JP2021194913A - Surface material - Google Patents

Abstract

To provide a surface material which can achieve an interior material that has good quality and rich in touch feeling even when a thickness is thin by acting heat and pressure thereon.SOLUTION: A surface material has a mass of a resin contained per 1 m2 of a print printed on a main surface of more than 11.2 g, and has a mass of particles contained per 1 m2 of a print printed on the main surface of more than 4.0 g, and thereby can achieve an interior material rich in touch feeling. A surface material has a mass of a resin contained per 1 m2 of a print printed on a main surface of less than 32.8 g, and thereby prevents blurring of a pattern caused by unintentional flow of the print when heat and pressure acts on the surface material, and/or prevents presence of a decolored part in the print, and can achieve an interior material having good quality.SELECTED DRAWING: Figure 1

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, conventionally, a cloth (for example, a fiber web, a non-woven fabric, a woven fabric, a knitted fabric, etc.) and a print composed of a resin and particles are included, and the cloth is described. A surface material having the print is used on at least one of the main surfaces of the above. In addition, by providing a print, it is possible to realize an interior with a design rich in patterns and colors by the surface material. 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 print pattern, it is possible to provide a surface material having a rich design.

Further, in recent years, improvement of the tactile sensation is required for the interior of automobiles and the like. The applicant of the present application has found that the size of the average particle size of the hollow particles provided in the print of the surface material and the tactile sensation are related to the surface material having the above-mentioned structure. Then, based on this knowledge, we proposed a surface material (International Publication WO2018 / 212245, Patent Document 3) that can realize an interior with excellent tactile sensation by optimizing the average particle size of the hollow particles contained in the print.

JP 2015-104848 JP 2016-147466 International release WO2018 / 21245

The applicant of the present application has studied a surface material according to the prior art as described above, that is, a surface material having a print composed of a resin and particles on at least one main surface of the fabric. In particular, in order to provide a surface material rich in design, a surface material in which the print is partially present on at least one main surface of the fabric was examined. However, the surface material according to the prior art has the following problems.

When a thin interior material is prepared by applying heat and pressure to the surface material, such as by applying it to a heat press using a mold, the tactile sensation of the main surface derived from the surface material in the interior material is reduced. There was a problem of being there. In particular, when a thinner interior material was prepared by applying more heat and pressure to the surface material, the tactile sensation was significantly reduced.

Also, if the amount of resin contained in the print is large, the print may unintentionally flow and the pattern may bleed when heat and pressure are applied to the surface material, and / or the print may lose color. It is not possible to provide a surface material that can realize an interior material with excellent designability (hereinafter sometimes referred to as "good quality") that has a clear pattern or a fine pattern as intended. was there.

Therefore, it has been required to provide a surface material that can realize an interior material having good quality and a rich tactile sensation even when the thickness is reduced by applying heat and pressure.

The present invention is a surface material comprising a fabric and a print comprising a resin and particles, wherein the print is partially provided on at least one main surface of the fabric. the per print 1 m ² having on the surface, the resin is included less than 32.8g more than 11.2 g, the per print 1 m ² was provided on the major surface, the particles 4 A surface material that contains more than 0.0 g. "

As a result of continued examination by the applicant of the present application, "a surface material having a cloth and a print composed of a resin and particles, and partially provided with the print on at least one main surface of the cloth. In the case of "", the thickness is reduced by applying heat and pressure by increasing the mass of both the resin and the particles contained in ^{1 m 2 of the print provided on the main surface more than a certain amount.} However, we have found that it is possible to provide a surface material that can realize an interior material with a rich tactile sensation. Specifically, the mass of the resin contained in ^{1 m 2 of} the print provided on the main surface is more than 11.2 g, and the particles contained in ^{1 m 2 of the print provided on the main surface.} It has been found that a surface material capable of realizing an interior material having a rich tactile sensation can be provided by having a mass of more than 4.0 g.

Furthermore, as a result of continued examination by the applicant of the present application, ^{the mass of the resin contained in 1 m 2 of} the print provided on the main surface is less than 32.8 g, so that heat and pressure are applied to the surface material. A surface material that can prevent the print from unintentionally flowing and blurring the pattern, and / or prevent the presence of color loss in the print, and realize a high-quality interior material. I found that I could provide it.

Therefore, the surface material according to the present invention can realize an interior material having good quality and a rich tactile sensation even when the thickness is reduced by applying heat and pressure.

It is a schematic diagram which shows the mode of printing provided by each surface material prepared in Examples 1-10 and Comparative Examples 1-8. The black line indicates the mode of the print layer derived from the printing liquid with respect to the main surface of the surface material represented by white. It is a schematic diagram which shows the mode of printing provided by each surface material prepared in Examples 11-18. The black line indicates the mode of the resin layer derived from the resin dispersion liquid and the print layer derived from the printing liquid with respect to the main surface of the surface material represented in white.

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 desired value. 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 cloth and a print composed of a resin and particles, and the print is partially present on at least one main surface of the cloth.

