CA1075981A - Process for making prepasted vinyl wall covering - Google Patents
Process for making prepasted vinyl wall coveringInfo
- Publication number
- CA1075981A CA1075981A CA259,565A CA259565A CA1075981A CA 1075981 A CA1075981 A CA 1075981A CA 259565 A CA259565 A CA 259565A CA 1075981 A CA1075981 A CA 1075981A
- Authority
- CA
- Canada
- Prior art keywords
- wall covering
- parts
- starch
- vinyl
- adhesive
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L3/00—Compositions of starch, amylose or amylopectin or of their derivatives or degradation products
- C08L3/02—Starch; Degradation products thereof, e.g. dextrin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C7/00—Paperhanging
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/04—Oxygen-containing compounds
- C08K5/07—Aldehydes; Ketones
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
- C08L33/04—Homopolymers or copolymers of esters
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0002—Wallpaper or wall covering on textile basis
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2201/00—Chemical constitution of the fibres, threads or yarns
- D06N2201/04—Vegetal fibres
- D06N2201/042—Cellulose fibres, e.g. cotton
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2203/00—Macromolecular materials of the coating layers
- D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06N2203/045—Vinyl (co)polymers
- D06N2203/048—Polyvinylchloride (co)polymers
Landscapes
- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Laminated Bodies (AREA)
- Adhesives Or Adhesive Processes (AREA)
- Manufacturing Of Multi-Layer Textile Fabrics (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
Abstract
PROCESS FOR MAKING PREPASTED VINYL WALL COVERING
Abstract of The Disclosure Fabric backed vinyl wall covering containing a dry, water activatable paste surface is made by the following process. The cotton-scrim backed vinyl wall covering is printed in a conventional manner. Immediately after the design is printed onto the fabric backed vinyl, an adhesive coating is applied. The coating, which is applied, com-prises 100 parts of pregelatinized starch particles having a dry particle size of less than 250 microns, 10 to 35 parts of an organic polymer and 100 to 300 parts of a volatile organic liquid which is a solvent for the organic polymer and a non-solvent for the pregelatinized starch.
The organic liquid is vaporized by heating. The resulting product is a vinyl wall covering containing a dried adhesive surface. In order to activate the adhesive surface, it is only necessary to wet the same. Due to the fact that little, if any, water is present in the initial adhesive application process, the fabric backing does not shrink during the manufacturing process. Nonuniform shrinking of the fabric backing interferes with adjacent edge matching and pattern matching of the wall covering when it is used.
Abstract of The Disclosure Fabric backed vinyl wall covering containing a dry, water activatable paste surface is made by the following process. The cotton-scrim backed vinyl wall covering is printed in a conventional manner. Immediately after the design is printed onto the fabric backed vinyl, an adhesive coating is applied. The coating, which is applied, com-prises 100 parts of pregelatinized starch particles having a dry particle size of less than 250 microns, 10 to 35 parts of an organic polymer and 100 to 300 parts of a volatile organic liquid which is a solvent for the organic polymer and a non-solvent for the pregelatinized starch.
The organic liquid is vaporized by heating. The resulting product is a vinyl wall covering containing a dried adhesive surface. In order to activate the adhesive surface, it is only necessary to wet the same. Due to the fact that little, if any, water is present in the initial adhesive application process, the fabric backing does not shrink during the manufacturing process. Nonuniform shrinking of the fabric backing interferes with adjacent edge matching and pattern matching of the wall covering when it is used.
Description
10~5981 :
PROCESS FOR MAKING PR~PASTED VINYL WALL COVERI~G
'' ~
BACKGROUND OF THE INVENTION
Field of the Invention This invention is directed to a process for making prepasted vinyl wall covering.
Description of the Prior Art - Many articles of manufacture are made with re--moistenable adhesive backings, such items include: postage stamps, envelopes, gummed labels, tape, wall paper (including cotton-scrim backed vinyl coated wall paper) and other cellulosic sheet. The remoistenable adhesive can apparently be applied to the paper articles without detrimentally changing the length and width dimensions of the paper articles. The use of water based adhesive on paper articles, however, does appear to cause curling.
See U.S. Patents 2,477,344; 3,200,091 and 3,425,968.
Vinyl wall covering is available with an adhesive backing, but the adhesive is generally a pressure sensitive type ;of adhesive. Attempts to apply starch water solutions to cotton-scrim backed vinyl wall covering have resulted in a nonuniform change in dimension of the wall covering.
