Wall materials

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] This invention relates to a wall material having excellent fire-retardant properties. [Background technology]

[0002] Conventionally, interior materials such as wall materials with non-combustible properties have been known from the standpoint of preventing fires and ensuring safety in the event of a fire. Non-combustible properties refer to the property of being difficult to burn. One indicator of such non-combustible properties is, for example, the performance that satisfies the following conditions based on the Building Standards Act: In a heat generation test in accordance with ISO 5660-1:2002, the total heat generation during the 20 minutes after the start of heating was 8 MJ / m³. 2 The following conditions must be met: for 20 minutes after the start of heating, there must be no cracks or holes penetrating to the back surface which would be harmful from a fire safety perspective, and for 20 minutes after the start of heating, the maximum heating rate must remain at 200 kW / m² for at least 10 seconds. 2 The condition is that it does not exceed [a certain value].

[0003] Furthermore, it is desirable that interior materials such as wall coverings possess not only fire-retardant properties but also various other functions. Conventionally, as a technology to impart more functions to interior materials such as wall coverings, it has been proposed to make the interior materials into a laminated structure. For example, as a fire-retardant sheet having such a laminated structure, Patent Document 1 describes a sheet body layer formed to be more than 0.25 mm thick and less than 0.50 mm thick, and a design layer laminated on the surface of the sheet body layer, wherein the sheet body layer contains a resin component including chlorinated polyvinyl chloride, an inorganic filler, and a plasticizer, and is radiated from a radiant electric heater to the sheet surface at a rate of 50 kW / m² 2 In a heat generation test involving irradiation with radiant heat, the total heat generated during the first 20 minutes after heating was 7.2 MJ / m³. 2 A non-combustible wall sheet that is less than [amount missing] is described. According to the non-combustible wall sheet described in Patent Document 1, it is described that the total heat generation is low, it is not only difficult to damage, but it also has an aesthetic appeal. [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2022-65322 [Overview of the project] [Problems that the invention aims to solve]

[0005] However, simply increasing the number of layers of wall material to add more functionality will increase the total thickness of the wall material. As a result, the wall material may become more susceptible to fire, potentially reducing its fire resistance. On the other hand, reducing the thickness of each layer to decrease the total thickness of the wall material may affect its physical resistance. Alternatively, the amount of various compounds included to provide fire resistance may decrease, which may also affect the fire resistance of the wall material. Therefore, adding further functionality to wall material while maintaining fire resistance is difficult because it requires adjusting various factors simultaneously.

[0006] The non-combustible wall sheet described in Patent Document 1 only provides aesthetic appeal and scratch resistance in addition to its non-combustible properties. Therefore, it would be preferable to have a wall material that maintains excellent non-combustible properties while also possessing other functions in addition to aesthetic appeal and scratch resistance. For example, since wall materials are used as interior materials, it would be preferable to have a wall material that has good flexibility in addition to non-combustible properties so that it can be suitably adapted to wall surfaces of various shapes.

[0007] Therefore, the present invention aims to provide a wall material that has excellent non-combustible properties while also possessing good scratch resistance, flexibility, and cushioning properties. [Means for solving the problem]

[0008] The inventors of the present invention have conducted diligent studies to solve the above problems and have arrived at the present invention. That is, the present invention encompasses the following preferred embodiments.

[0009] The wall material according to this aspect of the present invention is 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 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 per 100 parts by mass of the vinyl chloride resin, and In a heat generation test compliant with ISO 5660-1:2002, the total heat generation during the first 20 minutes after heating was 8 MJ / m³. 2 The following conditions must be met: for 20 minutes after the start of heating, there must be no cracks or holes penetrating to the back surface which would be harmful from a fire safety perspective, and for 20 minutes after the start of heating, the maximum heating rate must remain at 200 kW / m² for at least 10 seconds. 2 It does not exceed that.

[0010] In the above-described wall material, it is preferable that the phosphorus-based plasticizer is contained in the foamed resin layer in an amount of 20 to 40 parts by mass per 100 parts by mass of the vinyl chloride resin, and that the phosphorus-based plasticizer is contained in the transparent resin layer in an amount of 10 to 30 parts by mass per 100 parts by mass of the vinyl chloride resin.

