JPH0739100B2 - Marble tone decorative material mainly composed of suspension polymerization type vinyl chloride resin - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative material in the field of interiors such as wall coverings, ceilings and floors similar to natural marble.

[0002]

2. Description of the Related Art In recent years, natural materials have been reviewed, and especially natural stones from Italy have been used. However, due to the weight of the interior of natural stone, the holder requires considerable strength,
Due to difficulties involved in construction, synthetic resin interior materials that retain the atmosphere of natural stone have long been desired.

In response to such a demand, various interior materials made of synthetic resin have been disclosed thereafter, but these decorative materials had various problems due to their manufacturing methods. For example, as a natural stone similar to a terrazzo pattern, a product obtained by applying gravure printing, valley print printing, etc. on a film and pressing it on the substrate is commercially available at a low price, but the ink is a thin film and it lacks a three-dimensional effect. I could only do one thing.

Further, Japanese Patent Application Laid-Open No. 1-320162 discloses a terrazzo pattern decorative material obtained by dispersing coarse particles of polyvinyl chloride pattern particles in a matrix resin at a high density as a surface layer material for a decorative material and heating to gel. Has been done. in this case,
When the pattern coarse-grained piece aggregates are dispersed in the matrix resin at a high density and heated and gelled, there remains a problem that they tend to mix with the matrix resin and cause color mixing, and that the terrazzo pattern of natural stone can be completely reproduced. However, the present situation is that interior materials made of synthetic resin that sufficiently retain the atmosphere of natural stone have not yet been obtained. There has been a demand for the advent of decorative materials in the interior field, such as wall covering materials, ceiling materials, and floor materials, which are similar to natural marble and which can solve these drawbacks.

[0005]

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a novel marble-like decorative material containing a suspension polymerization type vinyl chloride resin composition as a main material.

Still another object of the present invention is to use a suspension polymerization type vinyl chloride resin composition as a main material, which is lightweight and excellent in workability, and is also excellent in similarity to the pattern of natural stone. To provide a cosmetic material.

[0007]

Means for Solving the Problems The inventors of the present invention have diligently studied a marble-like decorative material using at least two kinds of suspension polymerization type vinyl chloride resin compositions having different color tones. After crushing or cutting to a certain size, it is coated with an emulsion polymerization type vinyl resin paste sol to have a certain shape without mixing the suspension polymerization type vinyl chloride resin composition with different color tones.
It was found that the above object can be achieved by molding by heating and pressing in a mold , and the present invention has been completed based on this finding.

That is, in the present invention, at least two kinds of suspension polymerization type vinyl chloride resin compositions having different color tones are heated and kneaded to form a gelled block, which is then crushed and classified to obtain a rough pattern. and granules, after coating a paste sol color tone different emulsion polymerizable vinyl chloride resin該模like crude granules, emulsifying polymerizable vinyl chloride tree
Pattern coarse particles coated with grease paste sol
Drying of suspension polymerization type vinyl chloride resin composition with different color tones
It has a certain shape by mixing with the blended powder product.
It can be achieved by a marble-like decorative material characterized by being molded by heating and pressing in a mold.

Further, in the present invention, at least two or more suspension polymerization type vinyl chloride resin compositions having different colors are heated and kneaded to form a gelled block.
It is cut and further cut into a rod-shaped or polygonal cut, and after coating the cut sol with a paste sol of an emulsion polymerization type vinyl chloride resin having a different color tone ,
The present invention can be achieved by a marble-like decorative material characterized by being molded by heating and pressurizing in a mold having the same.

Further, according to the present invention, the rod-shaped or polygonal cut product is coated with a paste sol of an emulsion polymerization type vinyl chloride resin having a different color tone, and then 1 to 5 having different color tones are applied.
It can also be achieved by a marble-like decorative material characterized by being formed by heating and pressurizing in a mold having a certain shape together with a pattern coarse-grained material obtained by pulverizing and classifying to a size of cm. .

[0011]

The present invention will be described in detail below.

The degree of polymerization of the suspension polymerization type vinyl chloride resin in the suspension polymerization type vinyl chloride resin composition which can be used in the present invention is usually 400 to 1700, preferably 70.
It is in the range of 0 to 1300.

The compounding agent used in the present invention as a compounding agent in the above composition includes a plasticizer, a stabilizer, a filler and a pigment.

