JP2002192682A - Wall material with pattern and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for eliminating the disadvantage of a decrease in finishing feeling of a product due to the occurrence of a defect such as a waviness or a distortion on a front surface of a decorative composite material, by exposing a ruggedness on a front surface of a base material when the rugged base material and a decorative material are laminated, and improving the appearance of the product. SOLUTION: A wall material with a pattern is obtained by integrating the base material and the decorative material via an adhesive layer made of a polyurethane resin composition foam.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a patterned wall material having excellent surface smoothness and good impact resistance for bathroom units and interior decoration, and a method for producing the same.

[0002]

2. Description of the Related Art Various interior wall materials and bathroom unit wall materials include a veneer, a particle board, or another base material to which a decorative material is attached using an adhesive, a tile, or a plate-like natural stone. High-grade wall materials such as tiled wall materials and natural stone bonded wall materials, glass fiber cured plastics (FR
FRP wall materials using P), wall materials in which various decorative sheets are bonded to a gypsum board or a calcium silicate plate, and steel plate wall materials in which the surface of a steel plate is decorated with a vinyl chloride sheet are known.

[0003] These wall materials are classified into high-grade products and general-purpose products depending on the appearance of the product, especially the texture and the depth of the pattern, but each has advantages and disadvantages, can be easily manufactured at a low price, and has a "undulation" on the surface. There is a demand for a wall material free from defects such as “undulation”.

[0004] These wall materials are made of various kinds of decorative materials such as polyester decorative materials, melamine decorative materials, diallyl phthalate decorative materials, and decorative materials printed on various films, such as gypsum board or calcium silicate plate. It is manufactured by bonding via an epoxy resin or urethane resin adhesive.

[0005]

When a decorative material is adhered to a substrate having an uneven surface by such a method, the unevenness of the surface of the substrate is exposed on the surface of the decorative material, and the surface of the decorative composite material is exposed. Defects such as undulations and distortions are produced, thereby reducing the finished feeling of the product. Further, it has been found that uneven coating of the adhesive also reduces the surface design. Especially when the surface of the decorative material is mirror-finished or when the thickness of the decorative material is 1.
It appears more remarkably than the case of 0 mm or less. Further, when a gypsum board or a light cull board having a high rigidity as a material of the decorative material or the base material is used, a crack may be generated on the surface due to an impact at the time of construction, a drop of an article, or the like. The present invention provides a method for overcoming such disadvantages and improving the appearance of the product.

[0006]

Means for Solving the Problems (1) A patterned wall material in which a base material and a decorative material are integrated via an adhesive layer made of a polyurethane resin composition foam. (2) The patterned wall material according to (1), wherein the substrate is calcium silicate or gypsum board. (3) The patterned wall material according to (1), wherein the decorative material has a pattern applied to one surface of a translucent or transparent resin film. (4) Place the decorative material on the lower mold via the heat insulating cushioning material,
After the polyurethane resin composition is discharged onto the surface of the decorative material, the base material is further placed on the surface, the mold is closed, the polyurethane resin composition is foamed and cured, and the decorative material and the substrate are composited. A method for producing a patterned wall material.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described with reference to the drawings.

FIG. 1 is a sectional view of the decorative composite material of the present invention. In the patterned wall material 1, a decorative material 2 and a base material 3 are integrated via an adhesive layer made of a polyurethane foam 4.

FIGS. 2 and 3 are cross-sectional views showing a method of manufacturing a patterned wall material according to the present invention. As shown in FIG.
The heat insulating cushioning material 5 is placed in the lower mold b (preferably 30-6
(Heated to 0 ° C.), and the decorative material 2 is placed thereon, and the polyurethane resin composition 4
And the base material 3 is placed thereon. As shown in FIG. 3, the upper mold of the molding die 6 is closed and the polyurethane resin composition is foamed and cured to form the polyurethane foam 4, and the patterned wall material is formed. Manufactured.

In the present invention, the surface of the substrate may be caused by a mold, a material or a production method at the stage of producing the substrate, such as smooth irregularities or irregularities observed on the surface of pumice stone.

[0011] In the prior art, it is considered that the "wavy" or "distorted" surface of the decorative material exposed when the decorative material and the base material are bonded with an adhesive is generated by the following action. Since the decorative material is generally used as a thin material having a thickness of 1.0 mm or less, unevenness of the base material is transferred to the surface of the decorative material, or due to uneven application of the adhesive or curing of the adhesive. Non-uniform stress generated from non-uniform shrinkage can be considered.

According to the present invention, an adhesive layer made of a polyurethane resin foam is interposed between the decorative material and the base material so that the unevenness of the base material and the curing strain of the adhesive do not affect the surface of the decorative material. Rippling and distortion can be prevented.

