JP4109438B2 - Surface material and wallpaper and method for producing the same - Google Patents

Description

【００７３】
実施例１〜４の壁紙は、露出繊維本数も多く、繊維調を維持しており、湿式不織布と熱可塑性樹脂が一体化された防汚層を有するので、汚れの入り込みが少なく汚れ付着防止性に優れていた。また、いずれの汚れに対して４級以上の優れた払拭性を有するものであった。さらに、嵩高層を有しているので、紙壁紙のようなペーパーライクな風合ではなくボリューム感があり、鮮明なしぼを有するものであった。また、実施例５の壁紙は、熱可塑性樹脂の厚みが大きいため、露出繊維本数が少なく、若干フィルム調であり、若干透気性に劣るものの実用レベルであった。汚れ付着防止性および払拭性には優れていた。一方、比較例１の壁紙は、表層材が不織布のみからなるので、繊維調の風合であり、鮮明なしぼを有するものであったが、各種汚れが繊維間隙を通して内部にまで入り込み、実施例に比べて汚れの付着量が格段に多くなった。さらに、払拭しても汚れを十分に拭き取ることができなかった。
【００７４】
【発明の効果】
本発明の表層材は、湿式不織布を表面とし、前記湿式不織布と熱可塑性樹脂とが一体化された防汚層と、前記防汚層の裏面に防汚層の見かけの厚みより厚みが大きい嵩高不織布で構成された嵩高層とを積層一体化することにより、エンボス加工時において、シビアな温度や圧力の管理を必要とせず、表面に繊維調の風合を維持しつつ防汚性に優れた、特に壁紙表面を得ることができ、安定した品質の壁紙を得るのに好適である。さらに、透気性を損なうことなく、深みのあるしぼを付与することができ意匠性に優れた壁紙を得るのに好適な表層材を得ることができる。
【００７５】
特に、前記熱可塑性樹脂を前記湿式不織布および前記嵩高不織布の繊維間隙に入り込んで接着させることにより、壁紙の貼り換え時に壁紙の表層部自体が剥離することを防止するとともに、防汚層において、表面の繊維調の風合を維持しつつ汚れの侵入を表面近傍で抑えることができ、汚れの払拭性も向上させることができる。
【００７６】
本発明の壁紙は、前記表層材を表層部として用いることにより、表面に繊維調の風合を維持しつつ防汚性に優れた壁紙表面を得ることができ、防汚層が透気性を有するので、結露を抑制することができ、嵩高層を一体化されているので、深みのあるしぼを有し、意匠性に優れた壁紙を得ることができる。
【図面の簡単な説明】
【図１】本発明の表層材における断面の一例を示す。
【図２】本発明の表層材における表面の一例を示す。
【図３】本発明の壁紙における断面の一例を示す。
【図４】本発明の壁紙における表面の一例を示す。
【符号の説明】
１．表層材
２．湿式不織布
３．熱可塑性樹脂
４．嵩高不織布
５．防汚層
６．嵩高層
７．繊維間隙
８．交点
９．露出繊維
１０．エンボス部分
１１．非エンボス部分
１２．接着剤
１３．裏打ち紙
１４．壁紙[0001]
BACKGROUND OF THE INVENTION
The present invention is suitable for applications such as clothing, table cloths, place mats, headrests, interior materials, etc. that have a sense of volume and at the same time have excellent antifouling properties. More particularly, the present invention relates to a wallpaper having excellent embossability, having deep grain, air permeability, and excellent antifouling property while having a fiber-like surface.
[0002]
[Prior art]
In recent years, vinyl chloride resins that can generate toxic gases and dioxins during incineration tend to be avoided as wallpaper used for interior materials such as buildings and vehicles. Further, since the wallpaper made of vinyl chloride resin is film-like, various wallpaper having a fiber-like surface, which is a dechlorinated vinyl resin, has been proposed. For example, Japanese Utility Model Laid-Open No. 4-74000 proposes a wallpaper in which a foamed or non-foamed polyvinyl chloride resin layer is layered between a flame retardant paper and a nonwoven fabric made of thermoplastic fibers to form a wrinkle pattern on the surface. ing. In JP-A-3-294586, a non-foaming synthetic resin or a foaming synthetic resin is formed between a surface layer made of nonwoven fabric and a base material made of flame retardant paper, and the surface layer is partially embedded in the resin layer. Wallpapers that have been proposed have been proposed. Japanese Patent Laid-Open No. 5-116255 proposes a wallpaper using a composite sheet obtained by laminating an amorphous polyester resin on a nonwoven fabric containing amorphous polyester fibers as a surface material. Japanese Patent Laid-Open No. 2000-154499 proposes a wallpaper in which a non-organic solvent-based resin layer is provided on the top of a breathable sheet base material (wallpaper base paper) and a nonwoven fabric layer is further provided on the top.
[0003]
In addition, the wallpaper is required to have antifouling properties such that it is difficult to be stained against dirt during construction, dirt from users, and adhered dirt such as food, and the dirt can be easily wiped off. In general, a film layer is provided on the surface to improve antifouling properties, but since the texture is film-like, as wallpaper having improved antifouling properties while maintaining the fiber tone, for example, Japanese Patent No. 30199 proposes a wallpaper in which a hydrophobic fiber surface sheet having a fluorine-based processing agent attached to both sides of a sheet and a backing paper are integrated with an adhesive. Japanese Utility Model Laid-Open No. 5-57000 discloses a basis weight of 5 to 100 g / m made of synthetic fibers having an average fiber diameter of 1 to 5 μm. ² A wall paper in which the melt blown nonwoven fabrics are laminated and integrated has been proposed. Japanese Patent Application Laid-Open No. 2000-73269 proposes a wallpaper having a surface layer of a melt blown nonwoven fabric mainly composed of a saponified ethylene-vinyl acetate copolymer. In JP-A-11-217799, a base paper for wallpaper is adhered to the back surface of a nonwoven fabric having a card web of core-sheath composite fiber as a surface layer and a mixed web of cellulosic fibers and thermoplastic fibers as an inner layer, There has been proposed a wallpaper in which an embossed pattern is formed using an embossing roller and the surface is formed into a film. Furthermore, Japanese Patent Application Laid-Open No. 2001-1698 proposes a wallpaper in which a wet nonwoven fabric containing thermoplastic fibers is used as a surface, a hydroentangled nonwoven fabric is used as an intermediate layer, a backing paper is used as a backing paper, and glued with a paste. Yes.
[0004]
[Problems to be solved by the invention]
However, the wallpaper has the following problems. For example, in Japanese Utility Model Laid-Open No. 4-74000, Japanese Patent Laid-Open No. 3-294586, Japanese Patent Laid-Open No. 5-116255, and Japanese Patent Laid-Open No. 2000-154499, the surface nonwoven fabric layer and the backing paper are directly bonded by a resin. Therefore, it is possible to obtain a wallpaper having a fiber-like surface, but in order to provide embossing and providing deep wrinkles, it is necessary to form the surface with a bulky nonwoven fabric, so the fiber gap becomes too large. The dirt component enters the inside of the nonwoven fabric through the interstices of the fibers, and it is not possible to remove the attached dirt such as the glue attached at the time of construction, the dirt and dirt of the installer, or the dirt of the user, food and liquid. On the contrary, it is conceivable to maintain the bulkiness with the resin component, but the air permeability is extremely reduced, which causes problems such as condensation.
