JP2019120014A - Interior sheet and manufacturing method thereof - Google Patents

Abstract

To provide an interior sheet in which a concave portion having a sharp appearance is formed on the front surface.SOLUTION: An interior sheet 1 of the present invention comprises, from the front surface side, a sheet main body 2 having a surface layer 4, a colored print layer 5 and a synthetic resin layer 6 and a recess 3 formed on the front surface of the sheet main body 2 and constituted of a recess slope 31 and a deepest portion 32. A part or all of the colored print layer 5 has a color different from that of the synthetic resin layer 6, and the colored print layer 5 has a gradually decreasing portion 51 formed in a gradually thinner shape toward the deepest portion 32 in a region corresponding to the recess slope 31 of the recess 3.SELECTED DRAWING: Figure 3

Description

  The present invention relates to an interior sheet having a recess formed on the surface and a method of manufacturing the same.

Conventionally, a sheet mainly made of synthetic resin is used as an interior sheet for a building such as a floor material, a wall material, and a ceiling material of a building.
Also known is an interior sheet in which a recess is formed on the surface.
As a method of forming a dent in the surface of an interior sheet, the chemical embossing method using a foaming inhibitor and the mechanical embossing method which presses an embossing plate are known. The chemical emboss method is a method in which a portion to be foamed is made to be a convex portion and a portion not to be foamed is formed as a concave portion by making the portion to form a concave portion contain a foaming inhibitor.
However, chemical emboss method can not be applied to non-foamed interior sheets, and convex parts and concave parts having vague boundaries are formed, and the surface shape tends to have an overall gentle unevenness.
The mechanical emboss method can be formed on any non-foamed and foamed interior sheet, and can form asperities having a relatively sharp shape, but it is difficult to make the asperity match the design exposed on the interior sheet.

Patent Document 1 discloses a synthetic resin floor material comprising a synthetic resin base layer, a printing layer, and a surface layer, in order to make the embossed recess have a pattern and color tone different from those of the other portions, which is a surface layer Is formed of a synthetic resin and a heat-resistant transparent particle, and has a partially embossed recess, in which the transparent particle penetrates the printing layer and is buried in the base material layer. An embossed flooring is disclosed.
In Patent Document 1, particles of the surface layer corresponding to the recesses are embedded in the resin layer by embossing the laminate with an embossing roll or the like, and the printing is broken and mixed in the resin layer. It is stated that the embossed depressions have a pattern and color tone different from those of the other portions, and have the same effect as if the valley-stained embossing was applied.

Japanese Examined Patent Publication No. 6-043748

The method of Patent Document 1 corresponds to an embossed recess by forcibly moving the transparent particle in the vertical direction and embedding it in the printing layer by embossing the surface layer containing the transparent particle with an embossing roll. It tears off the printing at the place where the
However, when such transparent particles are moved in the vertical direction and forced to be embedded in the printing layer, the printing layer is divided at the boundary between the deepest part of the embossed recess and the recessed inclined part, corresponding to the deepest part of the embossed recess. In the absence of the printing layer, an end face of the printing layer divided corresponding to the depression slope is produced. As described above, if there is an area without a print layer at the concave slope, there is a problem that the appearance gives an unnatural impression in design.
In addition, in order to tear the printing layer with transparent particles, a large amount of transparent particles having a relatively large particle size must be contained in the surface layer, and the stain resistance of the surface is reduced, and a smooth surface design is obtained. There is no fear.

  The object of the present invention is an interior sheet having an appearance in which the boundary between the deepest part of the recess and the recessed inclined part is less noticeable and the color exposed from the deepest part of the recess is naturally felt in the design of the colored print layer It is to provide a manufacturing method.

  The interior sheet of the present invention comprises, in order from the surface side, a sheet main body having a surface layer, a colored print layer and a synthetic resin layer, and a concave portion formed on the surface of the sheet main body and comprising a concave slope portion and a deepest portion. And the synthetic resin layer has a color different from that of a part or all of the colored print layer, and the colored print layer is directed to the deepest portion in a region corresponding to the concave slope of the concave portion. And a gradually decreasing portion formed in a thin-walled shape.

In a preferred interior sheet according to the present invention, a first resin layer in which the synthetic resin layer is laminated on the back surface side of the colored print layer, and a second resin layer in which the synthetic resin layer is laminated on the back surface side of the first resin layer And a fiber reinforcing layer is laminated on the back surface side of the second resin layer.
In a preferred interior sheet according to the present invention, the colored print layer has a thinnest portion formed thinnest in a region corresponding to the deepest portion of the concave portion.
The preferred interior sheet of the present invention does not have a colored print layer in the region corresponding to the deepest portion of the recess.
In a preferred interior sheet of the present invention, the surface layer is substantially free of fine particles.

According to another aspect of the present invention, a method of manufacturing an interior sheet is provided.
The manufacturing method of the present invention comprises, in order from the surface side, a preparation step of preparing a laminate having a surface layer, a colored print layer and a synthetic resin layer, pressing the embossed plate having embossed projections from the surface side of the laminate to carry out the lamination Forming an indentation formed on the surface of the body from the depression slope and the deepest portion, and in the embossing step, the thickness of the colored print layer gradually increases from the depression slope toward the deepest portion The recess is formed while stretching the colored print layer so as to be thinner.

  The interior sheet of the present invention has an appearance in which the boundary between the deepest portion of the concave portion and the concave slope portion is less noticeable, and the color exposed from the deepest portion of the concave portion is naturally taken into the colored print layer. Such an interior sheet is excellent in decorativeness because the color of the concave portion and the colored print layer is integrated in design.

The partially omitted top view of the interior sheet of 1st Embodiment of this invention. The expanded sectional view cut | disconnected by the II-II line of FIG. Sectional drawing which expanded a part of FIG. 2 further. The expanded sectional view which shows the modification of the form of a recessed part. The expanded sectional view of the interior sheet of 2nd Embodiment of this invention. FIG. 6 is a cross-sectional view further enlarging a part of FIG. 5; Sectional drawing which shows the preparatory process of the laminated body at the time of manufacture of an interior sheet. Sectional drawing which shows the embossing process of the laminated body at the time of manufacture of an interior sheet. FIG. 7 is a cross-sectional view showing the manufacturing process of the interior sheet of Example 1; Sectional drawing which shows the manufacturing process of the interior sheet of Example 2. FIG.

Hereinafter, the present invention will be described with reference to the drawings as appropriate.
In the present specification, the plan view refers to viewing the surface of the interior sheet from a direction orthogonal to the horizontal direction, and the plan view shape refers to the shape in the plan view. Moreover, the cross-sectional view shape refers to the shape when the interior sheet is cut in the thickness direction.
In the present specification, the numerical range represented by “lower limit value X to upper limit value Y” means lower limit value X or more and upper limit value Y or less. When a plurality of the numerical value ranges are separately described, it is possible to select an arbitrary lower limit value and an arbitrary upper limit value, and set "arbitrary lower limit value to arbitrary upper limit value".

[Summary of interior sheet]
In FIG. 1 to FIG. 3, the interior sheet 1 has a seat body 2 and a plurality of recesses 3 provided on the surface of the seat body 2.
As shown in FIG. 1, the interior sheet 1 of the present invention may be formed in a long strip shape, or may be formed in a sheet-like shape. The long strip refers to a substantially rectangular shape in plan view having a length in one direction sufficiently longer than the other direction. The elongated belt-like interior sheet 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, and preferably a length of 10 m or more in the second direction. The first direction is a direction orthogonal to the second direction.
The sheet-like form is, for example, a tile floor material and is formed in a predetermined shape such as a substantially rectangular shape such as a substantially rectangular shape in plan view, and generally refers to a shape which can be stacked, stored and transported. The sheet-like interior sheet 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.

