JPH0428539A - Manufacture of foamed decorative material - Google Patents

Abstract

PURPOSE:To manufacture a foamed decorative material having large volume feeling as well as peculiar feeling by executing desired pattern printing on a first foaming agent-containing resin layer applied on a base material surface by ink including a foaming inhibitor and ink including no foaming inhibitor, laminating a second resin layer starting heating and foaming at approximately the same time as said first resin layer on the pattern printing and heating and foaming the second resin layer. CONSTITUTION:The surface of a base material 11 is coated with a first layer 2, desired pattern printings 3 by ink containing no foaming inhibitor and desired pattern printings 4 by foaming inhibiting ink are executed on the layer 2, and a second layer 5 starting heating and foaming at approximately the same time as the layer 2 is laminated on the pattern printings 4, and the layer 5 is heated and foamed, and cooled. Since foaming is started and progresses for approximately the same time in the layers 3 and the layers 4, a foamed gas is generated at a stroke, and the excess state of foaming is brought. When the whole is cooled, air expanded in the layers more than required is shrunk, and an irregular creasy indentation is formed in the surface.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for producing a foamed decorative material suitable for use in ceiling materials, wallpaper materials, etc. The present invention relates to a method for producing a foamed decorative material.

[Prior Art] Foaming cosmetics are effective by creating a distinct three-dimensional and voluminous feel, and methods that have been proposed in the past include, for example, Japanese Patent Application Laid-Open No. 57-13.
There is a method described in Publication No. 7120.

This method includes a first blowing agent-containing synthetic resin layer (hereinafter referred to as the first layer) on a substrate surface, and a second blowing agent-containing synthetic resin having a decomposition temperature higher than that of the first blowing agent. This is a method in which layers (hereinafter referred to as second layers) are laminated one after another, the times at which they start foaming are different, and the layers are heated and foamed.

[Problem to be solved by the invention] However, according to the conventional method described in the above publication, the first
The starting point of foaming is different for the layer and the second layer, and the first layer starts foaming first, so even if the first layer reaches the final stage of foaming, the second layer is still in the early stage of foaming. Moreover, since the foamed part of the second layer is a foamed material with appropriate elasticity, even if a fairly large cavity is formed in the first layer, it will be retained without collapsing, and the original foamed shape will remain. It will be done. Therefore, although large uneven steps are formed as a whole, the surface of the image area (that is, the second
The convex surface of the layer) is formed on a relatively smooth surface without roughness, so it tends to have a regular surface condition and has the disadvantage that it is not possible to obtain a surface condition with an irregular and unique texture. be.

The present invention was made in view of these conventional drawbacks.
The purpose of the present invention is to provide a method for producing a foamed decorative material having a large volume and a unique texture.

[Means for Solving the Problem] In order to achieve the above object, the method for producing a foamed decorative material according to the present invention includes coating a first foaming agent-containing resin layer on a base material surface, A desired pattern is printed on the foaming agent-containing resin layer using a foaming-inhibiting ink containing a foaming inhibitor and an ink not containing a foaming inhibitor, and on top of this, a layer approximately equal to the first foaming agent-containing resin layer is printed. At the same time, a second foaming agent-containing resin layer that starts heating and foaming is laminated, and after this is heated and foamed,
It is characterized by cooling.

[Function] According to the present invention, the area where the anti-foaming ink is printed is maintained in a non-foaming state due to the action of the anti-foaming agent, while the printing of the anti-foaming ink is In areas that are not covered, the first blowing agent-containing resin layer (hereinafter simply referred to as the first layer) and the second blowing agent-containing resin layer (hereinafter simply referred to as the second layer) are formed almost simultaneously. Since foaming starts and progresses, foaming gas is generated, resulting in an excessive foaming state. When the layer is cooled after heating and foaming, the air that has expanded more than necessary in the layer contracts, forming irregular wrinkle-like depressions on the surface. In other words, a large uneven shape is formed overall, and at the same time an irregular surface condition is formed, resulting in a foamed decorative material that has a large volume and a unique texture due to the irregular surface condition. can get.

[Example] Embodiments of the present invention will be described in detail below with reference to the drawings.

FIGS. 1(a) to 1(f) are sectional views showing each stage of the present invention.

In the present invention, the first layer 2 is coated on one surface of the base material as shown in FIG.
), a desired pattern printing 3 with an ink not containing a foaming inhibitor and a desired pattern printing 4 with a foaming suppressing ink are applied on the first layer 2 (see FIG. 1(b)), and then A second layer 5 which starts heating and foaming almost simultaneously with the first layer 2 is laminated thereon (see FIG. 1(C)).

The material of the base material 1 is not particularly limited as long as it has heat resistance to the extent that deformation does not occur during foaming and heating.

