Wallpaper

Abstract

To provide wallpaper which prevents occurrence of puncture regardless of a wallpaper manufacturing method, and can impart uniform water repellency to the surface.SOLUTION: Wallpaper has a base material layer 10, a base layer 20 on the base material layer 10, and a pattern layer 30 on the base layer 20, wherein the base layer 20 and the pattern layer 30 are layers containing a vinyl chloride resin and a functional material.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to wallpaper with functionality. [Background technology]

[0002] One type of wallpaper used as an interior material for buildings is one that has a base layer and a pattern layer laminated on a substrate layer. Wallpapers that have a functional layer provided on the entire surface of the wallpaper are also known, imparting functionality such as water repellency and stain resistance to the surface. Furthermore, wallpapers that have unevenness on the surface due to foaming or embossing for design purposes are also known. As a method for producing wallpaper having a surface that is functional and has an uneven shape, for example, the methods described in Patent Documents 1 and 2 are known.

[0003] Patent Document 1 describes wallpaper and a method for manufacturing the wallpaper, which comprises embossing the surface of foam wallpaper having a foam layer and a pattern layer provided on a base, and then applying a surface modifier to the entire embossed surface to form a functional layer. Patent Document 2 describes a method for producing wallpaper in which a paste-like vinyl chloride resin composition containing a thermally decomposable foaming agent is applied to the surface of a substrate by rotary screen printing, followed by heating and drying at a temperature below the thermal decomposition temperature of the foaming agent, and then an aqueous urethane resin composition is applied thereon and heated and dried at a temperature below the thermal decomposition temperature of the foaming agent to form a functional layer, followed by heating to a temperature above the thermal decomposition temperature of the foaming agent to foam the thermally decomposable foaming agent, and then embossing to create a textured finish. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2001-170552 [Patent Document 2] Japanese Patent Application Laid-Open No. 2011-162909 Summary of the Invention [Problem to be solved by the invention]

[0005] As described above, methods described in Patent Documents 1 and 2 are known as methods for providing functional layers such as a water-repellent layer and a stain-resistant layer over the entire surface of wallpaper. However, the conventional method has the following problems. That is, when forming a functional layer by applying a functional layer-forming composition by rotary screen printing after applying a textured finish to the wallpaper surface, as in the method described in Patent Document 1, the printed surface of the paste-like vinyl chloride resin composition has texture, so the functional layer-forming composition is not sufficiently applied to the recesses, making it difficult to form a uniform functional layer. In this case, application by a roll coater or spray coater is also possible, but the amount of application is large, which poses a cost issue.

[0006] Furthermore, in a method such as that described in Patent Document 2, in which a functional layer is formed on the surface of wallpaper and then unevenness is formed by foaming or embossing, depending on the composition of the paint (composition for forming the functional layer), air bubbles generated in the vinyl chloride resin layer (layer formed from the vinyl chloride resin composition) during embossing may be difficult to remove, resulting in horseshoe-shaped punctures and problems with appearance and quality. Therefore, there is a demand for wallpaper that can prevent punctures and impart uniform functionality to the surface, regardless of the wallpaper manufacturing method.

[0007] The present invention has been made in consideration of the problems and current circumstances of the prior art described above, and aims to provide wallpaper that prevents the occurrence of punctures and makes it possible to impart uniform water repellency to the surface, regardless of the wallpaper manufacturing method. [Means for solving the problem]

[0008] In order to solve the above problems, the present inventors have conducted extensive research into wallpaper in which a base layer and a pattern layer are laminated on a substrate layer, and in which functionality such as water repellency and stain resistance is imparted to the surface of the wallpaper. As a result, they have found that wallpaper in which the base layer and pattern layer are formed from a vinyl chloride resin composition containing a vinyl chloride resin and a water repellent agent is prevented from developing punctures and has uniform water repellency, regardless of the wallpaper manufacturing method, and have generalized this finding to complete the present invention.

[0009] In order to solve the above problems, the wallpaper of the present invention comprises: a substrate layer; a base layer on the substrate layer; A handle layer is provided on the base layer, The base layer and the pattern layer are layers containing a vinyl chloride resin and a functional material. It is characterized by:

[0010] In the wallpaper of the present invention, the functional material is preferably a water repellent. In the wallpaper of the present invention, the functional material is preferably a water repellent agent made of a block copolymer of a fluorine-based copolymer and an acrylic copolymer. In the wallpaper of the present invention, it is preferable that the base layer and the pattern layer are layers containing vinyl chloride resin and a water repellent, and the content of the water repellent is 0.2 parts by mass or more and 10 parts by mass or less per 100 parts by mass of the vinyl chloride resin. In the wallpaper of the present invention, the pattern layer is preferably a layer having an uneven surface. [Effects of the Invention]

[0011] According to the wallpaper of the present invention, the occurrence of punctures is prevented and uniform functionality can be imparted to the surface, regardless of the wallpaper manufacturing method. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a cross-sectional view of the layer structure of wallpaper according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0013] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. As shown in FIG. 1, wallpaper 1 of the present invention comprises a substrate layer 10, a base layer 20 on the substrate layer 10, and a pattern layer 30 on the base layer 20, and the base layer 20 and the pattern layer 30 are characterized in that they are layers containing vinyl chloride resin and functional materials.

