JP2001058376A - Wall covering sheet - Google Patents

Abstract

(57) [Summary] [Problem] A sheet for wall covering that is friendly to humans and the environment,
An object of the present invention is to provide an inexpensive wall covering sheet that is excellent in workability, has excellent surface properties such as stain resistance and scratch resistance, and is inexpensive. SOLUTION: On a base material layer, a foaming resin layer mainly comprising a foaming agent and an olefin resin or an acrylic resin,
In a wall covering sheet provided with a pattern layer and a surface protection layer formed by extrusion coating a heat-melted non-halogen thermoplastic resin, the flexural modulus of the surface protection layer is 1.0 × 10 ^{4 to} 2.0. × 10 ⁴ kgf / cm ² , a wall covering sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior decorative sheet to be attached to a wall surface or a ceiling surface of a house or the like, and more particularly to a decorative sheet to be applied on site, and more particularly, to an inexpensive and stain-resistant sheet. The present invention relates to a sheet for wall covering, which has excellent surface properties such as scratch resistance and excellent workability.

[0002]

2. Description of the Related Art Conventionally, as a wall covering sheet, a vinyl chloride resin layer is formed on a base material and a picture layer is provided on the vinyl chloride resin layer by printing or the like, or the vinyl chloride resin A PVC decorative sheet represented by a so-called PVC wallpaper, such as a foamed layer and an embossed pattern or the like, is widely used. However, this PVC decorative sheet generates harmful gas such as hydrogen chloride gas during combustion, so it cannot be incinerated in general incinerators. There is a problem of poisoning due to harm, and it has been avoided to use it.

[0003] Further, in these wall covering sheets, dirt adhering to the surface of the wall covering sheet tends to permeate and is difficult to remove, and there is a problem that the surface strength of the wall covering sheet is weak and easily broken. There is. this is,
In order for the wall covering sheet to be made of vinyl chloride resin with problems of contamination and abrasion, and for the purpose of enhancing workability and design, in order to perform processing to form foam and uneven patterns, This is because fine irregularities and voids are generated on the surface of the wall covering sheet.

[0004] In order to solve the above problem, a method of providing a surface protective layer on the surface of a wall covering sheet has conventionally been adopted. That is, (1) a method of applying, for example, an acrylic resin or the like to the surface of the wall covering sheet to form a surface protective layer, and (2) a method of coating the surface of the wall covering sheet with stain resistance, scratch resistance, and the like. A method has been adopted in which an excellent film, for example, a fluorine-based film or a saponified ethylene-vinyl acetate copolymer film or the like is bonded with an adhesive or the like to form a surface protective layer.

However, since the method (1) is adjusted to a relatively low viscosity by using a solvent such as an organic solvent or water in consideration of processability, a method suitable for providing a thin surface protective layer. However, when a thick surface protective layer is provided, the operation becomes complicated, for example, the number of processing steps increases. In addition, the surface protective layer provided in this manner, when performing processing to form a foam or an uneven pattern, it is not possible to follow the foam or the uneven pattern, and the thickness of the surface protective layer varies, and in extreme cases, There is a problem that the surface protective layer is partially cracked and the foamed layer is exposed.

In the method (2), since the surface protective layer is made of a film, the surface physical properties itself are good. However, for example, the foamed layer is foamed to form an uneven pattern on the foamed layer, and then the film is formed. When the surface protective layer is formed by bonding together, it is difficult to apply the film in a state where the film is fitted to the foamed layer. When processing is performed, there occurs a problem that an uneven pattern is not formed sharply. In addition, in this method, in addition to the step of bonding a film to be used as a surface protective layer using an adhesive or the like, this film needs to be formed in advance,
Due to the restrictions on film formation, it is necessary to use a layer having a thickness greater than the required thickness as the surface protective layer, which inevitably results in high cost. Further, the wall-mounting sheet of the method (2) has such a tendency that the wrinkles are hard to disappear and the curl is easily generated, and the waist is too strong to stick to the wall or the like (poor workability). Problems arise.

