JP2017056598A - Resin composition set, resin sheet, laminate sheet and foaming wall paper and manufacturing method of resin sheet and foaming wall paper - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin composition set or the like for producing a foam wallpaper having sufficient scratch resistance. SOLUTION: A foaming agent-containing resin composition containing a first resin component, a filler and a foaming agent, and a foaming agent-free resin composition containing a second resin component and not containing a foaming agent. A resin composition set for forming a resin sheet containing a laminated structure of a first layer composed of a foaming agent-containing resin composition and a second layer composed of a foaming agent-free resin composition. The melt mass flow rate (A) of the agent-containing resin composition at 130 ° C. and 2.16 kgf load and the melt mass flow rate (B) of the foaming agent-free resin composition at 130 ° C. and 2.16 kgf load are as follows (i). , (Ii) and (iii), a resin composition set satisfying all the conditions. (I) 1 g / 10 minutes ≤ (A) ≤ 10 g / 10 minutes (ii) 1 g / 10 minutes ≤ (B) ≤ 16 g / 10 minutes (iii) -3 g / 10 minutes ≤ (B)-(A) ≤ 6 g / 10 minutes [selection diagram] None

Description

  The present invention relates to a resin composition set, a resin sheet, a laminated sheet, a foamed wallpaper, and a method for producing a resin sheet and a foamed wallpaper. More specifically, the present invention relates to a foam wallpaper that can be used for decorating wall surfaces of buildings such as detached houses, apartment houses, stores, office buildings, and the like, and a resin composition set, resin sheet, and laminated sheet used therefor.

  As foam wallpaper used for wall decoration of buildings, etc., vinyl chloride resin foam wallpaper and plastic foam wallpaper in which a paper base is provided with a resin layer of vinyl chloride resin or other plastics are widely used.

  As a method for producing such foamed wallpaper, a resin composition containing a foaming agent is laminated on a base material while being formed into a sheet by a melt extrusion molding method such as a T-die, or separately sheeted and dried afterwards. A method of foaming a resin sheet printed on the surface as needed after obtaining a laminated sheet in which a resin sheet is provided on the substrate by laminating a substrate by lamination or heat lamination (For example, see Patent Document 1 below). These methods are advantageous in terms of production efficiency as compared with a coating method in which a resin composition is applied and dried on a substrate and a calendering method. On the other hand, in the extrusion molding method, since the amount of filler added is limited, it is difficult to ensure the scratch resistance of the resin sheet.

  As a technique for improving the surface strength of a foamed wallpaper, a foamed wallpaper in which a non-foamed resin layer is provided on a foamed resin layer has been proposed (see, for example, Patent Documents 2 and 3 above).

Patent No. 4629188 JP 2007-31893 A JP 2007-313900 A

  However, even the foamed wallpaper described in Patent Documents 2 and 3 may cause problems in practical use and need further improvement.

  The present invention has been made in view of the above circumstances, and includes a resin composition set, a resin sheet, a laminated sheet, a method for producing a resin sheet, and a foamed wallpaper that can produce a foamed wallpaper having sufficient scratch resistance. An object is to provide a manufacturing method.

In order to solve the above problems, the present invention includes a foaming agent-containing resin composition containing a first resin component, a filler, and a foaming agent, and a second resin component, and no foaming agent. A resin for forming a resin sheet comprising a laminated structure of a first layer comprising a foaming agent-containing resin composition and a second layer comprising a foaming agent-free resin composition A composition set comprising a foaming agent-containing resin composition at 130 ° C. under a load of 2.16 kgf (A) and a foaming agent-free resin composition at 130 ° C. under a load of 2.16 kgf (B) ) Provides a resin composition set that satisfies all of the following conditions (i), (ii), and (iii).
(I) 1 g / 10 min ≦ (A) ≦ 10 g / 10 min (ii) 1 g / 10 min ≦ (B) ≦ 16 g / 10 min (iii) -3 g / 10 min ≦ (B) − (A) ≦ 6 g / 10 minutes

  According to the resin composition set of the present invention, a resin sheet that enables realization of a foam wallpaper having sufficient scratch resistance can be formed by extrusion molding.

  Regarding the reason why such an effect is obtained, the present inventors have sufficiently suppressed the difference in viscosity between the first layer and the second layer at the time of coextrusion, thereby sufficiently ensuring the adhesion at the interface of the laminated structure, It is assumed that the effect of improving the surface strength by the second layer can be sufficiently obtained even if the first layer is sufficiently foamed. In addition, the present inventors suppress the difference in viscosity between the first layer and the second layer during coextrusion, thereby reducing the strain at the interface of the laminated structure, and improving the surface strength by the second layer. We think that it is to be obtained. That is, when the adhesive force at the interface of the laminated structure is secured and the strain is reduced, the second layer reaches the first layer when subjected to a mechanical load such as a scratch from the second layer side. The present inventors consider that scratches are less likely to occur.

  Moreover, this invention is obtained by coextrusion of the foaming agent containing resin composition and foaming agent non-containing resin composition of the resin composition set which concerns on the said invention, The 1st layer which consists of a foaming agent containing resin composition And a resin sheet including a laminated structure of the second layer made of the foaming agent-free resin composition.

  According to the resin sheet of the present invention, a foamed wallpaper having sufficient scratch resistance can be obtained.

  In the resin sheet of the present invention, part or all of the first resin component contained in the first layer may be crosslinked. By subjecting the first layer made of the foaming agent-containing resin composition to a crosslinking treatment, the foamed cells when foamed become fine, and a reduction in surface strength due to excessive foaming can be suppressed.

  The first resin component may contain a silane crosslinkable resin. By including the silane crosslinkable resin in the first resin component, only the first layer can be selectively crosslinked. Thereby, when the first layer is foamed, the followability of the second layer with respect to the first layer can be improved, the adhesion between both layers can be improved, and the surface strength can be further improved. .

  Moreover, this invention provides a laminated sheet provided with a base material and the resin sheet which concerns on the said this invention provided on this base material.

  Furthermore, the present invention is a foam wallpaper comprising a base material and a foamed resin layer provided on the base material, wherein the foaming agent contained in the first layer in the laminated sheet according to the present invention is foamed. To provide foamed wallpaper.

