JP2008012899A - Embossed sheet and method for production of embossed sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an embossed sheet with high designability by sharp embossing of a deposited paper, and also to provide an embossing method. <P>SOLUTION: A thermoplastic resin layer is provided on one surface of a base paper, and a thermoplastic deposition anchor layer, deposition layer, deposition top layer, printing layer and OP varnish layer are provided thereon in order. Then, those are pressure-bonded by using a plate heated to the nearly softening point of the thermoplastic resin, and the portion from the thermoplastic film to the OP varnish layer is unleveled. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to an embossed decorative sheet having a metallic luster and a method for processing the decorative sheet. More specifically, the present invention relates to a vapor-deposited paper-based decorative sheet and a decorative sheet manufacturing method, in which unevenness is formed sharper and has excellent design.

  Conventionally, vapor-deposited paper in which metal is vapor-deposited on a base paper has been widely used for labels, packages, posters, book covers, etc., because highly selective expression can be obtained. In addition, embossing has been performed to provide unevenness.

  In general, the method for producing the vapor-deposited paper is to provide a resin layer called a vapor-deposited anchor layer on the coated surface of the coated paper and deposit a metal thereon. As the resin for the vapor deposition anchor layer, thermosetting resins such as melamine resin, urea resin, amino alkyd resin, and epoxy resin have been often used. It is usual to provide a printing layer and an OP (overprint) varnish layer on the vapor-deposited paper.

  FIG. 3 is a cross-sectional view showing a configuration of a general vapor-deposited paper print. Here, 8 is a pulp layer, 9 is a clay coat layer, 3 is a vapor deposition anchor layer, 4 is a vapor deposition layer, 5 is a vapor deposition top layer, 6 is a printing layer, and 7 is an OP varnish layer.

  Since the base paper layer of the vapor-deposited paper printed matter having the above configuration is expanded and contracted by moisture and heat, the vapor-deposited layer is not expanded and contracted, so that cracks are easily generated on the vapor-deposited surface. In order to prevent this, it is necessary to harden the vapor deposition anchor layer, and thermosetting resins have been mainly used.

When the vapor-deposited anchor layer is hardened with a thermosetting resin, cracks are less likely to occur, but on the other hand, when an expression rich in irregularities is attempted by embossing, a clay coat layer made of an inorganic pigment and a thermosetting resin are used. Since the vapor deposition anchor layer made of is hard, it was not possible to express the unevenness easily. In particular, when a paper having a basis weight of 120 g / m ² or less is used, if a large pressure is applied to create a concavo-convex expression, a mold is formed even on the back surface and the paper is torn or the paper is torn.

Problems to be solved by the invention

  As can be seen from the above, it is difficult to obtain a sharp pattern even when embossing is performed on a printed matter of ordinary vapor-deposited paper. In particular, when thin paper was used, the back side was uneven and the entire surface was uneven, and the paper was torn.

  Therefore, the present inventors have intensively researched, provided a thermoplastic resin layer between the base paper and the vapor deposition layer, applied a printing layer, an OP varnish layer, and a plate heated near the softening point of the resin. By embossing, the idea that it was possible to sharpen the unevenness was obtained, and the present invention was completed.

  Accordingly, an object of the present invention is to provide an embossed sheet having high design that can be sharpened by embossing. In particular, it is an object to provide an embossed sheet in which the width of a line of unevenness is made fine and the angle is adjusted, whereby a highly designable expression in which the pattern changes or moves three-dimensionally in the viewing direction is possible. Moreover, it is providing the processing method.

Means for solving the problem

  An embossed sheet according to claim 1 of the present invention is provided with a thermoplastic resin film on one side of a base paper, a thermoplastic vapor deposition anchor layer, a vapor deposition layer, and a vapor deposition top layer thereon, and further a printing layer thereon. And an OP varnish layer, and unevenness is given by embossing from the thermoplastic film to the OP varnish layer.

  The embossed sheet according to claim 2 is a combination of one or more of the thermoplastic resin layers of claim 1, wherein the thermoplastic resin layer is polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-acrylic copolymer, vinyl chloride. It is characterized by comprising.

  Furthermore, the manufacturing method of the embossed sheet | seat concerning Claim 3 provides a thermoplastic resin membrane | film | coat on the single side | surface of a base paper, provides a thermoplastic vapor deposition anchor layer, a vapor deposition layer, and a vapor deposition top layer on it, and also on it. A printing layer and an OP varnish layer are provided, and then pressed with a heated plate near the softening point of the thermoplastic resin, and irregularities are provided from the thermoplastic film to the OP varnish layer.

