JPH04222300A - Wall-surface cladding material with embossed pattern and its manufacture - Google Patents

Abstract

PURPOSE: To provide a method for inexpensively producing a wall covering material bearing a surface fiber layer printable with any embossed pattern (without limitations involving yarn direction and/or thickness) while retaining its aesthetic appearance so as to be easily applicable onto wall. CONSTITUTION: This method for producing a wall covering material comprises the following procedure: first, one laminate (made by bonding a fiber layer to a basal paper layer) is subjected to various treatments for quality improvement; secondly, an aqueous adhesive layer is applied onto the resulting paper layer; thirdly, a cellulose-based 2nd paper layer is pressed against the adhesive layer; fourthly, the 2nd paper layer is printed with an embossed pattern so as to reach the surface; fifthly, the reverse face thereof is coated so as to afford smoothness followed by drying; finally, the resulting laminate is pressed again to obtain the aimed product.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wall covering material having an embossed pattern on the surface layer of fibers and a method for manufacturing the same.

0002

BACKGROUND OF THE INVENTION Walls are generally covered with wall coverings, so-called wallpapers, which are made entirely of paper, have patterns and/or figures, preferably embossed, on their surface and are rolled up. sold in the form of This is fixed to the wall with glue. Although this type of wallpaper and its application methods have a number of advantages (cost, simplicity of process), textile wall coverings may be preferred. This is because textiles are several orders of magnitude better than printed paper layers in terms of aesthetic qualities (warmth, attractive feel and durability).

0003

One known method of applying fiber coverings to walls is to hook or nail the fabric onto wooden slates that are fixed to the wall. If desired, various shapes, patterns, and embossing can be added to the fabric during manufacture. The disadvantage of this covering and of covering walls with it is that it is an expensive solution, it is far from simple and the advantages of traditional wallpaper cannot be found in it. be.

Another known method of applying fibrous coverings to walls often involves coverings with a layer of fabric glued to an underlying paper layer. The product is sold as a roll and is secured to the wall with this base paper layer. This allows it to retain some of the advantages of traditional wallpaper (easy handling and relatively inexpensive covering material itself);
It is now possible to apply fabric coverings to walls.

[0005] In one case, the fibrous layer of this wall covering material comprises:
It has fiber threads (natural or synthetic) glued parallel to each other on the paper. When applying a predetermined pattern, figure, or embossed pattern to this covering material, it is limited to geometric figures and/or embossed patterns drawn parallel to a specific direction, and the color and thickness of the threads must be selected in advance. must be kept.

Separately, when a fabric layer is used as a wall covering material, the thickness and color of the fiber threads used are selected and the desired pattern, figure and/or embossed pattern is applied to the fabric when it is woven. However, the finished covering material is still expensive.

The object of the present invention is to retain, on the one hand, the advantages of traditional wallpapers (sold in rolls, glueable, inexpensive) and, on the other hand, to combine the advantages of textile coverings (warmth, texture, durability). On the other hand, in order to create an embossed pattern, there is no need to select the thread thickness and color in advance as described above, and in the case of a fiber layer in which fiber threads are aligned and glued in the same direction, adjacent There are no restrictions on the direction in which the threads can be lined up. Among these examples, the example using adjacent adhesive threads is the most suitable for taking advantage of the advantages of the present invention, and is not only inexpensive, but also allows various embossed patterns to be applied, and by using the method of the present invention, it is possible to make various embossed patterns. It also has the potential to simplify configuration.

[0008]

SUMMARY OF THE INVENTION One of the subjects of the present invention relates to a manufacturing method, in which, in a first step of the procedure,
Wall coverings (laminates) with a fibrous surface made by gluing a fibrous surface layer onto a base layer made of paper (e.g. crepe paper) or other materials (e.g. non-woven materials) are available in various types. (treatment for fire resistance, water repellency, dust resistance, wash resistance, treatment for fire resistance, Scotchgard treatment, and treatment for imparting special surface effects), followed by a second stage Then, adhesive is applied to the back side of the laminate, and in the next step, another second sheet of paper is pressed on top of this, and then this, still wet, is transported to the next device. In this device, specific locations of the laminate are compressed and indented according to the desired embossing pattern. This can be seen as a raised pattern from the surface of the fiber layer. These recesses are characterized by the fact that they are permanently deformed when the paper is compressed in a wet state, so that they remain in that shape even after the pressure is removed.

