JPH11335958A - Production of wallpaper - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a mounting material which is a wallpaper or other mounting materials suitable as interior trims of buildings or vehicles and surface decorations, or the like, of pieces of furniture and readily removing sticking foulings and having a sharp uneven pattern without causing fuzzing or pilling on the surface while using a nonwoven fabric containing constituent fibers of staples. SOLUTION: A web for a surface layer containing thermally fusible fiber staples comprising a low-melting component and a high-melting component arranged in the direction parallel to the fiber axis as a principal component and having <=20 wt.% content of usual fiber staples for knitting and weaving other than the principal component is superimposed on a web for the back layer containing the usual fibers for knitting and weaving as a principal component and having <=20 wt.% content of the thermally fusible fiber staples other than the principal component and bonded by punching to provide a nonwoven fabric of a two-layer structure. The web for the surface layer of the resultant nonwoven fabric is then subjected to embossing processing.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing wallpaper and other decorative materials suitable for interior decoration of buildings and vehicles and for surface decoration of furniture and the like.

[0002]

2. Description of the Related Art As a method for producing wallpaper, two kinds of card webs, which are made of a mixture of polyester fiber staples and heat fusible fiber staples and have different amounts of heat fusible fiber staples, are stacked and punched. Combine 2
Manufacture a non-woven fabric with a layer structure, make the side with a large amount of heat-fusible fiber staples the front, glue the base paper for wallpaper with glue on the back, dry, apply the desired printing and flame retardant treatment on the front side, Then, a method is known in which a heating cylinder is brought into contact with the front side to preheat, or a high-temperature embossing roller is immediately pressed and pressed without preheating to form an uneven pattern.

[0003] The wallpaper produced by this method has a softer and warmer texture than the so-called PVC wallpaper obtained by printing and embossing the surface of a vinyl chloride resin obtained by coating a base paper, and has a heat resistant property. It has the advantage that it does not generate chlorine gas during incineration. On the other hand, it uses staples and the amount of heat fusible fibers used in the surface card web is 20 to 60%. However, there is a problem that pilling is liable to occur, it is difficult to remove the glue adhering at the time of construction, the edge of the obtained concavo-convex pattern is easily rounded, and it is difficult to obtain a sharp pattern.

[0004]

SUMMARY OF THE INVENTION The present invention relates to a method for producing a wallpaper or other decorative material suitable for interiors of buildings and vehicles and for surface decoration of furniture using a punched nonwoven fabric made of staples. No fluffing, no pilling, easy removal of dirt such as glue during construction, and a sharp uneven pattern can be obtained.

[0005]

According to a first aspect of the present invention, there is provided a method for manufacturing a facing material, comprising a heat-fusible fiber comprising a low melting point component and a high melting point component arranged in parallel with a fiber axis direction. A surface web containing staples as a main component and having a content of ordinary fiber staples for textiles other than the main component of 20% by weight or less; The content of adhesive fiber staple is 2
A nonwoven fabric having a two-layer structure is formed by superimposing a backing web of 0% by weight or less and joining by punching to form a two-layered nonwoven fabric. Then, while the nonwoven fabric is running, a heated embossing roll is pressed against the surface web to form an uneven pattern. Is formed.

The heat-fusible fiber used in the present invention comprises a low-melting component and a high-melting component arranged in parallel with the fiber axis direction, and comprises a low-melting thermoplastic synthetic fiber and a high-melting thermoplastic synthetic fiber. And a core-sheath structure having a high-melting thermoplastic synthetic fiber as a core and a low-melting thermoplastic synthetic resin as a sheath. The low-melting point component and the high-melting point component can be arbitrarily selected as long as they are other than polyvinyl chloride and polyvinylidene chloride. Examples thereof include polyester-based composite fibers having a bimetal structure and a core-sheath structure in which polyester has a low melting point component. The melting point of the low melting point component is 6
0 to 160 ° C, particularly preferably 80 to 130 ° C, and 60 ° C
If it is less than 1, the heat resistance as a surface material is reduced, and if it exceeds 160 ° C., fusion using a low melting point component becomes difficult.