As a method for solving these problems, there has been proposed a method in which a surface protective layer is formed by a heat-melt extrusion coating method using a T-die extruder. Although the problem that occurs when the surface protective layer is formed by the above methods (1) and (2) could be solved, especially in the case of a type of wall covering sheet of a type in which an adhesive is applied and applied on site. Normally, in order to improve the construction efficiency, apply the adhesive collectively at the site in advance and leave the adhesive coated surfaces in close contact with each other to prevent the adhesive from drying and reducing the adhesiveness However, if the surface protective layer has too much “stiffness” at that time, the adhesive surface will float to try to resist the stress applied near the bent part of the wall covering sheet, and the adhesive will dry quickly I'll do it, Iwayu Insufficient open time (time from application of adhesive to base material to application) is insufficient. Also, in the above process, press-bonding is performed so that the folded part is creased in order to adhere the adhesive surfaces together. However, during actual construction, even after a lapse of time after pasting to the wall surface, the problem that the mark of the fold did not disappear and the construction was defective occurred further.

[0008]

SUMMARY OF THE INVENTION Accordingly, the present invention has been made in view of the above problems, and an object of the present invention is to provide a wall covering sheet which is friendly to humans and the environment and has excellent workability. Further, it is an object of the present invention to provide an inexpensive wall covering sheet having excellent surface properties such as stain resistance and scratch resistance.

[0009]

Means for Solving the Problems To achieve the above object, a sheet for wall covering of the present invention comprises, on a base material layer, a foaming resin layer mainly comprising a foaming agent and an olefin resin or an acrylic resin; In a wall covering sheet provided with a pattern layer and a surface protection layer formed by extrusion coating a heat-melted non-halogen thermoplastic resin, the flexural modulus of the surface protection layer is 1.0 × 10 ^{4 to} 2.0. × 10 ⁴ kgf / cm ²
It is characterized by being. With such a configuration, the wall covering sheet has a moderate “stiffness” but is not in a strong elasticity in a bent state,
Adhesive ducks (irregularities on the glue-coated surface),
It can absorb irregularities on the surface of the substrate and can be finished into a flat surface, is friendly to humans and the environment, is inexpensive, and has excellent surface properties such as stain resistance and scratch resistance. Can be.

Further, the thickness of the surface protective layer is 2.0 to 10.0% of the thickness of the foamed resin layer after foaming. By doing so, it is excellent in surface physical properties such as stain resistance and scratch resistance, and when forming an embossed pattern on the surface protective layer side by embossing plate, it has excellent design property having a sharp uneven pattern. It can be a sheet.

Further, the heat-melted non-halogen thermoplastic resin forming the surface protective layer is made of a polypropylene resin. By doing so, the surface protective layer can be formed with an inexpensive resin having excellent surface properties, so that the cost can be further reduced.

[0012] Further, an uneven pattern is formed on the surface protective layer side. By doing this,
A wall covering sheet having excellent design properties can be obtained.

[0013]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, specific embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a cross-sectional view showing a laminated structure of a wall-mounting sheet of the present invention, wherein 1 is a wall-mounting sheet, 2 is a base material layer, 3 is a foamed resin layer, 4 is a picture layer, 5 is a surface protection layer, and 6 is Each represents an uneven pattern.

FIG. 1 is a layer configuration diagram showing an embodiment of the wall covering sheet of the present invention. The wall covering sheet 1 of the present invention has a foaming agent and an olefin resin or acrylic resin on the upper surface of a base material layer 2. A foamed resin layer 3 mainly composed of a resin is formed, a picture layer 4 is formed on the foamed resin layer 3, and a flexural modulus on the picture layer 4 is 1.0 × 10 ^{4 to} 2.0 × 10 ⁴ kgf / cm. ^The surface protection layer 5 is formed by applying a non-halogen type thermoplastic resin made of No. 2 by hot melt extrusion coating method, and an uneven pattern 6 is formed from the surface protection layer 5 side to the foamed resin layer 3.

