JP2001277407A - Multilayered foaming decorative material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a multilayered foaming decorative material having sufficient interlaminar strength, capable of obtaining stable surface properties by foaming and capable of stably obtaining an embossed pattern having high design effect by embossing by solving the point at issure such that conventional multilayered wallpaper based on a vinyl chloride resin is bad in interlaminar compatibility, surface stability at the time of foaming, embossing properties or the like. SOLUTION: Two or more foaming layers based on an aqueous emlusion resin are laminated on a base material 1 for a decorative material to form a multilayered foaming layer 2 and at least the uppermost foaming layer of the multilayered foaming layer 2 is envenly foamed and embossed to form an embossed pattern 4.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a multi-layer foamed decorative material mainly used as an interior material of a building and particularly suitable as a wall covering material such as a decorative sheet for a wall or a wallpaper.

[0002]

2. Description of the Related Art A conventional decorative sheet or wallpaper is obtained by applying a foamable resin composition containing a thermoplastic resin as a main component on a backing sheet or backing paper and heating and foaming to form a foamed layer. Account for the majority.

[0003] In recent years, olefin resins, acrylic resins, polyester resins, aqueous emulsion resins, and the like have been adopted as the above-mentioned thermoplastic resins. The use of polyvinyl chloride resin having excellent properties is still the majority.

[0004] The foam layer in such a decorative sheet or wallpaper,
Generally, only one layer is provided by applying a single foamable resin composition only once for ease of production.

However, in recent years, in the above-mentioned wallpaper containing vinyl chloride resin as a main component, for example, compatibility between flame retardancy and surface feel, development of a special design effect, utilization of recycled resin, etc. Due to various physical properties such as required physical properties and the suitability for application of the foamable resin composition to be used, production costs, etc., a foamable resin layer composed of a plurality of layers using the foamable resin composition having the same or different composition is used. Forming techniques are being attempted.

However, the foamed decorative material of a multi-layer type containing a vinyl chloride resin as a main component has poor compatibility between layers as compared with a single-layer type foamed decorative material. Can be Along with this, poor compatibility results in poor surface stability at the time of foaming due to insufficient continuity of air bubbles (cells), and a puncture phenomenon in which air bubbles burst and collapse during embossing. However, there is a problem that it is difficult to obtain embossed design.

[0007]

SUMMARY OF THE INVENTION The present invention solves problems such as poor compatibility between layers, surface stability at the time of foaming, and poor embossability in a conventional multilayer wallpaper mainly comprising a vinyl chloride resin. Another object of the present invention is to provide a multi-layer foam decorative material having a sufficient interlayer strength, a stable surface property obtained by foaming, and a stably embossed pattern having a high design property.

[0008]

According to the first aspect of the present invention, there is provided a multi-layer structure comprising two or more foamed layers mainly composed of an aqueous emulsion resin provided on a base material for decorative material. It is a multilayer foam decorative material characterized by being constituted by a foam layer.

The invention according to claim 2 of the present invention is characterized in that two or more foamed layers mainly composed of an aqueous emulsion resin provided on a base material for decorative material are laminated to constitute a multilayer foamed layer, A multilayer foam decorative material characterized in that at least the outermost foam layer of the multilayer foam layer is foamed and embossed in an uneven shape.

[0010] Next, the invention according to claim 3 of the present invention provides a multi-layer foamed layer comprising two or more foamed layers mainly composed of an aqueous emulsion resin provided on a base material for decorative material. The multilayer foam decorative material is characterized in that the multilayer foam layer is foamed and embossed in an uneven shape.

Next, the invention according to claim 4 of the present invention provides the multilayer foam decorative material according to any one of claims 1 to 3, wherein each of the foam layers constituting the multilayer foam layer has Of these, the amount of the foaming agent in the foamable resin composition forming the backside foam layer is larger than the amount of the foaming agent in the foamable resin composition forming the topmost foam layer. It is a multi-layer foam decorative material set in.

