JP2023009928A - Foam wallpaper and its manufacturing method - Google Patents

Abstract

To provide foamed wall paper which can be used without causing drying of paste or peeling off even when stored for a long time after gluing in construction.SOLUTION: There is provided a foamed wall paper 10, including a substrate 20, a foamed resin layer 30 laminated on the substrate 20, a pattern printed layer 40 laminated on the foamed resin layer 30, and a surface protective layer 50 laminated on the pattern printed layer 40, in which the foamed resin layer 30 is formed mainly of an aqueous emulsion resin, and the substrate 20 includes a moisture barrier 60 having an anchor coat layer 61 containing a first polyolefin having at least one selected from a carboxyl group, a salt of a carboxyl group, a carboxylic acid anhydride group and a carboxylic acid ester, a deposited layer 62, and an overcoat layer 63 containing a second polyolefin having at least one selected from a carboxyl group, a salt of a carboxyl group, a carboxylic acid anhydride group and a carboxylic acid ester in this order on one side facing the foamed resin layer 30.SELECTED DRAWING: Figure 1

Description

The present invention relates to a foamed wallpaper used for wall decoration of a building or the like and a method for producing the same, and to provide a usable foamed wallpaper that does not cause drying of the paste or peeling off even if stored for a long time after pasting during construction.

The current emulsion specification non-vinyl chloride wallpaper is characterized in that it does not have the problems of residual solvent components and the addition of a large amount of plasticizer, which are common to vinyl chloride wallpaper in the market. However, since the current wallpaper has high moisture permeability, it has the property of quickly releasing the moisture of the construction paste applied to the back surface to the surface layer via the backing paper. This characteristic is due to the fact that the glue on the back side dries up in a short time after gluing, and when it is applied after being stored for a long time, it loses its adhesiveness, or when the glued back sides are put on top of each other, they do not adhere to each other. There is a risk of causing a trouble called "Ai-Hagi", which is peeling off.
Adhesion with starch-based paste is important for wallpaper installation, so substrates with poor adhesion such as aluminum foil cannot be used. You want to use high pulp-based paper. However, plain paper has high moisture permeability and water absorption, and easily exposes moisture.

On the other hand, conventionally, for adhesive-backed articles that are adhesively bonded to an adherend, the microstructured surface of the adhesive causes the article to be subjected to sufficient pressure to form a bond between the surface of the adherend and the adhesive. It is known that it can slide over the surface of the adherend or can be easily peeled off from the surface of the adherend until the is applied (see paragraph [0008] of Patent Document 1 and FIG. 1) ).
In addition, conventionally, an adhesive layer is laminated on the surface of a sheet-like substrate, and the surface of the adhesive layer opposite to the sheet-like substrate side has a shape in which a large number of areas consisting of convex portions are arranged without gaps. is known (see paragraph [0007] and FIG. 1 of Patent Document 2).

Japanese Patent Publication No. 2002-544364 JP-A-2003-336017

Until now, wallpaper-related technologies have focused on those that give high moisture permeability to wallpaper for the purpose of improving the living environment, and no technology has been developed that dares to lower the moisture permeability.
However, due to the continual decrease in the number of construction workers in recent years, it was not possible to spare time for on-site immediate response work such as applying paste on site and immediately pasting it, and paste was applied to most of the wallpaper all at once before entering the site. In most cases, the wallpaper is brought in as a whole, or the unused wallpaper is carried over to the next day and used, and the storability of wallpaper with high moisture permeability has become a major issue.
The present invention has been made in view of the above circumstances, and has newly developed a base material having a strong moisture-proof layer. The purpose is to produce wallpaper.

A foamed wallpaper according to one aspect of the present invention comprises a base material, a foamed resin layer laminated on the base material, a pattern printed layer laminated on the foamed resin layer, and a surface protective layer laminated on the pattern printed layer. In the foamed wallpaper, the foamed resin layer is formed mainly of an aqueous emulsion resin, and the base material has a carboxyl group, a salt of a carboxyl group, a carboxylic acid an anchor coat layer containing a first polyolefin having at least one selected from an anhydride group and a carboxylic acid ester; a deposited layer; and a carboxyl group, a salt of a carboxyl group, a carboxylic anhydride group and a carboxylic acid ester. and an overcoat layer containing at least one second polyolefin in this order.

Further, the foamed wallpaper according to one aspect of the present invention is characterized by having a moisture permeability of 0.1 g/m ² ·24 hr or more and 10.0 g/m ² ·24 hr or less.
A foamed wallpaper according to an aspect of the present invention is characterized in that the anchor coat layer has a thickness of 1 μm or more.
A foamed wallpaper according to an aspect of the present invention is characterized in that an uneven shape is formed by embossing on the surface of the surface protective layer opposite to the surface facing the pattern printed layer.

