JP2003266549A - Raw material for foam decorative sheet and method for producing foam decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a raw material for a foam decorative sheet capable of realizing scratch resistance at low cost, and a method for producing a foam decorative sheet using the same. SOLUTION: As a raw sheet 10 for a decorative foam sheet having a thermoplastic resin surface protective layer 2 on an unfoamed resin layer 1A,
An unfoamed resin layer is formed into a sheet by a calender molding method, and then a raw material produced by continuously laminating a thermoplastic resin as a surface protective layer on the unfoamed resin layer by a T-die extrusion method. The foamed decorative sheet is manufactured using this. It is preferable to laminate the backing sheet 3 immediately after calendering in terms of mechanical strength and the like. When producing a decorative foam sheet, it is preferable to print a pattern layer on the surface protective layer, and then heat and foam to form an embossed pattern by embossing the side surface of the surface protective layer.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a foam decorative sheet that can be used as a wallpaper or ceiling material for buildings and other various decorative sheets.

[0002]

2. Description of the Related Art Conventionally, a foamed decorative sheet such as a wallpaper has been widely used in which a vinyl chloride resin is used as a foamed resin layer on a backing paper or the like. The resin layer, ethylene-vinyl acetate copolymer,
Acrylic resins or resins using halogen-free resins such as olefinic resins are being replaced (Japanese Patent Laid-Open No. 6-58242).
-47875, JP 2000-255011 A, JP 2001-347611 A, etc.). For example, a coating obtained by adding a microcapsule type foaming agent to an emulsion containing an acrylic resin and an ethylene-vinyl acetate copolymer is applied to a backing paper and dried, and then a pattern is printed on the surface thereof, followed by heat foaming. Emboss with an embossing plate to obtain a foamed decorative sheet. Alternatively, a resin composition obtained by adding a thermal decomposition type foaming agent to an ethylene-vinyl acetate copolymer as an olefin resin is melt-extruded on a backing paper with a T-die extruder at a temperature not higher than the foaming temperature, and then coated.
A pattern pattern is printed on the surface, then heat-foamed and embossed with an embossing plate to obtain a foam decorative sheet.

Further, when surface physical properties such as scratch resistance and stain resistance are required, a surface protective layer is provided on the foamed resin layer. For example, when the foamed resin layer is formed by coating with an emulsion coating, an emulsion coating containing no foaming agent is coated on the surface (JP-A-11-198).
266, etc.). Alternatively, a resin film may be laminated, or a resin may be melt-extrusion coated with a T-die (see JP 2001-58376 A, etc.).

[0004]

As a more recent tendency, it is possible to reduce the cost by reducing the excess performance and limiting the performance to necessary and sufficient performance (for example, scratch resistance). The demand is increasing. On the other hand, the conventional non-vinyl chloride resin foam decorative sheet as described above leaves room for investigation. In a foamed decorative sheet in which a foamed resin layer or a surface protective layer is formed from an emulsion paint, the emulsion paint is a water-based paint that is difficult to dry, and thus there is a problem in productivity (production speed). That is, there is a difficulty in improving productivity which leads to cost reduction. In this respect, the foam decorative sheet in which the surface protective layer and the foamed resin layer are extrusion-molded with a T die is advantageous in that the step of drying the resin layer is unnecessary. However, since the surface protective layer is thin, the productivity is good in terms of formation of the surface protective layer, but the foamed resin layer requires a certain thickness, which is why Since it was necessary to increase the extrusion amount of, the production speed could not be increased and the productivity could not be improved.

That is, an object of the present invention is to realize scratch resistance in a foamed decorative sheet at low cost. For that purpose, a method for producing a raw material for a foamed decorative sheet and a foamed decorative sheet It is to provide a manufacturing method.

[0006]

Therefore, in order to solve the above-mentioned problems, the method for producing a raw fabric for a foam decorative sheet of the present invention is as follows:
In the method for producing a raw material for a foam decorative sheet having a surface protective layer made of a thermoplastic resin on the unfoamed resin layer before foaming, after molding the unfoamed resin layer into a sheet shape by a calender molding method, continuously. A thermoplastic resin as a surface protective layer was laminated on the unfoamed resin layer by a T-die extrusion method to prepare a raw sheet for a foam decorative sheet.

With such a manufacturing method, the unfoamed resin layer is formed by the calender molding method, and as a result, the production speed can be increased as compared with the case of forming by the T die extrusion method. Therefore, the cost can be reduced by improving the productivity. Moreover, the surface protective layer for improving the surface properties such as scratch resistance is not laminated as a resin sheet on which a film is formed in advance, but is continuously formed by T molding after calender molding of the unfoamed resin layer.
Since it is laminated in-line at the same time as the sheet molding of the unfoamed resin layer by the die extrusion method, it is possible to obtain a raw sheet that enables the production of a foamed decorative sheet that can realize scratch resistance at low cost. Since the surface protective layer can be formed while there is residual heat during molding, the surface protective layer can be laminated on the unfoamed resin layer with good adhesion, and provision of the primer layer between these layers can be omitted. Therefore,
The cost increase due to the provision of the primer layer can be avoided.
Therefore, also from this point, cost reduction can be realized.

