JPH11217799A - Interior material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain an interior material instead of a vinyl wall paper, hardly causing a poison synthesized when burning the interior material. SOLUTION: This interior material consists essentially of a cellulosic fiber and a heat-weldable fiber and is obtained by mixing these fibers to provide a web of a one-layer structure or the web of a multi-layered structure by lamination by a carding machine or the like, forming a nonwoven fabric or a felt from the obtained web, and subjecting the obtained nonwoven fabric or felt to an embossing on the surface thereof. The interior material has the surface with a relief embossing pattern 1, a film layer 2 obtained by melting and fusing the heat-weldable fiber and an inner layer part 3 obtained by melting and fusing the heat-weldable fiber to adhere to the cellulosic fiber or the like, arranged in order from the surface side. A base paper 4 for the wall paper is optionally attached to the back surface according to the use or the design thereof.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to interior materials for buildings, vehicles, railway vehicles and aircraft.

[0002]

2. Description of the Related Art Vinyl wallpaper is often used for interior materials (referred to as finishing materials, wallpaper, etc.) of buildings, railway vehicles, automobiles, and the like.

[0003] This vinyl wallpaper is obtained by adding a plasticizer, a filler, a stabilizer, a lubricant, a flame retardant, a foaming agent, titanium,
A coating method in which a mixture containing a diluent and a colorant (pigment) is coated on a base paper for wallpaper, and a calendering method in which a vinyl chloride resin film formed by extruding the above-described mixture by extrusion molding is bonded to the base paper for wallpaper. Thereby, a sheet material having a two-layer structure of the wallpaper and the mixed material is formed,
A predetermined pattern is printed and printed on the mixture material side surface of the sheet material, then passed through a preheating roll, further heated and softened by a heater, and heated and pressed with an embossing roll while foaming to form an emboss (irregularity) on the mixture material surface. ) It is manufactured by forming a pattern.

[0004] This vinyl wallpaper has been widely used as an interior material because it has little unevenness on the surface, is easily processed by embossing, printing, printing, and the like, and can be manufactured at low cost.

However, vinyl wallpaper is mainly made of vinyl chloride resin containing chlorine atoms, so that toxic gases such as chlorine and dioxins may be synthesized during incineration, which deteriorates the environment in waste treatment. There's a problem. Further, those which generate toxic gas at the time of combustion as described above at the time of fire occurrence are not suitable as interior materials.

[0006]

In order to provide an interior material that does not synthesize toxic substances during combustion, the interior material is manufactured from a fiber cloth (nonwoven fabric and felt) mainly composed of cellulosic fibers and heat-fused fibers. Have been tried to. When manufacturing interior materials using the above-mentioned cellulosic fibers and the like as raw materials, it is difficult to manufacture interior materials having appropriate texture and workability as interior materials, even when manufactured under conventional vinyl wallpaper processing conditions. .

An object of the present invention is to solve the problems of interior materials using the above-mentioned cellulosic fiber or the like as a raw material.

[0008]

The interior material of the present invention is manufactured from a mixed fiber web of cellulosic fibers and heat-sealing fibers, or a multi-layered web in which cellulosic fibers and heat-sealing fibers are laminated. An embossing roller is pressed against one surface of the nonwoven fabric or felt which has been heated to a temperature not lower than the melting point of the heat-fused fibers and at which the cellulosic fibers and the heat-fused fibers are not denatured to form an embossed pattern. Has a film layer formed by the fusion-bonding of heat-fusible fibers.

In the above interior material, the heat-fusible fiber is a composite fiber having a high-melting-point heat-fusible fiber in a core portion and a low-melting-point heat-fusible fiber in a sheath portion. The embossing roller is heated to a temperature not lower than the melting point of the heat-fusible fiber and heated to a temperature at which the cellulosic fiber and the heat-fusible fiber are not denatured to form an embossed pattern. It may have a film layer to be formed.

[0010] One surface of a nonwoven fabric or felt made of a mixed fiber web of a cellulosic fiber, a thermoplastic fiber for weaving, and a heat fusion fiber having a lower melting point than the thermoplastic fiber for weaving, An embossing roller heated at a temperature not lower than the melting point and heated to a temperature at which the cellulosic fibers, thermoplastic fibers for weaving and heat-fusible fibers are not denatured is pressed to form an embossed pattern, and the heat-fused fibers are fused to the surface. May have a film layer formed by the following.

A nonwoven fabric or felt obtained by laminating one or more nonwoven fabrics or felts on the surface of the above nonwoven fabric or felt with heat-fusible fibers, wherein the surface of the heat-fusible fibers is By applying an embossing process with fusion bonding, the laminated nonwoven fabric or felt is fused, an embossed pattern is formed on the surface, and a film having a film layer formed on the surface by fusion bonding of heat-fused fibers is also used. Good. Alternatively, a carbon-based material such as activated carbon or ceramics may be applied to the nonwoven fabric or felt to remove or suppress formaldehyde and the like.

Further, by setting the mixing ratio of the heat-fusible fibers in the nonwoven fabric or felt forming the surface layer to 5 to 30%, the surface layer can have a woven feel.

In the above-mentioned interior material, it is desirable that the decorative processing by printing or printing on the surface of the nonwoven fabric or felt be performed before the embossed pattern is formed, and that the decorative step by spray painting be performed after the embossed pattern is formed.

In order to improve the workability of the interior material,
A base paper for wallpaper may be adhered to the back surface of the interior material.

In the interior material described above, the condition of the embossing machine when forming an embossed pattern on the surface is as follows. In order to improve the quality of the product, an embossed roller having a depth of 0.1 to 0.8 mm is engraved. Heat to a temperature of 135-250 ° C., set the total pressure to 4000-25000 kg and 10
It is desirable that the pressure contact be performed at a speed of 50 m / min. (Here, the total pressure refers to the total load acting on the embossing roller when manufacturing the interior material for one half.)

In the above interior material, the basis weight of the non-woven fabric or felt as an intermediate product is desirably 25 to 150 g / m ² in consideration of workability and economy, and the thickness of the embossed pattern is Is desirably 0.2 to 5 mm so as to clearly appear.

[0017]

Embodiments of the present invention will be described below.

FIG. 1 is a sectional view of an interior material according to the present invention.
The interior material of the present invention is mainly composed of a cellulosic fiber and a heat-sealing fiber, and these are mixed to form a single-layered web (hereinafter, referred to as a mixed web) or a multilayered web ( Hereinafter, a multi-layered web is produced by a card machine or the like, a nonwoven fabric or felt is manufactured from the web, and the surface is embossed. (Here, the multi-layered web includes one obtained by laminating two or more mixed webs obtained by mixing cellulosic fibers and heat fusion fibers at different ratios in a multi-layer structure.)

That is, in the interior material of the present invention, an embossed pattern (1) composed of irregularities is formed on the surface, and the film layer (2) formed by melting and melting the heat-fusible fibers from the surface side and the heat-fusible fibers such as cellulose fibers. And an inner layer portion (3) to which the attached fibers are fused. Further, the base paper for wallpaper may be provided on the back surface depending on the use or design.

[0020] The surface of the interior material may be subjected to a flame retardant treatment, a cosmetic treatment or the like. The interior material of the present invention is cut into a predetermined shape by a cutter or the like, and is installed on a wall surface or a ceiling of a building, a railway vehicle, or the like, similarly to a conventional interior material.

As the cellulosic fibers, cellulosic regenerated fibers such as rayon, and cellulosic semisynthetic fibers such as acetate are used. The cellulosic fiber improves cutter cutting in construction and does not synthesize toxic substances during incineration.

The heat fusible fibers are thermoplastic synthetic fibers (excluding fibers that synthesize toxic substances such as chlorine and dioxin during combustion), and have a function of melting by embossing to increase the bonding force between the fibers. In addition, a film layer is formed on the surface during embossing to maintain an embossed pattern, suppress fluffing on the surface, and make the shape less likely to collapse.
Such a heat-fused fiber has a melting point of 110 to 135 ° C.
It is preferable to use low-melting thermoplastic synthetic fibers (excluding fibers that synthesize toxic substances when burned).

The heat-fused fiber may have a low melting point as a whole, but as shown in FIG. 2, has a high-melting thermoplastic synthetic fiber as a core component (5) and a low melting point as a sheath component (6). It is preferable to use a core-sheath composite fiber having a thermoplastic synthetic fiber having a melting point. When this core-sheath type composite fiber is used, even if the sheath portion is melted and melted by embossing, the fiber form of the core component remains in addition to the cellulose fiber, so that the interior material surface can have an appropriate texture. . As the core-sheath type composite fiber, for example, the melting point is 255 to 260 ° C. as a core component.
(Hereinafter, referred to as high-melting-point polyethylene terephthalate) or thermoplastic polyethylene having a melting point of 125 to 135 ° C (hereinafter, referred to as thermoplastic polyethylene), and a melting point of 110 to 135 as a sheath component. One having thermoplastic polyethylene terephthalate having a temperature of ° C. (hereinafter, referred to as low melting point polyethylene terephthalate) may be used.

The core component is a thermoplastic polyethylene (specific gravity:
The core-sheath type composite fiber using 0.94 g / cm ² )
High melting point polyethylene terephthalate (specific gravity:
1.38 g / cm ² ), the specific gravity of the core component is lighter, resulting in a bulky material after embossing.

