KR102333019B1 - An wall paper and method for preparing the same - Google Patents

Abstract

The present invention relates to a wallpaper and a method for manufacturing the same, and more particularly, to a wallpaper having excellent thermal insulation properties due to low thermal conductivity and a method for manufacturing the same.

Description

Wallpaper and its manufacturing method {AN WALL PAPER AND METHOD FOR PREPARING THE SAME}

The present invention relates to a wallpaper and a method for manufacturing the same, and more particularly, to a wallpaper having excellent thermal insulation properties due to low thermal conductivity and a method for manufacturing the same.

Wallpaper contains various patterns or three-dimensional shapes, and is an interior means to give decorative beauty to the wall.

Recently, silk wallpaper that has a smooth surface texture like silk and excellent embossing effect, which can express a three-dimensional feeling, is preferred. The material of such silk wallpaper is usually PVC (polyvinyl chloride), and as an example of such PVC wallpaper, Korean Patent Publication No. 10-0467775 sequentially includes a base paper, a PVC foam layer, a printing layer, and a surface treatment layer from the bottom. Disclosed is a PVC wallpaper.

However, since the PVC wallpaper uses calcium carbonate (900 mW/m·K) having high thermal conductivity as a filler, there is a problem in that the insulation properties are not good.

In addition, the calcium carbonate has a large specific gravity (2.4-2.7), so that when the coating amount of the PVC foam layer composition is additionally increased to further improve the three-dimensional effect, the weight of the wallpaper becomes heavy (usually, when the weight of the wallpaper is 460 g/m ² or more) construction is difficult), and the workability such as seams between wallpapers is widened after construction is deteriorated, and there is a problem in construction quality due to the occurrence of fold marks on the wallpaper.

On the other hand, in the conventional PVC wallpaper 200, when performing an embossing process of pressing with an emboss roll for an appearance effect (see FIG. 1), the foam cells in the PVC foam layer 220 on the base paper 210 are pressed while the air layer It was destroyed and became the main cause of deterioration of the insulation of the wallpaper.

Accordingly, there is a need for the development of a lightweight wallpaper capable of improving the three-dimensional effect and heat insulation while securing workability and construction quality.

KR 10-0467775B (Announcement Date: 2005. 01. 24)

In order to solve the problems of the prior art as described above, an object of the present invention is to provide a wallpaper having excellent thermal insulation properties due to low thermal conductivity.

In order to achieve the above object,

The present invention sequentially from the bottom, the base layer; a first resin layer; a second resin layer; and a third resin layer; providing a wallpaper having a thermal conductivity of less than 100mW/m·k.

In addition, the present invention provides a base layer preparation step of preparing a base layer (S1);

A first resin layer forming composition application step (S3) of applying a first resin layer forming composition on the upper portion of the base layer;

Applying the composition for forming a second resin layer on the first composition for forming a resin layer on top of the composition for forming a second resin layer (S5);

a third resin layer forming composition application step (S7) of applying a third resin layer forming composition on the second resin layer forming composition; and

The applied composition for forming the first resin layer; a composition for forming a second resin layer; and a third composition for forming a resin layer; a foaming step of foaming (S9); It provides a method of manufacturing a wallpaper having a thermal conductivity of less than 100 mW / m · k comprising a.

The wallpaper of the present invention has an effect of providing a wallpaper having excellent thermal insulation properties due to low thermal conductivity.

1 is a view showing an embossing process of forming an embossing pattern by pressing the wallpaper with an embossing roll in the related art.
2 is a side cross-sectional view schematically showing the laminated structure of the wallpaper of the present invention.
3 is a view schematically showing an embodiment of the pattern of the first resin layer of the present invention.
4 is a flowchart of a method for manufacturing a wallpaper according to the present invention.

Hereinafter, the present invention will be described in detail with the accompanying drawings.

The present invention sequentially from the bottom, the base layer 110; a first resin layer 120; a second resin layer 130; and a third resin layer 140; to the wallpaper 100 having a thermal conductivity of less than 100 mW/m·k (see FIG. 2).

Specifically, the wallpaper 100 of the present invention may have a thermal conductivity of less than 100 mW/m·k, 80 mW/m·k or less, or 55 mW/m·k or less. Therefore, it can have a thermal conductivity within the above range.

Hereinafter, each layer of the wallpaper 100 of the present invention will be described in detail.

Base layer 110

The base layer 110 may use a general base paper for wallpaper known in the art of the present invention, for example, imitation paper or non-woven fabric (eg, polyester/pulp composite non-woven fabric), etc., but is limited thereto. it is not

The base layer 110 may have a basis weight of 80-200 g/m 2 or 90-150 g/m 2 . When the basis weight of the base layer 110 is within the above range, damage such as tearing of the wallpaper during construction or use can be prevented, and workability problems such as gapping and curling can be prevented.

The thickness of the base layer 110 may be, for example, 0.1-0.3 mm or 0.1-0.25 mm, but is not necessarily limited thereto.

first resin layer 120

The first resin layer 120 is coated on the base layer 110 and then foamed to form an air layer, thereby providing insulation to the wallpaper.

In particular, the first resin layer 120 may be partially formed on the base layer 110 and have a pattern of a certain shape.

An embodiment of the pattern may be a circular pattern.

As a specific example of the circular pattern, circles having a diameter of 0.3-0.7 mm may be formed at intervals of 0.3-0.7 mm, or circles having a diameter of 0.4-0.6 mm may be patterns formed at intervals of 0.4-0.6 mm (Fig. see 3). In the case of a circular pattern having the same diameter and spacing as described above, even if the first resin layer 120 is foamed at a high magnification, it is possible to prevent deterioration of the workability of the wallpaper.

In the present invention, the circle of the circular pattern is an approximate shape when viewed in a plan view, and may be in the shape of a substantially cut sphere in three dimensions (refer to FIGS. 2 and 3 ). The roughly circular shape means a concept encompassing not only a geometrically perfect circle, but also a level that can be referred to as an approximate circle.

In the present invention, the diameter of a circle may mean a diameter when it is a perfect circle, and a length of the longest line segment (ie, a major axis) passing through the center when it is not a perfect circle.