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 highly flexible and has excellent moldability such as excellent followability to a mold. 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 is more flexible and has excellent 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 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, total 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, it is preferable that 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, the elasticity is increased and the followability to the mold 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.

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

The fineness of the constituent fibers is not particularly limited, but is preferably 1 dtex or more, more preferably 1.5 dtex or more, and more preferably 2 dtex or more so as to provide a surface material having excellent rigidity. preferable. On the other hand, it is preferably 100 dtex or less, more preferably 50 dtex or less, more preferably 30 dtex or less, still more preferably 10 dtex or less so as to be a surface material having excellent moldability.

Further, the fiber length of the constituent fibers is not particularly limited, but from the viewpoint of rigidity, it is preferably 20 mm or more, more preferably 25 mm or more, and further preferably 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 fabric, which may result in a surface material having poor moldability. Therefore, the fiber length is preferably 110 mm or less, preferably 60 mm or less. 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 applied to 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. Examples include a method of integrating.

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, which is preferable.

The basis weight of the binder contained in the fabric is appropriately selected, but the basis weight of the binder ^{is preferably 1 g / m 2} or more because it is easier to provide a surface material having a smooth main surface as the amount of the binder is large. On the other hand, if the amount of the binder is excessively large, the surface material may be inferior in flexibility. Therefore, the basis weight of the binder ^{is preferably 50 g / m 2} or less, and is 30 g / m ² or less. Is preferable, and it is preferably 10 g / m ² or less.

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.

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.

Further, the density calculated by dividing the basis weight of the fabric by the thickness is appropriately adjusted so that the effect of the present invention can be efficiently exhibited. However, the higher the density of the surface material, the more heat and heat. Even when the thickness is reduced by applying pressure, it tends to be a surface material that makes it easy to realize an interior with a rich tactile sensation. Therefore, the density of the fabric constituting the surface material ^{is preferably 116 kg / m 3} or more, preferably 132 kg / m ³ or more, and preferably 142 kg / m ³ or more. The upper limit of the density can be adjusted as appropriate, but as long as the examples described later are referred to, even when the thickness is reduced by applying heat and pressure, a surface that can realize an interior material with good quality and rich tactile sensation. Since the material can be provided, it ^{is preferably 154 kg / m 3} or less. A part of the fabric constituting the surface material is collected from the surface material, the density of a part of the fabric is calculated from the basis weight and the thickness of the part of the fabric, and the fabric constituting the surface material is calculated from the calculated value. The density of can be calculated.

If the basis weight and thickness of the fabric used to prepare the surface material are known in the surface material manufacturing process, the density of the fabric is calculated and the density of the fabric constituting the surface material is determined. It may be regarded as the calculated value. As a specific example, the surface material was prepared using the fabric of density 116 kg / m ^3, the density of the fabric constituting the surface material can be considered to be 116 kg / m ^3.

The print in the present invention refers to a mixture of resin and particles that is partially present on at least one main surface of the fabric and mainly plays a role in improving the design and tactile sensation of the surface material. It should be noted that the print according to the present invention may have another resin layer (for example, another resin layer containing no particles) in between, even if the print is in direct contact with the main surface of the fabric and exists on the main surface. ) May be present on the main surface. Specifically, a surface material having a structure of cloth-another resin layer-print from one main surface to the other main surface can also satisfy the configuration of the present invention.

The resin constituting the print can mainly play a role of improving the design and tactile sensation of the surface material, and also play a role of supporting particles on at least one main surface of the fabric. The type can be appropriately selected, and the same resin as the above-mentioned binder can be adopted. 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. Therefore, the resin constituting the print contains an acrylic resin. Is preferable. In addition to the resin and particles, the print contains additives such as flame retardants, fragrances, pigments, antibacterial agents, anti-mold materials, photocatalysts, emulsifiers, dispersants, surfactants, thickeners, and cross-linking agents. May be.

It should be noted that if the print contains the above-mentioned resin cross-linking agent, more heat and pressure are applied to the surface material to prepare a thinner interior material, and / or unevenness. Even when an interior material molded into a large shape is prepared, it is preferable to provide a surface material capable of realizing an interior material having good quality and a richer tactile sensation. The type of such a cross-linking agent can be appropriately selected depending on the combination with the resin, but as a specific example, when the resin contained in the print according to the present invention is an acrylic resin, a cross-linking agent having an oxazoline group as the cross-linking agent ( An oxazoline-based cross-linking agent), a cross-linking agent having an isocyanate group protected by a blocking agent (blocked isocyanate cross-linking agent), and the like can be adopted. As the blocked isocyanate cross-linking agent, a hexamethylene diisocyanate-based cross-linking agent or a toluene diisocyanate-based cross-linking agent can be adopted. In particular, it is preferable to use an oxazoline-based cross-linking agent or a blocked isocyanate cross-linking agent because the above-mentioned effects are easily exhibited.

The mass of the cross-linking agent contained in the print according to the present invention is appropriately adjusted, but the mass of the cross-linking agent can be 1 to 20 and 2 to 15 with respect to the mass of 100 of the resin, 4 to 15. It can be 10.