The present invention also provides a foaming agent-containing resin composition containing a first resin component, a filler, and a foaming agent, and a second resin component and no foaming agent. A resin sheet forming step of forming a resin sheet including a laminated structure of a first layer composed of a foaming agent-containing resin composition and a second layer composed of a foaming agent-free resin composition The melt mass flow rate (A) at 130 ° C. and 2.16 kgf load of the foaming agent-containing resin composition and the melt mass flow rate (B) at 130 ° C. and 2.16 kgf load of the foaming agent-free resin composition are as follows: Provided is a method for producing a resin sheet that satisfies all the conditions shown in (i), (ii) and (iii).
(I) 1 g / 10 min ≦ (A) ≦ 10 g / 10 min (ii) 1 g / 10 min ≦ (B) ≦ 16 g / 10 min (iii) -3 g / 10 min ≦ (B) − (A) ≦ 6 g / 10 minutes

  According to the method for producing a resin sheet of the present invention, it is possible to efficiently produce a resin sheet that enables realization of a foam wallpaper having sufficient scratch resistance.

  The present invention is also a method for producing a foam wallpaper comprising a base material and a foamed resin layer provided on the base material, wherein the resin sheet is produced on the base material by the method for producing a resin sheet according to the present invention. A laminated sheet forming step of obtaining a laminated sheet by laminating the first layer side of the obtained resin sheet; and a foaming step of forming a foamed resin layer by foaming a foaming agent contained in the first layer in the laminated sheet. Provided is a method for producing foam wallpaper.

  According to the method for producing a foam wallpaper of the present invention, a foam wallpaper having sufficient scratch resistance can be efficiently produced.

  The foaming step may include heating the laminated sheet with superheated steam.

  Moreover, the manufacturing method of the foaming wallpaper of this invention may further be equipped with the bridge | crosslinking process which bridge | crosslinks a part or all of the 1st resin part contained in a 1st layer before the said foaming process. In this case, the first resin component may contain a silane crosslinkable resin, and the laminated sheet may be heated with superheated steam to crosslink part or all of the silane crosslinkable resin.

  Moreover, in the method for producing foam wallpaper according to the present invention, the first resin component contains a silane crosslinkable resin, and the laminated sheet is heated with superheated steam in the foaming step, so that part or all of the silane crosslinkable resin is obtained. The foaming agent may be foamed while being crosslinked.

  ADVANTAGE OF THE INVENTION According to this invention, the resin composition set for manufacturing the foaming wallpaper which has sufficient scratch resistance, a resin sheet, a lamination sheet, the manufacturing method of a resin sheet, and the manufacturing method of a foaming wallpaper can be provided.

It is process drawing which shows one embodiment of the manufacturing method of the foam wallpaper based on this embodiment. It is process drawing which shows the other embodiment of the manufacturing method of the foam wallpaper based on this embodiment. It is process drawing which shows the other embodiment of the manufacturing method of the foam wallpaper based on this embodiment.

[Resin composition set]
The resin composition set according to the present embodiment includes a foaming agent-containing resin composition that includes a first resin component, a filler, and a foaming agent, and a second resin component that does not include a foaming agent. Agent-free resin composition.

<Foaming agent-containing resin composition>
As the first resin component in the foaming agent-containing resin composition, halogen-based resins such as polyvinyl chloride resin can be used. From the viewpoint of preventing generation of toxic gases such as dioxins during combustion, non-halogen-based resins are used. It is preferable to include. Non-halogen resins include, for example, ethylene homopolymers, copolymers of ethylene and other olefins, polyolefin resins (single olefin polymers such as polypropylene, polybutene, polymethylpentene, etc., random of two or more olefins) Or block copolymer), styrene resin (polystyrene, acrylonitrile / styrene copolymer (AS), acrylonitrile / butadiene / styrene copolymer (ABS), etc.), ethylene copolymer (ethylene-vinyl acetate copolymer, ethylene). -Methyl methacrylate copolymer, ethylene-acrylic acid copolymer, ethylene-ethyl acrylate copolymer, ethylene-methyl acrylate copolymer, ethylene-methacrylic acid copolymer, etc.). These can be used alone or in combination of two or more.

  Especially, it is preferable that the 1st resin part which concerns on this embodiment contains an olefin resin, and it is more preferable that an ethylene homopolymer or a copolymer of ethylene and another olefin is included. By including the olefin-based resin, the film forming stability at the time of extrusion molding is further improved, and a resin sheet with little variation in quality can be obtained. In addition to the above, by using an ethylene homopolymer or a copolymer of ethylene and another olefin, the surface energy of the base resin is large, so that the effect of improving the ink affinity due to the reduction of bleed out is exhibited more greatly. Is done.

  An ethylene homopolymer and a copolymer of ethylene and another olefin are nonpolar non-halogen thermoplastic resins, and by using these, the increase in viscosity when the amount of filler is increased can be further suppressed. High quality wallpaper can be produced stably.

  Examples of the ethylene homopolymer include low density polyethylene synthesized by a high pressure method, high density polyethylene not containing a comonomer synthesized by a medium pressure method, and the like. Among these, low density polyethylene is preferable.

Low density polyethylene, for example, those in the density of 0.91 g / cm ³ or more 0.94 g / cm ³ or less. The density of low-density polyethylene is preferably not less density 0.91 g / cm ³ or more 0.93 g / cm ^3, more preferably less density 0.92 g / cm ³ or more 0.93 g / cm ^3. The molecular weight, melting point, melt flow rate (MFR) and the like of the low density polyethylene are not particularly limited, but the melting point is preferably 50 ° C to 140 ° C, more preferably 60 ° C to 110 ° C. If the melting point is 140 ° C. or lower, it is not necessary to melt the resin and mold it at a higher temperature, and the foaming agent is less likely to decompose during molding. On the other hand, if the melting point is 50 ° C. or higher, sufficient heat durability in actual use can be obtained. The MFR is preferably from 3 to 150, more preferably from 4 to 100. If the MFR is 3 or more, shear heat generated during molding can be suppressed, the processing temperature can be easily controlled, and there is little possibility that the foaming agent will be decomposed during molding. On the other hand, if the MFR is 150 or less, the mechanical strength of the produced foamed wallpaper is maintained, and the workability and durability are excellent.

  Examples of the low-density polyethylene include Novatec LD LC802A, Novatec LD LC604, LJ902 (above, manufactured by Nippon Polyethylene Co., Ltd.), Ube Polyethylene J2516 (produced by Ube Maruzen Polyethylene Co., Ltd.), Petrocene 202, 209, (above, Tosoh Corporation). (Commercially available) can be used.

  Examples of the copolymer of ethylene and other olefins include linear low density polyethylene, ultra-low density polyethylene, high density polyethylene obtained by copolymerization with a comonomer, and the like. Alternatively, two or more kinds can be used in combination. Among these, ultra-low density polyethylene is preferable.