The method for producing a foamed decorative sheet of the present invention is a method for producing a foamed decorative sheet by heating the above-mentioned raw material for a foamed decorative sheet to foam the unfoamed resin layer into a foamed resin layer. It was a method.

With such a manufacturing method, it is possible to enjoy the effects of the above-described original fabric for foam decorative sheet. Therefore, scratch resistance can be realized at low cost.

Further, the method for producing a foam decorative sheet of the present invention is the same as the method for producing a foam decorative sheet, wherein a pattern layer is formed on the surface protective layer before heating the raw material for the foam decorative sheet. Then, the unfoamed resin layer was heated to form a foamed resin layer, and then an uneven pattern by embossing was formed on the surface of the surface protective layer side to obtain a foamed decorative sheet.

By adopting such a manufacturing method, scratch resistance can be realized at low cost even for a foam decorative sheet which is highly designed with a picture layer and an uneven pattern.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

[Outline] First, the present invention will be outlined with reference to FIG. FIG. 1 is a conceptual diagram for conceptually explaining one form of the method for manufacturing the foamed decorative sheet raw fabric 10.

In FIG. 1, the unfoamed resin layer 1A in an unfoamed state before foaming is formed into a sheet by a calender device 30 having calender rollers 31 to 34. That is, the foamed resin material 1B is applied to the calender rollers 31 and 32.
Then, the foamed resin material 1B is supplied to the calender roller 3
The unfoamed resin layer 1A is formed into a sheet by kneading and rolling while passing between 1, 32, calender rollers 32, 33, and calender rollers 33, 34. In the present invention, the unfoamed resin layer 1A formed into a continuous strip-shaped sheet by the calender molding method is continuously in-line without winding it, and the surface protection is further performed on the unfoamed resin layer 1A. Layer 2 is simultaneously laminated by the T-die extrusion method. That is, the resin material 2A to be the surface protection layer is melt extruded from the T die 31 of the T die extruder 30 on the unfoamed resin layer 1A and laminated simultaneously with the film formation. As a result, a foamed decorative sheet material 10 having a structure in which the surface protective layer 2 is laminated on the unfoamed resin layer 1A is obtained.

In a wallpaper, which is a typical application of a foamed decorative sheet, a backing sheet such as backing paper is usually laminated on the lower side (back side) of the unfoamed resin layer 1A. FIG. 1 shows an example of a method for laminating such a backing sheet 3 as well, which is a step before laminating the surface resin layer 2 on the unfoamed resin layer 1A after calendar molding by T die extrusion method. Thus, this is an example of stacking backing sheets. The backing sheet can also be laminated in-line at the same time as laminating the surface resin layer as shown in the figure. Also, if the backing sheets are laminated in-line at the same time, it is efficient and the cost can be reduced in this respect as well.

Next, the cross-sectional view of FIG. 2 illustrates the foamed decorative sheet raw fabric 10 obtained as described above. Figure 2
The original fabric sheet 10 for a foamed decorative sheet shown in (A) is an example of a configuration without a backing sheet, and is an unfoamed resin layer 1A before foaming.
A surface protective layer 2 made of a thermoplastic resin is laminated on top of this, and the constitution is made up of these two layers. In addition, FIG. 2 (B)
The raw fabric 10 for a foamed decorative sheet shown in 1 is an example of the constitution in which the backing sheet 3 is also provided. The surface protective layer 2 made of a thermoplastic resin is laminated on the upper side of the unfoamed resin layer 1A, and the unfoamed resin layer is formed. A backing sheet 3 is laminated on the lower side (back side) of 1A, and the backing sheet 3 is composed of these three layers.

Then, such a raw fabric 1 for a foam decorative sheet
When 0 is heated to foam the unfoamed resin layer 1A to form a foamed resin layer, a foamed decorative sheet is obtained. However, the foamed decorative sheet is usually further provided with an uneven pattern, a pattern, etc. In that case, after the pattern layer 4 is appropriately printed on the surface protective layer 2 of the foamed decorative sheet material 10, it is heated. The unfoamed resin layer is foamed to form a foamed resin layer. The concavo-convex pattern is usually formed by utilizing the residual heat at the time of foaming to form the concavo-convex pattern from the surface on the surface resin layer side with an embossing plate after foaming.

The cross-sectional view of FIG. 3 illustrates the foam decorative sheet obtained as described above. In the foamed decorative sheet 20 shown in FIG. 3 (A), a backing sheet 3 / foamed resin layer 1 / surface protection layer 2 are laminated in this order from the back surface side, and an uneven pattern 5 is formed on the surface on the surface protection layer 2 side. It is a composition. Also, FIG.
The foamed decorative sheet 20 illustrated in the cross-sectional view of (B) has a backing sheet 3 / foamed resin layer 1 / surface protection layer 2 / pattern layer 4 laminated in this order from the back surface side, and a surface on the surface protection layer and pattern layer side. This is a configuration in which the uneven pattern 5 is formed.

