JP6217830B2 - Laminated sheet and foam laminated sheet - Google Patents

Description

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

  Conventionally, as wallpaper used for a wall surface of a house or the like, for example, there is a foam laminated sheet that provides a foamed resin layer laminated on a base material, which is known as a foam wallpaper. For such foamed wallpaper, attempts have been made to improve the foamed resin layer in order to improve various performances required for wallpaper such as scratch resistance.

For example, in Patent Document 1, in a foam wallpaper having at least a foam resin layer on a substrate,
The foaming agent-containing resin layer for forming the foamed resin layer contains low-density polyethylene showing a specific range of density and ultra-low-density polyethylene showing a specific range of density as the resin component, and the ultra-low-density polyethylene is specified A foamed wallpaper which is a mixture of ultra-low density polyethylene A and B having the structure is disclosed. Further, it is specifically disclosed that the contents of the low-density polyethylene and the ultra-low-density polyethylene are 80 parts by weight and 20 parts by weight, respectively [0070]
Paragraph (Table 1)).

  Here, foamed wallpaper is sometimes applied to the protruding corner of the wall surface, but there is a problem that objects are likely to collide because the protruding corner protrudes. In addition, the foamed wallpaper applied to the corners is bent and is partially stretched, so it is less resistant to scratches than when applied to a flat surface. . Therefore, the foamed wallpaper to be applied to the corners is used in a situation where the corners of the corners, that is, the corners of the corners of the corners are likely to occur. ) Is required.

However, although the foamed wallpaper disclosed in Patent Document 1 has excellent resistance to general scratches, there has been no sufficient study on the corner resistance against protrusion corners, and there is room for improvement. is there. In addition, it is conceivable to use a technique to improve the surface strength of foamed wallpaper in order to improve the corner resistance of protruding corners. However, if the surface strength is increased, the surface becomes brittle, and the corner corner resistance of the protruding corners decreases. In some cases, solving the problem is not easy.

  Furthermore, although the development of foam wallpaper with excellent surface strength has been widely addressed, the scratch resistance against sharp scratches with a small contact area, such as scratches caused by nails, etc. assumed in actual use. However, there is still room for improvement, and combined with the above-mentioned problem of scratch resistance at corners, foamed wallpaper that can withstand various usage modes in actual use has not been obtained.

  Therefore, development of a new foamed laminated sheet excellent in scratch resistance and corner resistance against protruding corners and a laminated sheet for obtaining the same are demanded.

JP 2009-235635 JP

  An object of the present invention is to provide a new foamed laminated sheet having excellent scratch resistance and corner resistance.

  Moreover, it aims at providing the laminated sheet (unfoamed raw fabric) useful for manufacture of the said foaming laminated sheet.

As a result of intensive studies, the inventor has at least a foaming agent-containing resin layer on a substrate, and the foaming agent-containing resin layer contains ultra-low density polyethylene and low density polyethylene, and contains the foaming agent. According to the laminated sheet in which the mass ratio (m1) / (m2) between the mass of the ultra-low density polyethylene (m1) and the mass of the low density polyethylene (m2) in the resin layer is 70/30 to 50/50 The present inventors have found that the above object can be achieved, and have completed the present invention.

That is, the present invention relates to the following laminated sheet and foamed laminated sheet.
1． A laminated sheet having at least a foaming agent-containing resin layer on a substrate,
(1) The foaming agent-containing resin layer contains ultra-low density polyethylene and low density polyethylene,
(2) The mass ratio (m1) / (m2) of the mass (m1) of the ultra-low density polyethylene and the mass (m2) of the low-density polyethylene in the foaming agent-containing resin layer is 70/30 to 50 / 50,
A laminated sheet characterized by that.
2． The resin component density of the foaming agent-containing resin layer is 0.910 g / cm ³ or more, 0.920 g / cm ³ or less.
Item 2. The laminated sheet according to Item 1 above.
3． Item 3. The laminated sheet according to Item 1 or 2, wherein a non-foamed resin layer A is laminated on the foaming agent-containing resin layer.
Four. Item 4. The laminated sheet according to Item 3, wherein the non-foamed resin layer A contains ultra-low density polyethylene.
Five. Item 5. The laminated sheet according to Item 4, wherein the non-foamed resin layer A further contains low-density polyethylene.
6． The non-foamed density of the resin component of the resin layer A is 0.880 g / cm ³ or more and 0.910 g / cm ³ or less, the laminated sheet according to any one of items 3-5.
7． 7. A foamed laminated sheet obtained by foaming the foaming agent-containing resin layer of the laminated sheet according to any one of items 1 to 6.
8． Item 8. The foamed laminated sheet according to Item 7, wherein embossing is performed from the top surface layer.

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

≪Laminated sheet≫
The laminated sheet of the present invention has at least a foaming agent-containing resin layer on the substrate,
(1) The foaming agent-containing resin layer contains ultra-low density polyethylene and low density polyethylene,
(2) The mass ratio (m1) / (m2) of the mass of the ultra-low density polyethylene (m1) to the mass of the low-density polyethylene (m2) in the foaming agent-containing resin layer is 70 / 30-50 / It is characterized by 50.

The laminated sheet of the present invention having the above characteristics has a mass ratio (m1) / (m2) between the mass (m1) of the ultra-low density polyethylene and the mass (m2) of the low-density polyethylene in the foaming agent-containing resin layer is 70 / When the foaming agent-containing resin layer is foamed by being 30-50 / 50, scratch resistance against scratches under higher load conditions such as scratches caused by nails, etc. assumed in actual use In addition, it is possible to obtain a foamed laminated sheet that is not easily scratched even when applied to the corners of the wall surface, that is, has excellent corner resistance.

