JP2018145621A - wallpaper - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide wallpaper in which paper is used as a base material, and which is composed of a foamed resin layer that is foamed and a patterned printing layer laminated on the base material, and which does not easily expand or shrink due to absorption of water.SOLUTION: Wallpaper comprises a paper base material 1, a foamed resin layer 2, a pattern printed layer 3 and a surface protective layer 4 which are laminated in this order, in which mixed paper containing hydrophobic synthetic fibers and natural pulp is used as the paper base material 1, and the surface protective layer 4 contains acrylic resin as a main component. Since synthetic fibers are poor in stretchability due to water absorption, even when an aqueous adhesive permeates the paper base material, it prevents its elongation. Since the surface protective layer 4 contains acrylic resin as a main component, expansion and contraction due to water absorption is small.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a wallpaper, and relates to a wallpaper in which paper is used as a base material and a foamed resin layer and a pattern printing layer are laminated on the base material.

  Traditionally, wallpaper has used soft vinyl chloride resin sheets as a base material, but soft vinyl chloride resin has generated concerns over the environment and safety, such as the generation of chlorine-based compounds upon combustion. Wallpapers based on paper instead of resin sheets have become widespread.

  Thus, wallpaper based on paper is well known. For example, Patent Document 1 describes a wallpaper in which a foamed resin layer and a pattern printing layer are laminated on a paper base material. The foamed resin layer has a role of improving decorativeness by absorbing and reducing unevenness of the underlying wall and the like when a wallpaper is applied to the wall or the like of the house. Further, the foamed resin layer also has a role of enhancing the unevenness due to the embossing when the wallpaper is embossed.

JP 2007-196590 A

  By the way, the wallpaper is generally applied by applying an aqueous adhesive (glue) and adhering it to a wall or the like with this aqueous adhesive. For this reason, in the wallpaper which uses paper as a base material, it constructs in the state which the said water-based adhesive osmose | permeated inside the paper base material. Since the paper base material is stretched by water absorption, the paper base material that has absorbed moisture in the water-based adhesive is bonded to a wall or the like in a stretched state.

  However, since the wallpaper stretched by absorbing water shrinks as it dries with time, there is a problem that, for example, a gap may be formed at the joint between the wallpaper and the wallpaper.

  Therefore, an object of the present invention is to provide a wallpaper that uses paper as a base material and is less likely to expand and contract due to water absorption.

That is, the invention according to claim 1 is a wallpaper in which a paper base material, a foamed resin layer, a pattern printing layer, and a surface protective layer are laminated in this order,
The wallpaper is characterized in that the paper base is made of a mixed paper containing hydrophobic synthetic fibers and natural pulp, and the surface protective layer is mainly composed of an acrylic resin.

  Next, the invention according to claim 2 is the wallpaper according to claim 1, wherein the weight of the synthetic fiber in the mixed paper is 50% or more of the weight of the natural pulp.

Next, the invention according to claim 3 is the wallpaper according to claim 1 or 2, wherein the basis weight of the mixed paper is 50 to 100 g / m ² .

  Next, the invention according to claim 4 is the wallpaper according to any one of claims 1 to 3, wherein the mixed paper has a thickness of 100 to 200 μm.

  Next, the invention according to claim 5 is the wallpaper according to any one of claims 1 to 4, wherein the surface protective layer is water repellent.

Next, the invention according to claim 6 is the wallpaper according to any one of claims 1 to 5, wherein the surface protective layer has a basis weight of 10 to 40 g / m ² .

  Next, the invention according to claim 7 is the wallpaper according to any one of claims 1 to 6, wherein the surface protective layer contains a filler.

  Next, the invention according to claim 8 is the wallpaper according to any one of claims 1 to 7, wherein embossing is performed from the surface protective layer side.

Next, the invention according to claim 9 is configured such that the foamed resin layer is formed by foaming a foamable resin composition containing an aqueous emulsion resin, an inorganic filler and a foaming agent at a foaming ratio of 4 times or more. The basis weight is 50 to 150 g / m ² , and the wallpaper according to claim 1.

  Next, in the invention described in claim 10, the foamed resin layer is within a range of 50 to 150 parts by weight of the inorganic filler with respect to 100 parts by weight of the aqueous emulsion resin, and 1 to 20 parts by weight of the foaming agent. It is contained within the range below a mass part, It is a wallpaper of Claim 9 characterized by the above-mentioned.

