Manufacturing method of paper-based foam board with protective layer

Abstract

A manufacturing method of a paper-based foam board with a protective layer. The manufacturing method includes the steps of: providing a paper substrate having a first surface and a second surface; forming a first protective layer by forming a waterproof/oil-proof layer on the first surface; forming a second protective layer by forming a waterproof/oil-proof layer on the second surface; and forming a foam layer by applying a water-based foaming coating material to the first protective layer, wherein the foaming coating material contains a water-based polyolefin constituting at least 50% by mass of the water-based foaming coating material, and wherein the foam layer is bonded to the first protective layer more tightly and is more heat-resistant than its prior art counterparts.

What is claimed is: 
     
         1 . A manufacturing method of a paper-based foam board with a protective layer on each of two sides of the foam board, comprising the steps of:
 preparing a foaming coating material by preparing a water-based foaming coating material containing a water-based polyolefin, wherein water-based polyolefin makes up at least 50% by mass of the water-based foaming coating material;   providing a paper substrate having a first surface and a second surface;   forming a first protective layer by forming a waterproof/oil-proof layer on the first surface;   forming a second protective layer by forming a waterproof/oil-proof layer on the second surface; and   forming a foam layer by applying the foaming coating material to the first protective layer.   
     
     
         2 . The manufacturing method as claimed in  claim 1 , wherein the waterproof/oil-proof layers are made of polyethylene, polypropylene, a water-based polyolefin, a water-based polyvinyl alcohol, a water-based acrylic resin, or a water-based polyurethane resin. 
     
     
         3 . The manufacturing method as claimed in  claim 1 , wherein the water-based foaming coating material is composed of a water-based ethylene-vinyl acetate, a water-based polyvinyl alcohol, a water-based acrylic resin, and/or a water-based polyurethane resin, in addition to the water-based polyolefin. 
     
     
         4 . The manufacturing method as claimed in  claim 1 , wherein the water-based polyolefin is added with a water-based acrylic resin, a water-based polyurethane, a water-based ethylene-vinyl acetate, a water-based polyvinyl alcohol, a water-based foaming agent in powder form, a dispersing agent, a defoaming agent, and/or a wetting agent. 
     
     
         5 . The manufacturing method as claimed in  claim 1 , wherein the step of forming a foam layer comprises applying the water-based foaming coating material by a printing or coating process so as to form a predetermined pattern and/or predetermined text. 
     
     
         6 . The manufacturing method as claimed in  claim 1 , wherein the foam layer is resistant to heat of a temperature in a range from 90° C. to 140° C.