Multi-function soft wall and manufacturing method thereof

• US 10,202,520 B2
• Filed: 04/28/2014
• Issued: 02/12/2019
• Est. Priority Date: 07/17/2013
• Status: Active Grant

• Current Assignee: Ningbo Callde Biomimetics Materials Co., Ltd.
• Original Assignee: Ningbo Callde Biomimetics Materials Co., Ltd.
• Inventors: Cheng, Huimin
• Primary Examiner(s): Powers, Laura C
• Application Number:
  US14/890,306
• Publication Number:
  US 20160130465A1
• Time in Patent Office: 1,751 Days
• Field of Search: None
• CPC Class Codes: B05D 3/007 After-treatment
• CPC Class Codes: B05D 7/50 Multilayers
• CPC Class Codes: B29C 44/06 Making multilayered articles B29C44/0407 - B29C44/0492 take precedence
• CPC Class Codes: B32B 2038/0084 Foaming
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/4026 within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2607/02 Wall papers, wall coverings
• CPC Class Codes: B32B 29/007 next to a foam layer
• CPC Class Codes: B32B 37/02 characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: B32B 7/06 permitting easy separation
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C08G 2150/90 Compositions for anticorrosive coatings
• CPC Class Codes: C08K 2003/2296 of zinc
• CPC Class Codes: C08K 2003/265 Calcium, strontium or barium carbonate
• CPC Class Codes: C08K 3/08 Metals
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 3/2279 of antimony
• CPC Class Codes: C08K 3/26 Carbonates; Bicarbonates
• CPC Class Codes: C08K 3/34 Silicon-containing compounds
• CPC Class Codes: C08K 3/36 : Silica
• CPC Class Codes: C08K 3/38 : Boron-containing compounds
• CPC Class Codes: C08K 5/09 : Carboxylic acids; Metal salts thereof; Anhydrides thereof
• CPC Class Codes: C08K 5/12 : of cyclic polycarboxylic acids
• CPC Class Codes: C09D 127/06 : Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: C09D 175/04 : Polyurethanes

Abstract

The invention discloses a multi-function soft wall, comprising a surface printing layer and a base material, the base material further including a top layer, and a second layer, a third layer and a bottom layer that are all foaming layers, wherein both the second layer and the third layer have a foaming ratio less than that of the bottom layer, and a fiber layer is disposed between the third layer and the bottom layer. The invention further provides a method of manufacturing a multi-function soft wall, comprising: sequentially coating a top layer, a second layer, a third layer, a fiber layer and a bottom layer on a release paper, respectively, and then obtaining a base material, and performing a foaming process with respect to the second layer, the third layer and the bottom layer, respectively, and performing a drying and cooling process after the coating step; and separating the base material from the release paper, and printing a surface printing layer on the top layer. The multi-function soft wall can release negative ions, and continuously eliminate various pollutions indoors.

Claims

1. A multi-function soft wall, comprising:

a printed layer; and

a base material, including;

a first layer;

a second layer, a third layer, and a bottom layer, wherein the second layer, the third layer, and the bottom layer are all foaming layers, and wherein both the second layer and the third layer have a foaming ratio less than that of the bottom layer; and

a fiber layer that is located between the third layer and the bottom layer,

wherein ingredients in a formulation for the first layer include nanocrystals; and

wherein the nanocrystals comprise at least nano-size rare earth, nano-size tourmaline, nano-size medical stone, and nano-size quartz, and wherein the formulation of the first layer includes, by weight percentage;

60%-90% of polyurethane resin material, 1%-6% of the nano-size rare earth, 5%-20% of the nano-size tourmaline, 2%-7% of the nano-size medical stone, and 2%-7% of the nano-size quartz.

2. The multi-function soft wall according to claim 1, wherein the formulation of the second layer includes, by weight:

100 parts of polyvinylchloride resin, 80 parts or less of dioctyl terephthalate, 40 parts or less of zeolite powder, 40 parts or less of calcium carbonate powder, 2.7 parts of composite stearic acid stabilizer, 15 parts or less of antimonous oxide, 2.5 parts of azodicarbonamide foaming agent, and 2.5 parts of zinc oxide, on a basis of the polyvinylchloride resin.

3. The multi-function soft wall according to claim 2, wherein the second layer comprises a thickness of 20-25 μ

m and a foaming ratio of 1.2-1.8 times.

4. The multi-function soft wall according to claim 1, wherein the third layer comprises a thickness of 12 μ

m and a foaming ratio of 1.2-1.8 times.

5. The multi-function soft wall according to claim 1, wherein the formulation of the bottom layer includes, by weight:

100 parts of polyvinylchloride resin, 90 parts or less of dioctyl terephthalate, 40 parts or less of zeolite powder;

80 parts or less of calcium carbonate, 2.7 parts of composite stearic acid stabilizer, 15 parts or less of antimonous oxide, and 3.5 parts of azodicarbonamide foaming agent, on a basis of the polyvinylchloride resin.

6. The multi-function soft wall according to claim 5, wherein the bottom layer comprises a thickness of 25-30 μ

m and a foaming ratio of 2.4-3 times.

7. The multi-function soft wall according to claim 2, wherein the azodicarbonamide foaming agent comprises fillers, which include diatomite.