JP5699345B2 - Method for producing foam wallpaper - Google Patents

Description

  The present invention relates to a method for producing foamed wallpaper useful for wall decoration.

  As the layer structure of the foamed wallpaper, a foamed resin layer is provided on a paper base material via an adhesive layer (non-foamed resin layer B), and further, the foamed resin layer is protected in order to protect the foamed resin layer and increase the surface strength. A configuration in which A is provided is common. The foamed resin layer is generally obtained by forming a foaming agent-containing resin layer containing a thermally decomposable foaming agent and then thermally foaming the layer. Moreover, in order to ensure the strength of the foamed resin layer, the foaming agent-containing resin layer is often irradiated with an electron beam to be crosslinked with resin and then heated and foamed in many cases.

Conventionally, in order to improve the surface strength, a hard material (high crystallinity material, low melt flow rate material) is used for the resin of the foamed resin layer, or ionizing radiation curable resin is used in a printing process before the foam embossing process. It has been realized by coating to form a surface protective layer. However, in the above method, there is a problem that the high design expression by embossing is lost, the wallpaper curls with time, and the workability is lowered.

  Patent Document 1 discloses a foam wallpaper using an active energy ray-curable resin for a foam resin layer. In the method according to Patent Document 1, since the resin becomes harder than a wallpaper that does not use an energy ray curable resin, embossing is difficult to enter and wrinkle return (spring back) is likely to occur.

  Therefore, it is desired to develop a foam wallpaper having excellent surface strength and having a high design expression formed by embossing, and further, a foam wallpaper having no influence on the curling property.

Japanese Patent Laid-Open No. 10-296894

  The main object of the present invention is to provide a method for producing a foamed wallpaper having excellent surface strength and having a high design expression shaped by embossing, and further a foamed wallpaper having no effect on curling properties.

  As a result of intensive studies, the present inventor has found that the above-described object can be achieved when foamed wallpaper is produced by embossing the foamed resin layer before forming the surface protective layer. The invention has been completed.

That is, this invention relates to the manufacturing method of the following foam wallpaper.
Item 1. A method for producing foam wallpaper, the method comprising:
A non-foamed resin layer B, a foaming agent-containing resin layer, and a non-foamed resin layer A each containing an olefin resin are coextruded on a paper base so that they are laminated in this order from the paper base. Forming a laminate, and irradiating the laminate with an electron beam (1),
A step (2) of forming the foamed resin layer by foaming the foaming agent-containing resin layer;
A step (3) of embossing from the non-foamed resin layer A side;
A step (4) of forming an ionizing radiation curable resin layer on the non-foamed resin layer A so as to conform to the concavo-convex shape formed by the embossing, and curing the ionizing radiation curable resin layer to form a surface protective layer Forming step (5)
The manufacturing method which has these in order.
Item 2. Item 2. The production method according to Item 1, wherein the ionizing radiation curable resin layer is formed by spraying the ionizing radiation curable resin in the step (4).
Item 3. Item 3. The manufacturing method according to Item 1 or 2, wherein the foamed resin layer has a thickness of 300 to 900 µm, and the unevenness formed by the embossing is 100 to 500 µm .

  Hereafter, the manufacturing method of the foam wallpaper of this invention is demonstrated in detail.

  The method for producing a foam wallpaper according to the present invention includes a step (1) of forming a foaming agent-containing resin layer on a paper-based substrate, a step (2) of foaming the foaming agent-containing resin layer to form a foamed resin layer, A step (3) of embossing from the foamed resin layer side, a step (4) of forming an ionizing radiation-curable resin layer on the foamed resin layer so as to conform to the uneven shape formed by the embossing, and the ionizing radiation curing It is a manufacturing method which has the process (5) in order to harden a type | mold resin layer and form a surface protective layer.

