JP2021098922A - Surface material and method for manufacturing the same - Google Patents

Abstract

To provide a surface material comprising main surfaces which have excellent feeling in touch and hardly cause fiber dropouts, and to provide a method for producing the same.SOLUTION: In a surface material 10 comprising binder 2 and a monolayer fabric 1, the surface material satisfies both of the configuration that there is no layer of binder on both main surfaces in the fabric and the configuration that there are layers of binder between both main surfaces in the fabric, the surface material with main surfaces which have excellent feeling in touch and hardly cause fiber dropouts. A method for manufacturing a surface material comprises a step of applying a solvent and/or dispersion medium to one main surface to which a binder liquid is applied in a monolayer fabric, wherein, the binder liquid applied to the main surface can be pushed from the one main surface to the inner side of the monolayer fabric by the solvent and/or dispersion medium, so that the binder liquid does not exist on the one main surface.SELECTED DRAWING: Figure 1

Description

The present invention relates to a surface material and a method for producing the same.

Conventionally, as a surface material that can be used for interiors of automobiles and the like, it is a surface material provided with a binder and a cloth having a single-layer structure, and fibers constituting the main surface of the surface material (main surface derived from the cloth having a single-layer structure). A surface material is used in which the binders are bonded and fixed to each other by a layer of binder. Then, the surface material is heat-molded into an intended shape to manufacture an interior material.

As a surface material having the above-mentioned structure, the applicant of the present application described in Japanese Patent Application Laid-Open No. 62-257472 (Patent Document 1), "One side of the fiber web is subjected to needle punching treatment, and the surface subjected to the needle punching treatment is a binder. The interior skin material was impregnated with a binder, which was impregnated with a binder, and then subjected to a calendar treatment, and then the opposite surface of the needle punched surface was impregnated with a binder having less tack.

Japanese Unexamined Patent Publication No. 62-257472

However, a binder layer exists on the main surface of the surface material (main surface derived from a single-layered fabric) according to the prior art, and the fiber portion exposed on the main surface is adhered by the binder layer. Since it was fixed, the main surface did not give a feeling of brushing to a person and had a bad tactile sensation.

On the other hand, in order to provide a surface material having a main surface that makes a person feel brushed and has an excellent tactile sensation, if a binder is not applied to the main surface of the surface material (main surface derived from a single-layered fabric), the present invention is applicable. There was a problem that the fibers were easily dropped from the main surface.

An object of the present invention is to provide a surface material having a main surface having an excellent tactile sensation and a main surface in which fibers are less likely to fall off, and a method for producing the same.

The first invention is "a surface material comprising a binder and a woven fabric having a single-layer structure, only on the inner side of one main surface of the fabric and on the inner side of the other main surface of the fabric. A surface material in which the binder layer is present. "

Further, the second invention is "(1) a step of preparing a cloth having a single layer structure, (2) a step of preparing a binder solution containing a binder and a solvent and / or a dispersion medium of the binder, (3). ) A step of applying the binder solution to one main surface of the cloth, (4) a step of applying the solvent and / or the dispersion medium to the one main surface of the cloth to which the binder solution is applied. (5) The method for producing a surface material according to claim 1, further comprising a step of removing the solvent and / or the dispersion medium from the cloth. "

As a result of examination, the applicant of the present application has found that in a surface material provided with a binder and a fabric having a single-layer structure,
-A configuration in which no binder layer exists on both main surfaces of the fabric, and
-A configuration in which a binder layer exists between both main surfaces of the fabric,
It was found that the surface material satisfying both of the above conditions is a surface material having a main surface which is excellent in tactile sensation and in which fibers are less likely to fall off.
That is, in the surface material of the present invention, no binder layer is present on both main surfaces of the single-layered fabric constituting the surface material. Therefore, since the fiber portions exposed on both main surfaces are not fixed by the binder layer, both main surfaces give a person a feeling of brushing and are excellent in tactile sensation.

On the other hand, the presence of a binder layer between both main surfaces of the fabric constituting the surface material causes the fibers to be exposed on each main surface and contribute to the improvement of the tactile sensation on the inner side of the fabric. The part is glued and fixed by a layer of binder. Therefore, the fibers (fibers that are exposed on each main surface and contribute to the improvement of tactile sensation) are unlikely to fall off from each of the main surfaces.

Further, in the method for producing a surface material according to the present invention, after applying a binder liquid to one main surface of the prepared single-layer structure cloth, "(4) the one main surface to which the binder liquid is applied in the cloth" is applied. A step of applying the solvent and / or the dispersion medium to the surface is provided. In the step, the binder liquid existing on one main surface of the fabric is then transferred from the one main surface to the inner side of the fabric by the solvent and / or the dispersion medium containing no binder to be applied. It can be pushed in so that there is no binder liquid on one of the main surfaces.
Then, by removing the solvent and / or the dispersion medium present in the fabric, a surface material satisfying the constitution according to claim 1 can be produced.

From the above, according to the present invention, it is possible to provide a surface material having a main surface which is excellent in tactile sensation and in which fibers are less likely to fall off.

It is a schematic cross-sectional view of the surface material which concerns on this invention. It is an optical micrograph which showed the cross section of the surface material prepared in the comparative example 1. FIG. It is an optical micrograph which showed the cross section of the surface material prepared in the comparative example 2. It is an optical micrograph which showed the cross section of the surface material prepared in Example 1. FIG. It is an optical micrograph which showed the cross section of the surface material prepared in Example 2. FIG. 3 is an optical micrograph showing a cross section of the surface material prepared in Example 3.

