JP7018335B2 - Interior materials and their manufacturing methods - Google Patents

Description

The present invention relates to an interior material having a fine sand grain pattern and the like.

Conventionally, resin interior materials having a so-called sand grain pattern have been known as interior materials for buildings such as floor materials, wall materials, and ceiling materials of buildings, and are particularly popular as floor materials.
Here, the sand grain pattern in the interior material is made by a method of forming a sheet with chips or flakes, or a method of designing a sand grain pattern by performing back printing on a transparent surface layer. It says a pattern like this. It can be said that the resin interior material having a grain-like pattern is an interior material in which the sand-grain pattern is artificially reproduced with the resin material.
A resin interior material having such a grain-like pattern can be obtained by crushing a colored vinyl chloride resin sheet, collecting the crushed material, rolling or pressurizing the crushed material (Patent Document 1).

Japanese Patent No. 2533978

The interior material that reproduces the grain-like pattern has an appearance like sandy ground with fine sand sprinkled (fine sand-grain pattern), giving the viewer a calm impression.
However, when the sand grain pattern is reproduced by printing, it looks like a flat pattern, and an appearance having three-dimensional sand grains cannot be obtained.
On the other hand, when the crushed material of the resin sheet is melted and rolled to form a sheet as it is as in Patent Document 1, the crushed material may be too melted to reproduce three-dimensional sand grains.
Another possible method is to disperse thermoplastic resin chips and flakes in a vinyl chloride paste resin, apply it to a substrate, and then heat and gel it to form a sheet. However, the chips and flakes are made of vinyl chloride. It is buried in the paste resin, and it is difficult to express the appearance of having three-dimensional sand grains.

An object of the present invention is to provide an interior material having a three-dimensional appearance as if fine sand is sprinkled on it, and a method for producing the same.

The interior material of the present invention has a sheet body containing a vinyl chloride resin, a colorant and a filler, and a portion in which colored vinyl chloride resin particles are aggregated is formed on the surface side of the sheet body, and the aggregated portion is formed. The vinyl chloride resin particles in the exposed portion include vinyl chloride resin particles having a maximum length of 50 μm to 200 μm in the exposed portion, and a recess is formed in the portion where the vinyl chloride resin particles are aggregated, and the chloride is formed. Filler fine particles smaller than the vinyl resin particles are gathered and adhered around the exposed portion of the vinyl chloride resin particles on the surface of the recess, and the filler fine particles contain calcium carbonate .

In the preferred interior material of the present invention, the vinyl chloride resin particles contain at least two types of vinyl chloride resin particles colored in different colors, and the filler fine particles represent the respective vinyl chloride resin particles . It gathers around the part and is attached .
The preferable interior material of the present invention forms a sea-island structure in which the aggregated portion serves as a sea in a plan view where the filler fine particles are gathered and adhered, and the exposed portion of the vinyl chloride resin particles is an island. There is.
In the preferred interior material of the present invention, the vinyl chloride resin particles exposed in the agglomerated portion satisfy at least one relationship selected from the following (a) to (c).
(A) There are 16 or more vinyl chloride resin particles in 1 square mm in which the maximum length of the exposed portion is in the range of 50 μm to 100 μm.
(B) There are 12 or more vinyl chloride resin particles in 1 square mm in which the maximum length of the exposed portion is in the range of more than 100 μm and 150 μm or less.
(C) There are 8 or more vinyl chloride resin particles in 1 square mm in which the maximum length of the exposed portion exceeds 150 μm and is in the range of 200 μm or less.
The preferable interior material of the present invention is composed of only the sheet body or the sheet body and a surface protective layer laminated on the surface thereof.

According to another aspect of the present invention, there is provided a method for manufacturing an interior material.
The method for producing an interior material of the present invention is colored by mixing vinyl chloride resin particles having a volume average particle size of 20 μm to 300 μm, filler fine particles containing calcium carbonate smaller than the particles, a colorant, and a plasticizer. It has a step of producing raw material particles in which filler fine particles smaller than the particles are scattered on the surface of the vinyl chloride resin particles, and a step of collecting the raw material particles and heating and pressurizing them to form a sheet.

The interior material of the present invention has an appearance as if fine sand was sprinkled on it. According to the present invention, it is possible to provide an interior material having a high design that expresses three-dimensional sand grains.

A partially omitted plan view of the interior material of the first embodiment of the present invention. FIG. 2 is a cross-sectional view taken along the line II-II of FIG. Sectional drawing of the interior material of 2nd Embodiment of this invention. Sectional drawing of the interior material of 3rd Embodiment of this invention. Sectional drawing of the interior material of 4th Embodiment of this invention. An enlarged plan view of the surface of the sheet body of the interior material (enlarged plan view of the VI portion in FIG. 1). FIG. 6 is a cross-sectional view taken along the line VII-VII of FIG. Front view of raw material particles. Front view of vinyl chloride resin particles. The schematic diagram of the manufacturing apparatus of the sheet body of an interior material. An enlarged photograph of the vinyl chloride resin used in the examples. Enlarged photograph of calcium carbonate used in the examples. Enlarged photograph of raw material particles. Photograph of the surface of the sheet body. Enlarged photograph of any part of the surface of the sheet. A reference enlarged photograph showing the vinyl chloride resin particles exposed on the surface of the sheet body.

Hereinafter, the present invention will be described with reference to the drawings as appropriate.
In the present specification, the plan view means a view from a direction orthogonal to the surface of the sheet body (interior material), and the plan view shape means a shape when viewed from that direction. The cross-sectional view shape refers to a shape when the sheet body (interior material) is cut in the thickness direction.
In the present specification, the numerical range represented by "lower limit value X to upper limit value Y" means a lower limit value X or more and an upper limit value Y or less. When a plurality of the numerical values are described separately, it is possible to select an arbitrary lower limit value and an arbitrary upper limit value and set "arbitrary lower limit value to arbitrary upper limit value".