The base material layer 2 used in the present invention is mainly composed of cellulose fibers, and optionally contains synthetic fibers, inorganic fibers, synthetic pulp, etc., as necessary.
Dry paper strength agent, wet paper strength agent, colorant, sizing agent,
It is obtained by appropriately adding a fixing agent and the like to make paper.
Thick having a basis weight of to 150 g / m ² 0.10 to 0.3
A flame-retardant paper for 0 mm wallpaper is preferably used.

Next, the foamed resin layer 3 of the present invention is composed of a composition mainly composed of a foaming agent and an olefin resin or an acrylic resin. Examples of the olefin resin include polyethylene, polypropylene, and the like. A copolymer of one or more polyolefins such as polybutene, polybutadiene, and polyisoprene or two or more of olefins such as ethylene, propylene, butene, butadiene, and isoprene, or a copolymer of α-olefin having 4 or more carbon atoms (wire Low-density polyethylene), or ethylene-vinyl acetate copolymer, saponified ethylene-vinyl acetate copolymer, or ethylene-acrylic acid copolymer,
Examples thereof include an ethylene-methacrylic acid copolymer, an ethylene-methyl acrylate copolymer, an ethylene-ethyl acrylate copolymer, an eye monomer, and a mixed resin thereof.

Further, as the acrylic resin, for example,
Poly (methyl) methacrylate, poly (meth) ethyl acrylate, poly (meth) butyl acrylate, methyl (meth) acrylate-butyl (meth) acrylate copolymer,
Methyl (meth) acrylate-2-hydroxyethyl (meth) acrylate copolymer, butyl (meth) acrylate
(Meth) acrylic acid 2-hydroxyethyl copolymer,
Methyl (meth) acrylate-2-hydroxypropyl (meth) acrylate copolymer, methyl (meth) acrylate-butyl (meth) acrylate- (meth) acrylic acid 2-
Examples thereof include those composed of a homo- or copolymer containing a (meth) acrylic ester such as a hydroxyethyl copolymer, an ethylene-methyl (meth) acrylate copolymer, and a styrene-methyl (meth) acrylate copolymer. . Here, (meth) acrylic acid is used in the meaning of acrylic acid and methacrylic acid.

The foamed resin layer 3 may be provided on the base material layer 2 by a known heat-melt extrusion method, a calendering method, or a method in which the non-halogen thermoplastic resin is mixed with a solvent such as water or an organic solvent. Applying a solution that has been emulsified with, for example, a roll coating method,
Any coating method such as an air knife coating method and a comma doctor coating method can be adopted.

The foaming agent used in the foamed resin layer 3 of the present invention may be a low-boiling hydrocarbon, a thermally expanding capsule foaming agent containing a volatile substance such as Freon gas or petroleum ether, or azo. Either or any of thermally decomposable foaming agents such as dicarbonamide and oxybisbenzenesulfonyl hydrazide can be used. However, in order to obtain smoothness of the surface layer 5, a thermally expanded capsule foaming agent is used. Is more preferred. Further, the amount of the foaming agent mixed with the non-halogen thermoplastic resin may be appropriately determined according to the type of the non-halogen thermoplastic resin and its coating amount, or the required design property. 0.5 to 100 parts by weight of the base resin
20 parts by weight are suitable.

The picture layer 4 of the present invention is generally formed by gravure printing, offset printing, silk screen printing,
It can be formed with ink by a known printing method such as transfer printing from a transfer sheet. Examples of the print pattern include a wood pattern, a stone pattern, a cloth pattern, a leather pattern, a geometric figure, a character, a symbol, and a print pattern such as a solid image. As the vehicle, chlorinated polyolefins such as chlorinated polyethylene and chlorinated polypropylene, polyester, polyurethane composed of isocyanate and polyol, acrylic, vinyl acetate, vinyl chloride-vinyl acetate copolymer, cellulose resin, polyamide resin These may be used as a mixture of one or more kinds, and pigments, solvents, various auxiliaries, etc. may be added thereto to form an ink. However, for the purpose of the present invention, polyesters, isocyanates and polyols may be used. Polyurethane, acrylic, vinyl acetate, cellulose resin, polyamide resin, etc.
A non-halogen thermoplastic resin in which two or more kinds are mixed is preferable.

