JPS63242633A - Manufacture of dew-condensation preventive foaming decorative material - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a method for manufacturing a dew-preventing foam decorative material used for wall covering materials, ceiling materials, etc.

<Prior Art> There are three general methods known as methods for imparting a dew-preventing effect (moisture permeability) to decorative materials using synthetic resins. That is, one is to mix a water-absorbing polymer into the synthetic resin layer as disclosed in JP-A-56-3302@publication, and the other is to mix a water-absorbing polymer into the synthetic resin layer, as disclosed in JP-A-53-317.
As shown in Japanese Patent Publication No. 72, one method is to form a foamed layer with countless interconnected microbubbles, and the other is to form a foamed layer with numerous interconnected microscopic cells, as described in Japanese Patent Publication No. 53-38102. The porous sheet provides moisture permeability. In addition, air permeability and moisture permeability were also ensured by mechanically punching fine holes using a cloth roll.

<Problems to be solved by the invention> Since these decorative materials are mainly used as interior wall covering materials, they are usually given an uneven pattern by mechanical embossing. At times, the dew condensation prevention effect (moisture permeability) was significantly impaired, and the desired function could not be achieved.

In the method of mixing water-absorbing polymers into the synthetic resin layer, the water-absorbing effect only moves on the water-absorbing polymers exposed on the surface, but when mechanical embossing is applied to obtain a decorative design, The exposed area of the water-absorbing polymer that was exposed on the surface became narrower, or in extreme cases it was crushed, making it impossible to expect the original dew condensation prevention effect.

In addition, when a foamed layer with countless interconnected microscopic cells is mechanically embossed to ensure the design, the foamed synthetic resin layer melts due to the heating during embossing and the interconnected microscopic cells form. In addition, the mechanical pressure during embossing crushed the communicating fine bubbles in the concave portions, and the desired dew condensation prevention effect was not achieved.

Even if a microporous olefin sheet is used to provide moisture permeability, if mechanical embossing is applied to create a design, the heating during embossing may melt and close the micropores in the sheet, or the micropores may close in the recesses. was crushed,
After all, the desired moisture permeability effect was significantly impaired.

Even when punching is used, the holes may become clogged during embossing, or the holes can only be made larger than chemical microbubbles, which may impair the design, or dirt may adhere to the holes made by the clothing. It had drawbacks such as:

Means for Solving the Problems> Therefore, the present invention provides four parts of a foamable synthetic resin containing a water-absorbing polymer and a blowing agent that creates fine cells that communicate with each other after heating and foaming in a final product. A method for producing a highly eroded condensation-preventing foam decorative material having an uneven pattern, which is used for both a base layer forming a foam layer and a pattern layer forming a convex foam layer, and combining this with a moisture-permeable resin coating. It provides:

In addition, although the conventional technology had a disadvantage in that the effect of preventing condensation on the concave portions was poor, according to the method of the present invention, the concave portions also have an extremely excellent dew condensation prevention function, and the concave portions and the white portions are roughly the same. Since it is made of a foam layer, it has heat insulation and sound insulation effects, and any design pattern can be created without mechanical embossing, and the pattern formation does not have any negative effect on the dew condensation prevention effect. Therefore, it is possible to provide a method for producing a foamed decorative material that prevents condensation.

The present invention provides a first foaming composition in which a base material such as paper contains a finely powdered water-absorbing polymer and a foaming agent that creates fine cells (open cells) that communicate with each other after heating and foaming. Resin is laminated on the entire surface, and then, on the first foamable synthetic resin layer, a water-absorbing polymer and a foaming agent that creates fine cells that communicate with each other after heating and foaming are added. At least one second foamable synthetic resin colored in the same or different color as the foamable synthetic resin layer is formed in an arbitrary pattern, and further
and a structure in which a moisture-permeable resin film is formed on the second foamable synthetic resin layer, and then the first and second foamable synthetic resins are heated and foamed to reveal a foamed uneven pattern having a dew condensation prevention function. This is what I did.

To explain in more detail below, the base materials include paper, cloth,
Any material such as non-woven fabric or aluminum hydroxide paper can be used.

These base materials are coated with a finely powdered water-absorbing polymer and a foaming agent that creates countless communicating microbubbles after heating by a known lamination method such as a coating method, a calendar method, or a laminator method. A first foamable synthetic resin layer is formed over the entire surface. As the resin used for this first foamable synthetic resin layer, any resin including heat-foamable vinyl chloride resin can be used.

The water-absorbing polymer is a well-known hydrophilic resin capable of absorbing water and expanding, and preferably has the ability to absorb 50 times or more of its own weight of pure water. Main water-absorbing polymers include starch/sodium acrylate graft copolymers, saponified vinyl esters/ethylenically unsaturated carboxylic acids or their derivatives, polysodium acrylate crosslinkers, and polyvinyl alcohol/acrylate graft copolymers. Polymers, etc. can be fried.

