Method for producing a recorded material having a three-dimensional image, apparatus for producing a recorded material having a three-dimensional image, and liquid composition

Abstract

To provide a production method of a recorded matter comprising a three-dimensional image capable of easily forming a three-dimensional image on which a clear uneven feeling is expressed and suppressing peeling of a foam formation layer from a substrate.SOLUTION: A production method of a recorded matter having a three-dimensional image comprises the steps of: applying foam formation promotion fluid which contains a foam formation promotion component and water to a recording medium which has a substrate and a foam formation layer including foam formation particles and a binder resin and provided on the substrate; and heating the foam formation layer for foaming the foam formation particles thereby forming a three-dimensional image. The foam formation particles include a shell layer containing a thermoplastic resin, and a volatile material encapsulated in the shell layer, the foam formation promotion component includes a compound having no hydroxy group, and a temperature at which the foam formation layer of the recording medium to which the foam formation promotion fluid is applied, is equal to or greater than a foam formation start temperature of the foam formation particles on which the foam formation promotion component acts, and less than a maximum foam formation temperature of the foam formation particles.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a recording medium having a three-dimensional image, an apparatus for manufacturing a recording medium having a three-dimensional image, and a foaming accelerating liquid.

Background Art

[0002] Conventionally, three-dimensional images such as wallpapers and Braille have been formed by an overprinting method using UV ink, a physical extrusion method such as embossing, a 3D printer, and a printing method using a thermally expandable plastic foam. Among them, it is known that a thermally expandable plastic foam exhibits functions such as heat insulation, heat insulation, sound insulation, sound absorption, vibration prevention, and weight reduction depending on the foam material and the state of the formed bubbles.

[0003] In the field of wallpapers, a technique is known in which an azo compound such as azodicarbonamide (ADCA) is used as a foaming agent, and a foaming layer containing such a foaming agent and a resin such as polyvinyl chloride is foamed to form an uneven structure. For example, a method has been proposed in which an image is recorded with an ink containing a light-absorbing coloring material and then irradiated with light to generate a difference in heating according to the light absorption, thereby selectively raising the foaming layer to form a three-dimensional image (Patent Document 1).

[0004] Further, a planar image is recorded on the surface of a foaming sheet, and a grayscale image (light absorption pattern) based on distance image data representing a three-dimensional shape is formed on the surface of the base material layer of the foaming sheet. Then, a method has been proposed in which light is irradiated from the base material layer side to generate heat according to the grayscale of the image, and the foaming sheet is expanded according to the distance image data (Patent Document 2). Furthermore, a method has been proposed in which a liquid for suppressing, preventing, or accelerating expansion is attached to a thermally expandable layer containing polyvinyl chloride or an acrylic resin and a chemical foaming agent, and then heated to form an uneven structure (Patent Document 3). In addition, a method has been proposed in which a plasticizer for the shell wall resin of a foaming capsule is applied or printed on a three-dimensional image forming layer of a recording material for three-dimensional image formation provided with a three-dimensional image forming layer containing foaming capsules, and then the foaming capsules are heated and foamed to form a three-dimensional image (Patent Document 4).

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Summary of the Invention

Problems to be Solved by the Invention

[0006] However, in the method proposed in Patent Document 1, it is necessary to apply an ink containing a highly light-absorbing coloring material such as black ink to the portion to be thermally foamed. Therefore, it is difficult to foam the portion to which an ink containing a coloring material with low light absorption is applied. Further, in the case of the method proposed in Patent Document 2, since a light-absorbing pattern is not directly formed on the foaming layer, it has been difficult to foam sufficiently. Furthermore, in the method proposed in Patent Document 3, since a chemical foaming agent is used, variations are likely to occur in the foaming site, and it has been difficult to express a clear uneven feeling. Also, in the method proposed in Patent Document 4, since the three-dimensional image forming layer may peel off from the support when the foamable capsules are foamed, further improvement has been required.

[0007] Accordingly, an object of the present invention is to provide a method for manufacturing a recording material having a three-dimensional image, which can easily form a three-dimensional image with a distinct uneven feeling and suppress peeling of the foamed layer from the base material. Another object of the present invention is to provide a manufacturing apparatus for a recording material having a three-dimensional image, which can easily form a three-dimensional image with a distinct uneven feeling and suppress peeling of the foamed layer from the base material. Further, an object of the present invention is to provide a foaming promoting liquid used in the method for manufacturing a recording material having the above three-dimensional image.

Means for Solving the Problems

[0008] That is, according to the present invention, a recording medium having a base material and a foamed layer provided on the base material and containing foaming particles that foam by heat and a binder resin is provided with a foaming promoting liquid containing a foaming promoting component that lowers the foaming start temperature of the foaming particles and water, and heating the foamed layer of the recording medium to which the foaming promoting liquid is applied to foam the foaming particles to form a three-dimensional image. A method for manufacturing a recording material having a three-dimensional image, wherein the foaming particles have a shell layer containing a thermoplastic resin and a volatile material encapsulated in the shell layer, the binder resin includes a water-insoluble resin, the foaming promoting component includes a compound having no hydroxyl group, and the temperature for heating the foamed layer of the recording medium to which the foaming promoting liquid is applied is not less than the foaming start temperature of the foaming particles on which the foaming promoting component acts and less than the maximum foaming temperature of the foaming particles. A method for manufacturing a recording material having a three-dimensional image is provided.

