JP2019157584A - Interior material and manufacturing method of the same - Google Patents

Abstract

To provide an interior material which has sufficient strength and in which clear pattern is exhibited.SOLUTION: An interior material 1 of this invention includes a sheet body 2 including a part in which a plurality of small lumps 6 containing vinyl chloride composition are aggregated on a surface side. The small lump 6 includes: a colored portion; and an uncolored portion or a colored portion with different color from that of the colored portion. The small lump includes: first small lump 61 in which two portions are exhibited in a stripe pattern; and second small lump 62 which includes a colored portion with different color from that of the colored portion of the first small lump and an uncolored portion or a colored portion with different color from that of the colored portion and in which the two portions are exhibited in a stripe pattern. The first small lump 61 and the small lump 62 are disposed at random.SELECTED DRAWING: Figure 6

Description

  The present invention relates to an interior material in which a clear pattern is expressed.

Conventionally, resin interior materials having a so-called terrazzo pattern are known as interior materials for buildings such as building floor materials, wall materials, and ceiling materials.
Here, the terrazzo pattern in the interior material is a polished marble-like pattern made by kneading marble powder or the like with cement or resin, and the resin interior material with a terrazzo pattern has a terrazzo pattern. It can be said that it is an interior material artificially reproduced with a resin material.
Such a resin interior material having a terrazzo pattern can be obtained by pulverizing a colored vinyl chloride resin sheet, collecting the pulverized material, and rolling or pressing (Patent Document 1).

Japanese Patent No. 3842420

As in the prior art, an interior material obtained by rolling a pulverized product of a colored vinyl chloride resin sheet needs to join the pulverized product with sufficient strength to ensure the required strength. As a general method for increasing the bonding strength between the pulverized products, it is conceivable to increase the fusion of the vinyl chloride resin by increasing the heating temperature and pressure when rolling the pulverized product.
However, when the fusion of the vinyl chloride resin is increased, the exposed pattern becomes blurred or close to solid (no pattern) due to the resin fusion.

  An object of the present invention is to provide an interior material having a sufficient strength and a clear pattern and a method for producing the interior material.

  The interior material of the present invention has a sheet body having a portion on the surface side where a plurality of small lumps containing a vinyl chloride composition are aggregated, and the small lumps are different from a colored portion and an uncolored portion or the colored portion. A small colored block having a colored portion, and the two portions are expressed in stripes.

The preferable interior material of the present invention has a portion in which the small blob extends while being inclined with respect to the surface of the sheet body in a cross-sectional view.
A preferable interior material according to the present invention includes a portion in which the small blob extends while inclining with respect to the surface of the sheet body from the inflection point and a back surface of the sheet body with respect to the inflection point. And extending portions.
In a preferred interior material of the present invention, the small blob has a colored portion and an uncolored portion or a colored portion having a color different from the colored portion, and the two portions are expressed in stripes. The first blob has a colored portion different from the colored portion of the first blob and an uncolored portion or a colored portion different from the colored portion, and the two portions form stripes. And the first small blob and the second small blob are randomly arranged.
In a preferred interior material of the present invention, the second blob has the uncolored portion, and the uncolored portion is transparent.

According to another situation of this invention, the manufacturing method of an interior material is provided.
The interior material manufacturing method of the present invention includes a first raw material containing a colored vinyl chloride composition and an uncolored vinyl chloride composition or a vinyl chloride composition colored in a color different from the color of the first raw material. A step of solidifying the second raw material including a flow pattern, a step of cutting the solidified material formed of the flow pattern into a plurality of small lumps, collecting the small lumps and heating and pressing to form a sheet Forming into a step.

  The interior material of the present invention has a clear exposed pattern and is excellent in strength and durability.

The partial omission plan view of the interior material of a 1st embodiment of the present invention. Sectional drawing cut | disconnected by the II-II line | wire of FIG. Sectional drawing of the interior material of 2nd Embodiment of this invention. Sectional drawing of the interior material of 3rd Embodiment of this invention. Sectional drawing of the interior material of 4th Embodiment of this invention. The top view which expanded the surface of the sheet | seat body of an interior material (enlarged plan view of the VI section of FIG. 1). Sectional drawing which shows an example of an internal structure when a sheet | seat body is cut | disconnected in the thickness direction (cut | disconnected by the VII-VII line of FIG. 6). Sectional drawing which shows the other example of an internal structure when a sheet | seat body is cut | disconnected in the thickness direction (cut | disconnected by the VII-VII line of FIG. 6). Reference sectional drawing which shows the manufacturing apparatus of the solidified material which made the flow pattern. The perspective view of the solidified material which made the flow pattern. The perspective view of the small lump cut out from the solidified material which made the flow pattern. The schematic of the manufacturing apparatus of the sheet | seat body of interior material. The photograph figure of the surface of the solidified material which made the flow pattern produced in the Example. The photograph figure of the surface of a sheet object. The procedure of the bending test is shown, (a) is a reference plan view of the sample piece, (b) is a reference plan view when the triangular portion of the sample piece is bent, and (c) is the arrow shown in (b) above. Reference side view seen from the direction.

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

[Outline of interior materials]
In FIG.1 and FIG.2, the interior material 1 of this invention has the sheet | seat body 2 containing a vinyl chloride composition.
As shown in FIG. 1, the interior material 1 of the present invention may be formed in a long band shape, or may be formed in a sheet shape, although not particularly illustrated. The elongate belt shape refers to a substantially rectangular shape in plan view in which the length in one direction is sufficiently longer than the other direction. The long strip-shaped interior material 1 has, for example, a length in the first direction of 1000 mm to 4000 mm, a length in the second direction of 5 m or more, and preferably a length in the second direction of 10 m or more. The first direction is a direction orthogonal to the second direction.
The sheet shape is formed in a predetermined shape such as a substantially polygonal shape such as a substantially rectangular shape in a plan view such as a tile flooring, and generally refers to a shape that can be stacked and stored and transported. Examples of the sheet-shaped interior material include a substantially rectangular shape having a length in the first direction of 200 mm to 1000 mm and a length in the second direction of 200 mm to 1000 mm.

