JPH10137678A - Three-dimensional pattern decorative sheet and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve three-dimensional designability by a method in which in a three-dimensional pattern decorative sheet having a liquid-repellent pattern layer and a top coat layer formed selectively on a substrate sheet, the pattern layer is formed from an oily liquid-repellent ink, and the top coat layer is formed from an aqueous top coating agent. SOLUTION: In the production of a three-dimensional pattern sheet, a liquid- repellent pattern layer 3 is formed on a substrate sheet 1 through an under coat pattern layer 2, the whole surface is coated with a top coating agent, and a top coat layer 4 is formed selectively on the surface excluding a part where the pattern layer 3 is formed. In this case, a liquid-repellent ink added with a liquid repelling agent, for example a fluororesin, a silicone resin, waxes, etc., is used for the pattern layer 3. Besides, an aqueous top coating agent containing water as a main diluent is used as the top coating agent which forms the top coat layer 4. In this way, the improvement in a liquid-repellent effect and the reduction of the use of an organic solvent are attempted.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a three-dimensional decorative sheet for use in building materials such as inner walls and ceilings of buildings, and for surface decoration of furniture, furniture and fixtures, and a method of manufacturing the same.

[0002]

2. Description of the Related Art In recent years, the cost and weight have been reduced as compared with the case where natural wood and stone materials are used as building materials such as inner walls and ceiling surfaces, fixtures, furniture, furniture and the like. Of course, for the purpose of obtaining the same or unique design properties as those, for example, on a surface of a base material such as plywood, particle board, medium-density fiber board, honeycomb material, etc., a decorative sheet on which a design of a desired pattern has been applied in advance. Pasting methods are becoming more and more widely used.

As the decorative sheet, there is a decorative sheet in which a pattern such as a wood pattern, a stone pattern, or an abstract pattern is printed on a base sheet made of, for example, paper, a synthetic resin film or a laminate thereof. In some cases, these may be applied to the surface of the base material and used as it is, but if the pattern layer is exposed on the surface, the pattern will be worn over time due to the action of various chemical substances such as abrasion and solvents during use. The design is impaired.

[0004] Of course, if the base sheet is a transparent material,
It is also possible to provide a picture layer on the back surface of the base sheet so that the base sheet functions to protect the picture layer. But,
For example, it is not possible to use an opaque material such as paper, woven fabric, non-woven fabric, veneer, or opaque synthetic resin film as the base sheet. For the purpose of imparting surface properties such as above, a method of further applying a transparent or translucent coating to the surface is used.

[0005] However, in the above-mentioned coating step, for example, it is difficult to carry out the coating operation efficiently on an article having a complicated shape industrially, and it is usually performed by a spray coating method. Are scattered and wasteful, and there are many problems in working environment hygiene. In addition, in addition to the above-mentioned problems, painting has to be performed manually on the inner wall surface and ceiling surface of the building, so labor costs are required, and a period for painting work and drying is required. Therefore, the construction period was prolonged.

Therefore, for the purpose of solving the above-mentioned problems, a top coat layer for imparting surface properties such as abrasion resistance and solvent resistance to the surface is previously provided on the pattern layer of the decorative sheet. The method is already in practical use. By doing this, it is possible to simultaneously apply the design of the pattern and the surface physical properties without passing through the painting process, simply by attaching the decorative sheet having the top coat layer on the base material. This greatly contributes to improving the environment and shortening the construction period.

[0007] As described above, the decorative sheet having the top coat layer provided on the entire surface of the pattern layer has a substantially planar surface, and therefore, compared to a natural wood-based material having irregularities such as annual rings and conduit grooves. However, it is inferior in terms of design. For the purpose of supplementing this, for example, a decorative sheet having a three-dimensional design property close to that of a natural wood-based material has been obtained by, for example, imparting unevenness by an embossing method, or further applying wiping to color the recess. .

However, in the embossing method and the wiping method described above, it is difficult to synchronize the pattern with the unevenness in the manufacturing process, so that the design is still inferior to natural wood-based materials. Therefore, on the pattern layer (base pattern layer) provided on the base sheet,
After providing a liquid-repellent pattern layer such as a conduit pattern synchronized with this, applying a topcoat agent on the entire surface thereof, and then repelling the topcoat agent in the portion provided with the liquid-repellent pattern layer, the liquid-repellent A method has been devised in which a top coat layer is selectively provided on the surface excluding the portion where the sexual pattern layer is provided to obtain a three-dimensional pattern synchronized with the underlying pattern layer (Japanese Patent Laid-Open No. 59-1).
0371).

As a printing ink or a top coating agent used for providing the above-mentioned pattern printing layer or top coat layer, an organic solvent is conventionally used as a diluting solvent, as in other printing fields and coating fields. In most cases, oil-based printing inks and topcoat agents were used, but in response to the growing awareness of environmental protection, the use of organic solvents has been abolished.
Attempts to produce a decorative sheet using an aqueous printing ink or a topcoat agent using water as a diluting solvent have already begun in some cases.

In addition, it is possible to manufacture a three-dimensional pattern decorative sheet by using a material such as a water-based ink or a water-based topcoat agent for all of the base pattern layer, the liquid repellent pattern layer, and the topcoat layer. (Japanese Patent Laid-Open No. 8-3)
No. 5199).