The invention's effect

  In claim 1, a thermoplastic resin film is provided on one side of the base paper, a thermoplastic deposition anchor layer, a deposition layer, and a deposition top layer are provided thereon, and a printing layer and an OP varnish layer are further provided thereon. Since the thermoplastic resin layer is easily uneven by processing heat, the unevenness is sharpened by embossing from the thermoplastic film to the OP varnish layer, and the pattern changes or moves three-dimensionally in the viewing direction. Design sheets are possible.

  The invention of claim 2 is the invention of claim 1, wherein the thermoplastic resin layer is a combination of one or more of polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-acrylic copolymer, vinyl chloride. Therefore, it is possible to provide a high-design sheet in which the unevenness processing is sharply performed and the pattern changes or moves three-dimensionally in the viewing direction.

  According to the invention of claim 3, a thermoplastic resin film is provided on one side of the base paper, a thermoplastic vapor deposition anchor layer, a vapor deposition layer, and a vapor deposition top layer are provided thereon, and further a printing layer and an OP varnish layer are provided thereon. Is then pressed with a heated plate, so that it is possible to sharpen irregularities from the thermoplastic film to the OP varnish layer. In particular, by selecting a material having excellent heat resistance as the OP varnish layer, it is possible to process at a high temperature during thermocompression bonding, and it is possible to process near the softening point of the thermoplastic resin.

  A method is disclosed in which a thermoplastic resin layer is directly embossed and deposited without applying a deposition anchor layer. For example, Japanese Patent Application Laid-Open No. 2005-352005 discloses a method in which when a thermoplastic resin is extruded onto paper and applied by lamination, an uneven cooling roll is used to make the thermoplastic resin uneven and vapor deposition is performed.

  However, this method has problems in the following points. First, after extrusion lamination, when the paper is rolled up, the convex portion of the thermoplastic resin and the back surface of the paper come into strong contact with each other, and the formed unevenness expression collapses, making it impossible to obtain a sharp unevenness expression. Can be raised. In addition, it is possible that the surface of the extruded resin is affected by the unevenness of the paper on the back surface during winding, and the gloss cannot be obtained as a whole.

  In addition, even a slight scratch on the cooling roller affects the life of the cooling roller, and it is suitable for making a large amount of vapor-deposited paper with the same pattern unevenness. It is not suitable for making a small amount. For this reason, the practical use is limited.

  Also disclosed is a method of applying a vapor deposition top layer and then embossing it. Utility Model No. 5-17238 discloses that an unevenness expression is provided by providing a vapor deposition top layer having a softening point of 60 ° C. or higher and then thermocompression-bonding a plate with unevenness. This method has the following problems. First, a resin having high heat resistance must be used for the vapor deposition topcoat layer, and there is a limit in adhesion and acceptability with the printing ink to be applied next, and the usable printing ink is limited. In addition, since the printing surface is uneven, it is difficult for the printing ink to be applied and it is necessary to apply a strong pressure, so that the printing method is limited, and the rough uneven expression is crushed.

  1 and 2 are sectional views showing an example of the configuration of the present invention. 1 is before embossing, and FIG. 2 is after embossing. 1 is a base paper, 2 is a thermoplastic resin layer, 3 is a vapor deposition anchor layer, 4 is a vapor deposition layer, 5 is a vapor deposition top layer, 6 is a printing layer, and 7 is an OP varnish layer.

As the base paper to be used, uncoated paper such as pure white roll, medium quality paper, and high quality paper, coated paper such as art paper and cast paper, synthetic paper, and the like are used. Basis weight is available paper 30~300g / ^{m 2,} particularly 120 g / ^{m 2} or less of the paper can also be used. When coated paper such as art paper or cast paper is used, it is possible to obtain a highly glossy vapor deposition surface because the paper is smooth. On the other hand, when using uncoated paper such as pure white roll, medium quality paper, high quality paper, etc. A calm and glossy deposition surface is obtained. By selecting the paper quality, a wide range of expressions are possible, and it is possible to select a texture that matches the intended use.

  For the thermoplastic resin layer, one or a combination of two or more of polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-acrylic copolymer, and vinyl chloride can be used.

  The thermoplastic resin layer can be formed by various methods such as a film laminating method, an extrusion laminating method, a roll coater method, a reverse coater method, and a gravure coater method. In the case of uncoated paper with rough paper and strong paint suction, film laminating and extrusion laminating methods are suitable. In the case of coated paper, it can be formed by a roll coater method, a reverse coater method, and a gravure coater method in addition to a film laminate method and an extrusion laminate method.

  Here, the film laminating method is a method of forming a thermoplastic resin layer on the base paper by applying an adhesive to the back surface of a predetermined thermoplastic resin film and pressing the adhesive on the base paper. The extrusion laminating method is a method in which a thermoplastic resin is heated and melted in a cylinder called a cylinder, extruded in a curtain shape from a thin slit provided at the tip, and applied onto a base paper and simultaneously pressed onto a cooled roll. This is a method of forming a thermoplastic resin layer on the base paper. The roll coater method, reverse coater method, and gravure coater method are methods in which a thermoplastic resin dissolved in a solvent is applied with a coater of each method, followed by heat drying to form a thermoplastic resin layer on the base paper. is there.