In the present specification, low density polyethylene means polyethylene having a density of 0.914 to 0.930 g / cm ³ . The ultra-low density polyethylene means a polyethylene having a density of 0.880 to 0.913 g / m ³ . The polyethylene also includes an ethylene-α olefin copolymer which is a copolymer of ethylene and a small amount of α olefin.

The layer structure of the laminated sheet of the present invention is not particularly limited as long as it has at least a foaming agent-containing resin layer on the substrate. For example, as a suitable layer configuration, a layer configuration having a non-foamed resin layer B, a foaming agent-containing resin layer, a non-foamed resin layer A, a design pattern layer, and a surface protective layer in that order on the substrate is preferable. Hereinafter, each layer will be described by taking this preferable layer configuration as an example. In the laminated sheet of the present invention, the foaming agent-containing resin layer (the non-foamed resin layer A, the pattern layer or the surface layer if it has a surface protective layer) is a so-called “front surface” (visible after construction). The surface). Therefore, in this specification, the direction in which the foaming agent-containing resin layer is present with respect to the substrate is referred to as “front” or “upper”, and the opposite side is referred to as “back” or “lower”.

It does not limit as a base material base material, A well-known fiber sheet (backing paper) etc. can be utilized.

  Specifically, wallpaper general paper (pulp-based sheet sized with a known sizing agent); flame-retardant paper (pulp-based sheet treated with a flame retardant such as guanidine sulfamate or guanidine phosphate) ); Inorganic paper containing inorganic additives such as aluminum hydroxide and magnesium hydroxide; fine paper; thin paper; fiber mixed paper (paper made by mixing pulp and synthetic fiber). In addition, what corresponds to a nonwoven fabric on classification is included in these fibrous base materials.

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

Foaming agent-containing resin layer The foaming agent-containing resin layer contains ultra-low density polyethylene as a resin component. When the foaming agent-containing resin layer contains ultra-low density polyethylene at a specific mass ratio, the foamed laminated sheet obtained by foaming the laminated sheet of the present invention can exhibit resistance to corner damage.

The ultra-low density polyethylene is not particularly limited as long as it is a polyethylene resin having a density of 0.880 to 0.913 g / m ³ , and a known commercial product can be used. Commercially available products include, for example, Ube Maruzen polyethylene “015AN” (trade name) density 0.911 g / cm ³ ; Ube Maruzen polyethylene “613A” (trade name) density 0.913 g / cm ³ ; Nippon Polyethylene “KS571” ( Product name) Density 0.907 g / cm ³ ; Nippon Polyethylene “KJ640T” (trade name) density 0.880 g / cm ³ ; Japan Polyethylene product name “KS560T” (trade name) density 0.898 g / cm ³ . The density of the ultra-low density polyethylene is preferably 0.880 to 0.907 g / m ³ .

  The foaming agent-containing resin layer contains low-density polyethylene as a resin component. When the foaming agent-containing resin layer contains low density polyethylene in a specific mass ratio, the foamed laminated sheet obtained by foaming the laminated sheet can exhibit scratch resistance.

The low density polyethylene is not particularly limited as long as it is a polyethylene resin having a density of 0.914 to 0.930 g / m ³ , and a known commercial product can be used. Examples of commercially available products include “L719” (trade name) density 0.918 g / cm ³ ) manufactured by Ube Maruzen Polyethylene. The density of the low density polyethylene is preferably 0.914 to 0.925 g / m ³ .

  In addition, the foaming agent-containing resin layer contains ultra-low density polyethylene and low density polyethylene in a specific mass ratio, thereby imparting appropriate stiffness to the foam laminate sheet obtained by foaming the laminate sheet of the present invention. Therefore, the generation of wrinkles in the foamed laminated sheet during construction is suppressed, and workability is improved.

The foaming agent-containing resin layer may contain a resin other than ultra-low density polyethylene and low-density polyethylene as a resin component as long as the object of the present invention is not impaired. Here, as the resin other than ultra-low density polyethylene and low density polyethylene, polyethylene having a density exceeding 0.930 g / cm ³ or an ethylene copolymer having a monomer other than ethylene and ethylene (hereinafter referred to as “ethylene copolymer”). Abbreviated as “union”). As described above, in the present specification, polyethylene includes an ethylene-α olefin copolymer, which is a copolymer of ethylene and a small amount of α olefin. Therefore, in the ethylene-α olefin copolymer, Those having a density exceeding 0.930 g / cm ³ are resins other than ultra-low density polyethylene and low density polyethylene.

Ethylene copolymers are suitable for extrusion film formation from the viewpoint of melting point and melt flow rate (MFR). Examples of the ethylene copolymer include an ethylene-vinyl acetate copolymer (EVA), an ethylene-methyl methacrylate copolymer (EMMA), and an ethylene-acrylic acid copolymer (EAA).
), Ethylene-ethyl acrylate copolymer (EEA), ethylene-methyl acrylate copolymer (EMA), ethylene-methacrylic acid copolymer (EMAA), and the like. These ethylene copolymers can be used alone or in admixture of two or more.

