JP2021187073A - Surface material - Google Patents

Abstract

To provide a surface material which is enhanced in designability due to that prints partially exist, has both sufficient smoothness and sufficient raising feeling, and is excellent in touch feeling.SOLUTION: With respect to a surface material in which prints partially exist at least on one principal surface of a fabric, the touch feeling of the principal surface in which prints partially exist in the surface material is influenced by a distribution state of print patterns existing on the principal surface. When the surface material has print patterns whose CV value calculated by a measuring method regulated by the invention and capable of quantitatively evaluating the distribution state of the print patterns is less than 0.38, the surface material having both sufficient smoothness and sufficient raising feeling and excellent in touch feeling can be provided.SELECTED DRAWING: None

Description

The present invention relates to a surface material that can form an interior of an automobile or the like.

As a surface material that can be used for interiors of automobiles and the like, a fabric (for example, a fiber web, a non-woven fabric, a woven fabric, a knitted fabric, etc.) and a print that is composed of a resin are conventionally included, and at least one of the fabrics. A surface material having the print is used on the main surface of the fabric. As such a surface material, for example, the techniques disclosed in Japanese Patent Application Laid-Open No. 2015-104748 (Patent Document 1) and Japanese Patent Application Laid-Open No. 2016-147466 (Patent Document 2) are known. Further, when the print is partially present to form the printed pattern, it is possible to provide a surface material having a rich design.

JP 2015-104848 JP 2016-147466

The applicant of the present application examined the tactile sensation of the surface material according to the prior art as described above, that is, the surface material in which the print is present on at least one main surface of the fabric. In particular, in order to provide a surface material rich in design, the tactile sensation of the surface material in which the print is partially present on at least one main surface of the fabric was examined.

As a result of the examination, on the main surface on the side where the print of the surface material is partially present, the part where the print is not present has a raised feeling without making a person feel smooth because the fabric is exposed. I found that it plays a role that makes me feel. On the other hand, it was found that the part where the print is present plays a role of making the person feel smooth without feeling brushed because the cloth is not exposed.
From these points of view, if the total area of the prints existing on the main surface of the surface material is increased, the smoothness is improved and the brushed feeling is lowered, and the total area of the prints existing on the main surface of the surface material is reduced. It was considered that the smoothness was reduced and the brushed feeling was improved. Therefore, it is considered that a surface material having a sufficient smoothness and a sufficient brushed feeling and having an excellent tactile sensation can be realized as long as the total area of the print existing on the main surface of the surface material is optimized.

However, when the applicant of the present application prepared and compared surface materials having the same total area of prints but different sizes of printed patterns and spacing between printed patterns, prints on those surface materials were partially present. The tactile sensations on the main surface were not the same but different. From this result, it was found that the tactile sensation of the main surface in which the print is partially present in the surface material is different from the initial assumption and does not depend only on the print area. Therefore, in order to realize a surface material having an excellent tactile sensation, it is considered necessary to find a new factor that contributes to the improvement of the tactile sensation and to optimize the factor.

It is an object of the present invention to provide a surface material having an excellent design due to the partial presence of a print, and having a sufficient smoothness and a sufficient brushed feeling, and having an excellent tactile sensation.

The present invention is "a surface material having a print partially present on at least one main surface of the fabric, wherein the CV value calculated by the following measuring method is less than 0.38.
Note 1. A micrograph of the main surface of the surface material on the side where the print is present is magnified 30 times, and micrographs are taken at different locations on the main surface to prepare a total of 10 micrographs. Adjust so that the main surface is larger than a rectangle with a long side of 10.2 mm and a short side of 7.6 mm in the photograph.
2. 2. A rectangle (long side 10.2 mm, short side 7.6 mm) is drawn on the main surface shown in each micrograph.
3. 3. Calculate the print area existing in the portion surrounded by the rectangle.
4. The ratio of the printed area to the area (area: 77.52 mm ^{2) of the portion surrounded by the rectangle is calculated.}
5. For each of the 10 micrographs, the ratio is calculated using the method of items 3 to 4 described above.
6. Using the calculated average value of the ratio of 10 points and the standard deviation of the ratio of 10 points, the CV value is calculated based on the following formula.
CV value = standard deviation of the ratio of 10 points / average value of the ratio of 10 points. ".

The applicant of the present application has stated that for a surface material in which a print is partially present on at least one main surface of the fabric, the tactile sensation of the main surface in which the print is partially present in the surface material is on the main surface. We found that it was affected by the distribution of existing print patterns.
Then, when the surface material has a printed pattern in which the CV value that can quantitatively evaluate the distribution state of the printed pattern calculated by the measuring method specified by the present invention is less than 0.38, the surface material is sufficiently smooth. It has been found that it is possible to provide a surface material having an excellent tactile sensation, which has both a sufficient brushed feeling and a sensation of raising.
From the above, according to the present invention, it is possible to provide a surface material having an excellent design, which is rich in design due to the partial presence of the print, and which has a sufficient smoothness and a sufficient brushed feeling, and has an excellent tactile sensation.

