WO2007102647A1

WO2007102647A1 - Breathable wall covering including olefin material and production method thereof

Info

Publication number: WO2007102647A1
Application number: PCT/KR2006/004789
Authority: WO
Inventors: Si-Young Lee; Phan-Seok Kim
Original assignee: Lg Chem, Ltd.
Priority date: 2006-03-06
Filing date: 2006-11-15
Publication date: 2007-09-13

Abstract

Disclosed are a breathable wall covering including olefin material and a production method thereof. The wall covering includes a surface paper layer and a surface protective layer formed on the surface paper layer, wherein the surface protective layer is breathable. The breathable surface protective layer is formed of an olefin resin compound containing an inorganic compound. The breathable wall covering includes a printed layer formed on the surface paper layer and/or the surface protective layer, and have pinholes formed therethrough. The breathable wall covering has excellent breathability due to the inorganic filler and the pores formed in the surface protective layer. The inorganic filler is contained in an adhesive composition used in the wall covering to impart breathability, and the pinholes are additionally formed through the wall covering so as to increase breathability.

Description

BREATHABLE WALL COVERING INCLUDING OLEFIN MATERIAL AND PRODUCTION METHOD THEREOF

Technical Field

[1] The present invention relates to a breathable wall covering including olefin material and a production method thereof, and more particularly to a wall covering comprising a surface paper layer and a surface protective layer formed on the surface paper layer, in which the surface protective layer is breathable, as well as a production method thereof.

[2]

Background Art

[3] Generally, wall coverings have been used to prevent a dew condensation phenomenon caused by the temperature difference between the inside and outside of cement walls, and to provide decorative effects. Recently, many studies have been conducted to provide wall coverings not only with fundamental basic properties such as water resistance, thermal insulation, sound absorption and easy installation properties, but also with properties such as air permeability, beauty, deodorization and temperature control properties. With the increase in the quality of living, products having both an elegant appearance and useful physical properties are required on the market.

[4] In attempts to perform such requirements, Japanese Patent Laid-Open Publication

Nos. 2005-200823, 2002-52665 and 1998-278199 disclose technologies relating to wall coverings comprising a foamed resin layer, based on a foaming agent and olefinic thermoplastic resin, a pattern layer and a surface layer, which are sequentially deposited on a base layer, in which said surface layer is made of nylon resin. However, in such wall coverings, the foamed resin layer is formed on the base layer, but not the surface layer, and thus these wall coverings have reduced breathability (or permeability), which results in mold after the processing thereof or during the use thereof.

[5] Also, Japanese Patent Laid-Open Publication No. 2005-2308 discloses a wall covering obtained by placing an expansion-molded sheet of resin on a base layer and adhering the two layers to each other using an adhesive agent or molten polyethylene deposited between the two layers. However, this wall covering has a problem in that it is impossible to roll the wall covering at temperatures above the decomposition temperature of the expanding agent.

[6] Also, Japanese Patent Laid-Open Publication No. 2003-129386 discloses a wall covering which has a sheet of olefinic synthetic resin as a surface layer in order to inhibit the shrinkage of the wall covering during the application thereof. However, it is difficult to process this wall covering due to gas ejection caused by the use of a chemical foaming agent.

[7] Also, Korean Patent Laid-Open Publication No. 2002-57870 discloses an embossed wall covering comprising a surface layer, a PE resin film layer and a printed layer, which are sequentially deposited on each other. However, this wall covering has a problem in that the film layer, comprising only PE resin, has insufficient breathability.

[8]

Disclosure of Invention Technical Problem

[9] The present invention has been made to solve the above-described problems occurring in the prior art, and it is an object of the present invention to provide a breathable wall covering that includes olefin material and has excellent breathability (or permeability), easy processability and a beautiful appearance, as well as a production method thereof.

