JPS639533A - Production of interior decorative material - Google Patents

Abstract

PURPOSE:To make it possible to impart a minute three-dimensional feeling or a feeling of shading, by heating a synthetic resin layer to a temperature at which a foaming agent is not decomposed but pattern embossing can be performed, embossing a rugged pattern including deep parts and shallow parts, rubbing in a printing ink to the pattern by a wiping method, and then foaming by heating. CONSTITUTION:A foamable flexible thermoplastic synthetic resin layer 2 containing foaming agent is provided on the surface of a backing member 1 such as a paper. The resin layer 2 is treated by an embossing roll at a temperature at which the foaming agent is not decomposed but pattern embossing can be performed, namely, a temperature lower than the foaming start temperature by about 20 deg.C, thereby providing the surface of the layer 2 with rugged patterns 3, 4, 5, 6. Then, by a wiping device, a printing ink 9 is rubbed into shallow and minute recesses 6 in a substantially uniform density, while printing inks 7, 8 are rubbed into deeper recesses 4, 5 (retaining a certain depth even after deformation) in quantities according to the depths, followed by drying. The backing member 1 with the resin layer 2 thus treated is then introduced into a foaming furnace heated to a predetermined temperature, and foaming is effected by heating.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application) The present invention relates to a method for manufacturing interior materials made of foamed synthetic resin used for interior materials of various buildings, particularly wall covering materials.

[Conventional technology]

In recent years, synthetic resin wall covering materials, especially soft vinyl chloride wallpaper (
PVC wallpaper) has been used for very large spears.

These PVC wallpapers are available in non-foamed products and foamed products, each of which has a printed pattern or a concave-convex drawing pattern on its surface, giving it an extremely excellent decorative effect.

Non-foamed PVC wallpaper is mainly used for device IIi due to the Inso pattern.
The foamed PVC wallpaper has an excellent decorative effect due to its uneven pattern.

As a method to give a convex and convex pattern to foamed PVC wallpaper, ■
A method of embossing an uneven pattern on a flat foamed sheet surface with an embossing roll; ■ A method of heating an unfoamed but expandable PVC sheet containing a foaming agent to foam it and simultaneously embossing the uneven pattern with an embossing roll; ■There is a method of chemically imparting irregularities by the so-called chemical embossing method, as typified by Japanese Patent Publication No. 43-28636.

In the case of methods ① and ②, it is also possible to use the so-called valley printing method, in which printing ink is applied only to the convex portions of the embossing roll and embossing is performed, or a gravure printing machine can be used as a post-processing method. It is also possible to use the so-called holding method, in which printing ink is applied to the concave portions of the concave and convex diaphragm.
In addition, as another method for post-processing, the roll wiping method proposed in Japanese Patent Publication No. 47-48643 allows for a wide variety of variations, including the ability to apply a processing method that creates a shadow feeling different from the valley staining method mentioned above. It is possible to expand including

Method (2) involves printing various patterns on the surface of a foamable synthetic resin sheet containing a foaming agent with a printing ink containing a foaming inhibitor, and then heating and foaming the sheet to suppress foaming in the printed area. This method is based on the principle that since the other parts show normal foaming, the printed part becomes a concave part and the normally foamed part forms a convex part, and this method has been widely used for floor coverings and wall coverings. It is.

[Problem that the invention seeks to solve]

However, all of these methods (1), (2), and (2) are unsatisfactory in terms of the three-dimensional appearance and shadowy appearance of the shibori pattern. ■
In the case of method (■), everything is determined by the pattern squeezed and pressed with the embossing roll, so even if the valley staining method or wiping method is used as post-processing, the three-dimensional effect and shadows of the uneven pattern expressed by the embossing roll will be affected. I can't get over the feeling. In the case of method (2), the difference between printed areas and non-printed areas using printing ink containing a foaming inhibitor is only a concave-convex pattern, and it is not possible to give a fine three-dimensional effect or a sense of shadow, even if it is used in combination with multicolor printing. It was impossible.