[Overview of interior materials]
In FIGS. 1 and 2, the interior material 1 of the present invention has a sheet body 2 containing a vinyl chloride resin, a colorant, and a filler.
As shown in FIG. 1, the interior material 1 of the present invention may be formed in a long strip shape, or may be formed in a single-wafer shape, although not particularly shown. The long strip is a substantially rectangular shape in a plan view in which the length in one direction is sufficiently longer than that in the other direction. The long strip-shaped interior material 1 has, for example, a length of 1000 mm to 4000 mm in the first direction, a length of 5 m or more in the second direction, and preferably a length of 10 m or more in the second direction. The first direction is a direction orthogonal to the second direction.
The single-wafer shape is formed into a predetermined shape such as a substantially rectangular shape or a substantially polygonal shape in a plan view such as a tile floor material, and generally refers to a shape that can be stacked, stored and transported. Examples of the single-wafer-shaped interior material 1 include a substantially rectangular shape having a length of 200 mm to 1000 mm in the first direction and a length of 200 mm to 1000 mm in the second direction.
As used herein, the "abbreviation" of a shape means a shape that is acceptable in the technical field to which the present invention belongs. An "abbreviation" such as a substantially rectangular shape, a substantially square shape, or a substantially rectangular shape means, for example, a shape in which corners are chamfered, a shape in which a part of a side is slightly bulged or recessed, or a shape in which a side is slightly curved. Shape etc. are included. Further, the "abbreviation" having a substantially elliptical shape or a substantially circular shape includes, for example, a shape in which a part of the circumference is slightly bulged or recessed, a shape in which a part of the circumference is slightly straight or diagonal, and the like.

2 shows the interior material of the first embodiment, FIG. 3 shows the interior material of the second embodiment, FIG. 4 shows the interior material of the third embodiment, and FIG. 5 shows the fourth embodiment. Shows the interior material of.
The plan views of the interior materials of the second to fourth embodiments are the same as those of FIG. 1, and are omitted.
In FIG. 2, the interior material 1 of the first embodiment is composed of only the sheet body 2. In other words, the interior material 1 has a single-layer structure composed of only the sheet body 2 containing a vinyl chloride resin, a colorant and a filler, and the front surface and the back surface of the sheet body 2 are the outermost surface and the outermost surface of the interior material 1. Is made up of.
In FIG. 3, the interior material 1 of the second embodiment is composed of a sheet body 2 containing a vinyl chloride resin, a colorant, and a filler, and a surface protective layer 3 laminated on the surface of the sheet body 2. There is. In the interior material 1, the surface of the surface protective layer 3 forms the outermost surface of the interior material 1, and the back surface of the sheet body 2 forms the outermost surface of the interior material 1.
In FIG. 4, the interior material 1 of the third embodiment is composed of a sheet body 2 containing a vinyl chloride resin, a colorant, and a filler, and a back layer 4 laminated on the back surface of the sheet body 2. .. In the interior material 1, the front surface of the sheet body 2 forms the outermost surface of the interior material 1, and the back surface of the back layer 4 forms the outermost surface of the interior material 1.
In FIG. 5, the interior material 1 of the fourth embodiment includes a sheet body 2 containing a vinyl chloride resin, a colorant, and a filler, a surface protective layer 3 laminated on the surface of the sheet body 2, and the sheet body 2. It is composed of a back layer 4 laminated on the back surface of the above. In the interior material 1, the surface of the surface protective layer 3 forms the outermost surface of the interior material 1, and the back surface of the back layer 4 forms the outermost surface of the interior material 1.

<Sheet body>
The sheet body 2 has flexibility. The sheet body 2 has flexibility so that it can be wound into a roll, for example, on a core material having a diameter of 20 cm. The sheet body 2 is made of a non-foamed material. It is preferable that the interior material 1 in which the back layer 4 or the like is laminated on the sheet body 2 as shown in FIGS. 4 and 5 also has the same flexibility as the sheet body 2.
The thickness of the sheet body 2 is not particularly limited, and is, for example, 0.5 mm to 8 mm, preferably 1.0 mm to 5.0 mm. When the back layer 4 is not laminated on the back surface of the sheet body 2 as in the first and second embodiments, the thickness of the sheet body 2 is preferably relatively large, for example, 1.0 mm to 8 mm. It is preferably 1.2 mm to 5 mm. Further, when the back layer 4 is laminated on the back surface of the sheet body 2 as in the third and fourth embodiments, the thickness of the sheet body 2 can be made relatively small.

The sheet body 2 contains a vinyl chloride resin, a colorant and a filler, and may further contain an additive such as a plasticizer. A portion where the colored vinyl chloride resin particles 5 are aggregated is formed on the surface side of the sheet body 2, a recess 21 is formed in the portion where the colored vinyl chloride resin particles 5 are aggregated, and chloride is formed on the surface of the recess 21. Filler fine particles 6 smaller than the vinyl resin particles 5 are gathered and adhered.
Hereinafter, the portion where the vinyl chloride resin particles 5 are aggregated is referred to as an “aggregated portion”.
A plurality of vinyl chloride resin particles 5 are gathered and joined to form a layer in the agglomerated portion, and extend to at least the surface side of the sheet body 2.
The colored vinyl chloride resin particles 5 mean a vinyl chloride resin in the form of particles and colored with a colorant, and the filler fine particles 6 mean the filler in the form of particles.