A method for producing a foamed wallpaper according to one aspect of the present invention comprises a base material, a foamed resin layer laminated on the base material, a pattern printed layer laminated on the foamed resin layer, and a surface protective layer laminated on the pattern printed layer. a layer selected from a carboxyl group, a salt of a carboxyl group, a carboxylic acid anhydride group and a carboxylic acid ester on one side of the base material before laminating the foamed resin layer. A solution containing a first polyolefin having at least one is applied, dried to form an anchor coat layer, vapor-deposited on the anchor coat layer, a vapor-deposited layer is formed, and a vapor-deposited layer is formed on the vapor-deposited layer. , a carboxyl group, a salt of a carboxyl group, a carboxylic acid anhydride group, and a second polyolefin having at least one selected from a carboxylic acid ester is coated and dried to form an overcoat layer, the anchor It is characterized by forming a moisture-proof layer composed of a coat layer, the vapor-deposited layer and the overcoat layer, and forming the foamed resin layer containing an aqueous emulsion resin as a main component on the overcoat layer.

ADVANTAGE OF THE INVENTION According to one aspect of the present invention, it is possible to provide an emulsion specification wallpaper excellent in workability, which does not cause problems such as rapid drying of paste and phase peeling during application, and a method for producing the same.

1 is a cross-sectional view showing the configuration of a foamed wallpaper according to a first embodiment of the present invention; FIG.

A first embodiment of the invention is described below with reference to the drawings. In the description of the drawings referred to in the following description, the same or similar parts are given the same or similar reference numerals. However, it should be noted that the drawings are schematic, and the relationship between thickness and planar dimension, the ratio of thickness of each layer, and the like are different from the actual ones. Therefore, specific thicknesses and dimensions should be determined with reference to the following description. In addition, it goes without saying that there are portions with different dimensional relationships and ratios between the drawings.

Furthermore, the first embodiment shown below exemplifies the configuration for embodying the technical idea of the present invention, and the technical idea of the present invention is the material of the component parts, their shape, The structure, arrangement, etc. are not specified to the following. Various changes can be made to the technical idea of the present invention within the technical scope defined by the claims. Further, the directions of "left and right" and "up and down" in the following description are merely definitions for convenience of description, and do not limit the technical idea of the present invention. Therefore, for example, if the page is rotated 90 degrees, "left and right" and "up and down" are read interchangeably, and if the page is rotated 180 degrees, "left" becomes "right" and "right" becomes "left." It goes without saying that

(First embodiment)
A first embodiment of the present invention will be described below with reference to the drawings.
(Foam wallpaper 10)
The configuration of the foamed wallpaper 10 will be described with reference to FIG.
As shown in FIG. 1, the foamed wallpaper 10 includes (1) a base material 20, (2) a foamed resin layer 30, (3) a pattern printed layer 40, and (4) a surface protective layer 50. Prepare in order.

(Base material 20)
The base material 20 is a sheet-like layer formed to support the foamed resin layer 30 .
As the paper material forming the base material 20, (1) a paper layer 70, (2) an anchor coat layer 61, (3) a deposition layer 62, and (4) an overcoat layer 63 are formed. be.
Although (1) to (4) described above are exemplified as the base material 20, it is not limited thereto, and for example, another coat layer (not shown) may be provided between the paper layer 70 and the anchor coat layer 61. may be provided.

The anchor coat layer 61 contains a first polyolefin having at least one selected from carboxyl groups, salts of carboxyl groups, carboxylic acid anhydride groups and carboxylic acid esters.
The overcoat layer 63 contains a second polyolefin having at least one selected from carboxyl groups, salts of carboxyl groups, carboxylic acid anhydride groups and carboxylic acid esters.

(paper layer 70)
The material of the paper layer 70 is not particularly limited, and may be appropriately selected according to the use of the wallpaper to be applied.
Specific examples of the paper layer 70 include thin paper, woodfree paper, art paper, cast coated paper, kraft paper, titanium paper, linter paper, paperboard, gypsum board paper, woodfree paper, coated paper, sulfuric acid paper, glassine paper, parchment paper, Examples include paraffin paper and Japanese paper.
^The basis ^weight is not particularly limited. m ² is preferred, and 40-100 g/m ² is more preferred.
Further, these paper layers 70 may be subjected to surface treatment such as corona treatment, plasma treatment, flame treatment, etc., as required.

(Other coat layers)
The paper layer 70 may be provided with another coat layer (not shown) at least on the side in contact with the anchor coat layer 61 described later.
By providing another coat layer, it is possible to prevent the anchor coat layer 61 from penetrating into the paper, and it can also play a role of a filler to fill the unevenness of the paper, and the anchor coat layer 61 can be uniformly manufactured without defects. can be membrane.

Other coating layers may include, for example, binder resins such as styrene/butadiene, styrene/acrylic, and ethylene/vinyl acetate copolymers, polyvinyl alcohol resins, cellulose resins, paraffin (WAX), and the like. and may contain clay, kaolin, calcium carbonate, talc, mica, etc. as fillers.
The thickness of the other coating layer is not particularly limited, but may be, for example, 1-10 μm, or 3-8 μm.

(Anchor coat layer 61)
The anchor coat layer 61 is provided on the base material 20 made of paper, and is provided to improve the adhesion between the paper layer 70 and the vapor deposition layer 62 described later and to improve the gas barrier properties of the gas barrier laminate. is.
The anchor coat layer 61 contains a first polyolefin having at least one selected from carboxyl groups, salts of carboxyl groups, carboxylic acid anhydride groups and carboxylic acid esters.

Such an anchor coat layer 61 is excellent in flexibility, can suppress cracking of the vapor deposition layer 62 , and can improve adhesion between the anchor coat layer 61 and the vapor deposition layer 62 . Furthermore, by containing the polyolefin described above, it is possible to form a dense film due to the crystallinity of the polyolefin. In addition, since polyolefin has few polar groups, it is excellent in water vapor barrier properties.

The anchor coat layer 61 may contain other components in addition to the first polyolefin.
Examples of other components include polyolefins other than the first polyolefin, silane coupling agents, organic titanates, polyacrylics, polyesters, polyurethanes, polycarbonates, polyureas, polyamides, polyimides, melamine, and phenols.

The content of the first polyolefin in the anchor coat layer 61 may be, for example, 50% by mass or more, 70% by mass or more, 90% by mass or more, or 100% by mass. .

The thickness of the anchor coat layer 61 may be, for example, 1 μm or more, 2 μm or more, 20 μm or less, 10 μm or less, or 5 μm or less.
If the anchor coat layer 61 has a thickness of 1 μm or more, it is possible to efficiently fill the unevenness of the paper base material 20 described above, and it is possible to uniformly laminate the vapor deposition layer 62 described later. Moreover, if the thickness of the anchor coat layer 61 is 20 μm or less, the deposition layer 62 can be uniformly laminated while suppressing the cost.

Examples of the solvent contained in the coating liquid of the anchor coat layer 61 include water, methyl alcohol, ethyl alcohol, isopropyl alcohol, n-propyl alcohol, n-butyl alcohol, n-pentyl alcohol, dimethylsulfoxide, dimethylformamide, and dimethylacetamide. , toluene, hexane, heptane, cyclohexane, acetone, methyl ethyl ketone, diethyl ether, dioxane, tetrahydrofuran, ethyl acetate, butyl acetate.

These solvents may be used singly or in combination of two or more. Among these, methyl alcohol, ethyl alcohol, isopropyl alcohol, toluene, ethyl acetate, methyl ethyl ketone, and water are preferred from the viewpoint of properties. Moreover, from the viewpoint of the environment, methyl alcohol, ethyl alcohol, isopropyl alcohol, and water are preferable.

As a method of providing the anchor coat layer 61, it can be obtained by applying a coating liquid containing at least the above-described first polyolefin and a solvent on the paper substrate 20 and drying it. The smaller the average particle size of the first polyolefin in the coating liquid, the better, from the viewpoint of smoothing the coated surface after drying, uniformly laminating the deposited layer 62, and improving barrier properties. Specifically, it may be 1 μm or less, 0.7 μm or less, or 0.5 μm or less. The lower limit of the average particle size of the first polyolefin is not particularly limited, but may be, for example, 1 nm or more.

(Vapor deposition layer 62)
The deposited layer 62 is a layer deposited with a metal or an inorganic compound. The deposited layer 62 may be obtained by depositing aluminum, or may contain aluminum oxide (AlOx), silicon oxide (SiOx), or the like.
The thickness of the deposited layer 62 may be appropriately set according to the intended use, preferably 10 to 300 nm, more preferably 30 to 100 nm. When the thickness of the deposition layer 62 is 10 nm or more, the continuity of the deposition layer 62 can be easily made sufficient, and when the thickness is 300 nm or less, the occurrence of curling and cracking can be sufficiently suppressed, and sufficient gas barrier performance and flexibility can be obtained. easy to achieve.

From the viewpoint of oxygen gas barrier performance and film uniformity, the deposited layer 62 is preferably formed by vacuum film forming means. Film formation means include known methods such as a vacuum deposition method, a sputtering method, and a chemical vapor deposition method (CVD method), but the vacuum deposition method is preferred because of its high film formation speed and high productivity. In addition, among the vacuum evaporation methods, the film formation method using electron beam heating in particular is easy to control the film formation speed by adjusting the irradiation area and the electron beam current, and the heating and cooling of the evaporation material can be performed in a short time. It is valid.

(Overcoat layer 63)
The overcoat layer 63 is provided on the vapor deposition layer 62 so as to be in contact with the vapor deposition layer 62, and has at least one selected from a carboxyl group, a salt of a carboxyl group, a carboxylic acid anhydride group, and a carboxylic acid ester. A second polyolefin is included.
Such an overcoat layer 63 has excellent flexibility and excellent adhesion to the deposited layer. Furthermore, by including the above-described second polyolefin, it is possible to form a dense film due to the crystallinity of the polyolefin. In addition, since polyolefin has few polar groups, it is excellent in water vapor barrier properties.

The overcoat layer 63 may contain other components in addition to the second polyolefin. Other components include, for example, silane coupling agents, organic titanates, polyacrylics, polyesters, polyurethanes, polycarbonates, polyureas, polyamides, polyolefin emulsions, polyimides, melamine, and phenols.
The content of the second polyolefin in the overcoat layer 63 may be, for example, 50% by mass or more, 70% by mass or more, 90% by mass or more, or 100% by mass. .

The thickness of the overcoat layer 63 may be, for example, 0.05 μm or more, 0.5 μm or more, 1 μm or more, 20 μm or less, 10 μm or less, or 5 μm. may be: If the thickness of the overcoat layer 63 is 0.05 μm or more, the role of the heat seal layer described above can be fully exhibited. Moreover, if the thickness of the overcoat layer 63 is 20 μm or less, it is possible to sufficiently exhibit the adhesiveness and barrier properties with respect to the deposition layer 62 while suppressing the cost.

Examples of the solvent contained in the coating liquid of the overcoat layer 63 include water, methyl alcohol, ethyl alcohol, isopropyl alcohol, n-propyl alcohol, n-butyl alcohol, n-pentyl alcohol, dimethylsulfoxide, dimethylformamide, and dimethylacetamide. , toluene, hexane, heptane, cyclohexane, acetone, methyl ethyl ketone, diethyl ether, dioxane, tetrahydrofuran, ethyl acetate, butyl acetate.

These solvents may be used singly or in combination of two or more. Among these, methyl alcohol, ethyl alcohol, isopropyl alcohol, toluene, ethyl acetate, methyl ethyl ketone, and water are preferred from the viewpoint of properties. Moreover, from the viewpoint of the environment, methyl alcohol, ethyl alcohol, isopropyl alcohol, and water are preferable.
As a method for providing the overcoat layer 63, it can be obtained by applying a coating liquid containing the above-mentioned second polyolefin and a solvent on the deposition layer 62 and drying it. The average particle size of the second polyolefin in the coating liquid is not particularly limited, but specifically may be 1 µm or less, 0.7 µm or less, or 0.5 µm or less.

The first polyolefin and the second polyolefin contained in the anchor coat layer 61 and the overcoat layer 63, respectively, may be of the same type or of different types. For example, they are preferably of the same type.

(Foamed resin layer 30)
The foamed resin layer 30 is laminated on the base material 20 . Specifically, the foamed resin layer 30 is laminated on the upper surface of the substrate 20 in FIG.
The foamed resin layer 30 contains a resin component, a filler, a foaming agent, a foaming aid, a resin component, an organic antibacterial agent, an additive, and an antibacterial agent. is formed by foaming.

The resin component contained in the foamed resin layer 30 contains an aqueous emulsion resin as a main component. That is, the foamed resin layer 30 is formed mainly of an aqueous emulsion resin.
As the filler contained in the foamed resin layer 30, for example, an inorganic filler can be used. Inorganic fillers can be used singly or in combination of two or more.

Examples of inorganic fillers that can be used include calcium carbonate, titanium dioxide, kaolin, and the like.
From the viewpoint of performance (expansion ratio, strength), the foaming agent (volatile expansion agent) contained in the foamed resin layer 30 is added to the resin component contained in the foamed resin layer 30 in the form of thermally expandable microcapsules. preferable. As the foaming agent contained in the foamed resin layer 30, azo-based, hydrazide-based, nitroso-based, etc. can be used.
Further, the foamed resin layer 30 may be colored by adding a pigment or the like as necessary.
Coloration by adding a pigment may be transparent, translucent, or opaque.

Examples of pigments that can be used include iron oxide and carbon black.
The amount of pigment added is preferably in the range of 5% by mass or more and 50% by mass or less, more preferably in the range of 10% by mass or more and 30% by mass or less, based on the total amount of the resin layer.
As the antibacterial agent contained in the foamed resin layer 30, it is possible to use, for example, a thiazole-based agent because it must be soluble in water (water-soluble).

The antibacterial agent contained in the foamed resin layer 30 includes nitrile, imidazole, alcohol, aldehyde, carboxylic acid, ester, disulfide, thiocarbamate, and phenol, as long as they are water-soluble. It is possible to use a system or the like.

Furthermore, the antibacterial agent contained in the foamed resin layer 30 includes pyridine/quinoline, triazine, isothiazolone, anilide, carboxylic acid, ether, and peroxide/epoxy agents as long as they are water-soluble. , biguanides, surfactants, and the like can be used.
Examples of flame retardants that can be used include metal oxide flame retardants such as magnesium hydroxide and aluminum hydroxide, phosphorus flame retardants such as phosphate esters, and brominated flame retardants such as tetrabromobisphenol A. is.

(Pattern printed layer 40)
The pattern printed layer 40 is laminated on the foamed resin layer 30 . Specifically, the pattern printed layer 40 is laminated on the upper surface of the foamed resin layer 30 in FIG.
Moreover, the pattern printed layer 40 imparts a desired pattern design to the foamed wallpaper 10, and the type of pattern is not particularly limited.
Examples of patterns include wood grain patterns, stone grain patterns, sand grain patterns, tile patterns, brickwork patterns, texture patterns, leather tie patterns, geometric figures, characters, symbols, abstract patterns, etc., where the foamed wallpaper 10 is used. It is possible to select a pattern suitable for

Regarding the printing ink that forms the pattern printed layer 40, the requirements for light resistance, color development, and safety of the components used (including heavy metals and sulfur compounds as pigments and additives), which are generally required for wallpaper, must be met. etc.) is not particularly limited.
In the first embodiment, as an example, the case where the printing ink forming the pattern printed layer 6 is a water-based ink using an acrylic polymer as a base resin will be described.

The printing ink that forms the pattern printed layer 40 is composed of the water-based emulsion as described above, and becomes a coating film of the pattern printed layer 40 by drying after printing.
The ink contains known pigments that form patterns.
By blending a pigment in combination with the printing ink that forms the pattern printed layer 40, it is possible to enrich the expression of the pattern. Moreover, by adding an ultraviolet absorber, a light stabilizer, or the like to the printing ink that forms the pattern printed layer 6, it is possible to improve the weather resistance.
As a method for printing the pattern, for example, known printing methods such as gravure printing, offset printing, silk screen printing, and inkjet printing can be used.
In particular, in the case of uniformly coloring the entire surface, a coating technique or apparatus may be used in addition to the printing method described above.

(Surface protective layer 50)
The surface protective layer 50 is laminated on the pattern printed layer 40 and is a layer also called a coat layer (coating layer). Specifically, the surface protective layer 50 is laminated on the upper surface of the pattern printed layer 40 in FIG.
The surface protective layer 50 is made of one or more selected from among acrylic acid (CH ₂ =CHCOOH), methacrylic acid (CH ₂ =C(CH ₃ )COOH), and their esters as a resin component other than silicon-based resin. It preferably contains a polymer formed from monomers or a polymer obtained by copolymerizing a polymer with one or more monomers or block copolymers selected from styrene, vinyl acetate, ethylene and α-olefins.

The structure of the surface protection layer 50 can also be a structure containing a resin such as polyvinyl chloride as a resin component other than the silicon-based resin.
The basis weight of the surface protective layer 50 is preferably 1.0 g/m ² or more and 30.0 g/m ² or less from the viewpoint of providing physical properties such as protection from heat and chlorine, surface strength, and stain resistance. . Furthermore, the basis weight of the surface protective layer 50 is more preferably 5.0 g/m ² or more and 25.0 g/m ² or less.

On the surface of the surface protective layer 50 opposite to the surface facing the pattern printed layer 40 (the upper surface of the surface protective layer 50 in FIG. 1), an embossed uneven shape 80 is formed.
As the uneven shape 80 by embossing, for example, it is possible to use cloth grain, wood grain plate conduit groove, stone plate surface unevenness, cloth surface texture, satin finish, sand grain, hairline, parallel groove, etc., and it is possible to select appropriately. is.

(Method for producing foamed wallpaper 10)
The method for manufacturing the foamed wallpaper 10 having the above configuration is as follows.
(Base material 20)
For the base material 20, the moisture-proof layer 60 is formed on, for example, reinforced paper (manufactured by Tenma Special Paper Co., Ltd.).
The moisture-proof layer 60 is composed of the following first to third steps.

(First step)
In the first step, at least one selected from carboxyl groups, salts of carboxyl groups, carboxylic acid anhydride groups, and carboxylic acid esters is formed on one surface of the base material 20 before the foamed resin layer 30 is laminated. In this step, a solution containing polyolefin is applied and dried to form the anchor coat layer 61 .
For example, a coating liquid containing a salt of a carboxyl group (trade name: Chemipearl S100, manufactured by Mitsui Chemicals) is used, coated with a bar coater, and dried in an oven to form the anchor coat layer 61 .

(Second step)
A second step is a step of forming a vapor deposition layer 62 by vapor deposition, for example, AL vapor deposition, on the anchor coat layer 61 .
(Third step)
In the third step, a solution containing a second polyolefin having at least one selected from a carboxyl group, a salt of a carboxyl group, a carboxylic acid anhydride group, and a carboxylic acid ester is applied onto the deposited layer 62, In this step, the overcoat layer 63 is formed by drying.
For example, a solution containing a salt of a carboxyl group (trade name: Chemipearl S100, manufactured by Mitsui Chemicals) was applied with a bar coater and dried in an oven to form an overcoat layer 63, thereby obtaining a gas barrier laminate.

(Foamed resin layer 30)
The foamed resin layer 30 contains, for example, an ethylene-vinyl acetate copolymer resin (EVA resin) as a main component, and 80 parts of calcium carbonate as a filler and 10 parts of a capsule foaming agent are added. Then, the expansion ratio was set to 5 times, and the basis weight was 100 g/m ² .
(Pattern printed layer 40)
The pattern printed layer 40 was formed using, for example, an acrylic resin-based ink so that the coating amount was 2 g/m ² .

(Surface protective layer 50)
The surface protective layer 50 is mainly composed of, for example, an acrylic resin and a silicone resin, and is formed to have a basis weight of 5 g/m ² .
(Uneven shape 80)
The uneven shape 80 is formed by embossing, for example, on the surface of the surface protective layer 50 opposite to the surface facing the pattern printed layer 40 (the upper surface of the surface protective layer 50 in FIG. 1).

(Characteristic points and effects according to the embodiment based on the present invention)
Aspects of embodiments in accordance with the present invention are as follows.
(First feature point)
The first feature is that the base material 20, the foamed resin layer 30 laminated on the base material 20, the pattern printed layer 40 laminated on the foamed resin layer 30, and the surface protective layer 50 laminated on the pattern printed layer 40. In the foamed wallpaper 10, the foamed resin layer 30 is formed mainly of an aqueous emulsion resin, and the substrate 20 has, on one surface facing the foamed resin layer 30, a carboxyl group, a salt of a carboxyl group, and a carboxylic acid. An anchor coat layer 61 containing a first polyolefin having at least one selected from an acid anhydride group and a carboxylic acid ester, a deposited layer 62, a carboxyl group, a salt of a carboxyl group, a carboxylic anhydride group and a carboxylic acid ester. and an overcoat layer 63 containing a second polyolefin having at least one selected from the above, and a moisture-proof layer 60 provided in this order.

(Effect of first feature point)
According to the first characteristic point, the base material 20 prevents the water content of the application paste on the back surface from appearing on the surface layer, and long-term storage after gluing is possible.
According to the first characteristic point, the anchor coat layer 61 is provided on the paper substrate 20 to improve the adhesion between the paper layer 70 and the vapor deposition layer 62 and improve the gas barrier properties of the gas barrier laminate. can improve sexuality.

According to the first feature, the anchor coat layer 61 contains a first polyolefin having at least one selected from a carboxyl group, a salt of a carboxyl group, a carboxylic acid anhydride group, and a carboxylic acid ester, thereby providing a flexible structure. It is possible to suppress cracking of the vapor deposition layer 62 and improve adhesion between the anchor coat layer 61 and the vapor deposition layer 62 . Furthermore, by containing polyolefin, it is possible to form a dense film due to the crystallinity of polyolefin. In addition, since polyolefin has few polar groups, it is excellent in water vapor barrier properties.

According to the first feature, the overcoat layer 63 contains a second polyolefin having at least one selected from carboxyl groups, salts of carboxyl groups, carboxylic acid anhydride groups, and carboxylic acid esters, thereby providing flexibility. It has excellent properties and excellent adhesion to the deposited layer 62 . Also, by including the second polyolefin, it is possible to form a dense film due to the crystallinity of the polyolefin. In addition, since polyolefin has few polar groups, it is excellent in water vapor barrier properties.

(Second feature point)
A second characteristic point is that the moisture permeability is 0.1 g/m ² ·24 hr or more and 10.0/m ² ·24 hr or less.
(Effect of second feature point)
According to the second characteristic point, by setting the moisture permeability within the range of 5.0 g/m ² ·24 hr or less, the foamed wallpaper 10 did not peel off even when stored for a long period of time.
That is, according to the second characteristic point, by adding an improvement to the moisture-proof layer 60, suppression of moisture permeability and the effect of preventing "phase peeling" due to it are recognized, and it can withstand long-term storage at the construction site. became possible. On the other hand, if the amount is less than 0.1 g/m ² ·24 hr, the drying of the paste during application is extremely slow.

(Third feature point)
A third characteristic point is that the thickness of the anchor coat layer 61 is 1 μm or more.
(Effect of the third feature point)
According to the third characteristic point, since the thickness of the anchor coat layer 61 is 1 μm or more, the unevenness of the paper base material 20 can be efficiently filled, and the vapor deposition layer 62 can be uniformly laminated. can.

(Fourth feature point)
A fourth characteristic point is that the surface of the surface protective layer 50 opposite to the surface facing the pattern printed layer 40 is formed with an uneven shape 80 by embossing.
(Effect of fourth feature point)
According to the fourth characteristic point, the decorativeness of the foamed wallpaper 10 can be improved by the uneven shape 80 formed by embossing.

(Fifth feature point)
The fifth characteristic point is that the base material 20, the foamed resin layer 30 laminated on the base material 20, the pattern printed layer 40 laminated on the foamed resin layer 30, and the surface protective layer 50 laminated on the pattern printed layer 40. A method for manufacturing a foamed wallpaper 10 comprising: at least one selected from a carboxyl group, a salt of a carboxyl group, a carboxylic acid anhydride group, and a carboxylic acid ester on one surface of a base material 20 before lamination of a foamed resin layer 30; A solution containing a first polyolefin having seeds is applied and dried to form an anchor coat layer 61, vapor deposition is performed on the anchor coat layer 61, a vapor deposition layer 62 is formed, and a vapor deposition layer 62 is formed on the vapor deposition layer 62. , a carboxyl group, a salt of a carboxyl group, a carboxylic acid anhydride group, and a carboxylic acid ester. The point is that the moisture-proof layer 60 is formed from the coat layer 61, the deposition layer 62 and the overcoat layer 63, and the foamed resin layer 30 containing the aqueous emulsion resin as the main component is formed on the overcoat layer 63.
(Effect of fifth feature point)
According to the fifth characteristic point, it is possible to provide a method for manufacturing the foamed wallpaper 10 which can prevent the water content of the applied paste on the back surface from appearing on the surface layer by the base material 20, and which can be stored for a long time after gluing.

(Sixth feature point)
A sixth characteristic point is that the thickness of the anchor coat layer 61 is 20 μm or less.
(Effect of sixth feature point)
According to the sixth characteristic point, if the thickness of the anchor coat layer 61 is 20 μm or less, the deposition layer 62 can be uniformly laminated while suppressing the cost.
stomach.
A sixth characteristic point is that the thickness of the anchor coat layer 61 is set to 1 μm or more and 20 μm or less.
That is, if the thickness is less than 1 μm, the unevenness of the paper substrate 20 cannot be efficiently filled, and the deposited layer 62 cannot be laminated uniformly. A disadvantage of 20 μm or more is an increase in cost.

(Seventh feature point)
A seventh characteristic point is that the vapor deposition layer 62 is a layer in which a metal or an inorganic compound is vapor deposited, and the thickness of the vapor deposition layer 62 is 10 to 300 nm.
(Effect of seventh feature point)
According to the seventh characteristic point, by setting the thickness of the vapor deposition layer 62 to 10 nm or more, the continuity of the vapor deposition layer 62 can be easily achieved, or by setting the thickness to 300 nm or less, curling and cracking can be sufficiently prevented. can be suppressed, and it is easy to achieve sufficient gas barrier performance and flexibility.

(Eighth feature point)
An eighth characteristic point is that the thickness of the overcoat layer 63 is 0.05 μm or more and 20 μm or less.
(Effect of eighth feature point)
According to the eighth characteristic point, if the thickness of the overcoat layer 63 is 0.05 μm or more, the role as a heat seal layer can be sufficiently exhibited, or if it is 20 μm or less, the cost can be reduced. Adhesion and barrier properties with the vapor deposition layer 62 can be sufficiently exhibited.

(Ninth feature point)
A ninth feature is that various copolymers such as styrene/butadiene, styrene/acrylic, ethylene/vinyl acetate, and polyvinyl alcohol are placed between the paper layer 70 and the anchor coat layer 61 as binder resins. The point is that another coat layer (not shown) using at least one of resin, cellulose resin, and paraffin (WAX) is provided.

(Effect of the ninth feature point)
According to the ninth feature, by providing another coat layer (not shown), it is possible to prevent the anchor coat layer 61 from soaking into the paper, and it also serves as a filler that fills the unevenness of the paper. Also, the anchor coat layer 61 can be formed uniformly without defects.

(Tenth feature point)
A tenth feature is that the anchor coat layer 61 and the overcoat layer 63 are made of ionomer resin.
(Effect of tenth feature point)
According to the tenth feature, the use of an ionomer-based resin can reduce moisture permeability and prevent phase peeling. On the other hand, if the ionomer-based resin is replaced with an EVA-based resin or a polyolefin resin, there is a demerit that the moisture permeability increases and the phase is easily peeled off.

The foamed wallpaper of Examples 1 and 2 and the foamed wallpaper of Comparative Examples 1 and 2 will be described below with reference to the first embodiment.
(Example 1)
The foamed wallpaper of Example 1 was configured as follows.

<Base material>
A coating liquid containing a salt of a carboxyl group (trade name: ^Chemipearl S100, ionomer type, particle size: <0.1 μm (particle size less than 0.1 μm, solvent: water, IPA, manufactured by Mitsui Chemicals) was applied with a bar coater and dried in an oven to form an anchor coat layer.
The thickness of the anchor coat layer was 3 μm. Subsequently, AL vapor deposition was performed on the anchor coat layer. The thickness of the AL deposition layer was 50 nm. After that, a solution containing a salt of a carboxyl group (trade name: Chemipearl S100, ionomer type, particle size: <0.1 μm (particle size is less than 0.1 μm), solvent: water, IPA, manufactured by Mitsui Chemicals ) was applied with a bar coater and dried in an oven to form an overcoat layer, thereby obtaining a gas barrier laminate. The thickness of the overcoat layer was 3 μm.
That is, the base material was composed of a paper layer composed of reinforced paper between papers, and a moisture-proof layer composed of an anchor coat layer, a vapor deposition layer and an overcoat layer.

<Foamed resin layer>
An ethylene-vinyl acetate copolymer resin (EVA resin) was used as a main component, and 80 parts of calcium carbonate and 10 parts of a capsule foaming agent were added as fillers. Then, the expansion ratio was set to 5 times, and the basis weight was 100 g/m ² .
Furthermore, the foamed resin layer contained an antibacterial agent (BC-477), and the mass ratio of the antibacterial agent to the foamed resin layer was set to 0.3%.

<Pattern printing layer>
An acrylic resin ink was used so that the coating amount was 2 g/m ² .
<Surface protective layer>
It was formed to have a basis weight of 5 g/m ² with acrylic resin and silicone resin as main components.

(Example 2)
Example 1 was prepared in the same manner as in Example 1 except that the solution of the anchor coat layer and overcoat layer was a coating solution containing a salt of a carboxyl group (trade name: Chemipearl S500, ionomer type, particle size: 0.7 μm). got 2.

(Comparative example 1)
The foamed wallpaper of Comparative Example 1 had the following structure.
<Base material>
It was formed using plain paper with a basis weight of 65 g/m ² .
<Foamed resin layer>
Ethylene-vinyl acetate copolymer resin (EVA resin) was used as the main component, and 80 parts of calcium carbonate as a filler and 10 parts of a capsule foaming agent were added. Then, the expansion ratio was set to 5 times, and the basis weight was 100 g/m ² .

(Comparative example 2)
Comparative Example 2 was obtained in the same manner as in Example 2, except that the anchor coat layer solution was a coating solution containing a vinyl acetate-based polyolefin resin.

(performance evaluation)
For the foamed wallpaper of Examples 1 and 2 and the foamed wallpaper of Comparative Examples 1 and 2, confirmation tests of moisture permeability and phase peeling were carried out.
(1) Moisture Permeability Based on JIS Z0208.
(2) Phase peeling test Apply 120 g/ ^m2 of starch paste "Lu-A Mild" made by Yayoi Chemical Co., Ltd. on the side of the base material of the foamed wallpaper, diluted with water at a ratio of 55:45, and overlap the paste surfaces. After 24 hours, the bag is folded and sealed in a polyethylene bag, and the presence or absence of breakage of the base material layer is checked when the bag is opened and unfolded after 24 hours.

(Evaluation results)
As is clear from the results in Table 1, the foamed wallpapers of Examples 1 and 2 have significantly lower moisture permeability than the foamed wallpapers of Comparative Examples 1 and 2, and peeling does not occur even after long-term storage. The results were obtained.
The foamed wallpapers of Examples 1 and 2 were found to have an effect of suppressing moisture permeability and thereby preventing phase peeling by adding improvements to the base material layer, making it possible to withstand long-term storage at construction sites. rice field.
On the other hand, the foamed wallpapers of Comparative Examples 1 and 2 had higher moisture permeability than those of Examples 1 and 2, and fracture occurred in the phase peeling test. This is presumably because Comparative Example 1 does not have a moisture-proof layer (anchor coat layer, vapor deposition layer and overcoat layer) in the base material.
The foamed wallpaper of Comparative Example 2 had a higher moisture permeability than those of Examples 1 and 2, and was slightly broken in the phase peeling test. This is because the resin used in the anchor coat layer of Comparative Example 2 was changed from the ionomer-based resin used in Examples 1 and 2 to a vinyl acetate-based polyolefin resin, which increased the moisture permeability. It can be assumed that this is the cause.

REFERENCE SIGNS LIST 10 foamed wallpaper 20 base material 30 foamed resin layer 40 pattern printed layer 50 surface protective layer 60 moisture-proof layer 61 anchor coat layer 62 deposition layer 63 overcoat layer 70 paper layer 80 uneven shape

Claims (5)

A foamed wallpaper comprising a substrate, a foamed resin layer laminated on the substrate, a pattern printed layer laminated on the foamed resin layer, and a surface protective layer laminated on the pattern printed layer,
The foamed resin layer is formed mainly of an aqueous emulsion resin,
An anchor coat layer containing a first polyolefin having at least one selected from a carboxyl group, a salt of a carboxyl group, a carboxylic acid anhydride group and a carboxylic acid ester on one surface of the base material facing the foamed resin layer. and a vapor-deposited layer, and an overcoat layer containing a second polyolefin having at least one selected from a carboxyl group, a salt of the carboxyl group, a carboxylic anhydride group and a carboxylic acid ester, in this order. A foamed wallpaper characterized by being provided. The foamed wallpaper according to claim 1, wherein the moisture permeability is 0.1 g/m ² ·24 hr or more and 10.0 g/m ² ·24 hr or less. 3. The foamed wallpaper according to claim 1, wherein the anchor coat layer has a thickness of 1 [mu]m or more. The foamed wallpaper according to any one of claims 1 to 3, wherein the surface of the surface protective layer opposite to the surface facing the pattern printed layer is embossed to form an uneven shape. . A method for producing foamed wallpaper comprising a base material, a foamed resin layer laminated on the base material, a pattern printed layer laminated on the foamed resin layer, and a surface protective layer laminated on the pattern printed layer,
A solution containing a first polyolefin having at least one selected from a carboxyl group, a salt of a carboxyl group, a carboxylic acid anhydride group and a carboxylic acid ester is applied to one surface of the base material before lamination of the foamed resin layer. processed and dried to form an anchor coat layer,
vapor deposition on the anchor coat layer to form a vapor deposition layer;
A solution containing a second polyolefin having at least one selected from a carboxyl group, a salt of a carboxyl group, a carboxylic acid anhydride group, and a carboxylic acid ester is applied onto the deposited layer and dried to form an overcoat layer. to form
forming a moisture-proof layer consisting of the anchor coat layer, the vapor deposition layer and the overcoat layer;
A method for producing a foamed wallpaper, wherein the foamed resin layer containing an aqueous emulsion resin as a main component is formed on the overcoat layer.

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