JP7001638B2 - Interior materials and their manufacturing methods - Google Patents

Description

The present invention relates to an interior material and a method for producing the same.

Conventionally, tufted carpets are often used as interior materials such as tile carpets, roll carpets, and wall coverings. On the other hand, interior materials that use woven fabric as the surface layer can form various patterns not only by changing the color but also by changing the structure, and therefore, unlike tufted carpet, they are elegant and elegant. You can express the texture. Therefore, interior materials using woven fabrics such as plain woven fabrics as the surface layer are often used.

Such interior materials are shown, for example, in Patent Documents 1 to 3. In the carpet of Patent Document 1, the warp and the weft are crossed, a convex portion is formed on the surface by one of the warp and the weft, and the molten yarn is mixed in one of the warp and the weft. In the carpet of Patent Document 2, one or both of the warp and weft is a core yarn composed of a core yarn and a sheath yarn having different melting points, and is heated at a temperature equal to or higher than the softening point of the sheath yarn and lower than the softening point of the core yarn. As a result, the warp and weft are heat-bonded. In the interior material of Patent Document 3, a part or all of the constituent yarns of the woven fabric or knitted fabric formed by plain weave are fixed to each other by a synthetic resin emulsion.

Japanese Unexamined Patent Publication No. 2000-28234 Japanese Unexamined Patent Publication No. 2005-245706 Japanese Unexamined Patent Publication No. 2005-60888

By the way, due to the nature of the woven fabric, "fraying" such as threads and piles is likely to occur from the cut edge. Therefore, in the interior material using woven fabric, the appearance and durability of the edge may be deteriorated. Note that FIG. 8 shows the fray 60. Fraying 60 occurs when the core yarn, which is a multifilament yarn of the coating yarn, is unraveled or falls off at the cut end surface of the woven fabric.

In order to prevent "fraying", carpets and the like using plain woven fabrics may be "overheaded" at the edges. However, the carpet that has been over-rimmed has a problem that the fibers at the ends are raised and the texture is distorted as it is used. Further, in order to prevent "fraying", a method of binding a backing material made of synthetic resin into a plain woven fabric to bond the plain woven fabric and the backing layer, or a method of binding the plain woven fabric and the backing layer with a hot melt resin or the like. Therefore, a method of fixing the fibers has been used, but it has not been sufficiently effective.

Further, in the carpets of Patent Documents 1 and 2, the morphology of the cut edge is stabilized by melting the warp or weft, but if the melting is insufficient, the edge or other parts may be melted. The morphology was not stable, and the appearance and durability of the carpet may deteriorate. On the other hand, when the heating temperature is raised in order to sufficiently melt the yarn, the surface of the woven fabric may undulate and a problem of "flare" may occur. Therefore, there is a problem that it is difficult to control the heating temperature for melting. Furthermore, since the yarn used must contain a molten component, there are restrictions on the types of yarn that can be used, which limits the strength, texture, durability, etc. of the yarn, resulting in color changes and texture. In some cases, the advantage of woven fabric, that various patterns can be constructed by changing, cannot be fully utilized.

Further, when a surface layer which is a woven fabric is provided on an interior material having a backing such as a tile carpet or a roll carpet, a "backing step" is required in which the surface layer and the backing layer are bonded together. In the "backing process", if the fibers of the woven fabric are not fixed or are not fixed sufficiently, the pattern of the woven fabric is distorted, which makes the production difficult. The interior material of Patent Document 3 attempts to solve this problem. In the invention of Patent Document 3, a part or all of the constituent yarns are fixed to each other by applying an adhesive made of a synthetic resin emulsion with a roll coater or a knife coater. When a backing layer is provided on a plain woven fabric to which wefts and warp threads are fixed, latex is applied to either or both of the backing layer and the back surface of a sheet-like material of the plain woven fabric, and the fabric is pressed by a press roll. , It is heated and dried in a heated oven to obtain an interior material having a backing layer on a surface layer made of a plain woven fabric. For this reason, if the coating amount is too small when a part or all of the constituent yarns are fixed to each other, the constituent yarns are not sufficiently fixed and may be displaced when pressed by the press roll. It becomes difficult to smoothly proceed with the "backing process", and in addition, a sufficient "fray" prevention effect may not be obtained. On the other hand, when the amount of the adhesive applied is too large, as shown in FIG. 7, the adhesive 400 constituting the adhesive layer leaks from the texture of the woven fabric 50 and is cured, that is, the adhesive. Since the cured product of 400 appears on the surface of the woven fabric 50, the appearance of the surface of the woven fabric 50 is deteriorated. Further, in the method of laminating the backing layer by the press roll, it is necessary to prevent the plain woven fabric from being displaced, distorted, or uneven at the time of pressing, and it is difficult to adjust the heat and pressure.

