JPH0416346A - Manufacture of decorative sheet - Google Patents

Abstract

PURPOSE:To obtain a decorative sheet 18 wherein an aggregate 17 is hardly fallen off and which has good wear resistance and is rich in durability by dividing the surface of a base sheet into projected parts and recessed parts and adhering only the recessed parts with the aggregate through an adhesive. CONSTITUTION:An aggregate 17 is scattered and thickly laminated on recessed and projected faces 12.13 transferred with an adhesive 16 from a hopper 20 and then, the base sheet 14 is turned over to fall down and to remove the excess aggregate 17 and it is passed through a drying zone 21. In this case, only the projected parts 12 of the base sheet are brought into contact with a roll coater and the recessed parts 13 are not transferred with the adhesive 16 and as the result, only the surfaces of the projected parts are adhered with the aggregate 17. As the result, a required uneven pattern is drawn based on difference in height and existence of the aggregate 17 between the projected parts 12 and the recessed parts 13 and if the base sheet 14, the adhesive 16 and the aggregate 17 are made into different colors each other and a coloring agent 22 is transferred on the recessed part 13, the uneven pattern becomes more colorful and rich in three dimensional feeling.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention is applicable to floor materials, building materials such as plywood and steel plates, surface materials for houses, interior materials such as wall coverings and floor coverings, or The present invention relates to a decorative sheet used as a substitute for synthetic leather for upholstery of chairs, curtain fabric, etc.

[Conventional technology]

Cosmetic seam I with aggregate sprinkled on the surface of the base seam
- Regarding the manufacturing method of
2-18440.

In other words, in order to create an uneven pattern on the surface of this type of decorative sheet, an embossing roll is applied to the aggregate surface layer that has been spread over the entire surface, or an adhesive is imprinted on the base seal and the aggregate is applied. A method of gluing it in a pattern is used.

[Problem that the invention seeks to solve]

In the method using an embossing roll, since there is aggregate on both the surfaces of the convex portions and the valley bottoms of the concave portions, an uneven pattern with a three-dimensional effect with clear edges between the convex portions and the concave portions cannot be drawn.

In particular, if the aggregate is hard inorganic material such as crushed ceramics or bricks, it is practically impossible to create an uneven pattern because the embossing roll will be damaged even if the base sheet is made thicker.

Alternatively, in the method of printing with adhesive, the aggregate is
An engraved roll with deep recesses is required to firmly adhere to the adhesive, but such an engraved roll with deep recesses is not only expensive, but also requires adjustment of the amount of adhesive applied. Therefore, if the aggregate has a large particle size, only a small part of the surface will come into contact with the extremely thin coating of the adhesive, making it easy to absorb the film, so even if the adhesive is applied thickly, it will not work. It is absorbed into the aggregate and forms an extremely thin coating, which makes it easy to fall off.

Of course, to make it difficult to fall off, it would be possible to make the aggregate grains tighter, but this would also reduce the difference in level between the convex parts and the four parts on the surface of the base sheet depending on the presence or absence of aggregate, giving it a three-dimensional feel. No uneven pattern is drawn.

Alternatively, it is possible to add a foaming agent to the adhesive to make the paint film foam and bulge, but in that case, the aggregate is a very thin layer of adhesive that is in a tacky, unfoamed state immediately after printing. Coating F: It is spray-adhered to i, and is not spray-adhered to a thick adhesive film that is solidified by foaming.As the foaming ratio increases, the adhesive film becomes brittle and breaks easily.
It is meaningless to mix a foaming agent into an adhesive in this way.

Furthermore, in the method of printing with an adhesive, disadvantages and inconveniences such as requiring a great deal of effort to wipe and clean the adhesive printing device after use cannot be avoided.

[Purpose of the invention]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to simply and efficiently obtain a decorative sheet which is highly durable and whose aggregates are difficult to fall off, and which also has a large step difference between the convex portions and the four portions and is rich in three-dimensional appearance.

[Structure of the invention]

That is, the method for manufacturing the decorative sheet 18 according to the present invention is to coat the base sheet 14 having the surface irregularities 12 and 13 with a roll coater.
15 to transfer the coating film 16 of the adhesive on the circumferential surface of the roll coater onto the surface of the convex portions 12 of the base sheet (12 and 13), and then spread the adhesive coating 17 on the uneven surface (12 and 13) of the base sheet. This method is characterized in that the aggregate adhered to the convex surface (12) and adhered to the concave portion 13 of the base seam is removed.

Various adhesives are used, including water-soluble adhesives such as carboxymethylcellulose and emulsion-latex compounds.

The base sheet 14 is made of paper lining, cloth, etc., and a foamed layer of thermoplastic resin may be laminated on the surface thereof.

The surface irregularities 12 and 13 can also be imparted by passing the base sheet 14 between the embossing roll 11 and the backup roll 23, but the non-thermoplastic base sheets 1 and 14, such as backing paper, do not have fine wrinkles or folds. Add wrinkles and unevenness 12
・You can also add 13.

