JPH04288228A - Preparation of slip-proof sheet - Google Patents

Abstract

PURPOSE:To obtain a slip-proof sheet by providing a layer incorporated with a foamable microcapsule on a supporting body. CONSTITUTION:One face of a thin film sheet 1 is coated with a coating contg. a foamable microcapsule, which is expanded by heating, and then, the opposite face is laminated with a thick sheet 2.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing an anti-slip sheet obtained by providing a support with a layer containing expandable microcapsules.

0002

[Prior Art] Sheets, which are made by providing a layer containing foamable microcapsules on a sheet-like support such as paper, nonwoven fabric, or film, can be used to make household goods such as tissues and rugs, etc. by taking advantage of their strong frictional resistance. sanitary and medical supplies such as sanitary napkins, disposable diapers, and bandages; seat headrests;
It is expected to be applied to a wide range of fields such as covers such as armrests and pillowcases; cloths such as tablecloths and tray napkins; sheets and mats. Among them, those that use nonwoven fabric as a support have good cushioning properties and flexibility, so they can be used by pasting them on the bottom of rugs such as flower mats, tatami mats, carpets, and mats, making the most of their characteristics. It can be expected to have many uses.

[0003] As a method for manufacturing an anti-slip sheet using a nonwoven fabric having such performance, a synthetic resin film layer is provided on the nonwoven fabric, an expandable microcapsule coating liquid is applied on this film layer, and then the capsules are coated. A method of heating and foaming (Japanese Patent Publication No. 2-32140) has been proposed.

[0004] However, the coating machine used in the process of applying or heating and foaming the microcapsule coating solution generally treats the support used for coating as a roll, and the coated sheet as a roll again. Since it is a so-called roll-to-roll type, there is a restriction that the diameter of the winding that can be used for this cannot exceed a certain value. Therefore, when processing a bulky sheet such as a synthetic resin film layer on a thick film sheet such as a nonwoven fabric using a coating machine, the length of the sheet that can be used as a winding is extremely short. When manufacturing the anti-slip sheet in large quantities, it is necessary to change the winding process frequently, which causes a large increase in cost in terms of work and time.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to provide a method for manufacturing a bulky anti-slip sheet that can minimize loss due to rewinding in a coating machine.

[0006]

[Means for Solving the Problems] The present invention is characterized in that a coating liquid containing foamable microcapsules is applied to one side of a thin film sheet, heated and foamed, and then the opposite side is bonded to a thick film sheet. This is a method for manufacturing an anti-slip sheet.

[0007]

[Operation] A coating solution containing expandable microcapsules is prepared using the capsules and an adhesive for fixing them to a substrate as basic components. The expandable microcapsules used in the present invention are microcapsules whose particle size increases when heated, and specifically, the core material is a low-boiling point material such as n-butane, i-butane, pentane, or neopentane. hydrocarbons, and a thermoplastic resin whose main components are vinylidene chloride, acrylonitrile, (meth)acrylic acid esters such as methyl methacrylate, and aromatic vinyl compounds such as styrene is used as the capsule wall agent. Capsules (commercially available capsules include Matsumoto Microsphere F-30, F-50, F-80 (manufactured by Matsumoto Yushi), Expancel WU-642, WU-551,
Examples include WU-461 (manufactured by Expancel).

As the adhesive, a water-soluble binder or a latex binder is used when the adhesive is applied as an aqueous system, and an oil-soluble binder is used when the adhesive is applied as a non-aqueous system. Furthermore, when curing with electron beams or ultraviolet rays, monomers, oligomers, or prepolymers having ethylenically unsaturated bonds are used.

Examples of water-soluble binders include gelatin, albumin, casein, cereal starch, pregelatinized starch, oxidized starch, etherified starch, esterified starch, carboxymethyl cellulose, hydroxyethyl cellulose, agar,
Water-soluble natural or semi-synthetic polymer compounds such as sodium alginate and gum arabic, polyvinyl alcohol, modified polyvinyl alcohol, polyvinylpyrrolidone, polyacrylic acid, polyacrylamide, ethylene/maleic anhydride copolymer, styrene/maleic anhydride copolymer Examples include water-soluble synthetic polymer compounds such as methyl vinyl ether/maleic anhydride copolymer, isobutylene/maleic anhydride copolymer, and the like.

[0010] Examples of latex binders include styrene-butadiene latex, acrylonitrile-butadiene latex, acrylic ester latex, vinyl acetate latex, vinylidene chloride latex,
Examples include methyl methacrylate-butadiene latex and carboxy-modified (for example, acrylic acid) latex thereof.