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

The resin component contained in the foaming agent-containing resin layer, that is, the resin component containing ultra-low density polyethylene and low-density polyethylene preferably has a density of 0.910 g / cm ³ or more, preferably 0.912 g / cm ³ or more. It is more preferable. By setting the density of the resin component within the above range, it is possible to obtain a laminated sheet with more excellent scratch resistance of the foamed laminated sheet obtained after foaming. The upper limit of the density of the resin component contained in the foaming agent-containing resin layer is not particularly limited, but is preferably 0.920 g / cm ³ or less, and more preferably 0.915 g / cm ³ or less.
In particular, when the density of the resin component is 0.915 g / cm ³ or less, the curled resistance of the foamed laminated sheet obtained after foaming can be improved and the workability can be improved. The curl resistance will be described later in the section of the non-foamed resin layer A.

The mass ratio (m1) / (m2) of the mass (m1) of the ultra-low density polyethylene and the mass (m2) of the low density polyethylene in the foaming agent-containing resin layer is 70/30 to 50/50. It is preferable that it is 70 / 30-55 / 45. By setting the mass ratio (m1) / (m2) in such a range, the foamed laminate sheet obtained by foaming the laminate sheet of the present invention has excellent scratch resistance and excellent corner resistance. It becomes a sheet that combines. If the mass ratio (m1) / (m2) is greater than 70/30, the scratch resistance is poor. On the other hand, if it is less than 50/50, it is inferior in the corner resistance against protruding corners. When the mass ratio (m1) / (m2) is greater than 70/30, the value of (m1) is greater than 70/30 (m2)
Is smaller (eg 80/20) and less than 50/50 means that (m1) is smaller than 50/50 (m2) is larger (eg 40 / 60).

In the present invention, the resin component contained in the foaming agent-containing resin layer preferably has an MFR measured at 190 ° C. and a load of 21.18 N described in JIS K 6922 of 10 to 35 g / 10 min. When the MFR is within the above range, there is little increase in temperature when the foaming agent-containing resin layer is formed by extrusion film formation, and the film can be formed in a non-foamed state. It can be printed on any surface and there are few patterns missing. If the MFR is too large, the resin is too soft and the resulting foamed resin layer may have insufficient scratch resistance.

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

Examples of the thermally decomposable foaming agent include azo series such as azodicarbonamide (ADCA) and azobisformamide; hydrazide series such as oxybenzenesulfonyl hydrazide (OBSH) and paratoluenesulfonyl hydrazide. The content of the pyrolytic foaming agent can be appropriately set according to the type of foaming agent, the expansion ratio, and the like. From the viewpoint of the expansion ratio, it is 3 times or more, preferably about 5 to 10 times, and the pyrolytic foaming agent is preferably about 1 to 20 parts by mass with respect to 100 parts by mass of the resin component.

  The foaming aid is preferably a metal oxide and / or a fatty acid metal salt. For example, zinc stearate, calcium stearate, magnesium stearate, zinc octylate, calcium octylate, magnesium octylate, zinc laurate, calcium laurate, laurin Magnesium acid, zinc oxide, magnesium oxide and the like can be used. About 0.001-20 mass parts is preferable with respect to 100 mass parts of resin components, and, as for content of these foaming adjuvants, about 0.001-10 mass parts is more preferable.

Examples of the inorganic filler include calcium carbonate, aluminum hydroxide, magnesium hydroxide, antimony trioxide, zinc borate, and a molybdenum compound. By including an inorganic filler, an effect of suppressing see-through, an effect of improving surface characteristics, and the like are obtained. The content of the inorganic filler is preferably about 0 to 100 parts by mass and more preferably about 20 to 70 parts by mass with respect to 100 parts by mass of the resin component.

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

In the present invention, the foaming agent-containing resin layer may be resin-crosslinked by electron beam irradiation. What is necessary is just to implement according to the method described in the manufacturing method mentioned later as the method of irradiating an electron beam to a foaming agent containing resin layer, and the method of making it foam. The thickness of the foaming agent-containing resin layer is preferably about 40 to 100 μm, and the thickness of the foamed resin layer after foaming is preferably about 300 to 700 μm.

Non-foamed resin layer A
The top surface of the foaming agent-containing resin layer may have a non-foamed resin layer A for the purpose of improving the scratch resistance of the foamed resin layer or clarifying the pattern when forming the pattern layer. .

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

Examples of the polyolefin resin include polyethylene, polypropylene, polybutene, polybutadiene, polyisoprene, and the like, a copolymer of ethylene and an α-olefin having 4 or more carbon atoms (linear low density polyethylene), ethylene-acrylic acid copolymer, and the like. Polymer, ethylene-methyl acrylate copolymer, ethylene-ethyl acrylate copolymer, ethylene- (meth) acrylic acid copolymer such as ethylene-methacrylic acid copolymer, ethylene-vinyl acetate copolymer ( EVA), ethylene-vinyl acetate copolymer saponified product, ionomer and the like.

Among these polyolefin resins, polyethylene is preferable, and the polyethylene is more preferably ultra-low density polyethylene having a density of 0.880 to 0.913 g / m ³ . The density of the ultra-low density polyethylene is more preferably 0.880 to 0.907 g / m ³ . The resin component of the non-foamed resin layer A preferably further contains low-density polyethylene in addition to the ultra-low-density polyethylene.

