JP2002355911A - Foam and decorative material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a foam and a decorative material having a soft surface and obtained by foaming a mixed resin composition, which is prepared by adding a woody powder to a thermoplastic resin, generating no 'bending'/'warpage' phenomenon. SOLUTION: The foam 1 comprising a mixture containing a thermoplastic resin consists of a central part comprising a low foamed layer 3 and both outer parts comprising highly foamed layers 4 adjacent to the low foamed layer of the central part. The decorative material is obtained by laminating a decorative sheet to the surface of at least either one of the highly foamed layers of the foam 1 or by laminating the decorative sheet, to which printing is applied, on the surface of at least either one of the highly foamed layers of the foam 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foam and a decorative material used for building surface materials such as flooring materials, wall materials, ceiling materials and fittings.

[0002]

2. Description of the Related Art Conventionally, decorative wood materials (decorative materials) are often used for building surface materials such as flooring materials, wall materials, ceiling materials, and fittings. That is, a decorative paper formed by printing on a natural veneer or paper, a decorative sheet formed by printing on a resin sheet, or the like is bonded to a wood substrate such as plywood or fiber board. However, these decorative wood materials have poor durability such that the wood substrate tends to “warp” due to moisture absorption and desorption, the wood substrate is eaten by insects, and the moisture and water resistance are poor and easily corroded. There is a problem. In addition, there is a problem that recycling is difficult (mostly treated by landfill or incineration).

[0003] In recent years, molded articles have been produced by a resin molding method from a low-priced and reduced mixed composition in which a woody powder as an organic filler is contained in a thermoplastic resin. It has good moisture resistance, water resistance, insect bite resistance, and corrosion resistance. Since it is a molding method, the shape can be complicated. Furthermore, since the mixed composition is a thermoplastic resin, it can be recycled and used for similar applications. Further, a decorative sheet can be laminated on the surface of the molded article. As the thermoplastic resin, a polyolefin resin that is relatively inexpensive is often used.

[0004] Further, in order to reduce the weight of the molded article and increase the volume, a mixed resin composition containing woody powder is foamed in a thermoplastic resin. Usually, a uniform foam is obtained by uniformly foaming the entire molded body. However, a product in which a multilayer foam is used in which a low-foaming layer is provided on the outside and a high-foaming layer is provided at a central portion has been attempted.

[0005] In the above-mentioned uniform foam, when a polyolefin-based resin is used, when the foam is made highly foamed, a softness comes out and a "bending" / "bending" phenomenon occurs. (In the use of building materials, in particular, plate-like ones are usually required to have almost no "bend" or "bending"). In the state of low foaming, there is no "bending" or "bending". However, although the surface is hard, it is weak to impact and has poor sound absorption, and when this uniform foam is laminated on a base material, there is a drawback that the surface of the base material is affected by unevenness. . Higher foaming and softness can eliminate or reduce this disadvantage. Further, in the above-mentioned multilayer foam product, the outside is a low foam layer, which has the above-mentioned drawbacks.

[0006]

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned disadvantages in a foam or a decorative material for a building surface material obtained by foaming a mixed resin composition containing a woody powder in a thermoplastic resin. That is, an object of the present invention is to provide a material having a soft surface and free from the "bend" and "bend" phenomena.

[0007]

Means for Solving the Problems In order to achieve the above object in the present invention, first, according to claim 1, a foam obtained by foaming a mixed composition containing a thermoplastic resin is provided. Is a foam having a low-foaming layer in the center and a high-foaming layer on both sides adjacent to the center.

According to a second aspect of the present invention, in the foam of the first aspect, a decorative sheet, which is a printed thermoplastic resin sheet, is laminated on at least one surface of the high foam layer. This is a featured cosmetic material.

According to a third aspect of the present invention, there is provided a foam characterized in that the mixed composition containing the thermoplastic resin according to the first aspect contains an organic filler.

[0010] In a fourth aspect, the thermoplastic resin of the mixed composition containing the thermoplastic resin according to the first aspect is a polyolefin-based resin, which is a foam.

