Wall cover and method for manufacturing the same

Abstract

According to an exemplary embodiment of the present invention, a wall cover is provided comprising a nonwoven fabric substrate layer having a backing layer and an intermediate layer disposed on one side of the backing layer, and a coating layer disposed on the intermediate layer. The backing layer comprises a mixture of cellulose fibers and coarse synthetic fibers. The present invention also relates to a method for manufacturing a wall covering. The present invention provides an environmentally friendly wall cover that can be manufactured in a single process step without requiring multiple manufacturing steps.

Description

[Technical Field]

[0001] The present invention relates to wall coverings, and more particularly to wall coverings intended for use in high-traffic areas. In particular, the present invention relates to a wall cover comprising a nonwoven fabric base layer having a backing layer, an intermediate layer disposed on one side of the backing layer, and a coating layer disposed on the intermediate layer. The present invention also relates to a method for manufacturing wall coverings. The present invention provides an environmentally friendly wall cover that can be manufactured in a single process step without requiring multiple manufacturing steps. [Background technology]

[0002] Traditionally, the construction of wall coverings involves a two-step process for producing a three-layer structure. This three-layer structure includes a base layer or backing layer, an intermediate layer, and a decorative layer. The base layer or backing layer typically consists of thin paper material, woven fabric, or other types of nonwoven fabric. The base layer is usually laminated to an intermediate layer containing vinyl or a vinyl substitute. The intermediate layer, containing vinyl or a vinyl substitute, provides strength and structure to the final product. The intermediate layer also provides background color and additional flexibility for embossing. The decorative layer is applied on top of the intermediate layer and can be manufactured using many types of methods, including rotary gravure printing, flexographic printing, digital printing, and screen printing. The decorative layer typically contains ink and an optional protective coating.

[0003] Conventional manufacturing processes involve applying a decorative layer on an intermediate vinyl / vinyl substitute layer, followed by laminating the intermediate layer onto a backing layer. Conventional processes and the wall coverings produced thereby have several drawbacks, including the need for an additional lamination process that increases labor and material costs, and the inclusion of an environmentally unfriendly vinyl / vinyl substitute layer in the wall covering.

[0004] In some countries, nationally recognized quality standards exist for wall coverings for institutional and commercial use. In the United States, different physical requirements and test methods are set for wall covers classified into Type I (light load, intended for use in low-wear areas such as residential), Type II (medium load, such as hotels), and Type III (heavy load, such as hospitals). These requirements and test methods are disclosed in the Wallcovering Association quality standards, specifications W-101 (2017, for polymer-coated woven wall covers) and W-102 (2019, for alternative structures other than vinyl wall covers).

[0005] Conventional wall coverings that meet Type II requirements are generally coated with PVC (polyvinyl chloride) or TPO (thermoplastic olefin). Such PVC-coated or TPO-coated paper is costly in terms of time and energy because it is coated offline. Furthermore, the use of PVC causes problems. Specifically, raw materials containing PVC may release undesirable volatile organic compounds during the manufacturing process and in use. PVC-coated paper is known to be particularly harmful when burned, which poses an additional health risk to residents and firefighters. When burned, PVC-coated wall coverings release harmful and toxic fumes such as hydrochloric acid.

[0006] A wall cover coated with a plastic layer of thermoplastic olefin-containing material is disclosed in Patent Document 1. The plastic layer contains a TPO polymer and optionally a filler such as CaCO3 or TiO2. This plastic layer is intended to be printed / embossed. The base material disclosed in this document is a nonwoven web comprising natural and / or synthetic fibers, a binder (more specifically an acrylic binder), and a filler (particularly clay). In one embodiment, the base material may be a two-ply nonwoven web. Furthermore, it should be noted that TPO-coated wall coverings tend to burn rapidly or have high flammability when exposed to fire, and are plastic-based materials that are not environmentally friendly. Patent Document 2 relates to a wall covering comprising a bottom layer made of polyester short fibers and a surface layer containing wood pulp fibers, wherein the two layers are manufactured in separate process steps. [Prior art documents] [Patent Documents]

[0007] [Patent Document 1] U.S. Patent Application Publication No. 2005 / 0014431 [Patent Document 2] Chinese Patent Application Publication No. 112318955 Specification [Overview of the Initiative] [Problems that the invention aims to solve]

[0008] To address the problems associated with conventional processes, it has been found that wall coverings can be constructed using a single-step process with more environmentally friendly materials and by eliminating the lamination process. Accordingly, the present invention discloses a wall cover that is made of environmentally friendly materials, can be constructed in a single-step process, and meets the quality standards set for wall coverings, particularly the Type II requirements defined in the W-102 Wall Covering Association quality standard. [Means for solving the problem]

[0009] The present invention is defined by the features of the independent claims. Some specific embodiments are defined in the dependent claims. As described above, one of the objects of the present invention is to solve at least a part of the problems related to the prior art and to provide a wall cover having the above-described advantageous characteristics and a method for manufacturing the wall cover.

[0010] The present invention is based on the concept of using a more environmentally considerate wet-laid nonwoven material as a constituent material of the wall cover, eliminating the vinyl / vinyl alternative intermediate layer, and yet the wall cover having required properties such as tear strength and scrub resistance necessary to meet the requirements of Type II. The method of the present invention includes a single-step process in which the intermediate layer and the backing layer of the wall cover are formed together through hydrogen bonding and fiber entanglement, thus eliminating the need for an additional lamination process.

[0011] According to a first aspect of the present invention, there is provided a wall cover, a nonwoven base material layer, a backing layer, and an intermediate layer disposed on one side of the backing layer, the nonwoven base material layer comprising: <00Q0084>a coating layer disposed on the intermediate layer, wherein the backing layer includes a mixture of cellulose fibers and coarse synthetic fibers, and the coarse synthetic fibers have a linear density of at least 5 dtex, a wall cover is provided Preferably, the nonwoven base material layer is a wet-laid nonwoven web.

[0012] According to a second aspect of the present invention, there is provided a method for manufacturing a wall cover, forming an intermediate layer by a wet-laid process; <000009Q> [[ID=J1]]forming a backing layer by a wet-laid process; optionally, pressing the layers together; drying the layers to obtain a seamless two-layer nonwoven sheet; Impregnating the dried two-layer non-woven fabric sheet by applying a binder composition that saturates both sides of the two-layer non-woven fabric sheet; Drying the binder-treated two-layer non-woven fabric sheet to form a non-woven fabric base layer; Applying a coating layer on top of the intermediate layer of the obtained non-woven fabric base layer, and The backing layer of the two-layer non-woven fabric sheet contains a mixture of cellulose fibers and coarse synthetic fibers, and the coarse synthetic fibers have a linear density of at least 5 dtex, a method is provided.

