JP2017051402A - Interior material and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an interior material having a woven fabric surface, the aesthetic appearance of which is not so bad.SOLUTION: The interior material comprises a laminate consisting of a backing layer 2, a glass fiber layer 3 formed thereon, an adhesive layer 4 formed thereon, and a woven fabric 5 formed thereon. The adhesive layer 4 is formed of a hardened material of adhesive consisting primarily of vinyl chloride resin, and sticks the woven fabric 5 to the glass fiber layer 3 and the backing layer 2. The woven fabric 5 has a weaving structure including a coating yarn that is formed by coating a core yarn by a coating material consisting primarily of vinyl chloride resin, used as a warp and a weft.SELECTED DRAWING: Figure 1

Description

  The present invention relates to an interior material and a manufacturing method thereof.

  Conventionally, tufted carpets are often used as interior materials such as tile carpets, roll carpets, and wall coverings. On the other hand, interior materials that use woven fabric as the surface layer can form various patterns not only due to changes in color but also due to changes in the structure. Therefore, they are different from tufted carpets and are elegant and elegant. The texture can be expressed. Therefore, many interior materials using a woven fabric such as a plain fabric as a surface layer are used.

  Such an interior material is shown by patent documents 1-3, for example. In the carpet of Patent Document 1, the warp and the weft intersect each other, and a convex portion is formed on the surface by one of the warp or the weft, and the melted yarn is mixed with one of the warp or the weft. In the carpet of Patent Document 2, one or both of the warp and the weft is a core-sheath yarn composed of a core yarn and a sheath yarn having different melting points, and is heated at a temperature not lower than the softening point of the sheath yarn and not higher than the softening point of the core yarn. Thus, the warp and the weft are thermally bonded. In the interior material of Patent Document 3, some or all of the constituent yarns of a woven or knitted fabric formed by plain weaving are fixed to each other by a synthetic resin emulsion.

JP 2000-282347 A Japanese Patent Laying-Open No. 2005-245706 Japanese Patent Laid-Open No. 2005-60888

  By the way, the woven fabric is likely to cause “hot” such as yarn and pile from the cut edge. Therefore, in the interior material using the woven fabric, the appearance of the edge and the durability may be deteriorated. Note that FIG. 8 shows a fray 60. The loose 60 is generated when the core yarn which is the multifilament yarn of the covering yarn is unwound or dropped off at the cut end surface of the woven fabric.

  In order to prevent “hot”, a carpet or the like using a plain woven fabric is sometimes subjected to “edge processing” at the end. However, the edge-finished carpet has a problem that, as it is used, the fiber at the end portion rises and the texture is distorted. Furthermore, in order to prevent “hot”, a method of binding a plain fabric and a backing layer by biting a backing material made of a synthetic resin into the plain fabric, or bonding the plain fabric and the backing layer with a hot melt resin or the like. Thus, a method for fixing fibers has been used, but there has been no sufficient effect.

  Moreover, in the carpets of Patent Documents 1 and 2, the warp or weft is melted to stabilize the shape of the cut edge, but if the melting is insufficient, the edge and other parts are In some cases, the form was not stable, and the appearance and durability of the carpet deteriorated. On the other hand, if the heating temperature is raised to sufficiently melt the yarn, the surface of the woven fabric may wave and cause a problem of “flare”. Therefore, there is a problem that it is difficult to control the heating temperature for melting. Furthermore, since it is necessary for the yarn to be used to contain a molten component, there are limitations on the types of yarn that can be used, and there are limitations on the strength, texture, durability, etc. of the yarn, and there are changes in color and texture. In some cases, the advantage of the woven fabric that various patterns can be formed by changes cannot be fully utilized.