2 shows the interior material of the first embodiment, FIG. 3 shows the interior material of the second embodiment, FIG. 4 shows the interior material of the third embodiment, and FIG. 5 shows the fourth embodiment. The interior material is shown.
Each plan view of the interior material of the second to fourth embodiments is the same as FIG.
In FIG. 2, the interior material 1 of the first embodiment is composed of only a sheet body 2. In other words, the interior material 1 has a single-layer structure including only the sheet body 2, and the front surface and the back surface of the sheet body 2 form the outermost surface and the back surface of the interior material 1.
In FIG. 3, the interior material 1 of the second embodiment includes a sheet body 2 and a surface protective layer 3 laminated on the surface of the sheet body 2. In the interior material 1, the surface of the surface protective layer 3 forms the outermost surface of the interior material 1, and the back surface of the sheet body 2 forms the outermost surface of the interior material 1.
In FIG. 4, the interior material 1 of the third embodiment includes a sheet body 2 and a back layer 4 laminated on the back surface of the sheet body 2. In the interior material 1, the surface of the sheet body 2 forms the outermost surface of the interior material 1, and the back surface of the back layer 4 forms the outermost surface of the interior material 1.
In FIG. 5, the interior material 1 of the fourth embodiment includes a sheet body 2, a surface protective layer 3 laminated on the surface of the sheet body 2, a back layer 4 laminated on the back surface of the sheet body 2, It is composed of In the interior material 1, the surface of the surface protective layer 3 forms the outermost surface of the interior material 1, and the back surface of the back layer 4 forms the outermost surface of the interior material 1.

<Sheet body>
The sheet body 2 has flexibility. The sheet body 2 has such flexibility that it can be wound around a core material having a diameter of 20 cm in a roll shape, for example. The sheet body 2 is composed of a non-foamed body. The interior material 1 in which the back layer 4 and the like are laminated on the sheet body 2 as shown in FIGS. 4 and 5 also preferably has the same flexibility as the sheet body 2.
The thickness of the sheet body 2 is not specifically limited, For example, it is 0.5 mm-8 mm, Preferably, it is 1.0 mm-5.0 mm. When the back layer 4 is not laminated on the back surface of the sheet body 2 as in the first and second embodiments, the thickness of the sheet body 2 is preferably relatively large, for example, 1.0 mm to 8 mm. The thickness is preferably 1.2 mm to 5 mm. Moreover, when the back layer 4 is laminated | stacked on the back surface of the sheet body 2 like 3rd and 4th embodiment, the thickness of the sheet body 2 can also be made comparatively small.

As shown in FIG. 6, the sheet body 2 has a portion where a plurality of small lumps 6 including a vinyl chloride composition are aggregated on the surface side. Preferably, the small blob 6 has a portion extending while being inclined with respect to the surface of the sheet body 2 in a cross-sectional view.
The nodule 6 includes a nodule having a colored part and an uncolored part or a colored part of a color different from the colored part, and the two parts are expressed in stripes.
Preferably, the nodule 6 includes at least a first nodule 61 and a second nodule 62. The first blob 61 has a colored part and an uncolored part or a colored part having a color different from that of the colored part, and the two parts are expressed in stripes. The second blob 62 has a colored portion different in color from the colored portion of the first blob and a colored portion different in color from the uncolored portion or the colored portion, and the two portions are striped. It is expressed. In the portion where the plurality of small nodules 6 are aggregated, the first nodule 61 and the second nodule 62 are randomly arranged.
The agglomerated portion may include a small blob 6 composed only of an uncolored portion, or may include a small blob 6 composed only of a colored portion of one color. A nodule consisting only of an uncolored part and an nodule consisting only of a colored part of one color are nodules that are not striped in terms of color.
Hereinafter, a portion where a plurality of small blob 6 is aggregated is referred to as “aggregated portion”. Further, in order to distinguish each colored portion and the uncolored portion, the two colored portions and the uncolored portion of the first blob 61 are referred to as “colored portion C11”, “colored portion C12”, and “uncolored portion N1”. The two colored parts of the second small blob 62, the uncolored parts are written as "colored part C21", "colored part C22", "uncolored part N2", and two colored parts of the third small blob 63, Uncolored sites are referred to as “colored site C31”, “colored site C32”, and “uncolored site N3”.
The aggregation portion may be formed on a part of the surface of the sheet body 2, but preferably the aggregation portion is formed over the entire surface of the sheet body 2.

  Here, from the viewpoint of the forming material, the colored portion is formed from a vinyl chloride composition containing a colorant, and the uncolored portion is formed from a vinyl chloride composition not containing a colorant. From the viewpoint of color, the uncolored part is composed of the color of the vinyl chloride composition itself, and the colored part is composed of the color caused by the colorant or the color obtained by fusing the colorant and the vinyl chloride composition. As will be described later, the uncolored portion is transparent or opaque, but is preferably transparent.

The colored portion is exposed on at least a part of the surface of the nodule 6 or on the entire surface of the nodule 6. The coloring part should just be expressed from the part or the whole of the surface of the small lump 6, and may extend from the exposed part to the inside of the small lump 6.
The uncolored part is exposed on at least a part of the surface of the nodule 6. The uncolored part should just be exposed from a part of surface of the small lump 6, and may be extended to the inside of the small lump 6 from the exposed part.

