JP6930066B2 - Foam wallpaper and manufacturing method of foam wallpaper - Google Patents

Description

The present invention relates to a foam wallpaper used for use as a building interior material such as a floor, a wall, and a ceiling, and a method for manufacturing the foam wallpaper.

Manufacture of foamed wallpaper by cross-linking a foamed resin layer of a laminated sheet (so-called raw fabric for foamed wallpaper) in which at least a foamed resin layer is laminated on a paper base material (so-called backing paper for wallpaper) and then foaming. Can be done. As an example of such a foam wallpaper, Patent Document 1 discloses a foam wallpaper having a paper base material, a resin layer and a pattern pattern layer, and having improved adhesion and surface rubbing characteristics of the pattern pattern layer.

JP-A-2007-196590

In the method for manufacturing foam wallpaper, especially plastic foam wallpaper, as a method of simultaneously imparting design and product thickness and surface physical properties such as strength and smoothness, a resin layer is made of a high foam layer and a low / non-foam layer. Multi-layering has been done. However, there is a problem that the multi-layering of the resin layer causes a decrease in productivity such as a complicated process and a decrease in line speed.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a single-layer plastic foam wallpaper having high strength, stain resistance, and non-land concealment property, and a method for producing the same.

In order to solve the above problems, the foam wallpaper according to one aspect of the present invention includes a paper base material, a foam resin layer containing an aqueous emulsion resin, a foaming agent and an inorganic filler, and an acrylic resin and a filler. The surface protective layer containing the above is laminated.
The paper substrate has a basis weight of 50 g / m ² or more and 100 g / m ² or less and a thickness of 80 μm or more and 150 μm or less. The foamed resin layer has a basis weight of 50 g / m ² or more and 220 g / m ² or less and a foaming ratio of 3 times or more. The surface protective layer has a basis weight of 5 g / m ² or more and 40 g / m ² or less. The total basis weight of the paper base material, the foamed resin layer, and the surface protection layer ^{is preferably 170 g / m 2} or less. The foaming agent is preferably a heat-expandable microcapsule foaming agent.

For example, in the method for producing foamed wallpaper according to one aspect of the present invention, ^{plain paper having a basis weight of 50 g / m 2} or more and 100 g / m ² or less and a thickness of 80 μm or more and 150 μm or less is used as a paper base material, and ethylene-is used as a foamed resin layer. A paste obtained by adding 80 parts by mass of an inorganic filler and 10 parts by mass of a heat-expandable microcapsule foaming agent to 100 parts by mass of a vinyl acetate copolymer resin is coated so as to ^{have a basis weight of 50 g / m 2} or more and 220 g / m ^{2 or less.} Apply by the method, and apply acrylic resin as a surface protective layer ^{by the lip coater method so that the basis weight is 5 g / m 2} or more and 40 g / m ² or less, and the foam furnace outlet paper surface temperature is 150 ° C. and the embossed heater outlet paper surface temperature is 180 ° C. At the same time, immediately after passing through the embossing heater, pressurize with an embossing roll to give an embossed pattern, and then cool and dry.

According to one aspect of the present invention, it is possible to produce a single-layer plastic foam wallpaper having high strength, stain resistance, and non-land concealment property.

It is a schematic cross-sectional view which shows an example of the cross-sectional shape of the foam wallpaper which concerns on one Embodiment of this invention.

<Embodiment>
Hereinafter, a method for manufacturing a foam wallpaper according to an embodiment of the present invention will be described with reference to the drawings. Here, the drawings are schematic, and the relationship between the thickness and the plane dimensions, the ratio of the thickness of each layer, and the like are different from the actual ones. Further, the embodiments shown below exemplify a configuration for embodying the technical idea of the present invention, and the technical idea of the present invention describes the material, shape, structure, etc. of the constituent parts as follows. It is not specific to the thing. The technical idea of the present invention may be modified in various ways within the technical scope specified by the claims stated in the claims.

(Foam wallpaper)
FIG. 1 shows an example of the cross-sectional shape of the foam wallpaper 10 according to the embodiment of the present invention.
In the foamed wallpaper 10 according to the present embodiment, the foamed resin layer 2, the appropriately provided pattern layer 3, and the surface protective layer 4 are laminated in this order on the paper base material 1 as the base material. Further, an embossed pattern 5 is formed on the surface of the foam wallpaper 10 according to the present embodiment.