  Further, when a surface layer that is a woven fabric is provided on an interior material having a backing such as a tile carpet or a roll carpet, a “backing step” for bonding the surface layer and the backing layer is necessary. In the “backing step”, when the fibers of the woven fabric are not fixed or insufficiently fixed, the pattern of the woven fabric is distorted, which makes it difficult to manufacture. The interior material of patent document 3 is going to solve this. In the invention of Patent Document 3, a part or all of the constituent yarns are fixed to each other by applying an adhesive made of a synthetic resin emulsion using a roll coater or a knife coater. When providing a backing layer on a plain woven fabric with wefts and warps fixed, apply latex to either or both of the backing layer or the back of the plain woven sheet and press it with a press roll. The interior material is obtained by heating and drying in a heated oven to provide a backing layer on the surface layer made of plain woven fabric. For this reason, when the application amount is too small when part or all of the constituent yarns are fixed to each other, fixing of the constituent yarns becomes insufficient, and there is a possibility that a deviation may occur when pressing with a press roll. It may be difficult to smoothly perform the “backing process”, and in addition, a sufficient “hot” prevention effect may not be obtained. On the other hand, when the application amount of the adhesive is too large, as shown in FIG. 7, the adhesive 400 constituting the adhesive layer leaks from the weave of the woven fabric 50 and hardens, that is, the adhesive. Since 400 hardened | cured material will appear on the surface of the woven fabric 50, the appearance of the woven fabric 50 surface falls. In addition, the method of laminating the backing layer with a press roll requires that the plain woven fabric not be displaced, distorted or uneven during pressing, and it is difficult to adjust heat and pressure.

  Moreover, when providing a backing layer on the back side of the woven fabric, it is necessary to bond the woven fabric and the backing layer after fixing the back side of the woven fabric with a resin. Furthermore, there is a possibility that defects such as wrinkles, flares and distortions may occur in the woven fabric in the bonding step.

  Further, in the conventional woven fabric 50, as shown in FIG. 9, the warp yarn 51 and the weft yarn 52 extending along the cut edge 501 are often not accurately parallel to the edge. In that case, in the vicinity of the cut edge 501, the straightness of the woven pattern made of the warp 51 is impaired. This state is called “turning”.

  An object of the present invention is to provide an interior material that does not have a bad appearance on the surface of a woven fabric, and to provide a method for producing such an interior material.

1st aspect of this invention consists of a laminated body which consists of a backing layer, the glass fiber layer on it, the adhesive layer on it, and the woven fabric on it,
The backing layer is made of a cured material of a backing material mainly composed of vinyl chloride resin,
The glass fiber layer contains glass fiber,
The adhesive layer is made of a cured product of an adhesive mainly composed of vinyl chloride resin, and the woven fabric is bonded to the glass fiber layer and the backing layer,
The woven fabric has a woven structure having, as warps and wefts, coated yarns in which core yarns are coated with a coating material mainly composed of vinyl chloride resin.
It is an interior material characterized by this.

In the first aspect of the present invention, it is preferable to arbitrarily employ one or more of the following configurations (i) and (ii).
(I) The covering yarn of the woven fabric has a form in which a core yarn is covered with a covering material mainly composed of vinyl chloride resin,
The coating layer made of the coating material has a plurality of colors by having a plurality of different color portions in the circumferential direction when viewed in cross section,
The warp or the weft is twisted about an axis.

(Ii) The core yarn of the coated yarn of the woven fabric is made of a monofilament.

In the second aspect of the present invention, a glass sheet made of glass fiber is placed on a backing material layer made of a backing material mainly composed of vinyl chloride resin, and the vinyl chloride resin is mainly placed on the surface of the glass sheet. Applying an adhesive as a component to form an adhesive layer, and further placing a woven fabric on the adhesive layer, a laminating step,
Heating the laminated body composed of the backing material layer, the glass sheet, the adhesive layer, and the woven fabric, thereby curing the backing material layer and the adhesive layer to obtain an interior material, heating. Process,
Have
The woven fabric has a woven structure having, as warps and wefts, a coated yarn in which a core yarn is coated with a coating material mainly composed of a vinyl chloride resin, and the woven density is first. We are using a woven fabric set to a predetermined value,
In the laminating step, at least one of the viscosity of the adhesive and the thickness of the adhesive layer is set to a second predetermined value,
The first predetermined value and the second predetermined value are determined so as to prevent the adhesive from oozing out on the surface of the woven fabric in the heating step.
It is the manufacturing method of the interior material characterized by this.

  In the second aspect of the present invention, it is preferable to arbitrarily adopt one or more of the following configurations (iii), (iv), and (v).