Examples of the plasticizer include dibutyl phthalate, dihexyl phthalate, di-2-ethylhexyl phthalate, di-n-octyl phthalate, di-isooctyl phthalate, didecyl phthalate, di-isodecyl phthalate, dimethyl glycol phthalate, Butylbenzyl phthalate, dioctyl adipate, dioctyl azelate, dibutyl sebacate, dioctyl sebacate, trixylenyl phosphate, monooctyl diphenyl phosphate, monobutyl-dixylenyl phosphate, trioctyl phosphate, tricresyl phosphate, tri-2-ethylhexyl Phosphate, butylphthalyl butyl glycolate, butyl acetyl ricinoleate, tributyl acetyl citrate, diisononyl phthalate, chlorine Mention may be made of paraffin and the like. Among them, di-2-ethylhexyl phthalate and dibutyl phthalate are inexpensive and are preferable plasticizers in production.

The blending amount of the plasticizer is usually 20 to 50% by weight based on 100% by weight of the suspension polymerization type vinyl chloride resin.
And more preferably 25 to 40% by weight.

Examples of the stabilizer include barium-zinc soap, barium-potassium-zinc soap, potassium-zinc soap, sodium-zinc soap, calcium-zinc soap, lead soap, cadmium soap, barium soap, calcium soap, sodium. Metal soaps such as soap, dibutyltin dilaurate, dibutyltin maleate, dibutyltin mercaptide, lead white, tribasic lead sulfate, trihydrochloric acid lead phosphite, dibasic lead phthalate, dibasic lead stearate, tribasic acid Examples thereof include basic lead maleate and lead silicate, and these may be used alone or in combination of two or more kinds. Among them, zinc soap and other metal soap are used in combination, for example, barium-zinc soap, barium-potassium-zinc soap, potassium-zinc soap, sodium-zinc soap, calcium-zinc soap, etc. are zinc soap alone. The stability effect is small, but
When used in combination with other metal soaps, a remarkable synergistic effect is exhibited, and thus it is a preferred stabilizer in production. Examples of the fatty acids of the metal soaps used as the stabilizer include stearic acid, lauric acid, ricinoleic acid, naphthenic acid, 2-ethylhexylic acid, and balsatic acid. Among them, stearic acid and lauric acid are fatty acids of powder metal soap, and 2-ethylhexylic acid and balsatic acid are fatty acids of liquid metal soap, which are preferable fatty acids of metal soaps in production.

The amount of stabilizer added is preferably in the range of 3 to 4% by weight, based on 100% by weight of the suspension polymerization type vinyl chloride resin.

Examples of the filler include calcium carbonate, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, talc, silica, clay and hydrated calcium silicate.

The blending amount of the filler is in the range of 0 to 200% by weight, preferably in the range of 0 to 150% by weight, based on 100% by weight of the suspension polymerization type vinyl chloride resin.

Examples of the pigment include titanium oxide, titanium yellow, phthalocyanine blue, polya red, carbon black and pearl pigment.

[0021] The amount of the pigment is the suspension polymerization type vinyl chloride resin 1
It is usually more than 0 and 4% by weight or less with respect to 00% by weight.

Next, the manufacturing method of the present invention will be sequentially described according to the manufacturing steps.

First, the suspension polymerization type vinyl chloride resin composition adjusted in the above ratio is heated and stirred by using a mixer, and then gelled by a kneader. A Henschel mixer, a super mixer, or the like can be used as the mixer. The heating temperature is in the range of 100 to 180 ° C, preferably 120 to 140 ° C. Examples of the kneader include a Banbury mixer and a pressure type kneader.

Subsequently, two or more kinds of the gelled products having different color tones are extruded by an extruder, and each has a length of 10 to 20.
cm lumps and length 50-100 cm with diameter 5-
Cut into 10 cm rods or polygons. Examples of the extruder include a single screw extruder and a twin screw extruder.

By the above cutting process, two kinds of cut pieces having different sizes can be obtained, and desired marble-like decorative materials can be obtained by the following different methods for each.

First method: a method using a lump having a length of 10 to 20 cm.

The agglomerate having a length of 10 to 20 cm is pulverized by a pulverizer into a size of 20 mesh to 5 cm and classified . Thus, the appearance of the patterned coarse-grained material which has been crushed to a size of 20 mesh to 5 cm and classified is the same as a state in which natural stone is mechanically crushed. Subsequently, the pattern coarse particles are coated with a paste sol of an emulsion polymerization type vinyl chloride resin having a transparent or different color tone.

Examples of the crusher include a pin type crusher and an impeller type crusher. The polymerization degree of the paste sol of the emulsion polymerization type vinyl chloride resin is usually 400 to
It is in the range of 1700, preferably in the range of 700 to 1300. Further, the coating can be carried out by using a generally known dipping method or a mixing method in a ribbon mixer.