[Paper base material]
The paper base material 1 is a so-called wallpaper backing paper (fiber sheet). Examples of the paper base material 1 include general paper for wallpaper (pulp-based sheet size-treated with a known sizing agent); flame-retardant paper (pulp-based sheet treated with a flame-retardant agent such as guanidine sulfamate and guadinin phosphate). Inorganic paper containing inorganic additives such as aluminum hydroxide and magnesium hydroxide; high-quality paper; thin paper; fiber-blended paper (made by mixing pulp and synthetic fiber) and the like. ..

In the present embodiment, plain paper can be applied as the paper base material 1 ^{, and the wall covering material has a basis weight of 50 g / m 2} or more and 100 g / m ² or less and a thickness of 80 μm or more and 150 μm or less. The rigidity required for this is ensured.

[Effervescent resin layer]
The foamed resin layer 2 is formed by applying a resin containing a foaming agent to the surface of the paper base material 1. In the present embodiment, a foaming agent, a plasticizer, a stabilizer, a thickener and other organic additives, and an inorganic powder (inorganic filler) as a filler are appropriately mixed with the resin according to the intended use, and paper is mixed. The foamed resin layer 2 is provided by coating the surface of the base material 1 in the form of a sheet or a pattern.
Examples of the resin coating method include a knife coating method, a nozzle coating method, a die coating method, a lip coating method, a comma coating method, a gravure coating method, a rotary screen coating method, a reverse roll coating method, and the like. ..

As the resin contained in the foamed resin layer 2, a resin that can be used in the form of an aqueous emulsion, for example, a polyolefin-based resin can be used, and in particular, at least an ethylene copolymer having ethylene and a component other than ethylene as a monomer. One is more preferable. Furthermore, ethylene-vinyl acetate copolymer (EVA) resin can be preferably used.

Ethylene copolymers are suitable for extrusion film formation in terms of melting point and MFR. Examples of the ethylene copolymer include an ethylene-vinyl acetate copolymer (EVA), an ethylene-methyl methacrylate copolymer (EMMA), an ethylene-ethyl acrylate copolymer (EEA), and an ethylene-methyl acrylate copolymer (EEA). EMA), ethylene-methacrylic acid copolymer (EMAA), ethylene-α-olefin copolymer and the like can be mentioned. These ethylene copolymers can be used alone or in admixture of two or more. Among these ethylene copolymers, at least one of ethylene-vinyl acetate copolymer, ethylene-methylmethacrylate copolymer and ethylene-methacrylic acid copolymer is particularly preferable, and when these are used in combination with other resins, it is preferable. The content of at least one of the ethylene-vinyl acetate copolymer, the ethylene-methyl methacrylate copolymer and the ethylene-methacrylic acid copolymer is preferably 70% by mass or more, more preferably 80% by mass or more.

The content of the monomer other than ethylene contained in the ethylene copolymer is, for example, preferably 5% by mass or more and 25% by mass or less, and more preferably 9% by mass or more and 20% by mass or less. By adopting such a copolymerization ratio, the extruded film-forming property is further enhanced. As a specific example, the ethylene-vinyl acetate copolymer preferably has a copolymerization ratio (VA amount) of vinyl acetate of 9% by mass or more and 25% by mass or less, and more preferably 9% by mass or more and 20% by mass or less. The ethylene-methylmethacrylate copolymer preferably has a copolymerization ratio (MMA amount) of 5% by mass or more and 25% by mass or less, and more preferably 5% by mass or more and 15% by mass or less. The ethylene-methacrylic acid copolymer preferably has an acrylic acid copolymerization ratio (MAA amount) of 2% by mass or more and 15% by mass or less, and more preferably 5% by mass or more and 11% by mass or less.

Here, the resin contained in the foamed resin layer 2 has an MFR (melt flow rate) of 10 g or more and 100 g or less (10 g) per 10 minutes measured under the conditions of 190 ° C. and a load of 21.18 N described in JIS K 6922, for example. / 10 minutes or more and 100 g / 10 minutes or less) is preferable. When the MFR is within the above range, the temperature rise when the foamed resin layer 2 is formed by extrusion film formation is small, and the film can be formed in a non-foamed state. Therefore, when the pattern layer 3 is formed later, it is smooth. It is possible to print on various surfaces and there is little pattern omission. If the MFR is too large, the resin is too soft, and the scratch resistance of the foamed resin layer 2 to be formed may be insufficient.

