JPH0243618B2 - - Google Patents

Description

[Detailed Description of the Invention] <Industrial Application Field> The present invention relates to a method for producing foamed decorative materials, and more specifically, the present invention relates to a method for manufacturing foamed decorative materials, and more specifically, a foamed decorative material is produced using a transfer sheet on which a pattern is formed using a foamed paste and a foamed ink. The present invention relates to a method for producing a decorative material having an uneven pattern formed on the surface by transferring the pattern onto the surface of a resin layer and then heating and foaming the pattern.

<Prior Art and Problems to be Solved by the Invention> Foamed decorative materials having an uneven pattern on the surface are widely used because of their design, cushioning properties, and the like. Methods for producing such foamed decorative materials include a method in which a pattern is applied to the surface of the foamable resin layer using foaming suppressing ink or foaming promoting ink to create a difference in the foaming state between other parts; There are methods such as applying foamable resin in a pattern on the surface of the base material and then heating and foaming it, or simply physically embossing it, but with these methods, it is difficult to give multi-step unevenness, and it is difficult to create multi-step unevenness. Even with a method of applying foamable resin in a pattern, which is relatively easy to apply, it was not possible to form a delicate uneven pattern.

<Means for Solving the Problems> The present invention has been made in order to solve the above-mentioned drawbacks, and it further includes protrusions made of a foamable paste on the surface of the foamable resin layer and foamable ink melted therein. By forming concave portions obtained by reducing the volume of the foam, it is possible to provide multi-stage unevenness, and a pattern made of the foaming paste and foaming ink is formed by a transfer method. This makes it possible to form delicate uneven patterns.

The present invention will be described in detail below with reference to the drawings.
Figures 1a to 1h show the structure of the transfer sheet used in the present invention, and in a, a foaming paste 2 is first applied to the surface of the transfer sheet base 1, and then foaming ink is applied thereon. This is a case where a pattern is formed, and the paste and foaming ink at this time are 1
It is also possible to use a combination of different types or two or more types of pastes and foaming inks having different colors and expansion ratios. Contrary to a, b is a case where the transfer sheet base 1 is first printed with foaming ink 3 and then a pattern is formed with foaming paste 2; In the case where the foaming paste 2 and foaming ink 3 are printed in this order in the same way as in d, a pattern of normal ink 4 is provided in advance, and then the foaming ink 3 and foaming paste 2 are printed in that order in the same way as in b. In this case, e is when a pattern of normal ink 5 is further formed on the transfer sheet of a,
f shows the case where a pattern of normal ink 5 is further formed on the transfer sheet b, and h shows a case where a pattern of normal ink 5 is further formed on the transfer sheet d. Note that the foamable ink pattern, the foamable paste pattern, the normal ink pattern 4, and the normal pattern 5 may or may not be in sync with each other.

Next, using the transfer sheet configured as described above, the pattern on the transfer sheet is transferred onto the surface of the foamable resin composition 7 provided on the base material 6, as shown in FIG. In Fig. 2, using the transfer paper b, a pattern is formed on the surface of the foamable resin composition 7 by the foaming paste 2, and then a pattern is formed by the unfoamed foaming ink 3, and then the surface is protected. A layer 8 is provided.

After the pattern is formed as described above, only the foamable ink is foamed in the first step, then a surface protective resin layer is provided, and then heated and foamed.
As shown in the figure, a foamed decorative material 9 in which both the foamable paste and the foamable resin layer are foamed is obtained. At this time, the foamed ink 3 foams due to the heat applied to foam the paste, etc., and its volume decreases, so as shown in the figure, the surface protective layer 8
A recessed portion 10 is formed in. The depth of the recess 10 can be freely changed depending on the volume of the foamable ink 3, that is, the amount applied during printing. In addition, as shown in Figure 3, the foamed paste 2' is all expressed at the same height, but since the pattern of this paste can be formed using the gravure printing method, its thickness can also vary. The adhesion area can also be arbitrarily selected, and for example, a decorative material as shown in FIG. 4 can be obtained.