Further, when producing a nonwoven fabric or a felt, a thermoplastic synthetic fiber for knitting and weaving made of ordinary organic fibers is mixed in a mixed web or a multilayered web of cellulosic fibers and heat-fusible fibers. good. The thermoplastic synthetic fiber for weaving is made of high melting point polyethylene terephthalate and has a melting point of 1.
Thermoplastic polypropylene having a temperature of 65 to 173 ° C, thermoplastic polyethylene, flame-retardant polyethylene terephthalate, or the like is mixed in the web at a ratio of 5 to 50%. Further, as the heat-fusible fibers, those having a lower melting point than the thermoplastic fibers for weaving are used. Thereby, after the embossing, the cellulosic fiber, (the core component of the heat-fusible fiber), and the thermoplastic synthetic fiber for weaving remain in the form of fibers, so that the interior material surface can have an appropriate texture.

The amount of the heat-fused fiber is set in the range of 5 to 90%. If the amount of the heat-fused fiber is too small, the strength of the embossed pattern is insufficient and the shape tends to collapse.
The strength is increased, and the workability such as cutting of the cutter deteriorates. In particular, by setting the proportion of the heat-fusible fiber in the nonwoven fabric (felt) forming the surface layer to 5 to 30%, it is possible to obtain a woven texture. When used as a finishing material for buildings, ceilings, etc., it is preferable to increase the proportion of the heat-fused fibers in order to impart rigidity.

In this case, a web composed of a combination of two types of fibers, ie, a cellulosic fiber and a heat-fusible fiber (core component: high-melting-point polyethylene terephthalate / sheath component: low-melting-point polyethylene terephthalate); It is appropriate to use a web formed by combining three types of fibers of terephthalate and heat-fused fibers (core component: high melting point polyethylene terephthalate or thermoplastic polyethylene / sheath component: low melting point polyethylene terephthalate).

It is preferable that the fiber material itself has chemical resistance, fungicide resistance, germ resistance and non-allergenicity, and is nontoxic and safe. The above-mentioned fiber materials do not generate toxic gases such as chlorine gas and dioxin during combustion.

The non-woven fabric or felt is prepared from a single-layered web obtained by mixing the above-mentioned cellulosic fibers and heat-sealing fibers, a laminated multilayered web, or a web obtained by mixing thermoplastic synthetic fibers for knitting and weaving. It is formed. Before the nonwoven fabric or felt manufacturing process, a card web system in which short fibers are aligned in one direction by a card machine is particularly preferable. This is because, in the card web system, the fibers are arranged in one direction, so that blurring during printing is small. The above-mentioned web is manufactured by other methods such as a spunbond web system made by laminating long fibers obtained by spinning a dissolved resin, or a wet web system in which fibers and pulp are dispersed in water and scooped by a wire mesh. But it is good.

As a method of combining the constituent fibers of the web into a nonwoven fabric, a fluid punch method (spunlace method) using a water flow is particularly preferable. This is because the spunlace method involves entanglement of web fibers in one direction by the pressure of a water stream, so that the surface is less fuzzy and has good printability. In addition, spun bond nonwoven fabric, wet nonwoven fabric, thermal nonwoven fabric, needle ring nonwoven fabric, dry nonwoven fabric, dry pulp nonwoven fabric, melt blown nonwoven fabric, flash spun nonwoven fabric, air laid nonwoven fabric, binder bonding method and the like can also be used.

A nonwoven fabric or felt having heat-fusible fibers may be superimposed on the back surface of the above nonwoven fabric, and the surface may be embossed. Thereby, the material composition of the interior material can be changed between the surface layer and the back layer, and the surface layer is made of a nonwoven fabric suitable for surface formation in consideration of embossability, printability, texture, antifouling property, feel, etc. Felt), and a nonwoven fabric (felt) can be selected for the back layer (inner layer) in consideration of workability, economy, nonflammability, bulkiness, and the like.

Further, a non-woven fabric or felt mixed with a carbon-based material such as activated carbon, carbon fiber or ceramics may be used. In this case, the action of the carbon-based material can give the nonwoven fabric (felt) itself an action of removing and suppressing formaldehyde and the like.

The basis weight and thickness of the nonwoven fabric or felt are set according to the depth of the embossing roll and the application.

The basis weight of the nonwoven fabric or felt is 25 g /
If it is less than m ² , the embossed pattern will have poor three-dimensional appearance,
It exceeds 0 g / m ² is too increased strength, construction adaptability, processing suitability upper deteriorates, so uneconomical bulge material costs, but is set to 25 to 150 g / m ^2, in particular 55
It is desirably 〜80 g / m ² . When the thickness of the nonwoven fabric or felt is less than 0.2 mm, the unevenness does not clearly appear, and when it exceeds 5 mm, the difference in the unevenness is too large, and it becomes difficult to remove dirt from the concave portion. 5m
m, but particularly preferably 0.3 to 0.8 mm.

The nonwoven fabric or felt formed as described above may be provided with a base paper for wallpaper (plain paper, New Year's holiday, aluminum hydroxide paper, etc.) on the back surface. For sticking, a starch-based adhesive is used so that no toxic substance is generated even when incinerated. By applying the base paper for wallpaper, the suitability for construction is improved, and it becomes an interior material suitable as a finishing material for buildings, ceilings and the like.

The surface of the non-woven fabric or felt may be solid or flame-retardant, water-repellent, stain-proof,
Surface treatments such as mold prevention, antibacterial, and makeup are applied. These may be provided in the material at the raw cotton stage.

The flame retardant is preferably guanidine sulfamate, guanidine phosphate, antimony trioxide, zirconium hydroxide, barium metaborate, aluminum hydroxide, magnesium hydroxide, etc., which do not synthesize poisons during combustion. When used as a finishing material for buildings, ceilings, etc., it is possible to obtain a second-class fire protection certification set by the Ministry of Construction without applying a flame retardant by attaching a flame retardant paper to the back surface.

The addition amount of the flame retardant is preferably 10 to 40% of the finishing material such as a building or a ceiling. Particularly, it is preferably from 15 to 30%, and if it is less than 10%, the flame retardant effect is insufficient, and if it exceeds 40%, it becomes uneconomical.

The makeup process is performed by printing, printing, dyeing, and spraying.

In the case of printing and printing, it is preferable to perform the printing before the embossing step. This is because if you print or print after the embossing process, the embossed pattern will lose its shape,
This is because the product value may be lost. However, depending on the printing pattern (printing pattern), embossing after printing (printing) may cause print spots or print spots to be noticeable. In this case, printing or printing is particularly performed after embossing.

In the case of spraying, it is preferable to carry out after the embossing step. This is because if spraying is performed before the embossing step, the particles of the pigment or the like contained in the spray coating agent are large and hard, so that the grooves of the engraving embossing roll may be clogged, which may cause inconvenience in production. In the case of spray coating, if necessary, a water repellent, a fungicide, an antifouling agent, etc. may be added to the coating solution to simultaneously perform a surface treatment such as water repellency, antifungal, and antifouling. Can be.

For embossing for forming a pattern on the surface of the interior material, a hot embossing machine conventionally used for producing paper and some nonwoven fabrics, woven fabrics, leather products and the like is used. The conditions of the embossing machine used in the present invention are shown below.

The embossing machine is provided with an embossing roll having an engraving of a predetermined pattern on the surface, and presses the embossing roll heated to a predetermined temperature against a nonwoven fabric or the like to form a pattern corresponding to the embossing roll pattern on the surface of the nonwoven fabric. Is what you do.

The depth of the embossing roll is changed depending on the pattern or pattern. This is usually set in the range of 0.1 to 0.8 mm, because if you set a deep depth to a sharp pattern or pattern, there is a possibility of strikethrough or tearing of the material,
In particular, it is preferably 0.3 to 0.6 mm in order to form a stable embossed pattern and to give the pattern a sense of volume.

In embossing, an embossing roller heated to a temperature of 135 to 250 ° C. is pressed at a total pressure of 4000 to 250 °.
It is carried out at a processing speed of 10 to 50 m / min while being pressed against the surface of the nonwoven fabric or felt at 00 kg.

At this time, the temperature of the embossing roll was 135
When the temperature is lower than 250 ° C., the melting effect is small and the shape tends to collapse. When the temperature exceeds 250 ° C., the cellulosic fiber reaches the carbonization point and the surface starts to burn. 190 to 220 to sufficiently melt and melt the attached fiber and to improve the processing efficiency.
It is preferable to set to ° C. If the pressure of the embossing roll is less than 4000 kg, moderate unevenness cannot be formed, and if it exceeds 25,000 kg, the unevenness becomes unnecessarily large and the concealment property deteriorates.
In particular, the weight is preferably 12,000 to 19000 kg in order to efficiently form a good embossed pattern. If the processing speed is less than 10 m / min, it is uneconomical, and if it exceeds 50 m / min, a good embossed pattern cannot be obtained. Therefore, the processing speed is set to 10 to 50 m / min.
10-2 to efficiently form a good embossed pattern
It is preferably 0 m / min.

The interior material of the first embodiment (hereinafter referred to as interior material) will be described.

The method of manufacturing the interior material is as follows.