Next, the invention according to claim 5 of the present invention provides the multilayer foam decorative material according to any one of claims 1 to 4, wherein each of the foam layers constituting the multilayer foam layer is Of these, the amount of filler such as calcium carbonate or aluminum hydroxide in the foamable resin composition forming the foam layer on the outermost layer or the foam layer on the side close to the outermost layer forms the foam layer on the inner layer side. It is a multi-layer foamed decorative material which is set to 0 or a smaller value based on the amount of the foaming agent added to the foamable resin composition to be formed.

Next, according to a sixth aspect of the present invention, there is provided the multilayer foamed decorative material according to any one of the first to fourth aspects, wherein each of the foamed layers constituting the multilayered foamed layer has Among them, the compounding amount of a filler such as calcium carbonate or aluminum hydroxide to the foamable resin composition forming the foam layer on the inner layer side from the foam layer of the outermost layer or the foam layer on the side closer to the outermost layer, respectively. And a multi-layer foam decorative material which is set to be relatively large with respect to the blending amount of the foaming agent in the foamable resin composition forming the outermost foam layer or the foam layer on the side close to the outermost layer.

Next, according to a seventh aspect of the present invention, there is provided the multilayer foamed decorative material according to any one of the first to sixth aspects, wherein each of the foamed layers constituting the multilayer foamed layer is The coating amount after drying of the foamable resin composition forming the foam layer on the outermost layer or the foam layer on the side close to the outermost layer is after drying the foamable resin composition forming the foam layer on the inner layer side. This is a multi-layer foam decorative material set to be smaller than the application amount.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION As shown in FIG. 1, for example, a multilayer foamed decorative material of the present invention has a multilayer foamed layer in which two or more foamed layers are laminated on a substrate 1, for example, a first foamed layer 21. A multi-layer foam layer 2 (also referred to as a multi-layer foam layer) composed of the second foam layer 22 is provided.

Further, a picture pattern 3 is printed on the surface of the multilayer foam layer 2, and an embossed pattern 4 is formed by embossing. In the example shown in FIG.
Has a two-layer structure of first and second foam layers 21 and 22,
It may have a three-layer configuration or a multi-layer configuration of more layers.

The substrate 1 serves as a support for the intended multi-layer foam decorative material of the present invention, and has heat resistance to such an extent that the multi-layer foam layer 2 is not deformed by heat at the time of heating and foaming. The material is not particularly limited as long as it is a material. Specifically, paper such as thin paper, titanium paper, inorganic paper, or flame retardant paper, cloth such as woven or nonwoven fabric, synthetic resin film or sheet, wood veneer, plywood or fiber plate A material may be appropriately selected from a plate, a gypsum board, an inorganic plate such as a calcium silicate plate, a metal foil or a metal plate, or a laminate or a composite thereof according to the intended use.

The multilayer foam layer 2 is formed for the purpose of giving a soft touch by foaming to the surface of the intended foam decorative material and facilitating the embossing of the uneven pattern 4. The multilayer foamed layer 2 is formed from a foamable resin composition in which various additives such as a filler, a foaming agent, a colorant, a dispersant, an antiblocking agent, an antifoaming agent, and a thickener are appropriately mixed with an aqueous emulsion resin. Is done. In the multilayer foam decorative material of the present invention, the multilayer foam layer 2 has two first layers,
The second foamed layers 21, 22 or more than the first, second, to n-th multi-layered foamed layers are used. The aqueous emulsion resin used in the foamable resin composition is The foam layers 21 and 22 may be the same or different.

By the way, as in the prior art, for example, when the foamable resin composition is a vinyl chloride resin composition using a vinyl chloride resin as a main synthetic resin component in the composition, volatile components Is less than 10%,
Most of them are diluents (such as terpenes) and evaporate mainly from the surface.

However, in the case of an aqueous emulsion composition such as the foamable resin composition used in the present invention, the volatile content is 10% or more (mostly 30% or more).
And more than the vinyl chloride resin composition, and the volatile component is water.

