JP2016166429A - Wallpaper and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide wallpaper that can reduce environmental burden compared to PVC wallpaper and is excellent in contamination resistance while being moisture-permeable; and its manufacturing method.SOLUTION: Wallpaper is characterized by providing a foamed resin layer made of olefin-based resin on a paper substrate, providing a contamination resistant resin layer on the surface of the foamed resin layer, and having a venting hole venting through the contamination resistant resin layer and the foamed resin layer. A method of manufacturing wallpaper having the foamed resin layer made of the olefin-based resin on the paper substrate is characterized by consisting of: a first process of forming the olefin-based resin layer with an extruder and laminating together with the paper substrate; a second process of forming the contamination resistant resin layer after performing picture-printing on the olefin-based resin layer surface; a third process of foaming the olefin-based resin layer and forming unevenness by pattern-embossing; and a punching process for providing the venting hole through the contamination resistant resin layer and the foamed resin layer.SELECTED DRAWING: Figure 1

Description

  The present invention relates to wallpaper. In particular, the present invention relates to a wallpaper that is not a vinyl wallpaper but has a low environmental load and has moisture permeability.

  In recent years, the existence of wallpaper as a member for housing has played a major role. Wallpapers have become widely used with the development of residential buildings, but now they are also being used in condominiums and public buildings.

  In addition, textile cloth was used in the past, but in the current general houses, vinyl wallpaper is often used not only for walls, but also for ceilings and closets to help change lifestyles. It is not uncommon for vinyl wallpaper to cover several times the floor area.

  In this way, vinyl chloride is used for the resin foam layer as a wallpaper for housing use, with vinyl wallpaper having a resin foam layer with paper as the base material and designs with patterns and irregularities on the surface. There were a lot of things. However, since vinyl chloride contains a plasticizer, there are opinions that raise questions about the safety of housing components. On the other hand, there are many opinions that raise concerns about exhaust gas and environmental impact during disposal and incineration. Against the backdrop of this heightened environmental awareness, there is a growing demand for vinyl chloride for vinyl wallpaper.

  On the other hand, there are various demands for changes in the living environment and comfort, and in order to meet these demands in the field of building interiors, for example, wallpaper is more resistant to stains, scratches and durability than ever before. Various foamed laminated sheets with improved properties and crack resistance have been developed as vinyl wallpaper.

  For example, Patent Document 1 proposes a wallpaper in which a coating layer composed of a foaming agent, an aqueous emulsion resin, and other additives is provided on a base material, and a resin film having a stain resistance is further adhered and foamed. However, a foam laminated sheet provided with a surface protective layer and a foamed resin layer made of a resin film has excellent surface strength, chemical resistance, solvent resistance, and contamination resistance, but has a defect that moisture permeability is impaired by the surface protective layer. .

  When the wallpaper has low moisture permeability, there is a problem that condensation occurs on the front or back of the wall surface due to the temperature difference between the room temperature, humidity, and outside air. In addition, it has been pointed out that the wallpaper with low moisture permeability is difficult to dry the construction paste during construction. These dew condensation and residual moisture in the construction glue also contribute to mold generation.

  As described in Patent Documents 2 to 4, it is known that moisture permeability can be secured by providing a through hole in a film or sheet. In the case of wallpaper, it is also known that by providing a through hole, not only moisture permeability but also peel-up property can be imparted or air puncture can be prevented. However, in the case where the through hole is provided, there is a possibility that contaminants or the like may infiltrate into the inside from the through hole.

  In this way, on the premise of reducing the environmental burden described above, in addition to the design, construction, and functionality as interior materials, the wallpaper also requires functionality as durable consumer materials. There is a need for a wallpaper that combines both, in particular, moisture permeability and excellent stain resistance.

JP-A-8-309903 JP-A-4-246537 Japanese Patent Publication No. 60-252262 Japanese Patent Publication No. 60-39544 JP2013-0731320A

  The present invention has been made in view of the situation to be applied, and can provide a wallpaper that can reduce the environmental burden compared to a PVC wallpaper and that is excellent in stain resistance while having moisture permeability, and a method for producing the same. Let it be an issue.

