Foamed wall paper

Abstract

To provide a foamed wall paper having workability and incombustibility.SOLUTION: A foamed wall paper 1 comprises: a substrate layer 10 that is made of paper and has basis weight of 50 g / m2 or more and 100 g / m2 or less; a foamed resin layer 20 provided on the substrate layer; a pattern layer 30 provided on the foamed resin layer; and a resin film layer 40 provided on the pattern layer. The foamed resin layer contains, as resin component, ethylene-vinyl acetate copolymer or ethylene-unsaturated carboxylic acid copolymer most. The resin film layer is formed of a resin film that is made of ethylene-vinyl acetate copolymer or fluorine-based resin and has basis weight of 10 g / m2 or more and 20 g / m2 or less.SELECTED DRAWING: Figure 1

Description

[Technical Field]

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

[0002] Foamed wallpaper (see, for example, Patent Document 1) in which a foamed resin layer is formed on the surface of a substrate is widely used in detached houses, apartments, condominiums, store interiors, and the like. Foam wallpaper is attached to a wall or the like by gluing it to the backside of a substrate. Paper substrates are sometimes used as the substrate from the viewpoint of moisture permeability, etc. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2000-096496 Summary of the Invention [Problem to be solved by the invention]

[0004] Foam wallpaper has the problem that the moisture in the glue appears over time during the gluing process, which makes the surface of the foam wallpaper sticky, attracts dust in the application environment, and is uncomfortable to the touch. On the other hand, in non-residential buildings such as stores and hospitals, where an unspecified number of people come and go, foam wallpaper is often required to be certified as a fire-resistant material under the Building Standards Act.

[0005] An object of the present invention is to provide a foam wallpaper that is both easy to apply and non-flammable. [Means for solving the problem]

[0006] The present invention is made of paper and has a basis weight of 50 g / m 2 More than 100g / m 2This foamed wallpaper comprises a substrate layer, a foamed resin layer provided on the substrate layer, a pattern layer provided on the foamed resin layer, and a resin film layer provided on the pattern layer. The foamed resin layer contains, as the resin component, an ethylene-vinyl acetate copolymer or an ethylene-unsaturated carboxylic acid copolymer in the largest amount. The resin film layer is made of ethylene-vinyl acetate copolymer or fluorine-based resin and has a basis weight of 10 g / m 2 More than 20g / m 2 It consists of the following resin films. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide foam wallpaper that is both easy to apply and non-flammable. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a schematic cross-sectional view showing a foam wallpaper according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0009] An embodiment of the present invention will be described with reference to FIG. 1 is a schematic cross-sectional view of a foamed wallpaper 1 according to this embodiment. The foamed wallpaper 1 has a configuration in which a foamed resin layer 20, a pattern layer 30, and a resin film layer 40 are sequentially formed on a paper substrate layer 10.

[0010] Examples of the substrate layer 10 include general wallpaper paper (a pulp-based sheet sized with a known sizing agent); flame-retardant paper (a pulp-based sheet treated with a flame retardant such as guanidine sulfamate or guanidinium phosphate); inorganic paper containing inorganic additives such as aluminum hydroxide or magnesium hydroxide; fine paper; thin paper; and fiber-mixed paper (paper made by mixing pulp and synthetic fibers). Known wallpaper backing paper (fibrous sheet) can also be used as the substrate layer 10.

[0011] The basis weight of the base layer 10 is 50 g / m 2More than 100g / m 2 The thickness of the base material layer 10 can be set to 80 μm or more and 150 μm or less, which allows the foam wallpaper 1 to have sufficient rigidity.

[0012] The foamed resin layer 20 can be formed by applying a resin containing a foaming agent to the surface of the base layer 10. The applied resin may contain, in addition to the foaming agent, a plasticizer, a stabilizer, a viscosity reducer, and other organic additives, as necessary. Examples of coating methods include various known methods such as knife coating, nozzle coating, die coating, lip coating, comma coating, gravure coating, rotary screen coating, and reverse roll coating.

[0013] The resin component of the foamed resin layer in this embodiment contains ethylene-vinyl acetate copolymer (EVA) or ethylene-unsaturated carboxylic acid copolymer in the largest amount, or may contain both. Furthermore, other resins such as acrylic may be contained in an amount less than the EVA and ethylene-unsaturated carboxylic acid copolymer (or less than the sum of the amounts when both are contained). The coating amount when forming the foamed resin layer 20 can be set appropriately, for example, 50 g / m 2 More than 220g / m 2 The following can be done.

[0014] From the viewpoint of performance (expansion ratio, strength), it is preferable to add the foaming agent (volatile expanding agent) to the resin component in the form of thermally expandable microcapsules. The content of the foaming agent can be, for example, 5 to 20 parts by mass per 100 parts by mass of the resin component. By setting the amount of foaming agent within this range, it becomes easier to adjust the expansion ratio of the foamed resin layer to a suitable range of about 7 to 10 times. The foaming agent is not limited to this, and various thermally decomposable foaming agents such as azo-based, hydrazide-based, and nitroso-based foaming agents can also be used.

