Wall material

Abstract

To provide a wall material having good scratch resistance, flexibility and cushioning property, while having excellent incombustible performance.SOLUTION: A wall material is formed by laminating a non-woven fabric layer, a foam resin layer, a decorative layer, a transparent resin layer in this order, wherein the thickness of the wall material is 0.45 mm or more and 0.70 m or less, the thickness of the foam resin layer is 0.15 mm or more and 0.30 mm or less, the thickness of the transparent resin layer is 0.10 mm or more and 0.20 mm or less, the form resin layer and the transparent resin layer contain a vinyl chloride resin, a phosphorus-based plasticizer and a phosphorus-based flame retardant, in the foam resin layer and the transparent resin layer, 5 pts.mass or more of the phosphorus-based flame retardant is contained with respect to 100 pts.mass of the vinyl chloride resin, in a heat generation test according to ISO 5660-1:2002, a total calorific value for 20 minutes after start of heating is 8 MJ / m2 or less, any crack or hole penetrating to the back face, which is harmful in view of fireproofness, is not formed, and the maximum heat generation rate does not exceed 200 kW / m2 for 10 seconds or more.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a wall material having excellent fireproofing properties. [Background technology]

[0002] Conventionally, from the viewpoint of preventing fire outbreaks and safety during fires, interior materials such as wall materials that have non-flammable properties have been known. Non-flammable performance means the property of being difficult to burn. As an index of such non-flammable performance, for example, the performance of satisfying the following conditions based on the Building Standards Act is known. In a heat generation test conforming to ISO 5660-1:2002, the total heat generation amount for 20 minutes after the start of heating is 8 MJ / m 2 There are no cracks or holes penetrating to the back surface that are harmful to fire prevention for 20 minutes after heating starts, and the maximum heat generation rate is 200 kW / m or less for 10 seconds or more for 20 minutes after heating starts. 2 The condition is that it does not exceed.

[0003] Furthermore, it is desirable for interior materials such as wall materials to have various functions in addition to non-combustibility. Conventionally, as a technique for imparting more functions to interior materials such as wall materials, it has been proposed to give the interior materials a laminate structure. For example, as an example of a non-combustible sheet having such a laminate structure, Patent Document 1 discloses a sheet having a sheet body layer formed to a thickness of more than 0.25 mm and less than 0.50 mm, and a design layer laminated on the surface of the sheet body layer, the sheet body layer containing a resin component containing chlorinated polyvinyl chloride, an inorganic filler, and a plasticizer, and a heat of 50 kW / m radiated from a radiant electric heater to the sheet surface. 2 In a heat generation test using radiant heat of 7.2 MJ / m for 20 minutes after the start of heating, the total heat generation was 7.2 MJ / m 2 The noncombustible wall sheet described in Patent Document 1 is not only less in total heat generation and less susceptible to damage, but also has a designability. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent Publication No. 2022-65322 Summary of the Invention [Problem to be solved by the invention]

[0005] However, simply increasing the number of layers of the wall material excessively in order to provide more functions increases the total thickness of the wall material. As a result, the wall material may become more susceptible to fire and the non-combustible performance of the wall material may decrease. On the other hand, reducing the thickness of each layer in order to reduce the total thickness of the wall material may affect the physical resistance of the wall material. Alternatively, the content of various compounds contained to provide non-combustible properties may decrease, which may affect the non-combustible performance of the wall material. Therefore, it is difficult to provide additional functions to the wall material while maintaining its non-combustible performance, because it is necessary to adjust various factors at the same time.

[0006] The non-combustible wall sheet described in Patent Document 1 is merely provided with design and scratch resistance functions in addition to non-combustible performance. Therefore, it would be preferable to have a wall material that has not only design and scratch resistance but also other functions while maintaining excellent non-combustible performance. For example, since the wall material is used as an interior material, it would be preferable to have a wall material that has good flexibility as well as non-combustible performance so that it can be suitably adapted to wall surfaces of various shapes.

[0007] Therefore, an object of the present invention is to provide a wall material that has excellent fireproofing properties, as well as good scratch resistance, flexibility and cushioning properties. [Means for solving the problem]

[0008] The present inventors have conducted extensive research to solve the above problems and have arrived at the present invention. That is, the present invention includes the following preferred embodiments.

[0009] A wall material according to an aspect of the present invention is a wall material including a nonwoven fabric layer, a foamed resin layer, a decorative layer, and a transparent resin layer laminated in this order, The thickness of the wall material is 0.45 mm or more and 0.70 mm or less, the thickness of the foamed resin layer is 0.15 mm or more and 0.30 mm or less, and the thickness of the transparent resin layer is 0.10 mm or more and 0.20 mm or less, the foamed resin layer and the transparent resin layer contain a polyvinyl chloride resin, a phosphorus-based plasticizer, and a phosphorus-based flame retardant, In the foamed resin layer and the transparent resin layer, the phosphorus-based flame retardant is contained in an amount of 5 parts by mass or more relative to 100 parts by mass of the vinyl chloride resin, and In heat generation tests conforming to ISO 5660-1:2002, the total heat generation rate for 20 minutes after the start of heating is 8MJ / m 2 There are no cracks or holes penetrating to the back surface that are harmful to fire prevention for 20 minutes after heating starts, and the maximum heat generation rate is 200 kW / m or less for 10 seconds or more for 20 minutes after heating starts. 2 not exceed.

[0010] In the above wall material, it is preferable that the foamed resin layer contains 20 parts by mass or more and 40 parts by mass or less of the phosphorus-based plasticizer per 100 parts by mass of the vinyl chloride resin, and that the transparent resin layer contains 10 parts by mass or more and 30 parts by mass or less of the phosphorus-based plasticizer per 100 parts by mass of the vinyl chloride resin.

