JP2014069577A - Foamed and laminated sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a foamed and laminated sheet used for a house interior and having excellent followability in a shift of an under layer, and a decorative plate using the laminated sheet.SOLUTION: The foamed and laminated sheet having a foamed resin layer laminated on a fiber base material can have excellent followability to a shift of an under layer by satisfying that a displacement from a first maximum point A (the fracture start point of the fiber base material) to a second maximum point B (the fracture start point of the resin layer) of tensile strength in a width direction is 1-5 mm when measured at a tensile speed of 3 mm/min in a sheet tear strength test method defined in JISK7128-3.

Description

  The present invention relates to a foamed laminated sheet having excellent followability with respect to base displacement. Furthermore, this invention relates to the decorative board using the said foaming lamination sheet.

  Conventionally, a decorative sheet (wallpaper) is used as a finishing material for house interiors, and decorativeness is imparted to the indoor space. Among decorative sheets, a foamed laminated sheet in which a foamed resin layer is laminated on a fibrous base material imparts useful functions such as flexibility, a design with a three-dimensional effect, unevenness absorbency of construction surface, and heat retention. Is widely used.

  On the other hand, there is always a seam (border) between boards such as gypsum board on the base to which the foamed laminated sheet is applied. For example, the base plane portion has a seam due to the board end portion, and the base corner portion (entrance corner) has a seam because the board end portion is assembled so as to be orthogonal. The seam of the groundwork may shift due to aging of buildings or earthquakes. Therefore, if the foam laminate sheet cannot follow the deviation of the joint of the foundation, the resin layer will crack and the decorative properties will be impaired. ) Is required.

  Conventionally, a foamed laminated sheet used as a decorative sheet includes a foamed resin obtained by foaming a resin such as an ethylene-vinyl acetate copolymer resin, an acrylic resin, or an olefin resin on a fibrous base material (backing paper). A sheet having a laminated structure in which resin layers are laminated is known (see Patent Documents 1 and 2). However, in the conventional foamed laminated sheet, it has not been sufficiently studied from the viewpoint that it can be provided with excellent background displacement followability, in fact, in recent years, the foamed decorative sheet breaks due to the secular change of buildings and earthquakes Many cases have been reported. With such a conventional technology as a background, if it is possible to develop a foamed laminated sheet having excellent background misalignment followability, its practical value will be very high.

  On the other hand, foamed laminated sheets are often used in an environment where they are easily scratched or scratched because they often come into contact with furniture, daily necessities, human bodies, etc. in daily life. Therefore, it is considered desirable for the foamed laminated sheet to have scratch resistance (scratch resistance) in addition to excellent base displacement followability. However, as described above, the conventional technology has not established even a technology for providing an excellent background displacement followability to the foam laminated sheet, and moreover, the foam lamination that sufficiently satisfies both the background displacement followability and the scratch resistance. The present situation is that even the sheet cannot be speculated as to what characteristics it should be designed to have.

JP 2000-255011 A JP 2001-347611 A

  A main object of the present invention is to provide a foamed laminated sheet having excellent background deviation followability and a decorative board using the laminated sheet.

  The present inventor has intensively studied to solve the above-mentioned problems. As a result, the sheet tear strength test method defined in JIS K7128-3 is used in a foam laminate sheet in which a foam resin layer is laminated on a fibrous base material. In the above, it has been found that when the displacement from the first maximum point to the second maximum point in the tensile strength in the width direction at a tensile speed of 3 mm / min satisfies 1 to 5 mm, it can be provided with excellent follow-up tracking ability. In addition, in addition to the above-mentioned physical properties, the foamed laminated sheet has been found to have excellent scratch resistance when the test result in the surface-enhanced wallpaper performance regulation stipulated by the Wallpaper Industry Association satisfies grade 4 or higher. . Further, in the foamed laminated sheet in which the foamed resin fat layer is laminated on the fibrous base material, the olefin copolymer containing at least an α, β unsaturated carboxylic acid anhydride as a constituent comonomer and selected from the group consisting of polyethylene 1 At least one or two selected from the group consisting of one or two or more resin components (1), an olefin-carboxylic acid vinyl ester copolymer, and an olefin-α, β unsaturated carboxylic acid ester copolymer It has been found that by using a combination of the above resin components (2), it is possible to have both excellent ground displacement followability and scratch resistance. The present invention has been completed by further studies based on such knowledge.

That is, this invention provides the invention of the aspect hung up below.
Item 1. A foam laminate sheet in which a resin layer including at least a foam resin layer is laminated on a fibrous base material,
In the sheet tear strength test method specified in JIS K7128-3, the foamed laminated sheet has a displacement from the first maximum point to the second maximum point of the tensile strength in the width direction at a tensile speed of 3 mm / min. A foamed laminated sheet, which is ˜5 mm.
Item 2. Furthermore, the foaming lamination sheet of claim | item 1 whose test result by the surface reinforcement | strengthening wallpaper performance regulation prescribed | regulated by the wallpaper industry association is 4th grade or more.
Item 3. The resin layer contains polyethylene, an olefin-carboxylic acid vinyl ester copolymer, an olefin-α, β unsaturated carboxylic acid ester copolymer, and at least an α, β unsaturated carboxylic acid anhydride as a constituent comonomer. Item 3. The foamed laminated sheet according to Item 1 or 2, comprising two or more kinds of resin components selected from the group consisting of coalescence.
Item 4. Item 4. The foamed laminated sheet according to any one of Items 1 to 3, wherein the resin layer has a laminated structure in which a non-foamed resin layer is disposed on an upper surface and / or a lower surface of the foamed resin layer.
Item 5. The foam according to any one of Items 1 to 4, wherein the resin layer has a laminated structure in which a non-foamed resin layer, a foamed resin layer, a non-foamed resin layer, a pattern layer, and a surface protective layer are arranged in this order. Laminated sheet.
Item 6. Item 6. The foamed laminated sheet according to any one of Items 1 to 5, which is a decorative sheet for a wall surface or a ceiling surface.
Item 7. Claim | item 1-6 The decorative board formed by affixing the foaming lamination sheet in any one on a to-be-adhered body.
Item 8. Item 8. The decorative board according to Item 7, wherein the adherend is a base board for interior use.
Item 9. A non-foamed laminated sheet in which a resin layer containing at least a non-foamed resin layer containing a resin component and a foaming agent is laminated on a fibrous base material,
When the non-foamed resin layer is foamed into a foamed laminated sheet, the foamed laminated sheet has a tensile strength in the width direction at a tensile speed of 3 mm / min in the sheet tear strength test method specified in JIS K7128-3. A non-foamed laminated sheet characterized in that the displacement from the first local maximum point to the second local maximum point satisfies 1 to 5 mm.
Item 10. Item 10. The non-foamed product according to Item 9, wherein when the non-foamed resin layer is foamed to obtain a foamed laminated sheet, the foamed laminated sheet satisfies a test result according to the surface-enhanced wallpaper performance regulation stipulated by the Wallpaper Industry Association. Laminated sheet.
Item 11. A foam laminate sheet in which a resin layer including at least a foam resin fat layer is laminated on a fibrous base material,
The foamed resin layer comprises at least one resin component (1) selected from the group consisting of an olefin copolymer containing at least an α, β unsaturated carboxylic acid anhydride as a constituent comonomer, and polyethylene, an olefin -Containing at least one or two or more resin components (2) selected from the group consisting of a carboxylic acid vinyl ester copolymer and an olefin-α, β unsaturated carboxylic ester copolymer , Foam laminated sheet.
Item 12. The foamed resin layer comprises one or more resin components (1) selected from the group consisting of polyethylene and ethylene-maleic anhydride-methyl acrylate copolymer, ethylene-vinyl acetate copolymer, ethylene- Item 12. The foamed laminated sheet according to Item 11, comprising one or more resin components (2) selected from the group consisting of a methyl methacrylate copolymer and an ethylene-methyl acrylate copolymer.
Item 13. Item 13. The foamed laminated sheet according to Item 11 or 12, wherein the foamed resin layer comprises polyethylene and an olefin-carboxylic acid vinyl ester copolymer.
Item 14. Item 14. The foamed laminated sheet according to Item 13, wherein the olefin-carboxylic acid vinyl ester copolymer is an ethylene-vinyl acetate copolymer.
Item 15. The foamed resin layer comprises an olefin copolymer containing at least an α, β unsaturated carboxylic anhydride as a constituent comonomer, an olefin-α, β unsaturated carboxylic ester copolymer, and an olefin-carboxylic acid vinyl ester copolymer. Item 13. The foamed laminated sheet according to Item 11 or 12, comprising one or more selected from the group consisting of:
Item 16. Item 16. The foamed laminated sheet according to Item 15, wherein the olefin copolymer is an ethylene-α, β-unsaturated carboxylic acid ester-α, β-unsaturated carboxylic acid anhydride copolymer.
Item 17. Item 16. The olefin-α, β-unsaturated carboxylic acid ester copolymer is at least one selected from the group consisting of an ethylene-methyl methacrylate copolymer and an ethylene-methyl acrylate copolymer. Foam laminated sheet.
Item 18. Item 16. The foamed laminated sheet according to Item 15, wherein the olefin-carboxylic acid vinyl ester copolymer is an ethylene-vinyl acetate copolymer.
Item 19. Item 19. The foamed laminated sheet according to any one of Items 11 to 18, wherein in the foamed resin layer, 100 to 1000 parts by mass of the resin component (2) is contained per 100 parts by mass of the resin component (1).
Item 20. Item 20. The foamed laminated sheet according to any one of Items 11 to 19, wherein the resin layer has a laminated structure in which a non-foamed resin layer is disposed on the upper surface and / or the lower surface of the foamed resin layer.
Item 21. The foam according to any one of Items 11 to 20, wherein the resin layer has a laminated structure in which a non-foamed resin layer, a foamed resin layer, a non-foamed resin layer, a pattern layer, and a surface protective layer are arranged in this order. Laminated sheet.
Item 22. Item 22. The foamed laminated sheet according to any one of Items 11 to 21, which is a decorative sheet for a wall surface or a ceiling surface.
Item 23. Item 23. A decorative board obtained by attaching the foamed laminated sheet according to any one of Items 11 to 22 to an adherend.
Item 24. Item 24. The decorative board according to Item 23, wherein the adherend is a base board for interior use.
Item 25. A non-foamed laminated sheet in which a resin layer containing at least a non-foamed resin layer containing a resin component and a foaming agent is laminated on a fibrous base material,
The resin component is an olefin copolymer containing at least an α, β unsaturated carboxylic acid anhydride as a constituent comonomer, and one or more resin components (1) selected from the group consisting of polyethylene, It contains at least one or two or more resin components (2) selected from the group consisting of a carboxylic acid vinyl ester copolymer and an olefin-α, β-unsaturated carboxylic acid ester copolymer, Non-foamed laminated sheet.

