JP7581632B2 - Non-combustible sheets, composite sheets, absorbent articles, and non-combustible decorative panels - Google Patents

Description

The present invention relates to a non-combustible sheet for use in fittings such as doors, a composite sheet comprising the non-combustible sheet, an absorbent article comprising the non-combustible sheet, and a non-combustible decorative board comprising the non-combustible sheet.

An example of a moisture-permeable non-flammable sheet is the one disclosed in Patent Document 1. The structure disclosed in Patent Document 1 is produced by melt-forming a resin composition containing a filler into a film using various molding methods such as the T-die method and the inflation method, and then stretching the film at least uniaxially.

JP 2001-261868 A

However, the configuration disclosed in Patent Document 1 has a problem in that, for example, the strength is low for use in building fixtures, and warping is likely to occur.
The present invention has been made in consideration of the above-mentioned circumstances, and aims to provide a non-combustible sheet, a composite sheet comprising a non-combustible sheet, an absorbent article comprising a non-combustible sheet, and a non-combustible decorative panel comprising a non-combustible sheet, which have moisture permeability and can improve strength.

In order to solve the above problems, one aspect of the present invention is a non-flammable sheet that includes a polyolefin resin composition containing an inorganic filler in a range of 15% by mass to 90% by mass relative to the polyolefin resin, is at least uniaxially stretched, has a total light transmittance of 50% or more, has a moisture permeability in a range of 3600 [g/( ^m2 ·24h)] to 8400 [g/( ^m2 ·24h)] and has a basis weight in a range of 50 [g/ ^m2 ] to 350 [g/ ^m2 ]. In addition, the polyolefin resin composition has a melt flow rate in a range of 6 [g/10min] to 25 [g/10min] at a load of 21.18N in an environment of a temperature of 190°C, and has a melt flow ratio of 85 or less, which is the ratio of the melt flow rate at a load of 98.07N to the melt flow rate at a load of 9.81N. Furthermore, the polyolefin resin contains 80% by mass or more and 99% by mass or less of linear low-density polyethylene having a melt flow rate of 1 [g/10 min] or more and 5 [g/10 min] or less and a density of 0.920 [g/cm ³ ] or more and 0.935 [g/cm ³ ] or less, and also contains 1% by mass or more and 20% by mass or less of branched low-density polyethylene having a melt flow rate of 6 [g/10 min] or more and 15 [g/10 min] or less and a density of 0.910 [g/cm ³ ] or more and 0.930 [g/cm ³ ] or less.

In order to solve the above problems, one aspect of the present invention is a composite sheet comprising a non-combustible sheet and a fiber sheet bonded to one side of the non-combustible sheet.
In order to solve the above problems, one aspect of the present invention is an absorbent article including a top sheet having liquid permeability, a back sheet having liquid impermeability, and an absorbent body having liquid retention disposed between the top sheet and the back sheet, wherein the back sheet is a fireproof sheet or a composite sheet.
In order to solve the above problems, one aspect of the present invention is a non-combustible decorative board comprising a non-combustible sheet, an anchor layer laminated on at least one surface of the non-combustible sheet, and a decorative layer laminated on the anchor layer. The decorative layer also comprises a top coat layer formed using a curable resin, and the organic content of the anchor layer and the decorative layer is 150 g/ ^m2 or less.

According to one aspect of the present invention, it is possible to provide a non-combustible sheet, a composite sheet including a non-combustible sheet, an absorbent article including a non-combustible sheet, and a non-combustible decorative panel including a non-combustible sheet, which have moisture permeability and can improve strength.

1 is a cross-sectional view showing a configuration of a non-combustible decorative board according to a first embodiment of the present invention. 1 is a cross-sectional view showing a configuration of a composite sheet according to a first embodiment of the present invention. 1 is a cross-sectional view showing a configuration of an absorbent article according to a first embodiment of the present invention.

The following describes the embodiments of the present technology with reference to the drawings. In the description of the drawings, the same or similar parts are denoted by the same or similar reference numerals, and duplicate descriptions are omitted. Each drawing is schematic and may differ from the actual one. The following embodiments are examples of devices and methods for embodying the technical ideas of the present technology, and the technical ideas of the present technology are not limited to the devices and methods exemplified in the following embodiments. The technical ideas of the present technology can be modified in various ways within the technical scope described in the claims. In addition, the directions of "left and right" and "up and down" in the following description are simply defined for the convenience of explanation and do not limit the technical ideas of the present invention. Therefore, for example, if the paper is rotated 90 degrees, "left and right" and "up and down" are read interchangeably, and of course, if the paper is rotated 180 degrees, "left" becomes "right" and "right" becomes "left".

First Embodiment
The non-combustible decorative board, the non-combustible sheet included in the non-combustible decorative board, the composite sheet, and the absorbent article will be described below.

(Non-flammable decorative panel)
The configuration of a non-combustible decorative board 10 will be described with reference to FIG.
As shown in FIG. 1 , the noncombustible decorative board 10 includes a noncombustible sheet 1 , a first anchor layer 2 , a second anchor layer 4 , a primer layer 6 , and a decorative layer 8 .

(Non-combustible sheet)
The noncombustible sheet 1 (sometimes referred to as a raw material layer) contains a polyolefin resin composition. The polyolefin resin composition contains an inorganic filler in an amount of 15% by mass to 90% by mass relative to the polyolefin resin.
In the first embodiment, as an example, a case will be described in which the polyolefin-based resin composition contains more than 50% by mass of an inorganic filler relative to the polyolefin-based resin.
In addition, the noncombustible sheet 1 is at least uniaxially stretched, has a total light transmittance of 50% or more, and has a moisture permeability of 3600 g/( ^m2 ·24h) to 8400 g/( ^m2 ·24h). Furthermore, the noncombustible sheet 1 has a basis weight of 50 g/ ^m2 to 350 g/ ^m2 .
In the first embodiment, as an example, a case will be described in which the stretch ratio of the noncombustible sheet 1 is within a range of 3.0 times or more and 6.0 times or less.

The thickness of the noncombustible sheet 1 is preferably in the range of 50 μm to 250 μm, more preferably in the range of 70 μm to 200 μm. If the thickness of the noncombustible sheet 1 is less than 50 μm, the lamination suitability tends to decrease. If the thickness of the noncombustible sheet 1 is more than 250 μm, cracks may occur at the folded portion of the sheet.
Therefore, if the thickness of the noncombustible sheet 1 is within the above-mentioned numerical range, it is possible to improve the lamination suitability and reduce the occurrence of cracks in the folded portions of the sheet.

In addition, it is preferable to perform a surface treatment such as a corona treatment or a plasma treatment on the noncombustible sheet 1 before forming the first anchor layer 2 and the second anchor layer 4. By performing a surface treatment such as a corona treatment or a plasma treatment on the noncombustible sheet 1, it is possible to improve the adhesion (adhesion) between the first anchor layer 2 and the second anchor layer 4 and the noncombustible sheet 1.
In addition, the non-combustible sheet 1 may be brushed before forming the first anchor layer 2 and the second anchor layer 4 to remove powdered inorganic filler (e.g., calcium carbonate and calcium carbonate salts) in advance.

(Polyolefin Resin Composition)
The polyolefin resin composition has a melt flow rate in the range of 6 [g/10 min] to 25 [g/10 min] at a load of 21.18 N in an environment at a temperature of 190° C. In addition, the melt flow ratio, which is the ratio of the melt flow rate at a load of 98.07 N to the melt flow rate at a load of 9.81 N, is 85 or less.
The polyolefin resin contains 80% by mass or more and 99% by mass or less of linear low-density polyethylene having a melt flow rate of 1 [g/10 min] or more and 5 [g/10 min] or less and a density of 0.920 [g/cm ³ ] or more and 0.935 [g/cm ³ ] or less, and also contains 1% by mass or more and 20% by mass or less of branched low-density polyethylene having a melt flow rate of 6 [g/10 min] or more and 15 [g/10 min] or less and a density of 0.910 [g/cm ³ ] or more and 0.930 [g/cm ³ ] or less.
In addition, in order to improve the dispersibility in the polyolefin resin composition, stearic acid may be blended in the polyolefin resin composition. In this case, the stearic acid is preferably blended in an amount of 0.5 parts by mass to 3 parts by mass, particularly 0.8 parts by mass to 2 parts by mass, per 100 parts by mass of the inorganic filler.