The nonuniform change in dimension was probably due to a shrinking of the cotton-scrim backing when the cotton scrim-backing was impregnated with the water solution then dried. This lack of dimensional uniformity in the wall covering results in patterns in adjacent sheets not matching - . .: .
` `- 1075981 '~
when the sheets are hung on the walls and also in the edges of the sheets not meeting properly.
Starch particles suspended in an organic solution of a binder polymer are appl;ed to a fabric backing of vin~l wall covering. The solvent is then removed leaving the starch e~bedded in an organic binder pol~mer matrix. The binder matrix holds the starch particles in place with respect to each other and onto the cotton-scrim backing.
Accordingly, the mvention provides a process for prepasting a wall covering consisting essentially of a flexible vinyl film having a fabric backing which process comprises applying to the fabric backing a composition comprising 100 parts of a water moistenable starch, 10 to 35 parts of an organic polymer characterized by a tangent mLdulus of elasticity in bending at 5~ of from 10 to 3,000 M Pa and 100 to 300 parts of an organic liquid having a boiling point of frQm 45 & to 150C which liquid is a solvent .
~ for the o~ganic polymer and a non-solvent for the pregelatinized starch.
: .
When the matrix containing staxch particles is brought into con-tact with water the starch particles are wetted and become adhesive. The vinyl wall coveri~ng produced does not shrink due to the application of the ,.
non aqueous adhesive to the fabric backing resulting in good pattern match in ` 20 use. In addition, good edge match is achieved. The organic solvent causes neither shrinking nor stretch of the fabric backing.
BRIEF DESCRIPTION OF THE DR~WING
~- Figure 1 is a schematic drawing of a typical vinyl wall covering design printing machine containing an additional adhesive application stage.
The one additional stage employs the use of a turnaround roller and an adh~sive applicator. The turnorownd roller turns the wall covering fr~m vinyl side down to fabric backing side down so that the adhesive applicator can apply the supended starch and binder in organic solvent to the fabric ~acking.
, -" 1075981 The drying stage of the device is conventional.
Figure 2 is an isometric view of the adhesive appli-cator section of the machine of Figure 1.
; DESCRIPTION OF THE PREFERRED EMBODIMENT
A prepasted fabric backed vinyl wall covering is made by applying an adhesive to the fabric back. The adhesive, as applied, contains a water moistenable pre-gelatinized starch suspended in an organic solution of a binder polymer and is substantially free of water. The solvent has essentially the same volatility as the solvent for the ink used to print the vinyl so that the binder solvent will be moved at about the same time and rate that the solvent ink is removed. The term pregelatinized starch as used herein also includes water moistenable adhesive starches prepared by chemically modifying starches which - modification usually also involves pregelatinization.
,' The vinyl film used in making the wall covering is - conventional. It is composed of polyvinyl chloride con-taining plastizers, fillers and other conventional com-pounding ingredients. The film has a thickness of from about 5 to 15 mils. The film has a fabric backing applied directly to the film with no intermediate paper layer.
The fabric backing again is conventional in vinyl wall - covering. The vinyl is calendered onto the fabric backing in the known conventional manner using heat and pressure.
" 107S981 - The fabric backing which is employed in the practice of the present invention can be cotton scrim or any of the non-woven fabrics made from long filaments. By long filaments is meant filaments having an average length of at least 5 mm. The preferred non-woven fabrics are those made from polyester filaments These non-woven fabrics are well known and generally used in making fabric backed vinyl wall covering. The problems which the present invention solve however are primarily in the area of - 10 cotton-scrim backed wall coverings and hence for the pur-, poses of the present invention cotton scrim is the preferred fabric backing.
The starch, which is used in making the paste, is a water moistenable starch and preferably has a particle .~
size less than 250 microns. The lower limit of particle size is not critical though dusting occurs at lower levels.
The preferred starch is a pregelatinized amioca starch - having an amylopectin structure and a particle size of ; about 180 microns. Pregelatinized starches such as those derived from corn, wheat, rice, potato, and tapioca may be used. Also included are the known chemically modified starches used in adhesiues such as starch esters and starch ethers. Examples are starch acetate, hydroxy ethyl or hydroxy propyl starch and sodium carboxy methyl starch.
The starch is present at a level of 100 parts. By a "moistenable starch" is meant a starch that will become adhesive upon contact with water for one minute at room temperature. The term also includes British gums and dextrines but these latter two materials are not preferred.