  As means for solving the above-mentioned problems, the invention according to claim 1 is a wallpaper in which a foamed resin layer made of an olefin resin is provided on a paper substrate, and the surface of the foamed resin layer is resistant to the surface. The wallpaper is characterized in that a contamination resin layer is provided and has a ventilation hole penetrating the contamination-resistant resin layer and the foamed resin layer.

  The invention according to claim 2 is the wallpaper according to claim 1, wherein the average pore diameter of the openings on the surface of the contamination-resistant resin layer of the vent holes is 30 μm to 600 μm.

  Further, the invention described in claim 3 is characterized in that the shape of the vent hole is a conical shape whose bottom surface is the surface of the contamination-resistant resin layer, and the sharp angle is 3 degrees to 10 degrees. The wallpaper according to 1 or 2.

  The invention according to claim 4 is the wallpaper according to any one of claims 1 to 3, wherein the stain-resistant resin layer is made of an aqueous acrylic emulsion.

  The invention according to claim 5 is a method for producing a wallpaper in which a foamed resin layer made of an olefin resin is provided on a paper substrate, wherein the olefin resin layer is formed by an extruder and laminated with the paper substrate. A first step of performing pattern printing on the surface of the olefin-based resin layer as needed, a second step of further forming a stain-resistant resin layer, foaming the olefin-based resin layer, and embossing by embossing The method for producing wallpaper, comprising: a third step of forming irregularities in step 1; and a perforating step of providing a vent hole penetrating the contamination-resistant resin layer and the foamed resin layer.

  According to the present invention, by using an olefin-based resin, the wallpaper is higher in safety than the PVC wallpaper, can reduce the environmental burden, and has excellent moisture resistance while having moisture permeability, and a method for producing the same. Can be provided.

  Moreover, according to the invention of Claim 2, the wallpaper which has both moisture permeability and the mechanical strength of a wallpaper can be provided.

  In addition, according to the invention described in claim 3, it is possible to provide a wallpaper having moisture permeability without impairing the stain resistance.

Moreover, according to the invention of Claim 4, the wallpaper which has both moisture permeability and contamination | pollution resistance can be provided.

  Further, according to the invention described in claim 5, it is possible to provide a method for producing wallpaper that has moisture permeability and is excellent in stain resistance.

FIG. 1 is a partial cross-sectional schematic view for explaining an embodiment of wallpaper according to the present invention, in a state where a resin layer is laminated on a paper base material. FIG. 2 is a partial cross-sectional schematic diagram for explaining an embodiment of the wallpaper according to the present invention, in which a resin layer is laminated on a paper base material and then printed, and a stain-resistant resin layer is provided. belongs to. FIG. 3 is a partial cross-sectional schematic diagram for explaining an embodiment of the wallpaper according to the present invention, in which a resin layer is laminated on a paper substrate, and then printing is performed, and a stain-resistant resin layer is provided. A foamed resin layer is obtained by foaming a resin layer. FIG. 4 is a partial cross-sectional schematic diagram for explaining an embodiment of wallpaper according to the present invention, in which a resin layer is laminated on a paper substrate and then printed, and a stain-resistant resin layer is provided. A resin layer is foamed to obtain a foamed resin layer, which is embossed and embossed. FIG. 5 is a partial cross-sectional schematic diagram for explaining an embodiment of the wallpaper according to the present invention, in which a resin layer is laminated on a paper base material and then printed, and a stain-resistant resin layer is provided. This is a state in which a resin layer is foamed to form a foamed resin layer, embossed and embossed, and then vent holes are formed.

  Hereinafter, a detailed description will be given of embodiments for carrying out the present invention with reference to FIGS. However, the present invention is not limited to this example.