At least one kind of colored vinyl chloride resin particles 5 is used, and preferably at least two kinds of vinyl chloride resin particles 5 colored in different colors are used.
Filler fine particles 6 are scattered on the surface of the vinyl chloride resin particles 5, and the filler fine particles 6 are gathered on the surface of the recess 21 of the aggregated portion. Therefore, the aggregated portion includes a portion where the vinyl chloride resin particles 5 are exposed and a portion where the filler fine particles 6 are exposed, and the filler fine particles 6 are particularly concentrated in the recess 21. Exists in.
Details of additives such as vinyl chloride resin, colorants, fillers and plasticizers will be described in detail in the section [Method for manufacturing interior materials].
With reference to FIGS. 6 and 7, the surface side of the sheet body 2 has a portion in which a plurality of vinyl chloride resin particles 5 are aggregated, and the filler fine particles 6 are formed on the surface of each of the vinyl chloride resin particles 5. Are scattered around. Preferably, a plurality of two or more kinds of vinyl chloride resin particles 5 colored in different colors are aggregated.
The size of the filler fine particles 6 is smaller than that of the vinyl chloride resin particles 5. Since the filler fine particles 6 are small, the individual filler fine particles are not shown in FIGS. 6 and 7.
The agglomerated portion may be formed on a part of the surface of the sheet body 2, but preferably, the agglomerated portion is formed over the entire surface of the sheet body 2.

The vinyl chloride resin particles 5 colored in different colors in the agglomerated portion may be of two types or three or more types. Here, three types of vinyl chloride resin particles 5 colored in different colors will be described as an example. Hereinafter, when it is necessary to distinguish the vinyl chloride resin particles 5 having different colors, they are referred to as the first vinyl chloride resin particles 51, the second vinyl chloride resin particles 52, and the third vinyl chloride resin particles 53.
The colored vinyl chloride resin particles 5 (for example, the first to third vinyl chloride resin particles 51, 52, 53) are a resin composition containing a vinyl chloride resin and a colorant, and further containing an additive such as a plasticizer. Is atomized.

The compositions of the first to third vinyl chloride resin particles 51, 52, and 53 having different colors may be the same or different, provided that the colors (colorants) are different.

In the agglomerated portion, a plurality of vinyl chloride resin particles 5 are adjacent to each other, and the adjacent vinyl chloride resin particles are joined to form a layer. In FIG. 7, the space between the adjacent vinyl chloride resin particles 5 is represented by a clear solid line, but the adjacent vinyl chloride resin particles 5 do not have a clear boundary due to bonding (fusion). Please note that there is.
In the illustrated example, the plurality of vinyl chloride resin particles 5 have a plurality of first vinyl chloride resin particles 51, second vinyl chloride resin particles 52, and third vinyl chloride resin particles 53, and a part of them is the surface of the aggregated portion. It is irregularly exposed (the surface of the sheet body 2).
The first vinyl chloride resin particles 51 are colored in an arbitrary color (for example, black), the second vinyl chloride resin particles 52 are colored in a different color (for example, white), and the third vinyl chloride resin particles 53 are colored. Is colored in a different color (for example, brown).
The aggregated portion may contain uncolored vinyl chloride resin particles, provided that the particles have colored vinyl chloride resin particles 5.

As shown in FIG. 6, the planar view shape (planar view shape of the exposed portion) of each of the exposed vinyl chloride resin particles 5 is relatively irregular (the irregular shape has a disordered shape). However, some vinyl chloride resin particles 5 are expressed in a substantially elliptical shape or a substantially circular shape in a plan view. That is, the shape of each vinyl chloride resin particle 5 in a plan view is not uniform, but the aggregated portion has the vinyl chloride resin particle 5 whose exposed shape is a substantially elliptical shape or a substantially circular shape in a plan view. .. The plan view shape of the vinyl chloride resin particles 5 other than the substantially elliptical shape and the substantially circular shape in the plan view cannot be specified.
In other words, the vinyl chloride resin particles 5 on the surface of the aggregated portion are expressed in an indefinite shape in a plan view with the vinyl chloride resin particles 5 in a substantially elliptical shape or a substantially circular shape in a plan view. It is composed of vinyl chloride resin particles 5 and the like. As shown in FIG. 7, the three-dimensional shape of each vinyl chloride resin particle 5 is irregular.
In the agglomerated portion, some of the vinyl chloride resin particles 5 are expressed in a substantially elliptical shape and a substantially circular shape in a plan view, so that the interior material has an excellent three-dimensional effect like sandstone. Can be obtained.

In the aggregated portion, the size and number (ratio) of the exposed vinyl chloride resin particles 5 preferably satisfy at least one of the following (a) to (c).
(A) The maximum length of the exposed portion is in the range of 50 μm to 100 μm, and the number of vinyl chloride resin particles is 16 or more, preferably 30 or more, more preferably 40 or more in 1 square mm. .. The upper limit of the number of vinyl chloride resin particles in the range of 50 μm to 100 μm is not particularly limited, but is, for example, 400 or less, further 300 or less.
(B) The maximum length of the exposed portion is in the range of more than 100 μm and 150 μm or less, and the number of vinyl chloride resin particles is 12 or more, preferably 18 or more, more preferably 30 or more in 1 square mm. Is. The upper limit of the number of vinyl chloride resin particles exceeding 100 μm and 150 μm or less is not particularly limited, but is, for example, 100 or less, further 80 or less.
(C) The maximum length of the exposed portion is in the range of more than 150 μm and 200 μm or less, and the number of vinyl chloride resin particles is 8 or more, preferably 15 or more, more preferably 20 or more in 1 square mm. Is. The upper limit of the number of vinyl chloride resin particles exceeding 150 μm and 200 μm or less is not particularly limited, but is, for example, 50 or less, further 40 or less.

However, the size and number of the vinyl chloride resin particles 5 can be measured from the SEM image on the surface of the aggregated portion.
An arbitrary part on the surface of the agglomerated portion is imaged at 100 times to obtain an SEM photograph, and the exposed vinyl chloride resin particles are extracted from any 1 square mm in the SEM image. The above (a), (b) and (c) can be specified by measuring the maximum length of the exposed portion of all the extracted vinyl chloride resin particles.
The maximum length of the exposed portion is the maximum value of the straight lines that pass through the plane of the exposed portion and intersect the opposite edges of the exposed portion. In FIG. 6, a portion having the maximum length of the exposed portion is indicated by a reference numeral W on some vinyl chloride resin particles.

