JP2011093302A - Foamed decorative sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a foamed decorative sheet suppressed in the formation of creases and curls, and excelled in surface strength. <P>SOLUTION: The foamed decorative sheet has at least a foamed resin layer on a base material. (1) The foamed resin layer is formed by foaming a foaming agent-containing resin layer. (2) The foaming agent-containing resin layer is formed of (i) at least one polymer selected from a group composed of an ethylene-methyl methacrylate copolymer, an ethylene-ethyl acrylate copolymer, an ethylene-methyl acrylate copolymer, an ethylene-acrylic acid copolymer, an ethylene-methacrylic acid copolymer, an ionomer resin of an ethylene-acrylic acid copolymer, and an ionomer resin of an ethylene-methacrylic acid copolymer; and (ii) a resin composition containing a fiber material. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a foam decorative sheet.

  Conventionally, foamed decorative sheets (foamed wallpaper) are known in which a foamed resin layer of vinyl chloride resin is formed on a base material (for example, backing paper). In recent years, in consideration of the environment, halogen-free resins such as ethylene-vinyl acetate copolymer resin (EVA), acrylic resin, and olefin resin have been used for the foamed resin layer (Patent Document 1). ~ 3 etc.).

  For example, paint containing a microcapsule-type foaming agent added to an emulsion containing an acrylic resin and ethylene-vinyl acetate copolymer resin, coated on a substrate, dried, printed with a pattern on the surface, and then heated and foamed A foamed decorative sheet formed by forming an uneven pattern with an embossed plate is known. In addition, after forming an unfoamed resin layer made of a resin composition obtained by adding a thermally decomposable foaming agent to an ethylene-vinyl acetate copolymer resin on a substrate using a T-die extruder, a pattern layer is formed on the surface. A foamed decorative sheet is known which is printed and then heated and foamed to form an uneven pattern with an embossed plate.

Japanese Patent Laid-Open No. 6-47875 JP 2000-255011 A JP 2001-347611 A

  By the way, in the conventional olefin-type decorative sheet, since the surface strength is weak, the reinforcement is needed. As the method, for example, 1) a method of keeping the foaming ratio of the foamed resin layer low, and 2) a method of providing a film layer or a thick coating film on the foamed resin layer have been proposed.

  However, in the method 1), it is not possible to conceal the unevenness of the foundation when the decorative sheet is applied. In addition, the method 2) has a problem that the decorative sheet itself is hard, so that wrinkles and curls are likely to occur.

  Accordingly, the main object of the present invention is to provide a foamed decorative sheet which is improved in these drawbacks and excellent in surface strength.

  As a result of intensive studies, the present inventor has found that the above object can be achieved by employing a specific foamed resin layer, and has completed the present invention.

That is, the present invention relates to the following foamed decorative sheet.
1. A foamed decorative sheet having at least a foamed resin layer on a substrate,
(1) The foamed resin layer is formed by foaming a foaming agent-containing resin layer,
(2) The foaming agent-containing resin layer is
(I) ethylene-methyl methacrylate copolymer, ethylene-ethyl acrylate copolymer, ethylene-methyl acrylate copolymer, ethylene-acrylic acid copolymer, ethylene-methacrylic acid copolymer, ethylene-acrylic acid copolymer A layer formed by a resin composition containing at least one polymer selected from the group consisting of an ionomer resin of the above, and an ionomer resin of an ethylene-methacrylic acid copolymer, and (ii) a fibrous material,
A foamed decorative sheet characterized by that.
2. The fibrous material is polyamide fiber, polyvinyl alcohol fiber, cellulose semi-synthetic fiber, cellulose regenerated fiber, acrylic fiber, polyester fiber, polyurethane fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, aramid fiber, polyarylate fiber, At least one selected from the group consisting of polyimide fiber, polyparaphenylene benzobisoxazole fiber, polyphenylene sulfide fiber, polyethylene fiber, polypropylene fiber, fluorine fiber, carbon fiber, polycarbonate fiber, glass fiber, epoxy fiber, phenol fiber and melamine fiber Item 2. The foamed decorative sheet according to Item 1, wherein the foamed decorative sheet is a fiber.
3. The fibrous material is at least one fiber selected from the group consisting of polyamide fiber, polyvinyl alcohol fiber, polyurethane fiber, aramid fiber, acetate fiber, viscose rayon fiber, cupra fiber, epoxy fiber, phenol fiber and melamine fiber. Item 3. The foamed decorative sheet according to Item 1 or 2.
4). The foam according to any one of Items 1 to 3, wherein the fibrous material is contained in an amount of 0.1 to 30 parts by weight with respect to 100 parts by weight of the polymer represented by (i) in the resin composition. Makeup sheet.
5. The foamed decorative sheet according to any one of Items 1 to 4, wherein the foaming agent is contained in the resin composition in an amount of 0.1 to 10 parts by weight with respect to 100 parts by weight of the polymer represented by (i). .
6). Item 6. The foamed decorative sheet according to any one of Items 1 to 5, wherein the foaming agent-containing resin layer is crosslinked by electron beam irradiation.
7). The foamed decorative sheet according to any one of Items 1 to 6, wherein a non-foamed resin layer B, the foamed resin layer, and the non-foamed resin layer A are sequentially formed on a substrate.
8). Item 8. The foamed decorative sheet according to any one of Items 1 to 7, which is embossed from the top surface layer of the foamed decorative sheet.
9. The foam wallpaper which consists of a foaming decorative sheet in any one of said item | item 1-8.

