JP7039292B2 - Interior sheet and its manufacturing method - Google Patents

Description

The present invention relates to an interior sheet having recesses formed on its surface and a method for manufacturing the same.

Conventionally, a sheet mainly composed of synthetic resin has been used as an interior sheet for a building such as a floor material, a wall material, and a ceiling material of a building.
Further, an interior sheet having a dent formed on the surface is also known.
As a method for forming a dent on the surface of the interior sheet, a chemical embossing method using a foaming inhibitor and a mechanical embossing method for pressing an embossed plate are known. The chemical embossing method is a method in which a foaming inhibitor is contained in a portion where a recess is desired to be formed, so that the foamed portion is formed as a convex portion and the non-foamed portion is formed as a concave portion.
However, the chemical embossing method cannot be applied to non-foamed interior sheets, and convex portions and concave portions having ambiguous boundaries are formed, and the surface shape tends to have gentle irregularities as a whole.
The mechanical embossing method can be formed on both non-foamed and foamed interior sheets, and can form irregularities having a relatively sharp shape, but it is difficult to match the irregularities with the design expressed on the interior sheets.

Patent Document 1 describes a synthetic resin flooring material including a synthetic resin base material layer, a printing layer and a surface layer so that the embossed recesses have a pattern and color tone different from those of other parts, and the surface layer. Is formed of a synthetic resin and heat-resistant transparent particles, and has a partially embossed recess, in which the transparent particles penetrate the printing layer and are buried in the base material layer. The embossed flooring is disclosed.
In Patent Document 1, by embossing a laminate with an embossed roll or the like to form an embossed recess, particles in the surface layer corresponding to the recess are embedded in the resin layer to destroy printing and are mixed in the resin layer. It is described that the embossed recesses have a different pattern and color tone from the other parts, and have the same effect as if the valley dyeing embossing was applied.

Special Fair 6-043748 Gazette

The method of Patent Document 1 corresponds to an embossed recess by embossing a surface layer containing transparent particles with an embossing roll to forcibly move the transparent particles in the vertical direction and embossing the transparent particles in the printing layer. It tears and erases the printing of the printed part.
However, when such transparent particles are moved in the vertical direction and forcibly embedded in the print layer, the print layer is divided at the boundary between the deepest portion of the embossed recess and the recessed inclined portion, and corresponds to the deepest portion of the embossed recess. The print layer does not exist, and the end face of the printed layer is divided corresponding to the recessed inclined portion. If there is a region without a print layer in the recessed inclined portion, there is a problem that the appearance gives an unnatural impression in terms of design.
Further, in order to tear the print layer by the transparent particles, the surface layer must contain a large amount of transparent particles having a relatively large particle size, the antifouling property of the surface is lowered, and a smooth surface design can be obtained. There is no risk.

An object of the present invention is an interior sheet having an appearance in which the boundary between the deepest portion of the recess and the inclined portion of the recess is inconspicuous and the color expressed from the deepest portion of the recess is naturally incorporated into the design of the colored print layer. It is to provide the manufacturing method.

The interior sheet of the present invention comprises a sheet body having a surface layer, a colored printing layer , a synthetic resin layer and a fiber reinforcing layer in order from the surface side, and a recessed inclined portion and a deepest portion formed on the surface of the sheet body. The surface layer and the synthetic resin layer include a vinyl chloride resin as a main component resin, the thickness of the synthetic resin layer is 100 μm to 1.2 mm, and the colored printing layer has a recess. It is composed of an ink solidified layer having a thickness of 0.2 μm to 20 μm formed by printing ink provided on the surface of the synthetic resin layer, and the synthetic resin layer has a color different from a part or all of the colored printing layer. The colored printing layer has a gradually thinning portion formed in a region corresponding to the recessed inclined portion of the recess toward the deepest portion.

The preferred interior sheet of the present invention includes a portion in which the recess extends linearly in the first direction in a plan view, and a portion in which the recess extends linearly in a second direction, which is a direction orthogonal to the first direction in a plan view. The area surrounded by the concave portion forms a rectangular shape or a square shape in a plan view, and the deepest portion of the concave portion forms a flat surface .
A preferable interior sheet of the present invention comprises a first resin layer in which the synthetic resin layer is laminated on the back surface side of the colored printing layer, and a second resin layer laminated on the back surface side of the first resin layer. A fiber reinforcing layer is laminated on the back surface side of the second resin layer.
The preferred interior sheet of the present invention has the thinnest portion of the colored print layer formed in the thinnest region in the region corresponding to the deepest portion of the recess.
The preferred interior sheet of the present invention does not have a colored print layer in the region corresponding to the deepest portion of the recess.

According to another aspect of the present invention, there is provided a method for manufacturing an interior sheet.
The manufacturing method of the present invention is the method for manufacturing an interior sheet according to any one of the above, wherein the ink solidifying layer having a thickness of 0.2 μm to 20 μm, which is a colored printing layer, is the surface of a synthetic resin layer having a thickness of 100 μm to 1.2 mm. The step of preparing the film formed in the above, the step of preparing the laminate having the surface layer, the film having the colored printing layer and the synthetic resin layer, and the fiber reinforcing layer in order from the surface side, the laminate. The embossed plate having the embossed protrusions is pressed from the surface side of the laminate to form a recess formed by a recessed inclined portion and the deepest portion on the surface of the laminated body. The embossed plate is used to stretch the portion of the colored print layer corresponding to the embossed protrusion so that the thickness of the ink solidified layer, which is the print layer, gradually decreases from the recessed inclined portion toward the deepest portion. Form a recess.

The interior sheet of the present invention has an appearance in which the boundary between the deepest portion of the recess and the inclined portion of the recess is inconspicuous, and the color expressed from the deepest portion of the recess is naturally incorporated into the colored print layer. In such an interior sheet, the recess and the color of the colored printing layer are integrated in design, and the interior sheet is excellent in decorativeness .
Further, the interior sheet according to claim 2 has a tile-like appearance, and can be suitably used as a floor sheet or a wall sheet to be applied to a floor surface or a wall surface of a kitchen, a bathroom, or the like.

A partially omitted plan view of the interior sheet of the first embodiment of the present invention. FIG. 1 is an enlarged cross-sectional view taken along the line II-II of FIG. A cross-sectional view of a part of FIG. 2 which is further enlarged. An enlarged cross-sectional view showing a modified example of the shape of the concave portion. The enlarged sectional view of the interior sheet of the 2nd Embodiment of this invention. A cross-sectional view of a part of FIG. 5 which is further enlarged. The cross-sectional view which shows the preparation process of a laminated body at the time of manufacturing an interior sheet. The cross-sectional view which shows the embossing process of a laminated body at the time of manufacturing an interior sheet. The cross-sectional view which shows the manufacturing process of the interior sheet of Example 1. FIG. The cross-sectional view which shows the manufacturing process of the interior sheet of Example 2. FIG.

Hereinafter, the present invention will be described with reference to the drawings as appropriate.
In the present specification, the plan view means to see the surface of the interior sheet from a direction orthogonal to the horizontal direction, and the plan view shape means the shape in the plan view. Further, the cross-sectional view shape refers to a shape when the interior sheet 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 seats]
In FIGS. 1 to 3, the interior sheet 1 has a seat body 2 and a plurality of recesses 3 provided on the surface of the sheet body 2.
As shown in FIG. 1, the interior sheet 1 of the present invention may be formed in the shape of a long strip, or may be formed in the shape of a single leaf. 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 sheet 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 sheet 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.