(Melt Flow Rate)
The melt flow rate is preferably in the range of 7 [g/10 min] to 20 [g/10 min], more preferably in the range of 8 [g/10 min] to 18 [g/10 min]. When the melt flow rate is less than 6 [g/10 min], the flowability is poor and molding at low temperatures is impossible, so molding at high temperatures is necessary, and eye discharge, burn marks, gelled resin, etc. are generated more frequently. On the other hand, when the melt flow rate exceeds 25 [g/10 min], the melt tension is lowered, draw resonance occurs, and thin film moldability at high speed is deteriorated. In addition, the neck-in at the die outlet becomes large, the desired sheet width cannot be obtained, and productivity is deteriorated. The melt flow rate is measured according to the method specified in ASTM D-1238-57T (E) under the conditions of a temperature of 190 ° C and a load of 21.18 N.

(Melt flow ratio)
The melt flow ratio is an index of the shear rate dependency of a polyolefin resin composition, and the closer the melt flow ratio is to 1, the smaller the change in shear rate is even if the shear stress of the polyolefin resin composition changes. If a polyolefin resin composition with a melt flow ratio of more than 85 is used, the change in flowability becomes large with respect to the change in shear rate in an extruder, a single tube, a T-die, etc. As a result, the occurrence of burnt spots due to the retention of resin increases, and the thickness unevenness in the width direction occurs frequently, resulting in a sheet with poor appearance. The preferable range of the melt flow ratio is 10 to 75, particularly 15 to 70.

The method for measuring the melt flow rate at loads of 98.07 N and 9.81 N in an environment at a temperature of 190°C, which is used to calculate the melt flow ratio, conforms to the method specified in ASTM D-1238-57T(E). The load values for the two melt flow rates used to calculate the melt flow ratio were set to 98.07 N and 9.81 N, respectively, because the shear rate in a typical extruder to T-die falls roughly within the load range for this melt flow rate. In an environment with a temperature of 190°C, the melt flow rate values themselves at loads of 98.07N and 9.81N are preferably in the range of 60 [g/10min] to 120 [g/10min], particularly 70 [g/10min] to 110 [g/10min], for a load of 98.07N, and in the range of 0.5 [g/10min] to 5 [g/10min], particularly 1 [g/10min] to 4.5 [g/10min], for a load of 9.81N. If the melt flow rate values at each load are within this range, the change in the fluidity of the resin within this shear rate range is small, and the moldability is good.

(Polyolefin resin)
The polyolefin resin preferably contains at least one of polypropylene, polyethylene, and polyester, and more preferably contains polypropylene. By using at least one of polypropylene, polyethylene, and polyester as the polyolefin resin, the dispersibility of the inorganic filler is improved. In addition, by using polypropylene as the polyolefin resin, the dispersibility of the inorganic filler is further improved.

The total content of the polyolefin resin and the inorganic filler is preferably in the range of 90% by mass to 100% by mass of the non-combustible decorative board 10. If the total content of the polyolefin resin and the inorganic filler is less than 90% by mass of the non-combustible decorative board 10, sufficient non-combustibility or sufficient flame retardancy may not be obtained. In addition, printability or lamination suitability may decrease, and cracks may occur in the folded parts of the sheet.
Therefore, when the total content of the polyolefin resin and the inorganic filler is within the above-mentioned numerical range, it is possible to obtain sufficient non-combustibility or sufficient flame retardancy while improving printability and lamination suitability and reducing cracks that occur in the folded portions of the sheet.

In addition, when the total content of the polyolefin resin and the inorganic filler is 100% by mass relative to the mass of the non-combustible decorative board 10, it is preferable that the content of the polyolefin resin is in the range of 10% by mass to 85% by mass, and the content of the inorganic filler is in the range of 15% by mass to 90% by mass. It is more preferable that the content of the polyolefin resin is in the range of 20% by mass to 80% by mass, and the content of the inorganic filler is in the range of 20% by mass to 80% by mass. It is even more preferable that the content of the polyolefin resin is in the range of 20% by mass to 40% by mass, and the content of the inorganic filler is in the range of 60% by mass to 80% by mass. If the total content of the polyolefin resin and the inorganic filler is within the above-mentioned numerical range, it is possible to reliably obtain sufficient non-combustibility or sufficient flame retardancy, reliably improve printability and lamination suitability, and reliably reduce cracks occurring in the folded parts of the sheet.
In the first embodiment, as an example, a case will be described in which the polyolefin resin contains polypropylene or polyethylene.

(Ratio of Linear Low Density Polyethylene to Branched Low Density Polyethylene)
As described above, the blending ratio of the linear low-density polyethylene and the branched low-density polyethylene is set to a range of 80% by mass or more and 99% by mass or less, and the blending amount of the branched low-density polyethylene is set to a range of 1% by mass or more and 20% by mass or less, but preferably, the blending amount of the linear low-density polyethylene may be set to a range of 85% by mass or more and 99% by mass or less, and the blending amount of the branched low-density polyethylene may be set to a range of 1% by mass or more and 15% by mass or less. More preferably, the blending amount of the linear low-density polyethylene may be set to a range of 85% by mass or more and 95% by mass or less, and the blending amount of the branched low-density polyethylene may be set to a range of 5% by mass or more and 15% by mass or less. By setting the blending amount of each resin within the above-mentioned range, it is possible to obtain a non-combustible sheet 1 having good formability of the sheet, little thickness unevenness in the width direction and the flow direction, and good appearance. It is also possible to obtain a non-combustible sheet 1 having an excellent balance of moisture permeability, strength, and flexibility.

(Inorganic filler)
The inorganic filler is, for example, a powder containing at least one of calcium carbonate and calcium carbonate salt. The powder containing at least one of calcium carbonate and calcium carbonate salt preferably contains calcium carbonate, etc. in a range of 50 mass% to 100 mass% with respect to the mass of the entire powder. In other words, the purity of the powder containing at least one of calcium carbonate and calcium carbonate salt is preferably such that the content of calcium carbonate, etc. is in a range of 50 mass% to 100 mass%. If the powder contains at least one of calcium carbonate and calcium carbonate salt with a content of calcium carbonate, etc. of 50 mass% or more, it is possible to impart sufficient incombustibility or sufficient flame retardancy to the noncombustible sheet 1, and also to impart sufficient mechanical strength.

In addition to the powder containing at least one of the calcium carbonate and calcium carbonate salts, the inorganic filler may be, for example, silica (particularly hollow silica), alumina, antimony trioxide, antimony soda, zirconium compounds such as zirconium silicate and zirconium oxide. In addition, the inorganic filler may be at least one of magnesium hydroxide, aluminum hydroxide, basic magnesium carbonate, borax, zinc borate, molybdenum trioxide, or a complex of antimony dimolybdate and aluminum hydroxide, a complex of antimony trioxide and silica, a complex of antimony trioxide and zinc oxide, silicic acid of zirconium, a complex of a zirconium compound and antimony trioxide, and salts thereof. In addition, the inorganic filler may be, for example, a powder of limestone, a sintered powder of eggshell, or a sintered powder of oysters or scallops.

Of the inorganic materials mentioned above, calcium carbonate and calcium carbonate salts in particular are suitable from the viewpoint of reducing the cost of the non-flammable decorative panel 10, since it is easy to control the particle size through the manufacturing method and to control the compatibility with polyolefin-based resins, and the material costs are also low.
The inorganic filler may contain calcium carbonate having a specific surface area in the range of 16,000 ^cm2 /g to 24,000 ^cm2 /g. If the specific surface area of the inorganic filler, calcium carbonate, is within the above range, it is possible to form a fireproof sheet 1 having high moisture permeability and high water resistance.

