JPS5850180B2 - Manufacturing method for decorative building materials - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention provides a decorative building material that exhibits an extremely soft surface feel and has clearly defined and three-dimensional embossed edges.

Conventionally, the applicant owns a method in which a first embossing process is applied to a foamable synthetic resin layer to make it foam, a part of the embossed pattern remains, and a second embossed pattern is further applied to this surface. It is disclosed in Japanese Patent No. 513426.

However, in the above patent, since a second embossed pattern is applied after foaming, the soft feel of the surface tends to be lost, and there is still room for improvement.

In addition to the above-mentioned problems, the present inventors have completed the present invention as a result of intensive research into decorative building materials in which the edges of the embossed pattern are conspicuously clear and full of three-dimensional effect.

That is, the gist of the present invention is (a) a step of laminating a foamable synthetic resin layer on a base material, (b) a step of forming a rough surface on the layer, (c)
) then R-CH=C-COOHC, where R(CH2
) n-COOH: hydrogen, alkyl, allyl, n: 1 to 4) A step of embossing that also serves as application of a colored paint containing one or more of acids and derivatives thereof having the general formula: (d)
L. This is a method for producing a decorative building material, characterized in that the following steps are sequentially combined: 1. After that, the steps of foaming the foamable synthetic resin layer are sequentially combined.

Further, to explain the present invention in detail, the synthetic resin of the present invention includes vinyl resins such as polyvinyl chloride, polyvinyl acetate, and vinylidene chloride polymers, mixtures or copolymers of these, and other copolymers. Mutual mixtures or copolymers of other polymerized acrylic and methacrylic acids and their polymerized derivatives, polyethylene, polystyrene, butadiene, styrene copolymers, urethane, natural rubber, synthetic rubber, etc. etc. are used.

These synthetic resins are mixed with a foaming agent, a plasticizer, a stabilizer, and a coloring agent to form a foamable synthetic resin composition.

The blowing agent of the present invention must be such that the expansion of the resin is suppressed by the acid having the general formula R-CH=C-COOH and its derivatives, - Compounds containing bonds are particularly preferred because they contain residues that interact with the synthetic resin and decompose at high temperatures to generate inert gas containing a large amount of nitrogen, resulting in an excellent foamed structure. be.

I can do this.

Specifically, abdicarbonamide, azobisisobutyronitrile, P-P'-oxybis(benzenesulfonyl semicarbazide), P-P'oxybis(benzenesulfonylhydrazide), N-N'-dimethyl-N
-N'-dinitrosoterephthalamide and the like.

Plasticizers include dioctyl phthalate, dibutyl phthalate,
Dihebutyl phthalate, diisodecyl phthalate, cicapril phthalate, dibutoxyethyl phthalate, butylbenzyl phthalate, dibenzyl phthalate, etc., and stabilizers include organic compounds such as lead, zinc, calcium, and magnesium.

Next, the foamable synthetic resin composition obtained above is laminated onto a base material.

As a means for laminating, the above-mentioned foamable synthetic resin composition may be kneaded at a temperature below the decomposition temperature of the blowing agent, and the sheets may be laminated while being formed into sheets using a calender or the like.

Alternatively, the composition is made into a paste and the paste is laminated by a roll coating method or a knife coating method.

The base material may be any material that can reinforce the above composition, and paper (including asbestos paper), woven fabric (including glass fiber), knitted fabric, and non-woven fabric are used.

The foamable synthetic resin laminate is, if necessary, heat treated at a temperature below the decomposition temperature of the foaming agent, and then a rough surface is formed on the surface of the resin layer.

In the present invention, the rough surface refers to extremely fine irregularities such as sand grains or matte texture, and is carried out for the purpose of preventing surface roughness during foaming of the foamable synthetic resin layer in the subsequent foaming process. It is something.

(However, R: hydrogen, alkyl, allyl, n: 1 to 4) An embossing process that also serves as application of a colored paint containing one or more of acids and derivatives thereof is performed.

By making the color of this colored paint different from that of the foamable synthetic resin layer, or by creating a difference in shade, the design effect can be further improved.

This embossing can be easily carried out by applying the colored paint only to the western part of the uneven pattern engraved on the embossing roll and performing a normal embossing operation.

As a result, the embossed foamable synthetic resin layer has an uneven pattern formed therein, and a colored paint is adhered to the depressions to form a structure.

In the present invention, examples of the above and derivatives thereof include itaconic acid, methyl itaconic acid, ethyl itaconic acid, propyl itaconic acid, hexyl itaconic acid, isobutyl itaconic acid, phenyl itaconic acid, itaconic anhydride, itaconic acid monohydrazide. , itaconic acid dihydrazide, itaconic acid metal salts, sodium itaconic acid monoester, cultaric acid, ethylene glutaric acid, ethylidene glutaric acid, isoamylidene glutaric acid, maleic acid, methyl maleic acid, ethyl maleic acid, maleic anhydride, fumaric acid , methyl fumaric acid, ethyl fumaric acid, phthalic acid, methyl phthalic acid, ethyl phthalic acid, phthalic anhydride, adipic acid, methylene adipic acid, ethylene adipic acid, ethylidene adipic acid, pimelic acid, methylene pimelic acid, ethylene pimelic acid, ethylidene pimelic acid It is an organic acid such as

The embossed laminate is then heated to a temperature higher than the decomposition temperature of the blowing agent, which also serves as the application of the colored paint as described above.

