JP7262906B2 - Interior material and its manufacturing method - Google Patents

Description

TECHNICAL FIELD The present invention relates to an interior material or the like expressing a clear pattern.

2. Description of the Related Art Resin interior materials having a so-called terrazzo pattern are conventionally known as interior materials for buildings such as floor materials, wall materials, and ceiling materials for buildings.
Here, the terrazzo pattern in the interior material refers to a polished marble-like pattern produced by kneading powder obtained by pulverizing marble or the like with cement or resin. It can be said that it is an interior material artificially reproduced with a resin material.
A resin interior material having such a terrazzo pattern is obtained by pulverizing a colored vinyl chloride resin sheet, collecting the pulverized material, and rolling or pressing (Patent Document 1).

Japanese Patent No. 3842420

In the conventional interior material obtained by rolling pulverized colored vinyl chloride resin sheets, it is necessary to bond the pulverized materials with sufficient strength in order to secure the required strength. As a general method for increasing the bonding strength between pulverized materials, it is conceivable to increase the heating temperature and pressure during rolling of the pulverized materials to enhance the fusion of the vinyl chloride resin.
However, when the fusion of the vinyl chloride resin is enhanced, the pattern that appears becomes blurred or nearly plain (no pattern) due to the fusion of the resin.
Also, interior materials made of vinyl chloride resin generally tend to lose flexibility in a low-temperature environment, making construction difficult. It is required to improve the workability at such low temperatures.

An object of the present invention is to provide an interior material having sufficient strength, flexibility even at low temperatures, and a clear pattern, and a method for producing the same.

The interior material of the present invention has a sheet body having a portion where a plurality of small lumps containing a vinyl chloride resin and a rubbery material are aggregated on the surface side, and a colored portion and an uncolored portion or a color different from the colored portion. and a colored portion, wherein the two portions include a small mass that is exposed in stripes, and the small mass extends obliquely with respect to the surface of the sheet body in a cross-sectional view. and in the agglomerated portion, adjacent nodules have no clear boundary due to coalescence .

In a preferred interior material of the present invention, in a cross-sectional view, the small lump extends from the middle portion in the thickness direction while being inclined with respect to the surface of the sheet body, and from the middle portion in the thickness direction to the back surface of the sheet body. and a portion extending obliquely along the .

According to another aspect of the invention, a method of manufacturing an interior material is provided.
The method for producing an interior material of the present invention is a method for producing an interior material having the above configuration, and comprises a colored first raw material containing a vinyl chloride resin and a rubbery material, a step of solidifying the colored second raw material or the second raw material colored in a color different from the color of the first raw material containing the vinyl chloride resin and the rubbery material in a flow pattern, forming the flow pattern; a step of pulverizing the solidified material to obtain a plurality of small lumps of raw material; and a step of collecting the small lumps of raw material and applying heat and pressure to produce a sheet.

The interior material of the present invention has a clear exposed pattern, is flexible even at low temperatures, and is excellent in strength and durability.

BRIEF DESCRIPTION OF THE DRAWINGS The partially-omission top view of the interior material of 1st Embodiment of this invention. FIG. 2 is a cross-sectional view taken along line II-II of FIG. 1; Sectional drawing of the interior material of 2nd Embodiment of this invention. Sectional drawing of the interior material of 3rd Embodiment of this invention. Sectional drawing of the interior material of 4th Embodiment of this invention. The top view which expanded the surface of the sheet|seat body of an interior material (the enlarged plan view of the VI section of FIG. 1). FIG. 6 is a cross-sectional view showing an example of the internal structure when the sheet body is cut in the thickness direction (cut along line VII-VII in FIG. 6). FIG. 6 is a cross-sectional view showing another example of the internal structure when the sheet body is cut in the thickness direction (cut along line VII-VII in FIG. 6); FIG. 2 is a reference cross-sectional view showing an apparatus for producing a solidified material with flowing patterns. FIG. 3 is a perspective view of a solidified material forming a flow pattern; The perspective view of the small lump cut out from the solidified material which comprised the flowing pattern. The schematic of the manufacturing apparatus of the sheet|seat body of an interior material. FIG. 3 is a photograph of the surface of the solidified material having a flow pattern produced in Example. The photograph figure of the surface of a sheet|seat body. The procedure of the bending test is shown, (a) is a reference plan view of the sample piece, (b) is a reference plan view when the triangular portion of the sample piece is bent, (c) is the arrow shown in (b). The reference side view seen from the direction.

Hereinafter, the present invention will be described with appropriate reference to the drawings.
In this specification, the term "plan view" refers to a view from a direction orthogonal to the surface of the sheet body (interior material), and the term "plan view shape" refers to a shape when viewed from that direction. Further, the cross-sectional shape refers to the shape when the sheet body (interior material) is cut in the thickness direction.
In this specification, the numerical range represented by "lower limit value X to upper limit value Y" means the lower limit value X or higher and the upper limit value Y or lower. When a plurality of numerical ranges are described separately, an arbitrary lower limit value and an arbitrary upper limit value can be selected, and "an arbitrary lower limit value to an arbitrary upper limit value" can be set.

[Outline of interior materials]
1 and 2, an interior material 1 of the present invention has a sheet body 2 containing a vinyl chloride composition.
The interior material 1 of the present invention may be formed in a long belt shape as shown in FIG. 1, or may be formed in a leaf shape although not shown. The elongated belt-like shape means a generally rectangular shape in a plan view, the length of which is sufficiently longer in one direction than in the other direction. The long belt-shaped interior material 1 has, for example, a length of 1000 mm to 4000 mm in the first direction and a length of 5 m or more in the second direction, preferably 10 m or more in the second direction. Note that the first direction is a direction perpendicular to the second direction.
The leaf shape is formed in a predetermined shape such as a substantially polygonal shape such as a substantially rectangular shape in a plan view, such as a tile floor material, and generally refers to a shape that can be stored and transported by being stacked. The leaf-shaped interior material may be, for example, a substantially rectangular shape having a length of 200 mm to 1000 mm in the first direction and a length of 200 mm to 1000 mm in the second direction.

2 shows the interior material of the first embodiment, FIG. 3 shows the interior material of the second embodiment, FIG. 4 shows the interior material of the third embodiment, and FIG. 5 shows the fourth embodiment. interior materials.
Plan views of the interior materials of the second to fourth embodiments are omitted because they are the same as in FIG.
In FIG. 2, the interior material 1 of the first embodiment is composed of only the sheet body 2. As shown in FIG. In other words, the interior material 1 has a single-layer structure consisting only of the sheet body 2 , and the front surface and the rear surface of the sheet body 2 form the outermost surface and the rearmost surface of the interior material 1 .
In FIG. 3, the interior material 1 of the second embodiment is composed of a sheet body 2 and a surface protective layer 3 laminated on the surface of the sheet body 2 . In this interior material 1 , the surface of the surface protective layer 3 forms the outermost surface of the interior material 1 , and the back surface of the sheet body 2 forms the outermost surface of the interior material 1 .
In FIG. 4 , the interior material 1 of the third embodiment is composed of a sheet body 2 and a back layer 4 laminated on the back surface of the sheet body 2 . In this interior material 1, the surface of the sheet body 2 forms the outermost surface of the interior material 1, and the back surface of the back layer 4 forms the outermost surface of the interior material 1. - 特許庁
In FIG. 5, the interior material 1 of the fourth embodiment includes a sheet body 2, a surface protective layer 3 laminated on the surface of the sheet body 2, a back layer 4 laminated on the back surface of the sheet body 2, consists of In this interior material 1 , the surface of the surface protective layer 3 forms the outermost surface of the interior material 1 , and the back surface of the back layer 4 forms the outermost surface of the interior material 1 .

<Sheet body>
The sheet body 2 constituting the interior material 1 of the present invention has a portion where a plurality of small lumps 6 containing a vinyl chloride resin and a rubbery material are aggregated on the surface side, and the small lumps 6 are divided into colored portions and uncolored portions. It includes a nodule having a portion or a colored portion of a color different from the colored portion, wherein the two portions are expressed in stripes.
The sheet body 2 has flexibility. The sheet body 2 has flexibility such that it can be wound into a roll around a core material having a diameter of 20 cm, for example. The sheet body 2 is made of a non-foam material. The interior material 1 in which the back layer 4 and the like are laminated on the sheet body 2 as shown in FIGS. 4 and 5 also preferably has the same flexibility as the sheet body 2 .
The thickness of the sheet body 2 is not particularly limited, and is, for example, 0.5 mm to 8 mm, preferably 1.0 mm to 5.0 mm. When the back layer 4 is not laminated on the back surface of the sheet body 2 as in the first and second embodiments, the thickness of the sheet body 2 is preferably relatively large, for example, 1.0 mm to 8 mm. , preferably 1.2 mm to 5 mm. Moreover, when the back layer 4 is laminated on the back surface of the sheet body 2 as in the third and fourth embodiments, the thickness of the sheet body 2 can be made relatively small.