Therefore, the foaming resin composition using the aqueous emulsion composition as in the present invention has a vibration effect of water molecules at the time of gelation, and the foaming decorative layers 21 and 22 have compatibility due to vibration between layers. . Then, the movement and diffusion of water vapor further promotes compatibility between the layers, and accordingly, an open-cell action between the layers by the movement and diffusion paths is also exhibited. Further, since this movement and diffusion path (evaporation path) evaporates from both the upper and lower surfaces of the substrate 1 and the outermost surface layer of the multilayer foam layer 2 (for example, the surface of the foam layer 22), the compatibility and the open cell rate are further improved. Get higher. In addition, a large amount of volatile components also contributes to these. In addition to these effects, a good film is formed on the surface due to good compatibility, and there are effects such as improvement in surface strength and printability.

Due to the above effects, in the subsequent heating and foaming step, the surface stability at the time of foaming, which is a problem in the conventional vinyl chloride resin composition, is eliminated by compatibility between layers and formation of a dense film on the surface. In addition, the puncture phenomenon at the time of embossing is also eliminated by the compatibility between the layers and the accompanying open cells, which allow air to pass through.

The aqueous emulsion resin used in the present invention is not particularly limited, and examples thereof include acrylates, aromatic vinyl compounds, SBR, vinyl acetate, ethylene-vinyl acetate copolymer, and silicone. , Polyurethane, polybutene, and the like, and are not particularly limited in structure, and may be a common copolymer or a two-layer core / shell structure, a blend, or the like.

The filler to be incorporated into the foamable resin composition of the present invention includes aluminum hydroxide, magnesium hydroxide, barium hydroxide, calcium carbonate, magnesium carbonate, calcium sulfate, barium sulfate, silica sand, clay, talc, Examples include silicas and magnesium silicate. Preferred are aluminum hydroxide, magnesium hydroxide and calcium carbonate. The addition amount of the filler is preferably 50 to 300 parts by weight. If the amount is less than 50 parts by weight, the flame retardant effect is not sufficiently exhibited, and if it is more than 300 parts by weight, the surface strength of the foamed sheet tends to be weak.

The foaming agent to be incorporated into the foamable resin composition of the present invention is a capsule foaming agent, which comprises polyacrylonitrile, a copolymer of acrylonitrile and methyl acrylate, a copolymer of methyl methacrylate and acrylonitrile, and the like. It is composed of a capsule shell part and a low boiling point hydrocarbon (gas component) such as ethane, propane, butane, pentane, hexane, heptane or the like which is hermetically loaded inside the capsule shell, and is a sphere having a particle size of 2 to 30 μm. . The addition amount of the foaming agent is preferably 3 to 20 parts by weight. If the amount is less than 3 parts by weight, the volume feeling (expansion ratio) of the foamed sheet is insufficient, and if it is more than 20 parts by weight, the surface strength of the foamed sheet tends to be weak.

The foaming starting temperature of the capsule foaming agent is 120
It is preferable that it is -180 degreeC. When the temperature is 180 ° C. or higher, the foaming property is inferior, and the heat energy cost increases. On the other hand, when the foaming start temperature is less than 120 ° C., foaming of the capsule foaming agent easily occurs even under a temperature for drying the water of the aqueous emulsion resin as the foamed layer,
Since the foaming of the capsule foaming agent occurs before the so-called foaming layer dries, a good foam having an appropriate foaming ratio after heating and foaming cannot be obtained.

As other additives to the aqueous emulsion foamable resin composition of the present invention, a colorant, a dispersant, an antiblocking agent, an antifoaming agent and a thickener can be used.

Each foamed layer of the present invention (for example, the first foamed layer 2
1, the method of applying the foamable resin composition for forming the second foamed layer 22) is not particularly limited, and for example, a knife coater, a nozzle coater, a gravure coater, a rotary screen coater, a reverse roll coater, etc. A method is used. Further, all the foam layers 21 and 22 may be formed by the same coating method, or may be different from each other.
It is also optional to carry out a combination of more than one kind of coating method.

