JP7222291B2 - Incombustible decorative sheet - Google Patents

Description

The present invention relates to a nonflammable decorative sheet.

Conventionally, decorative sheets (decorative synthetic resin sheets) having a Japanese-style and rich Japanese paper design (decorative synthetic resin sheets) have been used as decorative sheets such as partitions in non-residential buildings such as hotels and restaurants.
Examples of such decorative sheets include synthetic resin that has been made translucent by adding pigments and printed with decorative patterns, and Japanese paper that has translucent synthetic resin films attached to both sides. (see, for example, Patent Document 1).

JP 2003-25514 A

However, according to Article 35-2 of the Building Standards Law, depending on the scale and type of building, noncombustible materials must be used for the finishing of walls and ceilings facing the interior of the interior of special buildings (mainly public facilities). is obligatory, and decorative sheets that are permanently installed on walls must be certified as noncombustible.
That is, the decorative sheet disclosed in Patent Document 1 does not have a specification that can be certified as noncombustible, so it is not suitable as a decorative sheet permanently installed on the wall surface of a special building.
The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a noncombustible decorative sheet having both noncombustibility and designability that can be used as an interior material for special buildings.

In order to solve the above problems, a nonflammable decorative sheet that is one aspect of the present invention includes a base layer containing a thermoplastic resin and an inorganic material, and one surface and the other surface of the base layer each include An anchor layer and a transparent resin layer are laminated in at least this order, and a printed layer is provided between the anchor layer and the transparent resin layer on at least one side of one surface and the other surface of the base material layer is provided, the content of the inorganic material with respect to 100 parts by mass of the thermoplastic resin is more than 50 parts by mass and 300 parts by mass or less, the transparent resin layer contains a vinyl chloride resin, and the basis weight of the transparent resin layer is It is characterized by being 10 [g/m ² ] or more and less than 100 [g/m ² ].

According to one aspect of the present invention, it is possible to realize a noncombustible decorative sheet having both noncombustibility and designability that can be used as an interior material for special buildings.

BRIEF DESCRIPTION OF THE DRAWINGS It is sectional drawing which shows an example of the incombustible decorative sheet which concerns on one Embodiment of this invention.

An embodiment of the present invention will be described below with reference to the drawings.
Here, in the description of the drawings below, the same or similar parts are denoted by the same or similar reference numerals. However, it should be noted that the drawings are schematic, and the relationship between thickness and planar dimensions, the thickness ratio of each layer, and the like may differ from the actual ones. Therefore, specific thicknesses and dimensions should be determined with reference to the following description. In addition, it is a matter of course that there are portions with different dimensional relationships and ratios between the drawings. In addition, in the following description, "parts by mass" may be referred to as "parts".
Further, the embodiments shown below are examples of configurations for embodying the technical idea of the present invention. It does not specify anything. Various modifications can be made to the technical idea of the present invention within the technical scope defined by the claims.

(composition)
The nonflammable decorative sheet 10 according to one embodiment of the present invention, as shown in FIG. The resin layers 4B are laminated at least in this order. That is, in the nonflammable decorative sheet 10 according to one embodiment of the present invention, the anchor layers 2 (2A, 2B) and the printing layers 3 (3A, 3B) and the transparent resin layer 4 (4A, 4B) are laminated at least in this order.

Here, as another aspect of the nonflammable decorative sheet 10 of the present invention, the printed layer 3 may be provided only on one surface 1a side or the other surface 1b side of the base material layer 1 . That is, as the configuration of the nonflammable decorative sheet of another embodiment, the anchor layer 2, the printed layer 3, and the transparent resin layer 4 are laminated in this order on one surface 1a side of the base material layer 1, and the other surface is laminated. A mode in which the anchor layer 2 and the transparent resin layer 4 are laminated at least in this order on the 1b side is included. Further, as a configuration of the nonflammable decorative sheet of another embodiment, the anchor layer 2 and the transparent resin layer 4 are laminated at least in this order on one surface 1a side of the base material layer 1, and the anchor layer 2 and the transparent resin layer 4 are laminated on the other surface 1b side. A mode in which the layer 2, the printed layer 3, and the transparent resin layer 4 are laminated at least in this order is included.