First, a core-sheath type composite fiber using a high melting point polyethylene terephthalate fiber having a melting point of 255 to 260 ° C. as a core component and a low melting point polyethylene terephthalate fiber having a melting point of 110 to 135 ° C. as a sheath component ( The first web composed of 100% of the heat-fused fiber) was used as the surface, and the second web was mixed with 10 to 100% of the cellulosic fiber and 90 to 0% of the same core-sheath composite fiber (heat-fused fiber) as above. With the web as the back side, two card webs are overlapped and punched with water pressure, and the basis weight is 25 to 150 g / m ² ,
A two-layer spunlace nonwoven fabric having a thickness of 0.2 to 5 mm is produced. (Felt may be used instead of non-woven fabric.)

A starch-based adhesive is applied to the back surface of the nonwoven fabric (felt), and the base paper for wallpaper is bonded.

Next, as a surface treatment of the nonwoven fabric (felt), printing, printing, and 10 to the weight of the nonwoven fabric are performed.
Apply 40% flame retardant (if necessary, anti-mold, anti-fouling,
Apply water repellency. ).

Finally, the temperature of the embossing roll engraved to a depth of 0.1 to 0.8 mm is set to 135 to 250 ° C., and the total pressure is set to 4000 to 25000 kg to set the embossing roll to 10 to 50 m.
Embossing is performed at a processing speed of / min, and an emboss pattern is formed on the surface of the nonwoven fabric (felt).

By embossing, the low-melting-point polyethylene terephthalate of the core-sheath type composite fiber is melted (heat-fused) to form a film layer on the surface.
The bonding force between the cellulose fiber remaining as a fiber form and the high melting point polyethylene terephthalate fiber is improved. The resulting interior material is non-woven (felt)
A film effect is obtained on the surface, and an embossed pattern having a thickness of 0.1 to 0.8 mm is finished with a glossless texture and has good form stability. Further, the interior material is excellent in flame retardancy (anti-mold, anti-soil, water-repellent) performance in the surface treatment.

Next, the interior material of the second embodiment (hereinafter referred to as interior material) will be described.

For the interior material, a starch-based adhesive was applied to the same nonwoven fabric (felt) as the interior material, the base paper for paper was adhered, and the temperature of the embossing roll engraved to a depth of 0.1 to 0.8 mm was 135 to 135 mm. 250 ° C, total pressure 4000 ~ 2
The embossing is performed at a processing speed of 10 to 50 m / min while setting to 5000 kg. Next, as a cosmetic process, a solution in which a pigment and a flame retardant are mixed (a water repellent,
A fungicide, an antifouling agent and the like can be mixed. ) Is spray-painted on the surface. Interior materials are Japanese-style earthen walls,
Finishing materials such as calm buildings and ceiling materials with a stone-like texture can be obtained.

Next, the interior material of Embodiment 3 (hereinafter referred to as interior material) will be described.

The interior material uses a thermoplastic polyethylene fiber having a melting point of 125 to 135 ° C. as a core component, and has a melting point of 110 ° C.
A first web composed of 100% of a core-in-sheath composite fiber (heat-fused fiber) using a low-melting polyethylene terephthalate fiber having a melting point of up to 135 ° C. as a sheath component is used as a surface, and the cellulosic fiber 10
100% and the same core-sheath type composite fiber as above (heat-bonded fiber)
The second web mixed at a ratio of 90 to 0% as a back surface,
A two-layer spunlaced nonwoven fabric (felt) is produced by superimposing two card webs and punching with water pressure to produce a nonwoven fabric (felt) having the same structure as that of the first embodiment. The interior material is formed by melting and melting (thermal fusion) the low-melting point polyethylene terephthalate of the core-sheath composite fibers by embossing to form a film layer on the surface, and the cellulosic fibers and the high melting point remaining in the fiber form. This is an improvement in the bonding strength between polyethylene fibers. As the interior material, thermoplastic polyethylene with a lower specific gravity remains in fiber form compared to high melting point polyethylene,
Even if the basis weight is smaller than the interior material, the thickness can be obtained.

Next, the interior material of Embodiment 4 (hereinafter referred to as interior material) will be described.

For the interior material, the same processing steps as in the second embodiment are performed on the same nonwoven fabric (felt) as the interior material. As for interior materials, similar to interior materials, finishing materials such as Japanese-style mud walls, calm buildings with stone-like texture, ceiling materials, etc. can be obtained. Is obtained.

Next, the interior material of the fifth embodiment (hereinafter referred to as interior material) will be described.

As the interior material, the above-mentioned core-sheath type composite fiber was used for 10 times.
1 to 90% and cellulosic fiber 90 to 10%
A second mixture of the web as a surface and a mixture of 10 to 90% of the cellulosic fiber and 90 to 10% of the core-sheath composite fiber described above.
With the web as the back side, two card webs are overlapped and punched with water pressure, and the basis weight is 25 to 150 g /
A two-layer spunlace nonwoven fabric having an m ² and a thickness of 0.2 to 5 mm was prepared, and the same processing as in the first embodiment was performed. The interior material has the same surface film effect as the interior material, and has a cellulosic fiber in the surface layer, so it is warmer, has excellent form stability, and has a glossy finish. Finished with no texture.

By using the same nonwoven fabric (felt) as the interior material and performing the same processing as in the second embodiment, it is possible to produce an interior material having a Japanese-style earthen wall and a texture like a stone. it can.

Next, the interior material of the sixth embodiment (hereinafter referred to as interior material) will be described.

The interior material is composed of cellulosic fibers 95 to 70
%, And a web in which the above-mentioned core-in-sheath type composite fibers are mixed at a ratio of 5 to 30% is subjected to punching with a water flow pressure, and a basis weight of 25 to 30%.
A spunlace nonwoven fabric having a single-layer structure of 150 g / m ² and a thickness of 0.2 to 5 mm is produced, and the same processing steps as those in the first or second embodiment are performed. The resulting interior material has a film effect and the cellulosic fibers that do not melt on the surface remain in a fluffy shape, giving a soft touch like a fiber material and a warm finish, and It has a natural texture.

Next, an interior material (hereinafter, referred to as interior material) of the seventh embodiment will be described.

The interior material uses a high melting point polyethylene terephthalate fiber having a melting point of 255 to 260 ° C. as a core component.
Mixing of a spun-pound process or a wet process nonwoven fabric composed of 100% of a core-in-sheath type conjugate fiber using a low melting point polyethylene terephthalate fiber having a melting point of 110 to 135 ° C. as a sheath component, with a cellulosic fiber and a heat-fusible fiber A synthetic nonwoven fabric bonded to the surface of a spunlace nonwoven fabric produced from a web or a multilayer web by subjecting it to water punching, needle punching, lamination or the like is produced, and then the same processing steps as in the first or second embodiment are performed.

The resulting interior material has a heat-fusible fiber film layer formed on the surface, has an appropriate texture according to the intended use as the interior material, and the nonwoven fabric on the back surface has the volume feeling and heat characteristic of spunlace. This provides an appropriate rigidity due to the fusion.

In the interior material according to the seventh embodiment, the rigidity and voluminousness according to the use of the interior material can be changed by changing the fiber structure and the manufacturing method of the nonwoven fabric laminated on the back surface. In this embodiment, a spunlace nonwoven fabric is used for the back surface, and a nonwoven fabric obtained by another manufacturing method is used for the front surface. However, the present invention is not limited to this, and the nonwoven fabric can be freely combined. For example, it is also possible to combine different nonwoven fabrics on the front surface, the interior, and the back surface.

Hereinafter, examples of the interior material according to the present invention will be shown and compared with interior materials not according to the present invention.

In Example 1, the first layer (surface layer) was a core-sheath type composite fiber staple (fineness: 2 denier, fiber length: 51 mm) having a low melting point polyethylene terephthalate as a sheath component and a high melting point polyethylene terephthalate as a core component. Part of the card web, the second layer (back layer) is 90 parts by weight of rayon table (1.5 denier fineness, fiber length 40 mm), low melting point polyethylene terephthalate is a sheath component, and high melting point polyethylene terephthalate is a core component. Core-sheath type composite fiber staple (fineness 2 denier, fiber length 5
1 mm) in a ratio of 10 parts by weight to obtain a card web, and these two card webs are weighed at a total weight of 80 g / m ^2.
To form a double-layered web, which is then punched with a water pressure to produce a nonwoven fabric having a thickness of 0.7 mm.

Next, a modified vinyl acetate copolymer adhesive is applied at a weight force of 20 g / m ^2, to bond the flame燃紙for wallpaper basis weight 120 g / m ^2. Next, a multicolored pattern is printed, and a flame retardant, a fluorine-based water-repellent and stain-proofing agent 20 g / m ²
It was applied at the applied amount. After drying it, the depth is 0.5m
m embossing roll having a lattice pattern sculpture at a temperature of 2
30 ° C, total pressure 16000kg, rotation speed 20m /
Perform embossing by setting to minutes.

As a result, the interior material of Example 1 has a film effect, does not have the luster of a cold feeling like a vinyl wallpaper, has antifouling performance, and has excellent workability. Material.

In Example 2, a nonwoven fabric similar to that of Example 1 is produced.

Next, a modified vinyl acetate copolymer adhesive is applied at a weight force of 20 g / m ^2, to bond the flame燃紙for wallpaper basis weight 120 g / m ^2. After drying, embossing is performed on the embossing roll having a grid pattern engraving with a depth of 0.5 mm at a temperature of 230 ° C., a total pressure of 16,000 kg, and a rotation speed of 20 m / min. next,
Spray painting is carried out with a spraying agent containing a multicolored inorganic pigment and a mixture of a flame retardant and a water repellent.