[0013] According to a third aspect of the present invention, there is provided a method of using a wall cover as described above on the surface of an inner wall of a building, preferably in a moderately worn area according to the quality standards of the W-102 Wall Covering Association.

[0014] According to a fourth aspect of the present invention, there is provided a method of protecting the surface of an inner wall of a building in a moderately worn area according to the quality standards of the W-102 Wall Covering Association with a wall cover as described above.

[0015] The present invention provides significant advantages. First, the wall cover of the present invention is more environmentally friendly because the use of vinyl, vinyl alternative materials, olefins and adhesives is avoided. However, the wall cover of the present invention meets the Type II requirements set for wall covers intended for use in moderately worn areas. Therefore, the present invention provides a Type II wall covering that meets or exceeds the characteristics for the quality standards of the W-102 Wall Covering Association for Type II wall coverings while being more environmentally friendly.

[0016] Secondly, the wall cover of the present invention can be manufactured in a single process step, and therefore can be manufactured more cheaply and quickly compared to existing Type II wall coverings that require multiple steps to manufacture. The base layer of the wall cover of the present invention is manufactured without the use of adhesives and without a lamination process.

[0017] Furthermore, the wall cover of the present invention exhibits superior results in combustion tests compared to existing PVC-containing Type II wall coverings that release harmful and toxic fumes when burned. In addition, the wall cover of the present invention is easily printable, resistant to dirt and abrasion, and exhibits good dimensional stability with minimal shrinkage.

[0018] Further features and advantages of this technology will become apparent from the following descriptions of several embodiments. [Brief explanation of the drawing]

[0019] [Figure 1] The following are side views of wall covers according to at least some embodiments of the present invention, with the following reference numerals: (1) wall cover, (3) nonwoven fabric base layer, (5) backing layer, (7) intermediate layer, (9) coating layer, and (11) printed surface of wall cover 1. [Modes for carrying out the invention]

[0020] Figure 1 shows a wall cover 1 according to the present invention, and the wall cover 1 is Nonwoven fabric base layer 3, Backing layer 5, A nonwoven fabric base layer 3 including an intermediate layer 7 disposed on one side of the backing layer 5, The coating layer 9 is disposed on the intermediate layer 7, The backing layer 5 comprises a mixture of cellulose fibers and coarse synthetic fibers, the coarse synthetic fibers having a linear density of at least 5 dtex.

[0021] As used herein and in the claims, the terms “nonwoven fabric” or “web” refer to an aggregate of fibers in a mass of fibers that are disorderly intertwined, entangled, and / or bonded together to form structural elements.

[0022] As used herein, “synthetic fiber” refers to a fiber made from fiber-forming materials, including polymers synthesized from compounds and modified or converted natural polymers. Preferred non-limiting examples of synthetic fibers include polyaramid fibers, polyamide fibers, polyester fibers, polyvinyl alcohol fibers, polypropylene fibers, glass fibers, and combinations thereof.

[0023] Synthetic fibers have a synthetic fiber length. As used herein, “coarse synthetic fiber” has a length of at least 12 mm, preferably at least 18 mm. In some embodiments, the length of the coarse synthetic fiber may be 45 mm or less, or 35 mm or less. For example, the coarse synthetic fiber may have a length in the range of 12 mm to 45 mm or 18 mm to 35 mm.

[0024] As used in this specification and in the claims, “fine synthetic fiber” has a synthetic fiber length. A preferred synthetic fiber length of a fine synthetic fiber may be 15 mm or less, and preferably a fine synthetic fiber has a length in the range of 5 mm to 12 mm.

[0025] Synthetic fibers may have a linear density or linear mass. Coarse synthetic fibers may have a linear density of at least 5 dtex. For example, coarse synthetic fibers may have a linear density of 5 to 10 dtex. Fine synthetic fibers may have a linear density of 1 to 4 dtex, preferably 1 to 3.5 dtex.

[0026] The backing layer 5 of the nonwoven fabric base layer 3 contains a mixture of cellulose fibers and coarse synthetic fibers. In some embodiments, the fibers in the backing layer 5 consist of cellulose fibers and coarse synthetic fibers.

[0027] In some embodiments, the backing layer 5 comprises a mixture of cellulose fibers, coarse synthetic fibers, and fine synthetic fibers. In some embodiments, the fibers in the backing layer 5 consist of cellulose fibers, coarse synthetic fibers, and fine synthetic fibers.

[0028] The amounts of cellulose fibers, coarse synthetic fibers, and any fine synthetic fibers can be expressed as weight percentages based on the total weight of fibers in the backing layer 5. In some embodiments, cellulose fibers may be present in the backing layer 5 at a rate of at least 50% by weight, preferably at least 60% by weight, based on the total weight of fibers in the backing layer 5. In some embodiments, coarse synthetic fibers may be present in the backing layer 5 at a rate of at least 5% by weight, preferably in the range of 5 to 30% by weight, more preferably in the range of 5 to 20% by weight, based on the total weight of fibers in the backing layer 5. In some embodiments, fine synthetic fibers may be present in the backing layer 5 at a rate of 15 to 30% by weight, based on the total weight of fibers in the backing layer 5. By varying the proportion of coarse synthetic fibers in the backing layer 5, the strength properties of the wall cover 1, such as tensile strength, tear strength, and puncture resistance, can be adjusted.

[0029] In some embodiments, the fibers in the backing layer 5 may consist of 5 to 20% by weight of coarse synthetic fibers and 20 to 25% by weight of fine synthetic fibers, based on the total weight of the fibers in the backing layer 5, with the remaining fibers consisting of cellulose fibers.

[0030] Preferably, coarse synthetic fibers are selected from polyaramid fibers, polyamide fibers, polyester fibers, polyvinyl alcohol fibers, polypropylene fibers, glass fibers, and combinations thereof. When used, fine synthetic fibers may be selected from polyaramid fibers, polyamide fibers, polyester fibers, polyvinyl alcohol fibers, polypropylene fibers, glass fibers, and combinations thereof. Non-limiting examples of polyester fibers include polyalkylene terephthalates such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT). Non-limiting examples of polyamide fibers include nylon, such as nylon-t, nylon 6,6, and nylon-6,12.

