JPH1034808A - Decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make a coating film of a resin compsn. flexible and hardly peeled off by coating and laminating the resin compsn. wherein an inorg. powder with needle-like crystal and a resin emulsion are essential ingredients on a backing paper contg. non-moisture absorptive fiber and specifying the thickness of the coating film of this resin compsn. SOLUTION: When compounding parts by wt. of substances to be compounded is expressed by P.H.R. to 100 pts.wt. resin, a resin compsn. wherein at least 60 P.H.R. inorg. powder contg. inorg. powder with needle-like crystal and a resin emulsion are essential ingredients, is applied and laminated on a backing paper contg. non-moisture absorptive fiber and the thickness of the coating film of the resin compsn. is made at most 2mm. In addition, in this case, the inorg. powder is sepiolite and at least 40wt.% of the inorg. powder included in the coating film is made of sepiolite and as the backing paper, a manufactured paper contg. glass fibers as a non-moisture absorptive fiber is used. In addition, at least 80wt.% of the inorg. powder included in the coating film is occupied with sepiolite and diatomaceous earth.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative sheet which is adhered to a wall surface or a ceiling surface as a wallpaper, an exterior sheet, a vehicle interior material and the like.

[0002]

2. Description of the Related Art In a decorative sheet formed by applying and laminating a resin composition on a backing paper, a large amount of an inorganic powder (filler) mainly composed of calcium carbonate is blended into the resin composition in order to reduce costs. In addition, a vinyl chloride paste resin which has good adhesiveness and can mix a large amount of inorganic powder is used for the resin composition.

[0003]

When a large amount of inorganic powder is added to the resin composition, the amount of the plasticizer is increased to make the resin composition viscous. However, the plasticizer is not only a harmful substance but also a flammable substance. Because it is a volatile substance, even if the compounding amount of the inorganic powder is increased, the decorative sheet does not become flame-retardant, and the vinyl chloride resin generates harmful combustion gas containing halogen (chlorine). An inexpensive decorative sheet excellent in flame retardancy cannot be obtained. For this reason, it has been attempted to use an emulsion type resin such as vinyl acetate or ethylene vinyl acetate or a latex instead of the vinyl chloride paste resin. However, these water-dispersible resins have 60
P. H. R. The resin composition containing the above-mentioned inorganic powder is not suitable for a decorative sheet since the coating film is hard and easily cracks and peels off. This is because the decorative sheet is required to have the flexibility required for close application along the undulations of the application base, and the thickness of the coating is generally 2 mm or less. 500 thickness
This is because, if the thickness is reduced to about 1 μm or 1 mm or less, the coating film is easily cracked in the transportation process and the construction process. In this specification, "PHR" means a compounding part by weight of a compounded substance (for example, inorganic powder) with respect to 100 parts by weight of the resin.

[0004]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to use a water-dispersible resin in place of a vinyl chloride paste resin, and to crack and exfoliate a coating film of a resin composition composed of a large amount of an inorganic powder. An object of the present invention is to obtain a decorative sheet which is difficult to produce and which does not generate harmful combustion gas at low cost.

[0005]

Means for Solving the Problems A decorative sheet according to the present invention is a decorative sheet containing inorganic powder having acicular crystals. H.
R. The above inorganic powder and a resin composition containing a resin emulsion as an essential component are formed by coating and laminating on a backing paper containing non-hygroscopic fibers, and the thickness of the coating film of the resin composition is 2 mm or less. This is a first feature.

A second feature of the decorative sheet according to the present invention is that
In addition to the first feature, the inorganic powder having acicular crystals is sepiolite, 40% by weight or more of the inorganic powder contained in the coating film is sepiolite, and the backing paper uses glass fibers as non-hygroscopic fibers. Papermaking paper.

[0007] A third feature of the decorative sheet according to the present invention is that
In addition to the second feature, sepiolite and diatomaceous earth account for 80% by weight or more of the inorganic powder contained in the coating film.

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 coating is laminated on the coating.

A fifth feature of the decorative sheet according to the present invention is that
In addition to any one of the first, second, third, and fourth features, the coating film is embossed.

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.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION The reason why the inorganic powder having needle-like crystals is blended with the resin composition applied to the backing paper is that even if each individual pulp fiber is a very short fine powder, the mixed water blended with it is The resin composition applied to the backing paper is made of a resin solid so that the fine pulp fiber powder floating in the finely touches the fine powder and becomes viscous, so that a papermaking in which the pulp fiber fine powder is entangled with evaporation of water is obtained. Even if it is a small amount, the inorganic powder having needle-like crystals in the form of fine fiber powder is blended and becomes viscous, and the inorganic powder having needle-like crystals is finely entangled with evaporating water and cracks. This is because a difficult coating film is formed.

