JP2781916B2 - Decorative material manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a method for producing a decorative material having a three-dimensional pattern. An object of the present invention is to provide an interior decoration material having a design property.

[Conventional technology]

In recent years, for interior materials for vehicles and buildings, products with progressively three-dimensional high-design patterns have been demanded with the increase in high-grade directivity.
Further, from the viewpoint of workability, it is further required to be lightweight.

Conventionally, as a method for producing a product having such a three-dimensional uneven pattern, (1) a gelled unfoamed thermoplastic synthetic resin layer is laminated on a base material, and this is laminated at a temperature not higher than the decomposition temperature of the foaming agent containing the same. After forming a concavo-convex pattern with an embossing roll while softening by heating at a processing temperature, a laminated sheet having a concavo-convex pattern is manufactured by further heating to a temperature not lower than the decomposition temperature of the contained foaming agent and foaming the laminated thermoplastic synthetic resin. Method (JP-A-51-63872)
No.).

(2) A method of applying a foaming agent-containing paint on a base material by using a rotary screen method or a gravure printing method, and heating and foaming the coating material to give a raised three-dimensional effect.

Etc. are known.

[Problems to be solved by the present invention]

However, in the above method (1), in order to clear the weight regulation in the fireproof standard applied to the interior material for walls, the above gelled unfoamed thermoplastic synthetic material laminated on the substrate is required. The thickness of the laminated sheet of the resin layer is limited, and the thickness of the resin layer has to be reduced. For this reason, the depth of the concavo-convex pattern formed on the layer is limited, and the three-dimensional appearance and sharpness with a very small difference in concavity and convexity are obtained. Only a monotonous, flat, foamed product with a chipped pattern can be obtained.

The only way to obtain a product with excellent three-dimensional effect and sharpness by this method is to increase the thickness of the above laminated sheet,
In this case, there is a problem in the above-mentioned weight regulation and workability, which is not preferable.

In the method (2), the above drawbacks can be eliminated for the time being. However, since a raised pattern with a foaming agent-containing paint is applied to a base material and then heated and foamed to form an uneven pattern, each of the uneven pattern parts is formed. The edge of the pattern becomes sweet, and it is difficult to form a uniform and sharp uneven pattern. This tendency is further increased in a delicate pattern, and a product having a good uneven pattern cannot be obtained.

[Means for solving the problem]

In the present invention, after laminating a foaming agent-containing synthetic resin layer on a substrate, a convex pattern is provided on the layer using a foaming agent-containing synthetic resin paint so that the formation area occupancy is 10 to 75%. Then, preheating at a temperature equal to or lower than the decomposition temperature of the two foaming agents, followed by shaping the concavo-convex pattern with an embossing roll device, followed by reheating to decompose and foam the two foaming agents to form irregularities. This is a method for manufacturing a decorative material that forms a three-dimensional pattern.

[Action]

In the present invention, first, a foaming agent-containing synthetic resin layer (hereinafter referred to as a foamed resin layer) is formed on a substrate. As the method, any of a calendering method, a coating method and an extrusion method can be used, but the coating method is particularly preferable.

Using any one of the above methods, the sheet thickness is 0.05 to 0, under processing conditions equal to or lower than the decomposition temperature of the foaming agent in the foamed resin layer.
The layers are laminated so as to have a thickness of 25 mm, preferably 0.10 to 0.20 mm. This is because when a convex pattern is formed on the sheet using a foaming agent-containing synthetic resin paint (hereinafter, referred to as a foam paint) described below, and when a concavo-convex pattern is formed, if the thickness is less than 0.05 mm, the layer is too thin and the wall thickness is insufficient. However, it is not possible to form a sharp and three-dimensional uneven pattern for the purpose of the present invention, and if it exceeds 0.25 mm, it becomes too heavy in weight, causing a problem in workability as an interior material, and particularly When used as an interior material for walls, the weight regulation in the fireproof standard applied to the material cannot be cleared, and the cost of the product is undesirably high.

The base material used in the present invention is generally a wall, a paper used for a vehicle interior material, a flame-retardant paper, a woven fabric,
Knitted fabrics, nonwoven fabrics, glass cloth, plastic sheets, etc. may be used alone or in a laminate of two or more types. The synthetic resin used for the foamed resin layer laminated on the substrate may be polyvinyl chloride other than polyvinyl chloride homopolymer. And polyvinyl acetate,
A copolymer of polyethylene, polyurethane or the like, or a homopolymer of vinyl chloride and a mixture thereof, to which a foaming agent and a plasticizer, a stabilizer, a lubricant, a chelator, a filler, a colorant or, if necessary, a volatile solvent And a diluent or the like.

