JP5486283B2 - Base material for foamed resin laminate sheet - Google Patents

Description

  The present invention relates to a base material for a foamed resin laminate sheet that can be used as a base material in a foamed resin laminate sheet having a synthetic resin foam layer, for example, used as a building interior material such as a wall material, a ceiling material, and a flooring material. It is.

  Conventionally, as an interior material for construction, it is formed of a vinyl chloride resin or the like that can easily express a design such as gravure printing, rotary screen printing, etc., has excellent durability, and can easily remove dirt and the like. Synthetic resin interior materials are the mainstream. Such interior materials are replaced by refurbishment or the like in accordance with the change of owner in stores such as restaurants and apartment houses.

  In such an interior material made of a synthetic resin, a paper base is usually used as a backing material, and is attached to a gypsum board or the like serving as a wall substrate through an adhesive such as starch paste. However, when refurbishing, if the paper base material is to be peeled off the interior material used as a backing material, there is a problem that the paper base material is easily broken and takes time and effort. In order to solve such problems, for example, Patent Document 1, Patent Document 2 and Patent Document 3, so far, the configuration of the foamed resin laminated sheet, the provision of a coating layer on the paper substrate, etc., more delamination Consideration has been made to improve performance.

  Patent Document 4 mentions a polyester nonwoven fabric as a base material of a specific resin. However, the specific content of the substrate is not shown.

Japanese Patent No. 3283639 Japanese Patent No. 2891760 Japanese Patent No. 3144777 Japanese Patent No. 3949797

  Therefore, the specific conditions that the base material should satisfy so as to obtain the function of ease of peeling have not been conventionally considered. In addition, improving delamination improves the ease of peeling during refurbishment, but makes it easier to peel off when subjected to impacts such as contact during construction and use, making handling difficult during construction and shortening durability Etc. had occurred. Further, when paper is used as a base material or backing material, there is a problem that a dimensional change occurs due to moisture absorption / release in the long-term use, and a gap is formed in the joint.

  The object of the present invention is to provide excellent adhesion to the foamed resin layer, high strength because the base material is densified, and a structure in which fibers are difficult to fall off, and is easy to peel off. To provide a base material for a foamed resin laminate sheet that is excellent in prevention of see-through during resin coating and dimensional stability due to heat during the drying process and foaming process, and also excellent in dimensional stability after construction. It is in.

The present inventor uses a polyester-based nonwoven fabric satisfying predetermined conditions as a base material of the foamed resin laminated sheet, and can be peeled without tearing during refurbishment, and foaming with little dimensional change due to environmental changes after construction. The present inventors have found that a resin laminated sheet can be obtained and have reached the present invention. That is, the present invention is as follows.
[1] The base material used for forming a foamed resin laminate sheet having a base material and a foamed resin layer formed on the base material,
A nonwoven fabric apparent density 0.3-0.9 g / cm ³ composed mainly of polyester fibers, irregularities of the surface to be formed surface of the foamed resin layer, Ri. 1 to 30 [mu] m der,
The base material is a laminated non-woven fabric in which a surface layer that provides a surface for forming the foamed resin layer, an intermediate layer in contact with the surface layer, and a back surface layer in contact with the intermediate layer are integrated by thermocompression bonding, and the following (1 ) To (3):
(1) The surface layer has at least one layer of thermoplastic resin long fibers having a fiber diameter of 7 to 30 μm,
(2) The intermediate layer has at least one layer composed of melt-blown fibers having a fiber diameter of 1 to 5 μm, has a basis weight of 1 g / m ² or more, and constitutes 30% by mass or less of the basis weight of the laminated nonwoven fabric. ,as well as
(3) the back surface layer, a layer made of thermoplastic resin long fibers having a fiber diameter of 7~30μm having at least one layer, and the basis weight is 3~40g / m ²
A base material for a foamed resin laminated sheet that satisfies the requirements.
[2] The base material for a foamed resin laminated sheet according to the above [1], comprising fibers having a fiber diameter of 1 to 30 μm, a basis weight of 30 to 100 g / m ² , and a thickness of 35 to 300 μm.
[3] The dimensional change rate of dry heat when held for 3 minutes under no tension in an environment of 180 ° C. is 0% to −5.0% in the warp direction and −1.0% to 3.0% in the weft direction. The base material for foamed resin laminated sheets according to [1] or [2].
[4] mosquitoes are rendered processed, the above-mentioned [1] to [3] foamed resin laminate sheet for a substrate according to any one of.

  The base material for the foamed resin laminate sheet of the present invention has good processability and can form the foamed resin layer directly by coating or the like. For example, adhesion between the base material and the foamed resin without backing of a paper base material or the like. A foamed resin laminate sheet with good properties can be formed. In other words, by controlling the apparent density of the base material within a predetermined range, the foamed resin is appropriately infiltrated and closely integrated with the base material, and when the base material is densified, the fibers are firmly pressed together and difficult to peel off. , Fiber scraps are hard to come out and strength is increased. For this reason, the base material for foamed resin laminate sheets of the present invention is excellent in strength, and the foamed resin laminate sheet formed using the base material can be affixed to, for example, a gypsum board as a base of a wall. Can be easily peeled off without tearing, such as when using a paper substrate. Furthermore, the base material for a foamed resin laminated sheet of the present invention has the advantage that there is little dimensional change due to environmental changes, and problems such as opening of joints are unlikely to occur even after a long period after construction.