In the present invention, the distance between circles means the distance between neighboring circles in the vertical or horizontal direction, and may mean the distance excluding the radius from the line connecting the center of one circle and the center of the neighboring circle in the vertical or horizontal direction. .

If the diameter of the circle is larger than the range and the interval is narrower than the range, the second resin layer 130 and the third resin layer 140 from the base layer 110 because the circles (ie, foam cells) are combined. ) may occur, causing the wallpaper to tear, or the workability may be reduced, such as seams opening due to shrinkage and expansion differences of the base layer 110 during wallpaper construction, and the diameter of the circle is smaller than the above range, and the gap is If it is wider than the range, it may not be possible to impart heat insulation to the wallpaper, so it may have a diameter and a spacing within the range.

In the present invention, as a specific embodiment of the circular pattern, a circle having a diameter of 0.5 mm may be a pattern formed at intervals of 0.5 mm, and in this case, the insulation and workability of the wallpaper may be excellent (see FIG. 3 ).

In the present invention, although a circular pattern is exemplified as an embodiment of the pattern, it may optionally be an oval pattern or a polygonal pattern. In this case, the diameter means the length of the longest line segment (that is, the major axis) passing through the center of the ellipse or polygon, and the spacing means the spacing between adjacent ellipses or polygons in the vertical or horizontal direction. Alternatively, it may mean a distance excluding the major axis from a line connecting the center of the polygon and the center of an ellipse or polygon neighboring in the vertical or horizontal direction.

On the other hand, the first resin layer 120 is for forming the first resin layer 120 in a sol state containing 4-20 parts by weight of a foaming agent and 50-100 parts by weight of a plasticizer with respect to 100 parts by weight of a polyvinyl chloride resin. It may be formed using the composition.

The foaming agent may be used alone or by mixing a chemical foaming agent and a capsule foaming agent.

The type of the chemical foaming agent is not limited as long as it can be used in the polyvinyl chloride resin, but as a specific example of the present invention, azodicarbonamide, p,p'-oxybisbenzenesulfonylhydrazide (p,p'-oxybisbenzene sulfonyl hydrazide), p-toluene sulfonyl hydrazide (p-toluene sulfonyl hydrazide) and benzene sulfonyl hydrazide (benzene sulfonyl hydrazide) may be at least one selected from the group consisting of.

The chemical foaming agent may be decomposed at 160-180° C. to generate a gas amount of 200-300 ml/gr. If it is less than the above temperature range, it may be difficult to realize a sufficient foaming effect because it is foamed in advance before the foaming molding step. A chemical foaming agent that decomposes within the above temperature range may be used.

As the foaming agent, when the chemical foaming agent is used alone, the chemical foaming agent may be used in an amount of 4-15 parts by weight or 5-10 parts by weight based on 100 parts by weight of the polyvinyl chloride resin. If it is less than the above range, the foaming ratio is lowered and a large air layer cannot be secured, so the effect of improving the insulation of the wallpaper may be insignificant. It can be used within the above range because the workability may be deteriorated, such as thinness.

In addition, the capsule foaming agent may be a thermally expandable microcapsule comprising a resin capsule layer, and an expanding agent contained in the capsule layer and having a boiling point below the softening point of the resin used in the capsule layer.

More specifically, when heat of an appropriate temperature is applied to the capsule foaming agent, softening of the capsule layer starts and at the same time the expanding agent contained in the capsule layer is vaporized, the internal pressure increases, and the inside and outside of the foaming cell formed by the foaming of the chemical foaming agent can be fired. Unlike chemical foaming agents, since the capsule foaming agent includes a capsule layer, it has resistance to external pressure or impact to prevent damage or breakage of the foaming cell.

The capsule layer may be at least one polyvinyl chloride resin selected from the group consisting of acrylonitrile copolymer, vinylidene chloride copolymer, polyethylene, polypropylene, and polystyrene, but is not necessarily limited thereto.

The expanding agent may be one or more liquid hydrocarbons selected from the group consisting of propane, propylene, butene, butane, isobutane, isopentane, neopentane, normal pentane, normal hexane, isohexane, heptane, octane, nonane and decane. have.

The capsule foaming agent may have an average particle diameter before foaming of 10-40 μm, or 15-35 μm.

In the present invention, the average particle diameter means an average of diameters when the capsule foaming agent has a spherical shape, and means an average length of a major axis when divided into a major axis and a minor axis when the capsule foaming agent has a shape other than a spherical shape.

If the average particle diameter is less than the above range, sufficient foaming effect may not be obtained, so the effect of improving the insulation properties of the wallpaper may be insignificant because a large air layer may not be secured. It may be lowered and may have an average particle diameter within the above range.

The particle size may be measured using a scanning electron microscope (SEM).

In addition, the capsule foaming agent may have a thermal expansion initiation temperature of, for example, 110-140°C, or 120-130°C. When it is less than the above range, the capsule foaming agent bursts due to premature foaming, and the effect of improving the insulation properties of the wallpaper may be insignificant.

When in the thermal expansion-starting temperature is thermal mechanical analysis device (Thermomechanical Analysis, hereinafter 'TMA') when heating the capsule blowing agent, it means the temperature at which the displacement in the vertical direction byeonhaeteul positively.

In addition, the capsule foaming agent may have a maximum thermal expansion temperature of 150-180°C, or 160-170°C. If it is less than the above range, there may be damage to the foaming cell because the capsule layer may burst, and if it exceeds the above range, sufficient foaming may not occur during the foaming molding step, so it may have a maximum thermal expansion temperature within the above range.

The maximum thermal expansion temperature means a temperature at which the capsule foaming agent becomes the maximum displacement when the diameter thereof is measured while heating the capsule foaming agent from room temperature with a thermomechanical analysis apparatus (TMA).

On the other hand, as a foaming agent, when the chemical foaming agent and the capsule foaming agent are mixed and used, based on 100 parts by weight of the polyvinyl chloride resin, the chemical foaming agent is 3.5-10 parts by weight or 4-8 parts by weight, and the capsule foaming agent is 0.5-5 weight parts parts, or 1-4 parts by weight. When the capsule foaming agent is included below the above range, the thermal insulation improvement effect may be insignificant, and when the capsule foaming agent is included in excess of the above range, the surface curvature of the first resin layer 120 is severe, so that the first resin layer 120 is described below on the upper part. Since it may be difficult to form the second resin layer 130 , the capsule foaming agent may be included within the content range.