Hereinafter, the foamed decorative sheet of the present invention will be described in detail.
1. Foaming decorative sheet The foaming decorative sheet of the present invention comprises:
A foamed decorative sheet having at least a foamed resin layer on a substrate,
(1) The foamed resin layer is formed by foaming a foaming agent-containing resin layer,
(2) The foaming agent-containing resin layer is
(I) ethylene-methyl methacrylate copolymer, ethylene-ethyl acrylate copolymer, ethylene-methyl acrylate copolymer, ethylene-acrylic acid copolymer, ethylene-methacrylic acid copolymer, ethylene-acrylic acid copolymer A layer formed by a resin composition containing at least one polymer selected from the group consisting of an ionomer resin of the above, and an ionomer resin of an ethylene-methacrylic acid copolymer, and (ii) a fibrous material,
It is characterized by that.

  The foamed decorative sheet of the present invention having the above-described characteristics can achieve excellent surface strength because the fibrous material is firmly bound to the polymer in the foamed resin layer.

The substrate used in the substrate present invention, as long as it is usually used as decorative sheet substrate is not particularly limited, various papers, plastic films, plastic sheets, metal foil, metal sheet, metal plate A wood-based board such as wood, a ceramic material, or the like can be appropriately selected depending on the application. Each of these materials may be used alone, but may be a laminate of any combination such as a composite of paper or a composite of paper and a plastic film.

  Various papers used as the base material are not particularly limited as long as they have mechanical strength, heat resistance, etc. suitable as a decorative sheet base material, and fibrous sheets can be generally used, such as thin paper, kraft paper, titanium paper, etc. Can be used. These paper base materials are used to reinforce the interlaminar strength between the fibers of the paper base material or between the other layers and the paper base material, and to prevent the occurrence of scuffing, in addition to these paper base materials, acrylic resin, styrene butadiene rubber, A resin such as a melamine resin or a urethane resin may be added (resin impregnation after paper making or embedded during paper making). For example, inter-paper reinforced paper, resin-impregnated paper and the like.

  Among fiber sheets, flame retardant paper (pulp-based sheets treated with flame retardants such as guanidine sulfamate and guanidine phosphate); inorganic paper containing inorganic additives such as aluminum hydroxide and magnesium hydroxide High-quality paper; thin paper.

  In addition to these, various papers often used in the field of building materials such as linter paper, paperboard, base paper for gypsum board, or a vinyl wallpaper raw material in which a vinyl chloride resin layer is provided on the surface of the paper can be mentioned. Furthermore, coated paper, art paper, sulfate paper, glassine paper, parchment paper, paraffin paper, Japanese paper, or the like used in the office field or normal printing and packaging can also be used. Moreover, although distinguished from these papers, woven fabrics and non-woven fabrics of various fibers having an appearance and properties similar to paper can be used as the base material. Examples of various fibers include inorganic fibers such as glass fibers, asbestos fibers, potassium titanate fibers, alumina fibers, silica fibers, and carbon fibers, and synthetic resin fibers such as polyester fibers, acrylic fibers, and vinylon fibers.