[0007] On the other hand, ordinary textile fibers other than polyvinyl chloride and polyvinylidene chloride include cellulosic fibers (eg, cotton, pulp, rayon, polynosic), wool, semi-synthetic fibers, and synthetic fibers (eg, Polyester, polypropylene, acrylic, nylon) non-crimped fiber, crimped fiber, hollow fiber, etc. can be arbitrarily selected, but rayon is inexpensive, rich in hygroscopicity, good in dyeability, and suitable for use as wallpaper. This is preferable in that cutting for pattern matching is easy. In addition, acrylic fiber has good dyeing properties, low specific gravity, large bulkiness when the basis weight is equalized, increases volume feeling, and has thermoplasticity. This is preferable in that it can be further enlarged and the cutting for pattern matching is easy. Polyester fibers are preferred because they have high productivity, are inexpensive, are stiff, have a large volume, and are easily available. However, the polyester fiber is excellent in strength and strong, but it is difficult to cut the knife at the time of pattern matching. Therefore, it is preferable that the polyester fiber is mixed with rayon or acrylic fiber to suppress the use amount to 50% or less.

As the above-mentioned knitting fiber, a functional fiber having at least one of functions such as hygroscopicity, antibacterial property, deodorant property and flame retardancy can be used. An example of the hygroscopic fiber is an acrylate fiber ("EX" manufactured by Toyobo Co., Ltd.). By using such a hygroscopic fiber, the humidity of the indoor air can be controlled by the surface covering material. Examples of the antibacterial fiber include an antibacterial acrylic fiber ("Feel Fresh" manufactured by Toyobo Co., Ltd.), which is used as a weaving fiber to form a web for a back layer, which is further processed into a facing material. By doing
Bacteria and molds can be prevented from being generated on the surface material.

Further, examples of the deodorant fiber include a deodorant acrylate fiber ("Dismel" manufactured by Toyobo Co., Ltd.), and a web for a back layer is formed by using this fiber as a fiber for weaving and further processed. By using the surface material, the formalin odor emitted from the base material on which the surface material is applied and the ammonia odor contained in the room air can be eliminated by the surface material. Examples of the flame-retardant fibers include meta-aramid fibers ("Nomex" manufactured by DuPont) and para-aramid fibers ("Kevlar 29" manufactured by DuPont). These fibers are used to form a backing web. By processing the surface material, the flame retardancy of the surface material can be improved.

According to the present invention, a needle punch or a water punch is formed by vertically stacking the surface web mainly composed of the heat-fusible fiber staple and the back layer web mainly composed of the fiber staple for weaving. The fiber staples constituting the surface layer web and the fiber staples constituting the back layer web are entangled with each other to integrate the surface layer web and the back layer web. The above-mentioned needle punch and water punch can be properly used depending on the total basis weight and the purpose of the surface layer web and the back layer web. If the basis weight is about 100 to 130 g / m ² , either the needle punch or the water punch may be used. A needle punch is preferred for a higher basis weight, and a water punch is preferred for a lower basis weight. In addition, the surface layer web and the back layer web are
The card web may be used, or the staple may be entangled in advance by applying the above punching to the card web, but the former can shorten the process when the basis weight is small, and the latter can also be used when the basis weight is large. Is easy.

The two-layered nonwoven fabric is embossed. The embossing is performed by placing the nonwoven fabric between a heated embossing roller and a back roll such as a rubber roll, a cotton roll, or a paper roll. The surface layer web is introduced so as to be in contact with the embossing roll, and then cooled. The surface temperature of the embossing roller is usually set to be higher than the melting point of the low melting point component constituting the heat-fusible fiber and lower than the softening point of the high melting point component. In this case, the temperature may be higher than the softening point of the high melting point component. Then, in the case of high-speed processing, it is preferable to preheat the nonwoven fabric with a heating cylinder, an infrared heater, or the like. The pressure is 50 to 300.
It is preferably set in the range of kgf / cm, particularly 50 to 200 kgf / cm, and is set appropriately according to the fiber used.

By the above-mentioned embossing, an uneven pattern is formed on the nonwoven fabric, and at the same time, the low melting point component of the heat-fusible fiber is once melted and then cooled and solidified.
Since the high melting point component and the fiber staple for knitting and weaving in the heat fusible fiber staple are fused with the above low melting point component, the irregularity pattern has good shape retention and does not lose its shape. And since the surface web is mainly composed of the heat-fusible fibers, the edges of the uneven pattern are sharply formed, the shape retention is particularly good, and the film is formed during embossing, and the surface of the nonwoven fabric is formed. No fluff and no pilling
Glue and other stains adhered during construction can be easily removed. In addition, since the high melting point component in the heat-fusible fiber remains on the surface of the nonwoven fabric while maintaining the fiber form, the warm texture of the nonwoven fabric is maintained.