[Sheet body]
The sheet body 2 may have flexibility or may not have flexibility not to be easily bent. In order to be able to easily store and transport the interior sheet 1 and to easily carry it into the bathroom at the time of construction, the sheet main body 2 is, for example, flexible so that it can be rolled around a core material of 20 cm in diameter. Preferably, it is formed from a sheet having The sheet body 2 may be composed only of non-foam, and may contain foam.
The thickness of the sheet body 2 is not particularly limited, and is, for example, 1.0 mm to 10 mm, and preferably 1.8 mm to 4.0 mm. However, the thickness of the sheet main body 2 excludes the thickness of the region corresponding to the recess 3.
The sheet main body 2 has a surface layer 4, a colored print layer 5 and a synthetic resin layer 6 in order from the surface side. The sheet body 2 may have other layers as necessary. For example, the fiber reinforcing layer 7 may be laminated on the back surface side of the synthetic resin layer 6 or the back surface side of the synthetic resin layer 6 (when the fiber reinforcing layer 7 is laminated, the back surface of the fiber reinforcing layer 7 The backing layer 8 or the reinforcing layer may be laminated on the side, or the protective layer 41 may be laminated on the surface of the surface layer 4. The synthetic resin layer 6 may be a single layer or may be composed of two or more layers.
The sheet main body 2 of the illustrated example has a protective layer 41, a surface layer 4, a colored print layer 5, a two-layered synthetic resin layer 6, a fiber reinforcing layer 7, and a backing layer 8 in this order from the surface side.
The protective layer 41 constitutes the outermost surface of the seat body 2 (interior sheet 1). When the protective layer 41 is not provided, the surface layer 4 constitutes the outermost surface of the sheet main body 2 (interior sheet 1).

<Surface>
The surface layer 4 is formed of, for example, a layer containing a resin. The surface layer 4 may be colored and transparent, but is preferably colorless and transparent. The surface layer 4 is directly adhered to the surface of the colored print layer 5. Moreover, the surface layer 4 is non-foaming.
The surface layer 4 may be composed of one layer, or may be a multilayer structure of two or more layers.
The surface layer 4 in the illustrated example has a single-layer structure.
The surface layer 4 contains a main component resin, and may contain a resin other than the main component resin and various additives as needed. As the additives, conventionally known ones can be used. For example, fillers, plasticizers, flame retardants, stabilizers, antioxidants, weathering agents such as UV absorbers, lubricants not of particle type, fungicides, etc. Can be mentioned. Preferably, the surface layer 4 contains a weathering agent as an additive. Examples of the weathering agent include benzophenone-based ultraviolet absorbers such as 2--4-dihydroxybenzophenone, benzotriazole-based ultraviolet absorbers such as 2- (2'-hydroxy-5'-methylphenyl) benzotriazole, and ethyl-2-cyano Acrylate UV absorbers such as -3,3'-diphenyl acrylate, salicylate UV absorbers such as phenyl salicylate, oxanilide UV absorbers such as 2-ethoxy-2'-ethyl oxalamic acid bis anilide, etc. Be
In the present specification, the main component resin refers to the resin component (weight ratio) having the largest mass among the resin components constituting the layer.
It is preferable that the surface layer 4 does not substantially contain fine particles as described in Patent Document 1. When the surface layer 4 contains the fine particles of Patent Document 1 or the like, the colored print layer 5 is torn by the fine particles when forming the concave portion 3, and it is difficult to stretch the colored print layer 5 to form a thin shape It becomes. In particular, when the particle diameter of the fine particles is large, there is a possibility that the formation of the recess may be hindered. For example, when the particles having a particle diameter of 30 μm or more, and further 50 μm or more are contained, the formation of the recess is hindered. Moreover, when the surface layer substantially does not contain the fine particles, the surface of the surface layer 4 can be formed relatively smoothly, and it is also possible to reproduce a smooth texture or design such as wood or stone.
The term "substantially free of fine particles" means that mixing of a minute amount of fine particles which is inevitably included is permitted, and that a significant amount of mixing is excluded.

It does not specifically limit as a main component resin which forms the surface layer 4, For example, a thermoplastic resin etc. are mentioned.
As a thermoplastic resin, vinyl chloride resins such as vinyl chloride and vinyl chloride-vinyl acetate copolymer; polyolefin resins; vinyl acetate resins such as ethylene-vinyl acetate copolymer; acrylic resins such as ethylene-methacrylate resin Resins; polyamide resins; ester resins; various thermoplastic elastomers such as olefin elastomers and styrene elastomers;
It is preferable that the surface layer 4 is formed of a thermoplastic resin because it is excellent in water resistance and flexibility, and further, because it deforms well when the embossed plate is pressed, a vinyl chloride resin as a main component resin More preferably, it is formed of one containing

Here, the vinyl chloride resin that can be used in the present invention will be briefly described.
As the vinyl chloride resin, those produced by an emulsion polymerization method, a suspension polymerization method, a solution polymerization method, a bulk polymerization method and the like can be mentioned. From the viewpoint of ease of processing and handling, vinyl chloride resins obtained by emulsion polymerization or suspension polymerization are preferred. These vinyl chloride resins may be used alone or in combination of two or more.
The vinyl chloride resin obtained by the above-mentioned emulsion polymerization method is one in which a surfactant is coated on the surface of a fine powder having a basic particle diameter of several μm or less (preferably 1 to 3 μm) consisting of a large number of fine particles. It becomes paste-like by blending a plasticizer etc. As the vinyl chloride resin by the emulsion polymerization method, one having an average polymerization degree of about 1000 to 2000 is preferably used.
The vinyl chloride resin obtained by the suspension polymerization method is preferably a fine powder of 20 to 100 μm and is used after being sheet-processed by a calendar molding method. The vinyl chloride resin produced by the suspension polymerization method preferably has an average degree of polymerization of about 700 to about 1500, and more preferably about 700 to about 1000, from the viewpoint of imparting roll tackiness suitable for the calendering method. preferable.
Hereinafter, the vinyl chloride resin obtained by the emulsion polymerization method may be referred to as "paste vinyl chloride", and the vinyl chloride resin obtained by the suspension polymerization method may be referred to as "suspension vinyl chloride".

The paste vinyl chloride resin has good processability at the time of production and low material cost. Suspension vinyl chloride is unlikely to cause water absorption whitening, has good stain resistance, and can be suitably used indoors as well as outdoors.
As a vinyl chloride resin used for the surface layer 4, paste vinyl chloride and / or suspension vinyl chloride is preferable.

  The thickness of the surface layer 4 is not particularly limited, but is, for example, 0.1 mm to 1.0 mm, preferably 0.15 mm to 0.5 mm, and more preferably 0.2 mm to 0.4 mm. .

<Protective layer>
The protective layer 41 is formed of, for example, a layer containing a resin. The protective layer 41 may be colored and transparent, but is preferably colorless and transparent. The protective layer 41 is directly adhered to the surface of the surface layer 4 to protect the surface layer 4. Moreover, the protective layer 41 is non-foaming.
The main component resin for forming the protective layer 41 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 and the like, the protective layer 41 is preferably formed of an ionizing radiation curable resin such as an ultraviolet curable resin.
Electron beam curable resins include unsaturated polyesters such as condensates of unsaturated dicarboxylic acid and polyhydric alcohol, polyester methacrylates, polyether methacrylates, polyol methacrylates, methacrylates such as melamine methacrylate, polyester acrylates, epoxy acrylates, urethanes UV-curable resins such as acrylates, polyether acrylates, polyol acrylates and melamine acrylates can be mentioned.
The protective layer 41 may contain fine particles of alumina or the like because the surface layer 4 is interposed between the colored print layer 5 and the protective layer can be formed after the formation of the concave portion. The protective layer 41 may not contain fine particles. In addition, the protective layer 41 may optionally contain an additive as exemplified in the column of <surface layer>, and in particular, by including a weathering agent, the outermost surface of the interior sheet Improve the weather resistance in
The thickness of the protective layer 41 is not particularly limited, and is, for example, 5 μm to 100 μm, preferably 10 μm to 50 μm. However, the thickness of the protective layer 41 excludes the thickness of the region corresponding to the recess 3.