  The wallpaper of the present invention uses a mixed paper containing a hydrophobic synthetic fiber and natural pulp as a base material, and since it contains natural pulp, a normal aqueous adhesive can be infiltrated and used. Can be attached to a wall. In addition, since the paper base material includes synthetic fibers, and the synthetic fibers have poor stretchability due to water absorption, even when the aqueous adhesive penetrates into the paper base material, the extension is prevented. In addition to this, the wallpaper has a surface protective layer mainly composed of an acrylic resin on the pattern printing layer, so that the wallpaper is less stretched by penetration into the aqueous adhesive (glue). And since there is little expansion | extension at the time of construction in this way, even if it dries after construction, there is little contraction and it can prevent generating a gap in the joint between wallpaper etc.

FIG. 1 is a schematic cross-sectional view showing an example of a cross-sectional shape of a specific example of the wallpaper of the present invention.

Below, with reference to drawings, the specific example of the wallpaper of this invention is demonstrated. As shown in FIG. 1, the wallpaper 10 is obtained by laminating a paper substrate 1, a foamed resin layer 2, a pattern printing layer 3, and a surface protective layer 4 in this order. The wallpaper 10 is provided with an embossed pattern 5 from the surface protective layer 4 side. In addition, it is desirable that the total basis weight of the wallpaper 1 is 200 g / m ² or less from the viewpoint of imparting fireproof performance.

[Paper base]
The paper substrate 1 is a so-called wallpaper backing paper (fibrous sheet). In the present invention, the paper base 1 needs to be composed of a mixed paper containing synthetic fibers and natural pulp.

The synthetic fiber has a role of preventing the paper substrate 1 from stretching due to water absorption and shrinking due to drying. For this reason, the synthetic fiber needs to be hydrophobic. For the same reason, it is desirable that the weight of the synthetic fiber occupies 50% or more of the weight of the natural pulp. For example, a paper obtained by mixing natural fiber pulp and hydrophobic synthetic fiber in a mass ratio of 2 to 3: 1. In addition, as such a hydrophobic synthetic fiber, the synthetic fiber which uses a polyester or an acrylic resin as a raw material can be used.

  Moreover, natural pulp has a function of ensuring adhesiveness with a wall or the like by penetrating a water-based adhesive (glue) when it is applied to a wall or the like. Natural pulp may be pulp made from hardwood or softwood.

In addition, the rigidity calculated | required as a wall covering is ensured by making the paper base material 1 into the range of 50-100 g / m < ² > of basic weights, and the thickness of 100-200 micrometers.

[Foamed resin layer]
The foamed resin layer 2 can be formed by applying a foaming agent-containing resin composition containing a foaming agent and then heating and foaming the foaming agent contained in the resin composition. The foaming agent-containing resin composition can be produced by mixing an aqueous emulsion resin, an inorganic filler, and a foaming agent. In addition, other additives can be added to the foaming agent-containing resin composition. For example, a colorant.

  As the aqueous emulsion-based resin, a resin that can be used in the form of an aqueous emulsion, for example, a polyolefin-based resin can be used, and at least one ethylene copolymer having ethylene and a component other than ethylene as a monomer is more preferable. .

  In addition, as the foaming agent contained in the foaming agent-containing resin layer, a foaming agent that is commonly used for foamed wallpaper can be used. , Strength). In addition, azo, hydrazide, nitroso, etc. can be used.

  The amount of the foaming agent added depends on the thickness of the foamed resin layer 2 (foaming agent-containing resin layer) and the foaming ratio (volume expansion coefficient before and after foaming), for example, 1 mass per 100 parts by mass of the resin. Part to 20 parts by mass, preferably about 5 parts to 15 parts by mass.

In addition, by making the basis weight and expansion ratio of the foamed resin layer 2 (foaming agent-containing resin layer) a basis weight of 50 g / m ² or more and 150 g / m ² or less and 4 times or more, sufficient volume feeling can be obtained. In addition to having an excellent surface strength, it is possible to sharply reproduce the uneven shape of the surface by embossing described later.