In addition, the inorganic filler may be a powder material having crystallinity or a so-called crystalline powder, or may be a powder material having no crystallinity, a so-called amorphous type powder material. In this case, if the inorganic filler is a powder material having crystallinity, the powder itself is homogeneous and isotropic, so that the mechanical strength of the powder itself tends to be improved, and the scratch resistance and durability of the non-combustible sheet tend to be improved. In addition, if the inorganic filler is an amorphous type powder material, it is possible to appropriately adjust the electrical conductivity and thermal conductivity of the powder itself, or the light transmittance and light absorbance, so that it is possible to impart a design with a wide variety of textures, gloss, etc.
In the first embodiment, as an example, a case where the inorganic filler is calcium carbonate will be described.

The inorganic filler is preferably in a powder form, has an average particle size (mode diameter) in the range of 1 μm to 3 μm, and has a maximum particle size of 50 μm or less, for the reasons described below.
If the average particle size of the inorganic filler is less than 1 [μm], the cohesive force between the inorganic fillers may increase, and the dispersibility in the polyolefin resin may decrease. If the average particle size of the inorganic filler exceeds 3 [μm], the flatness of the surface of the non-combustible sheet 1 may decrease, and the thickness of the first anchor layer 2 and the second anchor layer 4 may become uneven, or unevenness or chipping may occur. If the maximum particle size of the inorganic filler exceeds 50 [μm], the flatness of the surface of the non-combustible sheet 1 may decrease, and the thickness of the first anchor layer 2 and the second anchor layer 4 may become uneven, or unevenness or chipping may occur.
As described above, when the average particle size and maximum particle size of the inorganic filler are within the above-mentioned numerical ranges, it is possible to improve the dispersibility of the inorganic filler in the polyolefin resin and maintain the flatness of the surface of the non-combustible sheet 1.

The reason why the content of the inorganic filler is set to the range of 15% by mass or more and 90% by mass or less with respect to the polyolefin resin will be explained below.
When the content of the inorganic filler is less than 15% by mass relative to the polyolefin resin, the proportion of the polyolefin resin is relatively high, so that it is difficult to obtain non-combustibility or flame retardancy. Furthermore, when the surface of the non-combustible sheet 1 is scratched using a Hoffman scratch tester, visible scratches are left, i.e., sufficient surface hardness may not be obtained.

On the other hand, when the content of the inorganic filler exceeds 90% by mass relative to the polyolefin resin, the proportion of the polyolefin resin is relatively small. For this reason, when the first anchor layer 2 or the second anchor layer 4 is formed, the so-called "powdering" may occur on the surface of the non-combustible sheet 1. Here, "powdering" refers to a state in which the inorganic filler contained in the non-combustible sheet 1 protrudes onto the surface of the non-combustible sheet 1. In addition, when the decorative layer 8 is formed, the inorganic filler protruding from the non-combustible sheet 1 may make it difficult to laminate the ink, and the printability may decrease. In addition, when a sheet on which at least one of the first anchor layer 2, the second anchor layer 4, and the decorative layer 8 is formed is laminated to a wood-based substrate and an inorganic material-based substrate in a roll or sheet, lamination becomes difficult and lamination suitability tends to decrease. In addition, when a sheet on which at least one of the first anchor layer 2, the second anchor layer 4, and the decorative layer 8 is formed is folded and opened again, cracks may occur in the folded part, and the inorganic filler may fall off. In addition, if cellophane tape is applied to the surface of the sheet on which the decorative layer 8 is formed and then forcefully peeled off, peeling may occur between the decorative layer 8 or the noncombustible sheet 1 (first anchor layer 2) and the decorative layer 8, resulting in reduced ink adhesion.

As explained above, by setting the content of inorganic filler within the above-mentioned range relative to the mass of the noncombustible sheet 1, it is possible to obtain noncombustibility or flame retardancy while reducing the occurrence of powdering. In addition, it is possible to improve printability and lamination suitability, reduce cracks that occur in the folded parts of the sheet, and further obtain sufficient surface hardness and improve ink adhesion.

(Linear low density polyethylene)
As the linear low density polyethylene, as described above, one having a melt flow rate in the range of 1 [g/10 min] to 5 [g/10 min] is used, preferably in the range of 2 [g/10 min] to 5 [g/10 min], more preferably in the range of 2.5 [g/10 min] to 4.5 [g/10 min]. This melt flow rate range is higher than the melt flow rate of polyolefin resins that have been used as raw materials for fireproof sheets. By using linear low density polyethylene with such a high melt flow rate, the fluidity is improved and the moldability is improved. In addition, it is possible to obtain a fireproof sheet with high moisture permeability. If the melt flow rate is less than 1 [g/10 min], the fluidity is low and sheet molding is difficult. On the other hand, if the melt flow rate exceeds 5 [g/10 min], holes are easily opened during stretching, and holes that cause problems in leak prevention occur frequently. The melt flow rate of the linear low density polyethylene is measured in the same manner as the melt flow rate of the polyolefin resin composition, under the conditions of a temperature of 190° C. and a load of 21.18 N in accordance with the method specified in ASTM D-1238-57T(E).

As described above, the density of the linear low-density polyethylene is in the range of 0.920 [g/cm ³ ] to 0.935 [g/cm ³ ], preferably in the range of 0.920 [g/cm ³ ] to 0.930 [g/cm ³ ]. By using a linear low-density polyethylene having a density in this range, it is possible to obtain a non-combustible sheet having sufficiently high moisture permeability, high strength such as longitudinal tear strength and CD breaking strength, high flexibility, and little unevenness in the stretching of the sheet in appearance. If the density of the linear low-density polyethylene is less than 0.920 [g/cm ³ ], the moisture permeability is low and the heat resistance is reduced. On the other hand, if the density of the linear low-density polyethylene exceeds 0.935 [g/cm ³ ], the flexibility is low, there is a lot of unevenness in the stretching of the sheet in appearance, and the appearance is deteriorated. The density of the linear low-density polyethylene is measured based on JIS K 7112, Method D (a measurement method using a density gradient tube).

The linear low-density polyethylene is preferably one produced using a metallocene catalyst. This makes it possible to obtain a fireproof sheet having a good balance between moldability and sheet properties, particularly moisture permeability, strength, and flexibility. In this case, the linear low-density polyethylene is preferably a copolymer of ethylene and an α-olefin having 3 to 8 carbon atoms.
As the linear low-density polyethylene, commercially available products can be used, such as "UMERIT 2540F" and "UMERIT 2525F" manufactured by Ube Industries, Ltd., and "HARMOLEX NC479A" and "HARMOLEX NC564A" manufactured by Japan Polyolefins Co., Ltd.

(Branched low density polyethylene)
As the branched low density polyethylene, as described above, one having a melt flow rate in the range of 6 [g/10 min] to 15 [g/10 min] is used, but preferably one having a melt flow rate in the range of 7 [g/10 min] to 12 [g/10 min]. This melt flow rate range is higher than the melt flow rate of polyolefin resins that have been used conventionally. By using a branched low density polyethylene with such a high melt flow rate, the fluidity is improved and the moldability is good. In addition, it is possible to obtain a fireproof sheet with high moisture permeability. If the melt flow rate is less than 6 [g/10 min], the moldability is poor, there is a lot of thickness unevenness in the width direction, the sheet has a poor appearance in terms of appearance, and further, the moisture permeability is low. On the other hand, if the melt flow rate exceeds 15 [g/10 min], holes are easily opened during stretching, and holes that cause problems in leak prevention occur frequently. The melt flow rate of the branched low density polyethylene is measured in the same manner as the melt flow rate of the polyolefin resin composition, under conditions of a temperature of 190° C. and a load of 21.18 N in accordance with the method specified in ASTM D-1238-57T(E).