<Colored printing layer>
The colored print layer 5 is a layer for displaying a color to be a design of the interior sheet. The colored print layer 5 can be formed, for example, by a conventionally known printing ink. The colored printing layer 5 formed from printing ink consists of an ink solidified layer. The colored print layer 5 is directly adhered to the surface of the synthetic resin layer 6. In other words, the colored print layer 5 is laminated between the surface layer 4 and the synthetic resin layer 6.
The colored print layer 5 has a desired design or the like in one color or multiple colors. When the colored print layer 5 is a single color, the single color ink is provided in a solid form, or a single shade of light is applied separately, or a single color ink and a non-ink portion are mixed, or A design can be represented by a method such as a combination of these.
The ink which comprises the coloring printing layer 5 contains coloring agents, such as a pigment or dye, a resin component, and an additive as needed. The resin component of the ink is not particularly limited, and examples thereof include acrylic resins, cellulose resins, urethane resins, and vinyl chloride resins. A relatively soft colored print layer 5 (ink solidified layer) is preferable because the colored print layer 5 is easily stretched when the embossed plate is pressed. As such an ink, a vinyl chloride resin as a resin component is used. Those containing a resin are preferred. Examples of the vinyl chloride resin of the colored printing layer 5 include those described in the column of <surface layer>, and in particular, it is preferable to use paste vinyl chloride or / and suspension vinyl chloride. In addition, the colored print layer 5 may optionally contain an additive as exemplified in the <surface layer> column, and in particular, the colored print layer 5 may contain a weathering agent. Weather resistance is improved.
The thickness of the colored print layer 5 is not particularly limited, but is, for example, 0.2 μm to 20 μm, and preferably 0.4 μm to 10 μm. However, the thickness of the colored print layer 5 excludes the thickness of the region corresponding to the concave portion 3 and refers to the thickness of the colored print layer 5 corresponding to the convex portion described later.

<Synthetic resin layer>
The synthetic resin layer 6 is provided to fix the colored print layer 5. Furthermore, the synthetic resin layer 6 also functions as a background color layer that exhibits the color of the deepest portion 32 of the recess 3.
The synthetic resin layer 6 is directly adhered to the surface of the fiber reinforcing layer 7 (the backing layer 8 when not having the fiber reinforcing layer 7).
The synthetic resin layer 6 is colored transparent or colored opaque, preferably colored opaque. That is, the synthetic resin layer 6 has a color. The color of the synthetic resin layer 6 is different from the color of part or all of the colored print layer 5, preferably different from the entire color of the colored print layer 5. The colored synthetic resin layer 6 different from the color of the colored printing layer 5 is disposed on the back surface side of the colored printing layer 5, whereby the deepest portion 32 of the recess 3 is included in the color caused by the colored printing layer 5. In the above, the color of the synthetic resin layer 6 is exposed, and the concave portion 3 becomes noticeable in appearance.
In addition, the synthetic resin layer 6 may have a color with high brightness compared to the colored print layer 5 or may have a color with low brightness compared to the colored print layer 5. When the synthetic resin layer 6 has a color having a lightness higher than that of the colored print layer 5, the color exposed from the deepest portion 32 of the concave portion 3 becomes prominent in relation to the colored print layer 5.

In addition, although the synthetic resin layer 6 may be foamed, it is preferable that the synthetic resin layer 6 be non-foaming because the colored print layer 5 is easily stretched when the embossed plate is pressed.
In the example of illustration, the synthetic resin layer 6 is comprised from the resin layer of 2 layers (The 1st resin layer 61 and the 2nd resin layer 62 in order from the surface side). Although not particularly shown, the synthetic resin layer 6 may be composed of a single resin layer, or may be composed of three or more resin layers. When the synthetic resin layer 6 is formed of one resin layer, the second resin layer 62 is omitted. When the synthetic resin layer 6 is composed of three or more resin layers, the third and subsequent resin layers are laminated on the back surface of the second resin layer 62.

The first resin layer 61 is directly adhered to the surface of the second resin layer 62, and the second resin layer 62 is the surface of the fiber reinforcing layer 7 (the backing layer 8 when not having the fiber reinforcing layer 7). Directly attached to the The colored print layer 5 is directly adhered to the surface of the first resin layer 61.
At least one of the first resin layer 61 and the second resin layer 62 is colored transparent or colored opaque (that is, it has a color), and is preferably colored opaque. When any one has a color, the synthetic resin layer 6 having a color different from that of the colored print layer 5 can be disposed on the back surface side of the colored print layer 5.
For example, when the first resin layer 61 has a color, the second resin layer 62 may be colorless and transparent, or may be colored and transparent or colored and opaque. When the second resin layer 62 has a color, the first resin layer 61 may be colorless and transparent, or may be colored and transparent or colored and opaque.
Preferably, both the first resin layer 61 and the second resin layer 62 are colored. Even when either of the first resin layer 61 and the second resin layer 62 disappears in the deepest part 32 of the recess 3 because the layers 61 and 62 have a color, the other remains, The color of the synthetic resin layer 6 appears in the deepest part 32 of 3. When each of the first resin layer 61 and the second resin layer 62 has a color, the color thereof is different from the color of a part or all of the colored print layer 5, preferably, the entire color of the colored print layer 5 It is different from Also, in this case, the first resin layer 61 and the second resin layer 62 may have the same color or may have different colors, but the color of one color in the deepest portion 32 of the recess 3 Preferably, both layers 61 and 62 have the same color.
For example, when (a) the first resin layer 61 and the second resin layer 62 have a white color including milky white and the colored print layer 5 has a color other than white, (b) the first resin layer 61 and the second resin layer When 62 shows yellow and colored printing layer 5 shows colors other than yellow, etc. may be mentioned.
The colored first resin layer 61 and the second resin layer 62 can be formed by blending a colorant into the materials for forming them. For example, the white synthetic resin layer 6 can be formed by blending a white pigment such as titanium oxide. When the forming material itself is colored, the first resin layer 61 and the second resin layer 62 may be formed without blending a colorant.

  Although the thickness of the said synthetic resin layer 6 is not specifically limited, For example, they are 100 micrometers-1.2 mm, Preferably they are 200 micrometers-1 mm. Although the thickness of the said 1st resin layer 61 is not specifically limited, For example, they are 20 micrometers-200 micrometers, Preferably they are 30 micrometers-150 micrometers. The thickness of the second resin layer 62 is not particularly limited, but is, for example, 100 μm to 800 μm, and preferably 200 μm to 600 μm. However, the thickness of the first resin layer 61 and the second resin layer 62 excludes the thickness of the portion corresponding to the recess 3.

The synthetic resin layer 6 (the first resin layer 61 and the second resin layer 62) contains a main component resin, and may contain a resin other than the main component resin and various additives as needed. It does not specifically limit as each main component resin of the 1st resin layer 61 and the 2nd resin layer 62, respectively independently, For example, a thermoplastic resin can be used. Specific examples of the thermoplastic resin and the additive include those described in the <surface layer> column. The weather resistance of the synthetic resin layer 6 (the first resin layer 61 and the second resin layer 62) is improved by containing a weathering agent.
The first resin layer 61 and the second resin layer 62 may have the same main component resin, or may have different main component resins, but preferably the same resin is used.
As a main component resin for forming the first resin layer 61 and the second resin layer 62, a vinyl chloride resin is used because both layers easily adhere firmly to each other and deform well when the embossed plate is pressed. Preferably, paste vinyl chloride or / and suspension vinyl chloride is more preferably used.

The second resin layer 62 directly bonded to the surface of the fiber reinforcing layer 7 may be laminated in a state of being impregnated into the fiber reinforcing layer 7. The state in which the fiber reinforcing layer 7 is impregnated means that the material forming the second resin layer 62 enters the inside of the fiber reinforcing layer 7 and adheres to the surroundings of the fibers constituting the fiber reinforcing layer 7. States that exist.
When the second resin layer 62 contains paste vinyl chloride as a main component resin, the fiber reinforcing layer 7 is easily impregnated and adheres firmly around the fibers. Further, since the paste vinyl chloride is excellent in compatibility with suspension vinyl chloride, even when the first resin layer 61 contains suspension vinyl chloride as a main component, the second resin mainly composed of paste vinyl chloride The layer 62 adheres firmly to the first resin layer 61.