Further, the applicant of the present application has found that the surface material satisfying the configuration according to the present invention is less likely to cause fluffing on the main surface on which the print is present. Therefore, according to the present invention, it is possible to provide a surface material having a further excellent tactile sensation, in which fluffing is less likely to occur and a decrease in tactile sensation is prevented.

In the present invention, various configurations such as the following configurations can be appropriately selected. Unless otherwise specified or specified, the various measurements described in the present invention were carried out under normal pressure under 25 ° C. temperature conditions. Then, unless otherwise specified or specified, the various measurement results described in the present invention were obtained by measurement up 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, if 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 to the second decimal place. Then, this value was used as the value to be calculated. Further, each upper limit value and each lower limit value exemplified in the present invention can be arbitrarily combined.

The surface material according to the present invention has a fabric and a print, and the print is partially present on at least one main surface of the fabric.

The cloth 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. Since the surface material of the present invention contains a cloth, it is possible to provide a surface material having excellent moldability such as excellent flexibility and excellent followability to a mold, and also having an excellent tactile sensation. In particular, a surface material provided with a fabric (particularly, a non-woven fabric) in which all constituent fibers are randomly entangled is preferable because it can provide a surface material having more flexibility, excellent moldability, and a more excellent tactile sensation.

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 nitrile group or a halogen such as fluorine or chlorine), a styrene resin, and the like. , Polyvinyl alcohol-based resin, polyether-based resin (for example, polyetheretherketone, polyacetal, modified polyphenylene ether, aromatic polyetherketone, etc.), polyester-based resin (for example, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, etc.) Polyethylene naphthalate, polybutylene naphthalate, polycarbonate, polyarylate, all aromatic polyester resin, etc.), polyimide resin, polyamideimide resin, polyamide resin (for example, aromatic polyamide resin, aromatic polyetheramide resin, nylon resin) , Etc.), Ditril group-bearing resins (eg, polyacrylonitrile, etc.), urethane-based resins, epoxy-based resins, polysulfone-based resins (eg, polysulfone, polyethersulfone, etc.), fluororesins (eg, polytetrafluoroethylene, etc.) Polyacrylonitrile resin, which is a copolymer of polyvinylidene fluoride, cellulose resin, polybenzoimidazole resin, acrylic resin (for example, acrylic acid ester or methacrylic acid ester, etc.), Modaacrylic which is a copolymer of acrylonitrile and vinyl chloride or vinylidene chloride. It can be configured by using a known resin such as (based resin, etc.). In addition, these resins may be made of either a linear polymer or a branched polymer, and the resin may be a block copolymer or a random copolymer, and the presence or absence of the three-dimensional structure and crystallinity of the resin. Is not particularly limited to anything. Further, it may be a mixture of a multi-component resin.

When the surface material is required to be flame-retardant, it is preferable that the constituent fibers of the fabric contain the 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 retardant agents. Further, it may be a fiber prepared by kneading a pigment or a dyed fiber such as a dyed fiber. Further, a flame retardant may be supported by using a binder or the like.

The constituent fibers may be made of one kind of resin or may be made of a plurality of kinds 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.

When the fabric contains heat-sealing fibers as constituent fibers, the fibers can be heat-fused together to impart strength and morphological stability to the fabric. Such a heat-fused fiber may be a fully-fused type heat-fused fiber, or may be a partially fused-type heat-fused fiber such as the above-mentioned composite fiber. Is also good. As a component (resin) 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, it is possible to provide a surface material having increased elasticity, excellent followability to the mold, and excellent tactile sensation. 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.

These constituent fibers may contain irregular cross-section fibers in addition to substantially circular fibers and elliptical fibers. In addition, as the irregular cross-sectional fiber, a polygonal shape such as a hollow shape or a triangular shape, an alphabet 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.

The fineness of the constituent fibers is not particularly limited, but is preferably 0.1 to 50 dtex, more preferably 0.5 to 30 dtex, so as to provide a surface material having an excellent tactile sensation. It is more preferably 0 to 10 dtex.

Further, the fiber length of the constituent fibers is not particularly limited, but is preferably 20 mm or more, more preferably 25 mm or more, and more preferably 30 mm or more so that a surface material having an excellent tactile sensation can be provided. Is more preferable. On the other hand, if the fiber length exceeds 110 mm, fiber lumps tend to be formed during the preparation of the fabric, and it may be difficult to provide a surface material having an excellent tactile sensation. Therefore, the fiber length is preferably 110 mm or less, preferably 60 mm. The following is more preferable. The "fiber length" refers to a value measured according to JIS L1015 (2010), 8.4.1c) direct method (C method).