[Means to solve the problem]

The present invention has been made in view of this background, and the first step is the step of providing a foamable soft thermoplastic synthetic resin layer containing a foaming agent on the upper surface of a backing material such as paper. The laminated sheet is heated to a temperature at which the foaming agent contained therein does not decompose but it is possible to perform drawing processing, thereby imparting an uneven drawing pattern such as a fine uneven pattern or a deep and shallow uneven pattern to the surface of the synthetic resin layer. The second step is the second step, and then the third step is a step of rubbing insei ink from the surface of the concavo-convex shibori pattern by a wiping method, and coloring the shallow recesses uniformly to the details and the deep recesses to a density corresponding to the depth, After drying the rubbed printing ink, the fourth step is to introduce the processed laminated sheet into a foaming furnace and heat and foam the foamable soft thermoplastic synthetic resin layer. This is a unique method for manufacturing interior materials.

〔Example〕

An example of the implementation of the present invention will be explained with reference to the drawings.
In addition to paper and nonwoven fabrics, various knitted and woven fabrics are used, and if necessary, pre-processing such as sizing treatment is performed, and a foamable soft thermoplastic synthetic resin layer 2 containing a foaming agent is provided on the surface thereof.

The soft thermoplastic synthetic resin layer 2 is preferably a vinyl chloride resin paste, but in addition to these pastes, synthetic resins rolled by a calendering method or an extrusion method may also be used.

In the latter case, vinyl chloride resin is also optimal, but in addition to vinyl chloride resin, vinyl chloride copolymers are also suitable.

A soft thermoplastic synthetic resin used for this type of application, such as EVA, may be used. NBR again.

If necessary, so-called processing aids may be added to improve the density of foamed II cells by blending them with vinyl chloride resin such as polyurethane, saturated polyester, or acrylic elastomer, or to improve physical properties such as elasticity and scratch strength. This can be done by

As the blowing agent used in the foamable soft thermoplastic synthetic resin layer of the present invention, a chemical blowing agent of the pyrolysis gas generating type, typified by azodicarbonamide (ADCA), is suitable. Foaming methods obtained by mechanical foaming methods are unsuitable for the present invention.

When using vinyl chloride resin paste, paper is most suitable as the backing material, but when using textile fabric, it may be necessary to perform sealing treatment to prevent the paste from leaking. An interior material using tissue cloth as a backing material is suitable as a chair pasting material or a furniture pasting material.

The thus obtained laminated sheet A-1, which is composed of the backing material 1 and the foamable soft thermoplastic synthetic resin layer 2, is processed by an ordinary embossing device to have a concave-convex drawing pattern 3 formed by an embossing roll on its surface. .4, 5.6 will be given. The drawing conditions in this case are extremely important.

That is, as a condition in this case, it is important to heat the foamable soft thermoplastic synthetic resin layer 2 to a temperature at which the foaming agent contained in the layer does not decompose but allows drawing processing. Therefore, these conditions vary greatly depending on the decomposition temperature of the blowing agent used. That is, for a blowing agent that starts to decompose at 180°C, the synthetic resin layer temperature is always about 2 degrees below that temperature.
It is necessary to heat the temperature to 0°C lower, that is, 160°C, and if a blowing agent is used that starts decomposing at 200°C, the temperature is 18°C.
Heating to 0°C is required. However, in this case, the conditions should be set based on the decomposition starting temperature of the foamable soft thermoplastic synthetic resin layer, not the decomposition starting temperature of the blowing agent alone.

This is because these synthetic resin layers vary greatly depending on the type of synthetic resin used, the type and stone of the stabilizer, the type and amount of plasticizer, the presence or absence of fillers, the type of coloring material, etc. This is because the foaming start temperature changes even when a foaming agent is used. Therefore, when a formulation is determined, know the foaming start temperature for that formulation (this temperature can be determined by the color change due to the decomposition of the blowing agent), and then perform squeezing at a temperature approximately 20°C lower than that temperature. Try to push it.

Therefore, foaming agents with extremely low foaming initiation temperatures, such as ammonium bicarbonate and azobisisobutyronitrile (AI
It will be appreciated that the sole use of N,N'-dinitroso-N,N'-dimethylterephthalamide (DNDMTA), etc., is unsuitable for PVC formulations.

The concavo-convex pattern to be pressed in the present invention is suitable for a pattern that emphasizes the three-dimensional effect and shadow windows after foaming. Therefore, leather shibori consisting of only shallow shibori patterns is inappropriate, and even simple geometric patterns are inappropriate. In the method of the present invention, a pattern in which a fine uneven pattern and a deep uneven pattern are mixed is suitable as the uneven pattern.

