JP2013212606A - Laminated sheet, foam laminated sheet and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a foam laminated sheet that has holes for securing moisture permeability, and has an excellent design and moisture permeability, and a method of manufacturing the same, and to provide a laminated sheet that is useful in manufacturing the foam laminated sheet, and a method of manufacturing the same.SOLUTION: A method of manufacturing a laminated sheet, in which a foaming agent containing resin layer and a picture pattern layer are sequentially provided on a fiber sheet, and holes stretching from a surface layer to the fiber sheet is formed, includes: (1) a step 1 of preparing a laminated body in which the foaming agent containing resin layer and the picture pattern layer are sequentially formed on the fiber sheet; (2) a step 2 of acquiring image data A by shooting the surface of the laminated body; (3) a step 3 of converting the image data A to a gray scale image; (4) a step 4 of acquiring image data B obtained by extracting a low tone area based on the gray scale image; and (5) a step 5 of forming a hole stretching from the surface of the laminated body to the fiber sheet by applying a laser in the area corresponding to the low tone area of the laminated body based on the image data B.

Description

  The present invention relates to a laminated sheet, a foam laminated sheet, and a method for producing the same. The foamed laminated sheet has a foamed resin layer and is useful as foamed wallpaper, various decorative materials, and the like. Moreover, the said laminated sheet is a state before foaming of the said foaming laminated sheet, and means what is called an unfoamed original fabric.

  Conventionally, as a decorative sheet used for a wall surface, a foam laminated sheet in which a pattern layer and a foamed resin layer are provided on a fibrous base material is generally used (Patent Document 1). Usually, when applying a foaming laminated sheet to a wall surface, since water paste is used, the foaming laminated sheet is required to have excellent moisture permeability. As a method for improving the moisture permeability, there is a method of forming holes in the foamed laminated sheet by a laser or a mechanical method.

  However, if holes are randomly formed in the foamed laminated sheet, there is a problem that the design properties are lowered.

JP 2006-272893 A

  Then, this invention is a foaming laminated sheet which has a hole for ensuring moisture permeability, Comprising: It aims at providing the foaming laminated sheet which has favorable design property and moisture permeability, and its manufacturing method. Moreover, it aims at providing the lamination sheet (unfoamed raw fabric) useful for manufacture of the said foaming lamination sheet, and its manufacturing method.

  As a result of intensive studies, the present inventors have found that the above object can be achieved by forming a hole in a specific region of a laminated sheet or a foamed laminated sheet, and have completed the present invention.