[Sheet body]
The seat body 2 may be flexible or may not bend easily. In order to easily store and transport the interior sheet 1 and easily carry it into the bathroom during construction, the sheet body 2 is flexible so that it can be wound into a roll, for example, on a core material having a diameter of 20 cm. It is preferably formed from a sheet having. The sheet body 2 may be composed of only a non-foaming material, or may contain a foaming material.
The thickness of the sheet body 2 is not particularly limited, and is, for example, 1.0 mm to 10 mm, preferably 1.8 mm to 4.0 mm. However, the thickness of the sheet body 2 excludes the thickness of the region corresponding to the recess 3.
The sheet body 2 has a surface layer 4, a colored printing layer 5, and a synthetic resin layer 6 in this order from the surface side. The sheet body 2 may have layers other than these, if necessary. For example, the fiber reinforced layer 7 may be laminated on the back surface side of the synthetic resin layer 6, or the back surface side of the synthetic resin layer 6 (when the fiber reinforced layer 7 is laminated, the back surface of the fiber reinforced layer 7). The backing layer 8 or the reinforcing layer may be laminated on the side), or the protective layer 41 may be laminated on the surface of the surface layer 4. Further, the synthetic resin layer 6 may be one layer or may be composed of two or more layers.
The sheet body 2 of the illustrated example has a protective layer 41, a surface layer 4, a colored printing layer 5, a synthetic resin layer 6 having a two-layer structure, a fiber reinforced layer 7, and a backing layer 8 in this order from the surface side.
The protective layer 41 constitutes the outermost surface of the sheet body 2 (interior sheet 1). When the protective layer 41 is not provided, the surface layer 4 constitutes the outermost surface of the sheet body 2 (interior sheet 1).

<Surface layer>
The surface layer 4 is formed from, for example, a layer containing a resin. The surface layer 4 may be colored and transparent, but is preferably colorless and transparent. The surface layer 4 is directly adhered to the surface of the colored print layer 5. Further, the surface layer 4 is non-foaming.
The surface layer 4 may be composed of one layer or may have a multi-layer structure of two or more layers.
The surface layer 4 of the illustrated example has a one-layer structure.
The surface layer 4 contains a main component resin, and may contain a resin other than the main component resin and various additives, if necessary. As the additive, conventionally known additives can be used, for example, a filler, a plasticizer, a flame retardant, a stabilizer, an antioxidant, a weathering agent such as an ultraviolet absorber, a non-particle type lubricant, an antifungal agent and the like. Can be mentioned. Preferably, the surface layer 4 contains a weather resistant agent as an additive. Examples of the weather resistant agent include a benzophenone-based ultraviolet absorber such as 2-4-dihydroxybenzophenone, a benzotriazole-based ultraviolet absorber such as 2- (2'-hydroxy-5'-methylphenyl) benzotriazole, and ethyl-2-cyano. -3,3'-acrylate-based UV absorbers such as diphenyl acrylate, salicylate-based UV absorbers such as phenyl salicylate, and oxanilide-based UV absorbers such as 2-ethoxy-2'-ethyloxalic acidobisanilide. Be done.
In the present specification, the main component resin refers to the resin component (weight ratio) having the largest mass among the resin components constituting the layer.
It is preferable that the surface layer 4 does not substantially contain fine particles as in Patent Document 1. If the surface layer 4 contains fine particles such as Patent Document 1, the colored print layer 5 is torn by the fine particles when the concave portion 3 is formed, and it is difficult to stretch the colored print layer 5 to form a thin wall. It becomes. In particular, if the particle size of the fine particles is large, it may hinder the formation of recesses. For example, if the fine particles having a particle size of 30 μm or more and further 50 μm or more are contained, the formation of recesses is hindered. Further, since the surface layer does not substantially contain the fine particles, the surface of the surface layer 4 can be formed relatively smoothly, and it is possible to reproduce a smooth texture and design such as wood and stone.
The fact that the fine particles are not substantially contained means that a small amount of fine particles that are inevitably contained is allowed to be mixed, and a significant amount of the fine particles is excluded.

The main component resin forming the surface layer 4 is not particularly limited, and examples thereof include a thermoplastic resin.
Examples of the thermoplastic resin include vinyl chloride resins such as vinyl chloride and vinyl chloride-vinyl acetate copolymers; polyolefin resins; vinyl acetate resins such as ethylene-vinyl acetate copolymers; acrylic resins such as ethylene-methacrylate resins. Resins; polyamide-based resins; ester-based resins; various thermoplastic elastomers such as olefin-based elastomers and styrene-based elastomers; and the like.
The surface layer 4 is preferably made of a thermoplastic resin because of its excellent water resistance and flexibility, and further deforms satisfactorily when the embossed plate is pressed. Therefore, a vinyl chloride resin as a main component resin. It is more preferable that it is formed from those containing.

Here, the vinyl chloride resin that can be used in the present invention will be briefly described.
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. A vinyl chloride resin obtained by an emulsion polymerization method or a suspension polymerization method is preferable because it is easy to process and handle. These vinyl chloride resins may be used alone or in combination of two or more.
The vinyl chloride resin obtained by the emulsion polymerization method is obtained by coating the surface of a fine powder having a basic particle diameter of several μm or less (preferably 1 to 3 μm) composed of a large number of fine particle aggregates with a surfactant. It becomes a paste by blending a plasticizer or the like. As the vinyl chloride resin obtained by the emulsion polymerization method, a resin having an average degree of polymerization of about 1000 to 2000 is preferably used.
The vinyl chloride resin obtained by the suspension polymerization method is preferably a fine powder having a size of 20 to 100 μm, and is used after being sheet-processed by a calendar molding method. The vinyl chloride resin obtained by the suspension polymerization method preferably has an average degree of polymerization of about 700 to 1500, and more preferably about 700 to 1000, from the viewpoint of imparting roll tackiness suitable for the calendar molding method. preferable.
Hereinafter, the vinyl chloride resin obtained by the emulsification polymerization method may be referred to as "paste vinyl chloride", and the vinyl chloride resin obtained by the suspension polymerization method may be referred to as "suspension vinyl chloride".

The paste vinyl chloride resin has good processability at the time of manufacture and the material cost is low. Suspension vinyl chloride is less likely to cause water absorption and whitening, has good stain resistance, and can be suitably used not only indoors but also outdoors.
As the vinyl chloride resin used for the surface layer 4, paste vinyl chloride and / and suspension vinyl chloride are preferable.

The thickness of the surface layer 4 is not particularly limited, but is, for example, 0.1 mm to 1.0 mm, preferably 0.15 mm to 0.5 mm, and more preferably 0.2 mm to 0.4 mm. ..

<Protective layer>
The protective layer 41 is formed from, for example, a layer containing a resin. The protective layer 41 may be colored and transparent, but is preferably colorless and transparent. The protective layer 41 is directly adhered to the surface of the surface layer 4 to protect the surface layer 4. Further, the protective layer 41 is non-foaming.
The main component resin forming the protective layer 41 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 protective layer 41 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.
Since the surface layer 4 is interposed between the colored print layer 5 and the protective layer can be formed after the concave portion is formed, the protective layer 41 may contain fine particles such as alumina. The protective layer 41 may not contain fine particles. Further, the protective layer 41 may contain an additive as exemplified in the column of <surface layer>, if necessary, and in particular, the outermost surface of the interior sheet due to the inclusion of the weather resistant agent. Weather resistance is improved.
The thickness of the protective layer 41 is not particularly limited, and is, for example, 5 μm to 100 μm, preferably 10 μm to 50 μm. However, the thickness of the protective layer 41 excludes the thickness of the region corresponding to the recess 3.

<Colored print layer>
The colored printing layer 5 is a layer for displaying colors that are the design of the interior sheet. The colored printing layer 5 can be formed by, for example, a conventionally known printing ink. The colored printing layer 5 formed from the printing ink is composed of an ink solidifying layer. The colored printing layer 5 is directly adhered to the surface of the synthetic resin layer 6. In other words, the colored printing layer 5 is laminated between the surface layer 4 and the synthetic resin layer 6.
The colored print layer 5 is represented by one color or multiple colors to represent a desired design or the like. When the colored print layer 5 has one color, one color of ink is provided in a solid shape, one color of ink with shades is applied separately, one color of ink and a portion without ink are mixed, or The design can be expressed by a method such as a combination of these.
The ink constituting the colored printing layer 5 contains a coloring agent such as a pigment or a dye, a resin component, and an additive if necessary. The resin component of the ink is not particularly limited, and examples thereof include an acrylic resin, a cellulosic resin, a urethane resin, and a vinyl chloride resin. Since the colored printing layer 5 is easily stretched when the embossed plate is pressed, a relatively soft colored printing layer 5 (ink solidifying layer) is preferable, and such an ink is a vinyl chloride-based resin component. Those containing a resin are preferable. Examples of the vinyl chloride resin of the colored printing layer 5 include those described in the column of <Surface layer>, and it is particularly preferable to use paste vinyl chloride and / or suspension vinyl chloride. Further, the colored printing layer 5 may contain an additive as exemplified in the column of <surface layer>, if necessary, and in particular, the colored printing layer 5 contains a weather resistant agent. The weather resistance is improved.
The thickness of the colored print layer 5 is not particularly limited, but is, for example, 0.2 μm to 20 μm, preferably 0.4 μm to 10 μm. However, the thickness of the colored printing layer 5 excludes the thickness of the region corresponding to the concave portion 3, and refers to the thickness of the colored printing layer 5 corresponding to the convex portion described later.