  In one aspect of the foamed laminated sheet of the present invention (foamed laminated sheet (I)), in the sheet tear strength test method defined in JIS K7128-3, the tensile strength in the width direction at a tensile speed of 3 mm / min is measured. Since the displacement from the 1st maximum point to the 2nd maximum point satisfies 1-5mm, it has excellent ground displacement followability, so even if some displacement occurs in the ground seam due to secular change or earthquake of the building, It is possible to follow the base displacement and to suppress the occurrence of cracks in the resin layer and breakage of the foamed laminated sheet. Furthermore, in addition to the above-mentioned physical properties, the foamed laminated sheet can also have excellent scratch resistance when the test result in the surface-enhanced wallpaper performance regulation stipulated by the Wallpaper Industry Association satisfies grade 4 or higher, so furniture, daily necessities, Even if it comes into contact with a human body or the like, it is possible to suppress scratches and scratches.

  In another aspect of the foamed laminated sheet of the present invention (foamed laminated sheet (II)), by forming a foamed resin fat layer using a combination of specific resin components, excellent substrate misalignment followability and scratch resistance It can have sex. Moreover, since the foaming lamination sheet of such an aspect can also be equipped with the outstanding stain resistance, it can be used conveniently as a decorative sheet for wallpaper.

Chart (horizontal axis: tensile distance, vertical axis: tensile) obtained when a laminated sheet in which a foamed resin layer is laminated on a fibrous base material is subjected to a sheet tear strength test method specified in JIS K7128-3 An example of strength is shown. It is a figure which shows the sampling direction (left figure) of the test piece used for the tear strength test method of a sheet | seat prescribed | regulated to JISK7128-3, and the shape (right figure) of a test piece. The unit of the numerical value indicating the size of the shape of the test piece shown in the right figure is “mm”. When scratch resistance is evaluated, it is a figure which shows the nail | claw (left figure) and the holder (right figure) of the friction element attached to the friction tester type II.

1. Foamed laminated sheet (I)
The foamed laminated sheet of the present invention is a foamed laminated sheet obtained by laminating a foamed resin layer on a fibrous base material, and the foamed laminated sheet is a sheet tear strength test method defined in JIS K7128-3. The displacement from the first maximum point to the second maximum point of the tensile strength in the width direction at a tensile speed of 3 mm / min is 1 to 5 mm. In the present specification, the foamed laminated sheet may be referred to as “foamed laminated sheet (I)”. Hereinafter, the foamed laminated sheet (I) will be described in detail.

Physical properties (Tear strength)
The foamed laminated sheet (I) of the present invention is a sheet tear strength test method defined in JIS K7128-3, wherein the tensile strength in the width direction at the tensile speed of 3 mm / min is from the first maximum point to the second maximum point. The displacement is up to 1 to 5 mm. By satisfying such a tearing strength, it is possible to provide excellent base displacement followability, and it is possible to suppress the occurrence of cracks even if the base joint is displaced. On the other hand, when the displacement exceeds 5 mm, the crack resistance tends to be reduced, or it tends to be stretched more than necessary, and the sticking position tends to shift during construction. From the viewpoint of further improving the background deviation followability, the displacement is preferably 1 to 3 mm.

  In the tear strength test method, the tensile strength in the width direction is the tensile strength in the width direction (that is, lateral tension) of the fibrous base material used as the base material. The width direction of the fibrous base material is a direction orthogonal to the fiber arrangement direction of the fibrous base material, and visually or underwater elongation (the underwater elongation is greater in the width direction than in the longitudinal direction) is measured. Can be determined.

  Further, the displacement from the first maximum point to the second maximum point of the tensile strength in the width direction is a graph in which the tensile distance is plotted on the horizontal axis and the tensile strength is plotted on the vertical axis when the tear strength test is performed. First, the distance from the tensile distance (first maximum point) showing the maximum tensile strength to the tensile distance (second maximum point) showing the maximum tensile strength is shown. The first maximum point is a point where the fiber base material starts to break, and the second maximum point is a point where the resin layer starts to break. For example, when a foam laminate sheet having a foam resin layer laminated on a fibrous base material is subjected to the tear strength test method, a chart as shown in FIG. 1 (horizontal axis: tensile distance, vertical axis: tensile strength) is obtained. The distance from A (the break start point of the fibrous base material) to B (the break start point of the resin layer) shown in FIG. 1 corresponds to the displacement from the first maximum point to the second maximum point. In FIG. 1, point C represents a break point at which the foamed laminated sheet is completely broken. That is, the displacement from the first maximum point to the second maximum point corresponds to a stress range that can maintain a state in which the resin layer is not broken even if the fibrous base material is broken due to a base shift. The displacement is used as an index of the effect of suppressing the occurrence of breakage such as cracks when the base displacement occurs.

  The tear strength test method is performed by cutting a foamed laminated sheet into a shape defined in JIS K7128-3. Moreover, the tear strength test method of a sheet | seat prescribed | regulated to JISK7128-3 is specifically performed on the conditions as described in the column of the Example mentioned later.

(Surface strength)
In addition to satisfying the above-mentioned tear strength, the foamed laminated sheet (I) of the present invention preferably satisfies the test results according to the surface-enhanced wallpaper performance regulation stipulated by the Wallpaper Industry Association of Grade 4 or higher. By satisfying such surface strength, excellent scratch resistance can be provided, and scratches that may occur in daily life can be effectively suppressed.

  In addition, the test result by the test in the surface-enhanced wallpaper performance regulation means that it is grade 4 or higher in both the vertical direction and the horizontal direction. Here, “vertical direction” and “horizontal direction” have the same meanings as “longitudinal direction” and “width direction” in the tear strength test method, respectively.

  The foam laminated sheet (I) satisfying the surface strength, or the foam laminate sheet (I) satisfying the tear strength and, if necessary, the surface strength is a fibrous base material and a resin layer constituting the foam laminate sheet. It is prepared by appropriately adjusting the composition, thickness, and the like. In particular, the physical properties of the foamed resin layer in the resin layer greatly contribute to the satisfaction of the tear strength and surface strength. Therefore, after selecting the fibrous base material, the composition and thickness of the foamed resin layer are determined by the tearing. The foamed laminated sheet (I) of the present invention is prepared by appropriately adjusting the strength and, if necessary, the surface strength as required.

Laminated structure The foamed laminated sheet (I) of the present invention has a laminated structure in which a resin layer containing at least a foamed resin layer is laminated on a fibrous base material.

  In the foamed laminated sheet (I) of the present invention, the resin layer only needs to include at least the foamed resin layer, and other than the foamed resin layer, as long as the tear strength and, if necessary, the surface strength are satisfied. A laminated structure having one or a plurality of layers may be used.

  For example, in order to improve the adhesiveness between the fibrous base material and the resin layer, the non-foamed resin layer B may be formed between the base material and the foamed resin layer as necessary.

  Moreover, the pattern layer may be formed as needed on the upper surface (the surface opposite to the fibrous base material side) of the foamed resin layer for the purpose of imparting design properties to the foamed laminated sheet. Furthermore, for the purpose of clarifying the pattern or improving the scratch resistance of the foamed resin layer, if necessary, the top surface of the foamed resin layer (the surface opposite to the fibrous base material side) or the pattern pattern layer may be provided. When forming, the non-foamed resin layer A may be formed between the foamed resin layer and the pattern layer.