:, 1(:)75981 In addition to the starch, from 10 to 35 parts of an organic polymer are present in the paste. Organic polymers which can be employed include those which will adhere to the vinyl, are tack free in the solventless state and are pliable sO that the coated wall covering can be - rolled up. Such polymers have a tangent modulus of elas-ticity in bending at up to 5~ of from 10 to 3,000 MPa (mega Pascals) The modulus is determined according to ASTM
method D 790-71. The test is run at room temperature (15C-25C). The polymer is preferably an acrylic polymer such as a copolymer of ethyl acrylate and of methacrylate, or a terpolymer of methyl methacrylate, ethyl acrylate and acrylic or methacrylic acid. Rubbery copolymers such as those of butadiene and styrene are also useful, as are mixtures of polymers.
The solvent for the organic polymer, which is also the non-solvent suspending agent for the pregelatinized ~tarch has a boiling point of from 45C to 150C preferably 55C to 120C. The preferred solvents are methyl ethyl ketone or methyl isobutyl ketone and mixtures of one or more of the recited ketones with 1 - 10~ by weight based upon total solvent weight of isopropol alcohol. Other solvents such as methanol, ethanol, isopropanol, toluene, zylene, benzene and mixtures thereof can also be used.
Alcohol is normally present because it is used to solubilize the waxy stripping agent used.
Cellulosic materials can be used as a "slip agent"
to aid in sliding the covering into place on the surface being covered. Hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, hydroxypropyl ; methyl cellulose and the methyl ether of cellulose can be used for this purpose with minor adjustments in the formu-lation.
When the preferred combination of ingredients is used, the remoistened wall covering can be adjusted in position on wallboard up to ten minutes after application.
The slip agent is present at a level of from 1 to 30 preferably 10 to 20 parts.
Biocides can also be present in amounts of 0.1 to 10.0 parts preferably 1 to 5 parts. These materials are known in the starch adhesive art. They include among other things arsenics, mercurials and phenols.
Biocides which can be used are specifically exemplified by tributyltin oxide, phenyl mercury acetate N-trichoromethyl thio-4-cyclohexane 1,2-dicarboximide, parachlorometacresol, - 3,5-dimethyltetrahydro 1,3,5, 2-H-thiadiazine-2-thione, dodecylguanidine hydrochloride, dimethoxane, pentachloro-phenol, and 1-(3-chloroallyl)-3,5,7-triaza-1-azonia-adamantane chloride.
The preferred compositions also contain a release agent to allow the wall covering to be removed from the - wall when it is no longer wanted. Such release agents are present at a level of 0.1 to 10 parts and preferably 1 to 5 parts. They include hydrocarbon waxes such as a Carbo-wax release agent as well as other well known release agents.
The adhesive is applied to the fabric back of the vinyl wall covering at a level of from about 5 to 40 grams per square meter (gms/mz). The preferred method for applying adhesive is by using a 14 to 24 line per centimeter trihelical applicator roll. A doctor knife is positioned on the roll to provide uniform application of the adhesive.
In the Examples which follow as elsewhere in the specification, all parts and percentages are by weight unless otherwise specified.
To a container equipped with a *Cowles mixer was added 171 parts of methyl ethyl ketone. Then was added with stirring a ccpolymer of methyl ~i ` methacrylate and ethyl acrylate. The ratio of monomers was 64 moles of methyl methacrylate to every 36 moles of ethyl acrylate. The estimated flexural modulus was 1,400 M2a. m e mLxture was stirred for 15 minutes to dissolve the oopiolymer. To a separate contalner was added 1.8 parts of isopropanol and 1.8 parts of methyl ethyl ketone. Then 2.34 parts of *Carbowax 20M were added and the mixture was heated to 60C to form a solution.
*Ca~bowax 20M is a polyethylene wax having a weight average molecular weight of about two thousand. In this particular application it was a release agent. m e Carbowax solutian was then added to the acrylate solution in methyl ethyl ketone. Also added with agitation were 0.9 parts of N-trichloromethylthio-4-cyclohexene 1,2 dicarbco3nide fungicide and 15 parts of hydroxy propyl methyl oe llulose slip agent. m en 100 parts *Instant Amioca starch was added and mixing was continued for 15 minutes. *Instant Anioca is a pregelat mized, long chain carhohydrate with an amylopectin structure. It is derived from ';
~ * Trade marks ';
, ,, ~
; D, - 8 -., 10759~31 - waxy maize corn. The starch has a particle size of less than 180 microns.