Hereinafter, each layer will be described in detail in order.

[Unfoamed Resin Layer and Foamed Resin Layer] The unfoamed resin layer 1A is a layer made of a resin to which at least a foaming agent is added. The unfoamed resin layer 1A becomes the foamed resin layer 1 by heating the unfoamed resin layer to a temperature equal to or higher than the foaming temperature of the foaming agent to foam the unfoamed resin layer.

As the resin for the unfoamed resin layer or the foamed resin layer, it is preferable to use a halogen-free resin, in which a halogen-containing resin such as a vinyl chloride resin is avoided in consideration of the environment. As the halogen-free resin, a conventionally known resin may be appropriately selected and used. For example, the resin may be a polyolefin resin formed of a homopolymer or a copolymer of olefinic monomers such as polyethylene and polypropylene, or an ethylene-vinyl acetate copolymer (EVA), an ethylene-methyl methacrylate copolymer ( EMMA), ethylene-ethyl methacrylate copolymer, ethylene-methyl methacrylate copolymer, etc.,
Polyolefin resin made of a copolymer of α-olefin such as ethylene or propylene and other vinyl monomer such as vinyl acetate or acrylic acid monomer, or thermoplastic resin such as polystyrene, acrylic resin, polyester resin, etc. Can be mentioned.

Among these, ethylene-based resins containing ethylene as a copolymer monomer, such as ethylene-vinyl acetate copolymer (EVA) and ethylene-methyl methacrylate copolymer (EMMA), have a relatively small burning calorie. (Relating to flame retardancy and quasi-non-combustibility) and inexpensive resin is a preferable resin. The copolymerization ratio of vinyl acetate in the ethylene-vinyl acetate copolymer is usually 20 to 30.
A range of about mass% is preferable. If the copolymerization ratio of vinyl acetate is less than 20% by mass, the raw fabric for a foam decorative sheet is likely to be curled, especially when a backing sheet is laminated, and the printability of the raw fabric is deteriorated. Because. On the other hand, when the copolymerization ratio exceeds 30% by mass, the calendering moldability (roll separation) tends to be deteriorated. The copolymerization ratio of methyl methacrylate in the ethylene-methyl methacrylate copolymer is usually 20 to
A range of about 30% by mass is preferable. The reason is the same as in the case of vinyl acetate.

The resin used for the unfoamed resin layer has a melt flow rate (MFR) of 1 in view of strength such as foaming suitability (foaming ratio, cell density, etc.), scratch resistance and the like and calender molding suitability. It is preferably about 10 (g / 10 min), more preferably about 1-5. When the melt flow rate is less than 30, the calender moldability is lowered and the expansion ratio is also lowered, and conversely, the melt flow rate is 8
If it exceeds 0, the mechanical strength of the foamed resin layer tends to decrease. The melt flow rate is measured according to JIS
K 7210 (thermoplastic flow test method)
Done by. In that case, the test conditions are JIS K67.
Condition 4 specified in Table 1 of the JIS specified as test conditions for polyethylene in 60 [190 ° C., 21.1
8N (2.16 kgf)].

As the foaming agent, a conventionally known foaming agent may be appropriately selected and used. However, in order to realize low cost, the pyrolytic foaming agent is preferable to the microcapsule type foaming agent. Examples of the microcapsule type foaming agent include those in which a thermally expansive gas such as hexane or isobutane is enclosed in a resin spherical shell such as acrylonitrile. Examples of the thermal decomposition type foaming agents include azo-based compounds such as azodicarbonamide (ADCA) and azobisformamide, oxybenzenesulfonyl hydrazide (OBSH), and hydrazide compounds such as paratoluenesulfonyl hydrazide. Among these, as the heat-decomposable foaming agent, when a polyolefin resin is used as the resin, the azo foaming agent, especially azodicarbonamide (ADCA), is costly, foaming performance (foaming temperature, stability, foaming). It is preferable in terms of magnification). The amount of the foaming agent added is appropriately adjusted depending on the resin, the expansion ratio, etc., but is usually 1 to 2 with respect to the resin content.
It is about 0 mass%.

In the unfoamed resin layer 1A, various known additives such as an inorganic filler, a flame retardant, a colorant, a heat stabilizer and a light stabilizer are usually added as needed. For example, as the inorganic filler, flame retardants such as aluminum hydroxide, magnesium hydroxide and zinc borate, and powders of calcium carbonate, barium carbonate, barium sulfate, clay, talc and the like are used. Further, as the colorant, those described in the later-described pattern layer such as titanium white are used. Further, zinc-based, lead-based, bell-based, etc. are used as the foaming stabilizer, and ultraviolet absorbers, radical scavengers, etc. are used as the light stabilizer. The addition amount varies depending on the additive, but in the case of an inorganic filler, it is usually about 30 to 200 parts by mass with respect to 100 parts by mass of the resin content.

