RU2315144C1 - Method for manufacture of wallpaper and wallpaper manufactured by method - Google Patents

Abstract

FIELD: wallpaper manufacture.

SUBSTANCE: method involves applying foamed paint based on aqueous polymeric acryl dispersion onto base paper or non-woven material, preferably flizeline; exposing resulted material to thermal processing at temperature of 120-165 C; before applying onto fibrous base, additionally introducing 48-50%-aqueous composition containing alkyl methacrylate, butylacrylate, styrene, methacrylic acid, and polyethylene wax emulsion, said aqueous composition being used in an amount of 3-4% by weight of paint; providing application procedure with weight of dry coating of 12-50 g/m²; before applying of foamed paint onto fibrous base, forming printed pattern. Also, wallpaper produced by said method is described.

EFFECT: increased moisture resistance of decorative acrylic foam wall papers, wider range of wallpapers having increased resistance to wet wiping procedures.

4 cl, 1 tbl, 4 ex

Description

The invention relates to the production of wallpapers and relates to a method for manufacturing wallpapers using foams, as well as wallpapers made by this method.

Currently, in the wallpaper industry, much attention is paid to the development of wallpapers with improved decorative properties and the expansion of the range of these products due to increased demand.

The use of foam paints makes it possible to obtain wallpapers with highly decorative properties due to the use of blowing agents in the composition of paints, which make it possible to obtain a significant increase in the height of the coating level as a result of heat treatment of the canvas.

Thus, using foams, relief structures are obtained on paper and non-woven materials, which are considered as decorative decoration of wallpaper.

The following types of embossed wallpaper obtained using foam are known:

vinyl foam wallpaper and

acrylic foam wallpaper with foam acrylic coatings.

An example of a method for producing vinyl foamed wallpaper is a method for making wallpaper by applying a foam paint to a base paper consisting of plastisols based on polyvinyl chloride (PVC), a plasticizer and a blowing agent (see DE 2625051 B2, published 07.12.1978).

Dioxyl phthalate, diisooxyl phthalate or dibutyl phthalate are used as a plasticizer, and azodicarbonamide is a blowing agent.

The known method has the following negative features:

- the composition of the foam contains chlorine-containing organic compounds and plasticizers;

- the composition of the foam makes it necessary to install in the production of vinyl foamed wallpaper an expensive system of afterburning ventilation emissions from the drying channel.

Accordingly, the methods for producing foamed wallpaper based on acrylic do not have these negative features.

A known method of manufacturing wallpaper by applying foam paper to a base paper in the form of a water-polymer dispersion of the brand Folco-Alcantoresraum FQ 5608 containing microcapsules and subsequent heat treatment of the coated material at a temperature of 120-150 ° C (see RU 2259434, D21H 27/20 B2, publ. August 27, 2005).

In this case, acrylic foam is applied to the surface of the paper by intaglio printing using a shaft, in which 40% of the engraving area has a lineature of 30 lines / cm and a screening depth of 68 μm, and 60% of the area is a lineature of 40 lines / cm and a screening depth of 57 μm.

Embossed acrylic wallpaper obtained in a known manner, have an elastic and transparent coating with a decorative effect "suede".

This effect is obtained by applying an acrylic coating with two levels.

The closest analogue of the proposed method for making wallpapers is a method for making wallpapers by applying high-temperature foam in the form of a water-polymer acrylic dispersion onto the fibrous base and subsequent heat treatment of the resulting material at a temperature of 120-165 ° C (see US, 5360826 A, publ. 01.11.1994).

In the known method using 40-70% aqueous composition containing the following components (dry, in wt.%):

acrylic copolymer  30-90 blowing agent  1.0-8.0 mineral pigment  2.0-30 rheological modifier  0.001-2.0

In this case, a copolymer obtained by copolymerizing an ethylenically unsaturated carboxylic acid selected from the group consisting of acrylic acid, methacrylic acid, crotonic acid, fumaric acid or a mixture thereof, and a monoethylenically unsaturated monomer selected from the group consisting of ethylene, butadiene, butyl methacrylate is used as an acrylic copolymer. , butyl methacrylate, methacryamide or a mixture thereof.

The acrylic copolymer used in the known method comprises from 0.1 to 10 wt.% Of the first monomer (ethylenically unsaturated carboxylic acid) and from 90.0 to 99.9 wt.% Of the second monomer (monoethylenically unsaturated monomer) and may be a mixture of polymers with a molecular weight of 20,000 to 500,000

As a blowing agent in the known method using microcapsules with a shell of a thermoplastic resin, for example, based on acrylate monomer.

During the heat treatment of the material coated in a known manner, the maximum possible expansion of the microcapsules occurs. As a result of this, as well as a greater mass of dry coating, a greater height of the coating level is achieved and the pattern looks highly relief.