Non-foamed resin layer B
In the present invention, a non-foamed resin layer (non-foamed resin layer B) may be formed between the substrate and the foamed resin layer as necessary. In particular, when the non-foamed resin layer B is formed as an adhesive layer, excellent adhesion between the substrate and the foamed resin layer can be obtained.

  Examples of the non-foamed resin layer B include polyethylene resin (PE), ethylene-methacrylic acid copolymer (EMAA), ethylene-acrylic acid copolymer (EAA), ethylene-vinyl acetate copolymer (EVA), and epoxy. Resins, urethane resins and the like can be suitably used.

  The non-foamed resin layer B may contain known additives in addition to the resin component, but is preferably blended so that the content of the resin component is 70 to 100% by weight.

  The thickness of the non-foamed resin layer B is not limited, but is preferably about 5 to 50 μm, more preferably about 5 to 15 μm.

Foamed resin layer The foamed resin layer is a layer formed by foaming the foaming agent-containing resin layer.

  The foaming agent-containing resin layer is composed of an ethylene-methyl methacrylate copolymer (EMMA), an ethylene-ethyl acrylate copolymer (EEA), an ethylene-methyl acrylate copolymer (EMA), and an ethylene-acrylic acid copolymer (EAA). At least one polymer selected from the group consisting of ethylene-methacrylic acid copolymer (EMAA), ethylene-acrylic acid copolymer ionomer resin, and ethylene-methacrylic acid copolymer ionomer resin (of the present invention). It is a layer formed of a resin composition containing a polymer as a resin component. Among the above-described polymers, at least one selected from the group consisting of ethylene-methacrylic acid copolymer (EMAA) and ethylene-acrylic acid copolymer (EAA) is more preferable, and ethylene-methacrylic acid copolymer (EMAA). Is more preferable. As the ionomer resin, there is a resin having a structure in which the molecules of ethylene-acrylic acid copolymer (EAA) or ethylene-methacrylic acid copolymer (EMAA) are intermolecularly bonded with metal ions such as sodium and zinc. Can be used. When such a resin component is used, a strong layer caused by hydrogen bonds or the like in the resin can be formed, so that excellent scratch resistance and the like can be obtained. These may be known or commercially available.

  In addition to the polymer of the present invention, other resin components (for example, polyethylene resin (PE) and the like) can be included as the resin component. In this case, what is necessary is just to set suitably content of the said other resin component in the range with which the effect of this invention is show | played.

  When the polymer of the present invention is an ethylene-methacrylic acid copolymer, the content of methacrylic acid is preferably about 4 to 20% by weight.

  In addition, the melt flow rate value (JIS K7210: 190 ° C., 2.16 kg) of the resin component depends on the type of polymer used and the like, but is usually preferably 1 to 200 g / 10 minutes.

  The content of the polymer of the present invention in the resin composition is not limited, but it is usually preferably set appropriately within the range of 80 to 100% by weight.

  Although a foaming agent is not specifically limited, A thermal decomposition type foaming agent can be used conveniently. The pyrolytic foaming agent can be selected from known foaming agents. Examples include azo series such as azodicarbonamide (ADCA) and azobisformamide; hydrazide series such as oxybenzenesulfonyl hydrazide (OBSH) and paratoluenesulfonyl hydrazide. The content of the pyrolytic foaming agent can be appropriately set according to the type of foaming agent, the foaming ratio (the thickness of the foamed resin layer relative to the thickness of the foaming agent-containing resin layer), and the like. The expansion ratio is preferably 1.5 times or more, and more preferably about 3 to 8 times. From this viewpoint, the content of the pyrolytic foaming agent is preferably about 1 to 20 parts by weight, and more preferably 1 to 10 parts by weight with respect to 100 parts by weight of the resin component.

  If necessary, a foaming aid that accelerates the decomposition of the foaming agent can be used in combination in order to obtain a further foaming effect. The foaming aid varies depending on the type of foaming agent used. For example, when azodicarbonamide is used as the foaming agent, carboxylic acid hydrazides such as adipic acid dihydrazide and oxalic acid dihydrazide; zinc oxide; sulfuric acid Lead; urea; zinc stearate and the like are used. The content of the foaming aid is preferably about 0.3 to 10 parts by weight and more preferably about 1 to 5 parts by weight with respect to 100 parts by weight of the resin component.