The foam according to the present invention has a structure in which a low-foaming layer is present in the center and a high-foaming layer is provided on both outer layers, and rigidity is compensated by the low-foaming layer so that "bending" and "deflection" do not occur. As described above, the surface is made soft by forming a high foam layer, thereby achieving impact resistance, sound absorbing property, and absorbing irregularities of the base. By making the surface a high foaming layer, the foamed cells can be seen and hidden on the surface, and may resemble the surface of wood, leading to a feeling of wood.

[0012]

FIG. 1 shows a structure of a foam 1 according to the present invention in which a low foam layer 3 is present in the center and a high foam layer 4 is provided on both sides adjacent to the low foam layer 3 in the center. FIG. FIG. 2 is a cross-sectional view showing the structure of the decorative material 2 in which a decorative sheet 5 which is a printed thermoplastic resin sheet is layered and covered around the cross section of the foam 1 of FIG. FIG. 3 is a cross-sectional view showing the structure of a decorative material 2 in which a decorative sheet 5 which is a printed thermoplastic resin sheet is laminated on the surface of one of the outer high foam layers 4 in the foam material 1 of FIG. It is. The foam 1 in FIGS. 1, 2 and 3 is made of a thermoplastic resin,
It is obtained by foaming and molding a mixture of an organic filler and a foaming agent.

The thermoplastic resin can be appropriately selected from resins such as polyolefin, polystyrene, polycarbonate, polyester, polyamide, polyvinyl alcohol, acrylic, and polyvinyl chloride. However, environmental hormones such as generation of dioxin by incineration and landfill. The thermoplastic resin is desirably a polyolefin-based resin in order to satisfy performances such as outflow of water, weather resistance and heat resistance as a member, and resistance to chemicals and solvents. Polyolefin resin is
Polyethylene, polypropylene, polybutene, polyisoprene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-α-olefin copolymer, propylene-α-olefin copolymer, ethylene-ethyl acrylate copolymer It can be appropriately selected from those modified with an acid, ionomers and the like for the purpose of improving the content, and may be a single type or a mixture of plural types. However, in order to maintain the physical properties after recycling, the better the compatibility is, the better the result will be.For example, when incompatible resins such as mixing and lamination of polyethylene and polypropylene are mixed, these should be used. It is more desirable to blend, for example, an ethylene-propylene copolymer or the like to be compatible. Also,
If necessary, heat stabilizers, acid neutralizers, ultraviolet absorbers, light stabilizers, coloring agents such as pigments and dyes, fillers, antistatic agents,
Lubricants, nucleating agents, foaming agents, clutter, anti-blocking agents,
A light scattering agent, a gloss adjusting agent and the like for translucency can also be added.

Further, in the present invention, even when mixed with a similar thermoplastic resin, recycling can be performed without a large change in physical properties. Specifically, polyolefin, polystyrene, polycarbonate, polyester,
Polyamide, polyvinyl alcohol, acrylic,
Examples of polyvinyl chloride resins include, for example, polyolefin resins such as polyethylene, polypropylene, polybutene, polyisoprene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-α-olefin copolymer, and propylene-α-olefin copolymer. It is possible to appropriately select from a combination, an ethylene-ethyl acrylate copolymer, an acid-modified product thereof for the purpose of improving adhesiveness, an ionomer and the like, and the same or different resins selected from these can be used.

The organic filler can be selected from wood-based wood flour, wood chips, paper dust and the like without any particular limitation. In particular, wood flour is generally obtained by cutting wood with a cutter mill or the like. It is broken and pulverized with a ball mill or an impeller mill or the like to form a fine powder. Average particle size 1 to 200 μm, preferably 5 to 100 μm
It is important that Those having an average particle size of less than 1 μm are difficult to handle and, particularly when the amount of the wood-based filler is large, poor dispersion in the resin causes a decrease in mechanical strength. On the other hand, if it is larger than 200 μm, the homogeneity, flatness and mechanical strength of the molded product will be reduced.

