JP2003041488A - Method for producing embossed wallpaper - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing an embossed wallpaper enabling accurate transfer of an indented pattern by embossing to give a pattern having high quality. SOLUTION: The medium for the embossed wallpaper is composed of a backing paper 12, a thermoplastic resin layer 14 made of a material containing a thermoplastic resin and applied to the backing paper 12 and a water-insoluble porous ink-receptor layer 16 formed on the thermoplastic resin layer 14. The medium is heated and embossed to form an indented pattern on the ink receptor layer 16 and printed after the heating and embossing treatment by ink-jet printing to apply an image on the ink receptor layer.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing embossed wallpaper having an uneven pattern for decorating the inner wall surface of a building.

[0002]

2. Description of the Related Art There are various kinds of wallpaper as interior materials for buildings, but the most frequently used one is the heat-foamable thermoplastic resin layer provided on the backing paper, on which the pattern is made and the uneven pattern is formed. It is a wallpaper that has been given.

As described in "Converting &Printing", pages 164 to 169 (published by the Processing Technology Research Group), this type of wallpaper production method includes a step of giving an uneven pattern and a step of creating a pattern. There are various combinations.

As described in the above-mentioned document, mechanical embossing is the most frequently used processing method in the step of imparting an uneven pattern. The mechanical embossing is a process in which a layer of vinyl chloride or the like foamed by heating is transferred with an embossing roller to obtain an uneven pattern.

A printing method is used in all the steps of creating a wallpaper pattern. Typical printing methods include gravure printing, screen printing, rotary screen printing and flexo printing.

[0006] The production of wallpaper is performed by combining a process of making a pattern (applying makeup) and a process of giving a concavo-convex pattern, and in particular, a pattern is tending to be multicolored year by year.

[0007]

There are various kinds of patterns, and it takes a lot of cost and time to produce a color separation plate or a printing plate for printing the patterns. Examination of the design of the design requires more trial production than that for practical use, and it is strongly desired to save cost and time.

Up to now, the design of a pattern has been performed by printing. Therefore, it is necessary to prepare a color separation plate from the original image, prepare a printing plate based on the color separation plate, and apply the plate to a printing machine.

The production of a picture pattern by printing has a disadvantage that the process is complicated and requires skill, the cost is high due to the need for expensive dedicated equipment, and the work period is long.

Such an inconvenience is allowed when the same picture is mass-produced, but cost and work-in-progress are major obstacles in proofing a design picture or printing a small quantity of picture.

In such a case, it is conceivable to use an ink jet printing method to create a pattern instead of the conventional printing using a printing plate. However, the conventional medium for embossed wallpaper, which is supposed to create a pattern by printing, has a receptivity for printing ink, but does not have an absorbing power that receives a large amount of ink with a large solvent ratio such as inkjet ink. Missing. Therefore, even if the ink jet ink is directly ejected, the ink tends to be repelled and flow, and thus it is difficult to create a pattern by ink jet printing.

In addition, in the ink most frequently used in ink jet printers, the dye, which is a coloring agent, easily fades or discolors due to heating in the process of foaming or embossing performed after printing a picture. .

It is known as a general technique to enable ink jet printing by coating an ink receptive layer on a sheet that does not absorb ink.

However, the ink receiving layer for the water-based dye ink easily swells with water, and is easily dissolved or gelled.
In addition, because dye ink easily dissolves in water even after drying,
The image, that is, the pattern is easily blurred.

Accordingly, it is an object of the present invention to provide a method of making a practically embossed wallpaper.
Specifically, it is to provide a method for producing an embossed wallpaper, which is capable of favorably transferring an uneven pattern during embossing and forming a high quality pattern.

[0016]

A first embossed wallpaper producing method according to the present invention comprises a backing member, a thermoplastic resin layer provided on the backing member and made of a material containing a thermoplastic resin, For a medium for embossed wallpaper having a water-insoluble porous ink receiving layer provided on a thermoplastic resin layer, a heating step and an embossing step for forming an uneven pattern on the ink receiving layer. Then, after the heating step and the embossing step, an inkjet printing step for recording an image on the ink receiving layer is performed.

The second embossed wallpaper producing method of the present invention provides an embossed wallpaper medium having a backing member and a thermoplastic resin layer made of a material containing a thermoplastic resin provided on the backing member. On the other hand, heating and embossing are performed to form an uneven pattern on the medium surface, and inkjet printing is performed after the heating and embossing to absorb the inkjet ink ejected in the inkjet printing step. The ink receiving layer is formed on the thermoplastic resin layer before the heating step and the embossing step.