[10] Another object of the present invention is to provide a breathable wall covering including olefin material, which has excellent breathability because the surface protective layer thereof is formed with an olefin resin compound containing an inorganic filler, as well as a production method thereof.

[11] Still another object of the present invention is to provide a breathable wall covering, the breathability of which is further increased by forming pinholes, in addition to using said olefin resin compound.

[12]

Technical Solution

[13] To achieve the above objects, the present invention provides a breathable wall covering comprising a surface paper layer and a surface protective layer formed on the surface layer, in which the surface protective layer is breathable. [14] The breathable surface protective layer according to the present invention is preferably an olefin resin compound containing inorganic fillers. [15] Also, the breathable wall covering may comprise a printed layer formed on the surface layer and/or the surface protective layer, and may have pinholes formed therethrough. [16]

Brief Description of the Drawings [17] FIG. 1 is a cross-sectional view of a wall covering according to one embodiment of the present invention. [18] FIG. 2 is a cross-sectional view of a wall covering according to another embodiment of the present invention.

[19] FlG. 3 is a cross-sectional view of a wall covering according to still another embodiment of the present invention.

[20] FlG. 4 is a block diagram showing a process for producing the wall covering of

FlG. 1.

[21] FlG. 5 is a block diagram showing a process for producing the wall covering of

FIG. 3.

[22]

Best Mode for Carrying Out the Invention

[23] Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

[24] FlG. 1 is a cross-sectional view of a wall covering including olefin material. As shown in FIG. 1, the wall covering has a structure in which a surface layer 30, a printed layer 40 and a surface protective layer 50 are sequentially deposited on each other.

[25] The surface paper layer 30 consists of paper made from pulp, woven or non- woven fabric, synthetic fiber or the like. Paper constituting the surface layer may be colored paper (including white paper) having a basic weight of 20-100 g/m , on which a beautiful printed layer can be formed.

[26] The printed layer 40 can be formed by printing various patterns and letters in various colors on the surface paper layer 30. The printing (dot formation) process is preferably carried out using a mesh roll type gravure printing method in order to ensure breathability. The surface protective layer 50 is formed of an olefin resin compound on the surface paper layer 30 or the printed layer 40. The olefin resin compound contains an inorganic filler for imparting breathability to the surface protective layer.

[27] The olefin resin compound (or composition) comprises an olefin resin, an inorganic filler and a flame retardant. The inorganic filler and the flame retardant are preferably contained in amounts of 1-100 parts by weight and 1-10 parts by weight, respectively, based on 100 parts by weight of the olefin resin.

[28] Preferred examples of the olefin resin may include polyethylene, polypropylene and polyisobutylene, which have excellent processability, moldability, thermal resistance and the like.

[29] The filler is added for the purpose of imparting breathability, and can be at least one selected from among calcium carbonate, magnesium carbonate, silica, kaolin, titanium oxide, barium sulfate, aluminum hydroxide and talc. The filler is preferably used in an amount of 1-100 parts by weight based on 100 parts by weight of the olefin resin. If the filled is used in an amount of less than 1 part by weight, it will provide reduced breathability and reinforcing properties, and if it exceeds 100 parts by weight, it will deteriorate the surface properties (tensile strength, tear strength, etc.) of the wall covering and roughen the surface.

[30] The filler preferably has a particle diameter of 1-50 D. If the particle diameter of the filler exceeds 50 D, the polyolefin resin film layer of olefin resin will have a rough surface or reduced strength, and if the diameter of the filler is less than 1 D, the formed olefin resin film layer will have reduced breathability.

[31] The reason why the filler performs a breathable function is because, when the olefin resin composition containing the filler is used to form the surface protective layer, pores, which will serve as air passages, are formed due to the presence of the filler. Because wet air can also move through the pores, moisture on walls will be discharged to the external environment, such that the occurrence of mold caused by moisture can be inhibited.

