JP7740641B2 - Wallpaper cutting underlay tape and its manufacturing method - Google Patents

Description

This invention relates to a wallpaper cutting underlayment tape that is placed between the seams of wallpaper and the base material when pasting wallpaper (cloth) on a wall or other surface, to protect the base material from damage when cutting the wallpaper.

An example of an underlay tape for cutting wallpaper is disclosed in Patent Document 1 below.

This wallpaper cutting underlay tape consists of a flexible mesh sheet covered on both sides with synthetic resin film, with only the edges of the mesh sheet and the front and back synthetic resin films adhered together with adhesive.

With this structure, the mesh sheet is wrapped in a bag of synthetic resin film, with each layer separated from the other in the middle widthwise. When cutting wallpaper with a cutter, the cutting edge of the cutter cuts through the upper synthetic resin film and catches on the flexible weft threads of the mesh sheet. As this happens, the weft threads of the mesh sheet move, so they are not cut immediately, but rather remain caught on the cutting edge and slide in the cutting direction on the lower film. As a result, even when the cutting edge of the cutter hits the substrate, it only does so intermittently, preventing continuous scratches from being left on the substrate and providing extremely effective protection.

Patent No. 4235751

The underlay tape in Patent Document 1 has a structure in which only the edge portions on both sides of the mesh sheet are adhered to the synthetic resin film, so a certain width of the adhesive area is necessary to integrate the mesh sheet and the synthetic resin film, which pulls the weft threads when cut.

However, if the adhesive is applied over a large area, the underlay tape becomes heavy and hard, making it difficult to handle. In particular, if the underlay tape is hard, it can be difficult to remove it from under the wallpaper.

The main objective of this invention is to provide effective protection for the base material while remaining lightweight and flexible.

The means for achieving this is a wallpaper cutting underlay tape in which synthetic resin films are placed on both the front and back of a flexible mesh sheet. The intersections of the warp and weft threads that make up the mesh sheet are adhesively fixed to the film, and spaces are formed between the films in areas other than the intersections that prevent the films from adhering to each other.

In this configuration, the mesh sheet and film are bonded to each other at multiple points, i.e., at the intersections of the warp and weft threads distributed over the entire surface, allowing the wallpaper cutting underlay tape to be formed into a single sheet overall while reducing the amount of adhesive used. Although it is in the form of a single sheet, the spaces between the films encourage peripheral deformation by creating a time lag as the cutting edge moves from the front film to the back film, dispersing the force of the cutting tool's cutting edge and increasing the tape's cut resistance. Films that are highly integrated with the mesh sheet can be very thin and lightweight.

This invention allows for a reduction in the amount of adhesive used, resulting in a lighter weight and greater flexibility. Furthermore, because the mesh sheet and film are bonded together to form a highly integrated structure overall, a very thin and soft film can be used, further increasing flexibility and improving handleability.

In addition, the mesh sheet and film are bonded at multiple points distributed throughout the entire sheet. This means that, unlike the bag-like structure of the conventional tape in Patent Document 1, the area over which the weft yarn caught on the cutting edge is pulled during cutting is narrow, allowing for good distribution of the load. This means that it is possible to use an inexpensive, easily cut material for the mesh sheet, rather than a material that is difficult to cut.

FIG. 1 is a perspective view of a wallpaper cutting underlay tape. FIG. 2 is a partially cutaway plan view of a wallpaper cutting underlayment tape. 3 is a cross-sectional view taken along the line AA in FIG. 2; 1A to 1C are explanatory diagrams showing a method for manufacturing a wallpaper cutting underlay tape. FIG. FIG.

One embodiment of this invention is described below with reference to the drawings.

Figure 1 shows a perspective view of wallpaper cutting underlay tape 11 (hereinafter referred to as "underlay tape"). Underlay tape 11 is composed of synthetic resin films 13 and 14 disposed on both the front and back of a flexible mesh sheet 12, and is formed into a tape shape of a fixed width as shown in Figure 1. Although it has a layered structure as described above, underlay tape 11 as a whole appears as a single film.

In other words, the underlay tape 11 is fixed by bonding the intersections 23 of the warp threads 21 and weft threads 22 that make up the mesh sheet 12 to the films 13, 14 on both the front and back sides. Bonding is achieved with adhesive 15, which is present at the intersections 23 as shown in Figure 2. While it is preferable for the adhesive 15 to be present only at the intersections 23, it is also possible for the adhesive 15 to be present in areas other than the intersections 23, in other words, to be present mainly at the intersections 23.

By bonding as described above, spaces 16 are formed between the films 13 and 14 sandwiching the mesh sheet 12, preventing the films 13 and 14 from being bonded to each other, except for the areas corresponding to the intersections 23.