[0031] In some embodiments, the backing layer 5 may further include additives, typically wet strength additives, dry strength additives, or a combination thereof. Backing layer 5 is typically 130 g / m². 2 ~160g / m 2 It has a basis weight of [amount].

[0032] In addition to the backing layer 5, the nonwoven base layer 3 of the wall cover includes an intermediate layer 7 located on one side of the backing layer 5. The intermediate layer 7 typically contains or is substantially composed of cellulose fibers. The cellulose fibers may include bleached or unbleached hardwood pulp or softwood pulp, bleached or unbleached chemical thermomechanical pulp from hardwood or softwood, bleached or unbleached chemical pulp from hardwood or softwood, and combinations thereof.

[0033] In some embodiments, the intermediate layer 7 contains 0-50% by weight of softwood fibers and 50-100% by weight of hardwood fibers, based on the total weight of the fibers in the intermediate layer 7. In some embodiments, the intermediate layer 7 may contain up to 5% by weight of softwood fibers and at least 95% by weight of hardwood fibers. In some embodiments, the fibers of the intermediate layer 7 consist of hardwood fibers or substantially consist of hardwood fibers. An intermediate layer 7 containing a high proportion of hardwood fibers has very low porosity and therefore high smoothness.

[0034] In some embodiments, the hardwood fibers in the intermediate layer 7 comprise a mixture of eucalyptus fibers and birch fibers, preferably with eucalyptus fibers present in an amount of at least 50% by weight based on the total weight of the hardwood fibers, and birch fibers present in an amount of up to 50% by weight based on the total weight of the hardwood fibers. In some embodiments, the hardwood fibers may comprise a mixture of eucalyptus fibers and birch fibers, with eucalyptus fibers present in an amount of about 75% by weight based on the total weight of the hardwood fibers, and birch fibers present in an amount of about 25% by weight based on the total weight of the hardwood fibers. This mixture of hardwood fibers makes it possible to have an intermediate layer 7 with a smooth surface that improves the deposition quality of the coating layer 9, thereby also improving the printability of the wall cover 1. In particular, the eucalyptus fibers are small and help to improve the smoothness of the intermediate layer 7 and the formation of the sheet that forms this intermediate layer 7.

[0035] Intermediate layer 7 is typically 10 g / m² 2 ~30g / m 2 It has a basis weight of [amount]. The backing layer 5 and the intermediate layer 7, positioned on one side of the backing layer 5, mix with each other at the layer interface, and hydrogen bonds are formed between the layers during the dewatering and drying process, thereby forming the nonwoven fabric base layer 3. No adhesive layer or lamination process is required to enable adhesion between the backing layer 5 and the intermediate layer 7 in the nonwoven fabric base layer 3.

[0036] In some embodiments, the nonwoven fabric substrate layer 3 can be impregnated with an impregnation composition. The impregnation composition may include a binder, a filler, and optionally additives. Typically, suitable binders are selected from styrene acrylate, acrylic, latex, ultra-low (<20 ppm) formaldehyde acrylic, and combinations thereof. In some preferred embodiments, a binder having a glass transition temperature in the range of -25°C to +10°C can be selected. An impregnation composition containing a binder having a glass transition temperature of -25°C to +10°C allows the impregnated nonwoven fabric substrate layer 3 to be flexible.

[0037] The filler in the impregnation composition may be selected from kaolin, calcium carbonate, titanium dioxide, or a combination thereof. The impregnation composition may typically contain additives selected from pigments, defoamers, wetting agents, curing agents, fluorescent whitening agents, and any combination thereof.

[0038] When impregnated, the nonwoven base layer 3 has a density of 80 g / m². 2 ~120g / m 2 It can be impregnated with an amount of impregnation composition. The wall cover 1 further includes a coating layer 9 disposed on an intermediate layer 7 of the nonwoven fabric substrate layer 3. The coating layer 9 imparts additional resistance, smoothness, and abrasion resistance to the wall cover 1. The coating layer 9 may include, for example, an acrylic resin and a pigment. Typically, the acrylic resin is a hydrophobic styrene acrylic resin, which imparts additional stain resistance and printability. The upper surface of the coating layer 9 forms the printable surface 11 of the wall cover 1, which is intended to receive printing on it. Thus, in some embodiments, the printable surface 11 of the coating layer 9 is printed, and the printable surface 11 is located on the side of the coating layer opposite to the side in contact with the intermediate layer 7. Depending on the composition of the coating layer 9, the printable surface 11 of the wall cover 1 can be printed by various printing techniques such as web gravure printing, inkjet printing, flexographic printing, screen printing, or laser jet printing.

[0039] When impregnated, the surface of the nonwoven fabric substrate layer 3 is hydrophobic and has low porosity, which prevents the coating layer 9 from excessively penetrating into the nonwoven fabric substrate layer 3. The coating layer 9 may contain a pigment. Examples of suitable pigments include, but are not limited to, kaolin, calcium carbonate, and mixtures thereof, typically calcium carbonate.

[0040] Coating layer 9 has a dry weight of 10 g / m². 2 ~40g / m 2 This amount is applied onto the intermediate layer 7 of the nonwoven fabric base layer 3. In some embodiments, the coating layer 9 can be embossed.

[0041] Properties of the wall cover The wall cover 1 including the non-woven fabric base layer 3 and the coating layer 9 can have a basis weight of 250 to 350 g / m 2 , preferably about 280 to 320 g / m 2 . In some embodiments, the basis weight can be lower, for example, 230 g / m 2 .

[0042] The wall cover 1 has tear strength. As used herein and in the claims, tear strength refers to the tear strength measured according to the ASTM D-751 Pendulum Impulse Method standard. In a preferred embodiment, the wall cover 1 has at least 25% tear strength in the machine direction when measured according to the ASTM D-751 Pendulum Impulse Method standard. In a preferred embodiment, the wall cover 1 has at least 25% tear strength in the cross direction when measured according to the ASTM D-751 Pendulum Impulse Method standard.

[0043] The wall cover 1 also has a shrinkage value measured according to the quality standard of the W-102 Wall Covering Association. In some embodiments, the wall cover 1 has a maximum shrinkage of 2% in the machine direction when measured according to the quality standard of the W-102 Wall Covering Association as disclosed in the experimental example section. In some embodiments, the wall cover 1 has a maximum shrinkage of 2% in the cross direction when measured according to the quality standard of the W-102 Wall Covering Association as disclosed in the experimental example section.