As shown in FIG. 6, the sheet body 2 has, on its surface side, a portion where a plurality of small lumps 6 containing the vinyl chloride composition are aggregated. Preferably, the small lump 6 has a portion extending while being inclined with respect to the surface of the sheet body 2 in a cross-sectional view. The vinyl chloride composition contains a vinyl chloride resin and a rubbery material, and for details, refer to the section [Production method of interior material] described later.
The small mass 6 includes a small mass having a colored portion and an uncolored portion or a colored portion having a color different from that of the colored portion, and the two portions appearing in stripes.
In addition, "appearance" means that it appears on the surface so that it can distinguish visually. "Different colors (or different colors)" means different enough to be perceived as not being the same color by normal adult vision. For example, in this specification, when 8 or more out of 10 visually impaired adults aged 20 to 40 compare two colors and recognize that they are not the same color, they are "different colors."

Preferably, said blob 6 includes at least a first blob 61 and a second blob 62 . The first small mass 61 has a colored portion and an uncolored portion or a colored portion having a color different from that of the colored portion, and the two portions are expressed as stripes. That is, the first small mass 61 has a colored portion and an uncolored portion, and the colored portion and the uncolored portion are expressed in stripes, or the first small mass 61 has a colored portion and an uncolored portion. It has a part and a colored part with a different color from the colored part, and the colored part and the colored part are expressed in stripes. The second small mass 62 has a colored portion having a color different from that of the colored portion of the first small mass 61 and an uncolored portion or a colored portion having a color different from that of the colored portion, and the two portions are striped. is expressed as In other words, the second small mass 62 has a colored portion and an uncolored portion having colors different from those of the colored portion of the first small mass 61, and the colored portion and the uncolored portion appear in stripes. Alternatively, the second small mass 62 has a colored portion different in color from the colored portion of the first small mass 61 and a colored portion different in color from the colored portion of the second small mass 62. , the colored portion and the colored portion are expressed in stripes.
The first small lumps 61 and the second small lumps 62 are randomly arranged in the portion where the plurality of small lumps 6 aggregate.

The aggregated portion may contain small lumps 6 consisting of only uncolored parts, or may contain small lumps 6 consisting only of colored parts of one color. The nodules consisting only of uncolored parts and the nodules consisting only of colored parts of one color are no-stripe nodules in terms of color.
Hereinafter, a portion where a plurality of small lumps 6 aggregate is referred to as a "aggregated portion". In addition, in order to distinguish each colored portion and uncolored portion, the two colored portions and uncolored portion of the first small mass 61 are referred to as "colored portion C11", "colored portion C12", and "uncolored portion N1". The two colored portions and uncolored portions of the second small mass 62 are denoted as “colored portion C21,” “colored portion C22,” and “uncolored portion N2,” and the two colored portions of the third small mass 63, The uncolored portions are referred to as “colored portion C31”, “colored portion C32”, and “uncolored portion N3”.
The aggregated portion may be formed on a portion of the surface of the sheet body 2, but preferably the aggregated portion is formed over the entire surface of the sheet body 2. As shown in FIG.

Here, from the viewpoint of forming materials, the colored portion is formed from a vinyl chloride composition containing a coloring agent, and the uncolored portion is formed from a vinyl chloride composition that does not contain a coloring agent. From the viewpoint of color, the uncolored portion has the color of the vinyl chloride composition itself, and the colored portion has the color resulting from the coloring agent or the color obtained by combining the coloring agent and the vinyl chloride composition. As will be described later, the uncolored portion is transparent or opaque, preferably transparent.

The colored portion is exposed on at least part of the surface of the nodule 6 or on the entire surface of the nodule 6 . The colored portion may be exposed from a portion or the entire surface of the nodule 6 and may extend from the exposed portion to the inside of the nodule 6 .
The uncolored portion is exposed on at least part of the surface of the nodule 6 . The uncolored portion may be exposed from a portion of the surface of the nodule 6 and may extend from the exposed portion to the inside of the nodule 6 .

In the agglomerated portion, a plurality of nodules 6 are adjacent and adjacent nodules 6 are joined. In FIGS. 6 to 8, the space between the adjacent nodules 6 is indicated by a clear solid line. Note that we may not have
Each small lump 6 has an irregular shape in plan view, as shown in FIG. Amorphous is a state in which the shape is disordered and a specific shape cannot be recognized. In other words, the plan view shape of each small mass 6 is not uniform, and the plan view shape of the small mass 6 cannot be specified.

The agglomerated portion may be formed from three or more types of small lumps 6 provided that it has two types of small lumps 6 (the first small lump 61 and the second small lump 62). Each of the three or more types of small lumps 6 has at least one colored portion with a different color from each other, and preferably all of the three or more types of small lumps 6 have different colors from each other.
Preferably, the aggregated portion is a small lump 6 having one or two or more colored parts with different colors and an uncolored part, one or more kinds of small lumps 6 having two or more colored parts with different colors, consists of

In the illustrated example, the agglomerated portion is composed of three types of small lumps 6 (first small lump 61, second small lump 62 and third small lump 63) that are adjacent to each other and joined together.
The first small mass 61 has a colored portion C11 and an uncolored portion N1, and they are expressed in stripes, or a colored portion C11 and a colored portion C11 exhibiting colors different from those of the colored portion C11. It has parts C12 and they are expressed in stripes. In addition, unless the first small mass 61 is the same as other small masses such as the second small mass 62 and the third small mass 63, even if the first small mass 61 has a colored portion exhibiting a color other than the colored portions C11 and C12, good.
Forming stripes means that the colored portion C11 extends in a line-like state into the uncolored portion N1 or the colored portion C12, or that the colored portion C11 forms a line-like state. It means that the uncolored portion N1 or the colored portion C12 extends.

In the illustrated example, the first small mass 61 consists of a colored portion C11 and an uncolored portion N1 in terms of color. Such a first small mass 61 is obtained by mixing a vinyl chloride composition containing a coloring agent and a vinyl chloride composition containing no coloring agent to such an extent that the two are not completely mixed. Preferably, colored portion C11 and uncolored portion N1 are formed from similar vinyl chloride compositions, except that the former contains a colorant.
The planar view shape of each colored portion C11 of the plurality of first small lumps 61 is irregular.
It should be noted that in the first small mass 61, there are cases where the color boundary between the colored portion C11 and the uncolored portion N1 appears clearly, and there are cases where the color boundary between the two portions is ambiguous. want to be
In the first small block 61 shown in FIGS. 6 to 8, the colored portion C11 is shaded for convenience.

The second small mass 62 has a colored portion C21 and an uncolored portion N2 and they are expressed in stripes, or a coloring that exhibits a color different from the colors of the colored portion C21 and the colored portion C21. It has parts C22 and they are expressed in stripes. Preferably, the color of the colored portion C21 and the color of the colored portion C22 are different from the color of the colored portion C11 and the color of the colored portion C12 of the first nodule 61 . In addition, unless the second small mass 62 is the same as other small masses such as the first small mass 61 and the third small mass 63, even if the second small mass 62 has a colored portion exhibiting a color other than the colored portions C21 and C22, good.
Forming stripes means that the colored portion C21 extends in a line-like state into the uncolored portion N2 or the colored portion C22, or forms a line-like state in the colored portion C21. It means that the uncolored portion N2 or the colored portion C22 extends.

In the illustrated example, the second small mass 62 consists of a colored portion C21 and an uncolored portion N2 in terms of color. The color of the colored portion C21 is different from that of the colored portion C11 of the first nodule 61 at least in color. Such second small lumps 62 are obtained by mixing a vinyl chloride composition containing a coloring agent and a vinyl chloride composition containing no coloring agent to such an extent that the two are not completely mixed. Preferably, colored portion C21 and uncolored portion N2 are formed from similar vinyl chloride compositions, except that the former contains a colorant.
The planar view shape of each colored portion C21 of the plurality of second small lumps 62 is irregular.
It should be noted that in the second small mass 62, there are cases where the color boundary between the colored portion C21 and the uncolored portion N2 appears clearly, and there are cases where the color boundary between the two portions is ambiguous. want to be
In the second small block 62 shown in FIGS. 6 to 8, for the sake of convenience, countless dots are attached to the colored portion C21.