[0009] Also, according to the present invention, there is provided an apparatus for manufacturing a recorded article having a three-dimensional image, the apparatus comprising: a substrate; and a foam promoting liquid applying means for applying a foam promoting liquid containing a foam promoting component for lowering the foam start temperature of the foam particles and water to a recording medium having a foam layer provided on the substrate and containing foam particles that foam by heat and a binder resin; and a heating means for heating the foam layer of the recording medium to which the foam promoting liquid has been applied to foam the foam particles and form a three-dimensional image, wherein the foam particles have a shell layer containing a thermoplastic resin and a volatile material encapsulated in the shell layer, the binder resin contains a water-insoluble resin, the foam promoting component contains a compound having no hydroxyl group, and the temperature for heating the foam layer of the recording medium to which the foam promoting liquid has been applied is equal to or higher than the foam start temperature of the foam particles on which the foam promoting component has acted and lower than the maximum foam temperature of the foam particles.

[0010] Furthermore, according to the present invention, there is provided a foam promoting liquid used in a method for manufacturing a recorded article having a three-dimensional image, the method comprising: a step of applying a foam promoting liquid containing a foam promoting component for lowering the foam start temperature of the foam particles and water to a recording medium having a foam layer provided on the substrate and containing foam particles that foam by heat and a binder resin; and a step of heating the foam layer of the recording medium to which the foam promoting liquid has been applied to foam the foam particles and form a three-dimensional image, wherein the foam particles have a shell layer containing a thermoplastic resin and a volatile material encapsulated in the shell layer, the binder resin contains a water-insoluble resin, the foam promoting component contains a compound having no hydroxyl group, and the temperature for heating the foam layer of the recording medium to which the foam promoting liquid has been applied is equal to or higher than the foam start temperature of the foam particles on which the foam promoting component has acted and lower than the maximum foam temperature of the foam particles.

Effects of the Invention

[0011] According to the present invention, it is possible to provide a method for manufacturing a recording medium having a three-dimensional image, which can easily form a three-dimensional image with a distinct uneven feeling and suppress peeling of the foam layer from the base material.

[0012] Further, according to the present invention, it is possible to provide a manufacturing apparatus for a recording medium having a three-dimensional image, which can easily form a three-dimensional image with a distinct uneven feeling and suppress peeling of the foam layer from the base material.

[0013] Furthermore, according to the present invention, it is possible to provide a foam promoting liquid used in the method for manufacturing a recording medium having the above three-dimensional image.

Brief Description of the Drawings

[0014]

Figure 1

Figure 2

Embodiments for Carrying Out the Invention

[0015] Hereinafter, the present invention will be described in more detail by giving preferred embodiments. Hereinafter, the aqueous ink for inkjet may be simply referred to as "ink". Physical property values are values at normal temperature (25°C) unless otherwise specified.

[0016] <Method for Manufacturing a Recording Medium Having a Three-Dimensional Image> A method for manufacturing a recording medium having a three-dimensional image of the present invention (hereinafter, also simply referred to as "method for manufacturing a recording medium") includes a step of applying a foam-promoting liquid to a recording medium and a step of foaming foam particles to form a three-dimensional image. As the recording medium, a substrate and a foam layer provided on the substrate and containing foam particles that foam by heat and a binder resin are used. In the step of applying the foam-promoting liquid to the recording medium, a foam-promoting liquid containing a foam-promoting component that lowers the foam start temperature of the foam particles is applied to the recording medium. In the step of foaming the foam particles to form a three-dimensional image, the foam layer of the recording medium to which the foam-promoting liquid has been applied is heated to foam the foam particles and form a three-dimensional image. Further, the foam particles have a shell layer containing a thermoplastic resin and a volatile material encapsulated in the shell layer. The temperature at which the foam layer of the recording medium to which the foam-promoting liquid has been applied is heated is equal to or higher than the foam start temperature of the foam particles on which the foam-promoting component has acted and lower than the maximum foam temperature of the foam particles. Here, the maximum foam temperature of the foam particles means the maximum foam temperature of the foam particles on which the foam-promoting component has not acted.

