JPS6132159B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for forming a pattern on a decorative material, and more particularly to a method for highly efficiently forming a pattern on a decorative material that has a novel three-dimensional effect, a sense of fluidity, and is highly designed.

Conventionally, methods for imparting patterns to interior materials include gravure printing, lithographic press, calendar processing, etc.
For example, in the case of gravure printing, the pattern does not have a three-dimensional effect and the design is unsatisfactory. Furthermore, since the pattern layer itself is thin, it also has the disadvantage of being susceptible to abrasion. Furthermore, the method of heating and pressing polyvinyl chloride (PVC) gel chips using a lithographic press certainly produced a pattern with a three-dimensional effect, but it was not possible to obtain a long sheet material and productivity was low.

Furthermore, in the conventionally frequently used calendering method, that is, a method in which a pellet pattern material is sprinkled on a PVC resin that has been heated and softened to the extent that it can be plasticized, and the sheet is rolled after being formed into a certain sheet shape in advance. Due to the shear stress during rolling, the pattern changes only in the vertical direction in the form of stripes, and in the width direction, the pattern is only partially colored areas that exist randomly, and as a result, the pattern tends to deviate and lack regularity. There were many aspects that lacked design. Furthermore, with conventional calendering, the pattern tends to run in streaks as described above, but in order to prevent this, the sheet must be cut into a predetermined length at the stage of forming the pattern material into a sheet before rolling it. However, a method was also adopted in which the cut sheets were turned 90 degrees and rolled, but this method was extremely inefficient.

An object of the present invention is to provide a method for forming decorative material patterns with a three-dimensional effect, a fluid feel, and a high design quality with high productivity.

An object of the present invention is to provide a pattern forming method in which highly designed patterns are formed with appropriate regularity not only in the longitudinal direction but also in the width direction of a pattern material sheet.

An object of the present invention is to provide an excellent pattern forming method in which any desired pattern can be obtained based on a combination of different printing patterns, and multicolor effects can also be easily achieved.

An object of the present invention is to provide an excellent pattern forming method that can prevent the pattern from stretching and streaking during rolling.

The above objects of the present invention are achieved by continuously rolling a thermoplastic resin pattern sheet having a printed pattern having a directionality perpendicular to the machine direction of the pattern sheet.

The present invention will be explained in detail below. In the present invention, the rollable thermoplastic resin sheet is formed mainly of PVC, polyethylene, polypropylene, ethylene-vinyl acetate copolymer, acrylic acid-based or acrylic ester-based polymer, and various other thermoplastic resins. It may be a sheet that has been

Various known methods can be used to impart a printing pattern to such a thermoplastic resin sheet, such as a method of printing on the surface of the sheet with appropriate ink, a printing method such as screen printing,
A method of printing a pattern using ink on the surface of a thermoplastic resin sheet formed on a release paper, drying the ink, and removing the release paper to obtain a pattern material sheet;
Alternatively, a pattern material sheet may be obtained by directly printing a pattern with a thermoplastic resin-containing ink on a release paper to a predetermined thickness, and after drying the ink, removing the release paper.

In the present invention, the printed pattern has a directionality perpendicular to the flow direction of the pattern material sheet, so in addition to the change in the pattern in the flow direction, the directionality of the pattern in the width direction can also be obtained, and the resulting pattern The two-dimensional spread of will become even more remarkable. Further, by making at least one part of the constituent components of the pattern material sheet a transparent or translucent thermoplastic resin, the three-dimensional effect of the pattern obtained can be significantly increased. This transparent or translucent resin may coat the front or back side of the printed pattern on the pattern material sheet, or may be used as part of the printed pattern.

In the present invention, the pattern material sheet obtained above is then rolled. That is, the sheet is made of thermoplastic resin, which is softened and deformed by heating and rolling, and is a thin continuous sheet after rolling. During rolling, heating is usually carried out, but if the amount of heat in the rolling means is insufficient, preheating may be used. Calendar rolls are generally used as the rolling means, but any other known continuous rolling method such as roll press, Oma press, funnel press, etc. may be used. For example, when a calender roll is used, banks may be formed in the nip of the calender roll to the extent that the regularity of the printing pattern is not lost, depending on the customer's preference.

In the present invention, if the pattern material sheet is deformable during rolling, the desired pattern related to the present invention can be obtained, but it is better to form the pattern material sheet at the lowest possible temperature to achieve the final decorative material pattern. The surface is smooth. The obtained decorative material is used as it is as a decorative covering material, or it is used by being rolled up or laminated on a base material without being rolled up. The base material is foamed or non-foamed synthetic resin sheet, non-woven glass fabric, scrim, asbestos, etc., which are conventionally known as interior lining materials.
It may also be felt, rock wool paper, cellulose paper, or a composite thereof. Furthermore, when a plurality of decorative sheets obtained according to the present invention are used in a laminated manner, the three-dimensional effect is further increased, resulting in a preferable result.