(Iii) Before the laminating step, the method further includes a heat setting step of heating the woven fabric under a condition that the woven fabric surface temperature is the first predetermined temperature.

  In this case, it is preferable that the heating step is performed after the preheating step. The preheating step is a step of heating the woven fabric under a condition where the woven fabric surface temperature is a second predetermined temperature, and the main heating step is a condition where the woven fabric surface temperature is a third predetermined temperature. This is a process of heating the cloth. In this case, the first predetermined temperature is set to 0 to 20 ° C. higher than the third predetermined temperature, and the second predetermined temperature is set to 60 to 90 ° C. lower than the third predetermined temperature.

(Iv) The first predetermined value is a density when using 42 to 47 yarns / inch warp and 15 to 16 yarns / inch weft,
The second predetermined value is a viscosity of 5000 cps or more of the adhesive or a thickness of 0.25 to 0.5 mm of the adhesive layer.

  The second predetermined value is preferably a viscosity of 10000 cps or more of the adhesive and a thickness of 0.25 to 0.3 mm of the adhesive layer.

(V) using a coated yarn in which the coating layer made of the coating material has a plurality of colors;
The coating layer has the plurality of colors by having a plurality of different color portions in the circumferential direction when viewed in cross section.

  According to the interior material of the first aspect of the present invention, it is possible to prevent a decrease in appearance.

  According to the interior material manufacturing method of the second aspect of the present invention, the adhesive layer is formed on the glass sheet, so that an appropriate amount of adhesive can be uniformly spread, and the woven fabric and the glass sheet. Can be bonded sufficiently and firmly over the entire surface. Therefore, an interior material in which a cured product of the adhesive does not appear on the surface of the woven fabric can be obtained. Further, since the adhesive layer can be formed integrally with the backing material layer, the interlayer strength can be improved, the strength and durability of the entire interior material can be improved, and the manufacture is facilitated. Furthermore, since the woven fabric can be developed without load on the adhesive layer, it is possible to prevent defects such as wrinkles, flares, and distortions from occurring in the woven fabric in the heating step for bonding them together.

It is a cross-sectional schematic diagram which shows the interior material of one Embodiment of the 1st aspect of this invention. It is a plane enlarged view of the interior material of FIG. It is a cross-sectional schematic diagram which shows the lamination process in manufacture of the interior material of FIG. It is a perspective view of the edge part of the covering yarn used for the woven fabric of the interior material of FIG. It is a perspective view of the edge part of the covering yarn used for the woven fabric of the interior material of another embodiment of this invention. It is an enlarged plan view of the part along the cutting edge of the woven fabric of embodiment of FIG. It is an enlarged plan view which shows the surface of the woven fabric of the conventional interior material. It is an enlarged plan view of the cutting edge part of the conventional woven fabric. It is an enlarged plan view of the part along the cutting edge of the conventional woven fabric.

[First Embodiment]
The present embodiment is an embodiment of the interior material of the present invention and a method for producing the same. FIG. 1 is a schematic cross-sectional view showing the interior material of the present embodiment. The interior material 10 is formed of a laminate including a backing layer 2, a glass fiber layer 3 thereon, an adhesive layer 4 thereon, and a woven fabric 5 thereon. The backing layer 2 is made of a cured material of a backing material mainly composed of vinyl chloride resin. The glass fiber layer 3 includes a plurality of glass fibers. The adhesive layer 4 is made of a cured product of an adhesive mainly composed of a vinyl chloride resin, and joins the woven fabric 5 to the glass fiber layer 3 and the backing layer 2. The woven fabric 5 has a woven structure having, as warps and wefts, coated yarns in which a core yarn is coated with a coating material mainly composed of a vinyl chloride resin.

  FIG. 2 is a partially enlarged plan view of the interior material 10. That is, it is a partially enlarged plan view of the woven fabric 5. The woven fabric 5 has a woven structure in which warps 51 and wefts 52 are woven as shown in FIG.

  In the interior material 10, the cured product of the adhesive does not appear on the surface of the woven fabric 5. That is, as compared with the conventional case shown in FIG. 7, in the interior material 10, the cured product of the adhesive does not appear on the surface of the woven fabric 5 as shown in FIG. 2.