  As described above, the present invention is characterized by the method for producing foamed wallpaper. According to the manufacturing method, since the ionizing radiation curable resin layer can be formed on the foamed resin layer so as to conform to the uneven shape formed by embossing, the surface strength is excellent, and the embossed shape is high. A foam wallpaper having a design expression can be manufactured. In the case of a surface protective layer having functionality, the surface function is not impaired by heat or a mold embossing process. Furthermore, by spraying an ionizing radiation curable resin, it is possible to produce a foam wallpaper that does not affect the curling property unlike when using a hard film such as an EVOH resin film, an ionomer resin film, or a fluorine resin film. it can.

<Foam wallpaper>
The composition of the foam wallpaper produced by the present invention is as follows.

The material of the paper base is not particularly limited as long as it has mechanical strength, heat resistance and the like suitable as a wallpaper base, and a fiber sheet can be generally used.

  Specifically, among fiber sheets, flame retardant paper (pulp-based sheets treated with flame retardants such as guanidine sulfamate and guanidine phosphate); inorganic additives such as aluminum hydroxide and magnesium hydroxide Inorganic paper including; fine paper; thin paper and the like.

The basis weight of the paper quality substrate is not limited, but preferably about 50 to 300 g / ^{m 2,} about 50 to 80 g / ^{m 2} is more preferable.

Non-foamed resin layer B
In the present invention, a non-foamed resin layer (non-foamed resin layer B) may be formed between the paper substrate and the foamed resin layer as necessary. In particular, when the non-foamed resin layer B is formed as an adhesive layer, excellent adhesion can be obtained. As the non-foamed resin layer B, for example, ethylene-vinyl acetate copolymer (EVA) or the like can be suitably used.

  The non-foamed resin layer B may contain known additives in addition to the resin component, but is preferably blended so that the content of the resin component is 70 to 100% by weight.

  The thickness of the non-foamed resin layer B is not limited, but is preferably about 5 to 50 μm, more preferably about 5 to 15 μm.

Foamed resin layer The foamed resin layer is generally formed by foaming a foaming agent-containing resin layer.

  The foaming agent-containing resin layer is not limited as long as it foams by the action of the foaming agent (for example, foams when heated), but olefinic resins and vinyl chloride are preferable. In addition, it is preferable to use a resin obtained from a combination of monomers that does not contain hydrogen bonds in the resin layer. Therefore, for example, an ethylene copolymer resin obtained from a combination of ethylene and a monomer having no OH group or COOH group can be suitably used. From this viewpoint, examples of the ethylene copolymer resin include ethylene-vinyl acetate copolymer resin (hereinafter abbreviated as “EVA”), ethylene-methyl methacrylate (EMMA), ethylene-ethyl acrylate (EEA), ethylene-methyl. Acrylate (EMA) or the like can be used. For example, a resin composition containing an EVA resin, a thermally decomposable foaming agent, an inorganic filler, a pigment, a foaming aid (zinc compound), and a cell regulator can be suitably used. In addition, stabilizers, lubricants and the like can be used as additives.

  When EVA resin is used as the resin component, the vinyl acetate content (copolymerization ratio) of the EVA resin is not limited, but is preferably about 5 to 30% by weight, more preferably about 10 to 20% by weight. .

  The melt flow rate value (MFR) of the resin component is not particularly limited, but is preferably about 5 to 75 g / 10 minutes, and more preferably about 10 to 30 g / 10 minutes.

  In addition, MFR of this specification is the value measured by the test method of JISK7210 (flow test method of thermoplastics). As test conditions, “190 ° C., 21.18 N (2.16 kgf)” described in JIS K 6760 is adopted.

  The foamed state of the foamed resin layer (for example, the size of foamed cells, the density of foamed cells, etc.) is not limited, and can be appropriately designed according to the type and use of the foamed wallpaper.

  The pyrolytic foaming agent can be selected from known foaming agents. For example, azo compounds such as azodicarbonamide (ADCA) and azobisformamide; and bidazides such as oxybenzenesulfonyl hydrazide (OBSH) and paratoluenesulfonyl hydrazide. The content of the pyrolytic foaming agent can be appropriately set according to the type of foaming agent, the expansion ratio, and the like. From the viewpoint of the expansion ratio, it is 1.5 times or more, preferably about 3 to 7 times, and the pyrolytic foaming agent is preferably about 1 to 20 parts by weight with respect to 100 parts by weight of the resin component. .