In addition, non-constrained portions 24 that are not bonded to the films 13, 14 are formed in areas of the mesh sheet 12 other than the intersections 23. The non-constrained portions 24 may be non-constrained to both the front film 13 and the back film 14, or may be non-constrained to only one of them. Note that the adhesive 15 may be present mainly in the intersections 23, so not all linear portions of the warp threads 21 and weft threads 22 need to be non-constrained portions 24.

The mesh sheet 12 is composed of warp threads 21 and weft threads 22 made of spun yarn, and has an appropriate mesh size. The spacing between the weft threads 22 is preferably set to approximately 2 mm to 5 mm from the standpoints of flexibility and reduced cut resistance to the base material. The spacing between the warp threads 21 may be wider.

The mesh sheet 12 may be made of any flexible material, such as synthetic fibers like nylon (registered trademark), vinylon, polyester, polyethylene, polypropylene, acrylic, aramid, and polyarylate, or natural fibers like cotton, linen, wool, and silk. The warp threads 21 and weft threads 22 may be made of the same material or different materials. The underlay tape 11 may be made of polyester, for example, which can be cut by the blade of a cutter during use. The mesh sheet 12 may also be made of other materials, such as synthetic resin monofilament.

Films 13 and 14 can be made of suitable materials such as polyethylene or polypropylene, and it is desirable to use a lightweight, thin, and soft film with a thickness of approximately 8 to 25 μm. The front and back films 13 and 14 may be made of the same material, or may be made of different materials. Films 13 and 14 may also be embossed, for example.

The adhesive 15 that bonds the mesh sheet 12 and the films 13 and 14 is preferably transparent. However, if the mesh sheet 12 is white or transparent and the films 13 and 14 are transparent, the underlay tape 11 will be difficult to see during use. For this reason, it is recommended that a light-colored adhesive 15 be used in such cases.

Examples of adhesive 15 that become flexible when hardened include rubber-based adhesives, acrylic-based adhesives, silicone-based adhesives, and acrylic vinyl acetate-based adhesives. These may be used alone or in combination of two or more. As shown in Figure 2, adhesive 15 is applied to the intersections 23 of the mesh sheet 12, and adheres and holds the films 13 and 14 to both sides of the mesh sheet 12. As a result, the aforementioned space 16 is formed between the films 13 and 14, as shown in Figure 3, which is a cross-sectional view taken along A-A in Figure 2. The front film 13 and back film 14 that make up space 16 are free from each other and can move relative to each other.

In addition, the intersections 23 of the mesh sheet 12 are bonded to the films 13, 14, and the areas other than the intersections 23, i.e., the areas where the warp threads 21 and weft threads 22 extend linearly, form the aforementioned unrestrained areas 24 that are not bonded to the films 13, 14. In these unrestrained areas 24, the films 13, 14 on both sides and the warp threads 21 and weft threads 22 of the mesh sheet 12 are free to move relative to each other.

An underlay tape 11 with this configuration can be manufactured by applying adhesive 15 only to the intersections 23 of the mesh sheet 12 and then adhering the films 13 and 14 together, but it can be manufactured with good productivity using existing equipment by doing the following:

That is, as shown in Figure 4, the manufacturing method comprises an application process S1, a scraping process S2, and a bonding process S3. The application process S1 is a process of applying adhesive 15 to the mesh sheet 12. The scraping process S2 is a process of removing adhesive 15 from the mesh sheet 12 to which adhesive 15 has been applied, where the adhesive 15 is present in the individual warp yarns 21 and weft yarns 22. The bonding process S3 is a process of attaching films 13 and 14 to both sides of the mesh sheet 12 to form the aforementioned space portion 16 and unconstrained portion 24.

The coating process S1 and lamination process S3 can be performed using existing equipment, and the scraping process S2 can be performed using existing drying equipment 54. That is, in the lamination process S3, the mesh sheet 12 is unwound from a roll, and adhesive 15 in a liquid tank 53 is applied to the mesh sheet 12 using a backup roll 51 and a gravure roll 52. Note that the mesh sheet 12 is represented by a dashed line in Figure 4.

The mesh sheet 12 with the adhesive 15 applied is then transported into the drying device 54, where air 54a is blown onto the mesh sheet 12 to remove the adhesive 15 that has adhered to it, mainly from areas other than the intersections 23. The intersections 23 are structured so that the warp yarns 21 and weft yarns 22 intersect and easily attract and retain the adhesive 15, making it difficult for the adhesive 15 to be removed by blowing air 54a. However, the adhesive 15 is blown away from the individual portions of the warp yarns 21 and weft yarns 22, i.e., the linear portions between the intersections 23. As a result, the adhesive 15 remains mainly at the intersections 23.