The printing ink for the pattern 3 is a gravure printing method, an offset printing method, a screen printing method using an appropriate printing ink (non-foaming ink) or / and a foaming ink containing an aqueous emulsion resin as a main component. It can be formed by a method or the like.

The embossed concavo-convex pattern 4 may be formed by sufficiently drying the coated multilayer foam layer 2 and then foaming with hot air or infrared irradiation, or in some cases, using an embossing roll to form the multilayer foamed layer. An embossed pattern can be applied to the surface of the layer 2.

As a particularly preferred embodiment of the foamed decorative material of the present invention, each of the foamed layers 21 and 22 constituting the multilayer foamed layer 2 is provided.
Among them, the amount of the foaming agent in the foamable resin composition forming the outermost foam layer 22 is reduced, while the foaming agent in the foamable resin composition forming the foam layer 21 on the back surface side is reduced. By setting the blending amount of the multilayer foam to be relatively large, the multilayer foamed layer 2 has a large foaming ratio as a whole and has excellent properties such as soft touch feeling and embossing suitability, while maintaining surface strength and stain resistance. Also, a foamed decorative material excellent in surface physical properties such as can be obtained.

For the above purpose, the amount of the foaming agent to be added to the foamable resin composition forming each of the foamed layers 21 and 22 is about 3 to 7 parts by weight per 100 parts by weight of the resin in the foamed decorative layer 22 on the surface side. In the foam layer 21 on the back side, it is preferable that the amount is also about 7 to 20 parts by weight.

For the purpose of obtaining a foamed decorative material having excellent whiteness, the foaming resin composition for forming the foamed layer 22 on the surface side may contain a large amount of a coloring agent such as titanium oxide or zinc oxide. Preferably, specifically, it is preferable to add about 10 to 30 parts by weight per 100 parts by weight of the resin. on the other hand,
In the foamable resin composition forming the decorative foam layer 21 on the back side, in consideration of the influence on the expansion ratio and the production cost, etc., it is not necessary to mix or use a small amount at all, specifically, about 0 to 20 parts by weight. Is preferably within the range.

For the purpose of obtaining excellent surface properties, the amount of the filler such as calcium carbonate or aluminum hydroxide should be reduced in the foamable resin composition forming the foam layer 22 on the front side. Preferably, specifically, depending on the amount of the foaming agent added, about 30 to about 30 parts by weight per 100 parts by weight of the resin.
It is preferably in the range of about 150 parts by weight, more preferably about 50 to 120 parts by weight. On the other hand, it is advantageous to add a large amount to the foamable resin composition for forming the foam layer 21 on the back surface side in order to reduce the production cost, but if the amount is too large, the resin becomes brittle, and Since the magnification cannot be increased much, the compounding amount of the filler is about 50 to 300 parts by weight per 100 parts by weight of the resin, and more preferably 120 to 300 parts by weight.
It is preferably about 200 parts by weight. Incidentally, in order to provide the flame retardant effect of the filler, the ideal blending ratio of the filler with respect to the multilayer foam layer 2 is determined by changing the resin 10
It is necessary to set the filler to 50 parts by weight or more with respect to 0 parts by weight.

As for the thickness of each foam layer, the thickness of the foam layer on the front side (for example, the second foam layer 22) is more advantageous in terms of surface properties, but the foam layer on the back side is advantageous in terms of the expansion ratio. Since the thicker (for example, the first foam layer 21) is more advantageous,
In accordance with the intended use and required properties of the intended multi-layer foamed decorative material, it is necessary to appropriately determine the balance between the two. For example, in a general wallpaper application, the basis weight (the amount of application after drying) of the second foam layer 22 on the front side is 20 to 120 g / m ² , more preferably about 30 to 70 g / m ² , The basis weight (same as above) of the first foamed layer 21 is preferably in the range of about 50 to 300 g / m ² , more preferably about 80 to 200 g / m ² .