The thickness of the unfoamed resin layer 1A depends on the application,
The thickness may be an appropriate value in consideration of the foaming ratio, the presence or absence of the backing sheet, the cost, etc., and is usually 80 to 30 for wallpaper applications.
It is about 0 μm, preferably about 100 to 150 μm. The expansion ratio depends on the application but is 1.5 times or more, usually about 3 to 7 times. If the expansion ratio is too low, the effect of foaming itself cannot be sufficiently obtained, and if the expansion ratio is too high, the foamed resin layer becomes mechanically weak and scratch resistance decreases.

The formation of the unfoamed resin layer 1A is not impossible even by the T-die extrusion method, but the T-die extrusion method is inferior to the calender molding method in the supply capacity of the raw material resin, so that the layer thickness is particularly large. If it is thick, the sheet forming speed will decrease. Also, the resin loss when changing the raw material resin is large. On the other hand, if the calendar molding method is adopted as in the present invention,
Even if the layer thickness is thick, the sheet molding speed can be increased and resin loss is small. Therefore, the production cost can be further reduced by adopting the calendar molding method.

When the foamed decorative sheet is used as a wallpaper or the like, it is usually not used because the mechanical strength of the decorative sheet and the layer thickness necessary for the desired foaming are suppressed to reduce the cost. A backing sheet 3 such as backing paper is laminated on the back surface side of the foamed resin layer 1A [see FIG. 1]. However, in the calendar molding method, since the unfoamed resin layer 1A can be formed thick while maintaining the productivity, it is also possible to provide mechanical strength by the layer, and a constitution without a backing sheet is also possible depending on the application. There is also an advantage.

[Backing Sheet] The backing sheet 3 is not particularly limited as long as it has mechanical strength and heat resistance during heat foaming. A fibrous sheet is usually used in terms of satisfying these performances. Lamination of the backing sheet is preferable in that the backing sheet improves the mechanical strength, and the thickness of the unfoamed resin layer is suppressed to only the amount necessary for foaming, thus achieving cost reduction. Examples of the fibrous sheet used as the backing sheet include paper, non-woven fabric, woven fabric and the like. Among them, flame-retardant paper and inorganic paper are typical. The thickness of the backing sheet depends on the application, but for wallpaper applications, the grammage is usually 50
˜300 g / m ² and preferably 50 to 80 g / m ² .

An unfoamed resin layer 1 in which the backing sheet is in an unfoamed state
The method of laminating on the back side of A is not particularly limited. For example, as illustrated in the conceptual diagram of FIG. 1, immediately after the unfoamed resin layer 1A is calendered, the surface protective layer is laminated by the T-die extrusion method. Previously, it is laminated in-line using a pair of laminating rollers 50. The backing sheet may be laminated after the surface protective layer is laminated, but if it is immediately after calender molding, there is residual heat during calender molding, and adhesion is easy.

The timing for laminating the backing sheet 3 is preferably between calender molding and T-die extrusion, including calender molding, and more preferably, because adhesion by heat fusion without an adhesive is easy. It is after calender molding and before T-die extrusion, and more preferably immediately after calender molding (see FIGS. 1 and 5). The stacking timing on the most upstream side is, for example, the calendar bottom roller 3
5 is a laminated layer (see FIG. 4 (A)). However, in that case, after the backing sheet is laminated, it becomes impossible to form a thin film by stretching the resin, so that the line speed is difficult to obtain accordingly. However, if the stacking timing is immediately after calender molding (see FIG. 1), the backing sheet should be stacked by heat fusion without an adhesive while stretching the unfoamed resin layer to make it thin by the residual heat. Therefore, there is an advantage that the film thickness and the sheet width can be fixed by immediately stopping the stretching. Further, a surplus of both ears in the sheet width direction is cut by the laminating roller 5
If it is performed at the 0th portion, both ears have only the unfoamed resin layer and no contaminants, so that it can be reused by resin return. Realization of this resin return is an important factor for cost reduction as well as environmental consideration that does not generate waste.

Next, in the case of simultaneous three-layer lamination immediately below the T-die extrusion [FIG. 4 (B)], the binaural cut positions for reusable resin return cannot be taken. The backing sheet has already been laminated on the roller 42a, and the surface protective layer has also been laminated on the roller 42b and thereafter, so that the cut ears become a mixture. Further, in the case of simultaneous two-layer lamination immediately after the T-die extrusion [FIG. 4 (C)], even if the both ears cut CT can be performed by the roller 42a, the roller 42a is laminated in order to laminate the backing sheet by heat fusion thereafter. When the temperature is high, the roller 4
There is a problem that the peeling of the sheet from between 2a and 42b is not stable.

