JP2017155379A - Manufacturing method of original fabric for foamed wallpaper, original fabric for foamed wallpaper, and foamed wallpaper - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of original fabric for foamed wallpaper which can make a film production step to a lamination step inline easily in film production by a tubular film process.SOLUTION: A film production step making a cylindrical seat 1 that resin containing foaming agent is filmed in cylinder by a tubular film process, and a lamination step laminating the cylindrical seat 1 on paper backing 2 by heat in a state in which the inside of the cylindrical sheet 1 is put together are included. Besides, when the cylindrical seat 1 is filmed in the film production step, 50% or more in 100 mass% of the resin component in a layer of an inside diameter part of the cylindrical sheet 1 is formed with adhesive resin that the melting point is 80°C or lower.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for producing a foam wallpaper original, a foam wallpaper original produced by the production method, and a foam wallpaper using the foam wallpaper.

  A laminated sheet in which at least a foamed resin layer is laminated on a paper substrate is known as a so-called raw material for foamed wallpaper. A foamed wallpaper can be produced by arbitrarily adding decoration to the foamed wallpaper raw material and then foaming the foamed resin layer to obtain a foamed resin layer.

  As an example of a raw material for foamed wallpaper, Patent Document 1 discloses a raw material for foamed wallpaper in which at least an unfoamed resin layer (foamed resin layer) is formed on a paper substrate, and the foamed resin layer is formed. A raw material for foam wallpaper is described in which the resin to be used is an electron beam cross-linking resin and is cross-linked. And as a film forming method of the said foamed resin layer, the T-die method of extrusion film-forming using a T die is generally employ | adopted, and also in patent document 1, it describes describing extrusion film-forming using a T die. Has been.

JP 2006-97184 A

  As a method for forming a resin layer, an inflation method in which an extrusion film is formed using a cylindrical die is known along with the T die method in which an extrusion film is formed using the above T die. Film formation by the inflation method is superior to film formation by the T-die method in that there is no concept of an end and the flow velocity is all constant.

  However, in the conventional film formation by the inflation method, when extruding a cylindrical sheet in which a resin is formed into a cylindrical shape by a cylindrical die, the cylindrical sheet is cut in parallel with the extrusion flow direction, and the cylindrical sheet is cut open. Since it is necessary to bond it to a paper substrate after making it into two laminated sheets, it was difficult to inline from the film forming process to the laminating process. For example, in order to make this inline, it was necessary to provide two bonding units.

  The present invention has been made in view of the above circumstances, and in forming a film by an inflation method, a foamed wallpaper that does not require a step of cutting a cylindrical sheet into two laminated sheets before being bonded to a paper substrate. An object of the present invention is to provide a method for producing an original fabric, an original fabric for foamed wallpaper produced by the production method, and a foamed wallpaper using the raw fabric for foamed wallpaper.

  In order to solve the above-mentioned problem, a method for producing a foamed wallpaper raw material according to one aspect of the present invention includes a film forming step of forming a cylindrical sheet in which a foaming agent-containing resin is formed into a cylindrical shape by an inflation method. And a laminating step of thermally laminating the cylindrical sheet onto a paper base in a state where the inner surfaces of the cylindrical sheets overlap.

  According to one embodiment of the present invention, in-line from a film forming process to a stacking process can be easily realized in film formation by an inflation method.

It is explanatory drawing which shows the outline | summary of the manufacturing method of the raw material for foam wallpaper based on one Embodiment of this invention. (A) is explanatory drawing in case a cylindrical sheet | seat is a single layer structure. (B) is explanatory drawing in case a cylindrical sheet | seat is a multilayer structure. It is explanatory drawing which shows the outline | summary of the manufacturing method of the raw material for foam wallpaper based on other embodiment of this invention.

<Embodiment>
Below, with reference to drawings, the manufacturing method of the raw material for foam wallpaper which concerns on one Embodiment of this invention, the original fabric for foam wallpaper, and foam wallpaper are demonstrated. Here, the drawings are schematic, and the relationship between the thickness and the planar dimensions, the ratio of the thickness of each layer, and the like are different from the actual ones. Further, the embodiment described below exemplifies a configuration for embodying the technical idea of the present invention, and the technical idea of the present invention is that the material, shape, structure, etc. of the component parts are as follows. It is not something specific. The technical idea of the present invention can be variously modified within the technical scope defined by the claims described in the claims.