As the decorative material constituting the patterned wall material of the present invention, a material in which a pattern is printed on one surface of a translucent or transparent resin film is used, and is manufactured by the following method. After being stretched with a roll or the like, the mold or base film is sandwiched between a transparent or translucent resin on the surface of the base film and the patterning surface side of the transfer film formed on one side of the film with an ink soluble in the transparent resin. Alternatively, the translucent resin is cured. Thereafter, the mold or base film and the transfer film are peeled off. The transparent or translucent resin used for the cosmetic material is not particularly limited, but a thermosetting resin such as an unsaturated polyester resin, an epoxy resin, and an acrylic resin is used. These resins are used by appropriately compounding a curing agent, a curing accelerator, a filler, a pigment, various additives, and the like. Curing of these resins is performed by a known method such as room temperature curing, heat curing, ultraviolet curing, and the like. In this case, a curing agent, an accelerator, a sensitizer, and the like suitable for the curing method are used.

The transfer film used in the present invention is an ink in which a pigment or a dye is mixed with an unsaturated polyester resin, an acrylic resin, an epoxy resin, a nitrocellulose resin, or the like on one side of a plastic film such as polyethylene, polypropylene, or polyester. Manufactured with patterns. The pattern of the transfer film is transferred by rolling, stretching and curing a transparent or translucent resin. There is no limitation on the pattern printed on the transfer film, and wood grain, stone grain, shadow, abstract pattern, and the like are printed. There is no limitation on the method of stretching the transfer film into the resin, and the transfer film can be stretched with a roller or the like to have a thickness of 0.2 mm to 2 mm. Further, as the patterned decorative material, those obtained by impregnating a pattern paper on which a pattern is printed with a transparent or translucent resin, stretching and curing the resin, or printing a pattern on a transparent film, and the like are used.

The base material used in the present invention is not particularly limited, but gypsum board, calcium silicate plate, asbestos plate and the like are used. These base materials are used for improving the adhesion to the decorative material. May be applied in advance.

The polyurethane resin used in the present invention comprises polyol components such as polyester polyol, polyether polyol, polycarbonate polyol and acrylic polyol, and tolylene diisocyanate (TD).
I), diphenylmethane diisocyanate (MDI),
Polymeric MDI (consisting of polyisocyanate components such as polymethylene polyphenylene polyisocyanate, catalysts such as amine / tin, foaming agents such as highly active silicon, and foaming agents such as water and CFC-11, and further added as necessary. It is obtained from a foamable polyurethane composition containing a pigment and various additives as an agent, and the expansion ratio and thickness of the polyurethane foam vary depending on the thickness of the decorative material and the degree of unevenness of the base material. The heat-insulating cushioning material used in the present invention is a foam such as polyolefin (polyethylene, polypropylene, etc.), polyester (PET, polyethylene naphthalate, etc.), polyvinyl chloride or the like. The thickness of the cushioning material is preferably 0.5 to 2.0 mm.

[0017]

The present invention will be described below in more detail with reference to examples. Preparation of molding material

(1) Cosmetic material (A) On a polyester film (base film), 0.1 part of 6% cobalt naphthenate based on 100 parts of an unsaturated polyester resin polyset 3717 (trademark of Hitachi Chemical Co., Ltd.)
1.0% of 5% methyl ethyl ketone peroxide was added and a well-mixed resin was placed. A transfer film patterned with an ink obtained by mixing a pigment and a dye with a nitrified cotton-based resin was placed thereon. After stretching
After curing in a constant temperature bath at 50 ° C. for 1 hour, the polyester film as the base film and the transfer film were peeled off after cooling to obtain a decorative material (A) having a thickness of 0.8 mm. The obtained decorative material (A) was cut into a size of 300 × 300 mm to obtain a decorative material.

(2) Cosmetic material (B) On a polyester film (base film), 0.1 part of 6% cobalt naphthenate with respect to 100 parts of unsaturated polyester resin polyset 3717 (trademark of Hitachi Chemical Co., Ltd.)
A resin mixed with 1.0 part of 5% methyl ethyl ketone peroxide and mixed well is placed thereon, a decorative paper (basis weight 80 g / m ² ) on which a pattern is printed and a polyester film are placed thereon, and the resin is removed using a rubber roller. After stretching, 5
After curing in a thermostat at 0 ° C. for 1 hour, and cooling, the polyester films on both sides were peeled off to obtain a decorative material (B) having a thickness of 0.9 mm. 300 × 300 of the obtained decorative material (B)
It was cut into a size of mm to make a decorative material.

