JPS5865771A - Wall covering material composition and production of wall covering material - Google Patents

Abstract

PURPOSE:To obtain a wall covering material which has a cubic effect and an excellent flameproofing effect, by coating flameproof paper with a compsn. consisting of an aq. emulsion, a blowing agent, a filler, a flameproofing agent and a waterproofing agent, expanding the coated paper by heating, drying it, and embossing it. CONSTITUTION:100pts.wt. aq. emulsion such as an aq. emulsion of an ethylene/ vinyl acetate/vinyl chloride terpolymer, 10-20pts.wt. carbonic acid blowing agent such as sodium bicarbonate, 20-30pts.wt. inorg. filler composed of hollow sphere such as silicaballoon, 15-25pts.wt. flameproofing agent such as aluminum hydroxide and 3-10pts.wt. waterproofing agent such as a zirconium waterproofing agent are mixed together. A flameproofed rayon paper is coated with the resulting compsn., heated at 120-160 deg.C to expand it, dried and embossed to form a cubic uneven pattern, thus giving the desired wall covering material.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention provides a wall covering composition made of a non-combustible inorganic material to be coated on flame retardant paper, and a wall covering composition coated on flame retardant paper and foamed. The present invention relates to a method for manufacturing a wall covering material that has been embossed and has a three-dimensional uneven pattern.

In recent years, the demand for wall covering materials has increased dramatically as lifestyles have become more Westernized, but many of the wall covering materials used in the past were not completely non-combustible, but were only flame retardant. .

However, large gathering places where many people gather, large-scale retail stores,
In underground malls or high-rise buildings, it is necessary to pay the utmost attention to safety, especially in the event of a fire, and conventional flame-retardant wall covering materials generate a considerable amount of harmful gas. It has become necessary to use completely non-combustible wall coverings.

Conventional noncombustible wall coverings include asbestos wall coverings,
There were wall coverings made of glass fiber fabric and wall coverings made of vermiculite, but these were either thin or could not be formed into three-dimensional uneven patterns in a free design. Therefore, there are many cases where it is not possible to satisfy the first requirement of decorativeness as a wall covering material. The disadvantage is that conventional flame retardant wall coverings must be used.

It is also possible to form noncombustible wall covering materials into predetermined patterns on buildings, underground malls, etc. by hand by plasterers.
In this case, because the plasterer is a special skilled worker,
Not only are there significant individual differences, but if the conditions at the time of work change (e), the pattern will vary even if the same person is working, making it impossible to form the same pattern on a wide wall surface. It has the disadvantage of being.

Moreover, in this case, there is also a drawback that work efficiency is low.

Furthermore, in any of the above cases, since inorganic materials are mainly used, the overall weight is considerably increased, which is a cause of hindering workability.

The present invention is for a wall covering material, which is mainly composed of a water-based emulsion of ethylene, vinyl acetate, and vinyl chloride ternary weighted resin, and is blended with an inorganic filler consisting of a hollow body, a carbonate foaming agent, a flame retardant, and a water repellent. The present invention relates to a composition and a method for producing a wall covering material in which an uneven pattern is formed after the composition is coated on flameproof paper and foamed, and the above-mentioned drawbacks are solved.

This will be explained in detail below.

As a composition for wall covering material to be applied/covered on flameproof paper,
Ethylene, vinyl acetate, vinyl chloride terpolymer resin aqueous emulsion or styrene acrylic acid ester co-M fatty aqueous emulsion, etc., per 100 parts by weight of aqueous emulsion,
It contains 10 to 20 parts by weight of a carbonate blowing agent, 20 to 30 parts by weight of an inorganic filler made of hollow bodies, 15 to 25 parts by weight of a flame retardant, and 3 to 10 parts by weight of a zirconium waterproofing agent.

The reason why an aqueous emulsion of ethylene, vinyl acetate, and vinyl chloride terpolymer resin was used and a carbonate foaming agent was used was that foaming could be performed at a relatively low temperature of 90°C or higher, and the foaming rate could be controlled to an appropriate level. In order to stay within this range, the amount is set at 10 to 20 parts by weight. The inorganic filler consisting of a hollow body has a specific gravity of 0.
By using 20 to 30 parts by weight of 1 to 0.2, it is possible to increase the volume of the wall covering material without significantly increasing its weight. The reason why the range is 20 to 30 parts by weight is because if it is too small, it will not be possible to increase the volume without increasing the weight too much, and it will not be possible to improve the nonflammability too much. This is because it becomes weaker.

As the flame retardant, 15 to 25 parts by weight of aluminum hydroxide is used. The flame retardant enhances the flame retardant effect in combination with the inorganic filler made of hollow bodies, and when the amount of inorganic filler made of hollow bodies is increased, the amount of flame retardant is decreased; When the amount of inorganic filler is reduced, the amount of flame retardant is increased.