The expansion ratio of the first resin layer 120 may be 300% or more, 300-600%, or 400-500%. If it is less than the above range, the effect of improving the insulation properties of the wallpaper may be insignificant because a large number of air layers may not be secured.

The plasticizer is included to plasticize the polyvinyl chloride resin to facilitate coating of the composition for forming the first resin layer 120 on the base layer 110, terephthalate-based plasticizer, benzoate-based plasticizer , and may be at least one selected from the group consisting of citrate-based plasticizers and phosphate-based plasticizers.

The plasticizer may be included in an amount of 50-100 parts by weight or 50-80 parts by weight based on 100 parts by weight of the polyvinyl chloride resin. When it is less than the above range, the viscosity of the composition for forming the first resin layer 120 is high, so that when it is formed on the base layer 110, the coating property may be reduced, and if it exceeds the above range, the gelling property after coating is reduced and In addition, physical properties may be reduced due to plasticizer migration, and thus may be included within the above content range.

The composition for forming the first resin layer 120 may have a viscosity of 900-3000cps or 1000-2000cps at 20-25°C. If it is less than the above range, the viscosity may be too low and it may be difficult to partially apply it on the upper portion of the base layer 110, and if it exceeds the above range, the viscosity may be too high and the coating property may be lowered, so that it may have a viscosity within the above range.

The thickness of the first resin layer 120 before foaming may be, for example, 0.05-0.5 mm or 0.1-0.3 mm. If it is less than the above range, the insulation improvement effect may be insignificant due to not securing many air layers, and if it exceeds the above range, the weight of the wallpaper may be heavy, and there may be difficulties in construction such as folding of the wallpaper. can have

The second resin layer (130)

The second resin layer 130 is formed on the entire upper surface of the first resin layer 120 to provide a cushioning feeling to the wallpaper of the present invention, and to lighten the wallpaper by including a specific content of glass bubbles with low density and thermal conductivity as a filler. While providing, it serves to further improve the heat insulation, and may include 5-20 parts by weight of glass bubbles with respect to 100 parts by weight of the polyvinyl chloride resin.

Specifically, the second resin layer 130 is formed using a composition for forming the second resin layer 130 in a sol state containing 5-20 parts by weight of glass bubbles with respect to 100 parts by weight of a polyvinyl chloride resin. it could be

The glass bubble in the second resin layer 130 is a hollow particle that can be used as a substitute for calcium carbonate used as a filler in the conventional wallpaper. Light weight and heat insulation can be imparted to the

Specifically, the glass bubble may include at least 90% by weight, 94% by weight, or 97% by weight or more of soda-lime-borosilicate glass. The soda-lime-borosilicate glass contains 50-90% by weight of SiO ₂ , 2-20% by weight of alkali metal oxide, 1-30% by weight of divalent metal oxide, 1-30% by weight of B ₂ O ₃ , 0.005-1.5% by weight of sulfur or sulfur oxides. As a specific example of the soda-lime-borosilicate glass, 70-80% by weight of SiO ₂ , 3-8% by weight of Na ₂ O, 8-15% by weight of CaO, 2-6% by weight of B ₂ O ₃ , 0.125%-1.5% of SO ₃ may be exemplified, but not necessarily limited thereto.

In addition, the glass bubble may have an average true density of 0.15-0.3 g/cc or 0.17-0.25 g/cc. If it is less than the above range, the dispersibility of the glass bubbles in the second resin layer 130 may be lowered, so there may be a problem in productivity. The thermal insulation improvement effect may be insignificant and may have an average true density within the above range.

In the present invention, the average true density means a quotient obtained by dividing the mass of the sample of the glass bubble by the true volume of the glass bubble of the mass measured by a gas pycnometer.

Specifically, the average true density is determined according to ASTM D2840-69 (“Average True Particle Density of Hollow Microspheres”) using a pycnometer (as a specific example, AccuPcy 1330 from Micromeritics). It can be measured using

In addition, the glass bubble may have a particle size of 25-105 μm, or 30-95 μm. If it is less than the above range, the average true density of the glass bubble increases, so the effect of reducing the weight of the wallpaper and improving the insulation may be insignificant. Since the surface condition of the formation layer 130 may be poor, it may have a particle size within the above range.

In the present invention, the particle size means a diameter when the glass bubble has a spherical shape, and may mean a length of a major axis when divided into a major axis and a minor axis when the glass bubble has a shape other than a spherical shape.

The particle size of the glass bubble can be measured using a particle size analyzer (S3500, Microtrac).

In addition, the glass bubble may have a thermal conductivity of 0.06-0.10W/m·K or 0.065-0.08W/m·K at 20-23°C. Since the glass bubble has a thermal conductivity within the above range, thermal conductivity may be lower than that of a conventional wallpaper using calcium carbonate as a filler, thereby further improving thermal insulation properties.

The glass bubble may be included in an amount of 5-20 parts by weight, or 7-17 parts by weight based on 100 parts by weight of the polyvinyl chloride resin. If it is less than the above range, the effect of improving the insulation properties of the wallpaper may be insignificant, and the coating amount of the composition for forming the second resin layer 130 on the first resin layer 120 may be increased in order to decrease the physical properties and improve the three-dimensional effect. The three-dimensional effect is limited because it cannot may be insignificant, and since the viscosity of the composition for forming the second resin layer 130 increases, the content of the required plasticizer increases, which is undesirable, and thus may be included within the above range.

In addition, the second resin layer 130 may further include at least one selected from a plasticizer and a foaming agent.

Since the plasticizer is the same as the plasticizer included in the first resin layer 120 described above, the overlapping description will be omitted.

The plasticizer may be included in an amount of 50-90 parts by weight or 60-80 parts by weight based on 100 parts by weight of the polyvinyl chloride resin. When it is less than the above range, the viscosity of the composition for forming the second resin layer 130 is high, so that when it is formed on the first resin layer 120, the coatability may decrease, and when it exceeds the above range, the gelling property after coating In addition to this decrease, physical properties may be reduced due to plasticizer migration, and thus may be included within the above content range.