(3) Polyurethane resin composition A liquid (polyol component); HM-1110 (manufactured by Polyurethane Chemical Co., Ltd., 95% by weight of polyether polyol, 1.3% by weight of water, 3.7% by weight of catalyst, etc.) B Liquid (isocyanate); Polymec MDI (M-20
S, manufactured by Polyurethane Chemical Co., Ltd.) Foaming properties 1) Mixing ratio A liquid / B = 100; 135 (weight ratio) 2) Reactivity ・ Cream time: 18 seconds ・ Gel time: 58 seconds ・ Rise time: 105 seconds 3) Free Density: 80 kg / m ³

(4) Substrate Calcium silicate plate 5 mm thick (300 × 300 dimensions)
mm)

(5) Insulation cushioning material Polyethylene foam sheet (manufactured by Inoac Corporation, trade name: LSL-8) Thickness: 0.8 mm Expansion ratio: 20 times

Example 1 A heat insulating cushioning material was placed in a cavity of a lower mold 6b of a molding die 6 adjusted to a temperature of 40 ° C., a decorative material (A) was placed thereon, and a polyurethane resin composition (50 g of liquid A) was placed thereon. / B liquid 6
7.5 g of a mixture obtained by mixing with a high-speed mixer), immediately put a calcium silicate plate as a base material, close the upper mold 6a of the mold 6 so that the molding thickness becomes 7.0 mm, and form a polyurethane resin composition. The product was foam-cured. After 10 minutes from the introduction of the polyurethane resin composition, the mold 6 was opened and the molded product was taken out to obtain a patterned wall material in which the decorative material (A) and the calcium silicate plate were joined via a polyurethane foam. This molded article was excellent in design without any defects such as “undulation” and “distortion” in mirror appearance. Further, the obtained molded product is
No abnormality was found in a one-side immersion test in hot water of 300 ° C. for 300 hours, and it was found that the test piece could be used as a unit wall material.

Example 2 A heat insulating cushioning material was placed in a cavity of a lower mold 6b of a molding die 6 adjusted to 50 ° C., a decorative material (B) was placed thereon, and a polyurethane resin composition (50 g of liquid A) was placed thereon. / B liquid 6
7.5 g of a mixture obtained by mixing with a high-speed mixer), immediately put a calcium silicate plate as a base material, close the upper mold 6a of the mold 6 so that the molding thickness becomes 7.0 mm, and form a polyurethane resin composition. The product was foam-cured. After 10 minutes from the introduction of the polyurethane resin composition, the mold 6 was opened and the molded product was taken out to obtain a patterned wall material in which the decorative material (B) and the calcium silicate plate were joined via a polyurethane foam. This molded article was excellent in design without any defects such as “undulation” and “distortion” in mirror appearance. In addition, the obtained molded product is
No abnormality was found in a one-sided immersion test in hot water of 300 ° C. for 300 hours, and it was found that the film could be used as a unit wall material.

Comparative Example An epoxy resin-based adhesive (manufactured by Konishi Co., Ltd., Bond E25) was used in place of the polyurethane resin composition used in Example 1.
0) was applied to the decorative material (A), and a patterned wall material was obtained in the same manner as in the example. In the obtained wall material, "undulation" and "distortion" occurred, the design property was impaired, and no satisfactory material was obtained. When a hot water immersion test was performed on this product, “undulation” and “distortion” progressed, and the appearance was significantly reduced.

[0026]

According to the patterned wall material and the method of manufacturing the same of the present invention, a wall material having a high design property can be obtained without selecting a decorative material and a base material, and a mirror surface which has been a conventional problem. The appearance can be prevented from deteriorating during finishing. Also, by selecting the performance of the base material, it is expected that the usable applications can be expanded.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of an example of a patterned wall material of the present invention.

FIG. 2 is an explanatory cross-sectional view of the manufacturing method of the present invention.

FIG. 3 is an explanatory sectional view of the manufacturing method of the present invention.

[Explanation of symbols]

 1. Patterned wall material 2. Cosmetic materials 3. Base material 4. 4. Polyurethane foam (polyurethane resin composition) Insulation cushioning material 6. Mold 6a. Upper mold 6b. Lower mold

Continued on the front page F-term (reference) 2E110 AA57 AB04 AB23 BA02 BB03 GA24Z GA32W GA32Z GA33W GA33X GB16X GB17X GB54Z 4F100 AC10A AD02A AD09A AE06A AE09A AK41 AK41 AK44 AK51C AK51G AK51G AR00B AT00ABA02 EB01 BA01 BA03 BA07 BA08 HB00B JK10 JK15 JN01B

Claims (4)

[Claims] 1. A patterned wall material in which a base material and a decorative material are integrated via an adhesive layer made of a polyurethane resin composition foam. 2. The patterned wall material according to claim 1, wherein the substrate is calcium silicate or gypsum board. 3. The patterned wall material according to claim 1, wherein the decorative material is a translucent or transparent resin film provided with a pattern on one surface. 4. A cosmetic material is placed on a lower mold of a mold via a heat-insulating cushioning material, a polyurethane resin composition is discharged on the surface of the cosmetic material, and a base material is further placed on the surface to clamp the mold. A method for producing a patterned wall material, comprising foaming and curing a polyurethane resin composition to composite a decorative material and a substrate.