In the aggregation portion, a plurality of small nodules 6 are adjacent to each other, and the adjacent nodules 6 are joined. In FIGS. 6 to 8, the space between the adjacent small nodules 6 is indicated by a clear solid line. However, the boundary between adjacent small nodules 6 is a clear boundary by joining (fusion). Note that you may not have
The planar view shape of each small blob 6 is indefinite as shown in FIG. An indefinite shape is a state in which the shape is disordered and a specific shape cannot be recognized. That is, the planar view shape of each small blob 6 is not uniform, and the planar view shape of the small blob 6 cannot be specified.

The agglomerated portion may be formed of three or more types of small nodules 6 on the condition that it has two types of small nodules 6 (the first nodule 61 and the second nodule 62). Each of the three or more types of nodules 6 has at least one colored portion having a different color.
Preferably, the agglomerated portion includes one or more nodules 6 having two or more colored portions and uncolored portions having different colors, and one or more kinds of nodules 6 having two or more colored portions having different colors, and Consists of

In the illustrated example, the agglomerated portion is composed of three types of small blocks 6 (a first small block 61, a second small block 62, and a third small block 63) that are adjacent to each other and joined together.
The first blob 61 has a colored portion C11 and an uncolored portion N1 and they are expressed in stripes, or have a color different from the colors of the colored portion C11 and the colored portion C11. It has the part C12 and they are expressed in stripes. Note that the first blob 61 may have a colored portion exhibiting a color other than the colored portions C11 and C12 unless it is the same as the other small blob such as the second blob 62 and the third blob 63. Good.
The formation of stripes means that the colored portion C11 extends in a state like a line in the uncolored portion N1 or the colored portion C12, or the state like a line is formed in the colored portion C11. Thus, the uncolored portion N1 or the colored portion C12 extends.

In the illustrated example, the first blob 61 includes a colored portion C11 and an uncolored portion N1 in terms of color. Such a 1st blob 61 is obtained by mixing the vinyl chloride composition containing a coloring agent, and the vinyl chloride composition which does not contain a coloring agent to such an extent that both are not mixed completely. Preferably, the colored portion C11 and the uncolored portion N1 are formed from the same vinyl chloride composition except that the former contains a colorant.
The planar view shape of each colored portion C11 of the plurality of first small blobs 61 is indefinite.
It should be noted that in the first blob 61, the color boundary between the colored portion C11 and the uncolored portion N1 may clearly appear, or the color boundary between both portions may be ambiguous. I want to be.
In the first small blob 61 shown in FIGS. 6 to 8, the colored portion C11 is shaded for convenience.

The second blob 62 has a colored portion C21 and an uncolored portion N2 and they are expressed in stripes, or have a color different from the colors of the colored portion C21 and the colored portion C21. It has the site | part C22 and they are expressed with the stripe. The second blob 62 may have a colored portion exhibiting a color other than the colored portions C21 and C22 as long as it is not the same as another small blob such as the first blob 61 and the third blob 63. Good.
The formation of stripes means that the colored portion C21 extends in a state like a line in the uncolored portion N2 or the colored portion C22, or a state like a line is formed in the colored portion C21. Thus, the uncolored portion N2 or the colored portion C22 extends.

In the illustrated example, the second blob 62 includes a colored portion C21 and an uncolored portion N2 from the viewpoint of color. The color of the colored portion C21 differs from the colored portion C11 of the first small blob 61 at least in color. Such a second blob 62 is obtained by mixing a vinyl chloride composition containing a colorant and a vinyl chloride composition not containing a colorant to such an extent that they are not completely mixed. Preferably, the colored portion C21 and the uncolored portion N2 are formed from the same vinyl chloride composition except that the former contains a colorant.
The planar view shape of each colored portion C21 of the plurality of second small blobs 62 is indefinite.
Note that in the second blob 62, the color boundary between the colored part C21 and the uncolored part N2 may be clearly shown, or the color boundary between both parts may be ambiguous. I want to be.
In the second blob 62 shown in FIGS. 6 to 8, for the sake of convenience, countless dots are added to the colored portion C21.

The third blob 63 has a colored portion C31 and an uncolored portion N3 and they are displayed in stripes, or have a color different from the colors of the colored portion C31 and the colored portion C31. It has the part C32 and they are expressed in stripes. Note that the third blob 63 may have a colored portion exhibiting a color other than the colored portions C31 and C32 unless it is the same as the other small blob such as the first blob 61 and the second blob 62. Good.
The formation of a stripe means that a colored portion C31 extends in a state like a line in the uncolored portion N3 or a colored portion C32, or a state like a line is formed in the colored portion C31. Thus, the uncolored portion N3 or the colored portion C32 is extended.

In the illustrated example, the third blob 63 includes a colored portion C31 and a colored portion C32 in terms of color. At least one of the colored portions C31 and C32 is different in color at least from the colored portion C11 of the first blob 61 and the colored portion C21 of the second blob 62. Such a 3rd blob 63 is obtained by mixing the vinyl chloride composition containing a coloring agent, and the vinyl chloride composition containing a coloring agent different from this to such an extent that both are not mixed completely. Preferably, the colored portion C31 and the colored portion C32 are formed from the same vinyl chloride composition except that the colorant is different.
The planar view shapes of the colored portions C31 and C32 of the plurality of third small blobs 63 are indefinite.
It should be noted that in the third blob 63, the color boundary between the colored part C31 and the colored part C32 may appear clearly, or the color boundary between both parts may be ambiguous. I want.
In the third blob 63 shown in FIGS. 6 to 8, the colored portion C <b> 31 has a vertical line for convenience.

