JPH1053966A - Production of flame retardant wallpaper - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method by which sheets of flame retardant wallpaper comprising a polyolefin-based resin can be mass-produced according to a calendering processing method. SOLUTION: A filler and flame retardant comprising aluminum hydroxide or magnesium hydroxide or a mixture thereof is added to a thermoplastic polyolefin-based resin and the resultant mixture is then kneaded in a mixer 2. The prepared kneaded mixture is then passed through spacings between heated plural rolls 3 and 4 to carry out the calendering processing. Thereby, a resin sheet 10 having 0.1-0.3mm thickness is formed and a backing material 11 such as a sheet of flame retardant paper or a nonwoven fabric is then applied to the resultant resin sheet 10.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing flame-retardant wallpaper by a calendering method using a polyolefin resin.

[0002]

2. Description of the Related Art There are two types of wallpaper for interior use, one mainly composed of paper and the other mainly composed of synthetic resin. Synthetic resin is superior in terms of strength and design. Conventionally, most of the wallpaper mainly made of synthetic resin uses vinyl chloride (PVC). But,
Wallpapers mainly composed of vinyl chloride have the problem that a large amount of harmful gas is generated from halogen-based substances contained in the components when burning by fire or incineration accompanying replacement. The improvement has been desired in view of the above and protection of the natural environment.

[0003] On the other hand, calendering is suitable for mass production of resin sheets by passing vinyl chloride through a gap between a plurality of heated rolls, as is well known. With a wide range of uses, many calendering machines are in operation. However, in the past, calendering has been used exclusively for molding vinyl chloride or rubber, and other synthetic resin materials, such as polyolefin resins, are easily decomposed by contact with metal rolls and the viscosity is unstable, so the moldability is low. Was markedly degraded, so that calendering was ineligible.
For this reason, polyolefin resins have the advantage of not emitting harmful gases like vinyl chloride during combustion, but wallpaper made of these resins has not been mass-produced by conventional calendering.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above, and an object of the present invention is to establish a method for mass-producing a flame-retardant wallpaper made of a polyolefin resin by a calendering method.

[0005]

In order to achieve the object, a method for producing a flame-retardant wallpaper according to the present invention comprises adding a filler / flame retardant comprising aluminum hydroxide, magnesium hydroxide or a mixture thereof to a thermoplastic polyolefin resin. Kneading with a mixer, and passing it through a gap between a plurality of heated rolls to perform calendering, thereby obtaining a thickness of 0.1 to
A resin sheet having a thickness of 0.3 mm is formed, and a backing material such as flame-retardant paper or nonwoven fabric is adhered to the resin sheet. Further, the present invention is characterized in that in the method for producing a flame-retardant wallpaper, a phosphorus-based or phenol-based antioxidant and a heavy metal deactivator are added to a mixer.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, embodiments of the present invention will be described with reference to the drawings. FIG. 1 schematically shows the entire calendering machine. The polyolefin resin used here is a transparent resin having flexibility (polyolefin elastomer made by using a metallocene catalyst), and a length of the uniform copolymer of ethylene and octene close to the main chain. Since it contains long-chain branches, it has high viscosity and good moldability even without a plasticizer.

A filler / flame retardant made of a metal hydrate such as aluminum hydroxide or magnesium hydroxide having an average particle diameter of 01 to 8 microns or a mixture thereof is added to the polyolefin resin, and the mixture is blended with a blender 1 ( (Ribbon blender). The mixing ratio is such that 10 parts of the polyolefin resin is filled with 10% of the filler / flame retardant.
In order to exhibit more sufficient flame retardancy at 0 parts or more, the amount is preferably 160 parts or more. It should be noted that by preliminarily adding a filler such as a vinyl silane to a coupling agent before the addition of the filler and the flame retardant, it is possible to improve the dispersion in the polyolefin resin when the resin is mixed and stirred. In addition, a phosphorus-based or phenol-based antioxidant, a heavy metal deactivator, and a pigment are added to the blender 1. The appropriate amount of the antioxidant is 3 to 10 parts.

[0008] The polyolefin resin mixed and stirred in the blender 1 in this manner is then mixed with a Banbury mixer 2
And the mixture is sheared and mixed by rotating the rotor in a heating state of 140 to 160 ° C., and further passed through a mixing roll 3 and a warming roll 4 to 140 to 150 ° C.
To make a semi-molten state.

Reference numeral 5 denotes an inverted L-type four-roll calender, in which the semi-molten resin is loaded between the first and second rolls 6 and 7 maintained at 140 to 150 ° C. The resin sheet 10 having a thickness of 0.1 to 0.3 mm is formed by passing through the gap between the rolls and the third and fourth rolls 8 and 9 held at 130 ° C. below the rolls.

Reference numeral 11 denotes a backing material made of flame-retardant paper such as aluminum hydroxide paper. The backing material 11 is superposed on the back surface of the resin sheet 10 and is bonded by being passed between pressure rolls 12 and 12. By cooling through the cooling rolls 13, 13,... And winding up on the winding roll 14, the wallpaper according to the present invention can be manufactured. Note that an adhesive may be used to attach the backing material 11.

It is also possible to produce a foamed, highly elastic wallpaper by adding about 20% of low density polyethylene (LDPE) to a polyolefin resin together with a foaming agent.

Further, the antioxidant and the heavy metal deactivator have the effect of suppressing the decomposition that can occur when the polyolefin resin comes into contact with a metal surface such as a calender roll and stabilizing the adhesiveness.

The metal hydrate added as a filler / flame retardant causes a dehydration reaction at a high temperature (aluminum hydroxide is 245 to 320 ° C., magnesium hydroxide is 340 to 320 ° C.).
490 ° C.), thereby lowering the ambient temperature and exhibiting flame retardancy and smoke suppression effects.

[0014]

As described above, according to the present invention, flame-retardant wallpaper made of a polyolefin resin which does not emit harmful substances such as conventional vinyl chloride during combustion can be mass-produced using existing calendering equipment. This has various effects such as reduction of production cost and benefit of environmental protection.

[Brief description of the drawings]

FIG. 1 is a schematic view of a calendering facility showing a method for producing a flame-retardant wallpaper of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Blender 2 Banbury mixer 3 Mixing roll 4 Warming roll 5 Calender 10 Resin sheet 11 Backing material 12 Pressure roll 13 Cooling roll 14 Winding roll

Claims (2)

[Claims] 1. A filler / flame retardant comprising aluminum hydroxide or magnesium hydroxide or a mixture thereof is added to a thermoplastic polyolefin resin and kneaded by a mixer, and the mixture is passed through gaps between a plurality of heated rolls. 0.1-0.3m thick by calendering
A method for producing a flame-retardant wallpaper, comprising: forming a resin sheet of m. 2. The method according to claim 1, wherein a phosphorus-based or phenol-based antioxidant and a heavy metal deactivator are added to the mixer.