[0044] In some embodiments, wall cover 1 passed the stain resistance test for all 12 reagents when measured according to ASTM D-1308 standard. More specifically, these 12 reagents were distilled cold water (1 mL, 23.9 ± 2.8°C), distilled hot water (1 mL, 48.9 ± 2.8°C), ethyl alcohol (1 mL, 50% by volume), vinegar (3% acetic acid), alkaline solution (1 mL, 1% sodium hydroxide), acid solution (5% acetic acid or hydrochloric acid), soap solution (1 mL), detergent solution (1 mL), pure orange juice (1 mL), butter (1 mg), ketchup (1 g), and tea (1 mL). To perform the stain resistance test, a predetermined amount of reagent was placed on the wall cover and left on the wall cover for 24 hours. Then, the spot was wiped with water or a neutral detergent, and the contamination was visually inspected to confirm whether the wall cover retained the contamination and whether the surface of the wall cover was damaged by the presence of the reagent.

[0045] Wall cover 1 may have abrasion resistance. Wall cover 1 typically has abrasion resistance of at least 300 cycles when measured according to the ASTM F793 standard.

[0046] The wall cover 1 has a thickness of at least 400 μm, preferably in the range of 450 μm to 800 μm. The wall cover 1 may have a lightness L* of at least 90, a color channel a* between -7 and +3, and a color channel b* between 2 and 12, as measured according to the TAPPI 527 standard. The wall cover typically has an opacity of at least 90%, preferably at least 95%, as measured according to the ISO 2471 standard.

[0047] As described above, Wall Cover 1 meets the requirements of Type II according to the W-102 Wall Covering Association quality standard. Furthermore, Wall Cover 1 of the present invention exhibits 25% lower carbon monoxide emissions compared to vinyl-coated Type II wall covers, according to the Boeing Aircraft Standard BSS7239 toxicity test (with combustion). Moreover, Wall Cover 1 of the present invention has 50% lower carbon monoxide emissions compared to TPO-coated Type II wall covers, according to the Boeing Aircraft Standard BSS7239 toxicity test (without combustion). Therefore, Wall Cover 1 according to the present invention is more environmentally friendly than existing vinyl-coated or TPO-coated wall covers.

[0048] Due to the advantageous properties of the wall cover described above, it can be used on the surface of the interior walls of a building, preferably in areas of moderate wear in accordance with the W-102 Wall Covering Association quality standards. In a method of protecting the surface of the interior walls of a building in areas of moderate wear in accordance with the W-102 Wall Covering Association quality standards, the interior wall is protected by the wall cover described herein.

[0049] Manufacturing method for wall covers The nonwoven base layer 3 of the wall cover 1 described herein may be manufactured by wet-laid paper-making technology. Therefore, both the backing layer 5 and the intermediate layer 7 of the nonwoven base layer 3 may be wet-laid nonwoven webs.

[0050] The method for manufacturing the wall cover 1 includes at least the following steps. The steps include forming an intermediate layer 7 by a wet papermaking process, The steps include forming a backing layer 5 by a wet papermaking process, The optional step of pushing the layers together, The steps include drying the layers to obtain a seamless two-layer nonwoven fabric sheet, and The process involves impregnating a dried nonwoven fabric sheet by applying a binder composition that penetrates both sides of the two-layer nonwoven fabric sheet, The steps include drying two binder-treated nonwoven fabric sheets to form a nonwoven fabric base layer 3, The step includes applying a coating layer 9 onto the intermediate layer 7 of the obtained nonwoven fabric substrate layer 3, The backing layer (5) of the nonwoven fabric base layer (3) contains a mixture of cellulose fibers and coarse synthetic fibers, the coarse synthetic fibers having a linear density of at least 5 dtex.

[0051] According to one embodiment, the intermediate layer 7 and the backing layer 5 may be formed on the same forming wire. This process may be a wet papermaking dual-headbox method comprising the steps of: forming a first fiber slurry containing the fibers of the intermediate layer 7 and a first solvent; forming a second fiber slurry containing the fibers of the backing layer 5 and a second solvent; transferring the first fiber slurry to a first headbox zone and simultaneously transferring the second fiber slurry to a second headbox zone; depositing the first fiber slurry and the second fiber slurry on a single continuous moving forming wire such that the first fiber slurry is positioned on top of the second fiber slurry; and applying a vacuum to the first fiber slurry and the second fiber slurry to remove at least a portion of the first solvent and / or the second solvent.

[0052] In preferred embodiments, the first and second solvents may include water. In one embodiment, the first headbox zone and the second headbox zone may comprise separate compartments for a single headbox. In another embodiment, the first headbox zone and the second headbox zone may comprise separate headboxes operating in tandem.

[0053] According to another embodiment, the intermediate layer 7 and the backing layer 5 may also be formed on separate forming wires. When formed on separate forming wires, the intermediate layer 7 and the backing layer 5 are bonded together in a wet state and optionally pressed together, typically using a wet press, and dried as a single two-layer nonwoven sheet. Drying may be carried out by a ventilated dryer. During drying, hydrogen bonds may be formed within the layers.

[0054] Furthermore, the method for manufacturing the wall cover 1 of the present invention may include a step of calandering the wall cover 1 after drying the coating layer 9. It should be understood that the embodiments of the present invention disclosed herein are not limited to the specific structures, process steps, or materials disclosed herein, but also extend to their equivalents as recognized by those skilled in the art. Furthermore, it should be understood that the terms used herein are used solely for the purpose of describing specific embodiments and are not intended to limit them.

[0055] Throughout this specification, any reference to an embodiment or embodiment means that a particular feature, structure, or characteristic described in relation to the embodiment is included in at least one embodiment of the present invention. Therefore, occurrences of the phrase "in one embodiment" or "in a particular embodiment" in various places throughout this specification do not necessarily all refer to the same embodiment. For example, where numerical values ​​are referenced using terms such as approximately or substantially, the exact numerical values ​​are also disclosed.

[0056] As used herein, multiple items, structural elements, compositional elements, and / or materials may be presented as common lists for convenience. However, these lists should be interpreted as each component of the list being individually identified as a distinct and unique component. Therefore, unless otherwise indicated, no component in a list should be interpreted as being substantially equivalent to any other component in the same list simply because it is presented within the same group. In addition, various embodiments and examples of the present invention, along with alternative examples of its various components, may be referred to herein. It should be understood that such embodiments, examples, and alternative forms should not be interpreted as being substantially equivalent to one another, but rather should be considered as distinct and independent expressions of the present invention.