In the next step of the method of the invention, the embossed and still wet wall covering is transferred to the next device, a coating is applied to its back side and the recesses on that side are filled; It is characterized in that a flat back side is created and in the next step this wall covering is dried and the embossed pattern described above is fixed.

The method according to the invention is further characterized in that, in a final step, the wall covering produced in this way is compressed again in the dry state to produce a flat final product.

Another subject of the invention relates to a wall covering, which covering comprises a surface fiber layer glued onto a base layer made of paper or a similar material, and on the back side of this layer. One paper layer is glued and this side is provided with depressions that can be seen as protrusions from the front side, and a coating is applied on the paper layer on the back side of these composites to form the above-mentioned depressions. is filled in.

Further features of the method for manufacturing a wall covering material and the product of the present invention will be explained in the following examples with reference to the drawings. However, the present invention is not limited to these Examples.

[0013]

EXAMPLE In the method of manufacturing a wall covering material having an embossed pattern on the surface fiber layer according to the present invention, a known laminate (FIG. 1a) prepared in advance by a known method is used. This laminate has a weight of, for example, 100 to 130 g/m2.
, preferably 120 g/m2, a base layer 1 made of paper such as crepe paper or an equivalent material, a layer 2 of adhesive applied over the entire surface of this base layer 1, and this adhesive. a surface fiber layer 3 adhered to the base layer by a layer of
This fibrous layer is made up of a large number of fibrous threads that are in contact with each other on their sides and are lined up in a certain direction and extend over the entire surface of the laminate. Other materials that can be used as the base layer 1 are non-woven materials, which in addition to cellulose are polyester, nylon or other plastic materials, which differ from paper in their strength.

FIG. 1a is a cross-sectional view of this laminate taken at right angles to the direction in which the fiber threads 4 extend.

According to the method of the present invention, this laminate is subjected to a series of treatments along its fiber surface using known methods and known devices. This is a treatment that imparts fire resistance, water repellency, dust resistance (through the Scotchgard process), water washability, and the well-known surface effects that impart these properties to wall coverings. It will be done. In this case, the method of the invention is characterized in that these treatments are applied to the laminate as the very first step 8 of the entire treatment sequence (FIG. 2).

In the next second step 9, the method according to the invention comprises applying an adhesive 5 to the back side of the laminate (on top of the crepe paper layer) over its entire surface, and applying the adhesive to the aqueous base. adhesive, preferably ethylene vinyl acetate.

In the method for producing a wall covering material having an embossed pattern on the surface fiber layer according to the present invention, in the next third step 10, the paper layer 6 is pressed (laminated) on the adhesive layer, It is characterized in that the paper layer is made on the basis of cellulose and has a unit weight of 70 to 100 g/m2, preferably 90 g/m2.

Another feature of the method of the invention is that the aqueous adhesive 5, the two paper layers 1, 6 and the fiber layer 3 are wet.

The method according to the invention further comprises, in a fourth step 11, in which the laminate, in which the paper layer 6 is glued by the adhesive layer 5, is wetted with two cylindrical rollers 15.
, 16.

In this case, one of the rollers 15 is made of hardened metal, and a bulge is provided on its surface according to the desired embossed pattern to be applied to the wall covering material, so that the wall covering material is forced to is passed between these two rollers 15 and 16. On the other hand, the other roller 16 arranged to cooperate with the roller 15 rotates in the opposite direction to the roller 15 and comes into contact with it. This roller 16 is made of hardened paper and has a cavity that corresponds in shape to the bulge of the roller 15, into which the bulge fits as the two rollers rotate.

The assembly of the fully wet laminate and the paper layer 6 adhered thereto is then passed through the two rollers 15,
It is pressed between the rollers 16 and moves along the contact surface of the two rotating cylindrical rollers 15 and 16.

