JPH0197632A - Manufacture of dewing preventive foaming decorative material with embossed pattern - Google Patents

Abstract

PURPOSE:To maintain dewing preventive effect while enhancing design, by combining three layers, namely of water absorptive polymer, foaming layer with communicating microvoids, and moisture-permeable resin with normal foaming synthetic resin formed into patterns. CONSTITUTION:The first foaming synthetic resin layer 2 containing fine powder of water-absorptive polymer and foaming agent is formed on a base material 1 such as paper, cloth, and non-woven fabric aluminum hydride paper. The water-absorptive polymer is a hydroplrilic resin expanding by absorbing water and absorbs pure water over 50 times heavier than it own weight. The foaming agent is at a continuous void ratio 70% or more after foaming, a moisture- permeable resin film 3 should be composed of amino acid/metacrylic acid/ urethane copolymer that allows the passage of only steam but not liquid to avoid penetration of washing polluted water. The second foaming synthetic resin 4 is formed into patterns on the film, which in turn is guided into a foaming heating furnace for foaming heat treatment and foaming swell with the result that foaming embossed patterns are developed with the patterns as protrusions and the other part as recesses.

Description

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

<Prior Art> There are three known 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, and the other is to mix a water-absorbing polymer into the synthetic resin layer as disclosed in JP-A-53-31772.
As shown in the Japanese Patent Publication No. 1, the foam layer has countless interconnected microscopic cells.
As described in Japanese Patent No. 3-38102, the purpose is to provide moisture permeability by using an olefin-based microporous sheet.

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. 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 works 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 narrow, or in the case of crumpled edges, it was crushed and the original dew condensation prevention effect could not be expected.

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, creating interconnected microscopic cells. Not only that, but also the mechanical pressure during embossing crushed the communicating microbubbles in the concave portions, so that the desired dew condensation prevention effect could not be obtained.

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 was significantly impaired.

Even when punching is used, the holes may become clogged during embossing, the design may be impaired because holes that are generally larger than chemical microbubbles can be made, and dirt may adhere to the holes made by the clothing. Lack of? ! : had.

<Means for Solving the Problems> Therefore, the present invention provides a patterned structure on a base that has the three advantages of a water-absorbing polymer, a foam layer having communicating micro-cells, and a moisture-permeable resin. The object of this invention is to provide a method for manufacturing a foamed decorative material having an extremely excellent uneven pattern by combining the foamed synthetic resin with a foamed synthetic resin formed in the same way.

Furthermore, when comparing the concave and convex portions of the conventional technology, the disadvantage was that the concave portions were less effective at preventing condensation, but the method of the present invention ensures the dew condensation prevention effect of the concave portions, and the convex portions are To provide a method for manufacturing a foamed decorative material that maintains a dew condensation prevention effect while improving design, focusing on the fact that even without a dew condensation prevention function, dew condensation does not occur due to the difference in surface temperature.

Generally, dew condensation occurs on the surface of a decorative material attached to a wall when there is a large difference in the surface temperature of the decorative material directly attached to the wall due to indoor temperature and conductive heat from the back of the wall.

The present invention involves laminating a first foamable synthetic resin containing a finely powdered water-absorbing polymer and a foaming agent that creates countless interconnected microscopic cells after heating and foaming on a base material such as paper or cloth. After applying desired printing to the first foamable synthetic resin layer as necessary, a moisture-permeable resin film is formed thereon, and a second foamable synthetic resin containing a foaming agent is further applied thereon. After forming an arbitrary pattern, the first and second foamable synthetic resins are heated and foamed to reveal an uneven pattern. To explain in more detail below, the base materials include paper,
Any material such as cloth, nonwoven aluminum hydroxide paper, etc. can be used. In addition, if moisture permeability from the back side of the product is required, these base materials should also be selected to have moisture permeability (breathability as a substitute characteristic); If not, synthetic paper or polysand paper with a polyethylene layer in between may be selected.

On top of these base materials, coating methods, topping methods,
Using a known lamination method such as a laminator method or a rotary method, a first foamable synthetic resin layer containing a finely powdered water-absorbing polymer and a foaming agent that creates countless interconnected microbubbles after heating and foaming is formed. do.

