JP6837784B2 - Interior surface material and its manufacturing method - Google Patents

Description

The present invention relates to an interior surface material and a method for producing the same. In particular, the present invention relates to an interior surface material suitable for a surface material of an automobile interior material such as a ceiling, a door side, a pillar garnish, and a rear package, and a method for manufacturing the same.

For example, a fiber sheet having excellent decorativeness has been conventionally used as a skin material for the interior of an automobile. As such a fiber sheet, the applicant of the present application applies a decorative fiber sheet (Patent Document 1) printed so as to provide a gradation so that the interior of the automobile can be felt widely and the feeling of oppression can be alleviated, and colored fibers. A decorative fiber sheet (Patent Document 2) printed so as to have a minimum brightness difference of 0.9 or more on the sheet, a decorative fiber sheet (Patent Document 3) in which printing units whose brightness changes are repeatedly printed, and at least two types of prints. A decorative fiber sheet (Patent Document 4), which repeatedly has a first unit printed in a planar shape, and is printed or not printed in a state different from that of the first unit between adjacent first units. It has the same outer edge shape and the same size as one unit, and the combination of one or more first units and one or more second units has the same outer edge shape as the outer edge shape of the first unit. A printed decorative fiber sheet (Patent Document 5) was proposed.

Further, the applicant of the present application has applied a heat-bonded non-woven fabric for printing (Patent Document 6) containing 50 mass% or more of drawn polyester short fibers having a dry heat shrinkage rate of 4% or more so as to have excellent moldability, etc., and 15 g on one side. We have proposed a printed non-woven fabric (Patent Document 7) which is bonded with a fiber bonding binder resin in an amount of / m ^{2 or more and is printed containing a resin containing silicone or fluorine.}

In recent years, surface materials for interiors having a good tactile sensation have been desired, but none of the decorative fiber sheets or printed non-woven fabrics of Patent Documents 1 to 7 has a satisfactory tactile sensation.
Such a requirement is not limited to the surface material for automobile interiors, and similarly, when applied as a surface material for a wall or a partition in an office, a surface material having an excellent tactile sensation has been required.

Japanese Unexamined Patent Publication No. 2012-179985 Japanese Unexamined Patent Publication No. 2012-201172 Japanese Unexamined Patent Publication No. 2013-194348 Japanese Unexamined Patent Publication No. 2014-51268 Japanese Unexamined Patent Publication No. 2016-35126 Japanese Unexamined Patent Publication No. 2014-133959 Japanese Unexamined Patent Publication No. 2014-214395

The present invention has been made in view of such a situation, and an object of the present invention is to provide an interior surface material having an excellent tactile sensation (particularly, an automobile interior surface material) and a method for manufacturing the same.

The present invention
[1] An interior surface material having a resin pattern on the surface of the non-woven fabric, wherein the interior surface material is a first non-woven fabric layer having a surface having a resin pattern and a second non-woven fabric layer other than the first non-woven fabric layer. It contains two non-woven fabric layers, the first non-woven fabric layer and the second non-woven fabric layer are laminated and integrated, the fineness of the fibers constituting the non-woven fabric is 0.7 dtex or more, and the interior surface material has a pattern made of resin. The surface has a surface roughness (SMD) of 2.5 or less, a friction coefficient fluctuation (MMD) of 0.015 or less, and an average dynamic friction coefficient (MIU) of 0. Interior surface material of 3 or more and 1.0 or less ,
[2] The interior surface material of [1] having a thickness of the second non-woven fabric layer of 1.5 mm or more.
[3] The surface roughness (SMD) is 2.5 or less, the coefficient of friction fluctuation (MMD) is 0.015 or less, and the average dynamic friction coefficient (MIU) is 0. The step of forming the first non-woven fabric having a surface having a pattern made of resin, which is 15 or more, the surface roughness (SMD) measured by a surface tester (KES-FB4) is 3.5 or less, and the coefficient of friction fluctuates ( The step of forming the second non-woven fabric having a main surface having an MMD) of 0.015 or less and an average coefficient of dynamic friction (MIU) of 0.25 or more, and the surface of the first non-woven fabric having a pattern made of resin is the exposed surface. [1] The method for producing an interior surface material, which comprises a step of laminating and integrating the first non-woven fabric and the second non-woven fabric.
[4] The first non-woven fabric was produced by forming a fiber web using fibers having a fineness of 0.7 to 6.6 dtex, printing a resin on the fiber web to form a pattern, and then heating and pressurizing. The method for producing an interior surface material according to [3] , which is a non-woven fabric having a surface having a pattern made of smoothed resin.
[5] The second non-woven fabric is a non-woven fabric having a main surface smoothed by heating and pressurizing after forming a fiber web using fibers having a fineness of 0.7 to 6.6 dtex [3] or [4]. ] Manufacturing method of interior surface material,
[6] The method for producing an interior surface material according to [3] to [5] , wherein the thickness of the second non-woven fabric is 1.5 mm or more.
Is.

The interior surface material of the present invention [1] has a surface roughness (SMD) of 2.5 or less, a friction coefficient fluctuation (MMD) of 0.015 or less, and an average dynamic friction coefficient (MIU) of 0.3 or more. It is made of a non-woven fabric having a surface having a pattern made of resin (hereinafter, may be referred to as a "pattern surface"). It was found that the patterned surface having such surface roughness, fluctuation of friction coefficient, and average dynamic friction coefficient is excellent in tactile sensation. In other words, a small surface roughness means that the pattern surface is smooth, a small variation in friction coefficient means that the pattern surface is uniform, and a large average dynamic friction coefficient means that the interior surface material is flexible. It means that, when these conditions are satisfied, it is found that the tactile sensation is excellent.

The interior surface material of the present invention [2] easily satisfies the average dynamic friction coefficient as described above because the thickness of the second non-woven fabric layer is 1.5 mm or more.

The method for producing an interior surface material according to the present invention [3] is flexible with a first nonwoven fabric having a uniform patterned surface having a small surface roughness and smoothness and a small variation in friction coefficient and a large average dynamic friction coefficient. The interior surface material of [1] can be manufactured by laminating and integrating the second non-woven fabric having a main surface having excellent properties.