[0011] In the above wall material, it is more preferable that a surface protective layer containing an ultraviolet curable resin as a main component and having a thickness of 10 μm or more and 20 μm or less is further laminated on the side of the transparent resin layer opposite to the side on which the decorative layer is laminated. Effect of the Invention

[0012] According to the present invention, it is possible to provide a wall material that has excellent flame retardancy, as well as good scratch resistance, flexibility and cushioning properties. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a schematic cross-sectional view showing an example of a wall material according to the present embodiment. [Diagram 2]FIG. 2 is a schematic cross-sectional view showing a modified example of the wall material in this embodiment. [Diagram 3] FIG. 3 is a schematic diagram for explaining an example of a method for producing a wall material in this embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] As a result of extensive research by the inventors, it has been found that by setting the thickness (total thickness) of the wall material, the thickness of the foamed resin layer and the thickness of the transparent resin layer each within a specified range, making the foamed resin layer and the transparent resin layer contain both a phosphorus-based plasticizer and a phosphorus-based flame retardant, and setting the content of the phosphorus-based flame retardant to a specified value or more, a wall material can be obtained that has excellent flame retardancy while also having good scratch resistance, flexibility and cushioning properties.

[0015] In this specification, the term "wall material" refers to a wainscoting material used primarily as an interior or exterior material for buildings such as ordinary houses, buildings, commercial facilities, stores, etc., but may also be used as a sheet material for large furniture, floors, ceilings, etc. In addition, in this specification, as described in the examples below, the thickness (total thickness) of the wall material is a value measured using a dial gauge, and the thickness of each layer such as the foamed resin layer, transparent resin layer, etc. is a value measured using a micrometer.

[0016] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. Note that the scope of the present invention is not limited to the embodiment described here, and various modifications can be made without departing from the spirit of the present invention.

[0017] 1. Wall material composition 1-1. Configuration of the wall material in this embodiment A schematic cross-sectional view of an example of a wall material in this embodiment is shown in Fig. 1. As shown in Fig. 1, the wall material 1 in this embodiment is formed by laminating a nonwoven fabric layer 2, a foamed resin layer 3, a decorative layer 4, and a transparent resin layer 5 in this order. Each layer will be described in detail below.

[0018] (Non-woven layer) The nonwoven fabric layer is placed in the wall material at a position closest to an object to be bonded, such as a wall surface of a building, and is bonded to the object to be bonded using an adhesive, double-sided tape, or the like.

[0019] The material constituting the nonwoven fabric layer is not particularly limited, and any material known to those skilled in the art can be used. For example, the nonwoven fabric layer may be made of polyethylene terephthalate (PET) fiber, glass fiber, pulp, etc. For example, when the nonwoven fabric layer is made of glass fiber, the basis weight is, although not particularly limited, 100 g / m 2 ~200g / m 2 It's fine as long as it's to a certain extent.

[0020] The thickness of the nonwoven fabric layer is not particularly limited as long as it satisfies the thickness requirements of the foamed resin layer, the transparent resin layer, and the wall material described later and does not impair the effects of fireproofing, scratch resistance, flexibility, and cushioning of the wall material finally produced. For example, the thickness of the nonwoven fabric layer is preferably 0.10 mm or more and 0.40 mm or less, more preferably 0.15 mm or more and 0.30 mm or less.

[0021] (Foamed resin layer) The foamed resin layer is laminated on the side opposite to the side to be adhered, such as a wall surface, to which the nonwoven fabric layer is adhered. The foamed resin layer imparts not only impact resistance (shock absorption) but also nonflammability to the wall material. Specifically, the foamed resin layer can be formed from a mixture of the following components.

[0022] First, the foamed resin layer contains a vinyl chloride resin as a base resin.

[0023] The vinyl chloride resin is not particularly limited, but examples thereof include polyvinyl chloride, vinyl chloride-vinyl acetate copolymer resin, vinyl chloride-ethylene copolymer resin, etc. In addition, these vinyl chloride resins are preferably paste polyvinyl chloride resins (hereinafter also referred to as "paste PVC") having a K value of about 70. Alternatively, a mixture of vinyl chloride resins in which a blend polyvinyl chloride resin is blended with a paste PVC having a K value of 70 as the main component may be used as the vinyl chloride resin.

[0024] The foamed resin layer contains a phosphorus-based plasticizer. In this specification, the term "phosphorus-based plasticizer" refers to any phosphorus-containing compound known to those skilled in the art that is compatible with vinyl chloride resin and can impart flexibility to the foamed resin layer. By including a phosphorus-based plasticizer in the foamed resin layer together with a phosphorus-based flame retardant described later, the excellent flame retardant performance of the wall material can be more reliably maintained, and the flexibility of the wall material can also be improved.

[0025] The phosphorus-based plasticizer is not particularly limited, but examples thereof include cresyl diphenyl phosphate, tris(isopropylphenyl) phosphate, tricresyl phosphate, triphenyl phosphate, trixylenyl phosphate, 2-ethylhexyl diphenyl phosphate, 2-naphthyl diphenyl phosphate, cresyl di-2,6-xylenyl phosphate, tributyl phosphate, triethyl phosphate, etc. These phosphorus-based plasticizers may be used alone or in combination of two or more.

[0026] In the foamed resin layer, the phosphorus-based plasticizer is preferably contained in an amount of 20 parts by mass or more and 40 parts by mass or less per 100 parts by mass of the vinyl chloride resin. When the content of the phosphorus-based plasticizer is 20 parts by mass or more, a wall material having excellent fireproof performance, flexibility and cushioning properties can be produced. When the content of the phosphorus-based plasticizer is 40 parts by mass or less, the deterioration of the processability of the wall material produced in the end can be suppressed, and the production cost can also be suppressed.

[0027] In the foamed resin layer, the content of the phosphorus-based plasticizer is more preferably 22 parts by mass or more, and even more preferably 25 parts by mass or more, per 100 parts by mass of the vinyl chloride resin, and more preferably 38 parts by mass or less, and even more preferably 37 parts by mass or less, per 100 parts by mass of the vinyl chloride resin.

[0028] The foamed resin layer may contain a plasticizer other than a phosphorus-based plasticizer. By containing a plasticizer other than a phosphorus-based plasticizer in the foamed resin layer, flexibility can be more reliably imparted to the foamed resin layer.

[0029] The non-phosphorus plasticizer is not particularly limited, and any non-phosphorus plasticizer known to those skilled in the art can be used. Examples of the non-phosphorus plasticizer include phthalic acid plasticizers such as dioctyl phthalate, dibutyl phthalate, di-2-ethylhexyl phthalate, diisooctyl phthalate, dioctyldecyl phthalate, diisodecyl phthalate, butyl benzyl phthalate, and di-2-ethylhexyl isophthalate, adipic acid plasticizers such as 2-ethylhexyl adipate and di-2-decyl adipate, sebacic acid plasticizers such as dibutyl sebacic acid and 2-ethylhexyl sebacic acid, trimellitic acid plasticizers such as tri-2-ethylhexyl trimellitate and trioctyl trimellitate, polyester plasticizers such as adipic acid polyester plasticizers and phthalic acid polyester plasticizers, and terephthalic acid plasticizers. These non-phosphorus plasticizers may be used alone or in combination of two or more.

[0030] The content of the non-phosphorus plasticizer is not particularly limited as long as it does not impair the effects of fire resistance, scratch resistance, flexibility and cushioning of the final wall material. For example, the non-phosphorus plasticizer may be contained in an amount of about 10 parts by mass to 30 parts by mass relative to 100 parts by mass of vinyl chloride resin.

[0031] The foamed resin layer contains a phosphorus-based flame retardant. In this specification, the term "phosphorus-based flame retardant" refers to any phosphorus-containing compound known to those skilled in the art that has flame retardancy. The phosphorus-based flame retardant can impart not only flame retardancy but also plasticity to the foamed resin layer.

[0032] The phosphorus-based flame retardant is not particularly limited, and examples thereof include various phosphorus-based compounds such as aromatic phosphate ester compounds, aromatic condensed phosphate ester compounds, phosphazene compounds, phosphaphenanthrene compounds, metal phosphinates, phosphonic acid polymers, ammonium polyphosphate, melamine polyphosphate, phosphate ester amides, phosphoric acid, and red phosphorus. Furthermore, as the phosphorus-based flame retardant, for example, a flame retardant obtained by combining the various phosphorus-based compounds described above with inorganic compounds such as boron-based compounds, aluminum-based compounds, magnesium-based compounds, calcium-based compounds, antimony-based compounds, and zinc-based compounds may be used. These phosphorus-based flame retardants may be used alone or in combination of two or more.

[0033] The phosphorus-based flame retardant is contained in an amount of 5 parts by mass or more per 100 parts by mass of polyvinyl chloride resin. When the content of the phosphorus-based flame retardant is 5 parts by mass or more, a wall material having excellent non-combustibility can be finally produced. The content of the phosphorus-based flame retardant is more preferably 6 parts by mass or more, and even more preferably 7 parts by mass or more per 100 parts by mass of polyvinyl chloride resin.

[0034] In addition, the phosphorus-based flame retardant is preferably contained in an amount of 15 parts by mass or less per 100 parts by mass of vinyl chloride resin. If the content of the phosphorus-based flame retardant is 15 parts by mass or less, the deterioration of the processability of the final wall material can be suppressed, and the manufacturing cost can also be reduced. The content of the phosphorus-based flame retardant is more preferably 13 parts by mass or less, and even more preferably 10 parts by mass or less per 100 parts by mass of vinyl chloride resin.

[0035] The foamed resin layer may contain a flame retardant other than phosphorus-based. The flame retardant other than phosphorus-based may be any flame-retardant compound known to those skilled in the art that does not contain phosphorus, but is not particularly limited thereto. Examples of the flame retardant other than phosphorus-based include aluminum hydroxide, magnesium hydroxide, antimony trioxide, nitrogen-based compounds, boron compounds, and silicone-based compounds. These flame retardants other than phosphorus-based may be used alone or in combination of two or more.

[0036] The content of the non-phosphorus-based flame retardant is not particularly limited as long as it does not impair the effects of non-combustibility, scratch resistance, flexibility, and cushioning of the final wall material. For example, the non-phosphorus-based flame retardant may be contained in an amount of about 1 part by mass to 20 parts by mass relative to 100 parts by mass of the vinyl chloride resin.

[0037] The foamed resin layer may contain a filler, which can reliably improve the impact resistance (shock absorption) of the foamed resin layer.

[0038] The type of filler is not particularly limited, and may be any material known to those skilled in the art. Examples of fillers include calcium carbonate, magnesium carbonate, calcium sulfate, calcium oxide, titanium oxide, aluminum hydroxide, clay, and silica. These fillers may be used alone or in combination of two or more.

[0039] The content of the filler is not particularly limited as long as it does not impair the effects of non-combustibility, scratch resistance, flexibility and cushioning of the wall material finally produced. For example, the filler is preferably contained in an amount of about 40 parts by mass to about 80 parts by mass, more preferably about 50 parts by mass to about 70 parts by mass, based on 100 parts by mass of the vinyl chloride resin.

[0040] The foamed resin layer may contain a masking agent, which can mask the color of the base material of the nonwoven fabric layer located below the foamed resin layer.

[0041] The type of the masking agent is not particularly limited, and may be any material known to those skilled in the art. Examples of the masking agent include titanium dioxide, titanium oxide, silicone-containing coating powder, talc, clay, etc. These masking agents may be used alone or in combination of two or more.

[0042] The content of the masking agent is not particularly limited as long as it does not impair the effects of non-combustibility, scratch resistance, flexibility and cushioning of the wall material finally produced. For example, the masking agent is preferably contained in an amount of about 5 parts by mass to about 25 parts by mass, more preferably about 10 parts by mass to about 15 parts by mass, based on 100 parts by mass of the vinyl chloride resin.

[0043] The foamed resin layer may contain a foaming agent. When the foamed resin layer contains a foaming agent, a large number of closed cells are formed in the foamed resin layer, and the impact resistance (shock absorption property) of the foamed resin layer can be improved.

[0044] The type of foaming agent is not particularly limited, and may be any material known to those skilled in the art. Examples of the masking agent include thermal decomposition type organic foaming agents such as azodicarbonamide, azobisisobutyronitrile, benzenesulfonylhydrazide, p-toluenesulfonylhydrazide, and dinitrosopentamethylenetetramine. These foaming agents may be used alone or in combination of two or more.

[0045] The content of the foaming agent is not particularly limited as long as it does not impair the effects of non-combustibility, scratch resistance, flexibility and cushioning of the wall material finally produced. For example, the foaming agent is preferably contained in an amount of about 0.2 to 1.0 parts by mass, more preferably about 0.3 to 0.7 parts by mass, per 100 parts by mass of vinyl chloride resin.