Fiber Reinforcement Layer
The fiber reinforcing layer 7 is a layer for increasing the rigidity of the sheet body 2 and for providing the sheet body 2 with dimensional stability. Furthermore, the fiber reinforcing layer 7 also has a function of preventing excessive sinking when pressing the embossing plate at the time of formation of the recess 3. This function makes it possible to more easily create the effects of the present invention when forming the recess 3.
The fiber reinforcing layer 7 is not particularly limited as long as it contains fibers, and non-woven fabric, woven fabric and the like can be mentioned. The material of the fibers constituting the non-woven fabric or the 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. In particular, it is preferable to use a non-woven fabric containing inorganic fibers such as glass fibers or a woven fabric containing inorganic fibers as the fiber-reinforcing layer 7 because it is excellent in the function to prevent sinking. It is more preferable to use a glass mat) or a woven fabric (glass net) containing glass fibers. Among them, a nonwoven fabric containing glass fiber is used because it has a high function to support the pressing force of the embossed plate in a plane and prevent excessive sinking, and furthermore, it becomes difficult to see the fiber in the deepest part 32 of the recess 3. Is particularly preferred.

The thickness of the glass fiber is not particularly limited, and is, for example, 2 μm to 20 μm in diameter, and preferably 5 μm to 15 μm in diameter.
The glass fiber of the non-woven fabric containing glass fiber may be composed of only short fibers, may be composed of only long fibers, or may be composed of a mixture of short fibers and long fibers. A glass nonwoven fabric composed only of short fibers is excellent in dimensional stability, but a glass nonwoven fabric composed of a mixture of short fibers and long fibers is excellent not only in dimensional stability but also in tensile strength. The length of the short fibers is not particularly limited, but is, for example, 5 mm to 30 mm, preferably 10 mm to 15 mm. The length of the long fiber is larger than the length of the short fiber.
Moreover, the fiber which comprises the fiber reinforcement layer 7 may be only glass fiber, and may contain glass fiber and fibers other than this. Examples of fibers other than glass fibers include natural fibers such as pulp, synthetic resin fibers, inorganic fibers other than glass, and the like, with preference given to natural fibers. Although the thickness of natural fibers, such as the said pulp, is not specifically limited, For example, they are 10 micrometers-30 micrometers. In addition, since natural fibers such as pulp are generally mixed with various fiber lengths and fiber diameters in a distributed manner, the thickness of the natural fibers is a central range of the distribution.

Although the thickness of the non-woven fabric or the woven fabric constituting the fiber reinforcing layer 7 is not particularly limited, it is, for example, 0.05 mm to 1 mm, preferably 0.1 mm to 0.5 mm. Also, the basis weight of the nonwoven fabric or woven fabric forming the fiber reinforced layer 7 ^is a ^{10g / m 2 ~100g / m 2} , and ^{preferably, 20g / m 2 ~50g / m} 2.

<Backing layer>
The backing layer 8 is formed of, for example, a resin, rubber or the like.
The backing layer 8 is preferably made of a resin because it is impregnated into the inside of the fiber reinforcing layer 7 and firmly bonded to the fiber reinforcing layer 7. The backing layer 8 may be foamed or non-foamed. From the viewpoint of imparting an appropriate cushioning property to the inner sheet 1, the backing layer 8 is preferably foamed. Although the expansion ratio of the backing layer 8 made of foam is not particularly limited, it is, for example, 1.05 to 2 times, preferably 1.1 to 1.5 times.
The backing layer 8 contains a main component resin, and may optionally contain resins other than the main component resin and various additives. The main component resin of the backing layer 8 is not particularly limited, and, for example, a thermoplastic resin can be used. Specific examples of the thermoplastic resin and the additive include those described in the <surface layer> column.
As a main component resin for forming the backing layer 8, a vinyl chloride resin is preferable because it is excellent in flexibility.
Although the thickness of the said backing layer 8 is not specifically limited, For example, they are 0.5 mm-7 mm, Preferably they are 1 mm-3 mm.
Although not particularly illustrated, a reinforcing layer may be provided on the back surface of the backing layer 8 or in the middle of the backing layer 8. A non-woven fabric or a woven fabric is used as the reinforcing layer.

[Concave part]
A recess 3 is formed on the surface of the sheet main body 2.
The recess 3 is a portion recessed in the thickness direction relative to the surface of the sheet main body 2. The recess 3 is a recessed portion based on the surface of the sheet main body 2. When the recess 3 is used as a reference, the recess 3 can be said to be a portion sandwiched by the protrusions. That is, asperity is a relative concept, and in the following, the surface of the sheet main body 2 other than the recess may be referred to as a “convex” in relation to the recess 3.
As shown in FIG. 1, the recess 3 may be formed in a predetermined direction in a straight line in a plan view, or may be formed in a bent shape in a plan view, a curved shape in a plan view, an irregular shape in a plan view, etc. . In the illustrated example, in plan view, it has a recess 3 extending linearly in the first direction and a recess 3 extending linearly in the second direction, and the recess 3 extending in the first direction extends in the second direction The recess 3 is formed to intersect with the recess 3 in a T-shape. However, the plan view shape of the recess 3 is not limited to the illustrated example.

As shown in FIG. 2 and FIG. 3, the recess 3 is composed of a recess slope 31 and a deepest portion 32. The deepest portion 32 is the bottom of the recess 3 and refers to the deepest portion of the recess 3. The recessed inclined portion 31 is a portion between the convex portion 2 a and the deepest portion 32 and is inclined with respect to the horizontal direction in a cross sectional view. The depression slopes 31 face each other on both sides of the deepest portion 32. The facing concave slopes 31 may be symmetrical as in the illustrated example, or may be asymmetric. Due to the symmetrical shape, one concave slope 31 is less noticeable than the other concave slope 31.
The recessed inclined portion 31 may be generally linear in a cross sectional view, may be curved in a cross sectional view as a whole, may be polygonal in a cross sectional view, or is linear It may be a cross-sectional view shape in which the curved line and the curved line are combined. As for the cross-sectional curved shape, there are a curved shape that bulges inward and a curved shape that bulges outward, but preferably, it is a curved shape that bulges outward as shown in FIGS. 2 and 3. In addition, the concave slope 31 having a linear shape in a cross sectional view generally forms a plane in three dimensions, and the concave slope 31 having a curved shape in a cross sectional shape generally forms a curved surface in three dimensions. In a three-dimensional view, the concave inclined portion 31 having a polygonal shape in cross-sectional view forms a polygonal surface in which a plurality of flat surfaces intersect at an obtuse angle.

Here, FIG. 4 shows the recessed part 3 in which the recessed inclined part 31 is entirely formed in cross sectional view linear shape.
Preferably, the recess slope portion 31 is formed in a cross-sectional view shape in which a linear shape and a curved shape are combined as shown in FIG. 3 or a cross-sectional view shape as a whole as shown in FIG.
Curved concave sloped portion 31 is continuous with convex portion 2a and has curved start end portion 311 starting to be recessed from convex portion 2a to the back side, middle portion 312 greatly curved, and deepest portion from middle portion 312 32 and the end portion 313 which continues. The curvature of the start end portion 311 is smaller than the curvature of the middle portion 312 in a cross sectional view. The end portion 313 is formed in a straight line in cross section.
Referring to FIG. 4, the concaved inclined portion 31 which is generally linear in cross-sectional view includes the linear end portion 313 in cross-sectional view as described above. That is, the concave inclined portion 31 which is generally linear in cross section is continuous with the convex portion 2a and starts from the convex portion 2a to the back surface side, and the linear start end 311 and the start end 311 are continuous with the start end A straight intermediate portion 312 having the same inclination angle as 311, and a linear end portion 313 continuous to the intermediate portion 312 and having the same inclination angle as the intermediate portion 312, and conceptually, a linear end portion 313 is extended to the convex part 2a.
Although not shown in particular, the polygonal recess slope 31 includes the straight start end 311, the middle end 312, the end end 313, etc. in the cross sectional view as described above, and these continuously draw different arcs. It is what you are doing.