Further, when the backing layer is provided on the back surface of the woven fabric, it is necessary to bond the woven fabric and the backing layer after fixing the back surface of the woven fabric with a resin. Further, in the bonding step, there is a risk that the woven fabric may have problems such as wrinkles, flares, and distortions.

Further, in the conventional woven fabric 50, as shown in FIG. 9, the warp 51 and the weft 52 extending along the cut edge 501 are often not accurately parallel to the edge. In that case, in the vicinity of the cut edge 501, the straightness of the woven pattern made of the warp 51 is impaired. This state is called "bending".

It is an object of the present invention to provide an interior material in which the surface of the woven fabric does not look bad, and to provide a method for manufacturing such an interior material.

The first aspect of the present invention comprises a laminated body having a woven fabric on the backing layer at least via an adhesive layer.
The woven fabric is fixed by the adhesive layer and is fixed.
The woven fabric has a woven structure having warp and weft, and has a woven structure.
At least the warp is a coated yarn in which the core yarn is coated with a coating material containing vinyl chloride resin as a main component.
The woven fabric has a cut edge and has a cut edge.
The cut edge is formed at least substantially parallel to the warp.
The coating layer made of the coating material of the coating yarn has a plurality of colors by having a plurality of different color portions in the circumferential direction when viewed in a cross section.
At least the warp is twisted about an axis and extends along the cut edge , alternating in each color.
It is an interior material characterized by this.

In the first aspect of the present invention, it is preferable to arbitrarily adopt one or more of the following configurations (i) and (ii).
(I) The core yarn of the coated yarn is made of a monofilament.

(Ii) A glass fiber layer is provided between the backing layer and the adhesive layer.

In the second aspect of the present invention, at least an adhesive is applied on a backing material layer made of a backing material to form an adhesive layer, and a woven fabric is placed on the adhesive layer. , Laminating process and
The laminate containing the backing material layer and at least the adhesive layer and the woven fabric is heated, thereby curing the backing material layer and at least the adhesive layer to obtain the backing layer and at least. A heating step of obtaining a laminate composed of an adhesive layer and the woven fabric fixed by the adhesive layer .
Have and
The woven fabric has a woven structure having warp and weft.
At least the warp is a coated yarn in which the core yarn is coated with a coating material containing vinyl chloride resin as a main component.
The coating layer made of the coating material of the coating yarn has a plurality of colors by having a plurality of different color portions in the circumferential direction when viewed in a cross section.
Further, it has a cutting step of cutting the laminated body after the heating step at least along the warp to form a cut edge.
At least the warp is twisted about an axis and extends along the cut edge , alternating in each color.
This is a method for manufacturing interior materials.

According to the interior material of the first aspect of the present invention, it is possible to make it difficult to visually recognize the "bending" in the woven fabric, so that it is possible to prevent the appearance from being deteriorated.

According to the method for manufacturing an interior material according to the second aspect of the present invention, since the adhesive layer can be integrally formed with the backing material layer, the interlayer strength can be improved, the strength and durability of the entire interior material can be improved, and further manufacturing can be performed. Will also be easy. Further, since the woven fabric can be developed on the adhesive layer without a load, it is possible to prevent the woven fabric from having problems such as wrinkles, flares, and distortions in the heating process for bonding the two. In particular, since it is possible to make it difficult to visually recognize the "bending" of the woven fabric, it is possible to prevent the appearance from being deteriorated.

