JPS5833814B2 - Manufacturing method of lightweight upholstery material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a lightweight cladding material that is aesthetically and tactile and is used to clad walls, ceilings, etc.

Overlay materials in which foam particles are adhered to a flexible substrate have been known for a long time, and the surface of the overlay material may be textured by having the foam particles partially present or by embossing. It is also known that this gives a three-dimensional effect.

The present inventors improved the conventional manufacturing method and researched a method of bonding the foam to the base material more firmly and with an even better aesthetic feel, and as a result, they arrived at the present invention. A light-weight product characterized in that the foam particles are adhered with a primary adhesive and then embossed to form an uneven pattern, or a foamable secondary adhesive is applied without embossing and foamed adhesive is applied. In addition to the three-dimensional effect created by the lining, embossing, or the foam itself due to the manufacturing method of the upholstery material, the aesthetic feel is enhanced by the foam of the secondary adhesive, giving the upholstery material as a whole a deeper three-dimensional aesthetic and tactile sensation. The scales were discovered.

The flexible base materials referred to in the present invention are those conventionally known as base materials for upholstery materials such as paper, cloth, asbestos paper, nonwoven fabrics, and mats, and the foam particles are foamed synthetic resins, foamed It refers to fine grains of 50 to 5 mesh, such as vulcanized rubber and calcined mineral materials, with a high specific gravity of 0.5 or less, and may be a mixture or synthetic material of these materials.

Particularly preferred are fine grains of calcined minerals such as vermiculite and pearlite, fine grains of foam such as polyurethane, polyvinyl acetal, and ethylene-acetate-picopolymer, and fine grains of vulcanized rubber foam such as SBR rubber. be able to.

The adhesive may be either a natural glue or a synthetic resin adhesive.To impart foaming properties to these adhesives, a gas or easily volatile liquid may be added in advance by a mechanical method, or a foaming agent may be used. A chemical method of generating gas by heating may also be used.

Further, the adhesive may be of an emulsion type, a solvent type, or a melt type, and the resulting foamed layer preferably has flexibility and elasticity.

Next, each embodiment of the present invention will be explained.

A foaming adhesive or a non-foaming adhesive is used as the primary adhesive to adhere the foam particles to the entire surface of the substrate, and then the foam is partially compressed and defoamed to create a three-dimensional pattern by embossing. give

In addition, if the bubble is thick and shows a three-dimensional pattern even in number 11, only number 1 is used.

A foaming adhesive may be applied as a secondary adhesive over the entire surface or in part of the overlay material having the three-dimensional pattern thus obtained, and the adhesive may be foamed by an appropriate method such as heating and drying.

The foamable secondary adhesive especially foams in the gaps between the bubbles and rises at the same time as it fills the gaps.

- Although foaming occurs on the surface of the foam, there is an imbalance in the degree of foaming between the gap and the surface, making the three-dimensional pattern even more complex and presenting a natural three-dimensional pattern.

In addition, when the foam existing on the entire surface is partially compressed and defoamed and embossed, if a foaming secondary adhesive is applied and foamed, the embossed part will hardly foam and only the non-embossed part will foam. This has the unexpected effect of further enhancing the three-dimensional pattern.

The reason why foaming does not occur in the embossed area is unknown, but if a foamable plastisol containing a pyrolytic foaming agent is used as a secondary adhesive and the sol is applied at a rate of 200 to 500 g/rn, the embossed area will There is a significant difference between the non-foaming in the area and the foaming in the non-embossed area.

In addition, when applying a foaming adhesive after embossing, it is more preferable to apply a non-foaming adhesive to the entire surface in advance to complete the adhesion and then apply the foaming adhesive.

As described above, the surface of the present invention is covered with foam, and the foamed secondary adhesive layer that exists partially or entirely increases the bulge and enhances the three-dimensional effect. It has a beautiful three-dimensional pattern and is aesthetically pleasing.

Moreover, it has an excellent three-dimensional effect and a good tactile feel due to the elasticity of the foam of the secondary adhesive layer, and has a higher commercial value than conventional products.

Furthermore, since there are a large number of bubbles, it has superior sound absorption and heat insulation effects compared to conventional products.

By using a foam adhesive, a sufficient adhesion effect can be achieved even with a small amount of adhesive, and at the same time, it is possible to reduce the weight and reduce the amount of adhesive used.

Furthermore, changing the color tone of the base material and the non-foam foamable secondary adhesive gives an effect similar to two-color printing and further enhances the aesthetic appearance.

Furthermore, by using a flame-retardant base material, a flame-retardant adhesive, and calcined mineral granules, it is easy to apply flame-retardant or flame-retardant overlay materials.

Next, the present invention will be explained by examples.

Example I A polyvinyl acetate emulsion (solid content 25%, 200Ps) was coated on the entire surface of asbestos paper with a knife coating to a thickness of 0.3 mm, and 10 meshes of calcined vermiculite particles were adhered to the entire surface of asbestos paper. On top, 100 parts of base resin (Sumiritzu PX-N manufactured by Sumitomo Chemical), 50 parts of DOP, 50 parts of TCP, 5 parts of stabilizer (Mark 5C35 manufactured by Ateca Argus Chemical), 4 parts of foaming agent (Uniform A manufactured by Daikyo Chemical Co., Ltd.)
Z541) 20 copies.

A paste resin plastisol consisting of 20 parts of titanium oxide and 10 parts of Shiroenka (manufactured by Shiraishi Kogyo) was applied to a thickness of 0.3 mrrt and foamed by heating at 170°C for 5 minutes.

The resulting material had particularly foamy bulges in the gaps between the vermiculite particles, enhancing the three-dimensional appearance of the vermiculite itself.

Moreover, the state of the bumps was full of natural appearance and greatly enhanced the beauty.

Furthermore, the adhesion was perfect and the flexibility, elasticity, and feel were excellent.

Example 2 Using 30 mesh calcined vermiculite, 80 mesh was used in the same manner as in Example 1.
Vermiculite particles were adhered to the entire surface of a 9 m'' paper, and an uneven pattern was applied to the surface by colored embossing.

On top of this, the same plastisol as in Example 1 was colored and 0.2
The coating material was applied to a thickness of mm and foamed to produce an overlay material.

In the obtained product, foaming occurred only in the areas where vermiculite particles, which cause foaming, were present, which caused foaming in the embossed areas where the particles were compressed.

Therefore, the three-dimensional effect due to embossing was further enhanced.

Furthermore, as in Example 1, foaming in the non-embossed areas was remarkable in the gaps between the vermiculite particles, enhancing the natural feel of vermiculite.

Furthermore, the color used during embossing and the color of the plastisol were mixed, and the non-foamed areas of the emboss had a different hue, making it even more aesthetically pleasing.

In this way, the three-dimensional effect due to embossing was further enhanced, and the color tone changed, resulting in an even better aesthetic feel.

Furthermore, similar results were obtained when a secondary adhesive was applied as in the past to complete the adhesion of the vermiculite particles before embossing, and then the same plastisol was applied and foamed.

Claims (1)

[Scope of Claims] 1. In a method for producing a three-dimensional covering material in which foam particles are adhered to a flexible base material via an adhesive and a textured pattern is applied to the surface, the foam particles are applied to the entire surface of the base material. After bonding with a primary adhesive, embossing is applied to form an uneven pattern, or a foamable secondary adhesive is applied without embossing. A method for producing a lightweight upholstery material characterized by foam bonding.