JPH04226747A - Warpage resistant sheet material - Google Patents

Abstract

PURPOSE:To prevent the generation of warpage in a sheet material without generating a problem such as the separation of a backing material. CONSTITUTION:A backing material composed of a two-layer laminate of a glass fiber layer 12 and an org. fiber layer 11 is so fabricated that the glass fiber layer 12 is positioned on the org. fiber layer 11 and surface decorative layers (2-4) are formed on the glass fiber layer 12. The org. fiber layer 1 of the two-layer laminate shrinks in the same way as of the surface decorative layers (2-4) but the glass fiber layer 12 does not shrink to show shape holding action and the laminated part 13 of both layers has slightly relaxed shape holding action. The relaxed shape holding action of the laminated part 13 exerts effect on the shrinking action of the org. fiber single layer and the org. fiber single layer strongly shrinks on the surface side but is slightly relaxed in shrinkage as it approaches the laminated part 13. The release of the org. fiber layer and the glass fiber layer is not generated by the relaxed shrinkage and the mutual entanglement of both fibers at the laminated part 13 even when the org. fiber layer 11 shrinks.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet material that can prevent warping without causing problems such as peeling of the backing material.

0002

[Prior art] Traditionally, architecture (ceiling materials, wall materials, floor materials, etc.)
Decorative sheets made of synthetic resin are widely used as surface materials for furniture, vehicles, electrical products, footwear, bags, etc.

[0003] Generally, such decorative sheets include:
As shown in FIG. 2, a hollow layer 2 made of foamed or non-foamed polyvinyl chloride resin is formed on a backing material 1 such as woven fabric, knitted fabric, or paper, and on the hollow layer 2, A predetermined pattern is printed using foamed or non-foamed printing ink by various means such as a rotary screen method or a gravure method to form a so-called printed layer 3, and a wear-resistant layer is further applied to this surface. One in which a transparent upper layer 4 is formed is known.

[0004] In the case of flooring materials, high-strength materials such as glass fiber and pulp are often used as the backing material 1 to increase strength.

[0005]

[Problems to be Solved by the Invention] Incidentally, the above-mentioned decorative sheet is generally produced by coating the backing material 1 with polyvinyl chloride resin or the like for forming the hollow layer 2, and then heat-treating the coating layer. After gelling, a printing layer 3 is formed on the gelled layer, which is heated to dry, coated with a composition forming a transparent upper layer 4, and finally heated once again. processed and manufactured.

During this heat treatment for gelation and during the heat treatment in the final step, the polyvinyl chloride resin etc. that make up the middle layer 2 and the top layer 4 shrink, but the backing Since the glass fibers that make up material 1 do not shrink,
Distortion occurs in the product sheet due to these contradictory characteristics. However, the influence of this distortion does not appear on the product sheet immediately after manufacture, but is inherent as a latent characteristic. Therefore, after a long period of time has elapsed since manufacture, for example, when it is attached to a floor surface as a flooring material, or when a long period of time has passed after it has been attached to a floor surface, the problem of warping upward occurs. .

[0007] As a countermeasure to solve this problem, it is possible to laminate polyvinyl chloride resin, etc., which is the same material as the middle coating layer 2 and top coating layer 4, on the back side of the backing material 1. Therefore, it becomes extremely difficult to select an adhesive that firmly adheres a highly smooth layer of polyvinyl chloride resin or the like to a floor surface or the like.

[0008] In place of this layer of highly smooth polyvinyl chloride resin, etc., a synthetic resin fiber layer having the property of shrinking when heated is laminated on the back side of the backing material 1 using a conventional heat-press bonding technique. A method of stacking layers is also considered. With this method, adhesion to the floor surface is easy, but there is a problem with the adhesive strength between the backing material 1 and the synthetic fiber layer, and when the above-mentioned warpage occurs in the sheet, the backing material 1 and the synthetic fiber layer Peeling occurs (that is, peeling occurs at the interface between the synthetic fiber layer, which shrinks together with the middle layer 2 and the top layer 4, and the backing material 1, which does not shrink).

Furthermore, in order to prevent this peeling, a method of laminating the backing material 1 and the synthetic fiber layer with a synthetic resin layer interposed therebetween may be considered, but with this method, the shrinkability of the synthetic resin layer becomes a problem. , it becomes extremely difficult to select the optimum type of resin and the optimum thickness of the resin.

The present invention has been made in consideration of the above points, and it is an object of the present invention to provide a warp-preventing sheet material that is free from problems such as peeling of the backing material.

