JPS6049093B2 - Method for producing foamable floating decorative material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a foamed floating decorative material used in the fields of wallpaper, flooring, etc.

Conventionally, a method is known in which a non-foamable synthetic resin is partially provided in a foamable synthetic resin layer and then foamed to reveal an uneven pattern due to the foaming.

For example, in Japanese Patent Publication No. 52-41794, a non-foaming coloring material is partially applied onto a removable belt, the coloring material is slightly adhered by heating, and a foamable vinyl chloride resin composition is applied thereon. The material was applied to a uniform thickness and dried to form a gel, which was then peeled off from a peelable belt and then foamed. However, this method has the disadvantage that only coatable vinyl chloride paste resin can be used for the foamable synthetic resin layer. This paste resin is expensive, and since it is molded using the fluidity of plastisol at room temperature, it is easily influenced by the fluidity characteristics, viscosity, and time life of the sol, making quality control difficult. It is difficult to make a uniform product, and workability is low because it is necessary to prepare the non-foaming coloring material and the foamable vinyl chloride paste resin composition at the same time. There were disadvantages such as an increase in cost because a releasable belt had to be used. In addition, the method described in Japanese Patent Publication No. 49-21427 uses only a paste-like resin that can be coated, and also uses air spray to create patterns, so it is possible to create patterns such as floral patterns with the correct period, arabesque patterns, and geometric patterns. There were some difficulties in easily manufacturing academic patterns. The present invention has been made with the aim of eliminating these drawbacks of the conventional methods.

That is, in the present invention, a foamable synthetic resin layer laminated on a base material is heated and softened at a temperature below the decomposition temperature of the foaming agent, and then a non-woven material is printed in thick patterns on the surface of a roll-shaped transfer rotor. By pressing the foamable synthetic resin, the non-foamable synthetic resin is embedded into the foamable synthetic resin layer so that the surface is smooth, and then the foamable synthetic resin layer is heated and foamed to form foam irregularities. There are some that are characterized by revealing patterns. The present invention will be described in detail below. Paper, cloth,
In order to laminate a foamable synthetic resin layer on a base material such as asbestos paper or glass cloth, known processing methods such as coating method, calendar method, and laminator method can be freely used. It is not limited to vinyl, but can be applied to any thermoplastic synthetic resin, and in the case of vinyl chloride resin, it does not matter whether it is an emulsion type or a suspension type. It is relatively easy to heat such a sheet material to a sufficiently softened state by passing it through a far-infrared heating device, for example, to a temperature below the decomposition temperature of the blowing agent. On the other hand, by using a roll-shaped transfer rotor and means such as a rotary screen mechanism, a gravure printing mechanism, or a roll printing mechanism, it is relatively easy to perform thick printing of an appropriate pattern on the surface of the transfer rotor. .

The non-foaming synthetic resin thickly printed on the surface of the transfer rotor is passed through a drying device to dry into a gel or semi-gel and become solid or semi-solid. Therefore, by passing the sheet material having the sufficiently softened foamable synthetic resin layer through the narrow gap formed by the transfer rotor and the backup roll, the solid or semisolid state on the surface of the transfer rotor can be removed. The aged non-foaming synthetic resin is embedded in the foamable synthetic resin layer, thermally bonded, and peeled off from the transfer rotating body 3, so that the surface is smooth and the non-foaming synthetic resin remains in the foamable synthetic resin layer. It will be embedded in a pattern and sent out as a pattern.

When the non-foamable synthetic resin is embedded in a pattern in the foamable synthetic resin layer in this way, the embedded foamable synthetic resin portion is pushed away to the surroundings and remains in a thin film state.

Therefore, when the whole is placed in a foaming furnace and heated and foamed at a temperature higher than the decomposition temperature of the blowing agent, the foamable synthetic resin portion where the non-foaming synthetic resin is embedded remains in a thin film state as described above. In terms of foaming ratio, the non-foaming ratio is due to the fact that the non-foaming synthetic resin part acts as a weight, heating energy is consumed to raise the temperature of the non-foaming synthetic resin part, and the non-foaming synthetic resin part acts as a weight. The area where the synthetic resin is embedded is lower than the area where it is not embedded, and the foam cells themselves are also smaller, resulting in a convex-convex pattern with clear steps. 3. The effects obtained by the present invention are listed below. The first point is that a sheet material in which a foamable synthetic resin layer is laminated as a base material is used, but this resin can be any thermoplastic synthetic resin including vinyl chloride resin, and 4. Since it does not matter whether it is a type or a suspension type, a more economical resin can be selected, and the lamination method is not limited to a coating method, but any lamination method can be used, which is convenient.