It is recommended to use 3 to 10 parts by weight of the waterproofing agent, but if the amount of the waterproofing agent is reduced, the breathability will be high. limited to a range.

The above composition is uniformly kneaded and stirred (viscosity is 7
．． It is preferable that the number of voices be 000 to 10,000. ), one side of a long flame retardant paper (1) is coated with the composition (3) to a uniform thickness using a doctor knife (2), and then heated in an atmosphere at a temperature of 120°C to 160°C. By passing through (4), the composition is expanded to about 3 to 4 times its size and simultaneously dried.

After that, enholasing roll (5) and rubber roll (6)
), a predetermined uneven pattern can be formed.

The effect when foaming and drying are performed at the same time is as follows.

That is, when a carbonic acid blowing agent is used, mutually independent closed cells are formed, and continuous cells are also formed, and moreover, one of the carbon dioxide residues in the continuous cells is formed. part breaks through the surface of the coating layer and escapes into the atmosphere, and at the same time escapes from the composition together with ≠ dregs,
The amount of water that needs to be evaporated from the surface of the composition into the atmosphere is extremely small.

In the composition which is foamed and dried at the same time as described above, the inorganic filler from open cells, closed cells, and hollow bodies is uniformly present.

Therefore, when embossing is performed in the next step, the inorganic filler consisting of open cells, closed cells, and hollow bodies is partially crushed, creating a distinct three-dimensional effect between the crushed and uncrushed areas. can be expressed.

For example, when using wallpaper with a weight of 400 to 500 f7d,
It is possible to form an uneven pattern having a thickness difference of about 1.4 to 1.8 mm.

The wall covering material manufactured as described above has C on its surface.
It has a large number of fine holes formed when O2 gas escapes, so it has appropriate breathability, and the water-repellent properties of the waterproofing agent make the surface waterproof and stain-resistant, and it is also lightweight. This provides unique effects such as giving a sufficient three-dimensional effect.

Examples will be described below.

Example 1 Ethylene, vinyl acetate, vinyl chloride terpolymer resin aqueous emulsion 1
00 parts by weight Sodium hydrogen carbonate (foaming agent) 10 parts by weight Silica Barno (inorganic filler consisting of hollow bodies) 20 Aluminum hydroxide (flame retardant) 25 Phosphoric acid flame retardant 3 10% aqueous solution of sodium hexametaphosphate (min. M) 15 //Titanium oxide 15 Anhydrous cellulose
3.Fungicide
0.5′ Zirconium waterproofing agent
3. Mix and knead uniformly to produce a paste-like composition, and then coat the surface of flame-retardant rayon paper with a uniform thickness on flame-retardant paper to prevent foaming. After drying and embossing at the same time, it was possible to obtain non-combustible wallpaper.

The 10% aqueous solution of sodium hexametaphosphate not only uniformly disperses titanium oxide as a coloring agent in the composition, but also acts as a plasticizer along with sulfur and lithium hydrogen carbonate, making embossing easier. act.

Furthermore, since the proportion of the zirconium-based waterproofing agent is small, the effect of preventing CO2 gas from escaping into the atmosphere from the open cells formed by sodium bicarbonate is poor, and the foaming rate is as low as about 3 times.

Therefore, the wallpaper obtained in the above examples has a large number of ventilation pores and is therefore highly breathable, but its waterproof and stain-proof properties tend to be somewhat poor.

Furthermore, the weight of the wallpaper in this case was about 500 da/itf, and the height difference between the concave and convex areas was about 1.4 MM.

In addition, when wallpaper is exposed to flame, the remaining sodium hydrogen carbonate that is not decomposed by the heat added during the wallpaper manufacturing process is decomposed by the heat of the flame, and a large amount of 002 gas escapes. In addition to exhibiting a flame suppressing effect, the flame suppressing effect can be further enhanced by lowering the temperature with crystal water contained in aluminum hydroxide.

Example 2 Ethylene, vinyl acetate, vinyl chloride terpolymer resin aqueous emulsion 1
00 parts by weight Sodium hydrogen carbonate 20
Silica balloon 30 Aluminum hydroxide 15 Phosphoric acid flame retardant
1 part by weight 10% aqueous solution of sodium hexametaphosphate 15 Titanium oxide
15 Anhydrous cellulose
2 〃Fungicide
0.5' Zirconium waterproofing agent 101
A non-combustible wallpaper could be obtained in the same manner as in Example 1.

In this case, since the proportion of the zirconium-based waterproofing agent is high, it has an excellent effect of preventing CO2 gas from escaping into the atmosphere from the open cells formed by sodium bicarbonate, and the foaming rate is about four times as high.