For example, when crepe paper with wrinkles or creases is used for the base sheet 14, the paper is stretched to the extent that those wrinkles are not completely removed, and the height or depth of the unevenness of those wrinkles is approximately the same. It passes through the roll coater 15 in a constant alignment.

When providing surface irregularities 12 and 13 to a non-thermoplastic base sheet 14 like backing paper, the surface irregularities 12 and 13 are
Strong pressure is applied between the embossing roll 11 and the backup roll 23 to such an extent that the traces 24 of 13 are exposed on the back surface.

When passing through the embossing roll 1], the convex part carries a water purification agent, printing ink, paint TL and other coloring agents 22,
The convex part 12 and the concave part I3 may be made to have different colors by, for example, transferring a water repellent agent, a coloring agent, etc. 22 to the bottom of the concave part 13 formed at the same time as the embossing.

In that case, an antifouling agent such as silicone resin or fluororesin, wax, or the like is used as the cleansing agent (12).

As the aggregate 17, finely crushed materials such as 1s1/#, foam, ceramics, wood, etc. are used, but in particular, hard inorganic powders such as ceramics, pottery, M135, bricks, marble, and kansui stone are used. When used, the convex portions 12 should be provided so as to avoid a striped pattern or checkered pattern that continues in a straight line vertically and horizontally like the joints of tiles that have been constructed.

FIG. 1 illustrates an embodiment of the invention in which a base sheet 14 is passed through a heating zone 19 and then through an embossing roll 11 and coated with adhesive 16 by a roll coater 15.
is transcribed.

Next, the aggregate 17 is sprayed from the hopper 20 onto the uneven surfaces (12 and 13) onto which the adhesive 16 has been transferred, and is laminated thickly.Then, the base sheet 14 is turned over and the excess aggregate 17 is removed. Leads to drying zone 21.

Generally, the peripheral surface of the roll coater 15 is covered with a coating film of the adhesive 16 having a uniform thickness, but the convex a61 of the base sheet
Only adhesive 2 is in contact with the roll coater, and the recess 13 is filled with adhesive 1.
6 is not transferred, and as a result, the aggregate 17 is bonded only to the surface of the convex portion 12.

Thus, the height difference between the convex portion 12 and the concave portion 13 and the convex portion 12
A desired uneven pattern is drawn depending on the presence or absence of the aggregate 17 between the base sheet 14 and the recess 13.
By making the aggregate 17 a different color or by transferring a coloring agent 22 to the four parts 13, the uneven pattern becomes colorful and more three-dimensional.

In this way, in order to create an uneven pattern depending on the presence or absence of the aggregate 17 between the convex parts 12 and the four parts 13, adhesive 1 is applied to all the convex parts 12.
6 must be transferred from the roll coater 15, which has a plain circumferential surface, and the aggregate 17 must be adhered to it, so all convex portions 1
The heights of 2 must be kept approximately constant.

Therefore, in the case of outer paper 14 having irregularly uneven wrinkles, the wrinkles are spread out to such an extent that they do not disappear completely, and the paper is passed lightly through a press roll with a plain peripheral surface to reduce the height or depth of the unevenness of the wrinkles. It is preferable to pass the film through the roll coater 15 while aligning them substantially uniformly.

Furthermore, when applying the foamable resin composition to the base sheet 14 to impart irregularities (12 and 13), sufficient care must be taken to ensure that the heights of the convex portions 12 do not become uneven due to abnormal foaming. surface irregularities (12
- 13) is recommended to be applied using the embossing roll 11 instead of foaming.

The decorative sheet 18 obtained in this way can be finished flat by passing it through a press roll to eliminate the unevenness caused by the aggregate 17 protruding from the convex surface (12) (Fig. 3).
Alternatively, the entire surface can be overcoated with an antistatic agent, antifouling agent, or other resin kR parabolite.

In particular, when the aggregate 17 is made by crushing a foam made of thermoplastic resin such as vinyl chloride or ethylene/vinyl acetate, when the aggregate 17 is passed through a press roll in a heated state, the protruding aggregate 17 on the convex surface 12 becomes flat. It is crushed and expanded to obtain a stone-like decorative sheet 18 (FIG. 4).

〔Effect of the invention〕

In this way, in the present invention, the surface of the base sheet 14 is
2 and 4 parts 13, and the aggregate 17 is bonded only to the convex part 12 through the adhesive 16.In addition, the adhesive 16 is not printed by rolling, rolling, etc., but the surface is Since we decided to transfer from a plain reverse roll coater or doctor roll, the coating amount (coating film thickness)
can be adjusted as appropriate depending on the type and adhesiveness of the base sheet 14, adhesive 16, aggregate 17, etc.