It is sectional drawing which shows the interior material of one Embodiment of 1st Embodiment of this invention. It is a plan enlarged view of the interior material of FIG. It is sectional drawing which shows the laminating process in manufacturing of the interior material of FIG. FIG. 3 is a perspective view of an end portion of a coated yarn used for the woven fabric of the interior material of FIG. 1. It is a perspective view of the end part of the coating yarn used for the woven fabric of the interior material of another embodiment of this invention. It is an enlarged plan view of the portion along the cut edge of the woven fabric of the embodiment of FIG. It is an enlarged plan view which shows the surface of the woven cloth of the conventional interior material. It is an enlarged plan view of the cut end edge portion of the conventional woven fabric. It is an enlarged plan view of the part along the cut end edge of the conventional woven fabric.

[First Embodiment]
The present embodiment is an embodiment of the interior material of the present invention and a method for manufacturing the same. FIG. 1 is a schematic cross-sectional view showing an interior material of the present embodiment. The interior material 10 is composed of a laminated body including a backing layer 2, a glass fiber layer 3 on the backing layer 2, an adhesive layer 4 on the backing layer 2, and a woven fabric 5 on the backing layer 2. The backing layer 2 is made of a cured product of a backing material containing a vinyl chloride resin as a main component. The glass fiber layer 3 contains a plurality of glass fibers. The adhesive layer 4 is made of a cured product of an adhesive containing a vinyl chloride resin as a main component, and the woven fabric 5 is bonded to the glass fiber layer 3 and the backing layer 2. The woven fabric 5 has a woven structure in which a coated yarn in which a core yarn is coated with a coating material containing a vinyl chloride resin as a main component is used as a warp and a weft.

FIG. 2 is a plan enlarged partial view of the interior material 10. That is, it is a plan enlarged partial view of the woven fabric 5. The woven fabric 5 has a woven structure in which the warp 51 and the weft 52 are woven as shown in FIG.

Then, in the interior material 10, the cured product of the adhesive does not appear on the surface of the woven fabric 5. That is, as compared with the conventional case shown in FIG. 7, in the interior material 10, as shown in FIG. 2, the cured product of the adhesive does not appear on the surface of the woven fabric 5.

Therefore, according to the interior material 10 of the present embodiment, the cured product of the adhesive does not appear on the surface of the woven fabric 5, so that the appearance is good.

Next, a method of manufacturing the interior material 10 of the present embodiment will be described. The interior material 10 is obtained by going through the following "lamination step" and "heating step" in this order.

(1) Laminating Step As shown in FIG. 3, first, a backing material layer 20 made of a backing material 200 containing a vinyl chloride resin as a main component is formed, and then a glass fiber is formed on the backing material layer 20. A glass sheet 30 containing Place the woven cloth 5. As a result, a laminated body including the backing material layer 20, the glass sheet 30, the adhesive layer 40, and the woven fabric 5 can be obtained.

The backing material layer 20 serves as a grounding layer for the interior material 10. The backing material 200 preferably contains a vinyl chloride resin as a main component, but other synthetic resins such as vinyl chloride-vinyl acetate copolymer, polypropylene, polyethylene, ethylene-vinyl acetate copolymer and the like; or Other synthetic rubbers, such as SBR, NBR, etc .; may be used. Further, the backing material 200 may be mixed with various pigments such as black pigments such as carbon black; fillers such as calcium carbonate and barium sulfate; stabilizers; antiaging agents and the like, if necessary.

Further, the backing material layer 20 is preferably formed by a method of applying a paste-like backing material 200 on a conveyor. According to this method, the glass sheet 30 can be easily embedded in the backing material 200, and therefore, the glass sheet 30 and the backing material 200 can be firmly integrated by the “heating step” described later.

As the glass sheet 30, a glass non-woven fabric such as a glass mat or a glass woven fabric such as a glass cloth can be used. The fiber component of the glass sheet 30 may be composed of only the glass fiber, or may contain other fibers other than the glass fiber. As other fibers, natural fibers such as pulp, synthetic resin fibers, metal fibers and the like can be used. Since the glass fiber contained in the glass sheet 30 has a small change with respect to a temperature change and has excellent strength, it is possible to improve the dimensional stability of the entire interior material and the physical property stability such as reduction of warpage. can. In particular, the glass nonwoven fabric has excellent dimensional stability and processability, and is therefore preferably used. Moreover, since the glass nonwoven fabric is suitable for receiving the adhesive 400 in a uniform state, the woven fabric 5 can be joined without causing problems such as wrinkles, flares, and distortions.