In the present invention, various configurations such as the following configurations can be appropriately selected. Unless otherwise specified, the various measurements described in the present invention were performed under atmospheric pressure. Further, unless otherwise specified, the various measurements described in the present invention were carried out under a temperature condition of 25 ° C. Then, unless otherwise specified, the various measurement results described in the present invention were measured to a value one digit smaller than the desired value, and the value to be obtained was calculated by rounding off the value. As a specific example, when the value up to the first decimal place is the value to be obtained, the value up to the first decimal place is calculated by finding the value up to the second decimal place by measurement and rounding off the obtained value up to the second decimal place. Then, this value was used as the desired value.

The surface material of the present invention will be described with reference to FIG. 1, which is a schematic cross-sectional view of the surface material according to the present invention. The surface material (10) illustrated in FIG. 1 is a surface material (10) composed of only a single-layered fabric (1) and a binder layer (2).
The surface material (10) of the present invention includes a single-layered fabric (1) and a binder layer (2).

Here, the single-layered fabric (1) is a member that mainly plays a role of forming the skeleton of the surface material (10). The binder layer (2) has a role of adhering and integrating the constituent fibers of the single-layered fabric (1) to prevent the shape of the single-layered fabric (1) from being unintentionally deformed. , It plays a role of improving various physical properties such as the rigidity of the single-layer structure cloth (1). In addition, it can play a role of supporting an additive as described later in the surface or voids of the single-layered fabric (1).

The cloth referred to in the present invention is, for example, a fiber web, a non-woven fabric, or a sheet-like fiber aggregate such as a woven fabric or a knitted fabric.

Further, the single-layer structure referred to in the present invention means that the fabric is not a laminate of a plurality of fiber aggregates. Since the fabric has a single-layer structure, it is possible to provide a surface material (10) having excellent moldability in which delamination does not easily occur in the fabric when the interior material is produced by heat molding.

Further, since the fabric has a single-layer structure, the types of the constituent fibers on one main surface of the fabric and the constituent fibers on the other main surface can be the same. Therefore, when the interior material is manufactured by heat molding, the followability of the fabric on both main surfaces to the molding die becomes uniform, and the surface material (10) having excellent moldability can be provided.

For the present invention, for example, two fiber webs having a binder layer on one main surface are prepared, and the two fiber webs are bonded and integrated by the binder with the binder layers facing each other to form a surface. When the material is prepared, or when the surface material is prepared by performing an entanglement treatment such as needle punching on two fiber webs with the layers of the binder facing each other, a fabric having a laminated structure is provided. A surface material having the same structure as that of the present invention can be prepared except for the above. However, if the surface material is heat-molded to produce an interior material, delamination may easily occur. It is considered that the reason for this is that due to the presence of the binder layer, the layers between the fiber webs are weakly entangled with the constituent fibers, and the surface material has a portion where the layers are easily delaminated.

If the layer can be easily peeled off from the fabric, or if the types of constituent fibers on one main surface of the fabric and the constituent fibers on the other main surface are not the same, the fabric has a single-layer structure. It can be judged that there is no.

The surface material (10) of the present invention is flexible because it contains a cloth (particularly, a non-woven fabric formed by randomly entwining all constituent fibers), and is excellent in heat moldability. The surface material (10) provided with the cloth (particularly, non-woven fabric) in which all the constituent fibers are randomly entangled is more flexible and more excellent in heat moldability.

The constituent fibers of the fabric are, for example, a polyolefin resin (for example, polyethylene, polypropylene, polymethylpentene, a polyolefin resin having a structure in which a part of hydrocarbon is replaced with a cyano group or a halogen such as fluorine or chlorine), a styrene resin. , Polyvinyl alcohol resins, polyether resins (eg, polyether ether ketones, polyacetals, modified polyphenylene ethers, aromatic polyether ketones, etc.), polyester resins (eg, polyethylene terephthalates, polytrimethylene terephthalates, polybutylene terephthalates, etc.) Polyethylene naphthalate, polybutylene naphthalate, polycarbonate, polyarylate, total aromatic polyester resin, etc.), polyimide resin, polyamideimide resin, polyamide resin (for example, aromatic polyamide resin, aromatic polyetheramide resin, nylon resin) , Etc.), Resin having a nitrile group (for example, polyacrylonitrile), urethane resin, epoxy resin, polysulfone resin (for example, polysulfone, polyethersulfone, etc.), fluororesin (eg, polytetrafluoroethylene, polyfluor) Vinylidene chemicals, etc.), Cellulosic resin, Polybenzoimidazole resin, Acrylic resin (for example, polyacrylonitrile resin obtained by copolymerizing acrylic acid ester or methacrylic acid ester, etc., Modaacrylic resin obtained by copolymerizing acrylonitrile with vinyl chloride or vinylidene chloride. It can be configured by using a known resin such as resin).

These resins may be made of either a linear polymer or a branched polymer, the resin may be a block copolymer or a random copolymer, and the resin has a three-dimensional structure and crystallinity. However, there is no particular limitation. Further, a mixture of multi-component resins may be used. Further, it may be a fiber prepared by kneading a pigment or a dyed fiber such as a dyed fiber.