In addition, other layers may be provided between each layer as long as the effect of the present invention is not impaired.
The thickness of the nonflammable decorative sheet 10 of the present embodiment is preferably 0.021±0.004 mm or more and 0.29±0.03 mm or less. Further, the mass of the nonflammable decorative sheet 10 of the present embodiment is preferably, for example, 23±2.3 [g/m ² ] or more and 314±30.2 [g/m ² ] or less. Furthermore, it is preferable that the total light transmittance of the nonflammable decorative sheet 10 is 75% or more. That is, as shown in FIG. 1, when the nonflammable decorative sheet 10 is composed of a laminate of a substrate layer 1, an anchor layer 2, a printing layer 3, and a transparent resin layer 4, the total light transmittance of this laminate is It is preferably 75% or more. Further, for example, the nonflammable decorative sheet 10 has an anchor layer 2 and a transparent resin layer 4 laminated in this order on one surface 1a side of the base material layer 1, and an anchor layer 2 and a printed layer on the other surface 1b side. 3 and the transparent resin layer 4 are laminated in this order, the total light transmittance of this laminate is preferably 75% or more.

In the following description, with the substrate layer 1 as a reference, one surface 1a side may be referred to as the "front (surface) side", and the other surface 1b side on the opposite side may be referred to as the "back (surface) side". be. In addition, except for the case of distinguishing between the front side and the back side, the transparent resin layers 4A and 4B, the printed layers 3A and 3B (when the printed layers are provided on both sides of the base material layer 1), and the anchors. Layers 2A and 2B may be referred to as transparent resin layer 4, printed layer 3, and anchor layer 2, respectively.
The noncombustible decorative sheet 10 according to one embodiment of the present invention is a noncombustible sheet that is excellent in transparency, noncombustibility, and long-term stability by having such a configuration.

<Base material layer>
The base material layer 1 is a sheet-like layer containing a thermoplastic resin and an inorganic material.
In the substrate layer 1, the upper limit of the content of the inorganic material with respect to 100 parts by mass of the thermoplastic resin in the substrate layer 1 depends on the function of the substrate layer 1 and the application of the nonflammable decorative sheet 10 of the present embodiment. Although determined appropriately, for example, 300 parts by mass is preferable, and 200 parts by mass is more preferable. If the content of the inorganic material is 50 parts by mass or less with respect to 100 parts by mass of the thermoplastic resin, it tends to be difficult to obtain noncombustibility or flame retardancy.
Moreover, it is preferable that the thickness of the base material layer 1 is 0.021 [mm] or more and 0.05 [mm] or less. Moreover, the total light transmittance of the substrate layer 1 is preferably 90% or more.

[Inorganic material]
The inorganic material is preferably in the form of powder (powder shape), has an average particle size in the range of 1 [μm] or more and 3 [μm] or less, and has a maximum particle size of 50 [μm] or less. is preferred. When the average particle size and the maximum particle size of the inorganic material are within the above numerical ranges, the flatness of the surface of the substrate layer 1 can be maintained while improving the dispersibility of the inorganic material in the thermoplastic resin. If the average particle size of the inorganic material is less than 1 [μm], the cohesive force between the inorganic materials increases, and the dispersibility in the thermoplastic resin, which will be described later, may decrease. On the other hand, if the average particle size of the inorganic material exceeds 3 μm, the flatness of the surface of the base material layer 1 is reduced, and the thickness of the anchor layer 2 becomes uneven, and unevenness and chipping occur. There is On the other hand, if the maximum particle size of the inorganic material exceeds 50 [μm], the flatness of the surface of the base material layer 1 is reduced, and the thickness of the anchor layer 2 becomes uneven, and unevenness and chipping occur. There is In addition, in this embodiment, "average particle diameter" means a mode diameter.

The inorganic material is powder containing at least one of calcium carbonate and calcium carbonate salt. The inorganic material preferably contains at least one of calcium carbonate and calcium carbonate in the range of 50% by mass or more and 100% by mass or less. In other words, it is preferable that the content of calcium carbonate or the like is in the range of 50% by mass or more and 100% by mass or less. If the content of the inorganic material such as calcium carbonate is 50% by mass or more, the base material layer 1 can be imparted with sufficient noncombustibility or flame retardancy, and is imparted with sufficient mechanical strength. can be done.

Inorganic materials other than calcium carbonate include, for example, silica (especially hollow silica), alumina, antimony trioxide, antimony soda, zirconium compounds such as zirconium silicate and zirconium oxide, magnesium hydroxide, aluminum hydroxide, basic Magnesium carbonate, borax, zinc borate, molybdenum trioxide or antimony dimolybdate and aluminum hydroxide complexes, antimony trioxide and silica complexes, antimony trioxide and zinc oxide complexes, zirconium silicates, zirconium compounds and At least one of complexes of antimony trioxide and salts thereof can be mentioned. In particular, calcium carbonate and calcium carbonate salts are easy to control the particle size and compatibility with the thermoplastic resin by the manufacturing method, and the material cost is cheap, so from the viewpoint of reducing the cost of the noncombustible sheet. preferred.