The deepest portion 32 is formed, for example, in a linear shape in cross-sectional view, and more preferably in a linear shape in cross-sectional view extending in the horizontal direction. The deepest portion 32 having a linear shape in a cross-sectional view three-dimensionally forms a band-like flat surface having a predetermined width. By forming the deepest portion 32 in a linear shape in cross section, the color exposed from the deepest portion 32 is easily noticeable from the appearance.
In the recess 3, when the end portion 313 of the recessed inclined portion 31 and the deepest portion 32 are formed in a linear shape in a cross sectional view, an angle α (see FIGS. 3 and 4) between the end portion 313 and the deepest portion 32 is 90 degrees-140 degrees are preferable, 95 degrees-125 degrees are more preferable, and 100 degrees-110 degrees are further more preferable. By setting the angle to 90 degrees or more, when forming the recessed portion 3 using the embossed plate, stress concentration hardly occurs at the boundary between the recessed slope portion 31 and the deepest portion 32, and material breakage can be suppressed. In addition, when the angle is larger than 140 degrees, the dented inclined portion 31 is likely to be noticeable, and the design may be deteriorated.
In addition, the shape of the deepest part 32 of the recessed part 3 is not limited to a flat surface, A curved surface may be sufficient. However, it is preferable that the deepest portion 32 be a flat surface because pressure can be applied more uniformly when forming the recess 3 by the embossing plate.

With reference to FIG. 2, the depth 3D of the recess 3 is not particularly limited, but is preferably 0.8 mm or more and more preferably more than 0.8 mm from the viewpoint that the color exposed from the deepest portion 32 is easily noticeable Preferably, it is more preferably 0.9 mm or more, and particularly preferably 1 mm or more. In addition, since the colored print layer corresponding to the recessed inclined portion 31 can be formed in a thin-walled shape, the depth 3D of the recessed portion 3 is preferably 1.5 mm or less, more preferably less than 1.5 mm, and further 1.4 mm. The following is more preferable, and 1.3 mm or less is particularly preferable.
The width 32W of the deepest portion 32 of the recess 3 is not particularly limited, but is preferably 0.5 mm to 3 mm, and more preferably 1 mm to 2 mm.
Further, the width 31W of the recess slope 31 of the recess 3 is not particularly limited, but is preferably 0.5 mm to 2 mm, and more preferably 1 mm to 1.5 mm.
In the illustrated example, the surface of the convex portion 2 a is flat, but if necessary, the convex portion 2 a may be formed with a recessed portion whose depth is clearly smaller than that of the concave portion 3 (see FIG. Not shown). For example, on the surface of the convex portion 2a, a pattern composed of fine dents such as a satin pattern may be formed.

FIG.2 and FIG.3 is sectional drawing which shows the form of the coloring printing layer of the area | region corresponding to a recessed part of the interior sheet of 1st Embodiment.
In FIG. 2 and FIG. 3, the colored print layer 5 of the interior sheet 1 of the first embodiment is formed thinner toward the deepest portion 32 in the region corresponding to the recess slope 31 of the recess 3. The colored print layer 5 is formed to be the thinnest in the region corresponding to the deepest portion 32 of the recess 3. Hereinafter, the gradually formed portion of the region corresponding to the recess slope portion 31 of the recess 3 is referred to as a gradually decreasing portion, and the portion formed the thinnest portion of the region corresponding to the deepest portion 32 of the recess 3 is the thinnest portion It is said. Therefore, the colored print layer 5 has the gradually decreasing portion 51 and the thinnest portion 52 corresponding to the recess 3.
The thickness of the gradually decreasing portion 51 and the thickness of the thinnest portion 52 are smaller than the thickness of the colored print layer 5 corresponding to the convex portion 2 a.
One end of the gradual reduction portion 51 is continuously provided to the colored print layer 5 corresponding to the convex portion 2 a, and the other end of the gradual decrease portion 51 is continuously provided to the thinnest portion 52. The thickness of the gradually decreasing portion 51 gradually decreases toward the deepest portion 32 from the convex portion 2 a to the concave portion 31.
The thinnest portion 52 is in the form of a very thin film, and extends to the back side of the deepest portion 32 of the recess 3. In addition, since the thinnest portion 52 is a very thin film as described above, in addition to the case where it is present in a solid shape without holes, when viewed microscopically, pinholes are partially generated. Please note that there are cases.
The thickness of the thinnest part 52 of the colored print layer 5 is the thickness of the colored print layer 5 corresponding to the convex part 2a × 0.05 times to × 0.3 times, and preferably, the colored print corresponding to the convex part 2a Thickness of layer 5 × 0.1 times to × 0.2 times.

The surface layer 4 and the synthetic resin layer 6 (the first resin layer 61 and the second resin layer 62) are formed in a thin shape in the region corresponding to the recess 3. That is, the thicknesses of the surface layer 4 and the synthetic resin layer 6 (the first resin layer 61 and the second resin layer 62) in the region corresponding to the recess 3 are smaller than those in the region corresponding to the protrusion 2a. It is done.
Moreover, since the protective layer 41 is laminated after forming the recessed part 3 according to the manufacturing method mentioned later, the thickness of the protective layer 41 is substantially equal on the whole.
The surface layer 4 may not be substantially present in the region corresponding to the recess 3 (although it may be substantially eliminated in the recess formation process), but the water resistance and the antifouling in the recess 3 may be eliminated. From the viewpoint of properties, it is preferable that the surface layer 4 be present in the region corresponding to the recess 3 as described above.
Further, either one of the first resin layer 61 and the second resin layer 62 may not be substantially present in the region corresponding to the recess 3 (even if it is substantially eliminated in the recess formation process) Good).

  FIG.5 and FIG.6 is sectional drawing which shows the form of the coloring printing layer of the area | region corresponding to a recessed part of the interior sheet of 2nd Embodiment. The plan view of the interior sheet of the second embodiment is omitted because it is the same as that of the first embodiment. 5 and 6 are cross-sectional views of the interior sheet of the second embodiment taken along the same line as II-II in FIG.

In FIG. 5 and FIG. 6, the colored print layer 5 of the interior sheet 1 of the second embodiment is a gradually decreasing portion 51 formed in a thinner shape toward the deepest portion 32 in a region corresponding to the recess slope 31 of the recess 3. Have. In the second embodiment, the region corresponding to the deepest portion 32 of the recess 3 does not have a colored print layer.
Specifically, in the region corresponding to the two concave slopes 31, the colored print layer 5 is formed to be thinner toward the deepest portion 32 (that is, has the gradually decreasing portion 51). The thickness of the gradually decreasing portion 51 is smaller than the thickness of the colored print layer 5 corresponding to the convex portion 2 a. One end of the gradual reduction portion 51 is connected to the colored print layer 5 corresponding to the convex portion 2a, and the other end of the gradual reduction portion 51 is sharp. The other ends of the two taper portions 51 face each other at positions corresponding to both sides of the deepest portion 32 of the recess 3, and no colored print layer is provided between the other ends of the two taper portions 51.
The protective layer 41, the surface layer 4, and the synthetic resin layer 6 (the first resin layer 61 and the second resin layer 62) of the interior sheet 1 of the second embodiment are the same as those of the first embodiment.

In the interior sheet 1 of the present invention, the boundary between the deepest portion 32 of the recess 3 and the recessed inclined portion 31 is less noticeable, and the color exposed from the deepest portion 32 of the recess 3 is naturally taken into the design of the colored print layer 5 Have an elegant appearance. The interior sheet 1 is excellent in decorativeness because the color of the concave portion 3 and the color print layer 5 is integrated to form a design.
Specifically, in the interior sheet 1 of the first embodiment and the second embodiment, the colored print layer 5 has the gradually decreasing portion 51 in the region corresponding to the concave slope 31 of the recess 3. Since the gradually decreasing portion 51 of the colored print layer 5 is positioned corresponding to the depressed inclined portion 31, the color of the colored print layer 5 gradually changes in the depressed inclined portion 31. The boundary of the deepest portion 32 is inconspicuous and gives a natural feeling. On the other hand, in the deepest part 32, since the color of the synthetic resin layer 6 is exposed, the presence of the concave part 3 is noticeable, and the color of the deepest part 32 and the color of the colored print layer 5 can constitute a design with one unit. .
In the interior sheet 1 of the first embodiment, the thinnest portion 52 of the colored print layer 5 extends in a region corresponding to the deepest portion 32 of the concave portion 3, but the thinnest portion 52 is very thin. Color of the colored print layer 5 disappears, and the color of the synthetic resin layer 6 (the first resin layer 61 or the second resin layer 62) located on the back surface side of the thinnest portion 52 is exposed at the deepest portion 32 of the recess 3 You will come to Since the interior sheet 1 of the second embodiment does not have the colored print layer 5 in the region corresponding to the deepest portion 32 of the recess 3, the synthetic resin layer 6 (first resin layer) located on the back surface side of the thinnest portion 52 The color of the resin 61 or the second resin layer 62 comes to be exposed at the deepest portion 32 of the recess 3.
The interior sheet 1 of the present invention having a design in which the color expressed from the deepest portion 32 is naturally taken into the colored printing layer 5 is, for example, a range surrounded by the recess 3 as shown in FIG. By forming the recess 3 so as to form a rectangular or square in plan view, the tile has a tiled appearance.