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 itself is a well-known hydrophilic resin that can absorb water and expand, and it is desirable that it has the ability to absorb 50 times or more of its own weight of pure water. Examples of polymers include starch/sodium acrylate graft copolymer vinyl ester/saponified product of ethylenically unsaturated carboxylic acid or its derivatives, polysodium acrylate crosslinked product, polyvinyl alcohol/acrylate graft copolymer, etc. can be mentioned. Commercial products such as Sumikagel-8P (Sumitomo Chemical) and Sunwet IM-
300 (Sanyo Chemical Products), Aqua Keep 4S (Steel Chemical Industry Products), etc. These water-absorbing polymers are usually fine powders with a particle size of about 350μ to 0.1μ, but in consideration of dispersibility, an average particle size of 100μ or less is preferable.The number of parts added is usually 2 to 40 parts. Preferably 5-1
There are around 5 copies.

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 in the foamed state from the viewpoint of preventing 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, adjusting the foaming speed by selecting a stabilizer, or adjusting the foaming heating temperature and foaming heating time. can. The above-mentioned Japanese Patent Application Laid-Open No. 53-31772 describes a combination of a foaming material (Uniform AZ-F, a chemical agent) and a stabilizer (Stabilizer F, Kyodo Yakuhin), and a combination of a foaming agent (Onifine MO, a chemical agent) and an arbitrary stabilizer. Although there are examples of combinations, these known combinations can also be used in the present invention. In the case of vinyl chloride resin, common azosica-bonamide is often used.

Examples of moisture-permeable resins include urethane-based W10 emulsion resins, amino acid/methacrylic acid/urethane copolymers, and microporous sheets of the above-mentioned olefin resins. In order not to lose the performance of the moisture-permeable resin, and also to eliminate the seepage of cleaning waste water when wiping it off when it becomes dirty when used as a wall covering material, it is allowed to pass through only in the form of water vapor, but not in the form of liquid. An amino acid/methacrylic acid/urethane copolymer that does not allow it to pass through is preferred, but other moisture-permeable resins with equivalent functionality may also be used. In order to form a moisture-permeable resin film on the first foamable synthetic resin laminated on the base material, a moisture-permeable resin paint is applied by a coating method, or by surface treatment using a gravure printing machine. Alternatively, a pre-formed moisture-permeable resin film may be laminated.

In addition, in order to improve the design, before forming the moisture permeable resin film,
If necessary, any pattern can be printed on the first foamable synthetic resin layer, and if the printed pattern is small enough not to impair the function of the moisture-permeable resin film, the moisture-permeable resin film can be formed. Although a printed pattern may be applied later, it is preferable to do so before forming the moisture-permeable resin film.

Now, after laminating the first foamable synthetic resin on the base material and forming a moisture permeable resin film on it, a second foamable synthetic resin containing a foaming agent is further layered on top of it in an arbitrary pattern. However, since this second foamable synthetic resin does not contain a water-absorbing polymer and a foaming agent that creates communicating microbubbles, there is no condensation in this second foamable synthetic resin. The preventive effect cannot be expected. Therefore, the total area of the second foamable synthetic resin formed in this pattern is
The area of the foamable synthetic resin layer is preferably 80% or less, preferably up to 70%.This ratio depends on the design when forming the pattern, but on average in any part. It can be said that it is better to take care so that the first foamable synthetic resin layer is directly exposed. In this way, the first foamable synthetic resin is laminated on the base material, a moisture-permeable resin film is formed on top of the first foamable synthetic resin, and the second foamable synthetic resin is further formed in a pattern on top of that. When the first and second foamable synthetic resins are foamed and swollen by being guided into a foaming heating furnace and subjected to foaming heat treatment, the patterned portions of the second foamable synthetic resins become curved portions. , a foamed uneven pattern with open areas will appear where this is not the case.

In this foamed uneven pattern, since the open part is the part where the first foamable synthetic resin is foamed, communicating fine bubbles are created, and moreover, it contains a water-absorbing polymer. This becomes a concave portion with a moisture-permeable resin film formed thereon.

The convex portions are the first foamable synthetic resin of the concave portions, and the second foamable synthetic resin formed in a pattern is foamed in addition to the foamed resin layer.

When we tested the dew condensation prevention effect of the foamed decorative material with an uneven pattern manufactured in this way, we found that the thickness of the layer formed by the second foamed synthetic resin above the recesses was greater than the thickness of the foam layer of the convexities. It was confirmed that when it is thick, dew condensation is less likely to occur on the surface of the foamable synthetic resin layer located above the convex portion.