  When the pattern layer is formed, a surface protective layer is provided on the upper surface of the pattern layer in order to impart stain resistance, adjust the gloss on the surface of the pattern layer, and protect the pattern layer. May be.

  As described above, the foamed laminated sheet (I) of the present invention includes, as necessary, a non-foamed resin layer B, a non-foamed resin layer A, a design pattern layer, and a surface protective layer as a resin layer. It may include at least one layer selected from the group consisting of: That is, as an example of a laminated structure in the foamed laminated sheet (I), a fibrous base material / non-foamed resin layer B provided as necessary / foamed resin layer / non-foamed resin layer A provided as needed / necessary There is a laminated structure in which a pattern layer provided accordingly / a surface protective layer provided as necessary is laminated in order. In particular, as a suitable example of the laminated structure in the foam laminated sheet (I), a fibrous base material / non-foamed resin layer B / foamed resin layer / non-foamed resin layer A / pattern pattern layer / surface protective layer were laminated in order. A laminated structure is mentioned.

  In addition, the surface of the foamed laminated sheet (I) of the present invention opposite to the fibrous base material may be provided with a concavo-convex pattern by embossing in order to impart design properties.

Hereinafter, the composition and forming method of each layer constituting the foamed laminated sheet (I) of the present invention will be described.
[Fiber base material]
As the fibrous base material used in the present invention, those usually used as wallpaper paper can be used. The fibrous base material may contain a flame retardant, an inorganic agent, a dry paper strength enhancer, a wet paper strength enhancer, a colorant, a sizing agent, a fixing agent, and the like as necessary. Specific examples of fiber base materials include general paper for wallpaper (pulp-based sheets sized with a sizing agent), flame-retardant paper (pulp-based sheets such as guanidine sulfamate and guanidine phosphate) Inorganic paper containing inorganic additives such as aluminum hydroxide and magnesium hydroxide; fine paper; thin paper, fiber mixed paper (made by mixing synthetic fiber and pulp), and the like. The fibrous base material used in the present invention includes those that fall under the category of nonwoven fabrics.

The basis weight of the fibrous base material is not particularly limited, for example, 50 to 300 g / m ² approximately, and preferably about 50 to 120 / m ^2.

[Resin layer]
The resin layer is a layer that is provided on the upper surface of the fibrous base material and includes at least a foamed resin layer. The resin layer may have a single layer structure composed of a single foamed resin layer, and in addition to the foamed resin layer, a group consisting of a non-foamed resin layer B, a non-foamed resin layer A, a pattern layer, and a surface protective layer. A laminated structure including at least one layer selected from may be used.

The mass per unit area of the resin layer and the density of each layer constituting the resin layer are appropriately set according to the type of resin component to be used, the number of layers other than the foamed resin layer, etc., but satisfy the above tear strength. From the viewpoint of satisfying both the tear strength and the surface strength, the mass per unit area of the resin layer is 70 to 110 g / m ² , preferably 72 to 100 g / m ² , and the resin. The density of the foamed resin layer contained in the layer is 0.1 to 0.3 g / cm ³ , preferably 0.12 to 0.28 g / cm ³ .

  About the thickness of the resin layer, depending on the type of the resin component to be used, the number of layers other than the foamed resin layer, etc., the tear strength and, if necessary, the range to satisfy the surface strength may be appropriately set, For example, 300-1500 micrometers, Preferably 400-800 micrometers is mentioned.

(1) Foamed resin layer The foamed resin layer is an essential layer contained in the resin layer, and is formed by foaming a foaming agent-containing resin layer containing a resin component and a foaming agent.

(Resin component)
The resin component used in the foamed resin layer is not particularly limited as long as the foamed laminated sheet (I) of the present invention can satisfy the tear strength and, if necessary, the surface strength. Consists of at least one selected from the group consisting of :) polyethylene, or 2) carboxylic acid vinyl ester, α, β unsaturated carboxylic acid, α, β unsaturated carboxylic acid ester, and α, β unsaturated carboxylic anhydride Examples of the olefin resin include as a comonomer. Hereinafter, 1) polyethylene and 2) olefin resin will be described.

1) Polyethylene The polyethylene may be a homopolymer of ethylene or a copolymer of ethylene and α-olefin. The α-olefin used as the comonomer of the copolymer is appropriately set according to the density provided for the polyolefin, for example, linear or branched having 3 to 20 carbon atoms, preferably 3 to 8 carbon atoms. One type or a combination of two or more types may be mentioned among the α-olefins in the form of a solid.

As the polyethylene, specifically, density 0.942 g / cm ³ or more high-density polyethylene (HDPE) and density 0.93 g / cm ³ or more 0.942 g / cm ³ less than the medium density polyethylene (MDPE), density 0.91 g / cm ³ or more 0.93 g / cm ³ less than the low-density polyethylene (LDPE), density of 0.85 g / cm ³ or more 0.93 g / cm ³ less than the linear low density polyethylene, and the like (LLDPE) Can be mentioned. These polyethylenes may be used individually by 1 type, and may be used in combination of 2 or more type. Among these polyethylenes, from the viewpoint of satisfying both the tear strength and the surface strength, preferably, low density polyethylene, linear low density polyethylene, and more preferably linear low density polyethylene are used.

  Specific examples of the linear low density polyethylene include those containing a linear or branched α-olefin having 3 to 20 carbon atoms, preferably 3 to 8 carbon atoms, as a comonomer. Specific examples of the comonomer in the linear low density polyethylene include propylene, 1-butene, 1-pentene, 1-hexene, 4-methylpentene-1, 1-octene, 1-decene, 1-dodecene and the like. . These comonomers may be used individually by 1 type, and may be used in combination of 2 or more type.

2) Olefin resin The olefin resin comprises an olefin monomer, a carboxylic acid vinyl ester, an α, β unsaturated carboxylic acid, an α, β unsaturated carboxylic acid ester, and an α, β unsaturated carboxylic acid anhydride. It is a resin obtained by polymerizing at least one comonomer selected from the group.

  Although it does not restrict | limit especially as said olefin type monomer, For example, a C2-C12 olefin, Preferably a C2-C8 olefin is mentioned. More specifically, as the olefin monomer used in the olefin resin, ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 4-methylpentene-1, 1-octene, 1-decene, Examples include olefins such as 1-dodecene. Among these olefin monomers, ethylene is preferable. These olefinic monomers may be used alone or in combination of two or more.

  Specific examples of the vinyl carboxylate include vinyl acetate. Specific examples of the α, β unsaturated carboxylic acid include acrylic acid and methacrylic acid. Specific examples of the α, β unsaturated carboxylic acid ester include methyl acrylate and methyl methacrylate. As the α, β unsaturated carboxylic acid anhydride, a mixed acid anhydride obtained by dehydration condensation of two different unsaturated carboxylic acids, a symmetric acid anhydride obtained by dehydration condensation of two molecules of the same unsaturated carboxylic acid, and two One molecule of unsaturated carboxylic acid having a carboxyl group may be any of intramolecular cyclic anhydrides obtained by dehydration condensation of the two carboxyl groups. Specifically, maleic anhydride, itaconic anhydride, citraconic anhydride, etc. Can be mentioned.

  Among these comonomers, carboxylic acid vinyl esters, α, β unsaturated carboxylic acid esters, and α, β unsaturated carboxylic acid anhydrides are preferable from the viewpoint of satisfying both the tear strength and the surface strength. In particular, carboxylic acid vinyl ester, more preferably vinyl acetate; α, β saturated carboxylic acid ester, more preferably methyl acrylate, methyl methacrylate; α, β unsaturated carboxylic acid anhydride, more preferably unsaturated An intramolecular cyclic anhydride of carboxylic acid, particularly preferably maleic anhydride is mentioned.

  These comonomers may be used individually by 1 type, and may be used in combination of 2 or more type.

  Specific examples of the olefin resins include olefin-carboxylic acid vinyl ester copolymers, olefin-α, β unsaturated carboxylic acid copolymers, olefin-unsaturated carboxylic acid ester copolymers, and at least α, β-unsaturated copolymers. Examples thereof include olefin copolymers containing a saturated carboxylic acid anhydride as a constituent comonomer (hereinafter also referred to as “unsaturated carboxylic acid anhydride copolymer”). Examples of the unsaturated carboxylic acid anhydride copolymer include olefin-α, β unsaturated carboxylic acid anhydride copolymer, olefin-α, β unsaturated carboxylic acid ester-α, β unsaturated carboxylic acid. An anhydride copolymer etc. are mentioned, Preferably, an olefin- (alpha), (beta) unsaturated carboxylic acid ester- (alpha), (beta) unsaturated carboxylic acid anhydride copolymer is mentioned. In the unsaturated carboxylic acid anhydride copolymer, the α, β unsaturated carboxylic acid anhydride may constitute a main chain or a graft chain.