The adhesive prepared as described above was then applied to cotton-scrim backed vinyl wall covering as shown in the drawing and described below.
A cotton-scrim backed vinyl wall covering 1 was run through a series of conventional printing rollers 2a, 2b, 2c and 2d in order to imprint a design upon the vinyl , side of the wall covering. The wall covering 1 was then run through a reverse roll arrangement 4 where the adhesive 6 of the present example was applied to the fabric side of the wall covering by calender roll 5. Calender roll 5 draws adhesive 6 from pan 7. Doctor blade 8 limits the amount of adhesive on roll 5. The adhesive was applied at a level of 20.7 gms/m2 dry basis. The wall covering was then passed over heated roll 9 and through drying oven 10 where the solvent is removed both from the printed sur-face and from the adhesive surface by heated air. The adhesive was applied at a 45~ total solvent content. The air used for drying is first heated in heater 12, blown through drying oven 10 by blower 14 and exhausted through duct 16. The drying arrangement is conventional, known in the art and only shown schematically here.
The wall covering was applied to new dry wall to determine the ply adhesion. Prior to application to the wall the strips were soaked in water for 30 seconds, then drained for 30 seconds. The ply adhesion test consists of cutting a 5.16 cm wide strip about 46.4 cm long in the hung wall covering. The end is pulled away from the wall _ g _ 10'75~81 and the strip is pulled off with a tensiometer. A fish scale calibrated in grams is convenient to use. The test is run on the center and left and right sides. The results reported are the average of the three.
; 5 The ply adhesions in force units were as follows:
After After After 16 hrs. 40 hrs. 1 wk . . .
340 grams 556 grams 545 grams The ply adhesion to painted plaster at the end of 16 hours was 227 grams and at the end of one week was 113 grams.
The pattern matching and edge matching of the vinyl wall covering produced according to this example was excellent.
To a container equipped with a Cowles mixer was added 138.5 parts of methyl ethyl ketone. To the methyl ethyl ketone was then added with stirring a dry powered ; copolymer of methyl methacrylate and ethyl acrylate. There was a ratio of 64 moles of methyl methacrylate to every 36 moles of ethyl acrylate in the copolymer. The estimated flexural modulus was 1,400 MPa. The solution was stirred for 15 minutes to dissolve the copolymer. To a separate container was added 1.8 parts of isopropanol and 1.8 parts of methyl ethyl ketone. Then 2.34 parts of Carbowax 20M
heated to 60C. are dissolved in the solvent mixture.
Carbowax 20M is a polyethylene having a weight average molecular weight of about two thousand. In this particular application it is a release agent. The Carbowax solution , ~ ` ` .
'"
' .',''` . . . .
..
was then added to the acrylate solution in methyl ethyl - ket3ne. Also added with agitation were 0.9 parts of N-trichloromethylthio-4-cyclohexene 1,2-dicarboximide fungacide and 15 parts of hydroxy propyl methyl cellulose : .;
sli~ agent. Then 100 parts of a pregelatinized hydroxy propylated starch derived from a yellow dent corn having a particle size of about 200 microns was added and mixing was continued for 15 minutes.
A cotton-scrim backed vinyl wall covering was run through a series of conventional printing rollers 2a, 2b~
2c and 2d in order to imprint a design upon the vinyl side of the wall covering. The wall covering 1 was then run through a reverse roll arrangement to apply the adhesive and dried as in Example 1. The adhesive was applied at a 50~ total solvent content. There was some pick off when embossing was employed on the embosser heating drum and on t;he rubber embosser backup roll. The adhesive was applied at a level of 22.4 gms/m2 dry basis.
The wall covering was applied to new dry wall to ~; 20 determine the ply adhesion. The ply adhesion test was the same as that used in Example 1.
The ply adhesions in force units were as follows:
After After After 16 hrs. 40 hrs. 1 wk.
~` 25 556 grams 795 grams 880 grams The ply adhesion to painted plaster at the end of 16 hours was 340 grams and at the end of one week was 170 grams.
The pattern matching and edge matching of the vinyl wall covering produced according to this example was excellent.
.