However, making the printing ink and the top coat agent water-soluble as described above causes a serious problem at a manufacturing site. The reason is that water, which is a diluting solvent for aqueous printing inks and topcoat agents, has a higher heat of evaporation and specific heat than organic solvents that are diluting solvents for conventional oil-based printing inks. This is because the agent cannot be manufactured under the same manufacturing conditions because the drying speed of the agent is low and set-off and blocking due to poor drying are likely to occur.

More specifically, an example will be described. In the case of toluene, which is one of the typical diluents of the conventional oil-based printing ink, the heat of evaporation is 0.364 kJ / g and the specific heat is 1.76.
J / Kg, whereas water has a heat of evaporation of 2.26 kJ /
g and specific heat of 4.19 J / Kg (boiling point is 1
10.6 ° C and 100 ° C). Therefore, in order to evaporate the same weight of the diluting solvent, it is calculated that the amount of heat required for water is several times as large as that for toluene.

For this reason, when an attempt is made to manufacture a decorative sheet using an aqueous printing ink and a topcoat agent, the operating conditions of the dryer are the same as compared with the case where an oily printing ink and a topcoat agent are used. In such a case, it is necessary to reduce the printing speed by a factor of several. On the other hand, in order to manufacture at the same printing speed, the drying capacity of the dryer must be increased several times.

[0014] However, none of these methods is very practical. This is because the method of reducing the printing speed naturally reduces the production amount per unit time, which leads to an increase in manufacturing cost. On the other hand, in order to increase the drying capacity of the dryer, the printing device becomes large and expensive, and if a conventional printing device for oil-based ink is used, a considerably large-scale remodeling is required. This leads to an increase in manufacturing costs.

[0015] When any of the methods is adopted, a drastic increase in energy required for the operation of the dryer is inevitable. Therefore, where the organic solvent was successfully reduced by such a method, if the energy consumption increased significantly, there was a problem that it could not be said that it comprehensively contributed to environmental protection. .

[0016]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems of the conventional three-dimensional pattern decorative sheet, and reduces the productivity and the energy consumption required for production. An object of the present invention is to provide a three-dimensional decorative sheet that can contribute to environmental protection by reducing the amount of an organic solvent used without increasing the amount thereof, and that is excellent in three-dimensional design, and a method for producing the same.

[0017]

The three-dimensional pattern decorative sheet of the present invention is provided on a base sheet by selectively providing a liquid-repellent pattern layer and a surface excluding a portion provided with the liquid-repellent pattern layer. A three-dimensional pattern decorative sheet having at least a topcoat layer, wherein the liquid-repellent pattern layer is made of an oil-based liquid-repellent ink, and the topcoat layer is made of an aqueous topcoat agent. is there.

[0018] In particular, the present invention is characterized in that a base pattern layer made of oil-based ink is provided between the base sheet and the liquid repellent pattern layer.

Particularly, the solvent contained in the oil-based liquid-repellent ink is mainly composed of a non-polar organic solvent.

In particular, the solvent contained in the oil-based liquid-repellent ink is mainly composed of a non-polar organic solvent and a polar organic solvent having a higher evaporation rate than the non-polar organic solvent. is there.

In particular, the evaporation rate of the non-polar organic solvent (assuming that butyl acetate is 100) is 50 or more and 200 or less, and the evaporation rate of the polar organic solvent is 20 or less.
It is characterized by being 0 or more and 1000 or less.

In the method for producing a three-dimensionally patterned decorative sheet of the present invention, a liquid repellent pattern layer is provided on a base sheet, and then a top coat agent is applied on the entire surface to provide the liquid repellent pattern layer. In the method for producing a three-dimensional pattern decorative sheet in which a top coat agent is repelled to selectively provide a top coat layer on the surface excluding the portion provided with the liquid repellent pattern layer, the liquid repellent pattern layer includes An oil-based liquid-repellent ink is used, an aqueous topcoat agent is used as the topcoat agent, and a multicolor printing apparatus having an after-drying zone is used for printing and coating, and the liquid-repellent pattern is used. The layer is printed by a printing unit other than the final printing unit, and the aqueous topcoat agent is applied in the final printing unit, whereby an integrated production is performed in-line.

[0023] In particular, a printing unit closer to the paper supply unit than a printing unit used for printing the liquid-repellent pattern layer is provided between the base sheet and the liquid-repellent pattern layer,
It is characterized in that the base picture layer is printed with oil-based ink.

In the method for producing a three-dimensional pattern decorative sheet according to the present invention, a liquid repellent pattern layer is provided on a base sheet, and then a top coat agent is applied on the entire surface to provide the liquid repellent pattern layer. The top coat agent of the set portion is repelled, and in the method for producing a three-dimensional pattern decorative sheet in which a top coat layer is selectively provided on the surface excluding the portion provided with the lyophobic pattern layer, Uses an oil-based liquid-repellent ink, uses a water-based topcoat agent as the topcoat agent, and applies the water-based topcoat agent on a base sheet provided with the liquid-repellent picture layer. At the time, the liquid-repellent pattern layer contains a residual solvent to such an extent that it becomes tack-free.

In particular, a base pattern layer is provided between the base sheet and the lyophobic pattern layer with an oil-based ink.

In particular, the oil-based liquid-repellent ink is mainly composed of a non-polar organic solvent.

Particularly, the solvent contained in the oil-based liquid-repellent ink is mainly composed of a non-polar organic solvent and a polar organic solvent having a higher evaporation rate than the non-polar organic solvent, and
On the base sheet on which the liquid-repellent pattern layer is printed, at the time of applying the aqueous topcoat agent, the residual solvent contained in the liquid-repellent pattern layer is mainly composed of the nonpolar organic solvent. It is characterized by the following.