The constituent fibers are, for example, melt-spun, dry-spun, wet-spun, direct-spun (melt-blow, spunbonded, electrostatic-spun, etc.), and by removing one or more 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 and a method of beating the fibers to obtain divided fibers.

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), etc.) 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 heat treatment, the constituent fibers are bonded, integrated or melted by a binder or an adhesive fiber. The method of unifying them can be mentioned.

The method of heat treatment 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.

A binder may be used to bond the fibers constituting the fabric to each other. The type of binder that can be used is appropriately selected, and for example, polyolefins (modified polyolefins, etc.), ethylene vinyl alcohol copolymers, ethylene-acrylate copolymers such as ethylene-ethyl acrylate copolymers, various rubbers and derivatives thereof ( 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), polyvinyl Butyral (PVB), polyvinylpyrrolidone (PVP), epoxy resin, polyvinylidene fluoride (PVdF), vinylidene fluoride-hexafluoropropylene copolymer (PVdF-HFP), acrylic resin (acrylic acid ester resin, acrylonitrile styrene co-weight) Combined resin, etc.), polyurethane resin, etc. can be used. When the binder contains an acrylic resin, it is moderately softened during thermoforming such as heat pressing using a mold, so that it is possible to provide a surface material having excellent followability to the mold. In addition to the above-mentioned resins, the binder contains additives such as flame retardants, fragrances, pigments, antibacterial agents, anti-mold materials, photocatalytic particles, emulsifiers, dispersants, surfactants, and thickeners. You may.

The basis weight of the binder contained in the fabric is appropriately selected, but the smaller the amount of the binder, the more flexible the surface material tends to be provided. Therefore, the basis weight of the binder provided in the fabric is preferably 50 g / m ² or less, preferably 30 g / m ² or less, preferably 10 g / m ² or less, and the fabric without a binder is used. It is more preferable to have it.
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 composition of the fabric, for example, the thickness and the basis weight, is not particularly limited and may be adjusted as appropriate. The thickness of the fabric can be 0.5-5 mm, 1-3 mm, 1.1-1.9 mm. The basis weight of the fabric can be, for example, 50 to 500 g / m ² , 80 to 300 g / m ² , and 100 to 250 g / m ² . ^{In the present invention, the thickness means the length in the vertical direction when a compression load of 20 g / cm 2} is applied in the direction perpendicular to the main surface, and the grain means the surface having the widest area of the object to be measured (main surface). ) Refers to the mass per 1 m ^2.

The print in the present invention refers to a layer containing a resin that is partially present on at least one main surface of the fabric and mainly plays a role of improving the design and tactile sensation of the surface material. Even if the print according to the present invention is in an aspect of being present on the main surface of the fabric by directly contacting the main surface of the fabric, the main surface is interposed between the main surface and another resin layer (for example, another resin layer). It may be an aspect existing above. Specifically, in addition to the surface material having a structure of cloth-print from one main surface to the other main surface, a surface material having a structure of cloth-another resin layer-print is also a structure of the present invention. Can be satisfied.

The type of resin constituting the print can be appropriately selected, and the same resin as the above-mentioned binder can be used. In particular, since it is moderately softened during thermoforming such as heat pressing using a mold, it is possible to provide a surface material that follows the mold and has excellent moldability, and also provides a surface material with excellent tactile sensation. It is preferable that the constituent resin contains an acrylic resin. In addition to the resin, the print may contain additives such as flame retardants, fragrances, pigments, antibacterial agents, anti-mold materials, photocatalysts, emulsifiers, dispersants, surfactants, and thickeners.

The print according to the present invention may contain particles (solid particles or hollow particles). The particles can play a role of imparting color to the print to improve the design of the surface material and a role of giving unevenness to the main surface of the surface material to improve the tactile sensation. The average particle size of the particles contained in the print is appropriately adjusted, but the average particle size of the particles is preferably 106 μm or less, and the average particle size is 85 μm or less so as to be a surface material having an excellent tactile sensation. preferable. The lower limit of the average particle size can be appropriately selected, but it is realistic that it is 30 μm or more, and it is preferably larger than 35 μm. In the present invention, the average particle size of the particles is a value calculated by the following method.

(Calculation method of average particle size)
(1) A plurality of particles are collected from the print of the surface material, and an optical micrograph of 200 times the collected particles is taken in an atmosphere of room temperature (25 ° C.). Then, 10 particles are randomly selected from the particles shown in the photograph.
(2) The particle size of each of the 10 selected particles is calculated, and the average value of the calculated values is taken as the average particle size. The diameter of a circle having the same area as the area of the particles shown in the photograph is calculated, and the value of the diameter is regarded as the particle diameter of the particles.
The type of particles to be measured is known, and the average particle size (for example, in the case of heat-expanding particles, the average particle size after heating) is described in catalogs, specifications, etc. If so, the average particle size of the particles can be determined based on the values described.