  More specifically, as the olefin resin, ethylene-vinyl acetate copolymer (EVA), ethylene-methyl methacrylate copolymer (EMMA), ethylene-ethyl acrylate copolymer (EEA), ethylene-acrylic are used. Examples thereof include an acid methyl copolymer (EMA), an ethylene- (meth) acrylic acid copolymer (EMAA), an ethylene-olefin copolymer, and an ethylene-maleic anhydride-methyl acrylate copolymer. In the present specification, “(meth) acrylic acid” means acrylic acid or methacrylic acid. These ethylene copolymers may be used individually by 1 type, and may be used in combination of 2 or more type.

  Among these olefin resins, from the viewpoint of satisfying the tear strength, and further from the viewpoint of satisfying both the tear strength and the surface strength, an ethylene-carboxylic acid vinyl ester copolymer, ethylene-unsaturated are preferable. Examples thereof include carboxylic acid ester copolymers and unsaturated carboxylic acid anhydride-containing ethylene copolymers, more preferably ethylene-vinyl acetate copolymers, ethylene-methyl methacrylate copolymers, ethylene-methyl acrylate copolymers. And ethylene-maleic anhydride-methyl acrylate copolymer.

  Further, in the olefin resin, the ratio of the olefin monomer and the comonomer may be appropriately set according to the kind thereof. For example, the content of the comonomer is generally 5 to 42 per total mass of the olefin resin. % By mass, preferably 10 to 35% by mass.

(Suitable resin component)
As the resin component for forming the foamed resin layer, from the viewpoint of satisfying the tear strength to the foamed laminated sheet (I) of the present invention, and further from the viewpoint of satisfying both the tear strength and the surface strength, preferably, 1) polyethylene and a combination of two or more of the above 2) olefin-based resins; more preferably, polyethylene, olefin-carboxylic acid vinyl ester copolymer, olefin-α, β unsaturated carboxylic acid ester copolymer, And combinations of two or more of unsaturated carboxylic acid anhydride copolymers; particularly preferred are polyethylene, ethylene-carboxylic acid vinyl ester copolymers, ethylene-unsaturated carboxylic acid ester copolymers, and α, β unsaturated groups. Among the ethylene copolymers containing a saturated carboxylic acid anhydride as a constituent comonomer, two or more combinations may be mentioned. It is.

  As a specific example of the combination of the two or more resin components, at least one resin component (1) selected from the group consisting of polyethylene and an unsaturated carboxylic anhydride copolymer, and an olefin-carboxylic acid vinyl ester Examples thereof include a combination of at least one resin component (2) selected from the group consisting of a copolymer and an olefin-α, β unsaturated carboxylic ester copolymer. As a more preferred specific example, at least one resin component (1) selected from the group consisting of polyethylene and ethylene-unsaturated carboxylic acid ester-unsaturated carboxylic acid anhydride copolymer, and ethylene-carboxylic acid vinyl ester Examples include a combination of at least one resin component (2) selected from the group consisting of a copolymer and an ethylene-unsaturated carboxylic acid ester copolymer. As a particularly preferred specific example, at least one resin component (1) selected from the group consisting of polyethylene and an ethylene-maleic anhydride-methyl acrylate copolymer, an ethylene-vinyl acetate copolymer, an ethylene-methacrylate Examples include a combination of at least one resin component (2) selected from the group consisting of an acid methyl copolymer and an ethylene-methyl acrylate copolymer. By combining the resin components (1) and (2) as described above, the foamed laminated sheet (I) can satisfy both the tear strength and the surface strength more effectively, and further has excellent stain resistance. Can be provided.

  In particular, among the combinations of the resin components (1) and (2), as a preferred embodiment, a combination of polyethylene and an olefin-carboxylic acid vinyl ester copolymer; more preferably polyethylene and an ethylene-carboxylic acid vinyl ester copolymer. A combination with a polymer, particularly preferably a combination of linear low density polyethylene and an ethylene-vinyl acetate copolymer.

  Among the combinations of the resin components (1) and (2), as another preferred embodiment, an unsaturated carboxylic acid anhydride copolymer, an olefin-α, β unsaturated carboxylic acid ester copolymer, and / or Or a combination with an olefin-vinyl carboxylate copolymer; more preferably an ethylene copolymer containing an α, β unsaturated carboxylic acid anhydride as a constituent comonomer, an ethylene-α, β unsaturated carboxylic acid ester copolymer, and / Or a combination with ethylene-vinyl carboxylate copolymer; particularly preferably a combination of ethylene-maleic anhydride-methyl acrylate copolymer and ethylene-methyl methacrylate copolymer, ethylene-maleic anhydride-methyl acrylate Combination of copolymer and ethylene-methyl acrylate copolymer, and ethylene-maleic anhydride-methyl acrylate The combination of polymer and ethylene-vinyl acetate copolymer.

  When adopting a combination of the resin components (1) and (2) as the resin component of the foamed resin layer, these ratios may be set as appropriate, from the viewpoint of satisfying both the tear strength and the surface strength. For example, the resin component (2) is 100 to 1000 parts by mass, preferably 150 to 250 parts by mass, per 100 parts by mass of the resin component (1).

  More specifically, if a combination of polyethylene and an olefin-carboxylic acid vinyl ester copolymer is employed, the olefin-carboxylic acid vinyl ester copolymer is preferably 100 to 1000 parts by mass, preferably 100 parts by mass of polyethylene. 150-200 mass parts is mentioned. Further, if a combination of an unsaturated carboxylic acid anhydride copolymer and an olefin-α, β unsaturated carboxylic acid ester copolymer is employed, per 100 parts by mass of the unsaturated carboxylic acid anhydride copolymer. The ethylene-α, β unsaturated carboxylic acid ester copolymer is 60 to 900 parts by mass, preferably 100 to 250 parts by mass. Further, if a combination of an unsaturated carboxylic acid anhydride copolymer and an olefin-carboxylic acid vinyl ester copolymer is employed, the olefin-carboxylic acid per 100 parts by mass of the unsaturated carboxylic acid anhydride copolymer. A vinyl ester copolymer is 60-900 mass parts, Preferably 100-250 mass parts is mentioned.

(Content of resin component)
The content of the resin component in the foamed resin layer is appropriately set in consideration of the type and combination of resin components to be used, but from the viewpoint of satisfying the tear strength, and further, both the tear strength and the surface strength. From the viewpoint of satisfying, the total amount of the resin component is usually 50 to 80% by mass, preferably 55 to 70% by mass with respect to the total mass of the foamed resin layer.

(Foaming agent)
It does not restrict | limit especially as a foaming agent used for a foamed resin layer, It can select from a well-known foaming agent. For example, azo type such as azodicarbonamide (ADCA) and azobisformamide; organic thermal decomposition type blowing agent such as hydrazide type such as oxybenzenesulfonyl hydrazide (OBSH) and paratoluenesulfonyl hydrazide; microcapsule type blowing agent; baking soda Inorganic foaming agents such as These foaming agents may be used individually by 1 type, and may be used in combination of 2 or more type.

  The content of the foaming agent can be appropriately set according to the type of foaming agent, the expansion ratio, and the like. The expansion ratio may be 7 times or more, preferably about 7 to 10 times, and the foaming agent may be about 1 to 20 parts by mass with respect to 100 parts by mass of the resin component, for example.

(Other additives)
In order to improve the foaming effect of the foaming agent, a foaming aid may be included in the foamed resin layer as necessary. Although it does not restrict | limit especially as a foaming adjuvant, For example, a metal oxide, a fatty-acid metal salt, etc. are mentioned. More specifically, zinc stearate, calcium stearate, magnesium stearate, zinc octylate, calcium octylate, magnesium octylate, zinc laurate, calcium laurate, magnesium laurate, zinc oxide, magnesium oxide and the like can be mentioned. These foaming aids may be used alone or in combination of two or more. Although content of these foaming adjuvants is suitably set according to the kind of foaming adjuvant, the kind of foaming agent, content, etc., for example, 0.3-10 mass with respect to 100 mass parts of resin components About 1 part, preferably about 1 to 5 parts by mass.

  Further, the foamed resin layer may contain an inorganic filler as necessary for imparting flame retardancy, suppressing see-through, improving surface strength, and the like. The inorganic filler is not particularly limited, and examples thereof include calcium carbonate, aluminum hydroxide, magnesium hydroxide, antimony trioxide, zinc borate, and a molybdenum compound. These inorganic fillers may be used individually by 1 type, and may be used in combination of 2 or more type.

  The foamed resin layer may contain a pigment as necessary. The pigment is not particularly limited and may be either an inorganic pigment or an organic pigment. Inorganic pigments include, 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), and cadmium. Examples thereof include red, ultramarine blue, 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) and the like. These pigments may be used alone or in combination of two or more.

  As the content of the inorganic filler and / or pigment increases, the foamed resin layer tends to become brittle, and it tends to be difficult to satisfy the tear strength and surface strength. The tear strength and, if necessary, the surface strength can be set as appropriate. Specifically, the content of the inorganic filler and / or pigment is about 0 to 80 parts by mass, preferably about 10 to 70 parts by mass with respect to 100 parts by mass of the resin component.