Further, a slight recess 21 is formed on the surface of the aggregated portion (the surface of the sheet body 2). The recess 21 is formed between the adjacent vinyl chloride resin particles 5 on the surface side of the aggregated portion. The recess 21 is formed by pressing the outer surfaces of adjacent vinyl chloride resin particles 5 against each other, and is formed around the exposed portion 5a of the vinyl chloride resin particles 5.
The shape of the recess 21 in a plan view is irregular, but the recess 21 is formed in a disorderly bent plan line line shape so as to surround the exposed portion 5a of the vinyl chloride resin particles 5 in a plan view. The cross-sectional view shape of the recess 21 is also irregular.
The depth of the recess 21 is not particularly limited, but if it is too large, the surface of the aggregated portion is too roughened, and if it is too small, the recess 21 cannot be substantially formed. Considering this point, the depth of the recess 21 is preferably more than 0 and preferably 150 μm, more preferably 0.05 μm to 30 μm. From another viewpoint, the depth of the recess 21 is preferably 1/5 times or less, more preferably 1/6 times or less the particle size of the vinyl chloride resin particles 5.

Further, as a relative relationship with the concave portion 21, a convex portion is formed on the surface of the aggregated portion. The convex portion is mainly composed of an exposed portion 5a of each vinyl chloride resin particle 5.
As shown in FIG. 7, the exposed portion 5a of each of the vinyl chloride resin particles 5 preferably has a flat portion, and more preferably, the entire exposed portion 5a is formed in a substantially flat shape. ..
The front surface and / or the back surface of the sheet body 2 may be embossed with irregularities (not shown). The unevenness due to embossing is larger than that of the concave portion 21.

A plurality of filler fine particles 6 are scattered on the surface of the plurality of vinyl chloride resin particles 5 (for example, the first to third vinyl chloride resin particles 51, 52, 53). The fact that the filler fine particles 6 are scattered means that the entire surface of the vinyl chloride resin particles 5 is not covered, and that a plurality of filler fine particles 6 are adhered to some parts of the surface of the vinyl chloride resin particles 5. say.
In FIG. 6, the portion to which the plurality of filler fine particles 6 are attached is shaded, and the solid color in FIG. 6 shows the exposed portion 5a of the vinyl chloride resin particles 5.
In particular, the filler fine particles 6 are gathered and adhered to the surface of the recess 21. In the region where the plurality of filler fine particles 6 are gathered and adhered, the surface of the vinyl chloride resin particles 5 is covered with the filler fine particles 6.

With reference to FIG. 6, in the aggregated portion, a sea-island structure is formed in which the region where the filler fine particles 6 are gathered and adhered is the sea and the exposed portion 5a of the vinyl chloride resin particles 5 is the island. There is. In addition, the filler fine particles 6 may be attached to a part of the exposed portion 5a of the vinyl chloride resin particles 5, which means that the sea-island structure does not have a strict meaning but is generally in the shape of a sea-island. Is.
Since the filler fine particles 6 have a smaller particle size than the vinyl chloride resin particles 5, they are excellent in the effect of diffusely reflecting light. Therefore, as in the sea island structure, the filler fine particles 6 are gathered and adhered around the exposed portion 5a of the vinyl chloride resin particles 5 like a frame, so that the color and the three-dimensional effect of the vinyl chloride resin particles 5 can be obtained. You will be able to see strongly.
As shown in FIG. 7, the filler fine particles 6 are also present inside the sheet body 2 between the adjacent vinyl chloride resin particles 5. The plain portion shown in FIG. 7 represents bubbles generated inside the sheet body 2.

The planar view shape and the three-dimensional shape of the exposed filler fine particles 6 are irregular.
The filler fine particles 6 are much smaller than the vinyl chloride resin particles 5.
The filler fine particles 6 scattered and exposed in the agglomerated portion have, for example, a maximum length of 20 μm or less, preferably 10 μm or less, and more preferably 6 μm or less. The fact that the maximum length is 20 μm or less means that substantially all of the exposed filler fine particles 6 have a maximum diameter of 20 μm or less according to the following measurement method.
The maximum length of the filler fine particles 6 can be measured from the SEM image in the plan view of the aggregated portion.
An arbitrary part on the surface of the agglomerated portion is imaged at 1000 times to obtain an SEM photograph, and among the exposed filler fine particles in any 100 square μm in the SEM image, a relatively large one. Are extracted. The maximum length of all the extracted filler particles is measured.
The maximum length of the exposed filler fine particles is the same as the maximum length of the exposed vinyl chloride resin particles, which is a straight line that passes through the plane of the filler fine particles and intersects the opposite edge in a plan view. This is the maximum value of ours.

<Surface protective layer>
The surface protective layer 3 is provided as necessary for the purpose of protecting the surface of the sheet body 2.
The surface protective layer 3 may be colored and transparent, but is preferably colorless and transparent. The surface protective layer 3 is non-foaming.
The surface protective layer 3 contains a main component resin, and if necessary, contains a resin other than the main component resin and additives such as flame retardants, stabilizers, antioxidants, ultraviolet absorbers, and fungicides. May be good.
Here, in the present specification, the main component resin refers to the most abundant resin component (weight ratio) among the resin components constituting the layer.
The main component resin forming the surface protective layer 3 is not particularly limited, and examples thereof include an ionization ray-curable resin such as a thermoplastic resin and an ultraviolet curable resin. From the viewpoint of scratch resistance and the like, the surface protective layer 3 is preferably formed of an ionizing wire curable resin such as an ultraviolet curable resin.
Examples of the electron beam curable resin include unsaturated polyesters such as a condensate of unsaturated dicarboxylic acid and polyhydric alcohol, methacrylates such as polyester methacrylate, polyether methacrylate, polyol methacrylate and melamine methacrylate, polyester acrylate, epoxy acrylate and urethane. Examples thereof include ultraviolet curable resins such as acrylates, polyether acrylates, polyol acrylates, and melamine acrylates.
The thickness of the surface protective layer 3 is not particularly limited and is preferably as small as possible, for example, 3 μm to 50 μm, preferably 5 μm to 40 μm.

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

[Manufacturing method of interior materials]
The interior material of the present invention can be obtained, for example, by the following method. However, the interior material of the present invention is not limited to that obtained by the following manufacturing method.
The interior material of the present invention is a step of manufacturing raw material particles in which filler fine particles smaller than the particles are scattered on the surface of colored vinyl chloride resin particles, and the raw material particles are collected and heated and pressed to form a sheet. It is obtained through the process of molding into a shape.

<Manufacturing of raw material particles>
As shown in FIG. 8, the raw material particles A have filler fine particles C smaller than the particles B scattered on the surface of the colored vinyl chloride resin particles B. In FIG. 8, the portion to which the plurality of filler fine particles C are attached is shaded, and the solid color in FIG. 8 indicates the portion where the surface of the vinyl chloride resin particles B is exposed.
Hereinafter, in the production method of the present specification, the vinyl chloride resin particles 5 and the filler fine particles 6 formed on the interior material 1 and the vinyl chloride resin particles B and the filling as raw materials before forming the interior material are filled. For the purpose of distinguishing the agent fine particles C in terms of terms, the vinyl chloride resin particles B and the filler fine particles C constituting the raw material particles are referred to as “raw material resin particles B” and “raw material filler fine particles C”.

The production of the raw material particles A includes, for example, a step of producing particles using a vinyl chloride resin, a step of coloring the vinyl chloride resin, and a step of adhering the raw material filler fine particles C to the raw material resin particles B. These steps may be performed independently of each other, or at least two steps selected from these steps may be performed simultaneously. For example, the vinyl chloride resin may be colored when the particles are prepared from the vinyl chloride resin. Alternatively, after preparing the particles of the vinyl chloride resin, the particles may be colored and the raw material filler fine particles C may be attached. Since the number of steps can be reduced, it is preferable to perform the two steps at the same time.
Hereinafter, a case where the raw material particles A are produced by producing the particles of the vinyl chloride resin and then coloring the particles and attaching the raw material filler fine particles C will be described as an example.

Examples of the vinyl chloride resin include those produced by an emulsion polymerization method, a suspension polymerization method, a solution polymerization method, a bulk polymerization method and the like. Since it is easily formed into particles, a vinyl chloride resin obtained by an emulsion polymerization method or a suspension polymerization method is preferable, and a vinyl chloride resin obtained by a suspension polymerization method is particularly preferable.
In the suspension polymerization method, a vinyl chloride monomer liquefied by applying pressure is placed in a reactor containing water and a suspending agent, and the monomer is stirred at high speed to make the monomer into extremely fine droplets. This is a method for producing a vinyl chloride resin by putting a polymerization initiator into a reactor and reacting it at a predetermined pressure and temperature. Since the vinyl chloride resin obtained by the suspension polymerization method is usually particles having a size of several tens of μm to several hundreds of μm, the particles made of the vinyl chloride resin can be taken out by dehydrating and drying the particles.

As described above, the particles of the vinyl chloride resin obtained by the suspension polymerization method have a size of several tens of μm to several hundreds of μm, and therefore may be used as they are as the raw material resin particles B. In order to form an interior material having a good sand grain pattern, it is preferable to select raw material resin particles B having an appropriate size and a uniform particle size.
For example, the particles made of the vinyl chloride resin obtained by the suspension polymerization method are screened using a screen, and the raw material resin particles B having a desired particle size are taken out.
FIG. 9 shows a front view of the raw material resin particles B. The raw material resin particles B have some distorted portions as compared with the true spheres, but are generally spherical.
The volume average particle size (50% diameter) of the raw material resin particles B is preferably 20 μm to 300 μm, preferably 30 μm to 250 μm, and more preferably 50 μm to 200 μm.
The volume average particle size of the raw material resin particles B can be measured by a laser diffraction / scattering type particle size distribution measuring device.

The average degree of polymerization of the vinyl chloride resin constituting the raw material resin particles B is not particularly limited, but is, for example, 650 to 1000, preferably 700 to 900.
The average degree of polymerization can be measured by a solution viscosity measuring method using a Ubbelohde viscometer of JIS K 6721.
The K value of the vinyl chloride resin is not particularly limited, but is, for example, 58 to 70, preferably 60 to 65.
The K value can be measured according to JIS K 7376-2.
The apparent density of the vinyl chloride resin is not particularly limited, but is, for example, 0.45 to 0.75, preferably 0.5 to 0.7.
The apparent density can be measured according to JIS K 7365.

As the raw material filler fine particles C, an inorganic filler that is solid in a standard state (25 ° C., 1 atm) can be appropriately used, and for example, calcium carbonate, calcium oxide, barium carbonate, magnesium hydroxide, and water can be used. Various inorganic fillers such as aluminum oxide, clay, talc and mica can be mentioned.
Since it is inexpensive, it is preferable to use fine particles of calcium carbonate as the raw material filler fine particles C.

As the raw material filler fine particles C, those having a smaller particle size than the raw material resin particles B are used. As the raw material filler fine particles C, a fixed shape such as a spherical shape or an arbitrary shape such as an irregular shape can be used, but the irregular shape is preferable because it has a high effect of diffusely reflecting light.
It is preferable to use the raw material filler fine particles C having an appropriate size because it is difficult to be buried inside the raw material resin particles B and more raw material filler fine particles C can be attached to the surface of the raw material resin particles B.
The volume average particle size (50% diameter) of the raw material filler fine particles C is, for example, 0.05 μm to 20 μm, preferably 1 μm to 10 μm, and more preferably 2 μm to 6 μm.
The volume average particle size of the raw material filler fine particles C can be measured by a laser diffraction / scattering type particle size distribution measuring device. Since many of the raw material filler fine particles C are substantially flat, the volume average particle size of the raw material filler fine particles C represents a volume average value of a sphere-equivalent diameter.