The density of the branched low density polyethylene is, as described above, in the range of 0.910 [g/cm ³ ] to 0.930 [g/cm ³ ], preferably in the range of 0.910 [g/cm ³ ] to 0.925 [g/cm ³ ], more preferably in the range of 0.915 [g/cm ³ ] to 0.925 [g/cm ³ ]. By using a branched low density polyethylene having a density in this range, it is possible to obtain a non-combustible sheet having sufficiently high moisture permeability, high strength such as longitudinal tear strength and CD breaking strength, high flexibility, and little unevenness in the appearance of the sheet. If the density of the branched low density polyethylene is less than 0.910 [g/cm ³ ], the non-combustible sheet will have low moisture permeability and low heat resistance. On the other hand, if the density of the branched low density polyethylene exceeds 0.930 [g/cm ³ ], the flexibility will be low and the appearance of the non-flammable sheet will have many uneven stretching spots, resulting in an unattractive looking non-flammable sheet.
As the branched low density polyethylene, commercially available products can be used. Examples of commercially available branched low density polyethylene that can be used include "J1019" manufactured by Ube Industries, Ltd. and "JH606N" manufactured by Japan Polyolefins Co., Ltd.

(First anchor layer)
The first anchor layer 2 is laminated on the noncombustible sheet 1. Specifically, the first anchor layer 2 is laminated on the upper surface (surface) of the noncombustible sheet 1 in FIG. 1, and is formed so as to cover the entire surface of the noncombustible sheet 1. This prevents the inorganic filler contained in the noncombustible sheet 1 from falling off. If the inorganic filler contained in the noncombustible sheet 1 falls off in the printing system, specifically in the printing device, during printing or resin coating, it may contaminate the printing system. In addition, if the inorganic filler contained in the noncombustible sheet 1 falls off, problems such as ink loss may occur. Here, "ink loss" refers to ink not being printed in parts.

The first anchor layer 2 also has a function of improving adhesion between the noncombustible sheet 1 and the ink forming the picture pattern layer 8a described below. In a configuration without the first anchor layer 2, the ink forming the picture pattern layer 8a may not adhere to the noncombustible sheet 1 and may peel off.
As a material for forming the first anchor layer 2, for example, a material containing a urethane resin containing vinyl chloride acetate or an acrylic resin containing vinyl chloride acetate can be used. Here, "vinyl chloride acetate" means a copolymer of vinyl chloride and vinyl acetate. Also, "urethane resin containing vinyl chloride acetate" means a composition containing vinyl chloride acetate and a urethane resin.

The ratio of the vinyl chloride acetate content to the urethane resin content (vinyl chloride acetate content (mass)/urethane resin content (mass)) may be within a range of 80/20 to 1/99. The ratio of the vinyl chloride acetate content to the urethane resin content is preferably within a range of 50/50 to 5/95, and more preferably within a range of 20/80 to 10/90.
The first anchor layer 2 is formed by using any printing method such as gravure printing, offset printing, screen printing, flexographic printing, letterpress printing, inkjet printing, etc. Preferably, any coating method such as roll coating, gravure coating, rod coating, knife coating, air knife coating, spray coating, lip coating, die coating, etc. can be used.

(Second anchor layer)
The second anchor layer 4 is laminated on the noncombustible sheet 1. Specifically, the second anchor layer 4 is laminated on the lower surface (back surface) of the noncombustible sheet 1 in FIG. 1, and is formed so as to cover the entire back surface of the noncombustible sheet 1. This allows the second anchor layer 4 to prevent the inorganic filler contained in the noncombustible sheet 1 from falling off. If the inorganic filler contained in the noncombustible sheet 1 falls off in the printing system, specifically in the printing device, during printing or resin coating, it may contaminate the printing system. In addition, if the inorganic filler contained in the noncombustible sheet 1 falls off, problems such as ink loss may occur.
The second anchor layer 4 also has a function of improving adhesion between the noncombustible sheet 1 and the primer layer 6. If the second anchor layer 4 is not provided, the coating liquid forming the primer layer 6 may not adhere to the noncombustible sheet 1 and may peel off.
The second anchor layer 4 is formed, for example, in the same manner (material and method) as the first anchor layer 2 .

(Primer layer)
The primer layer 6 is laminated on the second anchor layer 4 and faces the back surface of the non-combustible sheet 1 with the second anchor layer 4 sandwiched therebetween.
As the material of the primer layer 6, for example, nitrocellulose, cellulose, vinyl chloride-vinyl acetate copolymer, polyvinyl butyral, polyurethane, acrylic, polyester, etc. as a binder, or each modified product thereof can be appropriately selected and used. These can be in any form, such as water-based, solvent-based, emulsion type, etc. In addition, as for the curing method, it is possible to appropriately select and use from a one-liquid type that cures alone, a two-liquid type that uses a curing agent in combination with a base agent, a type that cures by irradiation with ultraviolet rays or electron beams, etc. As a general curing method, a two-liquid type that cures by combining an isocyanate-based curing agent with a urethane-based base agent is used, and this method is suitable from the viewpoints of workability, cost, and cohesive force of the resin itself. In addition to the above-mentioned binders, colorants such as pigments and dyes, extender pigments, solvents, various additives, etc. are added.

In particular, since the primer layer 6 is located on the rearmost surface of the non-combustible decorative board 10, and considering that the non-combustible decorative board 10 will be wound up as a continuous plastic film (web-like), inorganic fillers such as silica, alumina, magnesia, titanium oxide, barium sulfate, etc. may be added to the primer layer 6 to prevent blocking, such as films adhering to each other and becoming difficult to slide or unable to peel off, and to improve adhesion to the adhesive. In addition, the thickness of the primer layer 6 is preferably within the range of, for example, 0.1 μm to 3.0 μm.

(Decorative Layer)
The decorative layer 8 is laminated on the first anchor layer 2 and faces the surface of the non-combustible sheet 1 with the first anchor layer 2 sandwiched therebetween.
The decorative layer 8 includes a picture pattern layer 8a and a top coat layer 8b.

(Pattern layer)
The picture pattern layer 8a is laminated on the first anchor layer 2. Specifically, the picture pattern layer 8a is laminated on the upper surface of the first anchor layer 2 in FIG.
As the material of the picture pattern layer 8a, it is possible to use a film-based substrate made of, for example, saturated polyester, low-density polyethylene (including linear low-density polyethylene), medium-density polyethylene, high-density polyethylene, homopolypropylene, ethylene-α-olefin copolymer, polymethylpentene, polybutene, ethylene-propylene copolymer, propylene-butene copolymer, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, or a mixture thereof, because it has excellent processability and does not generate harmful gases when burned. These materials may be in an unstretched state or in a uniaxially or biaxially stretched state, and the thickness is appropriately in the range of 25 μm to 125 μm. In addition, as the material of the picture pattern layer 8a, it is also possible to use, for example, paper-based substrates such as building material printing paper (building material tissue paper), pure white paper, or tissue paper mixed with synthetic resin to strengthen the interlayer strength, and titanium paper mixed with opaque pigments such as titanium oxide.

The basis weight of the picture pattern layer 8a is, for example, within the range of 23 [g/ ^m2 ] to 100 [g/ ^m2 ]. These film-based substrates or paper-based substrates may be subjected to an appropriate adhesion enhancing treatment such as corona discharge treatment, plasma treatment, or ozone treatment on the necessary surface as necessary.
In addition, in the picture pattern layer 8a, patterns such as wood grain patterns, stone grain patterns, fabric patterns, leather patterns, geometric patterns, letters, symbols, line drawings, various abstract patterns, etc. are formed using ink by a well-known printing method such as gravure printing, offset printing, silk screen printing, etc. As the ink, one or more of chlorinated polyolefins such as chlorinated polyethylene and chlorinated polypropylene, polyester, polyurethane containing isocyanate and polyol, polyacrylic, polyvinyl acetate, polyvinyl chloride, vinyl chloride-vinyl acetate copolymer, cellulose resin, polyamide resin, etc. may be used as a vehicle, and a pigment, solvent, various auxiliary agents, etc. may be added to the ink to make it into an ink. However, in consideration of environmental issues, a non-chlorine vehicle in which one or more of polyester, polyurethane containing isocyanate and polyol, polyacrylic, polyvinyl acetate, cellulose resin, polyamide resin, etc. are mixed is suitable, and more preferably, one or more of polyester, polyurethane containing isocyanate and polyol, polyacrylic, polyamide resin, etc. are mixed.