The first layer 2 and the second layer 5 have almost the same material composition, and in addition to the foaming agent, the binder resin contains a plasticizer, a stabilizer,
Fillers, additives for adjusting foaming timing, etc. are added. Here, as the binder resin, for example, vinyl chloride resin is preferably used. In particular, it is preferable to use a highly transparent vinyl chloride resin with a degree of polymerization of 1200 to 1600 for the second layer 5. Further, as the blowing agent, in addition to decomposable organic blowing agents such as azo, azide, and sulfohydrazide compounds, inorganic blowing agents and the like can be used. In addition, plasticizers include phthalate esters, adipate esters, trimellitate esters, phosphate esters, and polyester plasticizers; stabilizers include organic compound-based cell conditioners and heat stabilizers; and fillers include organic compound-based cell conditioners and heat stabilizers. Inorganic fillers such as calcium carbonate and magnesium carbonate, and stabilizers based on zinc, calcium, barium, and sodium can be used as additives for adjusting the foaming timing. The blending amount of each of these compounds is appropriately determined by considering the amount of foaming gas, the foaming speed, the foaming balance between the first layer 2 and the second layer 5, etc. In layer 2, it is preferably used in an amount of about 2 to 7% by weight based on the binder resin, and in the second layer 5, it is also preferably used in a range of about 2 to 5% by weight based on the binder resin. .

Regarding the material composition of the first layer 2 and the second layer 5, the compounds used, etc., the first layer 2 and the second layer 5 start heating and foaming almost simultaneously and proceed. If so, the two do not necessarily have to match, but from the viewpoint of ease of adjusting the foaming balance, convenience in manufacturing, etc., it is desirable that the two substantially match.

The coating and lamination of the first layer 2 and the second layer 5 can be carried out using any known method, but the layer thickness of each layer is appropriately determined in consideration of foaming balance and the like. Especially the second layer 5
It is desirable that the layer thickness is thinner than the layer thickness of the first layer 2,
Specifically, it is preferable that the first layer 2 has a thickness of about 100 to 250 μm, and the second layer 5 has a thickness of about 50 to 180 μm.

On the other hand, the pattern printing 3 and the pattern printing 4 using the anti-foaming ink are performed by known printing means, but the printing ink used for the pattern printing 3 has a resin (for example, vinyl chloride resin) on the printing surface. selected with certain considerations in mind.

The anti-foaming ink contains or consists of an anti-foaming agent, and specific examples of the anti-foaming agent include fumaric acid, maleic acid, itaconic acid, and trimellitic acid.

Next, the laminate shown in FIG. 1(C) obtained as described above is heated and foamed. Note that the heating temperature and time are determined depending on the type of blowing agent used, etc.

First, in the initial stage of foaming shown in FIG. 1(d), the area 4 printed with the foaming suppressing ink is maintained in an unfoamed state due to the action of the foaming suppressing agent, while the area 4 printed with the foaming suppressing ink is kept in a non-foaming state. In the areas not covered, the first layer 2 and the second layer 5 start foaming almost simultaneously, and foaming gas begins to be generated. The generated foaming gas forms minute cavities within the layer, and as the foaming progresses, the cavities grow larger and the first layer 2 and second layer 5 expand upward. Also, the second
The foaming gas in the layer 5 expands the second layer 5 and also expands the first layer 2 by passing through to the lower layer. In the present invention, since foaming starts and progresses in the first layer 2 and the second layer 5 almost simultaneously, a foaming gas is generated and an excessively foamed state immediately occurs. In this process, especially the first
In layer 2, a plurality of hollow parts are connected, as shown in Fig. 1 (e
), but the first layer 2
Due to the difference in the amount of foaming gas between and the second layer 5, the second layer 5
However, it is not possible to form such a large cavity.

Note that even in the state shown in FIG. 1(e), the portion 4 where the foaming suppressing ink is printed remains in a state where almost no foaming occurs.

In this way, an uneven shape with large steps is formed by heating and foaming, but the state shown in FIG. When cooled after heating and foaming, the large cavities 6 that expanded more than necessary in the first layer 2 contract and the upper part becomes wrinkled, and the second layer 5 also follows this. It has a crushed shape, and on its surface there is a first
Irregular wrinkle-like depressions 7 as shown in Figure (f) are formed. The wrinkle-like depressions 7 formed on the surface provide a unique texture due to the irregular surface condition. In other words, the feature of the present invention is that, although a large uneven shape is formed as a whole and a large sense of volume is obtained, at the same time an irregular surface condition is also formed, thereby giving a unique texture. be.

[Effects of the Invention] As explained in detail above, according to the method for producing a foamed decorative material of the present invention, the first layer is coated on the base material surface, and pattern printing and printing with foaming suppressing ink are performed. Furthermore, by heating and foaming a second layer that starts heating and foaming almost at the same time as the first layer and then cooling it, a rough surface with large steps and an irregular surface condition are created. Since the foam is formed, it has both a large volume and a unique texture due to the irregular surface condition, making it possible to obtain a foamed decorative material that has an unprecedented sense of design and luxury.

Further, according to the present invention, there are also effects of having a soft feel, good surface strength, and excellent compression recovery properties.

[Brief explanation of the drawing]

FIGS. 1(a) to 1(f) are sectional views showing each stage of the present invention. 1... Base material 2... First foaming agent-containing resin layer 3... Pattern printed portion 4... Printed portion with foaming suppressing ink 5... Second foaming agent-containing resin layer 6. ...Cavity 7...Wrinkle-like depression

Claims (1)

[Claims] A first foaming agent-containing resin layer is coated on the base material surface, and a desired pattern is formed on the first foaming agent-containing resin layer using a foaming inhibiting ink containing a foaming inhibitor and an ink not containing a foaming inhibitor. Applying pattern printing, further laminating a second foaming agent-containing resin layer that starts heating and foaming almost simultaneously with the first foaming agent-containing resin layer, heating and foaming this, and then cooling it. A method for producing a foamed decorative material characterized by: