JP6642441B2 - 積層シート及び発泡積層シート並びにそれらの製造方法及び施工方法 - Google Patents
積層シート及び発泡積層シート並びにそれらの製造方法及び施工方法 Download PDFInfo
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- JP6642441B2 JP6642441B2 JP2016552146A JP2016552146A JP6642441B2 JP 6642441 B2 JP6642441 B2 JP 6642441B2 JP 2016552146 A JP2016552146 A JP 2016552146A JP 2016552146 A JP2016552146 A JP 2016552146A JP 6642441 B2 JP6642441 B2 JP 6642441B2
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- B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H25/00—After-treatment of paper not provided for in groups D21H17/00 - D21H23/00
- D21H25/04—Physical treatment, e.g. heating, irradiating
- D21H25/06—Physical treatment, e.g. heating, irradiating of impregnated or coated paper
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/18—Paper- or board-based structures for surface covering
- D21H27/20—Flexible structures being applied by the user, e.g. wallpaper
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B2038/0052—Other operations not otherwise provided for
- B32B2038/0076—Curing, vulcanising, cross-linking
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/12—Coating on the layer surface on paper layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/028—Paper layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0242—Acrylic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/025—Polyolefin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/402—Coloured
- B32B2307/4023—Coloured on the layer surface, e.g. ink
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/718—Weight, e.g. weight per square meter
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/748—Releasability
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Laminated Bodies (AREA)
Description
1.繊維質基材上に少なくとも樹脂層が積層されている積層シートであって、前記繊維質基材は電離放射線架橋型材料の架橋物を含有し、前記樹脂層がオレフィン系樹脂層である、積層シート。
2.繊維質基材上に少なくとも樹脂層が積層されている積層シートであって、前記繊維質基材は電離放射線架橋型材料の架橋物を含有し、前記樹脂層が発泡剤含有樹脂層である、又は発泡剤含有樹脂層を含む積層体からなる層である積層シート。
3.前記発泡剤含有樹脂層は、片面又は両面に非発泡樹脂層を有する、上記項2に記載の積層シート。
4.前記発泡剤含有樹脂層は、電子線照射により樹脂架橋されている、上記項2又は3に記載の積層シート。
5.前記樹脂層がオレフィン系樹脂層である、上記項2〜4のいずれかに記載の積層シート。
6.上記項2〜5のいずれかに記載の積層シートの発泡剤含有樹脂層を発泡させることにより得られる発泡積層シート。
7.(1)繊維質基材上に少なくとも樹脂層を押出し製膜により形成する工程と、
(2)前記繊維質基材に電離放射線架橋型材料を含浸する工程と、
を有し、
上記2つの工程を経た後に、少なくとも前記繊維質基材に電離放射線を照射し、前記電離放射線架橋型材料を架橋させることにより架橋物を形成することを特徴とする積層シートの製造方法。
8.(1)繊維質基材上に少なくとも樹脂層を形成する工程と、
(2)前記繊維質基材に電離放射線架橋型材料を含浸する工程と、
を有し、