The print (layer of print) according to the present invention contains particles. The particles play a role of giving 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 contained in the print are collected from the print on 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.

The coefficient of variation in the particle size of the particles contained in the print (hereinafter, may be abbreviated as CV value) can be appropriately selected, but the smaller the CV value, the narrower the distribution of the particles, and the better the quality and tactile sensation. The surface material can be efficiently provided as intended. Therefore, the CV value in the particle size of the particles is preferably 17% or less, and preferably 16% or less. The lower limit can be appropriately selected, but ideally it is 0%.

The type of particles included in the surface material according to the present invention can be appropriately selected, and may be solid particles or hollow particles. However, since it is easy to provide a surface material having an improved tactile sensation, hollow particles are adopted. Is preferable. 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 better quality and excellent tactile sensation, only hollow particles having the above-mentioned constitution as particles contributing to the improvement of design and tactile sensation are used. It is preferably a surface material having a print containing it.

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 surface material according to the present invention partially comprises a print on at least one main surface of the fabric. Partially having a print on the main surface in the present invention means a part having a print and a part not having a print in a micrograph taken by the method described later (how to obtain a percentage of a print area). It means that is present. As a specific example, an embodiment in which a print is present in a pattern on at least one main surface of the fabric can be exemplified.

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 10 to 90%, 15 to 80, and 20 to 70. The percentage can be calculated by the following method.

(How to find the percentage of print area)
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 so as to be captured in the micrograph with a size of a square or more with a side of 50 mm.
2. 2. Draw a square with a side of 50 mm on the main surface shown in each micrograph.
3. 3. The print area existing in the portion surrounded by the square is calculated for each micrograph.
4. The calculated average value of each print area is substituted into the following formula to calculate the percentage of the print area.
Percentage of print area = 100 x (average value of each print area / 250)

The mode of existence of the print provided on the main surface of the fabric can be appropriately adjusted. For example, as shown in FIGS. 1 and 2, a pattern having a pattern such as a parallel line or a grid pattern, or a pattern such as a dot shape or an irregular shape is formed, and the print is partially over the entire main surface of at least one of the fabrics. It can be an aspect that exists in.

Further, 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, and the inclusions are the same. Alternatively, a plurality of different prints may be provided.

The print may be present entirely or partially on the other main surface of the fabric, in addition to the mode in which the print is partially present only on one main surface of the fabric. However, even when the thickness is reduced by applying heat and pressure, it is easy to provide a surface material that can realize an interior material with good quality and a rich tactile sensation, so that it can be applied only on one main surface of the fabric. A surface material with a partial print is preferred.

In addition to the mode in which the print exists only on the main surface of the fabric, the print may be in a mode in which a part of the components (resin, particles, etc.) constituting the print penetrates between the constituent fibers constituting the fabric. good.

The applicant of the present application applies heat and pressure to reduce the thickness by increasing the mass of both the resin and the particles contained in ^{1 m 2 of} the printed matter provided on the main surface to more than a certain amount. Even so, we have found that it is possible to provide a surface material that can realize an interior material with a rich tactile sensation. Specifically, the mass of the resin contained in ^{1 m 2 of} the print provided on the main surface is more than 11.2 g, and the particles contained in ^{1 m 2 of the print provided on the main surface.} It has been found that a surface material capable of realizing an interior material having a rich tactile sensation can be provided by having a mass of more than 4.0 g.

Furthermore, as a result of continued examination by the applicant of the present application, ^{the mass of the resin contained in 1 m 2 of} the print provided on the main surface is less than 32.8 g, so that heat and pressure are applied to the surface material. A surface material that can prevent the print from unintentionally flowing and blurring the pattern, and / or prevent the presence of color loss in the print, and realize a high-quality interior material. I found that I could provide it.

In the surface material according to the present invention, ^{the mass of the resin contained in 1 m 2 of} the print provided on the main surface is adjusted to be in a range of more than 11.2 g and less than 32.8 g. .. The mass of the resin can be appropriately adjusted within the range according to the present invention as long as the above-mentioned effect is effectively exhibited, but 13.5 to 27. It can be 0 g, 15.7 to 24.7 g, and 18.0 to 22.5 g.

In the surface material according to the present invention, ^{the mass of the particles contained in 1 m 2 of} the print provided on the main surface is adjusted to be larger than 4.0 g. The mass of the particles can be appropriately adjusted within the range according to the present invention as long as the above-mentioned effect is effectively exhibited, but is 4.5 g or more so that the above-mentioned effect can be more effectively exhibited. It can be 5.4 g or more, and can be 6.7 g or more. On the other hand, although the upper limit value can be adjusted as appropriate, if the print contains an excessive amount of particles, the particles are likely to fall off from the print, and as a result, the quality may be unintentionally deteriorated. Therefore, the mass of the particles is preferably 22.5 g or less, preferably 13.5 g or less, and preferably 11.2 g or less.