The method for producing an interior surface material according to [4] of the present invention is the first method, which uses relatively fine fibers and has a pattern surface smoothed by heating and pressurizing after printing a resin to form a pattern. Since the non-woven fabric is formed, it is easy to manufacture an interior surface material having a smooth and uniform pattern surface.

The method for producing an interior surface material according to the present invention [5] uses relatively fine fibers, and after forming a fiber web, forms a second non-woven fabric having a main surface smoothed by heating and pressurizing. Therefore, it is easy to manufacture an interior surface material having a smooth and uniform pattern surface.

In the method for producing an interior surface material according to the present invention [6] , since the thickness of the second nonwoven fabric is 1.5 mm or more, it is easy to produce an interior surface material satisfying the average dynamic friction coefficient as described above.

The interior surface material of the present invention (hereinafter, may be simply referred to as “surface material”) has a surface roughness (SMD) of 2.5 or less, a friction coefficient fluctuation (MMD) of 0.015 or less, and It has a patterned surface with an average coefficient of dynamic friction (MIU) of 0.3 or more. The present inventor has found that the tactile sensation is excellent by simultaneously satisfying such physical properties. The "patterned surface" in the present invention means a surface having the largest area among the surfaces of the non-woven fabric and a surface having a pattern made of resin.

This surface roughness is literally an index showing unevenness on the pattern surface, that is, smoothness, and according to the study of the present inventor, the surface roughness (SMD) is 2.5 or less even though the pattern is made of resin. If so, he found that it could contribute to an excellent tactile sensation. A smaller surface roughness (SMD) value tends to be smoother and have a better tactile sensation. Therefore, the surface roughness (SMD) is preferably 2.3 or less, preferably 2.1 or less. Is more preferable. The lower limit of the surface roughness (SMD) is not particularly limited, but ideally, it is 0, which indicates a surface roughness without any unevenness.

This surface roughness (SMD) is a value measured using a surface tester (KES-FB4), and a sample (20 cm square) of a surface material is set on the tester with a load of 400 g, and rough contact is made. A load of 10.0 g was applied to the child (0.5 mm wire, contact surface width: 5 mm) to bring the sample into contact with the patterned surface of the sample, and the sample was brought into contact with the sample at 1 mm / sec. It means the mean deviation measured by moving at the speed of.

Further, the fluctuation of the coefficient of friction (MMD) is measured by using a surface tester (KES-FB4). By bringing the friction element into contact with the pattern surface of the surface material and moving the surface material, the friction element becomes the surface material. Since the measurement is performed in a state of stroking, it means the uniformity of the pattern surface of the surface material, and according to the study of the present inventor, the fluctuation of the coefficient of friction (MMD) is 0.015 even though the pattern is due to the resin. It was found that the following can contribute to the excellent tactile sensation. The smaller the value of the coefficient of friction fluctuation (MMD), the more uniform the pattern surface tends to be, and the better the tactile sensation tends to be. Therefore, the fluctuation of the coefficient of friction (MMD) is preferably 0.013 or less. , 0.011 or less is more preferable. The lower limit of the fluctuation of the friction coefficient (MMD) is not particularly limited, but ideally, it is 0, which indicates that the friction coefficient is exactly the same and the pattern surface is uniform.

This variation in the coefficient of friction (MMD) is a value measured using a surface tester (KES-FB4), and a sample of surface material (20 cm square) is set on the tester with a load of 400 g and friction is applied. A load of 50 g was applied to the child (10 mm × 10 mm) to bring it into contact with the patterned surface of the sample, and the sample was placed at 1 mm / sec. It means the mean deviation measured by moving at the speed of.

Furthermore, the average dynamic friction coefficient (MIU) means the flexibility of the surface material, and according to the study of the present inventor, if the average dynamic friction coefficient (MIU) is 0.3 or more, it can contribute to excellent tactile sensation. I found it. In other words, the average dynamic friction coefficient (MIU) is measured by applying a weight to the friction element to bring it into contact with the patterned surface of the surface material, and then moving the surface material in that state. Therefore, if the surface material is soft, the friction element will move. Since the surface material is submerged in the surface material and the surface material is moved in that state, the average dynamic friction coefficient becomes large. Specifically, if the average dynamic friction coefficient (MIU) is 0.3 or more, the tactile sensation is excellent. It was found that it can contribute to being. The larger the value of the average dynamic friction coefficient, the more flexible and the better the tactile sensation tends to be. Therefore, the average dynamic friction coefficient (MIU) is preferably 0.31 or more, and more preferably 0.32 or more. preferable. On the other hand, if the value of the average dynamic friction coefficient (MIU) is too large, the frictional resistance is too strong and the finger feels like it is caught, which may impair the tactile sensation. Therefore, it is preferably 1.0 or less. ..

The average coefficient of dynamic friction (MIU) is a value measured using a surface tester (KES-FB4), and means an average value measured under the same conditions as the condition for measuring the fluctuation of the coefficient of friction (MMD). ..

It is preferable that the surface material having a patterned surface having such surface roughness, fluctuation of friction coefficient, and average dynamic friction coefficient includes two non-woven fabric layers. That is, the first non-woven fabric layer having the patterned surface of the surface material, which has a large contribution to satisfy the surface roughness and the fluctuation of the friction coefficient as described above, and the contribution to satisfy the average dynamic friction coefficient as described above. It is preferable to include a second non-woven fabric layer different from the first non-woven fabric layer having a large coefficient.

More specifically, the first non-woven fabric layer has a surface roughness (SMD) of 2.5 or less, a friction coefficient fluctuation (MMD) of 0.015 or less, is smooth and uniform, and has an average dynamic friction coefficient (MIU) of 0. It is preferably composed of a non-woven fabric having a patterned surface having a certain degree of softness of 15 or more. More preferably, it is made of a non-woven fabric having a surface roughness (SMD) of 2.3 or less, a coefficient of friction fluctuation (MMD) of 0.012 or less, and an average dynamic friction coefficient (MIU) of 0.16 or more. It is made of a non-woven fabric having a surface roughness (SMD) of 2.3 or less, a friction coefficient fluctuation (MMD) of 0.010 or less, and an average dynamic friction coefficient (MIU) of 0.18 or more.