Next, the surface protective layer 5 of the present invention is a non-halogen thermoplastic resin having a flexural modulus of 1.0 × 10 ⁴ to 2.
It is a composition mainly composed of a resin of 0 × 10 ⁴ kgf / cm ² formed by a hot melt extrusion coating method. By providing the surface protective layer 5, in the on-site construction where the adhesive is applied to a wall surface or a ceiling surface, an adhesive is collectively applied in advance and folded to make the adhesive-coated surfaces adhere to each other in order to improve construction efficiency. Even if left to stand, the adhesive is dried and the adhesiveness is reduced, and the fold marks do not disappear and the construction is not defective, and various physical properties required for the wall covering sheet, that is, The sheet for wall covering 1 excellent in chemical resistance, stain resistance, scratch resistance and the like can be obtained.

The thermoplastic resin used for the surface protective layer 5 may be any non-halogen thermoplastic resin which can be melted and extruded by a T-die extruder. Examples of the thermoplastic resin include an acrylic resin and an olefin resin. Resins, urethane resins, ester resins, etc. can be mentioned, but it is important that the flexibility is equivalent to that of the conventional polyvinyl chloride film, in other words, it has a moderate "stiffness" but does not have strong elasticity when bent. That is, the flexural modulus is 1.0
It is preferably in the range of × 10 ^{4 to} 2.0 × 10 ⁴ kgf / cm ² and relatively low in cost, so that olefin resins, for example, polyolefins such as polyethylene, polypropylene, polybutene, polybutadiene, polyisoprene, etc. 1 to ethylene, propylene, butene,
A copolymer of two or more olefins such as butadiene and isoprene, or a copolymer of an α-olefin having 4 or more carbon atoms is preferable, and a polypropylene resin is particularly preferable. When the flexural modulus is 1.0 × 10 ⁴ kgf / cm ² or less, there is not enough “stiffness” as a wall covering sheet, and when glued to the substrate, glue duck (unevenness of the glue-coated surface), When it is difficult to finish a flat surface by picking up irregularities and the flexural modulus exceeds 2.0 × 10 ⁴ kgf / cm ² , there is too much “stiffness” to resist the stress applied near the bent part of the wall covering sheet Because the adhesive surface floats, the open time is insufficient, the adhesive strength is reduced, and the end is poorly constructed,
The workability is poor such as the fold marks are not easily erased.

The thickness of the surface protective layer 5 depends on the surface properties such as stain resistance and abrasion resistance, the workability such as open time property, fold wrinkle resistance, and corner-to-corner corners, and the thickness of the surface protective layer 5 adhered to the substrate. From the viewpoint of flatness, cost effectiveness, etc., the thickness of the foamed resin layer 3 after heating and foaming is in the range of 2.0 to 10.0%, more preferably 3.0 to 8.0%.
It is. For example, if the thickness of the foamed resin layer 3 after heating and foaming is about 300 to 350 μm, the thickness of the surface protection layer 5 is 5 μm.
It is in the range of ３５35 μm, more preferably 9-28 μm. If the thickness is less than 5 μm, surface properties such as stain resistance required for a wall covering sheet cannot be obtained, and it is difficult to form a film by controlling the thickness with a T-die extruder.
When the thickness is more than 35 μm, not only a sharp uneven pattern cannot be formed, but also the “stiffness” becomes too strong when used as a wall covering sheet, so that open time properties, anti-folding properties, and corners at the corners are formed. Inferior in construction.

Next, as a method of forming the embossed pattern 6 of the present invention, aside from the stage at which the wall-mounting sheet of the present invention is formed, in short, the wall-mounting sheet in the manufacturing process is of some sort. It can be formed by heating and pressing with an embossing plate from the outermost layer side facing the base material layer 2 at a temperature at which embossing can be performed by the means. A well-known single-wafer or rotary embossing machine is used for processing the uneven pattern 6, and the shape of the uneven pattern 6 includes a wood grain board conduit groove, a stone board surface unevenness, a cloth surface texture, a satin finish, a grain, There are hairline, line and groove.

