JPH02127037A - Manufacture of laminate material - Google Patents

Abstract

PURPOSE:To improve the rigidity and heat resistance of a laminate material by a method wherein a coating agent of specific composition is applied on a water-permeable or water-absorbing base of which the temperature of thermal deformation is 150 deg.C or above and thereafter a connecting material is laminated on the enameling layer and heated at a prescribed temperature. CONSTITUTION:A coating agent is prepared by compounding resin water emulsion of 100 pts.wt. (amount of a solid), foaming resin particles of 50 to 70 pts.wt. and non-foamed resin particles of 5 to 50 pts.wt. This coating agent is applied on a water-permeable or water-absorbing base A of which the temperature of thermal deformation is 150 deg.C or above, so as to provide a coated layer, and a connecting material B is superposed on this coated layer to form a laminate. After the laminate is compressed from one or opposite sides thereof, it is heated at the foaming temperature of the foaming resin particles in a degree wherein the base A and the connecting material B are not deteriorated, so as to foam the foaming resin particles, and thereby a foamed body layer E is formed. A laminate material thus obtained is improved in rigidity, thermal resistance and a shielding property.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention is applicable to automobile ceiling materials, door trims, rear shells,
The present invention relates to a method for manufacturing a laminated material that has both rigidity and heat insulation properties and is useful as seat banks, trunk lids, trunk-related parts, interior materials such as floors, ceiling materials for buildings, wall materials, and cushioning materials.

[Prior art]

Conventionally, the above-mentioned automotive interior materials have been coated or impregnated with an aqueous emulsion of thermoplastic resin with a softening point of 100 to 130°C on resin felt or needle punch carpet made of phenol-aldehyde condensation resin filled with fibers, and then heated and dried. to remove moisture and obtain a moldable nonwoven fabric.
Automobile interior materials obtained by further heating and press-molding this material are well known. Among these materials, resin felt has excellent rigidity, heat-resistant shape retention, dimensional stability, and shielding properties, but has the drawbacks of poor moldability, impact resistance, and lightness. In addition, an interior material made of needle bunch carpet impregnated with emulsion resin has the advantage of being able to be laid in places with complex shapes, but the fixation of the fibers of this nonwoven fabric is achieved by entangling the fibers with each other by needle punching and by applying emulsion resin to the fibers. This is due to adhesion, but the emulsion is applied and
The apparent density of the impregnated nonwoven fabric is 0.08 to 0.13 g.
/cm', which has the disadvantage that the filling effect with emulsion resin is poor. Furthermore, since the filling effect is insufficient, there is a drawback that the shielding performance is inferior.

Separately, we have prepared (a) a resin aqueous emulsion with a solid content of 100 parts by weight and a particle size of 1.5 aun or less on a base fabric (A) made of a material with a heat distortion temperature of 150°C or higher. A backing coating agent containing 50 to 700 parts by weight of certain expandable styrene resin particles is applied, and then a layer of material with a heat deformation temperature of 150°C or higher is applied onto this applied banking coating layer. The base fabric (B) is layered to form a laminate, and the laminate is compressed from one or both sides of the laminate to impregnate a portion of the coating agent into the base fabric (B). The expandable styrene resin particles are foamed by heating at a temperature higher than the softening point of the resin of the expandable styrene resin particles and lower than the heat deformation temperature of the base fabrics (A) and (B). We proposed a method for producing a laminate material characterized by drying an aqueous emulsion to obtain a laminate having a foam layer between the base fabrics (A, B) (Japanese Unexamined Patent Publication No. 63-1
No. 39732).

This laminated material has the advantage of being rich in heat insulation, moldability, and barrier properties due to the presence of the foam layer.

[Problems to be Solved by the Invention] An object of the present invention is to improve the rigidity and heat resistance of the laminated material described in JP-A-63-139732.

The second object of the present invention is to expand the scope of the invention to various base materials and adherends, such as gypsum boards, decorative resin films, and paper, instead of the base fabrics (A) and (B). be.

[Specific Means for Solving the Problems] In the present invention, the foam layer forming composition described in JP-A-63-139732 contains an aqueous resin emulsion, expandable thermoplastic resin particles, and non-expandable resin particles. Blend.