The coating amount of the thermoplastic resin layer is 3 to 50 g / m ² , preferably 5 to 30 g / m ² . If the coating amount is too small, the unevenness of the base paper cannot be covered and a glossy vapor-deposited surface cannot be obtained, and at the same time, it is difficult to obtain the effect of expressing the unevenness by embossing. If the amount is too large, the embossing effect is not changed and the cost is increased.

  As the vapor deposition anchor layer, any resin can be used as long as it is a thermoplastic resin having good adhesion to the thermoplastic resin and good acceptability of the vapor deposition metal. For example, a nitrocellulose resin, an acrylic resin, a polyurethane resin, a polyester resin, a styrene-maleic acid resin, a chlorinated PP resin, or the like is used.

As the deposition anchor layer, a gravure coater method, a roll coater method, a reverse coater method or the like is used, and the coating amount is preferably 0.5 to 5 g / m ² . In order to improve adhesion, the surface of the thermoplastic resin layer may be subjected to surface treatment such as corona treatment, ozone treatment, or flame treatment.

The vapor deposition metal can be a metal such as aluminum, gold, silver, zinc, nickel, etc., but aluminum is optimal from the viewpoint of cost and appearance. The degree of vacuum is usually 10 ⁻⁴ to 10 ⁻⁵ Torr, and the deposition thickness is preferably 20 to 70 nm.

  As the vapor deposition top layer, various resins can be used as long as they have a role of protecting the vapor deposition surface and helping adhesion between the vapor deposition surface and the printed layer applied thereon. For example, urethane resin, polyethyleneimine resin, polyester resin, acrylic resin, rubber resin, vinyl chloride resin, and vinyl acetate resin can be used, and two or more kinds can be used in combination.

The deposition top layer can be applied by a gravure coater, roll coater, reverse coater, or the like. The coating amount is preferably 0.5 to 5 g / m ² . Since the aluminum layer is oxidized with time after the deposition and the adhesion with the deposition top layer is lowered, the deposition is preferably performed within 72 hours and more preferably within 24 hours after the deposition.

  Various printed layers are applied on the vapor-deposited paper coated with the vapor-deposited top layer. As a printing method, various methods such as planographic offset printing, relief printing, flexographic printing, gravure printing, and screen printing are possible. Further, printing may be performed with an ink jet type or toner type color printer. Various types of inks such as an oxidation polymerization drying type, an infiltration drying type, an evaporation drying type, a UV drying type, and an EB drying type can be used as the ink for the printing layer by selecting the type of the vapor deposition top layer.

  Further, when the printing surface is strongly rubbed or heated, an OP varnish layer can be applied to protect the printing surface. In particular, it is desirable to provide an OP varnish layer when a large unevenness is expressed at a higher temperature. The OP varnish layer can be applied by various methods such as planographic offset printing, relief printing, flexographic printing, gravure printing, and screen printing. For the OP varnish layer, various resins such as a modified phenolic resin, an acrylic resin, a chlorinated rubber resin, and a nitrocellulose resin are used. Moreover, in order to improve heat resistance, polyethylene type or silicon type WAX may be contained.

  Next, embossing is performed on the vapor-deposited paper on which the printing layer and the OP varnish layer are applied. The embossed plate is made of metal such as copper, brass, and magnesium alloy, and the unevenness is expressed by corrosion, laser polishing, or indentation.

In the embossing, the pressure is applied by applying heat close to the temperature at which the thermoplastic resin layer is softened. Various machines such as a flat pressure up / down system and a linear pressure cylinder system are used at a processing pressure of 500 to 5000 t / m ² . The heating temperature of the plate is preferably 60 to 150 ° C. and is processed in the vicinity of the softening temperature of the thermoplastic resin. In a linear pressure cylinder type machine, it is preferable to process at a temperature about 30-50 ° C. higher than a flat pressure up-down type machine.

Hereinafter, the present invention will be described by way of examples. As the base paper, commercially available pure white 35 g / m ² and 65 g / m ^{2 and} single-sided art paper 105 g / m ² were used as thin paper. In addition, a coated ball of 280 g / m ² was used as a cardboard.

  As the thermoplastic resin, a polyethylene resin having a softening temperature of about 110 ° C., an ethylene-acrylic copolymer resin at 80 ° C., and a vinyl chloride resin at 120 ° C. were used. The polyethylene and the ethylene-acrylic copolymer resin were extruded and the vinyl chloride resin was dissolved in a solvent and applied with a gravure coater. At that time, the surface was smoothed using a smoothing bar.

