JP4459840B2 - Method for producing olefin foam wallpaper - Google Patents

Description

Improved process for the preparation of olefin foam wall paper surface properties related.

  Conventionally, wallpaper including a foamed layer of vinyl chloride resin has been used, but recently, foamed wallpaper of olefin resin has been proposed. FIG. 8: is sectional drawing which shows the state (a) embossed with the olefin foam wallpaper, and the state (b) before embossing.

  Olefin-based resins are flammable and cannot be used as wallpaper as they are, so they are made flame retardant by adding more than half of the inorganic filler. However, the printability is poor due to surface irregularities, outgassing, and the like. In addition, since a large amount of the filler is added, a soft resin must be used as the resin, and the scratch resistance of the product surface is greatly reduced. Further, since the surface is porous, there are problems such as poor contamination resistance. A foam wallpaper having good surface properties using an olefinic resin has been desired.

The present invention provides a method for producing a surface scratch resistance and stain resistance good olefin foam wall paper.

The method for producing an olefin-based foam wallpaper according to the present invention is a method of laminating a base material and an olefin foam layer by forming an unfoamed olefin layer on the adhesive layer surface of the base material on which an adhesive layer is formed and then foaming by heating. and the body, then laminated to the printed pattern layer on the surface of the opposite side comes to the pre-printed pattern layer is made from a formed film unfoamed thermoplastic resin layer said olefin foam layer, as well as adhesive, the printing A method of providing unevenness by embossing the surface including the pattern layer while keeping the surface heated.
An unfoamed olefin layer was formed on the adhesive layer surface of the base material on which the adhesive layer was formed, and then heated to form a laminate of the base material and the olefin foam layer, and then a printed pattern layer was formed in advance. An unfoamed thermoplastic resin layer made of a film is embossed through an adhesive layer made of an adhesive resin melt-extruded onto the olefin foam layer so that the printed pattern layer comes out on the surface opposite to the olefin foam layer. A method of providing concavities and convexities by bonding with a plate and embossing.
Further, an unfoamed olefin layer is formed on the adhesive layer surface of the substrate on which the adhesive layer is formed, and a non-foamed film made of a film in which a printed pattern layer is previously formed on the unfoamed olefin layer via the adhesive layer. After the thermoplastic resin layer is laminated so that the printed pattern layer comes out on the surface opposite to the unfoamed olefin layer, the unfoamed olefin layer is foamed, and the printed pattern layer is A method of embossing the surface including the surface in a heated state to provide unevenness.
Further, the non-foamed olefin layer formed on the surface of the adhesive layer of the substrate is formed by extrusion lamination from a T-die.

  Since the surface of the olefin foam wallpaper of the present invention is composed of a non-foamed thermoplastic resin, sharp printing is reproduced compared to the conventional olefin foam wallpaper whose surface is composed of a foam resin layer, In addition, scratch resistance and contamination resistance were improved as surface properties. In addition, as a manufacturing method thereof, since the olefin foam layer is not foamed, non-foamed thermoplastic resin can be laminated and printed, and foaming and embossing can be performed at the same time. Furthermore, an olefin foam wallpaper having excellent physical properties can be produced.

The olefin foam wallpaper of the present invention is an olefin foam wallpaper in which a substrate, a foam olefin layer, a non-foamed thermoplastic resin layer, and a print layer are laminated in this order, and the surface including the print layer is provided with irregularities. An adhesive layer is interposed between the material and the foamed olefin layer, and between the foamed olefin layer and the non-foamed thermoplastic resin layer.
FIG. 1 is a cross-sectional view (a) of an olefin foam wallpaper according to an embodiment of the present invention, and cross-sectional views (b) and (c) showing the structure of a layer before lamination and embossing.
FIG. 2 is a cross-sectional view (a) of an olefin foam wallpaper according to an embodiment of the present invention and a cross-sectional view (b) showing the structure of a layer before foaming and embossing.
3-7 is a conceptual diagram for demonstrating the manufacturing method of the olefin foam wallpaper of this invention.

The base material used in the present invention, flame燃紙, aluminum hydroxide paper for wallpaper, inorganic paper, basis weight generally paper 50 to 300 g / m ^2, preferably, backing paper, etc. 70~160g / m ² It is.

  The olefin foam layer is formed by melting and extruding a resin in which a flame retardant inorganic filler, a colorant, a foaming agent, an antioxidant, etc. are mixed with a polyolefin-based resin, foaming at the same time, and then cooling and pasting the substrate sheet Match. Alternatively, it can be obtained by melt extrusion at a temperature lower than the decomposition temperature of the foaming agent, laminating on a base material sheet, and heating and foaming.