[0011] In the above-described wall material, it is more preferable that a surface protection layer, mainly composed of ultraviolet-curing resin and having a thickness of 10 μm to 20 μm, is further laminated on the side of the transparent resin layer opposite to the side on which the decorative layer is laminated. [Effects of the Invention]

[0012] According to the present invention, it is possible to provide a wall material that has excellent non-combustible properties while also possessing good scratch resistance, flexibility, and cushioning properties. [Brief explanation of the drawing]

[0013] [Figure 1] Figure 1 is a schematic cross-sectional view showing an example of a wall material in this embodiment. [Figure 2]FIG. 2 is a schematic cross-sectional view showing a modified example of the wall material in this embodiment. [Figure 3] FIG. 3 is a schematic diagram for explaining an example of a method for manufacturing the wall material in this embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] As a result of intensive studies by the present inventors, 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 within respective predetermined ranges, and by including both a phosphorus-based plasticizer and a phosphorus-based flame retardant in the foamed resin layer and the transparent resin layer, and by setting the content of the phosphorus-based flame retardant to a value of a predetermined amount or more, it has been found that a wall material having excellent non-combustion performance and good scratch resistance, flexibility, and cushioning properties can be obtained.

[0015] In this specification, the "wall material" mainly means a waist wall material used as an interior or exterior material for buildings such as ordinary houses, buildings, commercial facilities, stores, etc., but it may also be used as a sheet material for large furniture, floors, ceilings, etc. Further, 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 and the transparent resin layer is a value measured using a micrometer.

[0016] Hereinafter, embodiments 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 embodiments described here, and various modifications can be made without departing from the spirit of the present invention.

[0017] 1. Configuration of Wall Material 1-1. Configuration of Wall Material in this Embodiment FIG. 1 shows a schematic cross-sectional view of an example of the wall material in this embodiment. As shown in FIG. 1, the wall material 1 in this embodiment has a non-woven fabric layer 2, a foamed resin layer 3, a decorative layer 4, and a transparent resin layer 5 laminated in this order. Hereinafter, each layer will be described in detail.

[0018] (Non-woven Fabric Layer) The nonwoven fabric layer is placed in the wall material at the closest position to the object to be bonded, such as the building's wall surface, and is bonded to the object using adhesive, double-sided tape, etc.

[0019] The materials constituting the nonwoven fabric layer are not particularly limited, and any materials known to those skilled in the art can be used. For example, the nonwoven fabric layer may be composed of polyethylene terephthalate (PET) fibers, glass fibers, pulp, etc. For example, if the nonwoven fabric layer is composed of glass fibers, the basis weight is 100 g / m², although this is not particularly limited. 2 ~200g / m 2 A certain degree is acceptable.

[0020] The thickness of the nonwoven fabric layer is not particularly limited, as long as the conditions for the thickness of the foamed resin layer, transparent resin layer, and wall material described later are met, and the effects of non-flammability, scratch resistance, flexibility, and cushioning of the final manufactured wall material are not impaired. For example, the thickness of the nonwoven fabric layer is preferably 0.10 mm or more and 0.40 mm or less, and more preferably 0.15 mm or more and 0.30 mm or less.

[0021] (Foam resin layer) The foamed resin layer is laminated on the side opposite to the surface to which the nonwoven fabric layer is bonded, such as a wall. Furthermore, the foamed resin layer imparts not only impact resistance (shock absorption) but also non-combustibility 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 polyvinyl chloride resin as the base resin.

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

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

[0025] Phosphorus-based plasticizers are not particularly limited, but examples include cresyl diphenyl phosphate, tris(isopropylphenyl) phosphate, tricresyl phosphate, triphenyl phosphate, trixylenyl phosphate, 2-ethylhexyl diphenyl phosphate, 2-naphthyl diphenyl phosphate, cresyl di2,6-xylenyl phosphate, tributyl phosphate, triethyl phosphate, and the like. These phosphorus-based plasticizers may be used individually or in combination of two or more.

[0026] In the foamed resin layer, it is preferable that the phosphorus-based plasticizer is contained in an amount of 20 to 40 parts by mass per 100 parts by mass of vinyl chloride resin. When the phosphorus-based plasticizer content is 20 parts by mass or more, it is possible to produce a wall material that ultimately has excellent non-combustible properties, flexibility, and cushioning properties. When the phosphorus-based plasticizer content is 40 parts by mass or less, it is possible to suppress the deterioration of the processability of the final produced wall material and also reduce manufacturing costs.