The third small mass 63 has a colored portion C31 and an uncolored portion N3 and they are expressed in stripes, or has a color different from the colors of the colored portion C31 and the colored portion C31. It has parts C32 and they are expressed in stripes. Preferably, the color of the colored portion C31 and the color of the colored portion C32 are the same as the color of the colored portion C11 and the color of the colored portion C12 of the first small mass 61 and the color and coloring of the colored portion C21 of the second small mass 62. It differs from the color of the part C22. In addition, unless the third small mass 63 is the same as other small masses such as the first small mass 61 and the second small mass 62, even if the third small mass 63 has a colored portion exhibiting a color other than the colored portions C31 and C32, good.
Forming stripes means that the colored portion C31 extends in a line-like state into the uncolored portion N3 or the colored portion C32, or that the colored portion C31 forms a line-like state. It means that the uncolored portion N3 or the colored portion C32 extends.

In the illustrated example, the third small mass 63 consists of a colored portion C31 and a colored portion C32 in terms of color. At least one of the colored portions C31 and C32 is different in color from the colored portion C11 of the first small mass 61 and the colored portion C21 of the second small mass 62 . Such third small lumps 63 are obtained by mixing a vinyl chloride composition containing a coloring agent and a vinyl chloride composition containing a different coloring agent to such an extent that the two are not completely mixed. Preferably, the colored portion C31 and the colored portion C32 are formed from the same vinyl chloride composition except that the coloring agents are different.
The planar view shape of each of the colored portions C31 and C32 of the plurality of third small lumps 63 is irregular.
It should be noted that in the third small block 63, the color boundary between the colored portion C31 and the colored portion C32 may appear clearly, and the color boundary between the two portions may be ambiguous. sea bream.
In the third small block 63 shown in FIGS. 6 to 8, the colored portion C31 is indicated by a vertical line for convenience.

For example, the colored portion C11 of the first small mass 61 is colored in a dark color such as black, and the colored portion C21 of the second small mass 62 is colored in a light color such as yellow. The colored portion C31 of the three small lumps 63 is colored blue or the like.

The first small lumps 61, the second small lumps 62, and the third small lumps 63 are randomly arranged in plan view. Random means that they are arranged in a disorderly manner without a particular rule in plan view. Therefore, the direction of the stripes of the colored portion C11 included in the first blob 61, the direction of the stripes of the colored portion C21 included in the second blob 62, and the stripes of the colored portion C31 included in the third blob 63 are All directions are random in plan view. In other words, the stripes represented by the colors of the colored portions of the small lumps 6 have no directivity.
Also in the thickness direction of the sheet body 2, the first small lumps 61, the second small lumps 62, and the third small lumps 63 are randomly arranged in a cross-sectional view.

7 is a sectional view showing one example of the internal structure of the sheet body 2, and FIG. 8 is a sectional view showing another example of the internal structure of the sheet body 2. As shown in FIG. 7 and 8 are cross-sectional views taken along line VII-VII in FIG. Since FIGS. 7 and 8 are cross-sectional views, each small mass 6 should be hatched. hatching is omitted.

As shown in FIGS. 7 and 8, each small mass 6 extends in the thickness direction, and each small mass 6 is overlapped and joined.
Each of the small lumps 6 (the first small lump 61, the second small lump 62 and the third small lump 63) has a portion extending while being inclined with respect to the surface of the sheet body 2 in a cross-sectional view. 2 has a portion that extends obliquely from the surface of the sheet body 2 , reverses in the middle in the thickness direction, and extends obliquely toward the back side of the sheet body 2 . Note that the middle portion in the thickness direction means not only the central portion in the thickness direction in a strict sense, but also the portion near the front side from the middle portion in the thickness direction of the sheet body 2 or the portion near the back side from the middle portion in the thickness direction. This is the meaning of including the part.
Specifically, in the structure shown in FIG. 7, each small lump 6 is curved like a quadratic curve (parabola) that is convex on the left side of the page and opens to the right side of the page when viewed in cross section. Such a small mass 6 has a thickness direction middle portion located on the left side of the paper surface, a thickness direction surface portion and a thickness direction back surface portion located on the right side of the paper surface, and the middle portion, the surface portion, and the back surface portion. is curved and continuous. The cross-sectional shape of the small mass 6 is based on the middle part in the thickness direction (the inflection point that is the bottom of the parabola), the part extending obliquely to the right from the middle part in the thickness direction to the surface side, and the part extending diagonally to the right from the middle part in the thickness direction to the back surface and a portion extending obliquely to the right.
The portion obliquely extending toward the front surface side extends at a substantially acute angle with respect to the surface of the sheet body 2 , and the portion extending obliquely toward the back surface side forms a substantially acute angle with respect to the back surface of the sheet body 2 . and extends.

In the structure shown in FIG. 8, each small lump 6 has a portion extending while being inclined with respect to the surface of the sheet body in cross-sectional view, similarly to FIG. Specifically, each nodule 6 has a front surface portion in the thickness direction located on the left side of the paper surface and a back surface portion in the thickness direction located further to the right side of the paper surface when viewed in cross section, and the front surface portion and the back surface portion are curved. are consecutive. The cross-sectional shape of the small lump 6 extends obliquely to the right from the front side toward the back side.
As shown in FIGS. 7 and 8, each of the small lumps 6 has a diagonally twisted streak shape in a cross-sectional view, but in a plan view (viewed from the surface side of the sheet body 2), it is a clear lump-like shape. It is expressed as

<Surface protective layer>
The surface protective layer 3 is provided as necessary for the purpose of protecting the surface of the sheet body 2 .
The surface protective layer 3 may be colored and transparent, but is preferably colorless and transparent. The surface protective layer 3 is non-foamed.
The surface protective layer 3 contains a main component resin, and if necessary, resins other than the main component resin and additives such as flame retardants, stabilizers, antioxidants, ultraviolet absorbers, and antifungal agents. good too.
Here, in this specification, the main component resin refers to the resin component (weight ratio) that is the largest among the resin components that constitute the layer or the small lumps.
The main component resin that forms the surface protective layer 3 is not particularly limited, and examples thereof include ionizing radiation-curable resins such as thermoplastic resins and ultraviolet-curable resins. From the viewpoint of scratch resistance, the surface protective layer 3 is preferably made of an ionizing radiation curable resin such as an ultraviolet curable resin.
Electron beam curable resins include unsaturated polyesters such as condensation products of unsaturated dicarboxylic acids and polyhydric alcohols, methacrylates such as polyester methacrylates, polyether methacrylates, polyol methacrylates and melamine methacrylates, polyester acrylates, epoxy acrylates, and urethanes. UV curable resins such as acrylates, polyether acrylates, polyol acrylates, and melamine acrylates can be used.
The thickness of the surface protective layer 3 is not particularly limited, and is preferably as small as possible, for example, 3 μm to 50 μm, preferably 5 μm to 40 μm.

<Back layer>
As the back layer 4, those used in conventionally known floor materials, wall materials and ceiling materials can be appropriately used. A back layer 4 is provided as required. As the back layer 4, known floor materials, wall materials, and ceiling materials excluding surface layers (including decorative layers) can be used. For example, foamed resin layers, non-foamed resin layers, rubber layers , artificial or natural stone, wood, cloth, and the like.
For example, in FIGS. 4 and 5, the back layer 4 is interposed between the upper resin layer 41 and the lower resin layer 43 laminated on the back surface of the sheet body 2 and the upper resin layer 41 and the lower resin layer 43. and a fiber reinforcement layer 42 .
Materials for forming the upper resin layer 41 and the lower resin layer 43 are not particularly limited, and examples thereof include vinyl chloride resin such as vinyl chloride and vinyl chloride-vinyl acetate copolymer, polyolefin resin, and ethylene-vinyl acetate copolymer. Thermoplastic resins such as vinyl acetate resins such as vinyl acetate resins, ethylene-methacrylate resins such as acrylic resins, polyamide resins, and ester resins; various thermoplastic elastomers such as olefin elastomers and styrene elastomers; rubbers such as isoprene rubber; be done.
At least the upper resin layer 41 is preferably made of a material containing vinyl chloride resin as a main component resin because it adheres well to the sheet body 2 . Further, the upper resin layer 41 and the lower resin layer 43 is more preferably made of a material containing vinyl chloride resin as a main component resin.
The fiber reinforcement layer 42 is not particularly limited as long as it contains fibers, and examples thereof include nonwoven fabrics and woven fabrics. The material of the fibers constituting the nonwoven fabric or woven fabric is not particularly limited, and examples thereof include synthetic resin fibers such as polyester and polyolefin; inorganic fibers such as glass and carbon; and natural fibers.
The thickness of the back layer 4 is not particularly limited, and is, for example, 0.5 mm to 10 mm.