When the surface material (10) is required to be flame-retardant, it is preferable that the constituent fibers of the fabric contain a flame-retardant resin. As such a flame-retardant resin, for example, a moda acrylic resin, a vinylidene resin, a polyvinyl chloride resin, a polyvinylidene fluoride resin, a novoloid resin, a polyclar resin, a polyester resin obtained by copolymerizing a phosphorus compound, and a halogen-containing monomer are copolymerized. Examples thereof include acrylic resins, aramid resins, and resins kneaded with halogen-based, phosphorus-based, or metal compound-based flame retardants. Further, the surface material (10) may be a surface material (10) carrying a flame retardant by using a binder or the like.

The constituent fibers are, for example, melt spinning method, dry spinning method, wet spinning method, direct spinning method (melt blow method, spun bond method, electrostatic spinning method, etc.), and by removing one or more kinds of resin components from the composite fiber. It can be obtained by a known method such as a method of extracting fibers having a small fiber diameter or a method of beating the fibers to obtain divided fibers.

The constituent fibers may be composed of one type of resin or may be composed of a plurality of types of resins. As the fiber composed of a plurality of types of resins, it can be generally referred to as a composite fiber, for example, a core-sheath type, a sea-island type, a side-by-side type, an orange type, a bimetal type, or the like.

Further, the constituent fibers may include irregular cross-section fibers in addition to substantially circular fibers and elliptical fibers. The deformed cross-section fiber has a polygonal shape such as a hollow shape and a triangular shape, an alphabetical character shape such as a Y shape, an irregular shape, a multi-leaf shape, a symbolic shape such as an asterisk shape, or a plurality of these shapes. It may be a fiber having a fiber cross section such as a bonded shape.

When the fabric contains heat-sealing fibers as constituent fibers, it is preferable that the fibers are heat-sealed to each other to impart strength and morphological stability to the fabric and suppress scraping and unintended fluffing. .. Such a heat-fusing fiber may be a fully-fusing type heat-sealing fiber, or a partially-fusing type heat-sealing fiber having an embodiment such as the composite fiber described above. Is also good. As a component that exhibits heat-sealing properties in the heat-sealing fiber, for example, a heat-sealing fiber containing a low-melting-melt polyolefin resin or a low-melting polyester resin can be appropriately selected and used.

When the fabric contains crimpable fibers, the elasticity is increased and the followability to the molding die is excellent, which is preferable. As such a crimpable fiber, for example, a crimpable fiber expressing the crimp of a latent crimpable fiber, a fiber having a crimp, or the like can be used. In addition, it may contain latent crimp fibers that develop crimping when the fabric is heated.

When the cloth is a fiber web or a non-woven fabric, for example, a dry method in which the above-mentioned fibers are used in a card device or an air array device to entangle the fibers, or a wet method in which the fibers are dispersed in a solvent and the fibers are entangled in a sheet shape. , Direct spinning method (melt blow method, spunbond method, electrostatic spinning method, method of discharging a spinning stock solution and a gas flow in parallel to spin (for example, a method disclosed in Japanese Patent Application Laid-Open No. 2009-287138)) is used. It can be prepared by spinning fibers and collecting them.

The constituent fibers of the prepared fiber web can be entangled and / or integrated to prepare a non-woven fabric. As a method of entwining and / or integrating the constituent fibers with each other, for example, a method of entwining with a needle or a water stream, or a fiber web being subjected to a heat treatment, the constituent fibers are bonded and integrated or melted by a binder or an adhesive fiber. Examples include a method of integrating.

The heat treatment method can be appropriately selected. For example, a method of heating or heating and pressurizing with a roll, a method of heating by applying to a heater such as an oven dryer, a far-infrared heater, a dry heat dryer, or a hot air dryer, and infrared rays under no pressure. A method of heating the contained resin by irradiating with the above can be used.

When the fabric is a woven fabric or knitted fabric, the woven fabric or knitted fabric can be prepared by weaving or knitting the fibers prepared as described above.

In addition to the fiber web, a non-woven fabric or a cloth such as a woven fabric or a knit may be used for the above-mentioned method of entwining and / or integrating the constituent fibers with each other.

The fineness of the constituent fibers of the single-layer structure fabric (1) is not particularly limited, but it can be 0.1 dtex or more and 0.5 dtex or more so as to improve the appearance retention. , 1.0 dtex or more. On the other hand, the surface material (10) having excellent moldability can be prepared, which can be 100 dtex or less, 50 dtex or less, 30 dtex or less, and 10 dtex or less. ..

Further, the fiber length of the constituent fibers of the single-layer structure fabric (1) is not particularly limited, but it can be 20 mm or more and 25 mm or more so as to improve the appearance retention. It can be 30 mm or more. On the other hand, if the fiber length exceeds 110 mm, fiber lumps tend to be formed during the preparation of the single-layered fabric (1), which may make it difficult to prepare the surface material (10) having excellent moldability. Therefore, it is preferably 110 mm or less, and can be 70 mm or less. The "fiber length" refers to a value measured according to JIS L1015 (2010), 8.4.1c) direct method (C method).

The various configurations of the single-layer structure fabric (1), such as thickness and basis weight, are not particularly limited and are appropriately adjusted.

The thickness of the monolayer fabric (1) can be 500 to 50,000 μm, 1000 to 3000 μm, and 1100 to 1900 μm. In the present invention, the thickness of the single-layered fabric (1) is the end point (A) and the end point (B) in the line segment calculated in the item described later (method for confirming the existence mode of the binder layer). The length between (indicated as X in the figure).