[0011]

[Means for Solving the Problems] In order to achieve the above object, the anti-warping sheet material of the present invention has a backing material made of a two-layer paper combination of glass fiber and organic fiber, an upper glass fiber layer and a lower glass fiber layer. The organic fiber layer is placed in the
It is characterized in that a surface decoration layer is formed on the glass fiber layer.

[0012] The two-layer paper composite in the backing material of the sheet of the present invention is one prepared by the same method as for ordinary two-layer paper making, specifically, a paper product made of glass fiber or a net-like material and an organic fiber For example, a paper product prepared by separately preparing a paper product made from the above products and combining them in a wet state is used.

[0013] This glass fiber paper product is a mixture of glass fiber and an adhesive such as polyvinyl alcohol (PVA), or a mixture of these and synthetic fibers such as vinylon, polyester, polyvinyl chloride resin emulsion, SBR, etc.
Latex, etc., mixed with fillers such as calcium carbonate, etc., prepared by the normal wet papermaking method, etc. can be used, and glass fiber net-like materials can be woven into a net shape using glass fibers. Can be used.

[0014] The organic fiber paper product is a mixture of synthetic fibers such as polyester and vinylon with an adhesive such as PVA, or a mixture of these and natural fibers such as pulp, rayon, cotton, linen, and wool. Those prepared by a normal wet papermaking method can be used.

[0015] The amount of the adhesive to be mixed into the above-mentioned glass fiber and organic fiber paper products may be approximately the same as the amount mixed into ordinary glass fiber paper products and organic fiber paper products, respectively. .

The thickness (basis weight) of the backing material made of such a two-layer paper composite may be approximately the same as the basis weight of a normal backing material, but the ratio of the basis weight of the glass fiber layer and the organic fiber layer is Although it depends on the degree of shrinkage of the surface decoration layer and cannot be determined unconditionally, if the basis weight of the glass fiber layer is too large, the basis weight of the organic fiber layer will be relatively too small, and the desired If the shrinkage effect does not occur and the basis weight of the glass fiber layer is too small, problems such as a decrease in the strength of the sheet of the present invention will occur, so the glass fiber layer:
The optimum ratio is selected from the range of organic fiber layer=90-10:10-90, preferably glass fiber layer:organic fiber layer=80-20:20-80.

[0017] As described above, the surface decoration layer formed on the glass fiber paper product or the glass fiber net-like body (glass fiber layer) of the backing material includes a printing layer on which a hollow layer is formed. It may have a three-layer structure in which a backing layer and a top layer are formed, or it may have a two-layer structure in which a printing layer and a top layer are formed directly on the glass fiber layer of the backing material without using a middle layer. It's okay.

In the case of a surface decoration layer having a three-layer structure, the hollowing layer is made of foamed or non-foamed polyvinyl chloride, vinyl chloride and ethylene, vinyl acetate, vinyl ether, similar to the hollowing layer 2 of the conventional sheet described above. , maleic acid ester, (meth)acrylic acid, copolymer resin with (meth)acrylic acid ester, acrylonitrile, urethane, etc., other vinyl chloride resins, acrylic resin, vinyl acetate resin, polyethylene, polypropylene, ethylene-vinyl acetate Examples include copolymer resins and urethane resins, which may be used alone or in combination.

In addition to the plasticizer, additives such as a blowing agent, a coloring agent, a filler, a stabilizer, and an antifungal agent may be added to these synthetic resins as necessary.

As the plasticizer, for example, di-2 phthalate
-Ethylhexyl ester (DOP), diisononyl phthalate (DINP), butylbenzyl phthalate (BBP), diisodecyl phthalate (
DIDP), phthalic acid diundecyl ester (DUP)
General phthalate ester plasticizers represented by phthalate ester plasticizers, general fatty acid ester plasticizers represented by dioctyl adipate (DOA), dioctyl sebacate (DOS), dioctyl azelaate (DOZ), etc. Mellitic acid trioctyl ester (TOT
Trimellitic acid ester plasticizers represented by M), epoxy plasticizers represented by tricresyl phosphate (TCP), phosphate ester plasticizers represented by polypropylene adipate, polyester plasticizers General plasticizers such as polymer plasticizers such as, chlorinated paraffin, etc. can be used, and these can be used alone or in combination. The mixing ratio of the above-mentioned synthetic resin and plasticizer is appropriately selected depending on the type of resin and plasticizer, etc., but in general, 10 to 100 parts by weight of plasticizer per 100 parts by weight of synthetic resin. It is preferable to set it to about 1.5 parts.