[32] The flame retardant is added to prevent the occurrence of a fire caused by volatile organic compounds (VOC) during processing and molding and to impart flame retardency during the use of the wall covering, and may be, for example, at least one selected from the group consisting of antimony oxide (Sb O ), aluminum hydroxide (Al(OH) ) and magnesium hydroxide (Mg(OH) ). It is preferably used in an amount of 1-10 parts by weight based on 100 parts by weight of the olefin resin. If the flame retardant is used in an amount of less than 1 part by weight, it will provide reduced flame retardancy, and if it is used in an amount of more than 10 parts by weight, it will cause a processing problem of lowering the melting temperature of the olefin resin.

[33] The surface protective layer 50 of the inventive breathable wall covering including the olefin material can be formed either by coating and drying the olefin resin compound on the surface paper layer or the printed layer, through a T die (including flat die) molding method, or through a conventional deposition method, such as a method of directly laminating the olefin resin compound film.

[34] FlG. 2 shows a cross-sectional view of a wall covering according to another embodiment of the present invention. As shown in FlG. 2, a base layer 10 is laminated to the lower surface of the wall covering shown in FlG. 1 by means of an adhesive 20.

[35] The base layer 10 in FlG. 2 can consist of paper made of pulp, woven fabric, nonwoven fabric, synthetic fiber, etc., like the material of the surface paper layer. Alternatively, the base layer can consist of material that is the same as or different from that of the surface paper layer.

[36] The base layer 10 of the breathable wall covering according to the present invention is laminated to the lower surface of the surface paper layer by means of the adhesive 20.

[37] The adhesive is a urethane or acrylic adhesive composition, which contains an inorganic filler for imparting breathability. The inorganic filler contained in the adhesive composition may be the same inorganic filler as the inorganic filler contained in the surface protective layer 30, and may be used in an amount of 1-50 parts by weight based on 100 parts by weight of the adhesive.

[38] In the breathable wall covering including olefin material according to the present invention, a printed layer 60 may also be formed on the surface protective layer 50 (see FlG. 3). The printed layer 60 is a second printed layer, which can give spatial sensations together with the printed layer 40 formed on the surface paper payer, and thus provide a more beautiful appearance. Alternatively, the surface protective layer may be formed on the surface paper layer without the printed layer, and the printed layer 60 having various patterns can be formed only on the surface protective layer.

[39] The breathable wall covering including olefin material according to the present invention can have embossing formed on the surface layer thereof.

[40] The inventive breathable wall covering having embossing formed thereon has a bulky appearance.

[41] The breathable wall covering according to the present invention may have fine pinholes formed therethrough to improve the breathability thereof. Due to the movement of dry air and wet air through the pinholes, breathability is additionally ensured.

[42] The pinholes have a diameter of 0.01-1 mm, and are preferably formed at a density of 100-1,000,000 pinholes per m². The pinholes, formed in the breathable wall covering according to the present invention, can be formed by passing the wall covering through a pin roll having 100-1,000,000 pins per m², the pins having a diameter of 0.01-1 mm.

[43] Hereinafter, a method for producing the inventive wall covering having excellent breathability will be described.

[44] FlG. 4 is a block diagram showing a process for producing the inventive breathable wall covering having a layered structure as shown in FlG. 1, and FlG. 5 is a block diagram showing a process for producing the inventive breathable wall covering having a layered structure as shown in FlG. 3.

[45] As shown in FIGS. 4 and 5, a method for producing a breathable wall covering including olefin material according to the present invention comprises the steps of: preparing raw materials; introducing a surface paper layer as one of said prepared raw materials; and forming on the surface paper layer a surface protective layer 50 of an olefin resin compound containing an inorganic filler.

[46] The inventive production method may additionally comprise a step of laminating a base layer 10 to the lower surface of the surface paper layer 30 using an adhesive.

