JPH03227231A - Foamed sheet with excellent durability - Google Patents

Abstract

PURPOSE:To provide a minutely rugged pattern showing a sharp rugged appearance and enhance durability and moisture absorbing and releasing properties, by a method wherein a part of a foamed material constituting projected parts of numerous minutely rugged patterns is brought into contact simultaneously with both a backing paper and a non-foamable material making direct contact with the paper, and the projected parts of the foamed material brought into the simultaneous contact are formed in the state of being dispersed over the entire area of a surface to be provided with the minutely rugged patterns. CONSTITUTION:A backing paper 1 may be an ordinary one provided with flame resistance. It is preferable, however, that the backing paper 1 is thicker than those commonly used as a backing paper for this kind of foamed sheets. A foamed material and a non-foamable material which constitute rugged patterns 11 provided directly on the backing paper 1 are produced by printing a predetermined pattern with a foamable ink and a non-foamable ink, followed by heating to effect foaming and fixing. Of the numerous minutely rugged patterns 11 composed of the foamed and non-foamable materials, part of projected parts 31 composed of the foamed material is brought into contact simultaneously with both the backing paper 1 and the non-foamable material making direct contact with the paper 1, and the projected parts 31 of the foamed material brought into the simultaneous contact are formed in the state of being dispersed over the entire area of a surface to be provided with the minutely rugged patterns 11.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a highly durable foam sheet, and in particular, to a durable foam sheet that exhibits a sharp and clear uneven appearance and also has moisture absorption and desorption properties. Regarding foam sheets.

[Conventional technology]

Traditionally, for example, architecture, furniture, vehicles, and electrical products.

Various kinds of decorative sheets are known which have fine uneven patterns on the surface of the base material in order to improve the decorative effect.

This uneven pattern can be applied by various methods, but those applied using foaming ink are generally referred to as r-foamed sheets J.

Foamed sheets usually use paper (this paper is generally referred to as ``paper lining'') as a base material.

As mentioned above, this backing paper is generally provided with flame retardancy because it serves as a base material for decorative sheets for buildings, furniture, vehicles, etc.

Backing paper with flame retardant properties has low strength, discolors easily, lacks texture, and has low workability, so there are various restrictions when creating fine uneven patterns with foamable ink. It is said that it is extremely difficult to express highly decorative designs.

Therefore, prior to applying the above-mentioned uneven pattern to the backing paper which has been given flame retardant properties, it has been conventionally possible to cover the entire surface of the backing paper with the uneven pattern with, for example, polyvinyl chloride resin, etc., to increase the strength of the backing paper. Efforts have been made to improve this, eliminate the tendency for discoloration, and improve workability to express highly decorative designs.

On this coating layer of polyvinyl chloride resin, etc., a foaming ink made of polyvinyl chloride resin, etc. containing a foaming agent is used, or the foaming ink and polyvinyl chloride resin, etc. not containing a foaming agent are used. A predetermined pattern is thickly printed using a non-foaming ink, and then heated and foamed or heated and fixed to form a fine uneven pattern.

[Problem to be solved by the invention]

However, the above-mentioned coating layer of polyvinyl chloride resin, etc., and the foaming ink of the polyvinyl chloride resin ring containing a blowing agent printed on it, or the non-foaming ink of the polyvinyl chloride resin ring that does not contain a blowing agent. Since the ink is the same type of resin, it has good compatibility with the ink, and the ends of the convex portions of the above-mentioned uneven pattern are attracted to the coating layer side, making it easy to form a gentle slope.

For example, as shown in FIG. 3, the end 03' of the convex part 03 with the concave-convex pattern is drawn toward the coating layer 2 that covers the entire surface of the flame-retardant backing paper 1 with the concave-convex pattern, and the end 03' The slope becomes extremely gentle, and not only does the level difference between the convex and convex portions become unclear, but sometimes the edges 03', 03' of the adjacent convex portions 03.03
The comrades come into contact with each other and significantly inhibit the formation of an uneven pattern that has a sharp and clear uneven appearance.