[0046] The foamed resin layer may contain a viscosity reducing agent. By containing a viscosity reducing agent in the foamed resin layer, the viscosity of the resin liquid of the foamed resin layer can be adjusted to a viscosity appropriate for forming the foamed resin layer.

[0047] The type of viscosity reducing agent is not particularly limited, and any material capable of adjusting viscosity known to those skilled in the art can be used. Examples of viscosity reducing agents include zinc carboxylate, phosphoric acid ester, paraffin, and fatty acid ester compounds. These viscosity reducing agents may be used alone or in combination of two or more.

[0048] The content of the viscosity reducing agent is not particularly limited as long as it does not impair the effects of the non-flammability, scratch resistance, flexibility and cushioning of the wall material finally produced. For example, the viscosity reducing agent is preferably contained in an amount of about 2.0 parts by mass to about 10.0 parts by mass, more preferably about 3.0 parts by mass to about 8.0 parts by mass, per 100 parts by mass of the vinyl chloride resin.

[0049] The thickness of the foamed resin layer is 0.15 mm or more and 0.30 mm or less. When the conditions of the content of the phosphorus-based flame retardant in the foamed resin layer described above, the content of the phosphorus-based flame retardant in the transparent resin layer described below, and the thickness of the transparent resin layer and the wall material described below are satisfied, and the thickness of the foamed resin layer is 0.15 mm or more, a wall material can be obtained that does not generate cracks or holes in the heat generation test and has good scratch resistance and cushioning properties. When the same conditions are satisfied and the thickness of the foamed resin layer is 0.30 mm or less, a wall material can be obtained that has a small total heat generation amount and a slow maximum heat generation rate in the heat generation test, and also has good flexibility.

[0050] The thickness of the foamed resin layer is preferably 0.17 mm or more, and more preferably 0.20 mm or more, and is preferably 0.28 mm or less, and more preferably 0.25 mm or less.

[0051] (Decorative layer) The decorative layer is a layer laminated on the foamed resin layer on the side opposite to the nonwoven fabric layer in order to impart a design such as a pattern, color, decoration, etc. to the wall material. The decorative layer can be formed on the surface of the foamed resin layer by any method known to those skilled in the art. For example, the decorative layer can be formed by printing a pattern such as a wood grain pattern on the surface of the foamed resin layer.

[0052] The thickness of the decorative layer is not particularly limited as long as it satisfies the conditions of the thickness of the foamed resin layer described above, the thickness of the transparent resin layer described below, and the thickness of the wall material, and does not impair the effects of non-combustibility, scratch resistance, flexibility, and cushioning of the wall material to be finally manufactured. For example, the thickness of the decorative layer is about 5 μm to 40 μm.

[0053] (Transparent resin layer) The transparent resin layer is laminated on the side of the decorative layer opposite to the foamed resin layer. The transparent resin layer imparts not only scratch resistance but also flame retardancy to the wall material. Specifically, the transparent resin layer can be formed from a mixture of the following components:

[0054] The transparent resin layer contains a vinyl chloride resin as a base resin, similar to the foamed resin layer described above. The type of vinyl chloride resin is the same as that of the foamed resin layer described above.

[0055] The transparent resin layer contains a phosphorus-based plasticizer, similar to the foamed resin layer described above. By containing a phosphorus-based plasticizer together with a phosphorus-based flame retardant described below, the excellent fireproof performance of the wall material can be more reliably maintained, and the flexibility of the wall material can also be improved. The types of phosphorus-based plasticizers that can be used are the same as those for the foamed resin layer described above.

[0056] In the transparent resin layer, the phosphorus-based plasticizer is preferably contained in an amount of 10 parts by mass or more and 30 parts by mass or less per 100 parts by mass of the vinyl chloride resin. When the content of the phosphorus-based plasticizer is 10 parts by mass or more, a wall material having excellent fireproof performance, flexibility and cushioning properties can be produced. When the content of the phosphorus-based plasticizer is 30 parts by mass or less, the deterioration of the processability of the wall material produced in the end can be suppressed, and the production cost can also be suppressed.

[0057] In the transparent resin layer, the content of the phosphorus-based plasticizer is more preferably 13 parts by mass or more, and even more preferably 15 parts by mass or more, per 100 parts by mass of the vinyl chloride resin, and more preferably 25 parts by mass or less, and even more preferably 20 parts by mass or less, per 100 parts by mass of the vinyl chloride resin.

[0058] The transparent resin layer may contain a plasticizer other than phosphorus-based. The transparent resin layer contains a plasticizer other than phosphorus-based, which can impart flexibility to the foamed resin layer. The types of usable plasticizer other than phosphorus-based are the same as those of the foamed resin layer described above. In addition, the content of the plasticizer other than phosphorus-based in the transparent resin layer is not particularly limited as long as it does not impair the effects of non-flammability, scratch resistance, flexibility and cushioning of the wall material finally produced, as in the foamed resin layer described above. For example, the plasticizer other than phosphorus-based may be contained in an amount of about 20 parts by mass to 40 parts by mass relative to 100 parts by mass of vinyl chloride resin.

[0059] The transparent resin layer also contains a phosphorus-based flame retardant, similar to the foamed resin layer described above. The types of phosphorus-based flame retardants that can be used and the content of the phosphorus-based flame retardant per 100 parts by mass of the vinyl chloride resin are the same as those of the foamed resin layer described above.

[0060] Similarly to the foamed resin layer described above, the transparent resin layer may also contain a flame retardant other than a phosphorus-based flame retardant, and the type and content thereof are the same as those of the foamed resin layer described above.

[0061] The foamed resin layer may contain a stabilizer. By containing a stabilizer in the foamed resin layer, the compatibility with the polyvinyl chloride resin can be improved, and the flexibility of the wall material finally produced can also be contributed.

[0062] The type of stabilizer is not particularly limited, and may be any material known to those skilled in the art. Examples of stabilizers include epoxidized vegetable oils such as epoxidized soybean oil, epoxidized linseed oil, epoxidized cottonseed oil, epoxidized peanut oil, epoxidized safflower oil, and epoxidized grape seed oil, Ba-Zn stabilizers, and Ca-Zn stabilizers. These stabilizers may be used alone or in combination of two or more.