The foaming agent may be included in an amount of 2-10 parts by weight based on 100 parts by weight of the polyvinyl chloride resin.

A chemical foaming agent may be used alone or a mixture of a chemical foaming agent and a capsule foaming agent may be used as the foaming agent.

Since the chemical foaming agent and the capsule foaming agent are the same as the chemical foaming agent and the capsule foaming agent included in the first resin layer 120 described above, overlapping descriptions will be omitted.

As the foaming agent, when the chemical foaming agent is used alone, the chemical foaming agent may be included in an amount of 2-8 parts by weight or 3-6 parts by weight based on 100 parts by weight of the polyvinyl chloride resin. If the range is less than the above range, the foaming effect may be insignificant, and the effect of improving lightness and heat insulation may be insignificant, and cushioning properties may be reduced. It may be included within the above range.

In addition, as a foaming agent, when the chemical foaming agent and the capsule foaming agent are mixed and used, the chemical foaming agent is 1-5 parts by weight or 2-4 parts by weight, and the capsule foaming agent is 1-5 parts by weight based on 100 parts by weight of the polyvinyl chloride resin. parts, or 2-4 parts by weight. When the capsule foaming agent is included below the above range, the cushioning effect may be insignificant. 3 It may be difficult to form the resin layer 140 may include a capsule foaming agent within the content range.

The expansion ratio of the second resin layer 130 may be 230-380% or 250-300%, and when it is less than the above range, it is not possible to secure an air layer, so the lightness and heat insulation improvement effect is insignificant, and the cushioning property will be lowered. In addition, when the above range is exceeded, the durability of the wallpaper is reduced, and the workability such as the seam of the wallpaper is widened because the size of the foam cell is too large to have a foaming ratio within the above range.

The composition for forming the second resin layer 130 may have a viscosity of 2000-4000cps or 2500-3500cps at 20-25°C. If it is less than the above range, the viscosity is too low, so it may be difficult to form a desired thickness when coating on the upper part of the first resin layer 120, and the crack generation rate may be high after drying. It may have a viscosity within the above range.

The thickness of the second resin layer 130 before foaming may be, for example, 0.1-0.7 mm or 0.2-0.5 mm. If it is less than the above range, the effect of improving insulation may be insignificant, and if it exceeds the above range, the weight of the wallpaper may be heavy, and there may be difficulties in construction such as folding of the wallpaper, so that it may have a thickness within the above range.

Third resin layer (140)

The third resin layer 140 is partially formed on the second resin layer 130 to further improve the aesthetic effect by imparting various patterns and/or colors to the wallpaper. The embossing pattern can be formed only by the foaming process of the first resin layer 120, the second resin layer 130, and the third resin layer 140, so that when pressed with a conventional embossing roll, the PVC foam layer 220 is pressed. It can solve problems such as deterioration of thermal insulation performance.

The third resin layer 140 may contain 1-7 parts by weight of the capsule foaming agent based on 100 parts by weight of the polyvinyl chloride resin.

Specifically, the third resin layer 140 is formed by using a composition for forming the third resin layer 140 in a sol state containing 1-7 parts by weight of a capsule foaming agent with respect to 100 parts by weight of the polyvinyl chloride resin. may be formed.

Since the types of the polyvinyl chloride resin and the capsule foaming agent are the same as the polyvinyl chloride resin and the capsule foaming agent included in the second resin layer 130 described above, overlapping descriptions will be omitted.

The capsule foaming agent may be included in an amount of 1-7 parts by weight or 2-5 parts by weight based on 100 parts by weight of the polyvinyl chloride resin. If it is less than the above range, the effect of preventing the fold marks of the wallpaper is insignificant, and if it exceeds the above range, it is difficult to realize the intended embossing effect due to excessive foaming (spreading), so a capsule foaming agent within the above content range may be included.

In addition, the third resin layer 140 may further include at least one selected from a filler, a chemical foaming agent, and a plasticizer.

The filler may be at least one selected from glass bubbles and calcium carbonate.

When using the glass bubble alone as the filler, the glass bubble may be included in an amount of 1-20 parts by weight or 5-17 parts by weight based on 100 parts by weight of the polyvinyl chloride resin. If it exceeds the above range, the expansion ratio of the third resin layer 140 may be low and the surface state may not be smooth, the effect of lightening and heat insulation improvement may be insignificant compared to the price, and the viscosity of the composition for forming the third resin layer 140 It may be undesirable as the content of the plasticizer required increases as the increase increases, and thus may be included within the above range.

Since the characteristics of the glass bubble are the same as those of the glass bubble included in the second resin layer 130 described above, the overlapping description will be omitted.

When the calcium carbonate is used alone as the filler, the calcium carbonate may be 50-90 parts by weight or 60-80 parts by weight based on 100 parts by weight of the polyvinyl chloride resin. If it is less than the above range, the raw material price of the composition for forming the third resin layer 140 may increase and dimensional stability may decrease. may be included.

When using a mixture of glass bubbles and calcium carbonate as the filler, the glass bubbles may be 5-15 parts by weight or 7-13 parts by weight based on 100 parts by weight of the polyvinyl chloride resin, and the calcium carbonate is 100 parts by weight of the polyvinyl chloride resin. It may be 50-90 parts by weight or 60-80 parts by weight based on parts by weight.

The chemical foaming agent may be included in an amount of 1-6 parts by weight or 2-5 parts by weight based on 100 parts by weight of the polyvinyl chloride resin. If it is less than the above range, the implementation of the embossing effect may be insignificant due to insufficient foaming, and if it exceeds the above range, it may be difficult to implement the intended embossing effect due to excessive foaming (spreading). have.

The expansion ratio of the third resin layer 140 may be 100-220% or 100-200%, if it is less than the above range, it may be difficult to give a three-dimensional effect to the wallpaper, and if it exceeds the above range, excessive foaming (foaming) The cell shape spreads laterally), so that the three-dimensional effect may also be reduced, so it may have an expansion ratio within the above range.

The plasticizer may be included in an amount of 50-90 parts by weight or 60-80 parts by weight based on 100 parts by weight of the polyvinyl chloride resin. If it is less than the above range, the viscosity of the composition for forming the third resin layer 140 may be high and the coating property may be lowered. (130) It may be difficult to form a desired thickness when applied to the upper portion, so it may be included within the above content range.