In particular, the evaporation rate of the non-polar organic solvent (assuming that butyl acetate is 100) is 50 or more and 200 or less, and the evaporation rate of the polar organic solvent is 20 or less.
It is characterized by being 0 or more and 1000 or less.

[0029]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to the drawings. FIG. 1 is a side sectional view showing an embodiment of a three-dimensional pattern decorative sheet of the present invention, and FIG. 2 is an overall schematic side view showing an example of a printing apparatus used for manufacturing the three-dimensional pattern decorative sheet of the present invention.

The decorative sheet of the present invention, as shown in FIG.
A liquid-repellent pattern layer 3 and a top coat layer 4 provided on the surface excluding a portion where the liquid-repellent pattern layer 3 is provided on a base sheet 1 such as paper. The base pattern layer 2 is provided between the base sheet 1 and the liquid repellent pattern layer 3 or the top coat layer 4.

As the base sheet 1, various sheet-like or film-like materials can be used depending on the intended use as is conventionally known. Specifically, for example, thin paper, titanium paper, resin-impregnated paper, flame-retardant paper, paper such as inorganic paper, woven or nonwoven fabric made of natural or synthetic fibers, veneer, or polyolefin-based resin, polyester-based resin, Acrylic resin, styrene resin, polyamide resin, cellulose resin, polycarbonate resin, polyvinyl chloride resin, polyvinylidene chloride resin, synthetic resin such as fluororesin, a mixture thereof, transparent made of copolymer, etc. A conventionally known arbitrary material such as a translucent or opaque synthetic resin film, or a composite or a laminate thereof can be used.

The base pattern layer 2 may not be provided at all if unnecessary. However, in order to obtain an excellent design effect in which a three-dimensional pattern is added to a two-dimensional pattern, the lyophobic pattern layer 3 is formed. In general, the undercoating pattern layer 2 is provided on the top coat layer 4. When the base sheet 1 is made of a transparent or translucent material, it may be provided on the back side of the base sheet 1 or may be provided on both sides. However, considering the convenience for in-line integrated production using a multicolor printing apparatus, it is preferable that the base picture layer 2 be provided between the liquid-repellent picture layer 3 or the top coat layer 4 and the base sheet 1.

As the material used for the base pattern layer 2, any conventionally known printing ink or coating agent can be used, and it may be oily or aqueous. In recent years, examples of using water-based inks have been gradually increasing in consideration of environmental issues. However, in the three-dimensional pattern decorative sheet of the present invention, in consideration of in-line integrated production using a multicolor printing device, it is preferable to use a conventional oil-based ink which is more advantageous in terms of drying speed than a water-based ink.

The above-mentioned oil-based ink is obtained by dissolving or dispersing a colorant such as a dye or a pigment in an organic solvent together with a suitable binder resin. Examples of the coloring agent include inorganic pigments such as carbon black, titanium white, zinc white, red iron oxide, graphite, navy blue, and cadmium red, azo pigments, lake pigments, anthraquinone pigments, phthalocyanine pigments, isoindolinone pigments, and dioxazines. Organic pigments such as pigments, or a mixture of two or more thereof can be used.

As the binder resin, for example, acrylic resin, styrene resin, polyester resin,
Urethane resin, polyvinyl resin, alkyd resin, petroleum resin, ketone resin, epoxy resin, melamine resin, fluorine resin, silicone resin, cellulose resin,
Various synthetic resins such as a rubber-based resin, or a mixture thereof, a copolymer, or the like can be used.

Examples of the organic solvent include toluene, xylene, cyclohexane, ethyl acetate, butyl acetate, methyl alcohol, ethyl alcohol, isopropyl alcohol, acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone and the like, and mixtures thereof. Can be used.

In addition, if necessary, extenders and plasticizers,
Dispersant, surfactant, tackifier, adhesion aid, desiccant,
Various additives such as a curing agent, a curing accelerator or a curing retarder are appropriately used.

The base pattern layer 2 may be of one color, but usually is subjected to multicolor printing of two to several colors for the purpose of design of natural colors. In the case of an abstract pattern or the like, three colors of yellow, red, and indigo, or four colors obtained by adding black ink to the color may be used in the same manner as a general commercial multicolor print. On the other hand, as is well known, in the case of a wood grain pattern, it is common to separate the board into a solid background, a wood grain pattern, a pipe pattern, and the like. Among these, the pipe pattern is generally used as a lyophobic pattern layer 3 described later. Provided. When the base sheet 1 is transparent or translucent, for the purpose of imparting concealing properties,
It is common to provide a white or colored opaque solid printing layer as the lowermost layer. The application amount of the pattern printing layer 2 depends on the type of the pattern, but is usually 1 to 3 g / m 3 in total of all colors.
² (after drying).

The lyophobic pattern layer 3 is formed by adding at least a lyophobic agent, specifically, for example, a lyophobic substance such as a fluororesin, a silicone resin, or a wax. Ink is used. The addition amount of the liquid repellent is generally about 5 to 70% by weight of the solid content ratio. In the present invention, an oil-based liquid-repellent ink using an organic solvent as a diluting solvent is particularly used. As the colorant, the binder resin, and the solvent, the same materials as in the case of the base pattern layer 2 described above can be used. However, since the lyophobic pattern layer 3 is exposed on the surface in the completed state of the three-dimensional pattern decorative sheet, it is considered as a binder resin in consideration of abrasion resistance, solvent resistance and the like. It is preferable to use a curable resin.