  Therefore, according to the interior material 10 of the present embodiment, since the cured product of the adhesive does not appear on the surface of the woven fabric 5, it looks good.

  Next, the manufacturing method of the interior material 10 of this embodiment will be described. The interior material 10 is obtained by performing the following “lamination process” and “heating process” in this order.

(1) Laminating Step As shown in FIG. 3, first, a backing material layer 20 made of a backing material 200 containing vinyl chloride resin as a main component is formed, and then a glass fiber is formed on the backing material layer 20. Next, an adhesive layer 40 composed mainly of vinyl chloride resin is applied to the surface of the glass sheet 30 to form an adhesive layer 40, and then the adhesive layer 40 is formed on the surface of the adhesive layer 40. Place the woven fabric 5. Thereby, the laminated body which consists of the backing material layer 20, the glass sheet 30, the adhesive bond layer 40, and the woven fabric 5 is obtained.

  The backing material layer 20 serves as a grounding layer for the interior material 10. The backing material 200 is preferably composed mainly of vinyl chloride resin, but other synthetic resins such as vinyl chloride-vinyl acetate copolymer, polypropylene, polyethylene, ethylene-vinyl acetate copolymer, etc .; or Other synthetic rubbers such as SBR and NBR may be used. Further, the backing material 200 may be mixed with various pigments such as black pigments such as carbon black; fillers such as calcium carbonate and barium sulfate; stabilizers;

  Moreover, it is preferable to form the backing material layer 20 by the method of apply | coating the paste-like backing material 200 on a conveyor. According to this method, the glass sheet 30 can be easily embedded in the backing material 200, and therefore the glass sheet 30 and the backing material 200 can be firmly integrated by a “heating process” described later.

  As the glass sheet 30, a glass nonwoven fabric such as a glass mat or a glass woven fabric such as a glass cloth can be used. The fiber component of the glass sheet 30 may be composed only of glass fibers, or may contain other fibers in addition to the glass fibers. As other fibers, natural fibers such as pulp, synthetic resin fibers, metal fibers, and the like can be used. Since the glass fiber contained in the glass sheet 30 has a small change with respect to temperature change and excellent strength, it can improve the dimensional stability of the entire interior material and physical property stability such as warpage reduction. it can. In particular, the glass nonwoven fabric is suitably used because it has excellent dimensional stability and processability. Moreover, since the glass nonwoven fabric is suitable for receiving the adhesive 400 in a uniform state, the woven fabric 5 can be joined without causing defects such as wrinkles, flares, and distortions.

  In this lamination process, since the adhesive 400 is applied to the surface of the glass sheet 30, it can be uniformly developed with an appropriate application amount. Further, since the adhesive 400 can be easily applied and the woven fabric 5 can be spread on the adhesive layer 40 without load, it can be easily laminated on the woven fabric 5 without causing defects such as wrinkles, flares, and distortions. it can. In addition, since the edge of the woven fabric 5 is also sufficiently fixed, it is possible to suppress the occurrence of “hot” in the yarn.

  The woven fabric 5 has a woven structure having, as warps and wefts, coated yarns in which a core yarn is coated with a coating material mainly composed of a vinyl chloride resin. FIG. 4 is a perspective view of the end portion of the coated yarn 6. The covering yarn 6 includes a core yarn 61 and a covering layer 62 made of a covering material. Such a coated yarn 6 is obtained by putting the core yarn 61 into an extruder while being fed out by a yarn feeding machine, and pushing it out together with the coating material.

  In addition, from the viewpoint of improving physical stability such as improvement of dimensional stability, reduction of warpage, anti-slip on the back surface, etc., commonly used glass mats, polyester woven fabrics, or woven fabrics such as cold chills A cloth may be provided on the back surface of the backing material layer 20.

  In the present embodiment, a woven fabric having a woven density set to a “first predetermined value” described below is used as the woven fabric 5. Further, the viscosity ρ of the adhesive 400 and the thickness T of the adhesive layer 40 are set to a “second predetermined value” described below.