The deposition anchor layer, the aluminum deposition, and the deposition top layer were processed by a continuous deposition machine called a so-called air-to-air system. First, in order to improve the adhesion between the thermosetting resin layer and the vapor deposition anchor layer, the surface of the thermoplastic resin was subjected to corona discharge treatment, and then the vapor deposition anchor layer was applied with a gravure coater. The deposition anchor layer was coated with 1.3 g / m ² of an aqueous acrylic resin as the main resin. Then, it was introduced into a vapor deposition kettle kept at a vacuum of 10 ⁻⁵ Torr, and aluminum was vapor deposited. The deposition thickness is about 50 nm. A vapor deposition topcoat layer was applied to the vapor deposition surface of the sheet coming out of the vapor deposition kettle. As the vapor deposition top layer, nitrocellulose-based, rubber-based, and vinyl chloride-based resins were applied. The coating amount is 1.0 to 1.5 g / m ² . Table 1 shows the base paper used, the components and the coating amount of the thermoplastic resin, the resin composition of the vapor deposition top layer, and the coating amount.

As a comparative example, a commercially available vapor-deposited paper was used. The structure is such that a melamine-based resin deposition anchor layer is provided on the coated surface of 65 g / m ² coated paper, and a nitrocellulose-based resin is applied as a deposition TOP coating layer.

  Next, a printing layer and an OP varnish layer were applied to each vapor-deposited paper. In Example 1 and Comparative Example in Table 2, a printing layer and an OP varnish layer were applied with a gravure rotary printing press. The main component of the printing layer and OP varnish layer is an aqueous acrylic resin. Water as a solvent was dried with hot air at 80 ° C. In Examples 2, 5, and 6, the printing layer and the OP varnish layer were applied using a convex ring printing machine (letter press). The print layer and the OP varnish layer are UV curable ink, OP varnish, mainly composed of acrylic resin. The UV lamp was dried with 8 lamps of 100 W / cm. In Examples 3, 4, and 7, the printing layer was applied with a lithographic offset printing machine. The ink of the printing layer is an oxidation polymerization drying type. Further, an OP varnish layer of a water-based acrylic resin was applied with a single wafer gravure machine.

Next, each printed matter was embossed. The plate used was a brass plate with unevenness due to corrosion. Embossing uses a flat pressure cylinder machine, pressurization is 2500 t / m ² , and processing speed is 1000 sheets / h. Table 2 shows the processing conditions and the results of the unevenness expression for each example and comparative example. In terms of expression, sensory evaluation was performed on the degree to which the pattern changed or moved three-dimensionally in the viewing direction. The unevenness depth was measured from the position where the microscope was in focus. The appearance of the unevenness was visually evaluated.

Industrial applicability

  As described above, a thermoplastic resin film is provided on one side of the base paper, a thermoplastic vapor deposition anchor layer, a vapor deposition layer, and a vapor deposition top layer are provided thereon, and a printing layer and an OP varnish layer are further provided thereon. After that, since the unevenness is processed and pressed with a heated plate near the softening point of the thermoplastic resin, it is possible to provide unevenness from the thermoplastic film to the OP varnish layer. In particular, the OP varnish layer can be processed at a high temperature during thermocompression bonding by selecting a material with excellent slip and heat resistance. When processed near the softening point of a thermoplastic resin, sharp unevenness is obtained. It is done. As a result, it is possible to obtain a highly-designed sheet whose pattern changes or moves three-dimensionally in the viewing direction. The industrial value of printed materials such as labels, packages, posters, book covers, and promotional materials such as pops and prizes is great.

  An example of embodiment of the present invention is shown and it is a sectional view before embossing.   An example of embodiment of this invention is shown and it is sectional drawing after embossing.   It is an example of a commercially available printed material of vapor-deposited paper, and is a cross-sectional view.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Base paper 2 Thermoplastic resin layer 3 Deposition anchor layer 4 Deposition layer 5 Deposition top layer 6 Print layer 7 OP varnish layer 8 Pulp layer 9 Clay coat layer

Claims (3)

A thermoplastic resin film is provided on one side of the base paper, a thermoplastic vapor deposition anchor layer, a vapor deposition layer, and a vapor deposition top layer are provided thereon, and a printing layer and an OP varnish layer are further provided thereon. Embossed sheet characterized in that the varnish layer is uneven by embossing 2. The embossed sheet according to claim 1, wherein the thermoplastic resin layer comprises one or a combination of two or more of polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-acrylic copolymer, and vinyl chloride. A thermoplastic resin film is provided on one side of the base paper, a thermoplastic vapor deposition anchor layer, a vapor deposition layer, and a vapor deposition top layer are provided thereon, and a printing layer and an OP varnish layer are further provided thereon, and then the thermoplastic resin A method for producing an embossed sheet characterized by being pressed with a plate heated near the softening point of the sheet and having unevenness from the thermoplastic film to the OP varnish layer

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