JPH01110123A - Production of foamed decorative material - Google Patents

Production of foamed decorative material

Info

Publication number
JPH01110123A
JPH01110123A JP26771187A JP26771187A JPH01110123A JP H01110123 A JPH01110123 A JP H01110123A JP 26771187 A JP26771187 A JP 26771187A JP 26771187 A JP26771187 A JP 26771187A JP H01110123 A JPH01110123 A JP H01110123A
Authority
JP
Japan
Prior art keywords
pattern
patterns
foaming
layer
repeat
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
JP26771187A
Other languages
Japanese (ja)
Inventor
Yukio Okishio
沖汐 行雄
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kyowa Leather Cloth Co Ltd
Original Assignee
Kyowa Leather Cloth Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kyowa Leather Cloth Co Ltd filed Critical Kyowa Leather Cloth Co Ltd
Priority to JP26771187A priority Critical patent/JPH01110123A/en
Publication of JPH01110123A publication Critical patent/JPH01110123A/en
Pending legal-status Critical Current

Links

Abstract

PURPOSE:To produce various arbitrary patterns having repeat, by forming embossed patterns of repeat patterns by a chemical embossing method and applying sharp embossed patterns to the protruding parts of said patterns by a mechanical embossing method. CONSTITUTION:A synthetic resin layer 2 containing a foaming agent is laminated to a base material 1 and a colored or uncolored printing pattern 3 having repeat patterns containing a foaming inhibitor or crosslinking agent is applied to said layer 2. Subsequently the synthetic resin layer 2 is foamed under heating to form a foamed layer 2' having embossed pattern of repeat patterns by a so called chemical embossing method for suppressing the foaming of the part of the printing pattern 3 to form the recessed parts of repeat patterns and developing the parts 5 having no printing pattern of repeat patterns to bring the same to protruding parts. Continuously, the foamed laminate is reheated to temp. equal to or less than the foaming processing temp. of the previous process and sharp random embossed patterns 5' are formed to the surface of the above mentioned protruding parts 5 by a clearance embossing method using a cold emboss roll having random embossed patterns carved in the surface thereof.

Description

【発明の詳細な説明】 〔産業上の利用分野〕 本発明は発泡層表面にリピート柄を有する凹模様を施し
更に核層の凸模様部にシャープな凹凸模様を形成するこ
とにより複雑な立体感に富んだ凹凸模様を有する意匠性
に優れた室内発泡装飾材の製造方法に関するものである
[Detailed Description of the Invention] [Field of Industrial Application] The present invention provides a complex three-dimensional effect by applying a concave pattern with a repeat pattern to the surface of the foam layer and further forming a sharp concavo-convex pattern on the convex pattern portion of the core layer. The present invention relates to a method for producing an interior foam decorative material having an excellent design and having a rich uneven pattern.

〔従来の技術〕[Conventional technology]

近来車両用、建築用の内装材は高級志向性の高まりに伴
い次第に複雑なパターン柄の要望が強くなり、その具現
性−の−環として、基材上に積層した合成樹脂発泡体の
表面にリピートを有する柄模様を形成した凹部分と、該
層凸部に更にランダム状のシャープな凹凸模様を付与す
ることにより複雑で立体的な高意匠性の内装材の開発が
要望されている。
In recent years, as the desire for luxury interior materials for vehicles and buildings has increased, there has been a growing demand for increasingly complex patterns. There is a demand for the development of a complex, three-dimensional, highly designed interior material by providing a concave portion with a repeating pattern and a sharp random pattern of concavo-convex portions on the convex portions of the layer.

従来かかるパターンを有する内装材を製造する方法とし
ては(1)発泡剤を含有した合成樹脂層を加熱発泡し、
その直後に該層表面に冷エンボスロールを用いてランダ
ム状の凹凸絞模様を形成し次いでこれを加熱してリピー
ト柄の冷絞ロールにより開校模様を付与するいわゆる二
次エンボス加工方法、又は(2)発泡剤を含有した合成
樹脂層の表面に発泡抑制剤又は架橋剤を添加した塗料を
用いて上記の凹部及び凸部に対応する柄模様を印刷した
後、これを加熱発泡して上記の凹凸模様に相当したパタ
ーンを形成するケミカルエンボス方法が知られている。
Conventionally, methods for manufacturing interior materials having such patterns include (1) heating and foaming a synthetic resin layer containing a foaming agent;
Immediately after that, a so-called secondary embossing method is employed, in which a random concave-convex drawing pattern is formed on the surface of the layer using a cold embossing roll, and then this is heated to give an opening pattern using a cold drawing roll with a repeat pattern, or (2) ) After printing a pattern corresponding to the above concave and convex parts on the surface of the synthetic resin layer containing a foaming agent using a paint containing a foam suppressor or a crosslinking agent, this is heated and foamed to form the above concave and convex parts. A chemical embossing method for forming a pattern corresponding to a pattern is known.