  Examples of the inorganic filler include calcium carbonate, aluminum hydroxide, magnesium hydroxide, antimony trioxide, zinc borate, and a molybdenum compound. By including an inorganic filler, an effect of suppressing see-through, an effect of improving surface characteristics, and the like are obtained. About 0-100 weight part is preferable with respect to 100 weight part of resin components, and, as for content of an inorganic filler, about 20-70 weight part is more preferable.

As for the pigment, for example, titanium oxide, zinc white, carbon black, black iron oxide, yellow iron oxide, yellow lead, molybdate orange, cadmium yellow, nickel titanium yellow, chrome titanium yellow, iron oxide (valve), cadmium red, Inorganic pigments such as ultramarine, bitumen, cobalt blue, chromium oxide, cobalt green, aluminum powder, bronze powder, titanium mica, zinc sulfide; for example, aniline black, perylene black, azo (azo lake, insoluble azo, condensed azo), many Cyclic (isoindolinone, isoindoline, quinophthalone, perinone, flavantron, anthrapyrimidine, anthraquinone, quinacridone, perylene, diketopyrrolopyrrole, dibromanthanthrone, dioxazine, thioindigo, phthalocyanine, indanthrone And organic pigments halogenated phthalocyanine), or the like. The content of the pigment is preferably about 10 to 50 parts by weight and more preferably about 15 to 30 parts by weight with respect to 100 parts by weight of the resin component.

  Examples of the foaming aid (zinc compound) include zinc oxide, hydroxide, carbonate, basic carbonate, sulfate, nitrate, phosphite, carboxylate and the like. Such a zinc compound is preferably added from the viewpoint of improving the foaming speed. Examples of the carboxylate include acetic acid, propionic acid, 2-ethylhexanoic acid, nonanoic acid, isononanoic acid, isodecanoic acid, neodecanoic acid, lauric acid, myristic acid, palmitic acid, stearic acid, isostearic acid, oleic acid, Examples include aliphatic acids such as 12-hydroxystearic acid, ricinoleic acid, and behenic acid, and aromatic acids such as benzoic acid, p-tert-butylbenzoic acid, toluic acid, salicylic acid, and naphthenic acid. The zinc carboxylate using these carboxylic acids may be in the form of a normal salt, an acid salt, or a basic salt. The above-mentioned carboxylic acids constituting the zinc carboxylate can be used, but from the viewpoint of reducing VOC, those which are powders at room temperature using fatty acids having 12 or more carbon atoms, such as zinc stearate And zinc laurate are preferred. When other carboxylic acid is used, it may be liquid or may need to be dissolved in an organic solvent in order to improve handling properties.

  The content of the zinc compound is preferably about 0.001 to 20 parts by weight, more preferably about 0.001 to 10 parts by weight with respect to 100 parts by weight of the resin composition. The thickness of the foam layer is not limited, but is preferably 50 to 150 μm in an unfoamed state (before foaming). 300-900 micrometers is preferable after foaming.

  As the cell adjusting agent, for example, a metal soap such as zinc stearate can be used. The content of the cell modifier is preferably about 0.3 to 10 parts by weight and more preferably about 1 to 5 parts by weight with respect to 100 parts by weight of the resin component.

  What is necessary is just to implement according to the method described in the manufacturing method of the postscript as a method of foaming a foaming agent containing resin layer.

Non-foamed resin layer A (skin layer)
A non-foamed resin layer A may be further formed on the front surface of the foamed resin layer.

  The non-foamed resin layer (non-foamed resin layer A) mainly protects the foamed resin layer. The resin component contained in the non-foamed resin layer A is not limited. For example, ethylene-vinyl acetate copolymer resin (EVA), ethylene-methyl methacrylate (EMMA), ethylene-ethyl acrylate (EEA), ethylene-methyl acrylate (EMA) or the like can be used.