[0021] Fillers include, for example, calcium carbonate, clay, silica, shirasu balloon,
Glass balloons, wood powder, cork powder, etc., silica sand grains, silicic acid compound grains, glass powder, etc. for the purpose of providing wear resistance and anti-slip properties.
Hard powder particles such as ceramic crushed granules, carborundum, and alundum, inorganic short fibers such as glass fiber, calcium titanate short fibers, and MOS (calcium metasilicate) short fibers for the purpose of providing dimensional stability, and antistatic properties. Carbon black powder, carbon fibers, metal fibers (titanium fibers, etc.), glass fibers and other inorganic fibers or organic fibers whose surfaces are coated with metals, metal oxides, or other conductive substances, conductive titanium oxide (Titanium oxide surface treated with Sn-Sb compound) Powder, metal (silver, copper, nickel,
Conductive materials such as powder (aluminum, stainless steel, iron, etc.) or foil strips can be used.

[0022] The above-mentioned fillers, stabilizers, colorants,
Other additives such as lubricants, foaming agents, and antifungal agents are added in appropriate amounts depending on the purpose of use.

[0023] The printing layer formed directly on the hollow layer made of the materials detailed above or on the glass fiber layer of the backing material is made of printing ink made of plastisol or the like, similar to the conventional printing layer 3 described above. by rotary screen method or other conventional printing methods.

The transparent layer (overcoat layer) formed on this printing layer can be made of the same synthetic resin as that used for forming the above-mentioned hollow layer.

[0025] The sheet of the present invention constructed as described above is
Arranging the backing material made of the above two-layer paper composite so that the glass fiber layer is located on the top and the organic fiber layer is located on the bottom,
A surface decoration layer is formed thereon in the same manner as in the conventional method for preparing this type of sheet as described above. in particular,
If the surface decoration layer has a three-layer structure consisting of a middle layer, a printing layer, and a top layer, first coat the material of the middle layer described above using various coating methods such as a roll coating method, a doctor knife method, and a rotary screen method. After coating on the glass fiber layer of
Heat-treated to gel, then printed with an ordinary printing ink by an appropriate means such as a rotary screen method or gravure method, heat-treated again, and then the material for forming the transparent top layer is used in the same manner as the hollow layer. It is prepared by coating using the coating method described above, followed by heat treatment.

[0026] When the surface decoration layer has a two-layer structure of a printing layer and an overcoat layer, a normal printing ink is printed on the glass fiber layer by the same appropriate means as above, and then heat-treated. Then, a transparent upper layer may be formed by the same method as above and heat treated.

[0027]

[Function] In the sheet of the present invention, during the heat treatment during the formation of the surface decoration layer, the surface decoration layer contracts and the two-layer paper composite constituting the backing material also contracts.

The shrinkage mode of this two-layer paper composite is analyzed as follows. In other words, the organic fiber layer of the two-layer paper combination is
It contracts at the same degree of contraction as the surface decoration layer. On the other hand, the glass fiber layer does not shrink and exhibits a shape-retaining effect. In the combined area of these two layers, the shape-retaining effect of the glass fibers acts more strongly than the contraction effect of the organic fiber layer, and it seems that the shape-retaining effect actually appears, but it is not as strong as the single glass fiber layer mentioned above. It does not have a strong shape-retaining effect, but the shape-retaining effect is slightly softened by the organic fibers. The relaxed shape-retaining effect of this combined area affects the shrinkage effect of the above-mentioned single layer of organic fibers, and is stronger on the surface side of the single layer of organic fibers (the side to which the sheet of the present invention is attached to the floor surface, etc.). Shrinkage occurs, but the degree of shrinkage becomes less severe as it approaches the joining part. Due to this relaxed shrinkage and the intertwining of the organic fibers and the glass fibers at the joint, the organic fiber layer and the glass fiber layer do not separate even if the organic fiber layer shrinks.

Due to the above-described effects, the sheet of the present invention does not have latent distortion characteristics unlike conventional sheets, and therefore can prevent the occurrence of warping after manufacturing, and can also prevent the backing material from warping. It is also possible to solve problems such as peeling of the two-layer paper composite that constitutes the paper.