Next, as the stacking timing on the most downstream side,
It is possible even after T-die extrusion molding. In this case, the binaural cut CT can be performed by the roller 42a, but it is necessary to provide the heater 43 on the downstream side to reheat the core lining sheet for heat fusion. If not, the labor and cost of using the adhesive are required separately (see FIG. 1D).

As described above, the lamination timing of the backing sheet is preferably after calender molding and before T die extrusion.

It is not the best to use an adhesive for laminating the backing sheet, but if the use of the adhesive is allowed from the viewpoint of required performance, of course, it is possible to use the adhesive. I do not care. As the adhesive, a known adhesive, for example, a resin adhesive such as urethane resin, vinyl acetate resin, or polyester resin may be applied to the backing sheet, and then the backing sheet and the unfoamed resin layer may be laminated. . The adhesive coated surface may be an unfoamed resin layer, or both of them, in addition to the backing sheet.

Here, in a conceptual explanatory view of FIG. 4, a certain embodiment of the method for producing a raw fabric for a foam decorative sheet according to the present invention is shown. In the case of the same figure, as the calendar device 30, a composite 6-calender is used. The foamed resin material 1B, which is the source of the unfoamed resin layer 1A, is automatically supplied from an automatic raw material supply device and kneaded through a planetary extruder and a mixing mill in that order, and then calendered 3
Supplied to zero. Then, the unfoamed resin layer 1A is formed into a continuous strip-shaped sheet by the calendar device 30. In the case of the form illustrated in the figure, before laminating the surface protective layer 2 on the unfoamed resin layer 1A after the calendar molding, the backing sheet 3 is continuously formed inline before being laminated on the back surface. Lamination is performed using a pair of laminating rollers 50. In addition, before laminating, excess ears at both ends in the width direction are cut to have a desired width. The cut ears are the components of the unfoamed resin layer without any contaminants, and are returned to the mixing mill and reused as resin returns.

[Surface Protective Layer] In the present invention, the surface protective layer 2 is formed inline by a T-die extrusion method using a thermoplastic resin, continuously with the calendar molding of the unfoamed resin layer 1A. The surface protective layer is usually a non-foamed layer. This is because when the surface protective layer is also a foam layer, the surface strength, which is the original purpose of the surface protective layer, is lowered, and the scratch resistance, which is the object of the present invention, is lowered. However, within the range of the required scratch resistance, a low-foaming surface protection layer may be used in which the foaming ratio is suppressed to a low level by reducing the amount of the foaming agent added to the foamed resin layer. The thickness of the surface protective layer may be appropriately set according to the intended use and the required physical properties. For example, in the case of wallpaper use, the thickness is 5 to 20 μm, more preferably 1 μm.
It is about 0 to 15 μm. If the thickness is thin, scratch resistance is not sufficiently obtained, and if the thickness is too thick, curl to the surface protective layer side in the width direction of the sheet (the surface protective layer side is concave).
Increases, which causes troubles when applying the foamed decorative sheet.

As described above, the thickness of the surface protective layer 2 is not required to be the same as that of the unfoamed resin layer, and the raw material resin material can be smoothly supplied even by the T-die extrusion method, and the production rate is not reduced.
Further, for the surface protective layer composed of a thin resin layer, the T-die extrusion method is more preferable than the calender molding method in that the surface property can be improved with a uniform thickness. Therefore, in the present invention, the T-die extrusion method is used for forming the surface protective layer.

Further, the surface protective layer may have a multi-layer structure such as two layers made of different kinds or same kinds of resins. In that case, if it is the T-die extrusion method, it can be easily formed by a multi-layer co-extrusion method such as a two-layer co-extrusion method. As an example in which the surface protective layer has a multi-layered structure, for example, the unfoamed resin layer side is a layer in which the adhesiveness with the unfoamed resin layer is more taken into consideration, and the surface side has surface strength, printability, stain resistance, etc. It is a structure in which the layer is considered more.
In addition, by providing a surface protective layer, as a countermeasure when the curling of the foam decorative sheet as a wallpaper becomes a problem, the surface protective layer is made of a material having a different shrinkage factor when returning from the processing temperature to room temperature. By designing the layers to have a multilayer structure such as two layers, it is also effective to design such that the back side such as the backing sheet side is slightly warped (the surface protective layer side is convex).

The thermoplastic resin used for the surface protective layer is not particularly limited as long as the required scratch resistance can be obtained. However, from the basic gist of the present invention, a thermoplastic resin containing no halogen such as chlorine is preferable. Examples of halogen-free thermoplastic resins include polyolefin resins such as polypropylene (PP) and high-density polyethylene (HDPE), polyester resins such as polybutylene terephthalate (PBT), ethylene vinyl alcohol (EVOH), acrylic resins and the like. Vinyl resin,
Polyamide resin (nylon) and the like.