  First, the method for producing wallpaper according to the present invention will be described in detail. FIG. 1 is a partial cross-sectional schematic view for explaining an embodiment of wallpaper according to the present invention, in a state where a resin layer is laminated on a paper base material. A resin layer (2) is laminated on the paper substrate (1). The resin layer (2) uses an olefin resin and contains a foaming agent. The method for forming the resin layer is not particularly limited, and for example, a method of forming a film with an extruder and laminating it with a paper substrate can be used. This is the first step of the wallpaper manufacturing process according to the present invention.

  FIG. 2 is a partial cross-sectional schematic diagram for explaining an embodiment of the wallpaper according to the present invention, in which a resin layer is laminated on a paper base material and then printed, and a stain-resistant resin layer is provided. belongs to. When providing the pattern by printing, printing ink (3) can be printed on the surface of a resin layer (2). Although the printing method is not particularly limited, for example, a gravure printing method can be used.

  The type of printing ink is not particularly limited, but can be appropriately selected in consideration of adhesion to the resin layer, light resistance as wallpaper, and the like. For the purpose of improving the adhesion of the printing ink, it is also possible to provide an anchor coat on the surface of the resin layer or to perform a corona discharge treatment.

  After the resin layer (2) is formed or printed, a stain resistant resin layer (4) is provided on the surface of the resin layer (2) for the purpose of improving the stain resistance. The method for providing the contamination-resistant resin layer is not particularly limited, and generally known coating methods such as gravure coating, roll coating, lip coating, and the like can be used. This is the second step of the wallpaper manufacturing process according to the present invention.

  FIG. 3 is a partial cross-sectional schematic diagram for explaining an embodiment of the wallpaper according to the present invention, in which a resin layer is laminated on a paper substrate, and then printing is performed, and a stain-resistant resin layer is provided. A foamed resin layer is obtained by foaming a resin layer. As a method of forming the foamed resin layer (6), a method of foaming by heating is generally known.

  FIG. 4 is a partial cross-sectional schematic diagram for explaining an embodiment of wallpaper according to the present invention, in which a resin layer is laminated on a paper substrate and then printed, and a stain-resistant resin layer is provided. A resin layer is foamed to form a foamed resin layer, and embossing is embossed to form irregularities on the surface to obtain wallpaper (10). The embossing is generally performed by embossing using an embossing roll. This is the third step of the wallpaper manufacturing process according to the present invention.

  FIG. 5 is a partial cross-sectional schematic diagram for explaining an embodiment of the wallpaper according to the present invention, in which a resin layer is laminated on a paper base material and then printed, and a stain-resistant resin layer is provided. This is a state in which a resin layer is foamed to form a foamed resin layer, embossed and embossed, and then vent holes are formed.

  Since the present invention has an object to provide a wallpaper having moisture permeability and excellent stain resistance, in order to ensure moisture permeability, the emulsification is followed by a stain resistant resin layer (4) and A vent hole (5) penetrating the foamed resin layer (6) is drilled. This is a perforation process. By using this method, a wallpaper having excellent moisture permeability according to the present invention can be produced.

Hereinafter, each component of the wallpaper according to the present invention will be described in more detail. In the present invention, the paper substrate used may be plain paper or wallpaper base paper. The wallpaper base paper is not particularly limited, and can be appropriately selected from those conventionally used and used as wallpaper base paper by paper manufacturers. Can be used as a general basis weight ^50g / ^{m 2 ~200g} / m 2 as wallpaper base paper.

  When the paper base material is glued to the paper surface which is the back side of the wallpaper when the wallpaper is applied, it is necessary to be easy to apply as wallpaper in addition to the small dimensional change. Moreover, what gave the flame-retardant process can be selected and used as needed.

  The polyolefin resin is used by blending a foaming agent and a foaming accelerator. For forming a resin layer using a polyolefin-based resin on a paper substrate, for example, a film forming method using an extruder can be used, and the formed film can be used by being laminated on a paper substrate. At this time, the film formed may be used after being crosslinked.

