JPS5917662B2 - Manufacturing method for three-dimensional ornaments - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a three-dimensional decorative article, and more particularly to a method for manufacturing a three-dimensional decorative article having an uneven pattern corresponding to a printed pattern.

The present invention is a novel method that is different from the conventional mechanical method using an embossing plate or the chemical emboss method using foaming inhibitors and hardening inhibitors to produce interior materials such as wallpaper and leather, and wall decorative panels for interior decoration materials. It is possible to provide a three-dimensional ornament that can be used for a wide range of purposes such as reliefs, three-dimensional maps, etc., with corresponding colors and unevenness. Conventional methods for imparting unevenness to decorative materials can be roughly divided into the following 1 to 4 methods:
The following methods are known.

1. A mechanical embossing method in which the material is embossed by applying ink to the convex portions of an embossing plate that has irregularities using a method called valley printing (valley dyeing printing), and the concave portions are colored into patterns.

2. A foaming suppression method in which a pattern is printed on a material such as vinyl chloride containing a foaming agent using foaming suppressing ink, and the foaming is performed by heating to form a concave portion in the suppressing ink area.

3. A foaming ink method in which printing is performed using foaming ink containing a foaming agent, and the foaming ink is heated and foamed to form an uneven pattern when used in combination with regular ink.

4 '0 Curing suppression method in which curing is suppressed by applying an ink containing a curing inhibitor such as hydroquinone to a resin such as unsaturated polyester, and recesses are formed due to the difference in shrinkage of the resin.

The above methods 1 to 4 have the following drawbacks.

In other words, method 1 is mechanically embossed, so it is possible to form sharp and delicate embossments, but it is not suitable for embossed plates, which are expensive and have small heads.
It is difficult to produce multicolored patterns and the production speed is slow.

Method 2 uses printing ink to create an embossed effect, so it is possible to emboss a multicolor pattern or add tone (different depths) to the embossment. However, the resin is vinyl chloride-based. Limited.

Method 3 does not limit the number of colors and produces highly foamed embossing, but the sharpness is poor and the ink cost is high.

Since method 4 is applied to thermosetting resin, the cost of the resin is high, and it is not possible to produce a soft material.

■5 As a result of various studies to solve the above drawbacks, the inventor of the present invention found that by using ordinary ink and foaming using common materials such as water and solvent without using special chemical foaming agents. The present invention (1) was completed by discovering a method for manufacturing three-dimensional ornaments having a concavo-convex pattern. Conventional chemically embossed foam products either partially suppress foaming and make the area dented, or promote foaming in some areas and make them expand more than others. Specifically, foaming suppressants ( 15 When using a foaming accelerator (which reacts with a foaming accelerator that lowers the decomposition temperature of the foaming agent, or an agent that increases the decomposition temperature of the foaming agent by reacting with the foaming agent) and uses this as an incubator. (a) The stability of In+ is inferior to that of ordinary inks. (b) The printing suitability of 1-1J is poor. (c) The ink is extremely expensive.

Furthermore, these chemical embossing methods are difficult to apply to resins other than vinyl chloride resin.

The present invention eliminates all of these drawbacks. That is, the present invention includes a first layer in which a volatile substance is coated or impregnated on a base material, a second layer partially having a resin that suppresses air permeability on the first layer, and a thermoplastic resin on the upper surface of the second layer. The third layer having a thermoplastic resin coating is partially removed by creating a composite body consisting of a third layer having a resin coating, and heating the composite to vaporize volatile substances in the first layer. This is a method for producing a three-dimensional ornament, which is characterized by foaming to form an uneven pattern. According to the present invention, an uneven pattern can be formed without using a special foaming suppressor or foaming promoter, and further without using a chemical foaming agent.

The present invention will be explained in more detail with reference to the drawings.

In the present invention, first, a first layer is formed by coating or impregnating a volatile substance on a base material, a second layer partially has a resin that suppresses air permeability on the first layer, and a thermoplastic resin is applied to the upper surface of the second layer. A composite consisting of a third layer with a resin coating is created.