This is because when a foamed decorative material having an uneven pattern manufactured according to the present invention is attached to a wall surface, when the surface temperature of the foamed decorative material is influenced by heat radiation from the back side of the wall surface, the temperature is higher than that of the convex foam layer. This is because the convex foam layer inhibits heat dissipation from the back side of the wall surface, resulting in a temperature closer to room temperature, making it difficult for dew condensation to occur.

Taking a more detailed look, when foam decoration is pasted on an indoor wall, if the wall is located on the north side of the building and the outside temperature is lower than room temperature, the temperature on the back side of the wall will increase due to heat dissipation (
This causes a phenomenon in which the surface temperature of the foam decorative material attached to the indoor wall becomes much lower than room temperature, and due to the relationship with the indoor humidity at that time, Condensation will tend to form on the surface of the applied foam decoration material.

The condensation phenomenon is prevented by the action of a moisture-permeable resin coating, a water-absorbing polymer, and countless communicating microbubbles, but the products manufactured by the method of the present invention do not have these on the surface of the convex parts. Although it has no function, the thickness from the base material to the surface of the white part is thicker than the thickness of the recessed foam layer, so it has rich insulation properties and always shows a higher surface temperature than the surface temperature of the recessed foam layer. The inventor of the present invention noticed that, and furthermore, since the upper foam layer of the convex part is a foam layer made of closed cells rather than continuous cells, it is simply 2 times the thickness of the concave part.
We found that even if the thickness was twice as high, the insulation performance would be more than double, and we decided to utilize this for transshipment purposes.

Through various tests, it was found that when the difference between the foamed thickness of the convex portion and the foamed thickness of the concave portion satisfies the following conditions, no condensation occurs on the convex portion under normal indoor conditions.

Foaming thickness of the convex portion 〉 Four-part foaming thickness × 1.5 However, the foaming thickness of the convex portion in the above formula is the thickness from the base material surface, and is the total thickness of both the first and second foamable synthetic resin layers. .

Various combinations are possible to satisfy these conditions.

First, when the foaming ratio of the foaming agent is the same, the coating thickness of the second foamable synthetic resin layer formed in a pattern thereon is thicker than the laminated thickness of the first foamable synthetic resin. As a result, the thickness of the convex portions and concave portions after the foaming heat treatment can be determined according to the formula % formula % described above. (3) If the thickness of the second foamable synthetic resin is to be the same or slightly thinner, the thickness of the convex and concave parts after the foaming heat treatment can be adjusted by selecting the foaming agent. In the ceremony,
It will fit.

That is, by making the second foamable synthetic resin contain a foaming agent whose decomposition temperature is lower than that of the foaming agent that is contained in the first foamable synthetic resin layer and which creates countless interconnected microscopic cells after heating and foaming. When the first and second foamable synthetic resins are subjected to foaming heat treatment, if the foaming heating time and foaming heating time are the same, the foaming ratio of the second foamable synthetic resin layer can be increased. It was used.

In general, in synthetic resin foaming methods that use blowing agents, decomposable blowing agents are widely used as blowing agents, and such decomposable blowing agents include organic blowing agents such as azo compounds, sulfohydrazide compounds, nitroso compounds, and azizo compounds. It is well known that there are other inorganic blowing agents in addition to the above, and each has different decomposition temperatures and decomposition gas generation capabilities.

The sound path and decomposition temperature change greatly when mixed with synthetic resins or their raw materials, plasticizers, solvents, stabilizers, acids, bases, etc., and especially when blowing agents are dissolved in the compounding agent. However, for example, in the case of azosica-bonamide (ADCA), its decomposition temperature is around 200°C, whereas in the case of oxybisbenzenesulfonyl hydrazide (OBSH), its decomposition temperature is around 200°C.
) system, it is easy to select two types of decomposable blowing agents that exhibit relatively high decomposition temperatures, such as around 130°C.

Also in the present invention, the foaming agent contained in the first foamable synthetic resin is ADCA type, and the foaming agent contained in the second foamable synthetic resin is 0.
If a BSH-based foaming agent is included, the thickness of the foam layer in the curved portion can be made more than twice the thickness of the foam layer in the gargle recess.