PROCESS FOR MAKING PR~PASTED VINYL WALL COVERI~G
'' ~
BACKGROUND OF THE INVENTION
Field of the Invention This invention is directed to a process for making prepasted vinyl wall covering.
Description of the Prior Art - Many articles of manufacture are made with re--moistenable adhesive backings, such items include: postage stamps, envelopes, gummed labels, tape, wall paper (including cotton-scrim backed vinyl coated wall paper) and other cellulosic sheet. The remoistenable adhesive can apparently be applied to the paper articles without detrimentally changing the length and width dimensions of the paper articles. The use of water based adhesive on paper articles, however, does appear to cause curling.
See U.S. Patents 2,477,344; 3,200,091 and 3,425,968.
Vinyl wall covering is available with an adhesive backing, but the adhesive is generally a pressure sensitive type ;of adhesive. Attempts to apply starch water solutions to cotton-scrim backed vinyl wall covering have resulted in a nonuniform change in dimension of the wall covering.
The nonuniform change in dimension was probably due to a shrinking of the cotton-scrim backing when the cotton scrim-backing was impregnated with the water solution then dried. This lack of dimensional uniformity in the wall covering results in patterns in adjacent sheets not matching - . .: .
` `- 1075981 '~
when the sheets are hung on the walls and also in the edges of the sheets not meeting properly.
Starch particles suspended in an organic solution of a binder polymer are appl;ed to a fabric backing of vin~l wall covering. The solvent is then removed leaving the starch e~bedded in an organic binder pol~mer matrix. The binder matrix holds the starch particles in place with respect to each other and onto the cotton-scrim backing.
Accordingly, the mvention provides a process for prepasting a wall covering consisting essentially of a flexible vinyl film having a fabric backing which process comprises applying to the fabric backing a composition comprising 100 parts of a water moistenable starch, 10 to 35 parts of an organic polymer characterized by a tangent mLdulus of elasticity in bending at 5~ of from 10 to 3,000 M Pa and 100 to 300 parts of an organic liquid having a boiling point of frQm 45 & to 150C which liquid is a solvent .
~ for the o~ganic polymer and a non-solvent for the pregelatinized starch.
: .
When the matrix containing staxch particles is brought into con-tact with water the starch particles are wetted and become adhesive. The vinyl wall coveri~ng produced does not shrink due to the application of the ,.
non aqueous adhesive to the fabric backing resulting in good pattern match in ` 20 use. In addition, good edge match is achieved. The organic solvent causes neither shrinking nor stretch of the fabric backing.
BRIEF DESCRIPTION OF THE DR~WING
~- Figure 1 is a schematic drawing of a typical vinyl wall covering design printing machine containing an additional adhesive application stage.
The one additional stage employs the use of a turnaround roller and an adh~sive applicator. The turnorownd roller turns the wall covering fr~m vinyl side down to fabric backing side down so that the adhesive applicator can apply the supended starch and binder in organic solvent to the fabric ~acking.
, -" 1075981 The drying stage of the device is conventional.
Figure 2 is an isometric view of the adhesive appli-cator section of the machine of Figure 1.
; DESCRIPTION OF THE PREFERRED EMBODIMENT
A prepasted fabric backed vinyl wall covering is made by applying an adhesive to the fabric back. The adhesive, as applied, contains a water moistenable pre-gelatinized starch suspended in an organic solution of a binder polymer and is substantially free of water. The solvent has essentially the same volatility as the solvent for the ink used to print the vinyl so that the binder solvent will be moved at about the same time and rate that the solvent ink is removed. The term pregelatinized starch as used herein also includes water moistenable adhesive starches prepared by chemically modifying starches which - modification usually also involves pregelatinization.
,' The vinyl film used in making the wall covering is - conventional. It is composed of polyvinyl chloride con-taining plastizers, fillers and other conventional com-pounding ingredients. The film has a thickness of from about 5 to 15 mils. The film has a fabric backing applied directly to the film with no intermediate paper layer.
The fabric backing again is conventional in vinyl wall - covering. The vinyl is calendered onto the fabric backing in the known conventional manner using heat and pressure.
" 107S981 - The fabric backing which is employed in the practice of the present invention can be cotton scrim or any of the non-woven fabrics made from long filaments. By long filaments is meant filaments having an average length of at least 5 mm. The preferred non-woven fabrics are those made from polyester filaments These non-woven fabrics are well known and generally used in making fabric backed vinyl wall covering. The problems which the present invention solve however are primarily in the area of - 10 cotton-scrim backed wall coverings and hence for the pur-, poses of the present invention cotton scrim is the preferred fabric backing.