The ultra low density polyethylene, for example, those in the range of less than the density 0.85 g / cm ³ or more 0.91 g / cm ^3. The density of the ultra-low density polyethylene is preferably 0.86 g / cm ³ or more and 0.90 g / cm ³ or less, more preferably 0.87 g / cm ³ or more and 0.90 g / cm ³ or less, and still more preferably 0.87 g / cm ³ or more and 0.90 g / cm ³ or less, particularly preferably 0.88 g / cm ³ or more and 0.90 g / cm ³ or less, and most preferably 0.89 g / cm ³ or more and 0.000 or less. 90 g / cm ³ or less. The molecular weight, melting point, MFR and the like of the ultra-low density polyethylene are not particularly limited, but the melting point is preferably 50 to 100 ° C, more preferably 55 to 90 ° C. If the melting point is 100 ° C. or lower, it is not necessary to melt the resin and mold it at a higher temperature, and there is little possibility that the foaming agent will decompose during molding. On the other hand, if the melting point is 50 ° C. or higher, sufficient heat durability in actual use can be obtained. The MFR is preferably from 3 to 150, more preferably from 4 to 100. If the MFR is 3 or more, shear heat generated during molding can be suppressed, the processing temperature can be easily controlled, and there is little possibility that the foaming agent will be decomposed during molding. On the other hand, if the MFR is 150 or less, the mechanical strength of the produced foamed wallpaper is maintained, and the workability and durability are excellent.

  Examples of the ultra-low density polyethylene include TAFMER DF140, DF940, DF7350 (all manufactured by Mitsui Chemicals), Kernel KJ-640T (manufactured by Nippon Polyethylene Co., Ltd.), Excellen FX CX5508 (manufactured by Sumitomo Chemical Co., Ltd.), Engage 8400. / 8407 (manufactured by Dow Chemical Co., Ltd.), Evolue P SP90100 (manufactured by Prime Polymer Co., Ltd.), LumiTac 09L54A (manufactured by Tosoh Corporation) and the like can be used.

  As linear low density polyethylene, commercial items, such as Nipolon-LM55, LM65, LM-70, LM75 (above, Tosoh Corporation make), can be used, for example.

  The non-halogen resin as the first resin component may contain a silane crosslinkable resin. Examples of the silane crosslinkable resin include a resin having a hydrolyzable silyl group. For example, a silane crosslinkable polyolefin resin or the like can be used. Examples of the silane crosslinkable polyolefin resin include a resin in which a hydrolyzable silyl group is mainly introduced into a side chain in a polyolefin polymer as a matrix. Examples of such a resin include a resin in which a hydrolyzable silyl group is mainly introduced into a side chain in a polymer such as a low density polyethylene, a high density polyethylene, an ethylene-vinyl acetate copolymer, and a polypropylene. Crosslinking is performed by hydrolysis of substituted silyl groups. In addition, the polyolefin resin which this silyl group is located in the terminal may be contained.

  Silane crosslinkable polyolefin resin is a method of random copolymerization in a container of polyolefin polymer monomer and ethylenically unsaturated silane compound, or using a peroxide in the polyolefin polymer melt. It can be obtained by a method of graft copolymerizing a silane compound. Here, the polyolefin polymer as a matrix can be used alone or in combination of two or more of the above resins. Further, the base polyolefin-based resin may be a combination of the polyolefin-based resin and a resin different from the polyolefin-based resin as long as mixing or decomposition of the resins is allowed. The degree of mixing or dispersion varies greatly depending on the type of extruder to be used, and an appropriate compatibilizer can be used. Therefore, the combined resins cannot be generally distinguished, but are preferably the same type of resins. Specific examples of the silane crosslinkable resin include “LINKLON” manufactured by Mitsubishi Chemical Corporation.

  The content of the first resin is preferably in the range of 30 to 95% by mass based on the total amount of the foaming agent-containing resin composition, from the viewpoint of film formability of the resin sheet. More preferably, it is in the range of 50 to 90% by mass, still more preferably in the range of 55 to 80% by mass, and still more preferably in the range of 60 to 80% by mass.

  Examples of the filler in the present embodiment include inorganic fillers and organic fillers. Examples of inorganic fillers include calcium carbonate, titanium dioxide, and hydrated metal compounds. Examples of the organic filler include melamine cyanurate, polytetrafluoroethylene (PTFE), wood flour, cellulose and derivatives thereof. These fillers can be used alone or in combination of two or more.

  Especially, it is preferable that a hydrated metal compound and calcium carbonate are included as an inorganic filler. By using a hydrated metal compound and calcium carbonate in combination as a filler, a resin sheet excellent in scratch resistance can be obtained more effectively.

  A hydrated metal compound refers to a metal compound that dehydrates by heating. Such a hydrated metal compound can release moisture by heating. Examples of the hydrated metal compound include aluminum hydroxide, magnesium hydroxide, calcium hydroxide, manganese hydroxide, iron hydroxide, zinc hydroxide, copper hydroxide and the like.

  The hydrated metal compound is preferably in the form of particles. The average particle size of the hydrated metal compound is preferably 5 μm or less, and more preferably 3 μm or less. By setting the average particle size of the hydrated metal compound to 5 μm or less, the surface area is increased and a large amount of water is dehydrated at one time. As a result, the amount of water used for the silane crosslinking reaction is increased, and crosslinking is performed more efficiently. The lower limit of the average particle size of the hydrated metal compound is preferably 0.01 μm or more, and more preferably 0.1 μm or more, from the viewpoint of suppressing an increase in viscosity. The average particle size of the hydrated metal compound is a 50% average particle size corresponding to the median value of the particle size distribution, and can be measured using, for example, a commercially available particle size distribution measuring apparatus.

  The hydrated metal compound may be subjected to various surface treatments from the viewpoint of improving dispersibility, moldability, flame retardancy, and the like. Examples of the hydrated metal compound subjected to such surface treatment include, from the viewpoint of improving dispersibility and moldability, for example, nitrate anion-treated aluminum hydroxide, high-temperature hydrothermally treated aluminum hydroxide, and the like. From the viewpoint of improving flame retardancy, for example, nitrate-treated aluminum hydroxide, zinc stannate surface-treated aluminum hydroxide, nickel compound surface-treated magnesium hydroxide, etc., phlogopite treatment, silicone treatment, silicone polymer treatment, etc. Examples include hydrated metal compounds that have been treated.

