JPS5923261B2 - Decorative material manufacturing method - Google Patents

Description

Detailed Description of the Invention The present invention is a decoration aiming at a three-dimensional design effect by laminating a transparent protective layer on a printed base material, and interposing decorative pieces between the base material and the transparent protective layer. This relates to the method of manufacturing the material.

Conventionally, this type of decorative material has been laminated on a base material with a transparent protective layer in which a decorative material is dispersed.

In order to manufacture such a transparent protective layer in which a decorative material is dispersed, calendar sheeting is performed while supplying decorative pieces to a calendar top roll, or calender sheeting is performed after mixing the material for the transparent protective layer and decorative pieces. However, in both cases, calendar sheeting is performed with the material for the transparent protective layer and the decorative piece coexisting, so the decorative piece may be deformed and its outline may become unclear, or the decorative single edge may be kneaded into the protective layer. Therefore, it has been difficult to obtain a decorative material with a three-dimensional and vivid appearance in which decorative pieces with clear outlines are randomly dispersed. . Therefore, a method can be considered in which only the transparent protective layer is first manufactured by calender sheeting, and the decorative pieces are interposed between the base material and the transparent protective layer when manufacturing the decorative material. In this method, decorative pieces are sprinkled on the base material soil, and a transparent protective layer is further laminated on top of the decorative pieces. However, when laminating a transparent protective layer, the sprayed surface of the decorative pieces is heated in advance to coat the base material surface and the transparent protective layer. The decorative piece is softened, and a preheated transparent protective layer is laminated thereon and pressed. However, in this method, if interlayer adhesion is to be improved, the surface on which the decorative pieces are sprayed must be heated to a high temperature to sufficiently soften the base material surface and the decorative pieces. If heated to high temperatures in this way, the decorative piece may be greatly thermally deformed and its outline may become unclear, and especially if a foamable, unfoamed thermoplastic synthetic resin sheet is used as the base material, heating may cause the base material to expand. Initially, it is difficult to obtain a decorative material with a desirable appearance because foaming gas is trapped between the substrate and the transparent protective layer and the printing runs off. However, if the heating temperature is lowered, the interlayer adhesive strength will decrease and air will be more likely to be trapped around the decorative piece, making the decorative material less useful. The present invention aims to improve the above-mentioned drawbacks of the prior art, and its main purpose is to make the heat deformability of the decorative piece higher than that of the transparent protective layer.

The invention will be explained in detail below.

The base materials used in the present invention include asbestos sheets, inorganic sheets such as glass fiber boards, fiber sheets, plywood, hardboards, wooden boards such as verticle ports, polyvinyl chloride, polystyrene, polymethacrylmethyl, polyurethane, polyamide, All kinds of materials can be used, such as plastic sheets such as polyester, polyethylene, and polypropylene, metal sheets, or bonded sheets of these materials, but in order to obtain a decorative board with irregularities, for example, unfoamed thermoplastics mixed with a foaming agent are used. A synthetic resin sheet with a desired pattern printed on its surface with an ink partially or entirely containing a foaming inhibitor is used.

When such a sheet is heated, the sheet foams and irregularities are formed on the surface while suppressing foaming in the areas printed with the ink containing the foaming suppressant. The decorative pieces used in the present invention include polypinyl chloride, polymethacrylmethyl, polystyrene, polypinylidene chloride, polyethylene,
Thermoplastic synthetic resin such as polypropylene is colored with dye, etc., and if desired, a plasticizer, etc. is added thereto, and the sheet is formed by calender sheeting or T-die extrusion, and then crushed or cut into fine pieces. Alternatively, well-known micronization methods can be used, such as forming the colored thermoplastic synthetic resin into fine pellets by extrusion molding, or granulating it with a high-speed stirrer.

