JP2015174242A - decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative sheet having thermal sense like a tatami mat or carpet has, soft touching feeling like a backskin or suede has, and cleaning property like a flooring or cushion floor has, and capable of maintaining these effects for a long period.SOLUTION: A decorative sheet comprises: a base material layer 1; a synthetic resin foam layer 2; a print design layer 3; a transparent wear layer 4; a foam micro capsule-including layer 5; and a surface treatment layer 6. The micro capsule-including layer includes a foam micro capsule 7 by 1-10 mass% to 100 mass% of a transparent resin paste, and the surface treatment layer 4 is a functional layer.

Description

  The present invention relates to a decorative sheet such as a conventional vinyl chloride resin flooring material, which has a surface feel like a back skin or suede, has excellent warm feeling at the time of contact, and is easy to maintain against dirt.

  Examples of the decorative sheet include household floor materials such as tatami mats, carpets, flooring, and cushion floors.

  Among them, a cushion floor made of a vinyl chloride resin has been often used because it can easily wipe off water and dirt, and is easy to care for and can express a variety of designs (patterns).

  However, in recent years, flooring that has been reduced in price has spread rapidly, and the cushion floor made of vinyl chloride resin, which is slightly inferior in quality compared to flooring, can only be used in limited places around the water such as kitchens. ing.

In addition, both flooring and cushion floors feel that the surface is “cold” in cold winter seasons, and therefore, floor heating is often installed, and measures such as placing carpets or cloth mats on top are often taken. In addition, the sticky feel unique to the vinyl chloride resin cushion floor is inferior to the luxury.
By the way, when people touch things, they tend to feel that flooring and cushion floors are “cold” and tatami mats and carpets are “warm” even though they are at the same temperature. This kind of skin sensation is called a feeling of cold contact and changes depending on the amount of heat transferred from the person's skin to the object, and not only the “material” that makes up the object, but also the “fuzziness” It is said that "surface shape such as irregularities" also affects.

  On the other hand, tatami mats and carpets, which are excellent in warm feeling (not feeling cold), have a drawback that they are inferior in cleanability as compared with the above flooring and cushion floor because water and dirt are likely to penetrate.

  Along with the above problems, there is a technique of a floor material in which a surface layer is formed by applying and drying a coating containing thermally expanded microcapsules on the outermost surface (Patent Document 1). However, in this method, the floor layer on which walking is performed cannot obtain sufficient durability for the surface layer, and the surface layer is worn out in a short period of time, which is not practical. In addition, since the surface layer is formed by applying a paint containing thermally expanded microcapsules, it is difficult to perform a further surface treatment.

JP 2011-46048

  The present invention combines warm feeling like tatami mats and carpets with soft feel like backskin and suede, cleanability like flooring and cushion floor, and maintains these effects over a long period of time. It is an object to provide a decorative sheet that can be used.

(1) A decorative sheet comprising a base material layer, a synthetic resin foam layer, a printed design layer, a transparent wear layer, a foamed microcapsule-containing resin layer, and a surface treatment layer,
The microcapsule-containing resin layer contains 1 to 10% by weight of foamed microcapsules with respect to 100% by weight of the transparent resin paste,
The decorative sheet is characterized in that the surface treatment layer is a functional layer.
(2) The decorative sheet according to (1), wherein the surface treatment layer has a thickness of 2 to 20 μm.
(3) The decorative sheet according to (1) or (2), wherein the foaming temperature of the foamed microcapsule is 120 to 185 ° C.

(4) A resin composition containing a foaming agent is applied on the base material layer, and is heated and dried below the foaming start temperature of the resin composition to form an unfoamed foam layer. The layer and the transparent synthetic resin layer are sequentially applied and dried to form a laminate, and the foamed microcapsule-containing resin is further applied. After the foamed layer and the foamed microcapsule-containing layer are foamed by heat treatment, the functional material is applied. A method for producing a decorative sheet, which comprises drying to form a surface treatment layer.
(5) The heating temperature in the heat treatment for foaming the foamed layer and the foamed microcapsule-containing layer is equal to or higher than the foaming temperature of the foamed layer and higher than the maximum foaming temperature of the foamed microcapsule, and the foamed microcapsule The method for producing a decorative sheet according to claim 4, wherein the cell retention rate is not lower than 50%.