[Interior material manufacturing method]
The interior material of the present invention can be obtained, for example, by the following method. However, the interior material of the present invention is not limited to those obtained by the following manufacturing method.
The interior material of the present invention includes a first raw material containing a colored vinyl chloride composition, and a first raw material containing an uncolored vinyl chloride composition or a vinyl chloride composition colored in a color different from the color of the first raw material. A step of preparing two raw materials, a step of mixing the first raw material and the second raw material so as to form a flow pattern, and solidifying in a state in which the flow pattern is formed, and a plurality of solidified substances forming the flow pattern. and a step of collecting the small lumps and molding them into a sheet by heating and pressurizing them to form the sheet body 2 . Hereinafter, the solidified material having a flow pattern may be referred to as a "flow pattern solidified material".

In the step of forming the sheet into a sheet to produce the sheet body 2, the sheet body 2, which is the object to be manufactured, may be produced by independently heating and pressurizing a plurality of collected small lumps a plurality of times. The sheet body 2, which is the object to be manufactured, may be produced by heating and pressurizing a plurality of small lumps once.
When the sheet body 2 is formed by heating and pressurizing a plurality of times (for example, twice) as described above, the precursor is formed by heating and pressurizing the small lumps to fuse each small lump and forming it into a sheet shape. After obtaining, the sheet body 2 is produced by further heating and pressurizing the precursor to form a sheet. When the sheet body 2 is formed by heating and pressing once as described above, the sheet body 2 is produced by heating and pressing a plurality of small lumps to form a sheet. Hereinafter, the former will be referred to as a "multi-stage pressurization method" and the latter will be referred to as a "single pressurization method".
According to the multi-stage pressurization method, since the thickness is reduced step by step by pressurizing in multiple stages, it is possible to easily express a clear pattern in plan view, which is preferable. In particular, in the process of forming the precursor, if the pressure applied to the collected small lumps is set as low as possible and the small lumps are fused and joined mainly by heat, the planar shape of the small lumps becomes streaky (conveying direction). A clear lumpy pattern can be expressed on the surface of the sheet body 2 without forming an elongated shape extending along the . In such a sheet body 2, the conveying direction at the time of manufacturing is difficult to appear in the pattern, and a so-called non-directional pattern appears.

<Production of solidified product with flow pattern>
To obtain the nodules 6, a streamlined solid is prepared.
The flowing pattern solidified product is appropriately produced according to the type of the small lumps 6 .
For example, when producing the first small lump 61 having the colored portion C11 and the uncolored portion N1 as described above, the first raw material containing the colored vinyl chloride composition and the uncolored vinyl chloride composition A second raw material containing is prepared, and a flowing pattern solidified product is produced from these.
Similarly, when producing the second small lump 62, the first raw material containing the vinyl chloride composition colored in the color corresponding to the colored portion C21 of the second small lump 62 and the uncolored vinyl chloride composition are included. A second raw material is prepared, and a flowing pattern solidified product is produced from these.
Similarly, when producing the third small lump 63, the first raw material containing the vinyl chloride composition colored in the color corresponding to the colored portion C31 of the third small lump 63 and the colored portion C32 of the third small lump 63 are combined. A second raw material containing a vinyl chloride composition colored in a color corresponding to is prepared, and a flowing pattern solidified product is produced from these.
In addition, in producing the first small lump 61, the second small lump 62, and the third small lump 63, a raw material containing a vinyl chloride composition colored in a different color is further prepared and mixed to form a flow-patterned solidified product. , a first small mass 61, a second small mass 62, and a third small mass 63 having colored portions of other colors can be produced.

The vinyl chloride composition contains a vinyl chloride resin as a main component resin and a rubbery material, and optionally fillers, plasticizers and additives (additives here do not include colorants). ). Forming the small lumps 6 from a vinyl chloride composition containing a rubbery material makes it possible to obtain a sheet body 2 that is flexible even at low temperatures.
As the vinyl chloride resin, rubbery material, filler, plasticizer and additive, conventionally known ones can be used.
Examples of vinyl chloride resins include those produced by an emulsion polymerization method, a suspension polymerization method, a solution polymerization method, a bulk polymerization method, and the like. A vinyl chloride resin obtained by an emulsion polymerization method or a suspension polymerization method is preferable because it is easy to process and handle.
A rubbery material refers to a material having rubber elasticity at room temperature (25° C.), and typically rubber and/or elastomer can be used. In addition, in this specification, the rubbery material is not included in the resin component.

The rubber is not particularly limited, and examples thereof include synthetic rubbers such as butadiene rubber (BR), isoprene rubber (IR), and chloroprene (CR); natural rubber (NR); styrene-butadiene rubber (SBR), acrylonitrile-butadiene rubber ( NBR), copolymer rubber such as butyl rubber (IIR); The rubbers may be used alone or in combination of two or more.
The elastomer is not particularly limited, and examples thereof include polyethylene-based elastomers, polyester-based elastomers, polyamide-based elastomers, polystyrene-based elastomers, olefin-based elastomers, urethane-based elastomers, vinyl chloride-based elastomers, acrylic-based elastomers, and vinyl acetate-based elastomers. of thermoplastic elastomers. These may be used alone or in combination of two or more.
The rubbery material is preferably rubber, and more preferably includes acrylonitrile-butadiene rubber (NBR), because it can impart good flexibility at low temperatures.
Examples of fillers include various inorganic fillers such as calcium carbonate, titanium oxide, calcium oxide, barium carbonate, magnesium hydroxide, aluminum hydroxide, clay, talc and mica.
Examples of plasticizers include dioctyl phthalate (DOP), dibutyl phthalate (DBP), butyloctyl phthalate (BOP), dioctyl isophthalate (DOIP), diisononyl phthalate (DINP), di-2-ethylhexyl terephthalate (DOTP ), dioctyl adipate (DOA), diisononyl adipate (DINA), and the like.
Additives include stabilizers, processing aids, fungicides, flame retardants, ultraviolet absorbers, antioxidants, and the like.

Here, the vinyl chloride resin itself is generally colorless and transparent. A vinyl chloride composition obtained by blending a filler or the like with a vinyl chloride resin has reduced transparency due to components other than the vinyl chloride resin, such as the filler. A vinyl chloride composition containing a filler changes from colorless and transparent to translucent or opaque according to the amount of the filler, and in particular, a vinyl chloride composition containing a white filler such as calcium carbonate or titanium oxide. The substance changes from colorless and transparent to white translucent to white opaque, depending on the amount. In addition, some rubbery materials have low transparency, and vinyl chloride compositions containing such rubbery materials also have reduced transparency.
Here, in this specification, the term "transparent" simply means "colorless and transparent" or "translucent." Colorless and transparent is when you place a colorless and transparent object about 1 cm away from a white paper on which any number (12 point size) is printed with black ink and look through the object. , refers to the state in which the number can be identified from the front side. Semi-transparency refers to the state in which the presence of something black can be visually recognized when the numbers placed on the back side under the same conditions as above are seen from the front side through the semi-transparent object, and opaque is the state. , Under the same conditions as above, it refers to a state in which black cannot be visually recognized.

In this specification, the colorant refers to a component intended to color a material, and fillers such as calcium carbonate and components not intended to be colored such as rubbery materials are included in the category of colorants. Not included. In other words, the colorant and the vinyl chloride composition are separate concepts. However, as described above, the addition of calcium carbonate or the like results in white coloration, but this is the color of the vinyl chloride composition itself and should not be construed as a "colored vinyl chloride composition". Similarly, if it contains a rubbery material with low transparency, it will appear white as a result, but this is the color of the vinyl chloride composition itself and should not be interpreted as a "colored vinyl chloride composition". do.
From a practical point of view, when the vinyl chloride composition itself exhibits a color (for example, white) due to the rubbery material and/or the filler that is blended, each of the striped small lumps 6 due to the color is obtained. Therefore, the colored portion must be set to have a color other than that caused by the filler (for example, other than white).

