JP3893485B2 - Decorative sheet - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a decorative sheet that is bonded to a wall surface or a ceiling surface as wallpaper, an exterior sheet, a vehicle interior material, or the like.
[0002]
[Prior art]
In a decorative sheet constructed by applying and laminating a resin composition to a backing paper, a large amount of inorganic powder (filler) mainly composed of calcium carbonate is blended in the resin composition in order to reduce costs. Uses a vinyl chloride paste resin, which has good adhesiveness and enables the incorporation of a large amount of inorganic powder.
[0003]
[Problems to be solved by the invention]
When a large amount of inorganic powder is blended in the resin composition, the blending amount of the plasticizer is increased and the viscosity is adjusted. However, the plasticizer is not only a harmful substance but also a flammable substance. Even if the amount is increased, the decorative sheet does not become flame retardant, and the vinyl chloride resin generates harmful combustion gas containing halogen (chlorine), so it is inexpensive and has excellent flame resistance. A sheet cannot be obtained. For this reason, it has been attempted to use an emulsion type resin or latex such as vinyl acetate or ethylene vinyl acetate instead of the vinyl chloride paste resin. However, 60 P.A. H. R. The resin composition containing the above inorganic powder is not suitable for a decorative sheet because the coating film is hard and it is easy to crack and peel off. This is because the decorative sheet is required to have the flexibility necessary for close application along the undulations of the construction base, and the thickness of the coating film is generally 2 mm or less, so that the decorative sheet can be easily folded. This is because if the thickness is reduced to about 500 μm and 1 mm or less, the coating film is easily cracked in the conveyance process and the construction process.
In this specification, “PHR” means a weight part of a substance (for example, inorganic powder) to be blended with respect to 100 parts by weight of the resin.
[0004]
OBJECT OF THE INVENTION
Therefore, the present invention uses a water-dispersible resin instead of the vinyl chloride paste resin, and makes the coating film of the resin composition constituted by blending a large amount of inorganic powder with it flexible and difficult to peel off. The object is to obtain a decorative sheet that is flammable and does not generate harmful combustion gases at a low cost.
[0005]
[Means for Solving the Problems]
The decorative sheet according to the present invention includes 60P.M. containing inorganic powder having needle-like crystals. H. R. The above inorganic powder and a resin composition containing a resin emulsion as essential components are applied and laminated on a backing paper containing non-hygroscopic fibers, and the thickness of the coating film of the resin composition is 2 mm or less. It is a first feature.
[0006]
A second feature of the decorative sheet according to the present invention is that, in addition to the first feature, the inorganic powder having needle-like crystals is sepiolite, and 40% by weight or more of the inorganic powder contained in the coating film is sepiolite. The backing paper is a papermaking paper containing glass fibers as non-hygroscopic fibers.
[0007]
The third feature of the decorative sheet according to the present invention is that, in addition to the second feature, sepiolite and diatomaceous earth occupy 80% by weight or more of the inorganic powder contained in the coating film.
[0008]
A fourth feature of the decorative sheet according to the present invention is that, in addition to any of the first, second, and third features, a decorative paint film is laminated on the paint film.
[0009]
The fifth feature of the decorative sheet according to the present invention is that, in addition to any of the first, second, third and fourth features, the coating film is embossed.
[0010]
A sixth feature of the decorative sheet according to the present invention is that, in addition to any of the first, second, third, fourth and fifth features, the resin emulsion is an ethylene vinyl acetate resin emulsion. is there.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
The reason why the inorganic powder having needle-like crystals is blended in the resin composition to be applied to the backing paper is that even if each pulp fiber is a very short fine powder, the mixed water in which the blended water floats in the pulp The resin composition applied to the backing paper has a small amount of resin solids so that the paper fine paper is slightly touched to become viscous and a papermaking paper in which the pulp fiber fine powder is entangled with the evaporation of moisture is obtained. In addition, inorganic powders with needle-like crystals in the form of fine fiber powder are blended and become viscous, and with the evaporation of moisture, the inorganic powders with needle-like crystals are slightly entangled to form a coating film that is difficult to crack. Because.
[0012]
Due to the utility of the inorganic powder having such needle-like crystals, 60P. H. R. Even if the inorganic powder occupies the above, it is possible to laminate a coating film that is flexible and difficult to peel off. And so that the inorganic powder 60P. H. R. By blending as described above and reducing the ratio of the resin solid content in the coating film, the decorative sheet can be made inexpensive, flame retardant, and free from harmful combustion gases.
For this purpose, the inorganic powder having needle-like crystals accounts for 40% by weight or more of the coating film, and even if other inorganic powder is blended in the resin composition, 40% by weight of the inorganic powder contained in the coating film. The resin composition may be prepared so that the inorganic powder having needle-like crystals occupies the above.