The inorganic material may be a crystalline powder material, so-called crystalline powder, or a non-crystalline powder material, so-called amorphous powder material. If the inorganic material is a crystalline powder material, the powder itself is homogeneous and isotropic, so that the mechanical strength of the powder itself is improved, and the scratch resistance and durability of the noncombustible sheet tend to be improved. In addition, if the inorganic material is an amorphous type powder material, it is possible to appropriately adjust the electrical conductivity and thermal conductivity of the powder itself, or the light transmittance and light absorbance. It is possible to give a rich design property.

[Thermoplastic resin]
The thermoplastic resin preferably contains at least one of polypropylene, polyethylene and polyester, more preferably polypropylene. By using at least one of polypropylene, polyethylene and polyester as the thermoplastic resin, the dispersibility of the inorganic material is improved. Moreover, by using polypropylene as the thermoplastic resin, the dispersibility of the inorganic material is further improved.

Moreover, the total content of the thermoplastic resin and the inorganic material is preferably in the range of 90% by mass or more and 100% by mass or less with respect to the mass of the substrate layer 1 . If the total content of the thermoplastic resin and the inorganic material is within the above numerical range, it is possible to obtain sufficient nonflammability or flame retardancy, improve printability and lamination suitability, and generate at the folded portion of the sheet. cracks can be reduced. If the total content of the thermoplastic resin and the inorganic material is less than 90% by mass with respect to the mass of the substrate layer 1, sufficient noncombustibility or sufficient flame retardancy may not be obtained. In addition, printability and lamination suitability may be deteriorated, and cracks may occur at the folded portion of the sheet.
The content of the thermoplastic resin and the inorganic material is more than 50 parts by mass and 300 parts by mass or less, preferably 70 parts by mass or more and 300 parts by mass or less, relative to 100 parts by mass of the thermoplastic resin. is.
Further, it is preferable that the basis weight of the thermoplastic resin is 10 [g/m ² ] or more and 60 [g/m ² ] or less.

<Print layer and anchor layer>
The print layers 3 (3A, 3B) are provided on the front surface 1a and the back surface 1b of the substrate layer 1 via anchor layers 2 (2A, 2B). As described above, the printed layer 3 may be provided only between the anchor layer 2 and the transparent resin layer 4 on the front surface 1a side or the back surface 1b side of the base material layer 1 . Of the two surfaces of the printing layer 3 (3A, 3B), the surface facing the anchor layer 2 (2A, 2B) (the surface opposite to the surface facing the transparent resin layer 4) is coated with printing ink, for example, Japanese paper. A pattern is applied, and this surface functions as a printing surface.
The printing ink is a layer formed by coating one surface of the anchor layer 2 with an ink containing an acrylic resin as a binder (hereinafter also referred to as printing layer forming ink). Examples of the acrylic resin contained as a binder in the ink for forming the printed layer include ethylene-methyl acrylate copolymer resin (EMA), ethylene-ethyl acrylate copolymer resin (EEA), ethylene-methacrylic acid copolymer resin, Those based on acrylate-based copolymer resins such as coalesced resins (EMAA), ethylene-acrylic acid copolymer resins (EAA), ionomer resins, or mixtures thereof can be used. Here, the “main component” refers to the component with the highest content among the components constituting the print layer 3 .

<Transparent resin layer>
The thermoplastic resin composition that constitutes the transparent resin layer 4 is not particularly limited as long as it does not interfere with the effects of the present invention, and various films can be used. is preferred. The thermoplastic resin (composition) constituting the transparent resin layer 4 may be referred to as the transparent resin layer-constituting resin (composition) in this specification.
The basis weight of the thermoplastic resin composition constituting the transparent resin layer 4 is preferably 10 [g/m ² ] or more and less than 100 [g/m 2 ], ^{more preferably 10 [g/m 2 ]} or more and 70 [g /m ² ] or less.
Moreover, the thickness of the transparent resin layer 4 is preferably 0.01 [mm] or more and 0.05 [mm] or less, and more preferably 0.045 [mm] or less.
Here, in this embodiment, an anchor layer 2, for example, a printed layer 3 printed with a Japanese paper pattern, and a transparent resin layer 4 are laminated in this order on the front surface 1a and the back surface 1b of the base material layer 1. Even in the state, the total light transmittance preferably exceeds 75%.