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

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

[0029] While there are no particular limitations on non-phosphorus plasticizers, any non-phosphorus plasticizer known to those skilled in the art can be used. Examples of non-phosphorus plasticizers include phthalate-based plasticizers such as dioctyl phthalate, dibutyl phthalate, di-2-ethylhexyl phthalate, diisooctyl phthalate, dioctyldecyl phthalate, diisodecyl phthalate, butylbenzyl phthalate, and di-2-ethylhexyl isophthalate; adipic acid-based plasticizers such as 2-ethylhexyl adipic acid and di-2-decyl adipic acid; sebatic acid-based plasticizers such as dibutyl sebatate and 2-ethylhexyl sebatate; trimellitic acid-based plasticizers such as tri-2-ethylhexyl trimellitic acid and trioctyl trimellitic acid; polyester-based plasticizers such as adipic acid-based polyester plasticizers and phthalate-based polyester plasticizers; and terephthalic acid-based plasticizers. These non-phosphorus plasticizers may be used individually or in combination of two or more.

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

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

[0032] Phosphorus-based flame retardants are not particularly limited, but examples include various phosphorus compounds such as aromatic phosphate ester compounds, aromatic condensed phosphate ester compounds, phosphazene compounds, phosphaphenanthrene compounds, phosphinate metal salts, phosphonic acid polymers, ammonium polyphosphate, melamine polyphosphate, phosphate ester amides, phosphoric acid, and red phosphorus. Furthermore, as phosphorus-based flame retardants, for example, flame retardants may be used that combine the aforementioned phosphorus compounds with inorganic compounds such as boron compounds, aluminum compounds, magnesium compounds, calcium compounds, antimony compounds, and zinc compounds. These phosphorus-based flame retardants may be used individually 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 vinyl chloride resin. When the phosphorus-based flame retardant content is 5 parts by mass or more, a wall material with excellent fire resistance can be produced. It is more preferable that the phosphorus-based flame retardant content be 6 parts by mass or more, and even more preferable that be 7 parts by mass or more, per 100 parts by mass of vinyl chloride resin.

[0034] Furthermore, it is preferable that the phosphorus-based flame retardant is contained in an amount of 15 parts by mass or less per 100 parts by mass of vinyl chloride resin. When the phosphorus-based flame retardant content is 15 parts by mass or less, the reduction in the processability of the final manufactured wall material can be suppressed and manufacturing costs can also be reduced. It is more preferable that the phosphorus-based flame retardant content be 13 parts by mass or less, and even more preferable that be 10 parts by mass or less, per 100 parts by mass of vinyl chloride resin.

[0035] The foamed resin layer may contain flame retardants other than phosphorus-based ones. While not particularly limited, any phosphorus-free compound known to those skilled in the art and possessing flame retardant properties can be used. Examples of non-phosphorus flame retardants include aluminum hydroxide, magnesium hydroxide, antimony trioxide, nitrogen compounds, boron compounds, and silicone compounds. These non-phosphorus flame retardants may be used individually or in combination of two or more.

[0036] The amount of non-phosphorus flame retardants is not particularly limited, as long as it does not impair the non-flammability, scratch resistance, flexibility, and cushioning effects of the final manufactured wall material. For example, the non-phosphorus flame retardant may be present in an amount of 1 to 20 parts by mass per 100 parts by mass of polyvinyl chloride resin.

[0037] The foamed resin layer may contain fillers. The inclusion of fillers in the foamed resin layer can reliably improve its impact resistance (shock absorption).

[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, silica, etc. These fillers may be used individually or in combination of two or more types.

[0039] The amount of filler is not particularly limited, as long as it does not impair the non-flammability, scratch resistance, flexibility, and cushioning effects of the final wall material. For example, the amount of filler is preferably 40 parts by mass or more and 80 parts by mass or less, and more preferably 50 parts by mass or more and 70 parts by mass or less, per 100 parts by mass of polyvinyl chloride resin.

[0040] The foamed resin layer may contain an opacifier. The presence of an opacifier in the foamed resin layer allows for the concealment of the base color of the nonwoven fabric layer located beneath it.