The decorative sheet of the present invention can be used around the water like flooring and cushion floors and has excellent cleanability, but there is no peculiar feel (sticky feeling) to the cushion floor made of vinyl chloride resin. It has such a soft feel and luxury.
Moreover, when it is flooring, it feels cold in cold winter, etc., so it is often warmed using floor heating or hot carpet, whereas the decorative sheet of the present invention, for example, when touching with bare feet, The amount of heat taken away is small, and it is very excellent in temperature sensitivity (it is hard to feel cold), so there is no need for floor heating or hot carpet, leading to reduction of energy consumption in the home (eco) . Moreover, since it is possible to provide a surface treatment layer in the outermost surface of a decoration sheet, the performance (antifouling property, water repellency, scratch resistance, etc.) calculated | required by a use can be provided. Further, the durability is as high as that of a vinyl chloride resin cushion floor, and the above effects can be exhibited over a long period of time.

It is a figure which shows the cross-sectional structure of one embodiment of the decoration sheet | seat of this invention.

An embodiment of the decorative sheet of the present invention will be described with reference to the conceptual diagram shown in FIG.
In FIG. 1 showing an embodiment of the present invention, a decorative sheet 10 includes a base material layer 1, a foam layer 2, a printed design layer 3, a transparent wear layer 4, a foamed microcapsule-containing layer 5, and a surface treatment layer 6. Thus, the foamed microcapsule-containing layer 5 includes foamed microcapsules 7.

The base material layer 1 is provided in the lowermost layer of the decorative sheet 10.
The base material layer 1 is not particularly limited as long as it is generally used as a base material for a decorative sheet, and examples thereof include a fiber in which a synthetic resin is impregnated and cured. Specifically, it can be a non-woven fabric, knitted fabric or woven fabric composed of at least one of synthetic fibers, natural fibers, and inorganic fibers, or a mixed paper obtained by mixing a synthetic resin binder with various fibers and pulp materials. . Examples of the synthetic resin binder include acrylic resin and styrene butadiene rubber.
The base material layer 1 may be composed of a plurality of layers. For example, a synthetic fiber woven fabric or nonwoven fabric and a glass fiber nonwoven fabric may be laminated.

The foam layer 2 is provided on the upper surface of the base material layer, and the foam ratio is preferably 200 to 500%. Materials used include polyolefin resins such as polyethylene, polypropylene, ethylene vinyl acetate resin (EVA), and ethylene acrylic copolymer resins (EMA, EMMA, EEA, etc.), vinyl chloride resins, and acrylate copolymer resins. , A foamed layer of a thermoplastic resin composed of at least one of a urethane resin and a urethane acrylate resin.
As a foaming method of the foam layer 2, chemical foaming using a foaming agent is preferably used. As foaming agents used for chemical foaming, thermal expansion foaming agents such as microcapsules, heat such as azodicarboxylic acid (ADCA), dinitroso / pentamethylene / tetramine (DPI), oxybisbenzene / sulfonyl hydrazide (OBSH), etc. Any of the decomposable foaming agents can be used, and it is appropriately selected depending on the heating temperature and heating time during foam molding.

The printing design layer 3 is formed by applying a general printing method such as inkjet printing, gravure printing, screen printing, offset printing, or flexographic printing on the surface of the foam layer 2 or the back surface of the transparent wear layer 4 described below. Can be formed. The ink used at this time may be a commonly used polar ink such as vinyl acetate, acrylic or urethane, but is an ink having adhesiveness to the layer on which the printed design layer 3 is formed. It is preferable. The ink may contain a foaming agent to foam the printing design layer 3.
Or you may comprise the printing design layer 3 by dye | staining on the surface of the foaming layer 2, or the back surface of the transparent abrasion layer 4, or laminating | stacking a pattern woven fabric, a pattern knitted fabric, etc. FIG.