  The resin composition for forming the foaming agent-containing resin layer of the present invention contains not only the polymer of the present invention as a resin component but also a fibrous material. After the foam-containing resin layer formed by the resin composition is foamed, the fibrous material is dispersed in the polymer and is firmly bonded to the polymer. As a result, a foamed decorative sheet having excellent scratch resistance and high surface strength can be obtained.

  Examples of the fibrous material include polyamide fibers such as nylon (registered trademark) and nylon 66 (registered trademark); polyvinyl alcohol fibers (PVA fibers) such as vinylon (registered trademark); cellulosic semisynthetic fibers such as acetate; Cellulose-based recycled fibers such as coarse rayon and cupra; Acrylic fibers; Polyester fibers such as polyethylene terephthalate fibers (PET fibers); Polyurethane fibers; Polyvinyl chloride fibers; Polyvinylidene chloride fibers; Aramid fibers; Polyarylate fibers; Paraphenylene benzobisoxazole fiber (PBO fiber); Polyphenylene sulfide fiber (PPS fiber); Polyethylene fiber; Polypropylene fiber; Fluorine fiber; Carbon fiber; Polycarbonate fiber; Glass fiber; Epoxy fiber; It can be used melamine fibers.

Among the fibrous materials, at least one selected from the group consisting of polyamide fiber, polyvinyl alcohol fiber, polyurethane fiber, aramid fiber, acetate fiber, viscose rayon fiber, cupra fiber, epoxy fiber, phenol fiber and melamine fiber is preferable. .
Any of the fibrous materials consisting of the above groups has an atomic group having active hydrogen in the polymer molecule constituting the fibrous material. The atomic group having active hydrogen refers to an atomic group having a highly reactive hydrogen atom (mainly a hydrogen atom bonded to O, N, etc. having a high electronegativity). For example, a hydroxyl group (—OH ), Amino group (—NH ₂ ), carboxyl group (—COOH), amide bond (—NHCO—), urethane bond (—NHCOO—), imino bond (—NH—) and the like. Since the fibrous material consisting of the above group has an atomic group having active hydrogen, it is understood that the active hydrogen in the fibrous material interacts with the polymer of the present invention which is a resin component. Therefore, when such a fibrous material is used, a strong layer resulting from the above interaction can be formed, so that excellent surface strength and the like can be obtained. Among the fibrous materials, at least one selected from the group consisting of polyamide fibers, polyvinyl alcohol fibers, aramid fibers, and cupra fibers is more preferable.

  0.1-30 weight part is preferable with respect to 100 weight part of resin components, and, as for content of a fibrous material, 1-10 weight part is more preferable.

  The form of the fibrous material is not particularly limited, and usually includes any form such as a short fiber or a long fiber. As a preferable form, a monofilament (single fiber) on a straight line is cut short. Moreover, since the form put together easily in the pellet form with a poval resin, a urethane resin, etc. disperse | distributes uniformly with respect to resin, it is preferable.

  As for the size of the fibrous material, those having a diameter of usually 50 μm or less can be used, preferably 1 μm to 30 μm, more preferably 1 μm to 15 μm. Moreover, the length of 0.1 mm-10 mm can be used normally, 1 mm-5 mm are preferable, and 1 mm-3 mm are more preferable.

  In addition, a fibrous material can be used individually by 1 type or in mixture of 2 or more types.

  Various additives may be added to the resin composition. For example, inorganic fillers, pigments, cell regulators and the like. In addition, stabilizers, lubricants, and the like can be used as additives.

  The foamed state of the foamed resin layer (for example, the size of foamed cells, the density of foamed cells, etc.) is not limited, and can be appropriately designed according to the type and use of the foamed decorative sheet.

  As the cell adjusting agent, for example, a metal soap such as zinc stearate can be used. The content of the cell modifier is preferably about 0.3 to 10 parts by weight and more preferably about 1 to 5 parts by weight with respect to 100 parts by weight of the resin component.