In the surface protective layer, if necessary, various fillers, colorants, light stabilizers (ultraviolet absorbers, radical scavengers, radical scavengers, etc.) such as those mentioned in the unfoamed resin layer may be used to adjust various physical properties. Agents), foaming agents, and other known additives such as lubricants and antibacterial agents. The surface protective layer may be transparent or opaque. Further, it may be uncolored or colored by adding a coloring agent such as titanium white.

In the present invention, since the unfoamed resin layer 1A and the subsequent surface protection layer 2 are continuously formed in-line, the surface protection layer 2 is not formed with a pattern layer such as printing interposed therebetween. It is preferable to form it directly on the foamed resin layer 1A in terms of manufacturing apparatus. When a pattern layer is required, it may be formed on the surface protective layer of the original fabric for a foam decorative sheet later.

Here, one mode of forming the surface protective layer will be described with reference to the conceptual explanatory view of FIG. 4 referred to above. In the case of the same figure, a single-screw extruder is used as the T-die extruder 40. The resin material 2A that is the base of the surface protection layer is
The material is automatically supplied from the automatic material supply device to the T-die extrusion device 40 and extruded from the T-die 41 in a heated and melted state. Then, the surface protection layer is formed by being melt-coated on the front side surface of the unfoamed resin layer 1A on which the backing sheet 3 has been laminated, which flows from the upstream side, to form the foam decorative sheet material 10. After that, the foamed decorative sheet raw fabric 10 passes through an accumulator and is wound up for winding.

By the way, the surface protective layer 2 is the unfoamed resin layer 1
In terms of being laminated in contact with A, after the unfoamed resin layer 1A is formed into a sheet, the sheet is once wound, and then the surface protective layer is laminated on the sheet unwound off-line by the T-die extrusion method. Things are possible. However, in the present invention, the surface protective layer is formed in-line, that is, continuously, so that the surface protective layer can be laminated on the unfoamed resin layer with good adhesion. Moreover, the surface protective layer can be formed while the unfoamed resin layer has residual heat during calender molding, and in this respect also, the surface protective layer can be laminated on the unfoamed resin layer with good adhesion. Therefore, provision of a primer layer between these layers can be omitted. Therefore, the cost increase due to the provision of the primer layer can be avoided. Therefore, also from this point, cost reduction can be realized.

[Other Layers] Although a primer layer is not particularly required in the present invention, it is needless to say that the primer layer may be used if the use of the primer layer is allowed in terms of cost and the like. The primer layer is a two-component curing type urethane resin,
A known primer agent such as a silane coupling agent is appropriately used. The primer layer is applied to, for example, the unfoamed resin layer and the backing sheet. The primer layer can be formed by a known coating method such as gravure coating or roll coating.

If the adhesion is required to be enhanced, including the case where the primer layer is used or the case where the primer layer is not used, a known surface treatment may be applied. For example, corona discharge treatment, plasma treatment and the like. Such surface treatment is
This is performed for the unfoamed resin layer or the molten resin (surface protection layer) immediately below the T die.

[Use of Original Fabric for Foamed Decorative Sheet] The original fabric for foamed decorative sheet obtained by the above-described manufacturing method is used as a raw fabric for producing a foamed decorative sheet. As the foam decorative sheet, wallpaper is typically mentioned. In the case of wallpaper, etc., after normally printing a pattern layer on the surface protective layer surface of the original sheet for foam decorative sheet, it is heated and foamed, and then an uneven pattern is formed on the surface by embossing to obtain a desired foam makeup. Use as a sheet.

The method for producing a foamed decorative sheet according to the present invention is characterized in that the above-mentioned raw fabric for a foamed decorative sheet is used, and this raw fabric may be foamed, but usually this raw fabric is used. On the other hand, a decorative treatment is further applied to obtain a foam decorative sheet. As the decoration processing, for example, formation of a pattern layer,
Although there are irregular shapes and the like, conventionally known decoration treatment may be appropriately adopted depending on the application, required physical properties and the like. Hereinafter, the pattern layer, the concavo-convex pattern, and the foaming as the decoration processing will be further described.

[Picture Layer] The picture layer 4 is a layer for expressing a design by a picture, and when a high design is required, it is a known forming method and material such as a printing method and used for the foam decorative sheet described above. It may be provided on the surface protective layer surface of the original fabric. The printing method is, for example, gravure printing, silk screen printing,
Offset printing, letterpress printing, flexographic printing, electrostatic printing,
Known printing methods such as inkjet printing and transfer printing may be used. If the entire surface is solid, it may be formed by a known coating method. The pattern pattern of the pattern layer is, for example, a grain pattern, a stone pattern, a tile pattern, a brick pattern, a texture pattern, a wood pattern, a leather pattern, a geometric pattern, a character, a symbol, various abstract patterns, or a solid pattern. Etc., or a combination of these,
It may be a pattern according to the application.