In addition, at least one of the base material and adherend material constituting the laminated material may be water-absorbing or water-permeable in order to dry the water in the emulsion, and the other may or may not have water-absorbing properties. It's okay.

Therefore, the target materials for base materials and adherends are not only non-woven fabrics and woven fabrics, but also gypsum boards, decorative cement boards, paper, perforated resin films, cardboard, white pole paper, iron plates, galvanized iron, aluminum plates, wood, etc. This will expand its use to include building materials, roofing materials, automobile interior materials, packaging materials, and carpets.

That is, the first aspect of the present invention is to apply (a) a solid aqueous resin emulsion, 100 parts by weight (b) 0 foam, on a water-permeable or water-absorbing base material (A) having a heat distortion temperature of 150°C or higher. A coating agent containing 50 to 700 parts by weight of foamed resin particles (c) and 5 to 50 parts by weight of non-foamed resin particles is applied, and then adherend material (B) is applied on top of this coating layer. After stacking them to form a laminate and compressing the laminate from one or both sides of the laminate, the temperature is such that the expandable resin particles foam and the base material (A) and adherend material (B) do not deteriorate. It is characterized by foaming the expandable resin particles by heating at a temperature and drying the aqueous resin emulsion to obtain a laminate having a foam layer between the base material (A) and the adherend (B). The present invention provides a method for manufacturing a laminated material.

The second aspect of the present invention is that (a), 100 parts by weight of a resin aqueous emulsion solid content, (b) foaming A coating agent containing 50 to 700 parts by weight of foamed resin particles (c) and 5 to 50 parts by weight of non-foamed resin particles is applied, and then adherend material (B) is applied on top of this coating layer. After stacking them to form a laminate and compressing the laminate from one or both sides of the laminate, the temperature is such that the expandable resin particles foam and the base material (A) and adherend material (B) do not deteriorate. It is characterized by foaming the expandable resin particles by heating at a temperature and drying the aqueous resin emulsion to obtain a laminate having a foam layer between the base material (A) and the adherend (B). A method for manufacturing a laminated material is provided.

A B Base material A and adherend material B are different from each other because it is necessary for water in the aqueous resin emulsion to dissipate when heating the laminate to foam the expandable resin particles. It is sufficient that at least one of the material B has water absorbency and water permeability (breathability). Of course, both the base material A and the adherend material B have water absorbency
It may be made of a water-permeable material.

In the present invention, the base material A1 and the adherend material B are the base material A before being coated with the resin aqueous emulsion composition for forming the foam layer.
After coating, what is superimposed on this resin aqueous emulsion composition layer is defined as the adhesion process.
・ □Therefore, these materials include non-woven fabrics,
Woven fabric, gypsum board, decorative wood cement board□, tufted carpet, perforated resin film (including synthetic paper), open-cell foam sheet, super absorbent resin sheet, paper,
Water-absorbent and water-permeable materials such as white cardboard, cardboard, and wood;
Non-water-absorbing and water-impermeable materials such as resin films (including synthetic paper), closed-cell foam resin sheets, tiles, and metal plates are used.

These materials are further divided into the materials themselves, rigid tiles, decorative wood cement boards, metal plates, gypsum boards, wood, etc.; and the materials themselves, flexible non-woven fabrics, woven fabrics, resin films, foam sheets, paper, etc. When the latter flexible material is used as a partner of the base material (A) and the adherend (B), the laminated material has thermoformability (compression molding, mating die molding, vacuum molding).

The heat distortion temperature of the base material (A) and adherend material (B) is 15
．． The temperature is preferably 0°C or higher, which is 40°C or more higher than the softening point of the material resin of the expandable resin particles in the coating agent, and by selecting such a material, thermal shrinkage during foaming can be prevented.

1 tM In the present invention, the foamable resin liquid applied to the material (A) basically contains an aqueous resin emulsion, foamable resin particles, and non-foamed resin particles.