<Synthetic resin layer>
The synthetic resin layer 6 is provided for fixing the colored printing layer 5. Further, the synthetic resin layer 6 also functions as a background color layer exhibiting the color of the deepest portion 32 of the recess 3.
The synthetic resin layer 6 is directly adhered to the surface of the fiber reinforcing layer 7 (the backing layer 8 when the fiber reinforcing layer 7 is not provided).
The synthetic resin layer 6 is colored transparent or colored opaque, preferably colored opaque. That is, the synthetic resin layer 6 has a color. The color of the synthetic resin layer 6 is different from the color of a part or all of the colored printing layer 5, and preferably different from the color of all of the colored printing layer 5. By arranging a colored synthetic resin layer 6 different from the color of the colored printing layer 5 on the back surface side of the colored printing layer 5, the deepest portion 32 of the recess 3 is included in the color caused by the colored printing layer 5. In, the color of the synthetic resin layer 6 is exposed, and the concave portion 3 becomes conspicuous in appearance.
Further, the synthetic resin layer 6 may have a color having a higher lightness than the colored printing layer 5, or may have a color having a lower lightness than the colored printing layer 5. Since the synthetic resin layer 6 has a color having a higher brightness than the colored printing layer 5, the color expressed from the deepest portion 32 of the recess 3 becomes conspicuous in relation to the colored printing layer 5.

The synthetic resin layer 6 may be foamed, but is preferably non-foamed because the colored print layer 5 is easily stretched when the embossed plate is pressed.
In the illustrated example, the synthetic resin layer 6 is composed of two resin layers (first resin layer 61 and second resin layer 62 in order from the surface side). Although not particularly shown, the synthetic resin layer 6 may be composed of one resin layer or may be composed of three or more resin layers. When the synthetic resin layer 6 is composed of one resin layer, the second resin layer 62 is omitted. When the synthetic resin layer 6 is composed of three or more resin layers, the third resin layer and subsequent layers are laminated on the back surface of the second resin layer 62.

The first resin layer 61 is directly adhered to the surface of the second resin layer 62, and the second resin layer 62 is the surface of the fiber reinforcing layer 7 (the backing layer 8 when the fiber reinforcing layer 7 is not provided). It is directly glued to. The colored printing layer 5 is directly adhered to the surface of the first resin layer 61.
At least one of the first resin layer 61 and the second resin layer 62 is colored transparent or colored opaque (that is, has color), and is preferably colored opaque. When either one has a color, the synthetic resin layer 6 having a color different from that of the colored printing layer 5 can be arranged on the back surface side of the colored printing layer 5.
For example, when the first resin layer 61 has a color, the second resin layer 62 may be colorless and transparent, or may be colored transparent or colored opaque. When the second resin layer 62 has a color, the first resin layer 61 may be colorless and transparent, or may be colored transparent or colored opaque.
Preferably, both the first resin layer 61 and the second resin layer 62 are colored. Since both layers 61 and 62 have colors, even if either one of the first resin layer 61 and the second resin layer 62 disappears in the deepest portion 32 of the recess 3, the other remains, so that the recess remains. The color of the synthetic resin layer 6 appears in the deepest portion 32 of 3. When both the first resin layer 61 and the second resin layer 62 have colors, those colors are different from the colors of a part or all of the colored print layer 5, and preferably all the colors of the colored print layer 5. Is different. Further, in this case, the first resin layer 61 and the second resin layer 62 may have the same color or may have different colors, but one color may be obtained in the deepest portion 32 of the recess 3. It is preferable that both layers 61 and 62 have the same color.
For example, when (a) the first resin layer 61 and the second resin layer 62 exhibit white color including milky white, and the colored printing layer 5 exhibits a color other than white, (b) the first resin layer 61 and the second resin layer The case where 62 exhibits a yellow color and the colored print layer 5 exhibits a color other than yellow, and the like can be mentioned.
The colored first resin layer 61 and the second resin layer 62 can be formed by adding a colorant to their forming materials. For example, the white synthetic resin layer 6 can be formed by blending a white pigment such as titanium oxide. Further, when the forming material itself is colored, the first resin layer 61 and the second resin layer 62 may be formed without adding a colorant.

The thickness of the synthetic resin layer 6 is not particularly limited, but is, for example, 100 μm to 1.2 mm, preferably 200 μm to 1 mm. The thickness of the first resin layer 61 is not particularly limited, but is, for example, 20 μm to 200 μm, preferably 30 μm to 150 μm. The thickness of the second resin layer 62 is not particularly limited, but is, for example, 100 μm to 800 μm, preferably 200 μm to 600 μm. However, the thickness of the first resin layer 61 and the second resin layer 62 excludes the thickness of the portion corresponding to the recess 3.

The synthetic resin layer 6 (first resin layer 61 and second resin layer 62) contains a main component resin, and may contain a resin other than the main component resin and various additives, if necessary. The main component resin of the first resin layer 61 and the second resin layer 62 is independently and is not particularly limited, and for example, a thermoplastic resin can be used. Specific examples of the thermoplastic resin and the additive include those described in the column of <Surface layer>. Since the synthetic resin layer 6 (first resin layer 61 and second resin layer 62) contains a weather resistant agent, its weather resistance is improved.
The first resin layer 61 and the second resin layer 62 may have the same main component resin, or may have different main component resins, but the same one is preferably used.
As the main component resin forming the first resin layer 61 and the second resin layer 62, a vinyl chloride resin is used because both layers are easily firmly adhered to each other and are satisfactorily deformed when the embossed plate is pressed. It is preferable to use paste vinyl chloride and / and suspension vinyl chloride.

The second resin layer 62 that is directly adhered to the surface of the fiber reinforcing layer 7 may be laminated in a state of being impregnated in the fiber reinforcing layer 7. The state in which the fiber reinforcing layer 7 is impregnated means that the material for forming the second resin layer 62 has entered the inside of the fiber reinforcing layer 7 and is attached around the fibers constituting the fiber reinforcing layer 7. Refers to the state in which is present.
When the second resin layer 62 contains the paste vinyl chloride as the main component resin, it is easily impregnated into the fiber reinforcing layer 7 and firmly adheres around the fibers. Further, since the paste vinyl chloride has excellent compatibility with suspension vinyl chloride, even when the first resin layer 61 contains suspension vinyl chloride as a main component, the second resin containing paste vinyl chloride as a main component. The layer 62 is firmly adhered to the first resin layer 61.

<Fiber reinforcement layer>
The fiber reinforcing layer 7 is a layer for increasing the rigidity of the sheet body 2 and imparting dimensional stability to the sheet body 2. Further, the fiber reinforcing layer 7 also has a function of preventing excessive sinking when pressing the embossed plate at the time of forming the concave portion 3. This function makes it possible to more easily create the effect of the present invention when forming the recess 3.
The fiber reinforcing layer 7 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. In particular, since it is excellent in the sinking prevention function, it is preferable to use a non-woven fabric containing inorganic fibers such as glass fibers or a woven fabric containing inorganic fibers as the fiber reinforcing layer 7, and further, a non-woven fabric containing glass fibers ( It is more preferable to use a woven cloth (glass net) containing glass mat) or glass fiber. Above all, a non-woven fabric containing glass fiber is used because it has a high function of laterally supporting the pressing force of the embossed plate and preventing excessive sinking, and further, the fibers are difficult to see in the deepest portion 32 of the recess 3. Is particularly preferable.

