JP6821917B2 - How to manufacture wallpaper with non-combustible performance - Google Patents

Description

The present invention also relates to the manufacture how wallpaper with a non-combustible performance.

Wallpaper is provided to improve the design of the building, but it may also be provided to hide dents, gaps, steps, etc. on the underlying wall surface. Moreover, when it becomes dirty, it can be easily replaced with a new state.
In order to achieve the purpose of concealing dents, gaps, steps, etc. on the underlying wall surface, the wallpaper is required to have a voluminous feel in order to improve the concealing property. In wallpaper, the volume can be increased by foaming the resin and increasing the foaming ratio. For example, as a wallpaper having a foamed resin layer on a base material, there is one disclosed in Patent Document 1.
Further, as a nonflammable wallpaper having irregularities formed on its surface, there is one disclosed in Patent Document 2.

Japanese Unexamined Patent Publication No. 2013-144866 Japanese Unexamined Patent Publication No. 7-216759

By the way, when the uneven surface of the embossed plate is pressed against the surface of the wallpaper provided with the foamed resin layer to form the uneven surface (that is, embossing is performed), the depth of the uneven surface of the embossed plate (hereinafter referred to as "plate depth"). If it is too shallow (referred to as), there is a problem that unevenness cannot be sufficiently formed on the surface of the wallpaper and the design feeling is poor.
Further, if the plate depth of the embossed plate is too deep, there is a problem that air dust (a portion where air cannot escape) is generated between the uneven surface of the embossed plate and the surface of the wallpaper during the embossing process. When air shavings occur, the surface of the wallpaper has a portion pressed by the uneven surface of the embossed plate and a portion not pressed, resulting in a difference in gloss on the surface of the wallpaper. This difference in luster is particularly noticeable in dark-colored wallpaper, and the design feeling is impaired.

Accordingly, the present invention was made in view of such circumstances, has excellent design sense due to the unevenness shape, which aims to provide a manufacturing how wallpaper having non-combustibility.

In order to solve the above problems, in the method for producing a wallpaper having non-combustible performance according to one aspect of the present invention, a foamed resin layer, a pattern printing layer, and a resin film layer are laminated in this order on a base paper layer. A step of pressing an embossing plate against the surface of the resin film layer of the laminated sheet to form irregularities is provided, the foamed resin layer is made of vinyl chloride resin, and the resin constituting the resin film layer is both ethylene and vinyl alcohol. includes a polymer, plate depth of the embossing plate is Ri der than 200μm or less 50 [mu] m, the basis weight of the resin film layer is characterized in der Rukoto 13.4 g / ^{m 2} or more 18.0 g / ^{m 2} or less ..
A method for producing a wallpaper having non-combustible performance according to one aspect of the present invention is to obtain a resin film layer of a laminated sheet in which a foamed resin layer, a pattern printing layer, and a resin film layer are laminated in this order on a base paper layer. The embossed plate is provided with a step of pressing an embossed plate on the surface to form irregularities, the foamed resin layer is made of vinyl chloride resin, and the resin constituting the resin film layer contains an ethylene-vinyl alcohol copolymer. The plate depth is 50 μm or more and 200 μm or less, and the foamed resin layer forms a foaming agent-containing resin layer which is a resin layer containing a foaming agent on the base paper layer, and prints the pattern on the foaming agent-containing resin layer. The resin film layer is formed by foaming the foaming agent after forming the layer, and the resin film layer is formed on the foamed resin layer formed by foaming the foaming agent .

According to one aspect of the present invention, it has excellent design sense due to the unevenness, it is possible to provide a manufacturing how wallpaper having non-combustibility.

It is sectional drawing which shows the structural example of the wallpaper which has the noncombustible performance which concerns on embodiment of this invention. It is sectional drawing which shows the manufacturing method of the wallpaper which has the noncombustible performance which concerns on embodiment of this invention in process order.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In each of the figures described below, the parts corresponding to each other are designated by the same reference numerals, and the repeated description of the parts with the same reference numerals will be omitted as appropriate. Further, the embodiment of the present invention exemplifies a configuration for embodying the technical idea of the present invention, and specifies the material, shape, structure, arrangement, dimensions, etc. of each part as follows. Not. The technical idea of the present invention may be modified in various ways within the technical scope specified by the claims stated in the claims.

<Composition>
FIG. 1 is a cross-sectional view showing a configuration example of a wallpaper having non-combustible performance (hereinafter, also simply referred to as wallpaper) 10 according to an embodiment of the present invention. As shown in FIG. 1, the wallpaper 10 has a base paper layer 1, a foamed resin layer 3 formed on the base paper layer 1, a pattern printing layer 5 formed on the foamed resin layer 3, and a pattern printing layer 5. The resin film layer 7 formed on the top is provided. The resin constituting the resin film layer 7 contains an ethylene-vinyl alcohol copolymer. On the surface of the resin film layer, irregularities having a step of 50 μm or more and 200 μm or less are formed. The thickness of the wallpaper 10 is 200 μm or more and 400 μm or less. Hereinafter, each layer constituting the wallpaper 10 will be described with an example.

(Base paper layer)
The base paper layer 1 is, for example, plain paper, and its basis weight is 58.5 g / m ² or more and 71.5 g / m ² or less. Further, the base paper layer 1 may be one that is usually used for what is conventionally called a backing paper for wallpaper. The base paper layer 1 is a pulp-based flame retardant paper impregnated with a water-soluble flame retardant such as guanidine sulfamate or guanidine phosphate, or an inorganic paper mixed with an inorganic agent such as magnesium carbonate, aluminum hydroxide, or magnesium hydroxide. In that case, the basis weight is 50 g / m ² or more and 300 g / m ² or less, preferably 60 g / m ² or more and 160 g / m ² or less.
Further, the surface of the base paper layer 1 (that is, the surface on the side where the foamed resin layer 3 is provided) may be subjected to a base treatment such as a corona discharge treatment, a plasma treatment, an ozone treatment, or an acrylic-butyl copolymer. , An adhesive treatment layer (not shown) coated with polyurethane or the like composed of isocyanate and polyol may be provided.

(Foam resin layer)
The foamed resin layer 3 is, for example, a layer made of vinyl chloride resin, has a large number of voids 4 inside, and has a basis weight of 150 g / m ² or more and 205 g / m ² or less. The foamed resin layer 3 is formed, for example, by adding a foaming agent to a vinyl chloride resin and foaming it. Further, the foamed resin layer 3 may be formed by adding an inorganic filler and various other additives in addition to the foaming agent and foaming. The vinyl chloride resin has film forming property, flexibility, and processability at low temperature, and can be used as a wallpaper at a relatively low cost. The foamed resin layer 3 imparts flame retardancy to the wallpaper 10. Further, the foamed resin layer 3 suppresses the penetration of the ink composition (for example, acrylic resin-based ink) of the pattern printing layer 5 into the base paper layer 1.
In the present embodiment, the resin constituting the foamed resin layer 3 is not limited to the vinyl chloride resin. For example, the resin constituting the foamed resin layer 3 may be a polymer of a vinyl chloride resin and another resin, or a mixed resin of a vinyl chloride resin and another resin.

(Pattern printing layer)
The pattern printing layer 5 is, for example, a layer printed with an acrylic resin-based ink, and its basis weight is 0 g / m ² or more and 10 g / m ² or less. Acrylic resin-based inks are acrylic resins mixed with colorants such as pigments and dyes, extender pigments, solvents, stabilizers, plasticizers, catalysts, and curing agents.
The pattern printing layer 5 can be formed by a well-known printing method such as gravure printing, flexo printing, offset printing, silk screen printing, and transfer printing from a transfer sheet. Examples of the pattern of the pattern printing layer 5 include a wood grain pattern, a stone grain pattern imitating the surface of rock such as marble, a cloth pattern imitating a cloth grain or a cloth-like pattern, a tiled pattern, and a brick pile pattern.