[Method of manufacturing interior sheet]
The interior sheet of the present invention is prepared, for example, in the order of preparing a laminate having a surface layer, a colored print layer, a synthetic resin layer and a fiber reinforcing layer in this order from the surface side, an embossed plate having embossing projections from the surface side of the laminate And pressing on the surface of the laminate to form a recessed portion composed of a recessed slope portion and a deepest portion, and in the embossing step, the thickness of the colored print layer is from the recessed slope portion It is obtained by forming the recess while stretching the colored print layer so as to be gradually thinner toward the deepest part.
As mentioned above, although the surface layer 4 etc. can be formed using various resin, the manufacturing method of the interior sheet 1 using vinyl chloride type resin is demonstrated concretely here.

<When using paste vinyl chloride>
(Preparation process)
As a method of forming the colored printing layer 5, a method using a printed film in which the colored printing layer 5 is printed on a resin film such as a vinyl chloride resin (referred to as a first method) After forming the first resin layer 61, there is a method (referred to as a second method) of printing or transferring the colored print layer 5 on the surface of the first resin layer 61.

First Method On one surface of the fiber reinforcing layer 7, for example, a vinyl chloride paste (forming material of the backing layer 8) composed of a mixture of paste vinyl chloride, a plasticizer, a filler, a foaming agent, etc. Coat. Furthermore, after forming a layer by applying a vinyl chloride paste (forming material of the second resin layer 62) made of a mixture of paste vinyl chloride, a plasticizer, a filler and the like on the other surface of the fiber reinforcing layer 7, for example Pregelatize at 120 ° C to 140 ° C.
Next, the printed film is laminated on the surface of the second resin layer 62. The printed film is obtained by printing the colored print layer 5 on a resin film such as a vinyl chloride resin, and the resin film becomes the first resin layer 61. Although printing can be performed using well-known printing methods, such as gravure and rotary printing, since control of thickness is easy and design expression is also excellent, gravure is preferable.
After laminating the resin film surface of the printed film on the surface of the second resin layer 62, for example, vinyl chloride comprising a mixture of paste vinyl chloride, a plasticizer, a filler and the like on the surface of the colored print layer 5 After the paste (the forming material of the surface layer 4) is applied to form a layer, it is pregelled again at 130 ° C. to 150 ° C. and the forming material of the backing layer 8 is foamed.

Second Method On one surface of the fiber reinforcing layer 7, for example, a vinyl chloride paste (forming material of the backing layer 8) composed of a mixture of paste vinyl chloride, a plasticizer, a filler, a foaming agent, etc. Coat. Furthermore, a vinyl chloride paste (forming material of the second resin layer 62) made of, for example, a mixture of paste vinyl chloride, a plasticizer, a filler and the like is applied to the other surface of the fiber reinforcing layer 7 to form a layer. Further, a vinyl chloride paste (forming material of the first resin layer 61) formed of a mixture of paste vinyl chloride, a plasticizer, a filler and the like is applied thereon to form a layer, and then 120 ° C. to 140 Pregelatize at ° C.
Next, ink is printed on the surface of the first resin layer 61 to form the colored print layer 5. Although printing can be performed using well-known printing methods, such as gravure and rotary printing, since control of thickness is easy and design expression is also excellent, gravure is preferable. Instead of such direct printing, a transfer film provided with the colored print layer 5 may be attached to the surface of the first resin layer 61 to transfer only the colored print layer 5.
After the colored print layer 5 is formed, a polyvinyl chloride paste (forming material of the surface layer 4) made of, for example, a mixture of paste vinyl chloride, a plasticizer, a filler and the like is applied on the surface to form a layer , And the material for forming the backing layer 8 is foamed while pregelling again at 130 ° C to 150 ° C.
In this manner, the laminate 10 including the surface layer 4 / the colored print layer 5 / the first resin layer 61 / the second resin layer 62 / the fiber reinforcing layer 7 / the backing layer 8 is formed in this order from the surface side (see FIG. 7). ).

(Emboss process)
From the surface side of the laminate 10, the embossing plate 9 having the embossing projections 91 is pressed in the thickness direction of the laminate 10. For example, an embossing roller can be used as the embossing plate 9. The embossed protrusion 91 preferably has a shape corresponding to the shape of the recess 3. For example, as shown in the drawing, a convex end surface portion 911 which is an end corresponding to the deepest portion 32 and formed flatly And a convex side surface portion 912 which is a side portion corresponding to the recessed inclined portion 31 and is formed in a curved shape.
When pressing the embossing plate 9, as shown in FIG. 8, the embossing plate 9 is pressed while stretching the colored print layer 5 by the embossing protrusions 91.
After the depressions 3 are formed on the surface of the laminate 10 by pressing the embossing plate 9, the entire laminate 10 is heated at 160 ° C. to 200 ° C. to gelate the vinyl chloride paste.
Finally, the material for forming the protective layer 41 (ultraviolet curable resin or the like) is coated on the surface of the laminate 10, and the material is cured to obtain the interior sheet 1.

<When using suspension vinyl chloride>
In addition, the laminated body 10 can also be formed using suspension vinyl chloride other than the manufacturing method using the paste vinyl chloride mentioned above.

(Preparation process)
For example, a vinyl chloride paste (forming material of the second resin layer 62) consisting of a mixture of paste vinyl chloride, a plasticizer, a filler, a foaming agent and the like is applied to one surface of the fiber reinforcing layer 7 by an appropriate coater. After forming into a layer, it is pregelled at 120 ° C. to 140 ° C., and the polyvinyl chloride paste is integrated in the state of being impregnated in the fiber reinforcing layer 7. In this manner, an intermediate laminate in which the second resin layer 62 is laminated on the other surface of the fiber reinforcing layer 7 is prepared.
On the other hand, the sheet-like surface layer 4 and the backing layer 8 are formed using suspension vinyl chloride. The formation method of these is not specifically limited, For example, a calendar method, a melt extrusion method, a solution casting method etc. are mentioned.

Next, the resin film surface of the printed film is laminated on the surface of the second resin layer 62 of the intermediate laminate, and the sheet-like surface layer 4 is laminated thereon. The sheet-like backing layer 8 is laminated on the surface of the fiber reinforcing layer 7 of the intermediate laminate. These are heated and pressurized to integrate the respective layers to form the laminate 10. Examples of a method of bonding the layers by heating and pressing include a laminating method, a calendar molding method, and a continuous pressing method. Among them, a method of continuously joining the laminate by heating and pressing with a roll, such as a lamination method and a calendar molding method, is preferable because many products can be produced at one time. In particular, the laminating method can be suitably applied because many laminates can be joined at one time. The heating temperature and pressure of the laminating method are appropriately set according to known processing methods. For example, the heating temperature of the laminate 10 is 140 ° C. to 200 DEG ° C., the pressure between the rolls ^{is 20kgf / cm 2 ~100kgf / cm 2} .
In addition, as a printed film, what was demonstrated to the above-mentioned <when paste vinyl chloride is used> can be used.
In this manner, the laminate 10 including the surface layer 4 / the colored print layer 5 / the first resin layer 61 / the second resin layer 62 / the fiber reinforcing layer 7 / the backing layer 8 is formed in this order from the surface side (see FIG. 7). ).

(Emboss process)
The embossed plate is pressed against the obtained laminate 10 in the same manner as in the case of using the above-mentioned <Paste vinyl chloride>, and the material for forming the protective layer 41 (ultraviolet curable resin etc.) is coated, The interior sheet 1 can be obtained by curing.