The mass of the resin and the particles contained in ^{1 m 2 of} the print provided on the main surface can be calculated by the following method.
1. 1. A square-shaped sample (vertical: 50 mm, horizontal: 50 mm, vertical and horizontal directions are parallel to the direction in which the main surface of the sample extends) is collected from a surface material partially provided with a print on one main surface. ..
2. 2. The resin and particles are extracted from the print using a solvent that can dissolve the resin contained in the print provided with the sample.
3. 3. By removing the solvent contained in the extracted resin solution, the mass of the resin contained in the sample is determined. In addition, the mass of the particles contained in the sample is obtained.
4. The obtained mass of the resin and the mass of the particles contained in the sample are converted into the mass of the resin and the mass of the particles contained in about ^{1 m 2 of the sample.}
5. Prepared on the main surface of the surface material by dividing the mass of the resin contained in the area of 1 m ^{2 of the} sample by the value of the percentage of the printed area obtained in the above-mentioned (method of obtaining the percentage of the printed area) and multiplying by 100. The mass (unit: g) of the resin contained in ^{1 m 2 of} the printed print is calculated. ^{Similarly, by dividing the mass of the particles contained in the area of 1 m 2} of the sample by the value of the percentage obtained in the above-mentioned (method of obtaining the percentage of the printed area) and multiplying by 100, the surface material is prepared on the main surface. The mass (unit: g) of the particles contained in ^{1 m 2 of} the printed print is calculated.

As a specific example, in a square-shaped sample taken from a surface material partially printed on one main surface.
-Percentage of print area: 22.24%
-Mass of resin contained in 1 m ^{2 of sample: 4.2 g}
Sample 1 m ² of particles contained in around Weight: 1.1 g
If it was a mass of resin contained in the printed 1m per ² provided on the main surface is 18.9 g, the mass of particles contained in the print 1m per ² provided on the main surface Is 4.9 g.

If the mass of the resin and particles to be applied to the fabric is known in the process of manufacturing the surface material, the particles and resin constituting the print of the surface material are obtained from the mass applied to ^{the main surface of the fabric around 1 m 2.} The basis weight of can be calculated. If the composition of the printing liquid to be applied to the fabric (for example, a dispersion liquid obtained by mixing a resin and particles capable of forming a print in a dispersion medium) and the amount to be applied to the fabric are known, the printing liquid is used. From the mass of the particles contained, the mass of the resin, and the ^{amount of the printing liquid applied to the main surface of the fabric around 1 m 2} , the grain size of the particles and the resin constituting the print of the surface material can be calculated.

The surface material of the present invention may be provided with a top coat layer on the main surface (the main surface on the side where the print is exposed and present) on the side opposite to the side where the fabric is present in the print. The top coat layer is a resin that prevents particles contained in the print from falling off from the surface material and / or prevents the print from falling off from the interior formed by molding the surface material. It is a contained layer. The components of the print and the composition of the topcoat layer (for example, the presence or absence of particles) are not completely the same but different.

The type of resin constituting the top coat layer can be appropriately selected, and the same resin as the above-mentioned binder can be adopted. In particular, since it is moderately softened during thermoforming such as heat pressing using a mold, it is possible to provide a surface material having excellent moldability and moldability. Therefore, the resin constituting the top coat layer is an acrylic resin. It is preferable to include. In order to effectively exert the effect of the present invention, it is preferable that the resin constituting the top coat layer is only an acrylic resin.

In addition to the above-mentioned resin, the top coat layer may contain additives such as flame retardants, fragrances, pigments, antibacterial agents, anti-mold materials, photocatalysts, emulsifiers, dispersants, surfactants, and thickeners. good. It is preferable that the top coat layer does not contain the particles contained in the print so that the print containing the particles does not easily fall off from the top coat layer.

The mode of existence of the top coat layer can be appropriately selected, and even if the top coat layer exists so as to cover the entire print, a pattern having a pattern such as parallel lines or a grid pattern, or a pattern such as a dot shape or an irregular shape can be used. It may be an aspect that exists so as to cover a part or the whole of the print.

Further, the top coat layer may be present on both main surfaces of the surface material. Further, the top coat layer may be in a mode in which it penetrates between the constituent fibers constituting the fabric, in addition to the mode in which it exists only on the cloth or the print.

Basis weight of the top coat layer is appropriately selected, but the basis weight of the top coat layer may be 80 g / ^{m 2,} can be a 3~70g / ^{m 2,} a 5~55g / ^{m 2} Can be done.

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 and particles that can form a print with a dispersion medium.
3. 3. A step of partially applying a printing liquid onto at least one main surface of a fabric,
4. The process of removing the dispersion medium by heating the fabric to which the printing liquid is applied,
A method for manufacturing a surface material can be mentioned.

When preparing a surface material provided with a top coat layer, after the above-mentioned step 4,
5. A step of preparing a topcoat layer forming liquid by mixing a component containing a resin that can form a topcoat layer with a solvent or a dispersion medium.
6. A step of applying a top coat layer forming liquid on a main surface on the print side of a fabric provided with a print.
7. A step of removing a solvent or a dispersion medium by heating a fabric having a print to which a topcoat layer forming liquid is applied.
A method for manufacturing a surface material may be adopted.