The density of the resin component contained in the non-foamed resin layer A, 0.880 g / cm ³ or more, preferably 0.910 g / cm ³ or less, 0.880 g / cm ³ or more, 0.900 g / cm ³ or less is more preferable. By setting the density of the resin component contained in the non-foamed resin layer A within the above range, curling of the foamed laminated sheet during construction can be suppressed. When constructing foamed laminated sheets as wallpaper, apply construction glue on the back side of the foamed laminated sheet, fold the laminated sheet in half, and stack the backsides together to prevent the glue from drying out before construction. However, if the curl resistance is inferior (easy to curl), the end of the foam laminate sheet will bend and the construction paste applied to the curled part will dry, and the foam laminate sheet will be applied to the wall surface. However, there is a problem that the end portion is not sufficiently bonded and peeled off. In the laminated sheet of the present invention, since the density of the resin component contained in the non-foamed resin layer A is within the above range, the occurrence of curling of the foamed laminated sheet obtained after foaming is suppressed. The peeling of the end of the laminated sheet is suppressed, and the workability is excellent.

In addition, by setting the density of the resin component contained in the non-foamed resin layer A within the above-mentioned range, the foamed laminated sheet applied to the protruding corner part does not follow the shape of the base and floats, so-called springback occurs. In this respect, the workability is excellent.

That is, in the laminated sheet of the present invention, the density of the resin component contained in the foamed resin layer A is within the above-mentioned range, curling is suppressed, and the foamed laminated sheet having excellent workability is produced. Useful.

The thickness of the non-foamed resin layer A is not limited, but is preferably about 2 to 50 μm, and more preferably about 2 to 15 μm.

  In the present invention, from the viewpoint of production described later, when the foaming agent-containing resin layer is provided, an embodiment in which the non-foaming resin layer B, the foaming agent-containing resin layer, and the non-foaming resin layer A are formed in order is preferable. The non-foamed resin layer B and / or the non-foamed resin layer A may be formed by extrusion film formation, or may be formed by heat laminating each film.

Non-foamed resin layer B
In the present invention, a non-foamed resin layer B (adhesive resin layer) may be further provided on the back surface (surface on which the base material is laminated) of the foaming agent-containing resin layer for the purpose of improving the adhesive force with the base material. Good.

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

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

In the present invention, an embodiment in which the non-foamed resin layer B, the foaming agent-containing resin layer, and the non-foamed resin layer A are sequentially formed on the substrate is also preferable from the viewpoint of production described later.

On the pattern pattern layer foaming agent-containing resin layer (or non-foamed resin layer A), a pattern pattern layer may be formed as necessary.

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

  The pattern pattern layer can be formed, for example, by printing a pattern pattern. Examples of printing methods include gravure printing, flexographic printing, silk screen printing, offset printing, and the like. As the printing ink, a printing ink containing a colorant, a binder resin, and a solvent can be used. These inks can be known or commercially available.

  The binder resin can be set according to the type of the layer immediately below. For example, acrylic resin, styrene resin, polyester resin, urethane resin, chlorinated polyolefin resin, vinyl chloride-vinyl acetate copolymer resin, polyvinyl butyral resin, alkyd resin, petroleum resin, ketone resin, epoxy Resin, melamine resin, fluorine resin, silicone resin, fiber derivative, rubber resin and the like.

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

  As the colorant, a pigment used in a foaming agent-containing resin layer can be used as appropriate.

The thickness of the design pattern layer varies depending on the type of design pattern, but is generally preferably about 0.1 to 10 μm.

Protective layer (overcoat layer)
In the present invention, the surface of the foamed resin layer (or foaming agent-containing resin layer), the non-foamed resin layer A, or the pattern layer may have a protective layer. The protective layer is a layer formed in order to adjust the gloss of the surface of the laminated sheet or the foamed laminated sheet described later, or to impart strength and stain resistance to the surface. Moreover, when providing a picture pattern layer in a lamination sheet or a foaming lamination sheet, a protective layer is a layer formed on the said picture pattern layer as needed in order to protect the said pattern pattern layer.

  As a resin component used for forming the protective layer, a resin component capable of satisfying the tear strength (and surface strength as required) is appropriately selected from known resin components such as thermoplastic resins and curable resins. That's fine.

Examples of the thermoplastic resin used for forming the protective layer include polyolefin resins, acrylic resins, polyvinyl alcohol resins, and fluorine resins. Among these thermoplastic resins, ethylene-acrylic acid copolymer, ethylene-methacrylic acid copolymer, ethylene-methyl methacrylate copolymer, ethylene-methyl acrylate copolymer, ethylene-ethyl acrylate copolymer are preferable. Ethylene (meth) acrylic acid copolymer resin such as ethylene-vinyl acetate copolymer (EVA); Saponified ethylene-vinyl acetate copolymer resin; Ionomer; Ethylene copolymer such as ethylene-olefin copolymer And other polyolefin resins. These thermoplastic resins may be used alone or in combination of two or more. Further, when a crosslinkable thermoplastic resin such as an ethylene copolymer is used for forming the protective layer, the thermoplastic resin may be subjected to a crosslinking treatment as necessary.

In addition, the curable resin used for forming the protective layer is not particularly limited, and examples thereof include a room temperature curable resin, a heat curable resin, an ionizing radiation curable resin, a one-component reaction curable resin, and a two-component reaction curable resin. Any of a curable resin, an ionizing radiation curable resin, and the like may be used, but a one-component reaction curable resin is preferable. Among these curable resins, acrylic resins, urethane resins, and the like are preferable, and one-component reaction curable acrylic resins are more preferable. These curable resins may be used alone or in combination of two or more. Moreover, when using curable resin for formation of a protective layer, in order to advance hardening reaction, you may use a crosslinking agent, a polymerization initiator, a polymerization accelerator, etc. as needed.

Further, the protective layer may be a single layer, or two or more layers that are the same or different may be laminated. For example, it may have a two-layer structure in which a layer formed of a curable resin is formed on the outermost surface and a layer formed of a thermoplastic resin is laminated on the lower layer.