In this laminating step, the adhesive 400 is applied to the surface of the glass sheet 30, so that it can be uniformly developed with an appropriate application amount. Further, since the adhesive 400 can be easily applied and the woven fabric 5 can be spread on the adhesive layer 40 without a load, the woven fabric 5 can be easily laminated without causing problems such as wrinkles, flares, and distortions. can. In addition, since the edge portion of the woven fabric 5 is sufficiently fixed, it is possible to suppress the occurrence of "fray" in the yarn.

The woven fabric 5 has a woven structure in which a coated yarn in which a core yarn is coated with a coating material containing a vinyl chloride resin as a main component is used as a warp and a weft. FIG. 4 is a perspective view of the end portion of the coated yarn 6. The coating yarn 6 is composed of a core yarn 61 and a coating layer 62 made of a coating material. Such a coated yarn 6 is obtained by inserting the core yarn 61 into an extruder while feeding the core yarn 61 with a yarn feeding machine and extruding the core yarn 61 together with the covering material.

From the viewpoints of improving dimensional stability, improving physical stability such as warpage reduction, and preventing backside slippage, a commonly used glass mat, polyester woven cloth, or cloth weaving such as a lawn cloth is used. The cloth may be provided on the back surface of the backing material layer 20.

Then, in this embodiment, as the woven fabric 5, a woven fabric whose weaving density is set to the "first predetermined value" described below is used. Further, the viscosity ρ of the adhesive 400 and the thickness T of the adhesive layer 40 are set to the "second predetermined value" described below.

(2) Heating step The entire laminated body obtained in the laminating step is heated, whereby the backing material layer 20 and the adhesive layer 40 are cured, and the backing layer 2 and the adhesive layer 4 are integrated with the glass fiber layer 3. And form. As a result, the interior material 10 which is a laminated body including the backing layer 2, the glass fiber layer 3, the adhesive layer 4, and the woven fabric 5 can be obtained.

In this heating step, since the laminated body is heated, the bonding between the woven fabric 5 and the backing layer 2 can be sufficiently and firmly formed over the entire surface. Further, since the glass fiber layer 3 is integrally formed with both the woven fabric 5 and the backing layer 2, the interlayer strength can be improved, and therefore the strength and durability of the interior material 10 as a whole can be improved.

The interior material 10 thus obtained is cut into a desired shape, for example, a tile shape such as a rectangle, a long sheet shape, or the like, and used. The cut interior material 10 can be used by laying it on the floor surface as a floor material, or can be used by being attached to a wall surface or a ceiling surface as a wallpaper or a waist wall material.

(1st and 2nd predetermined values)
The first and second predetermined values are required so as to prevent the adhesive 400 from seeping out (leaking) onto the surface of the woven fabric 5 in the heating step. Specifically, the first predetermined value is the density when the warp 51 of 42 to 47 threads / inch and the weft 52 of 15 to 16 threads / inch are used. In this specification, it is "1 inch = 2.54 cm". The second predetermined value is the viscosity ρ of the adhesive 400 of 5000 cps or more, or the thickness T of the adhesive layer 40 of 0.25 to 0.5 mm, and preferably the viscosity ρ of the adhesive 400 of 10,000 cps or more. And, the thickness T of the adhesive layer 40 is 0.25 to 0.3 mm. Such first and second predetermined values were obtained as follows. The viscosity was determined by using a B-type BM type viscometer manufactured by Tokyo Keiki Co., Ltd. in an environment of 20 ° C. Measured at 4 and 6 rpm.

(A) Setting of the first level and the second level As the first level, 42 threads / inch warp 51 and 16 threads / inch weft 52 are used. The second level was to use 47 threads / inch warp 51 and 15 threads / inch weft 52.