Commercially available products include Sumikagel-3P (Sumitomo Chemical), Zanwet IM-300 (Sanyo Chemical), and Aquakey 1.
43 (steel manufacturing chemical industry products), etc.

These water-absorbing polymers usually have a particle size of 350 μm to 0.5 μm.
Although it is a fine powder of about 1 μm, in consideration of dispersibility, the average particle size is preferably 100 μm or less. The number of parts added is usually 2~
The amount is 40 parts, preferably around 5 to 15 parts.

The foaming agent contained in the first foamable synthetic resin described above is
It is preferable to have an open cell ratio of 70% or more after heating and foaming in order to prevent dew condensation. The ratio can be adjusted by adjusting the mixing ratio of the foaming agent for forming closed cells and the foaming agent for forming open cells (open cells), or by adjusting the foaming speed by selecting a stabilizer, or by adjusting the foaming heating temperature and foaming heating time. This can be achieved by etc. The above-mentioned Japanese Patent Application Laid-open No. 53-31772 discloses a combination of a foaming agent (UNIFORM AZ-F Daikyu Yakuhin) and a stabilizer (Stabilizer F Kyodo Yakuhin), a foaming agent (ONIFINE MO Daikyu Yakuhin) and an arbitrary stabilizer. There are examples of combinations. In the case of the present invention, these materials can also be used, and in the case of vinyl chloride resin, ordinary azosica-bonamide is often used. The first foamable synthetic resin layer is laminated on the entire surface of the base material. After that, a second foamable synthetic resin paint is formed in an arbitrary pattern on top of it using a known coating printing method such as rotary screen printing or gravure printing, and the temperature is below the decomposition temperature of the foaming agent. The second foamable synthetic resin layer is dried and semi-gelled.

This second foamable synthetic resin also contains a water-absorbing polymer having the same or similar performance as that contained in the first foamable synthetic resin, and a foaming agent that creates countless interconnected fine cells after heating and foaming. However, the second foamable synthetic resin applied in a pattern may be colored the same or different color from the first foamable synthetic resin.

Further, this second foamable synthetic resin may be of a single color, or may have a multicolor pattern from the viewpoint of aesthetic effect and design.

The first foamable synthetic resin is in the form of a paste paint,
When laminating on a base material by a coating method, it is possible to use the first foamable synthetic resin paint as it is or add a coloring pigment to it as a substitute for the second foamable synthetic resin paint. In the case of rotary screen printing or gravure printing, which forms the foamable synthetic resin paint into a pattern, the viscosity must be adjusted slightly lower.

In addition, by incorporating a large amount of filler into the first foamable synthetic resin, it is possible to reduce costs and improve the flame retardancy of wallpaper, etc. However, in the case of rotary screen printing and gravure textile printing, Since it is not possible to incorporate the filler into the first foamable synthetic resin due to problems such as blurring, clogging, and viscosity during coating and printing, it is desirable to separate the filler if possible.

After laminating the first foamable synthetic resin on the entire surface of the base material and further forming the second foamable synthetic resin in a pattern on the base material, in order to form a moisture permeable resin coating thereon, a transparent A wet resin paint may be applied by a coating method, a surface treatment may be applied using a gravure printing machine, or a moisture permeable resin film formed in advance may be laminated.

Moisture-permeable resins include, for example, urethane-based W10 emulsion resins, amino acid/methacrylic acid/urethane copolymers, and microporous sheets of the above-mentioned olefin-based resins. In order not to lose the performance of the wet resin, and also to eliminate the seepage of cleaning sewage that is handled when it becomes dirty when used as a wall covering, amino acids are allowed to pass through only in water vapor form, but not in liquid form. /methacrylic acid/urethane copolymer is preferred, but other moisture permeable resins having the same function can also be used.

Now, the first foamable synthetic resin is laminated on the base material, the second foamable synthetic resin is formed on it in a pattern, and the first and second foamable synthetic resin layers are laminated on the base material. After forming a moisture-permeable resin film thereon, this is heated and foamed in a foam heating furnace to reveal a foamed uneven pattern, thereby obtaining a dew condensation-preventing foamed decorative material.

The anti-condensation foam decorative material of the present invention having this uneven pattern is
Not only the convex portions but also the concave portions are foamed, and both the convex portions and concave portions contain countless communicating microscopic bubbles, and the water-absorbing polymer is evenly mixed in. A moisture-permeable resin film is formed on the surface of the material.