Further, as the foaming agent contained in the foamed resin layer 2, a foaming agent usually used for a known foaming wallpaper can be used, but in particular, the heat-expandable microcapsule foaming agent has a performance (expansion ratio, foaming ratio, It is preferable from the viewpoint of strength). In addition, azo, hydrazide, nitroso, etc. can be used.
The amount of the foaming agent added depends on the thickness of the foamed resin layer 2 and the expansion ratio (expansion rate of the volume before and after foaming), but for example, 1 part by mass or more and 20 parts by mass or less with respect to 100 parts by mass of the resin. It is preferably about 5 parts by mass or more and 15 parts by mass or less.
By setting the basis weight and foaming ratio of the foamed resin layer 2 to a basis weight of 50 g / m ² or more and 220 g / m ² or less and 3 times or more, a feeling of volume sufficient for obtaining non-land concealment. And has excellent surface strength, and the uneven shape of the embossed pattern 5, which will be described later, can be sharply reproduced.

Examples of the inorganic powder contained in the foamed resin layer 2 include calcium carbonate, aluminum hydroxide, magnesium hydroxide, silica sand, talc, silicas, magnesium silicate, zinc borate, titanium dioxide and the like. The amount of the inorganic powder is 50 parts by mass or more and 150 parts by mass or less with respect to 100 parts by mass of the resin.
As described above, the foamed resin layer 2 according to the present embodiment is formed of a resin composition containing an aqueous emulsion resin, a foaming agent, and an inorganic filler.

[Pattern pattern layer 3]
The pattern pattern layer 3 imparts design to the foam wallpaper 10. The pattern pattern layer 3 can be formed by printing a pattern on the surface of the foamed resin layer 2, for example. Alternatively, it can also be formed by coating the foamed resin layer 2 in a pattern pattern. The thickness of the pattern layer 3 varies depending on the type of pattern, but is generally preferably about 0.1 μm or more and 10 μm or less.

Examples of the pattern include a wood grain pattern, a stone grain pattern, a sand grain pattern, a tiled pattern, a brickwork pattern, a cloth grain pattern, a squeezed pattern, a geometric figure, a character, a symbol, and an abstract pattern. The pattern can be selected according to the purpose.

Examples of the pattern printing method include gravure printing, flexographic printing, silk screen printing, and offset printing. As the printing ink, for example, a printing ink containing a colorant, a binder resin, and a solvent can be used. These inks may be known or commercially available.

As the colorant, for example, a pigment can be appropriately used. Pigments include inorganic pigments and organic pigments. Examples of inorganic pigments include titanium oxide, zinc oxide, carbon black, black iron oxide, yellow iron oxide, chrome yellow, molybdate orange, cadmium yellow, nickel titanium yellow, chromium titanium yellow, iron oxide (valve handle), and cadmium. Examples thereof include red, ultramarine blue, dark blue, cobalt blue, chromium oxide, cobalt green, aluminum powder, bronze powder, mica titanium, zinc sulfide and the like. Examples of organic pigments include aniline black, perylene black, azo (azo lake, insoluble azo, condensed azo), polycyclic (isoindolinone, isoindolin, quinophthalone, perinone, flavantron, anthrapyrimidine, anthraquinone, etc.). Quinacridone, perylene, diketopyrrolopyrrole, dibrom anthraquinone, dioxazine, thioindigo, phthalocyanine, indantron, halogenated phthalocyanine) and the like can be mentioned. The content of the colorant is preferably about 10 parts by mass or more and 50 parts by mass or less, and more preferably about 15 parts by mass or more and 30 parts by mass or less with respect to 100 parts by mass of the resin.
Further, when the foamed resin layer 2 acts as a solid layer with respect to the pattern layer 3, or when the foamed resin layer 2 is coated in a pattern pattern, the foamed resin layer 2 may also contain a colorant. good.