For this reason, it has been impossible or extremely difficult to clearly form a fine and complicated uneven pattern by scratching.

As described above, the technical significance of the covering layer 2, which is provided to improve the workability of the backing paper 1 and realize a highly decorative design expression, may end up being ignored.

Furthermore, as is well known, the synthetic resin covering layer 2 as described above is not breathable, and has no moisture absorption or release properties (moisture absorption/release properties), so it cannot be used as wallpaper, vehicle interior materials, etc. When a foam sheet is used, it causes problems such as not being able to exchange with fresh outside air, causing dew condensation, and mold growth.

In order to solve these problems, the inventors of the present invention have:
By directly applying a fine uneven pattern with foam or non-foamed material, we can create a foam sheet that has clear uneven steps and a sharp and clear uneven appearance even when scratched with a fine and complex uneven pattern. , and (2) directly applying a fine uneven pattern made of synthetic resin to the backing paper without providing the above-mentioned coating layer, and at least a part of the concave portions of the fine uneven pattern being exposed parts of the backing paper. On the same day, we separately proposed decorative sheets with moisture absorption and desorption properties.

By the way, when applying a fine uneven pattern of foam directly onto the backing paper in this way, the foam is adhered to the backing paper through its fine cells, so the contact area between the foam and the backing paper is If this exists, strength problems will occur at the contact area.

For this reason, when a foam sheet is used as wallpaper, vehicle interior material, etc., if the surface of the foam sheet is subjected to a strong H vibration force, the foam that is in direct contact with the paper lining may peel off. Otherwise, the foam sheet may peel off, reducing the durability of the foam sheet.

The present invention was made in order to improve this durability, and is a foam sheet with excellent durability that has a fine uneven pattern with clear uneven steps and a sharp and clear uneven appearance. It is an object of the present invention to provide a foamed sheet that also has moisture absorption and desorption properties.

[Means to solve the problem]

As a result of repeated studies to achieve the above object, the present inventor found that the strength of the contact area between the non-foamed material and the backing paper is quite high (
Furthermore, they discovered that the strength of the contact area between the non-foamed material and the foamed material is quite high, leading to the proposal of the present invention.

That is, the present invention relates to a foam sheet in which a countless number of fine uneven patterns of foamed and non-foamed materials are directly applied to a backing paper, the foam forming the convex portions of the countless fine uneven patterns. A part of the lining paper and a non-foamed material that is in direct contact with the lining paper are simultaneously contacted, and the simultaneously contacted foam is scattered over the entire surface of the finely uneven patterned construction surface. The focus is on foam sheets with excellent performance.

As the backing paper in the present invention, the above-mentioned usual flame-retardant paper can be used.

However, as mentioned above, flame retardant materials have problems with strength, and because they do not have a coating layer, the concealment rate (J
(displayed with opacity as specified in I5-P-8138)
Since it is necessary to have a certain degree of high
The thickness of the paper used as the backing paper for this type of foam sheet (generally about 80 g/m2 in basis weight, above J I
5-P-8138 (the hiding rate indicated by the opacity is 90%) (for example, 90g in basis weight)
/m2 or more, preferably 10,090g/m2 or more in basis weight
It is preferable to use a material that is approximately m2 or more and has a concealment rate expressed by the opacity specified in J15-P-8138 above 90%.

However, if it is too thick, not only will the above-mentioned poor workability appear, but it will also reduce the workability when applying it as a decorative sheet to walls, furniture, vehicles, etc., so the upper limit is 1 in terms of basis weight.
It is preferable to set it to about 60 g/m''.

In addition, the foamed and non-foamed materials that are the constituent materials of the concavo-convex pattern directly formed on the above-mentioned backing paper include, for example, foamable ink made of a foamable resin containing a foaming agent and a foaming agent-containing foaming agent as described above. It is formed using non-foaming ink made of non-foaming resin.