The adhesive resin used in the aqueous medium in the resin aqueous emulsion (a) is a resin whose minimum film-forming temperature is lower than the heating temperature, and specifically, n-propyl methacrylate, styrene, acrylonitrile, methacryl, etc. Methyl acrylate, methacrylic acid, itaconic acid, acrylamide, 2-ethylhexyl acrylate, n-butyl acrylate, ethyl acrylate, isopropyl acrylate, 2-ethylhexyl methacrylate, n-propyl acrylate, n-butyl methacrylate , vinyl acetate, ethyl methacrylate, vinyl chloride, vinylidene chloride, acrylic acid 2
-Hydroxyethyl, 2-hydroxypropyl acrylate, 2-hydroxyethyl methacrylate, 2-methacrylate
- an aqueous emulsion of a homopolymer of hydroxypropyl, diethylene glycol monoacrylate, glycidyl methacrylate, glycidyl acrylate, N-methylol acrylamide, N-methylol methacrylamide, butadiene, or a copolymer of two or more of these monomers, and Tg is a mixture of an aqueous resin emulsion whose temperature is above the heating temperature and an aqueous resin emulsion whose temperature is below the heating temperature, and examples include those whose minimum film forming temperature of the mixture is below the heating temperature.

The resin solid content concentration in the aqueous emulsion of these resins is usually 20 to 60% by weight, and the diameter of the dispersed resin particles is usually 10 μm or less, preferably 0.05 to 1.0 μm.
It is μm.

The foamable resin particles (b) contained in the foamable resin liquid (coating agent) include styrene containing a polymerization initiator and, if necessary, vinyl monomers such as methyl methacrylate, vinylbenzene, and acrylic acid, in water. A vinyl monomer such as styrene is polymerized by dispersing the polymer particles in the Qi liquid and heating it, and then an expanding agent such as butane or heptane is injected into the Qi liquid in which the polymer particles are dispersed. When a vinyl monomer such as styrene is subjected to suspension polymerization, the polymerization is carried out while supplying the swelling agent to the suspension. or expandable α-methylstyrene/styrene copolymer particles manufactured by coexisting α-methylstyrene with the above styrene, or expandable α-methylstyrene/styrene copolymer particles manufactured by coexisting the above styrene with acrylonitrile and butadiene. A foamable acrylonitrile-butadiene-styrene copolymer resin (foamable ABS) or the like can be used.

These expandable resin particles generally have a particle size of 1.5 m.
If the above particle size exceeds 1.5 mm, the workability of mixing with the resin aqueous knee fulgion will be poor, and the expandable resin particles will not dissolve in the emulsion liquid. This is not preferable because it tends to move to the upper layer of the foam and separate, which deteriorates the storage stability of the foamable resin liquid itself. Moreover, if the diameter of the resin particles is large, it becomes difficult to coat the cement-based outer layer material and the coating properties are lowered, which is not preferable. Furthermore, after the foamable resin liquid is applied to the cement-based outer layer material and dried, the foamed resin particles tend to fall off.

Since the expandable resin particles used are finer than those used in the molding of ordinary foamed products, non-standard products can be utilized in the process of manufacturing expandable resin particles.

The non-foamed resin particles (c) have a particle size of 15 to 2.0.
00 Miku "J's polystyrene, polypropylene, polyethylene, polyamide, ABS, polyethylene terephthalate, polycarbonate-1, modified polyphenylene ether, etc. can be used, and the foamable resin particles (b) Sotsuki J
If a material resin having a melting point 20°C or more higher than that of lj is used, the heat resistance of the laminated material will be further improved.

In addition to the above essential ingredients, if necessary, extender pigments such as calcium carbonate, aluminum hydroxide, clay, talc, barium sulfate, pigments such as Portland cement, red iron oxide, titanium oxide, carbon, etc., and glass! Ali! Il,
Synthetic fibers, inorganic fibers, metal fibers, shirasu balloons, perlite, lightweight aggregates of vacuum light shade, flame retardants, dyes, iron powder, iron oxide, DOP, B [3P, CDU, XDP
plasticizers such as toluene, coalescent agents such as mineral spirits, methyl ethyl cellulose, polyvinyl alcohol,
Other thickeners, antifreeze agents, antifoaming agents, dispersants, foaming agents, wetting agents, emulsifiers, etc. can be blended.

Further, as a crosslinking agent, an aziridine compound, a hydrazine compound, a melamine, a urea compound, or an amine compound may be used in combination.