Further, the basis weight of the single-layer structure fabric (1) can be, for example, 50 to 500 g / m ² , 80 to 300 g / m ² , and 100 to 250 g / m ^2. it can. In the present invention, the basis weight means the mass per ^{1 m 2 on the} surface (main surface) having the widest area of the object to be measured.

The binder that can be used in the present invention is appropriately selected, and for example, a polyolefin resin (modified polyolefin, etc.), an ethylene vinyl alcohol copolymer, an ethylene-acrylate copolymer such as an ethylene-ethyl acrylate copolymer, various rubbers, and various rubbers. Derivatives (styrene-butadiene rubber (SBR), fluororubber, urethane rubber, ethylene-propylene-diene rubber (EPDM), etc.), cellulose derivatives (carboxymethyl cellulose (CMC), hydroxyethyl cellulose, hydroxypropyl cellulose, etc.), polyvinyl alcohol (PVA) ), Polyvinylbutyral (PVB), Polyvinylpyrrolidone (PVP), Polyurethane, Epoxy resin, Polyvinylidene fluoride (PVdF), Vinylidene fluoride-Hexafluoropropylene copolymer (PVdF-HFP), Acrylic resin (for example, versatic acid) Vinyl ester copolymerized acrylic resin) and the like can be used. It is preferable to use an acrylic resin as the binder because it softens appropriately during thermoforming and can provide a surface material (10) having excellent followability to the molding die.

Binders include, for example, flame retardants, fragrances, pigments, antibacterial agents, anti-mold materials, photocatalytic particles, inorganic particles such as silica, hollow particles such as heated and foamed particles or already foamed particles, emulsifiers, dispersants, surfactants and the like. It may contain an additive.

The basis weight of the binder contained in the single-layer structure fabric (1) is appropriately selected so as to provide a surface material (10) satisfying the configuration of the present invention. Specifically, the basis weight of the binder ^{can be 2} g / m 2 or more. Further, the basis weight of the binder can be 50 g / m ² or less, 30 g / m ² or less, and 20 g / m ² or less.

The surface material (10) according to the present invention is characterized by the presence mode of the binder layer (2) in the single-layer structure fabric (1). That is, the binder layer (2) exists only on the inner side of one main surface of the single-layered fabric (1) and on the inner side of the other main surface of the single-layered fabric (1). doing.

Here, the fact that the binder layer (2) exists only on the inner side of one main surface of the single-layered fabric (1) also means that the other of the single-layered fabric (1) has a layer (2). The fact that the binder layer (2) exists only on the inner side of the main surface of the fabric (1) is an optical microscope of a cross section of the single-layered fabric (1) photographed in the later description (method of confirming the binder layer). In the photograph, it means that the layer (2) of the binder exists without touching either one main surface and the other main surface.

The binder layer (2) existing in the single-layer structure fabric (1) can be determined by subjecting it to the following measuring method.

(How to check the binder layer)
1. 1. A sample (shape: square or rectangular) is collected from the cloth to be measured (for example, the cloth (1) or the surface material (10) having a single-layer structure).
2. Prepare a staining solution (for example, Kayastain Q (manufactured by Nippon Kayaku Co., Ltd.)) capable of staining the binder contained in the measurement target.
3. 3. The binder contained in the sample is stained with a staining solution.
4. The dyed sample is cut in the thickness direction, the glossy paper for inkjet printing (12) is placed on both main surfaces of the sample after cutting, and the glossy paper for inkjet printing (12) is further covered with a glass plate (11). The sample is sandwiched and held in the thickness direction and fixed (pressure applied by the glass plate (11) in the thickness direction of the sample: 20 g / cm ² ). Then, in that state, the cross section of the sample after cutting is photographed with a 30x optical microscope. It should be noted that the image is taken so that the entire thickness direction of the cross section of the stained sample is within the range in the vertical direction in the optical micrograph. In addition, the area of the square having a line segment indicating the length in the thickness direction of the sample as one side is photographed so as to fit in the optical micrograph.

In addition, the binder layer (2) has a series of binders so as to cross the lateral direction (direction perpendicular to the thickness direction of the sample cross section) of the above-mentioned square range in the optical micrograph. It refers to a layered form.

When the binder layer (2) is present only on the inner side of one main surface of the stained sample and on the inner side of the other main surface of the stained sample as shown in the optical micrograph. , The measurement target satisfies the configuration of the present invention. In other words, in the case described later (method for confirming the existence mode of the binder layer), when W and Y and Z are longer than 0 as shown in FIG. 1, the measurement target satisfies the configuration of the present invention.

When pressure is applied in the thickness direction of the single-layer structure fabric (1) provided with the binder layer (2) according to the present invention, the portion where the binder layer (2) exists is the portion. Since the constituent fibers are integrated with each other by a binder and are highly rigid, the portion is less likely to be deformed in the thickness direction and less likely to be thinner than the portion in which the binder layer (2) does not exist.

Further, the number of binder layers (2) included in the single-layer structure fabric (1) can be appropriately adjusted and may be plural. However, it is preferable to have only one binder layer (2) so that a surface material (10) having a main surface that is excellent in tactile sensation and is less likely to cause fibers to fall off can be easily provided. In addition to the binder layer (2), the surface material (10) according to the present invention may have a binder portion that does not exist continuously and does not form a layered form but has a band-shaped form. Good.

The thickness of the binder layer (2) can be adjusted as appropriate, but it is thinner than the thickness of the single-layered fabric (1) shown in the above-mentioned optical micrograph, and can be 200 to 1000 μm, 300. It can be ~ 500 μm. The thickness of the binder layer (2) can be obtained by the following method.