The ratio of the coating area of the raw material filler fine particles C to the entire surface of the raw material particles A is not particularly limited, but is preferably 3% to 50%, more preferably 5% to 20%. The ratio of the covering area of the raw material filler fine particles C is obtained by (covering area of the raw material filler fine particles C / surface area of the raw material particles A) × 100.

Conventionally known pigments and dyes can be used as the colorant. In addition, it is preferable to use toner as the colorant because it is easily mixed with the raw material resin particles B. Here, the toner is fine particles in which a pigment or the like is adhered to a fine resin, or fine particles obtained by dispersing the fine particles in a liquid substance.
The plasticizer is not particularly limited, and those conventionally added to vinyl chloride-based resins and the like can be appropriately used. For example, dioctyl phthalate (DOP), dibutyl phthalate (DBP), butyl octyl phthalate (BOP) can be used. , Dioctylisophthalate (DOIP), diisononyl phthalate (DINP), di-2-ethylhexyl terephthalate (DOTP) and the like. In particular, it is preferable to use a liquid plasticizer under standard conditions.
Examples of other additives include stabilizers, processing aids, fungicides, flame retardants, ultraviolet absorbers, antioxidants and the like.

The raw material particles A can be obtained by mixing the raw material resin particles B, the raw material filler fine particles C, the colorant, the plasticizer, and the additive if necessary.
The raw material particles A are produced in one type colored in at least one color, and preferably at least two types colored in different colors.
For example, as described above, in the case of producing an interior material having the first to third vinyl chloride resin particles 51, 52, 53, three types of raw material particles A having different colors are produced.
The composition of the raw material particles A of a plurality of types (for example, three types) having different colors may be the same or different, provided that the colors caused by the colorants are different. The composition of the raw material particles A is different from that of at least one selected from the vinyl chloride resin and its blending amount, the raw material filler fine particles C and their blending amount, the plasticizer and its blending amount, and the additive and its blending amount. It means that the two are different.
Since it is easy to produce, it is preferable that the plurality of kinds of raw material particles A having different colors have the same composition except for the colorant.

The blending amount of the raw material filler fine particles C is not particularly limited, but if it is too large, the raw material filler fine particles C may adhere to substantially the entire surface of the raw material resin particles B, and if it is too small, the surface of the raw material resin particles B may be attached. It's too exposed. From this point of view, the blending amount of the raw material filler fine particles C is 1 part by weight to 100 parts by weight, preferably 1 part by weight to 50 parts by weight with respect to 100 parts by weight of the raw material resin particles B.
The blending amount of the plasticizer is not particularly limited, and is, for example, 20 parts by weight to 50 parts by weight, preferably 30 parts by weight to 40 parts by weight with respect to 100 parts by weight of the raw material resin particles B.
The blending amount of the colorant can be appropriately set according to the type of the colorant, and is, for example, 0.1 part by weight to 10 parts by weight, preferably 1 part by weight, with respect to 100 parts by weight of the raw material resin particles B. Parts to 5 parts by weight.
The blending amount of the additive is the same as the conventional one, and is usually a small amount.

The mixing can be carried out using a conventionally known mixer such as a super mixer.
The mixing time is appropriately set depending on the scale of the mixer and the input amount, and as a guideline, it is, for example, 300 seconds to 3000 seconds.

When the raw material resin particles B, the raw material filler fine particles C, the colorant, the plasticizer and, if necessary, the additives are mixed, the temperature is sufficiently higher than room temperature (25 ° C.) and the vinyl chloride resin is melted. It is important to do it below a temperature that does not.
For example, the mixing is preferably carried out in a temperature range of 80 ° C. to 140 ° C., more preferably 100 ° C. to 125 ° C., and even more preferably 110 ° C. to 130 ° C.
Further, the mixing is preferably performed under normal pressure (particularly, in a state where no pressure is applied from the outside).

The mixing temperature may be set in the temperature range by using a heating device and a cooling device. Further, if the mixing temperature falls within the above temperature range due to frictional heat generated from the material during mixing, mixing may be performed without heating and / or cooling.
By mixing in the above temperature range, the raw material resin particles B do not melt and become slightly soft while maintaining a substantially spherical shape, and the raw material filler fine particles C and the colorant come into contact with the surface of the raw material resin particles B. ..
The plasticizer that is liquid in the standard state is easily mixed with the raw material resin particles B, and the plasticizer makes the raw material resin particles B soft. Since the colorant is fine, it is buried in the softened raw material resin particles B from the surface thereof, and the raw material resin particles B are colored. A small amount of the additive added as needed is also taken into the inside of the raw material resin particles B or adheres to the surface of the raw material resin particles B.

The raw material filler fine particles C are larger than the additives and the like, and some of them may enter the inside of the raw material resin particles B, but most or all of them are on the surface of the raw material resin particles B which have become soft. It will adhere. For example, the proportion of the mixed raw material filler fine particles C adhering to the surface of the raw material resin particles B is 60% by weight to 100% by weight, assuming that the total amount of the mixed raw material filler fine particles C is 100% by weight. It is preferably 80% by weight or more and less than 100% by weight.
In this way, as shown in FIG. 8, the raw material particles A in which the raw material filler fine particles C smaller than the particles are scattered on the surface of the colored raw material resin particles B can be obtained. The raw material resin particles B constituting the obtained raw material particles A have a larger degree of strain than the raw material resin particles B before mixing, but remain generally spherical.
By appropriately changing the colorant and mixing in the same manner, raw material particles A having different colors are produced. In this way, it is possible to obtain three types of raw material particles A having different colors corresponding to the first vinyl chloride resin particles 51, the second vinyl chloride resin particles 52, and the third vinyl chloride resin particles 53.
It should be noted that uncolored raw material particles can also be obtained by mixing in the same manner except that a colorant is not blended.