[0022] As a result, these laminates and the paper layer 6 bonded thereto are bonded to the hardened metal roller 1.
It is pushed through the bulge 5 into the recess of the hardened paper roller 16. Since all parts of the laminate and the paper layer 6 glued thereto are in a wet state, the two paper layers 1, 6, the fiber layer 3, and the adhesive layer 2 sandwiched between them. , 5 are permanently deformed (stretched).

More specifically, permanently deformed recesses with the desired embossed pattern are created locally by the rollers 15, 16, ie the bulge of the roller 15 presses against a specific part of the back paper layer 6 and this pressing down all partially overlapping layers 1, 2, 5, 6 into correspondingly complementary recesses of the roller 16;
When viewed from the surface, it creates localized bulges or bulges in the fiber layer 3. These bulges are created by stretching the fiber threads 4 by pressing these parts from the back side, the degree of this stretching determines the height of the individual bulges, and the width of the bulges is larger than that of the stretched adjacent ones. It depends on the number of threads and the length of the bulge depends on the length of said adjacent threads given the same draw. By creating bulges of different heights and/or widths and/or lengths adjacent to each other, all kinds of embossed patterns can be created in the wall covering.

[0024] This embossed pattern can be distinguished from the embossed part without compressing a particular part, if necessary.

According to the present invention, the method for producing a wall covering material having an embossed pattern on the surface fiber layer further includes a fifth step 12.
A coating 7, preferably of latex, is applied to the back side (second paper layer 6 on the back side), flattening this back side with recesses made by pressing embossing into said back side and applying the wall covering. The feature is that it can be easily pasted onto the wall.

[0026] This latex coating should not be too hard so that it does not crack when the wall covering is rolled up, and it should not cause problems when the covering is removed from the wall, as with conventional wallpaper. No.

The method according to the invention also includes the following sixth step 1
3, the layers stacked on top of each other are dried (fixed) with a layer of adhesive.

In a final step 14, which characterizes the method of the invention, the dry wall covering is pressed again in order to obtain a flat finished surface.

The method according to the invention also provides that all the above-mentioned stages (first to sixth and last stage) are carried out immediately after the previous stage, and that the wall covering is continuously passed through the machine. The laminate is mounted on one roller, from which it is flowed horizontally into the machine, where each step, treatment,
It is characterized in that the various layers are laid one after the other in succession, terminating in rollers at the opposite end of the machine, where the finished coating is continuously wound up.

The paper 6 which is superimposed on the back side of the stack is attached to another roller which continuously feeds the paper at the flowing height of the stack.

The method according to the invention can also process wide objects up to 170 cm, with a preferred width of 140 cm.
It is m.

The wall covering material according to the present invention produced using the method of the present invention consists of layers laminated to each other over the entire surface, and is constructed as follows (Fig. 1b).
First, the laminate consists of a surface fiber layer 3, a base layer 1, and an adhesive layer 2 for bonding these to each other.
and wherein the fibrous layer is made of fiber yarns 4 arranged closely to each other in a particular direction, the yarns 4 being fixed to the base layer 1 by the layer of adhesive 2 underneath, the base layer is, for example, a non-woven material or a unit weight of 100 to 130 g/
m2 (preferably 120 g/m2) of crepe paper, while layer 1 of said paper has a layer of adhesive (preferably ethylene vinyl acetate) on its back side, thereby providing a unit weight of 70 to 100 g/m2 ( Another paper layer 6 glued underneath, preferably 90 g/m2)
while each of the above layers 1, 2, 3, 5, 6 has at least one permanent recess made from its back side, which recess connects the fiber layer 3 through all these layers. These depressions are formed by permanent deformation (stretching) of all layers, this deformation is created in the fiber layer 3 by local stretching of a large number of adjacent threads 4, and this deformation is caused by pushing from the back side. It is made.

Furthermore, the wall covering according to the invention preferably has a coating 7 of latex applied to the side of the above-mentioned back paper layer 6, which coating fills the recesses of the above-mentioned paper layer and The wall covering material is characterized in that the entire back surface is smooth.