The ink (or coating liquid) used for forming the pattern layer is, for example, an acrylic resin, a vinyl acetate resin, a vinyl chloride-vinyl acetate copolymer, a cellulose resin, a urethane resin, a polyamide resin, as a binder resin. Polyester resin or chlorinated polyethylene,
A chlorinated polyolefin resin such as chlorinated polypropylene is used alone or as a mixture. The colorant of the ink (or coating liquid) includes inorganic pigments such as titanium white, carbon black, rouge, yellow lead and ultramarine, organic pigments such as aniline black, quinacridone, isoindolinone and phthalocyanine blue, and aluminum foil. Powder, bright pigment such as titanium dioxide-coated mica foil powder, or other dyes are used.

[Concavo-convex pattern] The concavo-convex pattern 5 is for expressing a design feeling due to surface irregularities, and may be provided by a known embossing method or the like when high design is required. The uneven pattern can be formed efficiently by using an embossing plate after the foaming while utilizing the heat during the foaming. For embossing, a known hot press type sheet-fed or rotary embossing machine can be used. As the uneven pattern, for example, cloth surface texture, satin, grain,
Stone board surface irregularities (granite cleavage surface, etc.), tiled or brickwork joint grooves, wood grain board conduit grooves, etc. The uneven pattern may be a combination of these.

[Foaming] The foaming of the unfoamed resin layer is usually performed after the picture layer is provided when the picture layer is provided. The foaming temperature depends on the type of resin, foaming agent, etc., but is 150-250
It is about ℃. The foaming time is about 0.5 to 2 minutes.

[0053]

EXAMPLES Next, the present invention will be described in more detail by way of examples.

[Example 1] A raw material 10 for a foam decorative sheet as shown in the sectional view of Fig. 2 (B) was manufactured as follows in a manufacturing line as shown in Fig. 5. An unfoamed resin layer 1 having a thickness of 110 μm was formed into a continuous strip-shaped sheet by calendering (foaming temperature 100 ° C.) a foaming resin having the following composition using a calendering machine.
A is molded, and immediately after that, the backing sheet 3 made of a flame-retardant backing paper for wallpaper having a basis weight of 60 g / m ² is continuously formed with a laminating roller to form an unfoamed resin layer while the remaining heat at the time of molding is maintained. The resin was adhered and laminated by heat fusion. At that time, both ears of the unfoamed resin layer were cut immediately before laminating the backing sheet, and the resin was reused as a molding material for the unfoamed resin layer as a resin return.

Blending of foaming resin : ethylene-vinyl acetate copolymer (EVA) 100 parts by mass (vinyl acetate content 23% by mass, MFR3) filler (calcium carbonate) 50 parts by mass coloring agent (titanium white) 15 parts by mass foaming agent (ADCA) 5 parts by mass Stabilizer (zinc-based) 5 parts by mass

Next, continuously, the backing sheet 3 /
The laminated sheet of the unfoamed resin layer 1A is introduced into a T-die extrusion device installed on the downstream side of the calender device, and uncolored high density polyethylene (HDPE) is heated and melted (resin temperature 280 ° C.). It was extruded from a T-die, and a surface protection layer 2 having a thickness of 10 μm was laminated on the unfoamed resin layer 1A at the same time as film formation to obtain a desired raw material 10 for a foam decorative sheet as shown in FIG. 2 (B).

Then, by using the above foamed decorative sheet material 10 as shown in the sectional view of FIG.
0 was produced. Specifically, the original fabric 10 for foam decorative sheet
After forming an abstract pattern layer 4 on the Noma surface protection layer 2 by gravure printing, it is heated at 220 ° C. for 40 seconds to foam the unfoamed resin layer 1A to form the foamed resin layer 1, and subsequently. 2 is formed by embossing with an embossing plate from the surface of the surface protective layer side to form an uneven pattern 5 having an abstract pattern, and
A desired foam decorative sheet 20 as shown in (B) was produced.

[Example 2] In Example 1, except that the resin used as the surface protective layer was laminated by the T-die extrusion method (resin temperature 210 ° C) in place of ethylene vinyl alcohol (EVOH) instead of high-density polyethylene. In the same manner as in Example 1, a raw fabric for a foam decorative sheet was produced. Then, a foam decorative sheet was prepared in the same manner as in Example 1.

Example 3 In Example 1, the resin used as the surface protective layer was changed from high-density polyethylene to polyamide resin (nylon), and the T-die extrusion method (resin temperature 240
A raw fabric for a foam decorative sheet was produced in the same manner as in Example 1 except that the sheets were laminated at the same temperature. Then, a foam decorative sheet was prepared in the same manner as in Example 1.

Example 4 In Example 1, except that the resin used as the surface protective layer was changed from high-density polyethylene to polybutylene terephthalate (PBT) by the T-die extrusion method (resin temperature 250 ° C.), In the same manner as in Example 1, a raw fabric for a foam decorative sheet was produced. Then, a foam decorative sheet was prepared in the same manner as in Example 1.