  Examples of the polyolefin resin as the main component of the olefin foam layer include ethylene homopolymer, α-olefin other than ethylene and ethylene as main components, vinyl ester (ex. Vinyl acetate), or unsaturated carboxylic acid ester (ex. Ethyl). Acrylate), a homopolymer of propylene, a copolymer of propylene as a main component and an olefin other than propylene, and the like, and two or more of these may be used in combination. In view of foaming properties, polyethylene is preferred.

  Because of the flame retardancy required for wallpaper, various flame retardants such as aluminum hydroxide, magnesium hydroxide, antimony trioxide, zinc borate, and molybdenum compounds are added to the olefin foam. Of these, aluminum hydroxide and magnesium hydroxide are preferred in view of cost and safety. In order to bring out the flame retardancy of the sheet, it is necessary to add 100 parts or more of a flame retardant inorganic filler to the resin 100. Desirably 140 parts or more can be said. Moreover, you may add an organic type flame retardant as needed.

  An organic pigment or an inorganic pigment may be added to the olefin foam layer.

  As the foaming agent for forming the olefin foamed layer, various foaming agents usually used as a foaming agent for olefinic resins can be used, but azo-based such as ADCA and hydradite-based such as OBSH are preferable. Moreover, phenol type, phosphorus type, hindered phenol type, etc. can be used as antioxidant.

  Various materials can be used as the non-foamed thermoplastic resin of the present invention (hereinafter referred to as non-foamed resin). The non-foamed resin may be transparent or colored and opaque. Further, the film may be laminated by melt extrusion lamination. For flame retardancy as a non-foamed resin, a flame retardant inorganic filler or an organic flame retardant may be used in combination. The film thickness of the non-foamed resin provided on the olefin foam wallpaper of the present invention is preferably 20 μm or less in view of embossability and flame retardancy. As the resin used for extrusion coating as a non-foamed resin, polyethylene, polypropylene, polybutene, polystyrene, methacrylic, thermoplastic polyester, PVA, and various copolymers can be used. Examples of the film used for forming the non-foamed resin include polyethylene terephthalate, polybutylene terephthalate, acrylic film, PP film, eval film, and the like, which may be either stretched or unstretched.

  As a method for producing olefin foam wallpaper, a foamed olefin sheet is bonded to the base material, or an unfoamed olefin layer is formed on the base material and foamed simultaneously to prepare a laminated sheet of the base material and the olefin foam layer. To do. On the other hand, if a film that will be a non-foamed resin is prepared and pattern printing is performed on the film surface that will be a non-foamed resin in advance, and the adhesiveness to the foamed olefin layer is weak, an adhesive may be coated on the back surface or adhesive The resin is melt extruded and coated. As the adhesive, various resin systems such as polyester, urethane, olefin-based, vinyl acetate-based, and polyamide-based can be used. The foamed olefin sheet provided on the substrate is heated to about 150 to 250 ° C. in a heating furnace, and simultaneously embossed and laminated with the preprinted sheet on the embossed plate to obtain an olefin foamed wallpaper. When the adhesive resin is melt-extruded, a laminate of a base material and an olefin foam layer and a film as a non-foamed resin may be directly bonded and embossed.

  As a method for producing the olefin foam wallpaper of the present invention, the base material is laminated with an unfoamed olefin layer containing a foaming agent via an adhesive layer, and further, a non-foamed resin layer is laminated via an adhesive layer, Heating the sheet formed as a laminate obtained by printing on the non-foamed resin, foaming the unfoamed olefin layer, and while maintaining the surface in a heated state, the embossing roll provides unevenness, the cooling roll, An olefin foam wallpaper can be obtained by fixing the uneven shape.

  Various printing methods such as gravure, offset, flexo, and silk are possible as the printing method for the olefin foam wallpaper of the present invention. As the ink used for printing, various solvent-based and water-based printing inks can be used. Examples of main resin systems include acrylic, urethane, polyester, cellulose, and casein.

  If the adhesion between the base material and the olefin foam layer or unfoamed olefin layer, or the adhesion between the olefin foam layer and the non-foamed resin layer is weak, the adhesive surface of the resin layer is corona treated, or an isocyanate and polyol resin are used. Thus, it is desirable to improve the adhesiveness between the respective layers by providing a coating such as a two-component curing adhesive or a thermal adhesive resin layer. In addition, organic, inorganic, and glitter pigments can be added to the non-foamed resin layer, the olefin foam layer, and the like, and a gloss-adjustable transparent coat may be applied to the non-foamed resin surface. Next, the manufacturing method of the olefin foam wallpaper of this invention is demonstrated concretely by an Example.