Examples of the oil-soluble binder include natural resins such as rosin, copal, dallman, gilsonite, and zein, hardened rosin, dimerized rosin, polymerized rosin, maleic acid resin, fumaric acid resin, methylcellulose, ethylcellulose, hydroxyethylcellulose, and hydroxyl. Semi-synthetic resins such as propyl cellulose, ethyl hydroxyethyl cellulose, cellulose acetate propionate, cellulose acetate butyrate, nitrocellulose, phenolic resin, xylene resin, urea resin, melamine resin, ketone resin, coumaron/indene resin, petroleum resin, terpene Resin, cyclized rubber, chlorinated rubber, alkyd resin,
Examples include polyamide resin, acrylic resin, polyvinyl chloride, polyvinyl acetate, vinyl chloride/vinyl acetate copolymer, chlorinated polypropylene styrene resin, epoxy resin, polyurethane resin, polyvinyl butyral, and the like.

Monomers, oligomers, and prepolymers having ethylenically unsaturated bonds that can be cured by electron beams or ultraviolet rays include, for example, styrene, methyl methacrylate,
Butyl methacrylate, polyethylene glycol diacrylate, propylene glycol diacrylate, pentaerythritol acrylate, trimethylolpropane diacrylate, pentaerythritol tetraacrylate, hexanediol diacrylate, 1,2-butanediol diacrylate, reaction between epoxy resin and acrylic acid and condensates of maleic acid, acrylic acid, and diethylene glycol. Among them, the most preferable adhesive is one with a glass transition point of 40° C. or lower, which easily exhibits high anti-slip properties.

[0013] The foamable microcapsules and adhesive are usually used in an amount of 1 to 90 parts by weight, preferably 3 to 50 parts by weight, more preferably 5 to 30 parts by weight per 100 parts by weight of the adhesive. It is blended as follows.

[0014] As the medium used for the non-aqueous coating liquid,
For example, benzene, toluene, xylene, hexane, cyclohexane, trichloroethylene, methyl ethyl ketone, methyl isobutyl ketone, methyl acetate, ethyl acetate,
Examples include butyl acetate, methyl cellosolve, ethyl cellosolve, butyl cellosolve, methanol, ethanol, n-propyl alcohol, isopropyl alcohol, n-butanol, n-hexanol, cyclohexanol, diethylene glycol, and the like.

When a monomer, oligomer, or prepolymer having an ethylenically unsaturated bond that is cured by ultraviolet rays is used as an adhesive and cured by ultraviolet rays, a photopolymerization initiator is added to the coating liquid, and if necessary, A sensitizer is added. Examples of photopolymerization initiators include benzoquinone, phenanthrenequinone, naphthoquinone, diisopropylphenanthrenequinone, benzoin butyl ether, benzoin,
Examples include furoinbutyl ether, Michler's ketone, Michler's thioketone, fluorenone, trinitrofluorenone, and the like. The amount of the photopolymerization initiator is usually in the range of 0.1 to 10 parts by weight per 100 parts by weight of the ethylenically unsaturated compound. Examples of the sensitizer include triethanolamine, N-methyldiethanolamine, N,N-dimethylethanolamine, and N-methylmorpholine.

The coating liquid containing expandable microcapsules may further contain pigments such as silica, calcium carbonate, aluminum hydroxide, clay, kaolin, titanium oxide, zinc oxide, plastic pigments, and a release agent such as polyethylene wax, if necessary. , micro-adhesive particles used in removable adhesive paper,
Surfactants, dispersants, antistatic agents, antifoaming agents, colorants, fluorescent dyes, etc. are added. In the present invention, it is preferable to add an inorganic pigment to the coating liquid, and usually 5 to 150 parts by weight, more preferably 10 to 80 parts by weight, per 100 parts by weight of the adhesive.

Coating machines used include air knife coaters, bar coaters, roll coaters, gravure coaters, etc., and printing machines include gravure, gravure, etc.
Screens, flexography, etc. are used.

[0018] The coating amount is 3 to 500 g/m2 in terms of dry weight.
, more preferably in the range of 12 to 70 g/m2. Incidentally, the coating amount is 3g/m
If it is less than 2, the anti-slip properties will be insufficient. Moreover, if it is less than 12 g/m2, the anti-slip properties tend to deteriorate due to repeated friction, which may cause problems when used for a long period of time. On the other hand, if a coating weight of 70 g/m2 or more is used, there is no problem in terms of anti-slip properties and abrasion resistance, but it is unfavorable from an economic point of view, and in particular, a coating weight of more than 500 g/m2 has no merit at all.

Foaming of the capsules is usually carried out at 80 to 300° C. using a heating device such as a hot air drying zone of a coating machine, an infrared ray irradiation device, or a heated super calender.