[0017] In the method for manufacturing a recorded object of the present invention, a foaming promoting liquid containing a foaming promoting component is applied to a recording medium having a foaming layer containing foamed particles. The foaming promoting component is a component capable of lowering the foaming start temperature of the foamed particles. That is, among the foamed particles, the foaming start temperature of the foamed particles in the foaming layer of the recording medium to which the foaming promoting liquid is applied is lowered. Therefore, after the application of the foaming promoting liquid, when the foaming layer of the recording medium is heated to a temperature equal to or higher than the foaming start temperature of the foamed particles on which the foaming promoting component acts and lower than the maximum foaming temperature of the foamed particles, the foamed particles in the foaming layer to which the foaming promoting liquid is applied can be efficiently foamed. Thereby, a three-dimensional image with a distinct concavo-convex structure is formed, and the intended recorded object can be obtained. Further, a compound having no hydroxyl group is used as the foaming promoting component. The reason why the foaming of the foamed particles during heating is promoted by this foaming promoting component is not necessarily clear. However, the inventors presume that the softening of the shell layer of the foamed particles and the binder resin in the foaming layer is further promoted by the foaming promoting component, and the foamability of the foamed particles is improved. Also, the temperature for heating the foaming layer to which the foaming promoting liquid is applied is preferably equal to or higher than the foaming start temperature of the foamed particles on which the foaming promoting component acts and lower than the maximum foaming temperature of the foamed particles on which the foaming promoting component acts. Thereby, since the foaming by heating of the foamed particles on which the foaming promoting component acts can be effectively performed, a three-dimensional image with a clearer concavo-convex structure can be formed. Also, the temperature for heating the foaming layer to which the foaming promoting liquid is applied is preferably equal to or higher than the foaming start temperature of the foamed particles on which the foaming promoting component acts and lower than the foaming start temperature of the foamed particles on which the foaming promoting component does not act. Thereby, while suppressing the foaming by heating of the foamed particles on which the foaming promoting component does not act, the foaming by heating of the foamed particles on which the foaming promoting component acts can be performed, so that a three-dimensional image with a clearer concavo-convex structure can be formed.

[0018] The foaming accelerator liquid contains water together with a foaming accelerator component. On the other hand, by using a water-insoluble resin as the binder resin contained in the foaming layer of the recording medium, dissolution of the binder resin by water in the foaming accelerator liquid can be suppressed. As a result, a decrease in the adhesion between the base material and the foaming layer can be suppressed, and peeling of the foaming layer from the base material when the foaming particles foam can be suppressed.

[0019] The foaming start temperature and the maximum foaming temperature of the foaming particles to which the foaming accelerator component has been applied can be measured by the method shown below. First, in order to make the foaming particles in a state where the foaming accelerator component is acting, the foaming particles are immersed in the foaming accelerator liquid containing the foaming accelerator component for 10 seconds. Using 25 μg of the foaming particles immersed in the foaming accelerator liquid as a sample, it is placed in an aluminum container with a diameter of 7 mm and a depth of 1 mm. The aluminum container is attached to a thermomechanical analyzer, and while applying a load of 0.1 N from above to the foaming particles, it is heated at a heating rate of 5 °C / min from 60 °C to 200 °C, and the displacement amount in the vertical direction of the measurement terminal (the displacement amount of the height of the part occupied by the sample) is measured. Then, the temperature at the time when the displacement starts is defined as the foaming start temperature of the foaming particles to which the foaming accelerator component has been applied. Also, the temperature at the time when the displacement amount becomes maximum is defined as the maximum foaming temperature of the foaming particles to which the foaming accelerator component has been applied. In addition, the foaming start temperature and the maximum foaming temperature of the foaming particles to which the foaming accelerator component has not been applied mean the following temperatures. That is, except for using the foaming particles to which the foaming accelerator component has not been applied as a sample, the temperature at the time when the displacement starts and the temperature at the time when the displacement amount becomes maximum, which are measured in the same manner as in the case of the foaming particles to which the foaming accelerator component has been applied, are meant respectively.

[0020] The method of heating the foaming layer to which the foaming accelerator liquid has been applied may be any method that uses a heating device capable of heating the foaming particles in the foaming layer to a desired temperature.

[0021] Before or after applying the foaming accelerator liquid to the foaming layer, or before or after heating the foaming layer to which the foaming accelerator liquid has been applied, an ink containing a dye or pigment as a coloring material may be applied to the recording medium to record (print) an arbitrary image. The printing is not limited to an inkjet recording method of applying ink by an inkjet method. For example, it may be an electrophotographic method using toner, or a printing method such as latex, UV, and sublimation transfer. Among them, it is preferable to record an image by an inkjet recording method in terms of being able to record a finer image.

[0022] (Recording medium) FIG. 1 is a cross-sectional view schematically showing an example of a recording medium used in the method for manufacturing a recorded matter having a three-dimensional image of the present invention. As shown in FIG. 1, the recording medium 10 has a base material 11 and a foaming layer 12 provided on the base material 11 and containing foaming particles 13 that foam by heat. Hereinafter, the details of the recording medium used in the method for manufacturing a recorded matter of the present invention will be described.

[0023] [Base material] The base material 11 functions as a support for supporting the foaming layer 12 (FIG. 1). The type of the base material is not particularly limited. Examples of the base material include paper made of ordinary natural pulp; kenaf paper; plastic film sheets such as polypropylene, polyethylene, and polyester; so-called synthetic paper or non-woven fabric obtained by papering synthetic fibers, synthetic pulp, and synthetic resin films; and the like.

[0024] [Foaming layer] As shown in FIG. 1, the foaming layer 12 is a layer containing foaming particles 13 and a binder resin 14 provided on at least one surface of the base material 11. The foaming particles 13 are thermally expandable microcapsules having a capsule-shaped shell layer 15 containing a thermoplastic resin and a volatile material 16 encapsulated in the shell layer 15. When heat is applied to the foaming particles 13, the thermoplastic resin constituting the shell layer 15 softens, and the volatile material 16 encapsulated in the shell layer 15 vaporizes and expands in volume. Therefore, the foaming particles 13 expand like balloons.