(2) Heating process The whole laminated body obtained in the laminating process is heated, whereby the backing material layer 20 and the adhesive layer 40 are cured to integrate the backing layer 2 and the adhesive layer 4 with the glass fiber layer 3. Let it form. Thereby, the interior material 10 which is a laminated body which consists of the backing layer 2, the glass fiber layer 3, the contact bonding layer 4, and the woven fabric 5 is obtained.

  In this heating step, since heating is performed in the state of the laminated body, the bonding between the woven fabric 5 and the backing layer 2 can be sufficiently and firmly performed over the entire surface. Further, since the glass fiber layer 3 is formed integrally with the woven fabric 5 and the backing layer 2, the interlayer strength can be improved, and therefore the strength and durability of the interior material 10 as a whole can be improved.

  The interior material 10 obtained as described above is used by cutting into a desired shape, for example, a tile shape such as a rectangle or a long sheet shape. The cut interior material 10 can be used by being laid on the floor surface as a flooring material, or can be used by being attached to a wall surface or a ceiling surface as a wallpaper or a waist wall material.

(First and second predetermined values)
The first and second predetermined values are required so that the adhesive 400 can be prevented from seeping out (leaking out) on the surface of the woven fabric 5 in the heating step. Specifically, the first predetermined value is a density when warp yarns 51 of 42 to 47 yarns / inch and weft yarns 52 of 15 to 16 yarns / inch are used. In this specification, “1 inch = 2.54 cm”. Further, the second predetermined value is a viscosity ρ of 5000 cps or more of the adhesive 400 or a thickness T of 0.25 to 0.5 mm of the adhesive layer 40, and preferably a viscosity ρ of 10000 cps or more of the adhesive 400. And a thickness T of the adhesive layer 40 of 0.25 to 0.3 mm. Such first and second predetermined values were obtained as follows. The viscosity was measured using a B-type BM viscometer manufactured by Tokyo Keiki Co., Ltd. Measurements were taken at 4 and 6 rpm.

(A) Setting of the first level and the second level In the first level, 42 yarns / inch warp 51 and 16 yarns / inch weft 52 were used. As the second level, 47 warps / inch warp 51 and 15 wefts / inch weft 52 were used.

(B) Examination of presence or absence of bleeding in the case of the first level In the case of the first level, the viscosity ρ of the adhesive 400 and the thickness T of the adhesive layer 40 are variously set, and the above manufacturing method is executed. Got interior material. And the surface of the woven fabric 5 was observed and the presence or absence of oozing (leakage) was confirmed. Table 1 shows the results. In Table 1, when there is no exudation, it is indicated by “、”, when there is slight exudation, it is indicated by “◯”, and when exudation is clearly present, it is indicated by “x”.

(C) Examination of presence or absence of bleeding in the case of the second level In the case of the second level, the presence or absence of the bleeding was confirmed in the same manner as in the case of the first level. The result was better than in the first level.

(D) Discussion As can be seen from Table 1, it is preferable that the viscosity ρ of the adhesive 400 is 5000 to 20000 cps, or the thickness T of the adhesive layer 40 is 0.25 to 0.5 mm. Is more preferable when the viscosity ρ of the adhesive 400 is 10,000 to 20000 cps, or when the thickness T of the adhesive layer 40 is 0.25 to 0.3 mm, and further, the viscosity ρ of the adhesive 400 is more preferable. Is particularly preferably 10000 to 20000 cps and the thickness T of the adhesive layer 40 is 0.25 to 0.3 mm. Therefore, the first and second predetermined values are set as described above.

  Thus, the interior material 10 in which the cured product of the adhesive 400 does not leak out to the surface of the woven fabric 5, that is, does not appear can be obtained.

[Second Embodiment]
This embodiment is another embodiment of the interior material of the present invention. In the woven fabric 5 of the interior material 10 of the present embodiment, the coated yarn 6A having a structure different from that of the coated yarn 6 of the woven fabric 5 of the first embodiment is used as the warp yarn 51 and the weft yarn 52, and around the axis. It is used to twist.

  FIG. 5 is a perspective view of the end portion of the coated yarn 6A of the present embodiment. The covering layer 62 has a different color in each of the circumferential halves 621 and 622 when viewed in cross section. That is, the surface of the covering yarn 6A has two colors, and each color portion occupies half of the circumferential direction of the surface of the covering yarn 6A and extends in the axial direction.