  Examples of the inorganic filler include calcium carbonate, aluminum hydroxide, magnesium hydroxide, antimony trioxide, zinc borate, and a molybdenum compound. By including an inorganic filler, an effect of suppressing see-through, an effect of improving surface characteristics, and the like are obtained. About 0-100 weight part is preferable with respect to 100 weight part of resin components, and, as for content of an inorganic filler, about 20-70 weight part is more preferable.

  As for the pigment, for example, titanium dioxide, zinc white, carbon black, black iron oxide, yellow iron oxide, yellow lead, molybdate orange, cadmium yellow, nickel titanium yellow, chrome titanium yellow, iron oxide (valve), cadmium red, Inorganic pigments such as ultramarine, bitumen, cobalt blue, chromium oxide, cobalt green, aluminum powder, bronze powder, titanium mica, zinc sulfide; for example, aniline black, perylene black, azo (azo lake, insoluble azo, condensed azo), many Cyclic (isoindolinone, isoindoline, quinophthalone, perinone, flavantron, anthrapyrimidine, anthraquinone, quinacridone, perylene, diketopyrrolopyrrole, dibromoanthanthrone, dioxazine, thioindigo, phthalocyanine, indanthro , And organic pigments halogenated phthalocyanine), or the like. The content of the pigment is preferably about 10 to 50 parts by weight and more preferably about 15 to 30 parts by weight with respect to 100 parts by weight of the resin component.

  What is necessary is just to implement according to the method described in the manufacturing method of the postscript as a method of foaming a foaming agent containing resin layer.

Non-foamed resin layer A
A non-foamed resin layer A may be further formed on the front surface of the foamed resin layer.

The non-foamed resin layer (non-foamed resin layer A) mainly protects the foamed resin layer. In the present invention, at least one of polypropylene resin (PP), polyethylene resin (PE), hard vinyl chloride resin, polycarbonate resin, acrylic acid (CH ₂ ═CHCOOH) and methacrylic acid (CH ₂ ═C (CH ₃ ) COOH). A layer formed of a resin composition containing, as a resin component, a polymer obtained using as a monomer can be used as a non-foamed resin layer.

  As the resin component, for example, a copolymer obtained by a combination of at least one monomer of acrylic acid and methacrylic acid and ethylene can be suitably used as the resin component. More specifically, it is desirable to use at least one of an ethylene-methacrylic acid copolymer, an ethylene-acrylic acid copolymer, and an ionomer resin. As the ionomer resin, the above-mentioned resins can be used similarly.

  The content of acrylic acid or methacrylic acid in the copolymer is preferably about 4 to 15% by weight. Such a resin can also use a commercial item. A known additive can also be blended in the resin composition.

  The thickness of the non-foamed resin layer is not limited, but is preferably about 5 to 50 μm, more preferably about 5 to 15 μm.

  Moreover, although content of the said resin component in a resin composition is not limited, Usually, it is preferable to set suitably in the range of 70 to 100 weight%.

Pattern Pattern Layer In the present invention, a pattern pattern layer may be provided on the front surface of the non-foamed resin layer A as necessary.

  The design pattern layer imparts design properties to the foamed decorative sheet. Examples of the design pattern include a wood grain pattern, a stone pattern, a grain pattern, a tiled pattern, a brickwork pattern, a cloth pattern, a leather pattern, a geometric figure, a character, a symbol, and an abstract pattern. A design pattern can be selected according to the kind of foaming decorative sheet.

  The pattern pattern layer can be formed, for example, by printing a pattern pattern on the front surface of the non-foamed resin layer A. In addition, when forming a picture pattern layer, you may form a primer layer previously as needed. Examples of printing methods include gravure printing, flexographic printing, silk screen printing, and offset printing. As the printing ink, a printing ink containing a colorant, a binder resin, and a solvent (or a dispersion medium) can be used. These inks may be known or commercially available.

  As the colorant, for example, a pigment used in the above-described foaming agent-containing resin layer can be appropriately used.

  The binder resin is, for example, an acrylic resin, a styrene resin, a polyester resin, a urethane resin, a chlorinated polyolefin resin, a vinyl chloride-vinyl acetate copolymer resin, a polyvinyl butyral resin, an alkyd resin, or a petroleum resin. Examples include resins, ketone resins, epoxy resins, melamine resins, fluorine resins, silicone resins, fiber derivatives, rubber resins, and the like.