In the resin aqueous emulsion (a), foamable resin particles (
b) is blended in an amount of 50 to 700 parts by weight, preferably 100 to 600 parts by weight, based on 100 parts by weight of the resin in the emulsion. The amount of non-foamed resin particles (c) is 5 to 100 parts by weight based on 100 parts by weight of the resin in the emulsion (n).
It is used at a rate of 50ffiffi parts.

The foaming resin liquid (coating agent) is generally applied using rolls, spray foam coating, etc., and is pressed with nip rolls to form an emulsion. ! Impregnate the ffi■I outer material layer.

The amount of foaming resin liquid applied is generally 100 to 100% as solid content.
1.700 g/em", preferably 300-1.3
It is about 00g/store 2.

In particular, when the resin emulsion is expanded 3 to 7 times, coating workability, coating amount, and thickness adjustment become easier.

In addition to acting as an adhesive for the foam particles described above, the aqueous resin emulsion also acts as a carrier when applying the foamable resin particles to the base material (A),
It also serves as an adhesive between the adherend (B) and the foam layer, and imparts flexibility and rigidity to the base material and adherend.

■Ririn■ Manufacturing method Excluded Laminated materials are obtained by applying a coating agent to the surface of the base material (A), and then stacking the adherend material (B) on the surface of this coating agent. The base material (A) and/or the adhesive (B) are impregnated with the emulsion by squeezing this laminate from one or both sides with a squeeze roll, press, etc., and then this laminate is made into a foamable material. The temperature is higher than the melting point of the resin particles, and the base material (A
), the foamable resin particles are foamed by heating at a temperature lower than the heat distortion temperature of the material of the adherend (B), and the foam layer (E ) on the front and back sides of the base material (A) and adherend material (
A laminated material (S) in which B) and B) are integrally bonded is manufactured (see FIG. 1). At this time, it is also possible to remove water at a temperature at which the expandable resin particles do not foam, for example, in the case of polystyrene, about 90° C., and then raise the temperature to a temperature at which foaming occurs.

When using expandable polystyrene particles (7 g at 104°C) and the base material or adherend is made of polyester (melting point is about 240°C) or polypropylene (melting point is 164°C), set the drying temperature to 110 to 140°C. be done.

The heating drying of the applied emulsion and the foaming of the expandable resin particles can be carried out by any method.

For example, a heating cylinder, an infrared heater, a hot air dryer, a crisp dryer, etc. can be used, but it is preferable to use a hot air dryer □.

This heating causes the expandable resin particles to expand approximately 2 to 50 times,
Foam particles or non-foamed resin particles having a particle size of 0.5 to 4.5 m also form a continuous foam 1).

This foam layer provides insulation, rigidity, and barrier properties to the laminate. When both the base material (A) and the adherend material (B) are flexible materials such as nonwoven fabric, woven fabric, resin film, or foamed resin sheet, thermoformability is also imparted to the laminated material.

As another embodiment, a case will be described in which the base material (A) is a rigid water-absorbing gypsum board and the adherend material (B) is a nonwoven fabric or a lath net.

A coating agent is applied on the plasterboard (A), and then a nonwoven fabric (B) is applied.
)' to form a laminate, heat is applied from the nonwoven fabric side to dry the aqueous emulsion and foam the expandable particles in the coating agent to form a foam layer (E) to form a laminate. (S) is formed. At this time, gypsum board (A)
The resin in the emulsion impregnated into the nonwoven fabric (B) improves the adhesive strength between the gypsum board and the foam layer, and between the foam layer and the nonwoven fabric. When used as an interior wall material, this laminated gypsum board has the effect of improving soundproofing, moisture absorption, heat insulation, and water resistance. Furthermore, it is also possible to coat the nonwoven fabric (B) side of this laminated structure with acrylic lysine (K) and use this laminated material as a building exterior wall material (sizing board) having heat insulating properties. Alternatively, resin mortar may be applied to the nonwoven fabric side. On the other hand, after obtaining a waterproof laminated plasterboard using resin film or paper instead of non-woven fabric, the foam layer is thermoformed by pressing the surface at 120-180'C to create an arbitrary uneven pattern. It is also possible to apply. These materials are best used as wall materials, but because they have water resistance, fire resistance, soundproofing, and heat insulation properties, they can be used as is or with patterns to be used as interior materials or ceiling materials. It can also be used as a material.