[0063] The content of the stabilizer is not particularly limited as long as it does not impair the effects of the non-combustibility, scratch resistance, flexibility and cushioning of the wall material finally produced. For example, the stabilizer is preferably contained in an amount of about 1.0 to 6.0 parts by mass, more preferably about 3.0 to 4.5 parts by mass, per 100 parts by mass of vinyl chloride resin.

[0064] The thickness of the transparent resin layer is 0.10 mm or more and 0.20 mm or less. When the conditions of the content of the phosphorus-based flame retardant in the foamed resin layer and the transparent resin layer, the thickness of the transparent resin layer, and the thickness of the wall material described below are satisfied, and the thickness of the foamed resin layer is 0.10 mm or more, a wall material having excellent overall non-flammability, good scratch resistance, and cushioning properties can be obtained. When the same conditions are satisfied and the thickness of the transparent resin layer is 0.20 mm or less, a wall material having a small total heat generation amount and a slow maximum heat generation rate in the heat generation test, and good flexibility can be obtained.

[0065] The transparent resin layer has a thickness of preferably 0.12 mm or more, more preferably 0.15 mm or more, and preferably 0.18 mm or less, more preferably 0.16 mm or less.

[0066] 1-2. Configuration of the wall material in the modified example of this embodiment Fig. 2 shows a schematic cross-sectional view of a modified example of the wall material in this embodiment. As shown in Fig. 2, the wall material 1 in the modified example further has a surface protective layer 6 laminated on the side of the transparent resin layer 5 opposite to the side on which the decorative layer 4 is laminated. The surface protective layer will be described below.

[0067] (Surface protective layer) The surface protective layer is a layer whose main component is an ultraviolet-curing resin, and can further enhance the wear resistance, scratch resistance, etc. of the wall material.

[0068] The surface protective layer contains an ultraviolet curing resin as a main component. The ultraviolet curing resin is not particularly limited, and may be any resin known to those skilled in the art that is cured by ultraviolet irradiation and does not impair the effects of the wall material's non-flammability, scratch resistance, flexibility, and cushioning. Examples of ultraviolet curing resins include resins such as trifunctional urethane acrylate, bifunctional urethane acrylate, monofunctional urethane acrylate, acrylate, methacrylate, fluorine acrylate, and silicone acrylate. Of these, from the viewpoint of maintaining appropriate flexibility, it is preferable that the ultraviolet curing resin contains one or more of trifunctional urethane acrylate, bifunctional urethane acrylate, and monofunctional urethane acrylate. These ultraviolet curing resins may be used alone or in combination of two or more.

[0069] The surface protective layer may contain resin beads. When the surface protective layer contains resin beads, the abrasion resistance of the wall material can be improved. The resin beads are not particularly limited, and any resin beads known to those skilled in the art can be used. Examples of the resin beads include urethane beads, acrylic beads, vinyl chloride beads, polyethylene beads, polypropylene beads, etc. Among these, the resin beads are preferably urethane beads from the viewpoint of good compatibility with urethane acrylate, which is generally used as an ultraviolet curing resin.

[0070] The content of the resin beads is not particularly limited as long as it does not impair the effects of non-combustibility, scratch resistance, flexibility and cushioning of the wall material finally produced. For example, the resin beads may be contained in an amount of about 5 parts by mass to 15 parts by mass relative to 100 parts by mass of the total amount of the ultraviolet curing resin. In addition, the average particle size of the resin beads is not particularly limited, and may be about 3 μm to 9 μm.

[0071] The surface protective layer may contain inorganic beads (inorganic particles). When the surface protective layer contains inorganic beads (inorganic particles), matte properties can be imparted to the wall material surface. The inorganic beads (inorganic particles) are not particularly limited, and any inorganic beads (inorganic particles) known to those skilled in the art can be used. Examples of inorganic beads (inorganic particles) include silica particles, aluminum oxide particles, and titanium oxide particles. Of these, from the viewpoint of matte properties and transparency, it is preferable that the inorganic beads (inorganic particles) contain silica particles.

[0072] The inorganic beads (inorganic particles) are not particularly limited as long as they do not impair the effects of non-combustibility, scratch resistance, flexibility and cushioning of the wall material finally produced. For example, the inorganic beads (inorganic particles) may be contained in an amount of about 0.5 parts by mass or more and 2.0 parts by mass or less with respect to 100 parts by mass of the total amount of the ultraviolet curing resin. In addition, the average particle diameter of the inorganic beads (inorganic particles) is not particularly limited, and may be about 2 μm to 8 μm.

[0073] These resin beads and inorganic beads (inorganic particles) may be used alone or in combination of two or more kinds.

[0074] The surface protective layer may contain a polymerization initiator. The type of polymerization initiator is not particularly limited, and may be any polymerization initiator known to those skilled in the art. Examples of the polymerization initiator include 1-hydroxycyclohexyl phenyl ketone, benzophenone, benzoin ethyl ether, 2,2-dimethoxy-2-phenylacetophenone, acetophenone, xanthone, 3-methylacetophenone, 4-chlorobenzophenone, 4,4'-dimethoxybenzophenone, N,N,N',N'-tetramethyl-4,4'-diaminobenzophenone, benzoin propyl ether, benzyl dimethyl ketal, 1-(4-isopropylphenyl)-2-hydroxy-2-methylpropan-1-one, and the like. These polymerization initiators may be used alone or in combination of two or more.

[0075] The content of the polymerization initiator is not particularly limited as long as it can properly cure the ultraviolet curing resin contained therein and does not impair the effects of non-flammability, scratch resistance, flexibility and cushioning of the wall material finally produced. For example, the polymerization initiator is preferably contained in an amount of about 2.0 parts by mass or more and 8.0 parts by mass or less relative to 100 parts by mass of the total amount of the ultraviolet curing resin, and more preferably contained in an amount of about 3.0 parts by mass or more and 6.0 parts by mass or less.

[0076] The thickness of the surface protective layer is preferably 10 μm or more and 20 μm or less. When the conditions of the content of the phosphorus-based flame retardant in the foamed resin layer and the transparent resin layer, the thickness of the foamed resin layer and the transparent resin layer, and the thickness of the wall material described below are satisfied, and the thickness of the surface protective layer is 10 μm or more, a wall material having significantly excellent scratch resistance can be obtained. When the same conditions are satisfied and the thickness of the foamed resin layer is 20 μm or less, the deterioration of the non-flammable performance of the wall material due to the excessive thickness of the total wall thickness can be suppressed.

