JP2007277803A - Method for producing foamed wallpaper - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing foamed wallpaper having excellent curling resistance. <P>SOLUTION: This is a method for producing foamed wallpaper and includes following three steps: (1) the first step where two or more layers including a resin layer including a foaming agent are melt-extruded to form a laminated body; (2) the second step where the laminated body formed in the first step is cooled and (3) the third step where the paper substrate material is laminated on the cooled laminated layer. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for producing foamed wallpaper.

  Foamed wallpaper is used for the wall interior of buildings.

  Conventionally, foamed wallpaper is known in which a resin layer of vinyl chloride resin is formed on a paper-based substrate (backing paper). In recent years, in consideration of the environment, resins that do not contain halogen such as ethylene-vinyl acetate copolymer resin, acrylic resin, and olefin resin have been used for the foamed resin layer (Patent Documents 1 to 3). In order to improve the scratch resistance of the surface, olefin resins are often used.

  In order to produce foamed wallpaper, it is necessary to laminate a paper-based substrate on the resin layer. As a laminating method, for example, a method is known in which a resin layer is laminated on a paper substrate simultaneously with extrusion by a T-die extruder (Patent Document 4). This utilizes the fact that the resin layer extruded by the T-die extruder has adhesiveness by heat melting.

However, according to the above method, when the resin layer is laminated on the paper-based substrate, there is a problem that the laminate easily causes a curl phenomenon.
Japanese Patent Laid-Open No. 6-47875 JP 2000-255011 A JP 2001-347611 A JP 2004-308039 A

  The main object of the present invention is to provide a method for producing foamed wallpaper having excellent curl resistance.

  As a result of intensive studies, the present inventor has found that a method for producing foamed wallpaper through a specific process can achieve the above object, and has completed the present invention.

That is, this invention relates to the manufacturing method of the following foam wallpaper.
1. A method of manufacturing foam wallpaper,
(1) a first step of forming a laminate by melting and extruding two or more resin layers including a foaming agent-containing resin layer;
(2) A method for producing foamed wallpaper, comprising: a second step of cooling the laminate obtained in the first step; and (3) a third step of laminating a paper base material on the cooled laminate.
2. In the first step, the laminate is formed by melting and extruding the foaming agent-containing resin layer and the non-foaming resin layer A, and in the third step, the paper base is laminated on the foaming agent-containing resin layer of the laminate. 2. A method for producing a foam wallpaper according to 1.
3. In the first step, a laminate is formed by melting and extruding each layer in the order of the non-foamed resin layer B, the foaming agent-containing resin layer, and the non-foamed resin layer A. In the third step, the non-foamed layer is formed. Item 2. The method for producing foamed wallpaper according to Item 1, wherein a paper base is laminated on the resin layer B.
4). Item 4. The method for producing foamed wallpaper according to Item 3, wherein the melt flow rate value of the non-foamed resin layer B is greater than the melt flow rate value of the foaming agent-containing resin layer.
5). Item 5. The method for producing foamed wallpaper according to Item 3 or 4, wherein the non-foamed resin layer B contains a resin obtained from a combination of monomers such that the resin layer does not contain hydrogen bonds.
6). Item 5. The method for producing a foamed wallpaper according to Item 3 or 4, wherein the non-foamed resin layer B includes an ethylene copolymer resin obtained from a combination of ethylene and a monomer having no OH group or COOH group.
7). Item 7. The method for producing foamed wallpaper according to any one of Items 1 to 6, wherein the foaming agent-containing resin layer contains a resin obtained from a combination of monomers such that the resin layer does not contain hydrogen bonds.
8). Item 7. The method for producing a foam wallpaper according to any one of Items 1 to 6, wherein the foaming agent-containing resin layer comprises an ethylene copolymer resin obtained from a combination of ethylene and a monomer having no OH group or COOH group.
9. Item 9. The method for producing foamed wallpaper according to any one of Items 1 to 8, wherein the non-foamed resin layer A contains 70 to 100% by weight of an ethylene-methacrylic acid copolymer resin.
10. Item 10. The method for producing a foam wallpaper according to any one of Items 1 to 9, wherein in the second step, the laminate is cooled so that the surface temperature of the laminate becomes 60 ° C or lower.
11. Item 11. The method for producing foamed wallpaper according to any one of Items 1 to 10, wherein the laminate is slit so that the laminate is smaller than the width of the paper substrate before the paper substrate is laminated on the laminate. .
12 Item 12. The method for producing a foam wallpaper according to any one of Items 1 to 11, wherein the laminate and the paper-based substrate are laminated by heating.
13. Item 13. The method for producing foamed wallpaper according to any one of Items 1 to 12, further comprising a step of irradiating the non-foamed resin layer A and / or the foaming agent-containing resin layer with an electron beam.