To create such a composite, a base material is coated or impregnated with a volatile substance to form a first layer 1, which is then coated with a resin 2'' that completely suppresses air permeability or an air permeable layer. A second layer is formed by applying one or both of the resins 2 that are incompletely suppressed, and then a third layer consisting of a thermoplastic resin coating 3 is applied.Also, when using an air-permeable base material, a layer on the base material is applied. The volatile substance may be applied or impregnated after applying the second or third layer.

The composite thus created is then heated to vaporize the volatile substances.

The vaporized gas causes the thermoplastic resin coating 3 to foam in areas where there is no resin that suppresses air permeability. As a result, this portion becomes a convex portion 4. In addition, in the area where the resin 2'' that completely suppresses air permeability is present, even when heated, the vaporized gas does not reach the lower surface of the thermoplastic resin coating 3, so the plastic resin coating 3 does not foam. This portion becomes a recess 6. In addition, in a portion of the resin 2 where air permeability is incompletely suppressed, the vaporized gas forms a recess 5 corresponding to the degree of air permeability suppression.

That is, the present invention forms a layer partially containing a resin that suppresses air permeability, forms a thermoplastic resin coating on the surface, and vaporizes the volatile substance coated or impregnated on the base material by heating. As a result, in the resin part where air permeability is suppressed, the thermoplastic resin coating is foamed or not foamed depending on the degree of suppression, and in the part where the resin that suppresses air permeability is not applied, the thermoplastic resin coating is This is a method for manufacturing three-dimensional ornaments by foaming a resin coating to form a concavo-convex pattern corresponding to the pattern of the resin that suppresses air permeability.

Furthermore, in the present invention, the foaming state can be changed depending on the amount of resin that suppresses air permeability. Further, in the present invention, it is preferable that the thermoplastic resin coating of the third layer softens at a temperature close to the vaporization temperature in the base material, and the type of resin is not particularly limited.

Therefore, unlike previous chemical embossed foam products, it is not limited to vinyl chloride resin. Base materials used in the present invention include paper, fibers, wood materials such as plywood, flexible boats, calcium silicate boards, gypsum boats, and the like. As the volatile substance, water and various other solvents such as ketone, aromatic, peraffin, alcohol, and ester solvents are used, and these may be used alone or as a mixture of two or more thereof.

Further, as the method of coating or impregnating the base material with a volatile substance, either a coating method or a dipping method may be used.

The resin that suppresses air permeability is generally used in ordinary inks such as gravure ink, offset ink, letterpress ink, etc., which may or may not contain coloring pigments.

In this case, the ink binder usually used in gravure printing includes cellulose resins such as cellulose acetate, nitrocellulose, and ethylcellulose, aminoalkyd resins, urethane resins, acrylic resins, vinyl chloride resins, polyester resins, and melamine resins. Resin is fine, but
In particular, the effect of suppressing air permeability is better if the printed film is not porous.

In other words, in halftones, microscopically there are areas where ink does not adhere, and the foaming of the thermoplastic resin film cannot be completely suppressed, resulting in a slightly foamed state as shown in the recess 5 in Figure 2. Become. The most common type of offset ink is linseed oil, but other types such as phenolic resin and alkyd resin can also be used.

In letterpress ink, rosin, ester gum, petroleum resin, etc. are used. Normal pigments may be used in any ink, but as the ratio of pigment to resin increases, the ink becomes porous, making it difficult to completely suppress air permeability.