  Hereinafter, the present invention will be described in detail.

[Base material for foamed resin laminate sheet]
One aspect of the present invention is a base material used for forming a foamed resin laminate sheet having a base material and a foamed resin layer formed on the base material, and is an appearance mainly composed of polyester fibers Provided is a base material for a foamed resin laminate sheet, which is a nonwoven fabric having a density of 0.3 to 0.9 g / cm ³ , and has a surface irregularity degree of 1 to 150 μm serving as a foamed resin layer forming surface. The base material for a foamed resin laminate sheet of the present invention (hereinafter sometimes referred to as a base material) is used as a base material for forming a foamed resin layer that serves as a decorative layer of a building interior material, for example. At the same time, a foamed resin laminated sheet (hereinafter sometimes referred to as a laminated sheet) can be formed. Details of the foamed resin layer will be described later. As the base material for the foamed resin laminated sheet of the present invention, a single layer nonwoven fabric or a laminated nonwoven fabric composed of a plurality of layers including one or more nonwoven fabric layers can be used.

  The base material for foamed resin laminated sheets of the present invention is a nonwoven fabric mainly composed of polyester fibers. In the present specification, the nonwoven fabric mainly composed of polyester fibers means a nonwoven fabric having the largest content (mass basis) of polyester fibers among the elements constituting the nonwoven fabric. It is a nonwoven fabric in which at least 70% by mass of polyester fiber occupies. The base material for the foamed resin laminate sheet of the present invention has a high breaking strength and, for example, a dimensional change during long-term use under environmental conditions by using polyester fiber as a main component, for example, compared to a conventional paper base material. Few. Therefore, by using the base material for the foamed resin laminate sheet of the present invention, it is possible to obtain a foamed resin laminate sheet that has high strength and is easy to peel off, has good handleability during construction, and good dimensional stability after construction. .

  Polyester fibers are polyester homopolymers such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and polytrimethylene terephthalate (PTT), polyester copolymers, mixtures of homopolymers and copolymers, etc. Can be formed from As polyester-based copolymers, aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, phthalic acid, and naphthalene dicarboxylic acid and diols such as ethylene glycol, diethylene glycol, 1,4-butanediol, and cyclohexanedimethanol are polymerized. And the like. Moreover, you may use biodegradable resin, for example, aliphatic polyester resin including polylactic acid. Further, for example, a polymer obtained by copolymerizing a phosphorus organic monomer or the like can be used in combination to impart flame retardancy. As the polyester fiber, short fibers or long fibers may be used alone, or two or more kinds of fibers may be laminated or mixed. Among these, a long fiber nonwoven fabric formed of polyethylene terephthalate is preferable from the viewpoint of heat resistance and strength. In addition, various additives such as pigments, matting agents, antioxidants, ultraviolet absorbers, flame retardants, and chain extenders may be mixed as less than 10% by mass in the polyester fiber.

  Examples of the cross-sectional shape of the polyester fiber include a round cross-section, and irregular cross-sections such as a flat type and a T type.

  The nonwoven fabric which has a polyester fiber as a main component can contain a binder fiber, an adhesive resin, etc. in 30 mass% or less other than a polyester fiber.

  Examples of the binder fiber include known unstretched PET fibers and polyester fibers such as low melting point polyester fibers. In addition, for example, in a range that does not affect the practical strength, a low-melting-point component such as polyolefin can be added to the polyester fiber to modify the flexibility of the nonwoven fabric. Other modifications include a core-sheath fiber using a polyester fiber as a core and a polyolefin or the like as a sheath. As content in the nonwoven fabric of binder fibers other than a polyester fiber, 3 mass% or more is preferable and 30 mass% or less is preferable from a viewpoint of strengthening the adhesive strength of fibers. The content is more preferably 5 to 20% by mass.

  The use of the adhesive resin is particularly useful when short fibers are used as the polyester fibers, and can give excellent shape retention to the nonwoven fabric. As the adhesive resin, an acrylic resin, a phenol resin, a polyester resin, a polyvinyl alcohol resin, a polyvinyl chloride resin, a thermoplastic resin made of a modified body or a mixture thereof, or the like can be used. As content in the nonwoven fabric of adhesive resin, 3 mass% or more is preferable from a viewpoint of strengthening the adhesive strength of fibers, and 30 mass% or less is preferable from a viewpoint of containing 70 mass% or more of polyester fiber. The content is more preferably 5 to 20% by mass.