[0013] However, if the content of ordinary fiber staples for weaving in the surface layer web exceeds 20% by weight, the sharpness of the uneven pattern becomes insufficient, fuzzing and pilling are liable to occur, and removal of adhered dirt is difficult. It becomes difficult. On the other hand, when the content of the heat-fusible fiber staples in the web for the back layer exceeds 20% by weight, the texture as the surface covering material becomes hard, and the bulkiness and voluminous feel become insufficient.

The preferred fineness of the heat-fusible fiber is 1
If it is less than 1 denier, it will be easy to cut during processing and it will be difficult to process it. Conversely, if it exceeds 10 denier, the surface of the nonwoven fabric will be rough and the sharpness of the uneven pattern will be insufficient. Further, the preferred basis weight of the surface layer web is 20 to 150 g / m ² , and if it is less than 20 g / m ^2, it is difficult to obtain a sharp uneven pattern, fuzzing, pilling and dirt increase, and conversely 150 g / m 2 ^If it exceeds ² ,
Unnecessarily bulky and uneconomical. The preferred basis weight of the back layer web is 20 to 200 g / m ² ,
If it is less than 0 g / m ² , the feeling of volume becomes insufficient, while if it exceeds 200 g / m ² , it is unnecessarily bulky and uneconomical.

The non-woven fabric having a two-layer structure obtained by the punching described above can have an increased strength and improved form stability by attaching an optional reinforcing material prior to embossing. As the reinforcing material, a reinforcing sheet having good form stability, for example, base paper or other paper for wallpaper, film,
Fabrics, spunbonded nonwoven fabrics and the like can be mentioned, and these are adhered to the back layer web with an adhesive. Further, a thermoplastic resin such as an acrylic resin or a rubber such as SBR may be used, and these may be applied to the back surface of the nonwoven fabric in the form of a solution or impregnated into the nonwoven fabric, and then dried and adhered to the nonwoven fabric. Selected. Then, by reinforcing the nonwoven fabric, the morphological stability of the nonwoven fabric is improved, and subsequent printing and embossing are facilitated. Therefore, it is particularly useful when the basis weight of the nonwoven fabric is small and the form stability is low. Further, when the adhesive is adhered to a wall or any other place with the adhesive, the adhesive can be prevented from floating.

[0016] The above non-woven fabric, with or without a reinforcing material,
Prior to embossing, the surface of the surface web may be printed with a single color or multicolor pattern using a dye or a pigment, and coated with a flame retardant or a water repellent. The flame retardant is preferably a phosphoric acid-based flame retardant, and the coating amount is preferably 20 to 40% of the weight of the nonwoven fabric.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiment 1 Polyethylene terephthalate is used as a core component and has a melting point of 60 to
Using a staple of a heat-fusible fiber having a modified polyester at 160 ° C. as a sheath component, a basis weight of 30 to 100 g /
to produce a card web m ^2, which is a surface layer web. On the other hand, a card web having a basis weight of 30 to 100 g / m ² is produced using a mixture of rayon staples and the above heat-fusible fiber staples (mixing ratio 9/1), and this is used as a back layer web.

The above-described surface layer web and back layer web are superimposed and water-punched. Alternatively, the above-described surface layer web and back layer web are individually water-punched and then superposed to form a water punch again. Or they are combined together. After performing desired printing on the surface layer web of the obtained nonwoven fabric, embossing is performed.
At the time of embossing, an uneven pattern is formed on the embossing roller to a depth of 0.2 to 0.8 mm, and the temperature of the embossing roller is set to 1
The pressure is set to 50 to 200 kgf / cm and the processing speed is set to 5 to 25 m / min.

The obtained covering material has both a beautiful printed pattern and a sharp uneven pattern, a soft texture, a warm feeling, and an excellent voluminous feel. It is suitable, and since the backing web is made of rayon, it has hygroscopicity and is easy to cut at the time of pattern matching.

Embodiment 2 In Embodiment 1, after a non-woven fabric having a two-layer structure composed of a surface layer web and a back layer web is produced by a water punch, a base paper for wallpaper is applied to the back layer web of the non-woven fabric with an adhesive. After bonding, a surface covering material (wallpaper) of the second embodiment is manufactured in the same manner as in the first embodiment. The obtained wallpaper has the same performance as that of the facing material of Embodiment 1, and the base paper for wallpaper is adhered to the back surface as a reinforcing sheet. Easy handling during embossing and construction.