The third layer of thermoplastic resin coating is one in which volatile substances drop under heating conditions to form a foamed layer. These resins are preferably thermoplastic resins having a softening point near the vaporization temperature of the volatile substance. Such resins include polyvinyl chloride,
polyvinyl acetate, acrylic, urethane, polyethylene,
It may be a single or copolymer of polypropylene, ethylene vinyl acetate copolymer, etc., or a mixture thereof. In addition, the thermoplastic resin coating is formed by dissolving it in a solvent or forming an emulsion and coating it by roll coating, gravure coating, knife coating, air knife coating, etc., and then heating and blowing the solvent or water. There is a method of evaporating the resin and gelling it, and a method of extruding the resin in a hot molten state from a T-die using an extruder or the like to form a film. The most suitable resins for the former method are polyvinyl chloride resin and their copolymers, while for the latter method, polyethylene, polypropylene, and ethylene-vinyl acetate copolymers are most suitable.

In the case of polyvinyl chloride resin, plastisol coating is also effective.

In addition, there is no particular limitation on the thickness of the thermoplastic resin coating, but 1
A range of 0 to 100μ is valid.

Next, a specific method of the present invention will be explained based on Examples.
Example 1 Gravure printing is carried out on 80'/A wallpaper base paper using cellulose ink, and then transparent polyvinyl chloride resin plastisol is coated with a 50μ knife coat and gelled.

Next, it is impregnated in a mixture of equal amounts of isopropyl alcohol and water and dried with cold air. The base paper is impregnated with isopropyl alcohol and water. Then, when heated at 150° C. for 1 minute, the cellulose-based ink part did not foam, but the other parts foamed, yielding a three-dimensional decorative article in which embossments corresponding to the ink pattern were formed. Example 2 Paperboard was printed with a pigmented offset ink using linseed oil as a binder, and then coated with 20μ of polyethylene using an extruder.

Next, after 24 hours of humidity control at 400C and 90%, it was heated to 130℃.
When heated for 2 minutes, the moisture absorbed in the paperboard evaporated, causing the polyethylene film to foam in areas other than the ink area, but not in the ink area. In the halftone area where the ink had halftone dots, unevenness was formed corresponding to the halftone dots. Example 3 In Example 2, after moisture absorption, the back surface was gravure coated with acrylic resin.

Low-temperature melting acrylic was used, and the solvent Troll was partially impregnated inside the paper during cold air drying. When this material was foamed under the conditions of Example 2, the unevenness effect was considerably better than that of Example 2. This is because the volatile gas does not evaporate from the back side of the paper during foaming. As described in detail above, in the three-dimensional decorative article of the present invention, the printed pattern and the unevenness are in sync with each other, which was difficult to achieve with the conventional mechanical embossing method, and the unevenness corresponding to the ink density can be obtained, and the halftone dots When a pattern is formed, there are effects such as unevenness corresponding to halftone dots.

In addition, conventional inks, base materials, and thermoplastic resins can be used as they are, and water, solvents, and
Any volatile substance such as a solid solution can be used, and it has the advantage that no special process is required other than coating or impregnating the volatile substance. Furthermore, unlike mechanical embossing, there is no need for an embossing plate according to the pattern, and since embossing can be freely formed using existing printing plates, there is no need to install new special equipment.

In addition, in the present invention, any printing method such as letterpress printing, offset printing, gravure printing, or screen printing may be used.
The scope of application of the present invention is extremely wide, as it is possible to use either a winding method or a sheet force method, and a wide range of base materials can be selected.

[Brief explanation of the drawing]

The drawings show one embodiment for explaining the present invention.
FIG. 1 shows a composite of the present invention before heating, and FIG. 2 shows a composite having an uneven pattern after heating. 1... First layer in which the base material is impregnated with a volatile substance, 2
・・・・・・Resin that completely suppresses air permeability, 2'...
...Resin that completely suppresses air permeability, 3...
Thermoplastic resin coating, 4... Convex portion, 5, 6...
・・・Concavity.

Claims (1)

[Claims] 1 A first layer having a base material coated or impregnated with a volatile substance, a second layer partially containing a resin that suppresses air permeability on the first layer, and a thermoplastic resin coating on the upper surface of the second layer. and a third layer, and partially foam the third layer having the thermoplastic resin coating by heating the composite and vaporizing the volatile substance in the first layer. A method for manufacturing a three-dimensional ornament characterized by forming an uneven pattern.