[0013]
When thickening the coating film to be applied and laminated, it is advisable to add fiber fine powder to the resin composition. As the fine fiber powder, hydrophilic fibers such as glass fibers, pulp fibers, vinylon, cotton, hemp, rayon, cupra, and cellulose-based fibers such as acetate may be used.
This is because these hydrophilic fibers are well adapted to the water-dispersible or water-soluble resin as an essential component of the resin composition and become a reinforcing material for the coating film.
[0014]
As the resin emulsion, ethylene vinyl acetate resin emulsion, vinyl acetate resin emulsion, ethylene vinyl acetate vinyl chloride resin emulsion, natural or synthetic latex, and other general commercially available resin emulsions and latexes are all used. Among them, the ethylene vinyl acetate resin emulsion is recommended because the coating film is flexible and has strong adhesiveness and heat-sealability, and it is easy to heat emboss the coating film of the resin composition.
[0015]
60P. H. R. The coating film containing the above inorganic powder is more susceptible to cracking than the coating film mainly composed of vinyl chloride paste resin like conventional decorative sheets, and bubbles generated during the preparation process and coating process of the resin composition When the coating film becomes porous due to the above, it becomes easy to be scratched when the surface is rubbed.
Therefore, it is recommended to add an antifoaming agent to the resin composition so that the coating film does not become porous due to bubbles generated in the preparation process and coating process of the resin composition. As the antifoaming agent, a commercially available silicone-based material may be used.
[0016]
As the backing paper, in addition to the paper-making paper having glass fibers, synthetic paper or nonwoven fabric mainly composed of polypropylene fibers or other thermoplastic non-hygroscopic synthetic fibers can be used.
The non-hygroscopic fiber is an essential component of the backing paper because the resin composition applied and laminated thereon has water as an essential component, and when it is applied, the backing paper absorbs moisture and does not shrink and deform. It is for doing so.
Therefore, the non-hygroscopic fiber mentioned here means a fiber that does not swell due to hygroscopic swelling, does not mean a fiber that does not absorb moisture at all, and a fiber material such as nylon or polyester fiber has some hygroscopicity. But you can.
Also, even if the fiber surface has moisture absorption due to fine irregularities, if the fiber material itself is hydrophilic and does not swell and absorb moisture, such as cellulosic fibers, it will not absorb moisture. Can be used as backing fiber for backing paper.
However, considering the heat shrinkage in the drying process of the coating film, expansion / contraction deformation after construction of the decorative sheet 15, water resistance, weather resistance, flame resistance, etc., glass fibers having a fiber length of 1 to 5 mm are 10 to 10. It is recommended to use papermaking containing 50% by weight for the backing paper.
[0017]
Inorganic powder was added to the resin composition at 60P. H. R. The above composition is not only for reducing the cost of the resin composition and making the resin composition flame retardant, but also increasing the hygroscopicity and printability of the decorative sheet, reducing the surface gloss of the decorative sheet and reducing the earth wall This is also to provide a tactile feel.
It is cosmetic that sepiolite and zeolite having humidity control properties are used as the inorganic powder having acicular crystals (acicular crystal structure), and diatomaceous earth is used as the other inorganic powder mixed with the inorganic powder having acicular crystals. This is advantageous in improving the hygroscopicity and printability of the sheet.
In addition, aluminum hydroxide is preferably added to the resin composition to make the decorative sheet flame-retardant, and barium sulfate is preferably added to the resin composition to impart sound insulation.
However, if the blending amount of the inorganic powder is too large, the decorative sheet becomes hard and easily cracks. H. Limit R.
[0018]
When the thickness of the coating is 1 mm or less and around 500 μm, like the coating film of a decorative sheet mainly made of conventional vinyl chloride paste resin, the particle size of the inorganic powder is around 60 mesh (particle size: 250 μm) or so. In the following, it is desirable to use the inorganic powder of about 60 mesh (particle size: 250 μm) mixed with the inorganic powder of about 300 mesh (particle size: 50 μm).
According to a preferred embodiment of the present invention, the inorganic powder has a particle size of 35 to 55 parts by weight (around 45 parts by weight) having a particle size of 250 to 100 μm (60 mesh pass) and a particle size of 100 to 50 μm (150 mesh pass). Of diatomaceous earth of 40 to 60 parts by weight (around 50 parts by weight) and a particle size distribution and a mixing ratio of 10 to 25 parts by weight (around 15 parts by weight) of sepiolite having a particle size of 50 μm or less (300 mesh pass).
[0019]
As described above, the surface of the coating film of the decorative sheet according to the present invention has fine irregularities and exhibits the appearance of a dirt wall, but in order to improve wear resistance and decorativeness, a required pattern on the coating film is required.・ Print the pattern.