On the other hand, the second non-woven fabric layer has a surface roughness (SMD) of 3.5 or less, a friction coefficient fluctuation (MMD) of 0.015 or less, is smooth and uniform, and has an average dynamic friction coefficient (MIU) of 0.25. It is preferably composed of a non-woven fabric having the above soft main surface (hereinafter, may be referred to as "flexible main surface"). More preferably, it is made of a non-woven fabric having a surface roughness (SMD) of 3.2 or less, a coefficient of friction fluctuation (MMD) of 0.013 or less, and an average dynamic friction coefficient (MIU) of 0.27 or more. It is made of a non-woven fabric having a surface roughness (SMD) of 3.0 or less, a friction coefficient fluctuation (MMD) of 0.011 or less, and an average dynamic friction coefficient (MIU) of 0.29 or more. As described above, it is preferable that the second non-woven fabric also has a smooth and uniform flexible main surface to some extent so that the influence of the first non-woven fabric layer on the originally smooth and uniform pattern surface is minimized. Therefore, it is preferable that the flexible main surface of the second non-woven fabric layer is in contact with the main surface of the first non-woven fabric layer facing the pattern surface having the physical characteristics and is laminated and integrated.

The surface material of the present invention preferably contains a first non-woven fabric layer and a second non-woven fabric layer as described above, but may include a third non-woven fabric layer other than the first non-woven fabric layer and the second non-woven fabric layer. good. When such a third non-woven fabric layer is included, the third non-woven fabric layer has a surface roughness (SMD) of 3 so as not to impair the tactile sensation achieved by the first non-woven fabric layer and the second non-woven fabric layer. It is preferable that the coefficient of friction (MMD) is 0.015 or less and the average coefficient of dynamic friction (MIU) is 0.15 or more. Even when such a third non-woven fabric layer is provided, the first non-woven fabric layer and the second non-woven fabric layer are in a state of being laminated and integrated adjacent to each other, and the pattern surface of the first non-woven fabric layer is exposed. , It is preferable that the patterned surface of the surface material is formed.

The "nonwoven fabric layer" means a layer of a non-woven fabric having morphological stability that can be handled by the layer itself. That is, it means that the layer itself is in the state of a non-woven fabric in which fibers are bonded to each other by entanglement, binder adhesion, and / or fiber fusion. Therefore, when two or more fiber webs in which fibers are not yet bonded to each other are laminated and then the fibers are bonded to each other to produce a non-woven fabric, the non-woven fabric layer is one layer, and a non-woven fabric layer having two or more layers is not available. Absent. When two or more fiber webs are laminated in this way, the surface of the laminated fiber web tends to be rough, and in order to improve this point, the surface is smoothed by heating and pressurizing the laminated fiber web. , The thickness becomes thin and the softness is impaired. As described above, in any case, it is difficult to obtain a surface material having an excellent tactile sensation that simultaneously satisfies the surface roughness, the fluctuation of the friction coefficient, and the average dynamic friction coefficient like the surface material of the present invention.

The fineness of the fibers constituting the surface material (for example, the first non-woven fabric layer and the second non-woven fabric layer) of the present invention is not particularly limited, but it is smooth and uniform because it is thin to some extent and has excellent dispersibility. It is preferably 0.5 to 6.6 dtex, more preferably 0.5 to 4.4 dtex, and 0.7 to 3.3 dtex so that a patterned surface or a flexible main surface can be easily formed. Is more preferable. This "fineness" means a value obtained by the method A specified in JIS L 1015 (2010) and 8.5.1 (positive amount fineness).

Further, the fiber length of the fibers constituting the surface material of the present invention (for example, the first non-woven fabric layer and the second non-woven fabric layer) is not particularly limited, but a smooth and uniform pattern is obtained due to the excellent dispersibility. It is preferably 20 to 110 mm, more preferably 30 to 80 mm so that a surface or a flexible main surface can be easily formed. The "fiber length" refers to a value measured according to JIS L1015 (2010), 8.4.1c) direct method (C method).

The fibers constituting the surface material (for example, the first non-woven fabric layer and the second non-woven fabric layer) of the present invention are not particularly limited, but for example, polyester fiber, nylon fiber, acrylic fiber, vinylon fiber, vinylidene fiber, polychloride. Synthetic fibers such as vinyl fiber, polyethylene fiber, polypropylene fiber, polyurethane fiber; regenerated fiber such as rayon fiber; semi-synthetic fiber such as acetate fiber; plant fiber such as cotton and hemp; animal fiber such as wool; it can. Among these, it is preferable to contain polyester fiber having excellent heat resistance, weather resistance, antifouling property and / or rayon fiber having excellent flame retardancy.

Further, the fibers constituting the surface material of the present invention (for example, the first non-woven fabric layer and the second non-woven fabric layer) may be white or may be colored in a color other than white. In particular, the non-woven fabric (for example, the first non-woven fabric layer) constituting the pattern surface of the surface material is preferably colored in a color other than white so as to have excellent design. The colored fibers can be prepared by kneading or adhering a pigment and / or dyeing with a dye.

The fibers constituting the surface material of the present invention (for example, the first non-woven fabric layer and the second non-woven fabric layer) may be oriented in any manner, but the fibers intersect with each other so as to have a smooth and uniform pattern surface. It is preferable that the fibers are oriented in this way. The non-woven fabric in such a state in which the fibers are oriented so as to intersect with each other can be produced, for example, by forming a cross raid web of unidirectional fiber webs with a cross layer or the like and bonding the fibers to each other.

The surface material of the present invention (for example, the first non-woven fabric layer and the second non-woven fabric layer) is preferably in a state in which fibers are entangled with each other so as to have excellent flexibility. The non-woven fabric in which the fibers are entangled with each other can be produced, for example, by subjecting the fiber web to a needle punching treatment or a water flow entanglement treatment. In particular, according to the needle punching process, a bulky non-woven fabric can be obtained, and the non-woven fabric is more excellent in flexibility, which is suitable.

Further, the surface material of the present invention (for example, the first non-woven fabric layer and the second non-woven fabric layer) suppresses fluffing of fibers so as to maintain the smoothness of the pattern surface, and is excellent in abrasion resistance. The non-woven fabric constituent fibers having a patterned surface are preferably in a state of being bonded with a binder. When such is the state of being bonded with the binder, if the binder amount is too large, there is a tendency that flexibility is impaired, it is preferable amount of binder is ^{1~20g / m 2, 1~10g / m} 2 Is more preferable, and 1 to 5 g / m ² is further preferable.