The types of the chemical foaming agent and the plasticizer are the same as the chemical foaming agent and the plasticizer included in the first resin layer 120 described above, and thus overlapping descriptions will be omitted.

The composition for forming the third resin layer 140 may have a viscosity of 2000-4000cps or 2500-3500cps at 20-25°C. If it is less than the above range, the viscosity is too low and it may be difficult to form a desired thickness when applied to the upper portion of the second resin layer 130, and the crack generation rate may be high after drying. It may have a viscosity within the above range.

The thickness of the third resin layer 140 before foaming may be, for example, 0.05-0.4 mm or 0.1-0.3 mm. If it is less than the above range, even if it is foamed, the embossing effect may be insignificant, and if it exceeds the above range, the weight of the wallpaper may be heavy, and the foldability of the wallpaper is prevented due to excessive foaming (spreading) of the third resin layer 140 . The effect may be reduced, and thus the thickness may be within the above range.

The composition for forming the first resin layer 120, the composition for forming the second resin layer 130, and the composition for forming the third resin layer 140 are optionally at least one selected from the group consisting of inorganic pigments and organic pigments. It may further include a pigment, a heat stabilizer and a viscosity modifier, and the type and content thereof are not particularly limited.

In addition, the composition for forming the first resin layer 120 , the composition for forming the second resin layer 130 , and the composition for forming the third resin layer 140 may further include known additives as necessary, and the The type and content are not limited as long as they do not affect the physical properties of the wallpaper.

The wallpaper of the present invention may further include an additional layer in addition to the layers exemplified above. For example, a surface treatment layer (not shown) formed by applying a surface treatment agent to the upper portion of the third resin layer 140 to prevent contamination is further added. may be included, but is not limited thereto.

The surface treatment agent is an emulsion prepared by dispersing an acrylic resin or PLA (Polylactic acid) resin in water, or an acrylic resin or PLA resin dissolved in water, an alcohol-based solvent, or a solvent such as MEK (Methyl Ethyl Ketone) can be used. .

The wallpaper of the present invention may have a basis weight of 380-450 g/m ² or 400-450 g/m ² , and within the above range, it may have a basis weight within the above range because it does not reduce workability while implementing the effect of improving lightness and heat insulation. .

In addition, the present invention provides a base layer preparation step of preparing a base layer (S1);

A first resin layer forming composition application step (S3) of applying a first resin layer forming composition on the upper portion of the base layer;

a second resin layer-forming composition application step (S5) of applying a second resin layer-forming composition on the first resin layer-forming composition;

a third resin layer forming composition application step (S7) of applying a third resin layer forming composition on the second resin layer forming composition; and

The applied composition for forming the first resin layer; a composition for forming a second resin layer; and a third composition for forming a resin layer; a foaming step of foaming (S9); It relates to a method for manufacturing a wallpaper having a thermal conductivity of less than 100 mW/m·k, including (see FIG. 4 ).

Hereinafter, each step will be described as follows.

Base layer preparation step (S1);

In the base layer preparation step (S1), the properties of the base layer are the same as those of the base layer described above, so the overlapping base material will be omitted.

Applying the composition for forming a first resin layer (S3);

The step of applying the composition for forming the first resin layer (S3) may be a step of gelling after partially applying the composition for forming the first resin layer as described above on the upper portion of the base layer.

The composition for forming the first resin layer may be prepared by adding each composition of the first resin layer described above to a mixer and then kneading the composition at room temperature.

The method of partially applying the composition for forming the first resin layer may be a rotary screen coating method, and more specifically, the composition for forming the first resin layer may be applied in a pattern of a predetermined shape. Since the pattern is the same as the content of the first resin layer described above, the overlapping description will be omitted.

The gelling may be performed at 150-180° C. for 10-20 seconds.

applying the composition for forming a second resin layer (S5);

In the step of applying the composition for forming the second resin layer (S5), the composition for forming the second resin layer described above may be applied over the entire surface of the first resin layer and then gelled.

The composition for forming the second resin layer may be prepared by adding each composition of the second resin layer described above to a mixer and then kneading the composition at room temperature.

A method of applying the composition for forming the second resin layer on the entire surface of the first resin layer may be a known coating method, and as a specific embodiment of the present invention, bar coating or knife coating may be used. may be, but is not limited thereto.

The gelling may be performed at 150-180° C. for 10-20 seconds.

A third resin layer-forming composition application step (S7);

In the step of applying the composition for forming the third resin layer (S7), the composition for forming the third resin layer as described above may be partially applied on the upper portion of the second resin layer and then gelled.

The composition for forming the third resin layer may be prepared by adding each composition of the third resin layer described above to a mixer and then kneading the composition at room temperature.

A method of partially applying the composition for forming the third resin layer on the upper portion of the second resin layer may be a rotary screen coating method.

In addition, when the composition for forming the third resin layer is partially applied on the second resin layer, it can have a pattern of a desired design, and the pattern is not particularly limited.

The gelling may be performed at 150-180° C. for 10-20 seconds.

foaming step (S9);

The foaming step (S9) is a step of foaming the composition for forming the first resin layer, the composition for forming the second resin layer, and the composition for forming the third resin layer, at 180-220°C or 190-210°C for 30-70 seconds. Or it may be foaming under the conditions of 40-60 seconds. If the temperature and time range is less than the above temperature and time range, the foaming is insignificant, and the effect of improving the lightness, cushioning and heat insulation of the wallpaper is insignificant, and a sufficient embossing effect cannot be implemented. In addition to this decrease, it is difficult to construct the wallpaper, so it can be foamed at the above temperature and time range.

Conventional wallpaper is pressurized with an embossing roll to form an embossed pattern in order to impart a three-dimensional and aesthetic effect. During this embossing process, pressure is applied to the foaming cells in the PVC foam layer to destroy the air layer serving as the insulation layer, thereby reducing the insulation performance of the wallpaper. There was a problem.

However, in the wallpaper manufacturing method of the present invention, as described above, the third resin layer is partially formed on top of the second resin layer in a rotary screen method and foamed to realize a three-dimensional effect. It may not include a pressing process (embossing process) of pressing with embossing in order to give an aesthetic effect.

Accordingly, in the manufacturing method of the present invention, the process can be simplified and the insulation performance of the manufactured wallpaper is not deteriorated.

Since the present invention as described above is not limited to the above-described embodiments, it can be changed within the scope without departing from the gist of the present invention claimed in the claims, and such changes are the present invention defined by the following claims. fall within the protection scope of the invention.

[Example]

Hereinafter, the compositions used in Examples, Comparative Examples and Reference Examples are as follows.

- Polyvinyl chloride resin: As the polyvinyl chloride resin included in the second resin layer and the third resin layer, PB900 of LG Chem with a polymerization degree of 900±50 was used.

- Glass bubble ¹⁾ : 3M's K20 having an average true density of 0.2 g/cc, a particle size of 55 μm, and a thermal conductivity of 0.07 W/m·K at 21°C was used.

- Glass bubble ²⁾ : 3M's S60 having an average true density of 0.60 g/cc, a particle size of 30 μm, and a thermal conductivity of 0.20 W/m·K at 21°C was used.

- Glass bubble ³⁾ : 3M's K1 having an average true density of 0.125 g/cc, a particle size of 65 μm, and a thermal conductivity of 0.047 W/m·K at 21°C was used.

- Plasticizer: dioctyl terephthalate (DOTP) of LG Chem was used.

- Chemical foaming agent: ADCA (azodicarbonamide), DWPX03 from Dongjin Semicam with a decomposition start temperature of 160-180℃ and a gas volume of 200-260ml/gr, was used.

- Capsule foaming agent: MS2001 of Dongjin Semicam, which had an average particle diameter of 18-24㎛ before foaming, a thermal expansion start temperature of 120-130°C, and a maximum thermal expansion temperature of 160-170°C, was used.

1. Wallpaper manufacturing

<Example 1>

(1) Base layer preparation step (S1)

Paper having a basis weight of 100 g/m ² and a thickness of 0.15 mm was prepared.

(2) Applying the composition for forming the first resin layer (S3)

4 parts by weight of a chemical foaming agent, 1 part by weight of a capsule foaming agent, 60 parts by weight of a plasticizer, and 2 parts by weight of a heat stabilizer with respect to 100 parts by weight of polyvinyl chloride resin, put in a mixer, and kneaded at room temperature to have a viscosity of 1500 cps (25° C.) 1 A composition for forming a resin layer was prepared.

Then, the composition for forming the first resin layer was applied to a thickness of 0.1 mm by a rotary screen coating method so that circles having a diameter of 0.5 mm were formed on the upper portion of the base layer at intervals of 0.5 mm, and then gelled at 160° C. for 15 seconds. .

(3) applying the composition for forming the second resin layer (S5)

For 100 parts by weight of polyvinyl chloride resin, ¹⁾ 10 parts by weight of glass bubbles, 70 parts by weight of plasticizer, 3.5 parts by weight of chemical foaming agent and 2 parts by weight of heat stabilizer were put in a mixer and kneaded at room temperature to have a viscosity of 3000 cps (25° C.) in a sol state. A composition for forming a second resin layer was prepared.

Then, the second composition for forming a resin layer was applied on top of the gelled composition for forming a resin layer to a thickness of 0.3 mm by a bar coating method, and then gelled at 160° C. for 15 seconds.

(4) applying the composition for forming a third resin layer (S7)

With respect to 100 parts by weight of polyvinyl chloride resin, 70 parts by weight of calcium carbonate, 70 parts by weight of plasticizer, 3 parts by weight of chemical foaming agent, 3 parts by weight of capsule foaming agent and 2 parts by weight of heat stabilizer were put in a mixer and kneaded at room temperature to achieve a viscosity of 3000 cps (25 ℃). ) to prepare a composition for forming the third resin layer in a sol state.

Then, the third composition for forming a resin layer was partially applied to the top of the gelled composition for forming a second resin layer by a rotary screen coating method to a thickness of 0.1 mm, and then gelled at 160° C. for 15 seconds.

(5) foaming step (S9)

a substrate layer sequentially stacked from the bottom; a composition for forming a first resin layer; a composition for forming a second resin layer; And the third resin layer-forming composition is foamed at 200° C. for 50 seconds to sequentially form a base layer (thickness: 0.15 mm) from the bottom; first resin layer (thickness: 0.5 mm); a second resin layer (thickness: 0.75 mm); And the wallpaper of Example 1 comprising a third resin layer (thickness: 0.2 mm) was prepared.

The expansion ratio of the first resin layer was 500%, the expansion ratio of the second resin layer was 250%, and the expansion ratio of the third resin layer was 200%.

<Example 2>

Example 2 in the same manner as in Example 1, except that in the step of applying the composition for forming the first resin layer, a rotary screen coating method was applied so that circles having a diameter of 0.6 mm were formed on the base layer at an interval of 0.6 mm. of wallpaper was prepared.

<Example 3>

Wallpaper of Example 3 was prepared in the same manner as in Example 1, except that the composition for forming the second resin layer and the composition for forming the third resin layer were prepared as follows.

Composition for forming the second resin layer ^{: 1)} 10 parts by weight of glass bubbles, 70 parts by weight of a plasticizer, 3.5 parts by weight of a chemical foaming agent, 3 parts by weight of a capsule foaming agent, and 2 parts by weight of a heat stabilizer with respect to 100 parts by weight of a polyvinyl chloride resin into a mixer A composition for forming a second resin layer in a sol state having a viscosity of 3000 cps (25° C.) was prepared by kneading at room temperature.

Composition for forming the third resin layer ^{: 1)} 10 parts by weight of glass bubbles, 70 parts by weight of a plasticizer, 3 parts by weight of a chemical foaming agent, 3 parts by weight of a capsule foaming agent, and 2 parts by weight of a heat stabilizer with respect to 100 parts by weight of a polyvinyl chloride resin into a mixer By kneading at room temperature, a composition for forming a sol-state third resin layer having a viscosity of 3000 cps (25° C.) was prepared.

<Example 4>

Wallpaper of Example 4 was prepared in the same manner as in Example 1, except that 16 parts by weight of the glass bubble 1) contained in the second resin layer was used based on 100 parts by weight of the polyvinyl chloride resin (b).

<Comparative Example 1>

A composition for forming a foaming layer in a sol state having a viscosity of 3000 cps (25° C.) comprising 75 parts by weight of a plasticizer, 4 parts by weight of a chemical foaming agent and 160 parts by weight of calcium carbonate was prepared with respect to 100 parts by weight of the polyvinyl chloride resin.

Then, the composition for forming the foam layer ^{was applied using a coating bar to a thickness of 0.4 mm on top of a paper having a basis weight of 100 g/m 2} and a thickness of 0.15 mm, and then gelled at 160° C. for 15 seconds.

Then, after foaming in an oven at 200° C. to form a foam layer, a printing layer is formed on the upper portion of the foam layer through a gravure printing method, and then softened at a temperature of 120° C. A wallpaper of Comparative Example 1 having a thickness of 1.1 mm was prepared.

<Reference Example 1>

Compared with Example 1, the wallpaper of Reference Example 1 was prepared in the same manner as in Example 1, except that 160 parts by weight of calcium carbonate instead ^{of glass bubble 1)} was used as the filler for the second resin layer.

<Reference Example 2>

Compared with Example 1, the wallpaper of Reference Example 2 was prepared in the same manner as in Example 1, except that 25 parts by weight of ^{glass bubble 1)} was used as the filler for the second resin layer.

<Reference Example 3>

Compared with Example 1, the wallpaper of Reference Example 3 was prepared in the same manner as in Example 1, except that 3 parts by weight of ^{glass bubble 1)} was used as the filler for the second resin layer.

<Reference Example 4>

Compared with Example 1, the wallpaper of Reference Example 4 was prepared in the same manner as in Example 1, except that the third resin layer did not contain the capsule foaming agent.

<Reference Example 5>

Compared with Example 1, the wallpaper of Reference Example 5 was prepared in the same manner as in Example 1, except that 15 parts by weight of the capsule foaming agent was used for the third resin layer as a foaming agent.

<Reference Example 6>

Compared with Comparative Example 1, the wallpaper of Reference Example 6 was prepared in the same manner as in Comparative Example 1, except that the ^{foaming layer included 10 parts by weight of glass bubbles 1)} instead of calcium carbonate as a filler.

<Reference Example 7>

Compared with Example 1, the wallpaper of Reference Example 7 was prepared in the same manner as in Example 1, except that 10 parts by weight of ^{glass bubble 2)} was used as the filler for the second resin layer.

<Reference Example 8>

Compared with Example 1, the wallpaper of Reference Example 8 was prepared in the same manner as in Example 1, except that 10 parts by weight of the ^{glass bubble 3)} was used as the filler for the second resin layer.

<Reference Example 9>

Reference Example 9 in the same manner as in Example 1, except that in the step of applying the composition for forming the first resin layer, the rotary screen coating method was applied so that circles having a diameter of 0.75 mm were formed on the base layer at intervals of 0.2 mm. of wallpaper was prepared.

<Reference Example 10>

Reference Example 10 in the same manner as in Example 1, except that in the step of applying the composition for forming the first resin layer, a rotary screen coating method was applied so that circles having a diameter of 0.2 mm were formed on the base layer at intervals of 0.8 mm. of wallpaper was prepared.

2. Measurement of the physical properties of wallpaper

The final thickness, lightness, heat insulation, workability, and fold marks of the wallpaper of Examples 1-4, Comparative Example 1, and Reference Example 1-10 prepared above were measured, and the results are shown in Table 1 below.

-The final thickness of the wallpaper was measured with a thickness gauge.

-The lightness of the wallpaper was measured by measuring the basis weight of the wallpaper with a scale.

- For thermal insulation, the wall paper prepared above was prepared as a specimen having a width, length, and thickness of about 200 x 200 x 1 mm, and then the thermal conductivity of the specimen was measured by a flat plate thermal conductivity measurement method (KS L ISO 8301).

The lower the thermal conductivity, the better the thermal insulation properties.

- The workability of the wallpaper was visually measured whether the wallpaper prepared above was installed on the wall, and whether the wallpaper floated or a seam between the wallpapers was visible.

(X: raised or seam between wallpapers is displayed, ○: raised or seam between wallpapers is not displayed)

- The fold marks on the wallpaper were visually measured whether the fold marks remain when the wallpaper is folded and unfolded again.

(X: there is a mark on the fold of the wallpaper, ○: there is no mark on the fold of the wallpaper)

As can be seen in Table 1, the wallpaper of Examples 1-4 according to the present invention can include a large amount of air layer compared to Comparative Example 1, so that it can achieve high thickness and weight reduction, and has excellent thermal insulation properties due to low thermal conductivity. , it was confirmed that the construction quality of the wallpaper was excellent as there were no traces on the folded part of the wallpaper, while the workability of the wallpaper was excellent.

On the other hand, in Reference Example 1, in which the third resin layer contained a capsule foaming agent as a foaming agent, and the second resin layer contained calcium carbonate instead of glass bubbles as a filler, there was no trace of the folded portion of the wallpaper, but the wallpaper of Examples 1-4 It was confirmed that the basis weight was heavy compared to that, and the thermal conductivity was high, and the insulation properties were low.

In addition, the wallpaper of Reference Example 2, in which the second resin layer contains glass bubbles as a filler in excess of a specific content range, is light, has low thermal conductivity, and has excellent thermal insulation properties, but the expansion ratio of the second resin layer is low and the surface state is not smooth, The light weight effect and heat insulation effect are low compared to the price, and the viscosity of the composition for forming the second resin layer is increased, so that the coating operation is not easy, which is undesirable.

In addition, the wallpaper of Reference Example 3 containing glass bubbles as a filler in less than a specific content range had a higher thermal conductivity than Examples 1-4, so the insulation properties were somewhat lowered, and the basis weight of the wallpaper ^{exceeded 460 g/m 2} , so the workability was lowered. , In Reference Example 4, in which the third resin layer did not contain the capsule foaming agent, there were marks on the folded portion of the wallpaper, and it was confirmed that the construction quality was deteriorated.

In addition, in Reference Example 5, in which the third resin layer contains an excessive amount of the capsule foaming agent, the third resin layer has a shape in which the third resin layer is spread due to excessive foaming, so that it is difficult to implement the intended embossing effect.

