JPH0582298B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Technical Field) The present invention relates to a method of embossing a synthetic resin sheet using an embossing sheet.

(Prior art) The following types of embossing sheets are conventionally known for use in embossing: (a) Paper embossing on release paper, (b) Hot embossing on thermoplastic synthetic resin film. (c) Films such as polyethylene terephthalate film printed with matte ink using polyurethane resin as a vehicle.

Items belonging to (a) above are used when manufacturing thermoplastic synthetic resin films by the casting method,
Used in manufacturing synthetic leather. However, this type uses a gold roll for embossing and a female roll made of paper that is paired with the gold roll, so when producing many types of convex patterns, these rolls must be used in pairs. In addition, since the release paper itself has unevenness that reaches the front and back, there is nothing on the back side of the protrusion to support the protrusion, and therefore it is easy to crush, so it can usually only be used once. It is difficult to perform gloss adjustment at the same time as embossing. Alternatively, cracks may occur in the release layer of the release paper.

Those belonging to the above (b) are used when manufacturing polyester decorative laminates, but economically they tend to lose their embossed shape, and due to their manufacturing method,
Generally not durable against heat.

Although it is possible to adjust the gloss in the areas corresponding to the convex portions of the embossing sheet in the above category (c), it is difficult to adjust the gloss in other areas, and in addition, it is difficult to adjust the gloss in the areas corresponding to the convex portions of the embossing sheet. Therefore, the adhesion of the pattern cannot be said to be sufficient.

(Object of the Invention) Therefore, the present invention solves the above-mentioned drawbacks of the prior art, is easy to manufacture, is durable, and has a structure in which the gloss of the thermosetting synthetic resin layer and the surface of the convex pattern can be adjusted separately. An object of the present invention is to provide an improved method for embossing a synthetic resin sheet.

(Structure of the Invention) The embossing sheet of the present invention has a thermosetting synthetic resin layer coated and laminated on a base sheet, and a convex pattern made of the thermosetting synthetic resin is formed on the thermosetting synthetic resin layer. It is characterized by being fixed.

Hereinafter, the present invention will be explained in detail using the drawings.

FIG. 1 is a schematic cross-sectional view showing an embodiment of the embossing sheet of the present invention, in which a thermosetting synthetic resin layer 2 is laminated on a base sheet 1.
Furthermore, a convex pattern 3 is provided on the thermosetting synthetic resin layer 2.

In the above, various materials can be used as the base sheet 1 depending on the usage conditions, and flexible sheets such as paper, plastic film, metal foil, etc. can be used. When particularly heat resistance is required for the embossing sheet, use heat-resistant materials such as polypropylene, polyvinyl chloride, polyvinideline chloride, polyvinyl alcohol, polyethylene terephthalate, polycarbonate, nylon, cellulose diacetate, cellulose triacetate, polysulfone, and polyimide. It is best to use high quality plastic film. When even higher heat resistance is required, considering mechanical strength, polyethylene terephthalate, polyamide, polyimide, polysulfone, etc. may be used. Paper can also be used as the base sheet 1, but when heat resistance is required, it is better to use paper with a high degree of size, such as clay-coated paper, and the basis weight of the paper is 30 to 30.
It is 300g/ ^m2 .

The thermosetting synthetic resin layer 2 laminated on the base sheet 1 has releasability when used as an embossing sheet, is gloss adjustable, and can firmly maintain the convex pattern described below. is desirable. The synthetic resins for forming the thermosetting synthetic resin layer 2 selected from this viewpoint include melamine resin, alkyd resin, amino alkyd resin, epoxy resin, and silicone resin, and the thickness of the layer 2 is 3 to 3.
It is 20μm. Further, in order to adjust the gloss of the surface of the thermosetting synthetic resin layer 2, a necessary amount of a matting agent may be dispersed therein. Silica, alumina, clay, calcium carbonate, etc. can be used as the matting agent.

Next, the convex pattern 3 provided on the thermosetting synthetic resin layer 2 will be explained. The convex pattern 3 is formed using the same thermosetting synthetic resin as the layer 2,
Considering the adhesion with layer 2 among these synthetic resins, it is desirable that the synthetic resins constituting layer 2 and convex pattern 3 are the same, but they may be different if sufficient adhesion strength is obtained. Good too.

As in layer 2, it is best to add a matting agent to the convex pattern 3 to adjust the surface gloss of the convex pattern 3, and usually the surface gloss of layer 2 is controlled to a desired degree. If the surface of the convex pattern 3 is made matte by lowering the gloss of the surface of the layer 2, the product obtained by embossing using such an embossing sheet will have the convex pattern 3. As a result, it is formed to have a surface consisting of a concave portion that has lost its luster and a flat surface that is more glossy than the concave portion. Alternatively, the convex pattern 3 may be formed as two or more types of patterns each having a different gloss.

Next, the method for manufacturing the embossing sheet of the present invention will be described. First, a thermosetting synthetic resin liquid or a resin solution or diluted liquid is applied to a heat-resistant base sheet by an appropriate method. Examples of the coating method include gravure coating, roll coating, reverse coating, and curtain coating. The amount of coating may be as long as it can achieve the thickness of the layer 2 described above, for example, about 3 to 50 g/m ² (dry basis). Since a thermosetting synthetic resin liquid or a resin solution or diluted liquid usually requires a curing process such as heating or ultraviolet irradiation, the layer 2 is semi-cured when it is visually dry after coating.