上記2つの工程を経た後に、少なくとも前記繊維質基材に電離放射線を照射し、前記電離放射線架橋型材料を架橋させることにより架橋物を形成する積層シートの製造方法であって、
前記樹脂層が発泡剤含有樹脂層である、又は発泡剤含有樹脂層を含む積層体からなる層であり、且つ、前記電離放射線が電子線であり、前記電子線の照射により、前記電離放射線架橋型材料の架橋と前記発泡剤含有樹脂層の樹脂架橋とを同時に行うことを特徴とする積層シートの製造方法。
9.前記繊維質基材上に少なくとも前記樹脂層を押出し製膜により形成する、上記項8に記載の積層シートの製造方法。
10.前記樹脂層が発泡剤含有樹脂層である、又は発泡剤含有樹脂層を含む積層体からなる層である、上記項7〜9のいずれかに記載の製造方法により製造される積層シートの前記発泡剤含有樹脂層を加熱により発泡させる発泡積層シートの製造方法。
11.接着剤を塗工した被施工面に、繊維質基材上に少なくとも樹脂層が積層されている積層シートであって、前記繊維質基材が電離放射線架橋型材料の架橋物を含有する積層シートを貼着することを特徴とする施工方法。
12.接着剤を塗工した被施工面に上記項1〜6のいずれかに記載の積層シート又は発泡積層シートを貼着することを特徴とする施工方法。
13.繊維質基材上に少なくとも樹脂層が積層されている積層シートであって、前記繊維質基材が電離放射線架橋型材料の架橋物を含有する積層シートの裏側に接着剤を塗工後、被施工面に貼着することを特徴とする施工方法。
14.上記項1〜6のいずれかに記載の積層シート又は発泡積層シートの裏側に接着剤を塗工後、被施工面に貼着することを特徴とする施工方法。
15.前記被施工面は、壁面及び/又は天井である、上記項11〜14のいずれかに記載の施工方法。
本発明の積層シートは、繊維質基材上に少なくとも樹脂層が積層されている積層シートであって、前記繊維質基材は電離放射線架橋型材料の架橋物を含有することを特徴とする。
繊維質基材としては、電離放射線架橋型材料の架橋物を含有するものを用いる。ここで、電離放射線架橋型材料の架橋物は、繊維質基材(繊維質シートの状態にあるもの)に電離放射線架橋型材料を含浸(含浸には浸漬、塗布、噴霧等の各種の態様が含まれる)させた後に電離放射線を照射することにより形成する。
本発明の積層シートは、繊維質基材の上に少なくとも樹脂層が積層されている。この樹脂層は、Tダイ製膜法、カレンダー製膜法等の既知の製膜法により形成できる。
発泡剤含有樹脂層は、その片面又は両面に非発泡樹脂層を有していてもよい。
本発明の積層シートは、樹脂層(発泡剤含有樹脂層、非発泡樹脂層A等)又は後述のプライマー層の上には、必要に応じて絵柄模様層を形成してもよい。
樹脂層(発泡剤含有樹脂層、非発泡樹脂層A等)又は絵柄模様層の上には、必要に応じてプライマー層を形成してもよい。
樹脂層(発泡剤含有樹脂層、非発泡樹脂層A等)、絵柄模様層又はプライマー層の表面には艶調整及び/又は絵柄模様層の保護を意図して表面保護層を有してもよい。
積層シート又は発泡積層シートのおもて面にはエンボス模様を付してもよい。この場合、最表面層(繊維質シートと反対側)の上からエンボス加工すれば良い。エンボス加工は、エンボス版の押圧等、公知の手段により実施することができる。例えば、最表面層が表面保護層である場合は、そのおもて面を加熱軟化後、エンボス版を押圧することにより所望のエンボス模様を賦型できる。エンボス模様としては、例えば木目板導管溝、石板表面凹凸、布表面テクスチャア、梨地、砂目、ヘアライン、幾何学模様、万線条溝、輪郭模様等がある。
本発明の発泡積層シートは、上記積層シートの発泡剤含有樹脂層を発泡させることにより得られる。
本発明の積層シートの製造方法は限定的ではないが、例えば、
(1)繊維質基材上に少なくとも樹脂層を形成する工程と、
(2)前記繊維質基材に電離放射線架橋型材料を含浸する工程と、を有し、
上記2つの工程を経た後に、少なくとも前記繊維質基材に電離放射線を照射し、前記電離放射線架橋型材料を架橋させることにより架橋物を形成することを特徴とする製造方法によって製造することができる。
本発明の積層シート及び発泡積層シートは、前述の通り、被施工面に接着剤を塗工した後、当該被施工面に貼着することで施工することができる。本発明の積層シート及び発泡積層シートが適用される被施工面としては特に限定されず、装飾が要求される各種の用途が適用でき、被施工面として壁面及び/又は天井が好適に挙げられる。即ち、本発明の積層シート及び発泡積層シートは、壁紙及び/又は天井材として特に有用である。
3種3層マルチマニホールドTダイ押出し機を用い、i)非発泡樹脂層B、ii)発泡剤含有樹脂層及びiii)非発泡樹脂層Aの順に、厚み7μm、70μm及び7μmになるように製膜した。押し出し条件は、前記i)層の樹脂はシリンダー温度100℃とし、前記ii)層の樹脂組成物はシリンダー温度120℃とし、前記iii)層の樹脂はシリンダー温度130℃とした。ダイス温度は全て120℃とした。
i)非発泡樹脂層Bは、EVA「エバフレックスEV150(VA含有量=33重量%)、三井・デュポン ポリケミカル製」により形成した。
ii)発泡剤含有樹脂層は、EVA「エバテートH4011(VA含有量=20重量%)、住友化学製」100重量部、炭酸カルシウム「ホワイトンH、東洋ファインケミカル製」30重量部、二酸化チタン「CR-63、石原産業製」25重量部、発泡剤「ビニホールAC#3、永和化成工業製」4重量部、発泡助剤「エフコ・ケムZNS-P ADEKA製」4重量部、架橋助剤「オプスターJUA-702、JSR製」1重量部を含む樹脂組成物により形成した。