Specific examples of the curable resin include urethane resins, melamine resins, epoxy resins, alkyd resins, acrylic resins, polyester resins, and the like.
Thermosetting resin such as silicone resin or room temperature curable resin, acrylic resin, urethane acrylate resin,
An ionizing radiation-curable resin such as an ester acrylate resin, an epoxy acrylate resin, and a silicone resin can be suitably used.

The solvent contained in the oil-based liquid-repellent ink used for forming the liquid-repellent picture layer 3 is preferably mainly a non-polar organic solvent having strong hydrophobicity. The use of a non-polar organic solvent has high solubility in a hydrophobic binder resin or liquid repellent which is highly repellent to water, and has a high liquid repellent pattern layer 3.
If a small amount remains in the water-repellent pattern layer 3, the water-repellent pattern layer 3 has an effect of increasing the water repellency. This is effective in improving the printing speed and preventing the occurrence of defects such as unremoved marks.

Specific examples of the nonpolar organic solvent include aliphatic hydrocarbon solvents such as hexane, octane, isooctane, and trimethylhexane; cyclopentane;
Alicyclic hydrocarbon solvents such as cyclohexane, methylcyclohexane, and ethylcyclohexane; aromatic hydrocarbon solvents such as benzene, toluene, xylene, and ethylbenzene; petroleum solvents such as ligroin, petroleum benzene, and mineral spirits; It is preferable that two or more kinds of mixed solvents and the like are mainly used.

However, the above-mentioned non-polar organic solvents often have insufficient solubility in the binder resin.
In particular, when a curable resin is used as the binder resin, the curable resin often contains a polar group such as an isocyanate group, an epoxy group, and a (meth) acryloyl group, and therefore, only a nonpolar organic solvent is used. Because I used
In many cases, sufficient printability cannot be obtained due to poor dissolution. In such a case, a method in which a non-polar organic solvent and a polar organic solvent are used in combination is widely used for the purpose of ensuring solubility.

Specific examples of the polar organic solvent include alcohols such as methanol, ethanol, isopropyl alcohol and isobutyl alcohol, ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone and cyclohexanone, methyl acetate, ethyl acetate, and the like. Esters such as normal butyl acetate and isobutyl acetate, ethers such as diethyl ether, dioxane and tetrahydrofuran, and a mixed solvent of two or more thereof are generally used.

However, at this time, if a polar organic solvent having a lower evaporation rate than the non-polar organic solvent is used in combination, the non-polar organic solvent evaporates first in the drying step, and a large amount of the polar organic solvent tends to remain. There is a possibility that the repulsion to the aqueous topcoat agent to be worked is reduced. Therefore, when a non-polar organic solvent and a polar organic solvent are used in combination, it is preferable to mainly use a combination of a non-polar organic solvent having a low evaporation rate and a polar organic solvent having a high evaporation rate.

As a standard of the evaporation rate of these solvents, the evaporation rate of a non-polar organic solvent (normal butyl acetate is taken as 100)
And the evaporation rate of the polar organic solvent is preferably about 200 or more and 1000 or less. If the evaporation rate of the non-polar organic solvent is less than 50, the drying of the ink is too slow in the printing process, so that it is likely to cause blocking or streaking. On the other hand, if it exceeds 200, the time until the top coat agent is applied In some cases, it may not sufficiently improve the liquid repellency. On the other hand, when the evaporation rate of the polar organic solvent is less than 200, it may not be possible to sufficiently evaporate and dry by the time of the application of the top coat agent, and the liquid repellency may be reduced. If the ratio is more than 1, the evaporative drying is too fast, the on-machine stability of the ink is reduced, and the printing workability and the printing quality may be adversely affected.

Specifically, examples of the non-polar organic solvent include octane, trimethylhexane, ethylcyclohexane, mineral spirit, toluene, xylene, and ethylbenzene. Examples of the polar organic solvent include methanol, ethanol, and isopropyl alcohol. Methyl ethyl ketone, ethyl acetate, propyl acetate,
It is preferable that one or more of isopropyl acetate, propyl formate, and the like are appropriately selected and combined as a main component.

With this configuration, of the non-polar organic solvent and the polar organic solvent contained in the oil-based liquid-repellent ink at the time of printing the liquid-repellent picture layer 3, the polar organic solvent having a high evaporation rate has priority. The non-polar organic solvent having a low evaporation rate tends to remain in a large amount, and therefore, the effect of improving the repulsion of the water-based top coat agent applied thereon can be sufficiently exerted. However, in the present invention, as is widely practiced in the past, for the purpose of preventing the liquid-repellent pattern layer 3 from whitening or dusting, a small amount of a relatively dry and slow-drying polar organic solvent is added. It does not hinder.

When the underlying picture layer 2 is provided, the lyophobic picture layer 3 may or may not be synchronized with the picture of the underlying picture layer 2 depending on the properties of the intended design. good. However, in the case of a wood-grained design, for example, when the wood-grained base pattern layer 2 and the lyophobic pattern layer 3 with the conduit pattern are synchronized, it is extremely superior to natural wood-based materials. It is possible to obtain a design and it is very suitable.

The top coat layer 4 is provided for the purpose of imparting surface properties such as abrasion resistance, scratch resistance, solvent resistance and stain resistance to the surface of the decorative sheet. 2 is provided with a transparent, colored transparent or translucent resin layer having transparency so that it can be seen through. In the present invention, since the top coat layer 4 is selectively provided on the surface excluding the portion where the lyophobic pattern layer 3 is provided, the difference in film thickness between the lyophobic pattern layer 3 and The surface has a three-dimensional effect of unevenness.