[0012] Due to the effect of the inorganic powder having needle-like crystals, 60P. H. R. Even if the above is occupied by the inorganic powder, it is possible to laminate a coating film which is flexible and hard to peel off. Then, the inorganic powder is 60P. H. R. By reducing the ratio of the resin solid content in the coating film by blending as described above, the decorative sheet can be made inexpensive, flame-retardant, and free of harmful combustion gas. For this purpose, the inorganic powder having needle-like crystals accounts for 40% by weight or more of the coating film, and even if another inorganic powder is blended with the resin composition, 40% by weight of the inorganic powder contained in the coating film It is preferable to prepare the resin composition so that the inorganic powder having needle-like crystals occupies the above.

When the thickness of the coating film to be applied and laminated is increased, fine fiber powder is preferably blended with the resin composition. The fiber fine powder includes glass fiber and pulp fiber, vinylon and cotton,
It is preferable to use hydrophilic fibers such as cellulosic fibers such as hemp, rayon, cupra, and acetate. This is because these hydrophilic fibers become familiar with the water-dispersible or water-soluble resin which is an essential component of the resin composition, and serve as a reinforcing material for the coating film.

As the resin emulsion, ethylene vinyl acetate resin emulsion, vinyl acetate resin emulsion, ethylene vinyl acetate vinyl chloride resin emulsion,
All natural or synthetic latexes and other commercially available resin emulsions and latexes are used. Among them, an ethylene vinyl acetate resin emulsion is recommended because the coating film is flexible and has strong adhesiveness and heat fusion property, and the coating film of the resin composition can be easily heated and embossed.

60P. H. R. The coating film containing the inorganic powder described above is easily cracked as compared with a coating film mainly composed of a vinyl chloride paste resin like a conventional decorative sheet, and air bubbles generated in the process of preparing and applying the resin composition. When the coating film becomes porous, scratches are likely to occur when the surface is rubbed. Therefore, in order to prevent the coating film from becoming porous due to air bubbles generated in the resin composition preparation process and application process,
It is recommended that an antifoaming agent be added to the resin composition. As the defoaming agent, a commercially available silicone-based one may be used.

As the backing paper, in addition to papermaking 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 the backing paper absorbs moisture and does not shrink when applied. That's why. Therefore, the non-hygroscopic fiber mentioned here means a fiber that does not expand and contract due to moisture absorption and swelling, does not mean a fiber that does not absorb moisture at all, and a fiber material having a slight hygroscopic property such as nylon or polyester fiber. May be. In addition, even if the fiber material itself has a hygroscopic property due to fine irregularities on the fiber surface, if the fiber material itself is not hydrophilic and does not absorb moisture and swells as in the case of cellulosic fiber, it is not hygroscopic. It can be used for backing paper as a conductive fiber. However, in consideration of heat shrinkage in the drying process of the coating film, expansion and contraction deformation after application of the decorative sheet 15, water resistance, weather resistance, flame retardancy, etc., glass fibers having a fiber length of 1 to 5 mm It is recommended to use a papermaking paper containing 50% by weight for the backing paper.

The inorganic powder is added to the resin composition at 60 P. H.
R. The above compounding reduces the cost of the resin composition,
This is not only to make the resin composition flame-retardant, but also to improve the moisture absorption and printability of the decorative sheet, to reduce the surface gloss of the decorative sheet, and to impart a clay-wall-like touch feeling.
As the inorganic powder having acicular crystals (acicular crystal structure), sepiolite or zeolite having humidity controllability is used, and diatomaceous earth is used as the other inorganic powder mixed with the inorganic powder having acicular crystals. This is advantageous in improving the sheet's hygroscopicity and printability. Further, aluminum hydroxide may be added to the resin composition to make the decorative sheet flame-retardant, and barium sulfate may be added to the resin composition to give sound insulation. However, if the amount of the inorganic powder is too large, the decorative sheet becomes hard and easily cracks. H. R is the limit.