[vinyl chloride resin]
Examples of the vinyl chloride resin include the following requirements.
- Thickness [mm]: 0.045 ± 0.005 or less - Mass [g/m ² ]: 56.0 ± 5.0 or less (Organic mass [g/m ² ]: 55.9 ± 5.5 or less )
・ Composition (% by mass):
・Vinyl chloride resin: 85.4±1.452
・Acrylic resin: 0.2±0.02
· Plasticizer (DINCH, epoxidized soybean oil, etc.): 7.74 ± 0.77
・Organic additives (ultraviolet absorbers, etc.): 2.32±0.23
・ Organic stabilizer (Ba-Zn system, etc.): 4.32 ± 0.43
・ Inorganic additive (ultramarine blue): 0.02 ± 0.002

In addition, the vinyl chloride resin may include, for example, the following required acrylic resin-based paints.
- Mass (g/m ² ): 10 ± 1.0 or less (solid content) (Organic mass (g/m ² ): 10 ± 1.0 or less)
・ Composition (% by mass):
・Acrylic resin: 73.4±7.3 to 88.9±8.8
・Organic additives: 9.64±0.96 to 13.7±1.3
・ Inorganic additives (silica, etc.): 0 to 16.8 ± 1.6

[Top coat layer]
The top coat layer (surface protective layer) 1 is provided to impart surface physical properties such as weather resistance and stain resistance required for the nonflammable decorative sheet 10 .
The topcoat layer 5 (5A, 5B) is formed along the shape of the front surface of the transparent resin layer 4 (the surface opposite to the surface facing the printed layer 3). The shape of the front surface of the topcoat layer 5 is preferably smooth, for example, but may be embossed if necessary. Weather resistance and stain resistance can be improved by forming the top coat layer 5 (5A, 5B).
As the resin forming the topcoat layer 5, a thermosetting resin or a curable resin such as an ionizing radiation curable resin is preferable. Additives such as a weather-resistant agent and a matting agent may be added to the top coat layer 5 (5A, 5B) as necessary. By adding a matting agent, it is possible to produce a non-combustible decorative sheet with a texture closer to that of Japanese paper.
As described above, the nonflammable decorative sheet of the present embodiment can provide a nonflammable and transparent nonflammable decorative sheet by having a base layer containing a thermoplastic resin and an inorganic material. can. Furthermore, by providing a printed layer on the front side and the back side of the base material layer, it is possible to add a design such as a Japanese paper pattern. can provide.

<Method for producing nonflammable decorative sheet>
The method for manufacturing the nonflammable decorative sheet of the present embodiment is not particularly limited as long as it is a method for manufacturing a nonflammable decorative sheet that satisfies the above configuration.
For example, first, the base material layer 1 is formed from a thermoplastic resin and an inorganic material with the content of the inorganic material exceeding 50 parts by mass and 300 parts by mass with respect to 100 parts by mass of the thermoplastic resin. At this time, a resin having a basis weight of 10 [g/m ² ] to 60 [g/m ² ] is used as the thermoplastic resin. Further, the substrate layer 1 is prepared so that the total light transmittance of the substrate layer 1 is 90% or more.
Next, on the front surface 1a and the back surface 1b of this base material layer 1, the anchor layer 2, the printing layer 3 and the vinyl chloride resin are included, and the basis weight is 10 [g/m ² ] or more and 100 [g/m ² ] are laminated in this order. At this time, the substrate layer 1 is formed so that the total light transmittance of the laminate of the substrate layer 1, the anchor layer 2, the printed layer 3 and the transparent resin layer 4 exceeds 75%.

(Example)
A substrate layer 1 was formed from an inorganic material and polypropylene resin, which is a thermoplastic resin, and had a thickness of 100 [μm]. As for the purity of the inorganic material, calcium carbonate used was 90% by mass. In addition, two different inorganic materials with average particle diameters (mode diameters) of 2 [μm] and 8 [μm] were mixed as inorganic materials, and an inorganic material with a maximum particle diameter of 50 μm or less was used. . At this time, the content of the inorganic material was 55 parts by mass with respect to 100 parts by mass of polypropylene. Further, a resin having a basis weight of 10 [g/m ² ] to 60 [g/m ² ] is used as the thermoplastic resin. Further, the substrate layer 1 is prepared so that the total light transmittance of the substrate layer 1 is 90% or more.

