JP2001270017A - Air permeable interior material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an interior trim material such as wall paper or the like having air permeability, making the open time of bonding paste applied at the time of bonding execution properly long and excellent in execution properties. SOLUTION: The interior trim material is formed by bonding a nonwoven fabric surface material having air permeability and backing paper by a molten synthetic resin having a basis weight of a 3-40 g/m2 and has air permeability of 5 cm3/cm2.sec or less and moisture permeability of 100 g/m2.24 hr or more.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior material such as a moisture permeable wallpaper using a nonwoven fabric as a surface material.

[0002]

2. Description of the Related Art A nonwoven fabric has recently been used as a surface material for interior materials such as wallpaper in place of a polyvinyl chloride sheet which has been widely used in the past. This is because the nonwoven fabric is an environmentally friendly material that does not cause a pollution problem at the time of disposal, and has properties such as high quality appearance and feel unique to fibers and being affordable.

[0003] Generally, when affixing wallpaper or the like, vinyl acetate, ethylene vinyl acetate,
Elongated glue pool with a water-soluble synthetic resin glue, such as an acrylic emulsion, polyvinyl alcohol, or starch, applied alone or in combination, and a glued wallpaper folded over with its back inside. The so-called glue pool construction method of successively spreading and attaching to a wall is used. With impermeable wallpaper such as polyvinyl chloride sheet, the moisture contained in the glue does not evaporate from the surface through the wallpaper, etc., so the glue drying time (so-called open time) is long, and the wallpaper in the glue pool is Since there is no risk of adhesion, a large amount of (long) glue storage can be performed at one time.
The work efficiency of attaching to the wall is very good. On the other hand, the nonwoven fabric has a very high air permeability, so in the case of wallpaper using the nonwoven fabric as a surface material, the moisture of the applied glue quickly evaporates through the nonwoven fabric (open time is short). ) Since glue pooling is not possible, it is necessary to perform wall pasting work immediately after application, and there is a disadvantage that work efficiency is significantly reduced.

[0004] In addition, completely impervious wallpapers such as ordinary polyvinyl chloride sheets have drawbacks such as dew condensation and mold on the front and back surfaces of the wallpapers and the like. It is desired to have some moisture permeability.

Conventionally, as described above, an aqueous resin emulsion or an aqueous starch solution has been used for bonding the nonwoven fabric and the backing paper. However, in these methods, the nonwoven fabric and the backing paper contain moisture. Heat energy for evaporating and removing water is required, which has been a factor in increasing the cost required for bonding.

[0006]

SUMMARY OF THE INVENTION The present invention is intended to solve the above-mentioned problems, and efficiently adheres a nonwoven fabric surface material to a backing paper so that an interior material such as wallpaper can be adhered. The open time of the applied glue is long,
It is an object of the present invention to provide an interior material which is capable of forming a long-sized glue storage, and has excellent moisture permeability and an excellent effect of preventing dew condensation and mold.

[0007]

According to the present invention, as a result of various studies on the above-mentioned problems, the basis weight of the nonwoven fabric surface material and the backing paper has been determined.
The present inventors have found that the above-mentioned problems can be solved by bonding with a synthetic resin in a molten state of about 40 g / m ² , and have completed the present invention.

That is, in the present invention, the nonwoven surface material having air permeability and the backing paper are joined by a molten synthetic resin having a basis weight of 3 to 40 g / m ² , and the air permeability is 5 cm ³ / cm ^2.・ Second or less, moisture permeability 100g /
a interior material, characterized in that m is ² · 24 hr or more. It is desirable that the nonwoven surface material having air permeability and the backing paper are joined by applying a molten hot melt resin in a continuous or discontinuous fibrous form using a melt blown method. Further, it is desirable that the air-permeable nonwoven fabric surface material and the backing paper are joined by applying a powdery hot melt resin continuously or discontinuously and melting. Further, it is preferable that the nonwoven surface material having air permeability and the backing paper are joined by a synthetic resin melt-extruded into a film.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION The nonwoven fabric used as a surface material in the present invention is composed of cellulosic fibers such as cotton, viscose rayon and pulp, and synthetic fibers such as polyester, polyamide, polypropylene, polyvinyl alcohol and acrylic. Single fibers such as staples, spunbonds, and meltblowns are singly, mixed, or combined in a web-like form and combined.

[0010] The above-mentioned fibers may be various combinations of fibers having a small fineness or large fibers, and also a combination or lamination of various fibers such as matted fibers in order to provide concealing properties and bulkiness as an interior material. Can be Deodorant fibers and antibacterial fibers are also used. For the purpose of imparting shape stability and the like, hot-melt conjugate fibers are often used. The web obtained by accumulating the above fibers in a web form may be prepared by a dry method or a wet method.