Examples of such patterns include fabrics woven with fine fibers such as jute fabrics and Hellasian fabrics in a coarse weave structure, as well as multi-layer paint exterior wall patterns applied with a roller to concrete exterior walls, such as those typified by stucco finishes. Patterns such as fine stitches and stitches are also suitable.

The laminated sheet A-2, which has been embossed under the shipping conditions using a metal embossing roll engraved with such a pattern and provided with the concave-convex drawing pattern 3.4.5.6, is then wiped with a wiping device to give the surface an appropriate shape. Colored printing ink 7.8.9 is rubbed in. The wiping device used in the present invention is a device typified by the device proposed in Japanese Patent Publication No. 47-48643, and rotates in the same direction as the traveling direction of the laminated sheet A-2. The uneven aperture pattern surface is brought into contact with an ink pumping roll that is rotating at a surface speed 2 to 3 times faster than the laminated sheet, and the printing ink is rubbed in by pressing from the back with a backup rubber roll that is rotating at the same speed as the laminated sheet. It is a mechanism.

When this device is used, a large amount of printing ink enters the concave portions 4° 5.6 of the concave-convex aperture pattern, and the convex portions 3 are strongly scraped off by the ink pumping roll, so that only a very small amount of printing ink adheres to the concave portions. Furthermore, when the printing ink is rubbed into the recesses, the recesses are pressed and deformed depending on the pressing force of the backup rubber roll, so the printing ink 9 is rubbed into the shallow and fine recesses 6 with almost uniform concentration, and even with this deformation, An amount of printing ink 7.8 corresponding to the depth of the recesses 4, 5 is rubbed into them. Therefore, in the case of a concave-convex shibori pattern on a jute woven fabric, the printing ink is clearly and uniformly applied to each and every thin hemp fiber that makes up the warp and weft threads of the woven fabric. , at the apex of the intersection of the warp and weft threads (the part where the warp threads and weft threads overlap to form the convex portion 3), almost no printing ink is applied, and only a small amount of printing ink is attached. In addition, the concave portion at the intersection of the warp and weft yarns is not sufficiently deformed despite the pressure of the backup rubber roll, so the rubbing by the lifting roll surface does not reach the depth of the concave portion. Since the printing ink of the corresponding company is imprinted, a difference in shading occurs depending on the depth of the recess.

The laminated sheet A-3 into which the printing ink 7.8.9 was rubbed in in this manner exhibits an extremely clear sense of shadow, but does not have the three-dimensional effect characteristic of foamed products.

After the laminated sheet A-3 obtained in this way is dried, it is introduced into a foaming furnace heated to a predetermined temperature and heated.
Foamed.

The resulting foamed sheet A-4 was foamed as a whole to increase its thickness, and the portions of the printing ink 7.8.9 rubbed into the recesses 4, 5.6 corresponded to the amount of ink applied. Although the thickness is increased by the magnification, the foaming ratio is lower than that of the convex portion 3'. That is, since only a small amount of printing ink 9 is applied to the shallow and fine concave portions 6, the foaming ratio is almost the same as that of the convex portions 3', but the medium-deep concave portions 5 are deformed by the backup rubber roll. A slightly darker printing ink 8 is imprinted without sufficient printing, and a larger amount of printing ink 7 is imprinted in the deep recess 4 than in the recess 5, so the magnification is adjusted according to the extent of the printing ink. All you can get is foam. This impression is probably related to the amount of resin component contained in the printing ink. That is, it is thought that the resin component constituting the vehicle of the printing ink forms a coating film having a thickness corresponding to the portion to which the printing ink is applied, and that the thickness of the film inhibits normal foaming. Since more printing ink 7 is applied to the deeper recesses 4, a thicker coating film is formed, and slightly less printing ink 8 is applied to the slightly shallower recesses 5 than in the recesses 4, so the coating film is thicker than the printing ink 7. A slightly thin coating film is formed, and when it is foamed 2', foaming 2'-7, 2'-8 of the synthetic resin layer portion is suppressed by 2' depending on the thickness of the coating 7.8.
11, the part with the printing ink 7 is the deepest, a recess 4', and the part with the printing ink 8 is a slightly shallower recess 5'.
It seems that this will be the case.

The interior material obtained in this way has deep shadows and an extremely excellent three-dimensional effect, and the deep recesses have a so-called undercut (or tapered) effect in which the inner pocket is widened. .

Next, specific embodiments of the present invention will be described in detail.