(Manufacturing method of raw material for foam wallpaper)
The manufacturing method of the raw material for foam wallpaper which concerns on one Embodiment of this invention includes a film forming process and a lamination process.
[Film forming process]
In the film forming step, a foaming agent-containing resin is formed into a cylindrical shape by an inflation method, and a cylindrical sheet 1 as shown in FIG. 1 is created. The cylindrical sheet 1 has at least one layer as shown in FIG. 1 (a), and may have a multilayer structure including two or more layers as shown in FIG. 1 (b).

  Specifically, after the foaming agent-containing resin is extruded into a cylindrical shape using a cylindrical die, the cylindrical foamed resin layer is obtained by air cooling. The thickness of the foamed resin layer is preferably about 40 μm to 100 μm, and the thickness of the foamed resin layer after foaming is preferably about 300 μm to 700 μm.

As the foaming agent-containing resin, for example, a resin composition containing a resin component, an inorganic filler, a pigment, a pyrolytic foaming agent, a foaming aid, a crosslinking aid, and the like can be suitably used. In addition, stabilizers, lubricants and the like can be used as additives.
As the resin component, for example, it may contain at least one of 1) polyethylene and 2) an ethylene copolymer having monomers other than ethylene and ethylene (hereinafter abbreviated as “ethylene copolymer”). preferable.
As the polyethylene, low-density polyethylene (LDPE), medium-density polyethylene (MDPE), high-density polyethylene (HDPE), linear low-density polyethylene (LLDPE), and the like can be widely used. Among these, low-density polyethylene is preferable.

  The ethylene copolymer is suitable for extrusion film formation from the viewpoint of the melting point and MFR. Examples of the ethylene copolymer include ethylene-vinyl acetate copolymer (EVA), ethylene-methyl methacrylate copolymer (EMMA), ethylene-ethyl acrylate copolymer (EEA), ethylene-methyl acrylate copolymer ( EMA), ethylene-methacrylic acid copolymer (EMAA), ethylene-α olefin copolymer, and the like. These ethylene copolymers can be used alone or in admixture of two or more. Among these ethylene copolymers, at least one of ethylene-vinyl acetate copolymer, ethylene-methyl methacrylate copolymer and ethylene-methacrylic acid copolymer is preferable, and when these are used in combination with other resins. The content of at least one of ethylene-vinyl acetate copolymer, ethylene-methyl methacrylate copolymer and ethylene-methacrylic acid copolymer is preferably 70% by mass or more, and more preferably 80% by mass or more.

  Moreover, as content of monomers other than ethylene contained in an ethylene copolymer, 5 to 25 mass% is preferable, for example, and 9 to 20 mass% is more preferable. By adopting such a copolymerization ratio, the extrusion film forming property is further enhanced. As a specific example, the ethylene-vinyl acetate copolymer has a vinyl acetate copolymerization ratio (VA amount) of preferably 9% by mass to 25% by mass, and more preferably 9% by mass to 20% by mass. The ethylene-methyl methacrylate copolymer has a methyl methacrylate copolymerization ratio (MMA amount) of preferably 5% by mass to 25% by mass, and more preferably 5% by mass to 15% by mass. The ethylene-methacrylic acid copolymer has an acrylic acid copolymerization ratio (MAA amount) of preferably 2% by mass or more and 15% by mass or less, and more preferably 5% by mass or more and 11% by mass or less.

  The resin component contained in the foamed resin layer has an MFR (melt flow rate) measured at 190 ° C. and a load of 21.18 N described in JIS K 6922 of 10 g to 100 g per 10 minutes (10 g / 10 min to 100 g / min). 10 minutes or less). When the MFR is within the above range, the temperature rise when the foamed resin layer is formed by extrusion film formation is small, and the film can be formed in a non-foamed state. The printing process can be performed easily, and there are few missing patterns. If the MFR is too large, the resin is too soft, and the formed foamed resin layer may have insufficient scratch resistance.

  Examples of the inorganic filler include calcium carbonate, aluminum hydroxide, magnesium hydroxide, antimony trioxide, zinc borate, and a molybdenum compound. By including 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 mass and more preferably about 20 to 70 parts by mass with respect to 100 parts by mass of the resin component.

