JP3912038B2 - Foam and cosmetics - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a foam and a decorative material used for building surface materials such as floor materials, wall materials, ceiling materials, and joinery.
[0002]
[Prior art]
Conventionally, decorative wood materials (decorative materials) are often used for building surface materials such as flooring, wall materials, ceiling materials, and joinery. That is, it is a laminate of a woody base material such as plywood or fiberboard, a decorative paper having a design applied to a natural veneer or paper, a decorative sheet having a design applied to a resin sheet, or the like.
However, these decorative wood materials have poor durability such that the wood base material is likely to “warp” due to moisture absorption / release, the wood base material is eaten by insects, and the moisture resistance / water resistance is poor and corrosive easily. There is a problem. In addition, there is a problem that recycling is difficult (most are treated by landfill or incineration).
[0003]
In recent years, a molded body has been made by a resin molding method from a mixed composition that has been reduced in price and reduced by including wood powder, which is an organic filler, in a thermoplastic resin. Water resistance, insect erosion resistance, and corrosion resistance are good. 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 purposes.
In addition, a decorative sheet can be laminated on the surface of the molded body.
As the thermoplastic resin, a polyolefin resin having a relatively low price is often used.
[0004]
Furthermore, in order to lighten the molded body and increase the volume, foaming of the mixed resin composition containing wood powder in the thermoplastic resin is also performed.
Usually, it is a uniform foam obtained by uniformly foaming the entire molded body, but a product in which a multilayer foam is formed by forming a low foam layer on the outside and a high foam layer on the center is also being tried.
[0005]
In the above-mentioned uniform foam, when polyolefin resin is used, if it is made highly foamed, softness will come out, and there will be a drawback that the phenomenon of “bending” and “deflection” will be seen (building materials) In particular, a plate-like material is usually required to have almost no “bending” or “deflection”).
There is no “bending” or “deflection” in the low foaming state. However, although the surface is hard, it is vulnerable to impact, sound absorption is poor, and when this uniform foam is laminated on the base material, the surface of the base material is affected by irregularities. . This defect can be eliminated or reduced by softening with high foaming.
Moreover, in the product of the said multilayer foam, the exterior is a low foaming layer and has the said fault.
[0006]
[Problems to be solved by the invention]
The object of the present invention is to solve the above-mentioned drawbacks in foams and decorative materials for building surface materials obtained by foaming a mixed resin composition containing wood powder in a thermoplastic resin, that is, the surface is soft, The purpose is to provide a product that does not have a “bending” or “deflection” phenomenon.
[0007]
[Means for Solving the Problems]
In order to achieve the above object in the present invention, first, in claim 1, as a thermoplastic resin, 90 parts by weight of homopolypropylene resin, 10 parts by weight of homopolypropylene modified with maleic acid, and wood powder having an average particle size of 20 μm are provided. In the decorative material including the foam obtained by foaming the mixed composition, the foam has a low foam layer at the center and high foam layers on both outsides adjacent to the center, and at least one of the foams. A decorative sheet containing a polypropylene resin with a wood grain pattern is laminated on the surface of the highly foamed layer.
[0011]
The foam according to the present invention has a structure in which a low foam layer is present in the central portion and a high foam layer is provided on both outer layers, and the rigidity is enhanced by the low foam layer so that `` bending '' and `` bending '' do not occur. The surface is made soft by making it a highly foamed layer, so that impact resistance, sound absorption, and unevenness of the foundation are absorbed.
When the surface is made of a highly foamed layer, the foam cells are visible and hidden on the surface, which may lead to a wood texture similar to the surface of wood.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a cross-sectional view showing the structure of a foam 1 in which a low foam layer 3 is present in the central portion of the present invention, and both exteriors adjacent to the low foam layer 3 in the central portion are high foam layers 4.
FIG. 2 is a cross-sectional view showing the structure of the decorative material 2 in which the decorative sheet 5 that is a printed thermoplastic resin sheet is laminated 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 thermoplastic resin sheet printed is laminated on the surface of one external high foam layer 4 in the foamed material 1 of FIG. It is.
The foam 1 in FIGS. 1, 2, and 3 is obtained by foaming and molding a mixture of a thermoplastic resin, an organic filler, a foaming agent, and the like.
[0013]
The thermoplastic resin can be appropriately selected from resins such as polyolefin, polystyrene, polycarbonate, polyester, polyamide, polyvinyl alcohol, acrylic, polyvinyl chloride, etc., but the inflow of environmental hormones such as generation of incinerated dioxins and landfilling, In order to satisfy performance such as weather resistance and heat resistance as a member and resistance to chemicals and solvents, it is desirable that the thermoplastic resin is a polyolefin resin.