  Furthermore, the foamed resin layer contains additives such as an antioxidant, a crosslinking agent, a crosslinking aid, and a surface treatment agent as necessary, as long as the tear strength and, if necessary, the surface strength can be satisfied. May be.

(Crosslinking of foamed resin layer)
In order to provide the foamed laminated sheet (I) of the present invention with the tear strength and, if necessary, the surface strength, the foamed resin layer is preferably crosslinked. In order to crosslink the foamed resin layer, for example, the foaming agent-containing resin layer before foaming may be previously subjected to a crosslinking treatment and then foamed. Specific examples of the crosslinking treatment method include electron beam crosslinking and chemical crosslinking, preferably electron beam crosslinking. Specifically, the electron beam cross-linking conditions are an acceleration voltage of 100 to 300 kV, preferably 100 to 200 kV, an irradiation amount of 2 to 100 kGy, preferably 2.5 to 70 kGy, and an electron beam irradiation treatment. The method of performing is illustrated. Moreover, as conditions for performing chemical crosslinking, specifically, an organic peroxide such as dicumyl peroxide is contained in the foaming agent-containing resin layer and heated at a temperature of about 160 to 180 ° C. for a heating time of 5 to 10 minutes. The method of performing a process is illustrated.

(Thickness of foamed resin layer)
The thickness of the foamed resin layer may be appropriately set within a range where the tear strength and, if necessary, the surface strength can be satisfied, and examples thereof include 300 to 700 μm. As thickness before foaming of a foamed resin layer (namely, thickness of a foaming agent containing resin layer), 40-120 micrometers is mentioned, for example.

(Method for forming foamed resin layer)
The foamed resin layer is a non-foamed resin when the non-foamed resin layer B is provided on the base fibrous base material using a resin composition containing a resin component, a foaming agent, and other additives as required. What is necessary is just to apply on the layer B. A method for forming the foamed resin layer is not particularly limited, but a method of forming by foam molding is preferable, and a method of forming by extrusion with a T-die extruder is more preferable.

(2) Non-foamed resin layer B (adhesive resin layer)
The non-foamed resin layer B is a layer constituting the resin layer. For the purpose of improving the adhesive force between the fibrous base material and the foamed resin layer, the lower surface of the foamed resin layer (contacts with the fibrous base material) as necessary. It is an adhesive resin layer formed on the surface.

  The resin component of the non-foamed resin layer B is not particularly limited as long as it can satisfy the tear strength and, if necessary, the surface strength, and can improve the adhesive force between the fibrous base material and the foamed resin layer. The components can be appropriately selected and used. The resin component of the non-foamed resin layer B is preferably an ethylene-vinyl acetate copolymer from the viewpoint of satisfying the tear strength, and further from the viewpoint of satisfying both the tear strength and the surface strength.

  In the ethylene-vinyl acetate copolymer used for the non-foamed resin layer B, the ratio of vinyl acetate is not particularly limited, but for example, 10 to 46% by mass, preferably 10% to 46% by mass, based on the total mass of the ethylene-vinyl acetate copolymer. 15-41 mass% is mentioned.

  Although it does not restrict | limit especially about the thickness of the non-foaming resin layer B, For example, about 3-50 micrometers, Preferably about 3-20 micrometers is mentioned.

  The method for forming the non-foamed resin layer B is not particularly limited, and examples thereof include a method of forming by melt molding, preferably a method of forming by extrusion using a T-die extruder. In particular, it is desirable to form the foamed resin layer and the non-foamed resin layer B by coextrusion using a multi-manifold type T die that can simultaneously form two or more layers by extruding molten resin simultaneously.

(3) Non-foamed resin layer A
The non-foamed resin layer A is a foamed resin, as necessary, for the purpose of clarifying the pattern when forming the pattern layer or improving the scratch resistance of the foamed resin layer as a layer constituting the resin layer. It is a layer formed on the upper surface of the layer.

  The resin component of the non-foamed resin layer A is not particularly limited as long as the tear strength and, if necessary, the surface strength can be satisfied. For example, polyolefin resin, methacrylic resin, thermoplastic polyester resin, polyvinyl Examples include alcohol resins and fluorine resins. These resin components may be used individually by 1 type, and may be used in combination of 2 or more type. Among these resin components, a polyolefin resin is preferable.

  Specific examples of polyolefin resins include polyethylene, polypropylene, polybutene, polybutadiene, polyisoprene, ethylene-methyl acrylate copolymer, ethylene-ethyl acrylate copolymer, ethylene- (meth) acrylic acid copolymer, ethylene. -Vinyl acetate copolymer, saponified ethylene-vinyl acetate copolymer, ionomer and the like. Among these, an ethylene- (meth) acrylic acid copolymer is preferable from the viewpoint of satisfying the tear strength, and further from the viewpoint of satisfying both the tear strength and the surface strength.

  In the ethylene- (meth) acrylic acid copolymer used for the non-foamed resin layer A, the ratio of (meth) acrylic acid is not particularly limited. For example, the total mass of the ethylene- (meth) acrylic acid copolymer 5 to 15% by mass per unit, preferably 11 to 15% by mass.

  Although it does not restrict | limit especially about the thickness of the non-foaming resin layer A, For example, about 3-30 micrometers, Preferably about 3-15 micrometers is mentioned.

  The method for forming the non-foamed resin layer A is not particularly limited, and examples thereof include a method of forming by melt molding, preferably a method of forming by extrusion with a T-die extruder. In particular, it is desirable to form the foamed resin layer and the non-foamed resin layer B by coextrusion using a multi-manifold type T die. When three layers of the non-foamed resin layer A, the foamed resin layer, and the non-foamed resin layer B are provided, a multi-manifold type T die capable of simultaneous film formation of three layers is used. It is desirable to form the layers by coextrusion.

(4) Pattern pattern layer The pattern pattern layer is a layer constituting the resin layer, and for the purpose of imparting design properties to the foamed laminate sheet (I), if necessary, a foam resin layer (or a non-foam resin layer A) ).

  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 suitably selected according to the use of a foaming lamination sheet.

  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, a solvent (or a dispersion medium) and the like can be used. These inks may be known or commercially available.

  Although it does not restrict | limit especially as a coloring agent, For example, the pigment used with the said foamed resin layer can be used suitably.

  The binder resin may be appropriately set according to the type of the base sheet. For example, acrylic resin, styrene resin, polyester resin, urethane resin, chlorinated polyolefin resin, vinyl chloride-vinyl acetate. Examples include copolymer resins, polyvinyl butyral resins, alkyd resins, petroleum resins, ketone resins, epoxy resins, melamine resins, fluorine resins, silicone resins, fiber derivatives, rubber resins, and the like. These binder resins may be used alone or in combination of two or more.

  Although it does not restrict | limit especially as a solvent (or dispersion medium), For example, petroleum-type organic solvents, such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, methylcyclohexane; Ethyl acetate, butyl acetate, 2-methoxyacetate Ester-based organic solvents such as ethyl and 2-ethoxyethyl acetate; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, propylene glycol; acetone, methyl ethyl ketone, methyl isobutyl ketone Ketone organic solvents such as cyclohexanone; ether organic solvents such as diethyl ether, dioxane and tetrahydrofuran; dichloromethane, carbon tetrachloride, trichloroethylene, Chlorinated organic solvents such as tiger chloroethylene; and water. These solvents (or dispersion media) may be used individually by 1 type, and may be used in combination of 2 or more type.

  The thickness of the design pattern layer is appropriately set according to the type of design pattern and the like, and may be about 0.1 to 10 μm, for example.

(5) Surface protective layer When a pattern layer is provided as a layer constituting the resin layer, the surface protective layer is provided with stain resistance, gloss adjustment on the surface of the pattern layer, protection of the pattern layer, etc. Furthermore, it is a layer formed on the upper surface of the picture pattern layer as required.

  As for the resin component used for forming the surface protective layer, a resin component capable of satisfying the tear strength and, if necessary, the surface strength is appropriately selected from known resin components such as thermoplastic resins and curable resins. do it.

  Examples of the thermoplastic resin used for forming the surface protective layer include polyolefin resins, acrylic resins, polyvinyl alcohol meter resins, and fluorine resins. Among these thermoplastic resins, from the viewpoint of effectively satisfying the tear strength, preferably an ethylene-acrylic acid copolymer resin, an ethylene-methyl acrylate copolymer resin, an ethylene-ethyl acrylate copolymer. Copolymer resin, ethylene (meth) acrylic acid copolymer resin such as ethylene-methacrylic acid copolymer resin, ethylene-vinyl acetate copolymer (EVA), saponified ethylene-vinyl acetate copolymer resin, ionomer, ethylene -Polyolefin resins such as ethylene copolymers such as olefin copolymers. These thermoplastic resins may be used individually by 1 type, and may be used in combination of 2 or more type. Moreover, when using a crosslinkable thermoplastic resin like an ethylene copolymer for formation of a surface protective layer, you may perform a crosslinking process to the said thermoplastic resin as needed.