The transparent wear layer 4 is not limited to a transparent resin as long as the design of the printed design layer 3 in the lower layer can be visually recognized, and may be a translucent resin, which is colored with a pigment or a dye. It may be. The thickness of the transparent wear layer 4 is usually about 0.05 to 0.5 mm.
The resin constituting the transparent wear layer 4 is a layer made of at least one thermoplastic resin such as polyolefin resin, vinyl chloride resin, acrylate copolymer resin, urethane resin, urethane acrylate resin, or the like. .

The foamed microcapsule-containing layer 5 is provided on the transparent wear layer 4 as described above, and imparts a fine uneven shape to the surface of the decorative sheet. For this reason, the touch at the time of a decorative sheet surface contact and a warm feeling become favorable. In the present invention, it is important that the foamed microcapsule-containing layer 5 contains the foamed microcapsules 7 in the transparent resin paste.
The foamed microcapsule-containing layer 5 is formed by, for example, applying a resin compound in which foamed microcapsules 7 before foaming are contained and dispersed in a transparent resin paste to a known coating such as a roll coater, a rotary screen, a gravure coater, or a gravure / offset roll coater. It can be formed by means of construction.

The foamed microcapsule 7 is, for example, a liquid low-boiling point hydrocarbon (such as isobutane or isopentane) sealed in a shell of a thermoplastic resin (such as an acrylic copolymer resin), and has a diameter of 4 to 5 by heat treatment. What expand | swells about twice is sufficient and what is generally marketed can be used as it is. Examples thereof include thermally expandable microspheres manufactured by Dainichi Seika Kogyo Co., Ltd .: Die Form H750D, Die Form H850, Die Form H1100, and the like.
When the size of the foamed microcapsule 7 is too small, the decorative sheet obtained after the foaming treatment does not sufficiently obtain the soft feeling and warmth sensitivity at the time of contact, which is the object of the present invention. Since the durability of the containing layer 5 is low and it cannot withstand abrasion during walking or cleaning, it is preferable that the average particle diameter before foaming is about 10 to 50 μm.
Further, the foaming temperature of the foamed microcapsule 7 is not determined unconditionally because the conditions are appropriately determined depending on the resin composition of the foamed layer 2, but those having a maximum foaming temperature of 120 to 185 ° C. from the foaming start temperature are preferable. The one of 135 to 165 ° C. is more preferable. When the foamed microcapsule 7 having a foaming temperature condition (foaming peak) of the foamed microcapsule-containing layer 5 within the above temperature range and lower than the foaming temperature condition of the foamed layer 2 is used, the foamed layer 2 and the foamed microcapsule contained by heat treatment are contained. Since simultaneous foaming with the layer 5 can be performed well and a decorative sheet having a good tactile sensation can be obtained, it is preferable. In the case of a capsule having a foaming start temperature of 70 ° C. or less, there is a risk of thermal expansion when the floor surface is warmed by direct sunlight or the like when the decorative sheet is used.

  In the present invention, in order to improve the design of the decorative sheet and the durability of the foamed microcapsule-containing layer 5, two or more kinds of foamed microcapsules 7 that differ in color, particle size, expansion start temperature, expansion rate, constituent material, and the like are used. It can also be used in combination.

As for the resin compound in which the foamed microcapsules 7 are dispersed, the transparent resin paste to be used may be selected so that both the foamed microcapsules 7 and the transparent wear layer 4 have good adhesion. Specific examples include resins such as vinyl chloride resins, urethane resins, urethane acrylate resins, and acrylic resins.
In order to obtain a soft feel more reliably, it is preferable to select a resin with low hardness.

In the resin compound, the content of the foamed microcapsule 7 with respect to 100% by weight of the transparent resin paste is preferably 1.0 to 10.0% by weight, and more preferably 3.0 to 7.0% by weight.
If the blended amount of the foamed microcapsules 7 is too small relative to the resin as the dispersion medium, the touch and thermal sensation at the time of contact intended by the present invention cannot be obtained sufficiently, and if it is too large, printing in the lower layer is performed. Not only is the visibility of the design of the design layer 3 impaired, but the durability of the foamed microcapsule-containing layer is lowered, and there is a possibility that it cannot withstand wear during walking or cleaning when used as a decorative sheet.
Thus, the foamed microcapsule-containing layer 5 is laminated on the transparent synthetic wear layer 4 of the decorative sheet 10.

