JPS6145539B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a decorative sheet that has a pattern extending from the surface of the sheet to the inside in the thickness direction, is itself robust, and the pattern does not disappear even if one surface is worn.

Decorative sheets with various colored patterns are used as floor covering materials and other interior upholstery materials. Since the patterns of such lining materials, especially floor covering materials, may disappear due to surface abrasion caused by frequent friction, it is necessary to take some means to prevent the patterns from disappearing.
Conventionally, as such means, a) embedding a chip with a shape equal to the sheet thickness during sheet forming;
2) Applying screen printing method to thickly pile up high viscosity ink resin on the base material sheet, or 3) Applying transparent plastic after pattern forming. A protective film was formed by attaching a film or coating with a transparent resin.

However, the conventional methods for preventing pattern disappearance described above are not necessarily satisfactory. That is, in the method (a) above, the patterns that can be obtained are limited and a sufficient decorative effect cannot be provided. In addition, method (b) requires special screen printing equipment, and the structure of the plate is complicated, especially since the ink resin is piled up thickly.Also, there are limits to the patterns that can be drawn for this reason, and sufficient decorative effects cannot be obtained. is not given. Furthermore, method c) has the disadvantage that the texture of the decorative sheet itself is damaged due to the reflection of reflected light and smoothing of the surface, and the transparency decreases due to abrasion, the sharpness of the pattern decreases, and the sharpness of the pattern cannot be maintained. .

In view of the above-mentioned drawbacks of the conventional method for preventing pattern disappearance, the present invention has been developed by obtaining an ink pattern extending from the surface of the sheet base material to the inside by a printing method, and then fixing this pattern with a resin that is later impregnated. It also provides a pattern that does not disappear due to surface abrasion. More specifically, in the method for producing a decorative sheet of the present invention, ink is applied to one surface of a porous seal-like substrate to form a pattern extending from the surface to the inside in the thickness direction, and then the surface is It is characterized in that the entire surface is impregnated with liquid or paste resin, and the entire surface is further heated to solidify the impregnated resin.

Hereinafter, the present invention will be explained in more detail with reference to the drawings as necessary.

The porous seal-like base material used in the present invention includes:
Synthetic fibers obtained from synthetic resins such as nylon, polyester, polyvinyl chloride, polyvinyl alcohol, polyethylene, polypropylene, and acrylic resin; semi-synthetic fibers such as rayon and acetate; one or two types of natural fibers such as cotton and linen A nonwoven fabric, a raised cloth, an asbestos sheet, a rock wool sheet, a glass fiber sheet, an artificial flocked sheet made of the above materials, or a porous seal having open cells prepared by an extraction method or the like can be used. These sheet-like substrates are subjected to the method of the present invention in the form of sheets or continuous sheets having an apparent specific gravity of 0.01 to 0.6 and a thickness of 0.5 to 4 mm.

In the present invention, the porous seal-like base material described above can be used as is, but preferably, as shown in FIG. It is preferable to use a glass paper 2 having a diameter of 2 mm and attached with an adhesive such as polyvinyl acetate, polyvinyl chloride, or acrylic ester. This glass paper is made by hardening gas fibers with resin, and it has rigidity, dimensional stability, and is attached to a porous seal-like base material using an adhesive, so the eyes of the glass paper are clogged due to the action of this adhesive. Excellent liquid barrier properties. Therefore, when the method of the present invention is directly applied to the above-mentioned porous seal-like base material, distortion of the picture due to elongation or contraction of the base material, misalignment of the picture in multicolor printing, and furthermore, contamination due to ink passing through. , it becomes possible to eliminate defects such as deviations in the dimensions of the product sheet.

According to the invention, a porous seal-like substrate, preferably lined with glass paper, is
Apply ink from one side. This operation allows the ink to penetrate in the thickness direction to a thickness of 0.5 mm or more, preferably 2 mm or more, thereby imparting durability to the pattern against abrasion. The amount of ink applied for this purpose is 500 g/m ² or more, preferably 750 g/m ² for the pattern area.
The above shall apply. If it is less than 500 g/m ² , it is difficult to obtain the desired penetration depth, and even if the desired penetration depth is obtained, there are many voids and a clear pattern cannot be obtained.