According to the prototype experiments conducted by the present inventors, the pencil hardness was 4H or more (however, the pencil hardness referred to here was a load of 4 according to JIS K5400) according to the above method.
00g), the foaming ratio is 5 times or more as a whole of the multilayer foamed layer 2 (the first foam decorative layer 21 on the back side is 7 times or more), which is an excellent foaming cosmetic having both high surface strength and high foaming ratio. Material can be obtained.

Although the typical embodiments of the multi-layer foam decorative material of the present invention have been described above, the present invention is not limited to these, and may be variously modified and implemented without changing the gist of the present invention. it can.

[0038]

The present invention will be described in detail below with reference to specific examples.

Example 1 ^On a flame-retardant paper machine having a basis weight of 100 g / m ² , a resin composition represented by a resin composition 1 in Table 1 below was coated with a basis weight (amount applied after drying) of 120 g / m ^2. To form a first foamed layer 21. Next, a second foam layer 22 was formed thereon by applying a resin composition represented by a resin composition 2 shown in Table 2 below to a basis weight (the same) of 50 g / m ² . (Refer to FIG. 1; however, the same type of aqueous emulsion is used in relation to the comparative example.) Then, the mixture is dried in an oven at a drying temperature of 120 ° C. for 2 minutes, gelled, and foamed to form a base layer (multilayer). Foam layer 2)
Was formed. At this time, the adhesion between the two layers was good. After forming a pattern 3 by gravure printing using an aqueous ink on this base layer, an embossing die is placed on a press machine,
Foaming and embossing were simultaneously performed at a heating temperature of 210 ° C. for a time of 30 seconds to form an embossed concavo-convex pattern 4. At this time, no puncture occurred during embossing, the surface stability was good, and the uneven pattern 4 could be obtained stably.

[0040]

[Table 1]

[0041]

[Table 2]

Comparative Example 1 A resin composition represented by a resin composition 3 in Table 3 below was coated on a flame-retardant paper machine having a basis weight of 100 g / m ² with a basis weight (application amount after drying) of 120 g / m ^2. To form a first foamed layer 21. Next, a resin composition represented by a resin composition 4 shown in Table 4 below was added thereto at 50 g / m ^2.
To form a second foam layer 22. Then, it was dried in an oven at a drying temperature of 120 ° C. for 2 minutes and gelled to form a foaming base layer (multilayer foamed layer 2).
After the pattern 3 is formed on the base layer by gravure printing using an aqueous ink, an embossing die is placed in a press machine, and foaming and embossing are simultaneously performed at a heating temperature of 210 ° C. for a time of 30 seconds to obtain embossed irregularities. Pattern 4 was formed. At this time, puncture occurs frequently during embossing, surface stability is poor,
A good product could not be obtained as compared to the invention of Example 1 above.

[0043]

[Table 3]

[0044]

[Table 4]

Comparative Example 2 A resin composition represented by resin composition 5 in Table 5 below was coated on a flame-retardant paper machine having a basis weight of 100 g / m ² with a basis weight (amount applied after drying) of 170 g / m ^2. To form a single-layer foamed layer. Then, it was dried in an oven at a drying temperature of 120 ° C. for 2 minutes and gelled to form a foaming base layer (single-layer foamed layer). However, the expansion ratio of the single-layer foamed layer made of the resin composition 5 was matched with the total expansion ratio of the first foamed layer and the second foamed layer made of the resin compositions 1 and 2 in Tables 1 and 2 in Example 1 above. . Further, materials having the same trade name were used for all the materials below the aqueous emulsion. After the pattern 3 is formed on the base layer by gravure printing using an aqueous ink, an embossing die is placed in a press machine, and foaming and embossing are simultaneously performed at a heating temperature of 210 ° C. for a time of 30 seconds to obtain embossed irregularities. A pattern was formed. At this time, no puncture was generated during embossing, the surface stability was good, and a concavo-convex pattern could be obtained stably. However, Comparative Example 2 and Example 1 were compared in terms of performance. At that time, the expansion ratio was matched, and both were 5 times. However, the surface strength of the product of the present invention of Example 1 was 4H, whereas that of Comparative Example 2 was 2B, which was worse. . Furthermore, when considering the whole, Comparative Example 2 requires a larger amount of the foaming agent than Example 1, and the addition amount of the filler must be suppressed in consideration of the surface strength of the foamed layer. No, and therefore expensive.