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

[0042] The amount of the opacifier is not particularly limited, as long as it does not impair the non-combustibility, scratch resistance, flexibility, and cushioning effects of the final manufactured wall material. For example, the opacifier is preferably present in an amount of 5 to 25 parts by mass, and more preferably 10 to 15 parts by mass, per 100 parts by mass of vinyl chloride resin.

[0043] The foamed resin layer may contain a foaming agent. By including a foaming agent in the foamed resin layer, a large number of independent cells can be formed within the foamed resin layer, thereby improving the impact resistance (shock absorption) of the foamed resin layer.

[0044] The type of blowing agent is not particularly limited and may be any material known to those skilled in the art. Examples of opacifying agents include pyrolysis-type organic blowing agents such as azodicarbonamide, azobisisobutyronitrile, benzenesulfonyl hydrazide, p-toluenesulfonyl hydrazide, and dinitrosopentamethylenetetramine. These blowing agents may be used individually or in combination of two or more.

[0045] The amount of foaming agent is not particularly limited, as long as it does not impair the non-flammability, scratch resistance, flexibility, and cushioning effects of the final wall material. For example, it is preferable that the foaming agent is present in an amount of approximately 0.2 parts by mass to 1.0 part by mass per 100 parts by mass of polyvinyl chloride resin, and more preferably 0.3 parts by mass to 0.7 parts by mass.

[0046] The foamed resin layer may contain a viscosity reducer. By including a viscosity reducer in the foamed resin layer, the viscosity of the resin liquid in the foamed resin layer can be adjusted to a viscosity appropriate for the formation of the foamed resin layer.

[0047] The type of viscosity reducer is not particularly limited, and any viscosity-adjustable material known to those skilled in the art can be used. Examples of viscosity reducers include zinc carboxylates, phosphate esters, paraffins, and fatty acid ester compounds. These viscosity reducers may be used individually or in combination of two or more.

[0048] The amount of the viscosity reducer is not particularly limited, as long as it does not impair the non-flammability, scratch resistance, flexibility, and cushioning effects of the final wall material. For example, the viscosity reducer is preferably present in an amount of 2.0 parts by mass or more and 10.0 parts by mass or less per 100 parts by mass of polyvinyl chloride resin, and more preferably in an amount of 3.0 parts by mass or more and 8.0 parts by mass or less.

[0049] The thickness of the foamed resin layer is 0.15 mm or more and 0.30 mm or less. When the above-mentioned phosphorus-based flame retardant content in the foamed resin layer, the phosphorus-based flame retardant content in the transparent resin layer described later, and the thickness of the transparent resin layer and wall material described later are met, and the thickness of the foamed resin layer is 0.15 mm or more, a wall material can be obtained that does not develop cracks or holes in the heat generation test and has good scratch resistance and cushioning properties. When the same conditions are met, and the thickness of the foamed resin layer is 0.30 mm or less, a wall material can be obtained that has a low total heat generation and a slow maximum heat generation rate in the heat generation test, and in addition, 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. Furthermore, the thickness of the foamed resin layer is preferably 0.28 mm or less, and more preferably 0.25 mm or less.

[0051] (Decorative layer) The decorative layer is laminated on the side of the foamed resin layer opposite to the nonwoven fabric layer, and is a layer laminated to impart designs such as patterns, colors, and decorations 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 wood grain pattern or the like on the surface of the foamed resin layer.

[0052] The thickness of the decorative layer is not particularly limited, as long as the conditions for the thickness of the foamed resin layer, the thickness of the transparent resin layer described later, and the thickness of the wall material are met, and the effects of non-combustibility, scratch resistance, flexibility, and cushioning of the final manufactured wall material are not impaired. For example, the thickness of the decorative layer is approximately 5 μm to 40 μm.

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

[0054] The transparent resin layer, like the foamed resin layer described above, contains polyvinyl chloride resin as its base resin. The type of polyvinyl chloride resin is the same as that used for the foamed resin layer described above.