Next, as a method for producing the wall covering sheet 1, a foaming agent and a foaming layer forming composition mainly comprising an olefin resin or an acrylic resin are applied on the base layer 2, and the foaming layer is formed. The surface protective layer 5 is formed by extruding and applying a polypropylene resin heated and melted by a T-die extruder to the pattern layer 4 side of the laminate in which the pattern layer 4 is provided on the forming composition, and then forming a heating foaming furnace. The foaming layer forming composition is foamed to form a foamed resin layer 3 and the surface protective layer 5 side is heated and pressurized with an embossing plate, whereby a wall covering sheet having an uneven pattern 6 on the surface protective layer 5 side 1 can be obtained.

If necessary, the base material layer 2 and the foamed resin layer 3 may be made of one of inorganic materials such as aluminum hydroxide, magnesium hydroxide, calcium carbonate, barium carbonate, antimony trioxide and titanium oxide. An inorganic filler composed of a mixture of two or more kinds or a flame retardant may be added, and if necessary, a pigment or the like may be added for coloring. The coloring by adding the pigment may be transparent coloring or opaque (concealing) coloring.

The surface protective layer 5 may have an antibacterial property by adding an antibacterial agent. Examples of the antibacterial agent to be added to the surface protective layer 5 include inorganic adsorbents such as activated carbon, activated alumina and silica gel, zeolites,
Inorganic ion exchangers such as hydroxyapatite, zirconium phosphate, titanium phosphate, potassium titanate, hydrated bismuth, hydrated zirconium, hydrotalside, etc. are used together with silver ion or silver ion as well as copper ion and zinc ion. Well-known silver-based antibacterial agents, or zinc oxide compounds obtained by combining antibacterial inorganic salts with zinc oxide particles.

Although not shown, the substrate layer 2
To improve the interlayer adhesion between the foamed resin layer 3, or between the foamed resin layer 3 and the pattern layer 4, or between the pattern layer 4 and the surface protection layer 5. In addition, an adhesive force improving means such as adhesive application or corona discharge treatment may be used as appropriate.

[0029]

EXAMPLES Test Examples First, a foamed resin layer forming composition (aqueous emulsion) having the following composition was dried on a flame-retardant backing paper having a basis weight of 105 g / m ² (manufactured by Tokushu Paper Co., Ltd.). 170 g /
m ² was applied by a comma doctor coating method, and the coated surface was printed by a gravure printing method using an acrylic resin-based aqueous ink to produce an intermediate sheet A having a picture layer formed thereon. A polyolefin-based adhesive [UNISTOL P, manufactured by Mitsui Chemicals, Inc.] is applied on the surface of the intermediate sheet A on which the pattern layer is formed so as to have a thickness of 3 μm after drying, and then the olefin-based resin is coated with a predetermined thickness. After extruding with a two-type three-layer T-die extruder to form a surface protective layer, the foamed resin layer-forming composition is subjected to heat treatment at 170 ° C. for 60 seconds to foam the composition. Embossing was performed from the protective layer side with a cross-tone embossing plate to prepare a wall-mounting sheet. At this time, the kind of the olefin resin as the surface protective layer and the thickness of the surface protective layer were variously changed as shown in Table 1. At this time, the thickness of the foamed resin layer was 300 μm.

[Blending of foamed resin layer forming composition] parts by weight ethylene-vinyl acetate copolymer resin 100 aluminum hydroxide (inorganic filler) 120 titanium dioxide (pigment) 10 thermal expansion type capsule foaming agent 13 dispersant 1 dilution Agent

[0031]

With respect to the wall covering sheet produced in the above test example, open time property, folding wrinkle resistance,
Table 2 shows the results of the tests for the outgoing and incoming corners and the flatness, and Table 3 shows the results of the stain resistance test.