In the present invention, among the above, a resin composition containing, as a resin component, a polymer obtained using at least one of acrylic acid (CH ₂ ═CHCOOH) and methacrylic acid (CH ₂ ═C (CH ₃ ) COOH) as a monomer. The formed layer is preferably a non-foamed resin layer A.

As the resin component, for example, a copolymer obtained by a combination of at least one monomer of acrylic acid and methacrylic acid and ethylene can be suitably used as the resin component. More specifically, it is desirable to use at least one of EMAA, ethylene-acrylic acid copolymer, and ionomer resin. As the ionomer resin, a resin having a structure in which EMAA and / or ethylene-acrylic acid copolymer molecules are intermolecularly bonded with metal ions such as sodium and zinc can be used. When such a resin component is used, it is possible to form a strong layer particularly due to hydrogen bonds in the resin, so that excellent scratch resistance, abrasion resistance, and the like can be obtained. These may be known or commercially available.

  The content of acrylic acid or methacrylic acid in the copolymer is not limited, but is preferably 15% by weight or less, more preferably about 4 to 15% by weight. Such a resin can also use a commercial item.

  The thickness of the non-foamed resin layer A is not limited, but is preferably about 5 to 50 μm, more preferably about 5 to 15 μm.

  Although the melt flow rate value of the resin component depends on the type of the resin component to be used, etc., it is generally set as appropriate within a range of 10 g / 10 min or more. Usually, it is preferably 10 to 100 g / 10 minutes, particularly preferably 10 to 95 g / 10 minutes, and more preferably 20 to 80 g / 10 minutes. By using a material having such a numerical range, more excellent scratch resistance, wear resistance and the like can be obtained.

Pattern Pattern Layer In the present invention, a pattern pattern layer may be provided on the front surface of the non-foamed resin layer A as necessary.

  The pattern layer imparts design properties to the foamed wallpaper. Examples of the design pattern include a wood grain pattern, a stone pattern, a grain pattern, a tiled pattern, a brickwork pattern, a cloth pattern, a leather pattern, a geometric figure, a character, a symbol, and an abstract pattern. The pattern can be selected according to the type of foam wallpaper.

  The pattern pattern layer can be formed, for example, by printing a pattern pattern on the front surface of the non-foamed resin layer A. In addition, when forming a pattern pattern layer, you may form a primer layer previously as needed. Examples of printing methods include gravure printing, flexographic printing, silk screen printing, and offset printing. As the printing ink, a printing ink containing a colorant, a binder resin, and a solvent (or a dispersion medium) can be used. These inks may be known or commercially available.

  As the printing ink, a printing ink containing a colorant, a binder resin, and a solvent (or a dispersion medium) can be used. These inks may be known or commercially available.

  As the colorant, known pigments or dyes can be appropriately used.

  The binder resin is, for example, an acrylic resin, a styrene resin, a polyester resin, a urethane resin, a chlorinated polyolefin resin, a vinyl chloride-vinyl acetate copolymer resin, a polyvinyl butyral resin, an alkyd resin, or a petroleum resin. Examples include resins, ketone resins, epoxy resins, melamine resins, fluorine resins, silicone resins, fiber derivatives, rubber resins, and the like.

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

  The thickness of the design pattern layer is different from the type of design pattern, but is generally preferably about 0.1 to 10 μm.

Surface protective layer (topcoat layer)
In the present invention, a surface protective layer is formed on the surface of the foamed wallpaper for the purpose of surface strength (scratch resistance, etc.), contamination resistance, and protection of the pattern layer.

  The surface protective layer contains an ionizing radiation curable resin as a resin component.