That is, this invention relates to the following laminated sheet and foaming laminated sheet, and its manufacturing method.
1. It has a foaming agent-containing resin layer and a pattern layer on the fibrous sheet in order, and is a method for producing a laminated sheet in which holes from the surface layer to the fibrous sheet are formed,
(1) Step 1 of preparing a laminate in which a foaming agent-containing resin layer and a pattern layer are sequentially formed on a fibrous sheet,
(2) Step 2 of acquiring image data A by photographing the surface of the laminate.
(3) Step 3 of converting the image data A into a grayscale image,
(4) Step 4 of acquiring image data B from which a low gradation region is extracted based on the gray scale image;
(5) A step of forming a hole from the surface of the laminate to the fibrous sheet by irradiating a laser in a region corresponding to the low gradation region of the laminate based on the image data B 5,
A method for producing a laminated sheet, comprising:
2. Item 2. The method for producing a laminated sheet according to Item 1, wherein in the step 3, the image is converted into a grayscale image having 256 gradations by an NTSC weighted average method.
3. Item 3. The method for producing a laminated sheet according to Item 1 or 2, wherein the gray scale value of the low gradation region is 180 or less.
4). The manufacturing method of a foaming lamination sheet characterized by making the said foaming agent containing resin layer of the lamination sheet obtained by the manufacturing method in any one of said items 1-3 foam.
5. Furthermore, the manufacturing method of the foaming lamination sheet of the said claim | item 4 including the process of embossing from a surface layer.
6). It has a foamed resin layer and a pattern layer in order on a fibrous sheet, and is a method for producing a foamed laminated sheet in which holes from the surface layer to the fibrous sheet are formed,
(1) Step 1 of preparing a foamed laminate in which a foamed resin layer and a pattern layer are sequentially formed on a fibrous sheet,
(2) Step 2 of obtaining image data A by photographing the surface of the foam laminate.
(3) Step 3 of converting the image data A into a grayscale image,
(4) Step 4 of acquiring image data B from which a low gradation region is extracted based on the gray scale image;
(5) Based on the image data B, by irradiating a laser in a region corresponding to the low gradation region of the foam laminate, a hole extending from the surface of the foam laminate to the fibrous sheet is formed. Step 5,
The manufacturing method of a foaming lamination sheet characterized by including this.
7). Item 7. The method for producing a foamed laminated sheet according to Item 6, wherein in the step 3, the image is converted into a grayscale image having 256 gradations by an NTSC weighted average method.
8). The manufacturing method of the foaming lamination sheet of said claim | item 6 or 7 whose gray scale value of the said low gradation area | region is 180 or less.
9. Item 9. The method for producing a foamed laminated sheet according to any one of Items 6 to 8, wherein embossing is performed from the surface layer after any of Steps 1 to 5.
10. A laminated sheet in which a foaming agent-containing resin layer and a pattern layer are sequentially formed on the fibrous sheet, and a hole from the surface layer to the fibrous sheet is formed,
The hole is
(1) After acquiring the image data a by photographing the surface of the laminated sheet,
(2) converting the image data a into a grayscale image;
(3) Acquire image data b obtained by extracting a low gradation area based on the gray scale image;
(4) Based on the image data b, formed in a region corresponding to the low gradation region of the laminated sheet,
A laminated sheet characterized by that.
11. Item 11. The laminated sheet according to Item 10, wherein the gray scale value of the low gradation region is 180 or less.
12 A foamed laminated sheet having a foamed resin layer and a pattern layer on the fibrous sheet in order, and a hole from the surface layer to the fibrous sheet is formed,
The hole is
(1) After acquiring the image data a by photographing the surface of the foamed laminated sheet,
(2) converting the image data a into a grayscale image;
(3) Acquire image data b obtained by extracting a low gradation area based on the gray scale image;
(4) Based on the image data b, formed in a region corresponding to the low gradation region of the foamed laminated sheet,
A foamed laminated sheet characterized by that.
13. Item 13. The foamed laminated sheet according to Item 12, wherein the gray scale value of the low gradation region is 180 or less.
14 Item 14. The foamed laminated sheet according to Item 12 or 13, wherein the surface layer is embossed.

   Hereinafter, the laminated sheet and the foamed laminated sheet of the present invention and the production method thereof will be described in detail.

≪Method for producing laminated sheet and foam laminated sheet≫
The method for producing a laminated sheet of the present invention is a method for producing a laminated sheet in which a foaming agent-containing resin layer and a pattern layer are sequentially formed on a fibrous sheet, and holes from the surface layer to the fibrous sheet are formed. There,
(1) Step 1 of preparing a laminate in which a foaming agent-containing resin layer and a pattern layer are sequentially formed on a fibrous sheet,
(2) Step 2 of acquiring image data A by photographing the surface of the laminate.
(3) Step 3 of converting the image data A into a grayscale image,
(4) Step 4 of acquiring image data B from which a low gradation region is extracted based on the gray scale image;
(5) A step of forming a hole from the surface of the laminate to the fibrous sheet by irradiating a laser in a region corresponding to the low gradation region of the laminate based on the image data B 5,
It is characterized by including.

  The method for producing a foamed laminated sheet of the present invention is the same as the method for producing a laminated sheet of the present invention, except that a foamed laminated body is prepared in place of the laminated body in Step 1.

  According to the manufacturing method of the laminated sheet and the foamed laminated sheet of the present invention having the above characteristics, the surface of the laminated body or the foamed laminated body (the uppermost layer of the laminated body or the foamed laminated body) is placed in a specific region. It is possible to form a hole reaching the fibrous sheet, thereby obtaining a sheet having good design properties and moisture permeability.

  Hereinafter, each process of the manufacturing method of a lamination sheet and a foaming lamination sheet is demonstrated.

Process 1
In step 1, a laminate or a foam laminate in which a foaming agent-containing resin layer or a foam resin layer and a pattern layer are sequentially formed on a fibrous sheet is prepared.

[Fibre sheet]
As a fibrous sheet (so-called backing paper), wallpaper general paper (pulp-based sheet sized with a known sizing agent); flame-retardant paper (pulp-based sheet such as guanidine sulfamate or guanidine phosphate) Treated with flame retardant); inorganic paper containing inorganic additives such as aluminum hydroxide and magnesium hydroxide; fine paper; thin paper; synthetic fiber mixed paper.