Application of the ink is preferably carried out by screen printing using a flatbed screen printer or a rotary screen printer. general paper,
The planographic, letterpress, and intaglio plates used for printing plastic films cannot supply the above-mentioned amount of ink required to create the desired internal pattern, but screen printing can supply a sufficient amount of ink. Because it will be done. One reason why the ink permeates into the sheet base material is thought to be due to capillary action, but another effective method is that the ink is forced into the porous sheet base material by the squeegee of the screen printing machine. It is thought that it is acting on

The components used in the ink for providing a pattern in the present invention are not particularly different from those known in the art. That is, vehicles include oils and fats such as linseed oil, soybean oil, and synthetic drying oil; natural and processed resins such as rosin, copal, dammar, hardened rosin, rosin ester, and polymerized rosin; rosin-modified phenolic resin; and 100% phenol. resin, maleic acid resin,
Synthetic resins such as alkyd resins, petroleum resins, vinyl resins, acrylic resins, polyamide resins, epoxy resins, and aminoalkyd resins; fiber derivatives such as nitrocellulose and ethyl cellulose; rubbers such as chlorinated rubber and cyclized rubber Derivatives, other glues, mold, dextrin, zein, etc. can be used.

The ink is produced by adding a coloring agent such as a dye or pigment having a desired color tone to these vehicles, and further adding, for example, a plasticizer, a stabilizer, a wax, a grease, a desiccant, an auxiliary desiccant, a curing agent, a viscous agent, a dispersing agent, etc. Alternatively, a filler such as barium sulfate, calcium carbonate, aluminum hydroxide, diatomaceous earth, mica powder, cellulosin, etc. may be added and thoroughly kneaded together with a solvent or diluent.

Ink viscosity is important in this invention, 1500
Must be within ~30000CPS (centipores). Preferably it is 2500~18000CPS. If the ink is less than 1,500 CPS, the ink applied in a relatively large amount will smear and a clear pattern cannot be obtained, and if it exceeds 30,000 CPS, the ink will not penetrate sufficiently into the thickness of the porous sheet-like base material. That is,
In the present invention, in order to suppress the spread of the applied ink in the sheet plane direction as much as possible and actively promote penetration in the thickness direction, it is essential to adjust the ink viscosity and apply a screen printing method that applies an appropriate pushing force to the ink. This brings about a positive effect.

The ink is applied repeatedly as necessary as described above to form a pattern 3 that has penetrated into the thickness direction at the required portions as shown in FIG. 2, and further leaves a partially colored portion 4 as necessary. A patterned sheet is obtained.

In this case, it is preferable to dry the applied ink each time printing is applied once or repeatedly. If drying is not carried out, for example, in the case of single-fed sheets, the ink will stain other sheets, stain the printing machine, or disrupt the pattern, and the same can be said for continuous sheets. The drying temperature and drying time vary depending on the type of ink used, and should be selected to be sufficient to avoid problems caused by undried ink.

The patterned sheet obtained above has considerable voids (for example, 3 to 30%) in the patterned portion 3, and is hygroscopic as a whole. Therefore, if this sheet is used as it is as a decorative sheet, it not only has disadvantages such as being weak in strength, becoming fluffy and easily stained, but also the pattern itself is very likely to turn brown due to contact with moisture or solvents. Therefore, in the present invention, such a patterned sheet is further impregnated with a liquid or paste resin from above the pattern to the inside of the sheet applied to the entire surface. As the impregnating resin, any of the resins listed above as the ink vehicle can be used. These resins may be applied as solutions, emulsions or liquid or pasty mixtures in suitable solvents, oil plasticizers, water, etc., or as liquids themselves, as in the case of thermosetting resins. . It is highly desirable that the liquid medium used be selected from one that does not dissolve the ink vehicle described above. Otherwise, the pattern will inevitably become disordered during impregnation with the resin. Liquid or paste resins have a viscosity of 1000 for impregnation.
It is preferably within the range of ~10000CPS.

The liquid or paste resin may be coated with a knife coater once or several times depending on the thickness of the sheet base material used.
It is applied to the patterned sheet using a roll coater, dip coater, or the like. On this occasion,
If repeated applications are required, it is best to lower the initial resin viscosity using a suitable diluent and apply progressively higher viscosities.

Next, the obtained resin impregnated sheet is heated as a whole to solidify the resin. The heating temperature and solidification mechanism depend on the type of impregnating resin. In the case of solutions or emulsions of thermoplastic resins, this is the evaporation of the liquid medium, in the case of pastes (plastisols) it is gelling, and in the case of thermosetting resins it is curing. In order to enhance the impregnation effect and provide a dense decorative sheet, it is preferable to use a thermoplastic resin paste or a thermosetting resin.