〔本発明が解決しようとする問題点〕[Problems to be solved by the present invention]

しかしながら、上記(1)の方法では第2次紋押時の加
熱のため先に形成した一次エンボスの絞模様が変形し、
又−次、二次の紋押のため2回の加熱を上記発泡層が受
けるため繰返加熱による発泡層自体のへたり、セル荒れ
等の変形及び熱劣化現象を起し好ましくない。
However, in method (1) above, the squeeze pattern of the primary embossing formed earlier is deformed due to the heating during the secondary embossing.
Furthermore, since the foamed layer is heated twice for the second embossing, repeated heating causes deformation and thermal deterioration of the foamed layer itself such as fatigue, cell roughness, etc., which is undesirable.

また、高価なエンボスロール2本が必要となり、コスト
高で経済的でなく、かつ該ロールのパターンは上記理由
により相当な差を有する柄深度のものが必要となり、一
定深度と形状の安定した絞模様を付与することが困難で
あるという諸欠点を有する。又(2)の方法では一応上
記(1)の欠点は排除することが出来るが、使用する抑
制剤又は架橋剤が印刷表面より下部へのみ浸透すること
が困難で、その周囲にも拡散する傾向があるため、柄際
の凹凸が不鮮明となり又凹凸模様を形成する発泡時の温
度9時間のコントロールがむづかしく、このため鮮明で
凹凸差が大きく、かつ繊細な柄際を有するパターンを形
成することが出来ないという欠点を有する。
In addition, two expensive embossing rolls are required, which is expensive and uneconomical, and the pattern of the rolls needs to have pattern depths with considerable differences due to the above-mentioned reasons. It has various disadvantages in that it is difficult to apply patterns. In addition, method (2) can eliminate the drawback of (1) above to some extent, but it is difficult for the inhibitor or crosslinking agent used to penetrate only below the printed surface, and it tends to diffuse into the surrounding area as well. As a result, the unevenness on the pattern edge becomes unclear, and it is difficult to control the temperature during foaming for 9 hours to form an uneven pattern.As a result, a pattern with a clear pattern with a large difference in unevenness and a delicate pattern is formed. The disadvantage is that it cannot be done.

本発明は前述従来のような諸問題を解決すべく鋭意研究
の結果、ケミカルエンボス法とメカニカルエンボス法を
組合せ使用することによりリピート柄を有する凹部と更
に上記曲部分にシャープで複雑なランダム状模様を有す
る発泡装飾材の製造方法を提供するものである。
The present invention was developed as a result of intensive research to solve the above-mentioned conventional problems.By using a combination of chemical embossing method and mechanical embossing method, a sharp and complex random pattern is created in the concave portion having a repeat pattern and also in the curved portion. The present invention provides a method for producing a foamed decorative material having the following properties.

〔問題点を解決するための手段〕[Means for solving problems]

本発明は基材上に発泡剤を含有した合成樹脂層を積層し
た後、該層表面に発泡抑制剤もしく= 3− は架橋剤を混入した塗料を用いてリピート柄を有する印
刷模様を施し、これを加熱発泡して凹凸模様を有する発
泡層とし、次いで上記発泡層形成時の発泡温度以下の温
度を用いて核層を再加熱し、続いて冷エンボスルールに
より核層の上記の凸模様形成部分に更にシャープな形状
の凹凸のランダム状模様を付形する発泡装飾材の製造方
法である。
In the present invention, after laminating a synthetic resin layer containing a foaming agent on a base material, a printed pattern having a repeat pattern is applied to the surface of the layer using a paint containing a foaming inhibitor or a crosslinking agent. This is heated and foamed to form a foamed layer having an uneven pattern, and then the core layer is reheated at a temperature lower than the foaming temperature during the formation of the foamed layer, and then a cold embossing rule is applied to form the above-mentioned uneven pattern on the core layer. This is a method for producing a foamed decorative material in which a random pattern of sharply shaped irregularities is formed on the formed portion.

〔作   用〕[For production]

以下本発明の製造方法について詳細に説明する0 本発明においては先づ基材に発泡剤を含有した合成樹脂
層を形成する。その方法としてはカレンダー法、コーテ
ィング法又は押出法のいずれかの方法を用いて該含有発
泡剤の分解温度以下の加工条件でそのシート厚が0.0
5〜0.3闘好ましくは0.10〜0.25++mにな
る様積層する。これは該シートを加熱し発泡層を形成し
前述の凹凸模様を付形する場合0.05mm以下では薄
すぎるため肉厚が不足し本発明の目的とする凹凸模様を
付形することが出来ず、又0.25mm以上では前記凹
凸模様の形成には満足するものとなるが、重量的に重く
なりすぎ内装材としての施工性に問題が生じ、又特に壁
装用内装材として用いる場合核材に適用されている防燃
規格上の重量規制をクリアー出来ず、又製品コスト的に
も高価となり好ましくない。
The manufacturing method of the present invention will be described in detail below. In the present invention, first, a synthetic resin layer containing a foaming agent is formed on a base material. The method is to use any of the calendering method, coating method, or extrusion method, and the sheet thickness is 0.0% under processing conditions below the decomposition temperature of the foaming agent contained.
The layers are laminated to a thickness of 5 to 0.3 m, preferably 0.10 to 0.25 ++ m. This is because when the sheet is heated to form a foam layer and the above-mentioned uneven pattern is formed, if it is less than 0.05 mm, it is too thin and the thickness is insufficient, making it impossible to form the uneven pattern that is the object of the present invention. If the thickness is 0.25 mm or more, the uneven pattern can be formed satisfactorily, but it becomes too heavy, causing problems in workability as an interior material, and especially when used as an interior material for walls, the core material This is undesirable because it cannot meet the weight restrictions in the applicable flame-retardant standards, and the product cost is also high.