[0018]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. The inkjet ink receiving paper for wallpaper of the first embodiment of the present invention, in other words, the inkjet print medium for embossed wallpaper will be described with reference to FIG.

As shown in FIG. 1, an inkjet print medium 10 for embossed wallpaper includes a backing paper 12 and
An unfoamed thermoplastic resin layer 14 containing a foaming agent and an ink receiving layer 16 formed of a water-insoluble porous layer capable of absorbing and fixing a liquid pigment inkjet ink are provided on one surface thereof. Have

The backing paper 12 has an unfoamed thermoplastic resin layer 14
It is used as an adhesive surface for supporting a paper and attaching a wallpaper, and paper, non-woven fabric, synthetic paper, titanium paper, glass non-woven fabric or the like is used.

The unfoamed thermoplastic resin layer 14 is a coating layer in which a thermoplastic resin, a plasticizer, a stabilizer, a foaming agent, a lubricant, an antioxidant, a filler, a surfactant and the like are uniformly mixed. Polyvinyl chloride resin is most commonly used as the thermoplastic resin, but other than that, polyacrylic resin, polyvinyl acetate resin, polyurethane resin, polystyrene resin, polyethylene resin, synthetic rubber and the like are applied.

As the plasticizer, dioctyl phthalate,
Phthalates such as dibutyl phthalate and butyl benzyl phthalate, phosphoric esters, chlorinated fatty acid esters, chlorinated paraffins, epoxies, polyesters and adipic ester plasticizers are used.

The stabilizer controls the decomposition temperature of the foaming agent, that is, the foaming temperature, and a composite stabilizer such as cadmium / barium / zinc, a lead stabilizer, a tin stabilizer, a calcium stabilizer and the like are applied. To be done.

As the foaming agent, dinitropentamethylenetetramine, azodicarbonamide, toluenesulfonylhydrazine, azobisisobutylnitrile, benzenesulfonylhydrazine and the like are used.

The lubricant improves the workability of embossing, and paraffin type, low molecular weight polyolefin type, stearic acid, stearic acid ester, stearyl alcohol, petrolatum, polyglycol ester of fatty acid and the like are used.

The filler is for obtaining texture and whiteness, and calcium carbonate, calcium hydroxide, zinc oxide, magnesium oxide, inorganic spheres, organic hollow spheres and the like are used.

As the surfactant for emulsifying the thermoplastic resin, phosphoric acid monoester, phosphoric acid diester, polyoxyethylene sorbitan monooleate, polyoxyethylene lauryl ether, polyethylene glycol monolaurylate and the like are added.

These mixtures are coated on a backing paper so that the dried and gelled coating film has a thickness of about 0.1 to 0.3 mm. Further, the formulation is adjusted by heating at a temperature of 180 ° C. to 230 ° C. for several tens of seconds to 2 minutes so that a sufficient foaming state is obtained. The total thickness after foaming is 0.
When the thickness is about 5 mm to 1.5 mm, it is possible to accurately form an uneven pattern having an appropriate depth during embossing, which is extremely convenient.

Porous inkjet ink receiving layer 16
The ink for forming the pattern is heated at 180 to 230 ° C. for several tens of seconds to 2 minutes in the wallpaper making process, as described later.

Dye inks that are often used in ink jet printers are not preferable because they are decomposed by heat and are discolored or discolored, and it is preferable to use pigment inks that are resistant to heat. In addition, dye ink is not preferable because the pattern flows or bleeds with water after wallpaper is made,
It is preferable to use a pigment ink.

Accordingly, the ink jet ink receiving layer 16
Must be in a porous state so as to absorb the solvent of the pigment ink and retain the pigment particles without dropping off.

The porous ink-receiving layer 16 can be formulated in various ways. Fine particles of silica, alumina, etc., alone or in combination, are used as an acrylic resin, a polymethylmethacrylate resin, or a copolymer of methylmethacrylate and an amide resin. It is prepared by coating and drying a liquid dispersed in a binder resin such as resin, polyester resin, ethylene-vinyl acetate copolymer polymer.

In particular, since the ethylene-vinyl acetate copolymer polymer is rubbery, it has a function of making the ink receiving layer soft, and the ink receiving layer is cracked or peeled off even if a large deformation is applied during embossing. Can be prevented.

Therefore, it is preferable to add a rubber-like binder such as an ethylene-vinyl acetate copolymer polymer in the binder resin in an amount of 20 to 100% by weight or more.