  The method for producing foam wallpaper of the present invention is obtained in (1) a first step of forming a laminate by melt extrusion of two or more resin layers including a foaming agent-containing resin layer, and (2) obtained in the first step. By including the second step of cooling the laminated body and (3) the third step of laminating the paper base material on the cooled laminated body, a foam wallpaper having excellent curl resistance can be produced.

  In particular, the production method of the present invention can produce a foam wallpaper having excellent curl resistance even when a highly crystalline resin such as an ethylene-methacrylic acid copolymer resin is employed as the resin constituting the resin layer. Therefore, according to the method for producing a foam wallpaper of the present invention, a foam wallpaper having excellent scratch resistance and curl resistance can be suitably produced.

  The method for producing foam wallpaper of the present invention is obtained in (1) a first step of forming a laminate by melt extrusion of two or more resin layers including a foaming agent-containing resin layer, and (2) obtained in the first step. A second step of cooling the laminated body, and (3) a third step of laminating a paper base material on the cooled laminated body.

First Step In the first step, a laminate is formed by melting and extruding two or more resin layers including a foaming agent-containing resin layer.

  The laminate of the resin layer is not limited as long as it includes a foaming agent-containing resin layer. For example, the case where a foaming agent containing resin layer and a non-foaming resin layer are included is mentioned. Hereinafter, this case will be described as a representative example.

(I) Foaming agent containing resin layer The resin component which comprises a foaming agent containing resin layer is not specifically limited, What is necessary is just to set suitably according to the foaming agent to be used, the kind of paper-type base material, etc. In particular, the foaming agent-containing resin layer is preferably a resin obtained from a combination of monomers that does not contain hydrogen bonds in the resin layer. Therefore, for example, an ethylene copolymer resin obtained from a combination of ethylene and a monomer having no OH group or COOH group can be suitably used. From this viewpoint, as the ethylene copolymer resin, for example, ethylene-vinyl acetate copolymer resin (hereinafter abbreviated as “EVA”), ethylene-methyl methacrylate copolymer resin (hereinafter abbreviated as “EMMA”), An ethylene-ethyl acrylate copolymer resin (hereinafter abbreviated as “EEA”), an ethylene methyl acrylate copolymer resin (hereinafter abbreviated as “EMA”), and the like can be used. Among these, EVA is particularly preferable.

  It does not specifically limit as a foaming agent, For example, well-known foaming agents, such as an inorganic type foaming agent and an organic type foaming agent, can be used.

  Examples of the inorganic foaming agent include sodium hydrogen carbonate, sodium carbonate, ammonium hydrogen carbonate, ammonium carbonate, ammonium nitrite and the like.

  Examples of the organic foaming agent include nitroso compounds, azo compounds, sulfonyl hydrazide compounds, azide compounds and the like. Examples of the nitroso compound include N, N′-dimethyl-N, N′-dinitrosoterephthalamide, N, N′-dinitrosopentamethylenetetramine and the like. Examples of the azo compound include azodicarbonamide, azobisisobutyronitrile, azocyclohexylnitrile, azodiamminobenzene, barium azodicarboxylate and the like. Examples of the sulfonyl hydrazide compound include benzenesulfonyl hydrazide, toluenesulfonyl hydrazide, p, p'-oxybis (benzenesulfonyl hydrazide), diphenylsulfone-3,3'-disulfonyl hydrazide and the like. Examples of the azide compound include calcium azide, 4,4'-diphenyldisulfonyl azide, p-toluenesulfonyl azide and the like. These foaming agents can be used alone or in combination of two or more.