Further, even if the amount of the binder is within the above range, if the binder resin itself is hard, the flexibility of the non-woven fabric tends to be impaired. Therefore, the glass transition temperature of the binder resin is preferably 0 ° C. or lower. It is more preferably 10 ° C. or lower, further preferably −20 ° C. or lower, and further preferably −30 ° C. or lower. On the other hand, if the glass transition temperature of the binder resin is too low, the adhesiveness tends to be high and the tactile sensation tends to be poor, and when molding the surface material, the moldability tends to be poor. It is preferably 50 ° C. or higher. The "glass transition temperature" in the present invention means the intermediate point glass transition temperature (Tmg) read from the DSC curve drawn according to JIS K7121 (2012).

The binder resin can be composed of, for example, a resin such as ethylene-vinyl chloride type, ethylene-vinyl acetate type, ethylene-vinyl acetate-vinyl chloride type, vinylidene chloride type, vinyl chloride type, polyester type, and acrylic acid ester type.

Since the surface material of the present invention has a pattern made of resin on the surface of the non-woven fabric, it is excellent in designability. As described above, when the non-woven fabric bonded with the binder has a pattern surface, the surface bonded with the binder of the non-woven fabric is made of resin so that the smoothness of the pattern surface is excellent and a clear pattern can be obtained. It is preferable that it has a pattern and constitutes a pattern surface.

The pattern of the pattern surface in the surface material of the present invention is not particularly limited, and for example, a checkered pattern, a check pattern, a wavy pattern, a lattice pattern, a pattern in which geometric patterns are arranged in a staggered or lattice pattern, and a striped pattern. , Herringbone pattern, or a pattern in which the color difference gradually changes as disclosed in JP2012-179985, a three-dimensional pattern as disclosed in Practical New Design Registration No. 3072493, JP2012-179985. It can be a gradation pattern as disclosed in Japanese Patent Application Laid-Open No. 2013-194348, a pattern in which print units whose brightness changes are repeated as disclosed in Japanese Patent Application Laid-Open No. 2013-194348, and the like.

The resin that forms the pattern on the pattern surface of the surface material of the present invention is not particularly limited as long as it can form the pattern, but can be composed of the same resin as the binder of the above-mentioned non-woven fabric constituent fibers. That is, for example, it can be composed of resins such as ethylene-vinyl chloride type, ethylene-vinyl acetate type, ethylene-vinyl acetate-vinyl chloride type, vinylidene chloride type, vinyl chloride type, polyester type and acrylic acid ester type.

Further, the glass transition temperature of the resin is preferably 0 ° C. or lower, more preferably −10 ° C. or lower, and more preferably −20 ° C. so that the resin constituting the pattern does not impair the flexibility of the pattern surface. It is more preferably 30 ° C. or lower, and further preferably −30 ° C. or lower. On the other hand, if the glass transition temperature of the resin is too low, the adhesiveness tends to be high and the tactile sensation tends to be poor. Therefore, the temperature is preferably −50 ° C. or higher.

In addition, it is preferable that the surface material of the present invention has a pattern having a pattern in which the pigment is fixed by a resin so that the surface material has excellent designability.

Further, the amount of resin on the pattern surface (when other components such as pigments are contained, the amount including other components) is ^{preferably 1 g / m 2} or more so that the pattern does not easily change due to friction or the like. and more preferably at 2 g / ^{m 2} or more, and more preferably 3 g / ^{m 2} or more. On the other hand, if the amount of resin is too large, it is difficult to satisfy the above-mentioned surface roughness, fluctuation of friction coefficient and average dynamic friction coefficient, and the tactile sensation tends to deteriorate. Therefore, it ^{is preferably 40 g / m 2} or less. , 20 g / m ² or less, more preferably 10 g / m ² or less.

The basis weight of the surface material of the present invention is not particularly limited as long as it satisfies the above-mentioned surface roughness, fluctuation of friction coefficient, and average dynamic friction coefficient, but is 150 g / m ^{2 so that see-through or tearing is unlikely to occur.} The above is preferable, and the weight is preferably 500 g / m ² or less so as to be excellent in moldability in the case of molding. When the surface material contains the first non-woven fabric layer and the second non-woven fabric layer, the basis weight of the first non-woven fabric layer is 50 to 50 so that the pattern surface is smooth and uniform and has a certain degree of softness. it is preferably from 200 g / ^{m 2,} more preferably from 100 to 200 g / ^{m 2,} and even more preferably 150 to 200 g / ^{m 2.} On the other hand, the basis weight of the second non-woven fabric layer is preferably 100 to 300 g / m ² , more preferably 130 to 250 ^{g / m 2, and 150 to 200 g so as to impart flexibility to the surface material.} It is more preferably / m ^2.

The thickness of the surface material of the present invention is not particularly limited, but is preferably 2.0 mm or more, more preferably 2.3 mm or more so that it has excellent flexibility and tactile sensation. , 2.5 mm or more is more preferable. The upper limit of the thickness of the non-woven fabric is not particularly limited, but it is preferably 3.5 mm or less, and more preferably 3.0 mm or less so as to be lightweight. When the surface material contains the first non-woven fabric layer and the second non-woven fabric layer, the thickness of the first non-woven fabric layer is 0.5 to 2.0 mm so as to be excellent in flexibility to some extent. It is preferably 0.8 to 1.8 mm, more preferably 1.0 to 1.5 mm. On the other hand, the thickness of the second non-woven fabric layer is preferably 1.5 mm or more, and more preferably 1.6 mm or more so as to impart flexibility to the surface material. The upper limit of the thickness of the second non-woven fabric layer is not particularly limited, but it is preferably 3.5 mm or less so as to be lightweight. This "thickness" means a value under a load of 2.0 kPa, and when the surface material has a first non-woven fabric layer and a second non-woven fabric layer, the cross section in the thickness direction of the surface material under a load of 2.0 kPa It means the arithmetic mean value of the thickness at 5 points randomly selected by taking a stereomicrograph.