Although the basis weight of the fibrous sheet is not critical, preferably about 50 to 300 g / m ^2, more preferably about 50~120 g / m ^2.

[Foaming agent-containing resin layer and foamed resin layer]
The foaming agent-containing resin layer is obtained by forming a foaming agent-containing resin composition containing at least a resin component and a foaming agent by a known method. The foamed resin layer is obtained by foaming the obtained foaming agent-containing resin layer by heat treatment.

  In the present invention, the foaming agent-containing resin layer comprises at least one of 1) polyethylene as a resin component and 2) an ethylene copolymer having monomers other than ethylene and ethylene (hereinafter abbreviated as “ethylene copolymer”). It is preferable to contain 1 type.

  As the polyethylene (PE), low density polyethylene (LDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), linear low density polyethylene (LLDPE), etc. can be widely used. Among these, low density polyethylene is preferable. .

  Ethylene copolymers are suitable for extrusion film formation in terms of melting point and MFR. Examples of the ethylene copolymer include an ethylene-vinyl acetate copolymer (EVA), an ethylene-methyl methacrylate copolymer (EMMA), an ethylene-ethyl acrylate copolymer (EEA), and an ethylene-methyl acrylate copolymer ( EMA), ethylene-methacrylic acid copolymer (EMAA), ethylene-α olefin copolymer, and the like. These ethylene copolymers can be used alone or in admixture of two or more. Among these ethylene copolymers, at least one of ethylene-vinyl acetate copolymer, ethylene-methyl methacrylate copolymer and ethylene-methacrylic acid copolymer is preferable, and when these are used in combination with other resins The content of at least one of ethylene-vinyl acetate copolymer, ethylene-methyl methacrylate copolymer, and ethylene-methacrylic acid copolymer is preferably 70% by mass or more, and more preferably 80% by mass or more.

  In the ethylene copolymer, the content of monomers other than ethylene is preferably 5 to 25% by mass, more preferably 9 to 20% by mass. By adopting such a copolymerization ratio, the extrusion film forming property is further enhanced. As a specific example, the ethylene-vinyl acetate copolymer has a vinyl acetate copolymerization ratio (VA amount) of preferably 9 to 25% by mass, and more preferably 9 to 20% by mass. The ethylene-methyl methacrylate copolymer has a methyl methacrylate copolymerization ratio (MMA amount) of preferably 5 to 25% by mass, more preferably 5 to 15% by mass. Further, the ethylene-methacrylic acid copolymer is preferably 2 to 15% by mass, more preferably 5 to 11% by mass as the copolymerization ratio (MAA amount) of acrylic acid.

  In the present invention, the resin component contained in the foaming agent-containing resin layer has an MFR (melt flow rate) of 10 to 25 g / 10 min measured under the conditions of 190 ° C. and a load of 21.18 N described in JIS K 6922. preferable. When the MFR is within the above range, there is little increase in temperature when the foaming agent-containing resin layer is formed by extrusion film formation, and the film can be formed in a non-foamed state. It can be printed on any surface and there are few patterns missing. If the MFR is too large, the resin is too soft and the resulting foamed resin layer may have insufficient scratch resistance.

  As the resin composition for forming the foaming agent-containing resin layer, for example, a resin composition containing the above resin component, inorganic filler, pigment, pyrolytic foaming agent, foaming aid, crosslinking aid and the like can be suitably used. . In addition, stabilizers, lubricants and the like can be used as additives.

  Examples of the thermally decomposable foaming agent 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 expansion ratio, and the like. From the viewpoint of the expansion ratio, it is 7 times or more, preferably about 7 to 10 times, and the pyrolytic foaming agent is preferably about 1 to 20 parts by mass with respect to 100 parts by mass of the resin component.

  The foaming aid is preferably a metal oxide and / or a fatty acid metal salt. For example, zinc stearate, calcium stearate, magnesium stearate, zinc octylate, calcium octylate, magnesium octylate, zinc laurate, calcium laurate, laurin Magnesium acid, zinc oxide, magnesium oxide and the like can be used. About 0.3-10 mass parts is preferable with respect to 100 mass parts of resin components, and, as for content of these foaming adjuvants, about 1-5 mass parts is more preferable.