  Further, if the thickness of the foamed microcapsule-containing layer in the decorative sheet of the present invention is too thin, the decorative sheet obtained after the foaming treatment cannot sufficiently obtain the soft feeling and warmth sensitivity at the time of contact intended by the present invention. On the other hand, if it is too thick, it is difficult to visually recognize the design of the printed design layer 3 in the lower layer, and the surface durability as a flooring material tends to be impaired. Is more preferable, and 0.1 to 0.25 mm is more preferable.

The surface treatment layer 6 is provided on the outermost surface of the decorative sheet in order to impart functionality to the resulting decorative sheet. Examples of the functionality to be imparted include antifouling properties, water repellency, scratch resistance, and the like, which are appropriately selected depending on the purpose of use. For example, when it is intended for use around water, it is preferable to provide a functional layer having antifouling properties and water repellency. It is preferable to provide an excellent functional layer. Examples of the functional layer include an antifouling layer coated and formed with an acrylic antifouling treatment agent.
The surface treatment layer 6 is configured by applying and drying a functional paint. In addition, regarding the thickness, if it is too thin, the required functionality cannot be sufficiently exhibited, and if it is too thick, the feel and temperature sensitivity at the time of surface contact that are produced from the fine uneven shape by the foamed microcapsule-containing layer 5 There is a possibility that the effect of such may be impaired. For this reason, 2-50 micrometers is preferable in the dry state, and, as for the thickness of the preferable surface treatment layer 6 in this invention, it is more preferable when it shall be 5-20 micrometers.

  In the present invention, if necessary, the base layer, the foam layer, the printed design layer, the transparent wear layer, the foamed microcapsule-containing layer, and the surface treatment layer are within the range that does not impair the effects of the present invention. Various additives such as an agent, an antistatic agent, a lubricant, a bactericidal agent, an insect repellent, and a coloring agent can be appropriately added. In addition, as these additives, the usual thing mix | blended with a normal decoration sheet can be used.

  The total thickness of the decorative sheet 10 of the present invention is about 1.0 to 5.0 mm, preferably 1.5 to 3.0 mm.

As a manufacturing method of the above decoration sheets, it can carry out in the following procedures, for example.
The foam layer 2 is coated and heat-molded in an unfoamed state on the base material layer 1, the printed design layer 3 is provided thereon, and the transparent wear layer 4 is coated and heat-molded.
Subsequently, the foamed microcapsule-containing layer 5 is applied in an unfoamed state, and the resulting laminate is heat-treated to foam the foamed layer 2 and the foamed microcapsule-containing layer 5. Thereafter, a functional treatment agent is applied to the outermost surface and heated and dried to form the surface treatment layer 6.
The temperature of the heat treatment for foaming the foamed layer 2 and the foamed microcapsule-containing layer 5 is not less than the foaming temperature of the foamed layer 2 and not less than the maximum foaming temperature of the foamed microcapsule 7. It is preferable to set the temperature so that the cell retention rate does not fall below 50%. When the temperature of the heat treatment is too high and the cell retention rate is less than 50%, it may be difficult to obtain a soft feeling and warm feeling at the time of surface contact.

  About the decorative sheet in each Example and a comparative example, manufacture and evaluation were performed as follows.

Example 1
A vinyl chloride resin paste containing a foaming agent is applied with a knife coater so that the foaming ratio is 300% after foaming on a glass fiber-containing fibrous base material layer. A foamed foam layer is formed, a printed design layer is formed thereon by gravure printing, and a transparent wear layer made of vinyl chloride resin is applied and formed thereon. A resin compound containing 1% by weight of foamed microcapsules (H750D) with respect to 100% by weight of the vinyl chloride resin is applied on the screen coater so that the thickness in the dry state is 0.05 mm, and then heated. A foaming process is performed to foam the foamed layer and the foamed microcapsule-containing layer. Thereafter, an acrylic antifouling treatment agent was applied and dried on the outermost surface as a surface treatment layer to form an antifouling layer having a thickness of 10 μm to obtain a decorative sheet.