(B) Examination of the presence or absence of exudation in the case of the first level In the case of the first level, the viscosity ρ of the adhesive 400 and the thickness T of the adhesive layer 40 are variously set, and the above manufacturing method is executed. , Obtained interior material. Then, the surface of the woven fabric 5 was observed to confirm the presence or absence of exudation (leakage). Table 1 shows the results. In Table 1, when there is no exudation, it is indicated by "◎", when there is a slight exudation, it is indicated by "○", and when there is a clear exudation, it is indicated by "x".

(C) Examination of the presence or absence of exudation in the case of the second level In the case of the second level, the presence or absence of the exudation was confirmed in the same manner as in the case of the first level. The results were better than in the case of the first level.

(D) Consideration As can be seen from Table 1, it is preferable that the viscosity ρ of the adhesive 400 is 5000 to 20000 cps, or the thickness T of the adhesive layer 40 is 0.25 to 0.5 mm, and further. It is more preferable that the viscosity ρ of the adhesive 400 is 10,000 to 20,000 cps, or the thickness T of the adhesive layer 40 is 0.25 to 0.3 mm, and further, the viscosity ρ of the adhesive 400. Is particularly preferably 10000 to 20000 cps and the thickness T of the adhesive layer 40 is 0.25 to 0.3 mm. Therefore, the first and second predetermined values are set as described above.

In this way, it is possible to obtain the interior material 10 in which the cured product of the adhesive 400 does not leak to the surface of the woven fabric 5, that is, does not appear.

[Second Embodiment]
This embodiment is another embodiment of the interior material of the present invention. In the woven fabric 5 of the interior material 10 of the present embodiment, the coated yarn 6A having a structure different from that of the coated yarn 6 of the woven fabric 5 of the first embodiment is used as the warp 51 and the weft 52, and around the axis. It is used to twist.

FIG. 5 is a perspective view of an end portion of the coated yarn 6A of the present embodiment. The covering layer 62 has 621 and 622, which are half of the circumferential direction when viewed in cross section, having different colors. That is, the surface of the coated yarn 6A has two colors, and each color portion occupies half of the circumferential direction of the surface of the coated yarn 6A and extends in the axial direction.

Such a coated yarn 6A is obtained by inserting the core yarn 61 into an extruder while feeding the core yarn 61 with a yarn feeding machine and extruding the core yarn 61 together with two types of covering materials having different colors.

The woven fabric 5 of the present embodiment is obtained by using the coated yarn 6A as described above as the warp 51 and the weft 52 and twisting around the axis when the woven fabric 5 is manufactured by weaving.

FIG. 6 is an enlarged plan view of a portion of the woven fabric 5 of the present embodiment along the cut edge 501. Conventionally, since the warp 51 extending along the cut edge 501 is not parallel to the edge 501, "bending" is easily visible. However, in the woven fabric 5 of the present embodiment, since the coating yarn 6A has two colors and is woven so as to be twisted, the warp 51 in the vicinity of the edge 501 alternately presents the two colors. It extends along the edge 501. As a result, the warp 51 is visually recognized by changing its color in order in the axial direction. Therefore, it becomes less noticeable that the warp 51 is not parallel to the edge 501. Therefore, even if there is a "bend", it becomes difficult to visually recognize it. The same applies to the weft 52 with respect to the edge orthogonal to the edge 501.

As described above, according to the woven fabric 5 of the present embodiment, it is possible to make it difficult to visually recognize the "bending of the eyes". Further, according to the interior material 10 of the present embodiment, the cured product of the adhesive 400 does not appear on the surface of the woven fabric 5, and the "bending" is hard to be visually recognized, so that a better appearance is exhibited. be able to.

The coated yarn 6A of the present embodiment is not limited to two colors as long as it has a plurality of different colors. That is, the covering layer 62 may have a plurality of colors by having a plurality of different color portions in the circumferential direction when viewed in cross section. The plurality of colors are preferably 2 to 4 colors, and most preferably 2 colors. Further, as the different plurality of colors, it is preferable that the contrast, the brightness and the like are significantly different. This is because it becomes easier to visually recognize the difference in color.