また、本発明に用いる上記基材としては、−般に壁、車
輌用内装材に用いられている紙、難燃紙、織布1編布、
不織布、ガラスクロス、プラスチックシート等を単独又
はこれらの2種以上の積層物であり、又該基材上に積層
する発泡剤を含有した合成樹脂層に用いる合成樹脂とし
ては塩化ビニルのホモポリマー以外に塩化ビニルとポリ
酢酸ビニル、ポリエチレン、ポリウレタン等の共重合体
又は塩化ビニルのホモボリマーとこれらの混合物であり
、これに発泡剤としてアゾジカルボン酸アミド、ppL
オキシビスベンゼンスルホニルヒドラジッド、アソヒス
イソブチロニトリル等の汎用の加熱分解型の発泡剤と可
塑剤、安定剤、滑剤、キレータ−1充填剤1着色剤等を
混入して使用する。次いで上記積層シートの表面に発泡
抑制剤もしくは架橋剤を混入した着色又は無着色の塗料
を用いてリピート柄を有する印刷模様を形成する。上記
の印刷模様としてはリピートを有する柄模様であればい
かなるパターンのものでも良く、格子柄、花柄、幾何学
柄等意匠性の高いものを随意に選んで用いれば良い。
In addition, the above-mentioned base materials used in the present invention include - paper generally used for walls and vehicle interior materials, flame-retardant paper, woven fabric and knitted fabric;
Non-woven fabric, glass cloth, plastic sheet, etc. alone or a laminate of two or more of these, and the synthetic resin used for the synthetic resin layer containing a foaming agent laminated on the base material is other than homopolymer of vinyl chloride. A copolymer of vinyl chloride and polyvinyl acetate, polyethylene, polyurethane, etc. or a homopolymer of vinyl chloride and a mixture thereof, and azodicarboxylic acid amide, ppL as a blowing agent.
A general-purpose thermally decomposable blowing agent such as oxybisbenzenesulfonyl hydrazide or asohisisobutyronitrile is mixed with a plasticizer, a stabilizer, a lubricant, a chelator, a filler, a colorant, and the like. Next, a printed pattern having a repeat pattern is formed on the surface of the laminated sheet using a colored or uncolored paint mixed with a foam suppressor or a crosslinking agent. The above-mentioned printed pattern may be any pattern as long as it has repeats, and any highly designed pattern such as a lattice pattern, floral pattern, or geometric pattern may be selected and used.

該塗料に用いる樹脂としては、ポリ塩化ビニル又は塩化
ビニルと酢酸ビニルとの共重合体。
The resin used in the paint is polyvinyl chloride or a copolymer of vinyl chloride and vinyl acetate.

アクリル樹脂、ポリウレタン、酢酸セルロース等を用い
これに溶剤としてメチルエチルケトン、シクロヘキサノ
ン、メチルイソブチルケント等のケトン類、トルエン、
キシレン等の芳香族炭化水素、エチレンジクロライド、
メチレンクロライド等の塩素化炭化水素等使用樹脂の種
類により適宜選択し混合して使用する。又該塗料が着色
塗料である場合には耐候性、耐熱性に優れた種類の顔料
を選択して用い、製品に上記物性に秀で耐久性を保有せ
しめる。又本塗料に混入する発泡抑制剤としてはペソゾ
トリアゾール、有機酸(例えばマレイン酸、フマル酸、
アジピン酸)、・・ロゲン化有機酸(例えば塩化ガレフ
タロイル、無水テトラクロロフタル酸)。
Acrylic resin, polyurethane, cellulose acetate, etc. are used as a solvent, and ketones such as methyl ethyl ketone, cyclohexanone, and methyl isobutyl ketone, toluene,
Aromatic hydrocarbons such as xylene, ethylene dichloride,
Chlorinated hydrocarbons such as methylene chloride are appropriately selected and mixed depending on the type of resin used. When the paint is a colored paint, pigments with excellent weather resistance and heat resistance are selected and used, so that the product has excellent physical properties and durability. Foaming inhibitors mixed into this paint include pesozotriazole, organic acids (e.g. maleic acid, fumaric acid,
adipic acid), logogenated organic acids (e.g. galefthaloyl chloride, tetrachlorophthalic anhydride).