  Examples of the inorganic filler contained in the foamed resin layer 2 include calcium carbonate, aluminum hydroxide, magnesium hydroxide, silica sand, talc, silicas, magnesium silicate, zinc borate, and titanium dioxide. The inorganic powder is added in an amount of 50 to 150 parts by mass with respect to 100 parts by mass of the resin.

  The foaming agent-containing resin composition produced by mixing the aqueous emulsion resin, the inorganic filler and the foaming agent in this manner can be applied in the form of a paste. As the coating method, for example, a knife coating method, a nozzle coating method, a die coating method, a lip coating method, a comma coating method, a gravure coating method, a rotary screen coating method, a reverse roll coating method, or the like can be used. And it can be made to foam by heating following this coating.

[Picture printing layer 3]
The pattern print layer 3 imparts design properties to the foamed wallpaper 10. The pattern print layer 3 can be formed, for example, by printing a pattern on the surface of the foamed resin layer 2 (foaming agent-containing resin layer). The thickness of the pattern print layer 3 is different from the type of the pattern, but is generally preferably about 0.1 μm to 10 μm.

  Examples of the design pattern include a wood grain pattern, a stone pattern, a grain pattern, a tiled pattern, a brickwork pattern, a cloth pattern, a leather pattern, a geometric figure, a character, a symbol, and an abstract pattern. The pattern can be selected according to the purpose.

  In the present embodiment, the pattern printing layer 3 uses a printing ink (non-foaming ink) and / or a foaming ink whose main component is an aqueous emulsion resin, a foaming ink whose main component is a vinyl chloride paste resin, or the like. Then, it is formed by a gravure printing method, a screen printing method, a flexographic printing method, an ink jet printing method, or the like. In addition to the printing ink, for example, a printing ink containing a colorant, a binder resin, and a solvent can be used. These inks may be known or commercially available.

  As the colorant, for example, a pigment can be appropriately used. The pigment includes an inorganic pigment and an organic pigment. Inorganic pigments include, for example, titanium oxide, zinc white, carbon black, black iron oxide, yellow iron oxide, yellow lead, molybdate orange, cadmium yellow, nickel titanium yellow, chrome titanium yellow, iron oxide (valve), and cadmium. Examples thereof include red, ultramarine blue, bitumen, cobalt blue, chromium oxide, cobalt green, aluminum powder, bronze powder, titanium mica, and zinc sulfide. Examples of the organic pigment include aniline black, perylene black, azo (azo lake, insoluble azo, condensed azo), polycyclic (isoindolinone, isoindoline, quinophthalone, perinone, flavantron, anthrapyrimidine, anthraquinone, Quinacridone, perylene, diketopyrrolopyrrole, dibromoanthanthrone, dioxazine, thioindigo, phthalocyanine, indanthrone, halogenated phthalocyanine). The content of the colorant is preferably about 10 to 50 parts by mass, more preferably about 15 to 30 parts by mass with respect to 100 parts by mass of the resin.

  Further, when the foamed resin layer 2 serves as a solid layer for the pattern print layer 3 or when the foamed resin layer 2 is applied in a pattern pattern, the foamed resin layer 2 may also contain a colorant. good.

  Examples of the solvent (or dispersion medium) include petroleum organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and acetic acid-2 -Ester-based organic solvents such as ethoxyethyl; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, propylene glycol; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone Organic solvents; ether organic solvents such as diethyl ether, dioxane, tetrahydrofuran; dichloromethane, carbon tetrachloride, trichloroethylene, tetrachloroethylene, etc. Chlorinated organic solvents; water, and the like. These solvents (or dispersion media) can be used alone or in the form of a mixture.

[Surface protective layer]
The surface protective layer 4 is formed on the surface of the pattern printing layer 3 with the intention of adjusting the gloss and protecting the pattern printing layer 3. In addition to this, when a water-based adhesive (glue) is applied at the time of construction, it has a function of preventing the expansion of wallpaper and the shrinkage due to drying. In order to exhibit such a function, the surface protective layer 4 needs to be mainly composed of an acrylic resin. In addition to the acrylic resin, a filler can be added to the surface protective layer 4 for gloss adjustment. The surface protective layer 4 desirably has water repellency.