(Resin film layer)
The resin film layer 7 are, for example, ethylene - a layer comprising a vinyl alcohol copolymer, its basis weight is 13.4 g / ^{m 2} or more 18.0 g / ^{m 2} or less. The resin film layer 7 imparts flame retardancy to the wallpaper 10. Further, the surface of the resin film layer 7 is formed with irregularities having a step of 50 μm or more and 200 μm or less. Examples of the pattern (pattern) of the unevenness in a plan view include wood grain, conduit, grid, man line, hairline, sand, and cloth.
The L value of the resin film layer 7 is preferably 70 or less. Here, the L value is the brightness, and represents the whiteness of MgO as 100. The larger the L value, the brighter the image, and the smaller the L value, the darker the image. When the L value of the resin film layer is 70 or less, the air spill can be made inconspicuous.
In the present embodiment, the resin constituting the resin film layer 7 is not limited to the ethylene-vinyl alcohol copolymer. The resin film layer 7 may be a polymer of an ethylene-vinyl alcohol copolymer and another resin, or may be a mixed resin of an ethylene-vinyl alcohol copolymer and another resin.
The thickness of the resin film layer 7 is 10.0 μm or more and 14.0 μm or less.

<Manufacturing method>
Next, a method of manufacturing the wallpaper 10 shown in FIG. 1 will be described.
2 (a) to 2 (c) are cross-sectional views showing the manufacturing method of the wallpaper 10 according to the embodiment of the present invention in the order of steps. In FIG. 2A, first, a laminated sheet 10'in which the foamed resin layer 3, the pattern printing layer 5, and the resin film layer 7 are laminated in this order on the base paper layer 1 is produced.
For example, a T-die is used to extrude a foaming agent-containing resin layer to form a film. The foaming agent-containing resin layer contains vinyl chloride resin as a main component, and contains a foaming agent, an inorganic filler, and various other additives. Next, using a heat press machine, the formed foaming agent-containing resin layer is thermocompression-bonded onto one surface of the base paper layer 1. Then, the pattern printing layer 5 is gravure-printed on the foaming agent-containing resin layer using an acrylic resin-based ink. After forming the pattern printing layer 5, the foaming agent-containing resin layer is heated. As a result, the foaming agent-containing resin layer is foamed to form the foamed resin layer 3 on the base paper layer 1.
After that, the resin film layer 7 is laminated on the pattern printing layer 5. As described above, the resin constituting the resin film layer 7 contains an ethylene-vinyl alcohol copolymer. The basis weight of the resin film layer 7 is 13.4 g / ^{m 2} or more 18.0 g / ^{m 2} or less. Further, the L value of the resin film layer 7 is 70 or less. Through the above steps, the laminated sheet 10'in which the foamed resin layer 3, the pattern printing layer 5, and the resin film layer 7 are laminated in this order on the base paper layer 1 is completed.

Next, as shown in FIG. 2A, the laminated sheet 10'is arranged in the embossing machine, and the uneven surface 21 of the embossing plate 20 is directed to the surface 7a of the resin film layer 7. The depth (that is, plate depth) d of the uneven surface 21 is 50 μm or more and 200 μm or less. Then, as shown in FIG. 2B, the uneven surface of the embossed plate 20 is pressed against the surface 7a of the resin film layer 7. After that, as shown in FIG. 2C, the embossed plate 20 is separated from the surface of the resin film layer 7. As a result, unevenness with a step of 50 μm or more and 200 μm or less is formed on the surface of the resin film layer 7.
Through the above steps, the wallpaper 10 shown in FIG. 1 is completed.

<Effect of embodiment>
According to the embodiment of the present invention, when embossing the surface of the wallpaper, it is possible to prevent the generation of air shavings between the uneven surface 21 of the embossing plate 20 and the surface 7a of the resin film layer 7, and embossing. The entire uneven surface 21 of the plate 20 can be pressed against the surface 7a of the resin film layer 7. This makes it possible to prevent a difference in gloss from occurring on the surface 7a of the resin film layer 7. Therefore, it is possible to provide a method for manufacturing a wallpaper having non-combustible performance and having an excellent design feeling due to unevenness, and a wallpaper having non-combustible performance.