The binder resin can be set according to the type of resin in the lower layer forming the pattern layer 3. Examples of the binder resin include acrylic resin, styrene resin, polyester resin, urethane resin, chlorinated polyolefin resin, vinyl chloride-vinyl acetate copolymer resin, polyvinyl butyral resin, alkyd resin, and petroleum. Examples thereof include based resins, ketone resins, epoxy resins, melamine resins, fluorine resins, silicone resins, fibrous derivatives, rubber resins and the like.

Examples of the solvent (or dispersion medium) include petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ethyl acetate, butyl acetate, -2-methoxyethyl acetate, and -2 acetate. -Ethyl-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 and propylene glycol; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone and cyclohexanone. Examples thereof include ether-based organic solvents such as diethyl ether, dioxane and tetrahydrofuran; chlorine-based organic solvents such as dichloromethane, carbon tetrachloride, trichloroethylene and tetrachloroethylene; water and the like. These solvents (or dispersion media) can be used alone or in the form of a mixture.

In the present embodiment, the pattern layer 3 uses a printing ink (non-foaming ink) and / or a foaming ink containing a water-based emulsion resin as a main component, a foaming ink containing a vinyl chloride paste resin as a main component, and the like. , Gravure printing method, screen printing method, flexographic printing method, etc.

When the pattern layer 3 is not formed on the foamed resin layer 2, an undercoat layer (primer layer) may be formed as an alternative to the pattern layer 3. The undercoat layer contains a polyolefin resin, an acrylic resin, a polyvinyl alcohol resin, and the like, and the basis weight after drying ^{is preferably 1 g / m 2} or more and 3 g / m ² or less.

[Surface protective layer]
The surface protective layer 4 is formed on the surface of the pattern layer 3 with the intention of adjusting gloss and / or protecting the pattern layer 3. The thickness of the surface protective layer 4 is not limited, but is preferably about 0.1 μm or more and 15 μm or less. Here, the type of the surface protective layer 4 is not limited. As for the surface protective layer 4 for the purpose of adjusting gloss, for example, there is a surface protective layer 4 containing a known filler such as silica. As a method for forming the surface protective layer 4, for example, a known method such as gravure printing can be adopted. If the adhesion between the pattern layer 3 and the surface protection layer 4 cannot be sufficiently obtained, the surface protection layer 4 may be provided after the surface of the pattern layer 3 is easily adhered (primer treated). .. When the surface protective layer 4 is formed for the purpose of surface strength (scratch resistance, etc.), stain resistance, protection of the pattern layer 3, etc. of the foam wallpaper 10, those containing an ionizing radiation curable resin as a resin are used. Suitable. As the ionizing radiation curable resin, for example, one that is radically polymerized (cured) by irradiation with an electron beam is preferable.

In the present embodiment, the surface protective layer 4 is formed on the pattern layer 3, and a layer containing an aqueous emulsion resin as a main component is formed by a gravure printing method, a knife coating method, a nozzle coating method, a die coating method, or a lip. It is formed by a coating method, a comma coating method, etc.

Examples of the resin contained in the surface protective layer 4 include polyolefin-based resins, acrylic-based resins, polyvinyl alcohol-based resins, fluorine-based resins, and the like, and acrylic-based resins are particularly preferable. These resins may be used alone or in combination of two or more. When a crosslinkable resin is used to form the surface protective layer 4, the resin may be crosslinked, if necessary. The basis weight of the surface protective layer 4 after drying is preferably 5 g / m ² or more and 40 g / m ² or less, preferably 15 g / m ² or more and 30 g / m ² or less.

Further, a filler is added to the resin contained in the surface protective layer 4 as a matting agent (gloss adjusting agent). As the matting agent, for example, inorganic particles such as silica particles, alumina (α-alumina, etc.), calcium carbonate, barium sulfate, kaolinite, and aluminosilicate, or organic particles such as polycarbonate, nylon, and urethane resin are used. be able to.
As described above, the surface protective layer 4 according to the present embodiment contains an acrylic resin and a filler.

[Embossed pattern]
The surface of the surface protective layer 4, which is the outermost layer of the foam wallpaper 10, is embossed (concavo-convex embossing using an embossed plate), and the embossed pattern 5 is embossed (imbossed). In the embossing process, for example, the foamed wallpaper 10 is passed between an embossed roll having a recess of 15 μm or more in depth and a rubber back roll having a hardness of 50 degrees or more and less than 90 degrees, and the foamed wallpaper 10 has an uneven shape. May be applied. As a method for measuring hardness, for example, JIS K-6301 A type can be used. Examples of the embossed pattern include a wood grain board conduit groove, a stone board surface unevenness, a cloth surface texture, a satin finish, a grain, a hairline, and a perforated groove.