  For pigments, for example, 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) ), Cadmium red, ultramarine, bitumen, cobalt blue, chromium oxide, cobalt green, aluminum powder, bronze powder, titanium mica, and zinc sulfide. Examples of organic pigments include aniline black, perylene black, azo (azo lake, insoluble azo, condensed azo), polycyclic (isoindolinone, isoindoline, quinophthalone, perinone, flavantron, anthrapyrimidine, anthraquinone, quinacridone. Perylene, diketopyrrolopyrrole, dibromoanthanthrone, dioxazine, thioindigo, phthalocyanine, indanthrone, halogenated phthalocyanine). The content of the pigment is preferably about 10 to 50 parts by mass, more preferably about 15 to 30 parts by mass with respect to 100 parts by mass of the resin component.

  Examples of the thermally decomposable foaming agent include azo series such as azodicarbonamide (ADCA) and azobisformamide; hydrazide series such as oxybenzenesulfonyl hydrazide (OBSH) and paratoluenesulfonyl hydrazide. The content of the pyrolytic foaming agent can be appropriately set according to the type of foaming agent, the expansion ratio, and the like. From the viewpoint of the expansion ratio, it is 7 times or more, preferably about 7 to 10 times, and the pyrolytic foaming agent should be about 1 part by mass or more and 20 parts by mass or less with respect to 100 parts by mass of the resin component. Is preferred.

  The foaming aid is preferably a metal oxide and / or a fatty acid metal salt. For example, zinc stearate, calcium stearate, magnesium stearate, zinc octylate, calcium octylate, magnesium octylate, zinc laurate, calcium laurate, laurin Magnesium acid, zinc oxide, magnesium oxide and the like can be used. The content of these foaming auxiliaries is preferably about 0.3 to 10 parts by mass and more preferably about 1 to 5 parts by mass with respect to 100 parts by mass of the resin component.

  When these foaming aids, EMAA, and ADCA foaming agents are used in combination, the effect of the original foaming aid is impaired by the reaction of the acrylic acid portion of EMAA with the foaming aid in the foaming step. There is a problem. Therefore, when EMAA and ADCA foaming agent are used in combination, it is preferable to use a carboxylic acid hydrazide compound as a foaming aid as described in JP-A-2009-197219. At this time, the carboxylic acid hydrazide compound is preferably used in an amount of about 0.2 parts by mass or more and 1 part by mass or less with respect to 1 part by mass of the ADCA foaming agent.

  Further, the foamed resin layer may be formed simultaneously with a non-foamed resin layer laminated on one or both sides. For example, a first non-foamed resin layer (adhesive resin layer) may be formed on the back surface of the foamed resin layer (the surface on which the paper base material 2 is laminated) for the purpose of improving the adhesive force. The thickness of the first non-foamed resin layer (adhesive resin layer) is not limited, but is preferably about 3 μm to 50 μm.

  The resin component of the first non-foamed resin layer (adhesive resin layer) is not particularly limited, but for example, an ethylene-vinyl acetate copolymer (EVA) is preferable. EVA can be a known or commercially available one. In particular, the vinyl acetate component (VA component) is preferably 10% by mass or more and 46% by mass or less, and more preferably 15% by mass or more and 41% by mass or less.

  In addition, a second non-foamed resin layer may be formed on the top surface of the foamed resin layer for the purpose of clarifying the pattern when forming the pattern layer or improving the scratch resistance of the foamed resin layer. . The thickness of the second non-foamed resin layer is not limited, but is preferably about 3 μm or more and 50 μm or less.

  Examples of the resin component of the second non-foamed resin layer include polyolefin resins, methacrylic resins, thermoplastic polyester resins, polyvinyl alcohol resins, fluorine resins, and the like. Among these, polyolefin resins are preferable. Examples of polyolefin resins include polyethylene, polypropylene, polybutene, polybutadiene, polyisoprene, and the like; copolymers of α-olefins having 4 or more carbon atoms (linear low density polyethylene); ethylene-methyl acrylate copolymer Ethylene (meth) acrylic acid ester-based copolymers such as ethylene-ethyl acrylate copolymer; ethylene (meth) acrylic acid such as ethylene-acrylic acid copolymer, ethylene-methacrylic acid copolymer (EMAA) And at least one of ethylene-vinyl acetate copolymer (EVA); saponified ethylene-vinyl acetate copolymer; ionomer and the like.