The apparent density of the base material for a foamed resin laminate sheet of the present invention is required to be 0.3 to 0.9 g / cm ³ . The base material for the foamed resin laminate sheet has an apparent density of 0.3 to 0.9 g / cm ³ , so that the foamable resin permeates the base material appropriately, and the adhesion between the base material and the foamed resin layer is excellent. Since the base material is densified and the adhesiveness between the fibers is good, the structure is strong and the fibers are difficult to fall off. Therefore, it is easy to peel off, and at the same time, a substrate having excellent processability (that is, prevention of see-through at the time of synthetic resin coating and dimensional stability due to heat at the time of the drying process and the foaming process) can be obtained. When the apparent density is less than 0.3 g / cm ³ , it is not preferable because the resin can be easily exposed when the foamed resin layer is formed, and the processability in the resin coating process is deteriorated. Further, when the apparent density exceeds 0.9 g / cm ³ , the density of the nonwoven fabric becomes too high, and voids into which the foamable synthetic resin composition should enter when forming the foamed resin layer on the substrate by coating or the like Therefore, the adhesiveness between the foamed resin and the substrate becomes insufficient, which is not preferable. The adhesion between the substrate and the expandable resin can be adjusted by adjusting the viscosity of the expandable resin. If the viscosity is lowered, the adhesion is improved, but it is easy to see through, and if the viscosity is increased, the adhesion tends to be lowered. If the apparent density is adjusted to 0.4 to 0.9 g / cm ³ , it can be used without any problem even if any commonly used resin is used, which is preferable. More preferably, it is 0.5 to 0.8 g / cm ³ . The apparent density is calculated according to the formula: apparent density = (weight per unit area) / (thickness) from the basis weight and thickness measured by the method described later.

  The base material for the foamed resin laminate sheet of the present invention has unevenness of the base material resulting in uneven thickness of the foamed resin layer when the foamed resin is applied, and the surface becomes uneven after foaming of the foamed resin, affecting the design and patterning properties. give. Therefore, it is preferable that the substrate is smooth. In the base material for sheet | seat, if the unevenness | corrugation degree of the surface used as the formation surface (for example, coating surface) of a foamed resin layer is the range of 1-150 micrometers, designability is securable. When the unevenness of the surface is less than 1 μm, the adhesion between the foamed resin layer and the substrate is low, and when it exceeds 150 μm, the foamed resin that is thickly attached to the recesses on the surface of the substrate during the formation of the foamed resin (for example, coating) Since it floats when foaming, the pattern of the interior material or the like is limited due to the smoothness of the resin surface. As said unevenness degree, 1-100 micrometers is preferable and 1-30 micrometers is still more preferable. When the unevenness is in the range of 1 to 30 μm, it can be used particularly advantageously without being influenced by the thickness and pattern of the foamed resin layer. The degree of unevenness of the above surface is determined so that the surface of the base material to be the foamed resin layer forming surface is up using a non-contact high-speed three-dimensional shape system (for example, non-contact high-speed three-dimensional shape system MAP-3D manufactured by Cosm) It can be obtained by fixing to a slide glass with double-sided tape, measuring surface irregularities at a pitch of 100 μm between 20 mm, measuring 20 heights between adjacent peaks and valleys, and averaging the numbers. When there is a pattern (for example, embossing) that repeats unevenness at a specific period, the height between peaks and valleys of the unevenness of the pattern is measured. If the measured values are different between the warp direction and the weft direction when measuring a distance of 20 mm × 20 mm at a pitch of 100 μm, the degree of unevenness means a value in a direction where the degree of unevenness is larger.

  The base material for a foamed resin laminate sheet of the present invention is preferably made of fibers having a fiber diameter of 1 to 30 μm. The base material can be formed of a single-layer nonwoven fabric having an average fiber diameter of preferably 7 to 30 μm, but in this case, it is more easily densified by mixing or laminating ultrafine fibers having an average fiber diameter of 1 to 5 μm. preferable. When the fiber diameter is less than 1 μm, the productivity of the substrate tends to decrease. On the other hand, when the fiber diameter exceeds 30 μm, the smoothness of the surface is lowered and the back-through preventing property of the foamable synthetic resin tends to be lowered. The fiber diameter is appropriately 1 to 5 μm for forming a meltblown layer that enhances the prevention of breakthrough, and preferably 7 to 30 μm for forming long fiber nonwoven fabrics and short fiber nonwoven fabrics. The fiber diameter is a value calculated, for example, as a number average value of 30 points when the diameter of the fiber (diameter of circumscribed circle in the case of an irregular cross section) is measured with a microscope.

It is preferable that the fabric weight of the base material for foamed resin laminate sheets of the present invention is 30 to 100 g / m ² . When the basis weight is less than 30 g / m ² , the resin tends to be easily exposed when forming the foamed resin. Moreover, when a fabric weight exceeds 100 g / m < ² >, when using a foamed resin laminated sheet as an interior material etc., there exists a tendency for the weight per unit area of foamed resin laminated sheet itself to increase, and for workability to fall. The basis weight is more preferably 40 to 80 g / m ² . The basis weight can be determined in accordance with JIS-L-1906.