  When these foaming aids are used in combination with EMAA and ADCA foaming agents, the effect of the original foaming aid is impaired by the reaction of the acrylic acid part of EMAA with the foaming aid in the foaming process. There is a problem. Therefore, when EMAA and ADCA foaming agent are used in combination, it is preferable to use a carboxylic acid hydrazide compound as a foaming aid as described in JP-A-2009-197219. At this time, the carboxylic acid hydrazide compound is preferably used in an amount of about 0.2 to 1 part by mass with respect to 1 part by mass of the ADCA foaming agent.

  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. The content of the inorganic filler is preferably about 0 to 100 parts by mass and more preferably about 20 to 70 parts by mass with respect to 100 parts by mass of the resin component.

  For pigments, for example, titanium oxide, 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, ultramarine, bitumen, cobalt blue, chromium oxide, cobalt green, aluminum powder, bronze powder, titanium mica, and zinc sulfide. Examples of organic pigments include aniline black, perylene black, azo (azo lake, insoluble azo, condensed azo), polycyclic (isoindolinone, isoindoline, quinophthalone, perinone, flavantron, anthrapyrimidine, anthraquinone, quinacridone. Perylene, diketopyrrolopyrrole, dibromoanthanthrone, dioxazine, thioindigo, phthalocyanine, indanthrone, halogenated phthalocyanine). The content of the pigment is preferably about 10 to 50 parts by mass, more preferably about 15 to 30 parts by mass with respect to 100 parts by mass of the resin component.

  The thickness of the foaming agent-containing resin layer is preferably about 40 to 100 μm, and the thickness of the foamed resin layer after foaming is preferably about 300 to 700 μm.

[Non-foamed resin layers A and B]
The foaming agent-containing resin layer or the foamed resin layer may have a non-foamed resin layer on one side or both sides thereof.

  For example, a non-foamed resin layer B (adhesive resin layer) is provided on the back surface of the foaming agent-containing resin layer or the foamed resin layer (surface on which the fibrous sheet is laminated) for the purpose of improving the adhesive strength with the fibrous sheet. May be.

  The resin component of the adhesive resin layer is not particularly limited, but an ethylene-vinyl acetate copolymer (EVA) is preferable. As the EVA, a known or commercially available EVA can be used. In particular, the vinyl acetate component (VA component) is preferably 10 to 46% by mass, more preferably 15 to 41% by mass.

  The thickness of the adhesive resin layer is not limited, but is preferably about 5 to 50 μm.

  On the upper surface of the foaming agent-containing resin layer, a non-foamed resin layer A may be provided for the purpose of clarifying the design pattern when forming the design pattern layer or improving the scratch resistance of the foamed resin layer.

  Examples of the resin component of the non-foamed resin layer A include polyolefin resins, methacrylic resins, thermoplastic polyester resins, polyvinyl alcohol resins, and fluorine resins. Of these, polyolefin resins are preferred.

  Examples of polyolefin resins include polyethylene, polypropylene, polybutene, polybutadiene, polyisoprene, and other resins, copolymers of α-olefins having 4 or more carbon atoms (linear low density polyethylene), and ethylene-acrylic acid copolymers. , Ethylene-methyl acrylate copolymer, ethylene-ethyl acrylate copolymer, ethylene (meth) acrylic acid copolymer such as ethylene-methacrylic acid copolymer (EMAA), ethylene-vinyl acetate copolymer ( EVA), ethylene-vinyl acetate copolymer saponified product, ionomer and the like. In addition, "(meth) acrylic acid" means acrylic acid or methacrylic acid, and the same applies to other parts described as (meth).

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

[Pattern pattern layer]
A pattern layer may be formed on the foaming agent-containing resin layer, the foamed resin layer, or the non-foamed resin layer A as necessary.

  The design pattern layer imparts design properties to the laminated sheet or the foamed laminated 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. The pattern can be selected according to the purpose. The pattern pattern layer can be formed, for example, by printing a pattern pattern. Examples of printing methods include gravure printing, flexographic printing, silk screen printing, offset printing, and the like. As the printing ink, a printing ink containing a colorant, a binder resin, and a solvent 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.