The starch, which is used in making the paste, is a water moistenable starch and preferably has a particle .~
size less than 250 microns. The lower limit of particle size is not critical though dusting occurs at lower levels.
The preferred starch is a pregelatinized amioca starch - having an amylopectin structure and a particle size of ; about 180 microns. Pregelatinized starches such as those derived from corn, wheat, rice, potato, and tapioca may be used. Also included are the known chemically modified starches used in adhesiues such as starch esters and starch ethers. Examples are starch acetate, hydroxy ethyl or hydroxy propyl starch and sodium carboxy methyl starch.
The starch is present at a level of 100 parts. By a "moistenable starch" is meant a starch that will become adhesive upon contact with water for one minute at room temperature. The term also includes British gums and dextrines but these latter two materials are not preferred.
:, 1(:)75981 In addition to the starch, from 10 to 35 parts of an organic polymer are present in the paste. Organic polymers which can be employed include those which will adhere to the vinyl, are tack free in the solventless state and are pliable sO that the coated wall covering can be - rolled up. Such polymers have a tangent modulus of elas-ticity in bending at up to 5~ of from 10 to 3,000 MPa (mega Pascals) The modulus is determined according to ASTM
method D 790-71. The test is run at room temperature (15C-25C). The polymer is preferably an acrylic polymer such as a copolymer of ethyl acrylate and of methacrylate, or a terpolymer of methyl methacrylate, ethyl acrylate and acrylic or methacrylic acid. Rubbery copolymers such as those of butadiene and styrene are also useful, as are mixtures of polymers.
The solvent for the organic polymer, which is also the non-solvent suspending agent for the pregelatinized ~tarch has a boiling point of from 45C to 150C preferably 55C to 120C. The preferred solvents are methyl ethyl ketone or methyl isobutyl ketone and mixtures of one or more of the recited ketones with 1 - 10~ by weight based upon total solvent weight of isopropol alcohol. Other solvents such as methanol, ethanol, isopropanol, toluene, zylene, benzene and mixtures thereof can also be used.
Alcohol is normally present because it is used to solubilize the waxy stripping agent used.
Cellulosic materials can be used as a "slip agent"
to aid in sliding the covering into place on the surface being covered. Hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, hydroxypropyl ; methyl cellulose and the methyl ether of cellulose can be used for this purpose with minor adjustments in the formu-lation.
When the preferred combination of ingredients is used, the remoistened wall covering can be adjusted in position on wallboard up to ten minutes after application.
The slip agent is present at a level of from 1 to 30 preferably 10 to 20 parts.
Biocides can also be present in amounts of 0.1 to 10.0 parts preferably 1 to 5 parts. These materials are known in the starch adhesive art. They include among other things arsenics, mercurials and phenols.
Biocides which can be used are specifically exemplified by tributyltin oxide, phenyl mercury acetate N-trichoromethyl thio-4-cyclohexane 1,2-dicarboximide, parachlorometacresol, - 3,5-dimethyltetrahydro 1,3,5, 2-H-thiadiazine-2-thione, dodecylguanidine hydrochloride, dimethoxane, pentachloro-phenol, and 1-(3-chloroallyl)-3,5,7-triaza-1-azonia-adamantane chloride.
The preferred compositions also contain a release agent to allow the wall covering to be removed from the - wall when it is no longer wanted. Such release agents are present at a level of 0.1 to 10 parts and preferably 1 to 5 parts. They include hydrocarbon waxes such as a Carbo-wax release agent as well as other well known release agents.
The adhesive is applied to the fabric back of the vinyl wall covering at a level of from about 5 to 40 grams per square meter (gms/mz). The preferred method for applying adhesive is by using a 14 to 24 line per centimeter trihelical applicator roll. A doctor knife is positioned on the roll to provide uniform application of the adhesive.
In the Examples which follow as elsewhere in the specification, all parts and percentages are by weight unless otherwise specified.
To a container equipped with a *Cowles mixer was added 171 parts of methyl ethyl ketone. Then was added with stirring a ccpolymer of methyl ~i ` methacrylate and ethyl acrylate. The ratio of monomers was 64 moles of methyl methacrylate to every 36 moles of ethyl acrylate. The estimated flexural modulus was 1,400 M2a. m e mLxture was stirred for 15 minutes to dissolve the oopiolymer. To a separate contalner was added 1.8 parts of isopropanol and 1.8 parts of methyl ethyl ketone. Then 2.34 parts of *Carbowax 20M were added and the mixture was heated to 60C to form a solution.
