JPH06305065A - Decorative sheet - Google Patents

Abstract

PURPOSE:To provide a decorative sheet with an excellent design having a contour with sharply raised patterns consisting of foam vinyl chloride resin. CONSTITUTION:The decorative sheet 1 is constituted in such a manner that there lie a base layer 3 consisting of foam vinyl chloride resin employing foam vinylchloride paste and a pattern layer 4 consisting of foam vinyl chloride resin employing foam vinyl chloride paste formed on the surface of the base layer 3, wherein an average polymerization degree of the paste resin in the base layer 3 is allowed to be larger than an average polymerization degree of the paste resin in the pattern layer 4.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative sheet used for forming a foamed resin layer using a vinyl chloride paste and attaching it to a wall or the like for decoration.

[0002]

2. Description of the Related Art Conventionally, as a decorative sheet, a base layer made of vinyl chloride resin is formed on a base material such as paper and made of a mixture of vinyl chloride paste resin (foaming PVC paste) to which a foaming agent is added. Background Art A wallpaper or the like is formed by printing a predetermined pattern on the surface of the base layer with an ink and then foaming the ink to form a pattern.

As the above-mentioned conventional decorative sheet, the one in which a foamed vinyl chloride resin pattern is provided on the surface of a foamed vinyl chloride resin base material by using a foamable PVC paste similar to the pattern for the base layer is more luxurious. It has been widely used since it can obtain such as. The decorative sheet, in which both the base layer and the pattern are formed from the expandable PVC paste, is formed by applying the expandable PVC paste of the base layer onto the surface of a base material such as paper to cause gelation, and further onto the surface of the base layer. Since the base layer and the pattern can be heated together to be foamed after applying the foamable PVC paste of the pattern and gelling, there is an advantage that a decorative sheet can be obtained by one foaming step. . Further, generally, the same resin is used for the paste resin for the pattern and the base layer.

[0004]

However, a decorative sheet obtained by foaming a pattern and a base layer in a single foaming step is a gelled paste resin base because the base layer and the pattern are simultaneously foamed. Since the layer and the pattern are melted at the same time and foaming proceeds, the state of the base layer becomes unstable and the pattern printed on the surface of the base layer is not formed as a sharp convex portion, and the base layer is not foamed. As compared with a decorative sheet having a pattern of expanded vinyl chloride resin formed on the surface of the base layer using the vinyl chloride resin sheet, etc., the design is inferior in terms of sharpness of the pattern.

The present invention has been made in view of the above-mentioned drawbacks of the prior art. In the decorative sheet in which both the base layer and the pattern are made of expanded vinyl chloride resin, the foamed pattern has a sharply rising contour. It is intended to provide an excellent decorative sheet.

[0006]

That is, the decorative sheet of the present invention comprises a base layer made of a foamed vinyl chloride resin using a foamable vinyl chloride paste, and a foamable chloride formed on the surface of the base layer. In a decorative sheet composed of a pattern layer made of a foamed vinyl chloride resin using a vinyl paste, the average degree of polymerization of the paste resin of the base layer is larger than the average degree of polymerization of the paste resin of the pattern layer, To do.

In the above decorative sheet of the present invention, the difference between the average degree of polymerization of the paste resin of the base layer and the average degree of polymerization of the paste resin of the handle layer is preferably 400 or more.

Further, in the above decorative sheet, the average degree of polymerization of the paste resin of the base layer is 1100 to 1800.
And the average degree of polymerization of the paste resin in the handle layer is 700 to
It is more preferably 1400.

The present invention will be described in more detail below with reference to the drawings. FIG. 1 shows an example of the present invention, (a) shows a decorative sheet before foaming, and (b) shows a decorative sheet after foaming.

The present invention is, for example, as shown in FIG.
Base layer 3 made of expanded vinyl chloride resin on the surface of base material 2
Is formed, and the decorative sheet 1 is composed of the pattern layer 4 made of expanded vinyl chloride resin provided on the surface of the base layer 3 as an arbitrary pattern. The pattern layer 4 may be provided over the entire surface of the base layer 3 or may be partially provided on the surface of the base layer 2.

The above-mentioned base material 2 may be paper, woven cloth, non-woven cloth, synthetic resin sheet, or a composite material thereof, and these may be imparted with flame retardancy. In the present invention, the decorative sheet 1 may be composed of only the base layer 3 and the handle layer 4 without using the base material 2.

In the present invention, the base layer 3 and the handle layer 4 are obtained by applying a foamable vinyl chloride paste (hereinafter abbreviated as PVC paste), gelling it, and then foaming it. The vinyl chloride paste resin (hereinafter abbreviated as paste resin) used in the paste may have an average degree of polymerization of about 700 to 1800. The foamable PVC paste uses a foamable ink obtained by adding a foaming agent to a composition in which a paste resin having a specific average degree of polymerization is dispersed in a plasticizer or a solvent.

In the present invention, it is important that the average degree of polymerization of the above-mentioned paste resin is larger in the base layer 3 than in the handle layer 4. By using paste resins having different average degrees of polymerization for the base layer and the pattern layer (however, the average degree of polymerization of the paste resin of the base layer> the average degree of polymerization of the paste resin of the pattern layer), both layers are heated together. When foamed, the degree of melting of the vinyl chloride resin in each layer is different due to the difference in the average degree of polymerization, and the base layer is delayed in melting and the handle layer is foamed before the base layer is foamed. Therefore, the pattern layer foams while the surface of the base layer, which is the base of the pattern layer, is stable,
It is estimated that a sharp foamed vinyl chloride resin pattern layer is formed.