  Binder resin can be set according to the kind of lower layer resin which forms a pattern layer. For example, acrylic resin, styrene resin, polyester resin, urethane resin, chlorinated polyolefin resin, vinyl chloride-vinyl acetate copolymer resin, polyvinyl butyral resin, alkyd resin, petroleum resin, ketone resin, epoxy Resin, melamine resin, fluorine resin, silicone resin, fiber derivative, rubber resin 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, acetic acid-2-methoxyethyl, 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, etc. Chlorinated organic solvents; and water. These solvents (or dispersion media) can be used alone or in the form of a mixture.

  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]
In the present invention, a surface protective layer may be provided on the surface of the foaming agent-containing resin layer, the foamed resin layer, or 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 (formation of a primer layer etc.) of the pattern pattern layer surface.

  When forming a surface protective layer for the purpose of surface strength (scratch resistance, etc.), contamination resistance, pattern layer protection, etc. of foamed laminated sheets, those containing ionizing radiation curable resins as resin components 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.

[Manufacturing method of laminate and foam laminate]
As a manufacturing method of a laminated body, it can manufacture by forming a foaming agent containing resin layer and a picture pattern layer in order on a fibrous sheet, for example.

  When the foaming agent-containing resin layer has a non-foamed resin layer on one side or both sides, simultaneous extrusion film formation by a T-die extruder is suitable. For example, in the case of having non-foamed resin layers on both sides, a multi-manifold type T die capable of simultaneously forming three layers by simultaneously extruding molten resins corresponding to the three layers can be used.

  In addition, when an inorganic filler is contained in the resin composition forming the foaming agent-containing resin layer and the foaming agent-containing resin layer is formed by extrusion film formation, an extrusion port (so-called die) of the extruder is used. Inorganic filler residues (so-called eyes and eyes) are easily generated, and this tends to be a foreign matter on the surface of the foaming agent-containing resin layer. Therefore, when an inorganic filler is included in the resin composition forming the foaming agent-containing resin layer, it is preferable to form a three-layer coextrusion film as described above. That is, it is possible to suppress the occurrence of the above-mentioned corners by co-extrusion film formation in a mode in which the foaming agent-containing resin layer is sandwiched between non-foamed resin layers.

  The foaming agent-containing resin layer may be irradiated with an electron beam after film formation. Thereby, the resin component can be cross-linked to adjust the surface strength, foaming characteristics, etc. of the foamed resin layer. The energy of the electron beam is preferably about 150 to 250 kV, more preferably about 175 to 200 kV. The irradiation amount is preferably about 10 to 100 kGy, and more preferably about 10 to 50 kGy. A known electron beam irradiation apparatus can be used as the electron beam source. This electron beam irradiation may be performed after the pattern layer or the surface protective layer is formed.

  As a method for forming the pattern layer and the surface protective layer, a known coating method or extrusion film forming method can be combined.

  The foam laminate can be formed by heating the foaming agent-containing resin layer to form a foamed 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 preferably about 210 to 240 ° C., and the heating time is preferably about 20 to 80 seconds.

  Moreover, as a manufacturing method of a foaming laminated body, for example, after manufacturing the said laminated body, it can manufacture by making a foaming resin layer into a foaming resin layer by heat-processing next. The foamed laminate may be embossed from the surface layer.

  Embossing can be performed by known means such as an embossed plate. For example, when the surface layer is the surface protective layer, a desired embossed pattern can be formed by pressing the embossed plate after heat softening the surface protective layer. 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.

Process 2
In step 2, image data (image data A) is obtained by photographing the surface of the laminate or foamed laminate. Thereby, in the process 3 mentioned later, the image data A can be converted into a gray scale image.

  Shooting may be in color or monochrome (black and white). When shooting in color, it is preferable to convert to RGB.

  The shooting method is not particularly limited. For example, a light source (fluorescent lamp, etc.) is vertically irradiated on the surface of the laminate or foam laminate, and a CCD camera (camera standard CameraLink or LVDS transmission method). And a method of photographing with a scanner or the like.

Process 3
In step 3, the image data A obtained by photographing in step 2 is converted into a gray scale image. Thereby, in the process 4 mentioned later, the image data B which extracted the low gradation area | region based on the converted gray scale image is acquirable.

For conversion to a grayscale image, (1) a method using the average of the maximum and minimum values of R, G, and B for each pixel, and (2) the average of each value of R, G, and B. The method can be performed by (3) multiplying each value of R, G, B by a predetermined weighting coefficient (NTSC, etc.) and then averaging them. For example, in the method (3), the following formula:
Y (output brightness) = 0.298912 x R + 0.568811 x G + 0.114478 x B
NTSC weighted average method can be used. Such an image processing method is not particularly limited, and can be performed by a known apparatus. For example, it can be performed with a personal computer body equipped with commercially available processing software.