When the print of the surface material according to the present invention contains particles, the type of the particles can be appropriately selected, and the surface material may be solid particles or hollow particles, but a surface material having an improved tactile sensation is provided. Since it is easy, it is preferable to use hollow particles. Further, the constituent components of the particles can be appropriately selected, for example, inorganic particles composed of an inorganic component such as silica or alumina, organic particles composed of a resin, or particles having a composition containing a resin and an inorganic component. You may.

The hollow particles here mean particles having cavities inside. Since hollow particles are more easily deformed in the particle diameter direction than solid particles, when a person touches the main surface of a surface material containing hollow particles, the person feels elasticity rather than the tactile sensation when touching a hard object. Feel the tactile sensation when you touch what you have. As a result, it is possible to provide a surface material having an improved tactile sensation due to the fact that the flexibility is easily felt when the main surface of the surface material is touched.

The components constituting the particles can be appropriately selected. When the particles are hollow particles, it is preferable that the component constituting the hollow particles contains a resin so that the particles are easily deformed in the particle diameter direction. Further, if hollow particles having a structure containing a resin and an inorganic component are adopted as the hollow particles, it becomes easy to prepare a printing liquid in which the hollow particles are uniformly dispersed in a dispersion medium. As a result, by applying the printing liquid to the fabric, it is preferable that a surface material having a print in which hollow particles are uniformly distributed and having a higher quality and an excellent tactile sensation can be efficiently provided as intended.

Specific examples of the hollow particles include MFL-81GTA, MFL-81GCA, MFL-SEVEN, MFL-HD30CA, MFL-HD60CA, MFL-100MCA, and MFL-110CAL of Matsumoto Yushi Pharmaceutical Co., Ltd. Further, particles that thermally expand when heated may be adopted. Examples of such particles include 920DU40, 909DU80, and 930DU120 of Nippon Philite Co., Ltd., which thermally expand to become hollow particles.

The print may contain a plurality of types of particles, but in order to provide a surface material having a better tactile sensation, the print contains only hollow particles having the above-mentioned configuration as particles that contribute to the improvement of the design and the tactile sensation. It is preferable that the surface material is provided with.

It should be noted that the particles may be present only on the exposed main surface of the print, or the particles may be present inside the print and on the exposed main surface.

The aspect of the print present on one main surface of the fabric can be appropriately adjusted as long as it is not present so that the print covers the entire main surface but is partially present. For example, a pattern having a pattern such as a parallel line or a grid pattern, a pattern having a dot-like pattern, a pattern having an indefinite shape such as a leather grain pattern, or the like can be used. The size per print pattern (the average value of the maximum lengths of line segments that can be drawn in each print pattern) can be adjusted as appropriate, and can be 0.1 to 15 mm, and 0.1 to 8 mm. It can be 0.1 to 2.0 mm. Further, the distance between the printed patterns (the average value of the shortest distances between the adjacent printed patterns) can be adjusted as appropriate, but can be 0.1 to 5 mm, 0.3 to 3 mm, and 0. It can be 5.5 to 1.0 mm.

For surface materials with a regular pattern of printed patterns, the tactile sensation felt when touching the part where the print is present and the part where the print is not present (the part where the fabric is exposed) are touched. It is easy for a person to judge that the difference in tactile sensation is in line with the regular pattern aspect of the printed pattern. As a result, the aspect of the printed pattern unintentionally affects the evaluation of the quality of the tactile sensation felt when the surface material is touched, and there is a possibility that it becomes difficult to unintentionally provide the surface material having an excellent tactile sensation. Therefore, in order to easily provide a surface material having an excellent tactile sensation, the size of each print pattern constituting the print and the spacing between the print patterns are irregular prints (hereinafter, may be referred to as irregular print patterns). ) Is preferable. As a surface material having such an irregular print pattern, for example, a surface material having a leather grain pattern print can be mentioned.

As long as the percentage of the printed area partially present on the main surface of the fabric is more than 0% and less than 100%, a surface material having an excellent tactile sensation can be provided as appropriate. Can be adjusted. Specifically, it can be 20 to 90%, 30 to 80, 40 to 70, and 50 to 60. In particular, as is clear from the examples described later, 20 to 50% is preferable because it is possible to provide a surface material having a further excellent tactile sensation.

The percentage can be calculated by the following method.
1. 1. A total of 10 micrographs are prepared by taking micrographs of the main surface of the surface material on the side where the print is present, magnified 30 times, at different locations on the main surface. It should be noted that the main surface is adjusted to be larger than a rectangle having a long side of 10.2 mm and a short side of 7.6 mm in the micrograph.
2. 2. Draw a rectangle (long side 10.2 mm, short side 7.6 mm) on the main surface shown in each micrograph.
3. 3. The print area existing in the portion surrounded by the rectangle is calculated for each micrograph.
4. The calculated average value of each print area is substituted into the following formula to calculate the percentage.
Percentage = 100 x (average value of each print area / 77.52)

The applicant of the present application can quantitatively evaluate the distribution state of the printed pattern calculated by the measuring method specified by the present invention on the surface material in which the print is partially present on at least one main surface of the fabric. It has been found that when the surface material has a printed pattern having a CV value of less than 0.38, it is possible to provide a surface material having a sufficient smoothness and a sufficient brushed feeling and having an excellent tactile sensation.