It is desirable that the fine pieces have a size of about 12 to 42 meshes, and that the thickness is thinner than that of the transparent protective layer described later. The transparent protective layer in the present invention uses a thermoplastic synthetic resin similar to that used for decorative pieces, and can be directly calendered or T-die extruded, or the thermoplastic synthetic resin can be kneaded with a plasticizer to form a paste sol. A sheet can be used which has been prepared by applying it to an easily peelable sheet, heating and solidifying it, and then peeling off the peelable sheet, or by any other suitable method.

The decorative piece can be made to have higher heat deformability than the transparent protective layer.

To achieve this, the synthetic resin material used for the decorative piece should have a lower degree of polymerization than the synthetic resin material used for the transparent protective layer, or more plasticizer should be added, or the synthetic resin material should have a lower softening point. or a combination of two or more of the above three methods. The decorative pieces may be spread onto the spreading surface of the substrate by hand or mechanically using a suitable device such as a vibrating screen.

The amount of decorative pieces to be sprayed is preferably in the range of 40 to 180, more preferably in the range of 60 to 140, assuming that the amount of decorative pieces to completely cover the sprayed surface is 100. The spraying surface is heated, and the transparent protective layer is also preheated, laminated on the spraying surface, and pressed. For heating the sprayed surface and the transparent protective layer, well-known means such as hot air, high frequency waves, far infrared rays, etc. are used. During such lamination, if the heating temperature of the sprayed surface is too high, the interlayer adhesion will increase, but excessive softening of the decorative material, deformation or discoloration of the printed surface of the base material, etc. may occur, and the preheating temperature of the transparent protective layer is too high. Although the interlayer adhesive force increases, the transparent protective layer becomes excessively soft and deformed, and the unevenness of the decorative piece appears on the surface of the decorative material. On the other hand, if the heating temperature is lowered, the pressing force must be increased to maintain interlayer adhesion, and the pressure may cause the decorative pieces to spread out or even pierce the printed surface. However, in the case of the present invention, the heat deformability of the decorative piece is higher than that of the transparent protective layer, so even if the pressing force is increased while heating at low temperature, the printed surface of the base material will not be damaged or deformed. As a result, a product having a high interlayer adhesion strength and a favorable appearance with no air entrapped between the layers can be obtained. In this way, a bonded layered material with a decorative layer sandwiched between the layers is obtained.Finally, the base material is a foamable unfoamed thermoplastic synthetic resin sheet surface with an ink containing some or all of the foaming inhibitor. When using a sheet with a desired pattern printed on it, if the sheet is heated to the foaming temperature to cause foaming, the sheet portion printed with the ink containing a foaming inhibitor will be inhibited from foaming. A decorative material is obtained in which irregularities are formed on the surface of the sheet, which has cushioning properties, heat insulation properties, and soundproof properties, and which also exhibits an extremely three-dimensional appearance.

The present invention provides a decorative material in which decorative pieces made of fine pieces of colored thermoplastic synthetic resin are dispersed on the surface of a printed base material as described above, and a transparent protective layer is further laminated thereon. In order to make the adhesiveness higher than that of the transparent protective layer, when laminating the decorative piece Q, a low temperature is applied so that thermal deformation and orientation due to the pressing force do not occur, and even if the pressing force is increased, the pressing force will not affect the decorative piece. Since it is absorbed, damage and deformation of the printed surface of the base material are prevented, and at the same time, a product with strong interlayer adhesion and no air entrapped between the layers can be obtained.

The decorative material of the present invention is used for architectural interior materials such as wall materials and floor materials.

Examples will be given below to further specifically explain the present invention. Example 1 The following composition was mixed and a sheet having a thickness of 1 was obtained by calender sheeting.

The sheet 1 thus obtained is lined with a hesher cloth 2, and a pattern 3 is printed on the surface to obtain a base material B shown in FIG.

As shown in FIG. 2, the base material B is pulled out from the roll 4 of the base material B in the direction of the arrow, and first, decorative pieces 5 are sprinkled onto the surface of the base material B from the scattering device 6. Here, the decorative piece 5 is made by mixing the following three types of compositions and calendering it to a thickness of 0.211 mm.
Three types of colored PVC sheets were obtained, and each sheet was crushed and sieved to obtain fine pieces that passed through 12 meshes, #140% and #2.
Mix at a ratio of 40% and #320%. Next, the spray surface is heated by the far-infrared heater 7A.