(Measuring method of binder layer thickness)
1. 1. A line segment connecting both main surfaces of the single-layered fabric (1) shown in the above-mentioned optical micrograph at the shortest distance is drawn on the optical micrograph. The end point (contact point between one main surface and the line segment) on one main surface side of the single-layer structure cloth (1) in the line segment is the end point (A), and the single-layer structure cloth (1) in the line segment. The end point on the other main surface side (the point of contact between the other main surface and the line segment) is defined as the end point (B). Then, the length between the end points (A) and the end points (B) in the line segment is defined as the thickness (unit: μm) of the fabric (1) having a single-layer structure. In the figure, the thickness of the single-layered fabric (1) is shown as X.
2. The contour of one main surface side of one binder layer (2) and the intersection (a) of the line segment shown in the light microscope photograph, and the other main surface side of the binder layer (2). The intersection (b) of the contour and the line segment is drawn on an optical micrograph.
Then, the length between the intersection (a) and the intersection (b) in the line segment is defined as the thickness (unit: μm) of the binder layer (2). In the figure, the thickness of the binder layer (2) is shown as W.

The percentage of the thickness of the binder layer (2) to the thickness of the single-layered fabric (1) can be adjusted as appropriate, but can be in the range of 5% to 80% and 10% to 60%. It can be in the range of%, and can be in the range of 20% to 30%. The percentage can be obtained by calculating the percentage of the thickness of the binder layer (2) to the thickness of the fabric (1) having a single-layer structure.

The extent to which the binder layer (2) exists on the inner side from the main surface of the single-layer structure fabric (1) can be appropriately adjusted. The existence mode of the binder layer (2) can be confirmed by the following method.

(Method of confirming the existence mode of the binder layer)
1. 1. The length (X) between the end points (A) and the end points (B) in the line segment and the distance between the end points (A) and the intersection (a) in the line segment drawn in the above (method for measuring the thickness of the binder layer). Length (shown as Y in the figure, meaning the depth from one main surface to the presence of the binder layer (2)), the length between the end point (B) and the intersection (b) in the line segment. (It means the depth from the other main surface to the presence of the binder layer (2), which is shown as Z in the figure).
2. Calculate the value of 100 × Y / X (unit:%). From the calculation result, it can be determined that the binder layer (2) exists in the range of the calculated value (unit:%) or more in the thickness direction of the single-layer structure fabric (1) from one main surface.
3. Calculate the value of 100 × Z / X (unit:%). From the calculation result, it can be determined that the binder layer (2) exists in the range of the calculated value (unit:%) or more in the thickness direction of the single-layer structure fabric (1) from the other main surface.

In the surface material (10) satisfying the configuration of the present invention, both the calculated value of 100 × Y / X and the calculated value of 100 × Z / X are larger than 0%. The calculated value can be appropriately adjusted as long as it satisfies the configuration of the present invention, but can be 5% or more, 7% or more, 10% or more, and 15%. It can be more than that. The upper limit of each calculated value can be adjusted as appropriate, but can be 73% or less, 70% or less, and 60% or less.

The surface material (10) according to the present invention satisfies the following constitution.
-W, X, Y, Z are all larger than 0.
The sum of the calculated value of 100 × Y / X and the calculated value of 100 × Z / X is less than 100%.
・ X is the sum of W + Y + Z.

Basis weight of the surface member (10), physical properties such as thickness, can be appropriately adjusted so that objects can be achieved according to the present invention, for example, can be the basis weight is ^{140~300g / m 2, 150~260g / m} 2 It can be 160-250 g / m ² . Further, the thickness can be 500 to 50,000 μm, 1000 to 3000 μm, and 1100 to 1900 μm.

The main surface of the surface material (10) (in the case of the surface material (10) composed only of the single-layer structure cloth (1) provided with the binder layer (2), the single-layer structure cloth (1)) The value of the dynamic friction coefficient of the main surface) can be 1.2 μk or less, 1.1 μk or less, and 1.0 μk or less. The coefficient of dynamic friction can be obtained by the following measuring method.

(Measurement method of dynamic friction coefficient)
The dynamic friction coefficient is a value measured using a surface tester (surface tester Tribostation Type: 32 manufactured by Shinto Kagaku Co., Ltd.). A sample (63.5 mm × about 130 mm) collected from the cloth to be measured is wrapped around a flat indenter without slack, fixed with clamps at both ends, and set on a glass plate. Then, a flat indenter is brought into contact with the exposed main surface of the sample set on the glass plate, and a load of 50 g is applied by the flat indenter in the thickness direction of the sample. Then, with the load still applied, the sample is moved at a speed of 100 mm / min by 60 mm in a direction perpendicular to the direction in which the load is applied.
From the measured dynamic friction value measured during that time (the force that resists when sliding on one surface on another surface), the dynamic friction coefficient μk (measured dynamic friction value and the force acting perpendicular to the main surface of the test piece) (Ratio with) is calculated.

The surface roughness (SMD), average friction coefficient (MIU), and variation (MMD) of the main surface of the surface material (10) are appropriately adjusted so that the surface material (10) having an excellent tactile sensation can be realized.