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

The first small blob 61, the second small blob 62, and the third small blob 63 are randomly arranged in a plan view. Random means that they are lined up in random order in plan view. Therefore, the direction of the stripe of the colored portion C11 included in the first nodule 61, the direction of the stripe of the colored portion C21 included in the second nodule 62, and the stripe of the colored portion C31 included in the third nodule 63 The direction is random in plan view. That is, the striped shapes represented by the colors of the colored portions of each small blob 6 are not directional.
Also in the thickness direction of the sheet body 2, the first small block 61, the second small block 62, and the third small block 63 are randomly arranged in a cross-sectional view.
FIG. 7 is a cross-sectional view showing one example of the internal structure of the sheet body 2, and FIG. 8 is a cross-sectional view showing another example of the internal structure of the sheet body 2. 7 and 8 are cross-sectional views taken along the line VII-VII in FIG. 7 and 8 are cross-sectional views, and each small blob 6 should be hatched originally. However, since each colored portion is shaded, dots and vertical lines are added, it is difficult to see. The hatching is omitted.

As shown in FIG.7 and FIG.8, each nodule 6 is extended in the thickness direction, and each nodule 6 is mutually overlapped and joined.
Each small block 6 (first small block 61, second small block 62, and third small block 63) has a portion that extends while being inclined with respect to the surface of the sheet body 2 in a cross-sectional view. In the example shown in FIG. 4, the sheet body 2 extends while inclining from the surface of the sheet body 2 and is inverted at the inflection point to extend toward the back surface side of the sheet body 2.
Specifically, in the structure shown in FIG. 7, each small blob 6 is curved like a quadratic curve in a cross-sectional view. The cross-sectional shape of the small blob 6 is based on an inflection point located in the middle in the thickness direction, a portion extending obliquely from the inflection point to the surface side, and a portion extending obliquely from the inflection point to the back surface And having.
The portion extends at a substantially acute angle with respect to the surface of the sheet body 2, and the portion extends at a substantially acute angle with respect to the back surface of the sheet body 2.
In the structure shown in FIG. 8, each small blob 6 is curved in a sectional view. The cross-sectional shape of the small blob 6 has a portion extending from the front surface side to the back surface side of the sheet body 2 while being curved while being inclined with respect to the surface of the sheet body 2.

<Surface protective layer>
The surface protective layer 3 is provided as needed for the purpose of protecting the surface of the sheet body 2.
The surface protective layer 3 may be colored and transparent, but is preferably colorless and transparent. The surface protective layer 3 is non-foamed.
The surface protective layer 3 contains a main component resin, and contains additives such as a resin other than the main component resin, a flame retardant, a stabilizer, an antioxidant, an ultraviolet absorber, and an antifungal agent as necessary. Also good.
Here, in the present specification, the main component resin refers to the most resin component (weight ratio) among the resin components constituting the layer.
The main component resin that forms the surface protective layer 3 is not particularly limited, and examples thereof include ionizing radiation curable resins such as thermoplastic resins and ultraviolet curable resins. From the viewpoint of scratch resistance and the like, the surface protective layer 3 is preferably formed of an ionizing radiation curable resin such as an ultraviolet curable resin.
As electron beam curable resins, unsaturated polyesters such as unsaturated dicarboxylic acid and polyhydric alcohol condensates, polyester methacrylates, polyether methacrylates, polyol methacrylates, methacrylates such as melamine methacrylates, polyester acrylates, epoxy acrylates, urethanes Examples thereof include ultraviolet curable resins such as acrylate, polyether acrylate, polyol acrylate, and melamine acrylate.
The thickness of the surface protective layer 3 is not particularly limited and is preferably as small as possible, for example, 3 μm to 50 μm, and preferably 5 μm to 40 μm.

<Back layer>
As the back layer 4, those conventionally used for floor materials, wall materials and ceiling materials can be appropriately used. As the back layer 4, a known floor material, wall material and ceiling material excluding a surface layer (including a decorative layer) can be used. For example, a foamed resin layer, a non-foamed resin layer, a rubber layer , Artificial or natural stone, wood, cloth and the like.
For example, in FIGS. 4 and 5, the back layer 4 is interposed between the upper resin layer 41 and the lower resin layer 43 laminated on the back surface of the sheet body 2, and the upper resin layer 41 and the lower resin layer 43. Fiber reinforced layer 42.
The material for forming the upper resin layer 41 and the lower resin layer 43 is not particularly limited, and examples thereof include vinyl chloride resins such as vinyl chloride and vinyl chloride-vinyl acetate copolymers, polyolefin resins, and ethylene-vinyl acetate copolymers. Examples include vinyl acetate resins such as acrylic resins such as ethylene-methacrylate resins, thermoplastic resins such as polyamide resins and ester resins; various thermoplastic elastomers such as olefin elastomers and styrene elastomers; rubbers such as isoprene rubber; It is done.
In order to adhere well to the sheet body 2, at least the upper resin layer 41 is preferably formed of a material containing a vinyl chloride resin as a main component resin, and further, the upper resin layer 41 and the lower resin layer 43. Is more preferably formed from a material containing a vinyl chloride resin as a main component resin.
The fiber reinforcing layer 42 is not particularly limited as long as it contains fibers, and examples thereof include a nonwoven fabric and a woven fabric. The material of the fibers constituting the nonwoven fabric or woven fabric is not particularly limited, and examples thereof include synthetic resin fibers such as polyester and polyolefin; inorganic fibers such as glass and carbon; natural fibers and the like.
The thickness of the back layer 4 is not particularly limited, and is, for example, 0.5 mm to 10 mm.

[Interior material manufacturing method]
The interior material of the present invention can be obtained by the following method, for example. However, the interior material of the present invention is not limited to those obtained by the following production method.
The interior material of the present invention includes a first raw material containing a colored vinyl chloride composition and an uncolored vinyl chloride composition or a vinyl chloride composition colored in a color different from the color of the first raw material. A step of preparing two raw materials, a step of mixing the first raw material and the second raw material so as to form a flow pattern, and solidifying in a state of forming the flow pattern, and a plurality of solidified products formed of the flow pattern. It is obtained through a step of cutting into small pieces, and a step of collecting the small pieces and heating and pressing them to form a sheet.
Hereinafter, the solidified product having a flow pattern may be referred to as a “flow-patterned solidified product”.