  In the conversion to the gray scale image by the NTSC weighted average method, it is preferable to set 256 gradations. Thereby, since the partition of light and dark can be made into an appropriate area, it is easy to ensure the area | region which forms a hole with the laser mentioned later.

Process 4
In step 4, based on the grayscale image obtained in step 3, image data (image data B) obtained by extracting the low gradation region is acquired. Thereby, the formation region of the hole for imparting moisture permeability can be recognized while maintaining good design properties. The low gradation area refers to an area equal to or lower than a predetermined threshold value when a predetermined threshold value is set for the grayscale image. The threshold is determined based on conditions such as the diameter (area) of holes to be punched, the pitch of holes, and the required designability, and the designability of the surface of the laminated sheet or foamed laminated sheet is determined to be impaired by punching. What is necessary is just to set to the boundary of the gradation area | region judged that it is not impaired with a gradation area | region.

  Specifically, when a grayscale image is converted to 256 gradations, the grayscale value serving as the threshold value of the low gradation region to be extracted is preferably 180 or less, and more preferably 160 or less. When the gray scale value is 180 or less, relatively dark perforations such as dark portions (locations where the pigment concentration is high in the pattern layer or portions that are shaded in the embossed recesses) on the surface of the laminate or foam laminate are conspicuous. Since it can pierce in a difficult place, moisture permeability can be given to a lamination sheet or a foam lamination sheet, without impairing design nature.

  The method for acquiring image data is not particularly limited, and can be performed by a known device. For example, it can be performed with a personal computer body equipped with commercially available processing software.

Process 5
In step 5, based on the image data B obtained in step 4, a fiber is irradiated from the surface of the laminate or foam laminate by irradiating a laser in a region corresponding to the low gradation region of the laminate or foam laminate. A hole reaching the quality sheet is formed. Thereby, the hole for providing moisture permeability, maintaining favorable design property can be formed. In addition, the hole may be formed so that the whole laminated body or a foaming laminated body may be penetrated.

  The average pore diameter is not particularly limited as long as the design properties are affected, but 1 to 20 μm is preferable. In particular, the average pore diameter of the holes in the laminated sheet may be set so that the average pore diameter after foaming is 1 to 20 μm.

  The interval between adjacent holes (hereinafter also simply referred to as a pitch) is not particularly limited as long as each hole is formed in the region of the laminate or foamed laminate corresponding to the low gradation region, but is 50 to 5000 μm. It is preferable.

  A known apparatus can be used as an apparatus for irradiating a laser. The intensity | strength of laser irradiation will not be specifically limited if the hole from the surface layer to the fiber sheet surface is formed. Further, the laser may be irradiated from either the front surface or the back surface.

The laminated sheet obtained by the other process steps 1 to 5 can be made into a foamed laminated sheet by foaming the foaming agent-containing resin layer. In this case, the conditions such as the heating temperature of foaming and the heating time are the same as the conditions described in Step 1 above. Moreover, foamability can be adjusted by irradiating an electron beam to a foaming agent containing resin layer before foaming. In this case, the conditions such as the energy of the electron beam, the irradiation amount, and the electron beam source are the same as the conditions described in Step 1 above.

  Furthermore, you may emboss from the surface layer of the obtained foaming lamination sheet. The embossing means is the same as the means described in Step 1 above.

≪Laminated sheet and foamed laminated sheet≫
The laminated sheet and the foamed laminated sheet of the present invention can be obtained by the aforementioned steps 1 to 5. Each of the laminated sheet and the foamed laminated sheet has a hole extending from the surface layer to the fibrous sheet, and the hole (1) obtained the image data a by photographing the surface of the laminated sheet or the foamed laminated sheet. Later, (2) the image data a is converted into a grayscale image, (3) image data b obtained by extracting a low gradation area based on the grayscale image is obtained, and (4) based on the image data b. The laminated sheet or the foamed laminated sheet is formed in a region corresponding to the low gradation region. Therefore, both the laminated sheet and the foamed laminated sheet of the present invention have good design properties and moisture permeability.