Therefore, when dispersing aggregate 17 that easily absorbs adhesive, such as crushed foam (sponge), the adhesive coating 16 is made sufficiently thick and the adhesive is allowed to bite into the coating 16 to remove the bones. Since the material 17 can be firmly bonded, the decorative sheet 18 is hard to fall off, has wear resistance, and is highly durable.
is obtained.

Furthermore, when the decorative sheet 18 on which the uneven pattern is drawn depending on the presence or absence of the aggregate 17 in the convex parts 12 and the four parts 13 is passed through a press roll, the part where the aggregate 17 is located is the raised convex part 12. The aggregate 17 can be easily pushed into the base sheet 14, thereby making it possible to finish the aggregate 17 into a decorative sheet 18 with excellent abrasion resistance and durability that is even more difficult to reduce (Figure 3). .

Moreover, the thickness of the adhesive film on the circumferential surface of the roll coater can be adjusted freely.
The application opening (coating film thickness) of base sheet 14 and adhesive 16
The base sheet 14, the adhesive 16, or the aggregate 17, etc., which are the materials of the decorative sheet 1-18, can be changed as appropriate depending on the type and adhesiveness of the aggregate 17. Can be used with adhesive 1
6. Since the coating device 41 is a plain reverse roll coater and doctor roll i.14, there is no need to worry about wiping and cleaning the adhesive after use.

Furthermore, since the uneven pattern is not created by an embossing roll, it can be drawn even on the very thin base sheet 14 using a hard inorganic aggregate 17 such as ceramic or chimney, and it can also be created using a plastic film that is easily melted by heat. or thin synthetic fiber cloth, or non-thermoplastic inorganic sheet or paper. It is also possible to obtain a colorful decorative sheet 18 in which the valley bottoms of the four parts 13 are different colors depending on the color of the base sheet 1-14, the adhesive 16, or the aggregate I7.

When passing the embossing roll 11, the bottom CZ of the recess 13
If the water repellent 22 is transferred and applied, the danger of the aggregate adhering to the recesses 13 due to the adhesive seeping out from the protrusions 12 is prevented, and the outline of the uneven pattern can be made even clearer. .

In particular, the protrusions 12 are attached in a striped or lattice pattern like filling of tiles, and hard inorganic aggregate 17 such as ceramic or brick is used.
If the material is spray-glued, it can be cut by applying force and vines along the four straight parts 13 without a lower part, so it can be cut by stacking and lubricating it like wall covering material [1]
It is also possible to connect @ construction by butting together.

Since the inorganic aggregate 17 obtained by crushing ceramics or bricks is a noncombustible material, it is possible to obtain noncombustible interior materials such as wall covering materials and floor coverings that require high fire resistance.

Also, if the inorganic aggregate 17 is bonded in this way, the entire decorative sheet will become hard, but in that case, it is necessary to press the base sheet strongly enough to expose the traces 24 on the back side to form the unevenness 12 and 13. (4th [N+)] Since it becomes easy to bend at the position of the trace 24, fold the decorative sheet 18 along the inside and outside corners of the wall covering and the L2 wall so as not to cause cracks on the surface. It can also be constructed.

In this way, the aggregate 17 is firmly adhered to prevent it from falling off, and the design is new, creating colorful patterns depending on the presence or absence of the aggregate.
(Naturally, the present invention is extremely convenient for producing vertical cosmetic sheets 1-18 simply and efficiently.)

Even if the adhesive slightly protrudes from the convex part 12 into the concave part 13, or if the concave part 13 is shallow and the adhesive adheres very thinly to the bottom of the valley, the aggregate Depending on the adhesive, it may not be adhered, and even if it is sometimes adhered, most of it will fall off, and at least the convex part 1 will be attached to the fourth part I3.
Since the aggregate will not be bonded as tightly as 2, the 4 parts 1
Even if a small amount of adhesive or aggregate is attached to 3, the effects unique to the present invention are not hindered, and the scope of the present invention is thereby limited. There isn't.

[Brief explanation of drawings]

Fig. 1 (i ). 11... Emboss roll, 12... Convex portion, 13
... recessed part, 14...--streak-1
, 15... Reverse coater 16... Adhesive,
17... Leopard wood, 18... Cured voltage sea 1-119... Heating zone, 20... Hosoha-2
1...Drying zone, 22...Coloring agent, etc., 2
3... Backup roll, 24... Traces of unevenness. Participant: Hokushin Cross Co., Ltd. Agent, Patent Attorney Shigeru Chiba, Procedural Publication, Published in 1990.

Claims (1)

[Claims] The base sheet 14 having surface irregularities 12 and 13 is passed through a roll coater 15, and the adhesive coating 16 on the peripheral surface of the roll coater is transferred to the surface of the convex portions 12 of the base sheet 14,
A decorative sheet characterized in that aggregate 17 is sprinkled on the uneven surfaces (12 and 13) of the base sheet and adhered to the convex surface (12), and the aggregate adhering to the concave portions 13 of the base sheet is removed. Manufacturing method.