The above-mentioned pattern coarse-grained material coated
And a separately-prepared suspension-polymerization type vinyl chloride resin composition having a different color tone and dry-blended powder product ,
Pressurize and heat gel in a mold with a certain shape
Then, it is molded into a desired shape, size and thickness to obtain a synthetic resin body having a coarse grain pattern. The coarse-grained synthetic resin body has an appearance similar to that of natural stone, and may be used as a marble-like decorative material as it is by polishing only the surface of the synthetic resin body to make a makeup finish. in addition to directly pressure pressed into the holding member for decorative material, in which may be used as a decorative material integral molded marble by a method such as further heat-sealing or bonding agent.

The suspension-polymerized vinyl chloride resin composition dry-blended powder product is prepared by heating and stirring in the same manner as the suspension-polymerized vinyl chloride resin composition described above except that the pigment is different. The size of the powdered product is usually 40 mesh to 200 mesh, preferably 40 mesh to 120 mesh. At this time, the ratio of the pattern coarse particles and the powdered product of the suspension polymerization type vinyl chloride resin composition dry-blended is usually 1: 0.5 to 2, preferably 1: 1 to 1.5 (weight ratio).
Is. Moreover, the temperature of the heat gelation is usually 160 to 200.
C., preferably 160 to 180.degree.

Second method: length 50 to 100 cm, diameter 5
A method of using a rod-shaped or polygonal cut piece of 10 cm.

The length of 50 to 50 obtained by the above cutting process
100 cm, 5-10 cm diameter rod-shaped or polygonal cut pieces are cut open, length 50-100 cm, diameter 2.5
A rod-shaped or polygonal cut piece having a size of up to 5 cm is coated with an emulsion polymerization type vinyl chloride resin paste sol having a different color tone.

The degree of polymerization of the paste sol of the emulsion polymerization type vinyl chloride resin is usually in the range of 400 to 1700, preferably 700 to 1300. Further, the coating can be carried out by using a generally known dipping method or a mixing method in a ribbon mixer.

The coated rod-shaped or polygonal cut material and the pattern coarse particles singly or crushed to 1 to 5 cm are both heated in a mold having a constant shape.
It is made into a desired shape, size and thickness to obtain a synthetic resin body having a coarse grain pattern. The coarse-grained synthetic resin body has an appearance similar to that of natural stone, and may be used as a marble-like decorative material as it is by polishing only the surface of the synthetic resin body to make a makeup finish. Direct pressure pressing on the holder for cosmetic material
Out, in which it may be used as a decorative material integral molded marble by further methods such as heat fusion or bonding agent.

The pattern coarse particles crushed to 1 to 5 cm are obtained by the same method as the pattern coarse particles crushed to the size of 20 mesh to 5 cm obtained by the first method. . At this time, a rod-shaped or polygonal cut and 1
The ratio of pattern coarse particles crushed to ~ 5 cm is usually 1:
It is 0.1 to 1, preferably 1: 0.5 (weight ratio).
The temperature of the heat gelation is usually 160 to 200 ° C, preferably 160 to 180 ° C.

[0036]

The present invention will be described in more detail with reference to the following examples, but it goes without saying that the present invention is not limited to these examples.

Example 1 A suspension polymerization type vinyl chloride resin composition having a formulation A shown in Table 1 below was kneaded with a mixer, dried at 120 to 140 ° C., and further kneaded with a Banbury mixer as a kneader. While heating and gelling at 160 to 180 ° C., the mixture was put into the hopper of the extruder. Then, the suspension polymerization type vinyl chloride resin composition of the formulation B shown in the following Table 2 having a different color tone from the formulation A is kneaded with a mixer to give 120 to 140.
Dry-up at ℃, put the dry powdered product of Formulation B on the gelled product of Formulation A that was previously charged into the hopper of the extruder, mix with the extruder, and then extrude the length It was cut to a size of 10 to 20 cm and 50 to 100 cm. The cutting resulted in marble-shaped lumps and round bar or polygonal cut pieces.

Next, the lumps cut into a size of 10 to 20 cm were further crushed using a crusher and then classified by sieving to a size of 20 mesh to 5 cm.
The pattern coarse particles thus classified to a size of 20 mesh to 5 cm are coated with a paste sol of an emulsion polymerization type vinyl chloride resin which is transparent or has a different color tone, and a suspension polymerization type vinyl chloride resin which is prepared separately and has a different color tone. After mixing with the dry-blended powder product of the composition ,
What was gelled by heating in a mold having a shape at 160 to 200 ° C. was applied to a 1 m square press plate which was a holder for the cosmetic material.
It was pressed under pressure to have a thickness of mm. Here, the ratio between the pattern coarse particles and the powder product was 1: 1 (weight ratio).

The decorative material of the pressed product thus obtained is
It was confirmed to be a terrazzo type having a deep pattern.