[0030]

[Example] Example 1 Glass fiber layer with the composition shown in Table 1 (basis weight 112 g/m2
paper structure) and the organic fiber layer shown in Table 2 (basis weight 48 g/m
2) A two-layer paper composite with a thickness of 0.4 mm was used, and the resin composition shown in Table 3 was coated on the glass fiber layer of the paper composite using a doctor knife coating method in an amount of 300 g/m2. After coating, it was heated at 180° C. for 3 minutes to form a gel, thereby forming a middle coating layer. Next, a predetermined pattern was printed on the intermediate coating layer using a conventional printing ink by a gravure printing method, and then heated and dried to form a printed layer. After this,
The resin composition shown in Table 4 was coated on the printed layer by a doctor knife coating method so that the coating amount was 200 g/m2, and then heated at 180 ° C. for 3 minutes to gel, thereby forming a top layer. A sheet of the present invention was obtained.

[0031]

[Table 1]

[0032]

[Table 2]

[0033]

[Table 3]

[0034]

[Table 4]

As schematically shown in FIG. 1, the sheet of the present invention obtained as described above has a backing material 1 consisting of an organic fiber layer 11, a glass fiber layer 12, and a composite portion 13 of both fibers. The above-mentioned hollow layer 2 was formed on the glass fiber layer 12, a printed layer 3 was formed thereon, and a transparent top layer 4 was further formed.

When the sheet of the present invention was observed after being left for 30 days, it was found that not only warping but also peeling between the organic fiber layer 11 and the glass fiber layer 12 of the backing material 1 did not occur. In addition, the peel strength between the glass fiber layer and the organic fiber layer of the backing material was determined by making a 1 cm cut in the combined area of the glass fiber and organic fiber and performing a 180° peel test using a chopper type tensile testing machine. , the two-layer paper composite exhibited such high interlayer peel strength that it could be torn to pieces without peeling between the layers.

Comparative Example 1 Commercially available glass fiber nonwoven fabric (with the same basis weight as the glass fiber layer of Example 1) and polyester fiber nonwoven fabric (Example 1)
A comparative sheet was prepared in the same manner as in Example 1, except that a laminate obtained by heat-pressing the organic fiber layer (with the same basis weight as the organic fiber layer) was used. When this comparative sheet was observed after being left for the same time as in Example 1, no warpage had occurred, but peeling between the glass fiber nonwoven fabric and the polyester fiber nonwoven fabric was confirmed.

Example 2 A glass fiber layer and an organic fiber layer having the same composition as in Example 1 were used, and the basis weight of each layer was 48 g/m2,
A sheet of the present invention was prepared in the same manner as in Example 1 except that the organic fiber layer was 112 g/m2. The thus obtained sheet of the present invention was confirmed to have the same warping prevention effect as in Example 1 and the peeling prevention effect between the glass fiber layer and the organic fiber layer of the backing material. Further, when the peel strength between the glass fiber layer and the organic fiber layer of the backing material was tested in the same manner as in Example 1, it showed a high strength equivalent to that in Example 1.

Example 3 A sheet of the present invention was prepared in the same manner as in Example 1, except that a glass net (basis weight: 112 g/m2) was used in place of the glass fiber layer (paper article) of Example 1. When this sheet was also observed after the same period of time as in Example 1 had elapsed, neither warping nor peeling between the glass net and the polyester fiber layer had occurred. Furthermore, when the peel strength between the glass net of the backing material and the organic fiber layer was tested in the same manner as in Example 1, it showed a high strength equivalent to that in Example 1.

[0040]

As described in detail above, according to the sheet of the present invention, sheet production is achieved mainly by the shrinkage effect of the organic fiber layer of the two-layer paper composite consisting of the glass fiber layer and the organic fiber layer constituting the backing material. It is possible to prevent warping from occurring later.

Furthermore, due to the entanglement of the glass fibers and organic fibers in the combined portion of the two-layer paper composite, the organic fiber layer and the glass fiber layer do not separate.

Furthermore, since the sheet of the present invention has an organic fiber layer at the bottom layer, it can obtain strong adhesive strength with a floor surface, etc.

[Brief explanation of the drawing]

FIG. 1 is a diagram schematically showing the structure of an embodiment of a sheet of the present invention.

FIG. 2 is an explanatory diagram showing the structure of a conventional sheet.

[Explanation of symbols]

1 Backing material 11 Organic fiber layer 12 Glass fiber layer 13 Combined portion of organic fiber and glass fiber 2 Middle layer 3 Print layer 4 Top layer

Claims (1)

[Claims] Claim 1: A backing material made of a two-layer composite of glass fibers and organic fibers is arranged such that the glass fiber layer is located on the top and the organic fiber layer is located on the bottom, and a surface decoration layer is provided on the glass fiber layer. A warpage-preventing sheet material characterized by being formed by forming.