<Manufacture of solidified product with flow pattern>
In order to obtain the blob 6, a solidified product having a flow pattern is prepared.
The flow pattern solidified product is appropriately prepared according to the type of the small blob 6.
For example, in the case of producing the first blob 61 having the colored portion C11 and the uncolored portion N1 as described above, the first raw material containing the colored vinyl chloride composition and the uncolored vinyl chloride composition And a second raw material containing a flow pattern solidified product.
Similarly, when the second small blob 62 is produced, the first raw material including the vinyl chloride composition colored in the color corresponding to the colored portion C21 of the second small blob 62 and the uncolored vinyl chloride composition are included. A second raw material is prepared, and a flow pattern solidified product is produced therefrom.
Similarly, in the case of producing the third blob 63, the first raw material containing the vinyl chloride composition colored in a color corresponding to the colored portion C31 of the third blob 63 and the colored portion C32 of the third blob 63 are also provided. And a second raw material containing a vinyl chloride composition colored in a color corresponding to the above, and a flow pattern solidified product is prepared therefrom.
In preparation of the first blob 61, the second blob 62, and the third blob 63, a raw material containing a vinyl chloride composition colored in another color is further prepared and mixed to obtain a flow pattern solidified product. By producing the first nodule 61, the second nodule 62 and the third nodule 63 having colored portions of other colors can be produced.

The vinyl chloride composition contains a vinyl chloride resin as a main component, and includes a filler, a plasticizer, and an additive (the additive here does not include a colorant) as necessary.
A conventionally well-known thing can be used for the said vinyl chloride resin, a filler, a plasticizer, and an additive.
Examples of the vinyl chloride resin include those produced by emulsion polymerization, suspension polymerization, solution polymerization, bulk polymerization, and the like. A vinyl chloride resin obtained by an emulsion polymerization method or a suspension polymerization method is preferred because it is easy to process and handle.
Examples of the filler include various inorganic fillers such as calcium carbonate, titanium oxide, calcium oxide, barium carbonate, magnesium hydroxide, aluminum hydroxide, clay, talc, and mica.
Examples of the plasticizer include dioctyl phthalate (DOP), dibutyl phthalate (DBP), butyl octyl phthalate (BOP), dioctyl isophthalate (DOIP), diisononyl phthalate (DINP), and di-2-ethylhexyl terephthalate (DOTP). ) And the like.
Additives include stabilizers, processing aids, fungicides, flame retardants, ultraviolet absorbers, antioxidants, and the like.

Here, the vinyl chloride resin itself is generally colorless and transparent. The transparency of a vinyl chloride composition obtained by blending a vinyl chloride resin with a filler or the like is reduced by components other than the vinyl chloride resin such as a filler. The vinyl chloride composition containing the filler changes from colorless and transparent to translucent to opaque according to the amount of the filler, and in particular, the vinyl chloride composition contains a filler exhibiting a white color such as calcium carbonate or titanium oxide. According to the amount, the product changes from colorless and transparent to white translucent to white opaque.
Here, in this specification, when it is simply transparent, it means colorless and transparent or translucent. Colorless and transparent is when the colorless and transparent object is placed about 1 cm apart on white paper printed with black ink and any number (size 12 points), and the object is viewed through The state where the number can be identified from the front side. Translucent means a state where the number placed on the back side under the same conditions as above can be visually recognized that something black exists when viewed from the front side through a translucent object. The state which cannot visually recognize black on the same conditions as the above.
In this specification, the colorant refers to a component intended to color the resin material, and a component not intended to be colored such as a filler such as calcium carbonate is not included in the category of the colorant. . That is, the colorant and the vinyl chloride composition are different concepts. However, as described above, when calcium carbonate or the like is blended, the resulting white color is the color of the vinyl chloride composition itself and should not be interpreted as a “colored vinyl chloride composition”. In terms of implementation, when the vinyl chloride composition itself exhibits a color (for example, white) due to the blended filler, in order to obtain the striped nodules 6 by the color, , It is necessary to set the color other than the color caused by the filler (for example, other than white).

As described above, when producing the first blob 61 having the colored portion C11 and the uncolored portion N1, the first raw material containing the colored vinyl chloride composition and the uncolored chloride containing no colorant. And a second raw material containing a vinyl composition.
The first raw material in this case is a mixture of a vinyl chloride composition and a colorant, and exhibits the color of the colorant. A 2nd raw material consists of a vinyl chloride composition which does not mix | blend a coloring agent.
The first raw material and the second raw material are melted and mixed together. At this time, the first raw material and the second raw material are gently mixed to such an extent that the first raw material and the second raw material are not completely mixed, and the flow pattern is maintained. Allow the mixture to solidify.
The mixing ratio of the first raw material and the second raw material is not particularly limited, and is, for example, 9: 1 to 5: 5 by weight.

For example, using a calendar molding machine as shown in FIG. 9, at least two raw materials (first raw material and second raw material) can be mixed to produce a flow pattern solidified product.
9A and 9B, a calendar molding machine 8 ′, 8 ″ includes a Banbury mixer 81, a mixing roll 82 disposed on the outlet side of the mixer 81, a calendar roll 83, and a grinder 84. Note that a calender molding machine 8 ″ shown in FIG. 4B is obtained by adding a spreader 85 to the calender molding machine 8 ′.

  As shown to Fig.9 (a), the 1st raw material (for example, vinyl chloride composition containing a vinyl chloride resin and a coloring agent) is mixed with the Banbury mixer 81 heated at 120 to 160 degreeC, and this is made into a pair of A sheet-like product 71 having a predetermined thickness is produced by passing between mixing rolls 82 and kneading. The sheet-like material 71 is rolled with calendar rolls 83 and 83 heated to 120 ° C. to 160 ° C., and naturally cooled or forcedly cooled, whereby a first sheet 72 having a predetermined thickness (for example, a thickness of about 1 to 3 mm) is obtained. After the production, the sheet 72 is pulverized randomly by the pulverizer 84 to obtain the first chip 73 having an irregular shape.