In the vinyl chloride composition that forms the small lumps 6, the amount of the rubbery material is not particularly limited. It is preferably contained in an amount of 0.5 to 10 parts by weight, more preferably 1 to 5 parts by weight, based on 100 parts by weight of the vinyl chloride resin.
The amount of additives contained in the vinyl chloride composition forming the small lumps 6 is not particularly limited, but generally, a filler such as calcium carbonate is added to 100 parts by weight of the vinyl chloride resin. 0 to 100 parts by weight, and 25 to 40 parts by weight of a plasticizer such as DOP. The small mass 6 having a colored portion contains more than 0 parts by weight and 5 parts by weight or less of the coloring agent with respect to 100 parts by weight of the vinyl chloride resin.
Although flexibility can be imparted to the vinyl chloride composition by adding a plasticizer, problems such as bleed-out tend to occur when the amount of the plasticizer is too large. In the present invention, by adding a rubbery material to the vinyl chloride composition, it is possible to maintain the flexibility even when the amount of the plasticizer added is small, and to suppress the bleeding out of the plasticizer.
The vinyl chloride compositions that form each blob, such as first blob 61, second blob 62 and third blob 63, may be of the same composition or may be of different compositions.

As described above, when producing the first small mass 61 having the colored portion C11 and the uncolored portion N1, the first raw material containing the colored vinyl chloride composition and the uncolored chloride containing no coloring agent are used. a second raw material comprising a vinyl composition;
In this case, the first raw material is a vinyl chloride composition mixed with a coloring agent, and exhibits the color of the coloring agent. The second raw material is a vinyl chloride composition containing no coloring agent.
The first raw material and the second raw material are melted and mixed together. At this time, the first raw material and the second raw material are gently mixed to the extent that the first raw material and the second raw material are not completely mixed, and a flowing pattern is maintained. Allow the mixture to solidify.
The mixing ratio of the first raw material and the second raw material is not particularly limited, and is, for example, 9:1 to 5:5 by weight.

For example, using a calender molding machine as shown in FIG. 9, at least two raw materials (a first raw material and a second raw material) can be mixed to produce a streamlined solidified material.
9(a) and 9(b), calendering machines 8′ and 8″ comprise a Banbury mixer 81, a mixing roll 82 arranged on the exit side of the mixer 81, a calender roll 83, and a pulverizer 84. The calendar molding machine 8'' shown in FIG.

As shown in FIG. 9(a), a first raw material (for example, a vinyl chloride composition containing a vinyl chloride resin, a rubbery material and a coloring agent) is mixed by a Banbury mixer 81 heated to 120° C. to 160° C., By passing this between a pair of mixing rolls 82 and kneading it, a sheet-like material 71 having a predetermined thickness is produced. This sheet material 71 is rolled by calender rolls 83, 83 heated to 120° C. to 160° C. and naturally or forcedly cooled to form a first sheet 72 having a predetermined thickness (for example, a thickness of about 1 to 3 mm). After the production, the sheet 72 is randomly pulverized by a pulverizer 84 to obtain irregular-shaped first chips 73 .

Next, as shown in FIG. 9(b), a second raw material (for example, a vinyl chloride composition containing no coloring agent and containing a vinyl chloride resin and a rubbery material) is heated to 120° C. to 160° C. to form a Banbury The materials are mixed by a mixer 81, passed between a pair of mixing rolls 82, 82, and kneaded to form a sheet-like material 74 having a predetermined thickness. The first chips 73 (chips made of the first raw material) heated to about 120.degree. C. to 160.degree. Thereafter, this sheet-like material 74 is rolled by calendar rolls 83, 83 heated to 120° C. to 160° C., and is naturally cooled or forcedly cooled to solidify in a flowing pattern with a predetermined thickness (for example, a thickness of about 1 to 3 mm). Item 7 is obtained. When the sheet 74 including the first chips 73 is stretched by rolling, the first raw material and the second raw material flow in the stretching direction in stripes. By doing so, a sheet-like flowing pattern solidified material 7 in which the second raw material (or the first raw material) is mixed in the first raw material (or the second raw material) in an arbitrary plurality of stripes. can be made.
As the calendering method, for example, the method described in Japanese Patent No. 4605928 can be used.

The method of mixing at least two raw materials (the first raw material and the second raw material) to produce the flow-patterned solidified product is not limited to the method using the calender molding machine. For example, as a method for producing a flow pattern solidified product, the production techniques described in Japanese Patent No. 3393588, Japanese Patent No. 3970568, Japanese Patent No. 5664987, Japanese Patent No. 5751562, Japanese Patent Application Laid-Open No. 2000-054552, etc. may be modified as appropriate and used. good.

As shown in FIG. 10, the flow pattern solidified material 7 has a flow pattern such as a wood grain pattern or a suminagashi pattern.
The flowing pattern solidified material 7 is a complex mixture of the first raw material and the second raw material, and has a colored portion of the first raw material, a colored portion of the mixed colors of the first raw material and the second raw material, and a colored portion of the second raw material. have The color portion where the colors of the first raw material and the second raw material are mixed often has a stepless gradation from a color close to that of the first raw material to a color close to that of the second raw material.
The thickness of the flow pattern solidified product 7 is not particularly limited, but is about 0.5 to 2 times, preferably 0.7 to 1.2 times, the thickness of the sheet body 2 to be finally manufactured. If the thickness of the flow pattern solidified material 7 is set too small, there is a possibility that a good flow pattern cannot be obtained.
Similarly, when producing the second small mass 62 having the colored portion C21 and the uncolored portion N2, the first raw material containing the colored vinyl chloride composition and the uncolored vinyl chloride composition containing no coloring agent are used. and a second raw material are prepared, and using them, a solidified material having a flow pattern is produced.
Similarly, when producing the third small lump 63, etc., a flow-patterned solidified product is produced.

<Production of small lumps>
A plurality of small lumps are obtained by pulverizing the flow-patterned solidified material 7 obtained as described above.
In order to distinguish between the small lumps produced in the manufacturing process of the sheet body 2 and the small lumps 6 forming the sheet body 2, the small lumps in the manufacturing process are referred to as "raw material small lumps."
For example, as shown in FIG. 9(b), by randomly pulverizing the substantially flat flow-patterned solidified material 7 with a pulverizer 84, as shown in FIG. . It should be noted that the contours shown in FIGS. 11(a) and 11(b) are for reference only, since the plurality of raw material small lumps A are indeterminate (chaotic shape).
FIG. 11(a) illustrates a deformed hexahedral small mass, and FIG. 11(b) illustrates a three-dimensional small mass without planes for reference. When the sheet body is produced, the small lumps of the raw material come into contact with each other at various angles, producing complex patterns in the vertical, horizontal, and diagonal directions. It is preferable to use three-dimensionally shaped nodules such as b) which do not have substantially flat surfaces.
The flow pattern solidified material 7 may be pulverized regularly to produce small lumps of raw materials of a regular shape such as a substantially cubic shape or a substantially rectangular parallelepiped shape. It is preferable that the raw material small lump A has an irregular shape.

The size of the raw material small lump A is not particularly limited, but for example, the maximum length, the maximum width and the maximum height are preferably in the range of 1 mm to 3 mm, and more preferably 1.4 mm to 3 mm. More preferably, it falls within the range of 2.4 mm. By using the raw material small lumps A having such a size range, it is possible to easily form the sheet body 2 having the small lumps 6 extending while being inclined in a cross-sectional view.
Note that FIG. 11 exemplifies the raw material small lump A that becomes the first small lump 61, and the corresponding colored portion C11 is shaded.
By pulverizing each flow-pattern solidified product, raw material small lumps A corresponding to the first small lump 61, the second small lump 62, etc. can be obtained.

<Forming of sheet body>
In the process of producing the sheet body 2 from the raw material small lump A, as described above, there are a multistage pressurization method and a single pressurization method. The multi-stage pressurization method and the single pressurization method will be separately described below in <Forming of sheet body>.