  Such a covered yarn 6A is obtained by putting the core yarn 61 into an extruder while being fed out by a yarn feeding machine and extruding it together with two types of coating materials having different colors.

  The woven fabric 5 of the present embodiment can be obtained by using the above-described covered yarn 6A as the warp yarn 51 and the weft yarn 52 and twisting around the axis when being manufactured by weaving.

  FIG. 6 is an enlarged plan view of a portion along the cut edge 501 of the woven fabric 5 of the present embodiment. Conventionally, since the warp yarn 51 extending along the cut edge 501 is not parallel to the edge 501, “bending” is easily visually recognized. However, in the woven fabric 5 of the present embodiment, the coated yarn 6A has two colors and is woven so as to be twisted, so that the warp yarn 51 near the edge 501 exhibits two colors alternately. It extends along the edge 501. Thereby, the warp 51 is visually recognized by changing the color in the axial direction. For this reason, it is difficult to notice that the warp 51 is not parallel to the edge 501. Therefore, even if there is a “turned bend”, it is difficult to be visually recognized. In the case of the weft yarn 52, the same applies to the edge perpendicular to the edge 501.

  As described above, according to the woven fabric 5 of this embodiment, it is possible to make it difficult to visually recognize “curved corners”. And according to the interior material 10 of this embodiment, since the hardened | cured material of the adhesive agent 400 does not appear on the surface of the woven fabric 5, and it is hard to visually recognize a "bending", it shows a more favorable appearance. be able to.

  The covered yarn 6A of the present embodiment is not limited to two colors as long as it has a plurality of different colors. That is, the covering layer 62 may have a plurality of colors by having a plurality of different color portions in the circumferential direction when viewed in cross section. The multiple colors are preferably 2 to 4 colors, and most preferably 2 colors. Moreover, it is preferable that the different colors have greatly different contrast or brightness. This is because it becomes easier to visually recognize the color difference.

  As the core yarn 61 of the coated yarn 6A, either monofilament or multifilament may be used. In addition, when using a multifilament, it is preferable to use a melt yarn.

[Third Embodiment]
This embodiment is still another embodiment of the interior material of the present invention. In the woven fabric 5 of the interior material 10 of the present embodiment, a coated yarn 6B having a structure different from the coated yarn 6A of the woven fabric 5 of the second embodiment is used. Other details are the same as in the second embodiment.

  The covered yarn 6B is different from the covered yarn 6A of the second embodiment in that the core yarn 61 is made of a monofilament.

  The material of the monofilament may be a synthetic resin, for example, polyester, nylon, polypropylene or the like. In addition, since polyester or nylon is excellent in intensity | strength, durability, and heat resistance, it is used suitably.

  The thickness of the monofilament is preferably 100 dtex or more and less than 500 dtex, and more preferably 300 to 360 dtex. When the thickness is 100 dtex or more, it is difficult to cut, and thus coating of the coating material on the core yarn is easy. When the thickness is less than 500 dtex, the core yarn hardly protrudes from the end face of the coated yarn, and therefore the coating layer is also difficult to peel off.

  In the present embodiment, a polyester monofilament having a thickness of 330 dtex is used as the monofilament.

  Further, the specific composition of the covering material in the covering yarn 6B is as shown in Table 2.

  By the way, as shown in FIG. 8, when the core yarn 61 of the covering yarn 6 is a multifilament composed of a plurality of fine fibers, a configuration in which the fray 60 of the core yarn 61 hardly occurs on the cut edge 501. Is desirable. In particular, in the interior material, since a person directly steps on or touches the interior material, the cut edge easily causes a fray. When the fray occurs, the core yarn 61 impairs the design. In particular, in the interior material 10 cut into a tile shape such as a rectangle, since the joints increase, the problem becomes more remarkable. Examples of the method for preventing the multifilament yarn from fraying include using a hot-melt yarn or a glass fiber yarn.