Embodiment 3 A covering material (wallpaper) of Embodiment 3 is manufactured in the same manner as in Embodiment 2, except that the back layer web is made only of acrylic crimped fiber staples. Since the surface material uses acrylic fibers having a small specific gravity and a crimp, the bulkiness and the voluminous feel are further increased.

Embodiment 4 In Embodiment 2, except that the back layer web is made of a mixture of rayon staple and polyester hollow fiber staple (however, the amount of the polyester hollow fiber staple used in the back layer web is 50% or less). Manufactures the wallpaper of the fourth embodiment in the same manner as in the second embodiment. Since this wallpaper uses polyester hollow fiber,
The sense of volume increases. And the usage is 50%
Because of the following, cutting is easy and there is no problem in pattern matching.

Embodiment 5 Embodiment 4 is the same as Embodiment 3 except that the back layer web is made using only deodorized acrylic fibers instead of acrylic crimped fibers. To manufacture wallpaper. When this wallpaper is attached to a wall, the deodorant acrylic fiber eliminates the ammonia odor indoors and the formalin odor emitted from the foundation building material of the wall, thereby providing a refreshing living space.

[0024]

EXAMPLE 1 Polyester heat-fusible fiber of a composite form having polyethylene terephthalate as a core and a modified polyester having a melting point of 110 ° C. as a sheath component (total denier 2.4 denier, fiber length 5)
1 mm) to produce a card web having a basis weight of 40 g / m ² , which was used as a surface layer web. On the other hand, a card web having a basis weight of 40 g / m ² was produced using only rayon staples (1.5 denier fineness, fiber length 51 mm), and this was used as a back layer web. Webs were stacked and integrated with a water punch. However, the punching conditions were as follows: the water pressure of the three upper nozzles was 40 kgf / cm ² , 80 kgf / cm ² , and 80 kgf
/ Cm ² and all three lower nozzles are 80 kgf / cm ²
The speed was 9 m / min, and a nonwoven fabric having a thickness of 0.67 mm was obtained.

The web weight for the back layer of the obtained nonwoven fabric was 1
A 20 g / m ² base paper for wallpaper is bonded with a modified vinyl acetate copolymer-based adhesive (30 g / m ² ) and dried, and then a multicolor pattern is printed with a gravure printing machine. It was applied at a coverage of 20 g / m ² , and then embossed. The embossing is performed by using an embossing roller obtained by engraving a sparse cloth texture so that the maximum engraving depth is 0.6 mm.
The running speed was set to 10 m / min. The obtained wallpaper of Example 1 was a new wallpaper having a sharp appearance having a sparse cloth surface, a soft texture, a warm feeling, and an excellent volume feeling.

Example 2 In Example 1, a part (10%) of the rayon staple of the back layer web was replaced with the above heat-fusible fiber staple, and the basis weight of the surface layer web and the back layer web was changed. The wallpaper of Example 2 was produced in the same manner as in Example 1 except that the wallpaper was reduced to 30 g / m ² . This wallpaper, like the wallpaper of Example 1, had a sparse cloth appearance on the surface, had a soft texture, was warm, had a voluminous feel, and was easy to cut during pattern matching.

Example 3 The procedure of Example 1 was repeated, except that the back layer web was made of only acrylic crimped fibers (denier 1.5 denier, fiber length 38 mm) instead of rayon staples. The wallpaper of Example 3 was produced. The obtained wallpaper has a good dyeing property and has a sense of volume because the backing layer web is made of acrylic fiber having a low specific gravity and crimping, and the sack cloth is similar to the wallpaper of Example 1. It had a shape-like appearance, had a soft and warm texture, and was easy to cut during pattern matching.

Example 4 Example 1 was repeated except that a part (40%) of the rayon staple constituting the backing layer web was replaced with a hollow polyester fiber (denier: 2 denier, fiber length: 38 mm). Similarly, the wallpaper of Example 4 was produced. The obtained wallpaper had the appearance of a sparse cloth as in Example 1, had a soft texture, was warm, and had an increased volume.