[0015] A filler may be added to the foamed resin layer 20 for the purposes of imparting non-combustibility, adjusting the balance between thickness and basis weight, and the like. The filler is typically an inorganic filler, and one type of inorganic filler may be used alone, or two or more types may be used in combination. Examples of inorganic fillers include calcium carbonate, titanium dioxide, and kaolin. The filler content is preferably between 60 and 120 parts by mass per 100 parts by mass of the resin component. Adding filler within this range reduces the combustion calories per unit area, further improving the fire resistance of the wallpaper while maintaining the required level of strength and product thickness.

[0016] The pattern layer 30 decorates the surface layer side with a pattern to improve the design of the foamed wallpaper. The pattern layer 30 can be formed on the surface of the foamed resin layer 20 by a printed layer. The material for the pattern layer 30 is not particularly limited as long as it meets the requirements for light resistance, color development, and safety of the ingredients used (such as not containing heavy metals or sulfur compounds as pigments or additives), which are generally required for wallpaper. A suitable example is a water-based ink with an acrylic polymer as the base resin. The design pattern is not particularly limited, but examples include a cloth pattern, a stone pattern, and a wood pattern.

[0017] The resin film layer 40 is formed by bonding a resin film onto the pattern layer 30 . The resin material constituting the film is EVA or fluororesin, such as polyvinyl fluoride, polyvinylidene fluoride, ethylene-tetrafluoroethylene, or perfluoroalkyl vinyl ether.

[0018] Foam wallpaper with a paper base layer is highly breathable and can be expected to provide humidity control and mildew prevention effects after installation. However, some of the glue applied to the base layer during gluing can sometimes penetrate the foam resin layer. In particular, when installing a large amount of foam wallpaper, a large amount of wallpaper may be glued at once and then left to cure for a long time (for example, more than three hours), which can easily cause stickiness during installation due to the penetration of the glue.

[0019] The inventors have conducted extensive research into a structure that can reduce stickiness during application due to glue permeating through the foamed resin layer, even after long-term curing. As a result, they have discovered that by forming a protective layer that covers a pattern layer, which is generally formed by coating and drying, with a film made of the above-mentioned resin, it is possible to create a foamed wallpaper that has a paper base layer but can effectively reduce stickiness during application.

[0020] The basis weight of the resin film constituting the resin film layer 40 is 10 g / m 2 More than 20g / m 2 When converted to a thickness based on the density of the resin material, this is roughly between 10 μm and 20 μm. When forming the resin film layer 40, the resin films may be bonded by thermocompression bonding or by using an adhesive.

[0021] The foam wallpaper 1 according to this embodiment has the above-described configuration, and therefore, even after long-term curing, discomfort during application caused by permeated glue is suppressed, allowing for smooth application. The resin film layer 40 that provides this effect is, as mentioned above, relatively thin for a resin film, so it does not significantly impair moisture permeability. In addition, it has the advantage of being able to reduce the total amount of resin in the wallpaper, making it easier to achieve both non-flammability and durability.

[0022] The foam wallpaper 1 according to this embodiment may have a desired uneven surface by embossing or the like. Examples of the uneven surface include cloth grain, wood grain duct grooves, stone slab surface unevenness, cloth surface texture, matte finish, sand grain, hairline, and linear grooves.

[0023] The foam wallpaper according to the present embodiment will be described in more detail using examples. The technical scope of the present invention is not limited solely by the specific content of each example.

[0024] Example 1 Base layer: 65g / m 2A wallpaper backing paper (WK665TMN manufactured by KJ Specialty Paper Co., Ltd.) with a thickness of 115 μm was used. The following materials were mixed to prepare a coating material for forming a foamed resin layer. EVA (Sumika Chemtex S-7400(HQ)) 80 parts by weight EVA and acrylic mixture (Japan Coating Resin Co., Ltd. FK-715) 20 parts by weight Thermally expandable microcapsule blowing agent (FT-16 manufactured by Matsumoto Yushi Pharmaceutical Co., Ltd.) 9 parts by weight Inorganic filler: calcium carbonate powder (MC-100 manufactured by Asahikomatsu Co., Ltd.) 90 parts by weight This coating material is applied at a coating amount of ○g / m 2 The sheet was then coated on the substrate layer with the composition in a solvent to form a coating layer, and a pattern layer was then formed on the coating layer by gravure printing using a water-based ink. The sheet was then heated to foam the foaming agent, thereby forming a foamed resin layer. Then, an EVA resin film (HF-M manufactured by Kuraray Co., Ltd., basis weight 15 g / m) was applied to the pattern layer. 2 ) While being heat-pressed, an uneven shape was given to the film using an embossing roll. In this way, the foamed wallpaper according to Example 1 was produced.