As a result, the interior material of Example 2 is a new interior material that is calm and has a voluminous feel due to the mud-wall style of Japan.

In Example 3, the first layer (surface layer) was a core-sheath type composite fiber staple (a fineness of 2 denier, a fiber length of 51 mm) containing low-melting-point polyethylene terephthalate as a sheath component and high-melting-point polyethylene terephthalate as a core component. Part of the card web, the second layer (back side layer) is 80 parts by weight of rayon staple (1.5 denier fineness, fiber length 40 mm) and 20 parts by weight of flame-retardant polyethylene terephthalate (2 denier fineness, 51 mm fiber length) , And the two card webs are superposed at a total basis weight of 80 g / m ² to form a two-layer structure, which is subjected to punching with water pressure to produce a nonwoven fabric having a thickness of 0.7 mm.

[0077] Next, a modified vinyl acetate copolymer adhesive is applied at a weight force of 20 g / m ^2, to bond the flame燃紙for wallpaper basis weight 120 g / m ^2. Next, a multicolored pattern is printed, and a fluorine-based water-repellent antifouling agent is applied in an amount of 20 g / m ² . After drying this, an embossing roll having a grid pattern engraving with a depth of 0.5 mm was heated at a temperature of 230 ° C.
Embossing is performed at a total pressure of 16000 kg and a rotation speed of 20 m / min.

As a result, the interior material of Example 3 has a film effect, but does not have the cool gloss of vinyl wallpaper, has antifouling properties, is excellent in workability, and has a nonwoven fabric effect. By providing the flame-retardant fiber in the production, the flame-retardant treatment in the post-processing becomes unnecessary, and it is economical and provides a new interior material that has never been seen before.

In Example 4, the first layer (surface layer) was a core-sheath type composite fiber staple (fineness: 2 denier, fiber length: 51 mm) having low melting point polyethylene terephthalate as a sheath component and high melting point polyethylene terephthalate as a core component. Part of the card web, the second layer (back layer) is 70 parts by weight of rayon staple (1.5 denier fineness, fiber length 40 mm), 20 parts by weight of flame retardant rayon, sheath component of low melting point polyethylene terephthalate, high A card web was prepared by mixing core-sheath composite fiber staples having a melting point of polyethylene terephthalate as a core component (fineness: 2 denier, fiber length: 51 mm) at a ratio of 10 parts by weight, and these two card webs were weighed at 80 g / m ^2. To form a two-layer card web, which is punched with water pressure to a thickness of 0.7 m. Make the non-woven fabric. Next, the same embossing as in the third embodiment is performed.

Thus, although the interior material of Example 4 has a film effect, it does not have the cool gloss of vinyl wallpaper, has an antifouling property, has excellent workability, and has a nonwoven fabric effect. By providing the flame-retardant fiber in the production, the flame-retardant treatment in the post-processing becomes unnecessary, and it is economical and provides a new interior material that has never been seen before.

In Example 5, the first layer (surface layer) was composed of 100 parts by weight of a core-in-sheath type composite fiber staple (fineness: 2 denier, fiber length: 51 mm) containing low melting point polyethylene terephthalate as a sheath component and thermoplastic polyethylene as a core component. The second layer (back layer) is 90 parts by weight of rayon staple (1.5 denier fineness, fiber length 40 mm), a sheath component of low melting point polyethylene terephthalate, and a core component of thermoplastic polyethylene as a core component. A staple (2 denier fineness, 51 mm fiber length) was mixed at a rate of 10 parts by weight to form a card web, and the two card webs were superimposed at a total weight of 80 g / m ² and punched by water pressure. To produce a non-woven fabric having a thickness of 0.7 mm. Next, the same embossing as in the first embodiment is performed.

As a result, in the interior material of Example 5, since the thermoplastic polyethylene having a relatively low specific gravity remains in the form of fibers, the voluminous feel is increased even if the nonwoven fabric has the same texture. Also,
It has a film effect, does not have the luster of a cold feeling like vinyl wallpaper, has antifouling performance, and has excellent workability.

In Example 6, a core-in-sheath type composite fiber staple (fineness: 90 parts by weight of rayon staple (1.5 denier fineness, fiber length: 40 mm), low-melting-point polyethylene terephthalate as a sheath component, and thermoplastic polyethylene as a core component) was used. 2 denier, fiber length 51 mm) was mixed at a ratio of 10 parts by weight, and a card web having a basis weight of 80 g / m ² was punched by a water flow pressure to produce a nonwoven fabric having a thickness of 0.7 mm.
Next, the same embossing as in the first embodiment is performed.

As a result, the interior material of Example 6 has a rayon stable that does not melt on the surface, so that the interior material has a warm, soft touch and a fabric-like texture with an appropriate elasticity. In addition, there is a film effect,
It is a new interior material that has never been seen before, without the cool gloss of vinyl wallpaper, antifouling performance, and excellent workability.

In Example 7, the first layer (surface layer) was made of rayon staple (denier 1.5 denier, fiber length 40 mm).
90 parts by weight, a sheath-core composite fiber staple (a fineness of 2 denier, a fiber length of 51 mm) having low melting point polyethylene terephthalate as a sheath component and thermoplastic polyethylene as a core component 1
The card web was mixed at a ratio of 0 parts by weight, the second layer (back layer) was 50 parts by weight of rayon staple (1.5 denier fineness, fiber length of 40 mm), a sheath component of low melting point polyethylene terephthalate, thermoplastic polyethylene. And a core-sheath composite fiber staple (denier: 2 denier, fiber length: 51 mm) having a core component of 50% by weight, and the total weight per unit area of these two card webs is 80 g / m ² . At the same time, a nonwoven fabric having a thickness of 0.7 mm is produced by punching with a water pressure. Next, Example 1
The same embossing is performed.

As a result, the interior material of Example 7 has a rayon stable that does not melt on the surface, similar to the interior material of Example 6, so that a warm, soft touch and a fabric-like texture with an appropriate elasticity are obtained. It has a finished finish. Furthermore, since the interior material of this example contains a relatively large amount of heat-fused fibers in the back layer, it has good form stability and moderate rigidity. In addition, it has a film effect, does not have the luster of a cold feeling like a vinyl wallpaper, has antifouling performance, and is excellent in workability.

In Comparative Example 1, the nonwoven fabric of Example 1 was replaced with
The same processing as in Example 1 is performed using a nonwoven fabric in which the raw material is made of high-melting-point polyethylene terephthalate staple or thermoplastic polypropylene 100%. The interior material of Comparative Example 1 has a blurred embossed pattern and is a product with poor workability.

In Comparative Example 2, the nonwoven fabric of Example 1 was replaced with
The same processing as in Example 1 is performed using a nonwoven fabric in which the raw material is 100% core-sheath type composite fiber staple (core component: high melting point polyethylene terephthalate / sheath component: low melting point polyethylene terephthalate). The interior material of Comparative Example 2 has an embossed pattern, but has a poor concealing property, and is very hard and has poor workability.

In Comparative Example 3, the nonwoven fabric of Example 1 was replaced with
The same processing as in Example 1 is performed using a nonwoven fabric in which the raw material is a core-sheath type composite fiber staple (core component: high-melting-point polyethylene terephthalate / sheath component: low-melting-point polyethylene terephthalate) of 10 to 90% and high-melting-point polyethylene terephthalate of 90 to 10%. . The interior material of Comparative Example 3 has an embossed pattern but is very hard and has poor workability.

In Comparative Example 4, the nonwoven fabric of Example 1 was replaced with
The same processing as in Example 1 is performed using a nonwoven fabric in which the raw material is 100% cellulose fiber staple. The interior material of Comparative Example 4 has a shallow and fuzzy embossed pattern, is extremely fuzzy, and has poor printability and workability.

In Comparative Example 5, the nonwoven fabric of Example 1 was replaced with
Raw materials are core-sheath type composite fiber staples (core component: high melting point polyethylene / sheath component: low melting point polyethylene terephthalate) 10 to 90%, thermoplastic polypropylene 90 to 10
%, The same processing as in Example 1 is performed. Comparative Example 5
The interior material has an embossed pattern, but has poor printability and poor workability.

With respect to the interior materials of Examples 1 to 7 and Comparative Examples 1 to 5, the embossed pattern on the surface of the obtained interior material was obtained.
The printability and workability were evaluated by visual observation and construction work according to the following criteria, and the results are shown in Table 1. ：: The gap between the irregularities is clear, the fiber does not come out of the surface,
The print is not blurred, the cutter is well cut, the surface does not come loose even with a roller or brush, and the joint does not open. ○ ': The gap between the irregularities is clear and has a woven texture.
The print is not blurred, the cutter is well cut, the surface does not come loose even with a roller or brush, and the joint does not open. Δ: The unevenness is clear, but the fibers come out of the surface, the printing is blurred, the cutter is poorly cut, and the workability is poor. ×: The gap between the irregularities is not clear, the fiber comes out of the surface, the printing is blurred, the cutter is poorly cut, and the surface is loosened and loses shape when a roller or a brush is applied, and the joint is opened.

[0093]

[Table 1]

[0094]

The interior material of the present invention is processed from a nonwoven fabric mainly composed of cellulosic fibers and heat-sealing fibers, so that it does not generate toxic substances such as chlorine and dioxin during combustion. There is the warmth of fiber. During embossing, the heat-fused fibers (low-melting thermoplastic fibers) are completely melted, and the bonding strength between fibers such as cellulose fibers (high-melting thermoplastic fibers) is increased. Since the layer is formed, a matte texture is produced, the embossed pattern is clearly formed, and a film effect such as preventing fluffing and shape loss of the surface is produced.