〔Example〕

The building material of the present invention will be specifically explained below with reference to Examples.

Example 1 Styrene (80% by weight) and n-butyl acrylate (20% by weight)
To 100 parts by weight of an aqueous resin emulsion (resin average particle size 0.2 μm, solids content 50%, glass transition point 80°C) produced by emulsion polymerization of 4% polycarbonate), aqueous resin with a particle size of 0.5 mm or less ( Expandable polystyrene particles with an average particle size of 0.33 mm,
゛Styro Ball IBE” [Mitsubishi Yuka Verdicier■
250 parts by weight of the product, containing 5.8% butane] and 25 parts by weight of polypropylene particles with a particle size of 300μ,
Furthermore, a thickener called ``Latecol'' manufactured by Mitsubishi Yuka Verdice ■ is added to this.

(Product name) to make the viscosity at 25℃ 3000 cps
The foaming resin liquid (coating agent) 3a prepared in
A foamable resin liquid layer 3a was formed by applying the resin to form a foamable resin liquid layer 3a.

Next, on this foamable resin liquid layer 3a, a polyester nonwoven fabric 4 manufactured by Nippon Lutrabil ■ was placed at 100 g/m''.

Then, this laminate was heated in a hot air drying foaming machine 8 at 140°C.
After heating and drying for 0 minutes, a foamed resin layer in which the expandable polystyrene particles were foamed approximately 10 times was formed, thereby obtaining the building material 1a of the present invention shown in FIG. 2.

When the water permeability of this building material 1a was measured according to the water permeability test of JIS A-9610, it was found to be 0.5 mf or less, indicating that it has excellent water-blocking properties.

When the polystyrene foam particles in the foamed resin layer in this building material 1a were measured, the particle size was 0.5 to 1.511.
IIll, and the bulk density was approximately 0.10 g 7 cm2.

Separately, this building material 1a was used as an inner wall material, and 1,0% of acrylic lysine 5 was applied to the nonwoven fabric surface of this building material 1a.
00 g/m2 to obtain an exterior wall material 6a shown in FIG.

The adhesion and heat insulation properties of the building material 1a and the exterior wall material 6a were measured using the following methods, and good results as shown in Table 1 were obtained.

1. Cut the outer wall into 4cm x 4cm pieces with a cutter knife, and measure (a) the adhesive strength between the acrylic lysine layer and the foamed resin particle layer and (
b) The adhesive strength between the foamed resin particle layer and the cement-based outer layer material was measured using an Instron universal testing machine.

The heat insulation properties of the foam layer were measured according to Mochizensa JIS A-1412.

Table 1 The above building material 1a was heated with a press at 180°C for 2 minutes to form a head cut texture pattern with unevenness of 10 mm in height. It was constructed by spraying a chemical agent (manufactured by Kagaku Kogyo ■).

〔Effect of the invention〕

The building material of the above example has a cement-based outer material layer and a foamed resin particle layer, so it has fire resistance, heat insulation, sound insulation, and waterproof properties, and is used for building materials such as wall materials, especially siding boards. It has extremely excellent performance as a material.

In particular, this construction material is manufactured in a factory with a foamed resin layer attached to the cement-based outer layer material in advance, so there is no need for insulation work at the construction site, and when used on external walls, ricin is applied directly onto it. Compared to conventional wall materials, it requires fewer steps and requires less material, so it can be constructed in an extremely short number of work days.

Example 2 Polyester fiber and polypropylene fiber 200g/
A plain type needle-punch carpet (80% polyester fiber) made of M2 was used and screen printing was performed on the surface.

JB-1 cloth 15 denier, a fiber mat (150 g/m) made of randomly stacked polyester fiber waste and polypropylene (melting point 164°C) fibers with a fiber length of about 100 aun.
50 per square inch using an 18-32-3 RBO needle
The carpet was needled at a book rate, heated to 200° C., and cool-pressed to obtain a needle-punched carpet (80% polyester fiber) with a thickness of about IM.