Particularly, in the case of a three-dimensional decorative sheet having a wood grain pattern, the thickness of the top coat layer 4 is generally made larger than the thickness of the colored liquid repellent picture layer 3 so that the repellency corresponding to the conduit pattern is obtained. The concave portion 5 is formed in the liquid pattern layer 3 to provide a three-dimensional conduit pattern similar to a natural wood-based material.

In addition, a gloss adjusting agent such as silica, alumina, calcium carbonate, barium sulfate or the like is appropriately added to one or both of the liquid repellent picture layer 3 and the top coat layer 4 to form a liquid repellent picture layer. By making the gloss state of the surface of the top coat layer 3 different from that of the top coat layer 4, it is possible to give a gloss change pattern synchronized with a picture or unevenness.

The top coat layer 4 is composed of the lyophobic pattern layer 3
After the top coat agent is applied to the entire surface including the portion where the liquid repellent pattern layer 3 is provided, the liquid repellent pattern layer 3 is made to repel the top coat agent applied thereon by the liquid repellent action of the liquid repellent pattern layer 3. 3 is selectively formed on the surface excluding the portion provided with 3. As such a top coating agent, an oily top coating agent using an organic solvent as a diluting solvent has been conventionally used. In the present invention, an aqueous top coating agent mainly using water as a main diluting solvent is used.

The first reason is, as mentioned above, the improvement of the lyophobic effect by combination with the oily lyophobic pattern layer 3, but the second reason for this is the recent awareness of environmental protection. In view of the increase, there is a reduction in the amount of organic solvent used.

The situation will be described in detail.
Although the coating amount depends on the target design and the required conditions such as abrasion resistance, it usually reaches about 5 to 10 g / m ² (after drying). , Much more than the base picture layer 2 and the lyophobic picture layer 3. The three-dimensional decorative sheet of the present invention achieves a drastic reduction in the amount of organic solvent used by using an aqueous topcoat agent containing water as a main diluent solvent as the topcoat agent used in the topcoat layer 4. Is what you do.

Another advantage of using an aqueous topcoat agent is that, since a water-soluble or water-dispersible hydrophilic resin is generally used as a constituent resin, the topcoat layer 4 obtained by curing this resin can be used. Can also point out that it has excellent solvent resistance to organic solvents.

Examples of the above-mentioned aqueous topcoat agent include an aqueous solution of a water-soluble curable resin such as a water-soluble melamine resin, or an aqueous emulsion of a vinyl acetate resin, an aqueous emulsion of a urethane resin, an aqueous emulsion of an acrylic resin, or a polyolefin. Any conventionally known aqueous topcoat agent such as an emulsion type topcoat agent obtained by dispersing fine particles of a water-insoluble resin in water by the action of a suitable dispersant, such as a resin-based aqueous emulsion, can be used. it can.

Of course, in order to obtain necessary surface properties, it is preferable to use a curable top coat agent to which melamines, epoxy compounds, aziridine and the like are added as a curing agent. In addition, in such an aqueous topcoat agent, solubility,
For the purpose of improving dispersibility or coating suitability, etc., in some cases, a solution obtained by adding a small amount of a water-soluble organic solvent such as alcohol to water as a diluting solvent is used, but the present invention excludes these. is not.

In producing the three-dimensional pattern decorative sheet of the present invention, the base pattern layer 2, the liquid repellent pattern layer 3, the top coat layer 4
For example, offset printing, screen printing, flexo printing, etc. may be possible as printing and coating methods, but multi-color continuous high-speed printing on a long printing substrate is possible and rich gradation The gravure printing method, which is excellent in tone stability, makes it easy to make an endless pattern with an arbitrary circumference, and also has excellent printing durability, is the most suitable for the production of such decorative sheets. It is well known that most decorative sheets are manufactured by the gravure printing method.

As described above, when an aqueous topcoat agent is used for the topcoat layer 4, the drying property is naturally lowered as compared with the case where a conventional oily topcoat agent is used.
Problems such as blocking and torsion are likely to occur. To avoid this problem, a method of increasing the drying capacity of the dryer 23 of each printing unit is conceivable, but this requires new capital investment. On the other hand, if it is attempted to manufacture a decorative sheet using an aqueous topcoat agent using an existing printing apparatus that has been used for manufacturing a conventional all-oil type decorative sheet, it is necessary to reduce the printing speed. It is of course conceivable that this will happen.

However, some conventional printing apparatuses for producing decorative sheets include a large-capacity dryer (after-drying zone) provided separately from the dryer of the printing unit after drying with the dryer of the final printing unit. A printing device equipped with
There are many. Therefore, as a printing device used for manufacturing the three-dimensional pattern decorative sheet of the present invention, a multicolor printing device having the above-mentioned after-drying zone is used, and if the top coat layer is coated with the final printing unit, an aqueous top Even if the drying capacity of the drying unit of the printing unit that coats the coating agent is insufficient, since it can be dried sufficiently in the after-drying zone afterwards, it does not cause defects such as blocking or turbulence, and at high speed Printing can be manufactured.

Of course, the base pattern layer 2 and the lyophobic pattern layer 3 use oil-based inks having better drying properties than water-based inks. Therefore, the same conditions as those of the conventional all-oil type decorative sheet are used. , Printing can be sufficiently performed by the dryer of the printing unit, so that the problem of poor drying does not occur.