Examples 2-5
A decorative sheet produced in the same manner as in Example 1 except that the content of the foamed microcapsules is as shown in Table 1.

Examples 6-9, Comparative Example 2
A decorative sheet produced by the same method as in Example 1 except that the thickness of the formed surface treatment layer is as shown in Table 1.

Examples 10 and 11
A decorative sheet produced by the same method as in Example 2 except that the type of foamed microcapsule used in the foamed microcapsule-containing layer is the kind shown in Table 2.

Comparative Example 1
A conventional decorative sheet produced by the same method as in Example 1 except that it does not have foamed microcapsules and a surface treatment layer.

Samples used in Examples and Comparative Examples described in Tables 1 and 2 (1) Foamed microcapsules (foamed microcapsule-containing layer)
H750D: Daiichi Seika Kogyo Co., Ltd. die foam, foaming start temperature 140 ° C., maximum foaming temperature 160 ° C., average particle size 20 μm
H850D: Daiichi Seika Kogyo Co., Ltd. die foam, foaming start temperature 125 ° C., maximum foaming temperature 175 ° C., average particle size 35 μm
H1100D: Daiichi Seika Kogyo Co., Ltd. die foam, foaming start temperature 195 ° C., maximum foaming temperature 210 ° C., average particle size 45 μm
(2) Surface treatment agent (surface treatment layer)
Acrylic antifouling treatment agent (3) Foaming agent (foamed layer)
ADCA foaming agent adjusted to a foaming start temperature of 170 ° C and a maximum foaming temperature of 200 ° C

  About each Example and the comparative example, (A) surface feeling, (B) cool / warm feeling, (C) antifouling property, (D) design nature, and (E) durability were evaluated. The results are also shown in the table.

The evaluation of the above (A) to (E) was examined as follows.
(A) Surface feel The softness of the surface was evaluated according to the following criteria based on the hand feel according to the following criteria.
◎: Excellent softness such as suede and backskin ○: Soft △: Slightly inferior and slightly sticky ×: No significant difference from conventional vinyl chloride resin cushion floor (B ) Cool sensation Standing with bare feet on each surface in a room at room temperature of 5 ° C., evaluation was performed according to the following criteria.
◎: Does not feel cold ○: Does not feel too cold △: Feels slightly cold ×: Feels cold (C) Contamination resistance Colored oil adjusted by adding red food to salad oil is placed on the document, left for 24 hours and then wiped with water The surface condition was confirmed visually and evaluated according to the following criteria.
A: Wiped cleanly. O: Dirt was wiped off (no coloring), but the gloss slightly changed.
Δ: Dirt was wiped off (no coloration), but gloss changed.
X: Dirt remained (colored)
(D) Designability The degree of visibility of the printed design layer by providing the foamed microcapsule-containing layer was evaluated according to the following criteria as compared with the case where the foamed microcapsule-containing layer was not provided.
A: The printed design layer can be visually recognized to the same extent as when the foamed microcapsule-containing layer is not provided. O: The foamed microcapsule-containing layer is slightly cloudy, but the printed design layer can be visually recognized without problems. Contained layer is cloudy and the printed design layer is difficult to see x: The printed design layer is not visible (E) Durability In accordance with JIS L-0849, cotton cloth, vinyl leather (assuming the bottom of slippers), rubber as contact piece After performing a Gakushin-type wear fastness test under conditions of 10,000 reciprocations under a load of 75 g / cm ² using three types of wheel casters, the surface condition of the sample was visually evaluated according to the following criteria.
○: There was no particular change, and the appearance almost the same as before the examination was maintained. Δ: Some wear, gloss change or some coloring occurred, but the good appearance was maintained and it can be used without any problem. The surface was worn or rubber ring marks were visible, or coloring was conspicuous