That is, a predetermined pattern is printed using the foaming ink and non-foaming ink, and this is heated to foam and fix, thereby producing the foamed and non-foamed materials.

Examples of the resin used in the foaming ink and non-foaming ink include vinyl chloride resin, vinyl acetate resin, vinyl chloride-vinyl acetate copolymer, acrylic resin, and mixtures of these resins.

Examples of the blowing agent to be contained in these resins or mixtures of these resins include dinitrosopentamethylenetetramine and N,N'-dimethyl-N.

N'-dinitrosoterephthalamide, benzenesulfonyl hydrazide, p-toluenesulfonyl hydrazide, p
, p'-oxybis(benzenesulfonylhydrazide)
, 3.3'-disulfone hydrazide diphenyl sulfone, toluene disulfonyl hydrazide, p-)luene disulfonyl hydrazide, p,p'-thiobis(benzenesulfonyl hydrazide), toluene disulfonyl hydrazine, p-toluenesulfonyl azide, P-toluene Examples include sulfonyl semicarbazide, abbisisobutyronitrile, azodicarbonamide, diethyl azodicarboxylate, and the like.

The content ratio of these foaming agents is appropriately selected depending on the degree of foaming of the foam, but is generally selected within the range of about 1.0 to 6.0 parts by weight per 100 parts by weight of the resin. .

Foamed and non-foamed products made from the above resin 9 blowing agent include:
Colorants, stabilizers and plasticizers as required.

Fillers, flame retardants, etc. may be added.

Among the countless fine uneven patterns made of the above-mentioned foam and non-foam, some of the convex parts made of foam are
Convex portions made of the foam that are in simultaneous contact with the backing paper and the non-foamed material that is in direct contact with the backing paper are scattered over the entire surface of the finely textured patterned construction surface.

For example, first a predetermined pattern (first pattern) is printed on the backing paper using the non-foaming ink, and then a pattern different from the first pattern (second pattern) is printed using the foaming ink. This second pattern uses a pattern in which a portion of the foaming ink contacts the previously printed non-foaming ink and the backing paper at the same time (in other words, across the non-foaming material and the backing paper). do it.

[Effect]

In the sheet of the present invention, countless fine uneven patterns are formed directly on the backing paper by the foamed material and the non-foamed material, and among the convex portions made of the foam, some of the convex portions are in direct contact with the backing paper and the backing paper. What is in contact with the non-foam at the same time (across the paper lining and the non-foam) is the high strength of the contact area between the non-foam and the paper lining, and the high strength of the contact area between the non-foam and the foam. It also possesses high strength and develops considerably high strength.

In the sheet of the present invention, the convex portions made of the above-mentioned simultaneous contact foam having high strength are scattered over the entire surface on which the countless fine unevenness patterns are applied, so that the strength of the entire sheet is considerably high.

The convex portions of the concavo-convex pattern made of the foamed material and the non-foamed material are not attracted to the coating layer of the backing paper as in the above-mentioned prior art, and the above-mentioned foamed ink and non-foamed material are not attracted to the coating layer of the backing paper. It maintains almost the same state as printed with foaming ink, and exhibits a sharp and clear fine uneven appearance with clear uneven steps.

Furthermore, since the sheet of the present invention is not provided with the above-mentioned covering layer of the lining paper, the lining paper may be exposed in some of the countless minute recesses of the above-mentioned fine unevenness pattern. Moreover, since these exposed areas are scattered over the entire surface of the textured pattern, the exposed areas of the backing paper not only have breathability, which is a characteristic unique to Mizuki, but also absorb and release moisture (moisture absorption and desorption). and imparts moisture absorption and desorption properties to the sheet of the present invention.

At this time, if the above-mentioned foam is an open-cell foam, the continuous cells in the foam exhibit breathability and moisture absorption/release properties, so the exposed portions of the lining paper exhibit breathability and moisture absorption/release properties. The air permeability and moisture absorption and desorption properties of the open cell foam are added to the humidity,
- Demonstrates the above-mentioned superior effects.