1fMU"I'?MLz&17 Acronal S-886: Cross-linked styrene manufactured by Mitsubishi Yuka Verdice ■
Acrylic acid ester copolymer aqueous emulsion (Film forming temperature 20℃5 Crosslinked resin Tg approx. 110℃1 Solid content concentration 5
0% by weight) Above needle punch carpet A (basis weight 200g/m
On the side opposite to the printed side of z), (a), 200 parts by weight of Acronal S-886 (b), 100 parts by weight of expanded polystyrene particles (containing 5.5% by weight of butane) with an average particle size of 33 mm. (c) A coating agent consisting of 10 parts by weight of non-foamed polypropylene particles with an average particle size of 300 μm was applied to a solid content of 700 g/m, and then needle punch carpet was used as the adherend (B). were laminated and then compressed from both sides with rolls to impregnate the nonwoven fabric layers on both sides with the emulsion.Then, the above needle punch carpet laminate impregnated with the emulsion was rolled from the needle punch carpet (B) side by 130 mm.
Heating with hot air at ℃ for 15 minutes removes moisture and expands the expandable polystyrene particles to a bulk density of approximately 0.14.
g/cI11! , a layer of continuous polystyrene foam particles with a particle size of 1.0 mm or less (density 0.6 g/c++
A laminated material was produced in which the laminate material (+') was sandwiched.

The thickness of the base material (A) of the laminate material was approximately 2 mm, the thickness of the foam layer was approximately 5 mm, and the thickness of the adherend material (B) was approximately III11 mm.

Furthermore, this laminated material was heated for 60 seconds in a far-infrared oven at 180°C to sufficiently soften the backing material resin and polystyrene foam, and then pressed into a 20 kg mold using a cooling press mold.
/c+m'' pressure was applied for 1 minute to produce a carpet for the interior floor of an automobile.

Comparative Example 1 In Example 2, a resin emulsion was used between the upper and lower nonwoven fabric layers, but the foamed polystyrene particles and non-expanded polystyrene particles were not sandwiched (not used). Approximately 3 aua, A layer 211
1111SB layer (1 mm thick) was obtained, and further molded to obtain a carpet for the interior floor of an automobile.

Comparison □Comparative example 2.・　　　　2.

When the same procedure was used as in Example 2 except that material (B) was not used, the smoothness of the back surface was poor, resulting in non-uniform foaming and foaming during drying and foaming, which resulted in a large amount of foaming on the substrate (A) side. I made it to Kano.

In addition, since the foaming was random, the surface had many irregularities, making it difficult to obtain smoothness and properties.

8. 'Three-point bending strength is Pa, Immediate breakage (cracking), Lo,
It was as low as 2.6 kg/5 cm wide.

Example 3-78, Comparative Examples 3 to 6 Automobile interior floor interior carpets were obtained in the same manner as in Example 2, except that the composition of the coating agent and the coating amount were changed as shown in Table 1.

In addition, evaluation of carpent is based on the following method.

Three-point bending strength: Test specimen (length 150+mm, width 50mm) span 100
The specimen was supported by a cylinder, and the maximum bending resistance value was measured when a deformation load was applied perpendicularly to the specimen at a rate of 50 mm/min using an Instron type testing machine at the central point of the specimen.

Impermeable: Conforms to JIS A-6910 water permeability test.

Water M250mm, and judgment is made after 12 hours.

×: Water did not penetrate through the back surface and remain.

△: Water bleeding is observed on the back side.

O: No water bleeding was observed on the back side.

Adhesive crab test piece (vertical 150III11, horizontal 30 plates) Peeling strength of the foam layer and base material (A) is measured using an Instron type tester at a speed of 50 mm/min.

Automotive interior carpet obtained by heat-resistant nibless molding is 250 mm long.
++un, cut horizontally 250M, and make X as shown in Figure 5.
The sample was placed on a test stand at the marked part, and the sagging height -h at 5 points (■) to (■) was measured when the sample was stored at 85° C. for 5 hours. The degree of deformation of the carpet was evaluated.

Rigidity: Place a test piece (length: 300 mm, width: 300 mm) on a stand with outer dimensions of 300 mm x 300 mm, +11 dimensions of 250 x 250 embryos, and place a 2.0 mm dia.
A pressure of "kg/cm" was applied, and if the sinking distance of the center of the sample piece was within the wall thickness of the sample piece, the rigidity was considered good, and if it exceeded the wall thickness, the stiffness was judged to be poor. , the abbreviations in Table 1 mean the following.