[0025] Examples of the thermoplastic resin contained in the shell layer include polystyrene, styrene-acrylic acid ester copolymer, polyamide resin, polyacrylate, polyvinylidene chloride, polyacrylonitrile, polymethyl methacrylate, vinylidene chloride-acrylonitrile, methacrylic acid ester-acrylic acid copolymer, vinylidene chloride-acrylic acid copolymer, vinylidene chloride-acrylic acid ester copolymer, and the like.

[0026] Examples of the volatile material include low molecular weight hydrocarbons such as ethane, ethylene, propane, propene, n-butane, isobutane, n-pentane, isopentane, neopentane, n-hexane, heptane, petroleum ether; CCl 3 F, CCl 2 F 2 、CClF 3 、CClF 2 -CClF 2 and other chlorofluorocarbons; tetraalkylsilanes such as tetramethylsilane, trimethylethylsilane, trimethylisopropylsilane, trimethyl-n-propylsilane; and the like. Among them, the volatile material is preferably a hydrocarbon having a molecular weight of 120 or less. Also, there is no particular limitation on the lower limit of the molecular weight of the volatile material (hydrocarbon), but for example, it is preferably 50 or more. The content of the foamed particles in the foamed layer is preferably 5% by mass or more and 95% by mass or less based on the total mass of the foamed layer.

[0027] The foamed layer 12 contains a binder resin 14 in order to enhance the adhesion to the base material 11 (Fig. 1). When the foamed particles in the foamed layer are foamed by heat, the binder resin plays an important role in suppressing the peeling of the foamed layer from the base material. As the binder resin, a water-insoluble resin is used. Since the binder resin contains a water-insoluble resin, it becomes difficult for the binder resin to be dissolved even by the water in the foaming promoting liquid, so that it is possible to suppress a decrease in the adhesion between the foamed layer and the base material due to the foaming promoting liquid. Further, even when an aqueous ink containing water is applied to the recording medium, for the same reason, it is possible to suppress a decrease in the adhesion between the foamed layer and the base material. Here, the water-insoluble resin means a resin in which 95% by mass or more remains when the resin is immersed in warm water at 80°C for 2 hours. The water-insoluble resin is preferably at least one selected from the group consisting of an acrylic resin and a urethane resin. Further, the water-insoluble resin is more preferably at least one selected from the group consisting of an acrylic resin having no ester group and a urethane resin having no ester group. And, the water-insoluble resin is preferably a non-water-absorbing resin. The content of the water-insoluble resin in the foamed layer is preferably 10% by mass or more and 95% by mass or less based on the total mass of the foamed layer. Further, the foamed layer may contain a water-soluble resin together with the water-insoluble resin as long as the effects of the present invention can be obtained. Further, the glass transition temperature of the binder resin is preferably -10°C or higher and 30°C or lower. By setting the glass transition temperature of the binder resin within the above range, it is possible to suppress the binder resin from hindering the foaming of the foamed particles.

[0028] The mass ratio of the foamed particles to the binder resin is preferably foamed particles: binder resin = 5:95 to 90:10. By setting the mass ratio of the foamed particles to the binder resin within the above range, it is possible to improve both the foamability of the foamed particles and the binding property to the base material by the binder resin. The foamed layer can further contain components such as a pigment, an antioxidant, a dye, and a surfactant within a range that does not impair the foamability.

[0029] (Method for manufacturing a recording medium) To manufacture a recording medium, first, a coating liquid for a foamed layer containing foamed particles is applied to the surface of a substrate to form a coated layer. Next, the formed coated layer is dried to form a foamed layer, whereby the recording medium can be obtained. To apply the coating liquid for the foamed layer to the surface of the substrate, conventionally known air knife coaters, die coaters, blade coaters, gate roll coaters, bar coaters, rod coaters, roll coaters, gravure coaters, curtain coaters, etc. can be used. Examples of methods for drying the coated layer include a method of blowing hot air. The drying conditions (temperature, air volume, time, etc.) may be appropriately set according to the type of substrate and the composition of the coating liquid. However, the temperature during drying needs to be lower than the foaming start temperature of the foamed particles used.

[0030] It is preferable to provide a foamed layer of 2 g / m or more per side of the substrate. 2 By providing a foamed layer of 2 g / m or more, the foamability can be further improved. Note that a recording medium (product) provided with a foamed layer containing foamed particles in advance may also be used. 2

[0031] A backcoat layer may be provided on the surface of the substrate opposite to the surface on which the foamed layer is provided. The backcoat layer may be the same layer as the foamed layer containing foamed particles, or may be a layer other than the foamed layer. Also, an adhesive layer containing an adhesive resin such as an acrylic resin or an ink receiving layer for fixing a coloring material may be formed.

[0032] (Foaming Promoter Liquid) The foaming promoter liquid of the present invention is a foaming promoter liquid used in the above-described method for manufacturing a recording material. Hereinafter, the details of the foaming promoter liquid will be described.