[0057] Furthermore, the described features, structures, or properties can be combined in any suitable manner in one or more embodiments. The following description provides numerous specific details, including examples of length, width, shape, etc., to provide a complete understanding of embodiments of the invention. However, those skilled in the art will recognize that the invention can be carried out without using one or more of the specific details, or using other methods, components, materials, etc. In other examples, detailed descriptions or illustrations of well-known structures, materials, or operations are omitted to avoid obscuring embodiments of the invention.

[0058] Experimental example The following test methods were used to obtain the data reported in the table below. Basis weight Basis weight is measured according to TAPPI standard T410, in grams per square meter (g / m²). 2 ) will be reported.

[0059] linear density dtex (deci-tex) is a measure of the grams per 10,000 meters of fiber or yarn. dtex is a direct indicator of linear density. tear strengthTear strength in the mechanical and transverse directions is measured according to the ASTM D-751 pendulum impact method standard.

[0060] contraction rate The mechanical and transverse shrinkage rates are measured according to the methods specified in sections 7.1.2 and 7.1.3 of the W-102 Wall Covering Society quality standard. Briefly, three test specimens (250 mm × 250 mm) are measured accurately to the smallest scale of 0.5 mm in each direction. The test specimens are immersed in distilled water at room temperature for 30 minutes, removed, and dried at 87°C for 30 minutes. The test specimens are then adjusted for at least 8 hours under standard conditions as specified in ASTM standard D-751 before remeasurement. The shrinkage rate in each direction is calculated using the following formula.

[0061] Contraction rate % = [(AB) / A] × 100 Here, A = length before the test, and B = length after the test. Scrub resistance Abrasion resistance is measured according to the ASTM F793 standard.

[0062] Brightness and color channels Lightness L, color channel a, and color channel b were measured according to the TAPPI 527 standard. Opacity Opacity was measured according to the ISO 2471 standard.

[0063] Toxic gas generation during combustion The generation of toxic gases during the combustion of materials was measured in accordance with Boeing aircraft standard BSS7239. Tests were conducted on a wall cover 1 having the following nonwoven fabric base layer 3. The table below illustrates the composition of each layer forming the nonwoven fabric base layer 3. Note that the percentages reported in the table below are expressed as percentages for each layer, and not as percentages for the entire nonwoven fabric base layer 3.

[0064] [Table 1]

[0065] Here, the backing layer 5 mentioned above is 144 g / m². 2 It has a dry basis weight of 22 g / m², and the intermediate layer 7 is 22 g / m². 2 It has a dry basis weight of . As mentioned above, the backing layer 5 and the intermediate layer 7 are mixed with each other, that is, the fibers forming the backing layer 5 and the intermediate layer 7 are mixed with each other, and this enables good adhesion between the backing layer 5 and the intermediate layer 7 without the need for lamination or adhesive known in the prior art.

[0066] The nonwoven fabric base layer 3 having the above composition is impregnated with the following binder composition by sizing after drying.

[0067] [Table 2]

[0068] The binder composition used to impregnate the nonwoven fabric substrate layer 3 has a solid content of 33%. Furthermore, the binder composition used to impregnate the nonwoven fabric substrate layer 3 may further contain several additives, either alone or in combination, such as pigments, defoamers, wetting agents, curing agents, or fluorescent whitening agents. 102 g / m² 2 It is impregnated with this binder composition in a dry amount.

[0069] After the impregnated nonwoven fabric base layer 3 is dried, the nonwoven fabric base layer 3 is coated with a coating layer 9 having the following composition.

[0070] [Table 3]

[0071] The coating layer 9 is applied to the intermediate layer 7 of the nonwoven fabric base layer 3 at a density of 25 g / m². 2 The coating is applied with a dry weight of 296 g / m². The manufactured wall cover 1, which includes an impregnated nonwoven base layer 3 and a coating layer 9, has a dry weight of 296 g / m². 2 It has a basis weight of [amount].

[0072] The wall cover 1 presented above was tested according to the W-102 Wall Covering Society quality standard. To evaluate the performance of wall cover 1 of the present invention, comparative wall covers coated with TPO (comparative example wall cover 1) and PVC (comparative example wall cover 2), both of which meet the requirements of Type II as defined in the W-102 Wall Covering Society quality standard, were also tested. The comparative example TPO coated wall cover had a weight of 339.1 g / m². 2 The PVC coated wall cover in the comparative example has a basis weight of 440.8 g / m². 2 It has the following basis weight. The results obtained are summarized in the table below.

[0073] [Table 4]

[0074] As shown in the table above, the wall cover 1 according to the present invention exhibits improved grab tensile strength and tensile strength in both the mechanical and transverse directions compared to existing walls coated with TPO or PVC. While not bound by theory, the inventors believe that these improvements are due to the presence of coarse synthetic fibers in the backing layer 5. The wall cover 1 according to the present invention has higher strength than other existing walls that meet the requirements of Type II.

[0075] Combustion test results Furthermore, several combustion tests (with combustion) were conducted on the wall covers described above in accordance with Boeing aircraft standard BBS7239, and the results are summarized in the table below.

[0076] [Table 5]

[0077] Typically, the wall cover of the present invention exhibits 25% lower carbon monoxide emissions compared to a vinyl-coated type II wall cover (comparative wall cover 2) when subjected to the Boeing aircraft standard BSS7239 toxicity test (with combustion). The test results show that the wall cover of the present invention generates 25 ppm of carbon monoxide, while the vinyl-coated type II wall cover generates 100 ppm of carbon monoxide in the same test.

[0078] Furthermore, the wall cover of the present invention has 50% less carbon monoxide emissions compared to a TPO-coated Type II wall cover (Comparative Wall Cover 1) in toxicity testing (non-combustion) according to Boeing Aircraft Standard BSS7239. The test results show that the wall cover of the present invention generates 25 ppm of carbon monoxide, while the TPO-coated Type II wall cover generates 50 ppm of carbon monoxide in the same test.

[0079] Embodiments of the present invention include, in particular, the following: 1. Wall cover (1), Nonwoven fabric base layer (3), Backing layer (5), A nonwoven fabric base layer (3) including an intermediate layer (7) positioned on one side of the backing layer (5), The device comprises an intermediate layer (7) and a coating layer (9) disposed on top of it, The backing layer (5) comprises a mixture of cellulose fibers and coarse synthetic fibers, the coarse synthetic fibers having a linear density of at least 5 dtex, the wall cover (1).

[0080] 2. The backing layer (5) comprises a mixture of cellulose fibers, coarse synthetic fibers, and fine synthetic fibers, as described in Embodiment 1, for the wall cover (1). 3. The wall cover (1) according to Embodiment 1 or 2, wherein the fine synthetic fibers are present in the backing layer (5) at a rate of 15 to 30% by weight, based on the total weight of the fibers in the backing layer (5).