[0025] Example 2 EVA resin film basis weight 10g / m 2 A foamed wallpaper according to Example 2 was produced in the same manner as in Example 1, except for the above change. Example 3 EVA resin film basis weight 20g / m 2 A foamed wallpaper according to Example 3 was produced in the same manner as in Example 1, except for the above change.

[0026] (Comparative Example 1) A foamed wallpaper according to Comparative Example 1 was produced in the same manner as in Example 1, except that the resin film layer was not provided. (Comparative Example 2) Instead of a resin film layer, a gravure print was made using a paint (DIC ATC-354) whose main component was acrylic resin, with a basis weight of 20 g / m on the pattern layer. 2A foamed wallpaper according to Comparative Example 2 was produced in the same manner as in Example 1 except for the above.

[0027] (Comparative Example 3) EVA resin film basis weight 9g / m 2 A foamed wallpaper according to Comparative Example 3 was produced in the same manner as in Example 1, except for the above change. Comparative Example 4 EVA resin film basis weight 21g / m 2 A foamed wallpaper according to Comparative Example 4 was produced in the same manner as in Example 1, except for the above change.

[0028] The foamed wallpaper according to each example was evaluated as follows. (Sensory evaluation after curing) The foam wallpaper according to each example was cut into a square with a side length of 20 cm, and glue was applied to the base layer (coating amount 150 g / m 2 ) and folded it in half so that the glue touched each other. This was placed in a polyethylene bag, sealed, and left to stand at 25°C for 5 hours, after which it was removed from the bag and ten examiners sensorily evaluated the presence or absence of stickiness on the surface by touching the resin film layer. The evaluation criteria were as follows: 1. Grade: ×; 2. Grade: Pass. ◎ (Excellent): 9 or more people rated it as non-sticky Good: 7-8 people rated it as not sticky △(Fair): 5-6 people rated it as not sticky × (Bad): 4 or fewer people rated it as not sticky

[0029] (Semi-non-flammable rating) Using the foam wallpaper in each example, a heat generation test (50 kW / m) of semi-non-combustible materials was conducted in accordance with the heat generation test method (ISO 5660) specified in the Building Standards Act. 2 The heating was carried out at 400 K for 10 minutes. A cone calorimeter C4 (manufactured by Toyo Seiki Seisakusho Co., Ltd.) was used as the device. Evaluation was based on the following two levels, with ○ being considered a pass. ○(Good): Meets all of the following criteria Total calorific value 8.0MJ or less - Maximum heat generation rate is 200kW / m for 10 seconds or more 2 not exceed · No cracks or holes that penetrate to the back surface are permitted, which may be harmful to fire safety. × (Bad): At least one of the above three points is not met. Furthermore, if the material meets the criteria for semi-non-combustible materials set forth in Japan's Building Standards Act, it will meet the criteria for semi-non-combustible materials. The results are shown in Table 1.

[0030] [Table 1]

[0031] In all of the Examples, both suppression of stickiness after curing and non-combustibility were achieved, and the effect was confirmed at both the lower and upper limits of the above-mentioned range for the resin film layer. On the other hand, in all the comparative examples, it was not possible to achieve both suppression of stickiness after curing and non-combustibility. In Comparative Example 3, in which the thickness of the resin film layer was smaller than the above-mentioned range, all the testers evaluated it as "sticky." On the other hand, in Comparative Example 4, in which the thickness of the resin film layer was larger than the above-mentioned range, the sensory evaluation was good, but the results of the non-combustibility evaluation were poor due to the increased resin amount. Interestingly, in Comparative Example 2, in which the surface protective layer was formed by coating, all testers evaluated it as "sticky" even though the layer thickness was equivalent to that of the resin film. These results show that by covering the surface with a resin film layer made of the above-mentioned materials and within the above-mentioned thickness range, it is possible to form foam wallpaper that combines good workability with non-flammability, which cannot be achieved with a protective layer made of a coating of the same thickness.

[0032] The present invention has been described above using embodiments and examples, but the specific configuration is not limited to these embodiments, and configuration changes and combinations within the scope that do not deviate from the gist of the present invention are also included. [Explanation of symbols]

[0033] 1. Foam wallpaper 10 Base material layer 20 foam resin layer 30 Picture Layer 40 resin film layer

Claims

1. Made of paper with a basis weight of 50 g / m ２ More than 100g / m ２ The following substrate layer: a foamed resin layer provided on the base material layer; a pattern layer provided on the foamed resin layer; a resin film layer provided on the pattern layer; Equipped with the foamed resin layer contains, as a resin component, an ethylene-vinyl acetate copolymer or an ethylene-unsaturated carboxylic acid copolymer in the largest amount; The resin film layer is made of an ethylene-vinyl acetate copolymer or a fluorine-based resin and has a basis weight of 10 g / m ２ 20g / m or more ２ The resin film is: Foam wallpaper.

2. The foamed resin layer contains 60 parts by mass or more and 120 parts by mass or less of an inorganic filler per 100 parts by mass of the resin component. The foam wallpaper according to claim 1.

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