Furthermore, a foaming inhibitor that changes the foaming temperature of the foamable resin layer 7 is blended into the normal ink, and as shown in FIG. It is also possible to do so. In addition, the pattern of regular ink may be formed partially on the surface of the decorative material, and in that case, in addition to adding a foam inhibitor to a part of the regular ink, it is necessary to add a foam inhibitor to the entire regular ink. It is also possible to mix them.

When using a transfer sheet in which the pattern of foamable ink 3 is applied directly to the transfer sheet base 1 like transfer sheets b and e, only the surface protection resin 8 is applied on the foamable ink after transfer. Therefore, the recesses caused by the melting of the foaming ink will be relatively sharp, but the sharpness will be less if the pattern etc. formed by the foaming paste 2 is formed on the foaming ink after transfer. Although it is somewhat inferior, depending on the pattern, less sharpness may be more natural, and it is preferable to use transfer sheets a to h depending on the purpose and use.

Foaming ink is used to provide foaming decorative materials with more delicate irregularities by shrinking the volume through vaporization or the like when heated above the foaming temperature at the same time as the foaming action.

The foaming ink mentioned above is New Daihome N (manufactured by Dainichiseika Co., Ltd.), which contains microcapsules of butadiene gas, or foaming paste with an extremely low foaming temperature (around 130°C). But it is possible. In addition, from among various known foaming agents, one that foams at a relatively low temperature is selected and added to a foaming paste or resin that melts when heating and foaming the foaming resin layer. You can use the one you made.

Since the foaming paste 2 dries more slowly than normal ink, it is possible to speed up the drying process by adding copolymer resin, etc., and to form the pattern of the foaming paste 2 before using normal ink. When using two or more types of paste, it is best to shrink the transfer sheet 1 sufficiently using a seasoning drum or the like before forming the pattern, to avoid shrinkage of the transfer sheet base during printing. It is possible to prevent misregistration due to

The relationship between the foaming temperature of the foaming paste and the foaming temperature of the foaming resin layer has a large effect on the uneven shape of the surface of the decorative material. If the foaming temperature is low, both the foaming paste and the foaming resin layer foam uniformly, as shown in Figures 3 and 4, but if the foaming temperature of the foaming paste is higher, or the foaming temperature of both is In the same case, the expansion ratio of the portion of the foamable resin layer to which the foamable paste is attached will be smaller than that of other portions, and the foaming state of the entire foamable resin layer will be non-uniform. This is because the area to which the foaming paste is attached has a larger heat capacity corresponding to the amount of adhesive, so foaming is delayed compared to other areas, and the paste layer sinks before it is sufficiently foamed. It is thought that as a result, the expansion ratio of the foamable resin layer in that area becomes smaller.

However, if this phenomenon is utilized, it is possible to form a certain degree of unevenness without using a foaming inhibitor or the like. Similarly, it is desirable that the melt viscosity of the foamable paste is higher than the melt viscosity of the foamable resin layer. This is because the resin temporarily melts due to heat during foaming, but at this time the foaming paste flows and the pattern becomes difficult to distinguish.

As the foaming paste, a mixture of polyvinyl chloride resin, ethylene vinyl acetate resin, vinyl chloride vinyl acetate resin, etc., with a known foaming agent as described below is used.

As the foamable resin composition, as mentioned above for the paste, polyvinyl chloride resin, ethylene vinyl acetate resin, vinyl chloride vinyl acetate resin, etc. are used, and a plasticizer, a known blowing agent, a stabilizer,
A mixture of pigments, fillers, etc. is used.

As the blowing agent, azodicarbonamide, azobisisobutyronitrile, benzenesulfonyl hydrazide, and others are used.

The foamed decorative material obtained by the method of the present invention is
Depending on the type of base material used, it can be used for a wide range of purposes, including flooring materials, wall covering materials, and household goods.

<Effects> The present invention having the above configuration has the following effects.

Patterns using foaming paste, foaming ink, and regular ink are all formed using printing methods such as gravure printing, so it is possible to express delicate patterns of any height and size. can. In particular, a multi-stage uneven pattern can be formed by using two or more types of pastes or foaming inks, or by combining with other techniques such as foaming inhibitors.