Since the coating film of the resin composition contains a large amount of hygroscopic sepiolite and diatomaceous earth, the decorative coating film of the printing ink adheres firmly to the coating film of the resin composition.
[0020]
【Example】
Paper made of glass fiber and pulp fiber with a basis weight of 90 g / m ² and a thickness of 0.16 mm, 200 parts by weight of ethylene vinyl acetate resin emulsion (solid content: 55%), and diatomaceous earth (particle size: 150 mesh pass, grain) 50 parts by weight of diameter: 100 μm or less, 45 parts by weight of sepiolite (particle size: 60 mesh pass, particle size: 250 μm or less), 15 parts by weight of sepiolite (particle size: 300 mesh pass, particle size: 50 μm or less), A resin composition consisting of 5 parts by weight of the agent and 150 parts by weight of water was applied and laminated at a coating amount of 300 g / m ² (dry weight) to produce a decorative sheet having a thickness of 0.8 mm.
The obtained decorative sheet had a flame retardancy of inorganic fire protection class 1 in the legal fire prevention material test (Wall Paper Material Association established wallpaper standard construction method 1983 test). Moreover, when this decorative sheet was bent 90 degrees, no cracks were generated in the coating film of the resin composition.
[0021]
【The invention's effect】
As described above, according to the present invention, the surface coating film contains a large amount of inorganic powder, has flame retardancy, and the inorganic powder is in the form of fiber powder (acicular crystal structure) having acicular crystals. It is difficult to crack because it is meshed in the coating film, and because most of its inorganic powder has hygroscopicity, it is easy to give a printed pattern, soft touch feeling, hygroscopic property and difficult to condense, vehicle interior A decorative sheet suitable for materials and wall coverings can be obtained.

Claims (9)

The inorganic powder having acicular crystals accounts for 40% by weight or more of the coating film . H. R. The above inorganic powder and a resin composition containing a resin emulsion as essential components are applied and laminated on a backing paper containing non-hygroscopic fibers, and the thickness of the coating film of the resin composition is 1 mm or less. A decorative sheet characterized by being. 60P. Containing sepiolite. H. R. The above inorganic powder and a resin composition containing a resin emulsion as essential components are applied and laminated on a papermaking paper containing glass fiber, and the thickness of the coating film of the resin composition is 1 mm or less, A decorative sheet characterized in that 40% by weight or more of the inorganic powder contained in the coating film is sepiolite. 60P. Containing sepiolite and diatomaceous earth. H. R. The above inorganic powder and a resin composition containing a resin emulsion as essential components are applied and laminated on a backing paper containing non-hygroscopic fibers, and the thickness of the coating film of the resin composition is 1 mm or less. A decorative sheet characterized in that 80% by weight or more of the inorganic powder contained in the coating film is sepiolite and diatomaceous earth. The inorganic powder having acicular crystals accounts for 40% by weight or more of the coating film . H. R. The above inorganic powder and a resin composition containing a resin emulsion as essential components are applied and laminated on a backing paper containing non-hygroscopic fibers, and the thickness of the coating film of the resin composition is 1 mm or less. A decorative sheet, wherein a decorative coating film is laminated on the coating film. The inorganic powder having acicular crystals accounts for 40% by weight or more of the coating film . H. R. And above inorganic powder, a resin composition for a resin emulsion as an essential component, is constructed by coating deposited on the backing paper containing a non-hygroscopic fibers, a thickness of the coating film of the resin composition is 1mm or less A decorative sheet characterized in that the coating film is embossed. The inorganic powder having acicular crystals accounts for 40% by weight or more of the coating film . H. R. The above inorganic powder and a resin composition having an ethylene vinyl acetate resin emulsion as essential components are applied and laminated on a backing paper containing non-hygroscopic fibers, and the thickness of the coating film of the resin composition is A decorative sheet having a thickness of 1 mm or less. The decorative sheet according to any one of claims 1, 2, 3, 4, 5, and 6, wherein the inorganic powder is a mixture of an inorganic powder having a particle size of 60 mesh pass and an inorganic powder having a particle size of 300 mesh pass. The makeup according to any one of claims 1, 2, 3, 4, 5 and 6, wherein the inorganic powder is a mixture of sepiolite having a particle size of 60 mesh pass, diatomaceous earth having a particle size of 150 mesh pass, and sepiolite having a particle size of 300 mesh pass. Sheet. Inorganic powder is 35 to 55 parts by weight of sepiolite having a particle size of 250 to 100 μm (60 mesh pass), 40 to 60 parts by weight of diatomaceous earth having a particle size of 100 to 50 μm (150 mesh pass), and a particle size of 50 μm or less (300 mesh). The decorative sheet according to any one of claims 1, 2, 3, 4, 5, and 6, which is mixed with a particle size distribution and a mixing ratio of 10 to 25 parts by weight of sepiolite.