[0081] 4. The wall cover (1) according to either Embodiment 2 or 3, wherein the fine synthetic fibers have a linear density of 1 dtex to 4 dtex, preferably 1 dtex to 3.5 dtex.

[0082] 5. The thin synthetic fiber is selected from polyaramid fiber, polyamide fiber, polyester fiber, polyvinyl alcohol fiber, polypropylene fiber, glass fiber, and combinations thereof, as described in any one of Embodiments 2 to 4 (1).

[0083] 6. A wall cover (1) according to any one of embodiments 1 to 5, wherein coarse synthetic fibers are present in the backing layer (5) in a proportion of at least 5% by weight, preferably in the range of 5 to 30% by weight, and more preferably in the range of 5 to 20% by weight, based on the total weight of the fibers in the backing layer (5).

[0084] 7. A nonwoven fabric material according to any one of Embodiments 1 to 6, wherein the coarse synthetic fibers have a length of at least 12 mm, preferably at least 18 mm. 8. The wall cover (1) according to any one of Embodiments 1 to 7, wherein the coarse and fine synthetic fibers are selected from polyaramid fibers, polyamide fibers, polyester fibers, polyvinyl alcohol fibers, polypropylene fibers, glass fibers, and combinations thereof.

[0085] 9. A wall cover (1) according to any one of embodiments 1 to 8, wherein cellulose fibers are present in the backing layer (5) in a proportion of at least 50% by weight, preferably at least 60% by weight, based on the total weight of the fibers in the backing layer (5).

[0086] 10. The wall cover (1) according to any one of embodiments 1 to 9, wherein the backing layer (5) further comprises a wet strength additive, a dry strength additive, or a combination thereof. 11. The backing layer (5) is 130 g / m². 2 ~160g / m 2A wall cover (1) according to any one of embodiments 1 to 10, having a basis weight.

[0087] 12. The wall cover (1) according to any one of embodiments 1 to 11, wherein the intermediate layer (7) contains cellulose fibers or is substantially composed of cellulose fibers. 13. The wall cover (1) according to any one of Embodiments 1 to 12, wherein the cellulose fibers are selected from bleached or unbleached hardwood pulp or softwood pulp, bleached or unbleached chemical thermomechanical pulp from hardwood or softwood, bleached or unbleached chemical pulp from hardwood or softwood, and combinations thereof.

[0088] 14. The wall cover (1) according to any one of embodiments 1 to 13, wherein the intermediate layer (7) comprises 0 to 50% by weight of coniferous fibers and 50 to 100% by weight of hardwood fibers, based on the total weight of the fibers in the intermediate layer (7).

[0089] 15. The wall cover (1) according to any one of Embodiments 1 to 14, wherein the hardwood fibers comprise a mixture of eucalyptus fibers and birch fibers, preferably the eucalyptus fibers are present in an amount of at least 50% by weight based on the total weight of the hardwood fibers, and the birch fibers are present in an amount of up to 50% by weight based on the total weight of the hardwood fibers.

[0090] 16. The intermediate layer (7) is 10 g / m² 2 ~30g / m 2 A wall cover (1) according to any one of embodiments 1 to 15, having a basis weight. 17. A wall cover (1) according to any one of embodiments 1 to 16, wherein the fibers from the backing layer (5) and the intermediate layer (7) are mixed with each other at the layer interface.

[0091] 18. A wall cover (1) according to any one of Embodiments 1 to 17, wherein the nonwoven fabric base layer (3) is impregnated with an impregnation composition. 19. The impregnation composition comprises a binder, a filler, and optionally an additive, as described in Embodiment 18 (1).

[0092] 20. The wall cover (1) according to Embodiment 19, wherein the binder is selected from styrene acrylate, acrylic, latex, ultra-low formaldehyde acrylic, and combinations thereof.

[0093] 21. The binder is a wall cover (1) according to Embodiment 19 or 20, having a glass transition temperature of -25°C to +10°C. 22. The filler is selected from kaolin, calcium carbonate, titanium dioxide, or a combination thereof, as described in any one of embodiments 19 to 21 (1).

[0094] 23. The nonwoven fabric base layer (3) is 80 g / m². 2 ~120g / m 2 A wall cover (1) according to any one of embodiments 18 to 22, which is impregnated with an amount of the impregnating composition. 24. The coating layer (9) comprises an acrylic resin and a pigment, as described in any one of Embodiments 1 to 23, for the wall cover (1).

[0095] 25. The wall cover (1) according to any one of Embodiments 1 to 24, wherein the acrylic resin is a hydrophobic styrene acrylic resin. 26. The wall cover (1) according to any one of Embodiments 24 or 25, wherein the pigment is selected from kaolin, calcium carbonate, and mixtures thereof.

[0096] 27. The coating layer (9) is 10 g / m² by dry weight. 2 ~40g / m 2 A wall cover (1) according to any one of embodiments 1 to 26, coated on the intermediate layer (7) of the nonwoven fabric base layer (3) in an amount.

[0097] 28. 250~350g / m 2Preferably about 280-320 g / m² 2 A wall cover (1) according to any one of embodiments 1 to 27, having a basis weight. 29. A wall cover (1) according to any one of Embodiments 1 to 28, having a tear strength of at least 25% in the mechanical direction when measured according to the ASTM D-751 pendulum impact method standard.

[0098] 30. A wall cover (1) according to any one of Embodiments 1 to 29, having a lateral tear strength of at least 25% when measured according to the ASTM D-751 pendulum impact method standard.

[0099] 31. A wall cover (1) according to any one of Embodiments 1 to 30, having a maximum mechanical shrinkage rate of 2% when measured according to the quality standards of the W-102 Wall Covering Association.

[0100] 32. A wall cover (1) according to any one of Embodiments 1 to 31, having a maximum lateral shrinkage rate of 2% when measured according to the quality standards of the W-102 Wall Covering Association.

[0101] 33. A wall cover (1) according to any one of embodiments 1 to 32, having abrasion resistance of at least 300 cycles as measured according to the ASTM F793 standard. 34. A wall cover (1) as described in any one of Embodiments 1 to 33, which meets the requirements of Type II according to the W-102 Wall Covering Association quality standard.

[0102] 35. When measured according to the TAPPI 527 standard, The lightness L* is at least 90, If the color channel a* is in the range of -7 to +3, A wall cover (1) according to any one of embodiments 1 to 34, wherein the color channel b* is in the range of -2 to 12.