The amount of the wood-based filler is 1
From 0 parts by weight to 500 parts by weight can be appropriately selected, but the optimal amount varies depending on the use of the cosmetic material. Specifically, when an olefin resin is used for the thermoplastic resin,
After being formed into a flat plate by compression molding or the like, the wood-based filler is used in an amount of 50 to 500 parts by weight, more preferably 100 to 500 parts by weight, based on 100 parts by weight of the thermoplastic resin for applications such as cutting and V-cutting. It is desirable to enhance post-processability such as machinability as a part, but for applications processed by profile extrusion or injection molding, the wood-based filler is made of thermoplastic resin 100 in order to improve moldability and homogeneity.
10 to 200 parts by weight, more preferably 1 to 100 parts by weight
It is desirable that the amount be 5 to 150 parts by weight. In addition, when the blending amount is more than 100 parts by weight based on 100 parts by weight of the thermoplastic resin, the dispersibility in the resin is particularly important, and it is possible to use a granular wood-based filler having relatively few cilia. preferable. As the wood-based filler with less cilia, a polishing material obtained by polishing a particle board or the like is mainly used. The wood-based resin molded article may contain a wood-based filler in its entirety, or if it does not impair the recyclability, woody feel, workability such as cutting and nailing, for example, a skin layer of a similar thermoplastic resin, etc. A layer containing no filler may be present.

The foaming agent used at this time is not particularly limited. Examples thereof include azodicarponamide, sodium hydrogencarbonate, sodium carbonate, benzenesulfonylhydrazide, dinitrosopentamethylenetetramine, toluenesulfonylhydrazide, , 4, oxybis (benzenesulfonyl hydrazide) and the like. These may be used alone or in combination. The amount of addition varies depending on the resin and the thickness of the layer to be selected. However, in order to form a low-foaming layer and prevent “bending”, in the case of a polyolefin-based resin, a resin 100
Parts, less than 3 parts by weight, preferably in the range of 1 to 3 parts by weight. If it is too small, there is no effect of reducing the weight of the foam and increasing the volume. If it exceeds 3 parts by weight, "bending" may appear. In addition, in order to form a high foaming layer and obtain softness, the amount is 3 to 6 parts by weight. If the amount is less than 3 parts by weight, the softness is insufficient, and if it exceeds 6 parts by weight, the material becomes too soft.

The kneading of the organic filler and the thermoplastic resin is carried out by kneading with a bumper mixer and beretizing with a beretizer, mixing and pelletizing with a twin-screw extruder or mixing with a twin-screw extruder. It is common to pelletize. In particular, if the organic filler has a high water content, it may cause foaming at the time of molding.
% Is desirable. When the product of the present invention is recycled, a filler, a thermoplastic resin, various additives, and the like are added to the crushed product of the present invention, if necessary, and pelletized again. In this case, the method is not particularly limited.

The foam is made by a plastic molding method using an ordinary thermoplastic resin. However, a simple material such as a plate having a rectangular cross-section or a material having a complicated cross-section and a long cross-section having the same cross-section in the longitudinal direction are used. A known molding method such as an injection molding method can be used for the extrusion molding method, the three-dimensional shape or the three-dimensional shape. In order to form a multilayer structure such as the outermost layer, the rearmost layer, and the intermediate layer, in the profile extrusion method, the respective layers are extruded and laminated. At this time, a foamed material can be extruded in an extruder, or may be foamed after being extruded. It is determined according to the selected resin and foaming agent. Further, a low-foaming layer can be provided by providing a cooling partition so that the intermediate layer (central layer) is restricted from foaming in the resin flow direction during the process from extrusion to cooling and sizing. A method other than extruding and laminating each layer may be used.

The decorative sheet is made of a thermoplastic resin film,
Printed ink is used to print designs such as wood grain, stone grain, cloth grain, and abstract patterns. In particular, recycling of the thermoplastic resin film is facilitated by using a thermoplastic resin film similar to the foam. In addition, the cosmetic material has good adhesion and adhesion to the foam layer.