By this heat treatment, the foaming agent is decomposed and the foamable synthetic resin layer is formed as a foam.

However, in the present invention, since ferric acid is added to the colored paint applied to the concave portions of the concave-convex pattern, foaming of the synthetic resin layer in the portions corresponding to the concave portions is suppressed, and the concave pattern is It will be retained as is.

On the other hand, the convex portions are foamed without any restrictions, forming even more convex protrusions, and a concave-convex pattern with an extremely three-dimensional effect is formed.

The reason for this is probably that the acid having the above general formula added to the colored paint has a certain effect on the foaming agent and suppresses foaming in the area.

As described above, the present invention provides a foaming inhibitor having the general formula R-CH=C-COOH, which is applied to a foamable synthetic resin layer whose entire surface has been embossed with fine drawing to form a rough surface before foaming. Since the method involves applying a colored paint containing a concave and convex pattern to the concave areas at the same time as forming the concave and convex pattern, the embossing process is performed and then foaming. It has an extremely soft feel without being destroyed or deformed, and in addition, foaming in the concave areas is suppressed, the convex areas are raised, and the initial roughening effect causes surface roughness throughout the foam layer. The resulting product has excellent aesthetics and can be used as wall coverings, flooring materials, etc. It is useful in many ways as a decorative building material.

Next, the present invention will be described in detail with reference to Examples, but the effectiveness of the present invention is not limited thereto.

Furthermore, in the examples, parts simply refer to parts by weight.

Example 1 [Foamable synthetic resin composition] 80 parts of vinyl chloride resin (degree of polymerization 1300), 20 parts of synthetic rubber (Biker), 65 parts of butylbenzyl phthalate,
5 parts of pigment (beige), 17 parts of cold water clay, 5 parts of benzenesulfonyl semicarbazide, and 2 parts of calcium/zinc stabilizer were kneaded using a mixing roll at about 160°C.
This is formed into a sheet with a thickness of 35 mm using a calendar roll, and is adhered to asbestos paper prepared in advance to form a laminate of foamable synthetic resin.

Next, the surface of the foamable synthetic resin layer is preheated and pressed with a grained embossing roll to form a rough surface.

[Colored paint composition]

A colored paint composition was prepared by mixing 100 parts of vinyl chloride/vinyl acetate copolymer, 200 parts of Kijirole, 330 parts of methyl ethyl ketone, 1.5 parts of zinc stabilizer, 30 parts of pigment (light green), and 7 parts of methyl itaconic acid. Manufactured.

The foamable synthetic resin layer was embossed using a normal embossing method while being adhered to the convex portion of an embossing roll having Shosoin style irregularities, and dried at a temperature below the decomposition temperature of the foaming agent.

The obtained product has the pale green colored paint composition adhered to the concave portions of the concavo-convex pattern provided on the foamable synthetic resin layer.

Next, the above laminate was introduced into a heating furnace at about 200° C. at a speed of 5 m/min to foam, and immediately wound up while being cooled.

What was obtained was that due to the effect of the methyl itaconic acid contained in the colored paint composition adhered to the concave portions of the uneven pattern, foaming in the concave portions was suppressed, and there was almost no change from the initial concave portions, but on the other hand, the coloring remained. The convex parts to which paint is not attached expand due to foaming and form protrusions, making the difference in height clearer and creating an uneven pattern with an extremely three-dimensional effect, which is foamed after being embossed. Therefore, since no pressing force was applied to the cells constituting the foam, a product with an extremely soft feel was obtained.

Example 2 [Foamable synthetic resin composition] 100 parts of vinyl chloride resin, 120 parts of dioctyl phthalate, 2 parts of barium/zinc stabilizer, 5 parts of azodicarbonamide, and 5 parts of pigment (golden brown) were mixed in a disper (rotation speed 1500
/min) to produce a vinyl chloride paste composition.

The above composition was coated on paper with a knife to a thickness of 0.3 mm, and then passed through a heating oven at about 130° C. to gel.

Subsequently, an embossing roll having a satin texture was applied to this surface to form a rough surface.

[Colored paint composition]

25 parts of polyurethane, 7 parts of methyl ethyl ketone, pigment (
A colored coating composition was prepared by adding 0.7 parts of 50 parts of glutaric acid dissolved in 50 parts of ethyl alcohol to 8 parts of yellow) solution and adding the solution while stirring.

The foamable synthetic resin layer was embossed using a conventional embossing method while this composition was applied only to the convex portions of the embossing roll, and then dried.

This product had the colored paint adhered to the concave portions of the foamable synthetic resin layer, and was then passed through a heating furnace at about 200° C. to foam and cool to form a product.

The product obtained was almost the same as that of Example 1.

Claims (1)

[Claims] 1(a) A step of laminating a foamable synthetic resin layer on a base material, (b)
) A step of embossing the entire surface of the layer before foaming to form a rough surface consisting of fine drawings, (C) then R-CH-C-
COOH (however, R: hydrogen, a(CH2) n-COO
A step of embossing by applying a colored paint containing one or more of acids having the general formula H alkyl, allyl, n: 1 to 4) and their derivatives to the concave portions at the same time as forming the concavo-convex pattern; (d) a step of foaming the foamable synthetic resin layer after sintering is combined in sequence.