The second point is that if you layer the foamable synthetic resin on the above-mentioned base material in advance, you only need to mix the non-foamable synthetic resin for embedded printing, which will improve quality control and inventory. It is easy to manage and has good workability.

The third point is that the non-foaming synthetic resin is thickly printed in the pattern as described above on the surface of the roll-shaped transfer rotor, and the foaming synthetic resin layer of the softened sheet material is embedded by pressing. Therefore, the work is extremely simple and the equipment can be small.

Examples are shown below. The outline of the apparatus used is shown in FIG.

A white suspension type foamable vinyl chloride resin composition having the formulation shown in Table 1 is kneaded with a mixing roll at about 150°C, and this is kneaded with a calender roll at about 160°C to form a resin layer 1a of about 0.2 gourd size. A sheet material 1 was obtained by pasting it onto flame-retardant paper 1b to which an adhesive had been applied in advance. This sheet material 1 is passed through a heating device 2 at about 160°C to sufficiently soften the resin layer without decomposing the foaming agent and to allow it to pass through the narrow gap between the transfer roll 3 and backup roll 8, which will be described later. I made it. Table 1 PVC10 saliva volume EVA2O〃 DOP6O〃 Chlorinated paraffin 4 〃 Chlorinated polyethylene 10〃 Stabilizer 3 〃 Foaming agent (/V) CA) 6 〃 CacO32O〃 TiO2lO〃 Meanwhile, embedded printing on the above white foamable synthetic resin layer The non-foaming synthetic resin coloring material 6 of the border color had the composition shown in Table 2.

Table 2 PVC10 saliva volume DOP6O〃 Stabilizer 2〃 Al(0H)330〃 TiO2lO〃 Green pigment 6〃 This paste-like non-foaming synthetic resin coloring material 6 is used as a rotary screen 4 having a perforated surface with a floral pattern and The squeegee 5 is used to print thickly on the circumferential surface of the silicone rubber-coated transfer roll 3, and the far-infrared heating device 7 is used to print a thick layer on the circumferential surface of the silicone rubber-coated transfer roll 3.
The sheet material 1 was heated at a temperature of .degree. C. to dry and semi-gel, and then pushed through the narrow gap formed by the backup roll 8 described above.

The cross-sectional view of the intermediate product after being pressed in this manner is shown in FIG. 2, and the surface was smooth. This was then passed through a foaming furnace 9 set at about 230°C to foam, cooled in a cooling device 10, and wound up. FIG. 3 is a cross-sectional view of the foamed product. The non-expandable synthetic resin coloring material 6 having a floral pattern printed by indentation had concave portions formed therein, and a product in which the synthetic resin layer 1a'' was formed by foaming and swelling could be obtained.

[Brief explanation of drawings]

FIG. 1 is an explanatory diagram of an apparatus for carrying out the method of the present invention, FIG. 2 is a sectional view of an intermediate product after indentation printing, and FIG. 3 is a sectional view of a foamed product. DESCRIPTION OF SYMBOLS 1... Sheet material, 1a... Foaming synthetic resin layer, 1b... Flame retardant paper, 2... Heating device, 3... - Transfer port, 6... Non-foaming synthetic resin coloring material, 9... Foaming furnace.

Claims (1)

[Claims] 1 A foamable synthetic resin layer laminated on a base material is heated and softened at a temperature below the decomposition temperature of the foaming agent, and then a non-foamable synthetic resin is printed in thick patterns on the surface of a roll-shaped transfer rotor. By pressing, the non-foaming synthetic resin is embedded into the foaming synthetic resin layer so that the surface becomes smooth, and then the foaming synthetic resin layer is heated and foamed to reveal a foamed uneven pattern. A method for producing a foam floating decorative material, characterized by: