JPH0245584B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a foamed decorative material rich in texture such as stone grain and painted walls (Jiuraku style).

The method for manufacturing decorative materials with the texture of natural stone, such as stone grain, is to apply an adhesive to the surface of the base material, and then sprinkle synthetic resin chips, metal powder, sawdust, etc. on top of it, and then bond it together. Conventionally, the method of dispersing chips, etc. has been used, but it requires a device to spread the chips, etc., it is difficult to spread them uniformly, and it is necessary to use adhesives to ensure that the chips, etc. adhere firmly to the substrate. This method has drawbacks such as restrictions on the amount of agent applied and the drying conditions.

Therefore, it may be possible to mix chips or metal powder in advance into the resin composition applied to the base material, but unless the resin layer is transparent, most of the mixed chips will be buried inside the resin layer. However, only a small amount of chips and the like that are exposed on the surface of the resin layer and contribute to the appearance of natural stone are economically disadvantageous.

The present invention solves the above-mentioned drawbacks and manufactures a foamed decorative material having the appearance of natural stone by simply mixing a very small amount of thermoplastic resin powder, granules, flakes, or lumps. It is intended to provide a method.

The present invention will be explained in detail below with reference to the drawings.

First, as shown in FIG. 1, a resin composition containing a known chemical blowing agent such as azodicarbonamide or oxybenzenesulfonyl hydrazide is prepared,
In addition, particles 2 of a first thermoplastic resin have a specific gravity lower than that of the composition, a melting point lower than the foaming temperature of the composition, and are colored in a different color from the composition.
to prepare a first foamable resin composition 1,
It is applied to the surface of any base material 3.

Furthermore, on top of that, a second thermoplastic resin granule 5 having the same specific gravity and melting point as the first thermoplastic resin granule 2 and a different color is mixed into the same resin composition. Apply the foamable resin composition 4.

At this time, the particle size of the first thermoplastic resin granules 2 and the particle size of the second thermoplastic resin granules 5 are as follows:
They may be the same or different.

FIG. 1 shows the same case, and FIG. 2 shows the different case.

When the composition and the substrate are then heated to or above the foaming temperature of the foamable resin composition, the foamable resin composition foams due to decomposition of the chemical blowing agent in the composition. However, prior to that,
The granules of the first and second thermoplastic resins having melting points lower than the foaming temperature of the composition are melted, and these granules have a smaller specific gravity than the first and second foamable resin compositions. As shown in FIGS. 3 and 4, as it melts, it rises to the surface of the resin layer and is exposed on the surface. At this time, the molten particulates float while adhering little by little to the wall surface of the resin layer along the floating path, so the volume of the particulates exposed on the surface of the resin layer is smaller than before floating. Therefore, the closer the particle is to the surface of the resin layer and the shorter the floating distance, the smaller the volume change will be, and conversely, the longer the floating distance is, the larger the volume change will be.

Therefore, if the particle size of the first thermoplastic resin granules is the same as that of the second thermoplastic resin granules as shown in FIG. The volume of the granules exposed on the layer surface becomes smaller than that of the first thermoplastic resin, and therefore the volume of the exposed granules corresponds to the difference in color of the granules.

In addition, in the case shown in a of Fig. 2, as shown in a of Fig. 4, and in the case shown in b of Fig. 2, as shown in b of Fig. 4, the color and color of the granules are The exposed volumes can be combined in various ways.

The thermoplastic resin particles are selected from polyethylene, polypropylene, etc., depending on the specific gravity of the resin used in the foamable resin composition and the foaming temperature of the foaming agent in the composition.

In addition, this thermoplastic resin granule can be colored in any color as long as it is different from the foamable resin composition, so for example, as shown in Figure 5, one layer may contain two or more types. It is also possible to mix in granules of different colors. Furthermore, the thermoplastic resin can be used not only in the form of granules but also in powders, flakes, lumps, and the like.

In addition, the foamable resin composition is not limited to two layers, but can also have three or four or more layers, and among them, there may be a layer of the foamable resin composition that does not contain thermoplastic resin particles, etc. You can also combine them.

As the resin constituting the foamable resin composition, polyvinyl chloride resin, vinyl acetate resin, acrylic resin, etc. can be used. The surface can also be made into an arbitrary uneven shape by chemical embossing.