(Topcoat layer)
The top coat layer 8b is laminated on the picture pattern layer 8a. Specifically, the top coat layer 8b is laminated on the upper surface of the picture pattern layer 8a in FIG.
The topcoat layer 8b is provided to protect the picture pattern layer 8a and to impart surface properties required of the non-flammable decorative board 10, such as stain resistance, scratch resistance, abrasion resistance, and water resistance.
The resin for forming the top coat layer 8b is suitably a curable resin such as a thermosetting resin or an ionizing radiation curable resin, but an ionizing radiation curable resin is more preferable because it has a high surface hardness, can be easily wiped off even if oxidized vegetable or animal oil adheres to it, and is also excellent in productivity.
In the first embodiment, as an example, a case where the topcoat layer 8b is formed using an ionizing radiation curable resin will be described.

Ionizing radiation curable resins are resins that undergo cross-linking polymerization reactions when irradiated with ionizing radiation, changing into a three-dimensional polymer structure. Ionizing radiation refers to electromagnetic waves or charged particle beams that have energy quanta capable of polymerizing and cross-linking molecules, and includes visible light, ultraviolet light (near ultraviolet light, vacuum ultraviolet light, etc.), X-rays, electron beams, ion beams, etc. Usually, ultraviolet light or electron beams are used. Ultra-high pressure mercury lamps, high pressure mercury lamps, low pressure mercury lamps, carbon arc lamps, black light fluorescent lamps, and metal halide lamps can be used as ultraviolet light sources. The wavelength of the ultraviolet light can be in the range of 190 nm to 380 nm. In addition, various electron beam accelerators such as Cockcroft-Walt type, Van de Graft type, resonant transformer type, insulating core transformer type, linear type, dynamitron type, and high frequency type can be used as electron beam sources. The electron beam used is in the range of 100 keV to 1000 keV, preferably 100 keV to 300 keV. The dose of the electron beam is usually in the range of 2 Mrad to 15 Mrad.

The ionizing radiation curable resin contains a monomer, prepolymer or polymer (hereinafter collectively referred to as a compound) having a radically polymerizable unsaturated group such as a (meth)acryloyl group or a (meth)acryloyloxy group, or a cationic polymerizable functional group such as an epoxy group, in the molecule. These monomers, prepolymers and polymers are used alone or in combination. Note that (meth)acrylate is used to mean acrylate or methacrylate.

Prepolymers having radically polymerizable unsaturated groups include polyester (meth)acrylate, urethane (meth)acrylate, epoxy (meth)acrylate, melamine (meth)acrylate, triazine (meth)acrylate, silicone (meth)acrylate, polyvinylpyrrolidone, etc. These prepolymers usually have a molecular weight of about 10,000 or less. If the molecular weight exceeds 10,000, the surface properties of the cured resin layer, such as scratch resistance, abrasion resistance, chemical resistance, and heat resistance, become insufficient. Acrylates and methacrylates can be used interchangeably, but acrylates have a faster crosslinking curing speed with ionizing radiation, so acrylates are more advantageous for the purpose of efficient curing at high speed in a short time.

Prepolymers having cationic polymerizable functional groups that can be used include epoxy resins such as bisphenol-type epoxy resins, novolac-type epoxy resins, and alicyclic epoxy resins; vinyl ether resins such as aliphatic vinyl ethers, aromatic vinyl ethers, urethane vinyl ethers, and ester vinyl ethers; cyclic ether compounds; and spiro compounds.

Examples of monomers having a radically polymerizable unsaturated group include monofunctional monomers of (meth)acrylate compounds, such as methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate, methoxyethyl (meth)acrylate, methoxybutyl (meth)acrylate, butoxyethyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, N,N-dimethylaminomethyl (meth)acrylate, N,N-dimethylaminoethyl (meth)acrylate, N,N-diethylaminoethyl (meth)acrylate, and N,N-diethylaminopropyl (meth)acrylate. Acrylate, N,N-dibenzylaminoethyl (meth)acrylate, lauryl (meth)acrylate, isobornyl (meth)acrylate, ethyl carbitol (meth)acrylate, phenoxyethyl (meth)acrylate, phenoxypolyethylene glycol (meth)acrylate, tetrahydrofurfuryl (meth)acrylate, methoxypropylene glycol (meth)acrylate, 2-(meth)acryloyloxyethyl-2-hydroxypropyl phthalate, 2-(meth)acryloyloxypropyl hydrogen terephthalate, etc. can be used.

In addition, examples of polyfunctional monomers having a radically polymerizable unsaturated group include ethylene glycol di(meth)acrylate, diethylene glycol di(meth)acrylate, triethylene glycol di(meth)acrylate, propylene glycol di(meth)acrylate, dipropylene glycol (meth)acrylate, neopentyl glycol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, 1,9-nonanediol di(meth)acrylate, tetraethylene glycol di(meth)acrylate, tripropylene glycol di(meth)acrylate, ) acrylate, bisphenol-A-di(meth)acrylate, trimethylolpropane tri(meth)acrylate, trimethylolpropane ethylene oxide tri(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, glycerin polyethylene oxide tri(meth)acrylate, tris(meth)acryloyloxyethyl phosphate, etc. The monomer having a cationic polymerizable functional group can be a monomer of a prepolymer having a cationic polymerizable functional group.

The above-mentioned ionizing radiation curable resins are sufficiently cured by irradiation with an electron beam, but when curing by irradiation with ultraviolet light, a photopolymerization initiator is added as a sensitizer. In the case of a resin system having a radically polymerizable unsaturated group, the photopolymerization initiator may be acetophenones, benzophenones, thioxanthones, benzoin, benzoin methyl ether, Michler's benzoyl benzoate, Michler's ketone, diphenyl sulfide, dibenzyl disulfide, diethyl oxide, triphenyl biimidazole, isopropyl-N,N-dimethylaminobenzoate, etc., either alone or in combination. In the case of a resin system having a cationic polymerizable functional group, aromatic diazonium salts, aromatic sulfonium salts, metallocene compounds, benzoin sulfonate esters, furyloxysulfoxonium diallyliodosyl salts, etc., may be used either alone or in combination. The amount of these photopolymerization initiators added is generally within the range of 0.1 to 10 parts by mass per 100 parts by mass of the ionizing radiation curable resin.

The top coat layer 8b can be formed from an ionizing radiation curable resin by, for example, adjusting the viscosity of the ionizing radiation curable resin to a coatable level and applying it by a well-known coating method such as gravure coating, roll coating, etc. The appropriate coating amount is generally within the range of 3 g/ ^m2 to 15 g/ ^m2 in terms of solid content.
In addition, a primer layer for ink or a primer layer for the topcoat layer can be provided between the picture pattern layer 8a and the topcoat layer 8b to improve the adhesive strength between the layers. These primer layers can be formed by a known application method such as gravure printing or roll coating using a two-component curing polyurethane adhesive containing a polyol component and an isocyanate component used in the first anchor layer 2. The application amount of the primer layer for ink or the primer layer for the topcoat layer after drying is in the range of 0.1 [g/m ² ] to 5.0 [g/m ² ], preferably in the range of 0.5 [g/m ² ] to 1.0 [g/m ² ].