  Although the thickness of a protective layer is not specifically limited, For example, 1-20 micrometers is preferable and 1-15 micrometers is more preferable.

  The protective layer may be formed by a method corresponding to the type of resin component used. For example, in the case of forming a protective layer using a thermoplastic resin, the protective layer may be formed by pasting a thermoplastic resin film prepared in advance to the surface of the pattern layer. The protective layer may be formed by forming a thermoplastic resin film on the surface of the layer.

In the case of forming a protective layer using a curable resin, for example, a resin composition containing various additives as required in a thermosetting resin can be used in gravure coating, bar coating, roll coating, reverse After coating the foamed resin layer (or foaming agent-containing resin layer), non-foamed resin layer A, or pattern layer by a method such as roll coating or comma coating, the above resin composition is dried by heating or the like as necessary. And curing.

In addition, before forming the protective layer, a surface treatment such as corona treatment or plasma treatment, or a primer layer may be provided on the surface of the non-foamed resin layer A or the pattern pattern layer in consideration of adhesiveness.

  As the resin contained in the primer layer, for example, acrylic resin, vinyl chloride-vinyl acetate copolymer, polyester, polyurethane, chlorinated polypropylene, chlorinated polyethylene, and the like can be used. Polypropylene or the like is desirable.

The thickness of the primer layer is not limited, but is preferably about 0.1 to 10 μm, more preferably about 0.1 to 5 μm.

≪Foamed laminated sheet≫
The foamed laminated sheet of the present invention can be obtained by foaming the foaming agent-containing resin layer of the laminated sheet. The heating conditions at the time of foaming are not limited as long as the foamed resin layer is formed by the decomposition of the foaming agent. The heating temperature is preferably about 210 to 240 ° C., and the heating time is preferably about 20 to 80 seconds.

The foamed laminated sheet of the present invention may be embossed from the top surface layer.
Examples of the embossed pattern include a wood grain plate conduit groove, a stone plate surface unevenness, a cloth surface texture, a satin texture, a grain texture, a hairline, and a multiline groove.

≪Laminated sheet and foamed laminated sheet manufacturing method≫
As a manufacturing method of a lamination sheet, first, a foaming agent containing resin layer is formed into a film using an extruder etc. on a base material, and it laminates | stacks on the preheated base material, and can obtain a laminated body. At this time, a multi-manifold type T die capable of simultaneously forming two layers by simultaneously extruding molten resin corresponding to two layers can be used.

When the foaming agent-containing resin layer has non-foaming resin layers on both sides (non-foaming resin layer A / foaming agent-containing resin layer / non-foaming resin layer B), a multi-manifold type that can form three layers simultaneously T
It is preferable to simultaneously extrude and form a molten resin corresponding to the three layers using a die extruder.

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

After forming the foaming agent-containing resin layer, electron beam irradiation may be performed. Thereby, a resin component can be bridge | crosslinked and the surface strength of a foamed resin layer, a foaming characteristic, etc. can be adjusted. The energy of the electron beam is preferably about 125 to 250 kV, and more preferably about 150 to 200 kV. The irradiation amount is preferably about 10 to 100 kGy, and more preferably about 10 to 50 kGy. A known electron beam irradiation apparatus can be used as the electron beam source.

After simultaneous lamination on the substrate, a pattern layer may be formed on the non-foamed resin layer A by a known method such as extrusion film formation. Furthermore, a surface protective layer may be provided on the non-foamed resin layer A or the pattern layer.

  Each of these layers can be laminated by combining printing such as coating, extrusion film formation, and the like in addition to printing.

  Next, a foamed laminated sheet can be manufactured by heat-treating the foaming agent-containing resin layer into a foamed resin layer.

  The heat treatment conditions may be any conditions as long as the foamed resin layer is formed by the decomposition of the pyrolytic foaming agent. The heating temperature is preferably about 210 to 240 ° C., and the heating time is preferably about 20 to 80 seconds.

In the laminated sheet of the present invention, the foaming agent-containing resin layer contains ultra-low density polyethylene and low-density polyethylene, and the mass (m1) of the ultra-low density polyethylene and the mass (m2) of the low-density polyethylene in the foaming agent-containing resin layer. When the mass ratio (m1) / (m2) is 70/30 to 50/50, by foaming the foaming agent-containing resin layer, scratches such as nails assumed in actual use, Foam with excellent scratch resistance against scratches under high load conditions and excellent surface strength even when applied to the corner of the wall surface, that is, excellent corner resistance A laminated sheet can be obtained.

It is a schematic diagram which shows an example of the layer structure of the lamination sheet of this invention.