[47] Furthermore, the method for producing the wall covering according to the present invention may additionally comprise printing steps of forming a printed layer 40 and/or a printed layer 60 on the surface paper layer and/or the surface protective layer 50 (see

FIG. 5). [48] Also, the method for producing the wall covering according to the present invention may additionally comprise an embossing step of forming embossed patterns on the surface layer. [49] Also, the method for producing the wall covering according to the present invention may additionally comprise, before or after the embossing step, a pin roll step of increasing the breathability of the wall covering. [50] The wall covering according to the present invention preferably has a thickness of

0.1-1 mm. [51]

Mode for the Invention [52] Hereinafter, a breathable wall covering including olefin material according to the present invention and a production method thereof will be described in further detail with reference to examples. [53] Example 1

[54] 1 kg of polyethylene was mixed with 50 g of aluminum hydroxide as a flame retardant and 250 g of talc having a particle size of 1-50 D as a filler, to prepare 1300 g of an olefin resin compound. [55] Previously printed colored titanium paper having a basic weight of 100 g/m and containing titanium oxide incorporated therein was used as a surface paper layer, on which a surface protective layer was then formed with the above-prepared olefin resin compound using a flat die method. [56] Meanwhile, titanium paper having a basic weight of 100 g/m and containing titanium oxide incorporated therein was used as a base layer, and a urethane adhesive containing a filler was applied to one side of the base layer to form an adhesive layer.

Then, the adhesive layer was adhered (laminated) to the back surface of the surface paper layer having the surface protective layer formed thereon. [57] The breathability of the wall covering was measured, and the measurement result is shown in Table 1 below. [58] Example 2

[59] A wall covering was produced in the same manner as in Example 1, except that a second printed layer was formed by printing patterns and colors on the surface protective layer of the wall covering produced in Example 1, using a mesh roll type gravure printing method. [60] The breathability of the wall covering according to Example 2 was measured, and the measurement result is shown in Table 1 below.

[61] Example 3 [62] A wall covering having pinholes formed therethrough was produced in the same manner as Example 2, except that the wall covering produced in Example 2 was passed through a pin roll having 100,000 pinholes/m , the pinholes having a diameter of 0.1 mm.

[63] The breathability of the wall covering according to Example 3 was measured, and the measurement result is shown in Table 1 below.

[64] Comparative Example 1 [65] A wall covering was produced in the same manner as in Example 1, except that the filler in the resin composition of Example 1 was not used.

[66] The breathability of the wall covering according to Comparative Example 1 was measured, and the measurement result is shown in Table 1 below.

[67] Comparative Example 2 [68] A wall covering was produced in the same manner as in Example 1, except that the filler in the resin composition of Example 1 was used in an amount of 1.1 kg, which was out of the range specified in the present invention.

[69] The breathability of the wall covering according to Comparative Example 2 was measured, and the measurement result is shown in Table 1 below.

[70] Comparative Example 3 [71] A wall covering was produced in the same manner as in Example 1, except that, as the filler in the resin composition of Example 1, talc was used, which had a particle size of 60 D, which was out of the particle size distribution range specified in the present invention.

[72] The breathability of the wall covering according to Comparative Example 3 was measured, and the measurement result is shown in Table 1 below.

[73] [74] Table 1 Measurement results for breathability of wall coverings including olefin material

[75] Note) Measurement method: KS K 0594: 2003, Water method [76] As shown in Table 1 above, the wall coverings including olefin material, according to Examples 1 to 3 of the present invention, showed excellent breathability compared to that of Comparative Example 1. [77] The wall covering of Comparative Example 2, in which the filler was used in an amount of 1.1 kg, which was out of the content range specified in the present invention, showed excellent breathability, but had reduced strength, a rough surface and insufficient printability.

[78] Also, the wall covering of Comparative Example 2, in which the filler having a particle size of 60 D was used, showed excellent breathability, but had reduced strength, a rough surface and insufficient printability.