  Further, as the curable resin used for forming the surface protective layer, the type of the curing reaction is not particularly limited as long as the tear strength and, if necessary, the surface strength can be satisfied. Curable resin, heat curable resin, ionizing radiation curable resin, one liquid reaction curable resin, two liquid reaction curable resin, ionizing radiation curable resin, etc., but preferably one liquid reaction curable Resin. From the viewpoint of effectively satisfying the tear strength and, if necessary, the surface strength, the curable resin is preferably an acrylic resin, a urethane resin, or the like, and more preferably a one-component reaction curable acrylic. Based resins. These curable resins may be used alone or in a combination of two or more. Moreover, when using curable resin for formation of a surface protective layer, in order to advance hardening reaction, you may use a crosslinking agent, a polymerization initiator, a polymerization accelerator, etc. as needed.

  The surface protective layer may be a single layer, or may be a laminate of two or more identical or different layers. For example, a two-layer structure in which a layer formed of a cured resin is formed on the outermost surface and a layer formed of a thermoplastic resin is laminated on the lower layer thereof may be used.

  Although it does not restrict | limit especially as thickness of a surface protective layer, For example, 1-20 micrometers, Preferably 1-5 micrometers is mentioned.

  The surface protective layer may be formed by a method corresponding to the type of resin component used. For example, in the case of forming a surface protective layer using a thermoplastic resin, it may be carried out by pasting a previously prepared thermoplastic resin film on the surface of the pattern layer, or the surface of the pattern layer Alternatively, a thermoplastic resin may be formed into a film. If the surface protective layer is formed using a curable resin, a gravure coating, a bar coating, a roll coating, a reverse coating can be prepared by mixing a thermosetting resin and various resin additives as required. After applying to the foamed resin layer (or non-foamed resin layer A or pattern layer) by a method such as roll coating or comma coating, the resin composition is dried and cured by heating or the like as necessary. .

(6) Concave and convex pattern In order to impart design properties to the foamed laminated sheet (I) of the invention, the concave and convex pattern by embossing is applied to the surface (surface opposite to the fibrous base material) as necessary. It may be. Embossing can be performed by known means such as pressing of an embossed plate. The concavo-convex pattern is not particularly limited, and examples thereof include a wood grain plate conduit groove, a stone plate surface unevenness, a cloth surface texture, a satin texture, a grain, a hairline, and a striated groove.

Production method of foamed laminated sheet (I) The foamed laminated sheet (I) of the present invention appropriately adjusts the composition, thickness, and laminated structure of each layer so as to satisfy the tear strength and, if necessary, the surface strength. An example of the manufacturing procedure will be described below. However, the production method of the foamed laminated sheet (I) of the present invention is not construed as being limited to the following contents. In the following description of the production method, the content of the foamed laminated sheet (I) of the present invention that has already been described for the method of forming each layer constituting the present invention is omitted.

  First, a resin layer including at least a foaming agent-containing resin layer is laminated on a fibrous base material. When the non-foamed resin layer A and / or the non-foamed resin layer B is provided as the resin layer, the non-foamed resin layer A, the foaming agent-containing resin layer, and the non-foamed resin layer B are used using a multi-manifold type T die. And coextrusion is desirable.

  What is necessary is just to set suitably according to the kind etc. of the resin component to be used about the cylinder temperature and die temperature at the time of extruding and forming a foaming agent containing resin layer with a T-die extruder, but generally it is about 100-140 degreeC.

  Next, a surface protective layer is laminated as a resin layer through a pattern layer as necessary. In the formation of the surface protective layer, when a curable resin is used, the curable resin is cured by performing a heat treatment, a crosslinking treatment or the like according to the type of the curing reaction of the resin. Further, when the surface protective layer uses a crosslinkable thermoplastic resin such as an ethylene-based copolymer, the thermoplastic resin may be subjected to a crosslinking treatment as necessary.

  Thus, a non-foamed laminated sheet in which the resin layer is laminated on the fibrous base material is prepared. The resin layer is provided as necessary: non-foamed resin layer B / foamed resin layer / non-foamed resin layer A provided as required / pattern layer provided as required / surface provided as needed It becomes a laminated structure in which the protective layers are sequentially laminated.

  Thereafter, the foamed laminated sheet (I) of the present invention is produced by foaming the foaming agent-containing resin layer in the resin layer of the obtained non-foamed laminated sheet.

  Although it does not restrict | limit especially as a heating condition at the time of foaming a foaming agent containing resin layer, For example, the heating temperature is about 210-240 degreeC and the heating time is about 20-80 seconds.

  Before foaming the foaming agent-containing resin layer, in order to adjust the melt tension of the foaming agent-containing resin layer to make it easier to obtain the desired foaming ratio, the foaming agent-containing resin layer is cross-linked as necessary. Processing can be performed. As described above, when a surface protective layer is provided and the surface protective layer is subjected to a crosslinking treatment, the foaming agent-containing resin layer and the surface protective layer may be crosslinked simultaneously.

  Further, the foamed laminated sheet (I) of the present invention may be embossed to form a concavo-convex pattern on the surface thereof. Embossing can be performed by known means such as an embossed plate. Specifically, a desired embossed pattern can be formed by pressing the embossed plate after heat-softening the foamed resin layer, the foamed resin layer, and the surface protective layer provided as necessary.

Use The foamed laminated sheet (I) of the present invention is suitably used as a decorative sheet for decorating an adherend. That is, a decorative board is provided by sticking the foamed laminated sheet (I) of the present invention to an adherend.

  Specific examples of the adherend of the foamed laminated sheet (I) of the present invention include an interior base board. The interior base board may be a wood substrate or a non-wood substrate. Examples of wood substrates include veneer boards made of various materials such as cedar, firewood, firewood, pine, lawan, teak, and melapy, wood-based boards such as wood veneer, wood plywood, particle board, and medium density fiberboard (MDF). Is mentioned. Moreover, as a non-woody board | substrate, inorganic boards, such as a concrete board and a stone board, a plastic board, a gypsum board etc. are mentioned, for example. These substrates may be composed of a single substrate or may be a laminate of two or more substrates. Since the foamed laminated sheet (I) of the present invention is suitably used as a decorative sheet for a wall surface or a ceiling surface, the adherend is preferably an interior base board for a wall surface or a ceiling surface.

  In addition, since the foamed laminated sheet (I) of the invention has an excellent base displacement followability, the effect of following the shift of the joint portion of the interior baseboard due to an earthquake is improved. It can also be used as a wearing decorative sheet. An “earthquake-resistant structure” is a structure that has the strength to withstand earthquakes and is designed not to eliminate the shaking caused by earthquakes, but rather to actively shake and absorb earthquake vibrations. They are distinguished from structures and seismic isolation structures.

  The adhesive used for adhering the foamed laminated sheet (I) of the invention and the adherend includes starch-based, urea-based, vinyl acetate resin-based, urea resin-based, melamine resin-based, phenolic resin-based, isocyanate An adhesive such as a system can be used, and it can be used alone or as a mixed adhesive mixed arbitrarily. For the adhesive, if necessary, inorganic powders such as talc, calcium carbonate, clay, titanium white, wheat flour, wood flour, plastic powder, coloring agents, insect repellents, fungicides and the like may be added and mixed. it can.

The adhesive can be applied using an application device such as a spray, a spreader, or a bar coater. In general, the adhesive has a solid content of 35 to 80% by mass, and is applied to the surface of the fibrous base material of the adherend or the foamed laminated sheet (I) of the present invention in a coating amount range of 50 to 300 g / m ² .

  As described above, the adhesion of the foamed laminated sheet (I) of the present invention to the adherend is usually performed by forming an adhesive layer on the back surface of the decorative sheet and adhering the adherend or the adherend. It is carried out by a method such as applying an adhesive on top and sticking a decorative sheet. For the application of the decorative sheet, in addition to using a sticking device such as a cold press, hot press, roll press, laminator, wrapping, edge pasting machine, vacuum press, etc., it can be pasted by a craftsman (on-site construction). it can.

  A decorative board obtained by sticking the foamed laminated sheet (I) of the present invention to an adherend is used as a wall material, a ceiling surface material or the like.

2. Foamed laminated sheet (II)
The present invention further relates to a foam laminated sheet in which a resin layer including at least a foamed resin fat layer is laminated on a fibrous base material, and the foamed resin layer constitutes at least an α, β unsaturated carboxylic anhydride. One or more resin components (1) selected from the group consisting of olefin copolymers and polyethylene as comonomer, olefin-carboxylic acid vinyl ester copolymer, and olefin-α, β unsaturated carboxylic Provided is a foamed laminated sheet containing one or more resin components (2) selected from the group consisting of acid ester copolymers. In the present specification, the foamed laminated sheet may be referred to as “foamed laminated sheet (II)”.

  The laminated structure in the foamed laminated sheet (II) of the present invention is as described in the column of “1. Foamed laminated sheet (I)” described above.