When a core-sheath type composite fiber having a high melting point thermoplastic fiber as a core component and a low melting point thermoplastic fiber as a sheath component is used as the heat-fusible fiber, the low melting point thermoplastic fiber during embossing is used. Even when is completely melted, the high melting point thermoplastic fiber remains in a fiber form and is fused with the cellulosic fiber or the thermoplastic fiber for weaving, so that the bonding strength of the fiber is increased and the shape stability is more excellent.

By increasing the amount of the heat-fused fibers, the rigidity of the interior material is increased, so that the interior material can be constituted without the base paper for wallpaper, and the processing cost can be reduced.

Further, since non-woven fabrics having different material compositions can be used for the surface layer and the back surface layer, it is possible to produce an interior material having different characteristics for the surface layer and the back surface layer depending on the application.

[0098] By performing the printing or the decorative step performed by printing before embossing, an embossed pattern having a multicolored pattern is formed on the nonwoven fabric.
Since the film layer is formed on the surface, an interior material having a good emboss pattern and a film effect can be obtained.

Further, by performing the cosmetic process performed by spraying after the embossing process is performed, the cosmetic process is performed after the normal embossing process is formed. Therefore, the embossed pattern can be formed without disturbing the embossed pattern by the sprayed pigment. The interior material has a calm texture, such as Japanese-style clay walls and stones.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view of an interior material of the present invention.

FIG. 2 is a schematic perspective view of a core-sheath composite fiber.

[Explanation of symbols]

 Reference Signs List 1 embossed pattern 2 film layer 3 inner layer 4 base paper for wallpaper 5 core component 6 sheath component

────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] April 28, 1999

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Full text

[Correction method] Change

[Correction contents]

[Document Name] Statement

[Title of the Invention] Interior materials

[Claims]

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to interior materials for buildings, vehicles, railway vehicles and aircraft.

[0002]

2. Description of the Related Art Vinyl wallpaper is often used for interior materials (referred to as finishing materials, wallpaper, etc.) of buildings, railway vehicles, automobiles, and the like.

[0003] This vinyl wallpaper is obtained by adding a plasticizer, a filler, a stabilizer, a lubricant, a flame retardant, a foaming agent, titanium,
A coating method in which a mixture containing a diluent and a colorant (pigment) is coated on a base paper for wallpaper, and a calendering method in which a vinyl chloride resin film formed by extruding the above-described mixture by extrusion molding is bonded to the base paper for wallpaper. Thereby, a sheet material having a two-layer structure of the wallpaper and the mixed material is formed,
A predetermined pattern is printed and printed on the mixture material side surface of the sheet material, then passed through a preheating roll, further heated and softened by a heater, and heated and pressed with an embossing roll while foaming to form an emboss (irregularity) on the mixture material surface. ) It is manufactured by forming a pattern.

[0004] This vinyl wallpaper has been widely used as an interior material because it has little unevenness on the surface, is easily processed by embossing, printing, printing, and the like, and can be manufactured at low cost.

However, vinyl wallpaper is mainly made of vinyl chloride resin containing chlorine atoms, so that toxic gases such as chlorine and dioxins may be synthesized during incineration, which deteriorates the environment in waste treatment. There's a problem. Further, those which generate toxic gas at the time of combustion as described above at the time of fire occurrence are not suitable as interior materials.

[0006]

In order to provide an interior material that does not synthesize toxic substances during combustion, the interior material is manufactured from a fiber cloth (nonwoven fabric and felt) mainly composed of cellulosic fibers and heat-fused fibers. Have been tried to. When manufacturing interior materials using the above-mentioned cellulosic fibers and the like as raw materials, it is difficult to manufacture interior materials having appropriate texture and workability as interior materials, even when manufactured under conventional vinyl wallpaper processing conditions. .

An object of the present invention is to solve the problems of interior materials using the above-mentioned cellulosic fiber or the like as a raw material.

[0008]

The interior material of the present invention has a high melting point.
Point heat-fused fiber sheath component as core component, low melting point heat-fused fiber sheath component
Surface of a card web of 100% core-sheath composite fiber
Layer, a mixed fabric of cellulosic fibers and thermoplastic fibers.
Material on the back of non-woven fabric or felt with
Adhere the paper and apply it above the melting point of the low melting
In addition to the temperature at which the cellulose and thermoplastic fibers do not denature,
Pressing the heated emboss roller to form an emboss pattern
And the surface thereof is melted by the low-melting heat-fused fiber.
Covered by the film layer formed
You.

The thermoplastic fiber of the inner layer is a core-sheath composite fiber
It is preferred that In addition, the mixing layer forming the inner layer
The mixing ratio of the heat-fusible fiber in Ebb is 5 to 30%.
Preferably.

[0010] After the embossed pattern is formed, the surface of the nonwoven fabric or felt may be printed or subjected to decorative processing by printing. In addition, the embossed pattern on the surface is obtained by heating an embossed roller having a depth of 0.1 to 0.8 mm on the surface of a nonwoven fabric or felt to a temperature of 135 to 250 ° C., and increasing the total pressure to 4000 to 25000 kg. It is preferable to set and press-contact at a speed of 10 to 50 m / min. Further, the basis weight of the nonwoven fabric or felt as an intermediate product is 25 to 150 g / m ² ,
The thickness is preferably 0.2 to 5 mm.

[0011]

Embodiments of the present invention will be described below.

The interior material of the present invention is a core-sheath type composite fiber 100
% Is used as a surface layer, a base paper for wallpaper is adhered to the back surface of a multi-layer nonwoven fabric having a mixed web of cellulosic fibers and thermoplastic fibers as an inner layer, and embossed on the surface. .

That is, in the interior material of the present invention, as shown in FIG. 1, an embossed pattern (1) composed of irregularities is formed on the surface, and the film layer (2a) is formed by melting and melting the low melting point heat-fusible fiber from the surface side. ), A surface layer (2) in which a low-melting-point heat-fusible fiber of a sheath component is heat-fused between the high-melting-point heat-fusible fibers of a core component remaining as a fiber form, and a thermoplastic fiber being melt-bonded to a cellulose fiber or the like. It has a cross-sectional structure of an inner layer portion (3) and a base paper for wallpaper (4) adhered to the back surface.

[0014] The surface of the interior material may be subjected to a flame-retardant treatment or a cosmetic treatment. The interior material of the present invention is cut into a predetermined shape by a cutter or the like, and is installed on a wall surface or a ceiling of a building, a railway vehicle, or the like, similarly to a conventional interior material.

As the cellulosic fibers, cellulosic regenerated fibers such as rayon and cellulosic semisynthetic fibers such as acetate are used. The cellulosic fiber improves cutter cutting in construction and does not synthesize toxic substances during incineration.

The heat fusible fibers are thermoplastic synthetic fibers (excluding fibers that synthesize toxic substances such as chlorine and dioxin during combustion), and have a function of melting by embossing to increase the bonding force between the fibers. In addition, a film layer is formed on the surface during embossing to maintain an embossed pattern, suppress fluffing on the surface, and make the shape less likely to collapse.
Such a heat-fused fiber has a melting point of 110 to 135 ° C.
It is preferable to use low-melting thermoplastic synthetic fibers (excluding fibers that synthesize toxic substances when burned).

The heat-fused fiber may have a low melting point as a whole, but as shown in FIG. 2, it has a high melting point thermoplastic synthetic fiber as a core component (5) and a low melting point as a sheath component (6). It is preferable to use a core-sheath composite fiber having a thermoplastic synthetic fiber having a melting point. When this core-sheath type composite fiber is used, even if the sheath portion is melted and melted by embossing, the fiber form of the core component remains in addition to the cellulose fiber, so that the interior material surface can have an appropriate texture. . As the core-sheath type composite fiber, for example, the melting point is 255 to 260 ° C. as a core component.
(Hereinafter, referred to as high-melting-point polyethylene terephthalate) or thermoplastic polyethylene having a melting point of 125 to 135 ° C (hereinafter, referred to as thermoplastic polyethylene), and a melting point of 110 to 135 as a sheath component. One having thermoplastic polyethylene terephthalate having a temperature of ° C. (hereinafter, referred to as low melting point polyethylene terephthalate) may be used.

The core component is a thermoplastic polyethylene (specific gravity:
The core-sheath type composite fiber using 0.94 g / cm ² )
High melting point polyethylene terephthalate (specific gravity:
1.38 g / cm ² ), the specific gravity of the core component is lighter, resulting in a bulky material after embossing.

Further, when producing a nonwoven fabric or felt, thermoplastic synthetic fibers for knitting and weaving made of ordinary organic fibers are mixed in a mixed web or a multilayer web of cellulosic fibers and heat-fusible fibers. good. The thermoplastic synthetic fiber for weaving is made of high melting point polyethylene terephthalate and has a melting point of 1.
Thermoplastic polypropylene having a temperature of 65 to 173 ° C, thermoplastic polyethylene, flame-retardant polyethylene terephthalate, or the like is mixed in the web at a ratio of 5 to 50%. Further, as the heat-fusible fibers, those having a lower melting point than the thermoplastic fibers for weaving are used. Thereby, after the embossing, the cellulosic fiber, (the core component of the heat-fusible fiber), and the thermoplastic synthetic fiber for weaving remain in the form of fibers, so that the interior material surface can have an appropriate texture.