The thickness of the glass fiber is not particularly limited, and is, for example, 2 μm to 20 μm in diameter, preferably 5 μm to 15 μm in diameter.
The glass fiber of the non-woven fabric containing the glass fiber may be composed of only short fibers, may be composed of only long fibers, or may be composed of a mixture of short fibers and long fibers. The glass nonwoven fabric composed of only short fibers is excellent in dimensional stability, while the glass nonwoven fabric composed of a mixture of short fibers and long fibers is excellent in tensile strength in addition to dimensional stability. The length of the staple fibers is not particularly limited, but is, for example, 5 mm to 30 mm, preferably 10 mm to 15 mm. The length of the long fibers is larger than the length of the short fibers.
Further, the fibers constituting the fiber reinforcing layer 7 may be only glass fibers, or may include glass fibers and other fibers. Examples of fibers other than glass fibers include natural fibers such as pulp, synthetic resin fibers, and inorganic fibers other than glass, but natural fibers are preferable. The thickness of the natural fiber such as pulp is not particularly limited, but is, for example, 10 μm to 30 μm. Since natural fibers such as pulp are generally mixed with various fiber lengths and diameters in a distributed manner, the thickness of the natural fibers is in the central range of the distribution.

The thickness of the nonwoven fabric or woven fabric constituting the fiber reinforcing layer 7 is not particularly limited, but is, for example, 0.05 mm to 1 mm, preferably 0.1 mm to 0.5 mm. The basis weight of the nonwoven fabric or woven fabric constituting the fiber reinforcing layer 7 is 10 g / m ² to 100 g / m ² , preferably 20 g / m ² to 50 g / m ² .

<Backing layer>
The backing layer 8 is formed of, for example, resin, rubber, or the like.
The backing layer 8 is preferably made of resin because it is impregnated inside the fiber reinforcing layer 7 and firmly bonded to the fiber reinforcing layer 7. Further, the backing layer 8 may be foamed or may not be foamed. The backing layer 8 is preferably foamed from the viewpoint of imparting an appropriate cushioning property to the interior sheet 1. The expansion ratio of the backing layer 8 made of the foam is not particularly limited, but is, for example, 1.05 times to 2 times, preferably 1.1 times to 1.5 times.
The backing layer 8 contains a main component resin, and may contain a resin other than the main component resin and various additives, if necessary. The main component resin of the backing layer 8 is not particularly limited, and for example, a thermoplastic resin can be used. Specific examples of the thermoplastic resin and the additive include those described in the column of <Surface layer>.
As the main component resin forming the backing layer 8, a vinyl chloride resin is preferable because it has excellent flexibility.
The thickness of the backing layer 8 is not particularly limited, but is, for example, 0.5 mm to 7 mm, preferably 1 mm to 3 mm.
Although not particularly shown, a reinforcing layer may be provided on the back surface of the backing layer 8 or in the middle of the backing layer 8. As the reinforcing layer, a non-woven fabric or a woven fabric is used.

[Concave]
A recess 3 is formed on the surface of the sheet body 2.
The recess 3 is a portion recessed in the thickness direction from the surface of the sheet body 2. The concave portion 3 is a recessed portion with reference to the surface of the sheet body 2, and when the concave portion 3 is used as a reference, the concave portion 3 can be said to be a portion sandwiched between the convex portions. That is, the unevenness is a relative concept, and hereinafter, the surface of the sheet body 2 other than the concave portion may be referred to as a "convex portion" in relation to the concave portion 3.
As shown in FIG. 1, the recess 3 may be formed in a straight line in a plane view in a predetermined direction, or may be formed in a bent shape in a plan view, a curved shape in a plan view, an indefinite shape in a plan view, or the like. .. In the illustrated example, in a plan view, the recess 3 extending linearly in the first direction and the recess 3 extending linearly in the second direction are provided, and the recess 3 extending in the first direction extends in the second direction. It is formed so as to intersect the concave portion 3 in a T shape. However, the plan view shape of the recess 3 is not limited to the illustrated example.

As shown in FIGS. 2 and 3, the recess 3 is composed of a recessed inclined portion 31 and a deepest portion 32. The deepest portion 32 is the bottom of the recess 3 and refers to the deepest portion of the recess 3. The recessed inclined portion 31 is a portion between the convex portion 2a and the deepest portion 32, and is inclined with respect to the horizontal direction in a cross-sectional view. The recessed inclined portion 31 exists so as to face both sides of the deepest portion 32. The recessed inclined portions 31 facing each other may have a symmetrical shape as shown in the illustrated example, or may have an asymmetrical shape. By making the shape symmetrical, one recessed inclined portion 31 becomes less noticeable with respect to the other recessed inclined portion 31.
The recessed inclined portion 31 may have a linear cross-sectional view as a whole, a curved cross-sectional view as a whole, a polygonal shape in a cross-sectional view, or a linear shape. It may be a cross-sectional view shape in which the shape and the curved shape are combined. The cross-sectional view curve has an inwardly bulging curve and an outwardly bulging curve, but is preferably an outwardly bulging curve as shown in FIGS. 2 and 3. It should be noted that the recessed inclined portion 31 having a linear cross-sectional view as a whole is three-dimensionally formed a plane, and the recessed inclined portion 31 having an overall cross-sectional view curve is formed into a curved surface three-dimensionally. The concave inclined portion 31 having a polygonal cross-sectional view is three-dimensionally formed by a continuous polygonal surface in which a plurality of planes intersect in a blunt angle shape.

Here, FIG. 4 shows a recess 3 in which the recessed inclined portion 31 is formed in a straight line in a cross-sectional view as a whole.
Preferably, the recessed inclined portion 31 is formed in a cross-sectional view shape in which a linear shape and a curved line shape are combined as shown in FIG. 3, or is formed in a cross-sectional view linear shape as a whole as shown in FIG.
The concave inclined portion 31 having a curved cross-sectional view is continuous with the convex portion 2a and starts to be recessed from the convex portion 2a to the back surface side. It is composed of a terminal portion 313 continuous to 32. In cross-sectional view, the curvature of the starting end 311 is smaller than the curvature of the midway 312. The end portion 313 is formed linearly in a cross-sectional view.
In addition, referring to FIG. 4, the recessed inclined portion 31 having a linear cross-sectional view as a whole includes the terminal portion 313 having a linear shape in a cross-sectional view as described above. That is, the dented inclined portion 31 having a linear cross-sectional view as a whole is continuous with the convex portion 2a and continuous with the linear start end portion 311 and starting to dent from the convex portion 2a toward the back surface side, and the start end portion is continuous with the start end portion 311. It consists of a linear halfway portion 312 having the same inclination angle as 311 and a linear end portion 313 that is continuous with the halfway portion 312 and has the same inclination angle as the halfway portion 312, and conceptually, a linear end portion. The 313 is extended to the convex portion 2a.
Although not particularly shown, the polygonal recessed inclined portion 31 includes a linear start end portion 311, a middle portion 312, an end portion 313, and the like in a cross-sectional view as described above, and these are continuous so as to draw different arcs. It is what you are doing.

The deepest portion 32 is formed, for example, in a straight line in cross-section, and more preferably in a straight line in cross-section extending in the horizontal direction. The deepest portion 32 having a linear cross-sectional view forms a strip-shaped and flat surface having a predetermined width in three dimensions. Since the deepest portion 32 is formed in a straight line in cross-sectional view, the color expressed from the deepest portion 32 becomes conspicuous in appearance.
In the recess 3, when the end portion 313 and the deepest portion 32 of the recess inclined portion 31 are formed linearly in a cross-sectional view, the angle α formed by the end portion 313 and the deepest portion 32 (see FIGS. 3 and 4) is , 90 degrees to 140 degrees, more preferably 95 degrees to 125 degrees, still more preferably 100 degrees to 110 degrees. By setting this angle to 90 degrees or more, when the recess 3 is formed by using the embossed plate, stress concentration is less likely to occur at the boundary between the recessed inclined portion 31 and the deepest portion 32, and material destruction can be suppressed. Further, if the angle is larger than 140 degrees, the recessed inclined portion 31 becomes conspicuous, and the design may be deteriorated.
The shape of the deepest portion 32 of the recess 3 is not limited to a flat surface, and may be a curved surface. However, when the recess 3 is formed by the embossed plate, the pressure can be applied more uniformly, so that the deepest portion 32 is preferably a flat surface.