<Manufacturing of sheet body>
As shown in FIG. 10, the desired raw material particles A are placed between a pair of rollers 93 using a spraying device 91 and pressed by the pair of rollers 93 to form an aggregate of a plurality of raw material particles A. A layered material 94 having a predetermined thickness is produced. The layered material 94 is guided onto an endless sheet conveyor 92 and heated by a heating device 95 such as an oven to melt the vinyl chloride resin of the raw material resin particles. The heating temperature may be any temperature higher than the temperature at which the vinyl chloride resin melts, for example, 160 ° C. or higher, preferably 170 ° C. or higher, and more preferably 175 ° C. or higher. Further, if the temperature is too high, the raw material filler fine particles C may be easily buried inside the raw material resin particles B. Therefore, the heating temperature is, for example, 210 ° C. or lower, preferably 210 ° C. It is less than or equal to, more preferably 200 ° C. or less.
The heating time is preferably about 300 seconds to 3000 seconds.

After heating, the layered material 94 is pressurized in the thickness direction to be processed into a sheet. The pressure is not particularly limited, and is, for example, 1.5 kgf / cm ² to 5 kgf / cm ² . Pressing may be performed by using a press machine, but when a device 9 for continuous production as shown in the figure is used, a pressure roll 96 is used and a layered material 94 is passed between the pressure rolls. , It is preferable to process it into a sheet shape.
When the melted raw material particles A are pressurized, the raw material resin particles B are irregularly deformed into an irregular shape and are joined between adjacent raw material resin particles.
After that, the sheet body 2 is obtained by performing natural cooling or forced cooling.
If necessary, the embossing roller 97 may be used to form embossed irregularities on the front surface and / or the back surface of the sheet body 2.
Further, if necessary, a surface protective layer may be formed on the surface of the sheet body 2 by using a coating machine 98. The coating machine 98 coats the surface of the sheet 2 with a surface protective layer forming material and solidifies the material. For example, when forming a surface protective layer made of an ionizing wire curable resin such as an ultraviolet curable resin. Has a coating portion for applying the ionization ray-curable resin and a light irradiation portion such as ultraviolet rays for curing the resin.
The obtained sheet body 2 is taken up by the recovery machine 99 and separated from the manufacturing apparatus 9.

In the above production method, the case where three kinds of raw material particles A are used is illustrated, but the raw material particles A may be one kind, two kinds, or four or more kinds may be prepared. For example, a plurality of types of raw material particles A having different colors may be prepared, and any one type of raw material particles A may be selected from the raw material particles A to prepare a sheet body, from which two or more types of raw material particles A may be selected. Moreover, you may make a sheet body by mixing them.
Preferably, five kinds of raw material particles A having different colors (for example, black, white, magenta, cyan, and yellow) are prepared in advance, and at least two kinds of raw material particles A are selected from the raw material particles A, whereby any sheet is selected. You can make a body. Since the raw material particles A exhibiting each color are not melted, the colors are not completely mixed, and the individual raw material particles A can macroscopically form sheets of various colors while expressing a sand grain pattern. For example, by mainly using the magenta and cyan raw material particles A from the above five types, a dark blue sand-grained sheet can be produced from a macroscopic view, and the cyan and yellow raw material particles A can be produced. By mainly using, it is possible to produce a sheet body having a greenish grain-like pattern when viewed macroscopically.
That is, by selecting some of the five types of raw material particles A and mixing them at a predetermined ratio, it is possible to produce a sheet body having a sand grain pattern of a wide variety of colors according to the principle of the three primary colors. According to the present invention, since the color is further expressed by the raw material particles, it is possible to create a design expression as if it were pointillistic.
The three primary colors are preferably magenta, cyan, and yellow, but red, blue, and green may be used.

[Effects and uses of interior materials]
In the interior material 1 of the present invention, since the filler fine particles smaller than the vinyl chloride resin particles are gathered and adhered to the surface of the recess 21 formed in the aggregated portion of the sheet body 2, fine sand is sprinkled on the surface. It has a three-dimensional appearance (sand grain pattern). Further, in the interior material 1 of the present invention, the recess 21 is formed as described above, and the filler fine particles 6 are gathered and adhered to the surface of the recess 21, so that the interior material 1 has an excellent matte feeling.
The interior material 1 of the present invention is applied to a construction surface such as a floor surface, a wall surface, and a ceiling surface of a building. The method of attaching the interior material to the construction surface is not particularly limited, and examples thereof include attaching the back surface of the interior material to the construction surface using an adhesive.
The interior material 1 of the present invention may be applied to a newly installed construction surface, or may be applied to an existing construction surface such as remodeling.
The interior material 1 of the present invention can be used as a floor material, a wall material, a ceiling material, etc., and can be particularly preferably used as a floor material, a wall material, and the like.
Although the sheet body 2 constitutes the design of the interior material, it has a predetermined thickness and a similar pattern appears even if it is worn by a shoe sole or the like, so that it has excellent durability and can be most preferably used as a floor material.

Hereinafter, the present invention will be described in more detail with reference to Examples. However, the present invention is not limited to the following examples.

[Material used]
<Vinyl chloride resin (raw material resin particles)>
Granular vinyl chloride resin by suspension polymerization method (trade name "ZEST 800Y" manufactured by Shin-Daiichi PVC Co., Ltd. Average degree of polymerization: 760 to 860, K value: 60.5 to 63.1, apparent density: 0. 53 to 0.63 (catalog value)). A vinyl chloride resin having a particle size of approximately 100 μm to 300 μm was used.
FIG. 11 shows an SEM photograph (600 times magnified) of the vinyl chloride resin used.
<Filler>
Granular calcium carbonate (trade name "Escalon # 200" manufactured by Sankyo Milling Co., Ltd.).
FIG. 12 shows an SEM photograph (600 times magnified) of the calcium carbonate used.
<Plasticizer>
DOP (general purpose product).
<Colorant>
Magenta Toner (manufactured by Nikko Bics Co., Ltd.).
Cyan toner (manufactured by Nikko Bics Co., Ltd.).
Yellow toner (manufactured by Nikko Bics Co., Ltd.).
White toner (manufactured by Nikko Bics Co., Ltd.).
Black toner (manufactured by Nikko Bics Co., Ltd.).