[Use of interior sheet]
The interior sheet 1 of the present invention is constructed on a construction surface such as a floor surface, a wall surface and a ceiling surface of a building. The attachment method with respect to the construction surface of the interior sheet 1 is not specifically limited, For example, sticking the back surface of the interior sheet 1 to a construction surface etc. using an adhesive agent etc. is mentioned.
In particular, according to the present invention, since the interior sheet 1 having a tiled appearance can be easily configured, it is suitable as a floor sheet or wall sheet constructed on a floor surface or wall surface such as a kitchen or bathroom.
In addition, the interior sheet 1 of the present invention may be constructed on a new construction surface, or may be constructed on an existing construction surface such as remodeling.
The interior sheet 1 of the present invention can be used as a floor material, a wall material, a ceiling material, etc., and in particular, can be suitably used as a floor material or a wall material. Moreover, in order to form the recessed part 3, since thickness is large enough, it is most suitable to use the interior sheet 1 of this invention as a flooring.

  Hereinafter, the present invention will be described in more detail by way of examples. However, the present invention is not limited to the following examples.

[Material used]
-Printed film Product name "Printed film for long polyvinyl chloride sheet".
A black ink (as a binder resin) on the surface of a 120 μm thick vinyl chloride resin-made white film (a film containing a vinyl chloride resin as a main component resin, titanium oxide as a white pigment and an ultraviolet absorber as a weathering agent) (A solvent volatile type ink) containing a vinyl chloride resin of the present invention, carbon black as a black pigment, and an ultraviolet absorber as a weathering agent, printed in a solid state by a gravure printing method. The thickness of the black print layer is about 12 μm.
-Suspension "PVC" made by Kaneka Corporation. Degree of polymerization: 1050, K value: 67.

Example 1
By adding a suitable amount of a benzophenone series ultraviolet absorber as a weathering agent to the above suspension vinyl chloride and subjecting it to calendering using a general-purpose calendering machine, the thickness: 0.28 mm, length: 100 cm, width: 100 cm A sheet-like transparent surface was prepared.
Separately, a suspension obtained by adding a suitable amount of white pigment, black pigment, calcium carbonate and stabilizer to the above-mentioned suspension vinyl chloride is extruded using a general-purpose extruder, and the thickness: 2 mm, length: 100 cm, width: A 100 cm sheet of gray backing layer was made.
The printed film was used as a colored printing layer and a synthetic resin layer.
The film surface of the printed film was laminated on the surface of the backing layer, and the surface layer was laminated on the surface of the printed layer of the printed film to constitute a laminate. While heating this laminated body to 180 ° C., an embossed plate (see FIG. 9) having embossed projections heated to 180 ° C. on the surface of the synthetic resin layer of the laminated body with a pressure of 4 kgf / cm ² with a press By continuing pressing for 120 seconds, the respective layers were integrated and at the same time a recess was formed. Thereafter, the embossed plate was pulled apart to produce an interior sheet having a concave portion having a concave portion and a deepest portion.

The embossed plate has an embossed protrusion protruding from the smooth surface. In FIG. 9, for convenience, innumerable dots are added to the portion corresponding to the embossed protrusion.
The emboss projection has a flat convex end face and a convex side face extended from both sides of the convex end face on the surface of the embossed plate in a curved shape in a cross sectional view (three-dimensionally curved). Of the convex side surface portion, a portion near the convex end surface portion is formed in a linear shape (three-dimensionally planar) substantially orthogonal to the convex end surface portion. The embossed projections are formed in a linear shape in plan view, and the two convex side surface portions are formed symmetrically with respect to the convex end surface portion.
In Example 1, an embossed plate was used in which the width A of the convex end face portion is 1 mm, the length B between the base ends of the two convex side portions is 4 mm, and the height C of the embossed projections is 0.8 mm. .

A part of the interior sheet of Example 1 was cut, and the part was enlarged and imaged to confirm the state of the recess.
The recesses formed on the surface of the interior sheet of Example 1 had a shape corresponding to the embossed projections used, and had curved and straight concave slopes as shown in FIG. . Moreover, when the depth of the recessed part and the width | variety of the deepest part were measured, as shown in Table 1, it corresponded to the dimension of the embossing protrusion.
The colored print layer in the area corresponding to the concaved inclined portion was gradually formed thinner toward the deepest portion. Moreover, the colored printing layer (thinnest part) in the area | region corresponding to the deepest part was formed in about 10 micrometers.

Example 2
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossing plate having embossing projections as shown in FIG. 10 was used.
In the embossed plate of Example 2, embossed projections are provided on a smooth surface. In FIG. 10, for the sake of convenience, innumerable dots are added to the portions corresponding to the embossed protrusions.
The embossed protrusion has a flat convex end face portion and a convex side face portion extended linearly on the surface of the embossed plate from both sides of the convex end face portion. The two convex side surface portions are formed symmetrically with the convex end surface portion interposed therebetween.
In Example 2, an embossed plate in which the width A of the convex end face portion is 1 mm, the length B between the base ends of the two convex side portions is 4 mm, and the height C of the embossed projections is 0.9 mm .

A part of the interior sheet of Example 2 was cut, and the part was enlarged and imaged to confirm the state of the recess.
The concave portion formed on the surface of the interior sheet of Example 2 had a shape corresponding to the used embossed protrusion, and had a concave slope having a linear cross-sectional view as shown in FIG. Moreover, when the depth of the recessed part and the width | variety of the deepest part were measured, as shown in Table 1, it corresponded to the dimension of the embossing protrusion.
The colored print layer in the area corresponding to the concaved inclined portion was gradually formed thinner toward the deepest portion. Moreover, the colored printing layer (thinnest part) in the area | region corresponding to the deepest part was formed in about 7 micrometers.

[Example 3]
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossing plate having embossing projections as shown in FIG. 10 was used.
In Example 3, the width A of the convex end face shown in FIG. 10 is 2 mm, the length B between the base ends of the two convex side faces is 4 mm, and the height C of the embossed protrusion is 0.9 mm. I used the version.

Also in the interior sheet of Example 3, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, and had a concave slope having a linear cross-sectional view, and the depth of the recess and The width of the deepest portion corresponded to the dimension of the embossed protrusion as shown in Table 1.
The colored print layer in the area corresponding to the concaved inclined portion was gradually formed thinner toward the deepest portion. Moreover, the colored printing layer in the area | region corresponding to the deepest part was formed in about 7 micrometers.

Example 4
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossing plate having embossing projections as shown in FIG. 9 was used.
In Example 4, an embossed plate having a width A of the convex end face shown in FIG. 9 of 1 mm, a length B between the base ends of the two convex side faces of 4 mm, and a height C of the embossed protrusion of 1 mm. used.

Also in the interior sheet of Example 4, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, and had a concaved portion with a curved shape and a linear cross-sectional view, The depth and the width of the deepest portion corresponded to the dimensions of the embossed protrusions as shown in Table 1.
The colored print layer in the area corresponding to the concaved inclined portion was gradually formed thinner toward the deepest portion. Moreover, the colored printing layer in the area | region corresponding to the deepest part was formed in about 4-6 micrometers.

[Example 5]
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossing plate having embossing projections as shown in FIG. 10 was used.
In Example 5, the width A of the convex end face shown in FIG. 10 is 1 mm, the length B between the base ends of the two convex side faces is 4 mm, and the height C of the embossed protrusion is 1.2 mm. I used the version.

Also in the interior sheet of Example 5, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, and had a concave slope having a linear cross-sectional view, and the depth of the recess and The width of the deepest portion corresponded to the dimension of the embossed protrusion as shown in Table 1.
The colored print layer in the area corresponding to the concaved inclined portion was gradually formed thinner toward the deepest portion. Moreover, the colored printing layer in the area | region corresponding to the deepest part was formed in about 1-3 micrometers.

[Example 6]
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossing plate having embossing projections as shown in FIG. 9 was used.
In Example 6, the width A of the convex end face portion shown in FIG. 9 is 1 mm, the length B between the base ends of the two convex side portions is 4 mm, and the height C of the embossed protrusion is 1.2 mm. I used the version.