[79]

Industrial Applicability

[80] As described above, the breathable wall covering including olefin material according to the present invention has excellent breathability due to the inorganic filler and the pores formed in the surface protective layer formed of the olefin resin compound containing the inorganic filler.

[81] Also, the inorganic filler is also contained in the adhesive composition so as to impart breathability, and the pinholes are formed through the wall covering so as to increase breathability.

[82] The wall covering according to the present invention has excellent breathability, such that it is permeable to dry air and wet air so as to inhibit the growth of mold in the wall covering, thus making the appearance thereof clean. Also, in the inventive wall covering, the surface protective layer is formed on the printed layer to protect the printed layer and also to make it possible to clean the wall covering with a cleaner and always maintain the wall covering in a clean state, thus improving the aesthetic appearance thereof. In addition, the inventive wall covering, having excellent breathability, has a simple structure, and thus can be simply applied.

Claims

[I] A breathable wall covering including olefin material, which comprises a surface paper layer and a surface protective layer, wherein the surface protective layer is breathable.

[2] The breathable wall covering of Claim 1, wherein the surface protective layer is formed of an olefin resin compound containing an inorganic filler. [3] The breathable wall covering of Claim 2, wherein the olefin resin compound comprises an olefin resin, the inorganic filler and a flame retardant. [4] The breathable wall covering of Claim 2, wherein the olefin resin compound comprises, based on 100 parts by weight of the olefin resin, 1-100 parts by weight of the inorganic filler and 1-10 parts by weight of the flame retardant. [5] The breathable wall covering of Claim 2, wherein the inorganic filler is one or a mixture of two or more selected form the group consisting of calcium carbonate, magnesium carbonate, silica, kaolin, titanium oxide, barium sulfate, aluminum hydroxide and talc. [6] The breathable wall covering of Claim 2, wherein the inorganic filler has a particle size of 1-50 D. [7] The breathable wall covering of any one of Claims 1 to 6, wherein a printed layer is formed on one or both of the surface paper layer and the surface protective layer. [8] The breathable wall covering of Claim 7, wherein the surface protective layer has embossed patterns formed thereon. [9] The breathable wall covering of Claim 8, wherein the wall covering has pinholes formed therethrough. [10] The breathable wall covering of Claim 9, wherein an adhesive layer, containing an inorganic layer, and a base layer are further sequentially formed on the lower surface of the surface paper layer.

[II] The breathable wall covering of any one of Claims 1 to 6, wherein the surface protective layer has embossed patterns formed thereon.

[12] The breathable wall covering of Claim 11, wherein the wall covering has pinholes formed therethrough. [13] The breathable wall covering of Claim 12, wherein an adhesive layer, containing an inorganic layer, and a base layer are further sequentially formed on the lower surface of the surface paper layer. [14] The breathable wall covering of any one of Claims 1 to 6, wherein the wall covering has pinholes formed therethrough. [15] The breathable wall covering of Claim 14, wherein an adhesive layer, containing an inorganic layer, and a base layer are further sequentially formed on the lower surface of the surface paper layer.

[16] The breathable wall covering of any one of Claims 1 to 6, wherein an adhesive layer, containing an inorganic layer, and a base layer are further sequentially formed on the lower surface of the surface paper layer.

[17] The breathable wall covering of Claim 16, wherein the wall covering has pinholes formed therethrough.

[18] A method for producing the breathable wall covering of any one of Claims 1 to

16, the method comprising the steps of: preparing an olefin resin compound containing an olefin resin; and forming a surface protective layer with the olefin resin compound on one surface of a surface paper layer.

[19] The method of Claim 18, which further comprises, before or after the step of forming the surface protective layer with the olefin resin compound on the surface paper layer, any one or two steps or more selected from among a step of forming a printed layer on one or both of the surface paper layer and the surface protective layer, a step of forming a base layer under the surface paper layer, a step of forming embossed patterns on the surface protective layer, and a step of forming pinholes through the wall covering.