JPS6036391B2 - Method of manufacturing foam decorative material - Google Patents

Description

[Detailed Description of the Invention] The present invention is a foamed decorative material that can meet the demands of the era of material saving and has an extremely large unevenness difference that would be unbelievable based on the conventional concept of foaming ratio. This relates to a manufacturing method.

Conventionally, in order to obtain decorative materials that are foamed products, foaming was carried out to a foaming ratio that was just one step before the foamed surface became rough, in order to create the most outstanding three-dimensional and voluminous feel possible.
Therefore, if it was desired to further increase the remarkable three-dimensional effect, the only solution was to increase the amount of resin containing a blowing agent.

However, increasing the amount of resin used means increasing the weight of the product, and if it is to be used as a wall covering material, it will meet the requirements for certification as "wallpaper", a legal fire-retardant wall covering material established by the Ministry of Construction. This would not only exceed the current weight limit, but also increase costs, and was not a desirable solution from the standpoint of saving resources, materials, and energy. By the way, when we consider what kind of foam structure should be in order to obtain a noticeable unevenness level difference, even if the foam layer forming the surface layer has the normal foaming ratio mentioned above, the foam layer on the surface layer is It can be said that a structure in which the core is raised upward by the interposition of a large hollow core portion in the height direction is a desirable embodiment.

Therefore, the present inventor has conducted extensive research on how to interpose a large hollow core portion in the height direction as described above, and has successfully used the attributes of the conventional three public decomposable blowing agents. It was found that the problem could be solved by doing the following, and the present invention was finally completed.

The present invention will be described in detail as follows.

In foaming methods that use blowing agents, decomposable blowing agents are widely used as blowing agents, including organic blowing agents such as azo compounds, sulfohydrazide compounds, nitroso compounds, and azide compounds, as well as inorganic blowing agents. It is well known that there are different decomposition temperatures and amounts of gas generated.

In general, the decomposition temperature changes greatly when mixed with resins, plasticizers, solvents, stabilizers, acids, bases, etc., and especially when blowing agents are dissolved in the compounding agent. For example, azodicarbonamide (ADCA) Select two types of decomposable blowing agents that exhibit a relatively large difference in decomposition temperature, such as approximately 20,000°C for the oxybisbenzenesulfonyl hydrazide (0% H) system, and approximately 130°C for the oxybisbenzenesulfonyl hydrazide (0% H) system. That's easy.

Therefore, in the present invention, the first foaming agent-containing synthetic resin layer is formed by using, for example, a doctor knife or a comma doctor, in the concave portions of the first surface of Motomura, which have been formed with a concavo-convex pattern in advance, as shown in Figure 1-A. 2 is coated and filled as shown in Figure 1-B, and this is covered with a second synthetic resin layer 3 containing a second blowing agent having a decomposition temperature higher than the decomposition temperature of the blowing agent.
The product in the state shown in Figure 1C was subjected to heating and foaming treatment.

The foaming of the first and second synthetic resin layers at that time is shown in Figure 1-○ showing the initial stage, Figure 1-E showing the intermediate stage,
The process is completed through the state shown in Figure 1-F, which shows the final stage, and eventually the surface layer, which is the foamed layer, of the second synthetic resin layer is removed under the condition that the second synthetic resin layer still maintains its airtightness. The hollow core portion, which is the trace of the foaming of the first synthetic resin layer, is made to bulge out. Each step is specifically explained as follows. At the initial stage of foaming shown in Figure 1-D, the foaming agent in the first layer 2 has already begun to decompose and generate decomposed gas, but the foaming agent in the second layer 3 covering it has already begun to decompose and generate decomposed gas. Since it has not yet reached the point of decomposition and the state of the sealed membrane is maintained as it is, the decomposed gas from the first layer 2 cannot escape to the outside and pushes the second layer 3 upward. In this process, the first layer 2 is scattered with tiny cells, but as the foaming progresses, the tiny cells grow larger, and furthermore, adjacent cells connect with each other. This changes into a collection of multiple coarse cells as shown in Figure 1-E.

Although foaming of the second layer 3, which corresponds to the state shown in FIG. It keeps increasing in height.

In the final stage of foaming shown in Fig. 1-F, when the plurality of coarse cells finally become one large bubble and form the hollow core portion 4, the second layer 3 is foamed with an appropriate foaming ratio.
The result is a foam with a good surface condition without any roughening. The size of the hollow core portion 4, which dramatically increases the swelling effect when the depth and shape of the recess on the base material 1 side are constant, is determined by the foaming agent contained in the first layer 2. Since the amount of blowing agent depends on the amount of decomposed gas, the amount of the blowing agent may be appropriately determined in relation to the desired size of the hollow core portion 4.

Further, the size of the hollow core portion 4 is also influenced by the depth and shape of the recessed portion of the base material 1, and this may be selected appropriately taking into consideration the design and aesthetic aspect of the final product. In addition, if the difference in decomposition temperature between the first and second blowing agents is small, there will be little deviation in the foaming state of the two synthetic resins, and the first blowing agent will not be retained in the decomposed gas inside, but will easily leak out. If the decomposition temperature escapes, we cannot expect much from the swelling effect of the hollow core portion 4, so an appropriate difference should be provided between the two decomposition temperatures, and the difference is preferably at least 30 qo or more.