The closer the CV value is to 0, the more the printed patterns constituting the print have the same size, and the printed patterns tend to be arranged at equal intervals. Means. The surface materials in which the printed patterns constituting the print have the same size and the printed patterns are arranged at equal intervals have a CV value of 0 and are sufficiently brushed. Since it becomes difficult to feel the feeling, it may be difficult to provide a surface material having an excellent tactile sensation. Therefore, the lower limit of the CV value is preferably larger than 0, and preferably 0.03 or more.

On the other hand, the larger the CV value of the surface material, such as the CV value of 0.38 or more, the more the size of each printed pattern constituting the print and the interval between the printed patterns tend to be irregular. .. As examined by the applicant of the present application, if the CV value is too large, it becomes impossible to provide a surface material having sufficient smoothness and sufficient brushed feeling and having an excellent tactile sensation. Therefore, the CV value is less than 0.38 and the CV. The upper limit of the value is preferably 0.35 or less, preferably 0.30 or less, and preferably 0.26 or less.

The CV value can be calculated by the following method.
1. 1. A total of 10 micrographs are prepared by taking micrographs of the main surface of the surface material on the side where the print is present, magnified 30 times, at different locations on the main surface. It should be noted that the main surface is adjusted to be larger than a rectangle having a long side of 10.2 mm and a short side of 7.6 mm in the micrograph.
2. 2. Draw a rectangle (long side 10.2 mm, short side 7.6 mm) on the main surface shown in each micrograph.
3. 3. The print area existing in the part surrounded by the rectangle is calculated.
4. The ratio of the printed area to the area (area: 77.52 mm ^{2) of the portion surrounded by the rectangle is calculated.}
5. For each of the 10 micrographs, the ratio is calculated using the method of items 3 to 4 described above.
6. Using the calculated average value of the ratio of 10 points (without unit) and the standard deviation of the ratio of 10 points (without unit), the CV value (without unit) is calculated based on the following formula.
CV value = standard deviation of the ratio of 10 points / average value of the ratio of 10 points

The print may be provided with a layer containing one type of resin, or may be provided with a plurality of layers containing one type or a plurality of types of resin, and specifically, the pattern, the resin, or the content is the same or different. You may have multiple prints.

If the print is partially present on one main surface of the fabric, the print may be partially present on both main surfaces of the fabric.
In addition to the mode in which the print partially exists only on the main surface of the fabric, the print is a mode in which a part of the components (resin, etc.) constituting the print penetrates between the constituent fibers constituting the fabric. May be good.

The basis weight of the print provided on the surface material is appropriately selected, and may be, for example, ² to 50 g / m ^{2 or 5} to 30 g / m 2.

Various configurations of the surface material, such as thickness and basis weight, are not particularly limited and are appropriately adjusted. The thickness of the surface material can be 0.5-5 mm, 1-3 mm, 1.1-1.9 mm. The basis weight of the fabric can be, for example, 50 to 500 g / m ² , 80 to 300 g / m ² , and 100 to 250 g / m ² .

The surface material of the present invention may further include constituent members such as a porous body, a film, and a foam. It is preferable that these constituent members are laminated on the main surface side of the surface material, which is different from the main surface on the side where the print is present.

Next, a method for producing the surface material of the present invention will be described. The points having the same configuration as the items described for the surface material described above will be omitted. The method for producing the surface material according to the present invention can be appropriately selected, but as an example,
1. 1. The process of preparing the fabric,
2. 2. A process of preparing a printing liquid by mixing a resin that can form a print with a solvent or a dispersion medium.
3. 3. A step of partially applying a printing liquid onto at least one main surface of a fabric,
4. A step of removing the solvent or dispersion medium contained in the printing liquid from the fabric to which the printing liquid is applied.
A method for manufacturing a surface material can be mentioned.

Step 1 will be described. As the cloth, for example, a fiber web, a non-woven fabric, or a sheet-shaped cloth such as a woven fabric or a knitted fabric is prepared. As the fineness and fiber length of the constituent fibers in the fabric, and the thickness and basis weight of the fabric, the above-mentioned numerical values can be adopted.

Step 2 will be described. The type of dispersion medium can be appropriately selected, but a solvent in which a resin capable of forming a print is dissolved is adopted so that a printing liquid can be suitably applied onto one main surface of the fabric, or a resin capable of forming a print is used. It is preferable to use a dispersion medium that does not dissolve and can be dispersed. In addition to resin, the printing liquid includes, for example, particles (solid particles and hollow particles), flame retardant, fragrance, pigment, antibacterial agent, anti-mold material, photocatalyst, emulsifier, dispersant, surfactant, and thickening agent. Additives such as agents may be dissolved or dispersed and contained. In particular, when the printing liquid contains a pigment, it is preferable because a surface material having excellent designability can be provided.