Example 1 A foamed vinyl chloride paste with the following composition was added with a particle size of
Wallpaper lining paper WK-80NX (manufactured by Kojin Co., Ltd.) is made by mixing 5 parts by weight of black polyethylene powder of around 0.1 mm with 100 parts by weight of polyvinyl chloride resin.
After applying it to a thickness of 0.2 mm, and after drying, brown powdered polyethylene with a particle size of around 0.1 mm was mixed into foamed vinyl chloride paste of the same composition as before in the same proportion. After applying and drying
The material is heated to 200℃ and foamed to obtain a foamed decorative material with a stone-like pattern on the surface.

Polyvinyl chloride resin containing foamed vinyl chloride paste 100 parts by weight Plasticizer (DOP) 60 〃 Foaming agent (azodicarbonamide) 5 〃 Calcium carbonate 50 〃 Foaming stabilizer 3 〃 Titanium 10 〃 Example 2 Powder diameter of brown powder polyethylene A foamed decorative material with a stone pattern having a different appearance from that of Example 1 was obtained in the same manner as in Example 1, except that the width was set to around 0.15 mm.

According to the method of the present invention as described above, the following effects can be obtained.

Since most of the thermoplastic resin particles and the like to be mixed are exposed on the surface of the cosmetic agent, only a small amount is necessary.

Compared to conventional products in which powder or the like is sprinkled from above, the adhesion between the granules and the resin layer is stronger.

By arbitrarily changing the color and particle size of the mixed thermoplastic resin particles, etc., the appearance of the resin layer surface can be expressed in various ways.

[Brief explanation of drawings]

The drawing is a schematic illustration explaining an example of the process of the method of the present invention, and FIG. 1 shows two particles having the same particle size and different colors.
A state in which two types of foamable resin compositions mixed with different types of thermoplastic resin particles, etc. are applied to a base material, a second
The figure shows a case where two types of thermoplastic resin granules with different particle sizes and colors are used. Figures 3 and 4 show that each is heated and foamed to float the granules and expose them on the surface of the resin layer. Fig. 5 shows a cross-sectional view of the foamed resin composition when two and three types of thermoplastic resin particles are mixed in one layer, and Fig. 6 shows a case where the foamable resin composition has four layers. A cross-sectional view of each case is shown. DESCRIPTION OF SYMBOLS 1... First foamable resin composition, 2... Particulate material of first thermoplastic resin, 3... Base material, 4... Second
foamable resin composition, 5... second thermoplastic resin granules, 6... third foamable resin composition, 7...
...A foamable resin composition that does not contain thermoplastic resin particles.

Claims (1)

[Scope of Claims] 1. A resin composition containing a chemical blowing agent is added to a foam having a specific gravity lower than that of the composition, a melting point lower than the foaming temperature of the composition, and colored differently from the composition. A first foamable resin composition mixed with one of thermoplastic resin powder, granules, flakes, and lumps is applied to the surface of the base material, and the chemical blowing agent is further applied thereon. A powder, granule, or flake of a second thermoplastic resin that is colored differently from the resin composition containing the resin composition and the first thermoplastic resin, and has the same specific gravity and melting point as the first thermoplastic resin. , a second foamable resin composition in which one of the lumps is mixed into the resin composition is applied to provide a plurality of layers of the foamable resin composition on the surface of the substrate, and then the foamable resin composition is coated. foaming the composition and exposing one of the thermoplastic resin powders, granules, flakes, and lumps on the surface of the foamed resin layer by heating to a foaming temperature or higher; A method for producing a foamed decorative material mixed with a thermoplastic resin, characterized by: 2. The thermoplastic according to claim 1, characterized in that the number of layers of the foamable resin composition is three or more by using thermoplastic resins of different colors such as third and fourth. A method for manufacturing decorative foam materials mixed with resin. 3. Claim 1, characterized in that the particle size of the thermoplastic resin mixed in each layer is all the same.
A method for producing a foamed decorative material containing the thermoplastic resin according to item 1 or 2. 4. A method for producing a foamed decorative material mixed with a thermoplastic resin according to claim 1 or 2, wherein the particle sizes of the thermoplastic resin mixed in each layer are all different. 5. The method for producing a foamed decorative material mixed with a thermoplastic resin according to claim 2, wherein the particle diameters of the thermoplastic resin mixed in each layer are partially the same and partially different.