[Example 1]
Backing paper: Aluminum hydroxide paper Cosmo WG 140 g / m ² (trade name, manufactured by Oji Paper Co., Ltd.) and an olefin foam sheet are laminated using a polyester polyol / isocyanate adhesive. In addition, the said olefin foam sheet was created by the following. Using the raw materials having the following composition, an inflation film was formed to obtain a foamed sheet {resin temperature during extrusion: 160 ° C., 0.3 m / m thick sheet, foaming ratio: 2.0}

1) Raw material composition Ethylene-α / olefin copolymer resin 100 parts by weight Magnesium hydroxide 120 parts by weight Foaming agent OBSH 10 parts by weight Titanium 10 parts by weight 2) Extrusion temperature of the film-forming resin 160 ° C. at the die discharge part
Film thickness 0.3m / m

Separately, non-foamed heat 12μm acrylic resin as a thermoplastic resin and a polyethylene terephthalate resin {hereinafter referred to as PET film} using a co-extruded film with, it performs gravure printing two colors in an acrylic resin surface of the film. The ink used was acrylic ink UE (trade name, manufactured by Showa Ink Industries, Ltd.). Further, the non-printed surface of the printed film, that is, the PET surface was subjected to corona treatment, a PET adhesion primer was applied, and an olefin adhesion primer was gravure coated so that it could be adhered to the foamed sheet.

“PET adhesion primer” polyester polyol / isocyanate two-component urethane (manufactured by Showa Ink Industries, Ltd.)
"Olefin adhesion primer" change of vinyl chloride-vinyl acetate copolymer (manufactured by Showa Ink Industries)

  When the foam sheet surface of the foam sheet / backing paper is heated with a far-infrared heater as shown in FIG. 3 and laminated with the olefin adhesion primer coat surface of the printed PET film at a surface temperature of 200 ° C. At the same time, an olefin foam wallpaper 1 was obtained by embossing with an embossing roll.

[Example 2]
The surface of the backing paper Cosmo WG (supra) is coated with a modified olefin paint for improving adhesion. As shown in FIG. 4, an unfoamed olefin resin was extruded from a T-die and laminated on the coated surface of the modified olefin paint on the backing paper.

Composition of extruded resin Ethylene-α / olefin copolymer resin 100 parts by weight Aluminum hydroxide 100 parts by weight Foaming agent ADCA 7 parts by weight Titanium 10 parts by weight

  Separately, as in Example 1, an acrylic / PET coextruded film was used as a non-foamed thermoplastic resin, printed on the acrylic surface, and a PET adhesion primer and an olefin adhesion primer were gravure coated on the PET surface. Next, as shown in FIG. 5, the unfoamed olefin resin laminated on the backing paper is foamed by heating at about 200 ° C. × 1 minute in the heating foaming unit 20, and in the heating unit 21 such as a far infrared heater, While maintaining the temperature, the printed PET film was laminated with the surface coated with the olefin primer and simultaneously embossed to obtain an olefin foam wallpaper 2.

Example 3
The surface of the backing paper Cosmo WG (supra) is coated with a modified olefin paint for improving adhesion. As shown in FIG. 4, unfoamed olefin resin 2 'was extruded from a T-die and laminated on the coated surface of the modified olefin paint on the backing paper.

Composition of extruded resin Ethylene-α / olefin copolymer resin 100 parts by weight Aluminum hydroxide 100 parts by weight Foaming agent ADCA 7 parts by weight Titanium 10 parts by weight

  The resulting unfoamed olefin resin 2 'surface is coated with a modified olefin paint Conistol P (trade name, manufactured by Mitsui Petrochemical Co., Ltd.) as a primer as shown in FIG. The non-foamed thermoplastic resin was extrusion coated.

<Resin composition>
Polypropylene block polymer 100 parts by weight Magnesium hydroxide 50 parts by weight

  After the corona treatment was applied to the coated surface of the polypropylene resin, a primer and two-color pattern printing were performed using a gravure printing machine. The used primers and inks are as follows.

Primer: Urethane two-component primer “AFS Medium” (trade name, manufactured by Showa Ink Industry Co., Ltd.)
Pattern printing ink: Acrylic ink "UE" (trade name, manufactured by Showa Ink Industry Co., Ltd.)

  The material structure of the obtained sheet is shown in the sectional view of FIG. Next, as shown in FIG. 7, after heating the unfoamed olefin layer by heating at 200 ° C. for about 1 minute in the heated foaming portion 20, the obtained sheet is heated using a far infrared heater as a heat source. Embossing was performed while maintaining a high temperature at the portion 21 to obtain an olefin foam wallpaper 3 having irregularities on the surface shown in FIG.

[Comparative Example 1]
Backing paper: Aluminum hydroxide paper Cosmo WG 140 g / m ² (trade name, manufactured by Oji Paper Co., Ltd.) and a foamed sheet are laminated using a urethane-based adhesive. The olefin foam sheet was formed into a film by the inflation method under the following conditions.