FIG. 2 shows an example of a multicolor printing apparatus having the after-drying zone 60 described above.
4 with four printing units 20, 30, 40, 50
It is a color gravure rotary printing apparatus.

In the method for producing a three-dimensionally patterned decorative sheet according to the present invention, for example, in the order from the paper feed unit 10 side, the first printing unit 20 uses a base solid and the second printing unit 30 uses a wood grain pattern using oil-based ink. Printing is performed to provide a base pattern layer 2, on which a third printing unit 40 is provided with a liquid-repellent picture layer 3 using an oil-based liquid-repellent ink, and finally, a fourth printing unit 50, which is the final printing unit, is a water-based top layer. Apply coating agent over the entire surface.

The lyophobic pattern layer 3 was provided by using the lyophobic property of the surface of the lyophobic pattern layer 3 to repel the aqueous topcoat agent on the lyophobic pattern layer 3. The top coat layer 4 is selectively formed on the surface excluding the portion. In this way, the concave portion 5 appears at the portion where the liquid-repellent picture layer 3 is provided due to the difference in the application amount between the liquid-repellent picture layer 3 and the top coat layer 4, and a design feeling of a three-dimensional pattern is obtained. is there.

Of course, the method for producing a three-dimensional decorative sheet of the present invention is not limited to the above. For example, using a printing device of three colors or less, the base pattern layer 2 is not provided or only one color is used. It is also possible to print the underlying pattern layer 2 in three or more colors or the lyophobic pattern layer 3 in two or more colors by using a printing device of five or more colors. is there. The printing method is not limited to the gravure method, and any printing method such as an offset printing method, a screen printing method, a relief printing method, a flexographic printing method, and a dry offset printing method can be applied.

In particular, as a method for forming the solid underlayer or the top coat layer 4, for example, a gravure coating method,
Any coating method such as a microgravure coating method, a roll coating method, a lip coating method, a knife coating method, an air knife coating method, a kiss coating method, a spray coating method, and a dip coating method can be applied.

In the method for producing a three-dimensional pattern decorative sheet according to the present invention, the lyophobic pattern layer 3 made of oily lyophobic ink is used.
By the time of the application of the aqueous topcoat agent, rather than drying sufficiently, to the extent that it contains a residual solvent to the extent that it is tack-free without generating blocking or turbulence, The liquid repellent effect of the residual solvent is added to the liquid repellent effect of the liquid repellent agent to increase the repulsion of the water-based topcoat agent, and to quickly and reliably flip, so that the printing speed is improved.
It is very effective in preventing occurrence of defects such as unplayed parts.

As described above, as a method of leaving the solvent in the liquid-repellent pattern layer 3, for example, the air volume and the drying temperature of a dryer of a printing unit for printing the liquid-repellent pattern layer 3 are set to be low. Appropriate methods such as a method and a method in which an organic solvent that is slower drying than a solvent used in ordinary oil-based printing inks are added to the oil-based liquid-repellent ink can be used.

It is not preferable that the solvent remains in the liquid-repellent picture layer 3 until after the top coat layer 4 is formed, because it causes blocking, set-off, odor and the like. However, after the application of the aqueous top coat agent in the final unit, the printed sheet is sufficiently dried by the dryer 23 and the large-capacity after-drying zone 60 in the final unit, so that the problem of the residual solvent usually occurs. There is no.

The solvent remaining in the liquid repellent pattern layer 3 at the time of application of the aqueous top coat agent is preferably a solvent having a high repulsive force against water, and a nonpolar organic solvent having a low surface tension is mainly used. It is preferable that
For that purpose, it is naturally most preferable that the solvent contained in the oil-based liquid-repellent ink used for the liquid-repellent picture layer 3 is mainly composed of a nonpolar organic solvent.

However, as described above, non-polar organic solvents generally do not always have sufficient solubility in various kinds of binder resins. Therefore, when a diluting solvent mainly containing a non-polar organic solvent is used, excellent printability is obtained. In many cases, it is difficult to obtain an inked ink. Therefore, in order to obtain an oil-based liquid-repellent ink that is excellent in printability and excellent in repellency to an aqueous topcoat agent while using a polar organic solvent having excellent solubility in various binder resins in combination, At the time of application of the aqueous top coat agent, the diluting solvent of the oil-based liquid-repellent ink is a non-polar organic solvent, such that the residual solvent contained in the liquid-repellent pattern layer 3 is mainly composed of a non-polar organic solvent. It is preferable to mainly use a combination with a polar organic solvent having a higher evaporation rate.

In this manner, in the drying step immediately after the formation of the liquid-repellent picture layer 3 by printing, the polar organic solvent having a high evaporation rate has priority over the non-polar organic solvent having a low evaporation rate. As a result of the evaporation and drying, the non-polar organic solvent is liable to remain selectively as a result, which can contribute to the improvement of repulsion.

In order to achieve the above object, as described above, the evaporation rate of the above-mentioned non-polar organic solvent (assuming that normal butyl acetate is 100) is 50 to 200,
On the other hand, the evaporation rate of the polar organic solvent used in combination therewith is preferably 200 or more and 1000 or less.

In addition, due to the structure of a normal printing apparatus, the time between the application of the aqueous topcoat agent and the application section in the dryer is extremely short, so that immediately after the coating, If dried, the water-based topcoat agent is forcibly dried and thickened by the dryer before it is completely repelled by the liquid-repellent picture layer 3, so that a poor remaining repelling is likely to occur. Also, depending on the conditions, the boiling of water occurs inside the aqueous topcoat agent, and the bubbles generated by this cause the viscosity of the aqueous topcoat agent to increase, so that the aqueous topcoat agent is not discharged to the outside air. May be dried and solidified, and a foamed defect may occur.