*Ca~bowax 20M is a polyethylene wax having a weight average molecular weight of about two thousand. In this particular application it was a release agent. m e Carbowax solutian was then added to the acrylate solution in methyl ethyl ketone. Also added with agitation were 0.9 parts of N-trichloromethylthio-4-cyclohexene 1,2 dicarbco3nide fungicide and 15 parts of hydroxy propyl methyl oe llulose slip agent. m en 100 parts *Instant Amioca starch was added and mixing was continued for 15 minutes. *Instant Anioca is a pregelat mized, long chain carhohydrate with an amylopectin structure. It is derived from ';
~ * Trade marks ';
, ,, ~
; D, - 8 -., 10759~31 - waxy maize corn. The starch has a particle size of less than 180 microns.
The adhesive prepared as described above was then applied to cotton-scrim backed vinyl wall covering as shown in the drawing and described below.
A cotton-scrim backed vinyl wall covering 1 was run through a series of conventional printing rollers 2a, 2b, 2c and 2d in order to imprint a design upon the vinyl , side of the wall covering. The wall covering 1 was then run through a reverse roll arrangement 4 where the adhesive 6 of the present example was applied to the fabric side of the wall covering by calender roll 5. Calender roll 5 draws adhesive 6 from pan 7. Doctor blade 8 limits the amount of adhesive on roll 5. The adhesive was applied at a level of 20.7 gms/m2 dry basis. The wall covering was then passed over heated roll 9 and through drying oven 10 where the solvent is removed both from the printed sur-face and from the adhesive surface by heated air. The adhesive was applied at a 45~ total solvent content. The air used for drying is first heated in heater 12, blown through drying oven 10 by blower 14 and exhausted through duct 16. The drying arrangement is conventional, known in the art and only shown schematically here.
The wall covering was applied to new dry wall to determine the ply adhesion. Prior to application to the wall the strips were soaked in water for 30 seconds, then drained for 30 seconds. The ply adhesion test consists of cutting a 5.16 cm wide strip about 46.4 cm long in the hung wall covering. The end is pulled away from the wall _ g _ 10'75~81 and the strip is pulled off with a tensiometer. A fish scale calibrated in grams is convenient to use. The test is run on the center and left and right sides. The results reported are the average of the three.
; 5 The ply adhesions in force units were as follows:
After After After 16 hrs. 40 hrs. 1 wk . . .
340 grams 556 grams 545 grams The ply adhesion to painted plaster at the end of 16 hours was 227 grams and at the end of one week was 113 grams.
The pattern matching and edge matching of the vinyl wall covering produced according to this example was excellent.
To a container equipped with a Cowles mixer was added 138.5 parts of methyl ethyl ketone. To the methyl ethyl ketone was then added with stirring a dry powered ; copolymer of methyl methacrylate and ethyl acrylate. There was a ratio of 64 moles of methyl methacrylate to every 36 moles of ethyl acrylate in the copolymer. The estimated flexural modulus was 1,400 MPa. The solution was stirred for 15 minutes to dissolve the copolymer. To a separate container was added 1.8 parts of isopropanol and 1.8 parts of methyl ethyl ketone. Then 2.34 parts of Carbowax 20M
heated to 60C. are dissolved in the solvent mixture.
Carbowax 20M is a polyethylene having a weight average molecular weight of about two thousand. In this particular application it is a release agent. The Carbowax solution , ~ ` ` .
'"
' .',''` . . . .
..
was then added to the acrylate solution in methyl ethyl - ket3ne. Also added with agitation were 0.9 parts of N-trichloromethylthio-4-cyclohexene 1,2-dicarboximide fungacide and 15 parts of hydroxy propyl methyl cellulose : .;
sli~ agent. Then 100 parts of a pregelatinized hydroxy propylated starch derived from a yellow dent corn having a particle size of about 200 microns was added and mixing was continued for 15 minutes.
A cotton-scrim backed vinyl wall covering was run through a series of conventional printing rollers 2a, 2b~
2c and 2d in order to imprint a design upon the vinyl side of the wall covering. The wall covering 1 was then run through a reverse roll arrangement to apply the adhesive and dried as in Example 1. The adhesive was applied at a 50~ total solvent content. There was some pick off when embossing was employed on the embosser heating drum and on t;he rubber embosser backup roll. The adhesive was applied at a level of 22.4 gms/m2 dry basis.