[Table 2] Workability evaluation test method [Open time property] After applying 120 g / m ^{2 of} an adhesive for wallpaper (Lua Mild, manufactured by Yayoi Chemical Co., Ltd.) on the entire back surface of a 1 m square wall covering sheet, Observe whether there is a decrease in adhesion after lamination and standing. Open time property 1: After leaving at 20 ° C for 6 hours 2: After leaving at 20 ° C for 12 hours 3: After leaving at 40 ° C for 3 hours Evaluation criteria ○: No hindrance □: Some of the edges are poorly constructed △: All the edges Poor construction ×: Poor overall construction [Fold wrinkle resistance] After applying an adhesive for wallpaper (Luamild, manufactured by Yayoi Chemical Co., Ltd.) to the back of the wall covering sheet, fold it in two and make a crease The surfaces are stuck together, the wall covering sheet is opened again, applied to the base material, and visually inspected for the presence of the fold after leaving for 24 hours. Folding wrinkle resistance 1: Folding wrinkle attached and bonded to adhesive surface 2: Folding wrinkle applied in advance and then applied immediately after applying adhesive Evaluation criteria ○: Indistinguishable ×: Easy to distinguish [Outer corner entering corner property] A step is provided on the base material, a wall covering sheet is constructed along the step, and the presence or absence of floating of the wall covering sheet in the corner portion after standing for 24 hours is visually observed. Steps are set at 1 cm and 2 cm. (A higher level of workability is required for 1 cm) Evaluation criteria ○: No lifting △: Slight floating ×: Large floating [Flatness] Adhesive for wallpaper (Yayoi Chemical Co., Ltd.) ), Luer mold), apply it to the base material (medium density fiberboard), and visually observe the flatness of the surface. Evaluation criteria ○: Smooth surface ×: Paste turbidity (unevenness of paste applied surface)

[0034] Test method: According to JIS K6902, after adhering contaminants, left in an atmosphere of 25 ° C. and 60% RH for 24 hours, and wiped off with a JK wiper. Visual observation Evaluation criteria ○: Stain completely removed □: Stain remains inconspicuously Δ: Slight stain remains ×: Stain remains

As can be seen from the above results, Test Examples 2 to 4,
In all of Test Examples 7 and 8, favorable results were obtained in open time property, folding wrinkle resistance, corner-out corner property, flatness, and stain resistance. On the other hand, Test Example 1 has good open time, folding wrinkle resistance, corner out and cornering, and stain resistance, but has poor flatness, and Test Example 6 has open time resistance and folding wrinkle resistance. The outgoing and incoming corners and the flatness were good, but the stain resistance was slightly inferior. Test Examples 5 and 9 and 10 had good flatness and stain resistance, but the open time, the fold wrinkle resistance, Both corners are slightly poor.

[0036]

As described above, the wall covering sheet of the present invention is a human or environmentally friendly wall covering sheet which does not generate harmful gases such as hydrogen chloride gas when incinerated. With excellent surface properties such as resistance and scratch resistance,
In particular, it is a sheet for wall covering which can prevent deterioration in workability due to the strength of the sheet such as open time property, folding wrinkle resistance, and come-in and come-out corner properties.

Further, since the surface protective layer can be formed with a minimum thickness required for obtaining surface properties such as stain resistance and scratch resistance, it can be made inexpensive and sharp. Since an uneven pattern can be obtained, an excellent effect can be obtained in design.

[Brief description of the drawings]

FIG. 1 is a layer configuration diagram showing one embodiment of a wall covering sheet according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Wall covering sheet 2 Base material layer 3 Foam resin layer 4 Picture layer 5 Surface protection layer 6 Uneven pattern

Claims (4)

[Claims] 1. A foaming agent and an olefin-based material on a base material layer.
A foamed resin layer mainly composed of resin or acrylic resin,
Press the pattern layer and the heat-melted non-halogen thermoplastic resin.
And a surface protection layer formed by a coating method.
Flexural modulus of the surface protective layer
But 1.0 × 10^Four~ 2.0 × 10^Fourkgf / cm ^TwoSpecially
This is the seat for the wall. 2. The wall covering sheet according to claim 1, wherein the thickness of the surface protective layer is 3.0 to 10.0% of the thickness of the foamed resin layer after foaming. 3. The wall covering sheet according to claim 1, wherein the heat-melted non-halogen thermoplastic resin forming the surface protective layer is made of a polypropylene resin. 4. The wall covering sheet according to claim 1, wherein an uneven pattern is formed on the surface protective layer side.