  The thickness of the base material for a foamed resin laminate sheet of the present invention is preferably 35 to 300 μm. When the thickness is less than 35 μm, even if the apparent density is increased, there is a tendency for the resin to prevent back-through. Moreover, when thickness exceeds 300 micrometers, a base material becomes thick too much and there exists a tendency for the workability of a wall surface corner part to fall. The thickness is more preferably in the range of 45 to 200 μm, still more preferably 45 to 110 μm, particularly preferably 60 to 100 μm. The said thickness can be calculated | required based on JIS-L-1906 using a thickness meter (for example, No.207 by PEACOCK).

  When the base material for foamed resin laminate sheets of the present invention is produced by the spunbond method and partially thermocompression bonded with an embossing roll, it is more preferable from the viewpoint of the smoothness of the base material to use a handle with a small embossing depth. For example, the emboss depth is preferably 1 mm or less, and more preferably 0.5 mm or less. In order to further improve the smoothness, it is preferable to further perform calendar processing. The apparent density can be improved by calendering. By using the flat roll surface as the foamed resin layer forming surface instead of the embossed roll surface, the resin can be foamed more smoothly than when the foamed resin layer is formed on the embossed roll surface.

The base material for a foamed resin laminate sheet of the present invention has a dry heat dimensional change rate of 0% to -5.0% in the warp direction and -1.0% in the weft direction when held for 3 minutes under no tension in an environment of 180 ° C. It is preferable that it is -3.0%. When the foamed resin layer is formed on the base material for the foamed resin laminate sheet of the present invention, for example, after the foamable synthetic resin composition is applied, it passes through a high-temperature treatment process called a drying process and a resin foaming process. In this case, when the dimensional change in the dry heat treatment of the substrate is large, the product width becomes short, and wrinkles enter and the product quality is lowered. In particular, when forming a foamed resin layer on a substrate, the MD (warp) direction is usually fixed by a roll, but the CD (lattice) direction is often not fixed. Especially easy to shrink. When the substrate is held at 180 ° C. under no tension for 3 minutes, the dimensional change rate of dry heat is 0% to −5.0% in the MD (longitudinal) direction and −1% to 3.0% in the CD (longitudinal) direction. Controlling within the range is advantageous in that a foamed resin laminated sheet with good product quality can be produced. The dry heat dimensional change rate is more preferably 0% to -3.5% in the MD direction, and more preferably 0% to 3.0% in the CD direction. The dry heat dimensional change rate is calculated according to the following formula from the dimensions before and after heat treatment of the substrate for 3 minutes in a dryer at a temperature of 180 ° C.
Dry heat dimensional change rate in the MD direction = {(MD dimension after heat treatment) − (MD dimension before heat treatment)} / (MD dimension before heat treatment)
Dry heat dimensional change rate in CD direction = {(CD dimension after heat treatment) − (CD dimension before heat treatment)} / (CD dimension before heat treatment)

  The melting point of the polyester fiber is preferably 200 ° C. or higher. When the foamed resin layer is formed on the base material for the foamed resin laminate sheet of the present invention, the foaming step is usually heated from the foamed resin surface side and is performed at around 180 ° C to 230 ° C. It is thought that it rises to around 170 ° C. If the melting point of the polyester fiber is 200 ° C. or higher, the substrate can be produced without severing even in the foaming process. The melting point of the polyester fiber is more preferably 210 to 280 ° C, still more preferably 210 to 270 ° C. The melting point is measured using a differential scanning calorimeter (for example, DSC210 manufactured by SII Nanotechnology) at a measurement atmosphere: nitrogen gas 50 mL / min, heating rate: 10 ° C./min, and at the melting peak introduction portion. This value is obtained as the temperature at which the asymptotic line of the inflection point intersects with the baseline in the temperature region higher than Tg.

  Thermoplastic resins such as polyester fibers soften at a temperature above the glass transition point. Nonwoven fabrics composed mainly of polyester fibers are more advantageous than paper bases in that the strength does not decrease when wet. However, non-woven fabrics composed mainly of polyester fibers tend to stretch when tension is applied in an environment where the temperature is higher than the glass transition point. Therefore, the tension between rolls during drying or foaming after foam resin coating is limited. For example, it is preferable to set the tension lower than that in the case of using a conventional paper base material because a foamed resin laminated sheet with good quality can be easily obtained. However, since it is considered that the temperature of the base material is also increased to about 150 ° C. to 170 ° C. during the foaming process of the foamable resin, the thermal break strength in a 150 ° C. environment of a nonwoven fabric mainly composed of polyester fiber is, for example, 150 N / 5 cm. In the case of the above, it is preferable that the conventional equipment can be used without any problem without particularly adjusting the tension. The hot breaking strength is a value measured by a method in which a nonwoven fabric test piece is set in a heating furnace set at 150 ° C., and the breaking strength is measured when the temperature in the cabinet reaches the predetermined temperature. .