Furthermore, the wall covering according to the invention is characterized in its preferred embodiment in that it is made wide, up to a width of 170 cm, preferably 140 cm, and is wound into a roll.

The method for manufacturing a wall covering material according to the present invention having an embossed pattern on the surface fiber layer 3 is further provided by bonding a woven fabric to the base layer 1 instead of the parallel fiber threads 4 as the surface fiber layer. This method can also be applied to a laminate made of cloth, and a pattern or figure can be drawn on the cloth in advance, and the rest can be processed in the same manner as the method described above.

[0036] Therefore, in another embodiment of the invention:
The wall covering material has the following characteristics: the surface fiber layer 3 is a woven fabric (with or without a pattern or figure drawn on it), and an embossed pattern is applied to it in the same manner as described above. It is possible to draw an embossed pattern by attaching a bulge and changing the dimensions (length, width, height) of this large number of adjacent bulges, for example by adding heights to the heights of the bulges.

The wall covering material according to the present invention can be applied to a wall in the same manner as ordinary wallpaper.

The advantage of the method of the present invention is that there is no limit to the number of embossed patterns for wall covering materials having a surface fiber layer, and the thickness can be selected by changing the threads constituting the fiber layer. Due to the difference in thickness, there is no need to perform embossing in advance. That is, the embossed pattern applied to a wall covering having a fibrous layer made of threads arranged next to each other in one direction is not limited by the direction in which these threads extend.

One of the advantages of the wall covering material of the present invention is that
It is possible to provide at a low cost a wall covering material with a surface fiber layer that can be applied with any embossed pattern (without restrictions due to the direction of the threads and/or its thickness), and also, The covering material can be easily applied to the wall (by gluing) in the same way as conventional wallpaper, and the invention therefore combines this economy and ease of handling with its aesthetic appearance. Wall coverings can be provided.

[Brief explanation of the drawing]

[Fig. 1] Fig. 1 consists of Fig. 1a and Fig. 1b.
Figure 1b is a sectional view of a laminate serving as a raw material for making a wall covering according to the invention by the method according to the invention; Figure 1b shows wall coverings according to an embodiment of the invention glued adjacent to each other; FIG. 3 is a cross-sectional view showing the fiber layer cut at right angles to the longitudinal direction of the yarn.

FIG. 2 is a schematic diagram of the manufacturing process of a wall covering material according to one embodiment of the present invention.

[Explanation of symbols]

Claims (15)