Next, as shown in FIG.9 (b), the 2nd raw material (for example, vinyl chloride composition which does not contain a coloring agent) is mixed by the Banbury mixer 81 heated at 120 to 160 degreeC, and this is made into a pair of A sheet-like material 74 having a predetermined thickness is produced by passing between the mixing rolls 82 and kneading. The first chip 73 (chip made of the first raw material) heated to about 120 ° C. to 160 ° C. is sprayed on the sheet-like material 74 through the spreader 85. Thereafter, the sheet-like material 74 is rolled with calendar rolls 83 and 83 heated to 120 ° C. to 160 ° C., and naturally or forcedly cooled to solidify a flow pattern having a predetermined thickness (for example, about 1 to 3 mm in thickness). Product 7 is obtained. When the sheet-like material 74 including the first chip 73 is stretched by rolling, the first raw material and the second raw material flow in stripes in the extending direction. By doing in this way, the sheet-like flow pattern solidified material 7 in which the second raw material (or the first raw material) is mixed in an arbitrary plurality of stripes in the first raw material (or the second raw material). Can be produced.
As the calendering method, for example, those described in Japanese Patent No. 46052828 can be used.

  The method of mixing at least two raw materials (first raw material and second raw material) to produce a flow pattern solidified product is not limited to the method using the calendar molding machine. For example, as a method for producing a flow pattern solidified product, the production techniques described in Japanese Patent No. 3393588, Japanese Patent No. 3970568, Japanese Patent No. 5664987, Japanese Patent No. 5751562, Japanese Patent Application Laid-Open No. 2000-045552 can be appropriately modified and used. Good.

As shown in FIG. 10, the flow pattern solidified product 7 has a flow pattern such as a wood grain pattern or an ink sink pattern.
The flow pattern solidified material 7 is a mixture of the first raw material and the second raw material in a complicated manner, the color part of the first raw material, the color part of the color of the first raw material and the second raw material, and the color part of the second raw material. Have The color portion in which the colors of the first raw material and the second raw material are mixed is often stepless and gradation from colors close to the first raw material to colors close to the second raw material.
The thickness of the flow pattern solidified product 7 is not particularly limited, but is about 0.5 to 2 times, preferably 0.7 to 1.2 times the thickness of the finally produced sheet body 2. If the thickness of the flow pattern solidified product 7 is set too small, a good flow pattern may not be obtained.
Similarly, when the second blob 62 having the colored portion C21 and the uncolored portion N2 is produced, the first raw material including the colored vinyl chloride composition and the uncolored vinyl chloride composition not including the colorant are similarly used. And a second raw material containing, and using them, a solidified product having a flow pattern is prepared.
Similarly, when the third blob 63 is produced, a solidified product having a flow pattern is produced.

<Manufacture of small chunks>
A plurality of small lumps are obtained by pulverizing the flow pattern solidified product 7 obtained as described above.
In order to distinguish the small lumps produced in the manufacturing process of the sheet body 2 from the small lumps 6 constituting the sheet body 2, the small lumps in the manufacturing process are referred to as “raw material small lumps”.
For example, as shown in FIG. 9 (b), an irregularly shaped raw material blob A can be obtained as shown in FIG. . It should be noted that the plurality of raw material agglomerates A have an indefinite shape (a disordered shape), so that the contours shown in FIGS. 11A and 11B are only for reference.
FIG. 11A illustrates a deformed hexahedral-shaped nodule as a reference, and FIG. 11B illustrates a solid-shaped nodule having no plane for reference. When the sheet body is produced, the raw material blob comes into contact at various angles, and a complicated pattern is generated in the vertical and horizontal directions, and a pattern having no directivity can be expressed in the sheet body 2 as shown in FIG. It is preferable to use a three-dimensionally shaped nodule having substantially no flat surface as in b).
The flow pattern solidified product 7 may be regularly cut to produce a raw material blob having a regular shape such as a substantially cubic shape or a substantially rectangular parallelepiped shape, but a pattern having no directionality is represented in the sheet body 2. Therefore, it is preferable that the raw material blob A is indefinite.
The size of the raw material agglomerate A is not particularly limited. For example, the maximum vertical length, the maximum horizontal length, and the maximum height are preferably included in the range of 1 mm to 3 mm, and further, 1.4 mm to 2.4 mm. More preferably, it is included in the range of.
In addition, FIG. 11 has illustrated the raw material nodule A used as the 1st nodule 61, and has shaded the corresponding coloring location C11.
By pulverizing each flow pattern solidified product, raw material nodules A corresponding to the first nodule 61, the second nodule 62 and the like can be obtained.

<Manufacture of sheet body>
At least one raw material block A (from the raw material block A corresponding to the first small block 61, the raw material block A corresponding to the second small block 62, the raw material block A corresponding to the third small block 63, etc. For example, at least the raw material agglomerates A corresponding to the first small agglomerates 61), preferably at least two raw material agglomerates A (for example, corresponding to at least the raw material agglomerates A corresponding to the first agglomerates 61 and the second agglomerates 62) Selected raw material blob A,).
As shown in FIG. 12, a plurality of raw material agglomerates A are placed between a pair of rollers 93 using a spraying device 91 and pressed by the pair of rollers 93, thereby collecting a plurality of raw material agglomerates A. A layered product 94 having a predetermined thickness is prepared. The layered material 94 is guided onto an endless sheet conveyor 92 and heated by a heating device 95 such as an oven to melt the vinyl chloride resin of the raw material small lump A. The heating temperature may be higher than the temperature at which the vinyl chloride resin melts, and is, for example, 160 ° C. or higher, preferably 170 ° C. or higher, more preferably 175 ° C. or higher. In addition, if the temperature is too high, the raw material blob A may be melted too much and the colored portion and the uncolored portion may be completely mixed. Therefore, the heating temperature is, for example, 210 ° C. or less, preferably Is 210 ° C. or lower, more preferably 200 ° C. or lower.
The heating time is preferably about 300 seconds to 3000 seconds.