The base material for a foamed resin laminate sheet of the present invention is preferably formed by mixing thin fibers and thick fibers in the range of 30 to 100 g / m ^{2 in} basis weight. In this case, the base material is further densified, and a more preferable wallpaper base material is easily obtained. A mixed example will be described. A surface non-woven fabric in which a surface layer for forming a foamed resin layer, an intermediate layer in contact with the surface layer, and a back layer in contact with the intermediate layer are integrated by thermocompression bonding, and the following (1) to (3):
(1) The surface layer has at least one layer of thermoplastic resin long fibers having a fiber diameter of 7 to 30 μm,
(2) The intermediate layer has at least one layer composed of melt-blown fibers having a fiber diameter of 1 to 5 μm, has a basis weight of 1 g / m ² or more, and constitutes 30% by mass or less of the basis weight of the laminated nonwoven fabric. And (3) the base material satisfying that the back surface layer has at least one layer made of a thermoplastic resin long fiber having a fiber diameter of 7 to 30 μm and the basis weight is 3 to 40 g / m ^2. Preferably, a foamed resin laminated sheet can be produced. When the base material of the present invention is a laminated nonwoven fabric in which the surface layer, the intermediate layer, and the back layer are integrated by thermocompression bonding, the base material has high uniformity, and the melt blown layer that is the intermediate layer forms a foamed resin layer. It is more preferable in order to prevent the resin from slipping through.

  The surface layer must be smooth and have a function of adhering the foamable resin and the substrate in a proper manner with the foamable resin soaked appropriately. If the fiber diameter is 7 to 30 μm, the smoothness of the surface is maintained and the apparent density at which the substrate is brought into close contact is easily controlled. Among these, the layer which makes the outermost surface of a base material consists of the long fiber selected from the said polyester fiber, and a fiber diameter becomes like this. Preferably it is 7-30 micrometers, More preferably, it is the range of 7-20 micrometers. When the fiber diameter is less than 7 μm, pressure bonding is too effective at the time of calendering, and it becomes easy to form a film. Therefore, it becomes difficult to control production conditions, and adhesion with a foaming resin tends to be lowered. When it exceeds 30 μm, the smoothness of the surface tends to decrease.

  At least one of the intermediate layers is made of, for example, meltblown fibers selected from the above-described polyester fibers and the like, and the fiber diameter is preferably in the range of 1 to 5 μm, more preferably 1 to 3 μm. The ultrafine fiber layer of the intermediate layer forms a denser layer and functions to prevent further penetration (back-through) of the foamed resin. When the fiber diameter is less than 1 μm, the productivity of the base material tends to decrease. When the fiber diameter exceeds 5 μm, the fiber gap becomes too large, and there is a tendency that the anti-through-through prevention property at the time of coating with the foamed resin cannot be exhibited sufficiently.

The meltblown fiber used for this intermediate layer also has the function of a binder fiber, and has a function of firmly adhering the back surface layer and the surface layer to help prevent delamination and fiber loss. If the basis weight of the intermediate layer is less than 1 g / m ² , the function of preventing foam from falling through and the function of bonding between fibers tend to deteriorate.

Basis weight of the intermediate layer is preferably from the viewpoint of prevention of strike-through of the foamed resin is at 1 g / m ² or more, and more preferably from ^{3g / m 2 ~25g / m 2} . Moreover, it is preferable that an intermediate | middle layer comprises 30 mass% or less with respect to the fabric weight of a laminated nonwoven fabric. If it exceeds 30% by mass, the apparent density of the substrate tends to be too high. The intermediate layer more preferably constitutes 1.5% by mass to 30% by mass of the basis weight of the laminated nonwoven fabric, and further preferably constitutes 3% by mass to 25% by mass.

  At least one layer of the back surface layer, preferably the layer forming the backmost surface of the base material, is made of a long fiber of a thermoplastic resin that can be selected from, for example, the same as described above in the surface layer, and the fiber diameter is preferably Is in the range of 7-30 μm, more preferably 7-20 μm. When producing this base material, the method of forming an intermediate | middle layer normally after forming a back layer normally is taken. Thereby, an intermediate | middle layer is formed so that it may get entangled between the fibers of a back surface layer, and is fixed by the back surface layer. For this reason, when the fiber diameter of the back surface layer exceeds 30 μm, the fiber gap between the long fibers becomes too wide to sufficiently fix the meltblown fibers, and due to the pressure generated during the formation of the foamed resin layer (for example, coating) Since the meltblown fibers move and the fiber gaps in the intermediate layer increase, there is a tendency that as a result, the back-through prevention property cannot be sufficiently exhibited. On the other hand, when the fiber diameter is less than 7 μm, the fiber gap is close to the meltblown layer (intermediate layer), and the force to suck the foamable resin (for example, coating resin) staying in the meltblown layer by capillary force becomes strong. , There is a tendency that sufficient anti-cracking prevention properties cannot be exhibited.

The basis weight of the back layer is preferably 3 to 40 g / m ² from the viewpoint of fixing the melt-blown fiber as the intermediate layer and preventing the foaming resin from being pulled through.