The surface roughness (SMD; surface loadness) is a value measured using a surface tester (KES-FB4, manufactured by Kato Tech Co., Ltd.), and a sample (20 cm square) collected from the surface material (10) is used. The tester was set with a load of 400 g, and a roughness contact (0.5 mm wire, contact surface width: 5 mm) was subjected to a load of 10.0 g to bring it into contact with the sample, and the sample was brought into contact with the sample at 1 mm / sec. It means the average deviation (average development of surface roughness data) of the surface unevenness data measured by moving at the speed of, and the unit is μm.

The surface roughness (SMD) is preferably 2.3 μm or more so that the surface material (10) on which a brushed feeling can be felt can be adjusted. The upper limit of the surface roughness (SMD) value is not particularly specified, but if the value is excessively high, the surface roughness may be strongly felt and the tactile sensation may be deteriorated. The SMD) is preferably 4.5 μm or less.

The average coefficient of friction (MIU) of the main surface of the surface material (10) is an index showing the flexibility of the main surface. The average friction coefficient (MIU) is an average value (average value of μ in a distance of 20 mm) between 20 mm of μ (friction coefficient) measured using a surface tester (KES-FB4). Yes, a sample (20 cm square) collected from the surface material (10) is set on a testing machine with a load of 400 g, and a friction element (5 mm x 5 mm) is put into contact with the sample by applying a load of 50 g to bring the sample to 1 mm. / Sec. It means the average value measured by moving at the speed of.

The average coefficient of friction (MIU) is preferably 0.19 or more. On the other hand, if the value of the average coefficient of friction (MIU) is too large, the frictional resistance may be too large and the tactile sensation may be impaired. Therefore, the value is preferably 1.6 or less.

The variation (MMD) of the average coefficient of friction of the main surface of the surface material (10) is an index showing the uniformity of the main surface. The fluctuation of the average coefficient of friction (MMD) means the average deviation in the measurement of the average coefficient of friction (MIU).

The upper limit of the variation in the average coefficient of friction (MMD) can be 0.01 or less, the lower limit can be 0.005 or more, and 0.008 or more.

The single-layered fabric (1) provided with the binder layer (2) according to the present invention may be used alone as the surface material (10), but may be further composed of another fabric, a porous body, a film, a foam, or the like. It may be a surface material (10) formed by laminating members. At this time, the fabric (1) having the single-layer structure is laminated on the surface material (10) so that the main surface is exposed.

The surface material (10) can be used as it is in the thermoforming process, but it can be processed by punching out the shape according to the application and usage mode, and various physical properties such as thickness and surface smoothness such as reliant press processing can be obtained. It may be subjected to various secondary steps such as a step of adjusting and then subjected to a thermoforming step.

Next, the method for producing the surface material (10) of the present invention will be described. The points having the same configuration as the above-mentioned items will be omitted.

The method for producing the surface material (10) according to the present invention can be appropriately selected, but as an example,
(1) Step of preparing a single-layer structure fabric (1),
(2) A step of preparing a binder liquid containing a binder and the solvent and / or dispersion medium of the binder.
(3) A step of applying the binder liquid to one main surface of the cloth (1).
(4) A step of applying the solvent and / or the dispersion medium to the one main surface of the cloth (1) to which the binder liquid is applied.
(5) A step of removing the solvent and / or the dispersion medium from the cloth (1).
Can be a method for producing the surface material (10).

The step (1) will be described.
As the cloth (1) having a single-layer structure, for example, a fiber web, a non-woven fabric, or a sheet-shaped cloth such as a woven fabric or knitting is prepared. The fineness and fiber length of the constituent fibers in the single-layered fabric (1), and the thickness and basis weight of the single-layered fabric (1) can be appropriately adjusted.

The step (2) will be described.
The type of binder can be selected as appropriate. Further, the type of solvent or dispersion medium can be appropriately selected, for example, water or the like can be adopted, but the binder can be dissolved and the single-layer structure cloth (1) can be suitably applied with the binder liquid so that the binder solution can be suitably applied to the single-layer structure cloth (1). It is preferable to use a solvent in which 1) does not dissolve, or a dispersion medium in which the binder can be dispersed and the monolayer-structured fabric (1) does not dissolve. Further, the concentration and viscosity of the binder in the binder liquid are appropriately adjusted so as to provide the surface material (10) according to the present invention.
Further, a binder liquid to which a thickener, an antifoaming agent, or the like is added may be used so that the surface material (10) of the present invention can be provided.

The step (3) will be described.
The method of applying the binder liquid to one main surface of the single-layered fabric (1) can be appropriately selected, but spraying or spraying the single-layered fabric (1) as it is or in a foamed state. A method of spraying or applying using an impregnated roll or the like, a method of immersing one main surface of the single-layer structure cloth (1) in a binder liquid, or the like can be adopted.
The amount of the binder liquid applied to one main surface of the single-layered fabric (1) is appropriately adjusted so that the surface material (10) according to the present invention can be provided. Further, the number of times the binder liquid is applied to one main surface of the single-layer structure cloth (1) may be once or a plurality of times.

Step (4) will be described.
In the step (3) described above, the solvent and / or the dispersion medium constituting the binder liquid is applied to the main surface of the single-layered fabric (1) after the binder liquid is applied to one of the main surfaces.
In the present invention, in the present step, the binder liquid existing on one main surface is transferred from the one main surface to the inner side of the fabric by the solvent and / or the dispersion medium containing no binder to be subsequently applied. It can be pushed in so that the binder liquid does not exist on one of the main surfaces.
A solvent and / or a dispersion medium-containing liquid obtained by removing the binder component from the binder liquid may be used as the solvent and / or the dispersion medium. Such a solvent and / or a dispersion medium-containing liquid may contain a thickener, an antifoaming agent, or the like.