Polyolefin resins include polyethylene, polypropylene, polybutene, polyisoprene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-α olefin copolymer, propylene-α olefin copolymer, ethylene-ethyl acrylate copolymer, These can be selected as appropriate from acid-modified ones for the purpose of improving touchability, ionomers, etc., and they may be single or mixed.
However, in order to maintain the physical properties after recycling, it is better to have as much compatibility as possible, so that good results are shown.For example, when incompatible resins are mixed, such as mixing and lamination of polyethylene and polypropylene, these should be used. For example, an ethylene-propylene copolymer or the like that is compatible is more desirable.
If necessary, heat stabilizer, acid neutralizer, ultraviolet absorber, light stabilizer, colorant such as pigment, dye, filler, antistatic agent, lubricant, nucleating agent, foaming agent, miscellaneous agent, An anti-blocking agent, a light scattering agent for making translucent, a gloss adjusting agent and the like can also be added.
[0014]
Further, in the present invention, even if mixed with a similar thermoplastic resin, it can be recycled without significant change in physical properties. Specific examples include polyolefins, polystyrenes, polycarbonates, polyesters, polyamides, polyvinyl alcohols, acrylics, and polyvinyl chlorides. For example, for polyolefin resins, polyethylene, polypropylene, polybutene, polyisoprene, Ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene-α olefin copolymer, propylene-α olefin copolymer, ethylene-ethyl acrylate copolymer and those obtained by acid modification for the purpose of improving adhesiveness, An ionomer or the like can be selected as appropriate, and the same or different resins selected from these can be used.
[0015]
The organic filler can be selected without any particular restrictions such as wood based wood powder, wood chips, paper powder, etc., but especially wood powder is generally broken by a cutter mill or the like. These are pulverized with a ball mill, an inverer mill or the like into a fine powder.
It is important that the average particle size is 1 to 200 μm, preferably 5 to 100 μm. 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, the mechanical strength is lowered if the dispersion into the resin is poor. On the other hand, if it is larger than 200 μm, the homogeneity, flatness and mechanical strength of the molded product are lowered.
[0016]
Further, the blending amount of the wooden filler can be appropriately selected from 10 parts by weight to 500 parts by weight, but the optimum blending amount varies depending on the use of the decorative material. Specifically, when an olefin resin is used as the thermoplastic resin, the wood-based filler is 100 parts by weight of the thermoplastic resin for applications such as cutting or V-cut processing after being molded into a flat plate by compression molding or the like. However, it is desirable to improve post-processability such as machinability by 50 to 500 parts by weight, more preferably 100 to 500 parts by weight, but for applications processed by profile extrusion or injection molding, moldability and homogeneity In order to increase the amount, the wood-based filler is preferably 10 to 200 parts by weight, more preferably 15 to 150 parts by weight with respect to 100 parts by weight of the thermoplastic resin.
In addition, when the blending amount is higher than 100 parts by weight with respect to 100 parts by weight of the thermoplastic resin, dispersibility in the resin is particularly important, and it is possible to use a granular wooden filler with relatively little cilia. preferable.
As a wooden filler with less cilia, a polishing rod obtained by polishing a particle board or the like is mainly used.
The wood resin molding may contain the wood filler as a whole, or if it does not impair recyclability, wood texture, workability such as cutting and nailing, for example, a skin layer made of a similar thermoplastic resin, etc. There may be a layer without filler.
[0017]
The foaming agent used at this time is not particularly limited. For example, azodicarponamide, sodium bicarbonate, sodium carbonate, benzenesulfonyl hydrazide, dinitrosopentamethylenetetramine, toluenesulfonyl hydrazide, 4, 4, And oxybis (benzenesulfonyl hydrazide). These may be used alone or in combination.
The amount of addition differs depending on the resin selected and the thickness of the layer, but in order to prevent the formation of a low foamed layer and prevent it from being bent, the polyolefin resin is less than 3 parts by weight relative to 100 parts of the resin. The proportion is preferably in the range of 1 to 3 parts by weight. If it is too small, there is no effect of lightening the foam and increasing the volume. If it exceeds 3 parts by weight, a “bending” may appear. Moreover, in order to form a highly foamed layer and to give softness, it is 3 to 6 parts by weight, and if it is less than 3 parts by weight, the softness is insufficient, and if it exceeds 6 parts by weight, it is too soft.
[0018]
The organic filler and the thermoplastic resin are kneaded with a bumper mixer, mixed with a pelletizer, mixed with a twin screw extruder kneader, or pelletized with a twin screw extruder kneader, or mixed into a pellet. It is common.
In particular, since the organic filler has a high moisture content, it causes foaming during molding. Therefore, it is desirable to reduce the moisture content to 8% or less in advance using a dryer or a hobber dryer before kneading.