This will be explained below based on the drawings. FIG. 1 is a process diagram of pattern formation according to the present invention, in which 1 is a thermoplastic resin printing sheet, 2, 4, 6 are printing devices, 2', 4', 6'
is the support roll for the printed sheet. For example, a printing pattern of each color is applied to the printing sheet by a printing device, and each ink is dried by heaters 3, 5, and 7. The thickness of the patterned sheet 8 thus obtained is usually about 0.3 to 2 mm, preferably about 0.5 mm.
~1.5mm. The patterned material sheet 8 is heated to about 50 DEG -150 DEG C. by a preheater 9, if necessary, and sent to the nip of rolling rolls 10, 10'. The rolling rolls are heated to about 140 to 200°C, rolling and deforming the pattern material sheet and gelling it. The decorative material 11 of the present invention is obtained through the above steps. Various thicknesses of the decorative material can be obtained, but preferably about 0.2
~1.5mm. During rolling, banks (not shown) may be formed at the nip of the rolls or the patterned sheets may be folded to the extent that the regularity of the pattern of the resulting decorative material is not lost.

FIGS. 2 and 3 show a state in which a printed pattern is formed on a ground color portion of a patterned material. The printed pattern exhibits orientation in the width direction, and when a pattern material sheet with such a printed pattern is rolled, there is a wide variation in both the machine direction and the width direction, as shown in Figures 4 and 5, respectively. Decorative materials are obtained.

The pattern forming method of the present invention described above exhibits many excellent effects as described below.

(1) Since the pattern material sheet of the present invention has a printed pattern, the pattern of the decorative material obtained has a certain degree of regularity, and the pattern can change not only in the vertical direction but also in the width direction of the pattern material sheet,
Highly designed patterns with a three-dimensional and fluid feel can be obtained with high efficiency. Furthermore, since the printed pattern has a directionality perpendicular to the flow direction of the pattern material sheet, changes in the pattern in the width direction are also promoted, and the two-dimensional spread of the resulting pattern becomes even more remarkable.
On the other hand, although patterns simply printed are arranged regularly, they do not provide the three-dimensional effect and fluidity of the present invention.

(2) By further changing the printing pattern,
Alternatively, the pattern can be easily changed by appropriately combining different printing patterns, and multicolor effects can also be easily achieved by adding printing means and changing the ink. On the other hand, with the conventional calendar method, it is necessary to go through the process of creating a colored sheet and pelletizing each color of pattern material, and it is extremely uneconomical as it requires a large number of pellets to be kept in stock at all times. . In addition, when patterning is done by the calendar method, the pattern tends to be unevenly distributed because only partial colored areas exist randomly, and as in the above-mentioned invention, a pattern with some degree of regularity, especially a multicolored pattern, is repeated. The pattern forming method that can be obtained by

(3) In addition, in the present invention, by thinning the lines composing the pattern and the directionality arranged in the width direction of the pattern of the printed pattern, it is possible to obtain a highly designed pattern without the pattern flowing in a streaky manner. On the other hand, in the conventional calendering method, in order to prevent the pattern from becoming streaky, the pattern sheet was cut into a predetermined length, and the direction was turned 90 degrees before rolling, which was extremely inefficient.

As described above, the present invention is an excellent pattern forming method having various effects. The pattern forming method of the present invention can be applied to a wide variety of fields, such as cloud patterns and marble patterns suitable for building materials such as flooring and wall materials, furniture and other interior goods, and various other covering decorative materials. It is useful for forming patterns such as

The present invention will be explained below with reference to Examples.

Example 1 PVC (=1000) 100 parts by weight Plasticizer (DOP) 45 Calcium carbonate 5 Ba-Zn stabilizer 2 Mineral spirits Small amount Pigment Small amount Colored paste sol of the above composition on a PVC transparent sheet Printing was carried out using three screen printers, and immediately dried in a hot air oven at 180°C to obtain a pattern material sheet with a thickness of 0.6 mm. This sheet is preheated at 110℃, then sent to the nip part of a calender roll at about 180℃ and rolled.
It was made into a 0.4mm thick sheet. A thin, soft decorative sheet with a high degree of design that has both a two-dimensional expanse and a three-dimensional effect was obtained.

Example 2 A colored paste with the same formulation as in Example 1 was applied on a transparent PVC sheet obtained by applying PVC paste to release paper and drying it in a pregel state using the same three screen printing machines as in Example 1. After that, a transparent PVC paste was applied evenly on top of the paste, and immediately dried in a hot air dryer at 180℃ to remove the release paper.The pattern layer with the printed pattern was sandwiched between the upper and lower transparent resin layers. Sandwich shape 1.0mm
A thick sheet of patterned material was obtained. This sheet was preheated at 80℃ and sent to the nip section of a calender roll at about 180℃, and the resulting decorative sheet was rolled with some folds and a bank at the nip.
It was 0.75mm thick and had a highly designed marble pattern that had both two-dimensional expanse and three-dimensional effect without losing the periodicity of the entire pattern. This decorative sheet was laminated to PVC foam and was suitable as a flooring material.

[Brief explanation of the drawing]

FIG. 1 is a process diagram of the pattern forming method of the present invention,
FIGS. 2 and 3 are print pattern diagrams of the present invention, and FIGS. 4 and 5 are pattern diagrams of decorative materials that are final products corresponding to FIGS. 2 and 3, respectively.

Claims (1)

[Scope of Claims] 1. A method for forming a pattern on a decorative material, which comprises continuously rolling a thermoplastic resin pattern material sheet having a printed pattern having a directionality perpendicular to the flow direction of the pattern material sheet. 2. The pattern forming method according to claim 1, wherein at least one of the constituent components of the pattern material sheet is a transparent or translucent thermoplastic resin.