[0014] In this specification, vinyl chloride resin 1 and vinyl chloride resin 2 described below are sometimes collectively referred to as "vinyl chloride resins," functional material 1 and functional material 2 are sometimes collectively referred to as "functional materials," and vinyl chloride resin composition 1 and vinyl chloride resin composition 2 are sometimes collectively referred to as "vinyl chloride resin compositions." Furthermore, the base foam layer and pattern foam layer are considered to be included in the base layer and pattern layer, respectively.

[0015] Base material layer The substrate layer 10 functions as a backing paper for the wallpaper 1, and conventionally used substrates for wallpaper can be used as they are. Examples of substrate sheets that can be used as the substrate layer 10 include paper, synthetic paper, flame-retardant paper, non-combustible paper, inorganic paper, laminated paper, synthetic resin film, and nonwoven fabric. The basis weight of the substrate sheet is not particularly limited, and may be within the range used for ordinary substrate sheets, for example, a basis weight of 50 to 300 g / m 2 , preferably 50 to 80 g / m 2 is. The thickness of the base layer 10 is usually within the range of 100 to 200 μm.

[0016] Base layer and pattern layer The base layer 20 constituting the wallpaper 1 of the present invention is a layer containing a vinyl chloride resin 1 and a functional material 1. The base layer 20 can be formed using a vinyl chloride resin composition 1 containing the vinyl chloride resin 1 and the functional material 1. The pattern layer 30 is a layer containing a vinyl chloride resin 2 and a functional material 2. The pattern layer 30 can be formed using a vinyl chloride resin composition 2 containing a vinyl chloride resin 2 and a functional material 2. The wallpaper of the present invention having a base layer and a pattern layer made of such a composition prevents the occurrence of punctures and makes it possible to impart uniform functionality to the surface, regardless of the wallpaper manufacturing method.

[0017] polyvinyl chloride resin The vinyl chloride resin used in the wallpaper of the present invention can be any vinyl chloride resin commonly used in wallpapers made from vinyl chloride resins, including vinyl chloride homopolymers and copolymers of vinyl chloride monomers with other monomers copolymerizable therewith. Other monomers copolymerizable with vinyl chloride monomers are not particularly limited, and include, for example, olefins such as ethylene, propylene, and butene; vinyl esters such as vinyl acetate, vinyl propionate, and vinyl stearate; vinyl ethers such as methyl vinyl ether, ethyl vinyl ether, octyl vinyl ether, and lauryl vinyl ether; vinylidenes such as vinylidene chloride; unsaturated carboxylic acids such as acrylic acid, methacrylic acid, fumaric acid, maleic acid, and itaconic acid; unsaturated carboxylic anhydrides such as maleic anhydride and itaconic anhydride; unsaturated carboxylic esters such as methyl acrylate, ethyl acrylate, monomethyl maleate, dimethyl maleate, and butylbenzyl maleate; aromatic vinyl compounds such as styrene, α-methylstyrene, and divinylbenzene; unsaturated nitriles such as acrylonitrile; and crosslinkable monomers such as diallyl phthalate.

[0018] The average degree of polymerization of the vinyl chloride resin is not limited, but is usually 500 to 6,000, and preferably 800 to 3,000. The reduced viscosity (K value) of the vinyl chloride resin is not limited, but it is generally 50 to 110, preferably 60 to 90, in accordance with JIS K7367-2.

[0019] The method for producing the vinyl chloride resin is not particularly limited, and examples thereof include suspension polymerization, bulk polymerization, emulsion polymerization, etc. The vinyl chloride resin may also be a plastisol or aqueous latex in which fine particles of the vinyl chloride resin are dispersed in an organic medium.

[0020] Each of the vinyl chloride resins 1 and 2 may be used alone or in combination of two or more. Furthermore, vinyl chloride resin 1 and vinyl chloride resin 2 may have the same monomer composition and average degree of polymerization, or may have different monomer compositions and / or average degrees of polymerization.

[0021] functional materials The functional material is a substance that is contained in the base layer 20 and the pattern layer 30 to impart various functions to the base layer 20 and the pattern layer 30, such as water repellency, stain resistance, and scratch resistance.