  The content of the filler is preferably 5% by mass or more based on the total amount of the foaming agent-containing resin composition, and 20% by mass or more, from the viewpoint of obtaining a foam wallpaper having excellent scratch resistance. More preferably, it is more preferably 25% by mass or more, and even more preferably 30% by mass or more. On the other hand, the upper limit of the content of the filler is preferably 60% by mass or less, and preferably 50% by mass or less, based on the total amount of the foaming agent-containing resin composition, from the viewpoint of suppressing an increase in the viscosity of the resin composition. Is more preferable, and it is still more preferable that it is 40 mass% or less.

  Examples of the filler include Softon 1000, 1200 (Bikita Powder Co., Ltd., calcium carbonate), Type CR-60, CR-60-2 (both made by Ishihara Sangyo Co., Ltd., titanium dioxide), B-303 ( Commercial products such as Sakai Kogyo Co., Ltd. (aluminum hydroxide) can be used.

  As the foaming agent according to the present embodiment, for example, a pyrolytic foaming agent can be used. Examples of the pyrolytic foaming agent include azo foaming agents such as azodicarbonamide (ADCA), azobutyronitrile, and diazoaminobenzene, hydrazide foaming agents such as p-toluenesulfonyl hydrazide, and N, N′-di. Examples thereof include nitroso-based foaming agents such as nitrosopentamethylenetetramine. Among these, ADCA is preferable because it has little toxicity, easily adjusts the foaming start temperature, and has a wide application range. These can be used alone or in combination of two or more.

  Examples of the foaming agent include VINYHALL AC # 3C-K2 (manufactured by Eiwa Kasei Co., Ltd., azodicarbonamide-based foaming agent), Cellular D (manufactured by Eiwa Kasei Co., Ltd., nitroso-based foaming agent), Neoselbon SB # 51 (Yewa Kasei). Commercial products such as a hydrazide-based foaming agent (manufactured by Corporation) can be used.

  Although content of a foaming agent is not restrict | limited in particular, It is preferable that the total amount is 1-20 mass% on the basis of the foaming agent containing resin composition whole quantity. When the content of the foaming agent is within the above range, it is possible to obtain a foamed resin layer in which gas escape from the surface due to generation of excessive gas is suppressed.

  The foaming agent-containing resin composition according to this embodiment may be colored by adding a pigment or the like as necessary. Coloring by adding a pigment may be transparent, translucent, or opaque. Examples of the pigment include inorganic pigments such as iron oxide and carbon black, and organic pigments such as aniline black and phthalocyanine blue.

  In addition, to the foaming agent-containing resin composition according to the present embodiment, known additions such as flame retardants other than fillers, foaming aids, cell regulators, stabilizers, lubricants, silane crosslinking aids, and the like are necessary. An agent can be used.

  Examples of the flame retardant other than the filler include phosphorus-based flame retardants such as phosphate esters, bromine-based flame retardants such as tetrabromobisphenol A, and the like.

  Examples of foaming aids include aliphatic systems such as stearic acid and lauric acid, fatty acid amide systems such as stearic acid amide and oleic acid amide, urea systems such as biurea, metal chlorides such as zinc chloride, and zinc oxide. A metal oxide etc. are mentioned.

  Moreover, you may use a fatty-acid metal salt as a foaming adjuvant. By including a fatty acid metal salt, a resin sheet having good foamability can be obtained.

  The fatty acid metal salt is preferably a functional group-containing fatty acid metal salt having a functional group on the carbon chain of the fatty acid metal salt. Here, the carbon chain of the fatty acid metal salt refers to a linear hydrocarbon group constituting the fatty acid. The linear hydrocarbon group may be saturated or unsaturated, and preferably has 6 to 30 carbon atoms. However, when the number of carbon atoms decreases, the melting point of the metal soap (fatty acid metal salt) decreases. The number of carbon atoms is more preferably from 10 to 24 from the viewpoint that it becomes liquid and difficult to handle, and that if the carbon chain is too long, the melting point becomes too high and the decomposability at the molding temperature decreases. Examples of fatty acids having such a hydrocarbon group include saturated fatty acids such as hexanoic acid, stearic acid, lauric acid, and behenic acid, dicarboxylic acids such as sebacic acid and azelaic acid, oleic acid, linoleic acid, and undecylenic acid. And the like, and the like.

  Examples of the functional group of the functional group-containing fatty acid metal salt include an organic group that is directly bonded to the linear hydrocarbon group. The number of functional groups is not particularly limited, and when two or more functional groups are present in the molecule, they may be the same as or different from each other.

  Examples of the functional group include a hydroxyl group, an alkyl group, a sulfonyl group (sulfonic acid ester), a phosphonyl group (phosphorous acid ester), and a trifluoromethyl group. Among these, the functional group is preferably a readily available hydroxyl group. By using the hydroxyl group-containing fatty acid metal salt, the electrical intermolecular interaction resulting from the strong polarization of the hydroxyl group works more strongly, bleed out is more effectively reduced, and printability can be further improved. In particular, when an ethylene homopolymer or a copolymer of ethylene and another olefin is combined as the resin component, the surface energy of the base resin is large, so the effect of improving ink affinity by reducing the bleed out is greater. A resin sheet or a laminated sheet can be obtained as a raw material for wallpaper that is exhibited and has good printability.

  Examples of the functional group-containing fatty acid of the functional group-containing fatty acid metal salt include 2-ethylhexanoic acid, hydroxylauric acid, hydroxystearic acid, ricinoleic acid, dihydroxystearic acid, dihydroxylauric acid and the like.

  Examples of the metal of the functional group-containing fatty acid metal salt include barium, magnesium, calcium, zinc, and the like, and are preferably at least one selected from the group consisting of magnesium, calcium, and zinc. Among these, zinc is particularly useful because it has a very strong surface-active effect and strong activity as a foaming aid.

  From the viewpoints described above, the functional group-containing fatty acid metal salt according to this embodiment includes 2-ethylhexanoic acid zinc salt, hydroxylauric acid zinc salt, hydroxystearic acid zinc salt, dihydroxystearic acid zinc salt, and dihydroxylauric acid zinc salt. A metal salt of 12-hydroxystearic acid such as zinc 12-hydroxystearate is more preferable from the viewpoint of availability and cost. These functional group-containing fatty acid metal salts can be used alone or in combination of two or more.