  When using a nonwoven fabric laminated with meltblown fibers as the base material for the foamed resin laminate sheet, when thermocompression bonding is performed with a flat roll, the surface layer is generally the resin-formed (coated) surface, but the back layer is There is no problem even if it is used on the resin coated surface. Moreover, when thermocompression bonding is performed with an embossing roll, it is more desirable from the viewpoint of smoothness that the flat roll surface (back surface layer) is a resin coating layer. However, this is not the case when performing calendar processing.

[Manufacture of base material for foamed resin laminate sheet]
The nonwoven fabric used as the base material for the foamed resin laminate sheet of the present invention can be produced by a conventionally known spunbond (SB) method, flash spinning method, spunlace method, needle punch method, papermaking method or the like. In particular, a long fiber nonwoven fabric obtained from the spunbond method is preferred. In addition, when a base material has a laminated structure, each layer can be formed by the same or different method.

  In the production of the base material for the foamed resin laminated sheet, a thermocompression bonding step is usually performed. Thermocompression bonding is performed at a temperature lower than the melting point of the polyester fiber by, for example, 50 ° C. to 120 ° C., using a flat roll or an emboss roll at a linear pressure of 100 to 1000 N / cm (between fibers and between layers in a laminated structure). Can be joined. The base material of the present invention is more preferably calendered. By performing the calendar treatment, the surface of the base material becomes smoother and the surface quality after foaming of the foamable resin is improved. In addition, the adhesive strength between the fibers of the base material is increased, fiber waste is less likely to fall off, and the strength of the base material is increased. In this case, after the above-described thermocompression bonding, for example, calendering is performed at a linear pressure of 100 to 1000 N / cm at a temperature higher than the thermocompression bonding temperature by 10 ° C. or more and 10 to 100 ° C. lower than the melting point of the polyester fiber, thereby obtaining good strength And the apparent density can be controlled. If the temperature in the calendering process is lower than the melting point of the polyester fiber and the temperature difference is less than 10 ° C, the apparent density may be too high, whereas if the temperature difference exceeds 100 ° C, The dry heat dimensional change rate cannot be controlled within a predetermined range, and the strength may be lowered.

  When the linear pressure in the thermocompression bonding process and the calendar process is less than 100 N / cm, it is difficult to obtain good adhesion, and good strength tends not to be expressed. On the other hand, when the linear pressure exceeds 1000 N / cm, the deformation of the fiber becomes too large, the apparent density becomes too high, and it tends to be difficult to make it within the scope of the present invention.

  Flame retardancy can be imparted to the base material for a foamed resin laminate sheet of the present invention by post-processing. For example, aluminum hydroxide or the like is preferably used in order to reduce the burned calories.

[Foamed resin laminate sheet]
The base material for a foamed resin laminate sheet of the present invention has a base material for a foam resin laminate sheet and a foam resin layer formed on the base material for the foam resin laminate sheet, and the foam resin layer is a foaming agent. Can be used to provide a foamed resin laminate sheet formed by heating and foaming a foamable synthetic resin composition.

  The foamed resin layer is formed from a synthetic resin (usually a soft resin). As the soft resin, polyvinyl chloride resin (PVC), EVA, polyolefin resin, or the like can be used.

  As the blowing agent, in addition to the commonly used azodicarboxamides, thermal decomposition types such as oxybisbenzenesulfonyl hydrazide, benzenesulfonyl hydrazide, p-toluenesulfonyl hydrazide, diazoaminobenzene, azobisisobutyronitrile, etc. Organic foaming agents can be used. Two or more of these foaming agents can be used in combination. Moreover, the addition amount of a foaming agent can be suitably added with the desired foaming ratio, the kind of foaming agent to be used, etc.

  The foamable synthetic resin composition containing a foaming agent comprises the above-described synthetic resin, the above-mentioned foaming agent, and a plasticizer, and optionally a stabilizer, a filler, a pigment, and the like. As the composition of the preferred foamable synthetic resin composition, for example, when the synthetic resin is a vinyl chloride resin, the vinyl chloride resin alone or vinyl chloride and vinyl acetate, ethylene, propylene, maleate, methacrylate, etc. As an optional component, 0.5 to 10 parts by mass of one or more foaming agents, 50 to 100 parts by mass of a plasticizer, and 100 parts by mass of one or more kinds of synthetic resins selected from the copolymer of , Stabilizers, fillers and pigments.

  The foamable synthetic resin composition as described above is coated on a substrate with a knife coater or the like, and foamed resin layers are formed on the substrate by appropriately selecting foaming conditions according to the resin specifications and heating and foaming. Can be formed. The foamed resin layer may be subjected to surface treatment such as patterning or embossing by a conventional method after foaming.

  Hereinafter, the present invention will be described more specifically with reference to examples, but the present invention is not limited thereto. The characteristics of the present invention were measured by the following methods.