  For example, when a resin layer is formed on a paper base material using an emulsion type resin, a drying process is required, so it is inevitable that traces of water evaporation remain as fine pores. This fine hole makes it easy for gas to escape during the foaming process, resulting in a reduction in the foaming ratio. However, there is no fear of film formation by an extruder, and it can be used effectively for foaming without letting the foaming gas escape. It is possible to increase the expansion ratio.

  A high foaming ratio leads to an increase in the volume of the wallpaper, and has the advantage of being able to conceal unevenness and irregularities in the base when constructing the wallpaper or re-covering, resulting in a uniform finish.

Contamination resistance, which is one of the required qualities of wallpaper, is also a cause of contamination from the fine pores and difficult to remove. For example, when using a film formed by an extruder or the like, the surface has no fine pores as in the case of using the emulsion type, and the surface does not become porous. Therefore, it is more preferable.

  Polyolefin resins are safer as housing materials because they do not contain plasticizers unlike vinyl chloride. In addition, since polyolefin resins do not contain halogens, they are safe without generating toxic gases even in the event of a fire in the event of a fire. Much lower than vinyl.

  A printed pattern can be provided on the surface of the resin layer as necessary. The printing method is not particularly limited, but can be appropriately selected from known printing methods. The type of printing ink is not particularly limited, but can be appropriately selected in consideration of adhesion to the resin layer, light resistance as wallpaper, and the like. For the purpose of improving the adhesion of the printing ink, it is also possible to provide an anchor coat on the surface of the resin layer or to perform a corona discharge treatment.

  The stain-resistant resin layer has water repellency and can be appropriately selected from resins having stain resistance. In particular, when an emulsion type is used, innumerable fine pores from which moisture is removed are formed on the surface during drying after coating, and the resin layer has air permeability and moisture permeability. However, the fine holes are large enough to block the stagnation of polka dots. For example, an aqueous acrylic emulsion can be used for the stain-resistant resin layer.

  The foamed resin layer is foamed by the action of the foaming agent and the foaming accelerator contained in the resin layer by heating, and the volume of the resin layer increases. In the subsequent embossing process, the embossing roll gives unevenness to the surface to complete the appearance as wallpaper.

  The wallpaper is perforated with a needle from the surface in the perforation process. The piercing by the needle is also called needle embossing, and is performed at a depth that penetrates at least the surface of the contamination-resistant resin layer and the foamed resin layer. The perforation process gives the wallpaper breathability and moisture permeability.

  However, if the surface hole due to this perforation is too large, there is an effect in air permeability and moisture permeability, but if a contaminant is attached, there is a possibility that the contaminant will stagnate from this hole, and further, there will be a breakthrough. .

  As a result of intensive studies, we have found that when the average pore diameter of the openings on the surface of the contamination-resistant resin layer is 30 μm to 600 μm, results satisfying both air permeability and contamination resistance can be obtained. If the pore diameter is within this range, the water-repellent effect of the stain-resistant resin layer is helped and the contamination of the contaminants can be prevented.

  As for the shape of the needle used in the perforation process, a needle having a conical shape may be used as long as it has sufficient strength to withstand the perforation of wallpaper. The angle of the needle point is preferably in the range of 3 ° to 10 °.

  As for this point, as a result of intensive investigations, by using a needle with a sharp angle in this range, the average pore diameter of the opening on the surface of the contamination-resistant resin layer is 30 μm to 600 μm, and the surface is resistant to contamination. It has been found that both the depth of penetration through the resin layer and the foamed resin layer can be satisfied.

According to the present invention, a wallpaper composed of such elements can reduce the environmental burden compared to a PVC wallpaper, and has excellent moisture resistance while having moisture permeability. A manufacturing method can be provided.

  Hereinafter, the present invention will be described more specifically based on examples. However, the present invention is not limited only to these examples.

