JPH0450440B2 - - Google Patents

Description

[Detailed Description of the Invention] This invention relates to a novel method for producing wallpaper, and its purpose is to make wallpaper that is moisture permeable and has moisture permeability through a unique laminated structure and embossing using paper, which is a natural material, as the main material. To manufacture completely ideal wallpaper that is resistant to water, has a sharp uneven pattern that does not lose its shape, and is easy to install.

In general, wallpaper that has various uneven patterns formed by embossing is different from wallpaper that has a flat pattern simply created by printing or cross-covering.
Because it can express powerful three-dimensional patterns with unique shadows and deep textures, it is in increasing demand for interior decoration work in modern buildings, but traditional embossed wallpaper, including imported products, is not water resistant. There is a weakness in this, and this is because the back side of the wallpaper has a concave part that is opposite to the convex part on the front surface during embossing.
Not only does the pattern on the surface of the wallpaper easily lose its shape when it contains moisture, but it is also difficult to apply glue to the back side in a uniform manner.As a result, despite having many excellent advantages, it is often avoided in terms of installation. It was often done.

The present invention is a method developed to address the above-mentioned problem, in which a melamine-based synthetic resin is applied in the form of an aqueous emulsion to thin western paper that will serve as the cover, embossed, and then heat set. The uneven shape of the cover is stabilized by processing, and then a backing paper made of machine-made Japanese paper is pasted to the back of the cover with an adhesive containing a filler and a foaming agent, and then heated. It is characterized in that the drying process and the foaming process are performed at the same time.

Hereinafter, this invention will be explained in detail with reference to drawings of examples. Fig. 1 shows the structure of wallpaper manufactured by the method of the invention, and Fig. 2 A, B, C, D, and H show the structure of wallpaper manufactured by the method of the invention. The manufacturing process of wallpaper is shown, and FIGS. 3 to 5 illustrate processing equipment used for manufacturing wallpaper.

In the case of the present invention, the base paper (cover 1) that is the main part of the wallpaper P is not Japanese paper with high hygroscopicity, but a thinner Western paper than ordinary base paper, and its surface is colored and printed with a predetermined pattern in advance. A pattern is printed using a method such as gravure printing, and a surface decoration process is applied.

In the method of the present invention, first, a melamine resin water-soluble emulsion solution with a solid content of 30% is applied to the back surface of the cover 1 using a coating device M1 as shown in FIG. let me,
A synthetic resin coating 2 is formed on the back surface as shown in FIG. 2A. At this time, in order to apply a melamine resin water-soluble emulsion solution with a solid content of 30% to the back side of the cover 1,
This coating liquid is impregnated into the amorphous material of the fiber layer on the cover 1, and the resin adsorbs to the fiber molecules, wrapping each fiber molecule.When further drying is performed, the emulsion moisture scatters and the resin wraps the liquid. Extremely fine gaps are created between each covered fiber molecule. This gap does not allow moisture to pass through, but allows moisture (water vapor) to pass through.

The cover 1 which has been subjected to the coating treatment is then passed between heated rollers 21 and 22 having vertically opposing uneven parts for pattern stamping using an embossing device M2 as shown in FIG. After forming the embossed pattern 3 on the surface as shown in FIG. In addition to improving the cover 1
Provides waterproof properties to prevent moisture from penetrating from the back side to the front side.

Once the processing of the cover 1 is completed in this way, the backing paper 5 is pasted on the back side of the cover 1 using a special adhesive 6 using a laminating device M3 as shown in FIG. do. During the lamination process, in the apparatus M3 of this embodiment, adhesive 6 is first applied to the back surface of cover 1 as shown in Fig. 2 (c). Magnesium carbonate or aluminum hydroxide is mixed as a filler, and an appropriate amount of low-temperature foaming agent and a flame retardant and others are mixed as necessary, and the solid content is 48 to 55%, and the remainder is water. After coating the paper uniformly, it is fed between the pressure rollers 32 and 33, where it is overlapped with the backing paper 5 (machine-made Japanese paper) supplied from the other side, and pressed by both rollers 32 and 33 to form the paper shown in Fig. 2. It is pasted like this.