With reference to FIG. 2, the depth 3D of the recess 3 is not particularly limited, but is preferably 0.8 mm or more, and more preferably more than 0.8 mm, from the viewpoint that the color expressed from the deepest portion 32 becomes conspicuous. It is preferable, more preferably 0.9 mm or more, and particularly preferably 1 mm or more. Further, since the colored print layer corresponding to the recessed inclined portion 31 can be formed in a good thin-walled shape, the depth 3D of the recess 3 is preferably 1.5 mm or less, more preferably less than 1.5 mm, and further 1.4 mm. The following is more preferable, and 1.3 mm or less is particularly preferable.
The width 32W of the deepest portion 32 of the recess 3 is not particularly limited, but is preferably 0.5 mm to 3 mm, more preferably 1 mm to 2 mm.
The width 31W of the recessed inclined portion 31 of the recess 3 is not particularly limited, but is preferably 0.5 mm to 2 mm, more preferably 1 mm to 1.5 mm.
In the illustrated example, the surface of the convex portion 2a is flat, but if necessary, a concave portion having a depth clearly smaller than that of the concave portion 3 may be formed in the convex portion 2a (Fig.). Not shown). For example, a pattern composed of fine concave portions such as a satin pattern may be formed on the surface of the convex portion 2a.

2 and 3 are cross-sectional views showing the form of the colored print layer in the region corresponding to the concave portion of the interior sheet of the first embodiment.
In FIGS. 2 and 3, the colored print layer 5 of the interior sheet 1 of the first embodiment is formed in a thin wall shape toward the deepest portion 32 in the region corresponding to the recessed inclined portion 31 of the recess 3. Further, the colored print layer 5 is formed to be the thinnest in the region corresponding to the deepest portion 32 of the recess 3. Hereinafter, the gradually thinned portion of the region corresponding to the recessed inclined portion 31 of the recess 3 is referred to as a gradual reduction portion, and the thinnest portion of the region corresponding to the deepest portion 32 of the recess 3 is the thinnest portion. That is. Therefore, the colored print layer 5 has a tapering portion 51 and a thinnest portion 52 corresponding to the recess 3.
The thickness of the gradually decreasing portion 51 and the thickness of the thinnest portion 52 are smaller than the thickness of the colored printing layer 5 corresponding to the convex portion 2a.
One end of the tapering portion 51 is connected to the colored printing layer 5 corresponding to the convex portion 2a, and the other end of the tapering portion 51 is connected to the thinnest portion 52. The thickness of the gradually decreasing portion 51 gradually decreases from the convex portion 2a to the concave inclined portion 31 toward the deepest portion 32.
The thinnest portion 52 has a very thin film shape and extends to the back surface side of the deepest portion 32 of the recess 3. Since the thinnest portion 52 has a very thin film-like shape as described above, pinholes are partially formed when viewed microscopically, in addition to the case where the thinnest portion 52 exists in a solid shape without holes. Please note that in some cases.
The thickness of the thinnest portion 52 of the colored printing layer 5 is the thickness of the colored printing layer 5 corresponding to the convex portion 2a × 0.05 times to × 0.3 times, preferably colored printing corresponding to the convex portion 2a. The thickness of the layer 5 is × 0.1 to × 0.2 times.

The surface layer 4 and the synthetic resin layer 6 (the first resin layer 61 and the second resin layer 62) are formed in a thin-walled shape in the region corresponding to the recess 3. That is, the thicknesses of the surface layer 4 and the synthetic resin layer 6 (first resin layer 61 and second resin layer 62) in the region corresponding to the concave portion 3 are formed to be smaller than those in the region corresponding to the convex portion 2a, respectively. Has been done.
Further, since the protective layer 41 is laminated after forming the recess 3 according to the manufacturing method described later, the thickness of the protective layer 41 is substantially uniform as a whole.
The surface layer 4 may not be substantially present in the region corresponding to the recess 3 (although it may be substantially disappeared in the recess forming process), but the water resistance and antifouling in the recess 3 are achieved. From the viewpoint of property, it is preferable that the surface layer 4 is present in the region corresponding to the recess 3 as described above.
Further, either one of the first resin layer 61 and the second resin layer 62 may not be substantially present in the region corresponding to the recess 3 (even if it is substantially eliminated in the recess forming process). good).

5 and 6 are cross-sectional views showing the form of the colored print layer in the region corresponding to the concave portion of the interior sheet of the second embodiment. The plan view of the interior sheet of the second embodiment is the same as that of the first embodiment, and is therefore omitted. 5 and 6 are cross-sectional views of the interior sheet of the second embodiment cut at the same points as those of the line II-II of FIG.

In FIGS. 5 and 6, the colored print layer 5 of the interior sheet 1 of the second embodiment has a tapering portion 51 formed in a thin shape toward the deepest portion 32 in the region corresponding to the recessed inclined portion 31 of the recess 3. Has. In the second embodiment, the colored print layer is not provided in the region corresponding to the deepest portion 32 of the recess 3.
Specifically, in the region corresponding to the two recessed inclined portions 31, the colored print layer 5 is formed in a thin wall shape toward the deepest portion 32 (that is, has a gradually decreasing portion 51). The thickness of the gradually decreasing portion 51 is smaller than the thickness of the colored printing layer 5 corresponding to the convex portion 2a. One end of the gradual reduction portion 51 is connected to the colored printing layer 5 corresponding to the convex portion 2a, and the other end of the gradual reduction portion 51 is sharp. The other ends of the two tapering portions 51 face each other at positions corresponding to both sides of the deepest portion 32 of the recess 3, and no colored printing layer is provided between the other ends of the two tapering portions 51.
The protective layer 41, the surface layer 4, and the synthetic resin layer 6 (the first resin layer 61 and the second resin layer 62) of the interior sheet 1 of the second embodiment are the same as those of the first embodiment.

In the interior sheet 1 of the present invention, the boundary between the deepest portion 32 of the recess 3 and the recessed inclined portion 31 is inconspicuous, and the colors expressed from the deepest portion 32 of the recess 3 are naturally incorporated into the design of the colored printing layer 5. Has a nice appearance. Since the interior sheet 1 has a design in which the colors of the recess 3 and the colored printing layer 5 are integrated, the interior sheet 1 is excellent in decorativeness.
Specifically, in the interior sheet 1 of the first embodiment and the second embodiment, the colored printing layer 5 has a gradual reduction portion 51 in the region corresponding to the recessed inclined portion 31 of the recess 3. By locating the gradually decreasing portion 51 of the colored printing layer 5 corresponding to the recessed inclined portion 31, the color of the colored printing layer 5 gradually changes in the recessed inclined portion 31, so that the recessed inclined portion 31 and the recessed inclined portion 31 The boundary of the deepest part 32 is inconspicuous and gives a natural feeling. On the other hand, in the deepest portion 32, the color of the synthetic resin layer 6 is exposed, so that the presence of the recess 3 is conspicuous, and the color of the deepest portion 32 and the color of the colored printing layer 5 can form a unified design. ..
In the interior sheet 1 of the first embodiment, the thinnest portion 52 of the colored printing layer 5 extends to the region corresponding to the deepest portion 32 of the recess 3, but the thinnest portion 52 is very thin, so that it is substantially thin. The color of the colored printing layer 5 disappears, and the color of the synthetic resin layer 6 (first resin layer 61 or second resin layer 62) located on the back surface side of the thinnest portion 52 appears in the deepest portion 32 of the recess 3. Will come to do. Since the interior sheet 1 of the second embodiment does not have the colored printing layer 5 in the region corresponding to the deepest portion 32 of the recess 3, the synthetic resin layer 6 (first resin layer) located on the back surface side of the thinnest portion 52. The color of 61 or the second resin layer 62) is exposed in the deepest portion 32 of the recess 3.
The interior sheet 1 of the present invention, which has a design in which the colors expressed from the deepest portion 32 are naturally incorporated into the colored print layer 5, is a range surrounded by the recesses 3, for example, as shown in FIG. By forming the recess 3 so as to form a rectangle or a square in a plan view, it has an appearance like a tile.

[Manufacturing method of interior sheet]
The interior sheet of the present invention is, for example, a preparatory step for preparing a laminate having a surface layer, a colored printing layer, a synthetic resin layer and a fiber reinforcing layer in order from the surface side, and an embossed plate having embossed protrusions from the surface side of the laminate. Has an embossing step of forming a recess composed of a recessed inclined portion and the deepest portion on the surface of the laminated body by pressing, and in the embossing step, the thickness of the colored print layer is increased from the recessed inclined portion. It is obtained by forming the recess while stretching the colored print layer so as to gradually become thinner toward the deepest portion.
As described above, the surface layer 4 and the like can be formed by using various resins, but here, a method for manufacturing the interior sheet 1 using a vinyl chloride resin will be specifically described.