[0005]
In addition, in Japanese Utility Model Publication No. 5-30199, a fluorine-based processing agent is attached, so that it is excellent in water resistance (moisture resistance), but the glue attached at the time of construction or the dirt, dirt, or use of the installer. It is ineffective against the user's dirt and attached stains such as food, and can be repelled by water with liquids, but it is not effective with liquid foods such as coffee and soy sauce, or detergents. In Japanese Utility Model Laid-Open No. 5-57000 and Japanese Patent Application Laid-Open No. 2000-73269, a melt blown nonwoven fabric is used on the surface, but because of the direct spinning method, the fiber itself is not stretched and the single fiber strength is extremely weak, In addition to being unable to withstand practical friction and the like, the fiber has low crystallinity, and thus heat treatment causes shrinkage, easily forms a film, extremely limits the processing temperature, and is inferior in embossability. In JP-A-11-217799, a core-sheath type composite fiber is embossed and melted to form a film surface. However, it is difficult to adjust the temperature and pressure in embossing. Remains and is inferior in antifouling property. If the temperature or pressure is too high, the film is completely formed and a fiber-like surface cannot be obtained. Furthermore, even if it can be adjusted well, the surface layer portion is formed only of the non-woven fabric, so that the stain component easily enters the inside of the fiber portion and cannot remove adhered stains such as dirt, food and liquid. JP-A-2001-1698 attempts to improve printing spots, surface strength, water repellency, stain resistance, and embossability by adopting the above-described configuration. Therefore, it is necessary to coat a water repellent and antifouling agent containing a fluororesin, and the current coating agent has a limit in suppressing antifouling. Furthermore, if it is a water-based or solvent-based paste, it is inferior in the formation of deep wrinkles by hot embossing.
Therefore, the processing area such as temperature and pressure at the time of embossing is wide, the quality is stable, deep wrinkles can be imparted, it has excellent design properties, air permeability and condensation etc. The actual situation is that no wallpaper having an excellent antifouling property is obtained although the surface texture is fiber.
[0006]
[Means for Solving the Problems]
In order to solve the above-mentioned problem, a wet non-woven fabric is used as the surface, the anti-stain layer in which the wet non-woven fabric and the thermoplastic resin are integrated, and the bulky surface having a thickness larger than the apparent thickness of the anti-stain layer on the back surface of the anti-stain layer It was found that a surface layer material having antifouling properties and volume feeling can be obtained by laminating and integrating a bulky layer composed of a nonwoven fabric, and the present invention has been achieved. That is, a wet non-woven fabric is used as a surface, and by forming an antifouling layer in which the wet non-woven fabric and the thermoplastic resin are integrated, there is no need for severe temperature and pressure management during embossing, and the surface has fibers. It is suitable for obtaining a wallpaper surface excellent in antifouling property while maintaining the texture of the tone, and a surface layer material suitable for obtaining a stable quality wallpaper can be obtained. Furthermore, by integrating the bulky layer, a surface material suitable for obtaining a wallpaper having a deep design that can impart a deep grain without impairing the air permeability can be obtained.
[0007]
When the thermoplastic resin enters and adheres to the fiber gap between the wet nonwoven fabric and the bulky nonwoven fabric, the surface layer portion of the wallpaper itself is prevented from peeling off when the wallpaper is replaced. It is preferable that the penetration of dirt can be suppressed in the vicinity of the surface while maintaining the fiber-like texture, and the wiping property of dirt is improved.
[0008]
The apparent thickness of the antifouling layer is in the range of 0.02 mm or more and 0.1 mm or less, the apparent thickness of the bulky layer is 0.15 mm or more, and the apparent thickness of the bulky layer and the antifouling layer is When the thickness ratio (bulky layer / antifouling layer) is 3 or more, it is possible to prevent dew condensation without impairing air permeability and to impart deep wrinkles.
[0009]
The fibers constituting at least one of the wet nonwoven fabric and the bulky nonwoven fabric are composed of a high melting component having a sheath component as a low melting component and a core component having a melting temperature of 15 ° C. or more higher than the melting temperature of the low melting component. When the sheath-core-type heat-meltable composite fiber is contained, not only the wear resistance such as fuzzing on the wallpaper surface is improved, but the exposed fiber portion of the surface is densified, and the antifouling property is excellent. A deep grain is preferable because it can be fixed.
[0010]
The surface material of the present invention has a basis weight of 10 g / m ² 30 g / m ² The following range, 2.94 cN / cm ² A wet nonwoven fabric with a thickness under load of 0.1 mm or less, and a basis weight of 30 g / m ² 80 g / m ² The following range, 2.94 cN / cm ² A bulky nonwoven fabric having a thickness under load of 0.25 mm or more is 2.94 cN / cm in a solidified state of a thermoplastic resin alone. ² It can be manufactured by bonding with a thin film thermoplastic resin in a molten state having a thickness under a load of 0.005 mm or more and 0.045 mm or less.
[0011]
The wallpaper of the present invention has a wet nonwoven fabric as a surface, an antifouling layer in which the wet nonwoven fabric and a gas-permeable thermoplastic resin are integrated, and a thickness larger than the apparent thickness of the antifouling layer on the back surface of the antifouling layer. It has a surface layer part in which bulky layers made of bulky nonwoven fabric are laminated and integrated. That is, the surface of the wallpaper is excellent in antifouling property while maintaining the fiber-like texture on the surface by forming the antifouling layer in which the wet nonwoven fabric is the surface and the wet nonwoven fabric and the air-permeable thermoplastic resin are integrated. Can be obtained. Moreover, since the antifouling layer has air permeability, dew condensation can be suppressed. Furthermore, since the bulky layer is integrated, a wallpaper having a deep wrinkle and excellent design can be obtained.
[0012]
The wallpaper of the present invention has a wet nonwoven fabric as a surface, an antifouling layer in which the wet nonwoven fabric and a gas-permeable thermoplastic resin are integrated, and a thickness larger than the apparent thickness of the antifouling layer on the back surface of the antifouling layer. A surface layer portion in which bulky layers made of bulky nonwoven fabric are laminated and integrated, and a backing paper are bonded together.
[0013]
It is preferable that the wallpaper has an embossed pattern.
[0014]
Among the embossed part and the non-embossed part constituting the embossed pattern, at least a part of the non-embossed part maintains a fiber form, and a thermoplastic resin exists in the vicinity of the surface of the nonwoven fabric, or a part of When the thermoplastic resin is exposed on the surface, the surface texture is particularly excellent in the antifouling effect while maintaining the fiber tone, which is preferable. Furthermore, the apparent thickness of the non-embossed portion in the antifouling layer is in the range of 0.01 mm or more and 0.09 mm or less, and the apparent thickness of the non-embossed portion in the bulky layer is 0.1 mm or more, It is preferable that the apparent thickness ratio (bulky layer / antifouling layer) of the bulky layer and the antifouling layer in the non-embossed portion is 1.2 or more.
[0015]
As the wallpaper, a surface layer material in which a wet nonwoven fabric and a bulky nonwoven fabric are bonded with a thermoplastic resin is prepared, a backing material is joined to the bulky nonwoven fabric surface with an adhesive, and the wet nonwoven fabric surface abuts on an embossing roll. Thus, it can manufacture by embossing and forming an embossed pattern in the nonwoven fabric surface.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
The wet nonwoven fabric used for the surface layer material of the present invention is preferably one that forms a basis weight, a thickness, or a fiber gap so that dirt does not penetrate deep inside the wallpaper while maintaining the fiber tone on the surface. The wet nonwoven fabric is superior to the nonwoven fabric made of other dry webs in that the thickness is small and has a dense fiber structure, and the fibers themselves lie mainly, so that the nonwoven fabric structure is less likely to get dirt. 2.94cN / cm of wet nonwoven fabric ² The thickness under load is preferably 0.1 mm or less. A more preferable lower limit of the thickness is 0.03 mm or more. A more preferable upper limit of the thickness is 0.09 mm or less. If the thickness of the wet nonwoven fabric is too small, the thermoplastic resin penetrates through the fiber gaps of the wet nonwoven fabric and is completely exposed to the surface, and there is a possibility that a fiber-like texture cannot be obtained. When the thickness of the wet nonwoven fabric exceeds 0.1 mm, dirt or the like enters deep inside the fiber gap of the wet nonwoven fabric, and sufficient antifouling property may not be obtained.
[0017]
The basis weight of the wet nonwoven fabric is 10 g / m ² 30 g / m ² The following range is preferable. The lower limit of the basis weight of the more preferable wet nonwoven fabric is 13 g / m. ² Or more, more preferably 15 g / m ² That's it. The upper limit of the weight of the more preferable wet nonwoven fabric is 25 g / m. ² Or less, more preferably 20 g / m ² It is as follows. Wet non-woven fabric weight is 10g / m ² If it is less than 1, not only the formation of the nonwoven fabric itself becomes uneven, but the thermoplastic resin may penetrate the fiber gap of the wet nonwoven fabric and be completely exposed to the surface. Wet non-woven fabric weight is 30g / m ² If it exceeds 1, the fiber-like texture is present, but dirt or the like enters deep inside the fiber gap of the wet nonwoven fabric, and there is a possibility that sufficient antifouling property cannot be obtained.
[0018]
The fibers constituting the wet nonwoven fabric are preferably composed of fibers made of non-halogen resin excluding halogen resin such as vinyl chloride resin. For example, pulp, manila hemp, rayon, acrylic fiber, polyester fiber, polyamide fiber, polyolefin fiber, etc. may be used alone or mixed and laminated. The fiber shape may be any of circular, irregular, hollow, etc. in cross section.
[0019]
In consideration of embossability and deep wrinkle formation, it is preferable to contain a thermoplastic synthetic fiber. For example, a single material having a low melting temperature typified by fibrillated polyethylene such as SWP manufactured by Mitsui Chemicals, Inc. Examples thereof include fibers, or composite fibers such as a sheath core type, a parallel type, and a split type. Among them, it is preferable that the sheath component is a low melting component, and the core component is a sheath core type heat-fusible composite fiber composed of a high melting component having a melting temperature higher by 15 ° C. or more than the melting temperature of the low melting component. . For example, copolyester / polyethylene terephthalate, copolyester / polybutylene terephthalate, polypropylene / polyethylene terephthalate, ethylene-propylene copolymer / polyethylene terephthalate, polyethylene / polyethylene terephthalate, ethylene-vinyl alcohol copolymer / polyethylene terephthalate, ethylene Examples include propylene copolymer / polypropylene, polyethylene / polypropylene, etc. Especially when polyethylene terephthalate is used as the core component, the fiber itself is stiff, has excellent embossing and deep wrinkle formation properties, suppresses fuzz on the surface, Excellent wear resistance and preferable. The content of the sheath-core type heat-meltable conjugate fiber is preferably 20% by mass or more. The lower limit of the content of the sheath-core type heat-meltable conjugate fiber is more preferably 30 mass% or more. The upper limit of the content of the sheath-core type heat-meltable conjugate fiber is more preferably 80 mass% or less. If the content is less than 20 mass%, not only the surface wear resistance is inferior, but also there is a possibility that a clear wart is difficult to be formed in embossing during wallpaper production.
[0020]
In consideration of the surface tactile sensation or the selectivity of the printing material, it is preferable to contain cellulosic fibers such as pulp and Manila hemp. For example, when mixing the said fiber, it is preferable that the ratio of a cellulosic fiber and a thermoplastic synthetic fiber is 20: 80-80: 20. In addition, in the case of laminating the fibers, for example, a layer of only cellulose-based fibers is provided on the front surface, a layer of only thermoplastic synthetic fibers is provided on the back surface, or a layer of only thermoplastic synthetic fibers is provided on the front surface, and You may provide the layer only of a system fiber, and it is good in the whole laminated body that the ratio of a cellulosic fiber and a thermoplastic synthetic fiber is 20: 80-80: 20.
[0021]
The wet nonwoven fabric preferably has a dense fiber structure as much as possible, and it is preferable to use a fiber having a short fiber length, such as pulp, or a fiber having a fiber fineness of 3 dtex or less. When the fiber fineness exceeds 3 dtex, the aggregated form of fibers becomes sparse, and it may be difficult to suppress entry of dirt and the like.
[0022]
The wet nonwoven fabric is preferably made by using a known paper machine such as a circular net type, a short net type, and a long net type and dried. Moreover, you may heat-melt a thermoplastic synthetic fiber using heat processing machines, such as a cylinder dryer, as needed.
[0023]
Next, as the bulky nonwoven fabric used for the surface layer material of the present invention, a bulky layer having a thickness larger than the apparent thickness of the antifouling layer in which the wet nonwoven fabric and a thermoplastic resin described later are integrated can be formed. Consists of non-woven fabric. Specifically, 2.94 cN / cm of bulky nonwoven fabric ² The thickness under load is preferably 0.25 mm or more. A more preferable lower limit of the thickness is 0.3 mm or more. A more preferable upper limit of the thickness is 1.6 mm or less. If the thickness of the bulky nonwoven fabric is too small, the nonwoven fabric cannot have a sufficient volume, and when embossed patterns are applied, it tends to be difficult to form deep wrinkles.
[0024]
The basis weight of the bulky nonwoven fabric is 30 g / m ² 80 g / m ² The following range is preferable. The lower limit of the basis weight of a more preferable bulky nonwoven fabric is 35 g / m. ² Or more, more preferably 40 g / m ² That's it. The upper limit of the basis weight of a more preferable bulky nonwoven fabric is 70 g / m. ² Or less, more preferably 65 g / m ² It is as follows. Bulky nonwoven fabric weight is 30g / m ² If it is less than this, a sufficient volume cannot be obtained in the nonwoven fabric, and when embossed patterns are applied, it tends to be difficult to form deep wrinkles. Bulky nonwoven fabric weight is 80g / m ² This is because exceeding the value increases the cost.
[0025]
The fibers constituting the bulky nonwoven fabric are preferably composed of fibers made of a non-halogen resin excluding a halogen resin such as a vinyl chloride resin. For example, pulp, manila hemp, rayon, acrylic fiber, polyester fiber, polyamide fiber, polyolefin fiber, etc. may be used alone or mixed and laminated. The fiber shape may be any of circular, irregular, hollow, etc. in cross section.
[0026]
In consideration of embossability and formation of deep wrinkles, or adhesion to the backing paper described later, it is preferably a thermoplastic synthetic fiber, for example, a single fiber having a low melting temperature, or a sheath core type, a parallel type And composite fibers such as a split type. Among them, it is preferable that the sheath component is a low melting component, and the core component is a sheath core type heat-fusible composite fiber composed of a high melting component having a melting temperature higher by 15 ° C. or more than the melting temperature of the low melting component. . For example, copolyester / polyethylene terephthalate, copolyester / polybutylene terephthalate, polypropylene / polyethylene terephthalate, ethylene-propylene copolymer / polyethylene terephthalate, polyethylene / polyethylene terephthalate, ethylene-vinyl alcohol copolymer / polyethylene terephthalate, ethylene Examples thereof include propylene copolymer / polypropylene and polyethylene / polypropylene. Particularly, when polyethylene terephthalate is used as the core component, the fiber itself is stiff and is excellent in embossability and deep wrinkle formation, which is preferable. The content of the sheath-core type heat-meltable conjugate fiber is preferably 20% by mass or more. The lower limit of the content of the sheath-core type heat-meltable conjugate fiber is more preferably 30 mass% or more. The upper limit of the content of the sheath-core type heat-meltable conjugate fiber is more preferably 80 mass% or less. When the content is less than 20 mass%, not only is it difficult to form a clear warp in the embossing process, but there is a possibility that the interlayer adhesion with a thermoplastic resin described later is inferior. For example, when mixing the said fiber, it is preferable that the ratio of a cellulosic fiber and a thermoplastic synthetic fiber is 20: 80-80: 20. Moreover, when laminating | stacking the said fiber, it is good in the whole laminated body that the ratio of a cellulosic fiber and a thermoplastic synthetic fiber is 20: 80-80: 20.