  What is necessary is just to set content of a foaming agent suitably according to the kind of foaming agent, an expansion ratio, etc. Usually, it may be about 1.2 to 4.7% by weight in the foaming agent-containing resin layer.

  Moreover, the said foaming agent containing resin layer may contain the foaming adjuvant. Examples of the foaming aid include zinc oxide, zinc stearate, salicylic acid, phthalic acid, and oxalic acid. The content of the foaming aid is not particularly limited, and may be set as appropriate according to the foaming agent and the like.

  The foaming agent-containing resin layer may further contain known additives such as inorganic fillers, pigments, flame retardants, and heat stabilizers.

  Among these, examples of the inorganic filler include calcium carbonate, aluminum hydroxide, magnesium hydroxide, antimony trioxide, zinc borate, and a molybdenum compound. By using an inorganic filler, an effect of suppressing see-through, an effect of improving surface characteristics, and the like are obtained. The content of the inorganic filler is preferably about 0 to 100 parts by weight and more preferably about 20 to 70 parts by weight with respect to 100 parts by weight of the resin constituting the resin layer.

As the pigment, known pigments such as inorganic pigments and organic pigments can be used. Examples of inorganic pigments include titanium oxide, zinc white, carbon black, black iron oxide, yellow iron oxide, yellow lead, molybdate orange, cadmium yellow, nickel titanium yellow, chrome titanium yellow, iron oxide (valve), and cadmium. Examples thereof include red, ultramarine blue, bitumen, cobalt blue, chromium oxide, cobalt green, aluminum powder, bronze powder, titanium mica, and zinc sulfide. Examples of the organic pigment include aniline black, perylene black, azo type (azo lake, insoluble azo, condensed azo), polycyclic (isoindolinone, isoindoline, quinophthalone, perinone, flavantron, anthrapyrimidine, anthraquinone, quinacridone, Perylene, diketopyrrolopyrrole, dibromoanthanthrone, dioxazine, thioindigo, phthalocyanine, indanthrone, halogenated phthalocyanine) and the like. Content of the pigment in a foaming agent containing resin layer is not specifically limited, What is necessary is just to set suitably from viewpoints, such as design property.

  The thickness of the foaming agent-containing resin layer is not limited, but is usually preferably about 70 to 150 μm.

(Ii) Non-foamed resin layer A
The resin constituting the non-foamed resin layer A is not particularly limited, and may be set as appropriate according to the performance of the intended foamed wallpaper. In particular, in the present invention, the non-foamed resin layer A preferably contains an ethylene-methacrylic acid copolymer resin (hereinafter abbreviated as “EMAA”). The content of EMAA is preferably 70 to 100% by weight.

  The thickness of the non-foamed resin layer A is not limited, but is preferably about 5 to 30 μm, and more preferably about 10 to 20 μm.

(Iii) Non-foamed resin layer B
The non-foamed resin layer B may be formed between the paper-based substrate and the foaming agent-containing resin layer. When the resin layer B is formed, the adhesion between the foaming agent-containing resin layer and the paper-based substrate can be improved.

  The resin component which comprises the said resin layer B is not specifically limited, What is necessary is just to select suitably according to the kind etc. of a paper-type base material. In particular, the resin layer B is preferably a resin obtained from a combination of monomers that does not contain hydrogen bonds in the resin layer. Therefore, for example, an ethylene copolymer resin obtained from a combination of ethylene and a monomer having no OH group or COOH group can be suitably used. From this standpoint, EVA, EMMA, EEA, EMA, etc. can be used as the ethylene copolymer resin. Among these, EVA is particularly preferable.

  From the viewpoint of ease of bonding to a paper-based substrate, the melt flow rate value (hereinafter abbreviated as “MFR”) of the non-foamed resin layer B is preferably larger than the MFR of the foaming agent-containing resin layer. The MFR can be measured by a test method described in JIS K 7210 (thermoplastic flow test method). As test conditions, “190 ° C., 21.18 N (2.16 kgf)” described in JIS K 6760 is adopted.