Moreover, the foamed layer of the first foamable synthetic resin can be formed into a countless number of communicating fine cells. It is also possible to create combinations simply by changing the content of the blowing agent.

In order to coat (paint) these second foamable synthetic resins on the first foamable synthetic resin provided with a moisture-permeable resin coating in an arbitrary pattern, a rotary screen printing machine or a gravure textile printing machine is used. It is possible to use known ones such as.

As mentioned above, if the foaming thickness of the convex portion > the foaming thickness of the concave portion x 1.5, 5. Under normal indoor living conditions, condensation hardly occurs on the surface of the convex portion, but the foaming thickness of the convex portion > Tests have shown that when the condition of 2 times the foam thickness in the concave part is satisfied, no condensation occurs on the convex part even under extremely harsh conditions.However, when used as a normal foam decorative material, It is desirable to set the foaming thickness of the part to 1.5 times or more, preferably about 1.7 times, the foaming thickness of the convex part.

<Effects of the Invention> According to the method of the present invention, the concave portion formed by foaming the first foamable synthetic resin layer is a foamable synthetic resin layer having communicating fine cells, and furthermore, the foamed layer contains The water-absorbing polymer in the form of fine powder is almost uniformly mixed and scattered, and a moisture-permeable resin film layer is formed on the surface of the foamed synthetic resin layer.

Therefore, even if dew condensation occurs on the surface of the recess, the moisture will pass through the moisture-permeable resin film layer and be absorbed by the continuous fine cells of the foamed synthetic resin layer and the water-absorbing polymer.
There is no possibility of condensation forming on the surface of the open part.

Further, the first foamable synthetic resin is present in a foamed state in the lower layer of the recess where the second foamable synthetic resin is foamed,
There is no moisture absorption from the surface of the convex part, but the moisture absorbed from the part where the concave part is the direct surface is diffused laterally, and the first foamable synthetic resin located below the convex part foams. The layer will also substantially reinforce the anti-condensation effect.

Furthermore, since the layer in which the first foamable synthetic resin is foamed is not mechanically embossed at all, the countless interconnected microscopic cells and the absorption effect of the water-absorbing polymer are not impaired.

In addition, the second foamable synthetic resin is formed in a pattern on the first foamable synthetic resin layer, but the first foamable synthetic resin layer coated with a moisture-permeable resin film is directly exposed. Even if the area of the concave foamed layer is about 20 to 30%, the moisture absorption effect of the entire foamed decorative material does not decrease, which is an excellent effect.

In addition, the second foamable synthetic resin foams to form a convex foam layer, but the foamed part of the second foamable synthetic resin is a foam layer made of closed cells, and compared to the concave portion. It has an extremely good insulation effect. Therefore, if the foam thickness is set to satisfy the formula for the foam thickness mentioned above, the surface temperature of the convex foam layer will be higher than that of the concave foam layer.
Under the same indoor humidity conditions that are always close to room temperature, no dew condensation occurs on the surface of the convex foam layer, and the concave foam layer absorbs moisture cumulatively. Moreover, even if the area ratio of the foam layer in the concave portions directly exposed to the surface is smaller than the area of the foam layer in the convex portions, as described above, the first foamable synthetic resin present in the layer below the convex portions is foamed. The synthetic resin part also absorbs moisture (
Since it functions as a water absorbing body, compared to conventional ones,
It has an excellent dew condensation prevention effect.

Furthermore, compared to conventional dew condensation prevention decorative materials, since both the concave and convex portions are formed of a foam layer, the decorative material is extremely superior in terms of appearance and warm and soft feel.

Example 〉 A first foamable vinyl chloride resin paste consisting of the following formulation was applied to flame-retardant paper for wallpaper using a doctor knife coating method.
The first foamable synthetic resin layer 2 was prepared by coating and laminating to a thickness of 0.1511++ m and drying and semi-gelling at a temperature lower than the decomposition temperature of the foaming agent (Figure 1-A).

Resin: Monopolyvinyl chloride resin! 00 parts Plasticizer --- DOP 50 glS Stabilizer --- B a -Z n system 3 Miyako foaming agent --- AD CA system 5 parts Water-absorbing polymer -- Sumiriki Gel 5P-520 10 parts Filler. - Calcium monocarbonate 50 parts Face - Titanium white 15 parts Antifungal agent
...Biocide 2.5 parts Next, on top of the first foamable synthetic resin layer 2, a moisture permeable resin paint consisting of an amino acid/methacrylic acid/urethane copolymer is applied using a Clavia printing machine. By drying, a moisture permeable resin film layer 3 was formed (Figure 1-B).