[0046]

[Table 5]

[0047]

The multilayer foam decorative material of the present invention is a multilayer foam layer (or a multilayer foam decorative layer) comprising an aqueous emulsion resin as a main component and two or more foam layers (or foam decorative layers) laminated. Has at least, compared to a single layer, performance, cost can be improved, furthermore, the compatibility between the layers, which is a problem in a multi-layer type of the vinyl chloride resin composition, surface stability, Problems such as embossability could be solved, and a good foamed decorative material could be obtained.

[Brief description of the drawings]

FIG. 1 is a side sectional view showing an embodiment of a multilayer foam decorative material of the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Base material layer 2 ... Multi-layer foam layer (multi-layer foam decorative layer) 3 ...
Picture pattern 4: Uneven pattern 21: First foam layer (first foam decorative layer) 22: Second foam layer (second foam decorative layer)

 ────────────────────────────────────────────────── ─── Continued on the front page F-term (reference) 4F100 AA08B AA08C AA19B AA19C AK01B AK01C AK68 AT00A BA03 BA04 BA05 BA10A BA10C BA25 BA27 CA01B CA01C CA23B CA23C DJ01B DJ01C EJ39 GB08 HB00 HB21JJB04JB05JB01B

Claims (7)

[Claims] 1. A multi-layer foamed makeup comprising two or more foamed layers mainly composed of an aqueous emulsion resin provided on a base material for decorative material and formed into a multi-layer foamed layer. Wood. 2. A multi-layered foamed layer comprising two or more foamed layers mainly composed of an aqueous emulsion resin provided on a base material for a decorative material, and formed as a multilayer foamed layer. Characterized in that the foam layer of (1) is foamed and embossed in an uneven shape. 3. A multi-layer foamed layer is formed by laminating two or more foamed layers mainly composed of an aqueous emulsion resin provided on a base material for a decorative material, and the multi-layered foamed layer is foamed in an uneven shape. A multilayer foam decorative material characterized by being embossed. 4. The foamed layer constituting the multilayer foamed layer, wherein:
The amount of the foaming agent in the foamable resin composition forming the innermost foam layer is set larger than the amount of the foaming agent in the foamable resin composition forming the outermost foam layer. The multilayer foamed decorative material according to any one of claims 1 to 3, wherein 5. The foamed layer constituting the multilayer foamed layer, wherein:
The amount of the filler such as calcium carbonate or aluminum hydroxide in the foamable resin composition forming the outermost foam layer or the foam layer on the side close to the outermost layer is higher than the foaming amount forming the inner foam layer. The multilayer foam decorative material according to any one of claims 1 to 4, wherein the amount is set to 0 or a smaller amount than the amount of the foaming agent added to the conductive resin composition. 6. Each of the foam layers constituting the multilayer foam layer,
The amount of filler such as calcium carbonate or aluminum hydroxide in the foamable resin composition forming the foam layer on the inner layer side from the foam layer on the outermost foam layer or the foam layer on the side close to the outermost layer is the lowest. The method according to any one of claims 1 to 4, wherein the amount of the foaming agent in the foamable resin composition for forming the foam layer on the surface layer or the foam layer on the side close to the outermost layer is set to be relatively large. Item 8. The multi-layer foam decorative material according to the above item. 7. Each of the foam layers constituting the multilayer foam layer,
The amount of the foamable resin composition forming the outermost foam layer or the foam layer on the side close to the outermost layer after drying is larger than the amount of the foamable resin composition forming the inner foam layer. The multilayer foamed decorative material according to any one of claims 1 to 6, which is set to be smaller than the amount.