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 the resin that can form the print is dissolved and the particles can be dispersed without being dissolved so that the printing liquid can be partially applied onto one of the main surfaces of the fabric. It is preferable to use a dispersion medium, or to use resin particles that can form a print and a dispersion medium in which the particles are not dissolved and can be dispersed. In addition to particles, additives such as flame retardants, fragrances, pigments, antibacterial agents, anti-mold materials, photocatalysts, emulsifiers, dispersants, surfactants, thickeners, and cross-linking agents are dissolved in the printing liquid. Alternatively, it may be 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. Further, when the printing liquid contains a cross-linking agent for the resin, more heat and pressure are applied to the surface material to prepare a thinner interior material, and / or unevenness. Even when an interior material molded into a large shape is prepared, it is preferable to provide a surface material capable of realizing an interior material having good quality and a rich tactile sensation.

Step 3 will be described.
The method of partially applying the printing liquid to one main surface of the fabric can be appropriately selected, but the printing liquid is applied to one main surface of the fabric as it is or in a foamed state by using a spray or a gravure roll. , A method of printing or printing so as to form a pattern on the main surface of the fabric can be selected. 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.
The method of preparing the fabric having the print by removing the dispersion medium can be appropriately selected. The solvent or dispersion medium can be evaporated and removed by allowing it to stand in a reduced pressure atmosphere. The heating temperature when removing the dispersion medium is the temperature at which the dispersion medium can volatilize, and the upper limit of the heating temperature is selected so that the shape and function of the constituent members such as cloth and hollow particles do not unintentionally decrease. do. When the fabric is a fiber web, the constituent fibers are bonded to each other by this step (bonding with a molten binder or melting and adhering a thermoplastic component contained in the constituent fibers) to form a non-woven fabric. You may. Further, the cross-linking agent may be cross-linked to the resin by this step.

Step 5 will be described.
The type of solvent or dispersion medium can be appropriately selected, but when preparing a surface material having a top coat layer, the resin that can form the top coat layer is dissolved and the cloth or cloth or the like so that the top coat layer forming liquid can be preferably applied. It is preferable to use a solvent or dispersion medium in which the constituents of the print do not dissolve, or a solvent or dispersion medium in which the resin that can form the top coat layer and the constituents of the fabric or the print do not dissolve. Further, the above-mentioned additives may be dissolved or dispersed in the topcoat layer forming liquid and contained therein. The top coat layer preferably does not contain the particles contained in the print so as to prevent the particles from falling off from the surface material.

Step 6 will be described.
The topcoat layer forming liquid is applied onto the main surface of the fabric provided with the print on the print side. The imparting method can be appropriately selected, and for example, the means mentioned in step 3 can be adopted. In addition to applying one type of topcoat layer forming liquid, a plurality of types of topcoat layer forming liquid may be applied. Further, when a plurality of types of topcoat layer forming liquids are applied, the mode of application of each topcoat layer forming liquid (pattern or composition of the topcoat layer forming liquid) may be different.

Step 7 will be described.
The method for preparing the surface material by removing the solvent or the dispersion medium can be appropriately selected, and for example, the means mentioned in step 4 can be adopted.

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. It should be noted that these constituent members can be laminated and provided on the main surface side of the surface material, which is different from the main surface on the top coat layer 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.

(Preparation of fabric)
Using 100% of the original polyester fiber (fineness: 2.2 dtex, fiber length: 38 mm), the fiber is opened by a card machine to form a fiber web, and then needle punching is performed ^{from one side with a needle density of 400 lines / m 2.} gone. ^{Then, the non-woven fabric of needle punch (grain: 180 g / m 2} , thickness: 1.5 mm) was prepared by subjecting it to heat rolls (gap interval: 0.4 mm, roll heating temperature: 165 ° C.).
Next, from the surface opposite to the needling surface of the needle punched non-woven fabric, the binder liquid blended in the ratio described below is applied in a foamed state, and between the second rolls (gap interval: 0.25 mm). Dedicated to. Then, by drying with a can dryer at a temperature of 160 ° C., the binder adhesive nonwoven fabric 1 (weight: 185 g / m ² , thickness: 1.6 mm, density: 116 kg / m ³ , all constituent fibers are randomly entangled. Non-woven fabric) was prepared.
The composition of the binder liquid was as follows.
-Acrylic acid ester resin emulsion A (Acrylic acid ester resin Tg: -40 ° C,
Solid content mass of acrylic ester resin emulsion: 50% by mass): 4.8 parts by mass ・ Surfactant: 0.5 parts by mass ・ 25% Ammonia water: 0.1 parts by mass ・ Water: 94.6 parts by mass In the same manner as described above, three types of binder-bonded non-woven fabrics 2 to 4 having different thicknesses and different densities were further prepared, except that the gap spacing between the second rolls was variously changed.

The configurations of the binder-bonded nonwoven fabrics 1 to 4 thus prepared are summarized in Table 1.