When the non-woven fabric constituting the surface material of the present invention has two or more non-woven fabric layers so as to have the first non-woven fabric layer and the second non-woven fabric layer, in what state the adjacent non-woven fabric layers are bonded to each other. However, when the first non-woven fabric layer and the second non-woven fabric layer are provided, the surface condition of the smooth and uniform patterned surface of the first non-woven fabric layer is not impaired, and the first non-woven fabric layer and the second non-woven fabric layer are present. It is preferably bonded by an adhesive so as not to impair the flexibility of the non-woven fabric layer. When bonded with an adhesive in this way, the amount of the adhesive is preferably 1 to 30 g / m ^{2 so that the surface material can be firmly bonded without impairing the flexibility of the surface material.} , 5 to 25 g / m ² , more preferably 10 to 20 g / m ² .

Examples of this adhesive include ethylene-based copolymers such as ethylene-vinyl chloride, ethylene-vinyl acetate, and ethylene-vinyl acetate-vinyl chloride; polyolefin resins such as polyethylene and polypropylene; polyamide-based copolymers and vinylidene chloride-based resins. It can be composed of a resin such as a resin, a vinyl chloride resin, a polyester resin, or an acrylic acid ester resin. The adhesive can be a hot melt type adhesive, an emulsion type, or a suspension type, but in the case of a hot melt type adhesive, when the adhesive action of the hot melt type adhesive is exhibited, the first non-woven layer and the first non-woven adhesive layer and the first 2 The melting point of the hot melt type adhesive is lower than the melting point of the resin having the lowest melting point among the resins constituting the first non-woven fabric and the second non-woven fabric so that the surface state of the non-woven fabric layer does not change. Is preferable, and it is more preferable that the temperature is 30 ° C. or higher lower than the melting point of the resin.

Since the surface material of the present invention is excellent in design and tactile sensation, it is suitable 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. Can be used.

The present invention has such a patterned surface having a surface roughness (SMD) of 2.5 or less, a friction coefficient fluctuation (MMD) of 0.015 or less, and an average dynamic friction coefficient (MIU) of 0.3 or more. The surface material has, for example, a surface roughness (SMD) of 2.5 or less (preferably 2.3 or less) and a coefficient of friction fluctuation (MMD) of 0.015 or less, as measured by a surface tester (KES-FB4). A patterned surface having an average dynamic friction coefficient (MIU) of 0.15 or more (preferably 0.16 or more, more preferably 0.18 or more) (preferably 0.012 or less, more preferably 0.010 or less). The first non-woven fabric to have, the surface roughness (SMD) measured by a surface tester (KES-FB4) is 3.5 or less (preferably 3.2 or less, more preferably 3.0 or less), and the coefficient of friction fluctuates. (MMD) is 0.015 or less (preferably 0.013 or less, more preferably 0.011 or less), and the average coefficient of dynamic friction (MIU) is 0.25 or more (preferably 0.27 or more, more preferably 0. 29 or more) After producing the second non-woven fabric having a flexible main surface, the first non-woven fabric and the second non-woven fabric are laminated and integrated so that the patterned surface of the first non-woven fabric becomes an exposed surface. be able to.

Specifically, first, a first non-woven fabric having a smooth and uniform pattern surface having a certain degree of flexibility is produced. As described above, the fineness is 0.5 to 6.6 dtex (preferably 0.5 to 4.4 dtex, more preferably 0.7 to 3.3 dtex) so as to facilitate the production of such a first non-woven fabric. Prepare fibers having a fiber length of 20 to 110 mm (preferably 30 to 80 mm). Further, as described above, the fibers are preferably polyester fibers and / or rayon fibers. Further, the fibers are preferably colored fibers.

The prepared fibers are then used to form a fiber web. The method for forming the fiber web is not particularly limited, but it is preferable to form the fiber web by a dry method such as a curd method, which is relatively bulky and can form a flexible fiber web. In addition, in order to easily form the first non-woven fabric having a smooth and uniform pattern surface, the fibers are oriented so that the fibers are in a crossed state on the main surface of the fiber web which is the source of the pattern surface of the first non-woven fabric. It is preferable to let it. For example, it is preferable that the fibers are crossed with each other by forming a cross raid web with a cross layer or the like on the unidirectional fiber web.

Next, the fibers are bonded to each other to produce a precursor first nonwoven fabric. This bonding method is not particularly limited, but it is preferable to bond the precursor first non-woven fabric by needle punching or water flow entanglement so that the precursor first nonwoven fabric is excellent in flexibility to some extent, and the precursor first is more flexible. It is preferable to bond the non-woven fabric by needle punching, which makes it easy to manufacture the non-woven fabric.

Further, it is preferable to bond the main surface of the fiber web with a binder so that the smoothness of the surface can be maintained, the fluffing of the fiber is suppressed, and the wear resistance is excellent. As described above, such a binder is an emulsion composed of a resin such as, for example, ethylene-vinyl chloride type, ethylene-vinyl acetate type, ethylene-vinyl acetate-vinyl chloride type, vinylidene chloride type, vinyl chloride type, polyester type, acrylic acid ester type, etc. Alternatively, suspension can be used. Adhesion using such a binder can be carried out by impregnating, foaming, coating, or spraying one or both sides of a fiber web (preferably a needle punch web or a water flow entangled web) and drying. As described above, the binder amount is ^{preferably 1 to 20} g / m 2 (preferably 1 to 10 g / m ² , more preferably ^{1 to 5 g / m 2} ). The glass transition temperature of the binder resin is preferably 0 to −50 ° C. (preferably −10 to −50 ° C., more preferably −20 to −50 ° C., still more preferably −30 ° C. to −50 ° C.). ..

Next, a resin can be printed on the main surface of such a precursor first nonwoven fabric and a pattern made of the resin can be applied to obtain the first nonwoven fabric. Such a resin printing method can be a conventionally known method. For example, a cylinder having an opening corresponding to a desired pattern is prepared, and a resin (preferably containing a pigment) is printed through the cylinder. Can be implemented. When there are two or more types of patterns, it can be carried out by repeating the above operation. As described above, the resin is composed of, for example, ethylene-vinyl chloride-based, ethylene-vinyl acetate-based, ethylene-vinyl acetate-vinyl chloride-based, vinylidene chloride-based, vinyl chloride-based, polyester-based, acrylic acid ester-based resins and the like. be able to. When a pigment is contained in addition to the resin, the color, type, and amount of the pigment can be appropriately adjusted. Further, the printing method is not limited to the method using a cylinder, and can be carried out by, for example, gravure printing, letterpress printing, offset printing, screen printing, or the like, and is not particularly limited.

