JPH082605B2 - Method for producing foam decorative material - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing a foamed decorative material suitable for use as a ceiling material, a wallpaper material, and the like. More specifically, it has a large volume feeling and a unique texture. The present invention relates to a method for producing a foam decorative material.

[Prior Art] A foamed decorative material exerts its effect by giving a remarkable three-dimensional effect and a sense of volume, and a conventionally proposed method is, for example, JP-A-57-1371.
There is a method described in Publication No. 20. The method comprises a first foaming agent-containing synthetic resin layer (hereinafter referred to as a first layer) on a substrate surface, and a second foaming agent-containing synthetic resin having a decomposition temperature higher than that of the first foaming agent. This is a method in which layers (hereinafter referred to as the second layer) are laminated in order, the foaming start time of both layers is made different, and this is foamed by heating.

[Problems to be Solved by the Invention] However, according to the conventional method described in the above publication, the foaming start time is different between the first layer and the second layer, and the first layer starts foaming first. Even when the first layer reaches the final stage of foaming, the second layer is still in the early stage of foaming, and the foamed portion of the second layer is a foam having an appropriate elasticity. Even if a large hollow portion is formed, it is retained without being crushed, and the original shape in the foamed state is retained. Therefore, although a large uneven step is formed as a whole, the surface of the convex portion (that is, the surface of the convex portion of the second layer) is not roughened and is formed on a comparatively smooth surface, so that a regular surface condition is obtained. However, there is a drawback in that the surface state having an irregular and unique texture cannot be obtained.

The present invention has been made in view of such conventional drawbacks, and an object of the present invention is to provide a method for producing a foamed decorative material having a large volume feeling and a unique texture.

[Means for Solving the Problems] In order to achieve the above object, in the method for producing a foam decorative material according to the present invention, a first foaming agent-containing resin layer is applied on the surface of a base material, and the first foaming agent-containing resin layer is applied. A desired pattern pattern printing is performed on the foaming agent-containing resin layer with a foaming suppressing ink containing a foaming suppressing agent and an ink not containing a foaming suppressing agent, and further, on top of this, the first foaming agent containing resin layer At the same time, a second foaming agent-containing resin layer that starts heat-foaming is laminated, and this is heat-foamed and then cooled.

[Operation] In the present invention as described above, in the portion where the foaming-suppressing ink is printed, due to the effect of the foaming-suppressing agent, the foaming-suppressing ink is kept in a state of hardly foaming, while the foaming-suppressing ink is not printed. In the portion, the first foaming agent-containing resin layer (hereinafter, simply referred to as the first layer) and the second foaming agent-containing resin layer (hereinafter, simply referred to as the second layer) start foaming at substantially the same time. As a result, the foaming gas is generated all at once, resulting in an excessive foaming state. After foaming by heating and cooling,
Air that has expanded in the layers more than necessary contracts, forming irregular wrinkle-shaped depressions on the surface. That is, since a large uneven shape is formed on the whole and an irregular surface state is formed at the same time, a foamed decorative material having a unique texture due to the irregular surface state with a large volume feeling is obtained. can get.

[Examples] Hereinafter, examples of the present invention will be described in detail with reference to the drawings.

1 (a) to 1 (f) are cross-sectional views showing the state of each stage in the present invention.

According to the present invention, a first layer 2 is coated on the surface of a substrate 1 (see FIG. 1 (a)), and a desired pattern pattern printing 3 is performed on the first layer 2 with an ink containing no foaming inhibitor. Then, a desired pattern pattern printing 4 with the foaming-suppressing ink is applied (see FIG. 1 (b)), and then a second layer 5 which starts thermal foaming at substantially the same time as the first layer 2 is further formed thereon. A laminate (see FIG. 1 (c)) is used.

The material of the base material 1 is not particularly limited as long as it has heat resistance that does not cause deformation or the like during foaming and heating.

The first layer 2 and the second layer 5 have substantially the same material constitution, and in addition to the foaming agent, a plasticizer, a stabilizer, a filler, a foaming timing adjusting additive, etc. are added to the binder resin. There is. Here, as the binder resin, for example, vinyl chloride resin is preferably used. Especially the second layer 5
It is preferable to use a highly transparent vinyl chloride resin having a polymerization degree of 1,200 to 1,600. As the foaming agent, for example, decomposable organic foaming agents such as azo, azide, and sulfohydrazide compounds, and inorganic foaming agents can be used. Further, as a plasticizer, a phthalic acid ester, an adipic acid ester, a trimellitic acid ester, a phosphoric acid ester, a polyester plasticizer, or the like, a stabilizer, an organic compound-based cell regulator, a heat stabilizer, or the like, and a filler, Inorganic fillers such as calcium carbonate and magnesium carbonate, etc., and zinc, calcium, barium, sodium stabilizers, etc. can be used as additives for adjusting the foaming timing. The compounding amount of each of these compounds is appropriately determined in consideration of the amount of foaming gas, the foaming rate, the foaming balance of the first layer 2 and the second layer 5, and the like. Layer 2 is preferably used in the range of about 2 to 7% by weight based on the binder resin, and second layer 5 is also preferably used in the range of about 2 to 5% by weight based on the binder resin. .