[0033] [Foaming Promoting Component] The foaming accelerator contains a foaming acceleration component that lowers the foaming start temperature of the foaming particles. When a foaming accelerator containing a foaming acceleration component is applied to the foaming layer of a recording medium by a method such as ejection or coating using an inkjet method, the thermoplastic resin contained in the shell layer of the foaming particles can be softened. As a result, it is presumed that the foaming start temperature and the maximum foaming temperature of the foaming particles can be shifted to the lower temperature side.

[0034] The foaming acceleration component may be a component capable of softening the thermoplastic resin contained in the shell layer of the foaming particles and may be a compound having no hydroxyl group, and can be appropriately selected and used according to the type of the thermoplastic resin. Examples of the foaming acceleration component include 2-pyrrolidone, dimethyl sulfoxide, N,N-dimethylformamide, N-methyl-2-pyrrolidone, and the like. The boiling point of the compound having no hydroxyl group, which is the foaming acceleration component, is preferably higher than the temperature at which the foaming layer is heated. Since the boiling point of this compound is higher than the temperature at which the foaming layer is heated, this compound is less likely to be vaporized even when the foaming layer is heated, and can contribute to the softening of the thermoplastic resin in the shell layer of the foaming particles. The content of the compound having no hydroxyl group, which is the foaming acceleration component, is preferably 10% by mass or more and 70% by mass or less based on the total mass of the foaming accelerator.

[0035] The solubility parameter (SP 1 ) of the thermoplastic resin forming the shell layer of the foaming particles (microcapsules) and the solubility parameter (SP 2 ) of the foaming acceleration component, the absolute value of the difference (|SP 1 - SP 2 |) is preferably 3.5 or less. By having the absolute value of the difference in solubility parameters within the above numerical range, the foamability of the region to which the foaming accelerator containing the foaming acceleration component is applied in the foaming layer can be further improved.

[0036] Further, the Hansen solubility parameter (HSP 1 ) of the thermoplastic resin forming the shell layer of the foaming particles (microcapsules) and the solubility parameter (HSP 2) and the absolute value of the difference therefrom (|HSP 1 - HSP 2 |) is preferably 20 or less. By the absolute value of the difference in Hansen solubility parameters being within the above numerical range, the foamability of the region to which the foam promoting liquid containing the foam promoting component in the foam layer is applied can be further improved.

[0037] The solubility parameters (SP values) of the thermoplastic resin forming the shell layer and the foam promoting component are both values calculated by calculation. Further, the Hansen solubility parameters (HSP values) of the thermoplastic resin forming the shell layer and the foam promoting component are both measured and calculated actual measurement values by the dynamic light scattering method.

[0038] [Other Components] When the foam promoting component is a liquid at normal temperature (25 ° C), the foam promoting component itself may be used as the foam promoting liquid. Further, the foam promoting liquid may further contain components other than the foam promoting component (other components). For example, in order to improve the discharge stability of the foam promoting liquid, it is preferable to further contain a liquid component such as a solvent. As the solvent, water and various water-soluble organic solvents can be used. As water, deionized water (ion-exchanged water) is preferably used. Examples of the water-soluble organic solvent include alcohols, glycols, glycol ethers, and nitrogen-containing compounds.

[0039] As other components other than the liquid component, water-soluble organic compounds that are solid at a temperature of 25 ° C such as urea and its derivatives, trimethylolpropane, and trimethylolethane can be used. Further, if necessary, various additives such as a pH adjuster, an antifoaming agent, a rust preventive agent, a preservative, a fungicide, an antioxidant, a reduction preventive agent, and a chelating agent may be contained in the foam promoting liquid.

[0040] <Apparatus for Manufacturing a Recorded Object Having a Stereoscopic Image> The manufacturing apparatus of a recording medium having a stereoscopic image of the present invention (hereinafter, also simply referred to as "manufacturing apparatus of a recording medium") includes a foaming promoting liquid applying means for applying a foaming promoting liquid to a recording medium, and a heating means for heating a foaming layer of the recording medium to which the foaming promoting liquid has been applied. The recording medium has a base material and a foaming layer provided on the base material and containing foaming particles that foam by heat and a binder resin. The foaming promoting liquid contains a foaming promoting component that lowers the foaming start temperature of the foaming particles and water. The heating means is a means for heating the foaming layer of the recording medium to foam the foaming particles to form a stereoscopic image. The foaming particles have a shell layer containing a thermoplastic resin and a volatile material encapsulated in the shell layer. The binder resin in the foaming layer includes a water-insoluble resin, and the foaming promoting component includes a compound having no hydroxyl group. And the temperature for heating the foaming layer of the recording medium to which the foaming promoting liquid has been applied is equal to or higher than the foaming start temperature of the foaming particles on which the foaming promoting component acts and lower than the maximum foaming temperature of the foaming particles. The ink, the foaming promoting liquid, and the recording medium used in this manufacturing apparatus of a recording medium are the same as the ink, the foaming promoting liquid, and the recording medium used in the manufacturing method of the recording medium described above. The manufacturing apparatus of a recording medium of the present invention can be suitably used in the manufacturing method of the recording medium described above.

[0041] The manufacturing apparatus of a recording medium can also include an ink storage section for storing ink and an ink applying means for discharging the ink from an inkjet recording head to record an image on the recording medium. Further, the manufacturing apparatus of a recording medium can also include a foaming promoting liquid storage section for storing the foaming promoting liquid. Furthermore, the manufacturing apparatus of a recording medium can also include a conveying means for conveying the recording medium.

[0042] The arrangements of the foaming promoting liquid applying means, the ink applying means, and the heating means can be adjusted as appropriate. Hereinafter, with reference to the drawings, the arrangements of the foaming promoting liquid applying means, the ink applying means, and the heating means in the manufacturing apparatus of a recording medium will be described.

[0043] FIG. 2 is a schematic diagram showing a schematic configuration of the manufacturing apparatus of a recording medium having a stereoscopic image of the present invention. In the manufacturing apparatus shown in FIG. 2, the recording medium 21 is conveyed in the direction of arrow A by a conveying means for conveying the recording medium. The ink application means 24 may be disposed either upstream or downstream of the foaming acceleration liquid application means 22 with respect to the conveying direction A of the recording medium 21, and may be disposed either upstream or downstream of the heating means 23. FIG. 2(a) shows a configuration in which the ink application device 24 is disposed downstream of the foaming acceleration liquid application means 22 and downstream of the heating means 23 with respect to the conveying direction A of the recording medium 21. FIG. 2(b) shows a configuration in which the ink application means 24 is disposed downstream of the foaming acceleration liquid application means 22 and upstream of the heating means 23 with respect to the conveying direction A of the recording medium 21. FIG. 2(c) shows a configuration in which the ink application means 24 is disposed upstream of the foaming acceleration liquid application means 22 and upstream of the heating means 23 with respect to the conveying direction A of the recording medium 21.

[0044] By discharging the foaming acceleration liquid from an inkjet recording head provided with a foaming acceleration liquid application means 22 disposed at a predetermined position along the conveying direction of the recording medium 21 (the direction of arrow A in FIG. 2), the foaming acceleration liquid can be applied to the foaming layer of the recording medium 21. The heating means 23 is a means for heating the foaming layer of the recording medium 21 to which the foaming acceleration liquid has been applied. The heating means 23 may be any heating device that can heat the foaming particles in the foaming layer to a desired temperature. Examples of such heating devices include a dryer, an oven, a heating heater, an iron, and the like.

Example

[0045] Hereinafter, the present invention will be described in more detail with reference to examples and comparative examples. However, the present invention is not limited to the following examples as long as the gist thereof is not exceeded. Regarding the amounts of components, “parts” and “%” are based on mass unless otherwise specified.

[0046] <Preparation of foaming particles> Expanded particles X, Y, and Z were prepared. Expanded particle X is the product named "Advancell EMH204" (manufactured by Sekisui Chemical Co., Ltd., volatile material: isopentane (molecular weight 72.2)). Expanded particle Y is the product named "Expancel 007-40" (manufactured by Nippon Fillite Co., Ltd., volatile material: isobutane (molecular weight 58.1)). Also, expanded particle Z is the product named "Matsumoto Microsphere F-30" (manufactured by Matsumoto Yushi-Seiyaku Co., Ltd., volatile material: isopentane (molecular weight 72.1)). The shell layers of expanded particles X, Y, and Z are all formed of a thermoplastic resin. Using a thermomechanical analyzer (TMA) (product name "TMA2940", manufactured by TA instruments), the foaming start temperature and maximum foaming temperature of expanded particles X, Y, and Z were measured by the following procedure. 25 μg of the sample was placed in an aluminum container with a diameter of 7 mm and a depth of 1 mm, and a load of 0.1 N was applied from above. In this state, heating was carried out at a heating rate of 5 °C / min from 60 °C to 200 °C, and the displacement in the vertical direction of the measurement terminal was measured. Then, the temperature at which the displacement started was defined as the "foaming start temperature", and the temperature at the time of the maximum displacement amount was defined as the "maximum foaming temperature". The results are shown in Table 1.

[0047] TIFF2025083526000001.tif43170

[0048] <Measurement of the foaming start temperature and maximum foaming temperature of expanded particles to which a foaming promoting component is applied> (Preparation of the foaming promoting liquid used when applying the foaming promoting component to the expanded particles) Components A to I of the types shown in Table 2 were prepared. 10 g of each of components A to I was mixed with 90 g of water, and liquids containing 10 g of each component and 90 g of water (100% water for component E) were designated as foaming promoting liquids A' to I'. These foaming promoting liquids A' to I' were respectively applied to 20 g of expanded particles (expanded particles X, Y, and Z) of the types shown in Table 2 and allowed to act. Then, in the same manner as in the case of expanded particles to which the foaming promoting component was not applied, the foaming start temperature and maximum foaming temperature of each expanded particle to which the foaming promoting component was applied were measured. The measurement results are shown in Table 2. The meanings of the abbreviations in Table 2 are shown below. · DMSO: Dimethyl sulfoxide ·DMF: N,N-Dimethylformamide ·NMP: N-Methyl-2-pyrrolidone ·iPrOH: Isopropanol ·PGME: Propylene glycol monomethyl ether