[Performance Evaluation Result] The foamed decorative sheet thus obtained was evaluated for its foaming state and scratch resistance. The foamed state was good in all of the examples, as judged by whether or not the thickness of the foamed resin layer after foaming was sufficient as a wallpaper (500 μm or more). The scratch resistance was evaluated by conducting a surface-reinforced wallpaper test (Japan Vinyl Industry Association) after the unfoamed resin layer was foamed five times. As a result, in each example,
The evaluation ranks were all grade 4, all showing some surface scratches, but no comparatively large peeling of the surface layer, and good scratch resistance.

Further, the original fabric for the foam decorative sheet of each example,
And, the foamed decorative sheet thus obtained did not curl and had good curl resistance, and did not cause any hindrance in the printing of the pattern layer or the application of the decorative sheet.
Further, regarding the independence of each layer, when the cross-section after foaming is observed with a microscope, it is possible to distinguish between the foamed resin layer and the surface protective layer, and the foaming agent added in the foamed resin layer foams up to the surface protective layer. There was nothing. Therefore, it was confirmed that the surface protective layer effectively functions to improve scratch resistance. In addition, the foam decorative sheets of each example were all classified as quasi-incombustible as a result of the heat generation test.

[0063]

(1) According to the method for producing a raw fabric for a foam decorative sheet of the present invention, the production speed can be increased, and the cost can be reduced by improving the productivity. Then, there can be obtained a raw material that enables the production of a foam decorative sheet that can realize scratch resistance at low cost. (2) According to the method for producing a foam decorative sheet of the present invention, scratch resistance can be realized at low cost.

[Brief description of drawings]

FIG. 1 is an explanatory view conceptually showing a method for producing a raw fabric for a foam decorative sheet according to the present invention.

FIG. 2 is a cross-sectional view showing a configuration example of a raw fabric for a foam decorative sheet according to the present invention.

FIG. 3 is a cross-sectional view showing a structural example of a foam decorative sheet according to the present invention.

FIG. 4 is an explanatory view conceptually showing various stacking timings of backing sheets.

FIG. 5 is an explanatory view conceptually showing one embodiment of the method for producing a raw fabric for a foam decorative sheet according to the present invention.

[Explanation of symbols]

1 Foamed resin layer 1A unfoamed resin layer 1B Foamed resin material 2 Surface protection layer 2A resin material 3 backing sheet 4 picture layers 5 uneven pattern 10 Original fabric for foam decorative sheet 20 Foaming decorative sheet 30 Calendar device 31-34 Calendar roller 35 Calendar bottom roller 40 T die extrusion equipment 41 T die 42a to 42c rollers 43 heater 50 Laminating roller 61, 62, 63 rollers CT both ears cut (position)

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) E04F 13/00 B29K 101: 12 // B29K 101: 12 105: 04 105: 04 B29L 9:00 B29L 9: 00 31:58 31:58 B29C 67/22 (72) Inventor Nobuyuki Ono 311 Takemasawa, Miyoshi-cho, Iruma-gun, Saitama Prefecture F-term (reference) within Dainichi Printing Co., Ltd. (reference) 4F100 AK01A AK011 AK05 AK68 AR00A BA02 CA01 CA05 CA13 CA23 DJ01B DJ04B DJ042 EA021 EH17A EH172 EJ17B EJ393 EJ42B EJ423 GB08 HB00A HB21A HB31 JB16A JB161 4F207 AA10 AG01 AG03 AG20 AH48 KA01 KA11 KB22 A02 AB11 A02 AB12 A02 AB11 A22 AB11 A22 AB11 A22 AB02 A01 AB02 A01 AB20 A01 AB20 A01 AB02 A01 AB02 A01 AB02 A01 AB02 AF01 A01 AB02 AF01 A01 AB02 AF01 A01 AB02 AF01 A01 AB02 AF01 A01 AB02 AF01 H01A22 WA15 WA33 WA38 WA43 WA53 WA97 WB02 WB11 WB22 WE06 WE07 WE16 WF01 WF05 WF06 WK01 WK03 WW06 WW15 WW21

Claims (3)

[Claims] 1. A method for producing an original fabric for a foam decorative sheet having a surface protective layer made of a thermoplastic resin on an unfoamed resin layer before foaming, wherein the unfoamed resin layer is formed into a sheet by a calender molding method. Then, a method for producing a raw fabric for a foam decorative sheet, which comprises successively forming a thermoplastic resin as a surface protective layer on the unfoamed resin layer by a T-die extrusion method to obtain a raw fabric for a foam decorative sheet. 2. A method for producing a foam decorative sheet, comprising: heating the raw fabric for a foam decorative sheet according to claim 1 to foam an unfoamed resin layer to form a foam resin layer, thereby obtaining a foam decorative sheet. 3. A pattern layer is formed on the surface protective layer before heating the foamed decorative sheet material sheet according to claim 1, and then the unfoamed resin layer is foamed to form a foamed resin layer. The method for producing a foam decorative sheet according to claim 2, wherein a foam decorative sheet is obtained by subsequently forming an uneven pattern by embossing on the surface of the surface protective layer side.