[0011] These webs may be laminated as required and bonded or integrated by single or combination such as bonding with a chemical bonding agent, hot-pressure fusion bonding such as calendering, or mechanical means such as needle punching or water entanglement. Is done.
The nonwoven fabric as a surface material of the interior material has a basis weight of 20 to 150.
g / ^{m 2,} preferably it is desirable in the range of 40 to 100 g / ^{m 2,} rich in generally very breathable sheet. The obtained nonwoven fabric is generally subjected to post-processing such as printing, coloring, resin processing and the like, and embossing after being bonded to a backing paper. This post-processing includes foaming resin processing and the like.

In the present invention, a melt-extruded thermoplastic synthetic resin is used as a bonding agent for bonding a backing paper such as flameproof paper to the above nonwoven fabric surface material. Examples of the synthetic resin to be used include polyolefin resins such as polyethylene and polypropylene, and various resins such as polyamide, polyester, synthetic rubber, polyvinyl alcohol and vinyl acetate copolymer.

[0013] Interior materials such as wallpaper must be printed uniformly on the surface in the longitudinal and width directions. Density differences and spots in printing result in defects. Therefore, it is important that the surface nonwoven fabric and the backing paper are uniformly bonded so that the thickness and the air permeability do not become uneven. Needless to say, the nonwoven fabric used in the present invention must be uniform, and it is particularly preferable to use a nonwoven fabric whose thickness unevenness is controlled to an average value of ± 0.02 mm or less.

The most uniform method of bonding the nonwoven fabric and the backing paper while maintaining their texture is to use a so-called melt blown method, in which a hot melt resin in a molten state is extruded simultaneously with heated air, in a continuous or discontinuous manner. This is a method of bonding both by applying to at least one of them. For extruding the hot melt resin, a method using a nozzle, a method using a slit, or the like is adopted. As a second best method, a method in which a powdery hot melt resin is applied continuously or discontinuously and melted to bond them together. These bonding methods can provide an interior material having a better feeling than a conventional method of bonding the both with an aqueous emulsion.

Another method of bonding a nonwoven fabric and a backing paper according to the present invention is a method in which the nonwoven fabric and the backing paper are bonded together by a melted and extruded film. In the bonding process between the nonwoven fabric and the backing paper, the nonwoven fabric and the backing paper are introduced from both sides of the molten film extruded from the T-die, and then the three members are lightly pressed by a rotating roll to instantly bond. Done. At this time, the molten film is pushed into the uneven structure of the nonwoven fabric by the pressing action of the roll, and as a result, the film becomes a partially opened state from the state of the continuous impermeable membrane of the film, and as a whole an appropriate mode The air permeability will be maintained. At this time,
By maintaining the temperature of the melt extrusion die at a high temperature and reducing the viscosity of the molten resin, for example, in the case of polyethylene, by maintaining the temperature at 280 ° C. or higher, preferably at 300 ° C. or higher, the interior with more excellent air permeability and moisture permeability Material can be obtained.

It is preferable that the surface of the nonwoven fabric in contact with the film in the molten state is not smoothed by calendering or the like, and the average fineness of the fibers constituting the surface is 3 denier or more. Gives better moisture permeability to the interior material after bonding.

In the present invention, the amount of the synthetic resin for bonding the nonwoven fabric and the backing paper is 3 to 40 g / m ² . When the amount of the synthetic resin is less than 3 g / m ^2, not only sufficient adhesive strength is not obtained, but also the air permeability increases, and the finally obtained interior material has an air permeability of 5 cm ³ / cm ² · sec or more. In this case, the open time of the applied glue at the time of attaching the interior material to the wall is too short, and the working efficiency is remarkably reduced, which is not desirable. On the other hand, if the amount of the molten resin exceeds 40 g / m ² , it is uneconomical, the texture of the interior material is reduced, and the moisture permeability of the interior material is 100 g / m ^2.
-It is less than 24 hours, and in this case, undesirable phenomena such as dew condensation and generation of mold occur, which is not desirable.

As described above, the air permeability and the moisture permeability of the obtained interior material vary depending on the amount of the synthetic resin used for bonding.
Desirable air permeability of interior materials 5 from the point of work efficiency of wallpaper pasting
It is important to adjust the amount of the synthetic resin so as to obtain a water permeability of 100 g / m ² · 24 hr or more from the viewpoint of physical properties of the interior material, that is, cm ³ / cm ² · sec or less.

[0019]

The present invention will be described below with reference to examples. Example 1 A basis weight of 60 wt. prepare the carded web m ^2, the water flow entangling treatment (orifice diameter 0.1 mm, using a nozzle pitch 1.0 mm, 3 times with water column flow-sided than 45 kg / cm ² pressure,
From the other surface, a water column flow treatment was performed three times with a water column flow of 70 kg / cm ² , that is, a total of six times. Thereafter, it was dried and calendered on one side to obtain an entangled nonwoven fabric. The thickness of this non-woven fabric is 0.3
It was controlled within the range of 8 mm to 0.42 mm.