The first non-woven fabric produced in this manner may have a pattern made of resin, has insufficient smoothness and uniformity, has a surface roughness (SMD) of 2.5 or less, and has a coefficient of friction fluctuation (MMD) of 0. Since it tends not to have a patterned surface of .015 or less, it is preferable to produce a first non-woven fabric having a smooth patterned surface by smoothing by heating and pressurizing. This heating and pressurizing condition has a patterned surface having a surface roughness (SMD) of 2.5 or less, a friction coefficient fluctuation (MMD) of 0.015 or less, and an average dynamic friction coefficient (MIU) of 0.15 or more. The conditions may be such that the first non-woven fabric is used, and since it differs depending on the first non-woven fabric constituent fibers, the type of binder, the type of resin constituting the pattern, etc., it is appropriately adjusted by experiment. In addition, heating and pressurization may be performed at the same time, or may be pressurized after heating. For example, if a heating roll is used, heating and pressurization can be performed at the same time, and if pressure is applied by a pair of rolls having a temperature lower than the heating temperature after heating in an oven or the like, heating and pressurization are performed separately. be able to.

The thickness of the first non-woven fabric can be adjusted to some extent by the heating and pressurizing, but in order to adjust the thickness, the thickness is adjusted after the heating and pressurizing treatment to reduce the thickness of the first non-woven fabric to 0. It is preferably .5 to 2.0 mm (more preferably 0.8 to 1.8 mm, still more preferably 1.0 to 1.6 mm). This thickness adjustment can be performed, for example, by passing between a pair of rolls.

On the other hand, a second nonwoven fabric having excellent flexibility, a certain degree of smoothness and a uniform flexible main surface is produced. As described above, the fineness is 0.5 to 6.6 dtex (preferably 0.5 to 4.4 dtex, more preferably 0.7 to 3.3 dtex) so as to facilitate the production of such a second non-woven fabric. Prepare fibers having a fiber length of 20 to 110 mm (preferably 30 to 80 mm). Further, as described above, the fibers are preferably polyester fibers and / or rayon fibers. Further, the fibers may or may not be colored, but when molding the surface material, if the fibers are colored in the same system as the first non-woven fabric constituent fibers, see-through during molding is prevented and the appearance is prevented. It is preferable to prepare fibers colored in the same hue as the first non-woven fabric constituent fibers, because the fibers are not easily damaged.

The prepared fibers are then used to form a fiber web. The method for forming the fiber web is not particularly limited, but it is preferable to form the fiber web by a dry method such as a curd method, which is relatively bulky and can form a flexible fiber web. In addition, in order to facilitate the formation of the second non-woven fabric having a smooth and uniform flexible main surface to some extent, the fibers are in a state of intersecting with each other on the main surface of the fiber web which is the source of the flexible main surface of the second non-woven fabric. It is preferable to orient the fibers. For example, it is preferable that the unidirectional fiber web is formed into a cross raid web by a cross layer or the like so that the fibers are crossed with each other.

Next, the fibers are bonded to each other to produce a precursor second nonwoven fabric. This bonding method is not particularly limited, but it is preferable to bond the precursor second nonwoven fabric by needle punching or water flow entanglement so that the precursor second nonwoven fabric is excellent in flexibility, and the precursor second nonwoven fabric having more flexibility is preferable. It is preferable to bond by needle punching, which is easy to manufacture.

Further, it is preferable to bond with a binder so that the smoothness of the surface can be maintained. Such binder bonding can be carried out by the same method using the same binder as the first non-woven fabric. As described above, the binder amount is ^{preferably 1 to 20} g / m 2 (preferably 1 to 10 g / m ² , more preferably ^{1 to 5 g / m 2} ). The glass transition temperature of the binder resin is preferably 0 to −50 ° C. (preferably −10 to −50 ° C., more preferably −20 to −50 ° C., still more preferably −30 ° C. to −50 ° C.). ..

The precursor second nonwoven fabric in which the fibers are bonded to each other in this way has insufficient smoothness and uniformity, has a surface roughness (SMD) of 3.5 or less, and a friction coefficient fluctuation (MMD) of 0.015 or less. Since it tends not to have a flexible main surface, it is preferable to smooth the surface of the precursor second non-woven fabric by heating and pressurizing to obtain the second non-woven fabric. The heating and pressurizing conditions are such that the flexible main surface has a surface roughness (SMD) of 3.5 or less, a friction coefficient fluctuation (MMD) of 0.015 or less, and an average dynamic friction coefficient (MIU) of 0.25 or more. It suffices as long as it is a condition for the second non-woven fabric to have, and it depends on the type of the second non-woven fabric constituent fiber, the binder and the like. Note that heating and pressurization may be performed at the same time as in the case of the first non-woven fabric, or may be pressurized after heating.

The thickness of the second non-woven fabric can be adjusted to some extent by the heating and pressurizing, but in order to adjust the thickness, the thickness is adjusted after the heating and pressurizing treatment to reduce the thickness of the second non-woven fabric to 1. It is preferably 5.5 mm or more (preferably 1.6 to 3.5 mm). This thickness adjustment can be performed, for example, by passing between a pair of rolls.

Next, in order to laminate and integrate the first non-woven fabric and the second non-woven fabric formed as described above, an adhesive capable of adhering the first non-woven fabric and the second non-woven fabric is prepared. This adhesive may be any adhesive as long as it can bond the first non-woven fabric and the second non-woven fabric, and is not particularly limited. For example, ethylene such as ethylene-vinyl chloride type, ethylene-vinyl acetate type, and ethylene-vinyl acetate-vinyl chloride type. It can be composed of a copolymer; a polyolefin resin such as polyethylene and polypropylene; a polyamide copolymer, a vinylidene chloride resin, a vinyl chloride resin, a polyester resin, an acrylic acid ester resin and the like. The mode of the adhesive is not particularly limited, but it is easy to suppress the generation of volatile organic substances, and it is easy to laminate and integrate the first non-woven fabric and the second non-woven fabric while maintaining the smoothness and flexibility. It is preferably a hot melt type adhesive that can be fused by.