[0027]
The bulky nonwoven fiber web forms include parallel webs made of staple fibers, card webs such as semi-random webs, random webs, cross lay webs, and Chris cross webs, spunbond webs made of long fibers, and air arrays made of short fibers. Examples thereof include dry fiber webs such as webs. Next, the fibers are bonded together by combining one or more chemical bonds, thermal bonds, needle punches, hydroentanglement, and the like. In particular, if a three-dimensional entanglement process such as needle punching or hydroentanglement is used, the fibers will also be arranged in the thickness direction, and in the thickness direction such as a laminated integration process or emboss pattern application process with the wet nonwoven fabric and thermoplastic resin. Even if pressure is applied, the bulkiness can be maintained, which is preferable.
[0028]
Next, the thermoplastic resin used for the surface layer material of the present invention preferably has a film-forming property and has an action of bonding the wet nonwoven fabric and the bulky nonwoven fabric. Furthermore, it is preferable to select a thermoplastic resin that can enter the inside of each non-woven fabric, in particular, until it is exposed to the vicinity of the surface or a part of the surface of the wet non-woven fabric.
[0029]
2.94 cN / cm in the solidified state of the thermoplastic resin alone ² The thickness under load is preferably in the range of 0.005 mm or more and 0.045 mm or less. A more preferable lower limit of the thickness is 0.007 mm or more. A more preferable upper limit of the thickness is 0.03 mm or less. The solidified state of the thermoplastic resin alone is when the resin is extruded and solidified in advance in order to determine the mass per unit area of the thermoplastic resin and the thickness of the thin film by adjusting the discharge amount of the resin, etc. Is used to measure the thickness of the film and manage the thickness in the molten state. If the thickness of the thermoplastic resin is less than 0.005 mm, the porosity may be excessive during embossing, which will be described later, and it may not be possible to prevent entry of dirt into the surface layer material. If it exceeds 0.045 mm, the air permeability is impaired, and condensation may occur.
[0030]
The thermoplastic resin is preferably made of a non-halogen resin excluding a halogen resin such as a vinyl chloride resin. Examples thereof include polyolefin resins such as polymers such as low density polyethylene, medium density polyethylene, high density polyethylene, polypropylene, ethylene-vinyl alcohol copolymer, and copolymers with other olefin components, and fluororesins. Polyolefin resins are preferred from the viewpoint of microporosity by embossing described later, and it is particularly preferred to use a low-density polyethylene resin from the viewpoint of the formation of wrinkles and the softness of the texture.
[0031]
Next, in the surface layer material of the present invention, the wet nonwoven fabric is used as a surface, and the wet nonwoven fabric and the thermoplastic resin are integrated to form an antifouling layer. In FIG. 1, an example of the cross section of the surface layer material of this invention is shown. When the thermoplastic resin 3 enters the wet nonwoven fabric 2 and enters the vicinity of the surface of the wet nonwoven fabric 2 or until it is exposed to a part of the surface, the antifouling layer 5 has a fiber texture. This is preferable because it can prevent entry of dirt to the maximum.
[0032]
The apparent thickness of the antifouling layer is preferably 0.02 mm or more and 0.1 mm or less. A more preferable lower limit of the apparent thickness is 0.03 mm or more. A more preferable upper limit of the apparent thickness is 0.08 mm or less. The apparent thickness here refers to the length from the surface to the boundary, with the cross section of the nonwoven fabric magnified 150 to 500 times with an electron microscope, with the thermoplastic resin and the bulky nonwoven fabric as the boundary. In the present invention, the thermoplastic resin may also enter the bulky nonwoven fabric, but in this case, the portion where the thermoplastic resin enters also has an antifouling action and is therefore regarded as an antifouling layer. When the apparent thickness of the antifouling layer is less than 0.02 mm, not only is it difficult to form a clear warp by embossing, but the surface wear resistance is also poor. If the apparent thickness exceeds 0.1 mm, the air permeability is impaired and condensation may occur.
[0033]
As shown in FIG. 1, the surface layer material 1 is configured by laminating and integrating a bulky layer 6 composed of a bulky nonwoven fabric 4 having a thickness larger than the apparent thickness of the soilproof layer 5 on the back surface of the soilproof layer 5. To do. The apparent thickness of the bulky layer 6 is preferably 0.15 mm or more. A more preferable lower limit of the apparent thickness is 0.2 mm or more. A more preferable upper limit of the apparent thickness is 1 mm. If the apparent thickness is less than 0.15 mm, there is a risk that it is difficult to form a clear grain during embossing. Further, the apparent thickness of the bulky layer 6 is preferably such that the ratio of the apparent thickness of the antifouling layer 5 (bulky layer / antifouling layer) is 3 or more. A more preferable lower limit of the thickness ratio is 5 or more. The apparent thickness of the bulky layer 6 here refers to the thickness from the boundary with the antifouling layer 5, and when the thermoplastic resin 3 of the antifouling layer 5 enters the bulky nonwoven fabric 4, The boundary of the plastic resin 3 is regarded as the antifouling layer 5. When the apparent thickness ratio is less than 3, the surface layer material itself does not have a sufficient volume, and thus it tends to be difficult to form deep wrinkles when an embossed pattern is applied.
[0034]
Further, in the surface layer material, the thermoplastic resin has an antifouling effect, and at the same time, there is a risk of impairing the air permeability of the surface layer material itself. Therefore, “J. TAPPI Paper Pulp Test Method No. 5 B It is preferable to adjust so that the air permeability according to “Method by tester (pressurization type)” is 1000 seconds or less. A more preferable air permeability is 500 seconds or less. This is because if the air permeability exceeds 1000 seconds, there is a possibility that sufficient air permeability for suppressing condensation or the like may not be obtained even if the air is made microporous by an embossing process described later.
[0035]
Next, the surface layer material can be manufactured as follows. For example, the wet nonwoven fabric and the bulky nonwoven fabric are prepared by the above-described method, while the thermoplastic resin is melted to form a thin film, and the thin film is bonded, or the wet nonwoven fabric, the thermoplastic resin thin film, and the bulky nonwoven fabric in advance. The method of preparing, laminating each, and bonding together by means, such as a heat | fever, is mentioned. Among them, the wet nonwoven fabric and the bulky nonwoven fabric are prepared, while the thermoplastic resin is melted and extruded with a T-die, and each nonwoven fabric is unwound and formed between rolls while forming a molten thin film. By using a method of bonding (extrusion laminating method), a wet nonwoven fabric and a bulky nonwoven fabric can be bonded efficiently, and a thermoplastic resin enters the gap between fibers, and an antifouling layer having an antifouling action and a depth. It is possible to obtain a bulky layer having an effect of imparting wrinkles, which is preferable.