The thickness of the coating film is 1 mm or less like the coating film of a decorative sheet mainly composed of a conventional vinyl chloride paste resin.
In the case of about 500 μm, the particle size of the inorganic powder should be about 60 mesh (particle diameter; 250 μm) or less,
The inorganic powder around the mesh (particle diameter: 250 μm) is 3
It is desirable to use it by mixing it with an inorganic powder having a size of about 00 mesh (particle diameter: 50 μm). According to a preferred embodiment of the present invention, the inorganic powder has a particle size of 250 to 100 μm.
m (60 mesh pass) of sepiolite 35 to 55 parts by weight (around 45 parts by weight), and a particle size of 100 to 50 μm (15
Diatomaceous earth 40 to 60 parts by weight (around 50 parts by weight) with a particle size of 50 μm or less (300 mesh path)
Is mixed with a particle size distribution of 10 to 25 parts by weight (about 15 parts by weight) and a mixing ratio.

The surface of the coating film of the decorative sheet according to the present invention is:
As described above, fine irregularities are formed and the appearance of the earth wall is exhibited. However, in order to enhance abrasion resistance and decorativeness, it is preferable to print a required pattern on the coating film. The decorative coating film of the printing ink strongly adheres to the coating film of the resin composition because the coating film of the resin composition contains a large amount of hygroscopic sepiolite or diatomaceous earth.

[0020]

DESCRIPTION OF THE PREFERRED EMBODIMENTS A basis weight of 90 consisting of glass fiber and pulp fiber
g / m ² , 0.16 mm thick paper, 200 parts by weight of ethylene vinyl acetate resin emulsion (solid content: 55%) and diatomaceous earth (particle size: 150 mesh pass, particle size: 10
0 μm or less) and 50 parts by weight of sepiolite (particle size: 60
Mesh pass, particle size: 250 μm or less) 45 parts by weight,
Sepiolite (particle size: 300 mesh pass, particle size: 50
μm or less) 15 parts by weight, defoamer 5 parts by weight, water 150
The resin composition consisting of parts by weight was applied and laminated at an application 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 the first-grade inorganic fire protection of the legal fire protection material test (the 1983 Wall Paper Materials Association Standard Wallpaper Standard Construction Method Test). or,
When this decorative sheet was bent at 90 degrees, no crack was generated in the coating film of the resin composition.

[0021]

As described above, according to the present invention, the surface coating film contains a large amount of inorganic powder and has flame retardancy, and the inorganic powder is in the form of a fiber powder having acicular crystals (acicular crystal structure).
It is not easily cracked because it is interspersed in the coating film in a mesh shape, and since many of the inorganic powders have a hygroscopic property, it is easy to apply a printed pattern, the tactile feel is soft, the moisture is absorbed and dew condensation occurs A decorative sheet suitable for vehicle interior materials and wall covering materials can be obtained.

Claims (6)

[Claims] 1. A composition comprising an inorganic powder having acicular crystals.
P. H. R. The above inorganic powder and a resin composition containing a resin emulsion as an essential component are formed by coating and laminating on a backing paper containing non-hygroscopic fibers, and the thickness of the coating film of the resin composition is 2 mm or less. A decorative sheet, characterized in that: 2. 60P.P. containing sepiolite. H. R. The above inorganic powder and a resin composition containing a resin emulsion as an essential component are formed by applying and laminating on a papermaking paper containing glass fiber, and the thickness of the coating film of the resin composition is 2 m.
m, and 40% by weight or more of the inorganic powder contained in the coating film is sepiolite. 3. A 60 P.P. containing sepiolite and diatomaceous earth.
H. R. The above inorganic powder and a resin composition containing a resin emulsion as an essential component are formed by coating and laminating on a backing paper containing non-hygroscopic fibers, and the thickness of the coating film of the resin composition is 2 mm or less. A decorative sheet, wherein 80% by weight or more of the inorganic powder contained in the coating film is sepiolite and diatomaceous earth. 4. A composition comprising an inorganic powder having acicular crystals.
P. H. R. The above inorganic powder and a resin composition containing a resin emulsion as an essential component are formed by coating and laminating on a backing paper containing non-hygroscopic fibers, and the thickness of the coating film of the resin composition is 2 mm or less. A decorative sheet, characterized in that a decorative coating film is laminated on the coating film. 5. A composition comprising an inorganic powder having needle-like crystals.
P. H. R. The above inorganic powder and a resin composition containing a resin emulsion as an essential component are formed by coating and laminating on a backing paper containing non-hygroscopic fibers, and the thickness of the coating film of the resin composition is 2 mm or less. A decorative sheet, characterized in that the coating film is embossed. 6. A composition comprising an inorganic powder having needle-like crystals.
P. H. R. The above inorganic powder and a resin composition containing an ethylene vinyl acetate resin emulsion as an essential component are formed by coating and laminating on a backing paper containing non-hygroscopic fibers, and the thickness of the coating film of the resin composition is reduced. A decorative sheet having a thickness of 2 mm or less.