The amount of the heat-fused fiber is set in the range of 5 to 90%. If the amount of the heat-fused fiber is too small, the strength of the embossed pattern becomes insufficient and the shape tends to collapse.
The strength is increased, and the workability such as cutting of the cutter deteriorates. In particular, by setting the proportion of the heat-fusible fibers to 5 to 30%, it is possible to finish the fabric like a fabric. When used as a finishing material for buildings, ceilings, etc., it is preferable to increase the proportion of the heat-fused fibers in order to impart rigidity.

In this case, a web composed of a combination of two types of fibers, ie, a cellulosic fiber and a heat-fusible fiber (core component: high-melting-point polyethylene terephthalate / sheath component: low-melting-point polyethylene terephthalate); It is appropriate to use a web formed by combining three types of fibers of terephthalate and heat-fused fibers (core component: high melting point polyethylene terephthalate or thermoplastic polyethylene / sheath component: low melting point polyethylene terephthalate).

It is preferable that the fibrous material itself has chemical resistance, fungicide, germ resistance and non-allergenicity, and is non-toxic and safe. The above-mentioned fiber materials do not generate toxic gases such as chlorine gas and dioxin during combustion. The nonwoven fabric or felt is formed from a single-layered web obtained by mixing the above-mentioned cellulosic fiber and the heat-sealing fiber, or a laminated multilayered web, or a web obtained by mixing these with thermoplastic synthetic fibers for weaving. . Before the nonwoven fabric or felt manufacturing process, a card web system in which short fibers are aligned in one direction by a card machine is particularly preferable. This is because, in the card web system, the fibers are arranged in one direction, so that blurring during printing is small. The above-mentioned web is manufactured by other methods such as a spunbond web system made by laminating long fibers obtained by spinning a dissolved resin, or a wet web system in which fibers and pulp are dispersed in water and scooped by a wire mesh. But it is good.

As a method of combining the constituent fibers of the web into a nonwoven fabric, a fluid punch method (spunlace method) using a water flow is particularly preferable. This is because the spunlace method involves entanglement of web fibers in one direction by the pressure of a water stream, so that the surface is less fuzzy and has good printability. In addition, spun bond nonwoven fabric, wet nonwoven fabric, thermal nonwoven fabric, needle ring nonwoven fabric, dry nonwoven fabric, dry pulp nonwoven fabric, melt blown nonwoven fabric, flash spun nonwoven fabric, air laid nonwoven fabric, binder bonding method and the like can also be used.

A nonwoven fabric or a felt having heat-fusible fibers may be superimposed on the back surface of the above nonwoven fabric, and the surface may be embossed. Thereby, the material composition of the interior material can be changed between the surface layer and the back layer, and the surface layer is made of a nonwoven fabric suitable for surface formation in consideration of embossability, printability, texture, antifouling property, feel, etc. Felt), and a nonwoven fabric (felt) can be selected for the back layer (inner layer) in consideration of workability, economy, nonflammability, bulkiness, and the like.

Further, a non-woven fabric or a felt obtained by mixing a carbon-based material such as activated carbon, carbon fiber or ceramics may be used. In this case, the action of the carbon-based material can give the nonwoven fabric (felt) itself an action of removing and suppressing formaldehyde and the like.

The basis weight and thickness of the nonwoven fabric or felt are set according to the depth of the embossing roll and the application.

The basis weight of the nonwoven fabric or felt is 25 g /
If it is less than m ² , the embossed pattern will have poor three-dimensional appearance,
It exceeds 0 g / m ² is too increased strength, construction adaptability, processing suitability upper deteriorates, so uneconomical bulge material costs, but is set to 25 to 150 g / m ^2, in particular 55
It is desirably 〜80 g / m ² . When the thickness of the nonwoven fabric or felt is less than 0.2 mm, the unevenness does not clearly appear, and when it exceeds 5 mm, the difference in the unevenness is too large, and it becomes difficult to remove dirt from the concave portion. 5m
m, but particularly preferably 0.3 to 0.8 mm.

The nonwoven fabric or felt formed as described above has a base paper for wallpaper (plain paper, new year's holiday, aluminum hydroxide paper, etc.) attached to the back surface. For sticking, a starch-based adhesive is used so that no toxic substance is generated even when incinerated.
By applying the base paper for wallpaper, the suitability for construction is improved,
It is an interior material suitable as a finishing material for buildings and ceilings.

The surface of the non-woven fabric or felt may be solid or flame-retardant, water-repellent, stain-proof,
Surface treatments such as mold prevention, antibacterial, and makeup are applied. These may be provided in the material at the raw cotton stage.

As the flame retardant, guanidine sulfamate, guanidine phosphate, antimony trioxide, zirconium hydroxide, barium metaborate, aluminum hydroxide, magnesium hydroxide, etc., which do not synthesize toxic substances during combustion are preferable. When used as a finishing material for buildings, ceilings, etc., it is possible to obtain a second-class fire protection certification set by the Ministry of Construction without applying a flame retardant by attaching a flame retardant paper to the back surface.

The addition amount of the flame retardant is preferably 10 to 40% of the finishing material such as a building or a ceiling. Particularly, it is preferably from 15 to 30%, and if it is less than 10%, the flame retardant effect is insufficient, and if it exceeds 40%, it becomes uneconomical.

The makeup process is performed by printing, printing, dyeing, and spraying.

In the case of printing and printing, it is preferable to perform the printing before the embossing step. This is because if you print or print after the embossing process, the embossed pattern will lose its shape,
This is because the product value may be lost. However, depending on the printing pattern (printing pattern), embossing after printing (printing) may cause print spots or print spots to be noticeable. In this case, printing or printing is particularly performed after embossing.

In the case of spraying, it is preferable to carry out after the embossing step. This is because if spraying is performed before the embossing step, the particles of the pigment or the like contained in the spray coating agent are large and hard, so that the grooves of the engraving embossing roll may be clogged, which may cause inconvenience in production. In the case of spray coating, if necessary, a water repellent, a fungicide, an antifouling agent, etc. may be added to the coating solution to simultaneously perform a surface treatment such as water repellency, antifungal, and antifouling. Can be.

The embossing process for forming the pattern on the surface of the interior material uses a hot embossing machine conventionally used for producing paper and some nonwoven fabrics, woven fabrics, leather products and the like. The conditions of the embossing machine used in the present invention are shown below.

The embossing machine is provided with an embossing roll having an engraving of a predetermined pattern on the surface, and presses the embossing roll heated to a predetermined temperature on a nonwoven fabric or the like to form a pattern corresponding to the embossing roll pattern on the surface of the nonwoven fabric. Is what you do.

The depth of the embossing roll is changed depending on the pattern or pattern. This is usually set in the range of 0.1 to 0.8 mm, because if you set a deep depth to a sharp pattern or pattern, there is a possibility of strikethrough or tearing of the material,
In particular, it is preferably 0.3 to 0.6 mm in order to form a stable embossed pattern and to give the pattern a sense of volume.

In embossing, an embossing roller heated to a temperature of 135 to 250 ° C. is pressed at a total pressure of 4000 to 250 °.
It is carried out at a processing speed of 10 to 50 m / min while being pressed against the surface of the nonwoven fabric or felt at 00 kg.

At this time, the temperature of the embossing roll was 135
When the temperature is lower than 250 ° C., the melting effect is small and the shape tends to collapse. When the temperature exceeds 250 ° C., the cellulosic fiber reaches the carbonization point and the surface starts to burn. 190 to 220 to sufficiently melt and melt the attached fiber and to improve the processing efficiency.
It is preferable to set to ° C. If the pressure of the embossing roll is less than 4000 kg, moderate unevenness cannot be formed, and if it exceeds 25,000 kg, the unevenness becomes unnecessarily large and the concealment property deteriorates.
In particular, the weight is preferably 12,000 to 19000 kg in order to efficiently form a good embossed pattern. If the processing speed is less than 10 m / min, it is uneconomical, and if it exceeds 50 m / min, a good embossed pattern cannot be obtained. Therefore, the processing speed is set to 10 to 50 m / min.
10-2 to efficiently form a good embossed pattern
It is preferably 0 m / min.

The interior material of the first embodiment (hereinafter referred to as interior material) will be described.

The method for producing the interior material is as follows.

First, a core-sheath type conjugate fiber using a high melting point polyethylene terephthalate fiber having a melting point of 255 to 260 ° C. as a core component and a low melting point polyethylene terephthalate fiber having a melting point of 110 to 135 ° C. as a sheath component ( The first web made of 100% of the heat-fused fiber) was used as the surface, and the second web was mixed with 10 to 100% of the cellulosic fiber and 90 to 0% of the same core-sheath type composite fiber (heat-fused fiber) as described above. With the web as the back side, two card webs are overlapped and punched with water pressure, and the basis weight is 25 to 150 g / m ² ,
A two-layer spunlace nonwoven fabric having a thickness of 0.2 to 5 mm is produced. (A felt may be used instead of the nonwoven fabric.) A starch-based adhesive is applied to the back surface of the nonwoven fabric (felt), and the base paper for wallpaper is bonded.

Next, as the surface treatment of the nonwoven fabric (felt), the printing, the printing, and the weight of the nonwoven fabric are 10 to 10%.
Apply 40% flame retardant (if necessary, anti-mold, anti-fouling,
Apply water repellency. ).