  The thickness of the non-foamed resin layer B is not limited, but is preferably about 5 to 20 μm, and more preferably about 10 to 15 μm.

(Iv) Lamination of each layer The method for forming the laminate by melt-extruding each of the resin layers is not particularly limited, and examples thereof include multilayer coextrusion by a T-die extruder. In particular, in the present invention, a multi-manifold type T die capable of simultaneously forming a plurality of layers by simultaneously extruding a plurality of types of molten resins can be preferably used.

  Specifically, in the case of forming a laminate by melt-extrusion of the foaming agent-containing resin layer and the non-foaming resin layer A, the composition for forming the non-foaming resin layer A, and the foaming agent-containing resin layer are The composition to be formed may be put in a separate cylinder, and two types and two layers may be extruded simultaneously to form a film and laminate it.

  Further, when forming the non-foamed resin layer B, a composition for forming the non-foamed resin layer A, a composition for forming the foaming agent-containing resin layer, and a composition for forming the non-foamed resin layer B What is necessary is to put a thing in a respectively separate cylinder, and to extrude 3 types and 3 layers simultaneously, and to form into a film and laminate.

  The molten resin temperature at the time of co-extrusion is not particularly limited, and may be appropriately set according to the resin used, the foaming agent, and the like.

  In addition, when the foaming agent-containing resin layer is extruded as a single layer, if an inorganic filler (filler) is included in the layer, the inorganic filler residue (so-called eyes) adheres to the extrusion port (so-called die). easy. If these eyes and eyes adhere to the surface of the foam wallpaper, it becomes a defective product.

  In order to solve the above problem, it is desirable to extrude three layers simultaneously with the foaming agent-containing resin layer sandwiched between non-foamed resin layers. For example, the non-foamed resin layer A, the foaming agent-containing resin layer, and the non-foamed resin layer B are coextruded so as to be laminated in this order.

  By simultaneously extruding three layers as described above, it becomes difficult for the eyes and eyes to adhere to the die. Moreover, the characteristic of foam wallpaper is also improved by using the non-foamed resin layer A as a layer that contributes to improving surface characteristics and the non-foamed resin layer B as a layer that contributes to improving adhesion.

Second Step In the second step, the laminated body obtained in the first step is cooled.

  In particular, in the present invention, it is preferable to cool the laminate so that the surface temperature is 60 ° C. or lower, particularly 30 to 40 ° C. When a paper-based substrate is laminated on a laminate having a surface temperature exceeding 60 ° C., the resulting foamed wallpaper tends to curl.

  The cooling means is not limited, and any known means may be adopted as appropriate. In particular, the laminate can be suitably cooled by holding the laminate in a metal roll (chill roll) through which cooling water is passed.

Third Step In the third step, a paper base is laminated on the cooled laminate. For example, when the laminate is a laminate of the foaming agent-containing resin layer and the non-foamed resin layer A as described above, a paper base is laminated on the foaming agent-containing resin layer of the laminate. Further, when the laminate is one obtained by laminating each layer by melt extrusion so that the non-foamed resin layer B, the foaming agent-containing resin layer, and the non-foamed resin layer A are in this order, A paper base is laminated on the non-foamed resin layer B. Hereinafter, the third step will be described using these laminates as examples.

  The paper base is not particularly limited as long as it has mechanical strength, heat resistance and the like suitable as a wallpaper base, and a fibrous sheet can be generally used.

Specifically, among fiber sheets, flame retardant paper (pulp-based sheets treated with flame retardants such as guanidine sulfamate and guanidine phosphate); inorganic additives such as aluminum hydroxide and magnesium hydroxide Inorganic paper including; fine paper; thin paper and the like.

The basis weight of the paper-based substrate is not limited, but is preferably about 50 to 300 g / m ² , and 50 to 8
About 0 g / m ² is more preferable.