(1) Weight per unit (g / m ² )
Samples measuring 20 cm in length and 25 cm in width were cut out at three locations, mass was measured, and the number average value was converted into mass per unit area (based on JIS-L-1906).
(2) Thickness (μm)
Ten locations in the width direction were measured at a contact pressure load of 100 g / cm ² , and the number average value was taken as the thickness. The thickness gauge is a PEACOCK No. 207 was used. Since the minimum scale was 0.01, after reading to the third decimal place and averaging, it was converted to μm with 2 significant figures (conforming to JIS-L-1906).
(3) Apparent density (g / cm ³ )
Using the basis weight (g / m ² ) measured in the above (1) and the thickness (μm) measured in the above (2), it was calculated by the following formula.
Apparent density = (weight) / (thickness)
(4) Average fiber diameter (μm)
Except for 10 cm at both ends of the sample (nonwoven fabric), 1 cm square test pieces were cut out from the area of each 20 cm width of the sample. About each test piece, the diameter of the fiber was measured at 30 points with a microscope, the number average value of the measured values (rounded to the first decimal place) was calculated, and the average fiber diameter of the fibers constituting the sample was obtained.
(5) Breaking strength (tensile strength) (N / 5cm)
A test piece having a width of 5 cm and a length of 20 cm was cut out except for 10 cm at both ends of the sample. The number average value at five locations of the strength at the maximum load of the test piece when measured under the following conditions was determined by MD (longitudinal direction).
Gripping length: 10 cm Tensile speed: 10 cm / min

(6) Hot breaking strength (thermal tensile strength) (N / 5cm)
A sample prepared in the same shape as in (5) above is set in a heating furnace set at a predetermined temperature (150 ° C.), and the same conditions as in (5) at the time when the internal temperature reaches the predetermined temperature. The sample was stretched to obtain the breaking strength.
(7) Dry heat dimensional change rate Samples were sampled to 30 cm x 30 cm, and 5 points were marked at intervals of 20 cm. Three samples were prepared, heat-treated with a dryer at a temperature of 180 ° C. for 3 minutes, and calculated according to the following formula from the dimension between the marks before and after the heat treatment.
Dry heat dimensional change rate in the MD direction = {(MD dimension after heat treatment) − (MD dimension before heat treatment)} / (MD dimension before heat treatment)
Dry heat dimensional change rate in CD direction = {(CD dimension after heat treatment) − (CD dimension before heat treatment)} / (CD dimension before heat treatment)
(8) Surface roughness (μm)
Using a non-contact high-speed three-dimensional shape system MAP-3D manufactured by Cosm Co., Ltd., the degree of unevenness on the surface of the base material to be the coating surface of the foamed resin layer was measured. The sample was fixed to a slide glass with double-sided tape, and surface irregularities were measured at a pitch of 100 μm between 20 mm. Twenty heights between adjacent peaks and valleys were measured and number averaged. When there was a pattern (for example, embossing) that repeated unevenness at a specific period, the height between the peaks and valleys of the uneven pattern was measured. The smaller this value, the better the surface smoothness.

(9) Resin back-through prevention property After coating a vinyl chloride resin composition having the following composition on a base material fixed on a stainless steel plate to a thickness of 0.2 mm with a knife coater, resin stains on the stainless steel plate The presence or absence of occurrence was confirmed.
Evaluation was performed according to the following criteria.
Good: No adhesion of the resin on the stainless steel plate. Bad: The resin is adhered on the stainless steel plate.
Compound containing vinyl chloride resin Paste vinyl chloride resin 43% by mass
Dioctyl phthalate 20% by mass
Heavy calcium carbonate 35% by mass
Foaming agent (azodicarbonamide) 2% by mass

[Examples 1-7]
A PET continuous fiber web was formed as the back layer. General-purpose PET (polyethylene terephthalate) is extruded by spunbonding at a spinning temperature of 300 ° C. toward the collection net surface that moves the filament group, spun at a spinning speed of 3500 m / min, and charged at a corona charge of about 3 μC / g. The PET continuous fiber web was prepared on a collection net. The fiber diameter was adjusted by changing the discharge amount.

Next, a layer made of meltblown fibers was formed as an intermediate layer. PET (solution viscosity: ηsp / c = 0.5) was spun by the meltblown method under a spinning temperature of 300 ° C. and heated air of 1000 Nm ³ / hr / m and sprayed onto the PET long fiber web. It was. At this time, the distance from the meltblown nozzle to the long fiber web was set to 100 mm, the suction force at the collection surface immediately below the meltblown nozzle was set to 0.2 kPa, and the wind speed was set to 7 m / sec. The fiber diameter was adjusted by changing the discharge amount.

Further, a PET continuous fiber is used as a surface layer in the same manner as the PET continuous fiber web of the back layer directly on the intermediate layer side of the laminated web composed of the back layer and the intermediate layer obtained above, and a predetermined fiber diameter and fiber amount. The layers were laminated so as to have a basis weight. As described above, a laminated web composed of surface layer: PET long fiber (S1) / intermediate layer: meltblown fiber (M) / back layer: PET long fiber (S2) was obtained. The obtained laminated web was thermocompression bonded with a flat roll, and then the thickness was adjusted with a calendar roll to obtain a laminated nonwoven fabric having an apparent density shown in Table 1.
Thermocompression bonding conditions: Linear pressure 265 N / cm Roll temperature Front side / Back side (180 ° C / 180 ° C)
Calendar conditions: Linear pressure 663 N / cm Roll temperature Front side / Back side (236 ° C./231° C.)