(Preparation of printing liquid)
Printing solutions 1 to 8 having the compositions shown in Tables 2 to 3 were prepared. The Tg of the acrylic acid ester resin contained in the acrylic acid ester resin emulsion 1 is −5 ° C., and the 920DU40 manufactured by Nippon Philite Co., Ltd. used as the hollow particles is a heat composed of a resin shell containing a liquid gas. It was an expanding hollow particle (expanded in a temperature atmosphere of 128 ° C. or higher).

(Comparative Example 1)
A portion of the binder adhesive nonwoven fabric 1 in which the print liquid 1 is applied to the main surface on the side to which the binder liquid is applied by using a cylinder so that the print of the pattern shown in FIG. 1 is formed over the entire main surface. Was given. Then, by drying with a dryer whose heating temperature is adjusted to 160 ° C., the print derived from the printing liquid 1 is partially formed on the entire main surface of the binder adhesive nonwoven fabric 1 by forming the pattern shown in FIG. Provided surface material (with a print layer having the pattern shown in FIG. 1) (grain: 189 g / m ² , of which print layer grain: 4 g / m ² , thickness: 1.6 mm, print pattern: FIG. 1 , Percentage of print area: 22.24%).
In the surface material (surface material before heat molding) prepared in this way, the pattern of the print was clear.

(Comparative Examples 2 to 5, Examples 1 to 3)
Various surface materials (print pattern: Fig. 1, print area percentage: 22.24%) in the same manner as in Comparative Example 1 except that any of the print liquids 2 to 8 was used instead of the print liquid 1. ) Was prepared.
In each surface material (surface material before heat molding) prepared in this way, the pattern of the print was clear.

By applying the surface materials of Comparative Examples and Examples prepared as described above to the following measurement methods, the tactile sensation and quality of the main surface on the side where the print is present in the surface material after heat molding are evaluated. did.

(Evaluation method of tactile sensation)
1. 1. A test piece (short side: 25 cm, long side: 25 cm, thickness: 1.5 mm or more) was collected from the surface material.
2. 2. An upper mold made by laying aluminum foil (thickness: 0.05 mm) on the main surface of a smooth plate was prepared, and the upper mold was heated to 120 ° C. Further, a lower mold made by laying aluminum foil (thickness: 0.05 mm) on the main surface of another smooth plate was prepared, and the lower mold was heated to 130 ° C.
3. 3. The test piece was sandwiched between the upper and lower molds with the aluminum foil surfaces facing each other. At this time, the main surface of the test piece on the side where the print was present and the aluminum foil surface of the upper mold faced each other. ..
4. ^{Using the upper and lower molds, a pressure of 19.9 kgf / cm 2} was applied to the entire surface of one main surface of the test piece from one main surface to the other main surface of the test piece for 30 seconds for the test. I pressed a piece. In addition, clearances are provided at the four corners of the upper and lower dies and pressed so that the test piece can be heat-molded to the required thickness (0.8 mm or 0.6 mm, and 0.3 mm in addition in Examples 15 to 18). rice field.
5. After releasing the action of pressure by the upper mold and the lower mold and taking out the test piece from between the upper mold and the lower mold, the taken out test piece was cooled to 20 ° C.
6. The main surface (the main surface on the side to which the printing liquid was applied) on which the print was exposed and present on each of the prepared surface materials was touched by the monitor with the pad of a finger.

The tactile sensation felt when the surface material of Comparative Example 1 was touched was evaluated as "x", and it was felt that the unevenness was richer than the standard and the aspect of the unevenness was in sync with the printed pattern. The surface material was evaluated as a surface material having an excellent tactile sensation, and "○" was marked in the table. Further, the surface material which is richer in unevenness than the surface material evaluated as "○" and which is felt that the aspect of the unevenness is more synchronized with the printed pattern is a surface material having further excellent tactile sensation. And marked with "◎" in the table. On the other hand, the surface material which is the same as or inferior to the tactile sensation felt when the surface material of Comparative Example 1 is touched and whose unevenness is felt to be out of sync with the printed pattern is It was evaluated as a surface material with inferior tactile sensation, and an "x" mark was given in the table.

(Evaluation method of quality)
The monitor was made to visually confirm the main surface (the main surface on the side to which the printing liquid was applied) in which the print was exposed and existed in each surface material prepared in the above-mentioned (method for evaluating the tactile sensation).

As a result of the confirmation, the surface material of Comparative Example 1 was evaluated as "○" because the printed pattern was clear even after heat molding and the quality was felt. Then, based on the surface material of Comparative Example 1, the surface material which is equivalent to the standard or has a better quality that the printed pattern is clearer even after heat molding is excellent in quality. It was evaluated as a surface material and marked with "○" in the table. Further, the surface material whose print pattern sharpness after heat molding was felt to be inferior to that of the surface material of Comparative Example 1 was evaluated as being inferior in quality, and an "x" mark was added in the table. Described.

The physical characteristics of the comparative examples and the examples and the evaluation results are summarized in Tables 4 to 6. The results of Comparative Example 1 are also shown in the table for easy comparison.