  The foamed laminated sheet (II) of the present invention is characterized in that the resin components (1) and (2) are used in combination in the foamed resin layer contained in the resin layer. By forming the foamed resin layer using a combination, it is possible to have both excellent ground displacement followability and scratch resistance. Furthermore, the foamed laminated sheet (II) of the present invention can also have excellent stain resistance by employing such a foamed resin layer having a specific composition.

  In the foamed laminated sheet (II) of the present invention, the types of the resin components used as the resin components (1) and (2), the ratio thereof, the preferred combinations of the resin components (1) and (2), etc. As described in the column of “1. Foamed laminated sheet (I)”. In addition, the components other than the resin component blended in the foamed resin layer, the content thereof, the thickness of the foamed resin layer, and the like are also as described in the column of “1. Foamed laminated sheet (I)” described above.

  In the foamed laminated sheet (II) of the present invention, the composition, thickness, etc. of the fiber base material and the layer other than the foamed resin layer provided as necessary as the resin layer are also described in “1”. .. “Foamed laminated sheet (I)”.

  Further, the production method, use, etc. of the foamed laminated sheet (II) of the present invention are also as described in the column of “1. Foamed laminated sheet (I)”.

3. Non-foamed laminated sheet (I)
The present invention further relates to a non-foamed laminated sheet in which a resin layer including at least a non-foamed resin layer containing a resin component and a foaming agent is laminated on a fibrous base material, and foaming the non-foamed resin layer by foaming the non-foamed resin layer When a laminated sheet is used, the foamed laminated sheet is a sheet tear strength test method specified in JIS K7128-3, and the second maximum is obtained from the first maximum point of the tensile strength in the width direction at a tensile speed of 3 mm / min. Disclosed is a non-foamed laminated sheet (also referred to as a non-foamed laminated sheet (I)) characterized in that the displacement up to a point satisfies 1 to 5 mm.
The non-foamed laminated sheet (I) is used as a raw material for producing the foamed laminated sheet (I). In the foamed laminated sheet (I), the foamed resin layer in the resin layer is a foaming agent-containing resin. Except for the replacement of the layers, the layer structure, the composition of each layer, and the like are the same as in the case of the foamed laminated sheet (I). That is, the foamed laminated sheet (I) is produced by foaming the foaming agent-containing resin layer in the non-foamed laminated sheet (I).

4). Non-foamed laminated sheet (II)
The present invention further provides a non-foamed laminated sheet in which a resin layer containing at least a non-foamed resin layer containing a resin component and a foaming agent is laminated on a fibrous base material, the resin component comprising an unsaturated carboxylic acid At least one resin component (1) selected from the group consisting of an anhydride copolymer and polyethylene, an olefin-carboxylic acid vinyl ester copolymer, and an olefin-α, β unsaturated carboxylic acid ester copolymer A non-foamed laminated sheet (sometimes referred to as a non-foamed laminated sheet (II)) comprising at least one resin component (2) selected from the group consisting of:
The non-foamed laminated sheet (II) is used as a raw material for producing the foamed laminated sheet (II). In the foamed laminated sheet (II), the foamed resin layer in the resin layer is a foaming agent-containing resin. Except for being replaced with layers, the layer structure, the composition of each layer, and the like are the same as in the case of the foamed laminated sheet (II). That is, the foamed laminated sheet (II) is produced by foaming the foaming agent-containing resin layer in the non-foamed laminated sheet (II).

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

[Manufacture of foam laminated sheet]
Example 1-6
Using a three-type three-layer T-die extruder, the extrusion amount was adjusted so that the thickness was 5 μm / 65 μm / 5 μm in the order of non-foamed resin layer A / foaming agent-containing resin layer / non-foamed resin layer B. A resin sheet (resin layer) having a structure was formed. Extrusion conditions were such that the cylinder temperature was 120 ° C. and the die temperature was 120 ° C. The foaming agent-containing resin layer in the obtained resin sheet maintained an unfoamed state. Both ends of the obtained resin layer were slit to a width of 960 mm. The non-foamed resin layer A, the foaming agent-containing resin layer, and the non-foamed resin layer B were formed using resin compositions having the compositions shown in Table 1, respectively.

  Next, the paper surface of wallpaper paper made of paper pulp having a width of 970 mm (“WK-665”, manufactured by KJ special paper) is heated to 120 ° C., and the non-foamed resin layer B of the resin sheet comes into contact with the wallpaper paper. The paper sheet and the resin sheet were thermocompression bonded through a laminating roll to obtain a laminated body. At this time, the resin sheet was placed and laminated in the center of the wallpaper paper, and 5 mm at both ends of the wallpaper paper was not laminated.

  Thereafter, the resin sheet surface of the obtained laminate was irradiated with an electron beam under the conditions of an accelerating voltage of 195 kV and an irradiation dose of 30 kGy, whereby a foaming agent-containing resin layer in the resin sheet was subjected to a crosslinking treatment.

  Next, after corona discharge treatment is applied to the surface of the laminate (non-foamed resin layer A), a texture pattern is printed using water-based ink ("Hydric", manufactured by Dainichi Seika Kogyo) as a pattern print by a gravure printing machine. A pattern pattern layer (thickness of about 2 μm) was formed. After that, the surface protective layer (thickness of about 2 μm) is formed by printing water-based ink (ALTOP-402B, manufactured by Dainichi Seika Kogyo Co., Ltd., acrylic one-component curable resin) on the pattern layer with a gravure printer. did.

  Next, while heating the obtained laminate in an oven (at 220 ° C. for 35 seconds), the foaming agent-containing resin layer is foamed to form the foamed resin layer, and the fabric has a fabric-like pattern on the surface protective layer. A foamed laminated sheet was obtained by pressing and pressing a metal roll.

The thickness of the obtained laminated sheet is 600 μm, and the mass per unit area of the resin layer (non-foamed resin layer B, foamed resin layer, non-foamed resin layer A, pattern layer, and surface protective layer) in the laminated sheet is The density of 91.4 g / m ² and the resin layer (non-foamed resin layer A, foaming agent-containing resin layer, non-foamed resin layer B, picture pattern layer, surface protective layer) was 0.18 g / cm ³ . The density of the resin layer was calculated by calculating the volume from the cross-sectional area of the foam sheet per unit length and dividing the mass of the resin by the volume.

Comparative Example 1
In Comparative Example 1, the non-foamed resin layer A, the foaming agent-containing resin layer, and the non-foaming resin layer B were formed using the resin compositions having the compositions shown in Table 2, respectively, and crosslinking with respect to the foaming agent-containing resin layer A foamed laminated sheet was produced under the same conditions as in the above example, except that the electron beam irradiation was performed under the conditions of an acceleration voltage of 195 kV and an irradiation dose of 60 kGy.

Comparative Examples 2 and 3
In Comparative Examples 2 and 3, the non-foamed resin layer A, the foaming agent-containing resin layer, and the non-foamed resin layer B were formed using the resin compositions having the compositions shown in Table 2, respectively, with the examples described above. A foamed laminated sheet was produced under the same conditions.

Comparative Example 4
100 parts by mass of vinyl chloride (“PQB83”, manufactured by Shin Daiichi Vinyl), 38 parts by mass of plasticizer (“DINP”, manufactured by CG Esther), 21 parts by mass of colorant (“DE-24”, manufactured by Nihongo Bix), 3 parts by mass of a foaming agent (“Vinhole AC # 3”, manufactured by Eiwa Kasei Kogyo), 3.25 parts by mass of a stabilizer (“ADK STAB FL-47”, manufactured by ADEKA), and a stabilizer (“ADK STAB O-111”, manufactured by ADEKA) ) A plastisol of a resin composition consisting of 2 parts by mass, 18.1 parts by mass of a diluent (“Shellsol S”, manufactured by Shell Chemical Japan), and 90 parts by mass of calcium carbonate (“Whiteon H”, manufactured by Shiroishi Kogyo) Produced. This plastisol is coated on the surface of wallpaper paper ("WK-665", manufactured by KJ Special Paper) made of 970 mm wide paper pulp using a comma coater, semi-gelled in a drying oven at 150 ° C, and then wallpaper paper The laminated body which laminated | stacked the foaming agent containing resin layer on it was obtained. The thickness of the foaming agent-containing resin layer of the obtained laminate was 110 μm.

  Next, on the surface of the foamed resin-containing resin layer of the obtained resin sheet, a texture pattern is printed by using a water-based ink (“Hydric”, manufactured by Dainichi Seika Kogyo) as a pattern print by a gravure printing machine. A thickness of about 2 μm). Thereafter, a water-based ink (ALTOP-402B, manufactured by Dainichi Seika Co., Ltd., acrylic one-component curable resin) was printed on the pattern layer by a gravure printing machine to form a surface protective layer (thickness of about 2 μm). .