The average degree of polymerization of the paste resin used in the present invention may be such that the paste resin of the base layer is larger than the paste resin of the handle layer, but a particularly preferable range of the average degree of polymerization is 700 to 1400 for the paste resin of the handle layer.
Further, it is desirable that the paste resin of the base layer is 1100 to 1800. The larger the average degree of polymerization of the paste resin, the better the physical properties and the lack of gloss and the like, which is desirable, but if it exceeds the above range, the processability will deteriorate. Also,
When the average degree of polymerization becomes small, the processability becomes good, but the physical properties deteriorate and the gloss becomes large.

If necessary, a plasticizer, a filler, a flame retardant, a fungicide, a stabilizer, a viscosity reducing agent, a coloring agent, etc. are added to the foamable PVC paste.

The decorative sheet 1 of the present invention can be manufactured in exactly the same manner as the conventional method for manufacturing a decorative sheet using a foamable PVC paste. For example, as shown in FIG. 1 (a), a base-forming foamed PVC paste is applied onto a base material 2 such as flame-retardant paper for wallpaper or non-combustible paper by any means such as rotary screen printing or gravure printing. Then, it is heated and gelled to form an unfoamed base layer 5. Then, an expandable PVC paste for pattern layer formation is coated on the unfoamed base layer 5 by any means such as rotary screen printing or doctor knife coating, and is heated to gel to form the unfoamed pattern layer 6. Form. Then, the whole is heated in a foaming furnace or the like to form the unfoamed handle layer 5 and base layer 6
Base layer 3 made of foamed vinyl chloride resin
The decorative sheet 1 of the present invention is obtained in which the patterned layer 4 made of expanded vinyl chloride resin is formed on the surface of the sheet.

The heating temperature for gelling the PVC paste is usually about 130 to 160 ° C. The temperature for foaming both layers is about 160 to 230 ° C, preferably about 190 to 210 ° C.

The decorative sheet of the present invention is used for vinyl wallpaper, vinyl chloride leather and the like.

[0019]

EXAMPLES The present invention will be described in more detail with reference to Examples and Comparative Examples. Examples 1 to 5 Using a paste resin having an average degree of polymerization shown in Table 1, a PVC paste for a base layer prepared by the following formulation was coated on a flame-retardant paper to a thickness of 0.11 mm, and heated gel After that, a paste for PVC for a handle layer prepared by using a paste resin having an average degree of polymerization shown in Table 1 and having the composition shown below is screen-printed on the surface of the base layer to be heat-gelled, and finally 190 ° C. The pattern layer and the base layer were foamed through the foaming furnace set to 1 to obtain a decorative sheet. The patterns of the obtained decorative sheets all had sharp contours and were excellent in unevenness. The results of evaluation of the sharpness of the design are also shown in Table 1, where ⊚ indicates very good, ∘ indicates good, and x indicates defective.

[Composition composition of PVC paste for handle layer] PVC paste resin 100 parts by weight Primary plasticizer (di-2-ethylhexyl phthalate) 53 parts by weight Filler (calcium carbonate) 50 parts by weight Stabilizer (Zn- K-type composite stabilizer) 2.5 parts by weight-Foaming agent (azodicarbonamide) 3 parts by weight-Thickening agent (mineral spirits) 4 parts by weight-Titanium oxide 15 parts by weight

[PVC paste compounding composition for base layer] PVC paste resin 100 parts by weight Primary plasticizer (di-2-ethylhexyl phthalate) 70 parts by weight Filler (calcium carbonate) 70 parts by weight Stabilizer (Zn- K-based composite stabilizer) 2.5 parts by weight in Examples 1 to 3 3 parts by weight in Examples 4 and 5 2 parts by weight blowing agent (azodicarbonamide) 7 parts by weight oxidizing agent (dry solvent) Titanium 15 parts by weight

Comparative Example 1 For comparison, a decorative sheet was manufactured by using the same materials and methods as in Example except that the paste resin for the base layer and the paste layer had the same average degree of polymerization (800). The decorative sheet thus obtained was inferior in design because it had no sharpness of the design as compared with those of the examples.

In Examples 1 to 5, a good comparison of the sharpness of the patterns of the decorative sheets revealed a difference. The sharpest pattern is A, B, C,
When evaluated in four grades of D, the results shown in Table 1 were obtained. As shown in Table 1, when the difference in average degree of polymerization is 400 or more and the average degree of polymerization of the base layer is 1500 or more, a particularly sharp pattern is obtained.

[0024]

[Table 1]

[0025]

As described above, the decorative sheet of the present invention adopts the constitution in which the paste resin having a polymerization degree higher than that of the paste resin of the handle layer is used for the base layer, so that the foaming step is performed once. By using the same production conditions as in the conventional method in which the pattern layer and the base layer are simultaneously foamed, a beautiful decorative sheet having a sharp contour of the pattern layer and excellent unevenness can be obtained.

[Brief description of drawings]

FIG. 1 shows an example of a decorative sheet of the present invention, (a) is a sectional view before foaming, and (b) is a sectional view after foaming.

[Explanation of symbols]

 1 Decorative sheet 3 Base layer 4 Pattern layer

Claims (3)

[Claims] 1. A base layer made of a foamed vinyl chloride resin using a foamable vinyl chloride paste, and a handle layer made of a foamed vinyl chloride resin formed on the surface of the base layer, made of a foamed vinyl chloride resin. A decorative sheet comprising: a base layer paste resin having an average degree of polymerization higher than that of a handle layer paste resin. 2. The decorative sheet according to claim 1, wherein the difference between the average degree of polymerization of the paste resin of the base layer and the average degree of polymerization of the paste resin of the handle layer is 400 or more. 3. The decorative sheet according to claim 2, wherein the paste layer in the base layer has an average degree of polymerization of 1100 to 1800, and the paste layer in the handle layer has an average degree of polymerization of 700 to 1400.