又は有機酸無水物(例えば無水マレイン酸、無水トリメ
リット酸)等を用いることが出来るが、ベンゾトリアゾ
ール又は無水トリメリット酸を用いることが特に好まし
い。又該塗料に混入する架橋剤としてはジチオール−8
−トリアジン誘導体(例えば2−ジブチルアミノ、2−
ジメチルアミノ、2−オクチルアミノ−等の5−)!J
アジン誘導体)を用いること、特に2−ジブチルアミノ
−5−トリアジン誘導体を用いることが本発明では好ま
しい。上記の発泡抑制剤もしくは架橋剤の該塗料に於け
る混入量としては塗料全重量に対して2〜30重量%で
、好ましくは5〜20重量%であり、該発泡抑制剤もし
くは架橋剤の混入量が2%以下では該塗料を用いた印刷
模様付与部分の上記積層シート層の発泡時の発泡抑制も
しくは架橋効果が不充分となり本発明の目的とするリピ
ート柄を有する充分な形状の凹部が得られず又30重量
%以上混入しても該発泡抑制もしくは架橋効果は向上し
ない。又本発明では上記発泡抑制剤もしくは架橋剤を混
入しない上記組成の着色一般塗料を用いて前記柄模様と
異なったパターンを有する着色柄模様を前記積層シート
上に更に併施工することにより、より複雑で高意匠効果
の製品とすることが出来る。後者の印刷模様の形成は該
層層シートの後工程である発泡層形成後施しても良い。
Alternatively, organic acid anhydrides (for example, maleic anhydride, trimellitic anhydride), etc. can be used, but it is particularly preferable to use benzotriazole or trimellitic anhydride. Also, as a crosslinking agent mixed into the paint, dithiol-8
-triazine derivatives (e.g. 2-dibutylamino, 2-
5-) such as dimethylamino, 2-octylamino-, etc. J
In the present invention, it is preferred to use 2-dibutylamino-5-triazine derivatives), particularly 2-dibutylamino-5-triazine derivatives. The amount of the foam suppressor or crosslinking agent mixed into the paint is 2 to 30% by weight, preferably 5 to 20% by weight, based on the total weight of the paint. If the amount is less than 2%, the foaming suppression or crosslinking effect during foaming of the laminated sheet layer of the printed pattern-applied portion using the paint will be insufficient, resulting in insufficient concavities having a repeat pattern, which is the object of the present invention. Moreover, even if 30% by weight or more is mixed in, the foaming suppression or crosslinking effect will not be improved. Further, in the present invention, a colored general paint with the above composition that does not contain the above foaming suppressor or crosslinking agent is used to further apply a colored pattern having a pattern different from the above pattern on the laminated sheet. This makes it possible to create products with high design effects. The latter printing pattern may be formed after forming the foam layer, which is a subsequent step of forming the layered sheet.

上記印刷模様を施す方法としては一般に用いられている
グラビア印刷法、ロータリースクリーン印刷法、フレキ
ソ印刷法等を用いる。
As a method for applying the above-mentioned printed pattern, generally used gravure printing method, rotary screen printing method, flexo printing method, etc. are used.

次いで核層の含有発泡剤の分解温度以下の温度を用いて
加熱乾燥せしめた後、該合成樹脂層を加熱炉により加熱
発泡せしめるとともに、上記の発泡抑制剤もしくは架橋
剤を混入した塗料を用いて柄模様を施した印刷部分の発
泡を抑制し、凹状のリピートパターンを有する凹凸発泡
層に形成する。
Next, after heating and drying at a temperature below the decomposition temperature of the foaming agent contained in the core layer, the synthetic resin layer is heated and foamed in a heating furnace, and a paint containing the foaming suppressor or crosslinking agent mentioned above is used. It suppresses foaming in the printed area with a pattern and forms a concave-convex foam layer with a concave repeat pattern.

核層の形成は、その発泡部分即ち凸模様部の発泡倍率を
2〜8倍とすることが肝要である。
In forming the core layer, it is important to set the foaming ratio of the foamed portion, that is, the convex pattern portion, to 2 to 8 times.

該発泡倍率が2倍(発泡シート厚で0.1〜0.6+m
++)以下では発泡層が薄すぎるため、上記のリピート
柄を有する凹部パターンの形成並びに次工程の冷却エン
ボスロールによる発泡層凸模様部に対するランダム状エ
ンボス凹凸模様がシャープで立体的な形状に形成されず
好ましくない。また、8倍(発泡シート厚で0.4〜2
.4朋)以上では前者のリピート柄を有する凹部の形成
は満足せしめることができるが、発泡倍率が高過ぎるた
め後者のランダム状の凹凸模様がシャープに形成されず
、本発明の目的の形状の製品を得ることができず、また
過発泡のため該層表面の荒れを生じ、製品の表面強度が
弱くなり好ましくない。
The foaming ratio is 2 times (foam sheet thickness 0.1 to 0.6+m)
++) or less, the foam layer is too thin, so the concave pattern with the above-mentioned repeat pattern is formed, and the random embossed uneven pattern on the convex pattern part of the foam layer by the cooling embossing roll in the next step is formed into a sharp three-dimensional shape. I don't like it. Also, 8 times (foam sheet thickness 0.4 to 2
.. 4) In the above case, the formation of concave portions with a repeat pattern in the former case can be satisfied, but because the foaming ratio is too high, the random uneven pattern in the latter case cannot be formed sharply, resulting in a product having the desired shape of the present invention. In addition, the surface of the layer becomes rough due to excessive foaming, and the surface strength of the product decreases, which is undesirable.

