; 1 degree printing step (S300); Second printing step (S400); And the embossing step (S500), the decorative pattern on the decorative sheet is matched with the emboss in producing the decorative sheet.

Substrate preparation step ( S100 )

In the substrate preparing step S100 according to an embodiment of the present invention, a substrate for printing and embossing is placed on the decorative sheet manufacturing process.

The substrate may preferably comprise polyvinyl chloride (PVC). Polyvinyl chloride is one of thermoplastic plastics that is easy to color and is flexible and is therefore suitable for use as a base material for a decorative sheet.

The substrate containing polyvinyl chloride may preferably further contain a plasticizer. The plasticizer softens the polyvinyl chloride by weakening the bond between vinyl chloride (vinyl chloride), which is a monomer of polyvinyl chloride. As the plasticizer, dioctyl terephthalate can be preferably used. The plasticizer may be contained in a proportion of 10 to 30 parts by weight based on 100 parts by weight of the polyvinyl chloride. The polyvinyl chloride has a degree of flexibility that is suitable for use as the base material of the decorative sheet by including the above-mentioned plasticizer.

The substrate containing polyvinyl chloride may further include a heat stabilizer, an impact modifier, etc. in addition to the plasticizer. The heat stabilizer may be included in the range of 2 to 5 parts by weight in the Ba-Zn series and 6 to 10 parts by weight in the MBS (methacrylate butadiene styrene) series.

The substrate according to one embodiment of the present invention may preferably have a thickness of 0.1 to 0.6 mm. When the thickness of the substrate is less than 0.1 mm, the decorative sheet may be torn even under a slight impact from the outside, resulting in durability of the decorative sheet. In this case, the ornamental sheet may tear in the decorative sheet manufacturing process, which can interrupt or delay the continuous process, which may hinder the process efficiency. If the thickness of the substrate exceeds 0.6 mm, the flexibility of the substrate may be deteriorated and it may be difficult to apply the decorative sheet to curved and three-dimensional shaped surfaces.

The substrate according to one embodiment of the present invention may preferably be prepared in the form of a rolled-up printing roll. The printed roll wound here means that the base material is rolled up in a rolled form. When the substrate is provided in the form of a rolled-up printing roll, the substrate can be efficiently supplied to the continuous decorative sheet manufacturing process.

Printing roll Removal  step( S110 )

As described above, according to an embodiment of the present invention, the substrate may be prepared in the form of a rolled-up printing roll. At this time, the method of manufacturing a decorative sheet according to an embodiment of the present invention may further include a step (S110) of winding up the rolled-up printing roll using an unwinder and sequentially providing the rolled printing roll to printing.

The unwinder winds the wound printing roll at a speed set by the user and feeds it into the printing process. The user can set the speed at which the printing roll is appropriately pulled in accordance with the speed of the first printing step and / or the second printing step. The kind of the unwinder is not particularly limited.

Foam ink preparation step ( S200 )

In the foaming ink preparing step (S200) according to an embodiment of the present invention, the foaming ink is prepared by mixing the ink and the foaming agent. The kind of the ink mixed with the foaming agent for preparing the foaming ink is not particularly limited, and the embossing formed by the foaming ink can determine the color in consideration of the pattern shown on the decorative sheet.

The foaming agent is for forming an emboss by generating bubbles on a decorative sheet, and preferably includes a chemical foaming agent. Chemical foaming agents can be classified into organic foaming agents and inorganic foaming agents. Organic foaming agents include azodicarbonamide (ADCA), dinitroso pentamethylenetetramine (DPT), p, p'-oxybisbenzylsulfonylhydrazide (OBSH), dichloromonofluoroethane. The organic foaming agent is decomposed by heat to generate one or more gases selected from the group of N2, CO, CO2, NOx, NH3, HCHO, and H2O.

The gas generated by the thermal decomposition of the blowing agent should preferably be zero ozone depletion potential (ODP) and be nonflammable and non-toxic. OBSH is suitable for use in foaming ink for embossing because it generates gases consisting of N2 and H2O, which have relatively low decomposition temperature and low toxicity when thermally decomposed.

According to one embodiment of the present invention, the foaming ink comprises 1 to 10 PHR of blowing agent. In the foaming agent content ratio, PHR stands for Part per hundred resin, which means the amount of foaming agent contained per 100 parts by weight of the foaming ink. The amount of the foaming agent contained in the foaming ink can be appropriately determined in consideration of the size and number of the embossments. However, when the foaming ink is contained at less than 1 PHR, the amount of gas generated by the thermal decomposition of the foaming agent is insufficient, so that the embossing may not be sufficiently formed. In addition, if the foaming ink is contained in excess of 10 PHR, the amount of gas generated by the thermal decomposition of the foaming agent is excessively large, so that the embossing can not be stably formed and the embossing can be torn.

The mixing of the ink and the foaming agent is carried out by stirring. When the ink and the foaming agent are not mixed uniformly, when the foaming ink is printed on the substrate, the emboss may not be formed to a certain size. If the size of the embossing is not uniform and irregular, it can damage the appearance of the decorative sheet.