<Effects of the Invention> According to the method of the present invention, both the concave portion formed by the foaming of the first foamable synthetic resin layer and the white portion formed by the foaming of the second foamable synthetic resin layer have countless shapes. It is a foamed synthetic resin layer with communicating micro-cells, and the foamed synthetic resin layer is almost uniformly mixed with water-absorbing polymers in the form of fine powder.
Furthermore, a moisture-permeable resin coating is formed on the surface of the foamed synthetic resin layer in the concave and convex portions. Therefore, even if dew condensation occurs on the surfaces of both the concave and convex portions, the moisture will pass through the moisture-permeable resin coating and actively affect the continuous micro-cells and water-absorbing polymer in the foamed synthetic resin layer of the concave and convex portions. Because it is absorbed by
There is no occurrence of dew condensation on the surfaces of either the concave portions or the convex portions.

As mentioned above, the dew condensation-preventing foam decorative material of the present invention is not mechanically embossed at all, and the concave portions are also foamed, and it has a dew condensation prevention effect, compared to the conventional technology. It has excellent functionality,
Furthermore, it is also excellent in that a desired unevenness level difference can be created by arbitrarily adjusting the lamination or coating thickness of each of the first and second foamable synthetic resins.

In particular, this product is unique from conventional products in that the appearance of the uneven pattern does not interfere with the dew condensation prevention function.

In the prior art, when the design has a large concave area, the dew condensation prevention function naturally deteriorates, but the method of the present invention does not have such a drawback. That is, in the case of a design in which the area of the recessed part is large, it is possible to increase the lamination thickness of the first foamable synthetic resin that becomes the recessed foamed synthetic resin layer in advance; In the case of a narrow design, the laminated thickness of the first foamable synthetic resin that will become the foamed synthetic resin layer in the concave areas is set thin in advance, and the coating thickness of the second foamed synthetic resin that will become the foamed synthetic resin layer in the convex areas is set thin in advance. By making adjustments such as setting the thickness to be thicker in advance, it is possible to easily obtain the desired dew condensation prevention effect.

In addition, when the unevenness level difference is set in advance from the design point of view, it may not be possible to adjust the lamination thickness or coating thickness of the first and second foamable synthetic resins, but in such a case, the method of the present invention Then, the amount of water-absorbing polymer added to the first foamable synthetic resin and the amount of water-absorbing polymer added to the second foamable synthetic resin may be adjusted to different amounts, or the water absorption performance may be adjusted to different amounts. By selecting and using different types of water-absorbing polymers, there is an advantage that the water-absorbing performance can be easily maintained and set at a desired level without being directly related to uneven steps.

With conventional technology, it was impossible to achieve such water absorption performance by changing the composition of concave and convex parts.
In the present invention, different types of water-absorbing polymers can be selectively used for the four parts and the convex part, and the addition orifice of the water-absorbing polymer can be freely selected. And since you can choose to arbitrarily set the lamination thickness or coating thickness of the second foamable synthetic resin, there is no need to worry about the dew condensation prevention effect being influenced by design constraints. It can be said to be extremely excellent.

Furthermore, the first. The amount of blowing agent added to the second foamable synthetic resin to create interconnected micro-cells may be varied depending on the number of heat-foamed cells, different types of blowing agents may be selected, or a stabilizer may be added. The present invention has the advantage that it is possible to change the combination, and that it is possible to easily maintain and set the dew condensation prevention performance at a desired level while adjusting the unevenness level difference depending on the addition level and type of the foaming agent. This is also an advantage over the conventional technology.

<Example> A first foamable vinyl chloride resin compound having the following formulation was laminated to a flame-retardant paper (base material) for wallpaper 1 to a thickness of 0.15 mm by a calender method to form a first foamable synthetic resin layer. 2 was laminated on the entire surface (Fig. 1).

Resin: Polyvinyl chloride resin 100 parts Plasticizer: DOP 50 parts Stabilizer: 3a-Zn system 3 parts Foaming agent: A
DCA type 5 parts Water-absorbing polymer... Sumikagel 5P-520 10 parts Filler... Calcium carbonate 70 parts Face
Material: Titanium white 15 parts Rust preventive agent
...Osaid part 1.5 and then the 1st part above.
On the foamable synthetic resin layer 2, using a rotary screen multicolor printing machine equipped with a screen cylinder with a floral pattern, apply a foamable vinyl chloride resin paste paint of the following composition to a thickness of 0.12 mm. The second foamable synthetic resin layer 3 was formed into a floral pattern (Fig. 2).

Resin: Polyvinyl chloride resin 100 parts Plasticizer: DOP 50 parts Stabilizer: 3a-Zn system 3 parts Foaming agent: A
DCA system 10 parts Water-absorbing polymer... Sunwet IIVI-3008 parts Filler... Calcium carbonate 30 parts Face
Materials: Titanium white 10 parts Colorant:
... Red pigment 5 parts Rust preventive agent ... Biocide 1.5 parts Subsequently, using a gravure printing machine, amino acid/methacrylic acid/urethane is applied to the surfaces of the first and second foamable synthetic resin layers. A moisture-permeable resin coating layer 4 was formed by applying and drying a moisture-permeable resin paint made of a copolymer (FIG. 3).