A 0.18#R vinyl chloride resin paste having the following composition is applied to the top surface of a paper of 80 g/7Tt and 0.12a thick.

(Composition) Vinyl chloride resin for paste 100DOP
45TCP
8 Ca-zn liquid stabilizer 3 Foaming agent (ADCA Bi15 Filler/calcium carbonate 25 Flame retardant 81)
203 5 pigment
Appropriate amount*1: This ADCA is 19 in this combination system.
Decomposition starts at 0°C and its peak temperature is 210°C.

Next, after solidifying by heating in a heating furnace at 120°C to form a laminated sheet A-1, this was fed to an embossing device, and the temperature of the expandable vinyl chloride resin layer was heated to 155 to 160°C to form a jute woven fabric. A jute weave pattern was embossed using an embossing roll with a squeeze.

Next, this embossed laminated sheet was fed to a wiping device and a brown printing ink with a vehicle containing 15% PVC/acrylic resin was rubbed into it.

Application (3) was about 50 coats/butt. After drying, the cross section of the obtained printed sheet was cut, and the coating thickness of each printed portion 3, 7, 8, and 9 was determined as follows using a scanning electron microscope.

Convex part 3: Shallow concave part 6' which is not recognized otherwise: 4 parts 4' of 0.1 micron or less
= 3.2 microns Recessed portion 5': 1.8 microns Then, it was introduced into a foaming furnace heated to 220°C and heated for 50 seconds to obtain beautiful foamed PVC wallpaper.

This wallpaper had the following structure.

Total thickness 1.18al+ Foaming ratio approx. 6x Deepest recess 0.4 Middle recess 0.8 Appearance: Jute II? The details of the ff are expressed, and the whole exhibits an undercut-like shibori pattern that has the texture of jute woven fabric, a three-dimensional effect, and a sense of shadow.

〔effect〕

In the present invention, a foamable soft thermoplastic synthetic resin layer containing a foaming agent is laminated on a backing material, and the synthetic resin layer is heated to a temperature that does not decompose the foaming agent contained in the core layer but allows press processing. Then, a deep and shallow concave and convex drawing pattern is applied to the surface, printing ink is rubbed into the concave and convex pattern from the surface of the concave and convex pattern by a wiping method, and after the printing ink is dried, it is introduced into a foaming furnace to create the foaming property. Since the synthetic resin layer is heated and foamed, a large amount of printing ink enters the concave portions and does not adhere to the convex portions, or only a very small amount of it adheres to the convex portions.Furthermore, the rubbing into the concave portions is shallow, and almost no ink is rubbed into the fine concave portions. The fine details are rubbed in, and the deep recesses are rubbed with hangers according to their depth, resulting in a printed pattern with a difference in lightness and foaming. Foaming is suppressed and the foaming magnification differs, with deep recesses, so-called areas with a large amount of printing ink, having small foaming and deep recesses, and shallower recesses becoming slightly shallower recesses with a three-dimensional effect and a deeper shadow feeling. It is possible to provide an interior material with a great decorative effect.

[Brief explanation of the drawing]

The drawings show an example of the implementation of the manufacturing method of the present invention, and FIGS. 1 to 3 are cross-sectional views in the order of steps, and FIG. 4 is a cross-sectional view of the manufactured product. 2 is a foamable soft thermoplastic synthetic resin layer, 3 is a convex portion, 4.5.6 is a concave portion having different depths, and 7 and 8.9 are printing ink rubbed into the concave portions. Patent applicant: Kuchun Seal Kogyo Co., Ltd. Figure 1

Claims (1)

[Claims] (1) A method for manufacturing an interior material, characterized by comprising the following steps: First step: providing a foamable soft thermoplastic synthetic resin layer containing a foaming agent on a backing material such as paper. 2nd step: heating to a temperature at which the foaming agent containing the foamable soft thermoplastic synthetic resin layer does not decompose but can be squeezed;
A step of imparting an uneven drawing pattern to the surface of the synthetic resin layer. Third step: A step in which printing ink is rubbed onto the surface of the concave-convex aperture pattern using a wiping method, and shallow concave areas are colored uniformly down to the details, and deep concave areas are colored to a density corresponding to the depth. Fourth step: After drying the rubbed printing ink, it is introduced into a foaming furnace to heat and foam the foamable soft thermoplastic synthetic resin layer.