Therefore, the wallpaper obtained in this example has only a few ventilation pores, so it is highly waterproof and stain resistant.
Breathability tends to be somewhat poor.

Furthermore, the weight of the wallpaper in this case was about 400 f/nl, and the height difference between the concave and convex areas was about 1.8 mm.

Example 3 Ethylene, vinyl acetate, vinyl chloride terpolymer resin aqueous emulsion 1
00 parts by weight Sodium hydrogen carbonate 20
Water-based Michael Capsule foaming agent 3 parts by weight Ricabalun 30 Aluminum hydroxide 15 Phosphoric acid flame retardant
8 Sodium hexametaphosphate-1
0% aqueous solution 15 Titanium oxide
15//Anhydrous cellulose
3 //Fungicide 0.
A noncombustible wallpaper could be obtained in the same manner as in Example 1 by mixing 10 parts of a zirconium-based waterproofing agent.

In this case, it has almost the same waterproofness, antifouling properties, and breathability as in Example 2.

However, regarding the rate of foaming, more foaming was observed than in Example 2 due to the mutual effect of the open cells formed by the sodium bicarbonate and the single cells formed by the aqueous Michael capsule blowing agent.

Example 4 Aqueous resin emulsion with styrene and acrinoyl ester copolymer 100 parts by weight Zinc carbonate 20 parts by weight Silica balloon 30 Aluminum hydroxide 15 10% sodium hexametaphosphate aqueous solution 15 Titanium oxide
15 Anhydrous cellulose
3.Fungicide
0.5 Zirconium waterproofing agent 5
A non-combustible wallpaper was obtained by mixing the above ingredients in the same manner as in Example 1.

In this case, since an aqueous emulsion of styrene and acrylic acid ester copolymer resin is used instead of an aqueous emulsion of ethylene, vinyl acetate, and vinyl chloride terpolymer resin, the nonflammability is slightly deteriorated, and the viscosity increases during kneading. Although it becomes high and impedes workability, there is no particular problem in practical use.

Furthermore, although zinc carbonate was used in place of sodium hydrogen carbonate, almost no change was observed in the foaming performance.

Furthermore, although we did not use any phosphoric acid-based flame retardants, which have excellent flame retardant effects, there were no practical problems in terms of flame retardant performance.

Examples 1 to 4 use flame-retardant paper obtained by applying flame-retardant treatment to rayon paper, but the flame-retardant paper is not limited to this, and other materials such as glass fiber, etc. It is also possible to use flameproof paper mixed with

However, these flame-retardant papers are required to be able to be directly attached to the wall surface by gluing, and to be able to easily peel off old wallpaper when re-pasting, so they do not suffice even if they get wet. Tensile 1) It is required to maintain strength.

Furthermore, in each of the above examples, the composition was foamed and dried at the same time, and then the embossing was immediately performed. However, before the embossing was performed, a heater (7
) may be preheated by applying heat to 170°C to 200°C; in this way, the moisture in the coating layer can be further evaporated, and the coating layer can be softened for embossing. It can be made easier.

However, care must be taken because embossing becomes difficult if the coating layer is allowed to dry too much.

As described above, the present invention can provide a wall covering material that is lightweight, has an extremely crowded three-dimensional appearance, and has an excellent flame retardant effect, thereby significantly improving the safety of various buildings, underground malls, etc. In addition, the wall covering material itself has appropriate breathability, waterproofness, and stain resistance, so it does not impair the aesthetic appearance of buildings, underground malls, etc., and it also prevents foaming and drying during the manufacturing process. Since they can be carried out simultaneously, manufacturing efficiency is improved, and the labor of pasting and replacing wall covering materials can be greatly reduced, which brings about unique effects.

[Brief explanation of drawings]

1 and 2 are simplified diagrams showing one embodiment of the method of the present invention, respectively.

Claims (1)

[Claims] 1. 100 parts by weight of aqueous emulsion, 10 parts by weight of carbonic acid blowing agent
~20 double parts, inorganic filler consisting of a hollow body 20~30
A composition for wall covering material, comprising 15 to 25 parts by weight of a flame retardant and 3 to 10 parts by weight of a waterproofing agent. 2. 100 parts by weight of aqueous emulsion, 10 parts by weight of carbonic acid blowing agent
~20 parts by weight, inorganic filler consisting of hollow bodies 20-30
A composition for wall coverings containing 15 to 25 parts by weight of a flame retardant, and 3 to IO parts by weight of a waterproofing agent is applied to a predetermined thickness on flame retardant paper and heated in an atmosphere at a temperature of 120°C to 160°C. A wall covering characterized by foaming the composition by about 3 to 4 times by passing it through the composition, simultaneously evaporating the moisture in the composition, and then forming a three-dimensional uneven pattern by performing embossing. Method of manufacturing wood.