In addition, when recycling the product of the present invention, if necessary, add a filler, a thermoplastic resin, various additives, etc. to the crushed invention product and pelletize again. In this case, the method is not particularly limited.
[0019]
Foam is made by a plastic molding method using ordinary thermoplastic resin. However, if the cross section of a plate or the like is a simple rectangle, or if the cross section is complicated and the long cross section is the same in the longitudinal direction, profile extrusion is used. For the molding method, three-dimensional shape or three-dimensional shape, a known molding method such as an injection molding method can be used.
In order to obtain a multilayer structure such as the outermost layer, the outermost layer, and the intermediate layer, in the profile extrusion molding method, each layer is extruded and overlapped. At this time, it is possible to extrude the foamed one in the extruder, or it may be foamed after the extrusion. Determined by the selected resin or foaming agent. In addition, a low foaming layer can be provided by providing a cooling partition so that the intermediate layer (center layer) is subjected to foaming restriction in the resin flow direction during the cooling and sizing from extrusion. A method other than extruding each layer and then laminating may be used.
[0020]
The decorative sheet is obtained by printing a design such as a wood grain, a stone pattern, a cloth pattern, and an abstract pattern on a thermoplastic resin film with a printing ink.
In particular, the thermoplastic resin film can be easily recycled by using a thermoplastic resin film similar to the foam. In addition, the decorative material has good adhesion and adhesion to the foamed layer.
[0021]
The ink used for printing may be suitably selected from nitrified cotton, cellulose, vinyl chloride-vinyl acetate copolymer, polypinyl petital, polyurethane, acrylic, polyester, and the like alone or each modified product as a binder.
These may be any of aqueous, solvent-based and emulsion types, and can be arbitrarily selected from a one-component type or a two-component 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 common method is a method of curing with isocyanate using urethane-based ink. In addition to these binders, colorants such as pigments and dyes, extender pigments, solvents, and various additives contained in ordinary inks are added.
Particularly frequently used pigments include condensed azo, insoluble azo, quinacridone, isoindoline, anthraquinone, imidazolone, cobalt, phthalocyanine, carbon, titanium oxide, iron oxide, mica and other pearl pigments.
In addition, 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 or a gloss mat method, etc. .
Moreover, the additive used for a thermoplastic resin layer can use the same thing as a foam.
[0022]
There is no restriction on the configuration of the decorative sheet itself. For example, back-printed single-layer decorative sheets printed on a colored sheet or printed on the back side of a transparent sheet, a transparent sheet on a sheet printed on a colored sheet, dry lamination, extrusion lamination, thermal lamination, etc. Can be appropriately selected according to the use from the reverse layer decorative sheet bonded together.
[0023]
Also, the lamination method for 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, in the case of a flat plate, an adhesive is applied to a flat plate or decorative sheet, and a roll laminating method in which it is bonded with a roll, a molded product having the same shape in the longitudinal direction, such as profile extrusion molding, a lapping method, A vacuum press laminating method or the like can be used for the foam having a three-dimensional surface.
In addition, simultaneous painting can be performed in which a decorative sheet is pasted simultaneously with molding by a profile extrusion molding simultaneous laminating method, an injection molding simultaneous laminating method, or the like.
In the case of thermoplastic resins that are difficult to adhere, such as olefin resins, surface treatment such as corona discharge treatment, ozone treatment, plasma discharge treatment, flame treatment, primer coating, etc., should be applied to the foam surface as necessary. Is desirable.
[0024]
【Example】
Hereinafter, the present invention will be described in detail by way of examples.
<Example 1>
As the thermoplastic resin, 90 parts by weight of homopolypropylene resin and 10 parts by weight of homopolypropylene modified with maleic acid were used. On the other hand, as an organic filler, wood was broken by a cutter mill and then ground by a ball mill. Using a woody powder with an average particle size of 20 μm in powder form, a blend with 100 parts by weight of this powder was uniformly mixed by a twin-screw extrusion kneader and pelletized to prepare a resin composition containing a woody powder. .
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 polypropylene resin as a thermoplastic resin.
This master batch is mixed with the pelletized resin composition containing a wood-based powder, and two types are prepared so that 1% (for low foaming) and 3% (for high foaming) of the total weight part are added. And fed to the profile extruder.
The profile extrusion machine has three profile extrusion heads arranged in parallel with the top, middle and bottom, and is equipped with two rolls that can adjust the gap between a pair of rolls in front of the head, and extruded resin. Is taken over.