  In the woven fabric 5 of this embodiment, since the core yarn 61 is made of monofilament, even if the core yarn 61 is exposed from the cut end surface of the coated yarn 6B at the cut edge 501, the core yarn 61 is unwound. There is nothing. Therefore, according to the present embodiment, it is possible to prevent the fray 60 (FIG. 8) at the cut edge 501 of the woven fabric 5, thereby preventing the appearance from being lowered and preventing the durability from being lowered. In addition, in the case of a hot melt yarn, it shrinks greatly when it is melted, but in the case of a monofilament, since it is not necessary to be a hot melt yarn, the shrinkage can be kept low. Also, in the case of glass fiber, the exposed end part collapses to become powder, or touching the exposed end part causes tingling and discomfort, but in the case of monofilament, Since there is nothing, it can be used suitably.

  According to the present embodiment, the cured product of the adhesive 400 does not appear on the surface of the woven fabric 5, and it is difficult to visually recognize “curved corners”. Since 8) does not occur, a very good appearance can be obtained.

[Fourth Embodiment]
This embodiment is another embodiment of a method for manufacturing an interior material. The interior material 10A obtained by the manufacturing method of the present embodiment has the same basic structure as the interior material 10 of FIG. That is, the interior material 10A is composed of a laminate including the backing layer 2, the glass fiber layer 3 thereon, the adhesive layer 4 thereon, and the woven fabric 5 thereon. The backing layer 2 is made of a cured material of a backing material mainly composed of vinyl chloride resin. The glass fiber layer 3 contains glass fibers. The adhesive layer 4 is made of a cured product of an adhesive mainly composed of a vinyl chloride resin, and joins the woven fabric 5 to the glass fiber layer 3 and the backing layer 2. The woven fabric 5 has a woven structure having, as warps and wefts, coated yarns in which a core yarn is coated with a coating material mainly composed of a vinyl chloride resin.

  The interior material 10A is obtained by performing the following “heat setting step”, “lamination step”, and “heating step” in this order. The manufacturing method of this embodiment is different from the first embodiment in that it includes a “heat setting step”. Other details are the same as in the first embodiment.

(1) Heat setting step The woven fabric 5 is heated under the condition that the woven fabric surface temperature becomes the “first predetermined temperature”. At that time, it is preferable to heat the woven fabric 5 while applying a pulling force in the plane direction, and thereby the flare of the woven fabric 5 can be suppressed and smoothed. Further, the bending of the woven fabric 5 can be reduced.

  The woven fabric 5 has a woven structure in which coated yarns, in which core yarns are coated with a coating material mainly composed of vinyl chloride resin, are used as warps and wefts.

(2) Laminating Step As shown in FIG. 3, first, a backing material layer 20 made of a backing material 200 containing vinyl chloride resin as a main component is formed, and then glass fiber is formed on the backing material layer 20. Next, an adhesive layer 40 composed mainly of vinyl chloride resin is applied to the surface of the glass sheet 30 to form an adhesive layer 40, and then the adhesive layer 40 is formed on the surface of the adhesive layer 40. Place the woven fabric 5. Thereby, the laminated body which consists of the backing material layer 20, the glass sheet 30, the adhesive bond layer 40, and the woven fabric 5 is obtained.

  In addition, according to the lamination | stacking process, since the woven fabric 5 is fixed, generation | occurrence | production of flare can be suppressed and also the anti-glare effect can be exhibited.

(3) Heating process The laminated body obtained at the lamination process is heated, and thereby the backing material layer 20 and the adhesive layer 40 are cured to form the backing layer 2 and the adhesive layer 4. Thereby, interior material 10A is obtained. In the present embodiment, this heating step is performed after the preheating step and the main heating step. In the preheating step, the woven fabric 5 is heated under the condition that the woven fabric surface temperature becomes the “second predetermined temperature”. In the main heating step, the woven fabric 5 is heated under the condition that the woven fabric surface temperature becomes the “third predetermined temperature”.