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

Example 1
Non-foamed resin layer A, foaming agent-containing resin layer, and non-foamed resin layer B using a 3-type 3-layer T-die extruder
In this order, the film was extruded onto a fibrous sheet heated to 90 ° C. so as to have a thickness of 5 μm, 60 μm and 5 μm. As a result, a laminate including the non-foamed resin layer A, the foaming agent-containing resin layer, the non-foamed resin layer B, and the fibrous sheet was obtained. As the fiber sheet, wallpaper paper “NI-65A, made by Nippon Paper Industries” was used. The resin or resin composition used for forming each layer is as follows.
(Non-foamed resin layer A)
・ Ultra low density polyethylene (trade name “KJ640T”, made of Nippon Polyethylene, density: 0.880 g / cm ³
) 80 parts by mass, low-density polyethylene (trade name “L719”, Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 20 parts by mass (foaming agent-containing resin layer)
・ Ultra low density polyethylene (trade name “015AN”, Ube Maruzen polyethylene, density: 0.911 g / cm ³ ) 60 parts by mass ・ Ultra low density polyethylene (trade name “613A”, Ube Maruzen polyethylene, density: 0.913 g / cm ³ ) 10 parts by mass • Low-density polyethylene (trade name “L719”, Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 30 parts by weight • Colorant (trade name “Tai Pure R350”, DuPont) 40 parts by weight Foaming agent (trade name “Vinihole AC # 3”, manufactured by Eiwa Kasei Kogyo Co., Ltd.) 6 parts by weight Foaming aid (trade name “Zinc stearate”, manufactured by NOF) 4 parts by weight, crosslinking aid (trade name “OPSTAR JUA702 ", Made by JSR) 1 part by mass (non-foamed resin layer B)
・ Ethylene-vinyl acetate copolymer (EVA) (trade name “Evaflex EV150”, made by Mitsui DuPont Polychemicals) 100 parts by mass The density of the resin component of the non-foamed resin layer A is 0.888 g / cm ³ The density of the resin component of the foaming agent-containing resin layer was 0.913 g / cm ³ .

Extrusion conditions were such that the cylinder temperature containing the resin for forming the non-foamed resin layer A was 140 ° C, and the cylinder temperature containing the resin composition for forming the foaming agent-containing resin layer was 120 ° C.
The cylinder temperature in which the resin for forming the non-foamed resin layer B was accommodated was 100 ° C. The die temperature was 120 ° C. for all.

The laminate was irradiated with an electron beam from the non-foamed resin layer A side under the conditions of an acceleration voltage of 200 kV and an irradiation dose of 30 kGy to crosslink the foaming agent-containing resin layer.

Next, a texture pattern is printed on the surface of the non-foamed resin layer A with a gravure printing machine using water-based ink ("Hydric", manufactured by Dainichi Seika Kogyo Co., Ltd.) to form a pattern layer, and a laminated sheet is obtained. It was.

The laminated sheet is heated in an oven (at 220 ° C for 35 seconds) to form a foamed resin layer by foaming the foaming agent-containing resin layer, and then embossed by pressing a metal roll having a textured pattern. The foamed laminated sheet having an embossed shape was obtained.

Example 2
A foamed laminated sheet was produced in the same manner as in Example 1 except that the resin component of the non-foamed resin layer A was changed as follows.
(Non-foamed resin layer A)
・ Super low density polyethylene (trade name “KS571”, made of Japan polyethylene, density: 0.907 g / cm ³ ) 80 parts by mass ・ Low density polyethylene (trade name “L719”, made by Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 20 parts by mass

Example 3
A foamed laminated sheet was produced in the same manner as in Example 1 except that the resin component of the foaming agent-containing resin layer was changed as follows.
(Foaming agent-containing resin layer)
・ Ultra low density polyethylene (trade name “KS571”, manufactured by Nippon Polyethylene, density: 0.907 g / cm ³ ) 10 parts by mass ・ Ultra low density polyethylene (trade name “015AN”, made by Ube Maruzen polyethylene, density: 0.911 g / cm ³ ) 50 parts by mass, low-density polyethylene (trade name “L719”, Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 40 parts by mass

Example 4
A foamed laminated sheet was produced in the same manner as in Example 1 except that the resin component of the foaming agent-containing resin layer was changed as follows.
(Foaming agent-containing resin layer)
・ Ultra low density polyethylene (trade name “015AN”, Ube Maruzen polyethylene, density: 0.911 g / cm ³ ) 50 parts by mass ・ Ultra low density polyethylene (trade name “613A”, Ube Maruzen polyethylene, density: 0.913 g / cm ³ ) 10 parts by mass Low density polyethylene (trade name “L719”, Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 40 parts by mass

Example 5
A foamed laminated sheet was produced in the same manner as in Example 1 except that the resin components of the non-foamed resin layer A and the foaming agent-containing resin layer were changed as follows.
(Non-foamed resin layer A)
・ Ultra low density polyethylene (trade name “KJ640T”, made of Nippon Polyethylene, density: 0.880 g / cm ³
) 100 parts by mass (foaming agent-containing resin layer)
・ Ultra low density polyethylene (trade name “KS571”, manufactured by Nippon Polyethylene, density: 0.907 g / cm ³ ) 10 parts by mass ・ Ultra low density polyethylene (trade name “015AN”, made by Ube Maruzen polyethylene, density: 0.911 g / cm ³ ) 50 parts by mass, low-density polyethylene (trade name “L719”, Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 40 parts by mass

Example 6
A foamed laminated sheet was produced in the same manner as in Example 1 except that the resin component of the foaming agent-containing resin layer was changed as follows.
(Foaming agent-containing resin layer)
・ Ultra low density polyethylene (trade name “KS571”, manufactured by Nippon Polyethylene, density: 0.907 g / cm ³ ) 20 parts by mass ・ Ultra low density polyethylene (trade name “015AN”, made by Ube Maruzen polyethylene, density: 0.911 g / cm ³ ) 35 parts by mass / low density polyethylene (trade name “L719”, Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 45 parts by mass

Example 7
A foamed laminated sheet was produced in the same manner as in Example 1 except that the resin component of the foaming agent-containing resin layer was changed as follows.
(Foaming agent-containing resin layer)
・ Ultra low density polyethylene (trade name “KJ640T”, made of Nippon Polyethylene, density: 0.880 g / cm ³
) 5 parts by mass, ultra-low density polyethylene (trade name “015AN”, Ube Maruzen polyethylene, density: 0.911 g / cm ³ ) 45 parts by mass, low density polyethylene (trade name “L719”, Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 50 parts by mass