As a method for forming an uneven shape on the surface of the surface protective layer 4, there are other methods such as a method of partially foaming with a foam suppression ink and a chemical embossing method of partially heating and foaming with hot air or infrared rays. In particular, mechanical embossing by pressure welding with an embossing roll is preferable because sharp unevenness can be obtained with respect to the foamed resin layer 2. Further, it is desirable to maintain the surface temperature of the foamed wallpaper 10 immediately before the contact of the embossed plate in the embossing step at 160 ° C. or higher and 190 ° C. or lower, preferably 170 ° C. or higher and 180 ° C. or lower.

As described above, the foamed wallpaper 10 according to the present embodiment has a foamed resin layer 2 made of a resin composition containing an aqueous emulsion resin, a foaming agent, and an inorganic filler on a paper base material 1, and an acrylic resin. The surface protective layer 4 containing the filler and the filler is laminated.
In the foamed wallpaper 10 according to the present embodiment, the foamed resin layer 2 has a single composition (single layer), and the coating amount of the foamed resin layer 2 is limited to prevent ink cracking in the pattern layer 3.

Further, from the viewpoint of imparting fire protection performance, it is desirable that the total basis weight of the foam wallpaper 10 according to the present embodiment is 170 g / m ^{2 or less.} That is, the total basis weight of the paper base material 1, the foamed resin layer 2, and the surface protective layer 4 ^{is preferably 170 g / m 2} or less. Regarding the basis weight of each layer in that case, for example, the basis weight of the paper base material 1 is 65 g / m ² or less, the basis weight of the foamed resin layer 2 is 85 g / m ² or less, and the basis weight of the surface protective layer 4 is 20 g / m / m. It is preferably m ^{2 or less.}

Examples and comparative examples of this embodiment are shown below. The present embodiment is not limited to the following examples.

[Example 1]
Plain paper (Nippon Paper Co., Ltd .: "WK685AP") with a basis weight of 85 g / m ² and a thickness of 130 μm is used as the paper base material 1, and EVA resin (manufactured by Sumika Chemtex: "S-7400 (HQ)" is used as the foamed resin layer 2. ) ”) 80 parts by mass of inorganic powder (inorganic filler) to impart fire protection performance to 100 parts by mass, and heat-expandable microcapsule foaming agent to obtain foam thickness (Matsumoto Yushi Seiyaku Seisakusho:“ FT- 16 ") After applying the paste to which 10 parts by mass has been added by a ^{coating method so that the total basis weight is 185 g / m 2} , acrylic resin (DIC Co., Ltd .:" ATC-354 ") is added as the surface protective layer 4. It is applied by the lip coater method so that the basis weight is 205 g / m ^2, and it is heated and foamed at a foam furnace outlet paper surface temperature of 150 ° C. and an embossed heater outlet paper surface temperature of 180 ° C. The embossed pattern 5 was applied, and then cooled and dried to prepare the foamed wallpaper of Example 1.

[Example 2]
Plain paper (Nippon Paper Co., Ltd .: "WK685AP") with a basis weight of 85 g / m ² and a thickness of 130 μm is used as the paper base material 1, and EVA resin (manufactured by Sumika Chemtex: "S-7400 (HQ)" is used as the foamed resin layer 2. ) ”) A paste obtained by adding 80 parts by mass of inorganic powder (inorganic filler) to 100 parts by mass is ^{applied by a coating method so that the total basis weight is 185 g / m 2,} and then water-based ink is applied as the pattern layer 3. After performing pattern printing by gravure printing using, acrylic resin (DIC Co., Ltd .: "ATC-354") is applied as the surface protective layer 4 by the lip coater method so ^{that the total basis weight is 205 g / m 2.} Then, heating and foaming is performed at a foaming furnace outlet paper surface temperature of 150 ° C. and an embossed heater outlet paper surface temperature of 180 ° C. The foamed wallpaper of Example 2 was created.