1 degree printing step ( S300 )

In the first printing step (S300) according to an embodiment of the present invention, the first color is printed on the entire surface of the substrate. 1 degree printing is to apply the base color of the decorative sheet to the substrate. For example, if the decorative sheet is intended to express the texture of wood, the underlying color will be yellow or brown, and yellow or brown ink will be printed on the substrate in the first printing step S300.

The method of printing is not particularly limited and may be performed in various ways such as gravure printing, screen printing, offset printing, rotary printing, or flexographic printing.

In addition, the type and color of the ink for 1-degree printing can be appropriately selected according to the pattern of the decorative sheet to be produced.

The first printed layer of the first color formed on the substrate by 1-degree printing may preferably have a thickness of 1 to 10 [mu] m. If the thickness of the first printing layer is less than 1 탆, the printing effect may be deteriorated. In addition, when the thickness of the first printing layer exceeds 10 탆, there is a problem that the first printing layer can be broken by the tension acting on the decorative sheet due to fragile nature of the dried ink.

3-degree printing step ( S310 )

In a third printing step S310 according to an embodiment of the present invention, a third color is printed on the substrate. The third color is preferably a different color than the first color. The three-dimensional printing step can also be accomplished through various methods such as gravure printing, screen printing, offset printing, rotary printing, or flexographic printing.

In another embodiment of the present invention, there may be additional printing steps between the third printing step (S310) and the second printing step (S400). The third printing step S310 and the additional printing step are determined depending on the design of the decorative sheet to be printed by the user.

2 degree printing step ( S400 )

In the second printing step (S400) according to an embodiment of the present invention, the foamed ink prepared is printed on the entire surface of the substrate on which the first color is printed to form the second printing layer in the form of a printed pattern. At this time, the second printing layer printed in the second printing step (S400) is formed on the first printing layer in accordance with the printing pattern set by the user.

The printing method used in the second-degree printing step (S400) is not particularly limited, but it is efficient in the process to use the same printing method as the first-degree printing.

Embo  Formation step ( S500 )

In the embossing step S500 according to an embodiment of the present invention, the base material on which the foamed ink is printed is dried in a drying oven, and at the same time, the foamed ink is foamed to form an embossing that matches the printed pattern.

Specifically, since the print pattern printed on the first print layer in the second-degree printing step (S400) is printed with the foamed ink, when heat is applied to the print pattern (second print layer) in the embossing step (S500) The foaming agent is thermally decomposed to generate gas and embossed in the form of a printed pattern. Since the printed pattern is embossed, the printed pattern and the emboss match even if the substrate is deformed by heat according to the present invention.

In the embossing step, the substrate is heated in a drying oven. The drying of the first printing layer and the second printing layer and the foaming of the foaming ink constituting the second printing layer are simultaneously achieved by heating in a drying oven. Therefore, according to the method for manufacturing a decorative sheet of the present invention, the embossing step and the ink drying step are integrated so that the efficiency of the decorative sheet manufacturing process is very high, and the expenditure for the drying apparatus and the foaming apparatus can be saved.

The present invention has various advantages as described above because it can simultaneously achieve printing layer drying and foaming ink foaming, but for this purpose, fine adjustment of heating time and heating temperature is required. That is, when the temperature is raised to increase the drying speed, the foaming speed can not be controlled and the desired emboss may not be formed. If the temperature is lowered only considering foaming, the printing layer may not be dried properly.

According to one embodiment of the present invention, drying and foaming in a drying oven can be preferably carried out at 80 to 120 ° C. As mentioned above, if the temperature in the drying oven is lower than 80 ° C, the printing layer may not be dried properly, and if the temperature in the drying oven exceeds 120 ° C, the foaming speed becomes too fast, .

According to one embodiment of the present invention, drying and foaming in a drying oven may preferably be carried out for 1 to 5 minutes. This time is a time at which drying and foaming can be reliably performed while avoiding excessive deformation of the substrate due to heat. Drying and foaming for a time out of this time range can lead to insufficient formation of embossing, insufficient drying or excessive deformation of the substrate.

Decorative sheet manufacturing equipment

Hereinafter, a decorative sheet manufacturing apparatus according to the present invention will be described in detail. An apparatus for manufacturing a decorative sheet according to an embodiment of the present invention includes: a first printing apparatus for printing a first color on a substrate to form a first printing layer; A second printing apparatus for printing a foamed ink on a substrate in a printed pattern to form a second printed layer; And a drying oven for drying the first printed layer and the second printed layer printed on the substrate and foaming the second printed layer to form an emboss.

The first printing apparatus and the second printing apparatus

The first printing apparatus and the second printing apparatus are devices for printing the first printing layer and the second printing layer on a substrate, respectively. As discussed above, the first printing apparatus and the second printing apparatus may be apparatuses using an appropriate printing method. For example, the first printing apparatus may be an apparatus using various printing methods such as gravure printing, screen printing, offset printing, rotary printing, or flexo printing, and the second printing apparatus may be an inkjet printing apparatus.

Drying oven

The drying oven is a device for drying the first print layer and the second print layer and for heating the substrate to foam the second print layer. The type of the drying oven is not particularly limited.