In addition, an ultraviolet absorbing agent and a light stabilizer may be appropriately added to the top coat layer 8b in order to improve the weather resistance of the non-flammable decorative board 10. In addition, functional additives such as antibacterial agents and antifungal agents may be added to impart various functions. Furthermore, alumina, silica, silicon nitride, silicon carbide, glass beads, etc. may be added to adjust the gloss from the viewpoint of surface design or to impart further abrasion resistance.
The organic content mass of the anchor layers (first anchor layer 2, second anchor layer 4) and decorative layer 8 may be 150 [g/ ^m2 ] or less. If the organic content mass of the anchor layers (first anchor layer 2, second anchor layer 4) and decorative layer 8 is within the above numerical range, the anchor layers (first anchor layer 2, second anchor layer 4) and decorative layer 8 have fire retardant performance as a noncombustible material, and therefore it is possible to provide a noncombustible decorative board 10 suitable for applications subject to interior decoration restrictions.

(Method of manufacturing non-flammable decorative board 10)
Hereinafter, a method for manufacturing the noncombustible sheet 1 and the noncombustible decorative board 10 according to the first embodiment will be described with reference to FIG.
First, a method for producing the noncombustible sheet 1 will be described.
The above-mentioned polyolefin resin composition is used as a raw material, and the raw material is melt-formed into a film by the T-die method, and then stretched at least uniaxially. Specifically, each component constituting the polyolefin resin composition is premixed using a Henschel mixer or a super mixer, and then kneaded and pelletized by a single-screw or twin-screw extruder. Next, the formed pellets are formed into a film by a T-die type molding machine. Then, the formed film is stretched uniaxially or biaxially to cause interfacial peeling between the resin and the inorganic filler to make it porous. For example, a roll method or a tenter method is used to stretch the film. In this manner, the noncombustible sheet 1 is manufactured.

The molding temperature of the non-combustible sheet 1 is in the range of 180°C to 220°C, which is lower than the conventional molding temperature. By combining the molding temperature using the T-die method with the polyolefin resin composition, the generation of so-called eye discharge, burn marks, gelled resin, etc. during molding is suppressed, and moldability is improved. Note that if inflation molding is performed using a polyolefin resin composition as a raw material under the same molding temperature conditions, the moldability is not good. In addition, it is preferable that the molding temperature is in the range of 180°C to 210°C, particularly in the range of 190°C to 210°C, because the generation of substances that interfere with molding is further suppressed and moldability is further improved. Note that the molding temperature is the temperature at the T-die.

The fireproof sheet 1 thus manufactured is made of a polyolefin resin composition, and therefore has a high total light transmittance of preferably 50% or more. Despite showing such a high total light transmittance, the fireproof sheet 1 has a high moisture permeability of 3600 [g/( ^m2 ·24h)] or more and 8400 [g/( ^m2 ·24h)] or less, preferably 4000 [g/( ^m2 ·24h)] or more and 8400 [g/( ^m2 ·24h)] or less, more preferably 5000 [g/( ^m2 ·24h)] or more and 8400 [g/( ^m2 ·24h)] or less. Thus, the fireproof sheet 1 has a high total light transmittance and a high moisture permeability that could not be achieved simultaneously in the past. The total light transmittance is measured in accordance with JIS K 7105 using a haze/transmittance/reflectance meter HR-100 manufactured by Murakami Color Research Laboratory Co., Ltd. The moisture permeability is measured in accordance with JIS Z 0208 in an environment with a temperature of 30° C.±0.5° C. and a humidity of 90±2% RH.

Next, a method for producing the non-flammable decorative board 10 will be described.
First, an ink for forming the first anchor layer 2 is applied to the surface of the noncombustible sheet 1 to form the first anchor layer 2 .
Next, ink for forming the picture pattern layer 8a is applied to the surface of the first anchor layer 2 opposite to the surface facing the noncombustible sheet 1, thereby forming the picture pattern layer 8a.
Next, ink for forming a top coat layer 8b is applied to the surface of the picture pattern layer 8a opposite to the surface facing the first anchor layer 2, to form the top coat layer 8b.

Next, ink for forming a second anchor layer 4 is applied to the back surface of the noncombustible sheet 1 to form the second anchor layer 4 .
Finally, ink for forming a primer layer 6 is applied to the surface of the second anchor layer 4 opposite to the surface facing the non-combustible sheet 1 to form the primer layer 6, thereby producing the non-combustible decorative board 10.
The second anchor layer 4 may be formed simultaneously with the first anchor layer 2 .
The primer layer 6 may be formed before the picture pattern layer 8a and the top coat layer 8b are formed. In this case, the second anchor layer 4 may be formed before the first anchor layer 2.

(Composite sheet)
The structure of the composite sheet 20 will be described with reference to FIG. 1 and FIG.
As shown in Fig. 2, the composite sheet 20 includes a noncombustible sheet 1 and a fiber sheet 12 bonded to one surface (the lower surface in Fig. 2) of the noncombustible sheet 1. In Fig. 2, the thickness of the noncombustible sheet 1 is shown as a different thickness from that in Fig. 1 to match the thickness of the fiber sheet 12.
The fiber sheet 12 is formed using, for example, a nonwoven fabric.
The basis weight of the composite sheet 20 is within the range of 10 g/ ^m2 to 35 g/ ^m2 , and preferably within the range of 15 g/ ^m2 to 30 g/ ^m2 . If the basis weight of the composite sheet 20 is within the above range, a good balance of sheet strength, water resistance, flexibility, and moisture permeability is achieved.

(Absorbent article)
The configuration of the absorbent article 30 will be described using FIG. 3 while referring to FIG. 1 and FIG.
The absorbent article 30 comprises a top sheet 31 , a back sheet 32 , and an absorbent body 33 .
The top sheet 31 is liquid permeable.
The back sheet 32 is a composite sheet 20 and is liquid impermeable.
The absorbent body 33 is disposed between the top sheet 31 and the back sheet 32 .
The above-described first embodiment is one example of the present invention, and the present invention is not limited to the above-described first embodiment. Various modifications can be made depending on the design, etc., even in forms other than this embodiment, as long as they do not deviate from the technical idea of the present invention.

(Effects of the First Embodiment)
The fireproof sheet 1 of the first embodiment can provide the following effects.
(1) A polyolefin resin composition containing an inorganic filler in a range of 15% by mass to 90% by mass relative to the polyolefin resin, which is at least uniaxially stretched, has a total light transmittance of 50% or more, a moisture permeability of 3600 [g/( ^m2 ·24h)] to 8400 [g/( ^m2 ·24h)] and a basis weight of 50 [g/ ^m2 ] to 350 [g/ ^m2 ]. In addition, the polyolefin resin composition has a melt flow rate of 6 [g/10min] to 25 [g/10min] under a load of 21.18N in an environment of 190°C, and a melt flow ratio of 85 or less. The polyolefin resin further contains 80% by mass ^{or more and 99% by mass or less of linear low-density polyethylene having a melt flow rate of 1 to 5 g/10 min and a density of 0.920 to 0.935 g/cm 3 .} In addition, the polyolefin resin contains 1% by mass or more and 20% by mass or less of branched low-density polyethylene having a melt flow rate of 6 to 15 g/ ^{10 min and a density of 0.910 to 0.930 g/cm 3 .}

As a result, it is possible to provide a non-combustible sheet 1 that is capable of maintaining high moisture permeability while also having high strength and flexibility, and thus has moisture permeability and improved strength. This makes it possible to suppress warping that occurs in the non-combustible sheet 1.

(2) The polyolefin resin composition includes an inorganic filler that is more than 50% by mass based on the polyolefin resin.
As a result, the strength of the noncombustible sheet 1 can be improved.
(3) The stretching ratio is within the range of 3.0 times or more and 6.0 times or less.
As a result, it is possible to improve the moisture permeability by utilizing the voids generated by the stretching, and it is possible to improve the moisture permeability of the noncombustible sheet 1 .