[0077] The thickness of the surface protective layer is more preferably 12 μm or more, and even more preferably 14 μm or more, and more preferably 18 μm or less, and even more preferably 15 μm or less.

[0078] 2. Physical properties of wall materials The thickness of the wall material in this embodiment is 0.45 mm or more and 0.70 mm or less. When the above-mentioned conditions of the content of phosphorus-based flame retardant in the foamed resin layer and the transparent resin layer, and the above-mentioned conditions of the thickness of the foamed resin layer and the transparent resin layer are satisfied, and the thickness of the wall material is 0.45 mm or more, a wall material can be obtained that does not have cracks or holes in the heat generation test and has good scratch resistance and cushioning properties. When the same conditions are satisfied and the thickness of the wall material is 0.70 mm or less, a wall material can be obtained that has a small total heat generation amount and a slow maximum heat generation rate in the heat generation test, and also has good flexibility.

[0079] The thickness of the wall material is preferably 0.50 mm or more, more preferably 0.55 mm or more, and is preferably 0.65 mm or less, more preferably 0.62 mm or less.

[0080] In the heat generation test according to ISO 5660-1:2002, the wall material in this embodiment has a total heat generation amount of 8 MJ / m for 20 minutes after the start of heating. 2 There are no cracks or holes penetrating to the back surface that are harmful to fire prevention for 20 minutes after heating starts, and the maximum heat generation rate is 200 kW / m or less for 10 seconds or more for 20 minutes after heating starts. 2 not exceed.

[0081] 3. Manufacturing method of wall materials The method for producing the wall material in this embodiment is not particularly limited, and the wall material can be produced by any method known to those skilled in the art. Hereinafter, an example of the method for producing the wall material will be described with reference to the drawings.

[0082] FIG. 3 is a schematic diagram for explaining an example of a manufacturing method of a wall material in this embodiment. The nonwoven fabric 10 is a long nonwoven fabric cut to a predetermined width, and is wound up in a roll before manufacturing. As shown in FIG. 3, first, the resin liquid 11a of the foamed resin layer supplied from the resin liquid supply roll 11c of the foamed resin layer is applied to one surface of the sent-out nonwoven fabric 10 by the resin liquid coating roll 11b of the foamed resin layer. The resin liquid 11a of the foamed resin layer is a material containing the raw material components of the foamed resin layer. Thereafter, the nonwoven fabric 10 to which the resin liquid 11a of the foamed resin layer has been applied is heated, pressed and dried using an oven or the like as necessary (not shown), and a foamed resin layer is formed on one surface of the nonwoven fabric 10 (foamed resin layer forming step A).

[0083] Thereafter, although not shown in FIG. 3, a decorative layer is printed (or laminated) on the surface of the formed foamed resin layer using transfer paper or the like.

[0084] Next, as shown in Fig. 3, the laminate in which the decorative layer is printed (or laminated) on the surface of the foamed resin layer is further sent out, and the transparent resin layer resin liquid 12a supplied from the transparent resin layer resin liquid supply roll 12c is applied onto the surface of the decorative layer by the transparent resin layer resin liquid coating roll 12b. The transparent resin layer resin liquid 12a is a material containing the raw material components of the transparent resin layer. After that, the laminate to which the transparent resin layer resin liquid 12a is applied is heated, pressed and dried using an oven or the like as necessary (not shown), and a transparent resin layer is formed on the surface of the decorative layer (transparent resin layer forming process B).

[0085] Next, as shown in FIG. 3, the laminate in which the transparent resin layer is laminated on the surface of the decorative layer is further sent out, and the resin liquid 13a of the surface protective layer supplied from the resin liquid supply roll 13c of the surface protective layer is applied onto the surface of the transparent resin layer by the resin liquid coating roll 13b of the surface protective layer. The resin liquid 13a of the surface protective layer is a material containing the raw material components of the surface protective layer. Thereafter, the surface of the laminate to which the resin liquid 13a of the surface protective layer has been applied is cured by ultraviolet irradiation (not shown), and a surface protective layer is formed on the surface of the transparent resin layer (surface protective layer forming step C). Finally, the formed laminate is wound up to obtain the wall material 1.

[0086] Although not shown, the thickness of the foamed resin layer, the thickness of the transparent resin layer, the thickness of the surface protective layer, and the total thickness of the wall material can be adjusted to a desired thickness by adjusting the application amount of the resin liquid 11a of the foamed resin layer, the resin liquid 12a of the transparent resin layer, and the resin liquid 13a of the surface protective layer using any device known to those skilled in the art, such as a doctor blade. Alternatively, the thickness of each layer can be adjusted by applying an appropriately adjusted pressure during the manufacturing process of the wall material.

[0087] In the example shown in FIG. 3, a method for manufacturing a wall material using a roll coater method has been described, but the wall material may also be manufactured by forming a layered structure using other methods such as dipping painting, bar coating, and spray coating.

[0088] As described above, the wall material in this embodiment is specified in terms of the types of plasticizer and flame retardant contained therein, and the thickness of each layer, the content of flame retardant, and other factors are also adjusted to appropriate values ​​at the same time. Therefore, the wall material in this embodiment has good scratch resistance, flexibility, and cushioning properties while satisfying the three conditions for excellent non-combustibility based on the Building Standards Act. EXAMPLES

[0089] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these examples in any way.

[0090] In this example, in a wall material in which a nonwoven fabric layer, a foamed resin layer, a decorative layer, and a transparent resin layer are laminated in this order, wall materials were actually manufactured in which the formulation of the transparent resin layer and the foamed resin layer, the thickness of the transparent resin layer and the foamed resin layer, and the total thickness of the wall material were changed. Next, a heat generation test was performed using a test piece of the manufactured wall material to confirm the non-flammable performance. In addition, a wall material in which a surface protective layer was further laminated on the transparent resin layer was also manufactured, and the non-flammable performance was similarly confirmed using the test piece. Finally, the scratch resistance, flexibility, and cushioning properties were evaluated using the test piece of each manufactured wall material. In this example, the thickness (total thickness) of the wall material was measured using a dial thickness gauge (manufactured by Ozaki Manufacturing Co., Ltd.), and the thickness of each layer such as the foamed resin layer and the transparent resin layer was measured using a digital microscope ("MS-300", manufactured by Asahi Optical Machinery Manufacturing Co., Ltd. (magnification: 200 times)).