Therefore, as described in JP-A-8-35199, the drying temperature after the application of the aqueous top coat agent is changed to
When drying is performed while changing the temperature stepwise from a low temperature side to a high temperature side, a sudden thickening in the initial stage of drying is suppressed, so that a sufficient time for the aqueous topcoat agent to be repelled can be secured, and the boiling phenomenon Itself is suppressed,
Since the time for discharging the air bubbles is also secured, it is effective for preventing defects such as unskid and foaming.

[0077]

EXAMPLE A conventional gravure five-color printer for producing decorative sheets having an after-drying zone was used to obtain a basis weight of 30 g / gram.
the tissue paper of m ^2, except using the nitrocellulose-based oil printing ink toluene and ethyl acetate as a main solvent, and one color solid background layer which also serves as a colored background hiding imparting, the vessel pattern 2
The color wood pattern layer is sequentially printed using the first to third printing units to provide a base pattern layer having a total coating amount of about 2 g / m ² after drying, and then the following printing unit is used in the fourth printing unit. Using an oil-based liquid-repellent ink having a composition, a liquid-repellent pattern layer of a conduit pattern synchronized with the wood pattern was provided, and further dried in a fifth printing unit using an aqueous topcoat agent having the following composition. A three-dimensional decorative sheet of the present invention was manufactured by providing a top coat layer having a later coating amount of about 6 g / m ² .

Oil-based liquid repellent ink composition Acrylic resin 20 parts by weight Silica gel powder 20 parts by weight Color pigment 5 parts by weight Isocyanate-based curing agent 20 parts by weight Silicone liquid repellent 3 parts by weight Toluene 30 parts by weight Methyl ethyl ketone 15 parts by weight Ethyl acetate 15 Parts by weight

Aqueous Topcoat Agent Composition Acrylic resin 75 parts by weight Epoxy curing agent 10 parts by weight Silicone release agent 0.5 part by weight Water 24.5 parts by weight

In the above printing process, the printing speed is 100
m / min, and the drying condition is 1 for the first to third printing units.
The temperature was set to 00 ° C. and dried sufficiently, but the fourth printing unit was set to a slightly lower temperature of 80 ° C. to leave a solvent content to such an extent that the lyophobic picture layer became tack-free. After the application of the aqueous top coat agent, in the after-drying zone divided into three zones of 5 m each, 80 ° C., 120 ° C., 18
Drying was performed at three temperature settings of 0 ° C.

In this way, the three-dimensional design is excellent without having problems such as blocking and transfer due to poor drying, unremoved parts, bubbles and the like, and having the embossing of the pipe pattern synchronized with the pattern of the grain. A three-dimensional pattern decorative sheet could be manufactured.

[0082]

The three-dimensional pattern decorative sheet of the present invention is a conventional all-oil type three-dimensional pattern by combining a liquid repellent pattern layer made of an oily liquid repellent ink and a top coat agent made of an aqueous top coat agent. Compared to decorative sheets, the amount of organic solvent used can be significantly reduced, which can contribute to environmental protection, and the work environment has been greatly improved. Like in the case of
It does not result in a significant increase in the energy consumption required for drying.

Further, since the liquid-repellent picture layer is made of an oil-based ink, it has excellent repulsion against the aqueous topcoat agent and can be quickly and reliably flipped. Printing can be manufactured, and a three-dimensional decorative sheet excellent in three-dimensional design with sharp repelling at the end of the conduit can be easily manufactured.

In addition, of the printing apparatuses widely used in the production of the conventional all-oil type decorative sheet, a multi-color printing apparatus having an after-drying zone is used to perform in-line integrated production. It is possible to manufacture with high productivity under almost the same conditions as the conventional one without requiring measures such as adding new equipment or lowering the printing speed.

Further, at the time of applying the aqueous top coat agent, since the residual solvent is contained to such an extent that the liquid repellent pattern layer becomes tack-free, the oily residual solvent is repelled by the liquid repellent pattern layer. It can improve the liquid properties and contribute to the improvement of productivity and the quality of three-dimensional design.

The solvent contained in the oil-based liquid-repellent ink used for the liquid-repellent picture layer is mainly composed of a nonpolar organic solvent or a nonpolar organic solvent and a polar organic solvent having a higher evaporation rate than the nonpolar organic solvent. When the aqueous topcoat agent is applied, the residual solvent contained in the liquid-repellent pattern layer tends to be mainly composed of a hydrophobic non-polar organic solvent, and Improves the liquid repellency of the liquid pattern layer,
It can contribute to improving the productivity and the quality of the three-dimensional design feeling.

In particular, when the solvent contained in the oil-based liquid-repellent ink used in the liquid-repellent picture layer is mainly composed of a nonpolar solvent and a polar organic solvent having a higher evaporation rate than the nonpolar solvent, Solvent evaporation rate of 50 or more and 200 or less,
By setting the evaporation rate of the polar organic solvent to 200 or more and 1000 or less, it is possible to prevent the remaining of the polar organic solvent at the time of the application of the aqueous top coat, and to easily allow the nonpolar organic solvent to remain selectively. The liquid repellency of the liquid repellent pattern layer can be improved, which can contribute to the improvement of productivity and the quality of a three-dimensional design feeling.