In the case of an ink receiving layer which can obtain good ink absorption and an appropriate print dot size, the film in a dried state is a porous film having fine particles connected by a binder resin and having a strong light scattering property, and thus a scanning electron microscope. The agglomerated particles and pores observed in 1 have a debris shape with a diameter of 1 to 30 μm. The volume ratio of the holes at this time is 20 to 70.
%. That is, the preferable ink receiving layer 16 is 1 to 30.
It has a micron pore size and its pore volume ratio is 20-7.
Since 0% of the fine particles themselves are porous or are agglomerates of small-sized particles, they have the property of absorbing the solvent of the pigment ink. An image is formed by the permeation and absorption of the pigment particles on the surface of the fine particles.

Next, a process of manufacturing the ink jet print medium for embossed wallpaper will be described. First,
As shown in FIG. 1A, as a starting material, a backing paper 12, an unfoamed thermoplastic resin layer 14 provided on one surface thereof, and an ink receiving layer 16 capable of absorbing and fixing a pigment inkjet ink. Prepare a material having

Next, this material is introduced into a heating device such as an oven and heated at a temperature of 180 ° C. to 230 ° C. for several tens of seconds to 2 seconds.
The unfoamed thermoplastic resin layer 14 is heated and foamed by heating for about a minute. By this heating, the unfoamed thermoplastic resin 14 becomes the already foamed thermoplastic resin layer 20 having a thickness of about 3 to 5 times, as shown in FIG.

Subsequently, the heated embossing roller or embossing plate is attached to the porous ink jet ink receiving layer 16
It is applied from the side to pattern unevenness. In this embossing process, the heat-foamed resin layer 20 has thermoplasticity and has a large number of holes, so that the resin layer 20 is easily adapted to the unevenness of the embossing roller. Therefore, as shown in FIG. 1C, the foamed thermoplastic resin layer 20 becomes the foamed embossed thermoplastic resin layer 22 to which the concavo-convex pattern of the embossing roller or the embossing plate is faithfully transferred. A form of inkjet print medium 10 "for embossed wallpaper is obtained.

For this ink jet print medium 10 "for embossed wallpaper, as shown in FIG.
An embossed wallpaper is obtained simply by jetting a pigment ink in a pattern with an inkjet printer to form a pattern 18 on the porous inkjet ink receiving layer 16.

Although the foaming step and the embossing step are described as separate steps here, the embossing step is preferably performed in a heated state, and the foaming step and the embossing step can be performed simultaneously.

In the print medium of this embodiment, since embossing is performed before printing, embossing can be left to a factory capable of processing a large amount. Further, since the embossing process accompanied by heating after printing is unnecessary, it is possible to form a high-quality image with little discoloration or change of the image.

[0042]

According to the production method of the present invention, it is possible to obtain an embossed wallpaper on which a good uneven pattern is formed and a high quality image is formed.

[Brief description of drawings]

FIG. 1 is a diagram illustrating a step of producing an inkjet ink image receiving paper for wallpaper according to a first embodiment of the present invention.

FIG. 2 is a cross-sectional view of a wallpaper produced by using the inkjet image-receiving paper for wallpaper shown in FIG.

[Explanation of symbols]

10 ... Inkjet ink receiving paper for wallpaper, 12 ... Backing paper, 14 ... Unfoamed thermoplastic resin layer, 16 ... Porous inkjet ink receiving layer

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Claims (4)

[Claims] 1. A backing member, a thermoplastic resin layer provided on the backing member and made of a material containing a thermoplastic resin, and a water-insoluble porous ink provided on the thermoplastic resin layer. A receiving layer and an embossed wallpaper medium having a heating step and an embossing step for forming an uneven pattern on the ink receiving layer, and after the heating step and the embossing step, on the ink receiving layer. A method for producing embossed wallpaper, which comprises performing an inkjet printing process for recording an image on a sheet. 2. The embossing process according to claim 1, wherein the embossing process is performed after the heating process, and is performed while the medium for embossing wallpaper is warmed by the heating process. How to create a wallpaper. 3. The method for producing an embossed wallpaper according to claim 1, wherein the embossing step is performed simultaneously with the heating step. 4. An embossed wallpaper medium having a backing member and a thermoplastic resin layer made of a material containing a thermoplastic resin provided on the backing member, for forming an uneven pattern on the medium surface. Is heated and embossed, and inkjet printing is performed after the heating and embossing, and the ink receiving layer for absorbing the inkjet ink ejected in the inkjet printing is the heating and embossing. The method for producing an embossed wallpaper, characterized in that it is formed on the thermoplastic resin layer before.