After heating, the layered product 94 is pressed in the thickness direction and processed into a sheet. The pressure is not particularly limited, for ^example, it is ^{1.5kgf / cm 2 ~5kgf / cm 2} . For pressurization, a press machine may be used. However, when the apparatus 9 for continuous production as shown in the figure is used, a pressure roll 96 is used and a layered product 94 is passed between the pressure rolls. It is preferable to process the sheet.
When the melted raw material agglomerate A is pressurized, the raw material agglomerate A is irregularly deformed into an irregular shape, and is joined between adjacent raw material agglomerates A.
Then, the said sheet | seat body 2 in which the small block 6 aggregated is obtained by performing natural cooling or forced cooling.
In addition, you may form an embossing unevenness | corrugation in the surface or / and the back surface of the sheet | seat body 2 using the embossing roller 97 as needed.
Moreover, you may form a surface protective layer on the surface of the sheet body 2 using the coating device 98 as needed. The applicator 98 applies a surface protective layer forming material to the surface of the sheet 2 and solidifies the material. For example, when a surface protective layer made of an ionizing radiation curable resin such as an ultraviolet curable resin is formed. Has an application part for applying the ionizing radiation curable resin and a light irradiation part such as an ultraviolet ray for curing the resin.
The obtained sheet body 2 is taken up by the collecting machine 99 and separated from the manufacturing apparatus 9.

[Effects and uses of interior materials]
The sheet body 2 of the interior material 1 of the present invention includes a first small blob 61 having an irregular colored portion C11 and an uncolored portion N1, a second small blob 62 having an irregular colored portion C21 and an uncolored portion N2, and Since the 3rd blob 63 which has the irregular colored part C31 and C32 is mutually joined and arrange | positioned at random, when it sees from the surface side, the pattern without directionality is expressed clearly.
Further, when the uncolored portion 6 is a small blob 6 and the uncolored portion is transparent, the back side can be visually recognized from the front side of the sheet body 2 through the uncolored portion, and the sheet body 2 having a three-dimensional effect. Can be configured. In particular, when each small block 6 (the first small block 61, the second small block 62, and the third small block 63) has a portion that extends while being inclined with respect to the surface of the sheet body 2 in a sectional view. When seen from the surface side of the sheet body 2, the sheet body 2 also has a portion that can be seen through in a stepwise manner.
Further, each of the small blocks 6 (the first small block 61, the second small block 62, and the third small block 63) has a portion that extends while being inclined with respect to the surface of the sheet body 2 in a cross-sectional view. The contact area of the small blob 6 to be increased is increased, and each small blob 6 is firmly joined. In particular, each small blob 6 has a portion that extends obliquely from the inflection point to the front surface side and a portion that extends obliquely from the inflection point to the back surface side, thereby forming the sheet body 2 that is extremely firmly joined. it can.
The interior material 1 of the present invention is constructed on construction surfaces 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 material is not particularly limited, and examples thereof include attaching the back surface of the interior material to the construction surface using an adhesive.
The interior material 1 of the present invention may be applied to a new construction surface or may be applied to an existing construction surface such as renovation.
The interior material 1 of the present invention can be used as a floor material, a wall material, a ceiling material, and the like, and can be particularly suitably used as a floor material and a wall material.
Although the sheet body 2 constitutes the design of the interior material, the sheet body 2 has a predetermined thickness, and since a similar pattern appears even when worn on a shoe sole or the like, it has excellent durability and can be most suitably used as a flooring material.

  EXAMPLES Hereinafter, an Example is shown and this invention is explained in full detail. However, the present invention is not limited to the following examples.

[Materials used]
<Vinyl chloride resin>
A granular vinyl chloride resin by a suspension polymerization method (trade name “ZEST 800Y” manufactured by Shin-Daiichi PVC Co., Ltd., average polymerization degree: 760 to 860, K value: 60.5 to 63.1, apparent density: 0.00. 53-0.63 (catalog value)). The particle size of the vinyl chloride resin was approximately 100 μm to 300 μm.
<Filler>
Granular calcium carbonate (trade name “ESCALON # 200” manufactured by Sankyo Flour Milling Co., Ltd.).
<Plasticizer>
DOP (general-purpose product).
<Colorant>
Red colorant (Bengara).
White colorant (titanium oxide).

[Preparation of raw material lump]
<Preparation of a raw material blob having a red striped colored portion>
50 parts by weight of filler, 38 parts by weight of plasticizer and 3 parts by weight of white colorant are added to 100 parts by weight of vinyl chloride resin in a Banbury mixer of an existing calendar molding machine, and about 6 at 140 ° C. After mixing for a minute, it was molded with a mixing roll and a calender roll heated to 140 ° C. to produce a sheet-like product of length × thickness = 600 mm × 3 mm. After cooling this sheet-like material to 20 ° C. in a water tank, it was pulverized to about 3 mm square by a pelletizer to produce a first chip (first raw material, vinyl chloride composition colored in white).

50 parts by weight filler, 38 parts by weight plasticizer and 3 parts by weight red colorant are added to 100 parts by weight of vinyl chloride resin in a Banbury mixer of a calendar molding machine and mixed at 140 ° C. for about 6 minutes. After that, a sheet (longitudinal × thickness = 600 mm × 3 mm) (second raw material, vinyl chloride composition colored red) was prepared with a mixing roll heated to 140 ° C.
Before the sheet-like material is cooled, the first chip (first material) heated to 140 ° C. with a hot air heater is placed on the sheet-like material (second material) in a weight ratio of the first material: the second material. = 1: 3 sprayed and then rolled while gently mixing with a calender roll heated to 140 ° C. to solidify a sheet-like flow pattern of length × width × thickness = about 200 mm × 200 mm × 2 mm A product was made.
FIG. 13 shows a photograph (no enlargement) of the surface of this flow pattern solidified product. In addition, FIG. 13 is a surface photograph in the range of length × width = about 120 mm × about 160 mm in the produced flow pattern solidified product.