However, the obtained moisture-resistant coating has insufficient moisture resistance. The degree of moisture resistance is determined by the requirements of consumers and is regulated by GOST 6810-2002 ("Wallpaper. Technical conditions"), and the higher the resistance of the outer surface of the wallpaper to a humid environment, the better their operational properties are considered among consumers. Existing foam acrylic paints based on acrylate latexes allow to obtain indicators of resistance to wet abrasion on wallpaper at the level of "VO" according to the specified GOST 6810-2002.

A new technical result from the use of the present invention is to increase the moisture resistance of decorative acrylic foamed wallpaper while expanding the range of wallpapers due to giving them the effect of increased resistance to wet abrasion (moisture resistance) at the level of M-2 GOST 6810-2002.

This technical result is achieved by the fact that in the proposed method for the manufacture of wallpaper by applying a high-temperature foam paint in the form of a water-polymer acrylic dispersion onto the fibrous base and subsequent heat treatment of the obtained material at a temperature of 120-165 ° C, 48-50% is additionally added to the base paint before application -a water composition based on acrylic dispersion of the following composition (dry. in wt.%):

alkyl methacrylates 57-76 butyl acrylate 5-10 styrene 16-23 methacrylate ethylene glycol 1-5 methacrylic acid 0.5-2.5 polyethylene wax emulsion 0.5-3.5

while the application is carried out with a coating weight of 12-50 g / m ² and the specified composition is taken in an amount of 3-4% by weight of the foam.

In the proposed method, paper or non-woven material, mainly non-woven, is used as the fibrous base, and a printed drawing is applied to the fibrous base before applying the foam.

Alkyl methacrylates used in the 48-50% aqueous composition are a mixture of the product “Alkyl methacrylates (C ₁₂ -C ₁₈ )”, manufactured according to TU 2435-198-05757593-2001, and technical methyl methacrylate, produced according to GOST 20370-74 “Ether methyl methacrylic acid ”at a ratio of 1: 0.21 to 1: 0.40, respectively.

At the same time, wallpapers made by the proposed method have an acrylic foam coating and have a high level of moisture resistance - 100 or more wet abrasions with the presence of detergent according to the method of GOST 6810-2002, Table 2, page 3.

Foaming is applied to the fibrous base with a rasterized intaglio roll, and foaming is carried out within 30-60 seconds.

In the proposed method, as a foam, use a 50-70% dispersion printing acrylic ink with a foaming effect, obtained from the following components (wt.%):

polyvinyl acetate  50-70 titanium oxide  1.0-8.0 thermal microcapsules  2-9 acrylic polymers  10-15 polyurethanes  1-7 dolomites  8.0-14.6 disinfectants  0.1-0.5 propylene glycol  0.5-2.5 cellulose  0.1-0.7

Thermo microcapsules are used as a blowing agent in the proposed method, and a wax emulsion manufactured by Lubrizol, Germany, Aquaslip TM-671 brand, can be used as an emulsion of polyethylene wax.

The authors of the present invention it was found that the addition of 3-4% (by weight of the foam) of the aforementioned aqueous composition based on an acrylic dispersion containing an emulsion of polyethylene wax to the composition of the foam leads to a significant increase in the moisture resistance of the resulting wallpaper.

The achieved effect is ensured by the fact that during the heat treatment (t = 140-165 ° C) of the obtained material, along with the process of expanding the microcapsules and obtaining the expanded surface of the material, a parallel process of wax melting and its emergence and distribution on the outer surface of the foam coating is carried out. The melting of the wax is carried out at a temperature of 120-125 ° C, which explains the possibility of using in the proposed method only high-temperature foam, that is, a foam containing a foaming agent operating at a temperature> 120 ° C.

The invention is illustrated by the following examples of its implementation.

Example 1. For the manufacture of wallpaper using wallpaper paper for intaglio printing weighing 120 g / m ² and a smoothness of 130 ° C.

The paper is sent to an intaglio printing machine, additionally equipped with a tunnel for heat treatment at a temperature of 120-165 ° C.

In the first four printing sections, a printed pattern is applied to the paper.

In the fifth section, foamed paper is applied to the sealed paper in the form of a water-polymer dispersion of the brand Folco-Foamcoat FQ-3135, containing 50% aqueous composition based on acrylic dispersion in an amount of 4% (by weight of the foam) of the following composition (dry. In wt.%) :

C ₁₂ -C ₁₈ alkyl methacrylates  57 butyl methacrylate  10 styrene  23 methacrylate ethylene glycol  5 methacrylic acid  2,5 polyethylene wax emulsion  2,5

Moreover, alkyl acrylates are a mixture of the product “Alkyl methacrylates (C ₁₂ -C ₁₈ )” and technical methacrylate with a ratio of 1: 0.31, respectively.

Foam application is carried out with a dry coating weight of 20 g / m ² .