The obtained entangled nonwoven fabric was bonded to a flame-retardant paper having a basis weight of 110 g / m ² and generally used for backing wallpaper by a melt blown method. In this bonding, an EVA hot melt resin (3300 manufactured by Hirodyne Co., Ltd.) was used as the melt blown nozzle, the nozzle temperature was 185 ° C., the air temperature was 190 ° C., the air pressure was 1.4 kg / cm ² , and the coating amount was 1
The coating was performed under the conditions of 5 g / m ² , curtain spray system manufactured by Suntool Co., Ltd. The hot-melt resin was coated on the flame-retardant paper, and immediately after the coating, the entangled nonwoven fabric was continuously supplied onto the hot-melt resin, and the three members were pressed by a rotating roll and bonded.

Subsequently, printing, resin processing and hot embossing were performed on the nonwoven fabric surface to obtain an interior material. No print density difference occurred. This interior material has an air permeability of 0.3 cm ³ / cm ^2.
sec (JISL1096, A method), moisture permeability 5750 g
/ ^M 2 · 24hr indicates (JISZ 0208), easy to construction, comprising a supple, excellent gluing reservoir properties, and was the preferred interior material excellent in antifungal and anti-condensation properties.

Example 2 50% by weight of full dal rayon and a core of polyester
A spun lace nonwoven fabric having a basis weight of 40 g / m ² composed of 50% by weight of a composite fiber made of polyethylene whose sheath melts at about 135 ° C. was prepared. The thickness of this nonwoven fabric is 0.
It was in the range of 28 mm to 0.32 mm.

20 g of a powdery polyester resin (Hadek A5410 manufactured by Asahi Kasei Corporation) is placed on the nonwoven fabric.
/ M was uniformly applied at a rate of ^2, and laminating the backing condemnation燃紙having basis weight 90 g / m ^2, was heated under pressure to melt the powdery polyester resin bonds the non-woven fabric and backing paper. Thereafter, the nonwoven fabric surface was subjected to a silicone-based water repellent treatment, printing, embossing, and the like to obtain wallpaper. The resulting wallpaper has a suppleness and an air permeability of 0.2 cm ³ / cm ²
· Sec, shows the moisture permeability 6210g ^/ m 2 · 24hr,
It had excellent glue pooling properties, and was also excellent in mold resistance and dew condensation prevention.

Example 3 A card web having a basis weight of 17 g / m ² was continuously produced from a composite fiber of polyethylene having a denier of 5 denier and having a core of polyethylene terephthalate and a sheath which started melting at about 135 ° C. , 2 denier fineness, 1 basis weight
A web of composite fibers of the same composition having 6 g / m ² was laminated. The web after lamination was treated in a hot air oven at 145 ° C. and calendered at the exit of the oven to obtain a so-called thermal bonded nonwoven fabric having a uniform thickness.

Next, the thus-obtained thermal-bonded nonwoven fabric and the flame-retardant backing paper having a basis weight of 100 g / m ² were adhered by polyethylene which was melt-extruded into a film as follows. That is, the area around the slit is 33
Using a T-die heated to 0 ° C., a basis weight of 12 g / m ²
A non-woven fabric and a backing paper are introduced from both sides of the melted film so that the 5-denier composite fiber surface is on the film side, and the three members are heated with a rotating roll. Pressing completed the laminate. Subsequently, printing and resin processing were performed by a nonwoven fabric screen method to obtain a wallpaper interior material. No print density difference occurred. The obtained wallpaper interior material has a permeability of 0.1 cm.
³ / cm ² · sec or less, moisture permeability 550 g / m ² · 24
hr, had an appropriate open time, and was excellent in mold resistance and the like.

[0026]

The interior material of the present invention has a moderately suppleness, and the open time of the applied adhesive in the pasting operation is appropriately long, so that a long glue storage is possible. It is extremely excellent in work efficiency at the time of construction, and also has preferable physical properties such as dew condensation prevention property and mold resistance.

Claims (4)

[Claims] 1. A nonwoven surface material having air permeability and a backing paper are joined by a synthetic resin in a molten state having a basis weight of 3 to 40 g / m ² , and the air permeability is 5 cm ³ / cm ^2.
· Sec or less, interior material moisture permeability is equal to or is 100g ^/ m 2 · 24hr or more. 2. The air-permeable nonwoven fabric surface material and the backing paper are joined by applying a molten hot melt resin in a continuous or discontinuous fibrous form using a melt blown method. The interior material according to claim 1, wherein 3. The air-permeable nonwoven fabric surface material and the backing paper are joined by applying or melting a powdery hot melt resin continuously or discontinuously. The interior material according to claim 1. 4. The interior material according to claim 1, wherein the nonwoven surface material having air permeability and the backing paper are joined by a synthetic resin melt-extruded into a film.