<Example 1>
An evaluation wallpaper sample was prepared with the following material composition and manufacturing method.
(First step) As a paper base material, on a plain paper with a basis weight of 65 g / m ² , a polyethylene resin is blended with a foaming agent, a stabilizer, an inorganic material, and other additives, and a paper is formed by an extruder. Laminated on the substrate.
(Second step) A printed pattern was formed on the resin surface using water-based ink, and a stain-resistant resin layer was formed with a thickness of 10 μm using water-based acrylic compound.
(Third step) After drying, the whole was heated and foamed to form irregularities on the surface using an embossed plate.
(Perforation step) The surface of the wallpaper was perforated using a needle to form a ventilation and moisture-permeable hole.
The perforation needle has a length of 4 mm, a maximum diameter of the needle base of 0.62 mm, and the density of the holes is 18 holes / cm ² . By using this perforation needle, it was confirmed that the average pore diameter of the openings on the surface of the contamination-resistant resin layer of the ventilation holes can be formed in the range of 30 μm to 600 μm.

<Comparative Example 1>
An evaluation wallpaper sample was prepared with the following material composition and manufacturing method.
(First Step) ^On a plain paper having a basis weight of 65 g / m ^{2 as} a paper substrate, a foaming agent was blended and used as an aqueous emulsion of an ethylene vinyl acetate copolymer resin as a resin layer.
(Second step) A printed pattern was formed on the resin surface using water-based ink, and a stain-resistant resin layer was formed with a thickness of 10 μm using water-based acrylic compound.
(Third step) After drying, the whole was heated and foamed to form irregularities on the surface using an embossed plate.
(Punching process) The drilling process was omitted.

<Comparative example 2>
An evaluation wallpaper sample was prepared with the following material composition and manufacturing method.
(First step) As a paper base material, on a plain paper with a basis weight of 65 g / m ² , a polyethylene resin is blended with a foaming agent, a stabilizer, an inorganic material, and other additives, and a paper is formed by an extruder. Laminated on the substrate.
(Second step) A printed pattern was provided on the resin surface using water-based ink. A contamination-resistant resin layer is not provided.
(Third step) After drying, the whole was heated and foamed to form irregularities on the surface using an embossed plate.
(Punching process) The drilling process was omitted.

<Comparative Example 3>
An evaluation wallpaper sample was prepared with the following material composition and manufacturing method.
(First step) As a paper base material, on a plain paper with a basis weight of 65 g / m ² , a polyethylene resin is blended with a foaming agent, a stabilizer, an inorganic material, and other additives, and a paper is formed by an extruder. Laminated on the substrate.
(Second step) A printed pattern was provided on the resin surface using water-based ink. A contamination-resistant resin layer is not provided.
(Third step) After drying, the whole was heated and foamed to form irregularities on the surface using an embossed plate.
(Perforation step) The surface of the wallpaper was perforated using a needle to form a ventilation and moisture-permeable hole.
The perforation needle has a length of 4 mm, a maximum diameter of the needle base of 0.62 mm, and the density of the holes is 18 holes / cm ² . By using this perforation needle, it was confirmed that the average pore diameter of the openings on the surface of the contamination-resistant resin layer of the ventilation holes can be formed in the range of 30 μm to 600 μm.

<Comparative example 4>
An evaluation wallpaper sample was prepared with the following material composition and manufacturing method.
A general PVC wallpaper was used. Therefore, the first step to the third step are for ordinary PVC wallpaper.
(Perforation step) The surface of the wallpaper was perforated using a needle to form a ventilation and moisture-permeable hole.
The perforation needle has a length of 4 mm, a maximum diameter of the needle base of 0.62 mm, and the density of the holes is 18 holes / cm ² . By using this perforation needle, it was confirmed that the average pore diameter of the openings on the surface of the contamination-resistant resin layer of the ventilation holes can be formed in the range of 30 μm to 600 μm.

(Evaluation items and evaluation methods)
Water repellency: The soy sauce is adhered and the state of repelling is observed. Good if repelled.
Contamination resistance: Adhering soy sauce and observing the state of massaging. Good if you can wipe off.
Contamination strikethrough: Check if the pollutant is seen through. Good if it does not pass through.
Moisture permeability (g / m ² · 24 hr): Measured by JIS Z2028 cup method. A score of 450 or higher is accepted.
Workability: Confirm that there is no influence of the substrate by gluing and construction. Those that do not have an impact will be accepted.
Foaming ratio: The foaming ratio of the resin layer is measured.