Example 8
A foamed laminated sheet was produced in the same manner as in Example 1 except that the resin components of the non-foamed resin layer A and the foaming agent-containing resin layer were changed as follows.
(Non-foamed resin layer A)
・ Ultra low density polyethylene (trade name “015AN”, Ube Maruzen polyethylene, density: 0.911 g / cm ³ ) 100 parts by mass (resin layer containing foaming agent)
・ Ultra low density polyethylene (trade name “KJ640T”, made of Nippon Polyethylene, density: 0.880 g / cm ³
) 5 parts by mass, ultra-low density polyethylene (trade name “015AN”, Ube Maruzen polyethylene, density: 0.911 g / cm ³ ) 45 parts by mass, low density polyethylene (trade name “L719”, Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 50 parts by mass

Comparative Example 1
A foamed laminated sheet was produced in the same manner as in Example 1 except that the resin components of the non-foamed resin layer A and the foaming agent-containing resin layer were changed as follows.
(Non-foamed resin layer A)
・ 100 parts by mass (resin layer containing foaming agent) of ultra-low density polyethylene (trade name “KS571”, manufactured by Nippon Polyethylene, density: 0.907 g / cm ³ )
・ Ultra low density polyethylene (trade name “KS560T”, made of Nippon Polyethylene, density: 0.898 g / cm ³
) 100 parts by mass

Comparative Example 2
A foamed laminated sheet was produced in the same manner as in Example 1 except that the resin components of the non-foamed resin layer A and the foaming agent-containing resin layer were changed as follows.
(Non-foamed resin layer A)
・ Ultra low density polyethylene (trade name “015AN”, Ube Maruzen polyethylene, density: 0.911 g / cm ³ ) 50 parts by mass ・ Ultra low density polyethylene (trade name “613A”, Ube Maruzen polyethylene, density: 0.913 g / cm ³ ) 30 parts by mass Low-density polyethylene (trade name “L719”, Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 20 parts by mass (foaming agent-containing resin layer)
・ Super low density polyethylene (trade name “KS571”, made of Japan polyethylene, density: 0.907 g / cm ³ ) 80 parts by mass ・ Low density polyethylene (trade name “L719”, made by Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 20 parts by mass

Comparative Example 3
A foamed laminated sheet was produced in the same manner as in Example 1 except that the resin components of the non-foamed resin layer A and the foaming agent-containing resin layer were changed as follows.
(Non-foamed resin layer A)
・ Super low density polyethylene (trade name “KS571”, made of Japan polyethylene, density: 0.907 g / cm ³ ) 80 parts by mass ・ Low density polyethylene (trade name “L719”, made by Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 20 parts by mass (foaming agent-containing resin layer)
・ Super low density polyethylene (trade name “KS571”, made of Japan polyethylene, density: 0.907 g / cm ³ ) 80 parts by mass ・ Low density polyethylene (trade name “L719”, made by Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 20 parts by mass

Comparative Example 4
A foamed laminated sheet was produced in the same manner as in Example 1 except that the resin component of the foaming agent-containing resin layer was changed as follows.
(Foaming agent-containing resin layer)
・ Super low density polyethylene (trade name “KS571”, made of Japan polyethylene, density: 0.907 g / cm ³ ) 80 parts by mass ・ Low density polyethylene (trade name “L719”, made by Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 20 parts by mass

Comparative Example 5
A foamed laminated sheet was produced in the same manner as in Example 1 except that the resin component of the foaming agent-containing resin layer was changed as follows.
(Foaming agent-containing resin layer)
・ Ultra low density polyethylene (trade name “015AN”, Ube Maruzen polyethylene, density: 0.911 g / cm ³ ) 50 parts by mass ・ Ultra low density polyethylene (trade name “613A”, Ube Maruzen polyethylene, density: 0.913 g / cm ³ ) 30 parts by mass Low-density polyethylene (trade name “L719”, Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 20 parts by mass

Comparative Example 6
A foamed laminated sheet was produced in the same manner as in Example 1 except that the resin component of the foaming agent-containing resin layer was changed as follows.
(Foaming agent-containing resin layer)
・ Ultra low density polyethylene (trade name “KS571”, manufactured by Nippon Polyethylene, density: 0.907 g / cm ³ ) 30 parts by mass ・ Ultra low density polyethylene (trade name “KS560T”, manufactured by Nippon Polyethylene, density: 0.898 g / cm ³⁾
) 10 parts by mass, low density polyethylene (trade name “L719”, made by Ube Maruzen polyethylene, density 0.918 g / cm ³ ) 60 parts by mass

  The foamed laminated sheets obtained in the examples and comparative examples were evaluated for scratch resistance, corner corner resistance, curl resistance and stiffness. Each test method and evaluation criteria are as follows. In addition, in the following test, if evaluation of 3-5 is obtained, it can be evaluated that it has the performance which can be used without a problem by actual use.