Next, a length of 50 to 50
Round bar or polygonal cut piece of 100 cm, diameter 5-10 cm, length 50-100 cm, diameter 2.5-5 cm
And was coated with an emulsion polymerization type vinyl chloride resin paste sol having different colors. The coated product of the round bar or polygonal cut product has different color tones from 1 to
With pattern coarse particles that have been crushed and classified to a size of 5 cm
The gel that had been heated and gelled at 160 to 200 ° C. in a mold having a constant shape was press- pressed to a thickness of 10 mm on a 1 m square press plate that is a holder for the cosmetic material. Here, the coated product of the round bar or the polygonal cut product and the above 1 to 5c
The ratio with the pattern coarse particles pulverized and classified to a size of m was 1: 0.5 (weight ratio).

The press decorative material thus obtained is
It was confirmed that it would be of the Italian natural marble type with a deep pattern.

[0042]

[Table 1]

[0043]

[Table 2]

[0044]

EFFECTS OF THE INVENTION Emulsion polymerization type vinyl chloride resins having different color tones are produced as pattern coarse particles or cuts by using at least two kinds of suspension polymerization type vinyl chloride resin compositions having different color tones. By coating the paste sol of the above, it is possible to form a marble-like decorative material while maintaining individual shapes without causing color mixing when heat-gelling pattern coarse particles having a marble-like pattern with different tones. .

Therefore, according to the present invention, it is possible to obtain a natural marble tone decorative material which is extremely lightweight, has excellent workability, and is excellent in similarity to the pattern of natural stone.

Further, the natural marble-like decorative material can be freely designed in the size, color tone and packing density of the pattern, and can produce a highly similar appearance such as a terrazzo pattern or an Italian natural marble pattern. Therefore, it can be widely used in various fields of exterior and interior such as wall coverings, ceiling coverings, floor coverings and the like as decorative materials.

Claims (9)

[Claims] 1. A pattern-coarse granular material is obtained by heating and kneading at least two kinds of suspension polymerization type vinyl chloride resin compositions each having a different color tone to form a gelled block, and then pulverizing and classifying the block. after coating a paste sol color tone different emulsion polymerizable vinyl chloride resin該模like crude granulate of emulsification polymerizable vinyl chloride resin paste sol
Coated pattern Coarse-grained and suspension with different tones
Dry blended powder of polymerized vinyl chloride resin composition
Mix with powder and heat and press in a mold with a certain shape.
Marble decorative material, which comprises forming by that. 2. The suspension polymerization type vinyl chloride resin composition is mainly composed of a suspension polymerization type vinyl chloride resin, and further contains a plasticizer, a stabilizer, a filler and a pigment as a compounding agent. The marble-like decorative material according to claim 1. 3. The pattern coarse particles are from 20 mesh to 5 mesh.
The marble-like decorative material according to claim 1, which is classified into cm. 4. The ratio of the pattern coarse particles coated with the paste sol of the emulsion polymerization type vinyl chloride resin and the dry blended powder product of the suspension polymerization type vinyl chloride resin composition is 1: 0. 5 to 2 (weight ratio)
Coat with a paste sol of the emulsion polymerization type vinyl chloride resin
Polymerization Chloride with Different Color Tones from Textured Coarse Particles
Mixed with dry blended powder of vinyl resin composition
The marble-like decorative material according to claim 1, wherein the marble-like decorative material is combined . 5. A suspension polymerization type vinyl chloride resin composition, each of which has a different color, is heated and kneaded by using at least two kinds to form a gelled block, which is then cut and further dried.
After cutting into a rod-shaped or polygonal cut product, the cut product is coated with a paste sol of an emulsion polymerization type vinyl chloride resin having a different color tone, and then in a mold having a certain shape.
A marble-like decorative material that is formed by being heated and pressed . 6. A coarse grained pattern obtained by coating the rod-shaped or polygonal cut product with a paste sol of an emulsion polymerization type vinyl chloride resin having different tones A certain shape with things
The marble-like decorative material according to claim 5, wherein the marble-like decorative material is formed by heating and pressurizing in a mold having the same . 7. The suspension polymerization type vinyl chloride resin composition comprises a suspension polymerization type vinyl chloride resin as a main component, and further contains a plasticizer, a stabilizer, a filler and a pigment as a compounding agent. The marble-like decorative material according to claim 5. 8. The cut product has a length of 50 to 100 cm,
The marble-like decorative material according to claim 5 or 6, which is cut open to have a diameter of 2.5 to 5 cm. 9. The ratio of the rod-shaped or polygonal cut material coated with the paste sol of the emulsion polymerization type vinyl chloride resin and the pattern coarse particles crushed and classified to the size of 1 to 5 cm is The marble-like decorative material according to claim 6, which is in the range of 1: 0.1 to 1 (weight ratio).