  The acquisition method (or conversion method) of the image data a, the grayscale image, and the image data b is the same as in steps 2 to 4 described above. The threshold value for setting the low gradation region is not particularly limited, but is preferably equal to or less than the gray scale value that is the threshold value for punching, and 180 or less when converting a gray scale image to 256 gradations. Is more preferable.

  The foamed laminated sheet of the present invention can be used as an application in addition to foamed wallpaper, for example, a laminated decorative board skin material, a cushioning flooring material, and a heat insulating cosmetic material.

  The laminated sheet of the present invention is the same as the foamed laminated sheet of the present invention except that a foaming agent-containing resin layer is formed instead of the foamed resin layer. Since the laminated sheet of the present invention can be made into the foamed laminated sheet of the present invention by foaming the foaming agent-containing resin layer, the laminated sheet is useful for the production of the foamed laminated sheet.

  According to the manufacturing method of the laminated sheet and the foamed laminated sheet of the present invention, it is possible to form a hole from the surface layer to the fibrous sheet in a specific region, whereby a sheet having good design properties and moisture permeability can be obtained. can get.

  The present invention will be specifically described below with reference to examples and reference examples. However, the present invention is not limited to the examples.

Example 1
Backing paper using a three-type three-layer multi-manifold T-die extruder, i) non-foamed resin layer A / ii) foaming agent-containing resin layer / iii) non-foamed resin layer B in order of thickness 10μm / 70μm / 10μm (WK-665DO, manufactured by Kojin Co., Ltd.) was formed into an extruded film. The extrusion conditions were 115 ° C. for the cylinder containing the resin for forming the non-foamed resin layer A, 110 ° C. for the cylinder containing the resin composition for forming the foam-containing resin layer, and no foaming. The cylinder temperature in which the resin for forming the resin layer B was accommodated was 100 ° C. The die temperature was 110 ° C. for all.

  Next, an electron beam (195 kV, 30 kGy) was irradiated from above the non-foamed resin layer A to crosslink the foaming agent-containing resin layer and the non-foamed resin layer A. Next, a corona discharge treatment is performed on the non-foamed resin layer A, and a fabric pattern is printed using a water-based ink (“Hydric”, manufactured by Dainichi Seika Kogyo Co., Ltd.) as a pattern print by a gravure printing machine. Produced.

  Next, the foaming agent-containing resin layer was made into a foamed resin layer by heating in an oven (220 ° C. × 35 seconds), and then a texture pattern uneven embossing was applied from the surface layer. This obtained the foaming laminated body.

  Next, using the CCD camera (“Multi-camera image sensor: CV-5000”, “Fluorescent lamp illumination: CV-R20” manufactured by KEYENCE), the above embossing was performed with 70% output received light quantity of fluorescent lamp illumination. The foam laminate was captured into an image and converted to a 256 grayscale image. Thereafter, based on the gray scale image, a low gradation region having a threshold gray scale value of 180 was extracted to obtain image data B. Thereafter, based on the image data B, the low gradation region was irradiated with a laser drilling machine (MCT-600 type, manufactured by Roffin Basel Japan) (CO2 laser, 100 W). Thereby, holes with an average pore diameter of 20 μm and a pitch of 0.5 mm were formed, and the foamed laminated sheet of Example 1 was obtained.

  Each layer was formed using the following components.

Example 2
A foamed laminate was obtained in the same manner as in Example 1. Next, using the image scan, the foamed laminate subjected to the above embossing was taken into an image and converted to a 256 gray scale image by the NTSC weighted average method. Thereafter, based on the gray scale image, a low gradation region having a threshold gray scale value of 200 was extracted to obtain image data B. Then, based on the said image data B, the said pattern part was irradiated with the laser. Thereby, holes with an average pore diameter of 20 μm and a pitch of 0.5 mm were formed, and the foamed laminated sheet of Example 2 was obtained.

Reference Example A foamed laminated sheet was obtained in the same manner as in Example 1 except that no laser was irradiated.
≪Evaluation method (breathability) ≫
The moisture permeability was measured according to JIS Z0208 (moisture permeability test method (cup method)). The evaluation criteria for moisture permeability are as follows. In addition, if evaluation is A, it is excellent in moisture permeability.
A: Moisture permeability is 150 g / m ² · 24 h or more B: Moisture permeability is less than 150 g / m ² · 24 h

≪Evaluation method (designability) ≫
Each foamed laminated sheet was observed visually. Specifically, the foam laminate sheet of the above reference example is used as a design sample, the sample and the foam laminate sheet of each example are arranged on a sample stand, and under illumination {straight tube fluorescent lamp: 110W type (Toshiba Watbrighter)} The surface was observed from a place 1 m away, and the difficulty of conspicuous holes was evaluated.