[Claims] Claim 1. A method for producing a wall covering material having an embossed pattern on the surface fiber layer, in which the fiber layer (3) is adhered onto the base paper layer (1), and the base paper layer (1) is bonded to the base paper layer (1). Layer (1)
In a method of manufacturing a product in which permanent deformation is carried out together or separately, and the recess formed on the back surface is filled and/or covered with flat paper or similar material, the first step of the step is
In step (8), in order to impart better properties to the single laminate consisting of the base layer and the fiber layer, i.e. fire resistance,
This is treated in order to provide water repellency, dust resistance, wash resistance and surface effects, and in a second step (9)
An adhesive (5) is applied to the base paper layer (1) and a third
In step (10), another second paper layer (6) is pressed onto said underlying paper layer (1), followed by a subsequent fourth step (11) in which the thus obtained While the entire composite is still wet, recesses are imparted to the composite by embossing the pattern, and in a subsequent fifth step (12) this embossed and still wet wall covering is recessed. A coating is applied on top of said second paper layer (6) and in a next sixth step (13) this wall covering is fixed by drying and in a final step (14) a flat finished surface is applied. 1. A method for producing a wall covering material with an embossed pattern, characterized in that the wall covering material is compressed to obtain an embossed pattern. Claim 2: The laminate has a unit weight of 100 g/m
2 to 130g/m2, preferably 120g/m2
, a base layer of crepe paper on which a fibrous layer (3) is glued;
A large number of fiber threads closely aligned in parallel in one specific direction (4)
2. A method according to claim 1, characterized in that the laminate is made of a material that covers the entire surface of the laminate or is made of a woven fabric. Claim 3: In the second step (9) of the above procedure,
a layer (5) of adhesive is provided over the entire back side of the laminate;
3. Method according to claim 1, characterized in that the adhesive layer is made of a water-based adhesive. [Claim 4] Ethylene vinyl acetate is
In the second step (9) of the above procedure, the layer of adhesive (5
) on the back side of the laminate. Claim 5: In the third step (10), the second
A paper layer (6) is pressed onto the adhesive layer (5), the paper layer being made from a cellulose base and having a unit weight of 70 g/m2 to 100 g/m2.
5. A method according to any one of claims 1 to 4, characterized in that the method is in the range of . 6. In the third step (10), the second paper layer (6) is pressed onto the adhesive layer (5), and the unit weight of the paper layer is 90 g/m2. 6. A method according to any one of claims 1 to 5, characterized in that: . 7. Any one of claims 1 to 6, characterized in that said adhesive (5) wets said two paper layers (1, 6) and said fibrous layer (3). The method described in. Claim 8: In the fourth step (11), the second
The laminate, in which the paper layer (6) is glued by the adhesive layer (5), is passed in a wet state between two cylindrical rotating rollers (15, 16), the first of which roller (15) is made of hardened metal and has a bulge in its wall;
6) is provided parallel to the roller (15), facing it, rotating in the opposite direction, and having a cavity made of hardened paper and having a shape complementary to the bulge of the first roller (15) on its wall surface. With a tee, when the two rollers rotate, the bulge fits into the cavity, and the bulge is designed according to the embossed pattern to be applied to the wall covering. 8. A method according to any one of claims 1 to 7, characterized in that: 9. In said fifth step (12), a coating (7) is applied to said second paper layer (6) on the back side, filling the recesses made on said back side according to said embossing, 9. A method according to any one of claims 1 to 8, characterized in that the back side of the wall covering is flattened. 10. The coating (7) applied to the back side of the wall covering material in the fifth step (12) is a latex coating that is not very hard, and when the wall covering material is rolled up, there are no cracks in it. 10. The method according to claim 1, wherein the wall covering material is easily removed from the wall. Claim 11: All the above steps (9, 10
, 11, 12, 13, 14) are carried out immediately one after the other while the wall covering is continuously progressing through the machine, the laminate being loaded onto one roll, from which it is unrolled, and the laminate being unrolled from the machine. It runs horizontally through the rollers, where various treatments are carried out, and ends with a roller at the other end of the machine, which continuously winds up the finished wall covering, while the laminate is The above-mentioned second paper (6), which is pressed against the back side of the 11. A method according to any one of claims 1 to 10, characterized in that the paper layer is pressed onto the laminate. 12. Any one of claims 1 to 11, characterized in that wide wall coverings can be made with a width of up to 170 cm, preferably this width is 140 cm.
The method described in. 13. A wall covering material having a fiber layer embossed on the surface, which, from the surface to the back, comprises:
a base layer (1) made of paper such as crepe paper or the like having a unit weight of 100 g/m2 to 130 g/m2, preferably 120 g/m2;
a layer (5) of a water-based adhesive, preferably such as ethylene vinyl acetate, adhering the second paper layer (6), said second paper layer having a unit weight between 70 g/m2 and 100 g/m2;
/m2, preferably 90 g/m2, of a cellulose base, and finally a coating (7), preferably a latex coating, which smoothes the back side of the wall covering. Material. 14. All of the above layers except the coating (7) are extruded through all the layers into the fibrous layer (3) and are positionally dispersed, which is sustained by permanent deformation or bulging of all the layers. On the other hand, the coating (7
) flatten these recesses on the back side of the wall cladding,
14. The wall covering material according to claim 13, wherein these recesses form irregularities that create a desired embossed pattern on the surface of the wall covering material. 15. Width up to 170 cm, preferably 1
Wall covering material according to claim 12 or 13, characterized in that it has a width of 40 cm.