Step 3 will be described. The method of applying the printing liquid on one main surface of the fabric can be appropriately selected, but the main surface of the fabric is mainly applied by spraying or gravure roll with the printing liquid as it is or in a foamed state. It is possible to select a method of partially applying the printing liquid to the surface and printing so as to form a pattern, or a method of printing and applying the printing liquid. In addition to applying one type of printing liquid, a plurality of types of printing liquid may be applied. Further, when a plurality of types of printing liquids are applied, the mode of application of each printing liquid (composition of contained particles, pattern, composition of printing liquid) may be different.

Step 4 will be described. A method of preparing a fabric having a print by removing a solvent or a dispersion medium can be appropriately selected. For example, a room temperature atmosphere in which the fabric is heated 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 by allowing it to stand underneath or in a reduced pressure atmosphere. The heating temperature at which the solvent or the dispersion medium is removed is a temperature at which the dispersion medium can volatilize, and is heated so that the shape and function of constituent members such as the resin constituting the fabric and the print do not unintentionally decrease. Select the upper limit of temperature. When the fabric is a fiber web, the non-woven fabric is formed by adhering the constituent fibers to each other by this step (adhering with a molten binder or melting and adhering the thermoplastic component contained in the constituent fibers). You may.

In the above-mentioned method for manufacturing a surface material, there are various secondary processes such as a process of laminating other constituent members such as a porous body, a film, and a foam, and a process of punching a shape according to an application and a mode of use. It may be a method of manufacturing a surface material including a process. In addition, these constituent members can be laminated and provided on the main surface side of the surface material different from the main surface on the print side. Further, it may be subjected to a pressure treatment step for smoothing the surface, such as a reliant press treatment.

Hereinafter, the present invention will be specifically described with reference to Examples, but these do not limit the scope of the present invention. The smoothness and raised feeling (tactile feeling) of each surface material prepared as described later, and the difficulty of fluffing were evaluated by using the following methods.

(Evaluation method of smoothness and brushed feeling (tactile feeling))
One main surface of the surface material (in the case of a surface material having a print, the main surface on the side where the print is exposed and present) was scored for the smoothness and brushed feeling felt when a person touched it. The measurement was performed by the same 10 monitors for each surface material.
Smoothness: Feels ... 2 points, feels a little ... 1 point, feels rough and does not feel smooth ... 0 points Brushed feeling: feels ... 2 points, feels a little ... 1 point, feels No ... 0 points Next, average values were calculated for each of the evaluation points of smoothness and brushed feeling. The higher the average value of smoothness is, the more the surface material has a main surface having excellent smoothness, and the higher the average value of the brushed feeling is, the more the surface material has a main surface having excellent brushed feeling. Means.
If the average value of smoothness calculated as described above is 1.0 points or more and less than 1.5 points, it is evaluated as "○" as being rich in smoothness, and the average value of smoothness is 1.5 points. Those with a score of 2.0 or less were evaluated as "◎" as being richer in smoothness. On the other hand, those having an average value of smoothness of less than 1.0 points were evaluated as "x" as being inferior in smoothness.
Further, if the average value of the raised feeling calculated as described above is 1.0 points or more and less than 1.5 points, it is evaluated as “〇” as having a rich raised feeling, and the average value of the raised feeling is 1. Those with a score of 5 or more and 2.0 or less were evaluated as "◎" as having a more brushed feeling. On the other hand, those having an average value of brushed feeling of less than 1.0 points were evaluated as "x" as being inferior in brushed feeling.

(Evaluation method for the difficulty of fluffing)
According to JIS K7204: 1999 (Plastic-wear test method using a wear ring), fluffing is applied to one main surface of each surface material (in the case of a surface material having a print, the main surface on the side where the print is exposed and exists). Was evaluated whether or not it was likely to occur. 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 abrasion tester Toyo Seiki Seisakusho Co., Ltd. (2) Rotational friction speed: 70r / min
(3) Worn wheel used No: CS-10
(4) Load applied to the worn wheel: 2.45N
(5) Number of times of wear: 50 times The treated portion of the wear ring on the main surface of the surface material after the test was visually observed and evaluated according to the following criteria. It should be noted that the larger the series, the more the surface material has a main surface that is less likely to cause fluffing.
Grade 4: No fluffing was observed.
Grade 3: Small fluffing was observed, but large fluffing caused by the continuous fluffing was not observed.
Grade 2: Small fluffing was observed, and large fluffing caused by the continuous fluffing was partially observed.
Grade 1: Small fluffing was observed, and it was further observed that large fluffing caused by the continuous fluffing formed a circle and occurred on the entire surface of the part.