Finally, the temperature of the embossing roll engraved to a depth of 0.1 to 0.8 mm is set to 135 to 250 ° C., and the total pressure is set to 4000 to 25000 kg, and 10 to 50 m
Embossing is performed at a processing speed of / min, and an emboss pattern is formed on the surface of the nonwoven fabric (felt).

By embossing, the low-melting polyethylene terephthalate of the core-sheath type conjugate fiber is melted and melted (heat-fused) to form a film layer on the surface.
The bonding force between the cellulose fiber remaining as a fiber form and the high melting point polyethylene terephthalate fiber is improved. The resulting interior material is non-woven (felt)
A film effect is obtained on the surface, and an embossed pattern having a thickness of 0.1 to 0.8 mm is finished with a glossless texture and has good form stability. Further, the interior material is excellent in flame retardancy (anti-mold, anti-soil, water-repellent) performance in the surface treatment.

Next, the interior material of the second embodiment (hereinafter referred to as interior material) will be described.

For the interior material, a starch-based adhesive was applied to the same nonwoven fabric (felt) as the interior material, the base paper for the wallpaper was adhered, and the temperature of the embossing roll engraved to a depth of 0.1 to 0.8 mm was 135 to 135 mm. 250 ° C, total pressure 4000 ~ 2
The embossing is performed at a processing speed of 10 to 50 m / min while setting to 5000 kg. Next, as a cosmetic process, a solution in which a pigment and a flame retardant are mixed (a water repellent,
A fungicide, an antifouling agent and the like can be mixed. ) Is spray-painted on the surface. The interior materials are Japanese-style earthen walls,
Finishing materials such as calm buildings and ceiling materials with a stone-like texture can be obtained.

Next, the interior material of Embodiment 3 (hereinafter referred to as interior material) will be described.

The interior material uses a thermoplastic polyethylene fiber having a melting point of 125 to 135 ° C. as a core component and a melting point of 110 ° C.
A first web composed of 100% of a core-in-sheath composite fiber (heat-fused fiber) using a low-melting polyethylene terephthalate fiber having a melting point of up to 135 ° C. as a sheath component is used as a surface, and the cellulosic fiber 10
100% and the same core-sheath type composite fiber as above (heat-bonded fiber)
The second web mixed at a ratio of 90 to 0% as a back surface,
A two-layer spunlaced nonwoven fabric (felt) is produced by superimposing two card webs and punching with water pressure to produce a nonwoven fabric (felt) having the same structure as that of the first embodiment. The interior material is formed by melting and melting (thermal fusion) the low-melting point polyethylene terephthalate of the core-sheath composite fibers by embossing to form a film layer on the surface, and the cellulosic fibers and the high melting point remaining in the fiber form. This is an improvement in the bonding strength between polyethylene fibers. As the interior material, thermoplastic polyethylene with a lower specific gravity remains in fiber form compared to high melting point polyethylene,
Even if the basis weight is smaller than the interior material, the thickness can be obtained.

Next, the interior material of Embodiment 4 (hereinafter referred to as interior material) will be described.

For the interior material, the same processing steps as in the second embodiment are performed on the same nonwoven fabric (felt) as the interior material. As for interior materials, similar to interior materials, finishing materials such as Japanese-style earthen walls, stone-textured calm buildings, ceiling materials, etc. can be obtained. Is obtained.

Next, the interior material of the fifth embodiment (hereinafter referred to as interior material) will be described.

The interior material uses a high melting point polyethylene terephthalate fiber having a melting point of 255 to 260 ° C. as a core component,
Mixing of a spun-pound process or a wet process nonwoven fabric composed of 100% of a core-in-sheath type conjugate fiber using a low melting point polyethylene terephthalate fiber having a melting point of 110 to 135 ° C. as a sheath component, with a cellulosic fiber and a heat-fusible fiber A synthetic nonwoven fabric bonded to the surface of a spunlace nonwoven fabric produced from a web or a multilayer web by subjecting it to water punching, needle punching, lamination or the like is produced, and then the same processing steps as in the first or second embodiment are performed.

The resulting interior material has a heat-fusible fiber film layer formed on the surface, has an appropriate texture for the intended use as the interior material, and has a nonwoven fabric on the back surface with the volume feeling and heat characteristic of spunlace. This provides an appropriate rigidity due to the fusion.

In the interior material of the fifth embodiment, the rigidity and voluminousness of the interior material can be changed by changing the fiber structure and the manufacturing method of the nonwoven fabric to be laminated on the back surface. In this embodiment, a spunlace nonwoven fabric is used for the back surface, and a nonwoven fabric obtained by another manufacturing method is used for the front surface. However, the present invention is not limited to this, and the nonwoven fabric can be freely combined. For example, surface, interior,
It is also possible to combine different nonwoven fabrics on the back surface.

Hereinafter, examples of the interior material according to the present invention will be shown and compared with interior materials not according to the present invention.

In Example 1, the first layer (surface layer) was composed of a core-sheath type composite fiber staple (a fineness of 2 denier and a fiber length of 51 mm) having a low melting point polyethylene terephthalate as a sheath component and a high melting point polyethylene terephthalate as a core component. Part of the card web, the second layer (back layer) is 90 parts by weight of rayon table (1.5 denier fineness, fiber length 40 mm), low melting point polyethylene terephthalate is a sheath component, and high melting point polyethylene terephthalate is a core component. Core-sheath type composite fiber staple (fineness 2 denier, fiber length 5
1 mm) in a ratio of 10 parts by weight to obtain a card web, and these two card webs are weighed at a total weight of 80 g / m ^2.
To form a double-layered web, which is then punched with a water pressure to produce a nonwoven fabric having a thickness of 0.7 mm.

Next, a modified vinyl acetate copolymer adhesive is applied at a weight force of 20 g / m ^2, to bond the flame燃紙for wallpaper basis weight 120 g / m ^2. Next, a multicolored pattern is printed, and a flame retardant, a fluorine-based water-repellent and stain-proofing agent 20 g / m ²
It was applied at the applied amount. After drying it, the depth is 0.5m
m embossing roll having a lattice pattern sculpture at a temperature of 2
30 ° C, total pressure 16000kg, rotation speed 20m /
Perform embossing by setting to minutes.

Thus, the interior material of Example 1 has a film effect, does not have the luster of a cold feeling like vinyl wallpaper, has antifouling performance, and has excellent workability. Material.

In Example 2, a nonwoven fabric similar to that of Example 1 is produced.

Next, a modified vinyl acetate copolymer adhesive is applied at a weight force of 20 g / m ^2, to bond the flame燃紙for wallpaper basis weight 120 g / m ^2. After drying, embossing is performed on the embossing roll having a grid pattern engraving with a depth of 0.5 mm at a temperature of 230 ° C., a total pressure of 16,000 kg, and a rotation speed of 20 m / min. next,
Spray painting is carried out with a spraying agent containing a multicolored inorganic pigment and a mixture of a flame retardant and a water repellent.

As a result, the interior material of Example 2 is a new interior material that is calm and has a voluminous feel in the style of Japanese mud wall.

In Example 3, the first layer (surface layer) was a core-sheath type composite fiber staple (a fineness of 2 denier, a fiber length of 51 mm) having a low-melting-point polyethylene terephthalate as a sheath component and a high-melting-point polyethylene terephthalate as a core component. Part of the card web, the second layer (back side layer) is 80 parts by weight of rayon staple (1.5 denier fineness, fiber length 40 mm) and 20 parts by weight of flame-retardant polyethylene terephthalate (2 denier fineness, 51 mm fiber length) , And the two card webs are superposed at a total basis weight of 80 g / m ² to form a two-layer structure, which is subjected to punching with water pressure to produce a nonwoven fabric having a thickness of 0.7 mm.

Next, a modified vinyl acetate copolymer adhesive is applied at a weight force of 20 g / m ^2, to bond the flame燃紙for wallpaper basis weight 120 g / m ^2. Next, a multicolored pattern is printed, and a fluorine-based water-repellent antifouling agent is applied in an amount of 20 g / m ² . After drying this, an embossing roll having a grid pattern engraving with a depth of 0.5 mm was heated at a temperature of 230 ° C.
Embossing is performed at a total pressure of 16000 kg and a rotation speed of 20 m / min.

As a result, the interior material of Example 3 has a film effect, but does not have a cool gloss like vinyl wallpaper, has an antifouling property, is excellent in workability, and has a nonwoven fabric effect. By providing the flame-retardant fiber in the production, the flame-retardant treatment in the post-processing becomes unnecessary, and it is economical and provides a new interior material that has never been seen before.

In Example 4, the first layer (surface layer) was a core-sheath type composite fiber staple (a fineness of 2 denier, a fiber length of 51 mm) having a low melting point polyethylene terephthalate as a sheath component and a high melting point polyethylene terephthalate as a core component. Part of the card web, the second layer (back layer) is 70 parts by weight of rayon staple (1.5 denier fineness, fiber length 40 mm), 20 parts by weight of flame retardant rayon, sheath component of low melting point polyethylene terephthalate, high A card web was prepared by mixing core-sheath composite fiber staples having a melting point of polyethylene terephthalate as a core component (fineness: 2 denier, fiber length: 51 mm) at a ratio of 10 parts by weight, and these two card webs were weighed at 80 g / m ^2. To form a two-layer card web, which is punched with water pressure to a thickness of 0.7 m. Make the non-woven fabric. Next, the same embossing as in the third embodiment is performed.