[0055] The transparent resin layer, like the foamed resin layer described above, contains a phosphorus-based plasticizer. By including a phosphorus-based plasticizer in the transparent resin layer along with the phosphorus-based flame retardant described later, the excellent fire-retardant properties 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, it is preferable that the phosphorus-based plasticizer is contained in an amount of 10 to 30 parts by mass per 100 parts by mass of vinyl chloride resin. When the phosphorus-based plasticizer content is 10 parts by mass or more, it is possible to manufacture a wall material that ultimately has excellent non-combustible properties, flexibility, and cushioning properties. When the phosphorus-based plasticizer content is 30 parts by mass or less, it is possible to suppress the deterioration of the processability of the final manufactured wall material and also reduce manufacturing costs.

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

[0058] The transparent resin layer may contain plasticizers other than phosphorus-based ones. The inclusion of non-phosphorus-based plasticizers in the transparent resin layer can impart flexibility to the foamed resin layer. The types of non-phosphorus-based plasticizers that can be used are the same as those for the foamed resin layer described above. Furthermore, the content of non-phosphorus-based plasticizers in the transparent resin layer is not particularly limited, as long as it does not impair the non-flammability, scratch resistance, flexibility, and cushioning effects of the final manufactured wall material, similar to the foamed resin layer described above. For example, the non-phosphorus-based plasticizer may be present in an amount of approximately 20 to 40 parts by mass per 100 parts by mass of polyvinyl chloride resin.

[0059] The transparent resin layer, like the foamed resin layer described above, also contains a phosphorus-based flame retardant. 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 polyvinyl chloride resin, are the same as those for the foamed resin layer described above.

[0060] Furthermore, the transparent resin layer may also contain flame retardants other than phosphorus-based ones, similar to the foamed resin layer described above, and the type and amount thereof are the same as those for the foamed resin layer described above.

[0061] transparent The resin layer may contain stabilizers. transparent By including a stabilizer in the resin layer, compatibility with the polyvinyl chloride resin can be improved, which can also contribute to the flexibility of the final manufactured wall material.

[0062] The type of stabilizer is not particularly limited and any material known to those skilled in the art may be used. 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, as well as Ba-Zn stabilizers and Ca-Zn stabilizers. These stabilizers may be used individually or in combination of two or more.

[0063] The amount of stabilizer is not particularly limited, as long as it does not impair the non-flammability, scratch resistance, flexibility, and cushioning effects of the final manufactured wall material. For example, the amount of stabilizer is preferably 1.0 part by mass or more and 6.0 parts by mass or less per 100 parts by mass of polyvinyl chloride resin, and more preferably 3.0 parts by mass or more and 4.5 parts by mass or less.

[0064] The thickness of the transparent resin layer is 0.10 mm or more and 0.20 mm or less. When the above-mentioned conditions regarding the phosphorus-based flame retardant content of the foamed resin layer and the transparent resin layer, the thickness of the transparent resin layer, and the thickness of the wall material described later are met, and the thickness of the foamed resin layer is 0.10 mm or more, a wall material can be obtained that has overall excellent non-combustible properties, as well as good scratch resistance and cushioning properties. When the same conditions are met, and the thickness of the transparent resin layer is 0.20 mm or less, a wall material can be obtained that has a low total heat output and a slow maximum heat output rate in the heat generation test, as well as good flexibility.

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

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

[0067] (Surface protective layer) The surface protection layer is a layer mainly composed of ultraviolet-curing resin, which can further enhance the abrasion resistance, scratch resistance, and other properties of the wall material.

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

[0069] The surface protective layer may contain resin beads. Including resin beads in the surface protective layer can improve the abrasion resistance of the wall material. The resin beads are not particularly limited, but any resin beads known to those skilled in the art can be used. Examples of resin beads include urethane beads, acrylic beads, polyvinyl chloride beads, polyethylene beads, and polypropylene beads. Of these, urethane beads are preferred because they have good compatibility with urethane acrylate, which is commonly used as an ultraviolet curing resin.

[0070] The resin bead content is not particularly limited, as long as it does not impair the non-flammability, scratch resistance, flexibility, and cushioning effects of the final manufactured wall material. For example, the resin beads may be present in an amount of 5 to 15 parts by mass per 100 parts by mass of the total amount of UV-curing resin. The average particle size of the resin beads is also not particularly limited, and can be approximately 3 μm to 9 μm.

[0071] The surface protective layer may contain inorganic beads (inorganic particles). By including inorganic beads (inorganic particles) in the surface protective layer, a matte finish can be imparted to the wall material surface. The inorganic beads (inorganic particles) are not particularly limited, but 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, titanium oxide particles, etc. Of these, from the viewpoint of exhibiting a matte finish and transparency, it is preferable that the inorganic beads (inorganic particles) include silica particles.