  In addition, when the foaming agent-containing resin contains an inorganic filler, an inorganic filler residue (so-called eyes) is easily generated at the extrusion port (cylindrical die) of the cylindrical die, and this is a foreign matter on the surface of the foamed resin layer. It is easy to become. Therefore, when an inorganic filler is contained in the foaming agent-containing resin, it is preferable to perform coextrusion film formation using a three-type three-layer cylindrical die. That is, by co-extrusion and film formation in a mode in which the foamed resin layer is sandwiched between non-foamed resin layers, it is possible to suppress the occurrence of the above-mentioned inorganic filler residue (in the eyes).

  The air cooling conditions after extrusion into a cylindrical shape are not limited as long as the air can be cooled to a desired temperature by circulating air inside and outside the cylindrical sheet 1. The air cooling temperature (the temperature of the circulating air) is preferably 10 ° C. or higher and 40 ° C. or lower, and more preferably 15 ° C. or higher and 30 ° C. or lower. The air cooling time is preferably 5 seconds or longer and 30 seconds or shorter, and more preferably 5 seconds or longer and 10 seconds or shorter.

  Further, in the present embodiment, when the cylindrical sheet 1 is formed in the film forming process, 50% or more of 100% by mass of the resin component of the inner diameter layer of the cylindrical sheet 1 (the layer overlapping in the lamination process) is added. It is preferable to use an adhesive resin (low temperature sealing resin) having a melting point of 80 ° C. or lower. If it is less than 50%, the heat-sealing conditions become severe. In addition, an adhesive resin having a melting point of 80 ° C. or more has poor heat-fusibility. Examples of the adhesive resin having a melting point of 80 ° C. or lower that guarantees the low temperature sealing property include Kernel KJ-640T having a melting point of 58 ° C. Thus, 50% or more of 100% by mass of the resin component of the inner diameter layer of the cylindrical sheet 1 is formed of an adhesive resin having a melting point of 80 ° C. or less, so that separation between the resins after foaming (interlayer) can be achieved. Can be suppressed.

[Lamination process]
In the laminating step, the outer surface of the cylindrical sheet 1 in this state is heat laminated on the surface of the paper base 2 in a state where the inner surfaces of the cylindrical sheet 1 created in the film forming step overlap. The state in which the inner surfaces of the cylindrical sheet 1 overlap each other is, for example, a state in which the inner wall surfaces of the cylindrical sheet 1 are in close contact with each other or close to each other. Actually, it is only necessary that the inner wall surfaces of the cylindrical sheet 1 are brought into close contact with each other after the heat laminating process to form a flat film sheet.

  In the method for manufacturing a foamed wallpaper raw material according to the present embodiment, the cylindrical sheet 1 created in the film forming process is not cut into two laminated sheets, and heat lamination is performed in the state of the cylindrical sheet 1. Therefore, the slit process before the stacking process is unnecessary and omitted.

The paper substrate 2 is a so-called backing paper (fibrous sheet). Examples of the paper base 2 include wallpaper general paper (pulp-based sheets sized with a known sizing agent); flame-retardant paper (pulp-based sheets such as guanidine sulfamate and guanidine phosphate) Inorganic paper containing inorganic additives such as aluminum hydroxide and magnesium hydroxide; fine paper; thin paper; fiber mixed paper (paper made by mixing pulp and synthetic fiber) .
The basis weight of the paper substrate 2 is not limited, but preferably the degree 50 g / ^{m 2} or more 300 g / ^{m 2} or less, and more preferably the degree 50 / ^{m 2} or more 120 g / ^{m 2} or less.

  In this embodiment, when laminating the cylindrical sheet 1 (cylindrical foamed resin layer or a laminate of a foamed resin layer and a non-foamed resin layer) on the paper substrate 2, the paper substrate 2 is heated. It is preferable to heat laminate. Although heating conditions are not limited, 110 to 160 degreeC is preferable and 120 to 150 degreeC is more preferable.