かくして、ケミカルエンボス法により上記発泡層にリピ
ート柄を有する凹凸模様を付与した後これを遠赤外ヒー
ター、熱風炉等の一般に用いられている加熱装置を使用
して、核層を前記発泡加熱温度以下(含有発泡剤の分解
温度以下)の温度で再加熱し、凹凸模様を有する冷エン
ボスロールを用いて、上記の凹凸模様の凸部にランダム
状のシャープな凹凸模様を形成する。
In this way, after giving the foamed layer an uneven pattern having a repeat pattern by the chemical embossing method, the core layer is heated to the foaming heating temperature using a commonly used heating device such as a far-infrared heater or a hot air stove. It is reheated at a temperature below (below the decomposition temperature of the foaming agent contained), and a random sharp uneven pattern is formed on the convex portions of the above uneven pattern using a cold embossing roll having an uneven pattern.

この場合前記の発泡倍率が約8倍に近い発泡層に対して
は該ロールの凹凸深度が約0.8〜2.0mm、低発泡
の約2倍の発泡倍率のものには該ロール深度が0.3〜
0.8門のロールを用いてクリヤランスエンボス加工法
により付形することが望ましい。これは上記の発泡層の
白部分の発泡セル構造を圧潰せずにランダム状のシャー
プで立体的な形状の凹凸模様を付与するためである。又
本発明においては必要に応じて上記発泡層表面にその発
泡前もしくは発泡後に一般に用いられているポリ塩化ビ
ニル系樹脂、アクリル系樹脂、ウレタン系樹脂その他の
樹脂の単独もしくはこれ等の共重合体又は混合物よりな
る表面処理剤を用いて、表面処理層を形成する。かくす
ることにより製品の耐汚染性、ツヤ消等の効果を付与す
ることができる。
In this case, the depth of the unevenness of the roll is approximately 0.8 to 2.0 mm for a foam layer with a foaming ratio of approximately 8 times, and the depth of the roll is approximately 0.8 to 2.0 mm for a foam layer with a foaming ratio of approximately 2 times that of the low foaming layer. 0.3~
It is preferable that the shape be formed by a clearance embossing method using a 0.8 roll. This is to provide a random, sharp, three-dimensional uneven pattern without crushing the foam cell structure of the white portion of the foam layer. In addition, in the present invention, if necessary, a commonly used polyvinyl chloride resin, acrylic resin, urethane resin, or other resin alone or a copolymer thereof may be applied to the surface of the foamed layer before or after foaming. Alternatively, a surface treatment layer is formed using a surface treatment agent consisting of a mixture. By doing so, effects such as stain resistance and matteness can be imparted to the product.

〔実 施 例〕〔Example〕

第1図は本発明の一実施例の発泡前の状態を示したもの
であるが、基材1上に発泡剤を含有した合成樹脂層2を
積層し、次いで該層表面に発泡抑制剤もしくは架橋剤を
混入したリピート柄を有する着色又は非着色の印刷模様
3を施したものである。
FIG. 1 shows the state before foaming of an embodiment of the present invention, in which a synthetic resin layer 2 containing a foaming agent is laminated on a base material 1, and then a foaming inhibitor or a foaming inhibitor is applied to the surface of the layer. A colored or non-colored printed pattern 3 having a repeat pattern mixed with a crosslinking agent is applied.

次いで上記の発泡剤を含有した合成樹脂層2を加熱発泡
して第2図に示す如く印刷模様3の部分の発泡が抑制さ
れてリピート柄の凹部6となり、また該リピート柄の印
刷模様のない部分5は発泡して凸部となる所謂ケミカル
エンボス法によりリピート柄の凹凸模様を有する発泡層
2′を形成し、続いてこれを前工程の発泡加工温度(含
有発泡剤の分解温度)以下の温度で再加熱しその表面よ
りランダム状の凹凸模様を彫刻した冷エンボスロールを
用いてクリヤランスエンボス法により上記の凸部5の表
面に第3図に示す如くシャープなランダム状の凹凸模様
5′を形成する。又本発明では上記の発泡工程前又は発
泡工程後の紋押加工前に通常一般に用いられている印刷
塗料を用いて上記合成樹脂層2又は発泡層2′のリピー
ト凹凸模様の凸部50表面に印刷模様4を付与すること
より更に高意匠性の製品とすることも出来る。又各図面
には図示されていないが、本発明には場合により該合成
樹脂発泡層の表面に一般に用いられている表面処理層を
形成することにより更に耐汚染性とツヤ消効果を付与す
ることが出来る。
Next, the synthetic resin layer 2 containing the above-mentioned foaming agent is heated and foamed to suppress the foaming of the printed pattern 3 and form the recesses 6 of the repeat pattern, as shown in FIG. In the portion 5, a foamed layer 2' having a repeating uneven pattern is formed by the so-called chemical embossing method, in which the portion 5 is foamed to form convex portions. A sharp random uneven pattern 5' is formed on the surface of the convex portion 5 by the clearance embossing method using a cold embossing roll that has been reheated at a high temperature and has a random uneven pattern engraved on its surface as shown in FIG. form. In addition, in the present invention, before the above-mentioned foaming step or before embossing after the foaming step, a commonly used printing paint is used to coat the surface of the convex portions 50 of the repeat uneven pattern of the synthetic resin layer 2 or foam layer 2'. By adding the printed pattern 4, it is possible to create a product with even higher design quality. Although not shown in the drawings, in the present invention, a commonly used surface treatment layer may be formed on the surface of the synthetic resin foam layer to further impart stain resistance and a matte effect. I can do it.