The amount of the solvent and / or the dispersion medium applied to one main surface of the single-layered fabric (1) is appropriately adjusted so as to provide the surface material (10) according to the present invention. The number of times the solvent and / or the dispersion medium is applied to one main surface of the single-layered fabric (1) may be once or a plurality of times. Further, the solvent and / or the dispersion medium may be similarly applied to the other main surface of the single-layered fabric (1).

When the amount of the solvent and / or the dispersion medium to be applied is adjusted to a small amount, the surface material (2) in which the binder layer (2) is present in a shallow portion on the inner side from one main surface of the single-layer structure fabric (1) ( 10) is easy to realize. Further, when the amount of the solvent and / or the dispersion medium to be applied is adjusted to a large amount, the surface of the single-layer structure fabric (1) in which the binder layer (2) is present in a deep portion from one main surface to the inner side. It is easy to realize the material (10). That is, by adjusting the amount of the solvent and / or the dispersion medium applied to one main surface of the single-layered fabric (1), the presence mode of the binder layer (2) in the single-layered fabric (1). Can be adjusted.

In order to efficiently exert the above-mentioned effects, it is preferable to apply a solvent and / or a dispersion medium before the binder liquid applied to one main surface of the single-layer structure cloth (1) is dried.

The step (5) will be described.
The method for removing the solvent or the dispersion medium can be appropriately selected, and for example, it is allowed to stand in a room temperature atmosphere or a reduced pressure atmosphere by being subjected to a heater such as an oven dryer, a far-infrared heater, a dry heat dryer, or a hot air dryer. The solvent or dispersion medium can be evaporated and removed. The heating temperature at which the solvent or the dispersion medium is removed is a temperature at which the solvent or the dispersion medium can be volatilized, and the components of the monolayered fabric (1) and the functions of the binder may be unintentionally lowered. Adjust the upper limit of the heating temperature so that it does not occur.
Further, when the particles are provided with particles that are heated and foamed, the particles may be foamed by this step.

By going through the above steps, a surface material (10) satisfying the constitution according to the present invention can be prepared. Then, the interior material can be prepared by subjecting the surface material (10) to the thermoforming means. Before and after the thermoforming means, the surface material (10) or the interior material may be punched or cut out, or may be subjected to secondary processing such as giving a three-dimensional shape.

Hereinafter, the present invention will be specifically described with reference to Examples, but these do not limit the scope of the present invention.

(Preparation of single-layered fabric)
Using 100% of the original polyester fiber (fineness: 1.3 dtex, fiber length: 51 mm), the fiber was opened by a card machine to form a fiber web. After that, needle punching is performed from one side with a needle density of 400 needles / cm ² , and then the fabric is subjected to a heat roll (roll heating temperature: 150 ° C.) to form a non-woven fabric having a single-layer structure (grain: 190 g / m ² , thickness). : 1960 μm) was prepared.

(Preparation of binder liquid)
A binder solution was prepared by mixing the following formulations.
・ Thickener A (solid content concentration: 0.36 parts by mass) ・ ・ ・ 24 parts by mass ・ Thickening agent B (solid content concentration: 0.28 parts by mass) ・ ・ ・ 1 part by mass ・ Antifoaming agent (solid) Mineral concentration: 0.07 parts by mass) ・ ・ ・ 0.5 parts by mass ・ Acrylic resin emulsion (solid content concentration: 4.5 parts by mass) ・ ・ ・ 10 parts by mass ・ Silicon resin emulsion (solid content concentration: 0) .96 parts by mass) ・ ・ ・ 3 parts by mass ・ 25% concentration Ammonia water ・ ・ ・ 1 part by mass ・ Water ・ ・ ・ 60.5 parts by mass The binder component contained in this binder liquid is an acrylic resin emulsion. This binder solution was an emulsion solution of binder particles.

(Preparation of dispersion medium-containing liquid)
A dispersion medium-containing liquid prepared by mixing the following formulations was prepared.
・ Thickener A (solid content concentration: 0.39 parts by mass) ・ ・ ・ 26 parts by mass ・ Defoamer (solid content concentration: 0.07 parts by mass) ・ ・ ・ 0.5 parts by mass ・ 25% concentration ammonia Water: 1 part by mass, water: 72.5 parts by mass In addition, the binder component was not contained in the liquid containing the dispersion medium.

(Comparative Example 1)
The non-woven fabric having a single layer structure was dried with a tenter dryer having a temperature of 180 ° C. Then, it was cooled by dissipating heat to prepare a surface material (weight: 190 g / m ² , thickness: 1960 μm).

(Comparative Example 2)
In the non-woven fabric having a single-layer structure, the binder liquid was applied using a cylinder only to the main surface opposite to the main surface on the side to which the need ring was applied.
By drying the non-woven fabric having a single-layer structure to which the binder liquid was applied with a tenter dryer at a temperature of 180 ° C., the constituent fibers were adhered and fixed to each other by the acrylic resin contained in the binder liquid, and the dispersion medium was removed. Then, it was cooled by dissipating heat to prepare a surface material (weight: 197 g / m ² , thickness: 1870 μm).