As described above, the sheet of the present invention not only has excellent durability, but also allows extremely fine and complex uneven patterns to be clearly and sharply expressed, and is breathable.

It also has the ability to absorb and release moisture.

〔Example〕

Example 1 A non-foaming ink having the following composition was placed on flame retardant backing paper (commercially available) having the basis weight shown in Table 1 and the hiding rate expressed by the opacity specified in Jl5-P-8138. The first pattern was printed using a rotary screen printing method, and a foaming ink having the following composition was used on top of the first pattern.
After printing the second pattern by rotary screen printing, the above foamable ink is foamed by heating to 200°C to form a fine uneven pattern composed of a non-foamed material and a foamed material. A foamed sheet was obtained.

Composition of non-foaming ink: 100 parts by weight of vinyl chloride resin (product name E7012, manufactured by Hils AG, West Germany), 50 parts by weight of plasticizer (DOP), stabilizer (B)
a-Zn type) 3 parts by weight filler (CaCOs)
50 parts by weight thinner (mineral spirit) 10
Composition of foamable ink in parts by weight: Vinyl chloride resin 50 parts by weight (trade name E7012, manufactured by West German Hils) Plasticizer (DOP) Stabilizer (Ba-Zn type) 65 parts by weight 4.5 parts by weight Filler (CaCOi) 20 Parts by Weight A diagram for explaining the structure of the foamed sheet obtained in this example is shown in FIG.

In the figure, Y is the foamed sheet obtained in this example, which has a fine uneven pattern layer 11 composed of a foamed material and a non-foamed material directly on the backing paper L.

That is, the fine unevenness pattern layer 11 has an infinite number of protrusions 3 made of a non-foamed material with an uneven pattern and protrusions 31 made of a foamed material. As shown in the figure, the part includes the backing paper 1 and the convex part 3 that is in direct contact with the backing paper 1.
(in other words, across the backing paper 1 and the convex portion 3).

The hem portions 3a, 31a of the convex portions 3, 31 rise from the surface of the backing paper 1 at a fairly steep angle.

Further, the recesses 4, 4 existing in the fine uneven pattern layer 11 described above
The concave portion 4' is an exposed portion of the backing paper.

In order to confirm the strength of the foamed sheet obtained in this example, the sheet surface was subjected to a load of 200 g using a Gakushin friction tester.
When a friction test was performed 120 times, no peeling or flaking of the above-mentioned convex portions 3.31 occurred.

Furthermore, in order to confirm moisture absorption and desorption properties, the basis weight was 110g/m"
The sheet obtained in this example (non-foamed material having a basis weight of 90 g/m2 and foamed material having a basis weight of 120 g/m2) in which the above-mentioned uneven pattern layer 11 was formed on the backing paper 1 was placed in a 10 cm×2 sheet.
Two sheet pieces cut to 0 cm were prepared, and the backing paper 1 sides of the two sheet pieces were pasted together to expose the uneven pattern surface 11 made of vinyl chloride resin on both sides.The sample was heated to a temperature of 23 cm. (1) Weight after being left in a desiccator for 2 hours (2) Removed from desiccator, 25.5°C, humidity 76%
Weight after being left for 2 hours in an atmosphere of
% and left for 2 hours (4) The temperature of the atmosphere in (3) above was reduced to 23.5 ° C. and the humidity was lowered to 68% and the weight was measured after being left for 2 hours.
The weight change was examined as an increase or decrease from the above reference value (0).

The results are shown in Table 2.

Table 2 As is clear from Table 2, the sheet obtained in this example showed a large change in weight, which was determined to be due to the sheet absorbing and releasing moisture in each atmosphere. be done.