(Preparation of cloth)
A fiber web was formed by opening 100% of the original polyester fiber (fineness: 1.3 dtex, fiber length: 38 mm) to a card machine. Next, a needle punching treatment was performed from one side of the fiber web ^{to prepare a needle punching nonwoven fabric (grain: 180 g / m 2} , thickness: 1.5 mm).

(Preparation of printing liquid)
A printing liquid prepared in the proportions described below was prepared.
-Acrylic acid ester resin emulsion (Tg of acrylic acid ester resin: -40 ° C, solid content mass of acrylic acid ester resin emulsion: 50% by mass): 20 parts by mass-Thickener (solid content mass: 1.5% by mass) ): 25 parts by mass, defoaming agent (solid content mass: 14% by mass): 0.5 parts by mass, silicon-based resin emulsion (solid content mass: 33.8% by mass): 3 parts by mass, pigment (solid content mass) : 3.8% by mass): 0.1 part by mass, 25% ammonia water: 1 part by mass, water: 50.4 part by mass

(Reference example 1)
The needle punched non-woven fabric was used as the surface material as it was.

(Reference example 2)
The printing liquid was printed on the entire surface of one of the main surfaces of the needle punched non-woven fabric. Then, by drying with a dryer at a temperature of 160 ° C., a surface material having a print derived from the printing liquid on the entire surface of one of the main surfaces of the needle punched non-woven fabric (weight: 205 g / m ² , thickness: 1.5 mm). Was prepared.
In the surface material prepared in this way, the printed material is present on the entire surface of one main surface of the binder adhesive nonwoven fabric, and the percentage of the printed area existing on the main surface in the main surface is It was 100%.

Table 1 summarizes the physical characteristics of the reference examples and the results of the tactile sensation evaluation method. In addition, "-" is described in the table for the configurations that are not provided. In addition, the percentage of the printed area existing on the main surface of the surface material is described in the "Print area percentage" column in the table.

(Example 1)
The printing liquid was partially printed on one main surface of the needle punched non-woven fabric using a cylinder having a convex portion of a leather grain pattern on the surface. Then, by drying using a dryer having a temperature of 160 ° C., a surface material having a print derived from the printing liquid partially on one main surface of the needle punched nonwoven fabric (weight: 185 g / m ² , thickness). S: 1.5 mm) was prepared.
The surface material prepared in this way has a print composed of a leather grain pattern printed pattern on the entire main surface of one of the needle punched nonwoven fabrics, and is on the main surface occupying the main surface. The percentage of the printed area present was 20%. Moreover, the CV value of the print provided in the surface material prepared in this way was as shown in Table 2.

(Example 2, Comparative Examples 1 and 2)
Similar to Example 1, a surface material having a print derived from a printing liquid partially on one main surface of the needle punched nonwoven fabric, except that the shape of the convex portion of the cylinder is changed. 185 g / m ² , thickness: 1.5 mm) was prepared.
The surface material prepared in this way has a print composed of a leather grain pattern printed pattern on the entire main surface of one of the needle punched nonwoven fabrics, and is on the main surface occupying the main surface. The percentage of the printed area present was 20%. Moreover, the CV value of the print provided in the surface material prepared in this way was as shown in Table 2.

Table 2 summarizes the physical characteristics of the comparative examples and the examples, and the results of the tactile sensation evaluation method. In addition, "-" is described in the table for the configurations that are not provided. In addition, the percentage of the printed area existing on the main surface of the surface material is described in the "Print area percentage" column in the table.

(Example 3)
Similar to Example 1, a surface material having a print derived from a printing liquid partially on one main surface of the needle punched nonwoven fabric, except that the shape of the convex portion of the cylinder is changed. 188 g / m ² , thickness: 1.5 mm) was prepared.
The surface material prepared in this way has a print composed of a leather grain pattern printed pattern on the entire main surface of one of the needle punched nonwoven fabrics, and is on the main surface occupying the main surface. The percentage of the printed area present was 30%. Moreover, the CV value of the print provided in the surface material prepared in this way was as shown in Table 3.

(Examples 4 to 5, Comparative Example 3)
Similar to Example 3, a surface material having a print derived from a printing liquid partially on one main surface of the needle punched nonwoven fabric, except that the shape of the convex portion of the cylinder is changed. 188 g / m ² , thickness: 1.5 mm) was prepared.
The surface material prepared in this way has a print composed of a leather grain pattern printed pattern on the entire main surface of one of the needle punched nonwoven fabrics, and is on the main surface occupying the main surface. The percentage of the printed area present was 30%. Moreover, the CV value of the print provided in the surface material prepared in this way was as shown in Table 3.

Table 3 summarizes the physical characteristics of the comparative examples and the examples, and the results of the tactile sensation evaluation method. In addition, "-" is described in the table for the configurations that are not provided. In addition, the percentage of the printed area existing on the main surface of the surface material is described in the "Print area percentage" column in the table.