The method for laminating the paper substrate on the laminate is not limited. For example, it is preferable to pressurize and laminate the laminate and the paper base. In particular, it is preferable to heat the surface of the paper substrate before pressurizing and laminating. Although heating temperature is not limited, 80-140 degreeC is preferable. What is necessary is just to set a heating time suitably according to heating temperature etc. FIG.

  When laminating the laminate and the paper base, the width of the laminate is preferably smaller than the width of the paper base. If the laminate is equal to or larger than the width of the paper-based substrate, the resin constituting the resin layer may protrude from the end of the foam when the foaming agent is heated and foamed in a subsequent step. As a result, problems such as fouling the inside of the foaming furnace occur.

  In order to avoid the above problem, in the method for producing foamed wallpaper according to the present invention, before laminating the paper-based substrate on the cooled laminate, the laminate is made to be smaller than the width of the paper-based substrate. It is preferable to slit.

  In addition, the slit waste obtained by slitting the laminate can be easily reused, and cost reduction in the production of foamed wallpaper can be achieved.

  The method for slitting is not particularly limited, and a known means may be employed. For example, a laser cut method, a shear cut method, a score cut method, etc. are mentioned.

  A pattern layer (described later) may be formed on the surface of the foaming agent-containing resin layer (or the surface of the non-foamed resin layer A) as necessary. A surface protective layer (overcoat layer) can be further provided on the surface of the pattern layer for the purpose of adjusting the gloss and / or protecting the pattern layer. In order to adjust the gloss, it is desirable to form a surface protective layer containing a known filler such as silica. If the surface protective layer is difficult to adhere, a primer layer may be interposed as necessary.

  As the surface protective layer, those containing an ionizing radiation curable resin as a resin component are also suitable. When ionizing radiation curable resin is used, it is easy to improve surface properties such as scratch resistance of foamed wallpaper.

  In some cases, the foaming agent-containing resin layer is irradiated with an electron beam to increase the melt tension, and then the layer is heated and foamed. That is, resin crosslinking by electron beam irradiation. The surface protective layer containing the ionizing radiation curable resin is also cured by electron beam irradiation. Production efficiency of foamed wallpaper can be increased by making both irradiations simultaneous (same processing).

  The thicknesses of the pattern pattern layer and the surface protective layer are not limited, but are preferably about 0.1 to 15 μm.

  After being laminated on the paper base, the foaming agent-containing resin layer is made into a foamed resin layer by heating the foaming agent. The heating conditions are not limited as long as the foamed resin layer is formed by the decomposition of the pyrolytic foaming agent. The heating temperature is preferably about 210 to 240 ° C. The heating time is preferably about 20 to 90 seconds.

  The expansion ratio of the foamed resin layer (the ratio as viewed from the foaming agent-containing resin layer) is not particularly limited, but is usually 4 times or more, preferably about 4 to 8 times. If the expansion ratio is too low, it is difficult to give an excellent appearance design. On the other hand, if the expansion ratio is too high, the foamed resin layer becomes mechanically weak, and the scratch resistance tends to decrease.

The method for producing a foamed wallpaper of the present invention preferably further includes a step of irradiating the non-foamed resin layer A and / or the foaming agent-containing resin layer with an electron beam before heating the foaming agent. Thereby, since the resin contained in the non-foamed resin layer A and / or the foaming agent-containing resin layer can be cross-linked, the surface strength of the foamed wallpaper, the degree of foaming, and the like can be controlled. The energy of the electron beam is preferably about 150 to 250 kV. The irradiation amount is preferably about 1 to 7 Mrad. A known electron beam irradiation apparatus can be used as the electron beam source. Crosslinking can also be performed using a chemical crosslinking agent (also referred to as a crosslinking agent or a crosslinking aid).

  When electron beam irradiation is performed, a crosslinking aid may be included in the resin layer. Any crosslinking assistant may be used as long as it promotes crosslinking by electron beam irradiation. Examples thereof include polyfunctional monomers such as neopentyl glycol dimethacrylate and trimethylolpropane trimethacrylate, oligomers, and the like. The crosslinking aid is preferably about 0 to 10 parts by weight and more preferably 1 to 4 parts by weight with respect to 100 parts by weight of EVA.