In addition, in comparison with Comparative Example 1, the foaming layer contains glass bubbles, not calcium carbonate, as a filler, and Reference Example 6, which was subjected to a pressing process with embossing, has a light weight effect, but due to pressurization with embossing, the foamed cells in the foaming layer It was confirmed that the air layer was destroyed as the shape of the wall was pressed, and the thermal insulation property was lowered, and the foam layer did not contain the capsule foaming agent, so it was undesirable because there were marks on the folded part of the wallpaper.

On the other hand, compared to Examples 1-4, Reference Example 7 including glass bubbles having a small particle size and high density as a filler had slightly higher thermal conductivity than Examples 1-4, and a larger particle size than Examples 1-4. Reference Example 8, which includes a glass bubble having a low density as a filler, has excellent thermal insulation properties, but the density is small compared to the density of the glass bubbles used in Examples 1-4, and there is a risk that the glass bubble may be damaged, so that the continuation of the insulation effect is difficult. There were some bad downsides.

In addition, in the circular pattern of the first resin layer compared to Examples 1-4, in Reference Example 9, the circles in the circular pattern of the first resin layer have a larger diameter and narrower intervals. It was confirmed that the workability deteriorated, such as the appearance of a mark.

In addition, in Reference Example 10, in which the diameter of the circle in the circular pattern of the first resin layer is small and the interval is wide compared to Examples 1-4, the volume occupied by the first resin layer is reduced while the volume occupied by the second resin layer is relatively small. Due to the increased ratio, the lightness may be somewhat superior to that of Example 1-4, but it was confirmed that the thermal conductivity was somewhat higher than that of the wallpaper of Example 1-4 because a sufficient air layer was not secured.

100: wallpaper 110: base layer
120: first resin layer 130: second resin layer
140: third resin layer
200: conventional wallpaper 210: base paper
220: PVC foam layer

Claims (23)

base layer 110;
a first resin layer 120 partially formed on the base layer 110;
a second resin layer 130 formed on the base layer 110 and the first resin layer 120 and including glass bubbles; and
A printed layer-free wallpaper in which a third resin layer 140 is partially formed on the second resin layer 130 and includes a capsule foaming agent;
The third resin layer 140 contains 1-7 parts by weight of the capsule foaming agent with respect to 100 parts by weight of the polyvinyl chloride resin,
The wallpaper has no fold marks and has a thermal conductivity of less than 80 mW/m·k. The method of claim 1,
The wallpaper has a thermal conductivity of less than 80mW/m·k. The method of claim 1,
The second resin layer 130 is a wallpaper formed by using a composition for forming a second resin layer having a viscosity of 2000 to 4000 cps at 20 to 25°C. The method of claim 1,
The wallpaper has a basis weight of 380-450g/m ² Wallpaper. The method of claim 1,
The wallpaper in which the second resin layer 130 contains 5-20 parts by weight of glass bubbles based on 100 parts by weight of polyvinyl chloride resin. delete The method of claim 1,
The first resin layer 120 is a wallpaper formed by rotary screen coating of a composition for forming the first resin layer having a viscosity of 900 to 3000 cps at 20 to 25°C. The method of claim 1,
The third resin layer 140 is a wallpaper formed by rotary screen coating of a composition for forming a third resin layer having a viscosity of 2000 to 4000 cps at 20 to 25°C. The method of claim 1,
The first resin layer 120 has a circular pattern, an oval pattern, or a polygonal pattern. 10. The method of claim 9,
The wallpaper is that the circular pattern is formed of circles with a diameter of 0.3-0.7 mm. 11. The method of claim 10,
In the circular pattern, the circles are formed at intervals of 0.3-0.7 mm. A base layer preparation step of preparing a base layer (S1);
On the upper portion of the base layer, the first resin layer-forming composition coating step (S3) of partially applying the composition for forming a first resin layer having a viscosity of 900 to 3000 cps at 20 to 25°C;
Applying the composition for forming a second resin layer on top of the composition for forming the base layer and the first resin layer, applying a composition for forming a second resin layer including glass bubbles and having a viscosity of 2000 to 4000 cps at 20 to 25° C. (S5);
On the upper part of the composition for forming the second resin layer, a third resin layer forming composition application step of partially applying a composition for forming a third resin layer containing a capsule foaming agent and having a viscosity of 2000 to 4000 cps at 20 to 25°C ( S7); and
The applied composition for forming the first resin layer; a composition for forming a second resin layer; and a third composition for forming a resin layer; a foaming step of foaming (S9); including,
The composition for forming the third resin layer contains 1-7 parts by weight of a capsule foaming agent based on 100 parts by weight of a polyvinyl chloride resin,
A method for producing a printed layer-free foamed wallpaper with a thermal conductivity of less than 100 mW/m·k and no fold marks on the wallpaper. delete 13. The method of claim 12,
The method for manufacturing a wallpaper, wherein the wallpaper has a thermal conductivity of 80 mW/m·k or less. delete 13. The method of claim 12,
The method for manufacturing the wallpaper, wherein the wallpaper has a basis weight of 380-450 g/m ^{2 .} 13. The method of claim 12,
The composition for forming the first resin layer comprises 3.5-10 parts by weight of a chemical foaming agent, 0.5-5 parts by weight of a capsule foaming agent, and 50-100 parts by weight of a plasticizer based on 100 parts by weight of a polyvinyl chloride resin. . 13. The method of claim 12,
The method for manufacturing a wallpaper, wherein the composition for forming the second resin layer contains 5-20 parts by weight of glass bubbles based on 100 parts by weight of polyvinyl chloride resin. 19. The method of claim 18,
The composition for forming the second resin layer further comprises 2-8 parts by weight of a chemical foaming agent. 19. The method of claim 18,
The composition for forming the second resin layer further comprises 1-5 parts by weight of each of a chemical foaming agent and a capsule foaming agent. delete 13. The method of claim 12,
The method for manufacturing a wallpaper wherein the composition for forming the first resin layer is applied in a circular pattern through a rotary screen coating method. 13. The method of claim 12,
The method for manufacturing a wallpaper wherein the composition for forming the third resin layer is partially applied on the second resin layer through a rotary screen coating method.

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