In this way, a decorative sheet according to the present invention (its appearance is almost the same as that shown in FIG. 2) is obtained. In order to improve the adhesion effect with the backing surface, a backing 5 of asbestos paper, cotton cloth, non-woven fabric, etc. having a thickness of about 0.5 to 1 mm may be attached as shown in FIG.

As described above, according to the present invention, an ink pattern is obtained from the surface of the sheet base material to the inside by a printing method, and then this pattern is fixed with a resin that is impregnated later, thereby making it durable and disappearing due to surface abrasion. Thus, a decorative sheet having a pattern that does not overlap can be obtained.

Hereinafter, the present invention will be explained in more detail with reference to Examples.

Example: One side of polyester nonwoven fabric (HP-21 manufactured by Nippon Vilene Co., Ltd.) with a thickness of 2 mm and an apparent specific gravity of 0.04 is thickened to prevent elongation and ink bleed through during printing.
A 0.15 mm glass paper was attached to obtain a porous sheet-like substrate as shown in FIG.

PVC ink (RSP manufactured by Moroboshi Ink Co., Ltd.) was printed on this sheet-like base material at a rate of 780 g/m ² using a rotary screen printer (hole diameter: 60 mesh), as shown in Figure 2. A patterned sheet was obtained.

At this time, the ink was dried after each printing to prevent various problems caused by undrying. The drying temperature was 200°C for 15 seconds.

The ink composition is approximately as follows.

Polyvinyl chloride 100 parts by weight Dioctyl phthalate 85 〃 Calcium-zinc stabilizer 4 〃 Pigment 25 〃 Aluminum hydroxide 34 〃 Antimony oxide 2 〃 A vinyl chloride paste of the following composition was further applied to the entire surface of the obtained patterned sheet, It was applied in three parts using a reverse roll coater, resulting in a total impregnation of 1480 g/m ² .

Vinyl chloride paste composition Polyvinyl chloride 100 parts by weight (Zeon 121 manufactured by Nippon Zeon Co., Ltd.) Octyl diphenyl phosphate
30 〃 Dioctyl sulfate 12 〃 Antimony oxide 5 〃 Mineral spirits 10 〃 Epoxy co-stabilizer 6 〃 Diisobutyl ketone 5 〃 Barium-zinc stabilizer 1 〃 Next, the impregnating agent sheet was heated at 200℃ for 5 minutes to form the impregnating paste. It turned into a gel.

Finally, add another layer of thickness 0.7 from the back of the glass paper.
mm Aspest paper (W5560 manufactured by Jujo Paper Co., Ltd.) was attached to obtain a desired decorative sheet as shown in FIG.

The decorative sheet thus obtained has a pattern not only on the surface, but also permeates into the interior, so even if the surface is worn out, the pattern will not disappear.Also, it is robust, so it can be used in places with heavy walking. It was recognized as having particularly excellent suitability as a flooring material. In addition, the patterns are created using a screen printing machine used for printing on paper, plastic sheets, etc., and there are no restrictions on the patterns due to factors related to the printing machine, such as the structure of the plate, and the patterns are beautiful. , almost no disturbance due to subsequent resin impregnation was observed.

[Brief explanation of the drawing]

The drawings schematically show an example of the method for manufacturing a decorative sheet of the present invention, in which FIG. 1 is a cross-sectional view of a porous seal-like base material, FIG. 2 is a cross-sectional view of a patterned sheet-like material, FIG. 3 is a schematic perspective view of a decorative sheet according to the invention with a backing material attached thereto. 1...Nonwoven fabric, 2...Glass paper, 3...
Patterned part, 4... Non-patterned part, 5... Backing material.

Claims (1)

[Claims] 1. Applying ink to one surface of a porous sheet-like base material to form a pattern extending from the surface to the inside in the thickness direction, and then impregnating the entire surface with a liquid or paste resin. A method for producing a decorative sheet having a pattern extending from the surface to the inside in the thickness direction, the method comprising: heating the entire surface to solidify the impregnated resin. 2. The method for producing a decorative sheet according to item 1 above, in which ink is applied by a screen printing method. 3. The method for producing a decorative sheet according to item 1 or 2 above, wherein a nonwoven fabric with glass paper laminated on the opposite side to the surface to which ink is applied is used as the porous sheet-like base material. 4. The method for producing a decorative sheet according to any one of items 1 to 3 above, in which a pattern is applied using ink having a viscosity of 1,500 to 30,000 centiboads.