[0022] The functional material 1 and the functional material 2 may each consist of only one kind or two or more kinds. Furthermore, functional material 1 and functional material 2 may be the same or different, but from the viewpoint of obtaining a base layer 20 and a pattern layer 30 that exhibit uniform functions regardless of the manufacturing method, it is preferable that the base layer 20 and the pattern layer 30 contain functional materials that have the same functions.

[0023] Examples of functional materials include water repellents, antifouling agents, surface protective agents, etc. Water repellents and antifouling agents are preferred, with water repellents being particularly preferred, as they allow the effects of the present invention to be more pronounced.

[0024] Water repellent The water repellent agent used in the present invention is a substance that imparts water repellency to the surfaces of the base layer 20 and the pattern layer 30. Here, "water repellency" refers to a surface property in which, when a water droplet is dropped on the surface of the base layer 20 or the pattern layer 30 and the contact angle of the water droplet is measured using a contact angle measuring device 30 seconds after the dropping, the contact angle is preferably 60° or more, more preferably 70° or more.

[0025] The water repellent agent used in the wallpaper of the present invention is not particularly limited as long as it imparts water repellency to the surfaces of the base layer 20 and the pattern layer 30 of the wallpaper. Examples of the water repellent agent that can be used include silicone-based water repellent agents and organic fluorinated polymer-based water repellent agents.

[0026] Examples of silicone-based water repellents include those made of a composition containing a silicone resin and a higher fatty acid amide in a base polyolefin-based resin, and those made of a block copolymer of a silicone-based copolymer and an acrylic-based copolymer. Examples of the base polyolefin resin used in the former include low-density polyethylene, high-density polyethylene, and polypropylene. Examples of silicone resins include organopolysiloxane, dimethylpolysiloxane, methylphenylpolysiloxane, and methylhydrogenpolysiloxane, with dimethylpolysiloxane being particularly preferred. Examples of higher fatty acid amides include saturated fatty acid amides (stearic acid amide, behenic acid amide, etc.), unsaturated fatty acid amides (oleic acid amide, erucic acid amide, etc.), saturated fatty acid bisamides (ethylenebisstearic acid amide, etc.), and unsaturated fatty acid bisamides (ethylenebisoleic acid amide, hexamethylenebisoleic acid amide, N,N'-dioleylsebacic acid amide, etc.).

[0027] Furthermore, examples of block copolymers of silicone copolymers and acrylic copolymers include product names: MODIPER FS710-1, MODIPER FS700, MODIPER FS720, MODIPER FS730, and MODIPER FS770 (all manufactured by NOF Corporation).

[0028] Examples of organic fluorinated polymer water repellents include polymers formed from (meth)acrylates having a perfluoroalkyl group or a polyfluoroalkyl group, copolymers of these monomers with monomers having no perfluoroalkyl group or no polyfluoroalkyl group, such as vinyl esters, vinyl ethers, acrylamides, and aliphatic isocyanates, and block copolymers of fluorine-based copolymers and acrylic copolymers.

[0029] Specific examples of organic fluorinated polymer-based water repellents include those described in JP-A-11-279997, JP-A-2000-178899, JP-A-2000-220097, JP-A-2002-363898, JP-A-2005-002536, JP-A-2014-113721, JP-A-2009-242550, and JP-A-2014-58673.

[0030] Furthermore, examples of block copolymers of fluorine-based copolymers and acrylic copolymers include product names: MODIPER F206, MODIPER F606, MODIPER F246, MODIPER F3636, and MODIPER F2266 (all manufactured by NOF Corporation).

[0031] Among these, from the viewpoint of having excellent compatibility with vinyl chloride resin and imparting superior water repellency to the base layer 20 and the pattern layer 30, those made of a block copolymer of a silicone copolymer or a fluorine-based copolymer and an acrylic copolymer are preferred, and those made of a block copolymer of a fluorine-based copolymer and an acrylic copolymer are more preferred.

[0032] antifouling agent The stain-proofing agent used in the wallpaper of the present invention is a substance that imparts a function to prevent stains from adhering to the surface of the wallpaper. Examples of the antifouling agent to be used include polyurethane paint, fluorine-based SG antifouling agents and SR antifouling agents described in JP-A-2003-129388, and fatty acid bisamide compounds described in JP-A-2013-35898.

[0033] Surface Protective Agents The surface protective agent used in the wallpaper of the present invention is a substance that provides the function of preventing scratches on the wallpaper surface and the function of suppressing the progress of deterioration of the wallpaper surface. Examples of the surface protective agent include vinyl chloride emulsion (for example, Vinyblan HD-057KM, manufactured by Nissin Chemical Industry Co., Ltd.).