<Example>
A laminated sheet was prepared in which a foamed resin layer, a pattern printing layer, and a resin film layer were laminated in this order on a base paper layer. The types (material, product name), basis weight, etc. of the base paper layer, foamed resin layer, pattern printing layer, and resin film layer are as follows.
-Base paper layer: plain paper, Nippon Paper Industries "NI65AT", basis weight 65 g / m ² , thickness 110 μm
-Foam resin layer: Vinyl chloride resin, Kaneka "PSL-275", basis weight 195 g / m ²
-Pattern printing layer: Acrylic resin ink, Dainichiseika "Hydric", basis weight 0 to 10 g / m ²
-Resin film layer: "Eval" made by Kuraray, basis weight 15 g / m ²
An embossed plate was pressed against the surface of the resin film layer of the above-mentioned laminated sheet to form irregularities. The plate depth of the embossed plate was 50 μm or more and 200 μm or less. The plate depth of the embossed plate was measured using the following device.
・ Tokyo Seimitsu "Surfcom 120A"
Through the above steps, the wallpaper was obtained.

<Evaluation of nonflammability>
The nonflammability of the wallpaper obtained in the examples was evaluated. The evaluation method is as follows.
In accordance with ISO5660-1, a heat generation test was conducted using a cone calorimeter tester in accordance with the fireproof test method and performance evaluation standard based on Article 2-9 of the Building Standards Act and Article 108-2 of the Construction Standards Act Construction Ordinance. .. The gross calorific value of the heating starting after 20 min (MJ / ^{m 2)} is at 8 MJ / ^{m 2} or less, the maximum heat release rate of the start of heating after 20 minutes, not exceed 200 kW / ^{m 2} to continue for 10 seconds or more Was passed. However, cracks in the base material were also evaluated, and the condition was that there were no cracks or holes in the base material.
It was confirmed that the wallpaper obtained in the examples passed the evaluation result of nonflammability and had sufficiently satisfactory nonflammability.

1 Base paper layer 3 Foamed resin layer 4 Void part 5 Pattern printing layer 7 Resin film layer 10 Wallpaper 10'Laminated sheet 20 Embossed plate 21 Concavo-convex surface

Claims (5)

A step of pressing an embossed plate against the surface of the resin film layer of a laminated sheet in which a foamed resin layer, a pattern printing layer, and a resin film layer are laminated in this order on a base paper layer is provided.
The foamed resin layer is made of vinyl chloride resin.
The resin constituting the resin film layer contains an ethylene-vinyl alcohol copolymer and contains
Ri plate depth is Der least 200μm below 50μm of the embossing plate,
The basis weight of the resin film layer is characterized in der Rukoto 13.4 g / ^{m 2} or more 18.0 g / ^{m 2} or less, the production method of wallpaper having non-combustibility. A step of pressing an embossed plate against the surface of the resin film layer of a laminated sheet in which a foamed resin layer, a pattern printing layer, and a resin film layer are laminated in this order on a base paper layer is provided.
The foamed resin layer is made of vinyl chloride resin.
The resin constituting the resin film layer contains an ethylene-vinyl alcohol copolymer and contains
Ri plate depth is Der least 200μm below 50μm of the embossing plate,
The foamed resin layer forms a foaming agent-containing resin layer which is a resin layer containing a foaming agent on the base paper layer, forms the pattern printing layer on the foaming agent-containing resin layer, and then foams the foaming agent. Formed by letting
The resin film layer, the foaming agent is foamed, characterized in Rukoto formed on the foamed resin layer formed by method of wallpaper having non-combustibility. The method for producing wallpaper having non-combustible performance according to claim 1 or 2, wherein the L value of the resin film layer is 70 or less. The base paper layer is a flame-retardant paper impregnated with guanidine sulfamate or guanidine phosphate, or an inorganic paper mixed with magnesium carbonate or magnesium hydroxide, according to claims 1 to 3. The method for producing a wallpaper having non-combustible performance according to any one item. The first aspect of the present invention is characterized in that a step of providing an adhesion treatment layer formed by applying a polyurethane composed of an acrylic-butyl copolymer or an isocyanate and a polyol is provided between the base paper layer and the foamed resin layer. The method for producing a wallpaper having non-combustible performance according to any one of claims 4.

Images