<When using paste vinyl chloride>
(Preparation process)
As a method for forming the colored printing layer 5, a method of using a printed film in which the colored printing layer 5 is printed on a resin film such as a vinyl chloride resin (referred to as the first method) and a method of forming the colored printing layer 5 on the surface of the second resin layer 62. After forming the first resin layer 61, there is a method (referred to as a second method) of printing or transferring the colored printing layer 5 on the surface of the first resin layer 61.

1. First method On one surface of the fiber reinforcing layer 7, for example, a vinyl chloride paste (material for forming the backing layer 8) made of a mixture of a paste vinyl chloride, a plasticizer, a filler, a foaming agent and the like is applied to an appropriate coater. And paint. Further, after applying a vinyl chloride paste (material for forming the second resin layer 62) composed of a mixture of, for example, vinyl chloride, a plasticizer, and a filler to the other surface of the fiber reinforcing layer 7 to form a layer. Pregels at 120 ° C to 140 ° C.
Next, the printed film is laminated on the surface of the second resin layer 62. The printed film is a resin film such as a vinyl chloride resin on which the colored printing layer 5 is printed, and the resin film serves as the first resin layer 61. The printing can be performed by using a known printing method such as gravure printing or rotary printing, but the gravure printing method is preferable because the thickness can be easily controlled and the design expressiveness is excellent.
After laminating the resin film surface of the printed film on the surface of the second resin layer 62, vinyl chloride composed of a mixture of, for example, paste vinyl chloride, a plasticizer, and a filler is placed on the surface of the colored printing layer 5. After the paste (material for forming the surface layer 4) is applied to form a layer, the material is pregelled again at 130 ° C. to 150 ° C. and the material for forming the backing layer 8 is foamed.

2. Second method On one surface of the fiber reinforcing layer 7, for example, a vinyl chloride paste (material for forming the backing layer 8) composed of a mixture of a paste vinyl chloride, a plasticizer, a filler, a foaming agent and the like is applied to an appropriate coater. And paint. Further, a vinyl chloride paste (material for forming the second resin layer 62) made of a mixture of, for example, vinyl chloride, a plasticizer, and a filler is applied to the other surface of the fiber reinforcing layer 7 to form a layer. Further, for example, a vinyl chloride paste (material for forming the first resin layer 61) composed of a mixture of vinyl chloride, a plasticizer, a filler and the like is applied onto the paste to form a layer, and then the temperature is 120 ° C. to 140 ° C. Pregels at ° C.
Next, ink is printed on the surface of the first resin layer 61 to form the colored print layer 5. The printing can be performed by using a known printing method such as gravure printing or rotary printing, but the gravure printing method is preferable because the thickness can be easily controlled and the design expressiveness is excellent. Instead of such direct printing, a transfer film provided with the colored printing layer 5 may be attached to the surface of the first resin layer 61 to transfer only the colored printing layer 5.
After forming the colored print layer 5, for example, a vinyl chloride paste (material for forming the surface layer 4) composed of a mixture of vinyl chloride, a plasticizer, a filler and the like is applied onto the surface thereof to form a layer. The material for forming the backing layer 8 is foamed while being pregelled again at 130 ° C. to 150 ° C.
In this way, the laminate 10 composed of the surface layer 4, the colored printing layer 5, the first resin layer 61, the second resin layer 62, the fiber reinforcing layer 7, and the backing layer 8 is formed in this order from the surface side (see FIG. 7). ).

(Embossing process)
From the surface side of the laminated body 10, the embossed plate 9 having the embossed protrusions 91 is pressed in the thickness direction of the laminated body 10. As the embossed version 9, for example, an embossed roller can be used. Further, the embossed protrusion 91 preferably has a shape corresponding to the shape of the concave portion 3, and for example, as shown in the drawing, the end portion corresponding to the deepest portion 32 and the convex end surface portion 911 formed in a flat shape. It has a convex side surface portion 912 which is a side portion corresponding to the recessed inclined portion 31 and is formed in a curved surface shape.
When pressing the embossed plate 9, as shown in FIG. 8, the embossed plate 9 is pressed while the colored print layer 5 is stretched by the embossed projection 91.
After the recess 3 is formed on the surface of the laminated body 10 by pressing the embossed plate 9, the entire laminated body 10 is heated at 160 ° C. to 200 ° C. to gel the vinyl chloride paste.
Finally, the interior sheet 1 can be obtained by applying a material for forming the protective layer 41 (ultraviolet curable resin or the like) to the surface of the laminated body 10 and curing the material.

<When using suspension vinyl chloride>
In addition to the above-mentioned manufacturing method using paste vinyl chloride, suspension vinyl chloride can also be used to form the laminate 10.

(Preparation process)
A vinyl chloride paste (material for forming the second resin layer 62) composed of a mixture of, for example, vinyl chloride, a plasticizer, a filler and a foaming agent is applied to one surface of the fiber reinforcing layer 7 with an appropriate coater. After forming a layer, the fiber is pregelled at 120 ° C to 140 ° C, and the fiber reinforcing layer 7 is impregnated with the vinyl chloride paste and integrated. In this way, an intermediate laminate in which the second resin layer 62 is laminated on the other surface of the fiber reinforcing layer 7 is prepared.
On the other hand, the suspension vinyl chloride is used to form the sheet-shaped surface layer 4 and the backing layer 8. These forming methods are not particularly limited, and examples thereof include a calendar method, a melt extrusion method, and a solution casting method.

Next, the resin film surface of the printed film is laminated on the surface of the second resin layer 62 of the intermediate laminate, and the sheet-shaped surface layer 4 is further laminated on the resin film surface. Further, the sheet-shaped backing layer 8 is laminated on the surface of the fiber reinforced layer 7 of the intermediate laminate. These are heated and pressed to integrate each layer to form a laminated body 10. Examples of the method for joining each layer by heating and pressurizing include a laminating method, a calendar forming method, and a continuous pressing method. Above all, a method of continuously joining laminated bodies by heating and pressurizing with a roll, such as a laminating method and a calendar forming method, is preferable because many products can be manufactured at one time. In particular, the laminating method can be suitably applied because many laminated bodies can be joined at one time. The heating temperature and pressure of the laminating method are appropriately set according to a known processing method. For example, the heating temperature of the laminate 10 is 140 ° C. to 200 ° C., and the pressure between the rolls is 20 kgf / cm ² to 100 kgf / cm ² .
As the printed film, the one described in <When using paste vinyl chloride> can be used.
In this way, the laminate 10 composed of the surface layer 4, the colored printing layer 5, the first resin layer 61, the second resin layer 62, the fiber reinforcing layer 7, and the backing layer 8 is formed in this order from the surface side (see FIG. 7). ).

(Embossing process)
The embossed plate is pressed against the obtained laminate 10 in the same manner as in the above <when paste vinyl chloride is used>, and a material for forming the protective layer 41 (ultraviolet curable resin or the like) is applied, and this is applied. By curing, the interior sheet 1 can be obtained.

[Use of interior sheet]
The interior sheet 1 of the present invention is installed on a construction surface such as a floor surface, a wall surface, and a ceiling surface of a building. The method of attaching the interior sheet 1 to the construction surface is not particularly limited, and examples thereof include attaching the back surface of the interior sheet 1 to the construction surface using an adhesive.
In particular, according to the present invention, since the interior sheet 1 having a tile-like appearance can be easily configured, it is suitable as a floor sheet or a wall sheet to be applied to a floor surface or a wall surface of a kitchen, a bathroom, or the like.
Further, the interior sheet 1 of the present invention may be constructed on a newly installed construction surface, or may be constructed on an existing construction surface such as remodeling.
The interior sheet 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. Further, since the recess 3 is formed and the thickness is sufficiently large, it is most preferable to use the interior sheet 1 of the present invention as a flooring 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]
-Printed film Product name "Printing film for long PVC sheets".
Black ink (as a binder resin) on the surface of a white film made of vinyl chloride resin with a thickness of 120 μm (a film containing vinyl chloride resin as a main component resin, titanium oxide as a white pigment, and an ultraviolet absorber as a weather resistant agent). A solvent-volatile ink containing vinyl chloride resin, carbon black as a black pigment, and an ultraviolet absorber as a weather resistant agent) printed in a solid shape by the gravure printing method. The thickness of the black print layer is about 12 μm.
・ Suspension Vinyl Chloride Product name "Kaneka" manufactured by Kaneka Corporation. Degree of polymerization: 1050, K value: 67.