The applied foam coating with the 48% aqueous composition based on an acrylic dispersion of the above composition introduced into it is sent to a special drying channel in which it is subjected to heat treatment at a temperature of 120 ° C, where the microthermocapsules expand, the wax melts and sublimates, and the modifying foam foams composition by composition based on acrylic dispersion and obtaining a sealed surface of the wallpaper with a wax film distributed on it.

The resulting wallpaper is subjected to tests, determining their moisture resistance. The indicator is presented in table 1.

Example 2. The method is carried out analogously to example 1, but non-woven material is used as the fibrous base - non-woven material weighing 60 g / m ² , density 0.38 g / cm ³ . Use a 50% aqueous composition based on acrylic dispersion of the following composition (in wt.%):

C ₁₂ -C ₁₈ alkyl methacrylates  76 butyl acrylate  5 styrene  16 methyl acrylate ethylene glycol  one methacrylic acid  1,5 polyethylene wax emulsion  0.5.

At the same time, alkyl methacrylates are a mixture of the product "Alkyl methacrylates (C ₁₂ -C ₁₈ )" and technical methacrylate with a ratio of 1: 0.20, respectively.

The application of the acrylic composition is carried out with a dry coating weight of 50 g / m ^{2 by} screen printing. Heat treatment is carried out at a temperature of 165 ° C.

The resulting wallpaper is subjected to tests, determining their moisture resistance. The indicator is presented in table 1.

Example 3. The method is carried out analogously to example 1, but as a fibrous base use non-woven material - non-woven mass of 50 g / m ² and a density of 0.30 g / cm ³ .

The application of the acrylic composition is carried out with a dry coating weight of 12 g / m ² .

Use a 49% aqueous composition based on acrylic dispersion in an amount of 3% (by weight of the foam) of the following composition (in wt.%):

C ₁₂ -C ₁₈ alkyl methacrylates  68 butyl acrylate  7 styrene  eighteen methacrylate ethylene glycol  3 methacrylic acid  0.5 polyethylene wax emulsion  3,5

At the same time, alkyl methacrylates are a mixture of the product “Alkyl methacrylates (C ₁₂ -C ₁₈ ) and technical methacrylate with a ratio of 1: 0.4, respectively.

The application of the acrylic composition is carried out with a mass of dry coating by screen printing.

The resulting wallpaper is subjected to tests, determining their moisture resistance. The indicator is presented in table 1.

Example 4 (control). For the manufacture of wallpaper using wallpaper paper for gravure printing weighing 120 g / m ² and a smoothness of 130 ° C.

The paper is sent to an intaglio printing machine.

In the first four printing sections, a printed pattern is applied to the paper.

Foam in the form of a water-polymer dispersion of the brand Folco Foamcoat FQ-3135 of the company "Folman" Germany is applied to the printed paper on the printed section.

Foam application is carried out with a dry coating weight of 20 g / m ² , and the web is dried by heat treatment at a temperature of> 120 ° C.

The resulting wallpaper is subjected to tests, determining their moisture resistance. The indicator is presented in table 1.

Analysis of the obtained data shows that the wallpaper obtained by the proposed method (example 1-3) has a significantly greater moisture resistance - 120-150 wet abrasions than wallpaper according to the prototype method — no more than 15 wet abrasions.

Thus, the decorative acrylic foam wallpaper made by the proposed method, having increased resistance to wet abrasion (increased moisture resistance), is a type of moisture-resistant wallpaper at the level of M-2 GOST 6810-2002.

Table 1. No. n / a example Foam FQ3153 Concentrate, additive in foam based on acrylic dispersion,% The mass of wallpaper paper, g / m ² Additive weight by weight of foam,% Dry coating weight, g / m ² Moisture resistance (number of wet abrasions) one Folco-Foamcoat FQ3153 fifty 120 four twenty 130 2 Folco-Foamcoat FQ3153 fifty nonwoven mass 60 four fifty 150 3 Folco-Foamcoat FQ3153 49 nonwoven mass 50 3 12 120 5 Folco-Foamcoat FQ3153 - 120 - twenty no more than 15

Claims (4)

1. A method of manufacturing wallpaper by applying a high-temperature foam paint to a fibrous base in the form of a water-polymer acrylic dispersion and subsequent heat treatment of the resulting material at a temperature of 120-165 ° C, characterized in that 48-50% are additionally introduced into the foam before applying to the base: aqueous composition based on an acrylic dispersion of the following composition (dry. in wt.%): alkyl methacrylates 57-76 butyl acrylate 5-10 styrene 16-23 methacrylate ethylene glycol 1-5 methacrylic acid 0.5-2.5 polyethylene wax emulsion 0.5-3.5 in the amount of 3-4% by weight of the foam, while the application is carried out with a dry coating weight of 12-50 g / m ² . 2. The method according to claim 1, characterized in that as the fibrous base use paper or non-woven material. 3. The method according to claim 1, characterized in that before applying the foam, a printed pattern is applied to the base. 4. Wallpaper, characterized in that they are made by the method according to claim 1.