[0034] Functional material content The content of the functional material in the base layer 20 and the pattern layer 30 is preferably 0.2 to 10 parts by mass, more preferably 0.3 to 5 parts by mass, and even more preferably 0.5 to 3 parts by mass, per 100 parts by mass of vinyl chloride resin.

[0035] If the base layer 20 and the pattern layer 30 do not contain functional materials or if the content of functional materials in the base layer 20 and the pattern layer 30 is too low, the functionality of the base layer 20 and the pattern layer 30 will not be manifested, or even if it is manifested, the effect will be insufficient. Furthermore, if the content of functional material in the base layer 20 and the pattern layer 30 is too high, the functional effects of the base layer 20 and the pattern layer 30 will be saturated, but there is a risk that roughness will occur on the surface of the vinyl chloride resin composition coating. Furthermore, the blending amounts of the functional material 1 contained in the base layer 20 and the pattern layer 30 may be the same or different.

[0036] Various additives In addition to the vinyl chloride resin and functional material, the base layer 20 and the pattern layer 30 may contain various conventionally known additives. Examples of additives that can be used include plasticizers, stabilizers, pigments, foaming agents, diluents, colorants, inorganic fillers, colorants, flame retardants, viscosity reducers, and foam stabilizers. These additives can be used alone or in combination of two or more.

[0037] plasticizer The vinyl chloride resin composition may contain a plasticizer. The plasticizer is added to impart flexibility and elasticity to the vinyl chloride resin. The plasticizer to be used is not particularly limited.For example, phthalic acid esters having an alkyl group having 1 to 12 carbon atoms, such as dimethyl phthalate, diethyl phthalate, dibutyl phthalate, diheptyl phthalate, di-2-ethylhexyl phthalate, di-n-octyl phthalate, diisodecyl phthalate, butyl benzyl phthalate, diisononyl phthalate, ethyl phthalyl ethyl glycolate, diundecyl phthalate, ditridecyl phthalate, didodecyl phthalate, diisocumyl phthalate, and dinonyl phthalate; diisobutyl adipate, dibutyl adipate, Fatty acid esters such as di-2-ethylhexyl adipate, diisodecyl adipate, dibutyl diglycol adipate, di-2-ethylhexyl azelate, dihexyl azelate, diisooctyl azelate, triethyl citrate, acetyl triethyl citrate, tributyl citrate, acetyl tributyl citrate, acetyl trioctyl citrate, dimethyl sebacate, dibutyl sebacate, di-2-ethylhexyl sebacate, methyl acetyl ricinoleate, and butyl acetyl ricinoleate; tri-(2-ethyl) Aromatic carboxylic acid esters such as tetra-(2-ethylhexyl) pyromellitate, tri-n-octyl trimellitate, triisooctyl trimellitate, tetra-(2-ethylhexyl) pyromellitate, tetra-n-octyl pyromellitate, tetraisooctyl pyromellitate, biphenyl tetracarboxylic acid tetrabutyl ester, biphenyl tetracarboxylic acid tetrapentyl ester, and biphenyl tetracarboxylic acid tetrahexyl ester; tri-2-ethylhexyl phosphate, tributoxyethyl phosphate, and trioleyl Examples of orthophosphate esters include phosphate, triphenyl phosphate, tricresyl phosphate, trixylenyl phosphate, cresyl diphenyl phosphate, xylenyl diphenyl phosphate, and 2-ethylhexyl diphenyl phosphate; chlorinated paraffin; chlorinated fatty acid esters; epoxidized soybean oil; epoxidized linseed oil; epoxy butyl stearate, epoxy octyl stearate; methyl phthalyl ethyl glycolate, ethyl phthalyl ethyl glycolate, and butyl phthalyl butyl glycolate. These plasticizers may be used alone or in combination of two or more compounds.

[0038] When a plasticizer is used, the blending amount is not limited, but is usually 1 to 150 parts by weight, preferably 15 to 120 parts by weight, and more preferably 20 to 100 parts by weight, per 100 parts by weight of vinyl chloride resin. If the blending amount of the plasticizer is less than the lower limit, flexibility tends to be insufficient. On the other hand, if the blending amount of the plasticizer is more than the upper limit, the plasticizer may bleed out from a molded article molded from the antifouling resin composition of the present invention, or moldability may be impaired.

[0039] stabilizers The vinyl chloride resin composition may contain a stabilizer. The stabilizer is added to prevent decomposition and deterioration of the vinyl chloride resin. The stabilizer used is not particularly limited and can be appropriately selected from known stabilizers for vinyl chloride resins. Examples include tribasic lead sulfate, dibasic lead phthalate, lead silicate, lead orthosilicate-silica gel coprecipitate, dibasic lead stearate, cadmium-barium stabilizers, barium-zinc stabilizers, calcium-zinc stabilizers, tin-based stabilizers, and stabilizers whose main component is an inorganic salt of magnesium, aluminum, silicon, or the like, such as hydrotalcite. These stabilizers may be used alone or in combination of two or more compounds.