As the blowing agent, azodicarboxylic amide, PP '
-Oxybisbenzenesulfonyl hydrazide, a general-purpose heat-decomposable foaming agent such as azobisisobutyronitrile is used by adding 0.5 to 10 parts by weight, preferably 2 to 5 parts by weight, based on 100 parts by weight of the resin. . If the addition amount is less than 0.5 part by weight, the foaming property of the synthetic resin becomes insufficient, so that the intended three-dimensional uneven pattern cannot be obtained, and
Even if it exceeds 10 parts by weight, the above effect is not improved.

As the plasticizer, a general-purpose thermoplastic synthetic resin such as a phthalic acid ester, an adipic acid ester, a sebacic acid ester or a phosphoric acid ester is appropriately selected, and its amount can be changed and used in a wide range. The other additives can be appropriately selected from those generally used for thermoplastic synthetic resins.

Also, after forming the foamed resin layer, a matte thin film layer is formed on the surface thereof by a gravure method, a rotary method, a doctor method, or the like using a surface treatment paint in which a matting agent commonly used in a thermoplastic synthetic resin is mixed. You may. By doing so, it is possible to obtain a variety of high-design products in which these are compounded by the convex pattern of the foamed paint formed in the next step and the drawn uneven pattern formed after foaming.

Next, a convex pattern is formed on the foamed resin layer by using a gravure printing method, a rotary screen printing method or a flexographic printing method so that the area occupied by the foamed paint is 10 to 75%, preferably 20 to 50%. To form When the formation area occupation ratio is less than 10%, the coating amount for forming the convex pattern is generally insufficient, and the unevenness pattern formed by the above-described drawing in the final step lacks three-dimensionality, A product with a sharp design cannot be obtained, and if it exceeds 75%, the above-mentioned disadvantages can be eliminated, but the interval between the convex patterns is too narrow and the coating amount of the convex patterns is too large, so that the final process In this case, the distance between the above-mentioned uneven patterns formed by the above-mentioned method becomes close and it is easy to join, so that the three-dimensionality of the product becomes insufficient, and only a product with poor unevenness is obtained, which is not preferable.

Further, in forming the convex pattern of the foamed paint, the formed coating thickness is set to 0.02 so that the formation area occupancy is in the above range.
0.20.25 mm, preferably 0.05 to 0.15 mm. This is because the convex pattern has sharpness, three-dimensionality and a design effect as a product, and the coating thickness is 0.
If the thickness is less than 02 mm, the wall thickness is insufficient to achieve the above-mentioned effect, and if the thickness exceeds 0.25 mm, the weight becomes too heavy, which causes a problem in workability as an interior material, and is used for a wall. When it is used as an interior material, it is not preferable because it cannot clear the fireproof specification and is expensive in terms of product cost.

Further, as a foam paint used for forming a convex pattern,
The same synthetic resin used for the foamed resin layer can be used, and a foaming agent, a plasticizer, a stabilizer, a volatile solvent, a diluent, and the like are appropriately mixed therein, and a colorant is added or added. Used as a paint.

As the foaming agent, the same type as that used for the foamed resin layer is used by adding 1 to 10 parts by weight, preferably 2 to 6 parts by weight, based on 100 parts by weight of the synthetic resin. When the addition amount is less than 1 part by weight, the foaming property of the convex pattern formed by the above-mentioned foaming paint is insufficient, so that a sharp uneven shape cannot be formed. Not only that, but also a variation in foaming occurs and a stable product cannot be obtained, which is not preferable.

After forming a convex pattern with the foaming paint as described above, this is gelled and dried using a heating device under processing conditions equal to or lower than the decomposition temperature of the foaming agent in the paint, and then the foamed resin layer and the foamed paint are formed. The synthetic resin composition is softened by preheating at a temperature not higher than the decomposition temperature of the foaming agent contained in both.

Next, an uneven pattern is applied to the one formed with the foamed resin layer and the foamed paint using an embossing roll engraved with the uneven pattern, and then the laminate provided with the uneven pattern is heated to about 200 to When heated and foamed at a temperature of 240 ° C. for 0.5 to 2 minutes or more at a temperature equal to or higher than the decomposition temperature of the foaming agents contained therein, the convex pattern portion of the foamed paint is added with the foaming effect of the foamed resin layer under the foamed paint layer. As a result, it is possible to obtain a sharp, highly-designed product having a three-dimensional uneven pattern that is more prominent than that of the concave portion and is rich in unevenness.

In addition, after the above-mentioned convex pattern is gelled and dried, only the convex part may be subjected to a matte head stain process by a gravure printing method or the like using a matte surface treatment agent generally used for a general thermoplastic synthetic resin. By doing so, the unevenness of the product is further emphasized, and a product having an excellent three-dimensional appearance and various high design properties can be obtained.

〔Example〕

1 to 3 show an embodiment of the present invention. Next, the present invention will be specifically described with reference to these drawings. As shown in FIG. 1, a foamed resin layer 2 is formed on a base material 1, and a foamed paint 3 is used on the surface of the foamed resin layer 2 so that the formed area occupancy is 10 to 75%.
After a convex pattern is formed, the foaming agent is heated and gelled at a temperature equal to or lower than the decomposition temperature of the two foaming agents, and then the foamed resin layer 2 and the foaming paint 3 are formed with an embossing roll as shown in FIG. The embossed pattern 4 is formed on the one formed in step (1).