Further, as the core yarn 61 of the coated yarn 6A, either a monofilament or a multifilament may be used. When a multifilament is used, it is preferable to use a molten yarn.

[Third Embodiment]
The present embodiment is still another embodiment of the interior material of the present invention. In the woven fabric 5 of the interior material 10 of the present embodiment, a coated yarn 6B having a structure different from that of the coated yarn 6A of the woven fabric 5 of the second embodiment is used. Other details are the same as in the second embodiment.

The coated yarn 6B is different from the coated yarn 6A of the second embodiment in that the core yarn 61 is made of a monofilament.

The material of the monofilament may be any synthetic resin, and may be, for example, polyester, nylon, polypropylene or the like. Since polyester or nylon is excellent in strength, durability and heat resistance, it is preferably used.

The thickness of the monofilament is preferably 100 decitex or more and less than 500 decitex, more preferably 300 to 360 decitex. When the thickness is 100 decitex or more, it is difficult to cut, so that it is easy to coat the core yarn with the coating material. Further, when the thickness is less than 500 decitex, the core yarn is difficult to pop out from the end face of the coated yarn, and therefore the coated layer is also difficult to peel off.

In this embodiment, a polyester monofilament having a thickness of 330 decitex is used as the monofilament.

The specific composition of the coating material in the coating yarn 6B is as shown in Table 2.

By the way, as shown in FIG. 8, when the core yarn 61 of the coated yarn 6 is a multifilament composed of a plurality of fine fibers, the core yarn 61 is unlikely to fray 60 at the cut end edge 501. Is desirable. Especially in the case of interior materials, since a person directly steps on or touches the material, fraying is likely to occur at the cut edge. If fraying occurs, the core thread 61 impairs the design. In particular, in the interior material 10 cut into tiles such as a rectangle, the number of joints increases, so that the problem becomes more remarkable. Examples of the method for preventing the multifilament yarn from fraying include the use of heat-melted yarn and glass fiber yarn.

In the woven fabric 5 of the present embodiment, since the core yarn 61 is made of a monofilament, the core yarn 61 is unwound even if the core yarn 61 is exposed from the cut end surface of the coating yarn 6B at the cut end edge 501. There is no such thing. Therefore, according to the present embodiment, it is possible to prevent the fraying 60 (FIG. 8) at the cut edge 501 of the woven fabric 5, thereby preventing the deterioration of the appearance and the deterioration of the durability. In addition, in the case of the heat-melted yarn, it shrinks significantly when it melts, but in the case of the monofilament, it does not need to be the heat-melted yarn, so that the shrinkage can be suppressed to a low level. Further, in the case of glass fiber, the exposed end collapses into powder, and when the exposed end is touched, it causes tingling and discomfort, but in the case of monofilament, such a case occurs. Since there is no such thing, it can be suitably used.

According to the present embodiment, the cured product of the adhesive 400 does not appear on the surface of the woven fabric 5, and moreover, it is difficult to visually recognize the "bending", and further, the fray 60 at the cut edge 501 (FIG. FIG. Since 8) has not occurred, an extremely good appearance can be obtained.

[Fourth Embodiment]
This embodiment is another embodiment of the method for manufacturing an interior material. The interior material 10A obtained by the manufacturing method of the present embodiment has the same basic structure as the interior material 10 of FIG. That is, the interior material 10A is composed of a laminated body composed of a backing layer 2, a glass fiber layer 3 on the backing layer 2, an adhesive layer 4 on the backing layer 2, and a woven fabric 5 on the backing layer 2. The backing layer 2 is made of a cured product of a backing material containing a vinyl chloride resin as a main component. The glass fiber layer 3 contains glass fibers. The adhesive layer 4 is made of a cured product of an adhesive containing a vinyl chloride resin as a main component, and the woven fabric 5 is bonded to the glass fiber layer 3 and the backing layer 2. The woven fabric 5 has a woven structure in which a coated yarn in which a core yarn is coated with a coating material containing a vinyl chloride resin as a main component is used as a warp and a weft.

The interior material 10A is obtained by going through the following "heat setting process", "lamination process" and "heating process" in this order. The manufacturing method of the present embodiment is different from the first embodiment in that it has a "heat setting step". Other details are the same as in the first embodiment.