[0040] When a stabilizer is used in the present invention, the blending amount is not limited, but is usually 1 to 30 parts by weight, preferably 2 to 20 parts by weight, and more preferably 3 to 15 parts by weight, per 100 parts by weight of vinyl chloride resin. When the stabilizer is blended in the above range, the thermal stability and moldability of the molded article obtained by molding the antifouling resin composition tend to be good.

[0041] inorganic fillers The vinyl chloride resin composition may contain an inorganic filler. Examples of inorganic fillers include titanium oxide, talc, calcium carbonate, zinc carbonate, wollastonite, silica, alumina, magnesium oxide, calcium silicate, sodium aluminate, calcium aluminate, sodium aluminosilicate, magnesium silicate, glass balloons, carbon black, zinc oxide, antimony trioxide, zeolite, hydrotalcite, metal fibers, metal whiskers, ceramic whiskers, potassium titanate, boron nitride, graphite, and carbon fibers. These may be used alone or in combination of two or more. From the viewpoint of facilitating the formation of an embossed textured pattern, the inorganic filler is preferably used in an amount of 5 to 300 parts by mass, more preferably 10 to 200 parts by mass, per 100 parts by mass of the vinyl chloride resin.

[0042] coloring agent As the colorant, for example, a pigment can be appropriately used. Pigments can be classified into inorganic pigments and organic pigments. Examples of inorganic pigments include zinc oxide, carbon black, black iron oxide, yellow iron oxide, chrome yellow, molybdate orange, cadmium yellow, nickel titanium yellow, chrome titanium yellow, iron oxide (red iron oxide), cadmium red, ultramarine, Prussian blue, cobalt blue, chromium oxide, cobalt green, aluminum powder, bronze powder, titanium mica, and zinc sulfide. Examples of organic pigments include aniline black, perylene black, azo pigments (azo lakes, insoluble azo pigments, condensed azo pigments), polycyclic pigments (isoindolinone, isoindoline, quinophthalone, perinone, flavanthrone, anthrapyrimidine, anthraquinone, quinacridone, perylene, diketopyrrolopyrrole, dibromoanzanthrone, dioxazine, thioindigo, phthalocyanine, indanthrone, and halogenated phthalocyanine pigments). The content of the colorant is preferably about 10 parts by mass or more and 50 parts by mass or less, and more preferably about 15 parts by mass or more and 30 parts by mass or less, per 100 parts by mass of the vinyl chloride resin.

[0043] foaming agent The vinyl chloride resin composition may contain a foaming agent. A foamed layer can be formed by heating and foaming the foaming agent contained in the vinyl chloride resin composition. By forming a foamed layer, it is possible to impart design properties to the base layer and the pattern layer. The foaming agent may be a thermally decomposable foaming agent commonly used in known foam wallpapers, such as a thermally expandable microcapsule foaming agent, an azo-based foaming agent such as azodicarbonamide, a hydrazide-based foaming agent such as oxybisbenzenesulfonylhydrazide, or a nitroso-based foaming agent. When a foaming agent is contained, the amount thereof is usually 1 to 10 parts by mass, preferably 1.5 to 6 parts by mass, and more preferably 2 to 5 parts by mass, per 100 parts by mass of the vinyl chloride resin.

[0044] Diluent The vinyl chloride resin composition may contain a diluent to improve coatability. Examples of solvents (or dispersion media) include petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ester-based organic solvents such as ethyl acetate, butyl acetate, 2-methoxyethyl acetate, and 2-ethoxyethyl acetate; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol, and propylene glycol; ketone-based organic solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclohexanone; ether-based organic solvents such as diethyl ether, dioxane, and tetrahydrofuran; chlorine-based organic solvents such as dichloromethane, carbon tetrachloride, trichloroethylene, and tetrachloroethylene; and water. These solvents (or dispersion media) can be used alone or in the form of a mixture. The solvent content can be determined appropriately taking into account coatability and other factors.

[0045] Other ingredients The base layer 20 and the pattern layer 30 may contain other components to the extent that they do not significantly impair the effects of the present invention. Examples of other components include viscosity reducers, antioxidants, UV absorbers, antioxidants, nucleating agents, impact modifiers, compatibilizers, antifoaming agents, thickeners, crosslinking agents, surfactants, lubricants, antiblocking agents, processing aids, antistatic agents, flame retardants, and flame retardant aids. These may be used alone or in any combination and ratio of two or more.

[0046] When these other components are used, their content in the base layer 20 and the handle layer 30 is not limited, but is usually 0.01% by weight or more, preferably 0.2% by weight or more, and is usually 10% by weight or less, preferably 5% by weight or less.