[Example 1]
By adding an appropriate amount of a benzophenone-based ultraviolet absorber as a weathering agent to the suspension vinyl chloride and calendar molding using a general-purpose calendar molding machine, the thickness is 0.28 mm, the length is 100 cm, and the width is 100 cm. A sheet-like transparent surface layer was prepared.
Separately, by adding an appropriate amount of a white pigment, a black pigment, calcium carbonate and a stabilizer to the suspension vinyl chloride by using a general-purpose extrusion molding machine, the thickness is 2 mm, the length is 100 cm, and the width is: A 100 cm sheet-like gray backing layer was prepared.
The printed film was used as a colored printing layer and a synthetic resin layer.
The laminated body was formed by laminating the film surface of the printed film on the surface of the backing layer and laminating the surface layer on the surface of the printed layer of the printed film. While heating this laminate to 180 ° C, an embossed plate (see FIG. 9) having embossed protrusions heated to 180 ° C on the surface of the synthetic resin layer of the laminate was pressed with a press machine at a pressure of 4 kgf / cm ² . By continuing to press for 120 seconds, each layer was integrated and a recess was formed at the same time. Then, by pulling the embossed plate apart, an interior sheet having a recessed inclined portion and a recessed portion having the deepest portion was produced.

The embossed plate has embossed protrusions projected on a smooth surface. In FIG. 9, for convenience, innumerable dots are added to the portion corresponding to the embossed protrusion.
The embossed protrusion has a flat convex end surface portion and a convex side surface portion extending from both sides of the convex end surface portion to the surface of the embossed plate in a curved cross-sectional view (three-dimensionally curved surface shape). The portion of the convex side surface portion in the vicinity of the convex end surface portion is formed in a linear shape (three-dimensionally planar) substantially orthogonal to the convex end surface portion. The embossed protrusions are formed linearly in a plan view, and the two convex side surface portions are formed symmetrically with the convex end surface portions interposed therebetween.
In Example 1, an embossed plate having a width A of a convex end surface portion of 1 mm, a length B between the base ends of two convex side surface portions of 4 mm, and an embossed protrusion height C of 0.8 mm was used. ..

A part of the interior sheet of Example 1 was cut, and the part was magnified and imaged to confirm the state of the recess.
The recess formed on the surface of the interior sheet of Example 1 has a shape corresponding to the embossed protrusion used, and has a curved and linear recessed inclined portion in a cross-sectional view as shown in FIG. .. Further, when the depth of the recess and the width of the deepest portion were measured, they corresponded to the dimensions of the embossed protrusions as shown in Table 1.
The colored print layer in the region corresponding to the recessed inclined portion was gradually formed in a thin wall shape toward the deepest portion. Further, the colored print layer (thinnest portion) in the region corresponding to the deepest portion was formed to be about 10 μm.

[Example 2]
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossed plate having embossed protrusions as shown in FIG. 10 was used.
In the embossed plate of Example 2, embossed protrusions are projected on a smooth surface. In FIG. 10, for convenience, innumerable dots are added to the portion corresponding to the embossed protrusion.
The embossed protrusion has a flat convex end surface portion and a convex side surface portion extending linearly in a cross-sectional view from both sides of the convex end surface portion to the surface of the embossed plate. The two convex side surface portions are formed symmetrically with the convex end surface portion interposed therebetween.
In Example 2, an embossed plate having a width A of the convex end surface portion of 1 mm, a length B between the base ends of the two convex side surface portions of 4 mm, and an embossed protrusion height C of 0.9 mm was used. ..

A part of the interior sheet of Example 2 was cut, and the part was magnified and imaged to confirm the state of the recess.
The recess formed on the surface of the interior sheet of Example 2 had a shape corresponding to the embossed protrusion used, and had a recessed inclined portion having a linear cross-sectional view as shown in FIG. Further, when the depth of the recess and the width of the deepest portion were measured, they corresponded to the dimensions of the embossed protrusions as shown in Table 1.
The colored print layer in the region corresponding to the recessed inclined portion was gradually formed in a thin wall shape toward the deepest portion. Further, the colored print layer (thinnest portion) in the region corresponding to the deepest portion was formed to be about 7 μm.

[Example 3]
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossed plate having embossed protrusions as shown in FIG. 10 was used.
In Example 3, the width A of the convex end surface portion shown in FIG. 10 is 2 mm, the length B between the base ends of the two convex end surface portions is 4 mm, and the height C of the embossed protrusion is 0.9 mm. I used the edition.

As for the interior sheet of Example 3, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, had a recessed inclined portion having a linear cross-sectional view, and the depth of the recess and the depth of the recess. The width of the deepest part corresponds to the size of the embossed protrusion as shown in Table 1.
The colored print layer in the region corresponding to the recessed inclined portion was gradually formed in a thin wall shape toward the deepest portion. Further, the colored print layer in the region corresponding to the deepest part was formed to be about 7 μm.

[Example 4]
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossed plate having embossed protrusions as shown in FIG. 9 was used.
In the fourth embodiment, an embossed plate having a width A of the convex end surface portion shown in FIG. 9 of 1 mm, a length B between the base ends of the two convex side surface portions of 4 mm, and an embossed projection height C of 1 mm. used.

As for the interior sheet of Example 4, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, and had a curved and linear recessed inclined portion in a cross-sectional view, and the recess had a concave portion. The depth and the width of the deepest part corresponded to the dimensions of the embossed protrusions as shown in Table 1.
The colored print layer in the region corresponding to the recessed inclined portion was gradually formed in a thin wall shape toward the deepest portion. Further, the colored print layer in the region corresponding to the deepest part was formed to be about 4 to 6 μm.

[Example 5]
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossed plate having embossed protrusions as shown in FIG. 10 was used.
In Example 5, the width A of the convex end face portion shown in FIG. 10 is 1 mm, the length B between the base ends of the two convex side surface portions is 4 mm, and the height C of the embossed protrusion is 1.2 mm. I used the edition.

As for the interior sheet of Example 5, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, had a recessed inclined portion having a linear cross-sectional view, and the depth of the recess and the depth of the recess. The width of the deepest part corresponds to the size of the embossed protrusion as shown in Table 1.
The colored print layer in the region corresponding to the recessed inclined portion was gradually formed in a thin wall shape toward the deepest portion. Further, the colored print layer in the region corresponding to the deepest part was formed to be about 1 to 3 μm.

[Example 6]
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossed plate having embossed protrusions as shown in FIG. 9 was used.
In Example 6, the width A of the convex end surface portion shown in FIG. 9 is 1 mm, the length B between the base ends of the two convex end surface portions is 4 mm, and the height C of the embossed protrusion is 1.2 mm. I used the edition.

As for the interior sheet of Example 6, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, and had a curved and linear recessed inclined portion in a cross-sectional view, and the recess had a concave portion. The depth and the width of the deepest part corresponded to the dimensions of the embossed protrusions as shown in Table 1.
The colored print layer in the region corresponding to the recessed inclined portion was gradually formed in a thin wall shape toward the deepest portion. Further, the colored print layer in the region corresponding to the deepest part was formed to be about 1 to 3 μm.

[Example 7]
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossed plate having embossed protrusions as shown in FIG. 10 was used.
In Example 7, the width A of the convex end surface portion shown in FIG. 10 is 2 mm, the length B between the base ends of the two convex end surface portions is 4 mm, and the height C of the embossed protrusion is 1.2 mm. I used the edition.

As for the interior sheet of Example 7, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, had a recessed inclined portion having a linear cross-sectional view, and the depth of the recess and the depth of the recess. The width of the deepest part corresponds to the size of the embossed protrusion as shown in Table 1.
The colored print layer in the region corresponding to the recessed inclined portion was gradually formed in a thin wall shape toward the deepest portion. Further, the colored print layer in the region corresponding to the deepest part was formed to be about 1 to 3 μm.