The cover 1 with the backing paper 5 pasted as described above is finally supplied to the upper heating cylinder 34, and while passing through the outer peripheral surface of each cylinder 34 arranged in a meandering manner while alternately pressing the front and back sides, Heated for several minutes at a temperature of 100°C to 120°C. When the heat treatment as described above is performed, the moisture in the adhesive 6 interposed between the cover 1 and the backing paper 5 passes through the water-permeable fiber structure of the backing paper 5 without escaping to the cover 1 side. The adhesive 6 is dried and solidified to strongly adhere the cover 1 and the backing paper 5. At this time, since the adhesive 6 contains a foaming agent, the foaming agent is removed at the same time as the adhesive. As a result of the action, the adhesive rapidly expands and penetrates into the irregularities on the back surface of the cover 1 without any gaps, and the thickness of the adhesive layer is increased, so that the entire wallpaper P can be given bulkiness. Wallpaper P having a structure as shown in FIG. 2E is manufactured.

As described above, when the method of the present invention is applied to the production of wallpaper, the melamine resin is applied in the form of an aqueous emulsion to the back surface of the cover, so the fibrous layer of the cover formed by this is impermeable to water. Many extremely fine gaps are formed that allow moisture (water vapor) to pass through.
Therefore, the surface layer of wallpaper has waterproof properties and
It also has the function of being moisture permeable. Therefore, wallpaper with this cover absorbs or releases moisture depending on the humidity in the air, making it difficult for dew condensation to form on the surface of the wallpaper, as well as reducing the amount of moisture inside the room to which this wallpaper is applied. It can make the environment more comfortable.

In addition, when embossing the cover, we use thin Western paper coated with melamine resin on the back side, and after applying roller stamping, we immediately heat set it and apply a water-resistant hard material impregnated into the fiber structure from the back side. Since a film is formed, a sharp embossed pattern with tight unevenness can be formed.

Moreover, after a backing paper made of machine-made Japanese paper is pasted on the back side of the cover with an adhesive containing a filler and a foaming agent, drying treatment by heating and foaming treatment are performed at the same time. Because there is an adhesive layer between the cover and backing paper that spreads quickly to every corner of the uneven surface due to the foaming process, it has just the right amount of bulk and excellent mechanical strength. However, it has extremely excellent water resistance, and even when the backing paper contains a large amount of water during gluing, etc., the water will not penetrate into the back side and the pattern will not lose its shape, and the back side will remain flat. In conjunction with this, we aim to provide ideal wallpaper at a relatively low cost that is not only extremely easy to apply to walls, but also retains the embossed pattern semi-permanently over a long period of time and has outstanding durability. It is something that can be done. Furthermore, the three-dimensional embossed pattern, which has unique shadows and a heavy texture, and is overflowing with a sense of strength, skillfully harmonizes with the soft appearance of the paper, creating a warm atmosphere in the room.

[Brief explanation of the drawing]

Fig. 1 is a plan view showing an example of the structure of wallpaper manufactured by the method of the present invention, Fig. 2 is a, b, c,
D and E are cross-sectional views showing the wallpaper manufacturing process according to the present invention, and FIGS. 3 to 5 are front views illustrating the apparatus used to carry out the method of the present invention. P... Wallpaper, 1... Cover, 2... Synthetic resin film, 3... Embossed pattern, 5... Backing paper, 6... Adhesive, M1... Coating device, 11... Coating roller, M2... Embossing device, 21, 22... Band Heat roller, 23... Curing furnace, M3... Lamination device, 31... Application roller, 32, 33... Press roller, 34... Heat cylinder.

Claims (1)

[Claims] 1 After applying melamine-based synthetic resin in the form of water-based emulsion to thin western paper that will become the cover and embossing it, a heat setting process is applied to stabilize the uneven shape of the cover, and then the back side of this cover is A method for producing wallpaper, which comprises adhering a backing paper made of machine-made Japanese paper with an adhesive containing a filler and a foaming agent, and then simultaneously performing a drying treatment by heating and a foaming treatment.