Inks used for printing include nitrated cotton, cellulose, vinyl chloride-vinyl acetate copolymer, polypinyl butyral, polyurethane, acrylic, and the like as binders.
What is necessary is just to select suitably from single or each modified products, such as a polyester system. These may be aqueous, solvent-based or emulsion-type, and may be arbitrarily selected from a one-pack type or a two-pack type using a curing agent. It is also possible to cure the ink by irradiation with ultraviolet rays or electron beams. Among them, the most general method is a method of curing with urethane-based ink using isocyanate.
In addition to these binders, coloring agents such as pigments and dyes, extenders, solvents, and various additives contained in ordinary inks are added. Particularly frequently used pigments include pearl pigments such as condensed azo, insoluble azo, quinacridone, isoindoline, anthraquinone, imidazolone, cobalt, phthalocyanine, carbon, titanium oxide, iron oxide, and mica. Also, any decorative sheet may be provided with a primer coat for bonding to a foam, a top coat for surface protection or gloss adjustment, a conduit expression by an embossing method, a gloss mat method, or the like. . The same additives as those used for the foam can be used for the thermoplastic resin layer.

The configuration of the decorative sheet itself is not subject to any restrictions. For example, a back-printed single-layer decorative sheet printed on a colored sheet or printed on the back of a transparent sheet, a dry lamination method, an extrusion lamination method, and a heat lamination method on a transparent sheet printed on a colored sheet Can be appropriately selected from a double-layer decorative sheet and the like, which are bonded together, depending on the use.

The method of laminating the decorative sheet on the foam is not particularly limited. An appropriate lamination method can be selected depending on the shape of the foam.
For example, if it is a flat plate, an adhesive is applied to a flat molded plate or a decorative sheet, and a roll laminating method in which the same shape is applied in the longitudinal direction such as a roll laminating method in which the adhesive is applied by a roll, a deformed extrusion molding method, a complicated lapping method, For a foam having a three-dimensional surface, a vacuum press lamination method or the like can be used.
Simultaneous painting, in which a decorative sheet is attached at the same time as molding by a simultaneous extrusion lamination method and an injection molding simultaneous lamination method, is also possible. In addition, in the case of thermoplastic resin such as olefin-based resin, which is difficult to adhere, surface treatment such as corona discharge treatment, ozone treatment, plasma discharge treatment, flame treatment, primer coating, etc. should be performed on the foam surface in advance if necessary. Is desirable.

[0024]

The present invention will be described in detail with reference to the following examples. <Example 1> As a thermoplastic resin, 90 parts by weight of a homopolypropylene resin and 10 parts by weight of a maleic acid-modified homopolypropylene were used. Using a wood-based powder having an average particle diameter of 20 μm, which has been pulverized into a powder form, and uniformly mixed with a mixture of 100 parts by weight of the powder by a twin-screw extruder to pelletize the resin containing the wood-based powder. A composition was made. On the other hand, azodicarbonamide was used as a foaming agent, and a master batch was prepared by mixing 10 parts by weight of azodicarbonamide and 90 parts by weight of a polypropylene resin as a thermoplastic resin. The masterbatch and the pelletized resin composition containing a wood-based powder are mixed, and two kinds of foaming agents are prepared so that 1% (for low foaming) and 3% (for high foaming) of the total weight parts are added. And fed to a profile extruder. The profile extruder has three profile extrusion heads arranged in parallel in upper, middle and lower positions. In front of the head, there are provided two rolls capable of adjusting a gap between a pair of rolls. Is to take over. The composition for low foaming was supplied to the middle head in this profile extruder, and the composition for high foaming was supplied to the upper and lower heads. The foamed extruded material extruded from the upper and lower heads has a width of 1.
A cross section of 00 mm x thickness of 2 mm, the foamed extrudate extruded from the head inside is 100 mm wide x 6 m thick
100 mm wide, 100 mm wide x 100 mm thick, with the high foam layer 4 at the outside and the low foam layer 3 at the center at the outside.
A foam 1 long in the longitudinal direction with a cross section of mm (FIG. 1) was prepared. This foam 1 has both surfaces (surface layers) that are soft, lightly depressed when pressed with a finger, and return to the original flat state when released, and are not damaged or cracked when struck with a timber. There was no (shock resistant) and little sound. One surface of this foam was affixed to a plywood to which a two-diameter wire was fixed as a base material, but the other surface remained flat. Further, in this foam 1, foam cells were visible and hidden on the surface, and a woody feeling was felt similar to the surface of wood.

Example 2 As a thermoplastic resin sheet,
Using a 100 μm colored polypropylene sheet formed by blending pigments such as iron oxide and titanium oxide with a random polypropylene resin, and performing grain printing with a urethane-based ink, homopolypropylene of 100 μm was formed by extrusion lamination. Laminated embossed sheet 5 made of polyolefin resin by simultaneously embossing with thickness, applying primer coat on the back side and top coat on the front side
It was created. On the other hand, the surface of the foam 1 produced in Example 1 was subjected to a corona discharge treatment,
The decorative sheet 5 was stuck and laminated and covered by a lapping method to prepare a decorative material 2 as shown in FIG. The decorative sheet 5 has a softness similar to that of the high-foaming layer 4 of the foam 2. Both the high-foaming layers 4 of the decorative material 2 on which the decorative sheet 5 is laminated are soft and lightly depressed when pressed with a finger. ,
When you release your finger, it returns to its original flat state. When you hit the timber, it did not scratch, cracked (shock resistant), and made little sound. Also,
One surface of the decorative material 2 was stuck to a plywood to which a wire having a diameter of 2 mm was fixed as a base material, but the other surface was kept flat.

Example 3 A decorative sheet 5 having a wood grain pattern printed on the back surface was prepared using a transparent random polypropylene resin sheet as a thermoplastic resin sheet. As shown in FIG. 3, the printing surface of the decorative sheet 5 was changed to the first embodiment.
Was applied to the surface of one high-foaming layer 4 of the foam 1 to form a decorative material 2. The decorative material 2 is such that the foam cells on the surface of the foam 1 are hidden and visible on the surface, and the wood texture is similar to the surface of the wood, and at the same time, the wood texture of the decorative sheet 5 is combined with the wood texture. Met.

[0027]

As described above, the present invention has the following effects. That is, the surface is soft, has impact resistance, has sound absorption, can absorb the unevenness of the base, has a woody feeling, and has the same effect even when a decorative sheet is stuck on the surface. And at the same time,
A product without "bend" and "bend" phenomena was obtained. Therefore, the present invention exerts excellent practical effects in applications such as building surface materials such as flooring materials, wall materials, ceiling materials, and fittings.

[Brief description of the drawings]

FIG. 1 shows a first embodiment of the present invention.
Is a cross-sectional view showing the structure of a foam 1 which is a multilayer body in which both outer sides adjacent to the low foam layer 3 at the center are high foam layers 4.

FIG. 2 shows a structure of a decorative material 2 in which a decorative sheet 5 which is a printed thermoplastic resin sheet is laminated and covered around the cross section of the foam 1 of FIG. FIG.

3 shows a third embodiment of the present invention, in which a decorative sheet 5 which is a printed thermoplastic resin sheet is laminated on the surface of one outer high foam layer 4 in the foam 1 of FIG. It is sectional drawing which shows the structure of the decorative material 2.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Foam 2 ... Decorative material 3 ... Low foam layer 4 ... High foam layer 5 ... Decorative sheet

 ──────────────────────────────────────────────────の Continuing on the front page (72) Inventor Hideki Yamamoto 1-5-1, Taito, Taito-ku, Tokyo Toppan Printing Co., Ltd. F-term (reference) 4F100 AK01A AK01B AK01C AK03A AK03B AK03C AK07 AL05A AL05B AL05C AL07 AP00 BA03 BA06 BA10A BA10C CA01 CA23A CA23B CA23C DE01 DJ01A DJ01B DJ01C EH17 GB08 HB00A HB00C HB31A HB31C JA14B JA15A JA15C JB16A JB16B JB16C JK13 JK14

Claims (4)

[Claims] 1. A foam obtained by foaming a mixed composition containing a thermoplastic resin, wherein the foam has a low foaming layer at a central portion and a high foaming layer at both outer sides adjacent to the central portion. Foam. 2. A decorative material according to claim 1, wherein a decorative sheet which is a printed thermoplastic resin sheet is laminated on at least one of the surfaces of the highly foamed layer. 3. The foam according to claim 1, wherein the mixed composition containing a thermoplastic resin contains an organic filler. 4. The foam according to claim 1, wherein the thermoplastic resin of the mixed composition containing the thermoplastic resin is a polyolefin resin.