As described in detail above, the three-dimensional decorative sheet and the method for producing the same according to the present invention can reduce the amount of the organic solvent used without reducing the productivity or significantly increasing the energy consumption required for the production. This has an excellent advantage that it is possible to contribute to environmental protection by reducing the number of sheets, and it is possible to easily obtain a three-dimensional pattern decorative sheet excellent in three-dimensional design.

[Brief description of the drawings]

FIG. 1 is a side sectional view showing an embodiment of a three-dimensional pattern decorative sheet of the present invention.

FIG. 2 is an overall schematic side view showing an example of a printing apparatus used for manufacturing the three-dimensional decorative sheet of the present invention.

[Explanation of symbols]

 DESCRIPTION OF REFERENCE NUMERALS 1 base sheet 2 base pattern layer 3 liquid repellent pattern layer 4 top coat layer 5 concave section 10 paper feed section 11 print medium 20 first print unit 21 ‥‥ plate cylinder 22 ‥‥ impression cylinder 23 ‥‥ dryer 30 ‥‥ second printing unit 40 ３ third printing unit 50 ‥‥ fourth printing unit 60 ‥‥ after-drying zone 70 ‥‥ inspection section 80 ‥‥ Paper output unit

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Hideaki Mori 1-5-1, Taito, Taito-ku, Tokyo Toppan Printing Co., Ltd. (72) Inventor Masaru Takahashi 1-5-1, Taito, Taito-ku, Tokyo 5-1-1 Toppan Printing Co., Ltd.

Claims (12)

[Claims] 1. A three-dimensional decorative sheet having at least a liquid repellent pattern layer on a base sheet and a top coat layer selectively provided on a surface excluding a portion provided with the liquid repellent pattern layer. 3. The three-dimensional pattern decorative sheet according to claim 1, wherein the liquid-repellent design layer is made of an oil-based liquid-repellent ink, and the top coat layer is made of an aqueous top coat agent. 2. The three-dimensional decorative sheet according to claim 1, further comprising a base pattern layer made of an oil-based ink between the base sheet and the liquid-repellent pattern layer. 3. The three-dimensional decorative sheet according to claim 1, wherein the solvent contained in the oil-based liquid-repellent ink mainly comprises a non-polar organic solvent. 4. The solvent contained in the oil-based liquid-repellent ink mainly comprises a non-polar organic solvent and a polar organic solvent having a higher evaporation rate than the non-polar organic solvent. Or the three-dimensional pattern decorative sheet according to 2. 5. The evaporation rate of said non-polar organic solvent (where butyl acetate is 100) is 50 or more and 200 or less;
And the evaporation rate of the polar organic solvent is 200 or more and 10 or more.
5. The three-dimensional pattern decorative sheet according to claim 4, wherein the number is 00 or less. 6. After providing a lyophobic pattern layer on a base sheet, a topcoat agent is applied to the entire surface, and the topcoat agent in a portion where the lyophobic pattern layer is provided is repelled, In the method for producing a three-dimensional pattern decorative sheet for selectively providing a top coat layer on the surface except for the portion provided with the liquid-repellent pattern layer, the liquid-repellent pattern layer uses an oil-based liquid-repellent ink, A water-based topcoat agent is used as the topcoat agent, and a multicolor printing apparatus having an after-drying zone is used for printing and coating, and the lyophobic pattern layer is used in a printing unit other than the final printing unit. A method for producing a three-dimensional decorative sheet, wherein printing is performed, and the aqueous topcoat agent is applied in a final printing unit to thereby perform integrated production in-line. 7. An oil-based ink between the base sheet and the lyophobic pattern layer by using a printing unit closer to a paper feed unit than a printing unit used for printing the lyophobic pattern layer. 7. The method according to claim 6, wherein the base pattern layer is printed by the following method.
3. The method for producing a three-dimensional pattern decorative sheet according to item 1. 8. After providing a lyophobic pattern layer on the base sheet, a top coat agent is applied to the entire surface, and the top coat agent in the portion where the lyophobic pattern layer is provided is repelled, In the method for producing a three-dimensional pattern decorative sheet for selectively providing a top coat layer on the surface except for the portion provided with the liquid-repellent pattern layer, the liquid-repellent pattern layer uses an oil-based liquid-repellent ink, Using a water-based topcoat agent as the topcoat agent, and, on the base sheet provided with the liquid-repellent pattern layer, at the time of applying the water-based topcoat agent, the liquid-repellent pattern layer, A method for producing a three-dimensionally patterned decorative sheet, comprising a residual solvent to such an extent that it becomes tack-free. 9. The method for producing a three-dimensionally patterned decorative sheet according to claim 8, wherein a base pattern layer is provided between the base sheet and the liquid repellent pattern layer with an oil-based ink. 10. The method according to claim 8, wherein the oil-based liquid-repellent ink mainly comprises a non-polar organic solvent. 11. A solvent contained in the oil-based liquid-repellent ink is mainly composed of a non-polar organic solvent and a polar organic solvent having a higher evaporation rate than the non-polar organic solvent. On the printed base sheet, at the time of applying the aqueous topcoat agent, the residual solvent contained in the lyophobic pattern layer is mainly composed of the non-polar organic solvent. The method for producing a three-dimensional pattern decorative sheet according to 8 or 9. 12. The evaporation rate of the non-polar organic solvent (where butyl acetate is 100) is 50 or more and 200 or less, and the evaporation rate of the polar organic solvent is 200 or more and 1000 or less. The method for producing a three-dimensionally patterned decorative sheet according to claim 11.