EPS: Expandable polystyrene particles HP: Expandable particles of α-methylstyrene/styrene/acrylonitrile copolymer with a particle size of 1.5 rtm PP: Polypropylene particles with a particle size of 300μ GPS:
Non-expandable polystyrene particles Acronal YJ~l1
00D: Aqueous emulsion of styrene/acrylic acid ester copolymer of 3'lt Yuka Verdice ■ (Tg 55°C 1 solid content concentration 4 solid content concentration 4) Aqueous vinylidene chloride copolymer emulsion of Sanmugi Yuka Verdice ■ Emulsion (7g20"c, solid content concentration 55% by weight) (Effect) The laminate material (interior material) of the present invention is a laminate material with significantly improved rigidity, heat insulation and shielding properties due to the presence of continuous foam layers. It becomes.

Further, by heating the laminated material to a temperature at which the foam softens and melts and press-molding the laminated material, the laminated material can be shaped into a desired shape and thickness.

Furthermore, since both sides of the foam layer are covered with the base material and the adherend, the sound of the foam layer rubbing is not generated, and the durability of the foam layer when it is broken is improved. Furthermore, it has excellent compatibility with other materials.

2 and 3 are cutaway sectional views of building materials according to embodiments of the present invention, FIG. 4 is a sectional view of an apparatus for producing a laminate material of the present invention, and is a perspective view of a heat-resistant measuring device,
Figure 5 (opening) is a back view of the sample piece showing the measurement location on the sample piece, and Figure 5 (c) is a side view of the measuring instrument.

la, lb...building material, 2...gypsum board, 2
a... Resin impregnated layer, 3... Foamed resin particle layer, 3a.
... Foaming resin liquid layer (coating agent), 4... Shape retaining material layer, 5... Exterior material, 6a, 6b... Exterior wall material, 7...
Licker roller, 8...Hot air drying foaming machine, A...
Base material, B...adherent material, E...foam layer.

Patent applicant Mitsubishi Yuka Verdissier Co., Ltd. Agent
Patent Attorney Masahisa Hase Agent Patent Attorney Takaya Yamamoto Figure 3 Figure 4 Figure 5 (B) Figure 5 (C)

Claims (1)

[Scope of Claims] 1) On a water-permeable or water-absorbing base material (A) having a heat distortion temperature of 150°C or higher, (a) 100 parts by weight of an aqueous resin emulsion (b) foamable A coating agent containing 50 to 700 parts by weight of resin particles (c) and 5 to 50 parts by weight of non-foamed resin particles is applied, and then an adherend (B) is layered on top of this coating layer. After combining them to form a laminate and compressing the laminate from one or both sides of the laminate, a temperature at which the expandable resin particles foam and at which the base material (A) and the adherend (B) do not deteriorate. A laminate characterized in that the foamable resin particles are foamed by heating at a temperature of 100 mL, and the aqueous resin emulsion is dried to obtain a laminate having a foam layer between the base material (A) and the adherend (B). Method of manufacturing wood. 2) The base material (A) is selected from nonwoven fabric, gypsum board, decorative cement board, tufted carpet, woven fabric, perforated resin film, open cell foam sheet, super absorbent resin sheet, and wood. , the adherend material (B) is selected from nonwoven fabric, gypsum board, decorative wood cement board, tufted carpet, woven fabric, resin film, foam sheet, paper, cardboard, metal plate, particle board, and tile. The method for manufacturing a laminate material according to claim 1, characterized in that: 3) On a water-impermeable or non-water-absorbing base material (A) having a heat distortion temperature of 150°C or higher, (a) 100 parts by weight of the solid resin aqueous emulsion (b) 50 to 50 parts by weight of expandable resin particles A coating agent containing 700 parts by weight (c) and 5 to 50 parts by weight of non-foamed resin particles is applied, and then the adherend (B) is superimposed on this coating layer to form a laminate. After compressing the laminate from one or both sides of the laminate, heating is performed at a temperature at which the expandable resin particles foam and at which the base material (A) and adherend material (B) do not deteriorate. A method for producing a laminate material, which comprises foaming expandable resin particles and drying an aqueous resin emulsion to obtain a laminate having a foam layer between a base material (A) and an adherend (B). .