  In this embodiment, the cylindrical sheet 1 (cylindrical foamed resin layer or a laminate of a foamed resin layer and a non-foamed resin layer) is obtained and then laminated on the paper substrate 2, but other implementations As an aspect, as shown in FIG. 2, the aspect which laminates | stacks on the paper base material 2 by pinching | interposing the cylindrical sheet 1 with the two paper base materials 2, pressing and bonding with a press machine is employ | adopted. You can also

[Crosslinking process]
Furthermore, the manufacturing method of the raw material for foam wallpaper which concerns on this embodiment may include the bridge | crosslinking process. There is a divergence (gap) between the viscosity of the resin optimal for film formation by the inflation method and the viscosity of the resin necessary for foaming, and a crosslinking step is performed to fill the gap. The crosslinking step is preferably performed between the film forming step and the laminating step.

  There are several methods for crosslinking. For example, electron beam crosslinking for crosslinking a foaming agent-containing resin by electron beam irradiation (EB irradiation) or a foaming agent-containing resin by a reaction of a silane crosslinkable resin (polyolefin). Chemical cross-linking and the like that cross-links can be used. In particular, the electron beam crosslinking is preferable because the thermal effect on the cylindrical sheet 1 is small and the crosslinking is completed instantaneously.

  In electron beam cross-linking, not only the foamed resin layer but also a laminate of the foamed resin layer and the non-foamed resin layer may be irradiated with an electron beam. In that case, when irradiating an electron beam with respect to a cylindrical foamed resin layer or a laminated body, it is preferable to irradiate an electron beam from one side or both sides after bending a cylindrical thing into a sheet form. As for the electron beam irradiation conditions, for example, the energy is preferably about 100 kV to 250 kV, and more preferably about 150 kV to 200 kV. About the irradiation amount of an electron beam, about 25 kGy or more and 70 kGy or less are preferable, for example, and about 30 kGy or more and 60 kGy or less are more preferable. By irradiating the electron beam, the melt tension of the foamed resin layer can be adjusted, and the foaming ratio and the uniformity of the foamed cells when forming the foamed resin layer can be ensured.

  However, since an electron beam is a kind of intense radiation, some additive components (such as phenolic antioxidants) may be deactivated or discolored depending on the mode of use. On the other hand, chemical cross-linking with a silane cross-linkable resin does not have such a concern, so the degree of freedom in material design is improved. That is, a crosslinking method can be appropriately selected according to the purpose.

(Raw material for foam wallpaper)
The raw material for foam wallpaper according to the present embodiment can be manufactured using the above-described method for manufacturing an original fabric for foam wallpaper according to the present embodiment. Therefore, the raw material for foam wallpaper according to the present embodiment includes the cylindrical sheet 1 formed of the foaming agent-containing resin and the paper base material 2 on which the cylindrical sheet 1 is bonded. 50% or more of 100% by mass of the resin component in the inner diameter layer of the cylindrical sheet 1 is formed of an adhesive resin having a melting point of 80 ° C. or less.

(Foam wallpaper)
The foamed wallpaper according to the present embodiment is formed by foaming the above-described foaming agent-containing resin for foamed wallpaper according to the present embodiment. The heating conditions at the time of foaming 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 ° C to 240 ° C, and the heating time is preferably about 20 seconds to 80 seconds.

  Prior to foaming of the foamed resin layer, if necessary, the following pattern layer or surface protective layer is laminated on the foamed resin layer (or the second non-foamed resin layer laminated thereon). You may do it. These layers can be laminated by combining coating such as printing and coating, extrusion film formation, and the like. Printing, coating, etc. can be performed according to conventional methods.

  For example, a pattern layer may be formed on the surface of the foamed resin layer as necessary. The pattern layer imparts design properties to the foamed wallpaper. The pattern pattern layer can be formed, for example, by printing a pattern pattern. The thickness of the design pattern layer is different from the type of design pattern, but is generally preferably about 0.1 μm or more and 10 μm or less.

  Examples of the design pattern include a wood grain pattern, a stone pattern, a grain pattern, a tiled pattern, a brickwork pattern, a cloth pattern, a leather pattern, a geometric figure, a character, a symbol, and an abstract pattern. The pattern can be selected according to the purpose.

  Examples of the pattern pattern printing technique include gravure printing, flexographic printing, silk screen printing, and offset printing. As the printing ink, for example, a printing ink containing a colorant, a binder resin, and a solvent can be used. These inks may be known or commercially available.