  The ionizing radiation curable resin is not limited as long as it is a resin that undergoes a crosslinking polymerization reaction upon irradiation with ionizing radiation and changes to a three-dimensional polymer structure. For example, one or more prepolymers, oligomers and monomers having a polymerizable unsaturated bond or epoxy group that can be crosslinked by irradiation with ionizing radiation in the molecule can be used. Examples thereof include acrylate resins such as urethane acrylate, polyester acrylate, and epoxy acrylate; silicon resins such as siloxane; polyester resins; epoxy resins and the like.

  The ionizing radiation curable resin is sufficiently cured when irradiated with an electron beam, but it is preferable to add a photopolymerization initiator (sensitizer) when it is cured by irradiation with ultraviolet rays.

  Photopolymerization initiators in the case of resin systems having radically polymerizable unsaturated groups include, for example, acetophenones, benzophenones, thioxanthones, benzoin, benzoin methyl ether, Michler benzoylbenzoate, Michler ketone, diphenyl sulfide, dibenzyl disulfide , Diethyl oxide, triphenylbiimidazole, isopropyl-N, N-dimethylaminobenzoate and the like can be used. In the case of a resin system having a cationic polymerizable functional group, for example, at least one kind such as an aromatic diazonium salt, an aromatic sulfonium salt, a metallocene compound, a benzoin sulfonic acid ester, and a freeloxysulfoxonium diallyl iodosyl salt. Can be used.

  Although the addition amount of a photoinitiator is not specifically limited, Generally it is about 0.1-10 weight part with respect to 100 weight part of ionizing radiation curable resins.

  As a method for forming a protective layer with an ionizing radiation curable resin, for example, a solution of an ionizing radiation curable resin may be applied by a coating method such as a gravure coating method or a roll coating method.

  In order to further impart scratch resistance and abrasion resistance to the surface protective layer formed from the ionizing radiation curable resin, an inorganic filler may be blended. Examples of inorganic fillers include powdered aluminum oxide, silicon carbide, silicon dioxide, calcium titanate, barium titanate, magnesium pyroborate, zinc oxide, silicon nitride, zirconium oxide, chromium oxide, iron oxide, boron nitride, Examples include diamond, gold sand and glass fiber.

  The addition amount of the inorganic filler is about 1 to 80 parts by weight with respect to 100 parts by weight of the ionizing radiation curable resin.

  The thickness of the surface protective layer is not limited, but is preferably about 0.1 to 15 μm.

<Method for producing foam wallpaper>
Process (1)
The method for forming the foaming agent-containing resin layer on the paper substrate in the step (1) is not particularly limited. When the resin component is vinyl chloride, a vinyl chloride paste or sheet is formed on the paper substrate by a coating method or a calendar method. When the resin component is an olefin resin, for example, co-extrusion by a T-die extruder is suitable for producing a foam wallpaper having a foam resin layer and a non-foam resin layer A on a paper base. is there. For this purpose, a multi-manifold type T-die capable of simultaneously forming two layers by simultaneously extruding molten resin corresponding to two layers can be used. In this case, the resin composition for forming the foaming agent-containing resin layer and the resin composition for forming the non-foamed resin layer are placed in separate cylinders, and two types and two layers are simultaneously extruded to form and laminate. That's fine. In this method, the coextruded laminate is simultaneously laminated (film formation) on a paper-based substrate. The resin layer laminated simultaneously with extrusion on the paper base is bonded to the paper base because it has adhesiveness by heat melting.

  Alternatively, a laminate in which two types and two layers are simultaneously formed in advance may be prepared, placed on a paper substrate, and bonded to the paper substrate by heat lamination.

  In addition, when an inorganic filler is contained in the resin composition forming the foaming agent-containing resin layer, an inorganic filler residue (so-called eyes) is easily generated at the extrusion port (so-called die) of the extrusion molding machine, and this is the sheet surface. It is easy to become a foreign material. Therefore, in such a case, in addition to the non-foamed resin layer A, the non-foamed resin layer B is preferably coextruded with the foaming agent-containing resin layer. The coextrusion molding can be performed, for example, by using a multi-manifold type T die. Thus, by simultaneously extruding and molding the foaming agent-containing resin layer between the non-foamed resin layers, it is possible to suppress the occurrence of the eyes.