[0036]
Specifically, the basis weight is 10 g / m. ² 30 g / m ² The following range, 2.94 cN / cm ² A wet nonwoven fabric having a thickness under load of 0.1 mm or less is prepared, and the basis weight is 30 g / m. ² 80 g / m ² The following range, 2.94 cN / cm ² A bulky nonwoven fabric having a thickness under load of 0.25 mm or more is prepared. Next, using a known T die, the viscosity and discharge amount of the resin are adjusted, and 2.94 cN / cm in the solidified state of the thermoplastic resin alone. ² Melt and extrude so that the thickness under load is in the range of 0.005 mm to 0.045 mm. And it can manufacture by unwinding each nonwoven fabric from the both sides of the thin film-like thermoplastic resin holding the molten state, and making it adhere | attach while pressing between a pair of rolls.
[0037]
At this time, the amount of penetration of the thermoplastic resin into each nonwoven fabric is determined by the relationship between the thickness of the wet nonwoven fabric and the thickness of the thermoplastic resin, or the molten state and pressure conditions of the thermoplastic resin. On the other hand, when the thickness of the thermoplastic resin is increased, the thermoplastic resin may be exposed on the entire surface of the nonwoven fabric. Therefore, the wet nonwoven fabric is preferably set to have a larger thickness. In particular, it is preferable to treat the thermoplastic resin so that it enters until it is exposed near the surface of the wet nonwoven fabric or a part of the surface. The vicinity of the surface here means that the thermoplastic resin has entered from the surface to a thickness portion position of about 50% with respect to the thickness of the original wet nonwoven fabric. More preferably, the thermoplastic resin is allowed to enter from the surface to a thickness portion position of about 30%. Moreover, exposure to a part of surface here refers to the thin film-like part except the part which is maintaining the fiber form in the wet nonwoven fabric surface. If the amount of thermoplastic resin entering is small, the distance in the thickness direction from the surface of the wet nonwoven fabric to the thermoplastic resin will increase, and dirt may enter the fiber gap of the wet nonwoven fabric, leaving dirt remaining even if wiped off. is there. When the degree of exposure to the surface of the thermoplastic resin is large, it may be difficult to obtain a fiber-like texture. When the degree of exposure is defined as follows, the number of exposed fibers is 15 / mm. ² More than 250 / mm ² The following is preferable. The number of exposed fibers referred to here is, as shown in FIG. 2, taken by enlarging the surface of the surface layer material 1 150 to 500 times with an electron microscope, 1 mm ² When the intersection 8a, the intersection 8b, the intersection 8c, and the intersection 8d forming the fiber gap 7 occupying the hit are regarded as one fiber each from the intersection constituting the gap to the adjacent intersection, the exposed fibers a (7a), The number of exposed fibers is measured as the exposed fiber b (7b), the exposed fiber c (7c), and the exposed fiber d (7d). When the number of exposed fibers satisfies the above range, it is considered that the degree of exposure of the thermoplastic resin is appropriate. A fiber in which the fibers are bonded together is regarded as one fiber. The term “fiber gap” as used herein refers to a void formed by at least one fiber having a fiber form.
[0038]
As a measure of the amount of the thermoplastic resin entering the nonwoven fabric, 2.94 cN / cm each of the nonwoven fabric and the solidified thermoplastic resin. ² Total thickness under load and 2.94 cN / cm of surface layer material ² It is good to adjust so that ratio (lamination compression ratio) with the thickness in load may be 0.8 or less.
[0039]
Next, the wallpaper of the present invention will be described. The wallpaper of the present invention has a wet nonwoven fabric as a surface, an antifouling layer in which the wet nonwoven fabric and a gas-permeable thermoplastic resin are integrated, and a thickness larger than the apparent thickness of the antifouling layer on the back surface of the antifouling layer. It has a surface layer part in which bulky layers made of bulky nonwoven fabric are laminated and integrated. Specifically, it is a wallpaper in which a surface layer portion is formed of the surface material.
[0040]
And as shown in FIG. 3, the said wallpaper is normally comprised by adhere | attaching the backing paper 13, such as a flame-retardant paper, on the back surface of the said surface layer material 1. As shown in FIG. As the backing paper, for example, paper that is usually used as backing paper such as vinyl wallpaper, paper wallpaper, woven wallpaper, or non-woven wallpaper can be used.
[0041]
Adhesion between the surface material 1 and the backing paper 13 is usually used as an adhesive 12 for backing paper such as vinyl wallpaper, paper wallpaper, woven wallpaper, or non-woven wallpaper, for example, an adhesive such as ethylene-vinyl acetate resin. Can be used.
[0042]
And the embossed pattern formed by the embossed part 10 and the non-embossed part 11 is provided to the surface of the said wallpaper by the embossing roll. The shape and depth of the embossed pattern are not particularly limited, but in order to maximize the characteristics of the wallpaper of the present invention, it is necessary to have as deep a wrinkle as possible so that the wallpaper has a three-dimensional effect, design, and fiber texture. It is preferable at the point which obtains the feeling of. The depth of the embossed pattern is preferably 0.05 mm or more.
[0043]
Moreover, by the said embossing process, on the wallpaper surface of this invention, an embossed part is pressed and a concave part of a wrinkle is formed, and a non-embossed part forms a convex part of a wrinkle. The non-embossed part has a structure in which at least a part thereof maintains a fiber form and a thermoplastic resin is present near the surface of the nonwoven fabric, or a part of the thermoplastic resin is exposed on the surface. In particular, since the non-embossed part is a part that is directly touched by a person, and is a part where dirt easily adheres due to contact of a person or an object, it is important to obtain the above structure. As shown in FIG. 4, the degree of exposure of the fiber in the non-embossed portion is 1 mm because the degree of exposure is further reduced by the number of the exposed fibers 9 of the surface layer material due to the thermocompression bonding action by the embossing and the thermoplastic resin penetration action. ² The number of exposed fibers per unit must be 4 or more preferable. The number of exposed fibers is more preferably 10 or more. This is because if the number of exposed fibers is less than 4, the texture of the fiber tone is lost and a film tone is obtained.
[0044]
On the other hand, since the thickness further decreases from the surface material in the thickness direction of the wallpaper by the embossing treatment, the apparent thickness of the non-embossed portion in the antifouling layer is in the range of 0.01 mm or more and 0.09 mm or less. Is preferred. The minimum of the apparent thickness of the non-embossed part in a more preferable antifouling layer is 0.02 mm or more. The upper limit of the apparent thickness of the non-embossed portion in the more preferable antifouling layer is 0.08 mm or less. Further, the apparent thickness of the non-embossed portion in the bulky layer is preferably 0.1 mm or more. Furthermore, the apparent thickness ratio (bulky layer / antifouling layer) between the bulky layer and the antifouling layer in the non-embossed portion is preferably 1.2 or more. A preferable lower limit of the apparent thickness ratio is 1.5 or more. When the apparent thickness of the antifouling layer in the non-embossed portion, the apparent thickness of the bulky layer, and the apparent thickness ratio are out of the above ranges, the same problem as the surface layer material may occur. Note that if the total apparent thickness of the antifouling layer and the bulky layer exceeds 0.6 mm, the volume of the wallpaper itself may become too large.
[0045]
The air permeability of the wallpaper of the present invention is preferably 300 seconds or less. A more preferable upper limit of the air permeability is 200 seconds or less. A more preferable lower limit of the air permeability is 20 seconds or more. Compared with the air permeability of the surface layer material, the air permeability after the embossing tends to be low. This is because the thermoplastic resin is microporous by an embossing process to be described later, thereby improving air permeability and moisture permeability. When the air permeability exceeds 300 seconds, dirt and liquid can be prevented from entering the wallpaper, but the air permeability is poor and condensation cannot be suppressed. If the air permeability is too small, dirt or liquid may enter the wallpaper, resulting in poor antifouling properties. Note that if the air permeability is too small, the air permeability and moisture permeability are improved, but it may be difficult to prevent the intrusion of dirt, so the embossing conditions may be adjusted as appropriate.