(4) The inorganic filler is calcium carbonate.
As a result, the non-combustibility of the non-combustible sheet 1 can be improved.
(5) The polyolefin resin includes polypropylene or polyethylene.
As a result, it is possible to form the noncombustible sheet 1 using materials that are easy to obtain and process, thereby making it possible to improve the productivity of the noncombustible sheet 1.
(6) Linear low density polyethylene is formed using a metallocene catalyst.
As a result, it is possible to form a fireproof sheet 1 that has a good balance between moldability, sheet properties, particularly moisture permeability, strength, and flexibility.

(7) The inorganic filler contains calcium carbonate having a specific surface area in the range of 16,000 [cm ² /g] to 24,000 [cm ² /g].
As a result, it is possible to form a fireproof sheet 1 that has high moisture permeability and high water resistance.
Furthermore, the composite sheet 20 of the first embodiment can provide the following effects.
(8) It comprises a non-combustible sheet 1 and a fiber sheet 12 bonded to one side of the non-combustible sheet 1.
As a result, it is possible to provide a composite sheet 20 that has moisture permeability and can have improved strength.
Furthermore, the absorbent article 30 of the first embodiment can achieve the effects described below.

(9) The diaper includes a top sheet 31 having liquid permeability, a back sheet 32 having liquid impermeability, and an absorbent 33 having liquid retention properties disposed between the top sheet 31 and the back sheet 32. In addition, the back sheet 32 is a composite sheet 20.
As a result, it is possible to provide an absorbent article 30 that has moisture permeability and can have improved strength.
Furthermore, the non-combustible decorative board 10 of the first embodiment can achieve the effects described below.

(10) A noncombustible sheet 1, anchor layers (first anchor layer 2, second anchor layer 4) laminated on at least one surface of the noncombustible sheet 1, and a decorative layer 8 laminated on the anchor layer (first anchor layer 2). In addition, the decorative layer 8 has a top coat layer 8b formed using a curable resin, and the organic content of the anchor layer and the decorative layer 8 is 150 g/ ^m2 or less.
As a result, since the decorative layer 8 is laminated on the noncombustible sheet 1 via the anchor layer, the noncombustible decorative board 10 can be configured with excellent design and surface smoothness. Furthermore, since the decorative layer 8 has a top coat layer 8b formed using a curable resin, it can be configured with excellent performance in terms of stain resistance and scratch resistance. In addition, by setting the organic content mass of the anchor layer and the decorative layer 8 to 150 [g/ ^m2 ] or less, it is possible to provide a noncombustible decorative board 10 that has fire resistance as a noncombustible material and is suitable for applications that are subject to interior decoration restrictions.

As a result, it is possible to provide a non-flammable decorative panel 10 that is moisture permeable and has improved strength.

(Modification)
(1) In the first embodiment, the first anchor layer 2 is formed on the front surface of the noncombustible sheet 1, and the second anchor layer 4 is formed on the back surface of the noncombustible sheet 1, but this is not limited thereto. That is, for example, the first anchor layer 2 may be formed only on the front surface of the noncombustible sheet 1.
(2) In the first embodiment, the noncombustible decorative board 10 is configured by laminating the decorative layer 8 onto the first anchor layer 2, but the present invention is not limited to this. That is, the noncombustible decorative board 10 may be configured by forming an adhesive layer between the first anchor layer 2 and the decorative layer 8 to improve the adhesion (adhesion) between the first anchor layer 2 and the decorative layer 8.
Similarly, the non-combustible decorative board 10 has a configuration in which the primer layer 6 is laminated onto the second anchor layer 4, but is not limited to this. That is, the non-combustible decorative board 10 may have a configuration in which an adhesive layer is formed between the second anchor layer 4 and the primer layer 6 in order to improve the adhesion (adhesion) between the second anchor layer 4 and the primer layer 6.
As an example of the material for the adhesive layer, it is possible to use a material that exhibits adhesiveness when heated, such as a material whose main component is a chlorinated polyolefin resin, a polyurethane resin, an epoxy resin, an acrylic resin, a vinyl resin, a vinyl acetate resin, a polyester resin, an ethylene-vinyl acetate copolymer resin, an acrylic-vinyl acetate copolymer resin, a polyamide resin, or an ionomer resin.
(3) In the first embodiment, the absorbent article 30 is configured such that the back sheet 32 is a composite sheet 20, but this is not limited to this, and the back sheet 32 may be a non-combustible sheet 1.

With reference to the first embodiment, the non-combustible decorative boards of the examples and the non-combustible decorative boards of the comparative examples will be described below.
Example 1
The non-combustible decorative board of Example 1 was produced using materials and methods that satisfied the following conditions (A-1) to (G-1).
(A-1) A polyolefin resin composition containing 15% by mass of an inorganic filler relative to the polyolefin resin.
(B-1) Uniaxially stretched at a stretch ratio of 1.1.
(C-1) Total light transmittance is 50%.
(D-1). Moisture permeability is 3600 [g / (m ² · 24 h)].
(E-1) The basis weight is 50 [g/m ² ].
(F-1) The polyolefin resin composition has a melt flow rate of 6 [g/10 min] and a melt flow ratio of 85 under a load of 21.18 N in an environment of 190° C.
(G-1) The polyolefin resin contains 80% by mass of linear low-density polyethylene having a melt flow rate of 1 [g/10 min] and a density of 0.920 [g/cm ³ ], and 20% by mass of branched low-density polyethylene having a melt flow rate of 6 [g/10 min] and a density of 0.910 [g/cm ³ ].

Example 2
The non-combustible decorative board of Example 2 was produced using materials and methods that satisfied the following conditions (A-2) to (G-2).
(A-2) A polyolefin resin composition containing 90% by mass of an inorganic filler relative to the polyolefin resin.
(B-2) Uniaxially stretched at a stretch ratio of 1.1.
(C-2) Total light transmittance is 50%.
(D-2). Moisture permeability is 8400 [g / (m ² · 24 h)].
(E-2) The basis weight is 350 [g/m ² ].
(F-2) The polyolefin resin composition has a melt flow rate of 25 [g/10 min] and a melt flow ratio of 85 under a load of 21.18 N in an environment of 190° C.
(G-2) The polyolefin resin contains 99% by mass of linear low-density polyethylene having a melt flow rate of 5 [g/10 min] and a density of 0.935 [g/cm ³ ], and 1% by mass of branched low-density polyethylene having a melt flow rate of 15 [g/10 min] and a density of 0.930 [g/cm ³ ].

Example 3
The non-combustible decorative board of Example 3 was produced using materials and methods that satisfied the following conditions (A-3) to (G-3).
(A-3) A polyolefin resin composition containing 50% by mass of an inorganic filler relative to the polyolefin resin.
(B-3) Uniaxially stretched at a stretch ratio of 4.0.
(C-3) Total light transmittance is 80%.
(D-3) Moisture permeability is 6000 [g / (m ² · 24 h)].
(E-3) The basis weight is 200 [g/m ² ].
(F-3) The polyolefin resin composition has a melt flow rate of 19 [g/10 min] and a melt flow ratio of 70 under a load of 21.18 N in an environment of 190° C.
(G-3) The polyolefin resin contains 85% by mass of linear low-density polyethylene having a melt flow rate of 3 [g/10 min] and a density of 0.930 [g/cm ³ ], and 15% by mass of branched low-density polyethylene having a melt flow rate of 11 [g/10 min] and a density of 0.920 [g/cm ³ ].

Example 4
The non-combustible decorative board of Example 4 was produced using materials and methods that satisfied the above-mentioned conditions (B-1) to (G-1) and the following condition (H).
(H) A polyolefin resin composition containing 80% by mass of an inorganic filler relative to the polyolefin resin.

Example 5
The non-combustible decorative board of Example 5 was produced using materials and methods that satisfied the above-mentioned conditions (A-1), (C-1) to (G-1) and the following condition (I).
(I). Uniaxially stretched at a stretch ratio of 3.0.