As the colorant, for example, a pigment used in a foamed resin layer can be appropriately used.
Binder resin can be set according to the kind of lower layer resin which forms a pattern layer. Examples of the binder resin include acrylic resin, styrene resin, polyester resin, urethane resin, chlorinated polyolefin resin, vinyl chloride-vinyl acetate copolymer resin, polyvinyl butyral resin, alkyd resin, petroleum Resin, ketone resin, epoxy resin, melamine resin, fluorine resin, silicone resin, fiber derivative, rubber resin and the like.

  Examples of the solvent (or dispersion medium) include petroleum organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and acetic acid-2 -Ester-based organic solvents such as ethoxyethyl; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, propylene glycol; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone Organic solvents; ether organic solvents such as diethyl ether, dioxane, tetrahydrofuran; dichloromethane, carbon tetrachloride, trichloroethylene, tetrachloroethylene Chlorinated organic solvents; water and the like. These solvents (or dispersion media) can be used alone or in the form of a mixture.

Further, a surface protective layer may be formed on the surface of the foamed resin layer or the design pattern layer in order to adjust the gloss and / or protect the design pattern layer. The thickness of the surface protective layer is not limited, but is preferably about 0.1 μm or more and 15 μm or less.
Here, the kind of surface protective layer is not limited. If it is a surface protective layer aiming at gloss adjustment, there exists a surface protective layer containing known fillers, such as a silica, for example. As a method for forming the surface protective layer, for example, a known method such as gravure printing can be employed. In addition, when the adhesiveness of a pattern pattern layer and a surface protective layer is not fully acquired, a surface protective layer can also be provided after carrying out the adhesion process (primer process) of the surface of a pattern pattern layer.
When forming a surface protective layer for the purpose of surface strength (scratch resistance, etc.) of foamed wallpaper, stain resistance, protection of the pattern layer, etc., those containing ionizing radiation curable resins as resin components are suitable. is there. As the ionizing radiation curable resin, for example, those that undergo radical polymerization (curing) by electron beam irradiation are preferable.

  Further, after foaming of the foamed resin layer, embossing (unevenness embossing using an embossed plate) may be applied to the outermost surface layer of the foamed wallpaper raw material, and an embossed pattern may be shaped (given). In the embossing, for example, a recess having a depth of 15 μm or more is passed between an embossing roll and a rubber back roll having a hardness of 50 ° C. or more and less than 90 ° C. to give the decorative sheet 10 an uneven shape. good. As a method for measuring hardness, for example, JIS K-6301 A type can be used. Examples of the embossed pattern include a wood grain plate conduit groove, a stone plate surface unevenness, a cloth surface texture, a satin texture, a grain texture, a hairline, and a multiline groove.

Examples of the present embodiment and comparative examples are shown below. In addition, this embodiment is not limited to the following Example.
(Pellet creation)
Using the same-direction meshing type twin screw extruder, pellets A to C were prepared according to the formulation shown in Table 1 below while controlling the resin temperature at 120 ° C. so that the foaming agent was not decomposed.

Example 1
Pellet A was extruded with an extruder with L / D = 28 and a screw diameter of 50 mm, and pellet C was extruded with an extruder with L / D = 28 and a screw diameter of 30 mm. A cylindrical sheet 1 was prepared by forming a cylindrical sheet with a layer ratio of resin of pellet A: resin of pellet C = 50 μm: 5 μm.
The prepared cylindrical sheet 1 was irradiated with an electron beam at an acceleration voltage of 200 kV and an irradiation dose of 60 kGy in a state where the inner surface of the cylindrical sheet 1 overlapped.
Thereafter, the cylindrical sheet 1 irradiated with the electron beam was laminated on the paper base material 2 (manufactured by KJ Special Paper: WK-665IHT weight 65 g / m ² ) in a cylindrical shape, and heated at 110 ° C. (pressing pressure) The sheet and the paper substrate 2 were bonded together by pressing at 2 MPa for 60 seconds.
At this point, the cylindrical sheet 1 has already been crushed. Here, since the cylindrical sheet 1 has a single-layer structure, the cylindrical sheet 1 is crushed into a single-layer flat film-like sheet having a thickness of about twice.
Subsequently, the surface of the crushed cylindrical sheet 1 is subjected to a corona treatment, and then water-based ink (manufactured by Dainichi Seika: Hydrick) is applied at 1 g / m ² by gravure printing, and a matte surface coating agent ( Nissin Chemical Industry Co., Ltd .: Viniblanc 890) was applied with a gravure coating at 2 g / m ² .
Further, heating and embossing for 40 seconds were performed in an oven at 220 ° C., and the foamed wallpaper of Example 1 was obtained.