[Preparation of raw material particles]
<Preparation of magenta raw material particles>
Under standard conditions, 20 parts by weight of a filler, 35 parts by weight of a plasticizer, and 2 parts by weight of magenta toner are added to a mixer with respect to 100 parts by weight of the vinyl chloride resin, and about 10 parts by weight are added without heating from the outside. Mix for minutes. The temperature started to rise from the start of mixing, and after about 10 minutes, the temperature reached about 120 ° C.
In this way, raw material particles exhibiting magenta (magenta raw material particles) were produced.
FIG. 13 shows an SEM photograph (600 times magnified) of the produced raw material particles. In FIG. 13, the small granular one is granular calcium carbonate, and the one to which it is attached is the granular vinyl chloride resin.

<Preparation of cyan raw material particles>
Cyan raw material particles were produced in the same manner as in the above-mentioned production of magenta raw material particles, except that the magenta toner was replaced with cyan toner.

<Preparation of yellow raw material particles>
Yellow raw material particles were produced in the same manner as in the above-mentioned production of magenta raw material particles, except that the magenta toner was replaced with yellow toner.

<Preparation of white raw material particles>
White raw material particles were produced in the same manner as in the above-mentioned production of magenta raw material particles, except that the magenta toner was replaced with white toner.

<Preparation of black raw material particles>
Black raw material particles were produced in the same manner as in the above-mentioned production of magenta raw material particles, except that the magenta toner was replaced with black toner.

[Example 1]
Magenta raw material particles, cyan raw material particles, yellow raw material particles and black raw material particles are mixed in a weight ratio of 7: 2: 0.5: 0.5, and this is combined with an existing sheet manufacturing apparatus (as shown in FIG. 10). After passing through a pair of rollers from the spraying device to temporarily form a sheet, place it on an endless sheet conveyor, heat and melt it in a hot air circulation oven at 200 ° C for 5 minutes, and then pressurize it at room temperature. A magenta-based sheet body having a thickness of 2 mm was produced by passing it through a roll and rolling it while applying a pressure of approximately 3 kgf / cm ² .
The speed of the seat conveyor was set to about 1 m / min.

[Example 2]
Similar to Example 1, the thickness is 2 mm, except that magenta raw material particles, cyan raw material particles, yellow raw material particles, and white raw material particles are mixed in a weight ratio of 1: 6: 1: 2. Cyan-based sheet body was prepared.

FIG. 14 shows a photograph (without enlargement) of the surface of the sheet body obtained in Example 1, and FIG. 15 shows an SEM photograph obtained by magnifying an arbitrary part of the surface of the sheet body by 180 times.
As shown in FIG. 14, the surface of the obtained sheet body had a three-dimensional appearance as if fine sand was sprinkled on it.
Further, FIG. 16 is a reference photographic diagram in which the upper right corner region of the photograph of FIG. 15 is cut out and the vinyl chloride resin particles exposed in the aggregated portion are partitioned by thick lines. It can be seen that some of the exposed vinyl chloride resin particles have a substantially elliptical shape or a substantially circular shape in a plan view.

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

1 Interior material 2 Sheet body 21 Recesses 5, 51, 52, 53 Colored vinyl chloride resin particles 6 Filler fine particles A Raw material particles B Vinyl chloride resin particles that make up the raw material particles C Filler fine particles that make up the raw material particles

Claims (6)

It has a sheet body containing a vinyl chloride resin, a colorant and a filler, and has a sheet body.
On the surface side of the sheet body, a portion in which colored vinyl chloride resin particles are aggregated is formed.
The vinyl chloride resin particles in the aggregated portion include vinyl chloride resin particles having a maximum length of 50 μm to 200 μm in the exposed portion.
A recess is formed in the portion where the vinyl chloride resin particles are aggregated, and filler fine particles smaller than the vinyl chloride resin particles gather around the surface of the recess and the exposed portion of the vinyl chloride resin particles. Is attached,
An interior material in which the filler fine particles contain calcium carbonate . The vinyl chloride resin particles contain at least two types of vinyl chloride resin particles colored in different colors, and the filler fine particles are gathered and adhered around the exposed portion of each of the vinyl chloride resin particles. The interior material according to claim 1. According to claim 1 or 2, the aggregated portion forms a sea-island structure in which the region where the filler fine particles are gathered and adhered is the sea and the exposed portion of the vinyl chloride resin particles is an island in a plan view. The listed interior materials. The interior according to any one of claims 1 to 3, wherein the vinyl chloride resin particles expressed in the aggregated portion satisfy at least one relationship selected from the following (a) to (c). Material.
(A) There are 16 or more vinyl chloride resin particles in 1 square mm in which the maximum length of the exposed portion is in the range of 50 μm to 100 μm.
(B) There are 12 or more vinyl chloride resin particles in 1 square mm in which the maximum length of the exposed portion is in the range of more than 100 μm and 150 μm or less.
(C) There are 8 or more vinyl chloride resin particles in 1 square mm in which the maximum length of the exposed portion exceeds 150 μm and is in the range of 200 μm or less. The interior material according to any one of claims 1 to 4, which is composed of only the sheet body or the sheet body and a surface protective layer laminated on the surface thereof. By mixing vinyl chloride resin particles having a volume average particle diameter of 20 μm to 300 μm, filler fine particles containing calcium carbonate smaller than the particles, a colorant, and a plasticizer, the surface of the vinyl chloride resin particles colored by the particles can be mixed. A process of producing raw material particles interspersed with filler particles smaller than the particles,
A method for producing an interior material, comprising a step of collecting the raw material particles, heating and pressurizing them to form a sheet, and the like.

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