<Example> A base paper with a basis weight of 80 g/m ³ with polypropylene extruder laminated on one side was heat-shrinked using a seasoning drum, and then a woven pattern was applied to the polypropylene laminated side using ordinary ink using a gravure printing machine. Next, a thin thread-like pattern was applied using a foaming ink containing butadiene gas encapsulated in microcapsules in an ethylene vinyl acetate binder; New Daihome (manufactured by Dainichiseika Chemical Co., Ltd.), and then a foaming ink with the following composition was applied. A transfer sheet was created by applying a thick pattern using the paste.

Foaming paste compounded vinyl chloride resin G-131A (manufactured by Nippon Zeon Co., Ltd.)
70 parts by weight Vinyl chloride resin 37J (manufactured by Nippon Zeon Co., Ltd.) 30 parts by weight plasticizer (DOP) 55 parts by weight Blowing agent K-30 (manufactured by Otsuka Chemical Co., Ltd.) 8 parts by weight Titanium white 20 parts by weight Stabilizer FL-23 (Adeka Argas) 3 parts by weight Calcium carbonate 30 parts by weight Next, a foamable resin of the following composition is applied to the surface of the asbestos sheet to a thickness of 500μ, and after gelling, the transfer sheet is applied to its pattern-forming surface. After removing the transfer sheet base, the foaming ink is foamed. Next, a transparent resin of the following composition is applied to a thickness of 200μ, and heated at 200℃ for 2 minutes to foam. Obtained cosmetic materials.

Polyvinyl chloride resin PSL-10 (manufactured by Kanebuchi Chemical Co., Ltd.) with foamable resin
100 parts by weight Plasticizer (DOP) 40 parts by weight Titanium white 5 parts by weight Zinc oxide 0.5 parts by weight Blowing agent AZ-S (manufactured by Otsuka Chemical Co., Ltd.) 2.5 parts by weight Vinyl chloride resin R-1069 (Mitsubishi Monsanto) (manufactured by Co., Ltd.)
100 parts by weight Plasticizer DOP 40 parts by weight Plasticizer DBP 10 parts by weight Stabilizer KS-20 (manufactured by Kyodo Yakuhin Co., Ltd.) 3 parts by weight

[Brief explanation of drawings]

The drawings show embodiments of the present invention.
The figure is a cross-sectional view showing the structure of the transfer sheet, Figure 2 shows a state in which a pattern has been transferred to the surface of a foamable resin layer and a surface protective resin layer has been provided, and Figures 3 and 4 show a state in which it has been heated and foamed. FIG. 5 shows cross-sectional views of the foamed decorative material of the present invention when a foaming inhibitor is used in combination. 1... Transfer sheet base, 2... Foaming paste, 2'... Foamed paste, 3... Foaming ink, 4, 5... Regular ink pattern, 6... Base material, 7... Foamable resin composition, 8... Surface protective layer, 9... Foamed decorative material, 10... Concavity, 11...
Ink containing foam inhibitor.

Claims (1)

[Claims] 1. A transfer sheet on which a pattern is formed using a foamable paste and a foamable ink is layered on the surface of a foamable resin layer, and after the design is transferred to the surface of the foamable resin layer, the foamable ink is applied. 1. A method for producing a foamed decorative material, which comprises foaming the material, applying a transparent resin, and then heating and foaming the foamable paste and the foamable resin layer. 2. Claim 1, characterized in that the foaming temperature of the foamable paste is lower than the foaming temperature of the foamable resin layer, and the melt viscosity of the foamable paste is higher than the melt viscosity of the foamable resin layer. A method for producing a foamed decorative material as described in Section 1. 3. Use a transfer sheet on which a pattern is applied to the base of the transfer sheet using foaming paste and foaming ink before or after, or before and after, a pattern that matches or does not match the pattern using normal ink. Claims 1 to 2 are characterized in that:
A method for producing a foamed decorative material according to any one of paragraphs. 4. The method for producing a foamed decorative material according to claim 3, wherein a part or all of the ordinary ink is blended with a foaming inhibitor that changes the foaming temperature of the foamable resin layer.