(Comparative Example 1)
The pellet A was formed into a cylindrical shape having a thickness of 50 μm using a single screw extruder having L / D = 28, a screw diameter of 50 mm, and a cylindrical die.
The produced cylindrical sheet 1 was irradiated with an electron beam with an acceleration voltage of 200 kV and an irradiation dose of 60 kGy in a state where the inner surfaces overlapped.
Thereafter, the cylindrical sheet 1 irradiated with the electron beam was laminated on the paper base material 2 (manufactured by KJ Special Paper: WK-665IHT weight 65 g / m ² ) in a cylindrical shape, and heated at 110 ° C. (pressing pressure) The sheet and the paper substrate 2 were bonded together by pressing at 2 MPa for 60 seconds.
At this point, the cylindrical sheet 1 has already been crushed. Here, since the cylindrical sheet 1 has a single-layer structure, the cylindrical sheet 1 is crushed into a single-layer flat film-like sheet having a thickness of about twice.
Subsequently, the surface of the crushed cylindrical sheet 1 is subjected to a corona treatment, and then water-based ink (manufactured by Dainichi Seika: Hydrick) is applied at 1 g / m ² by gravure printing, and a matte surface coating agent ( Nissin Chemical Industry Co., Ltd .: Viniblanc 890) was applied with a gravure coating at 2 g / m ² .
Furthermore, heating for 40 seconds and embossing were performed in an oven at 220 ° C. to obtain a foamed wallpaper of Comparative Example 1.

(Comparative Example 2)
The pellet B was formed into a cylindrical shape having a thickness of 50 μm using a single screw extruder having L / D = 28, a screw diameter of 50 mm, and a cylindrical die.
The produced cylindrical sheet 1 was laminated on a paper substrate 2 (made by KJ special paper: WK-665IHT weight 65 g / m ² ) in a cylindrical shape, and heated at 110 ° C. with a press machine (press pressure 2 MPa). The sheet was pressed for 2 seconds, and the sheet and the paper substrate 2 were bonded together.
At this point, the cylindrical sheet 1 has already been crushed. Here, since the cylindrical sheet 1 has a single-layer structure, the cylindrical sheet 1 is crushed into a single-layer flat film-like sheet having a thickness of about twice.
After this crushed cylindrical sheet 1 was cured and crosslinked for 3 days in an environment of 40 ° C. and 90%, the surface of the crushed cylindrical sheet 1 was subjected to corona treatment.
Subsequently, an aqueous ink (Dainichi Seika Ltd. Hyde Rick) was 1 g / m ² coated with gravure printing, matte surface coating agent (Nissin Chemical Industry Ltd. Vinyblan 890) 2 g / m ² coated by a gravure coating Worked.
Furthermore, heating for 40 seconds and embossing were performed in an oven at 220 ° C. to obtain a foamed wallpaper of Comparative Example 2.

(Comparative Example 3)
The pellet C of Example 1 was changed to pellet D. Otherwise, the foamed wallpaper of Comparative Example 3 was prepared in the same manner as in Example 1.

(Comparative Example 4)
The pellet C of Example 1 was changed to pellet E. Otherwise, the foamed wallpaper of Comparative Example 4 was prepared in the same manner as in Example 1.

(Change of pressing condition)
The foaming wallpaper of Example 1, Comparative Example 1 and Comparative Examples 2, 3, and 4 was changed to 60 seconds, 50 seconds, 40 seconds, and 30 seconds for the press time in the press, and the resin layer and paper base The adhesion strength with the material and the adhesion strength between the resin layers were confirmed. The results are shown in Table 2 below.