The evaluation criteria for designability are as follows. If evaluation is A or B, it is excellent in design property.
A: The hole is hardly conspicuous B: The hole is slightly conspicuous C: The hole is conspicuous

  The results are shown below.

Claims (14)

It has a foaming agent-containing resin layer and a pattern layer on the fibrous sheet in order, and is a method for producing a laminated sheet in which holes from the surface layer to the fibrous sheet are formed,
(1) Step 1 of preparing a laminate in which a foaming agent-containing resin layer and a pattern layer are sequentially formed on a fibrous sheet,
(2) Step 2 of acquiring image data A by photographing the surface of the laminate.
(3) Step 3 of converting the image data A into a grayscale image,
(4) Step 4 of acquiring image data B from which a low gradation region is extracted based on the gray scale image;
(5) A step of forming a hole from the surface of the laminate to the fibrous sheet by irradiating a laser in a region corresponding to the low gradation region of the laminate based on the image data B 5,
A method for producing a laminated sheet, comprising:   The manufacturing method of the lamination sheet of Claim 1 which converts into the gray scale image of 256 gradations by the NTSC weighted average method in the said process 3.   The manufacturing method of the lamination sheet of Claim 1 or 2 whose gray scale value of the said low gradation area | region is 180 or less.   The manufacturing method of a foaming lamination sheet characterized by foaming the said foaming agent containing resin layer of the lamination sheet obtained by the manufacturing method in any one of Claims 1-3.   Furthermore, the manufacturing method of the foaming lamination sheet of Claim 4 including the process of embossing from a surface layer. It has a foamed resin layer and a pattern layer in order on a fibrous sheet, and is a method for producing a foamed laminated sheet in which holes from the surface layer to the fibrous sheet are formed,
(1) Step 1 of preparing a foamed laminate in which a foamed resin layer and a pattern layer are sequentially formed on a fibrous sheet,
(2) Step 2 of obtaining image data A by photographing the surface of the foam laminate.
(3) Step 3 of converting the image data A into a grayscale image,
(4) Step 4 of acquiring image data B from which a low gradation region is extracted based on the gray scale image;
(5) Based on the image data B, by irradiating a laser in a region corresponding to the low gradation region of the foam laminate, a hole extending from the surface of the foam laminate to the fibrous sheet is formed. Step 5,
The manufacturing method of a foaming lamination sheet characterized by including this.   The manufacturing method of the foaming lamination sheet of Claim 6 which converts into the gray scale image of 256 gradations by the NTSC weighted average method in the said process 3.   The manufacturing method of the foaming lamination sheet of Claim 6 or 7 whose gray scale value of the said low gradation area | region is 180 or less.   The manufacturing method of the foaming lamination sheet in any one of Claims 6-8 which performs embossing from the surface layer after any of the processes 1-5. A laminated sheet in which a foaming agent-containing resin layer and a pattern layer are sequentially formed on the fibrous sheet, and a hole from the surface layer to the fibrous sheet is formed,
The hole is
(1) After acquiring the image data a by photographing the surface of the laminated sheet,
(2) converting the image data a into a grayscale image;
(3) Acquire image data b obtained by extracting a low gradation area based on the gray scale image;
(4) Based on the image data b, formed in a region corresponding to the low gradation region of the laminated sheet,
A laminated sheet characterized by that.   The laminated sheet according to claim 10, wherein a gray scale value of the low gradation region is 180 or less. A foamed laminated sheet having a foamed resin layer and a pattern layer on the fibrous sheet in order, and a hole from the surface layer to the fibrous sheet is formed,
The hole is
(1) After acquiring the image data a by photographing the surface of the foamed laminated sheet,
(2) converting the image data a into a grayscale image;
(3) Acquire image data b obtained by extracting a low gradation area based on the gray scale image;
(4) Based on the image data b, formed in a region corresponding to the low gradation region of the foamed laminated sheet,
A foamed laminated sheet characterized by that.   The foam laminate sheet according to claim 12, wherein a gray scale value of the low gradation region is 180 or less.   The foamed laminated sheet according to claim 12 or 13, wherein the surface layer is embossed.