[Comparative Example 1]
After applying an acrylic resin as the surface protective layer 4, heat foaming was performed at a foaming furnace outlet paper surface temperature of 150 ° C. and an embossing heater outlet paper surface temperature of 180 ° C., and the wallpaper was cooled and dried to prepare the foamed wallpaper of Example 1. That is, the embossed pattern 5 was not added. Other than that, the foam wallpaper of Comparative Example 1 was prepared in the same manner as in Example 1.

[Comparative Example 2]
Acrylic resin was not applied as the surface protective layer 4 (the surface protective layer 4 was removed), and the temperature of the embossed heater outlet paper surface was set to 160 ° C. Other than that, the foam wallpaper of Comparative Example 2 was prepared in the same manner as in Example 2.

[Comparative Example 3]
Plain paper (Nippon Paper Co., Ltd .: "WK685AP") with a basis weight of 85 g / m ² and a thickness of 130 μm is used as the paper base material 1, and EVA resin (manufactured by Sumika Chemtex: "S-7400 (HQ)" is used as the foamed resin layer 2. ) ”) A paste obtained by adding 80 parts by mass of inorganic powder (inorganic filler) to 100 parts by mass is ^{applied by a coating method so as to have a total basis weight of 185 g / m 2,} and then an acrylic resin (as a surface protective layer 4). DIC Co., Ltd .: "ATC-354") is ^{applied by the lip coater method so that the total basis weight is 205 g / m 2,} and heat foaming is performed at a foam furnace outlet paper surface temperature of 150 ° C. and an embossed heater outlet paper surface temperature of 180 ° C. , Cooled and dried to prepare the foam wallpaper of Comparative Example 3.

[Evaluation method]
(Non-land concealment)
In order to evaluate the non-landing concealment property, a circular sticker with a thickness of 110 μm and a diameter of 20 mm was attached to a semi-incombustible standard gypsum board (thickness 9.5 mm), and light was applied from the side to a visually non-landing place (a non-landing place (thickness 9.5 mm). It was evaluated whether or not it was possible to identify a non-horizontal place).
○ (Pass): Cannot identify the non-landing location × (Fail): Can identify the non-landing location

(Surface strength)
In order to evaluate the surface strength, whether the base paper layer (paper base material 1) is exposed by visually determining the damaged state of the surface at the time of scratching by a test based on the standard "Surface strengthened wallpaper performance regulation" established by the Wallpaper Industry Association. Evaluated whether or not.
○ (Pass): Base paper layer is not exposed × (Failure): Base paper layer is exposed

(Stain resistance)
In order to evaluate the stain resistance, we evaluated whether or not the contaminants adhering to the surface could be wiped off by a test based on the standard "Stain Prevention Wallpaper Performance Regulations" established by the Wallpaper Industry Association.
○ (Pass): Contaminants adhering to the surface can be wiped off × (Failure): Contaminants adhering to the surface cannot be wiped off

[Evaluation results]
The evaluation results are shown in Table 1 below.

Since Examples 1 and 2 passed all the items of non-land concealment, surface strength and stain resistance, the comprehensive evaluation was passed.
In Comparative Example 1, since the non-land concealment property was unacceptable, the surface strength and stain resistance were passed, but the comprehensive evaluation was unacceptable.
In Comparative Example 2, the non-land concealment property was passed, but the surface strength and stain resistance were not passed, so the comprehensive evaluation was rejected.
Comparative Example 3 failed the comprehensive evaluation because it failed in all the items of non-land concealment, surface strength, and stain resistance.

When the foam wallpaper of Example 1 and Example 2 was prepared, it was confirmed that the requirements were satisfied in all of the non-land concealment property, the surface strength and the stain resistance regardless of the presence or absence of the pattern pattern layer 3.
By comparing Example 1 and Comparative Example 1, it was confirmed that the non-landing location could be specified unless the embossed pattern 5 was added.
By comparing Example 2 and Comparative Example 2, it was confirmed that if the surface protective layer 4 was not formed, the base paper layer would be exposed and the contaminants adhering to the surface could not be wiped off.

The foam wallpaper according to the present embodiment can be used for wall decoration of buildings such as detached houses, apartment houses, stores, and office buildings.

Although the present invention has been described above with reference to specific embodiments, it is not intended to limit the invention by these explanations. By reference to the description of the present invention, other embodiments of the present invention will be apparent to those skilled in the art as well as various variations of the disclosed embodiments. Therefore, it should be understood that the scope of claims also covers these modifications or embodiments included in the scope and gist of the present invention.