  Examples of the solvent (or dispersion medium) include petroleum organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and acetic acid-2 -Ester-based organic solvents such as ethoxyethyl; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, propylene glycol; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone Organic solvents; ether organic solvents such as diethyl ether, dioxane, tetrahydrofuran; dichloromethane, carbon tetrachloride, trichloroethylene, tetrachloroethylene Chlorinated organic solvents; and water.

  The thickness of the design pattern layer is different from the type of design pattern, but is generally preferably about 0.1 to 10 μm.

Surface protective layer (overcoat layer)
In the present invention, a surface protective layer may be provided on the surface of the design pattern layer for the purpose of adjusting the gloss and / or protecting the design pattern layer. The kind of surface protective layer is not limited. If it is a surface protective layer aiming at gloss adjustment, there exists a surface protective layer containing known fillers, such as a silica, for example. As a method for forming the surface protective layer, a known method such as gravure printing can be employed. In addition, when the adhesiveness of a pattern pattern layer and a surface protective layer is not fully acquired, a surface protective layer can also be provided after carrying out the adhesion process (primer process) of the surface of a pattern pattern layer.

  When forming a surface protective layer for the purpose of surface strength (scratch resistance, etc.), stain resistance, and protection of a pattern layer of a foamed decorative sheet, those containing an ionizing radiation curable resin as a resin component are suitable. It is. The ionizing radiation curable resin is preferably one that undergoes radical polymerization (curing) by electron beam irradiation.

  The thickness of the surface protective layer is not limited, but is preferably about 0.1 to 15 μm.

Embossing In this invention, you may attach | subject an embossing pattern suitably. In this case, what is necessary is just to emboss from the uppermost surface layer (opposite side of a base material) of a foaming decorative sheet. Embossing can be performed by known means such as pressing an embossed plate. For example, when the outermost surface layer is a surface protective layer, a desired embossed pattern can be formed by pressing the embossed plate after heat-softening the front surface. Examples of the embossed pattern include a wood grain plate conduit groove, a stone plate surface unevenness, a cloth surface texture, a satin texture, a grain texture, a hairline, and a multiline groove.

2. The manufacturing method of a foaming decorative sheet The manufacturing method of a foaming decorative sheet is not specifically limited.

For example, known materials kneading machines such as a Banbury mixer, a pressure kneader, a roll, a single screw extruder, a twin screw extruder, etc. After melt-kneading and forming into a sheet using a known sheet molding machine such as a calendar or T-die, a foaming agent-containing sheet is laminated on the substrate. Under the present circumstances, you may laminate | stack a non-foaming resin layer on the upper and lower sides or one side of a foaming agent containing sheet as needed. Next, a pattern layer pattern layer and a surface protective layer are formed on the foaming agent-containing resin layer or the non-foaming resin layer, and then the foaming resin layer is formed by heating and foaming the foaming agent-containing resin layer. The heating conditions are not limited as long as the foamed resin layer is formed by the decomposition of the pyrolytic foaming agent. (The heating temperature is about 200 to 220 ° C., and the heating time is about 30 to 45 seconds.)
Note that electron beam irradiation may be performed before the heat treatment. Thereby, since a resin component can be bridge | crosslinked, the surface strength of a foaming decorative sheet, a foaming degree, etc. can be controlled. The energy of the electron beam is preferably about 150 to 250 kV. The irradiation amount is preferably about 1 to 7 Mrad. A known electron beam irradiation apparatus can be used as the electron beam source.

  In addition, when a surface protective layer containing an ionizing radiation curable resin is formed, the surface protective layer is formed simultaneously with the crosslinking of the resin component of the foaming agent-containing resin layer or the non-foamed resin layer by electron beam irradiation (same treatment). Can be cured. That is, a foaming agent-containing resin layer, a non-foaming resin layer, a pattern layer, and a surface protective layer containing an ionizing radiation curable resin are formed in this order, and then irradiated with an electron beam. The resin component contained in the resin can be cross-linked and the resin contained in the surface protective layer can be cured.