[0046]
Next, the wallpaper manufacturing method of the present invention will be described. First, the surface layer material and backing paper are prepared and laminated using an adhesive to prepare a wallpaper base material. At this time, the adhesive may be either dry or wet. If dry, it can be cooled and solidified by heat treatment. If wet, dipping, gravure coating, dot method, etc. An adhesive can be applied and dried for adhesion.
[0047]
Next, ink such as water-based ink and acrylic ink is applied to the surface of the wallpaper substrate using, for example, a general printing method such as gravure printing, flexographic printing, rotary screen printing, offset printing, transfer printing, letterpress printing, Printing is performed. Further, if necessary, an oily, silicone-based, or fluorine-based water repellent can be applied.
[0048]
The wallpaper base material is then embossed. As the embossing roll, one normally used for embossing of wallpaper is used. For example, the embossing rate is preferably given with an embossing area of 20 to 60% with respect to the entire roll area. The embossing height is preferably 0.1 to 0.6 mm. It is preferable that the embossing is performed at a temperature equal to or higher than a temperature at which at least a part of the thermoplastic synthetic fiber melts among the fibers constituting the surface layer material. If the temperature is lower than the temperature at which the thermoplastic synthetic fiber melts, it is difficult not only to form an antifouling layer on the wallpaper surface, but also to form deep wrinkles. For example, as a thermoplastic synthetic fiber, a sheath-core type thermomeltable composite fiber composed of a sheath component having a low melting component and a core component composed of a high melting component having a melting temperature higher by 15 ° C. than the melting temperature of the low melting component. When used, it is preferable to emboss at a temperature not lower than the melting temperature of the sheath component and lower than the melting temperature of the core component. In particular, when the treatment is performed at a temperature 20 ° C. lower than the melting temperature of the core component and lower than the melting temperature of the core component, the sheath component is completely melted to obtain a dense surface, and the core component is also deformed to form an embossed pattern. It is clearly formed and preferable.
[0049]
On the other hand, the thermoplastic resin forms an embossed pattern by the embossing treatment, and is microporous, so that a gas-permeable thermoplastic resin having appropriate gas permeability but preventing entry of dirt is obtained. The reason for microporosity is not clear, but when the thermoplastic resin is softened or remelted, the fibers constituting the nonwoven fabric are made microporous by piercing or biting in. Presumed. If the embossing temperature is less than 5 ° C. lower than the temperature at which the thermoplastic resin melts, not only is the microporous formability of the thermoplastic resin inferior, but the embossed pattern is not clearly formed.
[0050]
Therefore, it is preferable that the embossing temperature simultaneously satisfies a temperature higher than the temperature at which the thermoplastic synthetic fiber constituting the nonwoven fabric melts and a temperature lower by 5 ° C. than the temperature at which the thermoplastic resin melts. In particular, when the treatment is carried out at a temperature 20 ° C. lower than the melting temperature of the core component and lower than the melting temperature of the core component, the surface is dense and wrinkles are clearly formed, and the thermoplastic resin has micropores. Since many can be obtained, the contradicting properties of fiber-like texture, antifouling property and air permeability can be satisfied at the same time, which is preferable. Moreover, it is preferable that the pressure in embossing is 70 N / cm or more and 500 N / cm or less from the sharpness and workability of wrinkles.
[0051]
Then, if necessary, an oil-based, silicone-based, or fluorine-based water repellent is applied to the wallpaper base material that has been subjected to the embossing treatment, and a curing treatment is performed as necessary to obtain a wallpaper.
[0052]
【Example】
Hereinafter, an example is given and it demonstrates concretely. In addition, the thickness of the nonwoven fabric, the number of exposed fibers, the air permeability, and the wiping property test were measured as follows.
[0053]
[Thickness]
(1) 2.94 cN / cm ² Thickness at load
Using a thickness measuring machine (trade name: THICKNESS GAUGE model CR-60A, manufactured by Daiei Kagaku Seiki Seisakusho Co., Ltd.), 1 cm sample ² It measured in the state which added the load of 2.94cN per.
[0054]
(2) Apparent thickness
Three specimens were prepared, mounted on an electron microscope (manufactured by Hitachi Science Systems, S-3500N), magnified 200 times, photographed at three locations, each thickness was measured, and the average value was apparent thickness.
[0055]
[Number of exposed fibers]
The sample surface was photographed with an electron microscope at a magnification of 200x for wet non-woven fabric and surface material, and 30x for non-embossed parts of wallpaper. ² The number of exposed fibers was measured with one fiber from the intersection of the exposed fibers forming the gap between the adjacent fibers to the adjacent intersection, and the average value was defined as the number of exposed fibers.
[0056]
[Air permeability]
J. et al. TAPPI Paper Pulp Test Method No. 5 B It measured according to the method by the Oken type air permeability tester (pressurization type).
[0057]
[Disposability test]
(1) Dirt during construction (natural adhesion)
Collect 100g of starch-based construction paste (Yaoi Chemical Co., Ltd., You Mild) and collect a small amount of 5g of dust adhering to the equipment in the room and water-based sign pen (Pentel Co., Ltd.). Then, it was attached to a spatula and mixed with glue to prepare a dirty construction paste, and the soiling construction paste was adhered to the wallpaper surface in a size of about 4 cm × about 15 cm and about 0.5 g.
[0058]
(2) Dirt (rubbing adhesion) during construction
A dirty work gloves were made by letting the dust attached to the equipment in the room soak into the work gloves, and this was rubbed and attached to the wallpaper surface by hand with a size of about 4 cm × about 15 cm.
[0059]
(3) Coffee stains
Based on the “Stain Prevention Product Performance Labeling Regulations” (industry regulations) established by the Japan Vinyl Industry Association and the Vinyl Building Subcommittee, Nescafe Gold Blend (manufactured by Nestlé Co., Ltd.) is used and the concentration of coffee is 4 g per 100 g of water Was prepared at room temperature. Next, an A4 size test piece was affixed to a test stand inclined at about 45 ° C., and the coffee placed in the beaker was sprinkled on the test stand so that the contamination range was about 10 cm wide.
[0060]
(4) Soy sauce stains
Based on the “Stain Prevention Product Performance Labeling Regulations” (industry regulations) established by the Japan Vinyl Industry Association / Vinyl Building Subcommittee, use Kikkoman Co., Ltd.'s dark mouth soy sauce and sprinkle and adhere in the same manner as the above coffee stains. It was.
[0061]
(5) Wipeability test of dirty-walled wallpaper
After attaching various stains to the test piece, it is allowed to stand for 24 hours, and then carefully wiped with a white cotton cloth soaked with water. Judgment was made by comparing the part where the dirt was wiped off with the part where the dirt was not attached (original piece). Judgment display was made into 5 grades from the 5th grade (good) to the 1st grade (impossible) as follows, and when the grade spanned 2 grades, it was displayed as the 3rd to 4th grade.
1st grade: Dirt is greater than or equal to gray scale No. 1 for contamination (dirt remains dark)
2nd grade: Dirt is about gray scale No. 2 for contamination (pretty dirty remains)
3rd grade: Dirt is about gray scale No. 3 for contamination (slightly dirty)
Grade 4: Contamination is about gray scale No. 4 for contamination (almost no dirt remains)
Grade 5: Dirt is about gray scale No. 5 for contamination (no dirt remains)
[0062]
[Example 1]
(1) Preparation of wet nonwoven fabric
Pulp (NBKP) 50 mass%, fineness 2.2dtex, fiber length 10mm sheath component is a polyester polyester sheath core composite fiber made of polyethylene terephthalate (Toyobo Co., Ltd., EE7) Prepare 50mass%, wet paper making, 20g / m ² Wet non-woven fabric was obtained.