[0029]

According to the present invention, a non-woven surface covering material using staples as a constituent fiber is suitable for interior decoration of buildings and vehicles, and for surface makeup of furniture, etc., and generates fluff and pilling on the surface. Is easy to remove attached dirt,
In addition, it is possible to efficiently manufacture a surface material having a sharp uneven pattern. In particular, according to the second aspect of the present invention, an easy-to-handle surface covering material having good shape stability is obtained. According to the third aspect of the present invention, a surface covering material having at least one of functions such as hygroscopicity, antibacterial property, deodorant property, and flame retardancy can be obtained. According to the fourth aspect of the present invention, it is possible to manufacture a surface covering material which has good dyeing properties, is rich in porosity, and can be easily cut with a knife when patterning is performed when the surface covering material is constructed.

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[Procedure amendment]

[Submission date] July 5, 1999

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Full text

[Correction method] Change

[Correction contents]

[Document Name] Statement

Patent application title: Method for producing wallpaper

[Claims]

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to a process for the preparation of suitable wall paper and <br/> the interior of the building.

[0002]

2. Description of the Related Art As a method for producing wallpaper, two kinds of card webs, which are made of a mixture of polyester fiber staples and heat fusible fiber staples and have different amounts of heat fusible fiber staples, are stacked and punched. Combine 2
Manufacture a non-woven fabric with a layer structure, make the side with a large amount of heat-fusible fiber staples the front, glue the base paper for wallpaper with glue on the back, dry, apply the desired printing and flame retardant treatment on the front side, Then, a method is known in which a heating cylinder is brought into contact with the front side to preheat, or a high-temperature embossing roller is immediately pressed and pressed without preheating to form an uneven pattern.

[0003] The wallpaper produced by this method has a softer and warmer texture than the so-called PVC wallpaper obtained by printing and embossing the surface of a vinyl chloride resin obtained by coating a base paper, and has a heat resistant property. It has the advantage that it does not generate chlorine gas during incineration. On the other hand, it uses staples and the amount of heat fusible fibers used in the surface card web is 20 to 60%. However, there is a problem that pilling is liable to occur, it is difficult to remove the glue adhering at the time of construction, the edge of the obtained concavo-convex pattern is easily rounded, and it is difficult to obtain a sharp pattern.

[0004]

BRIEF Problem to be Solved] The invention relates to a process for preparing a suitable wall paper Te and interior of buildings <br/> with punching nonwoven fabric made of staple, no fuzz surface, pilling This makes it easy to remove even if dirt such as glue adheres at the time of construction, and a sharp uneven pattern can be obtained.

[0005]

Means for Solving the Problems The method for manufacturing wallpaper according to the present invention, as described in claim 1, polyethyleneterephthalate
Low-melting modified polyester with phthalate as the high melting point component
The main component is a web for surface layer having a basis weight of 30 to 100 g / m ² consisting only of a heat- fusible fiber staple having a core-sheath structure having a low melting point component, and a fiber staple for knitting of rayon or polynosic . The content of the heat-fusible fiber staples other than the above is 20% by weight or less , and the basis weight is 30 to 1
A backing web of 00 g / m ² is overlapped and joined by punching to form a two-layer nonwoven fabric, and the backing web of this nonwoven fabric
Wallpaper base paper and glued to, for this wallpaper later scold
An embossing roll heated to a temperature of 180 to 220 ° C. is pressed against the surface web at a pressure of 50 to 200 kgf / cm while the nonwoven fabric to which the base paper is adhered is run to form an uneven pattern.

[0006] heat-fusible fibers used in this invention, the thermoplastic synthetic fiber having a high melting point as a core, a low-melting thermoplastic synthetic resin is of a core-sheath structure with sheath, high melting point Po triethylene terephthalate and component is a polyester conjugate fiber core-sheath structure you a low melting point modified polyester with a low melting point component. The melting point of the low melting point component is 60 to 160.
° C, particularly preferably 80 to 130 ° C, and below 60 ° C the wall
Heat resistance as paper decreases, and if it exceeds 160 ° C., it becomes difficult to perform fusion using a low melting point component.

On the other hand, as a conventional knitted woven fabric, Les chromatography yo <br/> down or polynosic are used. Particularly, rayon is preferable because it is inexpensive, rich in hygroscopicity, good in dyeability, and easily cut for pattern matching when applied as wallpaper.