(Example 6)
Similar to Example 1, a surface material having a print derived from a printing liquid partially on one main surface of the needle punched nonwoven fabric, except that the shape of the convex portion of the cylinder is changed. 190 g / m ² , thickness: 1.5 mm) was prepared.
The surface material prepared in this way has a print composed of a leather grain pattern printed pattern on the entire main surface of one of the needle punched nonwoven fabrics, and is on the main surface occupying the main surface. The percentage of the printed area present was 40%. Moreover, the CV value of the print provided in the surface material prepared in this way was as shown in Table 4.

(Examples 7 to 8, Comparative Example 4)
Similar to Example 6, a surface material having a print derived from a printing liquid partially on one main surface of the needle punched nonwoven fabric, except that the shape of the convex portion of the cylinder is changed ((Metsuke). : 190 g / m ² , thickness: 1.5 mm) was prepared.
The surface material prepared in this way has a print composed of a leather grain pattern printed pattern on the entire main surface of one of the needle punched nonwoven fabrics, and is on the main surface occupying the main surface. The percentage of the printed area present was 40%. Moreover, the CV value of the print provided in the surface material prepared in this way was as shown in Table 4.

Table 4 summarizes the physical characteristics of the comparative examples and the examples, and the results of the tactile sensation evaluation method. In addition, "-" is described in the table for the configurations that are not provided. In addition, the percentage of the printed area existing on the main surface of the surface material is described in the "Print area percentage" column in the table.

(Example 9)
Similar to Example 1, a surface material having a print derived from a printing liquid partially on one main surface of the needle punched nonwoven fabric, except that the shape of the convex portion of the cylinder is changed. 193 g / m ² , thickness: 1.5 mm) was prepared.
The surface material prepared in this way has a print composed of a leather grain pattern printed pattern on the entire main surface of one of the needle punched nonwoven fabrics, and is on the main surface occupying the main surface. The percentage of the printed area present was 50%. Moreover, the CV value of the print provided in the surface material prepared in this way was as shown in Table 5.

(Examples 10 to 11, Comparative Example 5)
Similar to Example 9, a surface material having a print derived from a printing liquid partially on one main surface of the needle punched nonwoven fabric, except that the shape of the convex portion of the cylinder is changed. 193 g / m ² , thickness: 1.5 mm) was prepared.
The surface material prepared in this way has a print composed of a leather grain pattern printed pattern on the entire main surface of one of the needle punched nonwoven fabrics, and is on the main surface occupying the main surface. The percentage of the printed area present was 50%. Moreover, the CV value of the print provided in the surface material prepared in this way was as shown in Table 5.

Table 5 summarizes the physical characteristics of the comparative examples and the examples, and the results of the tactile sensation evaluation method. In addition, "-" is described in the table for the configurations that are not provided. In addition, the percentage of the printed area existing on the main surface of the surface material is described in the "Print area percentage" column in the table.

According to the present invention, it has been found that the partial presence of the print makes it possible to provide a surface material which is rich in design and has a sufficient smoothness and a sufficient brushed feeling and is excellent in tactile sensation.

Further, as a result of comparing Examples 1 and 2 with Comparative Examples 1 and 2, as a result of comparing Examples 3 to 5 with Comparative Example 3, and as a result of comparing Examples 6 to 8 with Comparative Example 4, Examples 9 to 9 to From the result of comparing 11 and Comparative Example 5, the print is partially present on at least one main surface of the fabric and the CV value is less than 0.38, so that the print on the surface material is partially present. It was found that fluffing is less likely to occur on the main surface that exists in.
Therefore, it has been found that the present invention also exerts an effect that it is possible to provide a surface material which is less likely to cause fluffing and thus is prevented from deteriorating in tactile sensation and has a further excellent tactile sensation.

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.

Claims (1)

A surface material in which a print is partially present on at least one main surface of the fabric.
A surface material having a CV value of less than 0.38 calculated by the following measuring method.
Note 1. A micrograph of the main surface of the surface material on the side where the print is present is magnified 30 times, and micrographs are taken at different locations on the main surface to prepare a total of 10 micrographs. Adjust so that the main surface is larger than a rectangle with a long side of 10.2 mm and a short side of 7.6 mm in the photograph.
2. 2. A rectangle (long side 10.2 mm, short side 7.6 mm) is drawn on the main surface shown in each micrograph.
3. 3. Calculate the print area existing in the portion surrounded by the rectangle.
4. The ratio of the printed area to the area (area: 77.52 mm ^{2) of the portion surrounded by the rectangle is calculated.}
5. For each of the 10 micrographs, the ratio is calculated using the method of items 3 to 4 described above.
6. Using the calculated average value of the ratio of 10 points and the standard deviation of the ratio of 10 points, the CV value is calculated based on the following formula.
CV value = standard deviation of the ratio of 10 points / average value of the ratio of 10 points.