(a) Multi-Stage Pressurization Method In the multi-stage pressurization method, for example, a plurality of raw material small lumps are collected and pressurized to produce a precursor, and the precursor is further pressurized to produce a sheet.
Precursor production At least one of the raw material small lump A corresponding to the first small lump 61, the raw material small lump A corresponding to the second small lump 62, the raw raw material small lump A corresponding to the third small lump 63, etc. Raw material blob A (eg, at least raw material blob A corresponding to first blob 61), preferably at least two raw material blobs A (eg, at least raw material blob A corresponding to first blob 61 and a second A raw material blob A) corresponding to the blob 62 is selected.

As described above, at the time of manufacturing the sheet body 2, from the viewpoint of the size of the raw material small lump A, the maximum longitudinal length, the maximum horizontal length, and the maximum height are all within the range of 1 mm to 3 mm. It is preferred to use blob A. Since the pulverized material obtained by pulverizing the flow pattern solidified material 7 contains raw material small lumps of various sizes, the pulverized material is sieved in order to select the raw material small lumps A of the preferred size. Select by
Most of the raw material small lumps A that have been sieved and size-selected fall within the preferred size range, but some of them may contain raw material small lumps smaller than the preferred range. . In this case, the raw material small lumps A having the preferred size range are preferably contained in an amount of 80% by weight or more, preferably 90% by weight or more, when the entirety of the sieved material is taken as 100% by weight. more preferably.
In addition, sieving may be carried out in two or more steps. For example, the pulverized material obtained by pulverizing the flow pattern solidified material 7 is passed through a fine sieve to obtain a relatively small pulverized material (for example, a raw material small lump having a maximum length, maximum width and maximum height of less than 1 mm). ) are sorted out and removed. Next, it is passed through a sieve with a coarser mesh than that, and raw material small lumps A having a maximum longitudinal length, a maximum lateral length and a maximum height of 3 mm or less are taken out.

As shown in FIG. 12(A), a plurality of raw material small lumps A containing the preferred size range are put between a pair of rolls 93 using a spraying device 91, and the raw material small lumps A are heated to a temperature of, for example, 200 ° C. By applying pressure with the pair of rolls 93 while heating to 250° C., a plurality of raw material small lumps A are fused together and formed into a sheet. For example, by using a roll 93 equipped with a heating device, the roll 93 can heat and press the raw material small lump A at the same time.
In this manner, a sheet-like precursor 94 having a predetermined thickness and consisting of an assembly of a plurality of raw material small lumps A is produced. The thickness of the precursor 94 may be larger than the thickness of the sheet body 2 to be manufactured, for example, 1.05 to 1.3 times the thickness of the sheet body 2 to be obtained, preferably 1.06 times. times to 1.2 times.
The precursor 94 is normally manufactured continuously in the conveying direction of the manufacturing line, and the obtained precursor 94 is in the form of a long belt-like sheet.

Formation of Sheet from Precursor The sheet 2 is produced by applying heat and pressure in the thickness direction while conveying the precursor 94 .
For example, the precursor 94 is guided onto an endless sheet conveyor 92 and heated by a heating device 95 such as an oven to melt the vinyl chloride resin of the raw material small lump A. 12A indicates the direction in which the sheet conveyor 92 moves, and the solid arrow indicates the direction in which the precursor 94 and the sheet 2 are conveyed.
The heating temperature may be the temperature at which the vinyl chloride resin melts or higher, and is, for example, 160° C. or higher, preferably 170° C. or higher, and more preferably 175° C. or higher. Also, if the temperature is too high, the raw material small lump A may melt too much and the colored part and the uncolored part may be completely mixed. Therefore, the heating temperature is preferably 210 ° C. or less, for example. is below 200°C.
The heating time is preferably about 300 seconds to 3000 seconds.

After heating, while conveying the precursor 94, the precursor 94 is pressurized in the thickness direction during the conveyance. A pressing machine may be used for pressurization, but when using the device 9 for continuously manufacturing the sheet body 2 as shown in the figure, the small lumps of raw material are easily deformed so as to extend while being inclined in a cross-sectional view. It is preferable to use the pressure roll 96 because the pressure roll 96 can be applied.
By applying pressure in the thickness direction while conveying the precursor 94, a shearing force is generated inside the precursor 94, and the raw material small lump A can be deformed so as to extend while being inclined.
The pressure is not particularly limited, and is, for example, 1.5 kgf/cm ² to 5 kgf/cm ² , preferably 2 kgf/cm ² to 4 kgf/cm ² . Also, the conveying speed of the precursor 94 is, for example, 1 m/min to 10 m/min, preferably 2 m/min to 6 m/min. With the above-described pressure and conveying speed, it is possible to easily obtain the sheet member 2 on which a clear lumpy pattern caused by the small lumps is expressed.
Further, when the thickness of the precursor 94 before pressurization is 1, the precursor after pressurization (that is, the sheet body 2 to be formed) has a thickness of 0.8 to 0.95 times. By compressing 94, it is possible to easily form the sheet body 2 in which the small lumps 6 extend while being inclined in a cross-sectional view.

As the heated raw material small lumps A are pressed while being conveyed as described above, the raw raw material small lumps A are obliquely deformed and adjacent raw raw material small lumps A are joined together. After that, by performing natural cooling or forced cooling, the sheet body 2 in which the small lumps 6 are aggregated is obtained.

(b) Single pressurization method In the single pressurization method, for example, a sheet body is produced by stacking a plurality of small lumps of raw material, heating and pressurizing the stack, and molding it into a sheet shape.
As in the case of the multi-stage pressurization method, the raw material small lump A is selected. As described above, it is preferable to use raw material small lumps A whose maximum vertical length, maximum horizontal length and maximum height are all within the range of 1 mm to 3 mm.
As shown in FIG. 12(B), the plurality of raw material small lumps A are spread and accumulated on a sheet conveyor 92 using a spreading device 91 . A leveling tool 911 is arranged at the destination of the sheet conveyor 92 , and the plurality of raw material small lumps A accumulated on the conveyor 92 form a sheet-like stack 941 spread over the conveyor 92 with a substantially uniform thickness. This accumulation 941 is formed by stacking a plurality of raw material small lumps A, and adjacent raw material small lumps A are in contact with each other without being combined. The thickness of the stack 941 may be larger than the thickness of the sheet body 2 to be manufactured, for example, 2.5 to 4 times, preferably 3 to 3 times, the thickness of the sheet body 2 to be obtained. .75 times.
The stack 941 is heated by a heating device 95 such as an oven to melt the vinyl chloride resin of the raw material small lump A. As shown in FIG. 12(B) indicates the direction in which the sheet conveyor 92 moves, and the solid arrow indicates the direction in which the stack 941 and the sheet 2 are conveyed. The heating temperature and the heating time can be set in the same manner as the heating temperature and the heating time of the precursor described in the section of "formation of sheet from precursor" in the multi-stage pressurization method. Moreover, it is preferable to heat the piled material 941 before pressurization, because a clear lump-like pattern caused by the small lumps can be expressed on the surface of the sheet body 2 .

After heating, while conveying the stack 941, the stack 941 is pressurized in the thickness direction during the transport. Although a press machine may be used for pressurization, it is preferable to use a pressure roll 96 for the same reason as in the multi-stage pressurization method.
By applying pressure in the thickness direction while conveying the stack 941, a shearing force is generated in the stack 941, and the raw material small lump A can be deformed so as to extend while being inclined.
The pressure and the conveying speed of the accumulated material 941 can be set in the same manner as the pressure and the conveying speed of the precursor described in the section "Forming the sheet body from the precursor" of the multi-stage pressurization method.
Further, when the thickness of the stack 941 before pressing is 1, the stack after pressing (that is, the sheet body 2 to be formed) is 0.2 to 0.4 times (preferably 0.27 times). 0.33 times), the sheet body 2 in which the small lumps 6 extend while being inclined can be easily formed in a cross-sectional view.
By pressurizing the heated raw material small lumps A as described above, the raw raw material small lumps A are obliquely deformed and adjacent raw raw material small lumps A are joined together. After that, by performing natural cooling or forced cooling, the sheet body 2 in which the small lumps 6 are aggregated is obtained.

Embossed unevenness may be formed on the front surface and/or the rear surface of the sheet body 2 using an embossing roll 97, if necessary, on the sheet body 2 molded by the multistage pressurization method or the single pressurization method. .
Moreover, a surface protective layer may be formed on the surface of the sheet body 2 using a coater 98 as necessary. The applicator 98 applies a surface protective layer forming material to the surface of the sheet body 2 and solidifies the material. In some cases, it has an application section for applying the ionizing radiation curable resin and a light irradiation section for curing the resin such as ultraviolet rays.
The obtained sheet body 2 is taken up by a collection machine 99 and separated from the manufacturing apparatus 9 .