  As content of a foaming adjuvant, it is preferable that the total amount exists in the range of 10-100 mass parts with respect to 100 mass parts of foaming agents, and it is more within the range of 30-70 mass parts. Preferably, it is still more preferably in the range of 30 to 65 parts by mass, and still more preferably in the range of 30 to 50 parts by mass. Moreover, as for content of a foaming adjuvant, it is especially preferable that the total amount is 40 mass parts or more with respect to 100 mass parts of foaming agents. If content of the foaming adjuvant with respect to 100 mass parts of foaming agents exists in the said range, the effect as surfactant and foaming adjuvant can fully be exhibited.

  As the cell regulator, either an organic cell regulator or an inorganic cell regulator may be used, and examples thereof include silica, phosphate ester compounds, acrylic ester resins, and methacrylic ester resins. . Commercially available products such as ADK STAB HP-10 (manufactured by ADEKA), Irgafos 38 (manufactured by BASF Japan), and JPP-2000 (manufactured by Johoku Chemical Industry Co., Ltd.) can be used as the cell regulator. it can.

  Stabilizers include, for example, radical scavengers such as phenol / amine antioxidants, hindered amine light stabilizers, peroxide decomposers such as phosphorus and sulfur, benzotriazoles, hydroxyphenyltriazines, and benzophenones. Examples include ultraviolet absorbers. From the viewpoint of suppressing discoloration, a radical scavenger or the like may be used.

  Examples of the lubricant include fatty acid-based lubricants such as stearic acid and lauric acid, fatty acid amide-based compounds such as stearic acid amide and oleic acid amide, and fatty acid metal salt-based lubricants such as zinc stearate, calcium laurate and zinc octylate. It is done.

  Examples of the silane crosslinking aid include a tin-based crosslinking aid.

<Foaming agent-free resin composition>
The foaming agent-free resin composition according to the present embodiment includes the second resin component and does not include the foaming agent.

  The 2nd resin part in a foaming agent non-containing resin composition can use the thing similar to the 1st resin part mentioned above. From the viewpoint of obtaining a foamed wallpaper having more sufficient scratch resistance, it is preferable to include polyethylene having a density higher than that of low-density polyethylene, such as linear low-density polyethylene and high-density polyethylene.

  The foaming agent-free resin composition according to the present embodiment may include each component (excluding the foaming agent) described in the foaming agent-containing resin composition as necessary.

The resin composition set according to the present embodiment includes the above-described foaming agent-containing resin composition at 130 ° C and a melt mass flow rate (A) at a load of 2.16 kgf and a foaming agent-free resin composition at 130 ° C and a 2.16 kgf load. The melt mass flow rate (B) in satisfies all the following conditions (i), (ii) and (iii).
(I) 1 g / 10 min ≦ (A) ≦ 10 g / 10 min (ii) 1 g / 10 min ≦ (B) ≦ 16 g / 10 min (iii) -3 g / 10 min ≦ (B) − (A) ≦ 6 g / 10 minutes

  By satisfy | filling the conditions shown in said (i), the resin sheet which has favorable foamability can be obtained, suppressing decomposition | disassembly of the foaming agent by the shear heat_generation | fever in an extruder. From such a viewpoint, it is preferable that 1 g / 10 minutes ≦ (A) ≦ 10 g / 10 minutes, more preferably 2 g / 10 minutes ≦ (A) ≦ 9 g / 10 minutes, and 3 g / 10 minutes ≦ (A) ≦ 8 g / 10 min is more preferable, and 4 g / 10 min ≦ (A) ≦ 7 g / 10 min is particularly preferable.

  By satisfying the conditions shown in (ii) above, a resin sheet having scratch resistance and durability can be obtained. From such a viewpoint, it is preferable that 1 g / 10 min ≦ (B) ≦ 16 g / 10 min, more preferably 3 g / 10 min ≦ (B) ≦ 16 g / 10 min, and more preferably 3 g / 10 min ≦. (B) ≦ 15 g / 10 min is more preferable, and 3.5 g / 10 min ≦ (B) 11 g / 10 min is particularly preferable.

  By satisfy | filling the conditions shown in said (iii), the strength reduction by the distortion | strain of a lamination | stacking interface is suppressed, and the resin sheet excellent in scratch resistance can be obtained. From such a viewpoint, it is preferable that −3 g / 10 minutes ≦ (B) − (A) ≦ 6 g / 10 minutes, and −3 g / 10 minutes ≦ (B) − (A) ≦ 5 g / 10 minutes. More preferably, 0 g / 10 min ≦ (B) − (A) ≦ 3 g / 10 min, and further preferably 0 g / 10 min ≦ (B) − (A) ≦ 2.5 g / 10 min. It is particularly preferable that 0 g / 10 min ≦ (B) − (A) ≦ 2 g / 10 min.

  The melt mass flow rate of the foaming agent-containing resin composition and the foaming agent-free resin composition can be adjusted by, for example, the molecular weight and molecular weight distribution of the resin, the shape and size of the filler, the type, and the surface treatment. In the present embodiment, the melt mass flow rate of the foaming agent-containing resin composition is preferably adjusted by the molecular weight or molecular weight distribution of the resin. The melt mass flow rate of the foaming agent-free resin composition is preferably adjusted by the molecular weight of the resin.

[Resin sheet]
The resin sheet according to the present embodiment is obtained by co-extrusion of the foaming agent-containing resin composition and the foaming agent-free resin composition of the resin composition set described above, and includes the foaming agent-containing resin composition. It includes a laminated structure of a first layer and a second layer made of a foaming agent-free resin composition.

  Such a resin sheet includes a foaming agent-containing resin composition that includes a first resin component, a filler, and a foaming agent, and a second resin component that does not include a foaming agent. A resin sheet forming step of forming a resin sheet including a laminated structure of a first layer made of a foaming agent-containing resin composition and a second layer made of a foaming agent-free resin composition by co-extrusion of the composition It can obtain by the manufacturing method provided with.

  Examples of the co-extrusion method include a co-extrusion method such as a T-die extrusion method, a T-die extrusion simultaneous lamination method, and a T-die extrusion tandem lamination method.

  Specifically, after the foaming agent-containing resin composition and the foaming agent-free resin composition are melted, kneaded, and dispersed by separate extruders (for example, a single screw extruder, a twin screw extruder, etc.), both Are fed into a feed block type, and then formed into a sheet with a T-die to obtain a resin sheet comprising two layers, a first layer composed of a foaming agent-containing resin composition and a second layer composed of a foaming agent-free resin composition. The method etc. are mentioned.