(Example 1)
In the non-woven fabric having a single-layer structure, the binder liquid was applied using a cylinder only to the main surface opposite to the main surface on the side to which the need ring was applied.
Further, the dispersion medium-containing liquid was applied to the main surface of the non-woven fabric having a single-layer structure on the side to which the binder liquid was applied so as to have the same volume as the binder liquid using a cylinder.
By drying the non-woven fabric having a single-layer structure to which the binder liquid and the dispersion medium-containing liquid are applied with a tenter dryer at a temperature of 180 ° C., the constituent fibers are adhered and fixed to each other by the acrylic resin contained in the binder liquid, and the dispersion medium is used. Removed. Then, it was cooled by dissipating heat to prepare a surface material (weight: 197 g / m ² , thickness: 1830 μm).

(Example 2)
^{A surface material (weight: 197 g / m 2} , thickness: 1840 μm) was prepared in the same manner as in Example 1 except that the amount of the applied dispersion medium-containing liquid was larger than that in Example 1.

(Example 3)
^{A surface material (weight: 197 g / m 2} , thickness: 1820 μm) was prepared in the same manner as in Example 2 except that the amount of the applied dispersion medium-containing liquid was larger than that in Example 2.

Optical micrographs showing a cross section of each surface material prepared as described above are shown in FIGS. 2 to 6. The white plate-like objects existing on both main surfaces of the surface material shown in each optical micrograph are glossy paper for inkjet printing. In addition, in order to make it easier to understand the existence of the binder layer, a schematic diagram showing the approximate relationship between the lengths is also shown on the left side of the optical micrograph. Since the surface material (FIG. 2) prepared in Comparative Example 1 does not have a binder layer, it does not have portions corresponding to W, Y, and Z. Further, since the surface material (FIG. 3) prepared in Comparative Example 2 has a binder layer in contact with one of the main surfaces, it does not have a portion corresponding to Y.

Table 1 summarizes the various configurations and evaluation results of each surface material prepared as described above. In addition, "fiber shedding property" and "sensory evaluation" in Table 1 were measured by the methods described below. Items that did not have a binder layer and were not subject to measurement are marked with "-" in the table.

(Measurement method of sensory evaluation)
The brushed feeling and smoothness felt when a person touched the main surface derived from the main surface on the side opposite to the side to which the non-woven fabric having a single-layer structure was needling was evaluated. The measurement was performed by the same 10 people for each surface material. Then, the total value of each item was calculated.
The larger the total value of the raised feeling, the better the raised feeling of the main surface, and the larger the total value of the smoothness, the better the smoothness of the main surface.
Brushed feeling: Feel ... 2 points, feel a little ... 1 point, do not feel ... 0 points Smoothness: Feel ... 2 points, feel a little ... 1 point, feel grainy and feel smooth No ... 0 points

(Evaluation method of fiber shedding property)
According to JIS K7204: 1999 (Plastic-wear test method using a wear ring), the fiber shedding property of the main surface derived from the main surface on the opposite side to the needling side of the non-woven fabric having a single layer structure was evaluated for each surface material. ..
The wear tester, rotational friction speed, used wear wheel, load applied to the wear wheel, and number of times of wear are as follows.
(1) Abrasion tester: Rotary ablation tester Toyo Seiki Seisakusho Co., Ltd. (2) Rotational friction speed: 70r / min
(3) Used wear wheel No .: CS-10
(4) Load applied to the worn wheel: 4.9N
(5) Number of times of wear: 100 times The treated portion of the wear ring on the main surface portion after the test was visually observed and evaluated according to the following criteria.
Grade 3: Only some fibers were found to fall off.
Grade 2: More fiber loss was observed than in Grade 3 results.
Therefore, the surface material having received the third grade evaluation is a surface material having a main surface in which fibers are less likely to fall off than the surface material having received the second grade evaluation.

From the results of comparing the comparative examples and the examples, the surface material satisfying the configuration according to the present invention has a main surface which is excellent in tactile sensation and is less likely to cause fibers to fall off.

The surface material of the present invention is a surface material to which various interior materials can be prepared. In particular, it is a surface material that can prepare interior materials such as vehicle ceilings, pillar garnishes, doors, instrument panels, steering wheels, shift levers, console boxes, tono covers, luggage floors, and luggage sides.

10: Surface material 1: Single-layered fabric 2: Binder layer 11: Glass plate 12: Glossy paper for inkjet printing W: Binder layer thickness X: Single-layered fabric thickness Y: One main Depth from the surface to the presence of the binder layer Z: Depth from the other main surface to the presence of the binder layer A: In the line segment connecting both main surfaces of the monolayer fabric with the shortest distance. , End point on one main surface side of single-layered fabric (contact point between one main surface and line segment)
B: The end point on the other main surface side of the single-layered fabric in the line segment connecting both main surfaces of the single-layered fabric at the shortest distance (contact point between the other main surface and the line segment).
a: Intersection of one main surface side contour and line segment in the binder layer b: Intersection of the other main surface side contour and line segment in the binder layer

Claims (2)

A surface material having a binder and a single-layered fabric.
The binder layer is present only on the inner side of one main surface of the fabric and on the inner side of the other main surface of the fabric.
Surface material. (1) Step of preparing a single-layered fabric,
(2) A step of preparing a binder liquid containing a binder and the solvent and / or dispersion medium of the binder.
(3) A step of applying the binder liquid to one main surface of the fabric.
(4) A step of applying the solvent and / or the dispersion medium to the one main surface of the cloth to which the binder liquid has been applied.
(5) A step of removing the solvent and / or the dispersion medium from the fabric.
To prepare
The method for producing a surface material according to claim 1.

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