[Effects and uses of interior materials]
The sheet body 2 of the interior material 1 of the present invention includes a first small block 61 having an irregular colored portion C11 and an uncolored portion N1, a second small block 62 having an irregular colored portion C21 and an uncolored portion N2, and Since the third small lumps 63 having irregular colored portions C31 and C32 are joined to each other and arranged at random, a directionless pattern is clearly shown when viewed from the surface side.
Furthermore, when the small mass 6 has an uncolored portion and the uncolored portion is transparent, the back side of the sheet body 2 can be visually recognized through the uncolored portion from the front side of the sheet body 2, and the sheet body 2 has a three-dimensional effect. can be configured. In particular, when each of the small lumps 6 (the first small lump 61, the second small lump 62, and the third small lump 63) has a portion extending while being inclined with respect to the surface of the sheet body 2 in a cross-sectional view. When viewed from the surface side of the sheet body 2, there is also a portion that can be obliquely seen through in a stepped manner.
Furthermore, each of the small lumps 6 (the first small lump 61, the second small lump 62, and the third small lump 63) has a portion extending while being inclined with respect to the surface of the sheet body 2 in a cross-sectional view. The contact area of the small lumps 6 is increased, and each small lump 6 is firmly joined. In particular, each small lump 6 has a portion extending obliquely from the point of inflection to the front surface side and a portion extending obliquely to the back surface side from the point of inflection, thereby constituting the sheet body 2 that is extremely firmly joined. can.
In addition, since the small lump 6 is formed of a vinyl chloride composition containing a rubbery material, it can be Flexibility can be maintained, and deterioration of workability can be prevented. In addition, it is possible to provide the sheet body 2 that is hard to crack even when it is transported at a low temperature.

The interior material 1 of the present invention is applied to construction surfaces such as floor surfaces, wall surfaces, and ceiling surfaces of buildings. The method of attaching the interior material to the construction surface is not particularly limited, and examples include sticking the back surface of the interior material to the construction surface using an adhesive.
The interior material 1 of the present invention may be applied to a newly constructed construction surface, or may be applied to an existing construction surface such as a renovation.
The interior material 1 of the present invention can be used as a flooring material, a wall material, a ceiling material, etc., and can be particularly suitably used as a flooring material and a wall material.
The sheet body 2, which constitutes the design of the interior material, has a predetermined thickness and shows a similar pattern even if worn by the sole of a shoe or the like.

The present invention will be described in more detail below with reference to Examples. However, the present invention is not limited to the following examples.

[Materials used]
<Vinyl chloride resin>
Granular vinyl chloride resin produced by suspension polymerization (trade name “ZEST 800Y” manufactured by Shin-Daiichi Vinyl Co., Ltd. Average degree of polymerization: 760 to 860, K value: 60.5 to 63.1, apparent density: 0. 53 to 0.63 (catalog value)). The vinyl chloride resin used had a particle size of approximately 100 μm to 300 μm.
<Rubber material>
Acrylonitrile butadiene rubber (trade name “Nipol 1411” manufactured by Nippon Zeon Co., Ltd.).
butadiene-based rubber (trade name “Metabrene C-223A” manufactured by Mitsubishi Chemical Corporation);
acrylic rubber (trade name "Metabrene W-450A" manufactured by Mitsubishi Chemical Corporation);
Silicon-acrylic rubber (trade name "Metabrene SX-005" manufactured by Mitsubishi Chemical Corporation).
<Filler>
Granular calcium carbonate (trade name “Escalon #200” manufactured by Sankyo Flour Milling Co., Ltd.).
<Plasticizer>
DOIP (manufactured by CG Ester Co., Ltd.).
DOA (manufactured by CG Ester Co., Ltd.).
Epoxidized plasticizer (manufactured by Sanwa Gosei Kagaku Co., Ltd. under the trade name of "Chemicizer T4000").
<Stabilizer>
Ba-based stabilizer (manufactured by ADEKA Co., Ltd. under the trade name of "ADEKA STAB AC-704").
Ba-zn-based stabilizer (manufactured by ADEKA Co., Ltd. under the trade name of "ADEKA STAB AC-755").
<Processing aid>
Acrylic processing aid (trade name “Metabrene P-530A” manufactured by Mitsubishi Chemical Corporation).
<Colorant>
Red colorant (red iron).
White colorant (titanium oxide).

[Example 1]
<Preparation of raw material small lump (1) having red striped colored part>
Per 100 parts by weight of vinyl chloride resin, 1 part by weight of acrylonitrile butadiene rubber, 20 parts by weight of calcium carbonate, 35 parts by weight of DOIP, 3 parts by weight of epoxidized plasticizer, 3 parts by weight of Ba-based stabilizer, 2 .5 parts by weight of a Ba-Zn stabilizer, 1 part by weight of an acrylic processing aid, and 3 parts by weight of a white colorant are put into a Banbury mixer of an existing calender molding machine and heated at 140°C for about 6 minutes. After mixing, the mixture was molded with a mixing roll heated to 140° C. and a calender roll to prepare a sheet material of length×thickness=600 mm×3 mm. This sheet-like material was cooled to 20° C. in a water bath, and then pulverized into approximately 3 mm squares with a pelletizer to produce first chips (first raw material, white-colored vinyl chloride composition).

Per 100 parts by weight of vinyl chloride resin, 1 part by weight of acrylonitrile butadiene rubber, 20 parts by weight of calcium carbonate, 35 parts by weight of DOIP, 3 parts by weight of epoxidized plasticizer, 3 parts by weight of Ba-based stabilizer, 2 .5 parts by weight of a Ba-Zn stabilizer, 1 part by weight of an acrylic processing aid, and 3 parts by weight of a red colorant were put into a Banbury mixer of a calender molding machine and mixed at 140°C for about 6 minutes. After that, a sheet-like material (second raw material: red-colored vinyl chloride composition) of length×thickness=600 mm×3 mm was produced with a mixing roll heated to 140°C.
Before this sheet-like material cools down, a first chip (first raw material) heated to 140° C. with a hot air heater is placed on the sheet-like material (second raw material) in a weight ratio of first raw material:second raw material. = 1:3 ratio, and then rolled while gently mixed with a calender roll heated to 140°C to solidify a sheet-like flow pattern of about 200 mm x 200 mm x 2 mm in length x width x thickness. made things.
FIG. 13 shows a photograph (not enlarged) of the surface of this stream pattern solidified material. FIG. 13 is a photograph of the surface of the flow-patterned solidified material produced as described above in a range of length×width=approximately 120 mm×approximately 160 mm.

The flow-patterned solidified product is randomly pulverized with a commercially available crusher, the pulverized product is sieved with an 8-mesh sieve, and the pulverized product having a maximum length of about 3 mm or less is taken out, and then further sieved with a 20-mesh sieve. Crush with a maximum length of less than about 1 mm was separated by sieving with. In this way, a small lump of raw material having a maximum length of about 1 mm to 3 mm was prepared (hereinafter referred to as a small lump of raw material (1)).

<Preparation of raw material small lump (2) having white striped colored portion>
Per 100 parts by weight of vinyl chloride resin, 1 part by weight of acrylonitrile butadiene rubber, 20 parts by weight of calcium carbonate, 35 parts by weight of DOIP, 3 parts by weight of epoxidized plasticizer, 3 parts by weight of Ba-based stabilizer, 2 .5 parts by weight of a Ba-Zn stabilizer and 1 part by weight of an acrylic processing aid are put into a Banbury mixer of a calender molding machine, mixed at 140°C for about 6 minutes, and then mixed with a mixing roll heated to 140°C. It was molded with a calender roll to produce a sheet-like material of length×thickness=600 mm×3 mm. This sheet-like material was cooled to 20° C. in a water bath, and then pulverized into approximately 3 mm squares with a pelletizer to produce third chips (third raw material, translucent vinyl chloride composition).