Regarding the material composition of the first layer 2 and the second layer 5, the compound used, etc., the first layer 2 and the second layer 5 start and foam the heat foaming at substantially the same time. If
The two do not necessarily have to be the same, but it is preferable that the two are substantially the same from the viewpoints of easy adjustment of the foaming balance and convenience in manufacturing.

The coating and laminating of the first layer 2 and the second layer 5 can be performed by optionally using a known method, but the layer thickness of each layer is appropriately determined in consideration of the foaming balance and the like. In particular, it is desirable that the layer thickness of the second layer 5 is thinner than the layer thickness of the first layer 2. Specifically, the layer thickness of the first layer 2 is about 100 to 250 μm, and the second layer 5 is The layer thickness is preferably about 50 to 180 μm.

On the other hand, the above-mentioned pattern pattern printing 3 and the pattern pattern printing 4 using the foam-suppressing ink are performed by known printing means.
The printing ink used for the pattern printing 3 is selected in consideration of the fact that the surface to be printed is resin (for example, vinyl chloride resin). The foaming-suppressing ink contains a foaming suppressor or consists of a foaming suppressor, and specific examples of the foaming suppressor include fumaric acid, maleic acid, itaconic acid, trimellitic acid and the like.

Next, the laminated body shown in FIG. 1 (c) obtained as described above is heat-treated to foam. The heating temperature and time are determined by the type of foaming agent used and the like.

First, at the initial stage of foaming shown in FIG. 1 (d), the portion 4 on which the foaming-suppressing ink is printed is kept in a non-foaming state by the action of the foaming-suppressing agent, while the foaming-suppressing ink is printed. Not the first layer 2 and the second layer
Foaming starts in layer 5 almost at the same time, and foaming gas starts to be generated. The generated foaming gas forms minute cavities in the layer, and as the foaming proceeds, the cavities grow larger and the first
The second layer 2 and the second layer 5 expand upward. Further, the foaming gas in the second layer 5 expands the second layer 5 and also escapes to the lower layer to expand the first layer 2 as well. In the present invention, since foaming starts and progresses in the first layer 2 and the second layer 5 almost at the same time, foaming gas is generated at a stretch,
Immediately becomes an excessive foaming state. In this process, especially in the first layer 2, a plurality of cavity portions are connected to form a large cavity 6 as shown in FIG. 1 (e), but the first layer 2 and the second layer 5 are Due to the difference in the amount of foaming gas, it is not possible to form such a large cavity in the second layer 5. Even in the state of FIG. 1 (e), the portion 4 on which the foaming-suppressing ink is printed remains in a state where it hardly foams.

In this way, the uneven shape having a large step is formed by the heat-foaming, but in the state of FIG. 1 (e), since the foaming progresses at once and the foaming is in an excessive state as described above, After foaming, when cooled, the large cavities 6 that expanded more than necessary in the first layer 2 contract and the upper part becomes crushed like a wrinkle, and the second layer 5 also follows this. It has a crushed shape, and irregular wrinkle-shaped depressions 7 are formed on the surface thereof as shown in FIG. 1 (f). The wrinkled depressions 7 formed on this surface give a unique texture, which is due to the irregular surface conditions. That is, the feature of the present invention is that a large unevenness is formed as a whole to give a large volume feeling, but at the same time an irregular surface state is also formed so that a unique texture is obtained. is there.

[Effects of the Invention] As described in detail above, according to the method for producing a foam decorative material of the present invention, the first layer is coated on the surface of the base material, and the pattern pattern printing and the printing with the foam suppression ink are performed. Further, by heating and foaming a laminate of a second layer that starts heating and foaming substantially at the same time as the first layer, and then cooling, an uneven surface with large steps and an irregular surface condition are obtained. Since it is formed, it has a large volume feeling and a unique texture due to the irregular surface condition, and it is possible to obtain a foamed decorative material having an unprecedented excellent design feeling and high-class feeling.

Further, according to the present invention, there is an effect that it has a soft feeling, has a good surface strength and is excellent in compression recovery.

[Brief description of drawings]

1 (a) to 1 (f) are cross-sectional views showing the state of each stage in the present invention. 1 ... Substrate 2 ... First foaming agent-containing resin layer 3 ... Pattern pattern printed portion 4 ... Printed portion with foaming suppression ink 5 ... Second foaming agent-containing resin layer 6 ... Cavity 7 ... Wrinkled depression

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI technical display location B29L 31:58

Claims (1)

[Claims] 1. A foaming-suppressing ink containing a foaming inhibitor and an ink not containing a foaming inhibitor, which is obtained by coating a first foaming agent-containing resin layer on the surface of a substrate, and forming a foaming inhibitor on the first foaming agent-containing resin layer. A desired pattern pattern was printed with, and a second foaming agent-containing resin layer for starting heat foaming was laminated at the same time as the first foaming agent-containing resin layer, and this was heat-foamed. Then, a method for producing a foamed decorative material, which comprises cooling.