〔実施例1〕 壁紙裏打用難燃紙(■薬入社製W K −7ONTP 
)上に発泡剤を含有した下記配合Aの塗料をコンマコー
ターを用いて厚さが約0.2順になる様に塗布した後、
熱風乾燥炉を使用して前記発泡剤の分解温度以下の約1
40°Cの温度で約2分間加熱してこれをゲル化乾燥せ
しめて発泡剤を含有した着色合成樹脂層を形成し、その
表面に下記配合Bの発泡抑制剤を混入した着色インキを
用いグラビア印刷法により格子柄のリピートを有する印
刷模様を付与し約110°Cの温度で約40°秒間熱風
乾燥した後、通常のグラビアインキを用いて上記の印刷
模様とリピートを異にした格子病を同じくグラビア印刷
法により付形しこれを上記の印刷模様と同様にして乾燥
し、次いでこれを発泡炉を用いて約220℃の温度で約
60秒間加熱し、上記の含有発泡剤を分解して前記合成
樹脂層を発泡せしめるとともに上記発泡抑制剤を含有し
た印刷部分の発泡を抑制し凹状の着色格子柄模様を有す
るタイル調の発泡体を得た。次に該発泡体の表面を遠赤
外線ヒーターを用いて前記の発泡温度以下の温度で再加
熱し、石目調のランダム状の模様を凹凸深度約1.5朋
に彫刻した冷エンボスロールヲ用イテクリャランスエン
ボス加工法により前記タイル調の発泡体の凸部に紋押加
工を施し、格子病のリピートを有する凹部パターンと凸
部に石目調のシャープなランダム状の凹凸パターンとを
複合した高意匠性を有するとともに顕著な立体感を具現
した建材内装用発泡装飾材を得た。
[Example 1] Flame-retardant paper for wallpaper lining (W K-7ONTP made by Yakusha Co., Ltd.)
) After applying a paint of the following formulation A containing a foaming agent using a comma coater so that the thickness is approximately 0.2,
about 1 below the decomposition temperature of the blowing agent using a hot air drying oven.
This is heated at a temperature of 40°C for about 2 minutes to gel and dry to form a colored synthetic resin layer containing a foaming agent, and on the surface of the layer, a colored ink mixed with a foaming inhibitor of the following formulation B is used for gravure printing. A printed pattern with repeats of a lattice pattern was applied by a printing method, and after drying with hot air at a temperature of about 110°C for about 40 seconds, a grid pattern with different repeats from the above printed pattern was created using ordinary gravure ink. Similarly, it was shaped by the gravure printing method and dried in the same manner as the above printed pattern, and then heated in a foaming furnace at a temperature of about 220°C for about 60 seconds to decompose the foaming agent contained above. By foaming the synthetic resin layer and suppressing foaming in the printed portion containing the foaming inhibitor, a tile-like foamed product having a concave colored checkered pattern was obtained. Next, the surface of the foam was reheated using a far-infrared heater at a temperature below the foaming temperature mentioned above, and a stone-like random pattern was engraved with an unevenness depth of about 1.5 mm to form a cold embossing roll. The convex portions of the tile-like foam are embossed using the ite clearance embossing method, and a concave pattern with lattice repeats is combined with a sharp random concavo-convex pattern with a stone grain pattern on the convex portions. A foamed decorative material for the interior of building materials, which has a high design quality and realizes a remarkable three-dimensional effect, is obtained.

配合A 配  合  B 〔実施例2〕 目付9017/rr?のポリエステル繊維不織布を基材
としこれに一般の塩化ビニルレザーに用いらhている下
引塗料をコーティングし接合層を形成した後、カレンダ
ー法により下記配合Cの発泡剤含有組成物をシート厚が
約0.18mmになる様に積層し、次いで該層表面に下
記配合りの架橋剤を混入した着色インキを用いてリピー
トを有する花柄模様を実施例1と同様の方法を用いて形
成し、これを発泡炉により約210°Cの温度で90秒
間加熱して発泡せしめて、該柄の凸部分厚さが0.9m
m、凹部分の厚みが約0.4朋の凹凸の発泡体を得た。
Mixture A Mixture B [Example 2] Fabric weight 9017/rr? The base material is polyester fiber non-woven fabric, and after coating it with a subbing paint used for general vinyl chloride leather to form a bonding layer, a foaming agent-containing composition of the following formulation C is applied to the sheet thickness by a calendering method. The layers were laminated to a thickness of about 0.18 mm, and then a floral pattern with repeats was formed on the surface of the layer using a colored ink mixed with a crosslinking agent of the following composition using the same method as in Example 1, This was heated in a foaming furnace at a temperature of about 210°C for 90 seconds to foam, and the thickness of the convex part of the handle was 0.9 m.
A foamed material having concavities and convexities with a thickness of about 0.4 m and a concave portion thickness was obtained.

次いでこれを実施例1と同様にクリヤランスエンボス方
法を用いて、ランダム状の布目調の模様を凹凸深度約0
.8問に彫刻した冷エンボスロールを使用して凹凸模様
を付形し、花柄の凹凸模様を有し、しかも該花柄模様の
曲部分に布目模様が表現された実施例1と同様の顕著な
凹凸形状と意匠に優れた車両内装用発泡装飾材を得た。
Next, using the same clear embossing method as in Example 1, a random cloth grain pattern is created with an unevenness depth of approximately 0.
.. A concavo-convex pattern was formed using a cold embossing roll engraved with 8 questions, and the convex-concave pattern was similar to Example 1, in which the concave-convex pattern had a floral pattern, and a cloth pattern was expressed in the curved part of the floral pattern. We have obtained a foam decorative material for vehicle interiors with an excellent uneven shape and design.

配合C 配合D 〔効   果〕 以上の如く本発明は基材に発泡剤を含有した合成樹脂層
を積層し、該層上に発泡抑制剤もしくは架橋剤を混入し
た塗料を用いていわゆるケミカルエンボス法によりリピ
ート柄の凹凸模様を形成し、該凸部にランダム状模様を
彫刻したエンボスロールヲ用いるいわゆるメカニカルエ
ンボス法によりシャープな凹凸模様を施すため、従来製
造し得なかった顕著な立体感と複雑な高意匠性の内装用
発泡装飾材の製造を可能とするばかりでなく、前記ケミ
カルエンボス法を用いることにより高価なエンボスロー
ルを各欄に応じて製造する弊害を排除することが可能と
なり、リピートを有する多種多様の柄模様を任意に選択
し安価に製造することができ、またさらに、該柄と後者
の少数のランダム模様との組合せからなるパターンの模
様によって極めて凹凸の立体感に富んだ高意匠性の発泡
装飾用内装材を得ることができる。
Formulation C Formulation D [Effects] As described above, the present invention uses the so-called chemical embossing method, in which a synthetic resin layer containing a foaming agent is laminated on a base material, and a paint containing a foaming inhibitor or a crosslinking agent is used on the layer. This creates a repeat pattern of concave and convex patterns, and the so-called mechanical embossing method uses an embossing roll with a random pattern engraved on the convex parts to create a sharp concavo-convex pattern, resulting in a remarkable three-dimensional effect and a complex pattern that could not be produced conventionally. In addition to making it possible to manufacture foam decorative materials for interiors with high design quality, using the chemical embossing method described above makes it possible to eliminate the disadvantages of manufacturing expensive embossing rolls according to each column, thereby increasing repeat sales. A wide variety of patterns can be arbitrarily selected and manufactured at a low cost, and furthermore, a high-quality design with an extremely uneven three-dimensional effect can be achieved by a pattern consisting of a combination of the pattern and a small number of random patterns. It is possible to obtain a foamed decorative interior material.

【図面の簡単な説明】[Brief explanation of the drawing]

第1図は本発明の一実施例の発泡前の断面図、第2図は
、その発泡後の断面図、第3図は第2図にさらにエンボ
ス模様を付形した断面図である。 に基材、2:発泡前の合成樹脂層、2パ:発泡層、3:
発泡抑制剤又は架橋剤含有印刷模様、4:常法の印刷模
様、5:リピート模様のない凸部、5′:ランダム状凹
凸模様、6:リピート柄の凹部。
FIG. 1 is a sectional view of an embodiment of the present invention before foaming, FIG. 2 is a sectional view after foaming, and FIG. 3 is a sectional view of FIG. 2 with an additional embossed pattern. Base material, 2: Synthetic resin layer before foaming, 2P: Foamed layer, 3:
Printed pattern containing foam suppressor or crosslinking agent, 4: Conventional printed pattern, 5: Convex portions without repeat pattern, 5': Random uneven pattern, 6: Concave portions with repeat pattern.

Claims (1)

【特許請求の範囲】[Claims]  基材上に発泡剤を含有した合成樹脂層を積層した後、
該層表面に発泡制御剤もしくは架橋剤を混入した塗料を
用いてリピート柄を有する印刷模様を施し、これを加熱
発泡して凹凸模様を有する発泡層とし、次いで上記発泡
層形成時の発泡温度以下の温度を用いて該層を再加熱し
、続いて冷エンボスロールにより該層の上記凸模様の形
成部分に更にシャープな形状の凹凸のランダム状模様を
付形することを特徴とする発泡装飾材の製造方法。
After laminating a synthetic resin layer containing a foaming agent on the base material,
A printed pattern having a repeat pattern is applied to the surface of the layer using a paint mixed with a foaming control agent or a crosslinking agent, and this is heated and foamed to form a foamed layer having an uneven pattern. A foamed decorative material characterized in that the layer is reheated using a temperature of manufacturing method.
JP26771187A 1987-10-23 1987-10-23 Production of foamed decorative material Pending JPH01110123A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP26771187A JPH01110123A (en) 1987-10-23 1987-10-23 Production of foamed decorative material

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP26771187A JPH01110123A (en) 1987-10-23 1987-10-23 Production of foamed decorative material

Publications (1)

Publication Number Publication Date
JPH01110123A true JPH01110123A (en) 1989-04-26

Family

ID=17448488

Family Applications (1)

Application Number Title Priority Date Filing Date
JP26771187A Pending JPH01110123A (en) 1987-10-23 1987-10-23 Production of foamed decorative material

Country Status (1)

Country Link
JP (1) JPH01110123A (en)

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6114008A (en) * 1997-02-20 2000-09-05 Mannington Mills, Inc. Surface coverings having a natural appearance and methods to make a surface covering having a natural appearance
US6228463B1 (en) 1997-02-20 2001-05-08 Mannington Mills, Inc. Contrasting gloss surface coverings optionally containing dispersed wear-resistant particles and methods of making the same
EP1144126A1 (en) 1998-12-22 2001-10-17 Mannington Mills, Inc. Surface covering having a natural appearance and method for making it
US6613256B2 (en) 2001-02-20 2003-09-02 Awi Licensing Company Mechanical embossing texture differentiation between chemically restricted areas and non-restricted areas
EP1382432A2 (en) 2002-07-17 2004-01-21 Armstrong World Industries, Inc. Method and apparatus for process control of mechanical embossing texturing
US6866737B2 (en) 2001-09-18 2005-03-15 Awi Licensing Company Method for mechanically embossing a surface covering using a recyclable solidified slurry embossing tool
US7014802B1 (en) 1997-02-20 2006-03-21 Mannington Mills, Of Delaware, Inc. Methods to make a surface covering having a natural appearance
JP2014069390A (en) * 2012-09-28 2014-04-21 Dainippon Printing Co Ltd Laminate sheet
JP2015193249A (en) * 2014-03-27 2015-11-05 大日本印刷株式会社 transfer sheet and decorative material
WO2021094625A1 (en) * 2019-11-15 2021-05-20 Beaulieu International Group Nv Multilayer floor panel based on a pvc plastisol
US11345116B2 (en) * 2016-07-18 2022-05-31 Beaulieu International Group Nv Multi-layered sheet suitable as floor or wall covering exhibiting a three-dimensional relief and a decorative image

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS55105554A (en) * 1979-02-06 1980-08-13 Toppan Printing Co Ltd Method of producing laminated flooring
JPS56121742A (en) * 1980-03-01 1981-09-24 Jiyouban Kaihatsu Kk Manufacture of high-foaming synthetic resin mold sheet

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS55105554A (en) * 1979-02-06 1980-08-13 Toppan Printing Co Ltd Method of producing laminated flooring
JPS56121742A (en) * 1980-03-01 1981-09-24 Jiyouban Kaihatsu Kk Manufacture of high-foaming synthetic resin mold sheet

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7014802B1 (en) 1997-02-20 2006-03-21 Mannington Mills, Of Delaware, Inc. Methods to make a surface covering having a natural appearance
US6228463B1 (en) 1997-02-20 2001-05-08 Mannington Mills, Inc. Contrasting gloss surface coverings optionally containing dispersed wear-resistant particles and methods of making the same
US6114008A (en) * 1997-02-20 2000-09-05 Mannington Mills, Inc. Surface coverings having a natural appearance and methods to make a surface covering having a natural appearance
EP1144126A1 (en) 1998-12-22 2001-10-17 Mannington Mills, Inc. Surface covering having a natural appearance and method for making it
US6613256B2 (en) 2001-02-20 2003-09-02 Awi Licensing Company Mechanical embossing texture differentiation between chemically restricted areas and non-restricted areas
US7022272B2 (en) 2001-02-20 2006-04-04 Awi Licensing Company Mechanical embossing texture differentiation between chemically restricted areas and non-restricted areas
US7101606B2 (en) 2001-02-20 2006-09-05 Awi Licensing Company Mechanical embossing texture differentiation between chemically restricted areas and non-restricted areas
US6866737B2 (en) 2001-09-18 2005-03-15 Awi Licensing Company Method for mechanically embossing a surface covering using a recyclable solidified slurry embossing tool
EP1382432A2 (en) 2002-07-17 2004-01-21 Armstrong World Industries, Inc. Method and apparatus for process control of mechanical embossing texturing
EP1382432A3 (en) * 2002-07-17 2007-05-02 Armstrong World Industries, Inc. Method and apparatus for process control of mechanical embossing texturing
JP2014069390A (en) * 2012-09-28 2014-04-21 Dainippon Printing Co Ltd Laminate sheet
JP2015193249A (en) * 2014-03-27 2015-11-05 大日本印刷株式会社 transfer sheet and decorative material
US11345116B2 (en) * 2016-07-18 2022-05-31 Beaulieu International Group Nv Multi-layered sheet suitable as floor or wall covering exhibiting a three-dimensional relief and a decorative image
WO2021094625A1 (en) * 2019-11-15 2021-05-20 Beaulieu International Group Nv Multilayer floor panel based on a pvc plastisol
CN114829472A (en) * 2019-11-15 2022-07-29 博优国际集团股份有限公司 Multilayer floor based on PVC (polyvinyl chloride) plastisol

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