1 ... Paper base material 2 ... Foam resin layer 3 ... Pattern pattern layer 4 ... Surface protection layer 5 ... Embossed pattern 10 ... Foam wallpaper

Claims (7)

Paper substrate and
A foamed resin layer containing an aqueous emulsion resin, a foaming agent, and an inorganic filler,
A surface protective layer containing a resin and a filler,
Are stacked,
An embossed pattern is formed on the surface of the laminate in which the paper base material, the foamed resin layer, and the surface protective layer are laminated.
The resin contained in the surface protective layer is a polyolefin-based resin, a polyvinyl alcohol-based resin, or a fluorine-based resin.
The total basis weight of the paper substrate, the foamed resin layer and the surface protective layer is 170 g / m ² or less.
The paper substrate has a basis weight of 50 g / m ² or more and 65 g / m ² or less and a thickness of 80 μm or more and 150 μm or less.
The foamed resin layer has a basis weight of 50 g / m ² or more and 85 g / m ² or less and a foaming ratio of 3 times or more.
The surface protective layer has a basis weight of 5 g / m ² or more and 20 g / m ² or less.
Wherein the aqueous emulsion resin contained in the foamed resin layer is meta copolymerization ratio (M A A amount) of acrylic acid ethylene is in the range of 5 mass% to 11 mass% - methacrylic acid copolymer The melt flow rate measured under the conditions of 190 ° C. and a load of 21.18 N is within the range of 10 g or more and 100 g or less per 10 minutes.
The foaming wallpaper contained in the foamed resin layer is a heat-expandable microcapsule foaming agent. The foamed wallpaper according to claim 1, wherein the resin contained in the surface protective layer is a fluororesin. Use plain paper with a basis weight of 50 g / m ² or more and 65 g / m ² or less and a thickness of 80 μm or more and 150 μm or less as the paper base material.
The paste obtained by adding 80 parts by mass of an inorganic filler and 10 parts by mass of a heat-expandable microcapsule foaming agent to 100 parts by mass of an aqueous emulsion resin as a foamed resin layer has a basis weight of 50 g / m ² or more and 85 g / m ² or less. Apply by coating method to
As the surface protective layer, a polyolefin resin, a polyvinyl alcohol resin, or a fluorine resin is applied by the lip coater method so as to ^{have a basis weight of 5 g / m 2} or more and 20 g / m ^{2 or less.}
Heat foaming is performed at a foaming furnace outlet paper surface temperature of 150 ° C. and an embossed heater outlet paper surface temperature of 180 ° C.
At the same time, immediately after passing through the emboss heater, pressurize with an emboss roll to give an emboss pattern.
After that, it has a process of cooling and drying,
Wherein the aqueous emulsion resin contained in the foamed resin layer is meta copolymerization ratio (M A A amount) of acrylic acid ethylene is in the range of 5 mass% to 11 mass% - methacrylic acid copolymer The melt flow rate measured under the conditions of 190 ° C. and a load of 21.18 N is within the range of 10 g or more and 100 g or less per 10 minutes.
A method for producing a foamed wallpaper, characterized in that the total basis weight of the paper base material, the foamed resin layer and the surface protective layer is 170 g / m ^{2 or less.} The method for producing a foamed wallpaper according to claim 3, wherein the foamed resin layer is applied by a coating method, and then the pattern is printed by gravure printing using a water-based ink as the pattern layer. The method for producing a foam wallpaper according to claim 4, wherein the pattern layer is formed of a foamable ink containing a water-based emulsion resin as a main component or a foamable ink containing a vinyl chloride paste resin as a main component. .. The binder resin contained in the pattern layer is a styrene resin, a polyvinyl butyral resin, an alkyd resin, a petroleum resin, a ketone resin, an epoxy resin, a melamine resin, a fluorine resin, a silicone resin, or a silicone resin. The method for producing a foamed wallpaper according to claim 4 or 5, wherein the foam resin is a rubber-based resin. The foaming according to any one of claims 3 to 6, wherein a fluororesin is applied as the surface protective layer ^{by a lip coater method so as to have a basis weight of 5 g / m 2} or more and 20 g / m ^{2 or less.} How to make wallpaper.

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