  Examples of the conditions for extrusion film formation using a T die include an extrusion temperature of 110 to 150 ° C. and an extrusion pressure of 5 to 50 MPa. The extrusion temperature is preferably 110 to 150 ° C, more preferably 115 to 135 ° C, from the viewpoint of setting the resin component to the melting point or higher while suppressing decomposition of the foaming agent component. From the viewpoint of extrusion stability, the extrusion pressure is preferably 5 to 50 MPa, more preferably 5 to 15 MPa.

  Although the thickness of the resin sheet can be set as appropriate according to the use, for example, in the case of foamed wallpaper, the thickness of the first layer can be 10 to 150 μm, and the thickness of the second layer can be 3 to 3. It can be 15 μm.

  The first layer in the resin sheet may be subjected to a crosslinking treatment. Examples of the crosslinking treatment include heat treatment such as electron beam irradiation treatment and superheated steam treatment. When the foaming agent-containing resin composition contains a silane crosslinkable resin, superheated steam treatment and water crosslinking treatment can be performed.

  In the electron beam irradiation treatment, for example, the resin sheet can be crosslinked by irradiating an electron beam from one side or both sides of the formed resin sheet. Although the electron beam irradiation conditions depend on the thickness of the resin layer, an acceleration voltage of 150 to 300 kV and an irradiation dose of 10 to 100 kGy are preferable. If the acceleration voltage is within the above range, the electron beam can be sufficiently reached deep in the thickness direction of the resin sheet, and deterioration due to the electron beam on the backing paper can be suppressed. Moreover, if irradiation dose is in the said range, it will become easy to give desired bridge | crosslinking to a resin sheet, suppressing the yellowing of a resin sheet and the change of a mechanical physical property.

  Examples of the superheated steam treatment include a method in which superheated steam (also referred to as superheated steam) is treated for 20 seconds to 15 minutes in an environment of 130 ° C. to 280 ° C. The superheated steam treatment includes, for example, a method in which a sheet-like material is arranged in a superheated steam atmosphere and the superheated steam is brought into contact with the sheet-like material. Moreover, as a method of water-crosslinking, there is a method of water-crosslinking by curing for 1 day to 1 month in a temperature range of 40 ° C. to 70 ° C. in an environment with a humidity of 60% or more. There is a method of curing and hydrocrosslinking in an environment of a 90% constant temperature and humidity chamber.

[Laminated sheet]
The laminated sheet according to the present embodiment includes a base material and the resin sheet provided on the base material. The laminated sheet can be obtained by laminating a resin sheet on a substrate. From the point that the effects of the present invention can be obtained more effectively, the laminated sheet is preferably obtained by laminating the first layer of the resin sheet on a substrate.

  The laminating method is not particularly limited, and examples thereof include a method in which a resin sheet and a base material are subjected to thermocompression bonding using a hot press machine, a method in which pressure bonding is performed using superheated steam, and the like. According to the method of pressure bonding using superheated steam, it becomes possible to laminate onto the base material while maintaining the molten state of the surface of the sheet-like material with superheated steam, and the surface of the base material to be adhered by the leveling effect It can suppress that the unevenness | corrugation of is transferred to a resin sheet. Moreover, when the 1st layer in a resin sheet contains a silane crosslinkable resin, a silane crosslinkable resin can be bridge | crosslinked efficiently with superheated steam.

The base material is not particularly limited as long as it is usually used as a paper base material such as a conventional backing paper for foam wallpaper. As such a substrate, for example, a pulp-based flame retardant paper impregnated with a water-soluble flame retardant such as guanidine sulfamate or guanidine phosphate, or an inorganic agent such as magnesium carbonate, aluminum hydroxide, magnesium hydroxide or the like. Examples include mixed paper. These weighings may be 50 to 300 g / m ² or 60 to 160 g / m ² .

  Further, from the viewpoint of improving the adhesion between the base material and the resin sheet, the surface on the side of the base material where the resin sheet is provided is subjected to easy adhesion processing such as corona discharge treatment, plasma treatment, ozone treatment, etc. Alternatively, an easy adhesion treatment layer formed from an acrylic-butyl copolymer, polyurethane composed of isocyanate and polyol, or the like may be provided.

[Foam wallpaper]
The foam wallpaper according to the present embodiment includes a base material and a foam resin layer provided on the base material, and can be obtained by foaming a foaming agent contained in the first layer of the laminated sheet. Such foamed wallpaper includes a laminated sheet forming step of obtaining a laminated sheet by laminating the first layer side of the resin sheet according to this embodiment described above on a base material, and foam contained in the first layer of the laminated sheet. And a foaming step of forming a foamed resin layer by foaming the agent.

  1-3 is process drawing which shows the manufacturing method of the foam wallpaper based on this embodiment. The method shown in FIG. 1 is obtained in steps S1 and S1 in which a resin sheet is obtained by coextrusion of a foaming agent-containing resin composition and a foaming agent-free resin composition in the resin composition set according to this embodiment. Step S2 of laminating the obtained resin sheet on a substrate to obtain a laminated sheet, and a crosslinking step of crosslinking part or all of the first resin contained in the first layer in the laminated sheet obtained in S2 S3 and foaming process S4 which forms a foamed resin layer by foaming the foaming agent contained in the 1st layer in the lamination sheet after bridge obtained by S3.

  Process S1 can be performed similarly to the manufacturing method of the resin sheet of this embodiment mentioned above.

  Step S2 can be performed in the same manner as the above-described method for manufacturing a laminated sheet of the present embodiment.

  Step S3 can be performed in the same manner as the above-described crosslinking method in the resin sheet of the present embodiment.

  In step S4, the foaming agent can be foamed by heating the resin sheet. The heating conditions can be appropriately set depending on the components constituting the resin sheet, and are not particularly limited. However, heating is preferably performed at 160 ° C. to 280 ° C. for 10 seconds to 120 seconds, and 220 ° C. to 240 ° C. at 20 ° C. It is more preferable to heat for 2 seconds to 40 seconds, and further more preferable to heat at 220 ° C. for 40 seconds.

  In the method shown in FIG. 2, the first resin component of the foaming agent-containing resin composition in the method shown in FIG. 1 contains a silane crosslinkable resin, and a laminated sheet obtained by S2 instead of steps S3 and S4. The method is the same as the method shown in FIG. 1 except that step S5 is performed in which the foaming agent is foamed while heating a part of or all of the silane crosslinkable resin by heating with superheated steam.

  In step S5, as a method of foaming the foaming agent while cross-linking part or all of the silane crosslinkable resin, a method of introducing a laminated sheet into a superheated steam furnace and performing a superheated steam treatment can be mentioned. Examples of the superheated steam treatment in this case include a method of treating superheated steam (also called superheated steam) for 20 seconds to 90 seconds in an environment of 180 ° C. to 250 ° C. The superheated steam treatment includes, for example, a method in which a sheet-like material is arranged in a superheated steam atmosphere and the superheated steam is brought into contact with the sheet-like material.