The wall covering was applied to new dry wall to ~; 20 determine the ply adhesion. The ply adhesion test was the same as that used in Example 1.
The ply adhesions in force units were as follows:
After After After 16 hrs. 40 hrs. 1 wk.
~` 25 556 grams 795 grams 880 grams The ply adhesion to painted plaster at the end of 16 hours was 340 grams and at the end of one week was 170 grams.
The pattern matching and edge matching of the vinyl wall covering produced according to this example was excellent.
.
Claims (8)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A process for prepasting a wall covering consisting essentially of a flexible vinyl film having a fabric backing which process comprises applying to the fabric backing a composition comprising 100 parts of a water moistenable starch, 10 to 35 parts of an organic polymer characterized by a tangent modulus of elasticity in bending at 5% of from 10 to 3,000 M Pa and 100 to 300 parts of an organic liquid having a boiling point of from 45°C to 150°C which liquid is a solvent for the organic polymer and a non-solvent for the pregelatinized starch.
2. The process of claim 1 wherein the starch is a pregelatinized amioca starch.
3. The process of claim 1 wherein the organic liquid is methyl ethyl ketone.
4. The process of claim 1 wherein the organic liquid is methyl isobutyl ketone.
5. The process of claim 1 wherein the liquid is a mixture of a ketone with an alcohol.
6. The process of claim 1 wherein the organic polymer is a copolymer of ethylacrylate and methyl methacrylate.
7. The process of claim 1 wherein the organic polymer is a copolymer of ethyl acrylate, methyl methacrylate and acrylic acid.
8. The process of claim 1 wherein the water moistenable starch has a particle size of less than 250 microns.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US66009176A | 1976-02-23 | 1976-02-23 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1075981A true CA1075981A (en) | 1980-04-22 |
Family
ID=24648101
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA259,565A Expired CA1075981A (en) | 1976-02-23 | 1976-08-20 | Process for making prepasted vinyl wall covering |
Country Status (6)
| Country | Link |
|---|---|
| JP (1) | JPS52103567A (en) |
| CA (1) | CA1075981A (en) |
| DE (1) | DE2644476C3 (en) |
| FR (1) | FR2341447A1 (en) |
| GB (1) | GB1511110A (en) |
| IT (1) | IT1070598B (en) |
Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2117271A (en) * | 1982-03-23 | 1983-10-12 | Reed International Ltd | Dry-on dry-off wallcovering |
| GB8612696D0 (en) * | 1986-05-23 | 1986-07-02 | House Of Mayfair Ltd | Producing self adhesive sheet materials |
| GB9119655D0 (en) * | 1991-09-13 | 1991-10-23 | Forbo Cp Ltd | Self-adhesive wallcoverings |
| EP1352939A1 (en) * | 2002-04-12 | 2003-10-15 | Remy Industries N.V. | Starch-based glue paste compositions |
| DE102009021555B4 (en) * | 2009-05-15 | 2011-06-22 | AGM Mader GmbH, 85221 | Process for the preparation of a binder and use of such a binder for the production of a shaped body |
-
1976
- 1976-08-20 CA CA259,565A patent/CA1075981A/en not_active Expired
- 1976-09-10 IT IT27105/76A patent/IT1070598B/en active
- 1976-10-01 DE DE2644476A patent/DE2644476C3/en not_active Expired
- 1976-10-04 GB GB41143/76A patent/GB1511110A/en not_active Expired
- 1976-10-25 JP JP12741276A patent/JPS52103567A/en active Pending
-
1977
- 1977-01-27 FR FR7702243A patent/FR2341447A1/en active Granted
Also Published As
| Publication number | Publication date |
|---|---|
| FR2341447B1 (en) | 1978-10-20 |
| GB1511110A (en) | 1978-05-17 |
| IT1070598B (en) | 1985-03-29 |
| JPS52103567A (en) | 1977-08-30 |
| DE2644476A1 (en) | 1977-08-25 |
| FR2341447A1 (en) | 1977-09-16 |
| DE2644476C3 (en) | 1980-08-21 |
| DE2644476B2 (en) | 1978-06-08 |
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| Date | Code | Title | Description |
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| MKEX | Expiry |