[0072] The inorganic beads (inorganic particles) are not particularly limited, as long as they do not impair the non-flammability, scratch resistance, flexibility, and cushioning effects of the final manufactured wall material. For example, the inorganic beads (inorganic particles) may be present in an amount of 0.5 parts by mass to 2.0 parts by mass per 100 parts by mass of the total amount of UV-curing resin. The average particle size of the inorganic beads (inorganic particles) is also not particularly limited, and can be approximately 2 μm to 8 μm.

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

[0074] The surface protective layer may contain a polymerization initiator. The type of polymerization initiator is not particularly limited and any polymerization initiator known to those skilled in the art may be used. Examples of polymerization initiators include 1-hydroxycyclohexylphenyl ketone, benzophenone, benzoin ethyl ether, 2,2-dimethoxy-2-phenylacetophenone, acetophenone, xanthone, 3-methylacetophenone, 4-chlorobenzophenone, 4,4'-dimethoxybezophenone, N,N,N',N'-tetramethyl-4,4'-diaminobenzophenone, benzoin propyl ether, benzyldimethyl ketal, and 1-(4-isopropylphenyl)-2-hydroxy-2-methylpropan-1-one. These polymerization initiators may be used individually 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 contained UV-curable resin and does not impair the non-flammability, scratch resistance, flexibility, and cushioning effects of the final wall material. For example, it is preferable that the polymerization initiator is contained in an amount of 2.0 parts by mass or more and 8.0 parts by mass or less, and more preferably 3.0 parts by mass or more and 6.0 parts by mass or less, per 100 parts by mass of the total amount of UV-curable resin.

[0076] The thickness of the surface protective layer is preferably 10 μm or more and 20 μm or less. When the conditions for the phosphorus-based flame retardant content of the foamed resin layer and transparent resin layer, the thickness of the foamed resin layer and transparent resin layer, and the thickness of the wall material described later are met, and the thickness of the surface protective layer is 10 μm or more, a wall material with remarkably excellent scratch resistance can be obtained. When the same conditions are met, and the thickness of the foamed resin layer is 20 μm or less, the decrease in the non-combustible performance of the wall material due to an excessively thick total wall material 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. Furthermore, the thickness of the surface protective layer is more preferably 18 μm or less, and even more preferably 15 μm or less.

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

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

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

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

[0082] FIG. 3 shows a schematic diagram for explaining an example of the manufacturing method of the wall material in this embodiment. The non-woven fabric 10 is a long non-woven fabric cut to a predetermined width and is wound in a roll shape 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 fed non-woven fabric 10 by the resin liquid coating roll 11b of the foamed resin layer. Note that the resin liquid 11a of the foamed resin layer is a material in which the raw material components of the foamed resin layer are blended. Thereafter, the non-woven fabric 10 coated with the resin liquid 11a of the foamed resin layer is heated, pressurized, and dried (not shown) using an oven or the like as necessary, and a foamed resin layer is formed on one surface of the non-woven fabric 10 (forming step A of the foamed resin layer).

[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 Figure 3, the laminate with the decorative layer printed (or laminated) on the surface of the foamed resin layer is further fed out, and the resin liquid 12a of the transparent resin layer, supplied from the resin liquid supply roll 12c of the transparent resin layer, is applied to the surface of the decorative layer by the resin liquid coating roll 12b of the transparent resin layer. The resin liquid 12a of the transparent resin layer is a material blended with the raw material components of the transparent resin layer. After that, the laminate to which the resin liquid 12a of the transparent resin layer has been applied is heated, pressurized and dried using an oven or the like as needed (not shown), and a transparent resin layer is formed on the surface of the decorative layer (transparent resin layer formation step B).

[0085] Next, as shown in Figure 3, the laminate in which a transparent resin layer is laminated on the surface of the decorative layer is further fed 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 to 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 blended with the raw material components of the surface protective layer. After that, 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 formation step C). Finally, the wall material 1 can be obtained by winding up the formed laminate.

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

[0087] The example shown in Figure 3 describes a method for manufacturing wall materials using a roll coater. However, wall materials may also be manufactured by applying other methods such as dipping paint, bar coating, or spray coating to form a laminated structure.