  The method shown in FIG. 3 replaces steps S2 and S3 in the method shown in FIG. 1 before the resin sheet obtained in S1 is laminated on the base material before the first layer included in the resin sheet. 1 except that it comprises a step S6 of cross-linking part or all of the resin content of 1 and a step S7 of obtaining a laminated sheet by laminating the resin sheet obtained in S6 on a substrate. It is the same as the method.

  The method for the crosslinking treatment in step S6 can be performed in the same manner as the method for the crosslinking treatment in the resin sheet of the present embodiment described above.

  Step S7 can be performed in the same manner as in the method for manufacturing the laminated sheet of the present embodiment described above.

  By these methods, the foamed wallpaper according to the present embodiment having sufficient scratch resistance can be obtained.

  In the foam wallpaper according to the present embodiment, the surface of the second layer opposite to the base material side may have an uneven shape. The method for providing the uneven shape is not particularly limited. For example, by using heat at the time of heating and foaming, the surface side is a cooling embossing roll, the base material side is a rubber roll, Examples of the method include forming a concavo-convex shape on the surface by niping (embossing) and cooling. The uneven shape is not particularly limited, and examples thereof include a wood grain plate conduit groove, a stone plate surface unevenness, a cloth surface texture, a satin texture, a grained grain, a hairline, and a straight line groove. Can be selected as appropriate.

  The foamed wallpaper according to the present embodiment may be provided with a pattern layer and a surface protective layer. The pattern layer and the surface protective layer can be appropriately provided using known materials. If the object of the present invention can be achieved, the pattern layer and the surface protective layer may not be provided. The pattern layer and the surface protective layer can be provided using a known printing technique such as gravure coating. In addition, a pattern layer and a surface protective layer can be provided before foaming a foaming agent.

  Hereinafter, the present invention will be specifically described with reference to Examples and Comparative Examples. However, the present invention is not limited to the following examples.

[Foaming agent-containing resin composition]
Using a same-direction meshing twin screw extruder, pellets of the foaming agent-containing resin composition were prepared with the formulation shown in Table 1 while controlling the resin temperature at 130 ° C. so that the foaming agent was not decomposed. Using the melt indexer (G-01, manufactured by Toyo Seiki Seisakusho Co., Ltd.), the melt mass flow rate at 130 ° C. and a load of 2.16 kgf was measured for the pellets of the produced foaming agent-containing resin composition. The results are shown in Table 1.

  The following materials were used for each component shown in Table 1.

[Low density polyethylene]
Resin A: Petrocene 202 (made by Tosoh Corporation, trade name, MFR = 24 (190 ° C.), density = 0.918 g / cm ³ )
Resin B: LJ902 (manufactured by Nippon Polyethylene Co., Ltd., trade name, MFR = 45 (190 ° C.), density = 0.915 g / cm ³ )

[Ultra low density polyethylene]
Resin C: Tuffmer DF7350 (Mitsui Chemicals, trade name, MFR = 35 (190 ° C.), density = 0.870 g / cm ³ )

[Silane crosslinkable resin]
Resin D: Linkron XCF710N (Mitsubishi Chemical Corporation, trade name, low density polyethylene base, MFR = 1.2 (190 ° C.), density = 0.918 g / cm ³ )

[Calcium carbonate]
Filler A: Softon 1200 (Bihoku Powder Chemical Co., Ltd., trade name)

[titanium dioxide]
Filler B: Taipei CR-60 (Ishihara Sangyo Co., Ltd., trade name)

Foaming agent: VINYHALL AC # 3C-K2 (manufactured by Eiwa Chemical Industry Co., Ltd., trade name, azodicarbonamide foaming agent)

Foaming aid: Zn-St (Nitto Kasei Kogyo Co., Ltd., trade name, zinc stearate)

Stabilizer: Neulizer P (made by Nippon Synthetic Chemical Industry Co., Ltd., trade name)

Silane crosslinking aid: Linkron LZ013 (Mitsubishi Chemical Corporation, trade name, polyethylene base)

[Foaming agent-free resin composition]
Using the same-direction meshing type twin screw extruder, pellets of the foaming agent-free resin composition were prepared with the formulation shown in Table 2 while controlling the resin temperature at 130 ° C. Using the melt indexer (G-01, manufactured by Toyo Seiki Seisakusho Co., Ltd.), the melt mass flow rate at 130 ° C. and a load of 2.16 kgf was measured for the pellets of the produced foaming agent-free resin composition. The results are shown in Table 2.

  The following materials were used for each component shown in Table 2.

[Linear low density polyethylene]
Resin E: Nipolon-LM55 (trade name, manufactured by Tosoh Corporation)
Resin F: Nipolon-LM65 (trade name, manufactured by Tosoh Corporation)
Resin G: Nipolon-LM75 (trade name, manufactured by Tosoh Corporation)

[Production of foam wallpaper]
(Examples 1-8, Comparative Examples 1-2)
The pellets of the foaming agent-containing resin compositions 1 to 3 and the foaming agent-free resin compositions 1 to 5 prepared above were used in combinations shown in Table 3 to prepare a resin sheet. Specifically, pellets of a foaming agent-containing resin composition were extruded using a screw 1 (screw diameter (D) 65 mm, L / D (screw length divided by screw diameter) = 28 single screw extruder). The pellet of the foaming agent-free resin composition was extruded using a screw 2 (single screw extruder with a screw diameter (D) of 50 mm, L / D = 28). A sheet was formed to obtain a resin sheet composed of two layers of a first layer (thickness 75 μm) made of a foaming agent-containing resin composition and a second layer (thickness 10 μm) made of a foaming agent-free resin composition.

Next, the resin sheet formed as described above is placed on a backing paper (KJ Special Paper, WK-6651HT, weight 65 g / m ² ), and heated at 110 ° C. for 2 minutes under a condition of a press pressure of 5 MPa. The laminate sheet was obtained by pressing and heat-sealing.

Furthermore, after the corona discharge treatment was applied to the surface on the second layer side, a pattern was printed at 1 g / m ² using a water-based ink (manufactured by Dainichi Seika Kogyo Co., Ltd., Hydrick WP) with a gravure printing machine. A matte surface coating agent (Nissin Chemical Industry Co., Ltd., Viniblanc 890) was applied at 2 g / m ² using a coating machine (manufactured by Kurashiki Boseki Co., Ltd., GP-10) to prepare a raw material before cross-linking.