[0091] First, the composition or structure of each layer is shown below.

[0092] (Transparent resin layer) As described above, in this Example, wall materials were manufactured in which the composition of the transparent resin layer was changed. Table 1 below shows the composition of each of the transparent resin layers 1 (C1) to 1 (C6). [Table 1]

[0093] (Decorative layer) As described later in the manufacturing method of the wall material, the decorative layer was formed using transfer paper.

[0094] (Foamed resin layer) As described above, in this Example, wall materials were manufactured in which the formulation of the foamed resin layer was changed. Table 2 below shows the formulations of the foamed resin layers 1 (F1) to 1 (F6). [Table 2]

[0095] (Non-woven layer) The nonwoven fabric layer is made of glass fiber nonwoven fabric (110 g / m 2 ) was used to form the

[0096] (Surface protective layer) Table 3 below shows the formulation of the surface protective layer. [Table 3]

[0097] Next, the manufacturing method of the wall material in each of the Examples and Comparative Examples, the heat generation test method, and the evaluation method for the scratch resistance, flexibility and cushioning property of the test pieces of the wall material will be described in detail.

[0098] [Wall material manufacturing method] First, in the formulations shown in Tables 1 to 3 above, the raw materials for the transparent resin layer ((C1) to (C6)), the foamed resin layer ((F1) to (F6)), and the surface protective layer were mixed to prepare materials (resin liquid (sol)) for forming each layer. The wall materials in Examples 1 to 9 and Comparative Examples 1 to 5 were manufactured by sequentially laminating a nonwoven fabric layer, a foamed resin layer, a decorative layer, a transparent resin layer, and an optional surface protective layer according to the manufacturing process by the roll coater method shown in FIG. 3 described above. Specifically, first, the prepared resin liquid (sol) for the foamed resin layer was applied to a nonwoven fabric made of glass fiber nonwoven fabric, and the applied resin liquid (sol) for the foamed resin layer was semi-gelled using an oven. Next, a decorative layer was formed on the semi-gelled foamed resin layer using transfer paper. Furthermore, the resin liquid (sol) for the transparent resin layer was applied on the decorative layer, and the foamed resin layer and the transparent resin layer were formed using an oven. In the wall materials of Examples 8 to 9, a resin liquid (sol) for the surface protective layer was applied onto the transparent resin layer, and cured by irradiation with ultraviolet light to form the surface protective layer.

[0099] As described above, in Examples 1 to 9 and Comparative Examples 1 to 5, the wall materials were manufactured by varying the types of blends of the transparent resin layers (C1) to (C6)) and the foamed resin layers (F1) to (F6) and varying the thicknesses of the transparent resin layers and the foamed resin layers as well as the total thickness of the wall material. The thickness of each layer was adjusted by the amount of resin liquid (sol) applied that formed each layer.

[0100] [Heat generation test method] The heat generation test was conducted in accordance with ISO 5660-1:2002. Specifically, a cone calorimeter was used, and a test piece of the wall material was attached to a dedicated jig, placed on a load cell, and heated from above the test piece by a cone-shaped electric heater at 50 kW / m 2 The wall material was subjected to radiant heating of 10 ... Total heat generation: The total heat generation for the first 20 minutes after heating starts is 8MJ / m 2 The following is the result. Cracks and holes: There are no cracks or holes that penetrate to the back surface and are harmful to fire protection for 20 minutes after heating begins. Maximum heat generation rate: 200kW / m for 20 minutes after heating starts, and the maximum heat generation rate continues for 10 seconds or more. 2 not exceed.

[0101] [Method for evaluating scratch resistance] The scratch resistance of the wall material was evaluated by the following method. First, the wall material in each Example and Comparative Example manufactured by the above-mentioned method was cut into 100 mm squares to prepare test pieces. Next, the test pieces of the wall material were attached to a gypsum board inclined at 60°. Then, an iron plate having a thickness of 1 mm and a weight of 180 g was vertically dropped naturally from a position of 450 mm height based on the collision point with the test piece so that the corner of the iron plate would collide with the attached test piece. The collision point of the test piece of the wall material was observed, and the scratch resistance was evaluated according to the following criteria. The evaluation results of the scratch resistance of the wall material in each Example and Comparative Example are summarized in Tables 4 and 5 below. ◎ (Very good): No change 〇 (Good): Dents are observed, but the wall material is not scraped off △(Poor): Wall material has been scraped off × (Very poor): Penetrated

[0102] [How to evaluate flexibility] First, the wall material in each example and each comparative example manufactured by the above-mentioned method was cut into a size of 50 mm length x 225 mm width to prepare a test piece. The flexibility of the wall material was evaluated by a method conforming to the flexibility test of JIS A 1454:2016. Specifically, when the test piece of the cut wall material was wrapped around a mandrel having a diameter of 40 mm, it was confirmed whether or not wrinkles were generated. The test piece was wrapped on both the front and back surfaces. The flexibility was evaluated according to the following criteria. The evaluation results of the flexibility in each example and each comparative example are summarized in Tables 4 and 5 below. 〇(Good): No change × (bad): wrinkles appear

[0103] [How to evaluate cushioning] First, the wall material in each example and each comparative example manufactured by the above-mentioned method was cut into a size of 50 mm square to prepare a test piece. The cushioning property of the wall material was evaluated by a method conforming to the residual dent test method B of JIS A 1454:2016. Specifically, the difference between the dent amount (mm) of the test piece immediately after applying a load of 222±1 N to the cut test piece of the wall material and the dent amount (mm) of the test piece after 1 hour was calculated. The cushioning property was evaluated according to the following criteria. The evaluation results of the cushioning property in each example and each comparative example are summarized in Tables 4 and 5 below. 〇(Good): 0.041mm or more × (defective): 0.041mm or less

[0104] Tables 4 and 5 below show the types of compositions and thickness values ​​of the wall materials of Examples 1 to 9 and Comparative Examples 1 to 5, as well as the heat generation test results and evaluation results.