In the case of such a suitable hot melt type adhesive, the melting point of the hot melt type adhesive is prevented so that the surface conditions of the first non-woven fabric and the second non-woven fabric do not change when the hot melt type adhesive exerts its adhesive action. Is preferably lower than the melting point of the resin having the lowest melting point among the resins constituting the first nonwoven fabric constituent fiber and the second nonwoven fabric constituent fiber, and more preferably 30 ° C. or more lower than the melting point of the resin.

Further, the first non-woven fabric and the second non-woven fabric can be firmly bonded without impairing the surface condition of the smooth and uniform patterned surface of the first non-woven fabric and without impairing the flexibility of the second non-woven fabric. to, 1~30g / ^{m 2} (preferably 5 to 25 g / ^{m 2,} more preferably 10 to 20 g / ^{m 2)} is preferred to prepare the adhesive quantity. For example, in the case of a hot melt type adhesive, the above amount of fiber web, fiber, or powder is prepared, and in the case of an emulsion type or suspension type adhesive, the amount of solid content after drying is the above amount. Prepare as much adhesive as possible.

Next, in order to laminate and integrate the first non-woven fabric and the second non-woven fabric, the surface roughness (SMD) of the second non-woven fabric is 3.5 or less, the coefficient of friction fluctuation (MMD) is 0.015 or less, and the average dynamic friction. A flexible main surface with a coefficient (MIU) of 0.25 or more, or a surface roughness (SMD) of the first non-woven fabric of 2.5 or less, a coefficient of friction fluctuation (MMD) of 0.015 or less, and an average dynamic friction coefficient (MIU). ) Is 0.15 or more, and the adhesive is applied to the main surface facing the pattern surface. For example, if the adhesive is a fiber web, it is laminated, if it is a fiber or powder, it is sprayed, and if it is an emulsion type or suspension type, it is applied or sprayed.

Next, on the adhesive, in the former case, it is laminated on the flexible main surface of the second non-woven fabric so that the main surface facing the pattern surface of the first non-woven fabric faces, and in the latter case, it is laminated. , The flexible main surface of the second non-woven fabric is laminated on the main surface facing the pattern surface of the first non-woven fabric. That is, the first non-woven fabric and the second non-woven fabric are laminated so that the patterned surface of the first non-woven fabric becomes the exposed surface of the laminate.

Then, the surface material of the present invention can be produced by exerting the adhesive action of the adhesive and integrating the first non-woven fabric and the second non-woven fabric. For example, in the case of a hot melt type adhesive, it is heated at a temperature equal to or higher than the melting point at which the adhesive melts, and in the case of an emulsion type or suspension type adhesive, it is heated at a temperature at which the solvent volatilizes. The first non-woven fabric and the second non-woven fabric are integrated by exerting the adhesive action of.

It is possible to heat and pressurize the adhesive so that the adhesive action can be sufficiently exerted. However, if the heating temperature is too high, the pressing force is too strong, and / or the heating and pressurizing time is long, the first non-woven fabric and Since the smoothness, uniformity, and / or flexibility of the second non-woven fabric tends to be impaired, heating and pressurizing under the minimum necessary conditions, the surface roughness (SMD) of the surface material is 2.5 or less, and the coefficient of friction The pattern surface has a variation (MMD) of 0.015 or less and an average coefficient of dynamic friction (MIU) of 0.3 or more. Since the heating and pressurizing conditions differ depending on the adhesive, they are appropriately adjusted by experiments.

Examples of the present invention will be described below, but the present invention is not limited to the following examples.

(Examples 1 and 2, Comparative Examples 1 and 4)
(Manufacturing of first non-woven fabric)
Using 100% of gray-colored polyester short fibers (fineness: 2.2 dtex, fiber length: 51 mm, melting point: 260 ° C.), the fibers are opened by a card machine to form a unidirectional fiber web, and then by a cross layer. , A crosslay web in which the fibers were crossed was formed, and further needle punching was performed to entangle the fibers to form a needle punching web as shown in Table 1.

Next, one side of the needle punch web was whipped and impregnated with an emulsion binder solution of acrylic acid ester (glass transition temperature: −40 ° C.), and dried with a can dryer at a temperature of 150 ° C.

Next, a printing liquid having the following solid content ratio was printed on the binder-impregnated surface of the needle punch web with a rotary screen type printing device, and then dried with a dryer having a temperature of 160 ° C. A first non-woven fabric having a pattern in which a character-shaped printed resin (line width: 0.3 mm) was arranged in a staggered pattern was produced.

(Print liquid)
Acrylic ester binder (glass transition temperature: -40 ° C): 90.6
Defoamer: 1.8
Thickener: 7.1
Pigment: 0.5

Then, under the conditions shown in Table 1, heat and pressurization was performed by passing between the thermal calendar rolls to smooth the pattern surface, and the first non-woven fabrics shown in Table 1 were produced.

(Manufacturing of second non-woven fabric)
Using 100% of gray-colored polyester short fibers (fineness: 2.2 dtex, fiber length: 51 mm, melting point: 260 ° C.), the fibers are opened by a card machine to form a unidirectional fiber web, and then by a cross layer. , A crosslay web in which the fibers were crossed was formed, and further needle punching was performed to entangle the fibers to form a needle punching web as shown in Table 2.

Next, one side of this needle punch web is whipped and impregnated with an emulsion binder solution of acrylic acid ester (glass transition temperature: -40 ° C), dried with a can dryer at a temperature of 150 ° C, and then as shown in Table 2. Under the conditions, heating and pressurization was performed by passing between the thermal calendar rolls to smooth them, and the second non-woven fabric as shown in Table 2 was produced.

(Preparation of adhesive non-woven fabric)
As the adhesive nonwoven fabric, a hot-melt adhesive nonwoven fabric having a ^{mesh size of 17 g / m 2 made} of polyethylene fibers (melting point: 110 ° C.) was prepared.