[0063]
(2) Preparation of bulky nonwoven fabric
60 mass% of rayon fiber (made by Daiwabo Rayon Co., Ltd.) with a fineness of 1.7 dtex and a fiber length of 40 mm, a polyester sheath with a sheath component with a fineness of 2.2 dtex and a fiber length of 51 mm, and a core component made of polyethylene terephthalate 40 mass% of core type composite fiber (Toyobo Co., Ltd. make, EE7) was prepared. The melting point (according to JIS-L-7122 (DSC method)) of the polyester sheath-core type composite fiber was confirmed only at about 253 ° C. of the core component. On the other hand, the melting temperature in the sheath component was about 110 ° C.
[0064]
After blending the two fibers into a fiber web using a semi-random card machine, the fiber web is placed on a plain weave net with a weft diameter of 0.132 mm and 90 mesh, respectively, and an orifice having a hole diameter of 0.1 mm Is sprayed with water pressure of 2MPa, 4MPa and 7MPa on the front side from nozzles provided at intervals of 0.6mm, water flow is sprayed twice at 7MPa on the back side, and the constituent fibers are entangled and then dried at 135 ° C. Polyester sheath / core composite fiber is melted to have a basis weight of 50 g / m ² The hydroentangled nonwoven fabric (bulky nonwoven fabric) was obtained.
[0065]
(3) Production of surface layer material (extrusion lamination process)
The wet nonwoven fabric and the bulky nonwoven fabric are prepared. On the other hand, a low-density polyethylene in a molten state is melted at 120 ° C. by melting a low-density polyethylene resin having a melting point of about 110 ° C. to a thickness of 0.015 mm from the slit of the T die. The thin film was extruded, each non-woven fabric was unwound, pressed between driving rolls and laminated and integrated to produce a surface layer material.
[0066]
(4) Production of wallpaper
110g / m per unit weight as backing paper ² A flame retardant paper was prepared, and an ethylene-vinyl acetate adhesive was applied on the flame retardant paper using a coater at a coating amount of 25 g / m. ² After coating, the bulky nonwoven fabric surface (back surface) of the surface layer material and flame retardant paper were bonded together, and dried at a temperature of about 150 ° C. using a hot air drum dryer to obtain a base material for wallpaper. Next, with the wet nonwoven fabric surface as the surface, the printing treatment and the silicone-based water repellent are about 10 g / m. ² After applying and water-repellent treatment, the embossing roll is wet nonwoven fabric surface under the conditions of roll temperature 250 ° C and linear pressure 260N / cm using embossing roll / flat roll with embossing rate of 50%. The embossing process was performed so that it might contact | abut. Furthermore, about 10g / m of silicone water repellent ² It was applied and subjected to water repellent treatment to obtain a wallpaper.
[0067]
[Example 2]
Constituent fiber of wet nonwoven fabric, 10g / m ² Of the pulp of Example 1 50 mass% and polyester sheath-core composite fiber 50 mass%, and the basis weight 10 g / m ² A surface layer material and a wallpaper were obtained in the same manner as in Example 1 except that 100 mass% of the polyester-based composite fiber of Example 1 was made and paper was made.
[0068]
[Example 3]
The constituent fiber of the wet nonwoven fabric is a sheath core type having a fineness of 2.2 dtex and a fiber length of 6 mm made of high-density polyethylene having a melting point of about 128 ° C and a core component of polypropylene having a melting point of about 162 ° C instead of the polyester composite fiber. A surface layer material and wallpaper were obtained in the same manner as in Example 1 except that heat-meltable conjugate fiber (manufactured by Daiwabo Co., Ltd., NBF (H)) was used.
[0069]
[Example 4]
The bulky nonwoven fabric is composed of 80 mass% rayon fiber (manufactured by Daiwabo Rayon Co., Ltd.) with a fineness of 1.7 dtex and a fiber length of 40 mm, a sheath component with a fineness of 2.2 dtex and a fiber length of 51 mm, high density polyethylene, and a core component. A surface layer material and wallpaper were obtained in the same manner as in Example 1 except that 20 mass% of a sheath-core type composite fiber made of polyethylene terephthalate (manufactured by Daiwabo Co., Ltd., NBF (SH)) was used. The melting point of the sheath-core composite fiber was about 253 ° C. for the core component and about 128 ° C. for the sheath component.
[0070]
[Example 5]
A surface layer material and wallpaper were obtained in the same manner as in Example 1 except that the low density polyethylene thin film was extruded from the T die so that the thickness of the low density polyethylene resin was 0.04 mm.
[0071]
[Comparative Example 1]
40 g / m per unit area of 100% by mass of the polyester sheath-core type composite fiber of Example 1 on the surface side ² The basis weight is 40 g / m with a semi-random card web of 80% by mass of rayon fiber of Example 1 and 20% by mass of polyester-based sheath-core composite fiber of Example 1 on the back side. ² As a semi-random card web, wallpaper was obtained in the same manner as in Example 1 except that both webs were laminated and subjected to hydroentanglement treatment and heat treatment under the same conditions as in Example 1 to obtain a surface layer material.
Table 1 shows the performance of the surface layer materials and wallpaper of Examples 1 to 5 and Comparative Example 1.
[0072]
[Table 1]

[0073]
The wallpaper of Examples 1 to 4 has a large number of exposed fibers, maintains a fiber tone, and has an antifouling layer in which a wet nonwoven fabric and a thermoplastic resin are integrated, so that dirt is less likely to enter and dirt adhesion is prevented. It was excellent. Moreover, it had excellent wiping performance of grade 4 or higher against any dirt. Furthermore, since it has a bulky layer, it has a volume feeling rather than a paper-like texture like paper wallpaper, and has a clear warp. In addition, the wallpaper of Example 5 was a practical level although the thickness of the thermoplastic resin was large, so the number of exposed fibers was small, it was slightly film-like, and was slightly inferior in air permeability. It was excellent in dirt adhesion prevention and wiping properties. On the other hand, the wallpaper of Comparative Example 1 has a fiber-like texture because the surface layer material is made only of a nonwoven fabric, and has a sharp bow, but various stains enter the inside through the fiber gaps. Compared with, the amount of dirt adhered was significantly increased. Furthermore, even if wiped off, the dirt could not be sufficiently wiped off.
[0074]
【The invention's effect】
The surface layer material of the present invention has a wet nonwoven fabric as a surface, an antifouling layer in which the wet nonwoven fabric and a thermoplastic resin are integrated, and a bulky surface having a thickness larger than the apparent thickness of the antifouling layer on the back surface of the antifouling layer By unifying the bulky layer composed of non-woven fabric, the embossing process has excellent antifouling properties while maintaining the fiber-like texture on the surface without the need for severe temperature and pressure management during embossing. In particular, it is possible to obtain a wallpaper surface, which is suitable for obtaining a stable quality wallpaper. Furthermore, a surface layer material suitable for obtaining a wallpaper having a good design and capable of imparting deep wrinkles without impairing air permeability can be obtained.
[0075]
In particular, the thermoplastic resin enters the fiber gaps of the wet nonwoven fabric and the bulky nonwoven fabric and adheres to prevent the surface layer portion of the wallpaper itself from being peeled off when the wallpaper is replaced. Intrusion of dirt can be suppressed in the vicinity of the surface while maintaining the fiber-like texture, and the wiping property of dirt can be improved.