Unwinder

According to an embodiment of the present invention, an apparatus for manufacturing a decorative sheet may further include an unwinder. The unwinder is a device for drawing out a printing roll in the case of a printing roll in which a substrate is wound and sequentially providing the printing roll in succession.

The unwinder winds the wound printing roll at a speed set by the user and feeds it into the printing process. The user can set the speed at which the printing roll is appropriately pulled in accordance with the speed of the first printing step and / or the second printing step. The kind of the unwinder is not particularly limited.

According to one embodiment of the present invention, the unwinder, the first printing device, the second printing device, and the drying oven are connected in series so that the decorative sheet can be continuously produced when the printing roll wound in the unwinder is drawn have.

< Example >

In this embodiment and the comparative example, a PVC base material having a thickness of 0.1 mm was used as a base material. The descriptions of the examples and the comparative examples were all 1 degree printing and 2 degree printing. However, in the case of the embodiment, the printed pattern was printed using the foaming ink in the 2-degree printing, and in the comparative example, the printed pattern was printed using the common ink in the 2-degree printing. In Examples 1 and 2, embossing was carried out using the foaming ink according to the present invention. In Comparative Example 1, embossing was performed through a method of taking a PVC base plate with a concave-convex pattern plate. In Examples 1 and 2, foaming inks each containing 1 PHR and 3 PHR of a foaming agent were used. The decorative sheets of Examples and Comparative Examples were heated at 85 DEG C for 10 minutes.

In order to evaluate the degree of correspondence between embosses and printed patterns formed according to Examples and Comparative Examples, when the printed pattern deviates from the emboss at a distance of less than 1 mm according to the degree of deviation of the printed pattern from the emboss, DELTA, and X when the distance exceeded 3 mm.

Decorative sheet Embo and  Evaluating whether or not printed patterns match Example 1 ○ Example 2 ○ Comparative Example 1 X

As can be seen from the above Table 1, in the case of the decorative sheet according to Examples 1 and 2, the embossing and the printing pattern coincided. However, in the case of Comparative Example 1, the embossed pattern and the printed pattern did not match. This is because the PVC sheet was deformed during the heating step in the drying oven, which is the last stage of the decorative sheet manufacturing process. That is, in the case of Examples 1 and 2 in which the foaming agent for embossing is contained in the ink itself, the printed pattern and the emboss match even if the PVC sheet is deformed. However, the printed pattern is printed with the general ink, In the case of Comparative Example 1, the printed pattern deviated from the original position due to thermal deformation of the PVC sheet.

Claims (13)

Preparing a substrate;
Mixing the ink and the foaming agent to prepare a foaming ink;
A first printing step of printing a first color on the front surface of the substrate;
A second printing step of printing the foamed ink on the entire surface of the substrate on which the first color is printed to form a second printed layer in the form of a printed pattern; And
Drying the substrate on which the foamed ink is printed in a drying oven and foaming the foamed ink to form an embossment corresponding to the printed pattern;
A method of manufacturing a decorative sheet.
The method according to claim 1,
Characterized in that the substrate comprises polyvinyl chloride (PVC)
A method of manufacturing a decorative sheet.
The method according to claim 1,
Characterized in that the substrate has a thickness of 0.1 to 0.6 mm
A method of manufacturing a decorative sheet.
The method according to claim 1,
Characterized in that the substrate is prepared in the form of a rolled-up printing roll
A method of manufacturing a decorative sheet.
5. The method of claim 4,
Further comprising a step of unwinding the rolled-up printing roll using an unwinder prior to the first-degree printing step, and sequentially providing the rolled printing roll to printing
A method of manufacturing a decorative sheet.
The method according to claim 1,
Characterized in that the foamed ink comprises 1 to 10 PHR of blowing agent
A method of manufacturing a decorative sheet.
The method according to claim 1,
Drying and foaming in the drying oven is performed at 80 to 120 ° C.
A method of manufacturing a decorative sheet.
The method according to claim 1,
Wherein the drying and foaming step is performed for 1 minute to 5 minutes
A method of manufacturing a decorative sheet.
The method according to claim 1,
Further comprising a third printing step for printing a third color between the first printing and the second printing
A method of manufacturing a decorative sheet.
A first printing apparatus for printing a first color on a substrate to form a first printing layer;
A second printing apparatus for forming a second printing layer by printing foamed ink in a printed pattern on the substrate; And
And a drying oven for drying the first printed layer and the second printed layer printed on the substrate and foaming the second printed layer to form an emboss
Ornamental sheet manufacturing apparatus.
11. The method of claim 10,
The substrate is in the form of a rolled-up printing roll,
Further comprising an unwinder to unwind the rolled-up printing roll prior to printing the first color on the front surface of the substrate
Ornamental sheet manufacturing apparatus.
11. The method of claim 10,
Characterized in that the second printing apparatus is an ink jet printing apparatus
Ornamental sheet manufacturing apparatus.
12. The method of claim 11,
Wherein the unwinder, the first printing apparatus, the second printing apparatus, and the drying oven are connected in series so that the decorative sheet can be continuously produced when the rolled-up printing roll is withdrawn.
Ornamental sheet manufacturing apparatus.

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