  And the 1st-3rd predetermined temperature is calculated | required so that it can prevent that flare, ie, an unevenness | corrugation, or a wave | undulation generate | occur | produces on the surface in 10 A of obtained interior materials. Specifically, the first predetermined temperature is 140 to 150 ° C, the second predetermined temperature is 70 to 115 ° C, and the third predetermined temperature is 135 to 145 ° C. The third predetermined temperature is preferably 135 ° C., and the second predetermined temperature C is preferably 70 to 80 ° C. The first predetermined temperature is preferably set to 0 to 20 ° C. higher than the third predetermined temperature. This is because if the heating process exceeds the surface temperature of the woven fabric at the time of heat setting, the effect of smoothing the woven fabric by the heat setting is reduced, the woven fabric 5 is bent again, and flare is likely to occur. Because. The second predetermined temperature is preferably set to be lower by 60 to 90 ° C. than the third predetermined temperature. Further, the first to third predetermined temperatures are particularly preferably 150 ° C., 70 ° C., and 135 ° C., respectively. Such a temperature was obtained by performing experiments 1 to 9 as shown in Table 3.

  As shown in Table 3, the heating operation is performed once or twice in the heat setting step. Moreover, the shrinkage rate after each heating is also calculated | required. In the flare generation column, “x” indicates that flare is clearly generated, “△” indicates that flare is slightly generated, and “○” indicates that flare is negligible. Is shown (that is, it can be regarded as not occurring).

  As described above, according to the manufacturing method of the present embodiment, it is possible to obtain the interior material 10A in which no flare is generated.

[Other Embodiments]
In the manufacturing method of the sixth embodiment, the following configuration or conditions may be adopted.
(A) The first and second predetermined value conditions of the first embodiment are additionally employed.
(B) In the weaving process, the covered yarn 6A of the second embodiment is used in place of the covered yarn 6.
(C) In the weaving process, the coated yarn 6B of the third embodiment is used in place of the coated yarn 6.
In addition, (a), (b), (c) may be employed alone, or (a) may be employed together with (b) or (c).

  Since the interior material of the present invention has a good appearance, the industrial utility value is great.

2 Backing Layer 20 Backing Material Layer 200 Backing Material 3 Glass Fiber Layer 30 Glass Sheet 4 Adhesive Layer 40 Adhesive Layer 400 Adhesive 5 Woven Fabric 51 Warp 52 Weft 6, 6A, 6B Cover Yarn 61 Core Yarn 62 Cover Layer 10, 10A Interior material

Claims (5)

It consists of a laminate consisting of a backing layer, a glass fiber layer above it, an adhesive layer above it and a woven fabric above it,
The backing layer is made of a cured material of a backing material mainly composed of vinyl chloride resin,
The glass fiber layer contains glass fiber,
The adhesive layer is made of a cured product of an adhesive mainly composed of vinyl chloride resin, and the woven fabric is bonded to the glass fiber layer and the backing layer,
The woven fabric has a woven structure having, as warps and wefts, coated yarns in which core yarns are coated with a coating material mainly composed of vinyl chloride resin.
An interior material characterized by that. The covering layer made of the covering material of the woven fabric has a plurality of colors by having a plurality of different color portions in the circumferential direction when viewed in cross section,
The warp or the weft is twisted about an axis;
The interior material according to claim 1. The core yarn of the coated yarn of the woven fabric is made of monofilament,
The interior material according to claim 1 or 2. A glass sheet made of glass fiber is placed on a backing material layer made of a backing material mainly composed of vinyl chloride resin, and an adhesive mainly composed of vinyl chloride resin is applied to the surface of the glass sheet. Forming an adhesive layer, and further placing a woven fabric on the adhesive layer; and a laminating step,
Heating the laminated body composed of the backing material layer, the glass sheet, the adhesive layer, and the woven fabric, thereby curing the backing material layer and the adhesive layer to obtain an interior material, heating. Process,
Have
The woven fabric has a woven structure having, as warps and wefts, a coated yarn in which a core yarn is coated with a coating material mainly composed of a vinyl chloride resin, and the woven density is first. We are using a woven fabric set to a predetermined value,
In the laminating step, at least one of the viscosity of the adhesive and the thickness of the adhesive layer is set to a second predetermined value,
The first predetermined value and the second predetermined value are determined so as to prevent the adhesive from oozing out on the surface of the woven fabric in the heating step.
An interior material manufacturing method characterized by the above. Prior to the laminating step, it further includes a heat setting step of heating the woven fabric under a condition that the woven fabric surface temperature is a first predetermined temperature.
The manufacturing method of the interior material of Claim 4.

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