The surface temperature of the sprayed surface during heating is approximately 150°C. A transparent protective layer 8, which has also been preheated by a far-infrared heater 7B, is laminated on the heated spraying surface and is pressed by a roll 9. The surface temperature of the transparent protective layer 8 during heating is approximately 150°C. The transparent protective layer can be obtained by mixing the following composition and calender-sheeting the mixture to a thickness of 0.5 nm. Thus, as shown in FIG.
A decorative material is obtained in which decorative pieces 5 are sprinkled on the surface of the base material B, and a transparent protective layer 8 is further laminated on the sprayed surface, but the decorative pieces 5 have a higher DOP content than the transparent protective layer 8. Therefore, since the thermal deformability is high, even when laminated under low temperature and high pressing force, no damage or deformation occurs to the printing surface of the base material, and no air is trapped between the spraying surface and the transparent protective layer 8. , the adhesion between the layers becomes stronger.

Therefore, a decorative material with a clear and three-dimensional appearance can be obtained. Example 2 The following composition is mixed to obtain a PVC paste sol.

Paste sol with the above composition has a thickness of 0.81! The mixture was spread and coated onto 0.4 inch asbestos paper using a roll coater to a thickness of 0.4 inch.

Immediately after application, the paste sol was heated at 170° C. for 2 minutes to solidify it into a semi-gel state. A pattern layer is formed on this surface by printing with the ink of color l containing a foaming inhibitor and the inks of other colors containing no foaming inhibitor.
Thus, as shown in FIG. 4, a base material B' is obtained in which the PVC semi-gel layer 11 is lined with asbestos paver 12 and a pattern layer 13 is provided on the surface. Using the base material B', a decorative material is produced in the same manner as in Example 1, but finally, it is heated to a foaming temperature to foam the base material B'. Thus, as shown in FIG.
However, the portion printed with the ink containing the foaming suppressant is inhibited from foaming and becomes the concave portion 14. In this way, a decorative material is obtained which has a clear and extremely rich three-dimensional effect and at the same time has cushioning, heat-insulating, and sound-insulating properties.

[Brief explanation of drawings]

FIG. 1 is a partial side view of an embodiment of the base material used in the present invention;
FIG. 2 is a system diagram of an embodiment of manufacturing the decorative material of the present invention;
Fig. 3 is a partial side view of one embodiment of the decorative material thus produced, Fig. 4 is a perspective view of another embodiment of the base material, and Fig. 5 is a decorative material in which the base material is foamed and provided with projections and depressions. FIG. 3 is a partial side cross-sectional view of one embodiment.

Claims (1)

[Scope of Claims] 1. Decorative pieces made of fine pieces of colored thermoplastic synthetic resin are sprinkled on the surface of a substrate that has been subjected to printing, etc., the surface of the substrate on which the decorative pieces have been sprinkled is heated, and 1. A method for manufacturing a decorative material in which a transparent protective layer is laminated after preheating, the method comprising making the decorative piece have higher thermal deformability than the transparent protective layer. 2. Decorative pieces made of fine pieces of colored thermoplastic synthetic resin are sprinkled on the surface of a printed substrate, the surface of the substrate on which the decorative pieces have been sprinkled is heated, and a transparent protective layer is preheated on top of it. In this method, the decorative material is made to have higher thermal deformability than the transparent protective layer, and the base material includes a foaming inhibitor partially or completely on the surface of the foamable unfoamed thermoplastic synthetic resin sheet. A transparent protective layer is laminated onto the base material using a material with a desired pattern printed with the ink containing the foaming agent, and then heated to suppress foaming in the area printed with the ink containing the foaming inhibitor. 1. A method for producing a decorative material, which comprises forming irregularities by foaming a base material.