  If necessary, the foaming agent-containing resin layer is then irradiated with an electron beam. Thereby, since the resin component can be crosslinked, the surface strength of the foamed wallpaper, the degree of foaming, etc. can be controlled. The energy of the electron beam is preferably about 150 to 250 kV. The irradiation amount is preferably about 10 to 70 kGy. A known electron beam irradiation apparatus can be used as the electron beam source. Crosslinking can also be performed using a chemical crosslinking agent (also referred to as a crosslinking agent or a crosslinking aid).

Process (2)
In the step (2), the foamed resin layer is formed by heating the foaming agent-containing resin layer. The heating conditions are not limited as long as the foamed resin layer is formed by the decomposition of the pyrolytic foaming agent. The heating temperature is preferably about 210 to 240 ° C., and the heating time is preferably about 20 to 80 seconds.

Step (3)
In step (3), embossing is performed from the foamed resin layer side to form an embossed pattern. Embossing can be performed by known means such as pressing an embossed plate. When it has the non-foamed resin layer A and / or the pattern layer, it is preferably embossed until it reaches the foamed resin layer. Examples of the embossed pattern include a wood grain plate conduit groove, a stone plate surface unevenness, a cloth surface texture, a satin texture, a grain texture, a hairline, and a multiline groove.

Step (4)
In the step (4), an ionizing radiation curable resin layer is formed on the foamed resin layer so as to follow the uneven shape formed by embossing.

As a method for applying a resin containing an ionizing radiation curable resin, a known method such as gravure printing can be adopted, but spraying is preferable. By spraying the ionizing radiation curable resin by spraying, the curling property is not affected unlike the case of using a hard film or the like. In addition, when the adhesiveness of a pattern pattern layer and a surface protective layer is not fully acquired, an ionizing radiation-curable resin layer can also be provided after carrying out the easy adhesion process (primer process) of the pattern pattern layer surface.

Process (5)
In the step (5), the surface protection layer is formed by curing the ionizing radiation curable resin layer.

  Examples of the ionizing radiation include visible light, ultraviolet light (near ultraviolet light, vacuum ultraviolet light, etc.), X-rays, electron beams, ion beams, etc. Among them, ultraviolet light and electron beams are preferable. When an electron beam is used and the foaming agent-containing resin layer is irradiated with an electron beam, the acceleration voltage is preferably lower than that of the irradiation.

  As the ultraviolet light source, a light source such as an ultra-high pressure mercury lamp, a high pressure mercury lamp, a low pressure mercury lamp, a carbon arc lamp, a black light fluorescent lamp, or a metal halide lamp can be used. The wavelength of ultraviolet light is about 190 to 380 nm.

  As the electron beam source, various electron beam accelerators such as a cockcroft-wald type, a bandegraft type, a resonant transformer type, an insulating core transformer type, a linear type, a dynamitron type, and a high frequency type can be used. The energy of the electron beam is preferably about 100 to 1000 keV, more preferably about 100 to 300 keV. The irradiation amount of the electron beam is preferably about 20 to 150 kGy.

  With the foamed wallpaper manufacturing method of the present invention, it is possible to manufacture a foamed wallpaper having excellent surface strength and a high design expression shaped by embossing. Further, by spray-coating an ionizing radiation curable resin, a foamed wallpaper that does not affect the curling property unlike the case of using a hard film or the like can be produced. In the case of a surface protective layer having functionality, the surface function is not impaired by heat or a mold embossing process.

It is a schematic diagram of the foam wallpaper used in Examples 1 and 2.

  Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to the examples.

Examples 1 and 2
A foamed resin layer (500 μm), a pattern pattern layer (1 μm), and a surface protective layer (5 g / m ² to 30 g / m ² ) on a paper base (product number “CP-60PDK”, manufactured by Chuetsu Pulp, thickness 100 μm) ) Were laminated in this order.
The composition of the foaming agent-containing resin layer for forming the foamed resin layer was as shown in Table 1 below.
The composition of the surface protective layer was 100% urethane acrylate.