[Comparative Example 1]
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossed plate having embossed protrusions as shown in FIG. 9 was used.
In Comparative Example 1, the width A of the convex end surface portion shown in FIG. 9 is 1 mm, the length B between the base ends of the two convex end surface portions is 4 mm, and the height C of the embossed protrusion is 0.7 mm. I used the edition.

As for the interior sheet of Comparative Example 1, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, and had a curved and linear recessed inclined portion in a cross-sectional view, and the recess had a concave portion. The depth and the width of the deepest part corresponded to the dimensions of the embossed protrusions as shown in Table 1.
The colored print layer in the region corresponding to the concave inclined portion had almost the same thickness as the colored print layer in the region corresponding to the convex portion. Further, the colored print layer was present in the region corresponding to the deepest portion, and the thickness of the colored print layer corresponding to the deepest portion was substantially the same as the thickness of the colored print layer in the region corresponding to the convex portion. That is, the colored print layer was almost constant as a whole.

[Comparative Example 2]
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossed plate having embossed protrusions as shown in FIG. 10 was used.
In Comparative Example 2, the width A of the convex end surface portion shown in FIG. 10 is 1 mm, the length B between the base ends of the two convex end surface portions is 4 mm, and the height C of the embossed protrusion is 1.5 mm. I used the edition.

As for the interior sheet of Comparative Example 2, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, had a recessed inclined portion having a linear cross-sectional view, and the depth of the recess and the depth of the recess. The width of the deepest part corresponds to the size of the embossed protrusion as shown in Table 1.
The colored print layer in the region corresponding to the dented inclined portion was torn, and the torn end face was confirmed. Further, the colored print layer did not exist in the region corresponding to the deepest part (the thickness of the colored print layer was almost constant in the place where the colored print layer existed).

[Comparative Example 3]
An interior sheet having recesses was produced in the same manner as in Example 1 except that an embossed plate having embossed protrusions as shown in FIG. 10 was used.
In Comparative Example 3, the width A of the convex end face portion shown in FIG. 10 is 2 mm, the length B between the base ends of the two convex side surface portions is 4 mm, and the height C of the embossed protrusion is 1.5 mm. I used the edition.

As for the interior sheet of Comparative Example 3, when the state of the recess was confirmed, the recess had a shape corresponding to the embossed protrusion used, had a recessed inclined portion having a linear cross-sectional view, and the depth of the recess and the depth of the recess. The width of the deepest part corresponds to the size of the embossed protrusion as shown in Table 1.
The colored print layer in the region corresponding to the dented inclined portion was torn, and the torn end face was confirmed. Further, the colored print layer did not exist in the region corresponding to the deepest part (the thickness of the colored print layer was almost constant in the place where the colored print layer existed).

[Appearance observation]
The interior sheets of each Example and Comparative Example were placed on a horizontal desk, and the surface of the interior sheets was visually observed from a position about 50 cm directly above the desk.
The results are shown in Table 1. The symbols in the appearance column of Table 1 are as follows.
○ 1: The deepest part of the concave part looks beautiful white, the convex part (the surface of the interior sheet other than the concave part) looks black, and the color gradually changes from black to white at the concave inclined part, and the design feels natural. It was.
○ 2: The deepest part of the concave part looks white, the convex part looks black, and the color gradually changes from black to white in the dented inclined part, resulting in a natural design.
○ 3: The deepest part of the recess appeared to be slightly grayish white, and the color gradually changed from black to white at the recessed slope, resulting in a natural design.
× 1: The recessed inclined portion and the deepest portion of the recess appeared to be black, and the interior sheet was designed to be entirely black.
× 2: The deepest part of the recess appeared to be beautiful white, but the boundary between black and white was conspicuous in the recessed inclined portion.

[Weather resistance test]
JIS A 1415 "Exposure test method for polymer-based building materials using a laboratory light source" was performed. Specifically, the interior sheets of each Example and Comparative Example were cut into a length × width = 300 mm × 300 mm including a recess to prepare a test piece. Using this test piece, according to JIS K 7350-2 specified in 6 test methods of "Exposure test method for polymer-based building materials with a laboratory light source", using a xenon arc lamp under predetermined conditions ( The black panel temperature was 63 ± 3 ° C., the spray cycle was 102 minutes, then 18 minutes irradiation and water spray), and the exposure test was performed. The specimen was exposed for 4000 hours. After exposure, changes in the appearance of the test pieces were observed. A gray scale for fading was used to determine the change in appearance.
The results are shown in Table 1. In the appearance column of Table 1, "○" indicates that there is a performance of 4th grade or higher, "Δ" indicates that it is 3rd grade, and "×" indicates that it is 2nd grade or lower.

[evaluation]
In terms of appearance, the interior sheets of Examples 5 to 7 were excellent, but in consideration of the appearance and light resistance, the interior sheets of Examples 2 to 4 were excellent. By setting the depth of the recess to 1.2 mm or less (particularly, 1 mm or less as in Examples 1 to 4) as in Examples 1 to 7, the interior sheet whose color changes gently in the recessed inclined portion can be obtained. Obtained.
In the interior sheets of Examples 5 to 7, the thickness of the surface layer and the colored printing layer is smaller in the recesses than in Examples 2 to 4, and it is presumed that this reduces the weather resistance.

The interior sheet 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 sheet 2 Sheet body 3 Recessed 31 Recessed inclined part 32 Deepest part 4 Surface layer 5 Colored printing layer 51 Gradual reduction part of colored printing layer 52 Thinnest part of colored printing layer 6 Synthetic resin layer 7 Fiber reinforced layer 8 Backing layer 9 Embossed plate

Claims (6)

From the surface side, a sheet body having a surface layer, a colored printing layer , a synthetic resin layer, and a fiber reinforced layer , and a recess formed on the surface of the sheet body and composed of a recessed inclined portion and a deepest portion are formed. Have and
The surface layer and the synthetic resin layer contain a vinyl chloride resin as a main component resin, the thickness of the synthetic resin layer is 100 μm to 1.2 mm, and the colored printing layer is provided on the surface of the synthetic resin layer. It consists of an ink solidifying layer having a thickness of 0.2 μm to 20 μm formed by printing ink.
The synthetic resin layer has a color different from that of a part or all of the colored printing layer.
An interior sheet in which the colored print layer has a gradually thinning portion formed in a region corresponding to the recessed inclined portion of the recess toward the deepest portion. The recess has a portion that extends linearly in the first direction in a plan view and a portion that extends linearly in a second direction that is orthogonal to the first direction in a plan view, and is surrounded by the recess. The interior sheet according to claim 1 , wherein the divided range forms a rectangular shape or a square shape in a plan view, and the deepest portion of the recess forms a flat surface . The synthetic resin layer has a first resin layer laminated on the back surface side of the colored printing layer and a second resin layer laminated on the back surface side of the first resin layer.
The interior sheet according to claim 1 or 2, wherein the fiber reinforcing layer is laminated on the back surface side of the second resin layer. The interior sheet according to any one of claims 1 to 3, wherein the colored print layer has the thinnest portion formed in the thinnest in the region corresponding to the deepest portion of the recess. The interior sheet according to any one of claims 1 to 3, which does not have a colored printing layer in the region corresponding to the deepest portion of the recess. The method for manufacturing an interior sheet according to any one of claims 1 to 5.
A step of preparing a film in which an ink solidifying layer having a thickness of 0.2 μm to 20 μm, which is a colored printing layer, is formed on the surface of a synthetic resin layer having a thickness of 100 μm to 1.2 mm.
A preparatory step for preparing a laminate having a surface layer, the film having the colored printing layer and the synthetic resin layer, and a fiber reinforcing layer in order from the surface side.
It has an embossing step of pressing an embossed plate having embossed protrusions from the surface side of the laminated body to form a concave portion composed of a recessed inclined portion and a deepest portion on the surface of the laminated body.
In the embossing step, the embossed protrusions of the colored printing layer are pressed by the pressing force of the embossing plate so that the thickness of the ink solidifying layer, which is the colored printing layer, gradually decreases from the recessed inclined portion toward the deepest portion. A method for manufacturing an interior sheet, in which the recess is formed while stretching the corresponding portion.

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