  As the acrylic resin, a thermoplastic acrylic resin, an ultraviolet curable acrylic resin, an electron beam curable acrylic resin, or the like can be used. As the filler, for example, inorganic particles such as silica particles, alumina (such as α-alumina), calcium carbonate, barium sulfate, kaolinite, and aluminosilicate, or organic particles such as polycarbonate, nylon, and urethane resin may be used. it can.

The surface protective layer 4 can be formed by mixing the acrylic resin or a filler with the acrylic resin to form a paint, applying the paint to a foaming agent-containing resin layer before foaming, and drying by heating. Moreover, what is necessary is just to irradiate with an ultraviolet-ray or an electron beam after this application | coating as needed. As a coating method, a gravure printing method, a knife coating method, a nozzle coating method, a die coating method, a lip coating method, a comma coating method, or the like can be used. In addition, when the adhesiveness of the pattern printing layer 3 and the surface protection layer 4 is not fully acquired, the surface protection layer 4 can also be provided after carrying out the adhesion process (primer process) of the surface of the pattern printing layer 3 easily. . The basis weight after drying of the surface protective layer 4 is preferably 10 g / m ² or more and 40 g / m ² or less, preferably 15 g / m ² or more and 30 g / m ² or less.

[wallpaper]
As described above, the wallpaper 10 sequentially coats or prints the foaming agent-containing resin layer, the pattern printing layer 3 and the surface protective layer 4 on the paper substrate 1, and then heat-foams the foaming agent-containing resin layer. It is possible to manufacture by forming the foamed resin layer 2. Moreover, the wallpaper 10 which has the embossed pattern 5 like FIG. 1 can be manufactured by embossing from the surface protective layer 4 side simultaneously with heat foaming or immediately after heat foaming.

  The embossed pattern 5 is possible, for example, by passing the foamed wallpaper 10 between an embossing roll having a recess having a depth of 15 μm or more and a rubber back roll having a hardness of 50 degrees or more and less than 90 degrees. Examples of the embossed pattern 5 include a wood grain board conduit groove, a stone board surface irregularity, a cloth surface texture, a satin texture, a grain, a hairline, and a multiline groove. Even if both are patterns, it is desirable that the pattern is synchronized with the pattern printing layer 3.

  In addition, as a method of forming an uneven shape (embossed pattern 5) on the surface of the surface protective layer 4, there are other methods such as a method of partially foaming with a foam suppression ink, or a chemical of partially heating and foaming with hot air or infrared rays. Although there is an embossing method, mechanical embossing by pressure welding with an embossing roll is particularly preferable because sharp unevenness can be obtained with respect to the foamed resin layer 2 and the like. In the present embodiment, in order to enhance the gas retention of the surface protective layer 4, the embossing pressure is desirably 9800 N / m or more and 24500 N / m or less, preferably 14700 N / m or more and 19600 N / m or less. . By setting the pressure within the range, the surface strength can be further increased.

  Moreover, it is desirable to maintain the surface temperature of the foamed wallpaper 10 immediately before the contact of the embossed plate in the embossing process at 160 ° C. or higher and 200 ° C. or lower, preferably 170 ° C. or higher and 180 ° C. or lower.

(Example)
As the paper base 1, a mixed paper obtained by mixing natural pulp and hydrophobic synthetic fibers at a mass ratio of 2 to 3: 1 was used. The basis weight is 85 g / m ² .

80 parts by mass of ethylene-vinyl acetate copolymer (“S-7400 (HQ)” manufactured by Sumika Chemtex Co., Ltd.) A mixture of ethylene-vinyl acetate copolymer and acrylic (manufactured by Japan Coating Resin Co., Ltd.) "FK-715") 20 parts by mass, thermally expandable microcapsule foaming agent ("FT-16" manufactured by Matsumoto Yushi Seiyaku Co., Ltd.) 12.2 parts by mass, calcium carbonate powder ("MC manufactured by Asahi Mineral Co., Ltd.") −100 ”) 90 parts by mass were mixed to produce a paste-like foaming agent-containing resin, which was applied onto the paper substrate 1 to form a foaming agent-containing resin layer. The basis weight of the foaming agent-containing resin layer after drying is 100 g / m ² .

Next, using the printing ink which uses acrylic resin as a resin component, it printed on the foaming agent containing resin layer by the gravure printing method, and the pattern printing layer 3 was formed. The basis weight of the pattern printing layer 3 is 2 g / m ² .