〇：接着した面積が９０％以上
△：接着した面積が５０％以上９０％未満
×：接着した面積が５０％未満

◯: Adhered area is 90% or more Δ: Adhered area is 50% or more and less than 90% ×: Adhered area is less than 50%

Regarding the adhesive force between the resin layer and the paper base material, the foamed wallpaper of each of Example 1 and Comparative Examples 1 to 4 is in close contact with the resin layer and the paper base material in the same time. There wasn't.
However, with respect to the adhesive strength between the resin layers, the foamed wallpaper of Example 1 is sufficient even when the pressing time of 30 seconds is sufficient for the bonded area to be 90% or more, whereas the foaming of Comparative Examples 1 and 2 is sufficient. The wallpaper is different in that it requires a pressing time of 50 seconds, and the foamed wallpaper of Comparative Examples 3 and 4 requires a pressing time of 40 seconds. That is, since the foamed wallpaper of Example 1 adheres to the foamed wallpaper in a shorter time than the foamed wallpaper of Comparative Examples 1-4, Example 1 is actually produced rather than Comparative Examples 1-4. In high-speed molding is possible.
Furthermore, in Comparative Example 1, the cross-linking process ends instantaneously, whereas in Comparative Example 2, the cross-linking process takes 3 days, but the adhesion between the resin layer and the paper substrate and the adhesion between the resin layers are different. It was confirmed that there was no significant difference between Comparative Example 1 and Comparative Example 2.

(Effect of this embodiment)
By using the method for producing a foam wallpaper raw material according to the present embodiment, the cylindrical sheet 1 formed by the inflation method is continuously bonded to a paper substrate without slitting to create a foam wallpaper raw material. can do.

  In addition, when the cylindrical sheet has a single-layer structure, it is crushed and becomes a single-layer flat film-like sheet state having a thickness of about twice, so that the thickness of the cylindrical sheet is anticipated to be doubled in advance. The thickness can be reduced to about half of the thickness of the flat film-like sheet. That is, the thickness of the cylindrical sheet can be reduced.

  In addition, when the cylindrical sheet has a multilayer structure, a symmetric layer can be formed in the stacking direction with the inner layer as the center. Therefore, as shown in FIG. Two flat film-like sheets having the same configuration are formed at the same time by inserting the base material 2 from both sides, pressing and bonding with a press machine, and then cutting at the end (fold) and separating at the position of the inner layer. be able to.

  The foam wallpaper according to the present embodiment can be used for wall decorations of buildings such as detached houses, apartment houses, stores, office buildings and the like.

  While the present invention has been described with reference to specific embodiments, it is not intended that the invention be limited by these descriptions. From the description of the invention, other embodiments of the invention will be apparent to persons skilled in the art, along with various variations of the disclosed embodiments. Therefore, it is to be understood that the claims encompass these modifications and embodiments that fall within the scope and spirit of the present invention.

1 Cylindrical sheet 2 Paper base material

Claims (8)

A film forming step of creating a cylindrical sheet obtained by forming a foam-containing resin into a cylindrical shape by an inflation method;
In a state where the inner surface of the cylindrical sheet overlaps, a lamination step of heat laminating the cylindrical sheet to a paper substrate;
The manufacturing method of the raw material for foaming wallpaper characterized by including.   The method for producing an original fabric for foamed wallpaper according to claim 1, further comprising a crosslinking step between the film forming step and the laminating step.   The said crosslinking process is an electron beam crosslinking process which bridge | crosslinks the said foaming agent containing resin by electron beam irradiation, The manufacturing method of the raw material for foam wallpaper of Claim 2 characterized by the above-mentioned.   The method for producing an original fabric for foamed wallpaper according to claim 2, wherein the crosslinking step is a chemical crosslinking step of crosslinking the foaming agent-containing resin by a reaction of a silane crosslinkable resin.   When forming the cylindrical sheet in the film forming step, 50% or more of 100% by mass of the resin component of the inner diameter layer of the cylindrical sheet is formed of an adhesive resin having a melting point of 80 ° C. or less. The manufacturing method of the raw material for foam wallpaper as described in any one of Claim 1 to 4 characterized by the above-mentioned. A cylindrical sheet formed of a foaming agent-containing resin;
A paper base material on which the cylindrical sheet is bonded;
An original fabric for foamed wallpaper, characterized by comprising:   The raw material for foamed wallpaper according to claim 6, wherein 50% or more of 100% by mass of the resin component in the inner diameter layer of the cylindrical sheet is formed of an adhesive resin having a melting point of 80 ° C or lower. Anti.   A foamed wallpaper obtained by foaming the foaming agent-containing resin of the raw fabric for foamed wallpaper according to claim 6 or 7.

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