  Here, the ionizing radiation curable resin is not limited to the surface protective layer resin composition, but can be added to any or all of the foamed resin layer resin composition and the non-foamed resin layer resin composition. By adding an ionizing radiation curable resin to the foamed resin layer resin composition and the non-foamed resin layer resin composition, crosslinking of the resin component can be promoted.

  In the foamed decorative sheet of the present invention, the foamed resin layer has an ethylene-methyl methacrylate copolymer, an ethylene-ethyl acrylate copolymer, an ethylene-methyl acrylate copolymer, an ethylene-acrylic acid copolymer, an ethylene-methacrylic acid copolymer. It is formed by a resin composition comprising a polymer, an ionomer resin of an ethylene-acrylic acid copolymer, and at least one polymer selected from the group consisting of an ionomer resin of an ethylene-methacrylic acid copolymer, and a fibrous material. By foaming the foaming agent-containing resin layer, the fibrous material is firmly bonded to the polymer, and an excellent surface strength can be achieved.

  Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples. However, the present invention is not limited to the examples.

Example 1
The foaming agent-containing resin composition was kneaded at 110 ° C. for 10 minutes with the following composition, then formed into a film having a thickness of 100 μm, and bonded to the backing paper. Then, electron beam irradiation was performed and the resin component in a foaming agent containing resin composition was bridge | crosslinked. Finally, OP “AL-TOP402B, manufactured by Dainichi Seika” is coated on the foaming agent-containing resin layer with a flat plate printing machine (GP-II), and heated in a gear oven (220 ° C. × 45 seconds). The foaming agent contained in the containing resin layer was foamed about 5 times to produce a desired foamed decorative sheet.

Foaming agent-containing resin composition:
Resin EMAA “Nucleel N1525H (methacrylic acid content = 15 wt%, melt flow rate value (MFR) = 25 g / 10 min), manufactured by Mitsui DuPont Polychemical Co., Ltd.”, 100 parts by weight,
25 parts by weight of titanium dioxide “R-108, manufactured by DuPont Co., Ltd.”
Foaming agent Azodicarbonamide “Vinole AC # 3, manufactured by Eiwa Chemical Industry Co., Ltd.” 5 parts by weight,
Foaming aid Adipic acid dihydrazide “ADHS, manufactured by Otsuka Chemical Co., Ltd.” 5 parts by weight,
Fibrous material Polyarylate fiber “Vectran (CFKK5, single fiber, diameter approximately 15 μm, length cut to 3 mm), manufactured by Kuraray Co., Ltd.” 5 parts by weight.

Example 2
As a fibrous material, instead of polyarylate fiber, aramid fiber “Kevlar (single fiber, length cut to 3 mm), manufactured by Toray DuPont Co., Ltd.” was used as in Example 1. A foamed decorative sheet was produced.

Example 3
Implemented except using PVA fiber "Vinylon (VPB103, single fiber, diameter 1-15 μm, length cut to 3 mm), Kuraray Co., Ltd." instead of polyarylate fiber as the fibrous material A foamed decorative sheet was produced in the same manner as in Example 1.

Example 4
As a fibrous material, instead of polyarylate fiber, a cupra fiber “Bemberg (single fiber, length cut to 3 mm), manufactured by Asahi Kasei Fibers Co., Ltd.” was used in the same manner as in Example 1. A foamed decorative sheet was prepared.

Example 5
Example 1 except that PPS fiber “Procon (250 dtex 60f, single fiber, length cut to 5 mm), manufactured by Toyobo Co., Ltd.” was used instead of polyarylate fiber as the fibrous material. Thus, a foamed decorative sheet was produced.

Example 6
Instead of using 5 parts by weight of polyarylate fiber as the fibrous material, 15 parts by weight of glass fiber “CS 3PE-907 (single fiber, length cut to 3 mm), manufactured by Nittobo Co., Ltd.” is used. Produced a foamed decorative sheet in the same manner as in Example 1.

Comparative Example 1
A foamed decorative sheet was produced in the same manner as in Example 1 except that no fibrous material was used.

Comparative Example 2
A foamed decorative sheet was produced in the same manner as in Example 1 except that EVA “EVA406, manufactured by Mitsui DuPont Polychemical Co., Ltd.” was used instead of EMAA “Nucleel N1525H” as the resin component.