[0088] As described above, the wall material in this embodiment has predetermined types of plasticizers and flame retardants, and in addition, elements such as the thickness of each layer and the content of flame retardants are also adjusted to appropriate values. Therefore, the wall material in this embodiment satisfies the three conditions for excellent non-combustible performance based on the Building Standards Act, while also possessing good scratch resistance, flexibility, and cushioning properties. [Examples]

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

[0090] In this embodiment, wall materials were manufactured in which a nonwoven fabric layer, a foamed resin layer, a decorative layer, and a transparent resin layer are laminated in that order. The composition 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 all varied. Next, a heat generation test was performed using test pieces of the manufactured wall material to confirm its non-combustibility. In addition, wall materials in which a surface protection layer was further laminated on top of the transparent resin layer were also manufactured, and the non-combustibility was similarly confirmed using test pieces. Finally, the scratch resistance, flexibility, and cushioning properties were evaluated using test pieces of each manufactured wall material. In this embodiment, the thickness (total thickness) of the wall material was measured using a dial thickness gauge (manufactured by Ozaki Seisakusho 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 Co., Ltd. (magnification: 200x))).

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

[0092] (Transparent resin layer) As mentioned above, in this embodiment, wall materials were manufactured with different formulations for the transparent resin layer. Table 1 below shows the formulations for transparent resin layer 1(C1) to transparent resin layer 1(C6). [Table 1]

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

[0094] (Foam resin layer) As mentioned above, in this embodiment, wall materials were manufactured with different formulations for the foamed resin layer. Table 2 below shows the formulations for foamed resin layer 1(F1) to foamed resin layer 1(F6). [Table 2]

[0095] (Non-woven layer) The nonwoven fabric layer is made of glass fiber nonwoven fabric (110g / m²). 2 It was formed using ).

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

[0097] Next, we will summarize the details of the manufacturing method of the wall material in each example and comparative example, the heat generation test method, and the evaluation method for the scratch resistance, flexibility, and cushioning properties of the test specimens of the wall material.

[0098] [Wall material manufacturing method] First, the raw materials for the transparent resin layer ((C1) to (C6)), the foamed resin layer ((F1) to (F6)), and the surface protection layer were mixed according to the formulations shown in Tables 1 to 3 above to prepare the materials (resin liquid (sol)) that form 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 protection layer according to the manufacturing process of the roll coater method shown in Figure 3 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 and 9, a surface protective layer was formed by applying a resin liquid (sol) for the surface protective layer onto the transparent resin layer and curing it with ultraviolet irradiation.

[0099] During manufacturing, as described above, in Examples 1 to 9 and Comparative Examples 1 to 5, the types of formulations for the transparent resin layer ((C1) to (C6)) and the foamed resin layer ((F1) to (F6)) were changed, and the thicknesses of the transparent resin layer and the foamed resin layer, as well as the total thickness of the wall material, were varied to produce the wall material. The thickness of each layer was adjusted by the amount of resin liquid (sol) applied to form each layer.

[0100] [Method for testing pyrogenicity] The heat generation test was conducted in accordance with ISO 5660-1:2002. Specifically, a cone calorimeter was used to mount a test specimen of the wall material in a dedicated jig, place it on a load cell, and apply a 50 kW / m² electric cone heater from above the specimen. 2 Radiant heating was applied, and ignition was performed using a spark igniter. In the heat generation test, each test piece of wall material was judged to pass or fail under the following three conditions. The results of the heat generation test for each example and comparative example of wall material are summarized in Tables 4 and 5 below. • Total heat output: The total heat output for the first 20 minutes after heating starts is 8 MJ / m³. 2 The following applies: • Cracks and holes: No cracks or holes penetrating to the back surface that would be harmful from a fire safety perspective were observed for the first 20 minutes after heating began. • Maximum heating rate: For the first 20 minutes after heating begins, the maximum heating rate remains at 200 kW / m² for at least 10 seconds. 2 It does not exceed that.