Also in the interior sheet of Example 6, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, and had a concaved portion with a curvilinear shape and a linear cross-sectional view; The depth and the width of the deepest portion corresponded to the dimensions of the embossed protrusions as shown in Table 1.
The colored print layer in the area corresponding to the concaved inclined portion was gradually formed thinner toward the deepest portion. Moreover, the colored printing layer in the area | region corresponding to the deepest part was formed in about 1-3 micrometers.

[Example 7]
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossing plate having embossing projections as shown in FIG. 10 was used.
In Example 7, the width A of the convex end face shown in FIG. 10 is 2 mm, the length B between the base ends of the two convex side faces is 4 mm, and the height C of the embossed protrusion is 1.2 mm. I used the version.

Also in the interior sheet of Example 7, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, and had a concave slope having a linear cross-sectional view, and the depth of the recess and The width of the deepest portion corresponded to the dimension of the embossed protrusion as shown in Table 1.
The colored print layer in the area corresponding to the concaved inclined portion was gradually formed thinner toward the deepest portion. Moreover, the colored printing layer in the area | region corresponding to the deepest part was formed in about 1-3 micrometers.

Comparative Example 1
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossing plate having embossing projections as shown in FIG. 9 was used.
In Comparative Example 1, embossing is performed in which the width A of the convex end face shown in FIG. 9 is 1 mm, the length B between the base ends of the two convex side faces is 4 mm, and the height C of the embossed protrusion is 0.7 mm. I used the version.

Also in the interior sheet of Comparative Example 1, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, and had a concaved portion with a curved shape and a linear cross-sectional view, The depth and the width of the deepest portion corresponded to the dimensions of the embossed protrusions as shown in Table 1.
The colored print layer in the area corresponding to the recessed slope portion had substantially the same thickness as the colored print layer in the area corresponding to the convex portion. Further, in the region corresponding to the deepest portion, the colored print layer was present, and the thickness of the colored print layer corresponding to the deepest portion was substantially the same as the thickness of the colored print layer in the region corresponding to the convex portion. That is, the colored printing layer was almost constant throughout.

Comparative Example 2
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossing plate having embossing projections as shown in FIG. 10 was used.
In Comparative Example 2, the width A of the convex end face shown in FIG. 10 is 1 mm, the length B between the base ends of the two convex side faces is 4 mm, and the height C of the embossed protrusion is 1.5 mm. I used the version.

Also in the interior sheet of Comparative Example 2, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, and had a concave slope having a linear cross-sectional view, and the depth of the recess and The width of the deepest portion corresponded to the dimension of the embossed protrusion as shown in Table 1.
The colored print layer in the area corresponding to the dented slope portion was torn, and the torn end face was confirmed. Moreover, in the area | region corresponding to the deepest part, the colored printing layer did not exist (The thickness of the colored printing layer was almost constant in the location where the colored printing layer exists).

Comparative Example 3
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossing plate having embossing projections as shown in FIG. 10 was used.
In Comparative Example 3, the width A of the convex end face portion shown in FIG. 10 is 2 mm, the length B between the base ends of the two convex side portions is 4 mm, and the height C of the embossed protrusion is 1.5 mm. I used the version.

Also in the interior sheet of Comparative Example 3, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, and had a concave slope portion having a linear cross-sectional view, and the depth of the recess and The width of the deepest portion corresponded to the dimension of the embossed protrusion as shown in Table 1.
The colored print layer in the area corresponding to the dented slope portion was torn, and the torn end face was confirmed. Moreover, in the area | region corresponding to the deepest part, the colored printing layer did not exist (The thickness of the colored printing layer was almost constant in the location where the colored printing layer exists).

[Appearance observation]
The interior sheet of each of the examples and the comparative examples was placed on a horizontal desk, and the surface of the interior sheet was visually observed from a position of about 50 cm immediately above.
The results are shown in Table 1. The symbols in the column of appearance in Table 1 are as follows.
○ 1: The deepest part of the concave part looks clear white, the convex part (the surface of the interior sheet other than the concave part) looks black, and the color changes gently from black to white in the dent slope part, a natural feeling design It had become.
○ 2: The deepest part of the concave part looks white, the convex part looks black, and the color changes gently from black to white in the dented slope part, and the design has a natural feeling.
○ 3: The deepest part of the concave part appeared slightly grayish white, and the color gradually changed from black to white at the concave slope, and the design was a natural feeling.
X1: The indented portion and the deepest portion of the recessed portion appeared black, and the interior sheet had a black overall design.
X2: The deepest portion of the concave portion appeared to be clear white, but the black and white boundaries were noticeable in the concave slope portion.

[Weatherability test]
JIS A 1415 “Method of exposure test of polymer building materials with laboratory light source” was conducted. Specifically, the inner sheet of each of the examples and the comparative examples was cut into a length × width = 300 mm × 300 mm including a recess to prepare a test piece. Using this test piece, use a xenon arc lamp according to JIS K 7350-2 defined under “Test method for exposure of polymer building materials with a laboratory light source using a laboratory light source” under prescribed conditions ( The exposure test was carried out at a black panel temperature of 63 ± 3 ° C. and a spray cycle of 102 minutes irradiation followed by 18 minutes irradiation and water spray). The specimens were exposed for 4000 hours. After the exposure, the appearance change of the test piece was observed. Gray scale for color change was used to determine the appearance change.
The results are shown in Table 1. In the column of the appearance in Table 1, "o" indicates that there is performance of grade 4 or higher, "△" indicates that it is grade 3 and "x" indicates that it is class 2 or lower.

[Evaluation]
Although the interior sheets of Examples 5 to 7 were excellent in appearance, the interior sheets of Examples 2 to 4 were excellent in consideration of the appearance and light resistance. As in Examples 1 to 7, by setting the depth of the recess to 1.2 mm or less (in particular, 1 mm or less as in Examples 1 to 4), the interior sheet in which the color changes gently in the recess slope portion It was obtained.
In the interior sheets of Examples 5 to 7, the thickness of the surface layer and the colored print layer in the recessed portion is smaller than that of Examples 2 to 4, and it is presumed that the weatherability is lowered.

  The interior sheet of the present invention can be used for flooring materials, wall materials, ceiling materials, etc. of various buildings such as general houses, office buildings, hotels, apartments, commercial facilities and the like.

DESCRIPTION OF SYMBOLS 1 interior sheet 2 sheet main body 3 recessed part 31 dented inclined part 32 deepest part 4 surface layer 5 coloring printing layer 51 gradual decrease part of coloring printing layer 52 thinnest part of coloring printing layer 6 synthetic resin layer 7 fiber reinforcement layer 8 backing layer 9 embossing plate

Claims (6)

From the surface side, it has a sheet main body having a surface layer, a colored print layer and a synthetic resin layer, and a concave portion formed on the surface of the sheet main body and constituted by a concave slope portion and a deepest portion
The synthetic resin layer has a color different from that of part or all of the colored print layer,
The interior sheet, wherein the colored print layer has a gradually decreasing portion formed in a gradually thinner shape toward the deepest portion in a region corresponding to a recess slope portion of the recess. The synthetic resin layer has a first resin layer laminated on the back surface side of the colored print layer, and a second resin layer laminated on the back surface side of the first resin layer,
The interior sheet according to claim 1, wherein a fiber reinforced layer is laminated on the back surface side of the second resin layer.   The interior sheet according to claim 1, wherein the colored print layer has a thinnest portion formed thinnest in a region corresponding to the deepest portion of the concave portion.   The interior sheet of Claim 1 or 2 which does not have a colored printing layer in the area | region corresponding to the deepest part of the said recessed part.   The interior sheet according to any one of claims 1 to 4, wherein the surface layer is substantially free of fine particles. Preparing a laminate having a surface layer, a colored print layer and a synthetic resin layer in this order from the surface side,
The embossing process which presses the embossing plate which has an embossing protrusion from the surface side of the said laminated body, and forms the recessed part comprised from a dent inclination part and the deepest part in the surface of the said laminated body,
A manufacturing method of an interior sheet which extends the coloring printing layer and forms the crevice so that thickness of the coloring printing layer may become thin gradually toward the deepest part from the depression slope part in the embossing process.

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