1) Raw material composition Ethylene-α / olefin copolymer resin 100 parts Magnesium hydroxide 120 parts Foaming agent OBSH 10 parts Titanium 10 parts 2) Film formation Extrusion temperature of resin 160 ° C at die discharge part
Film thickness 0.3m / m

  Next, two-color printing is performed on the surface of the olefin foam layer with a gravure printing machine. The obtained printed sheet was heated to a surface temperature of 200 ° C. with a heater as shown in FIG. 3, embossed with an embossing roll 11 and cooled to obtain an olefin foam wallpaper.

  Table 1 shows the performance of the obtained olefin foam wallpaper of Examples and Comparative Examples.

*) During the open time, apply starch paste to the backing paper, match the applied surface, and check the peelability after 1 hour.

Sectional configuration diagram (a) of an olefin foam wallpaper according to an embodiment of the present invention and sectional views (b) and (c) showing the configuration of a layer before lamination and embossing Sectional view (a) of olefin foam wallpaper according to an embodiment of the present invention and sectional view (b) showing the structure of a layer before foaming and embossing The conceptual diagram which shows the manufacturing method of the olefin foam wallpaper of this invention The conceptual diagram which shows the 2nd manufacturing method of the olefin foam wallpaper of this invention The conceptual diagram which shows the lamination embossing process of the said 2nd manufacturing method The conceptual diagram which shows the 3rd manufacturing method of the olefin foam wallpaper of this invention The conceptual diagram which shows the firing and embossing process of the said 3rd manufacturing method Cross section of wallpaper with uneven surface of conventional olefin foam wallpaper (a), Cross section of wallpaper before embossing (b)

Explanation of symbols

S Olefin foam wallpaper 1 Backing paper 2 Foam layer 2 'Unfoamed layer 3 Non-foamed thermoplastic resin layer 4, 4a, 4b Adhesive layer 5 Printing ink layer 6 Foamed portion 10 Emboss roll 11 Emboss pressure roll 12 Cooling roll 12N Nip roll 13 Supply Paper part 14 Winding upper part 15 Guide roll 16 T die 17 Adhesive 18 Coating roll 18N Coating pressure roll 19 Doctor 20 Heating foaming part 21 Heating part 22 Drying part

Claims (4)

A method for producing an olefin foam wallpaper in which an adhesive layer, an unfoamed olefin layer, an adhesive layer, and a non-foamed thermoplastic resin layer composed of a film on which a printed pattern layer has been previously formed are laminated in order on a base material. After forming an unfoamed olefin layer on the surface of the adhesive layer of the base material on which the layer was formed, a laminate of the base material and the olefin foam layer was formed by foaming by heating, and then a printed pattern layer was formed in advance. A non-foamed thermoplastic resin layer made of a film is laminated and bonded so that the printed pattern layer comes out on the surface opposite to the olefin foam layer, and embossed while the surface including the printed pattern layer is kept heated. A method for producing an olefin foam wallpaper, characterized by providing irregularities by processing. A method for producing an olefin foam wallpaper in which an adhesive layer, an unfoamed olefin layer, an adhesive layer, and a non-foamed thermoplastic resin layer composed of a film in which a printed pattern layer has been previously formed are laminated on a substrate in order. A film on which a non-foamed olefin layer is formed on the adhesive layer surface of the base material on which the layer has been formed, and then foamed by heating to form a laminate of the base material and the olefin foam layer, and then a printed pattern layer is formed in advance. An embossed plate through an adhesive layer made of an adhesive resin obtained by melting and extruding the non-foamed thermoplastic resin layer on the olefin foam layer so that the printed pattern layer comes out on the surface opposite to the olefin foam layer A method for producing an olefin foamed wallpaper, wherein the ruggedness is formed by embossing and bonding. A method for producing an olefin foam wallpaper in which an adhesive layer, an unfoamed olefin layer, an adhesive layer, and a non-foamed thermoplastic resin layer composed of a film in which a printed pattern layer is formed in advance are laminated on a substrate, A non-foamed heat comprising a film in which a non-foamed olefin layer is formed on the surface of the base material on which the adhesive layer is formed, and a printed pattern layer is previously formed on the unfoamed olefin layer via the adhesive layer. After forming a laminated body in which the printed resin layer is laminated so that the printed pattern layer is exposed on the surface opposite to the unfoamed olefin layer, the unfoamed olefin layer is foamed and includes the printed pattern layer A method for producing an olefin foamed wallpaper, which comprises embossing to provide unevenness while maintaining the surface in a heated state. The method for producing an olefin foam wallpaper according to any one of claims 1 to 3, wherein an unfoamed olefin layer formed on the surface of the adhesive layer of the base material is formed by extrusion lamination from a T-die.

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