[0047] Wallpaper manufacturing The wallpaper of the present invention can be produced, for example, as follows. (1) Step 1: Preparation of vinyl chloride resin composition First, vinyl chloride resin 1, functional material 1, other additives, and optionally a foaming agent are mixed to prepare vinyl chloride resin composition 1. Then, vinyl chloride resin 2, functional material 2, other additives, and optionally a foaming agent are mixed to prepare vinyl chloride resin composition 2.

[0048] (2) Step 2: Forming the base layer Next, a substrate sheet having a basis weight of, for example, 40 to 100 g / m is used as the substrate layer 10. 2 Next, vinyl chloride resin composition 1 is applied to the wallpaper base paper in an amount of, for example, 50 to 150 g / cm. 2 Apply with.

[0049] Examples of methods that can be used to apply the vinyl chloride resin composition 1 include knife coating, nozzle coating, die coating, lip coating, comma coating, gravure coating, rotary screen coating, and reverse roll coating.

[0050] Next, the resulting coating film is heated and dried to form a base layer. In this case, when the vinyl chloride resin composition 1 contains a thermally decomposable foaming agent, the coating film is dried by heating at a temperature below the thermal decomposition temperature of the foaming agent. Thereafter, the formed base layer is heated to a temperature equal to or higher than the thermal decomposition temperature of the foaming agent, thereby foaming the base layer and forming a base foam layer.

[0051] (3) Step 3: Forming the pattern layer Thereafter, the vinyl chloride resin composition 2 is applied onto the base layer (or base foam layer) 20 at a concentration of, for example, 50 to 150 g / cm 2 The resulting coating is then heated and dried to form the pattern layer 30.

[0052] Examples of methods for applying the vinyl chloride resin composition 2 include gravure printing, screen printing, flexographic printing, inkjet printing, and rotary screen printing. Thereafter, the coating of the vinyl chloride resin composition 2 is dried to form the pattern layer 30.

[0053] The pattern layer 30 is a layer that imparts design to the wallpaper 1. The pattern layer 30 can be formed, for example, by printing a picture pattern on the surface of the base layer 20. The handle layer may be a laminate of two or more layers. The thickness of the pattern layer 30 varies depending on the type of design, but is generally preferably about 0.1 μm or more and 10 μm or less.

[0054] Examples of the design pattern include wood grain, stone grain, sand grain, tiled pattern, brickwork pattern, fabric pattern, leather-striped pattern, geometric figures, letters, symbols, abstract patterns, etc. The design pattern can be selected depending on the purpose.

[0055] In addition, when the vinyl chloride resin composition 2 contains a thermally decomposable foaming agent, the formed pattern layer 30 can be foamed by heating it to a temperature higher than the foaming temperature, thereby forming a pattern foam layer.

[0056] (4) Step 4: Embossing After the pattern layer (or pattern foam layer) is formed, the pattern layer (or pattern foam layer) can be embossed using an embossing roll. By embossing from the base layer 20 and / or pattern layer 30 side simultaneously with or immediately after heat foaming, wallpaper with an embossed pattern can be produced.

[0057] The embossing can be carried out, for example, by passing the sheet between an embossing roll having recesses with a depth of 15 μm or more and a back roll made of rubber having a hardness of 50 degrees or more and less than 90 degrees.

[0058] There are other methods for forming an embossed pattern on the surface of the base layer 20 and the pattern layer 30, such as partially foaming using a foam-inhibiting ink or chemical embossing, which partially heats and foams using hot air or infrared rays. However, mechanical embossing, which involves pressing an embossing roll against the foam layer, is particularly preferred, as it can produce sharp irregularities on the foam layer, etc.

[0059] Examples of embossed patterns include wood grain vessel grooves, stone slab surface irregularities, cloth surface texture, matte finish, sand grain, hairline, linear grooves, etc. Regardless of the pattern, it is desirable that the pattern be in harmony with the pattern layer 30.

[0060] In this manner, functional wallpaper having an uneven surface can be produced. The wallpaper of the present invention is not limited to the above, as long as it has a substrate layer, a base layer on the substrate layer, and a pattern layer on the base layer, and the base layer and pattern layer contain vinyl chloride resin and a functional material. For example, the wallpaper may have layers other than the base layer and pattern layer, a base layer that is also a foam layer, a base layer that is also embossed, a pattern layer that is not a foam layer, or a pattern layer that is a foam layer but is not embossed. Furthermore, a general matte paint can be applied to the surface of the pattern layer, and even in this case, functionality such as water repellency and stain resistance can be maintained.