In addition, the method of imparting and forming the uneven pattern on the base material is a known method,
For example, an embossing machine, a paper embossing machine, etc. can be used.

The first synthetic resin 2 may be coated and filled into the concave portions of the base material 1 by a known method such as a doctor knife method or a comma doctor method, and the second synthetic resin may be coated with a coating machine such as a roll coater method or a knife coater method. Alternatively, the second blowing agent-containing synthetic resin may be formed into a sheet, and this may be laminated onto the base material 1 whose recesses are filled with the first blowing agent-containing synthetic resin.

As is clear from the above description, the method of the present invention includes a first foaming agent-containing synthetic resin layer coated with a second foaming agent-containing synthetic resin layer 3 for forming a surface foam layer. 2, due to the difference in blowing agent decomposition temperature, foaming occurs while the second layer 3 still maintains its airtightness, and changes from fine cells to coarse cells,
The coarse cells are actively expanded until they become a single hollow core portion 4, and when the second layer 3 forms a surface foam layer, it is expanded by the intervention of the hollow core portion 4, and the amount of resin is increased. It is extremely superior in that it is possible to reliably obtain a foamed decorative material with an extremely large level difference in unevenness, which is two to three times as large as that of ordinary foam, without increasing the surface area.

If the volume of the unevenness is the same as that of the conventional method, the method of the present invention can be said to be an extremely economical method considering the advantage that the amount of material required is about half.

In addition, the obtained product is lightweight, soft, has excellent heat insulation and sound absorption properties, and is extremely excellent in terms of resilience and cushioning properties. Examples are shown below.

The flow sheet of this example is shown in FIG.

Mixture table A was applied to the recesses of wallpaper scale-burning backing paper 1 with a thickness of about 0.15 willow, which had been given a fine pot-like uneven pattern in advance.
A first blowing agent-containing polyvinyl chloride paint 2' (decomposition temperature of the blowing agent: 130 qo) shown in FIG.

2 shows a coating layer of the first foaming agent-containing polyvinyl chloride paint filled in the concave portion of the base material 1.

The thickness of the filled coating layer 2 was about 0.04 mm, and the estimated amount of filling was extremely small. The hair dressing paper 1 with the coating layer 2 filled in the concave portion is then passed through a 120 oo drying oven 5 for 60 seconds to dry and gel, and then a second foaming agent shown in the formulation table B is applied in the coater 6. A polychloride-containing pinyl paint 3' (decomposition temperature of blowing agent: 20,000) was applied evenly over the entire surface.

3 shows the coating layer of the second blowing agent-containing polyvinyl chloride paint.

The thickness of the coating layer 3 was a normal coating layer thickness of about 0.15 mm. The backing paper 1 with the coating layer 3 formed on the filling coating layer 2 in this way is placed in a drying oven 7 at 120°C for 90 minutes.
After drying and gelling for a few seconds, a gravure printing machine 8 is used to perform an anti-glare surface treatment according to a conventional method, and then the first and second foaming agent-containing polyesters are passed through a 220 o 06 sand in a foaming furnace 9. The vinyl chloride paint was spooled through the foam chiller 10 as in the process described above.

The resulting product had a three-dimensional dewdrop pattern that stood out, and its height was about 4 degrees.

It was clearly confirmed that a hollow core portion was formed from the cut end surface and was raised by this.

Blend Table A (Parts are parts by weight) PVC IO Yuebu D〇P 7 parts Stabilizer (Board - Zn system) 3 parts Foaming agent (OB
SH type) 2 parts foaming aid
1 part combination Table B (parts by weight) PVC IO base DOP 28 parts flame retardant plasticizer 2 parts epoxy plasticizer 2 parts stabilizer (axis - Zn
system) 3-part blowing agent (ADCA system)
5 parts foaming agent
1.5 parts filler
5 Ankaribe pigment (Ti02)
2nd anchor

[Brief explanation of the drawing]

FIG. 11A to FIG. 11F are explanatory diagrams from before foaming to after foaming in the method of the present invention. FIG. 2 is a flow sheet showing the manufacturing process. 1
: base material, 2, 3: foaming agent-containing synthetic resin layer, 4: hollow core portion. Connection - Figure A Purple' - Figure B Figure 1 - Figure C Figure 1 - Figure D - Figure E Figure 1 - Figure 2

Claims (1)

[Claims] 1 A first synthetic resin containing a blowing agent is filled into the concave portions of the base material surface having an uneven pattern, and this is filled with a synthetic resin containing a second blowing agent having a decomposition temperature higher than the decomposition temperature of the blowing agent. The foamed surface layer of the second synthetic resin layer containing a foaming agent is covered with the first synthetic resin while maintaining the airtightness of the second synthetic resin layer. A method for producing a foamed decorative material, characterized in that the layer is expanded by a hollow core portion that is a trace of foaming.