(Comparative Example 1)
The non-combustible decorative board of Comparative Example 1 was produced using materials and methods that satisfied the above-mentioned conditions (C-1) to (G-1) and the following conditions (J-1) to (L-1).
(J-1) A polyolefin resin composition containing 100 parts by mass of an inorganic filler and 1 part by mass of a polyester, per 100 parts by mass of a polyolefin resin.
(K-1) Uniaxially stretched at a stretch ratio of 2.8 times.
(L-1) The polyester is a polybasic acid, a polyhydric alcohol, and a monobasic acid having 14 carbon atoms.

(Comparative Example 2)
A non-combustible decorative board of Comparative Example 2 was produced using materials and methods that satisfied the above-mentioned conditions (C-1) to (G-1) and the following conditions (J-2) to (L-2).
(J-2) A polyolefin resin composition containing 300 parts by mass of an inorganic filler and 30 parts by mass of a polyester relative to 100 parts by mass of a polyolefin resin.
(K-2) Uniaxially stretched at a stretch ratio of 2.8 times.
(L-2) The polyester is a polybasic acid, a polyhydric alcohol, and a monobasic acid having 22 carbon atoms.

(Comparative Example 3)
A non-combustible decorative board of Comparative Example 3 was produced using materials and methods that satisfied the above-mentioned conditions (C-1) to (G-1), (J-1) and (K-1) and the following condition (M).
(M) The polyester is a polybasic acid, a polyhydric alcohol, and a monohydric alcohol having 12 carbon atoms.

(Performance evaluation, evaluation results)
The non-combustible decorative boards of Examples 1 to 5 and Comparative Examples 1 to 3 were subjected to a non-combustible test, a bending strength test, a tensile strength test, and a breaking strength test. The results are shown in Table 1.

<Non-flammability test>
In a heat generation test using a cone calorimeter tester in accordance with ISO 5660-1, it was evaluated whether the following requirements 1 to 3 were met.
1. The total calorific value is 8 MJ/ ^m2 or less.
2. The maximum heat generation rate does not exceed 200kW/ ^m2 for 10 seconds or more.
3. No cracks or holes penetrating to the back surface, which are harmful in terms of fire resistance, will occur.
As the non-combustible base material, a gypsum board was used.

<Bending strength test>
In a bending strength test in accordance with ISO178, it was evaluated whether or not damage occurred.
<Tensile strength test>
In a tensile strength test in accordance with ISO 527-2/1B/5, it was evaluated whether or not damage occurred.
<Breaking strength test>
In a breaking strength test in accordance with ISO 527-2/1A, it was evaluated whether or not damage occurred.

(Evaluation Criteria)
⊚: No problems occurred during sheet production or processing for each item.
◯: No significant defects occurred during sheet production or processing for each item.
△: For each item, problems may occur in sheet production or processing depending on the conditions, but there are no problems in use.
×: Defects occur in each item.
In addition, a sheet rated as "x" was deemed to have failed as a whole sheet.

As shown in Table 1, the non-flammable decorative boards of Examples 1 to 5 showed excellent performance in all evaluation tests. In contrast, the non-flammable decorative boards of Comparative Examples 1 to 3 showed inferior performance in all evaluation tests compared to the non-flammable decorative boards of Examples 1 to 5.

1...fireproof sheet, 2...first anchor layer, 4...second anchor layer, 6...primer layer, 8...decorative layer, 8a...pattern layer, 8b...topcoat layer, 10...fireproof decorative board, 12...fiber sheet, 20...composite sheet, 30...absorbent article, 31...surface sheet, 32...back sheet, 33...absorbent body

Claims (8)

A non-combustible sheet formed from a polyolefin resin composition containing an inorganic filler in a range of 15% by mass or more and 90% by mass or less relative to the polyolefin resin, which is at least uniaxially stretched, has a total light transmittance of 50% or more, a moisture permeability of 3600 g/( ^m2 ·24h) to 8400 g/( ^m2 ·24h) and a basis weight of 200 g/ ^m2 to 350 g/ ^m2 ,
The polyolefin resin composition has a melt flow rate of 6 g/10 min or more and 25 g/10 min or less at a load of 21.18 N in an environment of a temperature of 190° C., and a melt flow ratio, which is a ratio of a melt flow rate at a load of 98.07 N to a melt flow rate at a load of 9.81 N, of 85 or less;
The polyolefin resin contains 80% by mass or more and 99% by mass or ^less of linear low-density polyethylene having a melt flow rate of 1 g/10 min or more and 5 g/10 min or less and a density of 0.920 g/cm3 ^{or more and} 0.935 g/cm3 ^or less, and 1% by mass or more and 20% by mass or less of branched low-density polyethylene having a melt flow rate of 6 g/10 min or more and 15 g/10 min or less and a density of 0.910 g/cm3 or more and 0.930 g/cm3 or less. This noncombustible sheet is characterized in that it contains 2. The noncombustible sheet according to claim 1, wherein the inorganic filler is contained in an amount of 80 mass % or more based on the polyolefin resin. A composite sheet comprising the non-combustible sheet described in claim 1 or claim 2 and a fiber sheet attached to one side of the non-combustible sheet. The present invention comprises a top sheet having liquid permeability, a back sheet having liquid impermeability, and an absorbent body having liquid retention disposed between the top sheet and the back sheet,
4. An absorbent article, wherein the back sheet is a fire-retardant sheet as set forth in claim 1 or claim 2, or a composite sheet as set forth in claim 3. A non-combustible decorative board comprising the non-combustible sheet according to claim 1 or 2, an anchor layer laminated on at least one surface of the non-combustible sheet, and a decorative layer laminated on the anchor layer,
The decorative layer includes a top coat layer formed using a curable resin,
A non-flammable decorative board, characterized in that the organic content mass of the anchor layer and the decorative layer is 150 g/ ^m2 or less. A non-combustible sheet formed from a polyolefin resin composition containing an inorganic filler in an amount within the range of 15% by mass or more and 90% by mass or less relative to the polyolefin resin, which is at least uniaxially stretched, has a total light transmittance of 50% or more, a moisture permeability within the range of 3600 g/(m2 ^· 24h) to 8400 g/(m2 ^· 24h) and a basis weight within the range of 50 g/m2 ^to 350 g/ ^m2 ,
The polyolefin resin composition has a melt flow rate of 6 g/10 min or more and 25 g/10 min or less at a load of 21.18 N in an environment of a temperature of 190° C., and a melt flow ratio, which is a ratio of a melt flow rate at a load of 98.07 N to a melt flow rate at a load of 9.81 N, of 85 or less;
The polyolefin resin contains 80% by mass or more and 99% by mass or less of linear low-density polyethylene having a melt flow rate of 1 g/10 min or more and 5 g/10 min or less and a density ^of 0.920 g/cm3 ^{or more and} 0.935 g/cm3 or less, and 1% by mass or more and 20% by mass or less of branched low-density polyethylene having a melt flow rate of 6 g/10 min or more and 15 g/ ¹⁰ min or less and a density of 0.910 g/cm3 or more and 0.930 g /cm3 or less, an anchor layer laminated on at least one surface of the noncombustible sheet, and a decorative layer laminated on the anchor layer,
The decorative layer includes a top coat layer formed using a curable resin,
A non-flammable decorative board, characterized in that the organic content mass of the anchor layer and the decorative layer is 150 g/ ^m2 or less. 7. The non-flammable decorative board according to claim 5 or 6 , wherein the anchor layer contains a urethane-based resin containing vinyl chloride and acetate, or an acrylic-based resin containing vinyl chloride and acetate. The non-flammable decorative board according to claim 5 or 6, characterized in that the anchor layer is made of a urethane-based resin containing vinyl chloride and acetate, and the ratio of the content of the vinyl chloride and acetate to the content of the urethane-based resin (content (mass) of vinyl chloride and acetate/content (mass) of urethane-based resin) is within a range of 80/20 to 1/99 .

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