Next, when the embossed pattern 4 is formed and heated in a heating and foaming furnace at a temperature equal to or higher than the decomposition temperature of the two foaming agents, the foamed paint 3 is foamed by the two foaming agents as shown in FIG. The convex pattern is further promoted and raised, and can be expressed as a concave / convex pattern having a sharp and three-dimensional appearance with a remarkable uneven step and having a high design effect.

[Example 1] On a flame-retardant paper for backing wallpaper (manufactured by Sanyo Kokusaku Pulp Co., Ltd., trade name: 70AF-10KP), a colored paint of the following formulation A containing a foaming agent was applied with a comma coater to a coating thickness of 0.15 mm. Then, the foaming agent in Formulation A was heated at a temperature of about 170 ° C. or lower, which was lower than the decomposition temperature, for about 1 minute by using a hot-air drying oven, and was gelled and dried to beige. A colored foamed resin layer is formed, and then a foamed paint of the following formulation B is formed using a rotary screen printing machine so that the occupation area of the foamed paint is about 50%. Formed below the decomposition temperature of the foaming agent of Formula A and Formula B
The gel was dried and gelled in a hot air drying oven at a temperature of 170 ° C. for about 1 minute to form a white convex pattern.

Subsequently, while preheating again at the above-mentioned temperature using a far-infrared heater, an uneven embossed pattern was formed by the uneven step, that is, an embossed roll of a cloth-like uneven pattern engraved to a depth of about 0.8 mm.

Furthermore, when this is heated and foamed at a temperature of about 220 ° C. for about 1 minute using a heating and foaming furnace, the woven pattern pattern and the cloth-grain-like convex portion are raised, and the uneven steps are remarkable, rich in sharp three-dimensional effect, and An excellent product was obtained, which was lightweight, had good workability, and also had the ability to sufficiently clear the fireproof standard for walls.

[Example 2] A foamed resin layer colored beige as in Example 1 was formed on a polyester fiber nonwoven fabric having a basis weight of 90 g / m ^{2 as} a substrate, and then applied to a polyvinyl chloride resin. Using an acrylic resin-based matte surface treatment paint, a matte thin film was applied on the layer by a gravure printing machine so that the solid content was about 15 g / m ^2. A foam decorative material having an uneven pattern was obtained in the same manner. The obtained product was a product having more various designs than the product obtained in Example 1 and having the same performance as that of Example 1.

[Example 3] After forming a convex pattern of a foamed paint on a foamed resin layer using the same material and method as in Example 1, the same matte paint and method as in Example 2 were used only for the convex portions. After applying the matte thin film, a foamed decorative material having an uneven pattern was obtained. The obtained product was more versatile in the concavo-convex pattern than the product obtained in Example 1, and had the same performance as that of Example 1.

〔effect〕

As described above, according to the present invention, a foamed resin layer and a foamed paint are laminated on a substrate, and both foaming agents are heated and foamed. Therefore, the production method is not only simple, but also the convex pattern formed by the foamed paint is used. Can realize a three-dimensional effect with a synergistic effect of both foaming effects and a sharp and markedly uneven step, and can provide a complex and diverse decorative material having a high design property.

In addition, the present invention is excellent in workability because the foamed resin layer is thin and the foaming paint to be further applied is also limited in the amount of the foamed coating, and is excellent in workability, and fully satisfies the weight regulation in the fireproof standard. It is possible to obtain an excellent interior decoration material which also has a clearing performance.

[Brief description of the drawings]

FIG. 1 is an explanatory view of an embodiment in a state where a foam paint is applied,
FIG. 2 is an explanatory view of a state after embossing, and FIG. 3 is an explanatory view of a state after foaming. 1: base material, 2: foam resin layer, 3: foam paint, 4: embossed pattern.

Continuation of the front page (56) References JP-A-63-56540 (JP, A) JP-A-57-203523 (JP, A) JP-B-58-33814 (JP, B2) JP-B-59-380 (JP-A) 58-37906 (JP, B2) (58) Fields investigated (Int. Cl. ⁶ , DB name) B29C 67/22 B05D 7/00, 7/24

Claims (1)

(57) [Claims] After laminating a foaming agent-containing synthetic resin layer on a substrate, a convex pattern is formed on the layer using a foaming agent-containing synthetic resin paint so that the formation area occupancy is 10 to 75%. And then preheated at a temperature equal to or lower than the decomposition temperature of the two foaming agents, followed by shaping the concavo-convex pattern with an embossing roll device, and then reheating to decompose and foam the two foaming agents. A method for manufacturing a decorative material, comprising forming a three-dimensional pattern of irregularities.