  In Examples 1 to 3 and 8, the obtained raw material before cross-linking was irradiated with an electron beam at an acceleration voltage of 180 kV and an irradiation dose of 70 kGy to cross-link the resin component, and then in an oven at 220 ° C. for 40 seconds. Heating was performed to foam the foaming agent to produce a foam wallpaper.

  In Examples 4 and 7, curing was performed for 72 hours in a constant temperature and humidity chamber having a temperature of 40 ° C. and a relative humidity of 90% RH, and the silane crosslinkable resin was crosslinked, followed by heating in a 220 ° C. oven for 40 seconds. A foaming wallpaper was prepared by foaming a foaming agent.

  Moreover, in Example 5, after putting into a superheated steam furnace with a steam temperature of 160 ° C. and an amount of superheated steam of 90 kg / hour, spraying with superheated steam for 90 seconds to crosslink the resin component, the oven was heated in a 220 ° C. oven for 40 seconds. Heating was performed to foam the foaming agent to produce a foam wallpaper.

  In Example 6, after putting into a superheated steam furnace with a steam temperature of 110 ° C. and a superheated steam amount of 150 kg / hour and performing a superheated steam spray for 60 seconds to crosslink the resin component, the steam temperature is 220 ° C. and the superheated steam amount is 90 kg / hour. Immediately transferred to another superheated steam furnace with time, sprayed with superheated steam for 25 seconds to foam the foaming agent to produce a foam wallpaper.

  In Comparative Examples 1 and 2, crosslinking and foaming were performed under the same conditions as in Example 1 to prepare foamed wallpaper.

[Evaluation of foam wallpaper]
About the produced foaming wallpaper, the expansion ratio and scratch resistance were evaluated according to the following method.

(Foaming ratio)
The thickness of the foamed wallpaper was measured with a thickness meter, and the value obtained by subtracting the thickness of the backing paper (100 μm) and dividing by the thickness of the resin sheet before foaming (85 μm) was calculated as the expansion ratio. The results are shown in Table 3.

(Scratch resistance)
The scratch resistance was evaluated using a Coins scratch tester. Specifically, the foamed wallpaper was placed on a horizontal surface, and the surface state was observed by scratching the foamed wallpaper with a load of 100 g, 200 g and 300 g using a 10 yen coin at an angle of 45 °. The scratch resistance was evaluated based on the following criteria. If it is A or B, it can be evaluated that the scratch resistance is sufficient. The results are shown in Table 3.
A: No scratch on the surface of the specimen.
B: Slight scratches remain on the surface.
C: Scratches enter the foam layer.

Claims (12)

A foaming agent-containing resin composition comprising a first resin component, a filler, and a foaming agent;
A foaming agent-free resin composition containing a second resin component and not containing a foaming agent,
A resin composition set for forming a resin sheet comprising a laminated structure of a first layer composed of the foaming agent-containing resin composition and a second layer composed of the foaming agent-free resin composition,
The melt mass flow rate (A) at 130 ° C. and 2.16 kgf load of the foaming agent-containing resin composition and the melt mass flow rate (B) at 130 ° C. and 2.16 kgf load of the foaming agent-free resin composition are as follows: A resin composition set that satisfies all the conditions shown in (i), (ii), and (iii).
(I) 1 g / 10 min ≦ (A) ≦ 10 g / 10 min (ii) 1 g / 10 min ≦ (B) ≦ 16 g / 10 min (iii) -3 g / 10 min ≦ (B) − (A) ≦ 6 g / 10 minutes It is obtained by co-extruding the foaming agent-containing resin composition and the foaming agent-free resin composition of the resin composition set according to claim 1,
The resin sheet containing the laminated structure of the 1st layer which consists of the said foaming agent containing resin composition, and the 2nd layer which consists of the said foaming agent non-containing resin composition.   The resin sheet according to claim 2, wherein a part or all of the first resin contained in the first layer is crosslinked.   The resin sheet according to claim 2 or 3, wherein the first resin component contains a silane crosslinkable resin.   A laminate comprising: a base material; and the resin sheet according to any one of claims 2 to 4 provided on the base material, wherein the first layer of the resin sheet is on the base material side. Sheet. A foam wallpaper comprising a base material and a foamed resin layer provided on the base material,
A foam wallpaper obtained by foaming the foaming agent contained in the first layer in the laminated sheet according to claim 5. A foaming agent-containing resin composition containing a first resin component, a filler and a foaming agent, and a foaming agent-free resin composition containing a second resin component and no foaming agent are coextruded. A resin sheet forming step of forming a resin sheet including a laminated structure of a first layer composed of the foaming agent-containing resin composition and a second layer composed of the foaming agent-free resin composition,
The melt mass flow rate (A) at 130 ° C. and 2.16 kgf load of the foaming agent-containing resin composition and the melt mass flow rate (B) at 130 ° C. and 2.16 kgf load of the foaming agent-free resin composition are as follows: (I) The manufacturing method of the resin sheet which satisfy | fills all the conditions shown to (ii) and (iii).
(I) 1 g / 10 min ≦ (A) ≦ 10 g / 10 min (ii) 1 g / 10 min ≦ (B) ≦ 16 g / 10 min (iii) -3 g / 10 min ≦ (B) − (A) ≦ 6 g / 10 minutes A foamed wallpaper manufacturing method comprising: a base material; and a foamed resin layer provided on the base material,
A laminated sheet forming step of obtaining a laminated sheet by laminating the first layer side of the resin sheet obtained by the method for producing a resin sheet according to claim 7 on a base material,
A foaming step of forming a foamed resin layer by foaming the foaming agent contained in the first layer in the laminated sheet;
A method for producing foam wallpaper.   The method for producing foamed wallpaper according to claim 8, wherein the foaming step includes heating the laminated sheet with superheated steam.   The method for producing foamed wallpaper according to claim 8 or 9, further comprising a crosslinking step of crosslinking a part or all of the first resin component contained in the first layer before the foaming step.   The method for producing a foam wallpaper according to claim 10, wherein the first resin component includes a silane crosslinkable resin, and the laminated sheet is heated with superheated steam to crosslink part or all of the silane crosslinkable resin.   The first resin component includes a silane crosslinkable resin, and the laminated sheet is heated with superheated steam in the foaming step to foam the foaming agent while cross-linking part or all of the silane crosslinkable resin. The method for producing a foam wallpaper according to claim 8.