[0049] TIFF2025083526000002.tif132170

[0050] <Fabrication of Recording Medium> (Recording Medium X) As the base material, polypropylene synthetic paper (trade name "New Yupo FGS110", manufactured by Yupo Corporation) was prepared. 100 parts of an acrylic resin with a glass transition temperature of 0 °C and 50 parts of foaming particles X were added to ion-exchanged water and stirred well to obtain coating liquid X. The obtained coating liquid X was coated on the base material so that the coating amount was 40 g / m 2 After that, it was dried in an oven at 80 °C for 5 minutes to form a foaming layer, and recording medium X was obtained. The acrylic resin used when fabricating this recording medium X is a water-insoluble and non-water-absorbent resin and does not have an ester group.

[0051] (Recording Medium Y) Coating liquid Y was obtained by using foaming particles Y instead of foaming particles X, and recording medium Y was obtained in the same manner as in the case of recording medium X described above, except that coating liquid Y was used instead of coating liquid X.

[0052] (Recording Medium Z) Coating liquid Z was obtained by using foaming particles Z instead of foaming particles X and using polyvinylpyrrolidone, which is a water-absorbent resin, instead of the acrylic resin. Then, after coating coating liquid Z on the base material instead of coating liquid X, it was dried in an oven at 60 °C for 5 minutes. Recording medium Z was obtained in the same manner as in the case of recording medium X described above, except for these things.

[0053] (Recording Medium W) Recording medium W was obtained in the same manner as in the case of recording medium Z described above, except that an acrylic ester having an ester group was used instead of polyvinylpyrrolidone to obtain coating liquid W.

[0054] <Preparation of Foaming Promoter Solution to be Applied to Recording Medium> 30 parts of Component A, 0.5 part of nonionic surfactant (trade name "Acetylenol E100", manufactured by Kawaken Fine Chemicals Co., Ltd.), and 69.5 parts of ion-exchanged water were mixed. After thorough stirring, it was pressure-filtered through a filter with a pore size of 1.2 μm to obtain Foaming Promoter Solution A. In addition, Foaming Promoter Solutions B to I were obtained in the same manner as in the case of Foaming Promoter Solution A above, except that Components B to I were used in place of Component A, respectively.

[0055] <Manufacture of Recorded Matter> Foaming Promoter Solutions A to I were each filled into a cartridge and mounted on an inkjet recording apparatus (trade name "PIXUS MG3630", manufactured by Canon Inc.). In this Example, the recording duty of an image recorded under the condition of applying 2 ink droplets of about 11.2 ng to a unit area of 1 / 600 inch × 1 / 600 inch was defined as 100%.

[0056] (Example 1) Using the above-described inkjet recording apparatus, Foaming Promoter Solution A was applied to the foaming layer of Recording Medium X so that the recording duty became 100%. Thereafter, using a hot air gun (trade name "HL2010E1", manufactured by Sakaguchi Denki Co., Ltd.), the foaming layer to which Foaming Promoter Solution A was applied was heated to 150°C. As a result, the foaming particles X in the foaming layer to which Foaming Promoter Solution A was applied were foamed to form a three-dimensional image, and Recorded Matter 1 was obtained.

[0057] (Examples 2 to 8, Comparative Examples 1 to 19) Recorded Matters 2 to 8 and 10 to 28 were obtained in the same manner as in Example 1 above, except that the conditions shown in Table 3 were used.

[0058] (Example 9) Foaming Promoter Solution B was applied to the foaming layer of Recording Medium Y using a polyspoon. Thereafter, using a hot air gun (trade name "HL2010E1", manufactured by Sakaguchi Denki Co., Ltd.), the foaming layer to which Foaming Promoter Solution B was applied was heated to 80°C. As a result, the foaming particles Y in the foaming layer to which Foaming Promoter Solution B was applied were foamed to form a three-dimensional image, and Recorded Matter 9 was obtained.

[0059] <Evaluation> (Unevenness) The surface of the manufactured recording material was visually observed, and the unevenness was evaluated according to the evaluation criteria shown below. The results are shown in Table 3. A: Unevenness could be confirmed. C: Unevenness could not be confirmed.

[0060] (Peeling of the foamed layer from the base material after heating) The surface of the manufactured recording material was visually observed, and the presence or absence of peeling of the foamed layer from the base material after heating was confirmed according to the evaluation criteria shown below. The results are shown in Table 3. A: No peeling of the foamed layer from the base material was confirmed. C: Peeling of the foamed layer from the base material was confirmed.