[0008]

[0009]

According to the present invention, a needle punch or a water punch is formed by vertically stacking the surface web mainly composed of the heat-fusible fiber staple and the back layer web mainly composed of the fiber staple for weaving. The fiber staples constituting the surface layer web and the fiber staples constituting the back layer web are entangled with each other to integrate the surface layer web and the back layer web. The above-mentioned needle punch and water punch can be properly used depending on the total basis weight and the purpose of the surface layer web and the back layer web. If the basis weight is about 100 to 130 g / m ² , either the needle punch or the water punch may be used. A needle punch is preferred for a higher basis weight, and a water punch is preferred for a lower basis weight. In addition, the surface layer web and the back layer web are
The card web may be used, or the staple may be entangled in advance by applying the above punching to the card web, but the former can shorten the process when the basis weight is small, and the latter can also be used when the basis weight is large. Is easy.

The two-layered nonwoven fabric is embossed. The embossing is performed by placing the nonwoven fabric between a heated embossing roller and a back roll such as a rubber roll, a cotton roll, or a paper roll. The surface layer web is introduced so as to be in contact with the embossing roll, and then cooled. The surface temperature of the emboss roller is in the range of 180 to 220 ° C., and the pressure is 50 to 200 k.
in the range of gf / cm Ru is set, respectively.

By the above-mentioned embossing, an uneven pattern is formed on the nonwoven fabric, and at the same time, the low melting point component of the heat-fusible fiber is once melted and then cooled and solidified.
Since the high melting point component and the fiber staple for knitting and weaving in the heat fusible fiber staple are fused with the above low melting point component, the irregularity pattern has good shape retention and does not lose its shape. Since the surface layer web is formed only of the heat-fusible fibers , the edges of the uneven pattern are sharply formed, the shape retention is particularly good, and the film is formed during embossing. As a result, there is no fuzzing or pilling on the surface of the nonwoven fabric, and it is easy to remove glue and other stains adhered during construction. In addition, since the high melting point component in the heat-fusible fiber remains on the surface of the nonwoven fabric while maintaining the fiber form, the warm texture of the nonwoven fabric is maintained.

However , when the content of the heat-fusible fiber staples in the web for the back layer exceeds 20% by weight, the texture as the wallpaper becomes hard, and the bulkiness and volume feeling are insufficient. Become.

The preferred fineness of the heat-fusible fiber is 1
If it is less than 1 denier, it will be easy to cut during processing and it will be difficult to process it. Conversely, if it exceeds 10 denier, the surface of the nonwoven fabric will be rough and the sharpness of the uneven pattern will be insufficient. In addition, the eyes with the amount of the surface layer for the web 3 0
To 100 g / m ^2, the basis weight of the web for or backing layer 3 0
To 100 g / m ² Ru respectively set.

[0015] nonwoven having a two-layer structure obtained by the above punching, prior to embossing, the original paper for wall <br/> sheet is adhesively bonded to the web for the backing layer, non-woven fabric is reinforced
Therefore , the morphological stability of the nonwoven fabric is improved, and subsequent printing and embossing are facilitated. Therefore, it is particularly useful when the basis weight of the nonwoven fabric is small and the form stability is low. Further, when the adhesive is adhered to a wall or any other place with the adhesive, the adhesive can be prevented from floating.

The non-woven fabric, prior to d Nbosu processing, on the surface layer web surface, to print a color or multicolored pattern design with dye or pigment, and may be coated with fire retardant and water repellent. As the flame retardant, a phosphoric acid type is preferable, and the coating amount is 20 to 40% of the weight of the nonwoven fabric.
Is preferred.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiment 1 Polyethylene terephthalate is used as a core component and has a melting point of 60 to
Using a staple of a heat-fusible fiber having a modified polyester at 160 ° C. as a sheath component, a basis weight of 30 to 100 g /
to produce a card web m ^2, which is a surface layer web. On the other hand, a card web having a basis weight of 30 to 100 g / m ² is produced using a mixture of rayon staples and the above heat-fusible fiber staples (mixing ratio 9/1), and this is used as a back layer web.

The above-described surface layer web and back layer web are superimposed and water-punched. Alternatively, the above-described surface layer web and back layer web are individually water-punched and then superposed to form a water punch again. Or they are combined together. For the back layer of the obtained nonwoven fabric
The base paper for wallpaper is adhered to the web with an adhesive, and then the desired printing on the surface layer web is performed, followed by embossing. At the time of embossing, a concave and convex pattern is formed on the embossing roller to a depth of 0.2 to 0.8 mm, the temperature of the embossing roller is set to 180 to 220 ° C, and the pressure is set to 50 to 200 kgf / cm.
Then, the processing speed is set to 5 to 25 m / min.