(Manufacturing of surface material)
A pattern in which the adhesive non-woven fabric is laminated on a flexible main surface having the physical properties as shown in Table 2 of the second non-woven fabric, and further, the adhesive non-woven fabric has the physical properties as shown in Table 1 of the first non-woven fabric. The first non-woven fabric is laminated so that the main surface facing the surface is in contact with the adhesive non-woven fabric, and in that state, heating and pressurizing at a temperature of 130 ° C. and a pressing force of 9.8 N is carried out for 10 seconds, and the first non-woven fabric and the first non-woven fabric are used. The two non-woven fabrics were adhered and integrated to produce surface materials as shown in Table 3. In Comparative Example 4, the surface of the surface material was smoothed by performing a heat roll treatment in which the rolls (gap: 0.2 mm) at a temperature of 180 ° C. were passed after the adhesive integration.

(Evaluation of surface material)
By having the monitor directly touch the pattern surface on the first non-woven fabric side of the surface material, the smoothness, uniformity, and softness were evaluated on a five-point scale. If it was excellent, it was evaluated as "5", if it was inferior, it was evaluated as "1", and in the middle, it was evaluated as "2-4". The results are as shown in Table 3.

From this Table 3, the following was found.
(1) From the comparison between Example 1 and Example 2, even if the amount of printed resin is different, the average coefficient of dynamic friction (MIU) of the patterned surface of the surface material is 0.30 or more, and the surface roughness (SMD) is 2.5. When the fluctuation of the friction coefficient (MMD) is 0.015 or less, the tactile sensation is excellent.
(2) From the comparison between Examples 1 and 2 and Comparative Example 1, the average dynamic friction coefficient (MIU) of the patterned surface of the surface material is 0.30 or more, so that the flexibility is excellent. Further, by having the second non-woven fabric layer, the flexibility is improved.
(3) From the comparison between Examples 1 and 2 and Comparative Example 2, the surface roughness (SMD) of the patterned surface of the surface material is 2.5 or less, and the fluctuation of the friction coefficient (MMD) is 0.015 or less. As a result, it is excellent in smoothness and uniformity. Further, even if the smoothness and uniformity of the second nonwoven fabric are excellent, if the smoothness and uniformity of the first nonwoven fabric constituting the patterned surface of the surface material is insufficient, the smoothness and uniformity are excellent. The smoothness and uniformity of the patterned surface of the first non-woven fabric have a great influence on the smoothness and uniformity of the surface material.
(4) From the comparison between Examples 1 and 2 and Comparative Example 3, the surface roughness (SMD) of the patterned surface of the surface material is 2.5 or less, and the fluctuation of the friction coefficient (MMD) is 0.015 or less. By being present, it is excellent in smoothness and uniformity. Further, even if the patterned surface of the first non-woven fabric is excellent in smoothness and uniformity, if the smoothness and uniformity of the second non-woven fabric are insufficient, the surface material does not have excellent smoothness and uniformity. , The smoothness and uniformity of the second non-woven fabric have a great influence on the smoothness and uniformity of the surface material.
(5) From the comparison between Examples 1 and 2 and Comparative Example 4, the flexibility is excellent because the average dynamic friction coefficient (MIU) of the patterned surface of the surface material has a patterned surface of 0.30 or more. Further, when heat roll treatment is performed in order to improve the smoothness and uniformity of the surface material, the average dynamic friction coefficient (MIU) of the patterned surface cannot be made into a highly flexible surface material of 0.30 or more. A first non-woven fabric having a patterned surface with a surface roughness (SMD) of 2.5 or less, a coefficient of friction fluctuation (MMD) of 0.015 or less, and an average coefficient of dynamic friction (MIU) of 0.15 or more, and a surface roughness. It is preferable to laminate with a second non-woven fabric having a flexible main surface having a (SMD) of 3.5 or less, a coefficient of friction fluctuation (MMD) of 0.015 or less, and an average dynamic friction coefficient (MIU) of 0.25 or more. thing.

Since the interior surface material of the present invention has excellent design and tactile sensation, it is 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. can do.

Claims (6)

A surface material for interiors that has a resin pattern on the surface of the non-woven fabric.
The interior surface material includes two non-woven fabric layers, a first non-woven fabric layer having a surface having a pattern made of resin and a second non-woven fabric layer other than the first non-woven fabric layer, and the first non-woven fabric layer and the second non-woven fabric layer are It is laminated and integrated,
The surface of the non-woven fabric having a fineness of 0.7 dtex or more and having a pattern made of resin on the interior surface material has a surface roughness (SMD) of 2 as measured by a surface tester (KES-FB4). A surface material for interior use, characterized in that the coefficient of friction (MMD) is 0.015 or less and the average coefficient of dynamic friction (MIU) is 0.3 or more and 1.0 or less. The interior surface material according to claim 1, wherein the thickness of the second non-woven fabric layer is 1.5 mm or more. When the surface roughness (SMD) is 2.5 or less, the coefficient of friction fluctuation (MMD) is 0.015 or less, and the average dynamic friction coefficient (MIU) is 0.15 or more, as measured by a surface tester (KES-FB4). A step of forming a first non-woven fabric having a surface with a resin pattern,
When the surface roughness (SMD) is 3.5 or less, the coefficient of friction fluctuation (MMD) is 0.015 or less, and the average dynamic friction coefficient (MIU) is 0.25 or more, as measured by a surface tester (KES-FB4). The process of forming a second non-woven fabric having a certain main surface, and
A step of laminating and integrating the first non-woven fabric and the second non-woven fabric so that the surface of the first non-woven fabric having a pattern made of resin becomes an exposed surface.
The method for producing an interior surface material according to claim 1, further comprising. The first non-woven fabric was smoothed by forming a fiber web using fibers having a fineness of 0.7 to 6.6 dtex, printing a resin on the fiber web to form a pattern, and then heating and pressurizing. The method for producing an interior surface material according to claim 3, wherein the non-woven fabric has a surface having a pattern made of resin. 3. The second non-woven fabric is a non-woven fabric having a main surface smoothed by heating and pressurizing after forming a fiber web using fibers having a fineness of 0.7 to 6.6 dtex. Alternatively, the method for manufacturing an interior surface material according to claim 4. The method for producing an interior surface material according to any one of claims 3 to 5, wherein the thickness of the second nonwoven fabric is 1.5 mm or more.