After forming the uncured layer 2 in this way, a convex pattern 3 is provided next. The convex pattern 3 is made by using an ink composition prepared by using a thermosetting synthetic resin as a vehicle, adding a matting agent and a coloring agent if necessary, and further adding a solvent and a diluent and kneading. Print and form. Various printing methods can be applied to form the convex pattern 3, but printing methods using a relatively deep gravure plate or a silk screen plate with large openings are suitable. Good. For example, the depth of the gravure version is
It is 50-500μ. Here, the pattern of the convex pattern 3 may be any pattern as long as it is a pattern of a portion to be made into a concave portion by embossing, but for example, a wood grain conduit groove is suitable, and other patterns or abstract patterns can also be used.

In addition, if the above-mentioned ink composition is appropriately colored with a coloring agent such as iron oxide, carbon black, phthalocyanine blue, quinacridone, or titanium white, it is confirmed that a convex pattern is attached to the embossed object during embossing. can.

After printing, the convex pattern and the lower thermosetting synthetic resin layer are completely cured by heating the whole.

Note that the conditions for semi-curing and complete curing depend on the thermosetting synthetic resin used, but as an example, semi-curing after coating layer 2 is performed at a temperature of 100 to 200°C for a short period of time.
10-30 seconds, complete curing after printing is 30 at 200℃
It is more than seconds.

In the present invention, the convex pattern 3 is provided with the layer 2 in a semi-cured state and then cured, thereby further improving the adhesion between the layer 2 and the convex pattern 3.
A synthetic resin paint or solution is applied to the entire surface of the embossed sheet thus formed so as to cover the convex pattern, and is dried and solidified by heating or the like to produce a synthetic resin sheet. Thereafter, the synthetic resin sheet and the embossing sheet are peeled off to form unevenness corresponding to the convex pattern of the embossing sheet on the surface of the synthetic resin sheet.

(Effects of the Invention) Since the method for embossing a synthetic resin sheet of the present invention has the above configuration, the convex pattern is difficult to collapse during use, and therefore the same embossing sheet can be used multiple times. In addition, the convex pattern will not be lost even when used at high temperatures, and the gloss of the thermosetting synthetic resin layer and the surface of the convex pattern can be controlled separately. is formed by coating, and the convex pattern is formed by printing, so it is possible to reproduce the shapes of real manuscripts, such as wood grain conduit grooves, or to reproduce abstract patterns that do not exist in real manuscripts. .

Example 1 The surface of high-quality paper (Sanyo Kokusaku Pulp, basis weight 50 g/m ² ) was coated with a paint based on amino alkyd resin (R-5X, manufactured by Moroboshi Ink Co., Ltd.) in an amount of 20 g/m 2 by roll coating. m ² (when dry). After coating, it was heated at 120°C for 10 seconds to semi-cure.

After that, gravure printing was performed using a gravure plate with a wood grain pattern with a line count of 80 lines/inch and a plate depth of 100 μm, and a gravure ink prepared using a vehicle also based on amino alkyd resin.
After printing, it was dried at a temperature of 150° C. for 15 seconds to harden the entire sheet to obtain an embossing sheet.

A THF solution of polyvinyl chloride resin (resin content 30%) is applied to the pattern surface of the obtained embossing sheet to a thickness.
Knife coat to 50μ, then temperature 50
℃ oven for 30 seconds and then 80℃ oven for 2 minutes. After heating, the embossing sheet was peeled off, and it had an embossed recess with a wood grain pattern.
A 50μ polyvinyl chloride resin sheet was obtained.

Example 2 A coated amount of alkyd resin paint (R-5X, manufactured by Moroboshi Ink Co., Ltd.) was 30% on high-quality paper (basis weight 100g/m ² ).
It was coated using a roll coating method so as to have a coating weight of g/m ² .

Next, using a gravure plate with a wood grain conduit groove pattern (150 lines/inch, plate depth 50μ), gravure printing was performed using an ink whose vehicle was the same resin used for coating, and then heated at 200℃. Heat for 30 seconds.

Using the embossing sheet thus obtained, a urethane resin paint for synthetic leather was applied to the patterned surface. On the other hand, 90 moss (45 per inch both vertically and horizontally)
Prepare a base fabric formed by coating a colored urethane resin (book cloth), and place the urethane resin coated side facing the urethane resin layer on the embossing sheet, and apply a urethane one-component adhesive (large After lamination, the embossing sheet was peeled off to obtain embossed synthetic leather.

[Brief explanation of drawings]

FIG. 1 is a schematic cross-sectional view showing an embodiment of the embossing sheet of the present invention. 1... Base sheet, 2... Thermosetting synthetic resin layer, 3... Convex pattern.

Claims (1)

[Claims] 1. A method for embossing a synthetic resin sheet, characterized by comprising the following steps: (a) Embossing a heat-resistant base sheet with a thickness of 3.
A semi-cured thermosetting synthetic resin layer of ~20 μm (dry basis) is applied, (b) a convex pattern made of thermosetting synthetic resin is printed on the thermosetting synthetic resin layer, and the semi-cured thermosetting synthetic resin layer is coated. An embossed sheet is produced by heating and curing it together with a thermosetting synthetic resin layer in a cured state, and (c) a synthetic resin paint or solution is applied to the entire surface of the embossed sheet so as to cover the convex pattern. death,
(d) After that, the synthetic resin sheet and the embossing sheet are peeled off to form unevenness corresponding to the convex pattern of the embossing sheet on the synthetic resin sheet. Form on the surface.