Subsequently, this was introduced into a foaming heating furnace set at about 230°C and heated for 1 minute to foam the first and second foamable vinyl chloride resin layers. 2 is foamed to form a concave foamed synthetic resin layer 5 with a thickness of approximately 1.2 mm, and the second foamable synthetic resin layer 3 is a synthetic resin layer 5 which has been foamed in a floral pattern and has convex portions approximately 1.5 mm thick. layer 6
was formed (Fig. 4).

As can be seen from FIG. 4, below the synthetic resin layer 6 formed by the second foamable synthetic resin layer 3 serving as the convex portion, there is a synthetic resin layer formed by the first foamed synthetic resin layer 2. 5 exists, the thickness of the convex portion viewed from the surface of the base material is approximately 2.5 mm.
The thickness was 7 mm, and a moisture-permeable resin coating 4 was formed on the surfaces of both the concave and convex portions.

This dew condensation-preventing foam decorative material having an uneven pattern is foamed in both the concave and convex portions, and furthermore, from its cross section, it can be seen that the first and second foamable synthetic resin layers have countless connections with the foamed synthetic resin layers 5 and 6. Microscopic bubbles that communicate with each other are created, and water-absorbing polymer in the form of fine powder is almost uniformly mixed in. The surface is covered with a moisture-permeable resin film 4, and there are no irregularities. Because the steps were large and the recesses were also foamed, it was a condensation-preventing foam decorative material with excellent heat and sound insulation properties.

In this example, the second vinyl chloride resin paste paint to be formed into a pattern had a floral pattern with only one red color, but if necessary, the second vinyl chloride resin paste paint could be made in multiple colors. It is also possible to form it in a plurality of patterns.

Table 1 shows the test results of a comparison between the present example and a conventional dew-preventing wallpaper having a similar uneven pattern.

Table 1 Comparative Example Δ: non-foamed synthetic resin rfBWJ mixed with a water-absorbing polymer and mechanically embossed with a pattern similar to the floral pattern of this example.

Comparative Example B: A foamed synthetic resin layer having countless interconnected microscopic cells was mechanically embossed with a pattern similar to the floral pattern of this example.

Comparative Example C: An olefin microporous sheet was laminated to a non-foamed synthetic resin layer and mechanically embossed to resemble the floral pattern of this example.

゛As can be seen from Table 1, the synthetic resin layer formed by the method of the present invention is a synthetic resin layer in which the concave portions are also foamed, and there are not only countless interconnected microbubbles, but also a fine powder-like layer. The water-absorbing polymer was almost uniformly mixed and scattered, and since it was not subjected to any mechanical embossing pressure, it was practically as effective in preventing condensation as the convex part.

In addition, when examining the cross-sectional view of the product of this example with a magnifying glass, it was found that the concave portion located below the convex portion and the convex portion above it were integrated during the foaming heat treatment, and the open cells in the concave portion and the convex portion were integrated. It was confirmed that the open cells in the sections were almost connected, and that moisture (moisture) absorbed from the surface of the convex sections easily passed through to the concave sections.

[Brief explanation of drawings]

1 to 4 are cross-sectional views for explaining aspects of different stages of an embodiment of the manufacturing method of the present invention. 1...Flame retardant paper (base material), 2...First expandable vinyl chloride resin layer containing a water-absorbing polymer and a blowing agent that creates countless interconnected fine bubbles after heating and foaming, 3 . . . A second expandable vinyl chloride resin layer containing a water-absorbing polymer and a blowing agent that creates countless interconnected fine bubbles after heating and foaming, 4
... Moisture-permeable resin coating, 5... Foamed synthetic resin layer in which the first foamable vinyl chloride resin layer 2 is foamed, 6... Foamed synthetic resin layer in which the second foamable vinyl chloride resin layer 3 is foamed. Synthetic resin layer.

Claims (1)

[Claims] 1. A first material containing a finely powdered water-absorbing polymer and a foaming agent that creates countless interconnected micro-cells after heating and foaming on the base material.
The first foamable synthetic resin layer contains a micropowdered water-absorbing polymer and a foaming agent that creates countless interconnected micro-cells after heating and foaming. At least one second foamable synthetic resin colored in the same or different color as the first foamable synthetic resin is formed in an arbitrary pattern, and further on the first and second foamable synthetic resin layers. A method for producing a dew-preventing foam decorative material, which comprises laminating a moisture-permeable resin film and then foaming and heating the above-described first and second foamable synthetic resins.