From the results of comparing Comparative Examples 1 to 3, when the mass of the particles contained in ^{1 m 2 of the print is 4.0 g, even if the mass of the resin contained in 1 m 2 of} the print is larger than 11.2 g, the heat is generated. When the thickness was reduced by applying pressure, it was not possible to provide a surface material that could realize an interior with good quality and a rich tactile sensation.

From the result of comparing Comparative Example 1 and Comparative Example 4, when the mass of the resin contained in ^{1 m 2 of} the print is 11.2 g, the mass of the particles contained in ^{1 m 2 of the print may be larger than 4.0 g.} When the thickness was reduced by the action of heat and pressure, it was not possible to provide a surface material that can realize an interior with good quality and a rich tactile sensation.

From the results of comparing Comparative Example 1, Examples 1 to 3 and Comparative Example 5, the mass of the particles contained in ^{1 m 2 of} the print is larger than 4.0 g, and the mass of the resin contained in ^{1 m 2 of the print is used.} By the amount of more than 11.2 g, it was possible to provide a surface material capable of realizing an interior material having a rich tactile sensation even when the thickness is reduced by applying heat and pressure.

On the other hand, from the results of comparing Example 3 and Comparative Example 5, ^{the mass of the resin contained in 1 m 2 of} the print is less than 32.8 g, so that heat and pressure are applied to reduce the thickness. However, we were able to provide a surface material that can realize a high-quality interior material.

From the above, it has been found that the present invention can provide a surface material capable of realizing an interior material having good quality and a rich tactile sensation even when the thickness is reduced by applying heat and pressure.

(Example 4)
A resin dispersion having the composition shown in Table 7 was applied to the entire surface of the main surface of the binder adhesive nonwoven fabric 1 on the side to which the binder liquid was applied. Then, the resin layer derived from the resin dispersion liquid was provided on one main surface of the binder adhesive nonwoven fabric 1 by drying with a dryer whose heating temperature was adjusted to 160 ° C.
Further, a print liquid 5 is applied to the main surface on the side coated with the resin dispersion liquid by using a cylinder in the same manner as in Example 1, and a print of the pattern shown in FIG. 1 is formed over the entire main surface. It was partially given in this way. Then, it was dried by the dryer which adjusted the heating temperature to 160 degreeC.
Finally, the topcoat layer forming liquid having the composition shown in Table 7 was applied to the entire surface of the main surface of the binder adhesive nonwoven fabric 1 on the side to which the binder liquid was applied. Then, by drying with a dryer whose heating temperature is adjusted to 160 ° C., a resin layer derived from the resin dispersion liquid and a print derived from the printing liquid 5 (the pattern shown in FIG. 1) are printed on one main surface of the binder adhesive non-woven fabric 1. the print layer constituting), surface material having in the order of the resin layer from the top coat layer forming liquid (basis weight: of 206 g / m ^2, of which resin dispersion from the resin layer basis weight: 6 g / m ^2, of among the print layer Grain: 6 g / m ² , of which the grain of the resin layer derived from the top coat layer forming liquid: 9 g / m ² , thickness: 1.5 mm, print pattern: Fig. 1, percentage of print area: 22.24%) is prepared. did. The mass of the particles contained in 1 m ^{2 of} the print was 4.9 g, and the mass of the resin contained in ^{1 m 2 of the print was 18.9 g.}

In the surface material (surface material before heat molding) prepared in this way, the pattern of the print was clear.

In addition, "-" mark is described in the table for the components not contained. The Tg of the acrylic acid ester resin contained in the acrylic acid ester resin emulsion 2 was −40 ° C.

(Examples 5 to 7)
In the same manner as in Example 4, various surface materials (print pattern: FIG. 1, percentage of print area: 22. 24%) was prepared. The mass of the particles contained in 1 m ^{2 of} the print was 4.9 g, and the mass of the resin contained in ^{1 m 2 of the print was 18.9 g.}

The evaluation results of Examples 4 to 7 are summarized in Table 8.

From the results of comparing Examples 4 to 5 and Examples 6 to 7, the fact that the ^{fabric having a density higher than 132 kg / m 3} (preferably a fabric having a density of 142 kg / m ³ or more) is provided with heat and heat. It has been found that it is possible to provide a surface material that can realize a more tactile interior even when the thickness is reduced by applying pressure.

(Comparative Examples 6 to 8, Examples 8 to 10)
Each surface material (print pattern: FIG. 1, print area percentage: 22.24%) was prepared in the same manner as in Example 4 except that the binder adhesive nonwoven fabric and the printing liquid shown in Table 9 were combined. did.
In each surface material (surface material before heat molding) prepared in this way, the pattern of the print was clear.

The evaluation results of Examples and Comparative Examples are summarized in Table 9. In addition, the results of Example 6 are also shown in the table for easy comparison.

As described above, even if the type of fabric is changed or the thickness is reduced by applying heat and pressure according to the present invention, the surface material can realize an interior material having good quality and rich tactile sensation. It turned out that we can provide.