Thus, although the interior material of Example 4 has a film effect, it does not have the cool gloss of vinyl wallpaper, has an antifouling property, has excellent workability, and has a nonwoven fabric effect. By providing the flame-retardant fiber in the production, the flame-retardant treatment in the post-processing becomes unnecessary, and it is economical and provides a new interior material that has never been seen before.

In Example 5, the first layer (surface layer) was 100 parts by weight of a core-in-sheath type composite fiber staple (fineness: 2 denier, fiber length: 51 mm) using low melting point polyethylene terephthalate as a sheath component and thermoplastic polyethylene as a core component. The second layer (back layer) is 90 parts by weight of rayon staple (1.5 denier fineness, fiber length 40 mm), a sheath component of low melting point polyethylene terephthalate, and a core component of thermoplastic polyethylene as a core component. A staple (2 denier fineness, 51 mm fiber length) was mixed at a rate of 10 parts by weight to form a card web, and the two card webs were superimposed at a total weight of 80 g / m ² and punched by water pressure. To produce a non-woven fabric having a thickness of 0.7 mm. Next, the same embossing as in the first embodiment is performed.

As a result, in the interior material of Example 5, since the thermoplastic polyethylene having a relatively low specific gravity remains in the form of fibers, the volume is increased even if the nonwoven fabric has the same texture. Also,
It has a film effect, does not have the luster of a cold feeling like vinyl wallpaper, has antifouling performance, and has excellent workability.

In Comparative Example 1, the nonwoven fabric of Example 1 was replaced with
The same processing as in Example 1 is performed using a nonwoven fabric in which the raw material is made of high-melting-point polyethylene terephthalate staple or thermoplastic polypropylene 100%. The interior material of Comparative Example 1 has a blurred embossed pattern and is a product with poor workability.

In Comparative Example 2, the nonwoven fabric of Example 1 was replaced with
The same processing as in Example 1 is performed using a nonwoven fabric in which the raw material is 100% core-sheath type composite fiber staple (core component: high melting point polyethylene terephthalate / sheath component: low melting point polyethylene terephthalate). The interior material of Comparative Example 2 has an embossed pattern, but has a poor concealing property, and is very hard and has poor workability.

In Comparative Example 3, the nonwoven fabric of Example 1 was replaced with
The same processing as in Example 1 is performed using a nonwoven fabric in which the raw material is a core-sheath type composite fiber staple (core component: high-melting-point polyethylene terephthalate / sheath component: low-melting-point polyethylene terephthalate) of 10 to 90% and high-melting-point polyethylene terephthalate of 90 to 10%. . The interior material of Comparative Example 3 has an embossed pattern but is very hard and has poor workability.

In Comparative Example 4, the nonwoven fabric of Example 1 was replaced with
The same processing as in Example 1 is performed using a nonwoven fabric in which the raw material is 100% cellulose fiber staple. The interior material of Comparative Example 4 has a shallow and fuzzy embossed pattern, is extremely fuzzy, and has poor printability and workability.

In Comparative Example 5, the nonwoven fabric of Example 1 was replaced with
Raw materials are core-sheath type composite fiber staples (core component: high melting point polyethylene / sheath component: low melting point polyethylene terephthalate) 10 to 90%, thermoplastic polypropylene 90 to 10
%, The same processing as in Example 1 is performed. Comparative Example 5
The interior material has an embossed pattern, but has poor printability and poor workability.

With respect to the interior materials of Examples 1 to 5 and Comparative Examples 1 to 5, an embossed pattern on the surface of the obtained interior material was obtained.
The printability and workability were evaluated by visual observation and construction work according to the following criteria, and the results are shown in Table 1. ：: The gap between the irregularities is clear, the fiber does not come out of the surface,
The print is not blurred, the cutter is well cut, the surface does not come loose even with a roller or brush, and the joint does not open. Δ: The unevenness is clear, but the fibers come out of the surface, the printing is blurred, the cutter is poorly cut, and the workability is poor. ×: The gap between the irregularities is not clear, the fiber comes out of the surface, the printing is blurred, the cutter is poorly cut, and the surface is loosened and loses shape when a roller or a brush is applied, and the joint is opened.

[0076]

[Table 1]

[0077]

The interior material of the present invention has a high melting point
Core-in-sheath composite using low-melting heat-sealed fiber for the sheathing fiber and sheath component
The surface of a card web made of 100% fiber
A mixed web of base fiber and thermoplastic fiber.
Adhere wallpaper to the back side of the non-woven fabric to be
Boss processing is applied.

This interior material has a low melting point heat-fusible fiber on the surface.
Excellent morphological stability because it is covered with a melting film layer
And fuzz on the surface can be prevented. Also the inner layer
Since the cellulosic fiber is included in the
Good crispness and excellent workability. In addition, surface layer and inside
Cell in which low-melting heat-fused fibers remain in fiber form in the layer
Heat fusion between each fiber of loin fiber and high melting point heat fusion fiber
Therefore, the shape can be prevented.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view of an interior material of the present invention.

FIG. 2 is a schematic perspective view of a core-sheath composite fiber.

[Description of Signs] 1 Embossed pattern 2a Film layer 2 Surface layer 3 Inner layer 4 Base paper for wallpaper 5 Core component 6 Sheath component

[Procedure amendment 2]

[Document name to be amended] Drawing

[Correction target item name] Fig. 1

[Correction method] Change

[Correction contents]

FIG.

Claims (13)

[Claims] 1. A nonwoven fabric or felt made of a mixed fiber web of cellulosic fibers and heat-fusible fibers, or a multi-layered web in which cellulosic fibers and heat-fusible fibers are laminated. The embossed roller is heated at a temperature not lower than the melting point of the bonded fiber and heated to a temperature at which the cellulosic fiber and the heat-fused fiber do not denature to form an embossed pattern, and is formed by fusion-bonding the heat-fused fiber to the surface. Interior material having a film layer. 2. The heat-sealing fiber according to claim 1, wherein said heat-fusible fiber is a core-sheath type composite fiber having a high-melting heat-fusing fiber in a core and a low-melting heat-fusing fiber in a sheath. The embossing roller is heated to a temperature not lower than the melting point of the low-melting heat-fused fiber of the sheath portion and at which the cellulosic fiber and the heat-fused fiber are not denatured to form an embossed pattern, and
An interior material having a film layer formed on its surface by fusion-bonding heat-fusion fibers. 3. A nonwoven fabric or felt produced from a mixed fiber web of a cellulosic fiber, a thermoplastic fiber for weaving, and a heat-fusible fiber having a lower melting point than the thermoplastic fiber for weaving, The embossing roller is heated to a temperature not lower than the melting point of the coated fiber and at which the cellulosic fiber, the thermoplastic fiber for weaving and the heat-fusible fiber are denatured to form an embossed pattern, and the heat-fusible fiber is formed on the surface. An interior material having a film layer formed by fusion-bonding. 4. The core-sheath composite fiber according to claim 3, wherein the heat-fusible fiber is a core-sheath type composite fiber having a high-melting-point heat-fusible fiber in a core portion and a low-melting-point heat-fusible fiber in a sheath portion. The embossing roller is heated to a temperature not lower than the melting point of the low-melting heat-fused fiber in the sheath and to a temperature at which the cellulosic fibers, thermoplastic fibers for weaving and heat-fused fibers are not denatured. And an interior material having a film layer formed on the surface by fusion bonding of heat fusion fibers. 5. The interior material according to claim 1, wherein the nonwoven fabric or the felt is formed by laminating one or more nonwoven fabrics or felts produced by providing a heat-sealing fiber on the surface of the nonwoven fabric or the felt. Non-woven fabric or felt, which is subjected to embossing with fusion of heat-fusible fibers on the surface, thereby fusing the laminated non-woven fabric or felt, forming an embossed pattern on the surface, and applying heat to the surface. An interior material having a film layer formed by fusion bonding of fusion fibers. 6. The interior material according to claim 1, wherein the nonwoven fabric or the felt is provided with a carbon-based material and embossed to thereby contain a carbon-based material therein. 7. The interior material according to claim 1, wherein a mixing ratio of the heat-fused fibers in the nonwoven fabric or felt forming the surface layer is 5 to 30%. 8. The interior material according to claim 1, wherein the surface of the nonwoven fabric or felt is printed or subjected to decorative processing by printing before the embossed pattern is formed. 9. The interior material according to claim 1, wherein after the embossed pattern is formed, the surface of the nonwoven fabric or felt is printed or subjected to decorative processing by printing. 10. The interior material according to claim 1, wherein after the embossed pattern is formed, the surface of the interior material is subjected to a makeup process by spray painting. 11. An interior material, wherein a base paper for paper is adhered to the back surface of the interior material according to claim 1. 12. The interior material according to claim 1, wherein the embossed pattern on the surface is a nonwoven fabric or a felt having an engraved roller having a depth of 0.1 to 0.8 mm formed on the surface of the felt. ° C, the total pressure is set to 4000-25000 kg, and 10-50
An interior material formed by pressing at a speed of m / min. 13. The interior material according to claim 1, wherein the non-woven fabric or felt as an intermediate product has a basis weight of 25.
An interior material characterized by having a thickness of 0.2 to 5 mm and a thickness of 150 to 150 g / m ² .