[0103] 36. A wall cover (1) according to any one of embodiments 1 to 35, having a thickness of at least 400 μm. 37. A wall cover (1) according to any one of embodiments 1 to 36, having an opacity of at least 90%, preferably at least 95%, when measured according to the ISO 2471 standard.

[0104] 38. A wall cover (1) according to any one of embodiments 1 to 37, wherein the coating layer (9) is embossed. 39. A wall cover according to any one of embodiments 1 to 38, wherein the printed surface (11) of the coating layer (9) is printed, and the printed surface (11) is located on the side of the coating layer (9) opposite to the side that contacts the intermediate layer (7).

[0105] 40. A method for manufacturing a wall cover (1), The steps include forming an intermediate layer (7) by a wet papermaking process, The steps include forming a backing layer (5) by a wet papermaking process, The steps include drying the layers to obtain a seamless two-layer nonwoven fabric sheet, The process involves impregnating a dried nonwoven fabric sheet by applying a binder composition that penetrates both sides of the two-layer nonwoven fabric sheet, The steps include drying two binder-treated nonwoven fabric sheets to form a nonwoven fabric base layer (3), The process includes the step of applying a coating layer (9) onto the intermediate layer (7) of the obtained nonwoven fabric base layer (3), The method wherein the backing layer (5) of the nonwoven fabric base layer (3) comprises a mixture of cellulose fibers and coarse synthetic fibers, the coarse synthetic fibers having a linear density of at least 5 dtex.

[0106] 41. The method according to Embodiment 40, wherein the backing layer (5) and the intermediate layer (7) are formed on the same forming wire. 42. The method according to Embodiment 40, wherein the backing layer (5) and the intermediate layer (7) are formed on separate forming wires, bonded together in a wet state, optionally pressed together, and dried on an air dryer as a single nonwoven sheet.

[0107] 43. The method according to any one of embodiments 40 to 42, further comprising the step of pressing the layers together, preferably using a wet press, prior to the step of drying the layers to obtain a seamless two-layer nonwoven fabric sheet.

[0108] 44. The method according to any one of embodiments 40 to 43, wherein the nonwoven web is calendered after the step of applying a coating layer (9). 45. A method of using a wall cover according to any one of Embodiments 1 to 39 on the surface of an interior wall of a building, preferably in an area of ​​moderate wear in accordance with the W-102 Wall Covering Association quality standard.

[0109] 46. ​​A method for protecting the surface of an interior wall of a building in an area of ​​moderate wear in accordance with the W-102 Wall Covering Association quality standard, using a wall cover as described in any one of Embodiments 1 to 39.

[0110] The examples described above illustrate the principles of the present invention in one or more specific applications, but it will be apparent to those skilled in the art that numerous modifications can be made to the form of implementation, usage, and details without requiring inventive creativity and without departing from the principles and concepts of the present invention. Accordingly, the present invention is not intended to be limited except by the claims set forth below.

[0111] In this specification, the verbs “to comprise” and “to include” are used as open limitations that do not exclude or require the existence of features not described. Features described in dependent claims may be freely combined with each other unless expressly stated otherwise. Furthermore, throughout this specification, the use of “a” or “an,” i.e., the singular form, should be understood not to exclude the plural. [Industrial applicability]

[0112] This technology can be used to manufacture wall covers that meet the Type II requirements set for wall covers intended for use in areas of moderate wear. These wall covers can be used in homes and public spaces as conventional wall covers for decorative purposes.

[0113] List of References Patent Documents U.S. Patent Application Publication No. 2005 / 0014431 Chinese Patent Application Publication No. 112318955 Specification

Claims

1. Wall cover (1), Nonwoven fabric base layer (3), Backing layer (5), The nonwoven fabric base layer (3) includes an intermediate layer (7) disposed on one side of the backing layer (5), The intermediate layer (7) comprises a coating layer (9) disposed on the intermediate layer (7), The backing layer (5) comprises a mixture of cellulose fibers and coarse synthetic fibers, wherein the coarse synthetic fibers have a linear density of at least 5 dtex, in the wall cover (1).

2. The wall cover (1) according to claim 1, wherein the backing layer (5) comprises a mixture of cellulose fibers, coarse synthetic fibers, and fine synthetic fibers.

3. The wall cover (1) according to claim 1 or 2, wherein the fine synthetic fibers are present in the backing layer (5) in a proportion of 15 to 30% by weight, based on the total weight of the fibers in the backing layer (5).

4. The wall cover (1) according to claim 2 or 3, wherein the thin synthetic fibers have a linear density of 1 dtex to 4 dtex, preferably 1 to 3.5 dtex.

5. The wall cover (1) according to any one of claims 2 to 4, wherein the thin synthetic fiber is selected from polyaramid fiber, polyamide fiber, polyester fiber, polyvinyl alcohol fiber, polypropylene fiber, glass fiber, and combinations thereof.

6. The wall cover (1) according to any one of claims 1 to 5, wherein the coarse synthetic fibers are present in the backing layer (5) in a proportion of at least 5% by weight, preferably in the range of 5 to 30% by weight, and more preferably in the range of 5 to 20% by weight, based on the total weight of the fibers in the backing layer (5).

7. The nonwoven fabric material according to any one of claims 1 to 6, wherein the coarse synthetic fibers have a length of at least 12 mm, preferably at least 18 mm.

8. The wall cover (1) according to any one of claims 1 to 7, wherein the coarse synthetic fiber and the fine synthetic fiber are selected from polyaramid fiber, polyamide fiber, polyester fiber, polyvinyl alcohol fiber, polypropylene fiber, glass fiber, and combinations thereof.

9. The wall cover (1) according to any one of claims 1 to 8, wherein the cellulose fibers are present in the backing layer (5) in a proportion of at least 50% by weight, preferably at least 60% by weight, based on the total weight of the fibers in the backing layer (5).

10. The wall cover (1) according to any one of claims 1 to 9, wherein the backing layer (5) further comprises a wet strength additive, a dry strength additive, or a combination thereof.

11. The aforementioned backing layer (5) is 130 g / m². ２ ~160g / m ２ A wall cover (1) according to any one of claims 1 to 10, having a basis weight.

12. The wall cover (1) according to any one of claims 1 to 11, wherein the intermediate layer (7) contains cellulose fibers or is substantially composed of cellulose fibers.