[0020] The thin film sheet used in the present invention is as follows:
Paper, synthetic paper, film, metal foil, etc. can be used. Examples of the film include colorless or colored films having a thickness of 5 to 500 μm and made of materials such as polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, ethylene/vinyl acetate copolymer, polyester, polyamide, and polystyrene. In addition, if the adhesiveness between the film and the anti-slip layer is insufficient, a film that has been previously treated with a primer is used.

[0021] As the thick film sheet, nonwoven fabric, woven fabric, cardboard, etc. can be used. Examples of nonwoven fabrics include polyethylene, polypropylene, polyester, polyamide,
Thickness: 5 μm to 50 μm manufactured by wet method, dry method, or direct method using glass fiber, carbon fiber, cellulose fiber, etc.
Examples include those of mm. Among these, in order to obtain sufficient cushioning properties, a thickness of 70 μm or more is preferable.

[0022] For bonding the thick film sheet and the thin film sheet in the present invention, methods known in the art such as wet lamination, dry lamination, hot melt lamination, extrusion lamination, etc. are used.

[0023] The thus obtained anti-slip sheet can be bonded to the back surface of a rug such as a tatami mat, mat, carpet, or the like, thereby imparting anti-slip properties and cushioning properties thereto.

Adhesives used for bonding include water-soluble binders, latex binders, oil-soluble binders, monomers having ethylenically unsaturated bonds, oligomers, prepolymers, etc. as mentioned above in the preparation of capsule-containing coating liquids. can be mentioned. In addition, for example, rubber-based,
Adhesives known in the art, such as acrylic, polyether, and ethylene-vinyl acetate, can also be used. Of course, the release paper used therewith may also be one known in the art. By the way,
The adhesive or pressure-sensitive adhesive usually has a dry weight of 5 to 100 g/
It is applied to cover an area of m2.

[0025] The anti-slip sheet used in the present invention may contain an insecticide such as acaricide, a fungicide, or an aromatic agent such as the smell of strawberry, if necessary.

[0026]

[Examples] The present invention will be explained below with reference to Examples.
The present invention is not limited only to the examples. Further, unless otherwise specified, parts and % in the examples refer to parts by weight and % by weight, respectively.

Example A coating solution containing foamable microcapsules having the following composition was prepared and applied to an anchor-treated stretched polyester film (40 g/m2) using a bar coater so that the dry weight was 20 g/m2. , and heated at 150° C. for 20 seconds to obtain an anti-slip film. Note that this anti-slip film was obtained as a roll of 10,000 m.

Next, the anti-slip film and a nonwoven fabric (trade name: polyester dry process nonwoven fabric, manufactured by Kuraray) were bonded together using polyethylene as a binder. Next, a polyacrylic acid ester adhesive (trade name: Olivine BPS-4940, manufactured by Toyo Ink) was applied to a release paper (polyethylene laminate paper (74 g/m2 coated with silicone) with a dry weight of 30 g/m2). m2 with a roll coater, and then laminated with the above anti-slip sheet to obtain a non-slip adhesive sheet.Next, after removing the release paper from the adhesive sheet, this was laminated onto a flower mat. A non-slip flower mat was obtained. The flower mat had excellent cushioning properties and was comfortable to sit on, and also exhibited good slip resistance when used on a wooden floor.

[Coating liquid composition of coating liquid containing expandable microcapsules (solid equivalent)] - Expandable microcapsules (trade name: Expancel W
U-642, manufactured by Expancel) 10 parts ethylene
Vinyl acetate latex (product name: Sumikaflex 7)
53, manufactured by Sumitomo Chemical Co., Ltd.) 70 parts, aluminum hydroxide (trade name: Hygilite H-42, manufactured by Showa Denko Co., Ltd.) 20 parts

Comparative Example An anti-slip tack sheet was obtained in the same manner as in the example except that the above paint was applied and foamed onto a sheet on which a film and a nonwoven fabric had been laminated in advance. . In addition, since the anti-slip sheet was too thick, it could only be obtained as a roll of 3000 m due to mechanical constraints.

[0031]

[Effects of the Invention] By the method of the present invention, it was possible to reduce production loss due to rewinding in a coating machine.

[Brief explanation of the drawing]

FIG. 1 is a sectional view showing an anti-slip sheet obtained by the present invention.

FIG. 2 is a cross-sectional view showing an anti-slip adhesive sheet obtained by further adhesive processing.

[Explanation of symbols]

1: Film (thin film sheet) 2: Nonwoven fabric (thick film sheet) 3: Binder 4: Anti-slip layer containing foamable microcapsules 5: Adhesive layer 6: Release paper

Claims (2)

[Claims] 1. A method for producing an anti-slip sheet, which comprises applying a coating liquid containing foamable microcapsules to one side of a thin film sheet, heating and foaming it, and then bonding the opposite side to a thick film sheet. 2. The method for producing an anti-slip sheet according to claim 1, wherein the thick film sheet is a nonwoven fabric.