[0061] In conventional methods for manufacturing wallpaper with functional surfaces, it has sometimes been difficult to uniformly apply a coating liquid containing a functional material to the uneven surface (especially the side and bottom surfaces of recesses), making it difficult to form a uniform functional layer on the outermost surface of the wallpaper. Furthermore, depending on the composition of the coating liquid containing the functional material, air bubbles generated in the layer formed from the vinyl chloride resin composition during embossing can become difficult to remove, causing horseshoe-shaped punctures and resulting in problems with appearance and quality. On the other hand, with the wallpaper of the present invention, the vinyl chloride resin composition that forms the base layer and pattern layer contains functional materials, so there is no need to form a functional layer on the outermost surface, preventing the occurrence of punctures. Furthermore, even when embossed, wallpaper can be obtained that has uniform functionality imparted to the surface.

[0062] The wallpaper 1 of the present invention may further have a surface protective layer on the base layer 20 and the pattern layer 30. The surface protective layer is formed on the surface of the pattern layer 30 with the intention of adjusting the gloss and protecting the picture print layer. In addition to this, it also has the function of preventing the wallpaper from expanding when a water-based adhesive (glue) is applied during installation, and of preventing shrinkage as it dries. To achieve these functions, the surface protective layer can be formed, for example, by applying a paint (surface protective layer-forming composition) whose main component is acrylic resin. [Example]

[0063] The following examples of the present invention will be described together with comparative examples, but these examples do not limit the present invention in any way. <Preparation of Vinyl Chloride Resin Compositions 1 and 2> Vinyl chloride resin compositions 1 and 2 having the formulations shown in Table 1 were prepared. In Table 1, the following ingredients were used as compounding agents. (1) Vinyl chloride resin Vinyl chloride resin 1: Kaneka Corporation, product name: PSM-671 Vinyl chloride resin 2: Kaneka Corporation, product name: PSL-290R Vinyl chloride resin 3: Kaneka Corporation, product name: XPS-300L

[0064] (2) Plasticizer Diisononyl phthalate: CG Ester Corporation, product name: DINP (3) Stabilizers Stabilizer: Daikyo Kasei Co., Ltd., product name: LFX-98E (4) Diluent Isoparaffin hydrocarbons: Manufactured by Idemitsu Kosan Co., Ltd., product name: IP Clean LX (5) Viscosity reducer Viscosity reducer: BYK, product name: BYK-4041 (6) Inorganic fillers Calcium carbonate: Nitto Funka Kogyo Co., Ltd., product name: NN-500A (7) Pigments Titanium oxide: Teika Co., Ltd., product name: JR-401 (8) Foaming agent Foaming agent: Otsuka Chemical Co., Ltd., product name: AZ-VI25 (9) Water repellent Block copolymer of fluorine-based copolymer and acrylic copolymer (solid content 30% by mass, diluent: paraffin-based solvent): NOF Corporation, product name: MODIPER F3636

[0065] [Table 1]

[0066] (10) Preparation of vinyl chloride resin composition In the formulation shown in Table 1, vinyl chloride resin compositions 1-1 to 1-11 and vinyl chloride resin compositions 2-1 to 2-11 were prepared by adjusting the amount of water repellent added to the amounts shown in Table 2 below.

[0067] [Table 2]

[0068] Example 1 Mass 75g / m 2Vinyl chloride resin composition 1-1 having the composition shown in Tables 1 and 2 was applied onto wallpaper base paper by rotary screen printing, and the coating was dried by heating at 140°C to form a base layer with a thickness of 150 μm. Next, vinyl chloride resin composition 2-1 having the composition shown in Tables 1 and 2 was applied onto the resulting base layer by rotary screen printing, and the coating was heated and dried at 140°C to form a 100 μm-thick pattern layer. The base layer and pattern layer were then heated to 225°C to thermally decompose the foaming agent, forming a base foam layer and a pattern foam layer, thereby obtaining the wallpaper of Example 1.

[0069] (Examples 2 to 8, Comparative Example 1) A base layer was formed in the same manner as in Example, except that vinyl chloride resin compositions 1-2 to 1-9 were used instead of vinyl chloride resin composition 1-1. Next, a pattern layer was formed in the same manner as in Example 2, except that vinyl chloride resin compositions 2-2 to 2-9 having the compositions shown in Tables 1 and 2 were used instead of vinyl chloride resin composition 2-1, and then heated to form a base foam layer and a pattern foam layer, thereby obtaining wallpapers of Examples 2 to 8 and Comparative Example 1.