Next, the surface protective layer 4 was formed by using a paint mainly composed of an acrylic resin and applying the paint on the picture print layer 3 by a lip coat method. The basis weight of the surface protective layer 4 after drying is 20 g / m ² .

  And the foaming agent containing resin layer was foamed by heating at the end, the foamed resin layer 2 was formed, and it embossed with the embossing roll immediately after that, and the embossed pattern 5 was formed.

(Comparative Example 1)
As the paper substrate 1, a paper (basis weight: 85 g / m ² ) containing only natural pulp as a pulp component and not containing a synthetic fiber was used, and a wallpaper was produced without forming the surface protective layer 4. Others are the same as the embodiment.

(Comparative Example 2)
A wallpaper was manufactured using paper (basis weight: 85 g / m ² ) containing only natural pulp as a pulp component and not containing synthetic fibers as the paper substrate 1. Others are the same as the embodiment.

(Evaluation)
About the wallpaper of an Example and Comparative Examples 1 and 2, the stretchability when immersed in water was evaluated. This evaluation result can be used as a measure of the shrinkage rate when the wallpaper is naturally dried after being applied with a water-based adhesive (glue).

  That is, a sample of 32 cm square was prepared from the wallpaper of Example and Comparative Examples 1 and 2, and a straight line of 30 mm in length and width was drawn on each sample.

  Each sample was immersed in water for 1 minute, stored without drying, and allowed to dry naturally. The length L of the straight line was measured at each storage time of 5 minutes, 10 minutes, 30 minutes, 60 minutes, and 120 minutes.

Then, of the length L thus measured, the longest measured value was Lmax and the shortest measured value was Lmin, and the stretchability was evaluated by the underwater stretch rate (%) calculated by the following formula.
Underwater expansion / contraction rate (%) = (Lmax−Lmin) / Lmax × 100%
The results are shown in Table 1. In the table, “◯” means that the wallpaper has excellent non-stretchability, and “x” indicates that there is not sufficient non-stretchability.

  As a result, the example in which the mixed paper was used as the paper base material 1 was longer than the comparative examples 1 and 2 in which the paper base material of 100% natural pulp was used. It can be understood that there is almost no change in the length and it is difficult to expand and contract. In comparison between Comparative Example 1 and Comparative Example 2, not only the material of the paper base material 1 but also the presence or absence of the surface protective layer 4 of the acrylic resin is greatly related to the magnitude of the stretchability. Understandable.

1: Paper base material 2: Foamed resin layer 3: Picture printing layer 4: Surface protective layer 5: Embossed pattern 10: Wallpaper

Claims (10)

In wallpaper in which a paper base material, foamed resin layer, pattern printing layer and surface protective layer are laminated in this order,
A wallpaper, wherein the paper base is made of mixed paper containing hydrophobic synthetic fibers and natural pulp, and the surface protective layer is mainly composed of an acrylic resin.   The wallpaper according to claim 1, wherein the weight of the synthetic fiber is 50% or more of the weight of natural pulp. Wallpaper as claimed in claim 1 or 2 basis weight of the composite paper is characterized in that it is a 50 to 100 g / ^{m 2.}   The wallpaper according to claim 1, wherein the mixed paper has a thickness of 100 to 200 μm.   The wallpaper according to any one of claims 1 to 4, wherein the surface protective layer is water repellent. The wallpaper according to claim 1, wherein the surface protective layer has a basis weight of 10 to 40 g / m ² .   The wallpaper according to claim 1, wherein the surface protective layer contains a filler.   The wallpaper according to any one of claims 1 to 7, wherein embossing is performed from the surface protective layer side. The foamed resin layer is formed by foaming a foamable resin composition containing an aqueous emulsion resin, an inorganic filler and a foaming agent at a foaming ratio of 4 or more, and the basis weight thereof is 50 to 150 g / m ^2. The wallpaper according to claim 1, wherein the wallpaper is one of the following.   The foamed resin layer contains an inorganic filler in the range of 50 to 150 parts by mass and the foaming agent in the range of 1 to 20 parts by mass with respect to 100 parts by mass of the aqueous emulsion resin. The wallpaper according to claim 9.

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