Next, the front surface 1a and the back surface 1b of the substrate layer 1 were subjected to corona treatment.
Next, on each of the front surface 1a and the back surface 1b of the base material layer 1 subjected to the corona treatment, an ink for forming a urethane-based anchor layer containing vinyl chloride was applied to a thickness of 1 [μm] or more and 2 [μm]. It was applied so that the values within the following ranges were obtained, and dried under the conditions of a drying temperature of 40° C. and a drying time of 30 seconds. Thus, the anchor layers 2A and 2B were formed on the front surface 1a and the back surface 1b of the base material layer 1, respectively.
Next, on the anchor layers 2A and 2B, the ink for forming a urethane-based printed layer is applied (printed) so that the coating thickness is 1 [μm] or more and 2 [μm] or less, and the drying temperature is 40° C. It was dried under the conditions of a drying time of 30 seconds. Thus, the print layers 3A and 3B were formed on the anchor layers 2A and 2B.
Thereafter, a vinyl chloride resin layer was formed as a transparent resin layer (surface protective layer) 4 on the printed layers 3A and 3B.

The noncombustible decorative sheet 10 thus produced was evaluated for noncombustibility and designability.
Specifically, the combustibility of the incombustible decorative sheet 10 was confirmed by a test method using a cone calorimeter (according to ISO5660-1). As a result, the total calorific value fell below 8 [MJ/m ² ]. Moreover, it did not exceed 200 [kW/m ² ] continuously for 10 seconds or longer. Moreover, no cracks reaching the back surface occurred for 20 minutes after the start of heating. Thus, it was confirmed that the noncombustible decorative sheet 10 based on this example satisfies the standards for noncombustible materials, that is, has noncombustibility.

As for designability, when 80 or more out of 100 people judged that the nonflammable decorative sheet 10 felt Japanese paper style, it was judged to have designability, and when less than 80 people, there was no designability. I decided. As a result, more than 80 people judged that the incombustible decorative sheet 10 based on the example felt a Japanese paper tone, and it was judged that the nonflammable decorative sheet 10 had a good design.
In addition, in the nonflammable decorative sheet 10 based on the example, samples of the nonflammable decorative sheet were prepared by changing the conditions for the content ratio of the thermoplastic resin and calcium carbonate and the basis weight of the transparent resin layer. The samples obtained were evaluated in the same manner as described above.

Specifically, in the incombustible decorative sheet 10 of Example 1, the content of calcium carbonate was set to 55 parts by mass with respect to 100 parts by mass of the thermoplastic resin, and the basis weight of the transparent resin layer was set to 10 [g/m ² ]. In the nonflammable decorative sheet 10 of Example 2, the content of calcium carbonate was set to 300 parts by mass with respect to 100 parts by mass of the thermoplastic resin, and the basis weight of the transparent resin layer was set to 60 [g/m ² ]. In the incombustible decorative sheet of Comparative Example 1, the content of calcium carbonate was 48 parts by mass with respect to 100 parts by mass of the thermoplastic resin, and the basis weight of the transparent resin layer was 8 [g/m ² ]. In the nonflammable decorative sheet of Comparative Example 2, the content of calcium carbonate was 302 parts by mass with respect to 100 parts by mass of the thermoplastic resin, and the basis weight of the transparent resin layer was 102 [g/m ² ].

These Examples 1 and 2 and Comparative Examples 1 and 2 were evaluated for nonflammability and designability in the same procedure as above. As a result, in the case of the nonflammable decorative sheets 10 of Examples 1 and 2, nonflammability and designability can be obtained, and in the case of the nonflammable decorative sheets of Comparative Examples 1 and 2, the nonflammable It was confirmed that it was not possible to obtain the quality and designability.

1 Base layer 2 (2A, 2B) Anchor layer 3 (3A, 3B) Print layer 4 (4A, 4B) Transparent resin layer 10 Nonflammable decorative sheet

Claims (4)

Equipped with a base layer containing a thermoplastic resin and an inorganic material,
An anchor layer and a transparent resin layer are laminated in at least this order on one surface and the other surface of the base material layer, respectively,
A printed layer is provided between the anchor layer and the transparent resin layer on at least one side of one surface and the other surface of the base material layer,
The content of the inorganic material with respect to 100 parts by mass of the thermoplastic resin is more than 50 parts by mass and 300 parts by mass or less,
The transparent resin layer contains a vinyl chloride resin,
A nonflammable decorative sheet, wherein the basis weight of the transparent resin layer is 10 g/m ² or more and less than 100 g/m ² . The nonflammable decorative sheet according to claim 1, wherein the thermoplastic resin has a basis weight of 10 g/m2 ^or more and 60 g/ ^m2 or less. 3. The incombustible decorative sheet according to claim 1, wherein the base layer has a total light transmittance of 90% or more. 4. The laminate according to any one of claims 1 to 3, wherein a total light transmittance of the laminate composed of the base material layer, the anchor layer, the printing layer, and the transparent resin layer exceeds 75%. Noncombustible decorative sheet according to the paragraph.

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