The mesh sheet 12, from which excess adhesive 15 has been scraped off in this way, is sent to laminating rolls 55 and 56, where films 13 and 14 fed from the film rolls are superimposed on both sides to complete lamination.

Then, it is cut to a fixed width in a slitting process (not shown) and wound into multiple rolls to form the rolled underlay tape 11.

As shown in Figure 5, the underlay tape 11 configured as described above is placed at the seam between wallpapers 72, 73 that are attached to a wall base material 71, protecting the base material 71 when the wallpapers 72, 73 are cut. When using it, first attach the wallpapers 72, 73 to the base material 71 so that the edges of the wallpapers 72, 73 to be joined overlap. At this time, the underlay tape 11 is placed under the lower wallpaper 72 that is located on the base material 71 side.

When laying the underlay tape 11, it doesn't matter which side is facing up; either the film 13 or 14 can be placed face down.

Next, the overlapping portions of the wallpaper 72 and 73 are cut vertically in a straight line with a cutter. After cutting, the underlay tape 11 is pulled out from under the wallpaper 72 and 73 and removed, and the wallpaper 72 and 73 are attached to the base material 71.

When cutting the wallpaper 72, 73, as shown in Figure 6, the cutting edge of the cutter 75 penetrates the wallpaper 72, 73 to a depth that cuts into part or all of the underlay tape 11. When cutting, even if the cutting edge of the cutter 75 penetrates the front film 13, the presence of the space 16 prevents the cutting edge from simultaneously reaching the back film 14; there is a time lag before this happens. The cutting edge also causes the front film 13 to move slightly relative to the back film 14.

In addition, the weft thread 22 caught on the cutting edge is pulled by the cutting edge, and in the unrestrained portion 24, it deforms and moves separately from the films 13 and 14.

In this way, the space 16 promotes deformation and displacement around it, dispersing the force of the cutting edge. As a result, the cut resistance of the base material 71 can be improved.

Furthermore, the mesh sheet 12 and films 13, 14 are bonded at intersections 23 that extend across the entire surface, and these intersections 23 are evenly distributed across the entire underlay tape 11. As a result, the portion of the weft thread 22 that is directly pulled by the cutting edge is not a wide area across the width of the underlay tape 11, but a narrow area corresponding to the mesh size, and the load on the cutting edge is distributed across the intersections 23. This also improves cut resistance, and as a result, it is possible to use an inexpensive, cuttable material for the mesh sheet 12 rather than a cut-resistant material.

Furthermore, because the mesh sheet 12 and films 13, 14 are bonded to each other at multiple points distributed in the surface direction, the amount of adhesive 15 used can be reduced compared to when bonding to a fixed width area to ensure a predetermined adhesive strength. Moreover, unlike bag-shaped products that have many separated areas in the thickness direction, the entire product can be formed into a single thin sheet, so the film can be made extremely thin. This lighter weight and improved flexibility make it easier to handle.

As described above, an underlay tape 11 is obtained that is lightweight, flexible, and easy to handle while effectively protecting the base material 71.

11... Wallpaper cutting underlay tape 12... Mesh sheet 13, 14... Film 15... Adhesive 16... Space portion 21... Warp thread 22... Weft thread 23... Intersection portion 24... Non-restraint portion 54a... Air S1... Application process S2... Scraping process S3... Bonding process

Claims (3)

A wallpaper cutting underlay tape having synthetic resin films on both the front and back sides of a flexible mesh sheet,
Intersections of warp yarns and weft yarns constituting the net sheet are adhesively fixed to the film,
The wallpaper cutting underlay tape has spaces formed between the films at locations other than the intersections to prevent the films from adhering to each other. 2. The wallpaper cutting underlay tape according to claim 1, wherein the mesh sheet has non-constrained portions that are not adhered to the film at portions other than the intersections. A method for manufacturing wallpaper cutting underlay tape, which comprises a flexible mesh sheet with synthetic resin films disposed on both the front and back sides thereof,
a coating step of applying an adhesive to the mesh sheet;
a scraping step of blowing air onto the mesh sheet to remove adhesive from individual portions of the warp and weft yarns in the mesh sheet;
A method for manufacturing wallpaper cutting underlay tape includes a bonding process in which the film is attached to both sides of the mesh sheet, the intersections of the warp and weft threads of the mesh sheet are adhesively fixed to the film, and spaces are formed between the films in areas other than those corresponding to the intersections to prevent the films from adhering to each other.