Next, on the moisture-permeable resin film layer 3, a second foamable vinyl chloride resin paste having the following composition was applied to a thickness of 0.19 mm in a hexagonal pattern using a rotary screen printing machine to decompose the foaming agent. The second foamable synthetic resin 4 was formed by drying and semi-gelling at a temperature lower than that temperature (Fig. 1-C). The area ratio of the second foamable synthetic resin layer 4 formed in a tortoiseshell pattern is about 60% in total, which is about 4%.
At 0%, the first foamable synthetic resin layer 2 coated with the moisture-permeable resin film layer 3 was directly visible from the surface.

Resin...-Polyvinyl chloride resin 100 parts Plasticizer--DOP 50 parts Stabilizer-o=Ba-Z, n-based 3 parts Foaming agent--
--OB S H-based 1O part filler--Calcium carbonate 20 parts Pigment--Titanium white 1O part Colorant--Blue coloring agent
Part 5 Antifungal agent -- Biocide
1.5 parts This was further 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. The layers were foamed to form a foamable synthetic resin layer 5 with a thickness of about 1.2 mm, and the second vinyl chloride resin layer was foamed to form a foamed layer 6 in a tortoiseshell pattern with a thickness of about 1.5 mm ( Figure 1-D).

As can be seen from this Figure 1-D, the recessed portion is formed by applying a moisture permeable resin film on the layer 5 made of the first polyvinyl chloride resin 2 foamed, and the thickness of the recessed portion is only the foamed layer 5. about 1
．． 2 mm, and the portion forming the convex portion is a foamed layer 6 made of a second polyvinyl chloride resin 4 foamed on top of the moisture-permeable resin film 3 on the foamed layer 5 made of the first polyvinyl chloride resin foamed. It is formed to a thickness of 1.5 mm, and the total thickness of the foam layer in the image area is about 2.7 mm, and the foam thickness in the convex part is more than twice the foam thickness in the concave part, and as mentioned above. The formula was satisfied.

This condensation-preventing foam decorative material having an uneven pattern is foamed in both the concave and convex portions, and furthermore, from its cross section, the foam layer 5 portion where the first foamable synthetic resin 2 is foamed has countless interconnected fine cells. It has been created with a water-absorbing polymer evenly mixed in, and has a sufficient effect of preventing condensation.It also has a design with large uneven steps, making it suitable for use as wallpaper. It was excellent.

Table 1 shows the test results of a comparison between this example and a conventional wallpaper having a similar uneven pattern.

Table 1 Mechanically embossed with a similar pattern.

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

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

As can be seen from Table 1, in the examples obtained by the method of the present invention, almost the upper half of the convex portion was a normal foam layer, and there were no open cells and no water-absorbing polymer was contained. However, due to its good insulation properties, the effect of the temperature on the surface where the wallpaper is pasted (the back side of the wallpaper) is alleviated, and it was confirmed that the temperature was 3℃ higher than the convex part due to the influence of room temperature, and under the test conditions, there was no condensation. did not occur.

[Brief explanation of the drawing]

1-A to 1-D are cross-sectional views for explaining aspects of different stages of the embodiment according to the manufacturing method of the present invention. 1.--1. Flame-retardant paper (base material), 2.-- A first containing a water-absorbing polymer and a blowing agent that creates communicating micro-cells.
foamable synthetic resin layer, 3 - moisture permeable resin film, 4
----Second foamable synthetic resin layer containing a foaming agent,
5-----The foamed synthetic resin layer of the first foamable synthetic resin layer 2, 6-----The foamed synthetic resin layer of the second foamable synthetic resin layer 4.

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.
After laminating the foamable synthetic resins and forming a moisture-permeable resin film on the first foamable synthetic resin, a second foamable synthetic resin containing a foaming agent is further applied on top of it in an arbitrary pattern. 1. A method for producing a condensation-preventing foam decorative material having a concave-convex pattern, the method comprising: forming a condensation-preventing foam decorative material, and then foaming and heating the above-described first and second foamable synthetic resins.