In the profile extruder, a low foaming composition was supplied to the middle head, and a high foaming composition was supplied to the upper and lower heads. The foamed extrudate extruded from the upper and lower heads has a cross section of width 100 mm × thickness 2 mm, and the foamed extrudate extruded from the inner head has a cross section of width 100 mm × thickness 6 mm, width 100 mm. The length of a cross section (Fig. 1) having a width of 100 mm and a thickness of 10 mm in which the outer surface is a high foamed layer 4 and the central part is a low foamed layer 3 is guided to two rolls so that the surfaces overlap with the top, middle and bottom. Foam 1 that was long in the direction was created.
Both surfaces (surface layers) of this foam 1 are soft, and when pressed with a finger, it is lightly recessed, and when released, it returns to its original flat state. Without (impact resistance), and almost no sound. When one surface of this foam was affixed to a plywood to which a 2-diameter wire was fixed as a base material, the other surface was kept flat.
In addition, in the foam 1, foam cells were visible and hidden on the surface, and the wood texture was similar to the surface of wood.
[0025]
<Example 2>
As a thermoplastic resin sheet, a 100 μm colored polypropylene sheet formed by blending a random polypropylene resin with a pigment such as iron oxide or titanium oxide is used to perform wood grain printing with urethane-based ink, and the extrusion lamination method is used. Homopolypropylene was simultaneously laminated with an embossed thickness of 100 μm, and further, a primer coat was applied to the back surface and a top coat was applied to the front surface to prepare a decorative sheet 5 made of a polyolefin resin.
On the other hand, the surface of the foam 1 produced in Example 1 is subjected to corona discharge treatment, and the decorative sheet 5 is laminated and covered around the cross-section of the foam 1 by a lapping method, as shown in FIG. A decorative material 2 as shown was prepared.
The decorative sheet 5 has a softness similar to that of the high foam layer 4 of the foam 2, and the two high foam layers 4 on which the decorative sheet 5 of the decorative material 2 is laminated are soft and lightly recessed when pressed with a finger. When I let go of my finger, it returned to its original flat state. I tried hitting the squares, but they were not scratched, cracked (impact resistance), and almost no sound. In addition, one surface of this decorative material 2 was attached to a plywood to which a wire having a diameter of 2 mm was fixed as a base material, but the other surface maintained a flat surface.
[0026]
<Example 3>
Using a transparent random polypropylene resin sheet as the thermoplastic resin sheet, a decorative sheet 5 having a wood grain pattern printed on the back surface was prepared.
As shown in FIG. 3, the decorative sheet 5 was attached to the surface of one highly foamed layer 4 in the foam 1 of Example 1 to prepare a decorative material 2.
This decorative material 2 has a wood texture similar to the surface of the wood with the foam cells on the surface of the foam 1 visible and hidden, and at the same time, the wood texture of the decorative sheet 5 so that it feels more woody. Met.
[0027]
【The invention's effect】
Since this invention is the above structure, there exist the following effects.
In other words, the surface is soft, impact-resistant, sound-absorbing, can absorb the unevenness of the foundation, has a wood texture, and even if a decorative sheet is attached to the surface, the same effect At the same time, it was possible to obtain a product having no “bending” or “deflection” phenomenon.
Therefore, the present invention exerts an excellent practical effect in applications to building surface materials such as floor materials, wall materials, ceiling materials, and joinery.
[Brief description of the drawings]
FIG. 1 shows a first embodiment of the present invention, which is a foam that has a low foam layer 3 in the center and is a multi-layered body that has a high foam layer 4 on both outsides adjacent to the low foam layer 3 in the center. 1 is a cross-sectional view showing the structure of 1. FIG.
2 shows the structure of a cosmetic material 2 in which a decorative sheet 5 that is a printed thermoplastic resin sheet is laminated and covered around the cross section of the foam 1 of FIG. 1 showing Example 2 of the present invention. It is sectional drawing shown.
3 shows a decorative sheet 5 which is a printed thermoplastic resin sheet on the surface of one external high foam layer 4 in the foam 1 of FIG. 1 showing Example 3 of the present invention. 3 is a cross-sectional view showing a structure of a decorative material 2. FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Foam 2 ... Cosmetic material 3 ... Low foam layer 4 ... High foam layer 5 ... Cosmetic sheet

Claims (1)

In a cosmetic comprising a foam obtained by foaming a mixed composition containing 90 parts by weight of a homopolypropylene resin as thermoplastic resin , 10 parts by weight of homopolypropylene modified with maleic acid, and a wood powder having an average particle size of 20 μm, The center portion is a low foam layer, both outer sides adjacent to the center portion are high foam layers, and the surface of at least one of the high foam layers of the foam includes a polypropylene resin with a wood grain pattern. A decorative material in which decorative sheets are laminated.

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