[Example 8]
A long fiber nonwoven fabric was obtained in the same manner as in Example 1 except that copolymer PET having a melting point of 205 ° C. was used in place of the general-purpose PET and the spinning temperature was 280 ° C. Furthermore, the thickness was adjusted with a calendar roll. The calendar conditions were the same as in Example 1.

[ Reference Example 9]
The laminated web (S1) / (M) / (S2) obtained by the same method as in Example 1 was thermocompression bonded with a lattice pattern embossing roll having an embossing ratio of 14%, and laminated nonwoven fabrics having an apparent density shown in Table 2 were obtained. Obtained.

[ Reference Example 10]
The laminated nonwoven fabric (S1) / (M) / (S2) obtained in Reference Example 9 was further thickness adjusted with a calender roll. The calendar conditions were the same as in Example 1.

[ Reference Example 11]
The back layer and the surface layer of Example 1 are laminated so as to have a predetermined fiber diameter and fiber amount (weight per unit area) shown in the table, and the surface layer: PET long fiber (S1) / back surface layer: PET long fiber ( A laminated web consisting of S2) was obtained. The obtained laminated web was thermocompression bonded with a lattice pattern embossing roll having an embossing ratio of 14% to obtain a laminated nonwoven fabric having an apparent density shown in Table 2.

[ Reference Example 12]
A stretched short fiber polyethylene terephthalate having a fiber diameter of 7 μm, a fiber length of 5 mm, and a titanium oxide content of 0.5% by mass, and an unstretched short fiber polyethylene terephthalate having a fiber diameter of 11 μm, a fiber length of 5 mm, and a titanium oxide content of 0.5% by mass. The mixture was mixed at a ratio of 7: 3 (mass ratio), collected on a net by a papermaking method, and dried at 120 ° C. to obtain a short fiber web of 70 g / m ² . The obtained web was calendered at a linear pressure of 663 N / cm and a roll temperature of 235 ° C.

[Comparative Example 1]
WK-70NTS flame-retardant backing paper (weight per unit area: 70 g / m ² ) manufactured by Kojin Co., Ltd. was used.

[Comparative Example 2]
A laminated web obtained by the same method as in Reference Example 11 was thermocompression bonded with a rectangular pattern embossing roll having an embossing ratio of 11% to obtain a laminated nonwoven fabric having an apparent density shown in Table 2.
[Comparative Example 3]
A laminated web obtained by the same method as in Reference Example 11 was thermocompression bonded with a rectangular pattern embossing roll having an embossing ratio of 11% to obtain a laminated nonwoven fabric having an apparent density shown in Table 2.

  The base material for the foamed resin laminate sheet of the present invention has good adhesion to the resin, can directly form the foamed resin layer by coating, etc., has high strength, and can be peeled cleanly without tearing when peeled during refurbishment. The work efficiency can be improved. Moreover, the interior material formed using this base material has the advantage that it has good dimensional stability and is less prone to problems such as opening joints during long-term use.

Claims (4)

The base material used for forming a foamed resin laminate sheet having a base material and a foamed resin layer formed on the base material,
A nonwoven fabric apparent density 0.3-0.9 g / cm ³ composed mainly of polyester fibers, irregularities of the surface to be formed surface of the foamed resin layer, Ri. 1 to 30 [mu] m der,
The base material is a laminated non-woven fabric in which a surface layer that provides a surface for forming the foamed resin layer, an intermediate layer in contact with the surface layer, and a back surface layer in contact with the intermediate layer are integrated by thermocompression bonding, and the following (1 ) To (3):
(1) The surface layer has at least one layer of thermoplastic resin long fibers having a fiber diameter of 7 to 30 μm,
(2) The intermediate layer has at least one layer composed of melt-blown fibers having a fiber diameter of 1 to 5 μm, has a basis weight of 1 g / m ² or more, and constitutes 30% by mass or less of the basis weight of the laminated nonwoven fabric. ,as well as
(3) the back surface layer, a layer made of thermoplastic resin long fibers having a fiber diameter of 7~30μm having at least one layer, and the basis weight is 3~40g / m ²
A base material for a foamed resin laminated sheet that satisfies the requirements. The base material for foamed resin laminated sheets according to claim 1, comprising fibers having a fiber diameter of 1 to 30 µm, a basis weight of 30 to 100 g / m ² , and a thickness of 35 to 300 µm.   The dimensional change rate of dry heat when held for 3 minutes under no tension in an environment of 180 ° C is 0% to -5.0% in the warp direction and -1.0% to 3.0% in the weft direction. The base material for foamed resin laminated sheets of 2. The base material for foamed resin laminated sheets according to any one of claims 1 to 3 , which is subjected to a calendar treatment.