  Further, the surface of the non-foamed resin layer A may be subjected to corona discharge treatment. The corona discharge treatment can be performed according to a known method.

  When producing a foam wallpaper having a pattern layer, it is preferable to form the pattern layer on the surface of the non-foamed resin layer A before the heat treatment of the foaming agent. The pattern pattern layer can be formed, for example, by printing a pattern pattern on the surface of the non-foamed resin layer A. Examples of printing methods include gravure printing, flexographic printing, silk screen printing, and offset printing. As the printing ink, a known printing ink containing a colorant, a vehicle, and a solvent can be used.

  An embossed pattern may be attached to the front surface of the foam wallpaper as necessary. The embossed pattern can be given by, for example, a known embossed plate. For example, a desired embossed pattern can be formed by pressing the embossed plate after heating and softening the front surface of the foamed resin layer. Embossed patterns include wood grain plate conduit grooves, stone plate surface irregularities, cloth surface textures, satin texture, sand texture, hair lines, and striated grooves.

  Hereinafter, the present invention will be described in more detail with reference to examples and comparative examples. However, the present invention is not limited to the examples.

Example 1
In order to form the non-foamed resin layer A, 100 parts by weight of EMAA (product name “Nucrel N1525”, MFR: 25 g / 10 min, manufactured by Mitsui DuPont Polychemical) was prepared.

  In order to form the non-foamed resin layer B, 100 parts by weight of EVA (product name “Evaate CV5053”, MFR: 70 g / 10 min, vinyl acetate content: 20% by weight, manufactured by Sumitomo Chemical Co., Ltd.) was prepared.

  In order to form a foaming agent containing resin layer, the composition containing the component of following Table 1 was prepared.

  The above resin and the resin-containing composition are melted and three-layer three-layer multi-manifold T-die extruder is used, and three-layer co-extrusion lamination is performed. Laminated in order. The thickness of each layer was 15 μm / 100 μm / 10 μm in the above order. In this T-die extruder, a cylinder containing EVA for forming the non-foamed resin layer B, a cylinder containing each component of Table 1 for forming the foaming agent-containing resin layer, and a non-foamed resin layer The temperature of the cylinder containing EMAA for forming A was 100 ° C., 120 ° C., and 160 ° C., respectively. The die temperatures were all 120 ° C.

And it cooled by making the obtained laminated body hold in the metal roll (chill roll) which let the cooling water pass so that surface temperature might be 60 degrees C or less.
Next, the cooled laminate was slit so that the width was 10 mm smaller than the paper base.

  The laminated body after the slit was pressed and laminated on a paper substrate having a thickness of 110 μm (basis weight 70 g) so that the paper substrate and the non-foamed resin layer B were in contact with each other. In addition, before pressurization and lamination, the paper base material surface was heated at 120 ° C. for 10 seconds in advance.

  Thereafter, an electron beam (175 kV, 3 Mrad) was irradiated from above the non-foamed resin layer A to cross-link EVA contained in the non-foamed resin layer A and EMAA contained in the foaming agent-containing resin layer. Furthermore, the surface of the non-foamed resin layer A was subjected to corona discharge treatment.

Subsequently, the primer treatment was performed by applying 2 g / m ² of the EVA aqueous emulsion to the surface of the non-foamed resin layer A by gravure printing. Furthermore, a texture pattern (pattern printing layer) was printed thereon using a water-based ink (product name “Hydric” manufactured by Dainichi Seika Kogyo Co., Ltd.).

  Then, the laminate was heated in a gear oven at 220 ° C. for 30 seconds. Thereby, the foaming agent was decomposed, and the foaming agent-containing resin layer was used as the foamed resin layer. The expansion ratio was 5 times, and the thickness of the foamed resin layer was 500 μm.

  Furthermore, the embossing was given to the front side of the foam, and the texture pattern was shaped.

  Through the above process, a foam wallpaper was produced.