Example 2 An uneven pattern layer 11 as shown in FIG. 2 was formed in place of the first pattern and second pattern of Example 1, and a foaming ink having a high foaming ratio having the following composition was used. A foamed sheet was obtained in exactly the same manner as in Example 1 except for the above.

Foaming ink: Plasticizer (DOP) 65 parts by weight Stabilizer (B
a-Zn type) 4.5 parts by weight Filler (CaCOs) 20 parts by weight In Fig. 2, the same symbols as in Fig. 1 indicate the same parts as in Fig. 1. The convex part 31 made of
are in contact with at the same time.

The sheet of this example has an uneven pattern layer 11 having a texture different from that of the sheet of Example 1 shown in FIG.

The sheet of this example was also subjected to the same friction test and moisture absorption/release test as in Example 1, and almost the same results as in Example 1 were obtained.

〔Effect of the invention〕

As detailed above, according to the foamed sheet of the present invention, some of the convex portions made of foam out of the countless fine uneven patterns made of foam and non-foamed material directly on the backing paper ,
Because the backing paper and the non-foamed material that is in direct contact with the backing paper are in simultaneous contact, the foam of the simultaneous contact increases the strength of the contact area between the backing paper and the non-foamed material and the strength of the non-foamed material and the foamed material. It also has high strength at the part that comes in contact with the body, resulting in strong strength.

Since this simultaneous contact foam is scattered over the entire surface on which the fine uneven pattern is applied, the strong strength of this simultaneous contact foam extends to the entire foam sheet of the present invention. The strength of the foamed sheet itself of the invention is also high.

Further, according to the foamed sheet of the present invention, since the above-mentioned fine unevenness pattern is directly applied to the backing paper, a situation in which the convex portions of the uneven pattern are attracted to the backing paper coating layer of the prior art described above does not occur. First, it is possible to obtain a concavo-convex pattern having a sharp and clear appearance of fine concavo-convexities with clear concavo-convex steps.

Furthermore, since some of the countless fine recesses in the fine uneven pattern become exposed parts of the lining paper, the exposed parts of the lining paper can exhibit the air permeability and moisture absorption and desorption properties peculiar to paper. can.

At this time, the convex portions made of non-foaming material are made finer,
By scattering a larger number of them, the exposed portion of the lining paper increases, and it is also possible to achieve higher moisture absorption and desorption properties.

By using foams with various expansion ratios, it is possible to obtain fine uneven patterns that have different textures and are highly aesthetically effective.

As described above, according to the foamed sheet of the present invention, it has high durability and is provided with a fine uneven pattern with an excellent design effect, and also has air permeability and moisture absorption and desorption properties.

In addition, as mentioned above, in the foamed sheet of the present invention, since the uneven pattern is applied directly to the backing paper, it is possible to omit the covering material and the covering process that is required to cover the conventional backing paper. , manufacturing costs can be significantly reduced, and manufacturing time can also be significantly shortened.

[Brief explanation of drawings]

Fig. 1 is a diagram for explaining the cross section of one embodiment of the foamed sheet of the present invention, Fig. 2 is a diagram for explaining the cross section of another embodiment of the foamed sheet of the present invention, and Fig. 3 is a diagram for explaining the cross section of one embodiment of the foamed sheet of the present invention. It is a figure for explaining the cross section of one example of a sheet. 1: Lining paper 3: Convex portions with a fine concavo-convex pattern made of foam 31: Convex portions with a fine concave-convex pattern made of non-foamed material Emeritus II Foam sheet of the present invention 11: Layer with a fine concavo-convex pattern 1st Figure 1b 2nd Figure 3

Claims (1)

[Claims] A foam sheet in which a countless number of fine uneven patterns of foamed and non-foamed materials are directly applied to a backing paper, and a part of the foam forming the protrusions of the countless fine unevenness patterns is formed on the backing paper. and a non-foamed material that is in direct contact with the backing paper, and the foamed material that is in simultaneous contact is scattered over the entire surface on which the finely uneven pattern is applied.