The resin dispersion liquid and the top coat layer forming liquid shown in Table 10 and the printing liquid shown in Table 11 were prepared. In addition, each of the cross-linking agents cross-linked with the acrylic acid ester resin contained in the acrylic acid ester resin emulsion 1 and the acrylic acid ester resin emulsion 2 under the temperature condition of 160 ° C.

(Example 11)
First, the resin dispersion liquid A is applied to the main surface of the binder adhesive nonwoven fabric 1 on the side to which the binder liquid is applied by using a cylinder in the same manner as in Example 1, and the entire surface of the main surface is shown in FIG. 2 (A). It was partially applied so that the resin layer of the illustrated handle was formed. Then, it was dried by the dryer which adjusted the heating temperature to 160 degreeC. The percentage of the area of the resin layer derived from the resin dispersion liquid A was 14.58%.
Next, the resin dispersion liquid B was applied to the main surface of the binder adhesive nonwoven fabric 1 on the side to which the binder liquid was applied by using a cylinder in the same manner as in Example 1, as shown in FIG. 2 (B) over the entire main surface. It was partially applied so that the resin layer of the illustrated handle was formed. Then, it was dried by the dryer which adjusted the heating temperature to 160 degreeC. The percentage of the area of the resin layer derived from the resin dispersion B was 22.24%.
After that, the printing liquid A is applied to the main surface of the binder adhesive nonwoven fabric 1 on the side to which the binder liquid is applied by using a cylinder in the same manner as in Example 1, and is shown in FIG. 2 (C) over the entire main surface. Partially applied so that a printed pattern was formed. Then, it was dried by the dryer which adjusted the heating temperature to 160 degreeC. The percentage of the printed area derived from the printing liquid A was 25.16%.
The pattern shown in FIG. 2D was formed on the main surface of the binder-bonded nonwoven fabric on the side to which the binder liquid was applied by the above-mentioned resin dispersion liquid and printing liquid.
Finally, as a method for forming the fourth layer, a top coat layer forming liquid having the composition shown in Table 10 is applied to the entire surface of the main surface of the binder adhesive nonwoven fabric 1 on the side to which the binder liquid is applied. Granted. Then, by drying with a dryer whose heating temperature is adjusted to 160 ° C., a two-layer resin layer derived from the resin dispersion liquid, a print derived from the printing liquid A, and a top coat layer are placed on one main surface of the binder adhesive nonwoven fabric 1. Surface material provided in the order of the resin layer derived from the forming liquid (grain: 214 g / m ² , of which the total texture of the two resin layers derived from the resin dispersion liquid: 10 g / m ² , of which the texture of the print layer: 10 g / m ^2. Of these, the texture of the resin layer derived from the top coat layer forming liquid: 9 g / m ² , the thickness: 1.5 mm, the pattern of the printed layer: FIG. 2 (C), the percentage of the printed area: 25.16%) was prepared. .. The mass of the particles contained in 1 m ^{2 of} the print was 7.3 g, and the mass of the resin contained in ^{1 m 2 of the print was 28.7 g.}
In the surface material (surface material before heat molding) prepared in this way, the pattern of the print was clear.

(Examples 12 to 14)
As shown in Table 12, two layers of resin derived from the resin dispersion liquid are placed on one main surface of the binder adhesive nonwoven fabric 1 in the same manner as in Example 11 except that the type of the printing liquid used is changed. A surface material having a layer, a print derived from the printing liquid, and a resin layer derived from the top coat layer forming liquid was prepared in this order.
In the surface material (surface material before heat molding) prepared in this way, the pattern of the print was clear.

The evaluation results of Examples 11 to 14 are summarized in Table 12.

As described above, it was found that the fact that the print contains a cross-linking agent makes it possible to provide a surface material that can realize an interior material with a richer tactile sensation even when the thickness is reduced by applying heat and pressure. did.

(Examples 15 to 17)
As shown in Table 13, the resin dispersion is derived on one main surface of the binder adhesive nonwoven fabric in the same manner as in Example 11 except that the type of printing liquid used and / or the binder adhesive nonwoven fabric is changed. A surface material having two resin layers, a print derived from the printing liquid, and a resin layer derived from the top coat layer forming liquid was prepared in this order.
In the surface material (surface material before heat molding) prepared in this way, the pattern of the print was clear.

The evaluation results of Examples 15 to 17 are summarized in Table 13. The results of Example 11 are also described for ease of understanding.

As described above, since the print contains a cross-linking agent, it feels tactile even when the thickness is reduced by further applying heat and pressure (when the thickness is reduced to 0.3 mm). It has been found that it is possible to provide a surface material that can realize a rich interior material.

The surface material of the present invention can be suitably used for automobiles such as ceilings, door sides, pillar garnishes, and rear packages; for interiors such as partitions; and for building materials such as wall coverings.

Claims (1)

A surface material comprising a fabric and a print comprising a resin and particles, wherein the print is partially provided on at least one main surface of the fabric.
The resin is contained in more than 11.2 g and less than 32.8 g per ^{1 m 2 of the} print provided on the main surface.
The particles are contained in an amount of more than 4.0 g per ^{1 m 2 of the} print provided on the main surface.
Surface material.

Images