Per 100 parts by weight of vinyl chloride resin, 1 part by weight of acrylonitrile butadiene rubber, 20 parts by weight of calcium carbonate, 35 parts by weight of DOIP, 3 parts by weight of epoxidized plasticizer, 3 parts by weight of Ba-based stabilizer, 2 .5 parts by weight of a Ba-Zn stabilizer, 1 part by weight of an acrylic processing aid, and 3 parts by weight of a white colorant were put into a Banbury mixer of a calendering machine and mixed at 140°C for about 6 minutes. After that, a sheet-like material (fourth raw material: white-colored vinyl chloride composition) of length x thickness = 600 mm x 3 mm was produced with a mixing roll heated to 140°C.
Before this sheet-like material cooled down, a third chip (third raw material) heated to 140° C. with a hot air heater was placed on the sheet-like material (fourth raw material) in a weight ratio of 3rd raw material:4th raw material. After spraying at a ratio of 2:3, it is rolled while gently mixed with a calender roll heated to 140 ° C. to solidify a sheet-like flow pattern of about 200 mm x 200 mm x 2 mm in length x width x thickness. made things.
This flowing pattern solidified product also had a flowing pattern similar to that of FIG. 13 .

The flow-patterned solidified product is randomly pulverized with a commercially available crusher, the pulverized product is sieved with an 8-mesh sieve, and the pulverized product having a maximum length of about 3 mm or less is taken out, and then further sieved with a 20-mesh sieve. Crush with a maximum length of less than about 1 mm was separated by sieving with. In this way, a small lump of raw material having a maximum length of about 1 mm to 3 mm was prepared (hereinafter referred to as a small lump of raw material (2)).

<Production of sheet body>
The raw material small lump (1) is sufficiently stirred, passed through a spraying device of an existing sheet manufacturing apparatus (such as shown in FIG. 12A) between a pair of rolls, and temporarily formed into a sheet with a thickness of about A 2.3 mm precursor was made.
The precursor was placed on an endless sheet conveyor, heated and melted in a hot air circulating oven at 200° C. for 5 minutes, passed through a pressure roll at room temperature (about 23° C.), and a pressure of approximately 3 kgf/cm ² was applied. A sheet body having a thickness of 2 mm was produced by rolling.
The speed of the sheet conveyor was 1 m/min.
14 shows a photograph (not enlarged) of the surface of the sheet body obtained in Example 1. FIG.

[Examples 2 to 11 and Comparative Example]
A sheet body having a thickness of 2 mm was prepared in the same manner as in Example 1 except that the composition of each raw material was changed as shown in Table 1 in the preparation of the raw material small lump (1) and the raw material small lump (2). made.
The compositions of the first to fourth raw materials in Table 1 are the compositions of the first raw material and the second raw material when producing the raw material small mass (1), and the third raw material when producing the raw material small mass (2). and the composition of the fourth raw material, respectively. However, in Table 1, it can be read that all raw materials contain a coloring agent. Note that it is not included.

[Appearance and cross-sectional observation of sheet body]
When the sheet bodies produced in each example and comparative example were visually observed from the surface side, a terrazzo pattern was clearly expressed.
When the sheet bodies produced in Examples and Comparative Examples were visually observed from the surface side, as shown in FIG. 14, a terrazzo pattern, that is, the shape of small lumps was clearly expressed. In addition, the plan view shape of the small lumps was not elongated along the transport direction of the manufacturing site, and a clear lump-like pattern with no pattern directionality was exhibited.
Moreover, when each sheet body was cut and the cut surface was visually observed, each small lump was joined while bending into a shape as shown in FIG. 7 or 8 .

[Bending test]
The sheet body produced in each example and comparative example was cut into a square of length×width=30 cm×30 cm to prepare a sample piece. As shown in FIG. 15, at a temperature of 23° C., a triangular portion defined by the corner and the reference line, with the point of about 5 cm in the diagonal direction from one corner of the sample piece as the reference line, was folded into the sheet. An adult man manually folded the tape from the front side to the back side until the corners touched the back side. The surface condition of the curved portion around the reference line was confirmed visually and by touch.
As a result, in all the sheet bodies of Examples and Comparative Examples, no cracking or splitting occurred, and each small lump was well bonded.

[Stiffness test]
The rigidity test was performed using an Olsen type rigidity tester (manufactured by Yasuda Seiki Seisakusho Co., Ltd.) according to the following procedure.
The sheet body produced in each example and comparative example was cut into length×width=25 mm×100 mm to obtain a sample.
(1) The sample and the tester are allowed to stand in advance at 23°C (or 5°C).
(2) Place the tester on a substantially horizontal table and level it by adjusting the leveling screw with a spirit level.
(3) Set the distance between the fulcrums with a straightedge (150 mm, JIS C type 1st class) and fix it with the fulcrum fixing screw.
(4) Remove the stopper to free the displacement angle scale plate, and balance it with a balance weight so that the disc can stop anywhere.
(5) Apply a specified load to the weight hook and confirm that the load scale needle points to 0 on the load scale plate.
(6) Continuously inching the inching changeover switch to set the start/reverse switch to start or reverse, and release the switch when the pointer of the deflection angle scale reaches 0 on the deflection angle scale to stop.
(7) Set the sample on the chuck with the surface facing up, continuously switch the continuous/inching changeover switch, turn the switch ON in the start direction, and rotate the rotating disk to the right.
(8) After reading the load scale when the deflection angle scale pointer reaches a predetermined deflection angle, stop it, return it by the reverse switch, and take out the sample.
(9) Measure the thickness of the sample with a micrometer.
(10) The measurement was carried out under conditions of distance between fulcrums (mm): 20, load (LB): 2, and reading angle (degrees): 4.

[Dragging amount test]
The sheet body produced in each example and comparative example was cut into length×width=25 mm×300 mm to produce a sample piece. After the sample piece was left to stand at 23 ° C. and 44% RH for 24 hours, 100 mm from the first horizontal end of the sample piece was fixed, and 200 mm from the second horizontal end (opposite side) was left free. , and the amount of sagging when left at a temperature of 23° C. for 10 seconds was measured. A similar sample piece was prepared for each example and comparative example, and the sample piece was allowed to stand at 5 ° C. and a humidity of 40% RH for 24 hours. With 200 mm free from the second end (opposite side), the drooping amount was measured when left at a temperature of 5° C. for 30 seconds.
The position of the lower surface of the second end of the sample piece immediately before the start of the test is set as a horizontal reference line, and the length (mm) that the second end drops vertically from the horizontal reference line at the end of the test is measured. and Table 1 shows the results.
However, for Examples 1 to 7, the drooping amount at 23° C. was not measured.

[High temperature thermal stability test]
The sheet bodies produced in Examples 5, 6, 7 and 8 were cut into length×width=20 mm×50 mm to produce sample pieces. A sample piece was heated in a gear oven at 180° C., and the degree of discoloration was visually evaluated every 10 minutes. Table 2 shows the results.
◯: No discoloration.
○△: Slightly discolored.
Δ: Slightly discolored.

The interior material of the present invention can be used for floor materials, wall materials, ceiling materials, etc. of various buildings such as general houses, office buildings, hotels, condominiums and commercial facilities.

1 interior material 2 sheet body 6 small mass 61 first small mass 62 second small mass 63 third small mass 7 flow pattern solidified material C11, C12, C21, C22, C31, C32 colored part N1, N2, N3 Uncolored part A Raw material small lump

Claims (3)

Having a sheet body having on the surface side a portion in which a plurality of small lumps containing vinyl chloride resin and a rubbery material are aggregated,
A small mass having a colored portion and an uncolored portion or a colored portion with a different color from the colored portion, wherein the two portions are expressed in stripes,
The small lump has a portion that extends while being inclined with respect to the surface of the sheet body in a cross-sectional view,
The interior material , wherein in the agglomerated portion, adjacent nodules have a portion that does not have a clear boundary due to fusion . In a cross-sectional view, the small mass has a portion extending from the middle portion in the thickness direction while being inclined with respect to the surface of the sheet body, a portion extending from the middle portion in the thickness direction while being inclined with respect to the back surface of the sheet body, The interior material according to claim 1, each comprising: A method for manufacturing an interior material according to any one of claims 1 and 2,
The color of the colored first raw material containing the vinyl chloride resin and the rubbery material is different from the color of the uncolored second raw material containing the vinyl chloride resin and the rubbery material or the first raw material containing the vinyl chloride resin and the rubbery material. a step of solidifying the colored second raw material in a flowing pattern;
pulverizing the flow-patterned solidified material to obtain a plurality of raw material small lumps;
A method for producing an interior material, comprising a step of gathering the raw material small lumps and applying heat and pressure to produce a sheet body.

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