  The flow pattern solidified product was randomly pulverized with a commercially available crusher, and the pulverized product was sieved with a 20-mesh sieve to produce a raw material lump having a certain size (hereinafter referred to as a raw material lump ( 1)).

<Preparation of a raw material lump having a white striped colored portion>
50 parts by weight of filler and 38 parts by weight of plasticizer with respect to 100 parts by weight of the vinyl chloride resin were put into a Banbury mixer of a calendar molding machine, mixed at 140 ° C. for about 6 minutes, and then heated to 140 ° C. It formed with the mixing roll and the calendar roll, and produced the sheet-like thing of length x thickness = 600mmx3mm. After cooling this sheet-like material to 20 ° C. in a water tank, it was pulverized to about 3 mm square with a pelletizer to produce a first chip (first raw material, translucent vinyl chloride composition).

50 parts by weight of filler, 38 parts by weight of plasticizer and 3 parts by weight of white colorant are added to 100 parts by weight of vinyl chloride resin in a Banbury mixer of a calendar molding machine and mixed at 140 ° C. for about 6 minutes. After that, a sheet (longitudinal × thickness = 600 mm × 3 mm) (second raw material, vinyl chloride composition colored in white) was produced with a mixing roll heated to 140 ° C.
Before the sheet-like material is cooled, the first chip (first material) heated to 140 ° C. with a hot air heater is placed on the sheet-like material (second material) in a weight ratio of the first material: the second material. = 2: 3 sprayed and then rolled while gently mixing with a calender roll heated to 140 ° C. to solidify sheet-like flow pattern of length x width x thickness = about 200 mm x 200 mm x 2 mm A product was made.
This flow pattern solidified product also had a flow pattern similar to FIG.

  The flow pattern solidified product was randomly pulverized with a commercially available crusher, and the pulverized product was sieved with a 20-mesh sieve to produce a raw material lump having a certain size (hereinafter referred to as a raw material lump ( 2)).

[Example 1]
The raw material lump (1) is sufficiently agitated and passed through a pair of rollers from a spreader of an existing sheet manufacturing apparatus (as shown in FIG. 12) to form a sheet generally, and this is an endless sheet conveyor. Place on top, melt and heat for 5 minutes in a hot air circulating oven at 200 ° C., and then pass through a pressure roll at room temperature and apply a pressure of approximately 3 kgf / cm ² to produce a 2 mm thick sheet. did.
The speed of the sheet conveyor was 1 m / min.
FIG. 14 shows a photograph (no enlargement) of the surface of the sheet body obtained in Example 1.

[Example 2]
A sheet body having a thickness of 2 mm was produced in the same manner as in Example 1 except that the raw material blob (2) was used instead of the raw material blob (1).

[Example 3]
In the same manner as in Example 1, except that instead of the raw material blob (1), a mixture of the raw material blob (1) and the raw material blob (2) at a ratio of 1: 1 by weight was used. A sheet body having a thickness of 2 mm was produced.

[Bending test]
The sheet body produced in each Example was cut into a square of length × width = 30 cm × 30 cm to produce a sample piece. As shown in FIG. 15, a triangular portion defined by the corner portion and the reference line is formed from one corner portion of the sample piece in a diagonal direction to a diagonal reference line, and the triangular portion defined by the corner portion and the reference line is moved from the sheet surface side to the back surface side. The adult male was bent by human power until the corner contacted the back surface. The surface condition of the curved portion around the reference line was confirmed visually and with a finger.
As a result, none of the sheet bodies of Examples 1 to 3 were cracked or raised, and each small blob was well bonded.

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

DESCRIPTION OF SYMBOLS 1 Interior material 2 Sheet body 6 Small lump 61 1st small lump 62 2nd small lump 63 3rd small lump 7 Solidified material which made the flow pattern C11, C21, C31, C32 Colored site N1, N2, N3 Uncolored site A Raw material blob

Claims (6)

A sheet body having a portion on the surface side where a plurality of small lumps containing a vinyl chloride composition are aggregated,
An interior material in which the small blob includes a small blob that has a colored portion and an uncolored portion or a colored portion having a color different from the colored portion, and the two portions are expressed in stripes.   The interior material according to claim 1, wherein the small blob has a portion extending while being inclined with respect to a surface of the sheet body in a cross-sectional view.   The small blob has a portion extending while inclining from the inflection point to the surface of the sheet body and a portion extending from the inflection point to the back surface of the sheet body in a sectional view. The interior material according to claim 1 or 2.   The small blob has a colored portion and an uncolored portion or a colored portion having a color different from the colored portion, and the two small portions are expressed in stripes, and the first blob A second portion in which a colored portion having a color different from a colored portion of one blob and an uncolored portion or a colored portion having a color different from the colored portion is present, and the two portions are expressed in stripes. The interior material according to any one of claims 1 to 3, wherein the first small blob and the second small blob are randomly arranged.   The interior material according to claim 4, wherein the second blob has the uncolored portion, and the uncolored portion is transparent. A flow pattern of a first raw material containing a colored vinyl chloride composition and a second raw material containing an uncolored vinyl chloride composition or a vinyl chloride composition colored in a color different from the color of the first raw material Solidifying in a state of forming,
Cutting the solidified product having the flow pattern into a plurality of small lumps;
A method for producing an interior material, comprising: collecting the small lumps and forming the sheet by heating and pressing.