[0105] [Table 4]

[0106] [Table 5]

[0107] <Consideration> As shown in Tables 4 and 5 above, the wall materials in Examples 1 to 9, which satisfy the conditions that the content of the phosphorus-based flame retardant in the transparent resin layer and the foamed resin layer is 5 parts by mass or more relative to 100 parts by mass of the vinyl chloride resin, the total thickness of the wall material is 0.45 mm to 0.70 mm, the thickness of the foamed resin layer is 0.15 mm to 0.30 mm, and the thickness of the transparent resin layer is 0.10 mm to 0.20 mm, all passed the three conditions of the heat generation test. Furthermore, the wall materials in Examples 1 to 9 were also evaluated as being good in terms of scratch resistance, flexibility, and cushioning. In particular, the wall materials in Examples 8 to 9, in which a surface protective layer was further laminated on the transparent resin layer, were remarkably excellent in scratch resistance.

[0108] The wall material in Comparative Example 1, in which the thickness of the transparent resin layer is more than 0.20 mm and the thickness of the foamed resin layer is less than 0.15 mm, failed the conditions of total heat generation amount and maximum heat generation rate of the heat generation test. This is thought to be because the wall material becomes flammable when the transparent resin layer, which is the outermost layer, is too thick. Furthermore, it is thought that the cushioning property was also inferior because the thickness of the foamed resin layer was small.

[0109] The wall material in Comparative Example 2, in which the thickness of the transparent resin layer is less than 0.10 mm, also failed the total heat generation amount and maximum heat generation rate conditions of the heat generation test. This is thought to be because when the transparent resin layer, which is the outermost layer, is too thin, the effect of the flame retardant contained in the transparent resin layer is insufficient, making the wall material more flammable. Furthermore, because the transparent resin layer, which is the outermost layer, is thin, it is thought that the scratch resistance was also slightly inferior.

[0110] The wall material in Comparative Example 3, in which the transparent resin layer was less than 0.10 mm thick, the foamed resin layer was less than 0.15 mm thick, and the total thickness of the wall material was less than 0.45 mm, failed the crack and hole conditions of the heat generation test. This is thought to be because when the transparent resin layer, the foamed resin layer, and the total thickness of the wall material are all thin, the resistance to heating for 20 minutes is insufficient. Furthermore, since both the transparent resin layer and the foamed resin layer, which are the outermost layers, are thin, it is thought that the scratch resistance and cushioning properties were also poor.

[0111] The wall material in Comparative Example 4, in which the transparent resin layer is thicker than 0.20 mm, the foamed resin layer is thicker than 0.30 mm, and the total thickness of the wall material is thicker than 0.70 mm, failed the total heat generation and maximum heat generation rate conditions of the heat generation test. This is thought to be because the wall material is more likely to catch fire when the transparent resin layer, the foamed resin layer, and the wall material are all thick. Furthermore, it is thought that the flexibility was poor because the transparent resin layer, the foamed resin layer, and the wall material are all thick.

[0112] The wall material in Comparative Example 5, in which the transparent resin layer 6 (C6) and the transparent resin layer 6 (F6) were formed with a type of compounding in which the content of the phosphorus-based flame retardant was less than 5 parts by mass relative to 100 parts by mass of the vinyl chloride resin, failed the conditions of the total heat generation amount and the maximum heat generation rate of the heat generation test. This is considered to be because the wall material becomes flammable when the amount of the phosphorus-based flame retardant contained in the transparent resin layer and the transparent resin layer is insufficient.

[0113] The embodiments and examples disclosed herein should be understood to be illustrative and not restrictive in all respects. The scope of the present invention is defined by the claims, not the above description, and is intended to include all modifications within the meaning and scope of the claims. [Explanation of symbols]

[0114] 1. Wall materials 2 non-woven layers 3. Foamed resin layer 4 Decorative layer 5 Transparent resin layer 6 Surface protective layer 10. Nonwoven Fabrics 11a Resin liquid of foamed resin layer 11b Resin liquid coating roll for foamed resin layer 11c Resin liquid supply roll for foamed resin layer 12a Transparent resin layer resin liquid 12b Transparent resin layer resin liquid coating roll 12c Transparent resin layer resin liquid supply roll 13a Resin liquid for surface protection layer 13b Resin liquid coating roll for surface protective layer 13c Resin liquid supply roll for surface protective layer

Claims

1. A wall material in which a nonwoven fabric layer, a foamed resin layer, a decorative layer, and a transparent resin layer are laminated in this order, The thickness of the wall material is 0.45 mm or more and 0.70 mm or less, the thickness of the foamed resin layer is 0.15 mm or more and 0.30 mm or less, and the thickness of the transparent resin layer is 0.10 mm or more and 0.20 mm or less, the foamed resin layer and the transparent resin layer contain a polyvinyl chloride resin, a phosphorus-based plasticizer, and a phosphorus-based flame retardant, In the foamed resin layer and the transparent resin layer, the phosphorus-based flame retardant is contained in an amount of 5 parts by mass or more relative to 100 parts by mass of the vinyl chloride resin, and In the heat generation test according to ISO 5660-1:2002, the total heat generation amount for 20 minutes after the start of heating was 8 MJ / m ２ There are no cracks or holes penetrating to the back surface that are harmful to fire prevention for 20 minutes after the start of heating, and the maximum heat generation rate is 200 kW / m or less for 10 seconds or more for 20 minutes after the start of heating. ２ Wall material that does not exceed.

2. 2. The wall material according to claim 1, wherein in the foamed resin layer, the phosphorus-based plasticizer is contained in an amount of 20 parts by mass or more and 40 parts by mass or less per 100 parts by mass of the vinyl chloride resin, and in the transparent resin layer, the phosphorus-based plasticizer is contained in an amount of 10 parts by mass or more and 30 parts by mass or less per 100 parts by mass of the vinyl chloride resin.

3. 3. The wall material according to claim 1, further comprising a surface protective layer, the surface protective layer being mainly composed of an ultraviolet curable resin and having a thickness of 10 μm to 20 μm, on the side of the transparent resin layer opposite to the side on which the decorative layer is laminated.

Images