From Table 1,
[Examples 1 to 5]
When the content of the foamed microcapsule in the foamed microcapsule-containing layer is small, the print design layer has good visibility and durability, but the surface feel and the cool / warm feeling are inferior. However, since the durability deteriorated, it was necessary to set an appropriate amount. For this reason, it turned out that 1.0-10.0 weight% is suitable with respect to 100 weight% of transparent resin paste as foaming microcapsule content.
[Examples 6 to 9, Comparative Example 2]
Even if the content of foamed microcapsules is within an appropriate range (3% by weight), the surface properties such as anti-contamination and durability are inferior depending on the presence or absence of the surface treatment layer. In order to maintain and exert it over time, it was found that it is necessary to provide a surface treatment layer in addition to containing an appropriate amount of the foamed microcapsules.

From Table 2,
[Example 2, Example 10, Example 11]
Since the foaming microcapsule used in Example 10 has a relatively low foaming start temperature compared to that used in Example 2, the foaming microcapsule-containing layer was more foamed than the other examples under the same foaming conditions. Although the visibility and durability were somewhat inferior, they were excellent in surface feel and cool / warm feeling. On the other hand, in Example 11, compared with the foamed microcapsules used in Example 2, those having higher foaming start temperature and maximum foaming temperature were used, so the foaming ratio of the foamed microcapsule-containing layer was lower than in other Examples, and the surface feel Although it was somewhat inferior to the cool and warm feeling, it was excellent in the visibility and durability of the printed design layer.

The decorative sheet of the present invention has a soft tactile sensation and a high-class feeling, is warm, and can easily remove water and dirt by wiping and cleaning, and maintains these effects over a long period of time.
For this reason, the decorative sheet according to the present invention can be used around the water in kitchens, toilets, washrooms, etc. like a conventional cushion floor, and can also be used as a high-quality rug such as a suede or a back skin. . In addition, because it does not involve construction, it can be laid in various places such as floor tiles such as toilets and washrooms, dining and living rooms, flooring in children's rooms, and tatami mats between bedrooms and guests.
Furthermore, since it is excellent in temperature sensitivity, it is also beneficial to make the base material layer water-resistant so that it is laid in a bathroom washing place in the cold winter season.

DESCRIPTION OF SYMBOLS 1 Base material layer 2 Foamed layer 3 Printed design layer 4 Transparent wear layer 5 Foamed microcapsule containing layer 6 Surface treatment layer 7 Foamed microcapsule

Claims (5)

A decorative sheet comprising a base material layer, a foam layer, a printed design layer, a transparent wear layer, a foam microcapsule-containing layer, and a surface treatment layer,
The microcapsule-containing resin layer contains 1.0 to 10.0% by weight of foamed microcapsules with respect to 100% by weight of the transparent resin paste,
The decorative sheet is characterized in that the surface treatment layer is a functional layer.   The decorative sheet according to claim 1, wherein the surface treatment layer has a thickness of 2 to 50 μm.   The decorative sheet according to claim 1 or 2, wherein the foaming temperature of the foamed microcapsule is from a foaming start temperature of 120 ° C to a maximum foaming temperature of 185 ° C. On the base material layer, a resin composition containing a foaming agent is applied, and heat-dried below the foaming start temperature of the resin composition to form an unfoamed foam layer, on which a printed design layer, transparent A synthetic resin layer is sequentially applied and dried to form a laminate, and further a foamed microcapsule-containing resin is applied. After the foamed layer and the foamed microcapsule-containing layer are foamed by heat treatment, the functional material is applied and dried. A method for producing a decorative sheet, comprising forming a surface treatment layer. The heating temperature in the heat treatment for foaming the foamed layer and the foamed microcapsule-containing layer is equal to or higher than the foaming temperature of the foamed layer and higher than the maximum foaming temperature of the foamed microcapsule, and the cell holding of the foamed microcapsule is maintained. The method for producing a decorative sheet according to claim 4, wherein the rate is a temperature that does not fall below 50%.