JPS6049092B2 - Method for producing valley-dyed foam decorative material with protective coating - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention provides a decorative material in which an uneven pattern is formed by foaming, the recesses are so-called 'valley dyed', and the uneven surface is covered with a protective film. The present invention relates to a method for manufacturing.

Since the surface of foamed products has the disadvantage of being relatively abrasive, it is necessary to coat the surface of foamed products with a protective coating in order to withstand use in areas such as wallpaper and flooring.

In this case, as a conventional method, there is known a method as disclosed in Japanese Patent Publication No. 53-11548. This uses a die roll with a diary pattern formed on it, fills the diagonal pattern with a synthetic resin paste containing a foaming agent, and then overlays a transparent film so that the paste surface is airtight, and then heats both. An intermediate product was created by bonding and foaming, and a protective film was then formed on the surface of the product. However, it is extremely difficult to pack the film faithfully onto the uneven surface, and forming the film by applying a synthetic resin paste is also difficult in order to make the film thickness uniform on each part of the uneven surface. It's difficult for friends.

In view of the above-mentioned circumstances, the present invention has been made with the object of providing a new method that allows both valley dyeing and the formation of a protective film on the surface to be carried out extremely easily.

That is, in the present invention, while a synthetic resin film is continuously transported, a non-foaming synthetic resin paint is printed thickly in a pattern on the surface of the film, the paint is dried to gel or semi-gel, and then First, the paint is pushed into a foamable synthetic resin layer laminated on a substrate that has been sufficiently heated and softened at a temperature below the decomposition temperature of the blowing agent, and the surface of the resin layer is covered with the film. It is then subjected to foaming and heat treatment.

Films that should serve as protective coatings include polyvinyl chloride, polyvinylidene chloride, vinyl fluoride, acrylic resin,
Transparent materials such as polyester are preferred, but
Depending on the purpose, it may be opaque, or may be colored or pre-printed with a pattern.

It is desirable that this film is a combination that has thermal adhesive properties with the material of the synthetic resin layer to be packed later, but if they do not have thermal adhesive properties, they are bonded with a suitable adhesive. In order to continuously transport the film, an endless belt is used in addition to a rotating roll made of rubber or synthetic resin.In addition, to print a thick pattern of non-foaming synthetic resin paint on the film surface, a known method is used. A rotary screen device can be used.

This is less expensive than the above-mentioned mold roll with an intaglio pattern formed thereon, and even viscous paint can be easily printed in thick patterns using a squeegee or the like. The dry gelling or semi-gelling of the paint applied to the film is the process of solidifying or semi-solidifying the paint, and embedding it in a sufficiently softened foamable synthetic resin layer at the next bonding section. This is to make it easier.

When the film is conveyed by a rotating roll, the film is fed in close contact with the rotating roll by passing a sufficiently softened foam synthetic resin layer through the narrow gap formed by the rotating roll and the pressure roll. The film will be laminated to cover the surface of the resin layer, and at this time, the paint will be sent out as being pushed into the softened foamable synthetic resin layer.

When the non-foaming synthetic resin paint is embedded in a pattern in the foamable synthetic resin layer in this way, the embedded foamable synthetic resin portion is pushed away to the surroundings and remains in a thin film state.

Therefore, when the whole is placed in a foaming furnace and heated and foamed at a temperature higher than the decomposition temperature of the blowing agent, the foamable synthetic resin portion where the non-foaming synthetic resin is embedded remains in a thin film state as described above. The amount of foaming at the embedded part is 2 to 3 times higher due to the fact that the non-foaming synthetic resin part acts as a weight, heating energy is consumed to raise the temperature of the non-foaming synthetic resin part, and the non-foaming synthetic resin part acts as a weight. However, in the unruined areas, the foam swells 8 to 10 times, and an uneven pattern with clear steps appears. As is clear from the above, the method of the present invention is to print three thick layers of non-foaming synthetic resin paint that will later be dyed directly onto a film that will become a protective film, and then soften it. Since it is laminated with a foamable synthetic resin, it is extremely convenient in that the formation of a protective film on the surface and the embedded printing of the non-foaming synthetic resin paint can be easily performed at the same time using the same device.

Furthermore, prior to lamination, the non-4-foaming synthetic resin paint on the film was dried and gelled or semi-gelled and then pushed into the softened foamable synthetic resin layer, so the print pattern would not be deformed. It can be pushed in correctly. As described above, the present invention is extremely superior as a method for manufacturing a valley-dyed foam decorative material with a protective coating. Examples are shown below.

The equipment used was as shown in Figure 1.

While a transparent vinyl chloride film 1 with a thickness of 40 μm is transferred by a pressure roll 2 in close contact with a rotating rubber roll 3, a composition as shown in Table 1 below is first applied using a rotary screen cylinder 4 and a squeegee 5. After printing a blue non-foaming synthetic resin paint 6 in an arabesque pattern with a thickness of about 0.15 inches on the film 1, it is passed through a far-infrared device 7 set at about 150°C. The paint 6 was slightly dried and semi-gelled, and this was transferred to the laminated area. Table 1 Part by weight of PVC 1 DOP6O Stabilizer 2 CacO32O Al(0H)320 Titanium oxide 6 Blue pigment 10 Separately, a white foamable vinyl chloride resin composition having the composition shown in Table 2 was kneaded with a mixing roll at about 150°C, and this was formed into a sheet 9a with a thickness of about 0.2? using a calendar roll at about 160°C. A foamable vinyl chloride resin sheet material 9 was obtained by pasting it onto flame-retardant paper 9b coated with an adhesive in advance.

Table 2 100 parts by weight of PVC DOP5O Stabilizer 4.5 Foaming agent 6 CacO32O Titanium oxide 10 This sheet material 9 was heated and softened using a heating device 8 set at about 150 to 160°C, and then The film 1 rotating in close contact with the rubber roll 3 and the softened sheet material 9 are pressed together using a pressure roll 10,
Both were pasted together.

A cross-sectional view of this product is shown in FIG. Next, add this to about 2
When the material was introduced into the foaming furnace 11 set at 30'C and heat-treated, the blue non-foaming synthetic resin-coated Fl6 embedded printed portion was only foamed to about twice the extent as shown in the cross-sectional view in Figure 3. A decorative material is obtained in which the white vinyl chloride foam layer 9a'' in the non-processed printed area expands to about 9 times the foam, the recesses in the arabesque pattern area are valley-dyed in blue, and the entire area is uniformly covered with the film 1. Ta.

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram of an apparatus for carrying out the method of the present invention;
FIG. 2 is a sectional view of the intermediate product after lamination, and FIG. 3 is a sectional view of the foamed product. DESCRIPTION OF SYMBOLS 1... Synthetic resin film, 6... Non-foaming synthetic resin paint, 9... Foaming synthetic resin sheet material, 11... Foaming furnace.

Claims (1)

[Claims] 1. While continuously transporting the synthetic resin film, a non-foaming synthetic resin paint is printed thickly in a pattern on the surface of the film, and the paint is dried to gel or semi-gel, and then,
The paint is pushed into a foamable synthetic resin layer laminated on a substrate that has been sufficiently heated and softened at a temperature below the decomposition temperature of the blowing agent, and the surface of the resin layer is covered with the film, and then A method for producing a valley-dyed foam decorative material with a protective coating, which comprises subjecting the foaming to heat treatment.