[0070] (Comparative Example 2) Mass 75g / m 2 Vinyl chloride resin composition 1-10 having the composition shown in Tables 1 and 2 was applied onto wallpaper base paper by rotary screen printing, and the coating was dried by heating at 140°C to form a base layer with a thickness of 150 μm. Next, vinyl chloride resin composition 2-10 having the composition shown in Tables 1 and 2 was applied onto the obtained base layer by rotary screen printing, and the coating film was heated and dried at 140°C to form a pattern layer 100 μm thick. Thereafter, a coating liquid containing a water repellent agent was applied onto the obtained pattern layer by gravure printing to form a water repellent layer. Furthermore, an embossing roll was pressed against the resulting water-repellent layer to perform embossing, thereby obtaining wallpaper of Comparative Example 2 having an uneven surface.

[0071] (Comparative Example 3) Mass 75g / m2 Vinyl chloride resin composition 1-11 having the composition shown in Tables 1 and 2 was applied onto wallpaper base paper by rotary screen printing, and the coating was dried by heating at 140°C to form a base layer with a thickness of 150 μm. Next, vinyl chloride resin composition 2-11 having the composition shown in Tables 1 and 2 was applied to the resulting base layer by rotary screen printing, and the coating was dried by heating at 140°C to form a 100 μm-thick pattern layer. The base layer and pattern layer were then heated at 225°C for 30 seconds to thermally decompose the foaming agent, forming a base foam layer and a pattern foam layer, and the wallpaper of Comparative Example 3 was obtained.

[0072] <Evaluation test> The wallpapers obtained in Examples 1 to 8 and Comparative Examples 1 to 3 were subjected to the following evaluation tests. (1) Coatability evaluation of vinyl chloride resin compositions When the vinyl chloride resin composition was applied to the wallpaper base paper, the coated surface was visually inspected for roughness, such as streaks, penetration of the reagent into the base paper, and the presence or absence of particles larger than the coating thickness. As a result, the coating surface was evaluated as "Good" if no roughness was observed, "Average" if some roughness was observed but the coating was still usable, and "Poor" if roughness was observed.

[0073] (2) Evaluation of foaming properties The uniformity of the cells on the surface of the base layer was visually observed after heating and foaming for 30 seconds at 225°C. The results were evaluated as follows: "Good" if no roughness was observed on the cross section or surface of the base layer; "Fair" if some roughness was observed on the cross section or surface of the base layer but it was still usable; and "Poor" if roughness was observed on the cross section or surface of the base layer.

[0074] (3) Water repellency evaluation The contact angle of the foamed base layer surface was measured 30 seconds after a water droplet was dropped on it using a contact angle measuring device (manufactured by Kyowa Interface Science Co., Ltd., product name: DM-SA) in accordance with JIS R 3257. The results were evaluated as follows: a water droplet contact angle of 70° or more was marked "Good", a water droplet contact angle of 60° or more but less than 70° was marked "Good", and a water droplet contact angle of less than 60° was marked "Poor". The results of the above evaluation tests are summarized in Tables 3 and 4.

[0075] [Table 3]

[0076] [Table 4]

[0077] From Tables 3 and 4, we can see the following: The wallpapers of Examples 1 to 6 showed excellent results in all evaluation tests of coating properties, foaming properties, and water repellency. The wallpaper of Example 7 had insufficient water repellency because the amount of water repellent agent contained in the base layer and pattern layer was small. The wallpaper of Example 8 had sufficient water repellency due to the large amount of water repellent contained in the base layer and pattern layer, but slight roughness was observed on the surface of the vinyl chloride resin composition coating. The wallpaper of Comparative Example 1 did not contain a water repellent agent in the base layer or pattern layer, and did not form a water repellent layer, so although the evaluation of the coating property and foaming property was good, no water repellency was observed. The wallpaper of Comparative Example 2 had no problem with foaming properties, but horseshoe-shaped punctures occurred during embossing, causing the surface to become rough, resulting in quality problems. The wallpaper of Comparative Example 3 had poor water repellency because the coating liquid containing the water repellent could not be evenly applied to the recesses due to the formation of unevenness on the surface caused by foaming. [Explanation of symbols]

[0078] 1...Wallpaper 10...Base material layer 20... Base layer 30...Pattern layer

Claims

1. a substrate layer; a base layer on the substrate layer; A handle layer is provided on the base layer, The base layer and the pattern layer are layers containing a vinyl chloride resin and a functional material. Wallpaper characterized by:

2. The functional material is a water repellent. The wallpaper according to claim 1.

3. the functional material is a water repellent agent composed of a block copolymer of a fluorine-based copolymer and an acrylic copolymer; The wallpaper according to claim 1.

4. The base layer and the pattern layer are layers containing a vinyl chloride resin and a water repellent agent, and the content of the water repellent agent is 0.2 parts by mass or more and 10 parts by mass or less per 100 parts by mass of the vinyl chloride resin. The wallpaper according to claim 1.

5. The pattern layer is a layer having an uneven surface. The wallpaper according to claim 1.

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