  (Evaluation results)

The evaluation results are shown in Table 1.

  With respect to water repellency, the effect was recognized only in Example 1 and Comparative Example 1 provided with a stain-resistant resin layer, and the effectiveness of the stain-resistant resin layer could be confirmed. In Comparative Examples 2 to 4, water repellency could not be confirmed.

  Regarding contamination resistance, it was confirmed that Comparative Example 4 was inferior. This is because Comparative Example 4 was perforated on a general PVC wallpaper, so there was no stain-resistant resin layer, and contaminants (soy sauce) were swallowed by fine pores on the surface of the PVC, so that wiping could not be completed completely. It shows that.

  Contamination strike-through results are shown in Comparative Example 3 and Comparative Example 4 with strike-through. This is the result of the perforations created by the perforations passing the contaminants. In Comparative Examples 1 and 2, there is no show-through, but this is considered to be due to the absence of perforations. Although Example 1 has perforations, it is considered that the contamination-resistant resin layer has a water repellent effect, and that the diameter and density of the perforations are formed in an appropriate range.

About moisture permeability, 450 (g / m < ² > * 24hr) was made into the acceptable value from the experience value based on the past performance. In Comparative Example 4, the evaluation is low because a general PVC wallpaper is used. In Comparative Example 2, the moisture permeability is low because there is no perforation.

  The moisture permeability of Comparative Example 3 is an acceptable value, which is considered to be a perforation effect. Although the comparative example 1 is a pass value, since the emulsion is used for the resin layer, it is thought that the fine small hole at the time of drying has improved the water vapor transmission rate. In Example 1, the moisture permeability is an acceptable value, which is considered to be an effect of perforation.

About workability, it was a pass except comparative example 1. This is because the foaming ratio of Comparative Example 1 was low, so that the defects of the base could not be concealed. In Example 1 of the pass evaluation and Comparative Examples 2 to 4, the expansion ratio is considered to be higher than that of Comparative Example 1.

  As described above, from the evaluation results summarized in Table 1, in Example 1 according to the present invention, favorable results as pass or wallpaper could be obtained for all evaluation items.

  From these results, according to the present invention, it is possible to provide a wallpaper that can reduce the environmental burden as compared with a PVC wallpaper, and that is excellent in stain resistance while having moisture permeability, and a method for producing the same. I was able to verify that.

DESCRIPTION OF SYMBOLS 1 ... Paper base material 2 ... Resin layer 3 ... Printing ink 4 ... Contamination-resistant resin layer 5 ... Vent hole 6 ... Foamed resin layer 10 ... Wallpaper

Claims (5)

A wallpaper in which a foamed resin layer made of an olefin resin is provided on a paper substrate,
The surface of the foamed resin layer is provided with a contamination-resistant resin layer,
A wallpaper comprising air holes penetrating through the contamination-resistant resin layer and the foamed resin layer.   The wallpaper according to claim 1, wherein an average pore diameter of the openings on the surface of the contamination-resistant resin layer of the ventilation holes is 30 μm to 600 μm.   The wallpaper according to claim 1 or 2, wherein the shape of the vent hole is a conical shape with the surface of the contamination-resistant resin layer as a bottom surface, and the angle of the sharpness is 3 degrees to 10 degrees.   The wallpaper according to any one of claims 1 to 3, wherein the stain-resistant resin layer is made of an aqueous acrylic emulsion. A method for producing wallpaper in which a foamed resin layer made of an olefin resin is provided on a paper substrate,
Forming an olefinic resin layer with an extruder and laminating it with a paper substrate;
A second step of forming a stain-resistant resin layer after pattern printing on the surface of the olefin-based resin layer;
The method comprises a third step of foaming the olefin-based resin layer and forming irregularities by embossing by embossing, and a perforating step of providing a vent hole penetrating the contamination-resistant resin layer and the foamed resin layer. To make wallpaper.