[0076]
The wallpaper of the present invention can obtain a wallpaper surface excellent in antifouling property while maintaining the fiber-like texture on the surface by using the surface layer material as a surface layer part, and the antifouling layer has air permeability. Therefore, dew condensation can be suppressed and the bulky layer is integrated, so that a wallpaper having a deep wrinkle and excellent design can be obtained.
[Brief description of the drawings]
FIG. 1 shows an example of a cross section of a surface layer material of the present invention.
FIG. 2 shows an example of the surface of the surface material of the present invention.
FIG. 3 shows an example of a cross section of the wallpaper of the present invention.
FIG. 4 shows an example of the surface of the wallpaper of the present invention.
[Explanation of symbols]
1. Surface material
2. Wet nonwoven fabric
3. Thermoplastic resin
4). Bulky nonwoven fabric
5. Antifouling layer
6). Bulky layer
7). Fiber gap
8). Intersection
9. Exposed fiber
10. Embossed part
11. Unembossed part
12 adhesive
13. Backing paper
14 wallpaper

Claims (10)

An antifouling layer in which the wet non-woven fabric is the surface, the wet non-woven fabric and the thermoplastic resin are integrated, and a bulky layer composed of a bulky non-woven fabric having a thickness larger than the apparent thickness of the antifouling layer on the back surface of the antifouling layer Is a surface layer material that is laminated and integrated,
The wet nonwoven fabric has a basis weight of 10 g / m ² or more and 30 g / m ² or less, and a thickness at a load of 2.94 cN / cm ² of 0.03 mm or more and 0.1 mm or less. Yes,
The bulky nonwoven fabric has a basis weight of 30 g / m ² or more and 80 g / m ² or less, and a thickness at a load of 2.94 cN / cm ² is 0.25 mm or more and 1.6 mm or less. Yes,
A thin film melted with a T-die so that the thickness at a load of 2.94 cN / cm ² in the solidified state of the thermoplastic resin alone is between 0.005 mm and 0.045 mm between each nonwoven fabric. melting the shaped heat thermoplastic resin, extruded, the sum of the thickness in each 2.94 cN / cm ² load alone each nonwoven and thermoplastic resin solidified state, 2.94 cN / cm ² load of the surface layer member While being pressed so that the ratio with the thickness (laminate compression ratio) is 0.8 or less,
The antifouling layer has entered until the thermoplastic resin enters the inside of the wet nonwoven fabric and is exposed to the vicinity of the surface of the wet nonwoven fabric or a part of the surface,
A surface layer material wherein the number of exposed fibers measured by the following method on the surface of the surface material is 15 / mm ² or more and 250 / mm ² or less.
[Number of exposed fibers] Using an electron microscope, the surface layer material surface was magnified 200 times and photographed at three locations. For each intersection forming a fiber gap per 1 mm ² , from the intersection constituting the gap to the adjacent intersection. fibers each with one exposed fiber was measured the number, and the average value and the exposed fiber number of the surface layer member.   The apparent thickness of the antifouling layer is in the range of 0.02 mm or more and 0.1 mm or less, the apparent thickness of the bulky layer is 0.15 mm or more, and the apparent thickness ratio between the bulky layer and the antifouling layer (bulk The surface layer material according to claim 1, wherein (high layer / antifouling layer) is 3 or more.   The fiber constituting at least one of the wet nonwoven fabric and the bulky nonwoven fabric is composed of a high melting component having a sheath component as a low melting component and a core component having a melting temperature of 15 ° C. or more higher than the melting temperature of the low melting component. The surface layer material of Claim 1 or 2 containing a sheath-core type heat-meltable conjugate fiber.   The surface material according to claim 3, wherein the sheath core type heat-fusible composite fiber has a fineness of 3 dtex or less. A wet non-woven fabric having a basis weight of 10 g / m ² or more and 30 g / m ² or less, and a thickness at a load of 2.94 cN / cm ² of 0.1 mm or less;
A bulky nonwoven fabric having a basis weight in the range of 30 g / m ² or more and 80 g / m ² or less and having a thickness at a load of 2.94 cN / cm ² of 0.25 mm or more is prepared.
A thin film thermoplastic in a molten state with a T-die so that the thickness at a load of 2.94 cN / cm ² in the solidified state of the thermoplastic resin alone is between 0.005 mm and 0.045 mm between each nonwoven fabric. The resin is melted, extruded, and bonded while being pressurized . The above pressure is applied to each of the nonwoven fabrics and the solidified thermoplastic resin individually at a total thickness of 2.94 cN / cm ² , and 2 of the surface layer material. The surface layer material according to any one of claims 1 to 4, wherein a ratio with respect to a thickness (lamination compression ratio) at a load of 0.94 cN / cm ² is adjusted to 0.8 or less. Production method. The surface layer material according to any one of claims 1 to 4 is a surface layer portion, and is a wallpaper having an embossed pattern,
The antifouling layer in the surface layer portion enters the inside of the wet nonwoven fabric until the thermoplastic resin is exposed to the vicinity of the surface of the wet nonwoven fabric or a part of the surface in the non-embossed portion. der exposed fiber number is 4 / mm ² or more as measured by the method is, picture, characterized in that less than the exposed fiber number of the surface layer member.
[Number of exposed fibers] The surface of the surface layer is scanned with an electron microscope, the non-embossed portion of the wallpaper is magnified 30 times, and three positions are photographed. For each intersection forming a fiber gap per 1 mm ² , an intersection is formed. The exposed fibers are measured with one fiber from each to the adjacent intersection, and the average value is defined as the number of exposed fibers in the wallpaper . A surface layer material according to any one of claims 1 to 4 is used as a surface layer portion, a backing paper is adhered, and further an embossed pattern is provided. The antifouling layer in the surface layer portion is thermoplastic. The resin enters the inside of the wet nonwoven fabric and enters the non-embossed portion until it is exposed to the vicinity of the surface of the wet nonwoven fabric or a part of the surface, and the number of exposed fibers defined and measured as follows on the surface of the surface layer portion is 4 / mm ² or more der is, picture, characterized in that less than the exposed fiber number of the surface layer member.
[Number of exposed fibers] The surface of the surface layer is scanned with an electron microscope, the non-embossed portion of the wallpaper is magnified 30 times, and three positions are photographed. For each intersection forming a fiber gap per 1 mm ² , an intersection is formed. The exposed fibers are measured with one fiber from each to the adjacent intersection, and the average value is defined as the number of exposed fibers in the wallpaper .   The apparent thickness of the non-embossed portion in the antifouling layer is in the range of 0.01 mm or more and 0.09 mm or less, the apparent thickness of the non-embossed portion in the bulky layer is 0.1 mm or more, The wallpaper according to claim 6 or 7, wherein an apparent thickness ratio (bulky layer / antifouling layer) to the antifouling layer is 1.2 or more.   The wallpaper according to any one of claims 6 to 8, wherein the thermoplastic resin in the embossed portion is microporous. A surface layer material according to any one of claims 1 to 4 is prepared, a backing material is joined to the bulky nonwoven fabric surface of the surface layer material with an adhesive, and the wet nonwoven surface of the surface layer material has a height of 0.1 to 0. .6 mm embossing is in contact with an embossing roll having an embossing area of 20% to 60% with respect to the total area of the embossing roll, and a temperature of 5 ° C. lower than the temperature at which the thermoplastic resin melts, and 70 The method for producing wallpaper according to any one of claims 6 to 9, wherein an embossed pattern is formed on the surface of the nonwoven fabric by embossing at a pressure of N / cm or more and 500 N / cm or less .

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