The foam wallpaper was produced by the following procedure.
(1) A composition for forming a foaming agent-containing resin layer was heated and melted, and the foamed layer was coated to form a laminate on a paper base.
(2) After the pattern layer was formed on the laminate, it was heated and foamed at about 240 ° C. in a foaming furnace. After foaming, a design was formed by embossing from the resin layer side (unevenness difference of 100 to 500 μm).
(3) The laminate was sprayed with an ionizing radiation curable resin from the resin layer side and cured with an electron beam (165 kV, 50 kGy).

Examples 3 and 4
Non-foamed resin layer B (10 μm), foamed resin layer (500 μm), non-foamed resin layer A (10 μm), pattern pattern layer (1 μm) on a paper-based substrate (product number “WK665DO”, manufactured by Kojin, thickness 110 μm) and a surface protective layer ^{(5 g / m 2 ~30 g} / m 2) to prepare a foamed wallpaper stacked in this order.
The composition of the non-foamed resin layer B was EVA 100%.
The composition of the foaming agent-containing resin layer for forming the foamed resin layer was as shown in Table 2 below.
The composition of the non-foamed resin layer A was EMAA 100%.
The composition of the surface protective layer was 100% urethane acrylate.

The foam wallpaper was produced by the following procedure.
(1) A composition for forming a foaming agent-containing resin layer and a composition for forming non-foamed resin layers A and B are heated and melted, and a laminate is formed on a paper base by simultaneously extruding three layers. Formed. (2) The laminate was irradiated with an electron beam from the resin layer side (200 kV, 30 kGy).
(3) Foam wallpaper was obtained in the same manner as in Examples 1 and 2 for the formation of the pattern layer, heating and foaming, embossed design, and formation of the surface protective layer on the laminate.

Comparative Example 1
The composition of the foaming agent-containing resin layer for forming the foamed resin layer, the composition of the surface protective layer, the coating amount and the forming method are as shown in Table 3 below, except that the surface protective sheet is foamed and embossed after laminating, Foamed wallpaper was obtained in the same manner as in Examples 1 and 2.

Test example 1
Curling property: A sample of 10 cm × 10 cm is immersed in room temperature water and left for 1 minute. After taking out the sample, lightly wipe off moisture, extend on a flat plate with both hands and leave for 1 minute. The ground contact area at that time was defined as follows and evaluated.
◎: 80% or more ○: 60% or more and less than 80% ×: Less than 60%

Test example 2
Designability: The embossed unevenness difference without the surface protective layer was defined and evaluated as follows.
◎: 90% or more ○: 70% or more and less than 90% ×: less than 70%

(Discussion)
From Table 3, it can be seen that desired properties in design and curl can be obtained by embossing the laminate before spraying the ionizing radiation curable resin before forming the surface protective layer.

Claims (3)

A method for producing foam wallpaper, the method comprising:
A non-foamed resin layer B, a foaming agent-containing resin layer, and a non-foamed resin layer A each containing an olefin resin are coextruded on a paper base so that they are laminated in this order from the paper base. Forming a laminate, and irradiating the laminate with an electron beam (1),
A step (2) of forming the foamed resin layer by foaming the foaming agent-containing resin layer;
A step (3) of embossing from the non-foamed resin layer A side;
A step (4) of forming an ionizing radiation curable resin layer on the non-foamed resin layer A so as to conform to the concavo-convex shape formed by the embossing, and curing the ionizing radiation curable resin layer to form a surface protective layer Forming step (5)
The manufacturing method which has these in order.   The manufacturing method according to claim 1, wherein the ionizing radiation curable resin layer is formed by spraying the ionizing radiation curable resin in the step (4). The manufacturing method of Claim 1 or 2 whose thickness of the said foaming resin layer is 300-900 micrometers, and the uneven | corrugated difference formed by the said embossing is 100-500 micrometers .

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