Example 2
The resin constituting the non-foamed resin layer B is EVA (product name “Evaate D4010” MFR: 10 g / 10 min, vinyl acetate content: 10% by weight, manufactured by Sumitomo Chemical), and the temperature of the cylinder containing the EVA is 180. A foamed wallpaper was prepared in the same manner as in Example 1 except that the temperature was changed to ° C.

Comparative Example 1
A foamed wallpaper is produced in the same manner as in Example 1 except that the laminate obtained by the three-layer coextrusion lamination is not cooled, that is, the laminate is laminated on the paper substrate simultaneously with the extrusion by the T-die extruder. did.

Test Example 1 (Curl resistance)
Starch glue was applied to the entire paper-based substrate side of the foamed wallpaper produced in the examples and comparative examples, and left in a 5 ° C. atmosphere for 10 minutes. Then, the edge part of the wallpaper was lifted and the curl state of the wallpaper was confirmed.

  A starch paste that did not adhere to the surface was evaluated as good, and a starch paste that adhered to the surface was evaluated as poor.

Test Example 2 (paper substrate adhesion)
In Examples and Comparative Examples, before the foaming agent-containing resin layer in the laminate is used as the foamed resin layer, a cut is made in a portion other than the paper-based substrate (only the resin layer portion) in the laminate, and the resin is cut from the cut. The layer was peeled off.

  After peeling, it was evaluated that the paper base material sufficiently remained in the peeled portion of the resin layer was good, and the paper base material remained slightly good.

  The results of the above test are shown in Table 2 below.

Claims (13)

A method of manufacturing foam wallpaper,
(1) a first step of forming a laminate by melting and extruding two or more resin layers including a foaming agent-containing resin layer;
(2) A method for producing foamed wallpaper, comprising: a second step of cooling the laminate obtained in the first step; and (3) a third step of laminating a paper base material on the cooled laminate. In the first step, a laminate is formed by melt-extruding the foaming agent-containing resin layer and the non-foaming resin layer A, and in the third step, a paper base is laminated on the foaming agent-containing resin layer of the laminate. 2. A method for producing a foam wallpaper according to 1. In the first step, a laminate is formed by melting and extruding each layer in the order of the non-foamed resin layer B, the foaming agent-containing resin layer, and the non-foamed resin layer A. In the third step, the non-foamed layer is formed. The method for producing a foam wallpaper according to claim 1, wherein a paper base is laminated on the resin layer B. The method for producing a foamed wallpaper according to claim 3, wherein the melt flow rate value of the non-foamed resin layer B is larger than the melt flow rate value of the foaming agent-containing resin layer. The method for producing a foamed wallpaper according to claim 3 or 4, wherein the non-foamed resin layer B contains a resin obtained from a combination of monomers such that the resin layer does not contain hydrogen bonds. The method for producing a foamed wallpaper according to claim 3 or 4, wherein the non-foamed resin layer B includes an ethylene copolymer resin obtained from a combination of ethylene and a monomer having no OH group or COOH group. The method for producing foamed wallpaper according to any one of claims 1 to 6, wherein the foaming agent-containing resin layer contains a resin obtained from a combination of monomers such that the resin layer does not contain hydrogen bonds. The method for producing a foam wallpaper according to any one of claims 1 to 6, wherein the foaming agent-containing resin layer comprises an ethylene copolymer resin obtained from a combination of ethylene and a monomer having no OH group or COOH group. The manufacturing method of the foam wallpaper in any one of Claims 1-8 in which the non-foaming resin layer A contains 70-100 weight% of ethylene-methacrylic acid copolymer resin. The manufacturing method of the foam wallpaper in any one of Claims 1-9 which cools so that the surface temperature of a laminated body may be 60 degrees C or less in a 2nd process. The method for producing foam wallpaper according to any one of claims 1 to 10, wherein the laminate is slit so that the laminate is smaller than the width of the paper substrate before the paper substrate is laminated on the laminate. . The method for producing a foam wallpaper according to any one of claims 1 to 11, wherein the laminate and the paper-based substrate are laminated by heating. The manufacturing method of the foam wallpaper in any one of Claims 1-12 which further has the process of irradiating an electron beam to the non-foaming resin layer A and / or a foaming agent containing resin layer.