1． Scratch resistance (Belmer scratch test)
Scratch resistance was evaluated using a Belmar scratch tester. Specifically, the metal chip was applied to the surface of the foamed laminated sheet, and the chip was slid while applying a load between 100 to 200 g. The test was performed by increasing the load step by step by 20 g, and the load at which whitening (scratches) was observed for the first time was measured. Evaluation was performed according to the following evaluation criteria.
5: No whitening was observed at a load of 180g and 200g
4: No whitening was observed at a load of 160g, but whitening was observed at 180g.
3: No whitening was observed at a load of 140g, but whitening was observed at 160g.
2: No whitening was observed at a load of 120g, but whitening was observed at 140g
1: No whitening was seen at 100g load, but whitening was seen at 120g

2． Corner resistance
Using a power cord coated with PVC (polyvinyl chloride) resin, the corner resistance of protruding corners was evaluated. Specifically, a foam laminate sheet was attached to a protruding corner-shaped jig (bent at 90 °) to prepare a test piece. Next, a power cord covered with PVC resin was attached to the friction element of the Gakushin type abrasion tester. The power cord was reciprocated to the left and right while contacting the protruding corner of the test piece under the condition of a load of 500 g to wear the foamed laminated sheet, and the surface state of the protruding corner of the foamed laminated sheet was visually observed. Evaluation was performed according to the following evaluation criteria.
5: The fiber sheet was not exposed even after 400 round trips
4: The fiber sheet was exposed after 300 round trips and less than 400 round trips
3: The fiber sheet was exposed after 200 to 300 reciprocations.
2: The fiber sheet was exposed after 100 round trips and less than 200 round trips
1: The fiber sheet was exposed in less than 100 round trips

3． Curl resistance Each of the foamed laminated sheets of Examples and Comparative Examples was cut into a rectangle 20 cm in the width direction and 10 cm in the flow direction to prepare a test piece. On the back of each test piece, apply the application paste at a coating amount of 130 g / m ² ,
It was folded in half so that the edges in the width direction overlapped, and allowed to stand on a flat place, and the curled state (raised edge) was observed after 30 minutes. Evaluation was performed according to the following evaluation criteria.
5: Lift at the end was within 90 °
3: The lift of the edge was 90 ° or more, but it did not become a ring
1: The edge part bounces up, curls, attaches to the surface of the foamed laminated sheet, and forms a ring.

Four. Evaluation of stiffness The foamed laminated sheets of the examples and comparative examples were cut to a width of 5 mm and a length of 160 mm to prepare test pieces. Using this test piece, a stiffness test was performed with a loop stiffness tester under the conditions of a compression speed of 3.5 mm / min and a crushing distance of 10 mm, and the presser pressure when the sample was looped was measured. Based on the measured pressing pressure, evaluation was performed according to the following evaluation criteria.
5: 7g or more and less than 10g
4: 6g or more and less than 7g
3: 5g or more and less than 6g
2: 4g or more but less than 5g
1: Less than 4g

  The results are shown in Tables 1 and 2.

Results As is apparent from the results in Table 1, in Examples 1 to 8, the foaming agent-containing resin layer contains ultra-low density polyethylene and low-density polyethylene, and the ultra-low-density polyethylene in the foaming agent-containing resin layer. The mass ratio (m1) / (m2) of the mass (m1) to the mass (m2) of the low density polyethylene is 70/30 to 50/50, and the density of the resin component in the foaming agent-containing resin is 0.910 g / cm ³ or more, 0.914g / cm ³
It was excellent in scratch resistance, corner resistance, and stiffness evaluation. In particular, in addition to the above-described configuration, Examples 1 to 7 having a configuration in which the density of the resin component of the non-foamed resin layer A is in the range of 0.880 g / cm ³ or more and 0.910 g / cm ³ or less are Excellent curling properties.

On the other hand, from the results in Table 2, in Comparative Examples 1 to 4, the mass ratio (m1) / (m2) of the resin component of the foaming agent-containing resin layer is greater than 70/30, Since the density was smaller than 0.910 g / cm ³ , the scratch resistance and stiffness evaluation were inferior. In particular, Comparative Example 2 in which the density of the resin component of the non-foamed resin layer A was as high as 0.913 g / cm ³ was inferior in curling resistance and inferior in workability.

In Comparative Example 5, the density of the resin component of the foaming agent-containing resin layer is within an appropriate range, but the mass ratio (m1) / (m2) is larger than 70/30 and the blending ratio of the ultra-low density polyethylene is large. Scratch resistance was inferior and stiffness evaluation was also inferior.

In Comparative Example 6, the density of the resin component of the foaming agent-containing resin layer is within an appropriate range, but the mass ratio (m1) / (m2) is smaller than 50/50 and the blending ratio of the low density polyethylene is large. As a result, the corner resistance of the exposed corners was inferior.

1. Base material
2. Non-foamed resin layer B
3. Foamed resin layer
4. Non-foamed resin layer A
5. Pattern pattern layer
6. Surface protective layer

Claims (6)

A laminated sheet having at least a foaming agent-containing resin layer on a substrate,
(1) The foaming agent-containing resin layer contains ultra-low density polyethylene and low density polyethylene,
(2) The mass ratio (m1) / (m2) between the mass (m1) of the ultra-low density polyethylene and the mass (m2) of the low-density polyethylene in the foaming agent-containing resin layer is 70/30 to 55 / 45, a laminated sheet characterized by that. 2. The laminated sheet according to claim 1, wherein the density of the resin component of the foaming agent-containing resin layer is 0.910 g / cm ³ or more and 0.920 g / cm ³ or less.   3. The laminated sheet according to claim 1, wherein a non-foamed resin layer A is laminated on the foaming agent-containing resin layer. The non-foamed density of the resin component of the resin layer A is 0.880 g / cm ³ or more and 0.910 g / cm ³ or less, the laminated sheet according to claim 3.   A foamed laminated sheet obtained by foaming the foaming agent-containing resin layer of the laminated sheet according to any one of claims 1 to 4.   6. The foamed laminated sheet according to claim 5, which is embossed from above the outermost surface layer.

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