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Explanation of symbols

[0062] 10: Recording medium 11: Base material 12: Foamed layer 13: Foamed particles 14: Binder resin 15: Shell layer 16: Volatile material 21: Recording medium 22: Foaming acceleration liquid applying means 23: Heating means 24: Ink applying means

Claims

1. A step of preparing a recording medium having a substrate and a thermal expansion layer provided on the substrate, the thermal expansion layer containing thermally expandable particles and a water-insoluble resin; applying a liquid composition to a first area of ​​the recording medium; and heating the recording medium to which the liquid composition has been applied to form a three-dimensional image, the thermally expandable particles contain hydrocarbons having a molecular weight of 120 or less encapsulated in a thermoplastic resin; the liquid composition contains (i) at least one compound selected from the group consisting of 2-pyrrolidone, dimethyl sulfoxide, N,N-dimethylformamide, and N-methyl-2-pyrrolidone, and (ii) water; A method for manufacturing a recorded material having a three-dimensional image, characterized in that in the process of forming the three-dimensional image, the temperature at which the recording medium to which the liquid composition has been applied is heated is set to be equal to or higher than the thermal expansion initiation temperature of the heat-expandable particles in contact with the compound and lower than the maximum thermal expansion temperature of the heat-expandable particles not in contact with the compound, thereby expanding the volume of the heat-expandable particles in the first region compared to the volume of the heat-expandable particles in a second region of the recording medium to which the liquid composition has not been applied.

2. 2. The method for producing a recorded matter having a three-dimensional image according to claim 1, wherein the molecular weight of the hydrocarbon is 50 or more and 120 or less.

3. 3. A method for producing a recorded material having a three-dimensional image according to claim 1 or 2, wherein the content of the heat-expandable particles in the heat-expandable layer is 5% by mass or more and 95% by mass or less, based on the total mass of the heat-expandable layer.

4. 4. The method for producing a recorded matter having a three-dimensional image according to claim 1, wherein the water-insoluble resin is a non-water-absorbent resin.

5. The method for producing a recorded matter having a three-dimensional image according to any one of claims 1 to 4, wherein the water-insoluble resin is an acrylic resin.

6. A method for producing a recorded material having a three-dimensional image described in any one of claims 1 to 5, wherein the content of the water-insoluble resin in the thermal expansion layer is 10% by mass or more and 95% by mass or less, based on the total mass of the thermal expansion layer.

7. 7. The method for producing a recorded material having a three-dimensional image according to claim 1, wherein the boiling point of the compound is higher than the temperature at which the recording medium to which the liquid composition has been applied is heated in the process of forming the three-dimensional image.

8. 8. The method for producing a recorded material having a three-dimensional image according to claim 1, wherein the content of the compound in the liquid composition is 10% by mass or more and 70% by mass or less, based on the total mass of the liquid composition.

9. The solubility parameter (SP １ ) and the solubility parameter (SP ２ ) and the absolute value of the difference (|SP １ -SP ２ 9. The method for producing a recorded matter having a three-dimensional image according to claim 1, wherein |) is 3.5 or less.

10. The Hansen solubility parameter (HSP) of the thermoplastic resin １ ) and the Hansen solubility parameter (HSP) of the compound ２ ) and the absolute value of the difference (|HSP １ -HSP ２ The method for producing a recorded matter having a three-dimensional image according to any one of claims 1 to 9, wherein |) is 20 or less.

11. A method for producing a recorded material having a three-dimensional image described in any one of claims 1 to 10, wherein the water-insoluble resin is a binder resin.

12. a liquid composition applying means for applying a liquid composition to a first region of a recording medium having a substrate and a thermal expansion layer provided on the substrate, the thermal expansion layer containing thermally expandable particles and a water-insoluble resin; a heating unit that heats the recording medium to which the liquid composition has been applied, thereby forming a three-dimensional image, the thermally expandable particles contain hydrocarbons having a molecular weight of 120 or less encapsulated in a thermoplastic resin; the liquid composition contains (i) at least one compound selected from the group consisting of 2-pyrrolidone, dimethyl sulfoxide, N,N-dimethylformamide, and N-methyl-2-pyrrolidone, and (ii) water; In order to form the three-dimensional image, the recording medium to which the liquid composition has been applied is heated to a temperature that is equal to or higher than the thermal expansion initiation temperature of the heat-expandable particles in contact with the compound and lower than the maximum expansion temperature of the heat-expandable particles not in contact with the compound, thereby expanding the volume of the heat-expandable particles in the first region compared to the volume of the heat-expandable particles in a second region of the recording medium to which the liquid composition has not been applied.

13. preparing a recording medium having a substrate and a thermal expansion layer provided on the substrate, the thermal expansion layer containing thermally expandable particles and a water-insoluble resin; applying a liquid composition to a first area of ​​the recording medium; a step of heating the recording medium to which the liquid composition has been applied to form a three-dimensional image, the thermally expandable particles contain hydrocarbons having a molecular weight of 120 or less encapsulated in a thermoplastic resin; the liquid composition contains (i) at least one compound selected from the group consisting of 2-pyrrolidone, dimethyl sulfoxide, N,N-dimethylformamide, and N-methyl-2-pyrrolidone, and (ii) water; A liquid composition characterized in that, in the process of forming the three-dimensional image, the temperature at which the recording medium to which the liquid composition has been applied is heated is set to be equal to or higher than the thermal expansion initiation temperature of the heat-expandable particles in contact with the compound and lower than the maximum thermal expansion temperature of the heat-expandable particles not in contact with the compound, thereby expanding the volume of the heat-expandable particles in the first region compared to the volume of the heat-expandable particles in a second region of the recording medium to which the liquid composition has not been applied.

Images