13. The wall cover (1) according to any one of claims 1 to 12, wherein the cellulose fibers are selected from bleached or unbleached hardwood pulp or softwood pulp, bleached or unbleached chemical thermomechanical pulp from hardwood or softwood, bleached or unbleached chemical pulp from hardwood or softwood, and combinations thereof.

14. The wall cover (1) according to any one of claims 1 to 13, wherein the intermediate layer (7) comprises 0 to 50% by weight of coniferous fibers and 50 to 100% by weight of hardwood fibers, based on the total weight of the fibers in the intermediate layer (7).

15. The wall cover (1) according to any one of claims 1 to 14, wherein the hardwood fibers comprise a mixture of eucalyptus fibers and birch fibers, preferably the eucalyptus fibers are present in an amount of at least 50% by weight based on the total weight of the hardwood fibers, and the birch fibers are present in an amount of up to 50% by weight based on the total weight of the hardwood fibers.

16. The intermediate layer (7) is 10 g / m². ２ ~30g / m ２ A wall cover (1) according to any one of claims 1 to 15, having a basis weight.

17. The wall cover (1) according to any one of claims 1 to 16, wherein the fibers from the backing layer (5) and the intermediate layer (7) are mixed with each other at the layer interface.

18. The wall cover (1) according to any one of claims 1 to 17, wherein the nonwoven fabric base layer (3) is impregnated with an impregnation composition.

19. The wall cover (1) according to claim 18, wherein the impregnation composition comprises a binder, a filler, and optionally an additive.

20. The wall cover (1) according to claim 19, wherein the binder is selected from styrene acrylate, acrylic, latex, ultra-low formaldehyde acrylic, and combinations thereof.

21. The wall cover (1) according to claim 19 or 20, wherein the binder has a glass transition temperature of -25°C to +10°C.

22. The wall cover (1) according to any one of claims 19 to 21, wherein the filler is selected from kaolin, calcium carbonate, titanium dioxide, or a combination thereof.

23. The nonwoven fabric base layer (3) is 80 g / m². ２ ~120g / m ２ A wall cover (1) according to any one of claims 18 to 22, which is impregnated with an amount of the impregnation composition.

24. The wall cover (1) according to any one of claims 1 to 23, wherein the coating layer (9) comprises an acrylic resin and a pigment.

25. The wall cover (1) according to any one of claims 1 to 24, wherein the acrylic resin is a hydrophobic styrene acrylic resin.

26. The wall cover (1) according to claim 24 or 25, wherein the pigment is selected from kaolin, calcium carbonate, and mixtures thereof.

27. The coating layer (9) has a dry weight of 10 g / m². ２ ~40g / m ２ The wall cover (1) according to any one of claims 1 to 26, wherein the amount is coated on the intermediate layer (7) of the nonwoven fabric base layer (3).

28. 250 to 350 g / m ２ , preferably about 280 to 320 g / m ２ of the wall covering (1) according to any one of claims 1 to 27.

29. A wall cover (1) according to any one of claims 1 to 28, having a tear strength of at least 25% in the mechanical direction when measured according to the ASTM D-751 pendulum impact method standard.

30. A wall cover (1) according to any one of claims 1 to 29, having a transverse tear strength of at least 25% when measured according to the ASTM D-751 pendulum impact method standard.

31. A wall cover (1) according to any one of claims 1 to 30, having a maximum mechanical shrinkage rate of 2% when measured according to the quality standards of the W-102 Wall Covering Association.

32. A wall cover (1) according to any one of claims 1 to 31, having a maximum lateral shrinkage rate of 2% when measured according to the quality standards of the W-102 Wall Covering Association.

33. A wall cover (1) according to any one of claims 1 to 32, having abrasion resistance of at least 300 cycles as measured according to the ASTM F793 standard.

34. A wall cover (1) according to any one of claims 1 to 33, which satisfies the requirements of Type II in accordance with the W-102 Wall Covering Association quality standard.

35. When measured according to the TAPPI 527 standard, The brightness L* is at least 90, If the color channel a* is in the range of -7 to +3, A wall cover (1) according to any one of claims 1 to 34, wherein the color channel b* is in the range of -2 to 12.

36. A wall cover (1) according to any one of claims 1 to 35, having a thickness of at least 400 μm.

37. A wall cover (1) according to any one of claims 1 to 36, having an opacity of at least 90%, preferably at least 95%, when measured according to the ISO 2471 standard.

38. The wall cover (1) according to any one of claims 1 to 37, wherein the coating layer (9) is embossed.

39. The wall cover (1) according to any one of claims 1 to 38, wherein the printed surface (11) of the coating layer (9) is printed, and the printed surface (11) is located on the side of the coating layer (9) opposite to the side that contacts the intermediate layer (7).

40. A method for manufacturing a wall cover (1), The steps include forming an intermediate layer (7) by a wet papermaking process, The steps include forming a backing layer (5) by a wet papermaking process, The steps include drying the layers to obtain a seamless two-layer nonwoven fabric sheet, The process involves impregnating the dried two-layer nonwoven fabric sheets by applying a binder composition that penetrates both sides of the two-layer nonwoven fabric sheets, The steps include drying the two layers of nonwoven fabric sheets that have been treated with a binder to form a nonwoven fabric base layer (3), The step includes applying a coating layer (9) onto the intermediate layer (7) of the obtained nonwoven fabric base layer (3), The method wherein the backing layer (5) of the nonwoven fabric base layer (3) comprises a mixture of cellulose fibers and coarse synthetic fibers, the coarse synthetic fibers having a linear density of at least 5 dtex.

41. The method according to claim 40, wherein the backing layer (5) and the intermediate layer (7) are formed on the same forming wire.

42. The method according to claim 40, wherein the backing layer (5) and the intermediate layer (7) are formed on separate forming wires, bonded together in a wet state, optionally pressed together, and dried on an air dryer as a single nonwoven sheet.

43. The method according to any one of claims 40 to 42, comprising the step of pressing the layers together, preferably using a wet press, prior to the step of drying the layers to obtain a continuous two-layer nonwoven fabric sheet.

44. The method according to any one of claims 40 to 43, wherein the nonwoven web is calendered after the step of applying the coating layer (9).

45. A method of using a wall cover according to any one of claims 1 to 39, preferably on the surface of an interior wall of a building, in an area of ​​moderate wear in accordance with the W-102 Wall Covering Association quality standards.

46. A method for protecting the surface of an interior wall of a building in an area of ​​moderate wear in accordance with the W-102 Wall Covering Association quality standard, using a wall cover according to any one of claims 1 to 39.

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