Comparative Example 3
A foamed decorative sheet was prepared in the same manner as in Example 2 except that EVA “EVA406, manufactured by Mitsui DuPont Polychemical Co., Ltd.” was used instead of EMAA “Nucleel N1525H” as the resin component.

Test example (scratch resistance test)
The scratch resistance test was performed in accordance with the “Surface Strengthened Wallpaper Performance Rules” established by the Japan Vinyl Industry Association Construction Department. In other words, the test piece was attached to the Gakushin Abrasion Tester (JIS L0849 Abrasion Tester Type II). The specimen was reciprocated five times, the surface condition of the specimen after the test was observed, and judgment was made based on how the surface was damaged. According to the above regulations, it is evaluated in 5 grades from 1st grade to 5th grade,
5th grade: No change 4th grade: There is a slight change on the surface 3rd grade: The surface appears torn 2nd grade: The surface is broken and the backing material such as paper is visible (length is less than 1 cm)
First grade: The surface is torn and the backing material such as paper can be seen (length 1cm or more)
It is said that. In this evaluation, it is indicated by ◎, ○, △, ×,
◎: Grade 5 ○: Grade 4 Δ: Grade 3 ×: Grades 2 to 1 were used.

  The sheets obtained in Examples and Comparative Examples were examined for scratch resistance. The results are shown in Table 1.

  As is clear from the above results, the foamed decorative sheet of the present invention has excellent scratch resistance and surface strength even after foam molding by adopting a combination of a specific resin component and a fibrous material in the foamed resin layer. Is played.

Claims (9)

A foamed decorative sheet having at least a foamed resin layer on a substrate,
(1) The foamed resin layer is formed by foaming a foaming agent-containing resin layer,
(2) The foaming agent-containing resin layer is
(I) ethylene-methyl methacrylate copolymer, ethylene-ethyl acrylate copolymer, ethylene-methyl acrylate copolymer, ethylene-acrylic acid copolymer, ethylene-methacrylic acid copolymer, ethylene-acrylic acid copolymer A layer formed by a resin composition containing at least one polymer selected from the group consisting of an ionomer resin of the above, and an ionomer resin of an ethylene-methacrylic acid copolymer, and (ii) a fibrous material,
A foamed decorative sheet characterized by that. The fibrous material is polyamide fiber, polyvinyl alcohol fiber, cellulose semi-synthetic fiber, cellulose regenerated fiber, acrylic fiber, polyester fiber, polyurethane fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, aramid fiber, polyarylate fiber, At least one selected from the group consisting of polyimide fiber, polyparaphenylene benzobisoxazole fiber, polyphenylene sulfide fiber, polyethylene fiber, polypropylene fiber, fluorine fiber, carbon fiber, polycarbonate fiber, glass fiber, epoxy fiber, phenol fiber and melamine fiber The foaming decorative sheet according to claim 1, wherein the foamed decorative sheet is a fiber. The fibrous material is at least one fiber selected from the group consisting of polyamide fiber, polyvinyl alcohol fiber, polyurethane fiber, aramid fiber, acetate fiber, viscose rayon fiber, cupra fiber, epoxy fiber, phenol fiber and melamine fiber. The foaming decorative sheet according to claim 1 or 2, wherein The foam in any one of Claims 1-3 in which the said fibrous material contains 0.1-30 weight part with respect to 100 weight part of polymers represented by said (i) in the said resin composition. Makeup sheet. The foaming decorative sheet according to any one of claims 1 to 4, wherein the foaming agent is contained in the resin composition in an amount of 0.1 to 10 parts by weight with respect to 100 parts by weight of the polymer represented by (i). . The foamed decorative sheet according to any one of claims 1 to 5, wherein the foaming agent-containing resin layer is crosslinked by electron beam irradiation. The foamed decorative sheet according to any one of claims 1 to 6, wherein a non-foamed resin layer B, the foamed resin layer, and the non-foamed resin layer A are sequentially formed on a substrate. The foaming decorative sheet according to any one of claims 1 to 7, wherein embossing is applied from above the outermost surface layer of the foaming decorative sheet. A foam wallpaper comprising the foam decorative sheet according to claim 1.