iii)非発泡樹脂層Aは、エチレン−メタクリル酸共重合体樹脂「ニュクレルN1560、三井・デュポン ポリケミカル製」により形成した。
裏打紙に電離放射線架橋型材料を含浸させない以外は、実施例1と同様にして積層シート及び発泡積層シートを作製した。
裏打紙としてパルプと合成繊維を混抄したフリース紙(アールストローム製)を用い、且つ、裏打紙に電離放射線架橋型材料を含浸させない以外は、実施例1と同様にして積層シート及び発泡積層シートを作製した。
樹脂層と裏打紙との密着性を、発泡積層シートの樹脂層を裏打紙から巾方向で剥がすことにより評価した。評価基準は次の通りである。
○:樹脂層が全巾にわたり裏打紙の繊維を持ってくる。
△:樹脂層が部分的に裏打紙の繊維を持ってくる。
×:樹脂層が全く裏打紙の繊維を持ってこない。
発泡積層シートの水中伸度を評価した。具体的には、発泡積層シートをMD方向5cm、TD方向11cmの寸法にカットし、MD方向の中央からTD方向の巾なりになるように10cm長の標線を引き、水中に1時間浸漬し、浸漬前後の標線長差より変化率を求めた。水中伸度の評価基準は次の通りである。
○:0.6%未満である
×:0.6%以上である。
石膏ボード面に(1)メチルセルロース系接着剤(メチランスペシャル ヘンケル製)、(2)デンプン系接着剤(デンプン+合成樹脂)(ルーアマイルド ヤヨイ化学工業製)を予め所定量を水に溶解させて接着剤として調製したものを塗工し、その上に各発泡積層シートの裏打紙面を貼り合せてから乾燥させて試験体とした。試験体に25mm巾の切り込みを入れて手で剥がして剥し面を観察した。評価基準は次の通りである。
○:裏打紙がボード面に残ることなく裏打紙、接着剤間で剥離する。
△:裏打紙が部分的に接着剤側に取られる。剥離が重い。
×※1:裏打紙が紙間で剥離して石膏ボード下地側に残る。
×※2:石膏ボード下地が剥がれる。
2. 非発泡樹脂層B
3. 発泡剤含有樹脂層
4. 非発泡樹脂層A
5. 絵柄模様層
6. プライマー層
7. 表面保護層
Claims (15)
- 繊維質基材上に少なくとも樹脂層が積層されている積層シートであって、前記繊維質基材は電離放射線架橋型材料の架橋物を含有し、前記樹脂層がオレフィン系樹脂層である、積層シート。
- 繊維質基材上に少なくとも樹脂層が積層されている積層シートであって、前記繊維質基材は電離放射線架橋型材料の架橋物を含有し、前記樹脂層が発泡剤含有樹脂層である、又は発泡剤含有樹脂層を含む積層体からなる層である積層シート。
- 前記発泡剤含有樹脂層は、片面又は両面に非発泡樹脂層を有する、請求項2に記載の積層シート。
- 前記発泡剤含有樹脂層は、電子線照射により樹脂架橋されている、請求項2又は3に記載の積層シート。
- 前記樹脂層がオレフィン系樹脂層である、請求項2〜4のいずれかに記載の積層シート。
- 請求項2〜5のいずれかに記載の積層シートの発泡剤含有樹脂層を発泡させることにより得られる発泡積層シート。
- (1)繊維質基材上に少なくとも樹脂層を押出し製膜により形成する工程と、
(2)前記繊維質基材に電離放射線架橋型材料を含浸する工程と、
を有し、
上記2つの工程を経た後に、少なくとも前記繊維質基材に電離放射線を照射し、前記電離放射線架橋型材料を架橋させることにより架橋物を形成することを特徴とする積層シートの製造方法。 - (1)繊維質基材上に少なくとも樹脂層を形成する工程と、
(2)前記繊維質基材に電離放射線架橋型材料を含浸する工程と、
を有し、
上記2つの工程を経た後に、少なくとも前記繊維質基材に電離放射線を照射し、前記電離放射線架橋型材料を架橋させることにより架橋物を形成する積層シートの製造方法であって、
前記樹脂層が発泡剤含有樹脂層である、又は発泡剤含有樹脂層を含む積層体からなる層であり、且つ、前記電離放射線が電子線であり、前記電子線の照射により、前記電離放射線架橋型材料の架橋と前記発泡剤含有樹脂層の樹脂架橋とを同時に行うことを特徴とする積層シートの製造方法。 - 前記繊維質基材上に少なくとも前記樹脂層を押出し製膜により形成する、請求項8に記載の積層シートの製造方法。
- 前記樹脂層が発泡剤含有樹脂層である、又は発泡剤含有樹脂層を含む積層体からなる層である、請求項7〜9のいずれかに記載の製造方法により製造される積層シートの前記発泡剤含有樹脂層を加熱により発泡させる発泡積層シートの製造方法。
- 接着剤を塗工した被施工面に、繊維質基材上に少なくとも樹脂層が積層されている積層シートであって、前記繊維質基材が電離放射線架橋型材料の架橋物を含有する積層シートを貼着することを特徴とする施工方法。
- 接着剤を塗工した被施工面に請求項1〜6のいずれかに記載の積層シート又は発泡積層シートを貼着することを特徴とする施工方法。
- 繊維質基材上に少なくとも樹脂層が積層されている積層シートであって、前記繊維質基材が電離放射線架橋型材料の架橋物を含有する積層シートの裏側に接着剤を塗工後、被施工面に貼着することを特徴とする施工方法。
- 請求項1〜6のいずれかに記載の積層シート又は発泡積層シートの裏側に接着剤を塗工後、被施工面に貼着することを特徴とする施工方法。
- 前記被施工面は、壁面及び/又は天井である、請求項11〜14のいずれかに記載の施工方法。
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