Next, while heating the obtained laminate in an oven (at 220 ° C. for 35 seconds), the foaming agent-containing resin layer is foamed to form the foamed resin layer, and the fabric has a fabric-like pattern on the surface protective layer. A laminated sheet was obtained by pressing and pressing a metal roll. The thickness of the obtained laminated sheet was 650 μm, the mass per unit area of the resin layer (the total of the foamed resin layer, the pattern layer, and the surface protective layer) in the laminated sheet was 91.0 g / m ² , and the resin layer (foamed) The density of the resin layer, the pattern layer, and the surface protective layer was 0.14 g / cm ³ .

[Evaluation of physical properties and performance of foamed laminated sheet]
The tear strength test of the sheet specified in JIS K7128-3 By performing the tear strength test of the sheet specified in JIS K7128-3, each of the foamed laminated sheets obtained above has a tensile strength in the width direction. The displacement from the first maximum point to the second maximum point was measured. Specifically, the measurement was performed according to the following procedure.

  First, each foamed laminated sheet was cut into the shape shown in FIG. 2, and stored at a temperature of 23 ± 2 ° C. and a relative humidity of 50 ± 5% for 88 hours or more. Next, using a Tensilon universal material testing machine (Orientec model number: RTC-1250A), set a tensile speed of 3 mm / min and a distance between grips of 800 mm, and conduct a tear strength test. Correlation between tensile distance and tensile strength Was measured, and the displacement from the first maximum point to the second maximum point of the tensile strength in the width direction was determined. The tear strength test was performed in an environment with a temperature of 23 ± 2 ° C. and a relative humidity of 50 ± 5%.

Breaking resistance against ground displacement About each foamed laminated sheet obtained above, the damage resistance against ground displacement was evaluated according to the following method.

  Two 9.5 mm-thick 99 mm × 99 mm square plaster boards (“Tiger Board” manufactured by Yoshino Gypsum) were prepared. Each foamed laminated sheet was pasted with a starch-based adhesive so as to cover the entire surface of the two gypsum boards in a state where one side of the two gypsum boards was abutted without gap. At this time, the flow direction of the foamed laminated sheet (the direction perpendicular to the width direction of the wallpaper paper) was set to be parallel to the side where the two gypsum boards were abutted.

Next, after drying at room temperature and sufficiently adhering the gypsum board and the foamed laminated sheet, pull the two gypsum boards perpendicularly to the side where the two gypsum boards are abutted, and then the two gypsum boards A gap of 1.5 mm, 2.0 mm, or 2.5 mm was generated at the butted portion. At that time, the appearance of the foamed laminated sheet was observed and evaluated according to the following criteria.
<Judgment criteria for appearance of laminated sheet>
○: No damage to the laminated sheet was observed.
Δ: Cracks are partially observed on the resin surface of the laminated sheet.
X: The laminated sheet of the butted portion of the two gypsum boards is completely broken.

Scratch resistance Each of the foamed laminated sheets obtained above was evaluated in accordance with the surface-enhanced wallpaper performance regulations stipulated by the Wallpaper Industry Association to evaluate the scratch resistance. Specifically, the measurement was performed according to the following procedure.

  Each foamed laminated sheet was cut into a 30 mm × 250 mm shape and stored at 20 ± 10 ° C. and a relative humidity of 65 ± 20% for 24 hours or more, and used as a test piece. Scratch resistance was measured using a friction tester type II (“Gakushin type friction tester”, manufactured by Tester Sangyo Co., Ltd.) stipulated in JIS L 0849. Was used. The friction tester II type friction element was attached so that the tip surface of the nail was horizontal with the test piece base and did not move left and right. The test piece was affixed to the fibrous sheet surface of the test piece using a double-sided tape so as to be parallel to the reciprocating direction of the friction element, and was firmly fixed to the test piece base so that the test piece did not move. Thereafter, the friction element was gently placed on the test piece and reciprocated 5 times at a reciprocating speed of 30 times per minute between the transition distance of 120 mm. The load of the friction element is 2N (200 gf), the size of the claw tip is 4.0 mm × 2.0 mm, the start side: R0.15 mm (± 0.03 mm), and the return side: R0.20 mm (± 0.00 mm). 03 mm). The test was conducted in an environment of 20 ± 10 ° C. and a relative humidity of 65 ± 20%.

About the length direction and the horizontal direction of each test piece, after performing a test on the said conditions, the damage degree of each test piece surface was confirmed visually, and scratch resistance was evaluated according to the following criteria.
<Scratch resistance criteria>
5th class: No change 4th class: Some change on the surface 3rd class: The surface appears to be torn 2nd class: The surface is torn and the fibrous base material is visible (less than 1 cm in length)
Grade 1: The surface is torn and the fibrous base material is visible (length 1 cm or more)

Contamination Resistance Each of the foamed laminated sheets obtained above was tested for scratch resistance by testing according to the surface-enhanced wallpaper performance regulations stipulated by the Wallpaper Industry Association. Specifically, the measurement was performed according to the following procedure.

Contaminants (coffee, soy sauce, red crayon, aqueous sign pen) were adhered to each foamed laminated sheet. After 24 hours, each contaminant was wiped off. The coffee and soy sauce were wiped off with water, and the red crayon and aqueous sign pen were wiped off with a neutral detergent. Next, the appearance after wiping off each contaminant was visually observed, and the contamination resistance was evaluated according to the following criteria.
<Criteria for contamination resistance>
5th grade: No dirt remains 4th grade: Little dirt remains 3rd grade: Some dirt remains 2nd grade: Very little dirt remains 1st grade: Dirt remains dark

The results obtained are shown in Table 3. As is clear from the results of Examples 1 and 4, when the displacement from the first maximum point to the second maximum point of the tensile strength in the tear strength test is 1 to 5 mm, the base displacement followability is good. Thus, it has been clarified that it has excellent resistance to breakage against misalignment of the substrate and that it can sufficiently satisfy scratch resistance. Examples 1 and 4 also had excellent scratch resistance.

  Further, as is clear from the results of Examples 1 to 6, as a resin component for forming the foamed resin layer in the foamed laminated sheet, ethylene and / or unsaturated carboxylic anhydride-containing ethylene copolymer and ethylene-carboxylic acid are used. It was also confirmed that the use of a vinyl ester copolymer and / or an ethylene-unsaturated carboxylic acid ester copolymer in combination can provide excellent background misalignment followability and scratch resistance. Moreover, in Examples 1-6, the antifouling property was also provided.

  On the other hand, as is clear from Comparative Examples 1 and 4, in the foamed laminated sheet in which the displacement from the first maximum point to the second maximum point of the tensile strength in the tear strength test is less than 1 mm, in terms of the ground misalignment followability. It was inferior.

First, each foamed laminated sheet was cut into the shape shown in FIG. 2, and stored at a temperature of 23 ± 2 ° C. and a relative humidity of 50 ± 5% for 88 hours or more. Next, using a Tensilon universal material testing machine (Orientec model number: RTC-1250A), set the tensile speed to 3 mm / min, perform a tear strength test, measure the correlation between the tensile distance and the tensile strength, The displacement from the first maximum point to the second maximum point of the tensile strength of was determined. The tear strength test was performed in an environment with a temperature of 23 ± 2 ° C. and a relative humidity of 50 ± 5%.

Claims (6)

A foam laminate sheet in which a resin layer including at least a foam resin layer is laminated on a fibrous base material,
From the first maximum point to the second maximum point of the tensile strength in the width direction when the foamed laminated sheet is measured at a tensile speed of 3 mm / min in the sheet tear strength test method specified in JIS K7128-3. The displacement is 1-5 mm,
A foam laminate sheet, which is affixed to a wall surface or a ceiling surface.   Furthermore, the foaming laminated sheet of Claim 1 whose test result by the surface reinforcement | strengthening wallpaper performance prescription | regulation prescribed | regulated by the wallpaper industry association is 4th grade or more.   The resin layer contains polyethylene, an olefin-carboxylic acid vinyl ester copolymer, an olefin-α, β unsaturated carboxylic acid ester copolymer, and at least an α, β unsaturated carboxylic acid anhydride as a constituent comonomer. The foaming laminated sheet of Claim 1 or 2 containing 2 or more types of resin components selected from the group which consists of coalescence.   The foamed resin layer comprises at least one resin component (1) selected from the group consisting of an olefin copolymer containing at least an α, β unsaturated carboxylic acid anhydride as a constituent comonomer, and polyethylene, and an olefin. -Comprising at least one resin component (2) selected from the group consisting of a -carboxylic acid vinyl ester copolymer and an olefin-α, β-unsaturated carboxylic acid ester copolymer. The foamed laminated sheet according to any one of 3 above.   The foamed resin layer comprises one or more resin components (1) selected from the group consisting of polyethylene and an ethylene-maleic anhydride-methyl acrylate copolymer, an ethylene-vinyl acetate copolymer, ethylene 5. The resin composition according to claim 1, comprising one or more resin components (2) selected from the group consisting of a methyl methacrylate copolymer and an ethylene-methyl acrylate copolymer. Foam laminated sheet.   The wall material or ceiling material formed by affixing the foaming lamination sheet in any one of Claims 1-5 on a to-be-adhered body.

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