[0101] [Method for evaluating scratch resistance] The scratch resistance of the wall material was evaluated by the following method. First, the wall material from each example and comparative example, manufactured using the method described above, was cut into 100 mm squares to form test specimens. Next, the test specimens of the wall material were attached to a gypsum board tilted at 60°. Then, a 1 mm thick, 180 g iron plate was dropped vertically from a height of 450 mm relative to the point of impact with the attached test specimen, so that the corner of the iron plate struck the attached test specimen. The impact point on the wall material test specimen 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. ◎ (Excellent): No change ○ (Good): A dent is observed, but the wall material has not been scraped. △ (Defective): Wall material has been scraped off. × (Extremely poor): Penetrating

[0102] [Methods for evaluating flexibility] First, the wall materials for each example and comparative example, manufactured using the method described above, were cut to a size of 50 mm (vertical) x 225 mm (horizontal) to serve as test specimens. The flexibility of the wall materials was evaluated using a method compliant with the flexibility test of JIS A 1454:2016. Specifically, the test specimens of the cut wall materials were wrapped around a 40 mm diameter mandrel, and it was checked whether or not wrinkles formed. The test specimens were wrapped around both the front and back surfaces. Flexibility was evaluated according to the following criteria. The evaluation results for the flexibility of each example and comparative example are summarized in Tables 4 and 5 below. ○ (Good): No change × (Defective): Wrinkles appear

[0103] [Method for evaluating cushioning] First, the wall materials used in each example and comparative example, manufactured using the method described above, were cut into 50 mm squares to serve as test specimens. The cushioning properties of the wall materials were evaluated using a method compliant with the residual indentation test method B of JIS A 1454:2016. Specifically, the difference between the indentation amount (mm) of the test specimen immediately after applying a load of 222 ± 1 N and the indentation amount (mm) of the test specimen after 1 hour was calculated. The cushioning properties were evaluated according to the following criteria. The evaluation results for the cushioning properties in each example and 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 summarize the composition types and thickness values ​​for the wall materials in Examples 1-9 and Comparative Examples 1-5, as well as the results of the heat generation tests and evaluations.

[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 met the conditions that the phosphorus-based flame retardant content in the transparent resin layer and foamed resin layer was 5 parts by mass or more per 100 parts by mass of vinyl chloride resin, the total thickness of the wall material was 0.45 mm to 0.70 mm, the thickness of the foamed resin layer was 0.15 mm to 0.30 mm, and the thickness of the transparent resin layer was 0.10 mm to 0.20 mm, passed all three conditions of the heat generation test. Furthermore, the wall materials in Examples 1 to 9 also received good evaluations for scratch resistance, flexibility, and cushioning. In particular, the wall materials in Examples 8 to 9, in which a surface protection layer was further laminated on top of the transparent resin layer, showed remarkably excellent scratch resistance.

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

[0109] The wall material in Comparative Example 2, which had a transparent resin layer thickness of less than 0.10 mm, also failed the total heat output and maximum heat output rate conditions in the heat generation test. This is thought to be because when the outermost transparent resin 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, it is thought that the thinness of the outermost transparent resin layer resulted in slightly inferior scratch resistance.

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

[0111] In Comparative Example 4, the wall material, which had a transparent resin layer thickness exceeding 0.20 mm, a foamed resin layer thickness exceeding 0.30 mm, and a total wall material thickness exceeding 0.70 mm, failed the heat generation test in terms of total heat generation and maximum heat generation rate. This is thought to be because when the transparent resin layer, foamed resin layer, and total wall material thickness are all thick, the wall material becomes more susceptible to fire spread. Furthermore, it is thought that the thickness of all three layers resulted in poor flexibility.

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

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

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

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 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 present in an amount of 5 parts by mass or more per 100 parts by mass of the vinyl chloride resin. In the foamed resin layer, the phosphorus-based plasticizer is contained in an amount of 20 to 40 parts by mass per 100 parts by mass of the vinyl chloride resin. 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, and In a heat generation test compliant with ISO 5660-1:2002, the total heat generation during the first 20 minutes after heating was 8 MJ / m³. ２ The following conditions must be met: for 20 minutes after the start of heating, there must be no cracks or holes penetrating to the back surface which would be harmful from a fire safety perspective, and for 20 minutes after the start of heating, the maximum heating rate must remain at 200 kW / m² for at least 10 seconds. ２ Wall material that does not exceed [a certain limit].

2. The wall material according to claim 1, wherein a surface protection layer, mainly composed of ultraviolet-curing resin 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.

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