The obtained wallpaper has both a beautiful printed pattern and a sharp uneven pattern, a soft texture, a warm feeling, and an excellent volume feeling. It is suitable for use by sticking it to the wall surface with an adhesive. In addition, since the back layer web is made of rayon, it has hygroscopicity and is easily cut at the time of pattern matching. Also, the base paper for wallpaper is adhered to the back side
Therefore, the morphological stability is lower than that without the base paper for wallpaper.
Good for printing, embossing and installation
Easy to handle.

[0020]

[0021]

[0022]

[0023]

[0024]

EXAMPLE 1 Polyester heat-fusible fiber of a composite form having polyethylene terephthalate as a core and a modified polyester having a melting point of 110 ° C. as a sheath component (total denier 2.4 denier, fiber length 5)
1 mm) to produce a card web having a basis weight of 40 g / m ² , which was used as a surface layer web. On the other hand, a card web having a basis weight of 40 g / m ² was produced using only rayon staples (1.5 denier fineness, fiber length 51 mm), and this was used as a back layer web. Webs were stacked and integrated with a water punch. However, the punching conditions were as follows: the water pressure of the three upper nozzles was 40 kgf / cm ² , 80 kgf / cm ² , and 80 kgf
/ Cm ² and all three lower nozzles are 80 kgf / cm ²
The speed was 9 m / min, and a nonwoven fabric having a thickness of 0.67 mm was obtained.

The web weight for the back layer of the obtained nonwoven fabric was 1
A 20 g / m ² base paper for wallpaper is bonded with a modified vinyl acetate copolymer-based adhesive (30 g / m ² ) and dried, and then a multicolor pattern is printed with a gravure printing machine. It was applied at a coverage of 20 g / m ² , and then embossed. The embossing is performed by using an embossing roller obtained by engraving a sparse cloth texture so that the maximum engraving depth is 0.6 mm.
The running speed was set to 10 m / min. The obtained wallpaper of Example 1 was a new wallpaper having a sharp appearance having a sparse cloth surface, a soft texture, a warm feeling, and an excellent volume feeling.

Example 2 In Example 1, a part (10%) of the rayon staple of the back layer web was replaced with the above heat-fusible fiber staple, and the basis weight of the surface layer web and the back layer web was changed. The wallpaper of Example 2 was produced in the same manner as in Example 1 except that the wallpaper was reduced to 30 g / m ² . This wallpaper, like the wallpaper of Example 1, had a sparse cloth appearance on the surface, had a soft texture, was warm, had a voluminous feel, and was easy to cut during pattern matching.

[0027]

[0028]

[0029]

Effects of the Invention According to the present invention, a nonwoven fabric made of wallpaper with staples constituent fibers, preferably in the interior of the building, there is no generation of fuzz or pilling of surface deposited stains Tore Easy and have a sharp uneven pattern , form
A good stability, Ru can be produced easily handled wallpaper efficiently.

Claims (4)

[Claims] 1. A heat-fusible fiber staple comprising a low-melting point component and a high-melting point component arranged in parallel with the fiber axis direction as a main component, and the content of a normal textile fiber staple other than the main component is 20% by weight. % Or less of the surface layer web and a back layer web having a content of the heat-fusible fiber staples of 20% by weight or less other than the main component, which is mainly composed of ordinary textile staples for weaving and weaving. A method of manufacturing a surface covering material, comprising bonding a heated embossing roll to a surface layer web to form a concavo-convex pattern while the nonwoven fabric having a two-layer structure is bonded to the surface layer web while the nonwoven fabric is running. 2. The method of manufacturing a facing material according to claim 1, wherein a reinforcing material is attached to the nonwoven fabric having a two-layer structure obtained by punching, and then embossing is performed. 3. The method for manufacturing a facing material according to claim 1, wherein the fiber staple for weaving has at least one of functions such as hygroscopicity, antibacterial property, deodorant property and flame retardancy. The manufacturing method of the surface material containing the functional fiber provided. 4. The method for producing a surface covering material according to claim 1, wherein a cellulosic fiber or an acrylic fiber and a polyester fiber are mixed as a textile staple.