(1) Heat setting step The woven fabric 5 is heated under the condition that the surface temperature of the woven fabric is the "first predetermined temperature". At that time, it is preferable to heat the woven fabric 5 while applying a pulling force in the surface direction, whereby flare of the woven fabric 5 can be suppressed and smoothed. It is also possible to reduce the bending of the woven fabric 5.

The woven fabric 5 has a woven structure in which a coated yarn in which a core yarn is coated with a coating material containing a vinyl chloride resin as a main component is used as a warp and a weft.

(2) Laminating Step As shown in FIG. 3, first, a backing material layer 20 made of a backing material 200 containing a vinyl chloride resin as a main component is formed, and then a glass fiber is formed on the backing material layer 20. A glass sheet 30 containing Place the woven cloth 5. As a result, a laminated body including the backing material layer 20, the glass sheet 30, the adhesive layer 40, and the woven fabric 5 can be obtained.

According to the laminating step, since the woven fabric 5 is fixed, the occurrence of flare can be suppressed, and further, the fray prevention effect can be exhibited.

(3) Heating Step The laminated body obtained in the laminating step is heated, thereby curing the backing material layer 20 and the adhesive layer 40 to form the backing layer 2 and the adhesive layer 4. As a result, the interior material 10A can be obtained. In this embodiment, in this heating step, the main heating step is carried out after the preheating step is carried out. In the preheating step, the woven fabric 5 is heated under the condition that the surface temperature of the woven fabric is the “second predetermined temperature”. In the main heating step, the woven fabric 5 is heated under the condition that the surface temperature of the woven fabric is the "third predetermined temperature".

The first to third predetermined temperatures are required so as to prevent flare, that is, unevenness or waviness, from occurring on the surface of the obtained interior material 10A. Specifically, the first predetermined temperature is 140 to 150 ° C, the second predetermined temperature is 70 to 115 ° C, and the third predetermined temperature is 135 to 145 ° C. The third predetermined temperature is preferably 135 ° C., and the second predetermined temperature C is preferably 70 to 80 ° C. The first predetermined temperature is preferably set to 0 to 20 ° C. higher than the third predetermined temperature. The reason is that if heating exceeding the surface temperature of the woven fabric at the time of heat setting is performed in the heating step, the effect of smoothing the woven fabric by the heat setting diminishes, the woven fabric 5 bends again, and flare is likely to occur. Because. Further, the second predetermined temperature is preferably set to be 60 to 90 ° C. lower than the third predetermined temperature. Further, the first to third predetermined temperatures are particularly preferably 150 ° C., 70 ° C., and 135 ° C., respectively. Such temperatures were determined by performing Experiments 1-9 as shown in Table 3.

As shown in Table 3, the heating operation is performed once or twice in the heat setting step. In addition, the shrinkage rate after each heating is also obtained. In the flare occurrence column, "x" indicates the case where flare is clearly generated, "△" indicates the case where flare is slightly generated, and "○" indicates the case where flare is negligible. (That is, it can be considered that it has not occurred).

As described above, according to the manufacturing method of the present embodiment, it is possible to obtain the interior material 10A in which flare does not occur.

[Other embodiments]
In the manufacturing method of the sixth embodiment, the following configurations or conditions may be adopted.
(A) The conditions of the first and second predetermined values of the first embodiment are additionally adopted.
(B) In the weaving process, the coated yarn 6A of the second embodiment is used instead of the coated yarn 6.
(C) In the weaving process, the coated yarn 6B of the third embodiment is used instead of the coated yarn 6.
In addition, (a), (b), (c) may be adopted alone, or (a) may be adopted together with (b) or (c).

Since the interior material of the present invention has a good appearance, it has great industrial utility value.

2 Backing layer 20 Backing material layer 200 Backing material 3 Glass fiber layer 30 Glass sheet 4 Adhesive layer 40 Adhesive layer 400 Adhesive 5 Woven cloth 51 Warp 52 Weft thread 6, 6A, 6B Coating thread 61 Core thread 62 Coating layer 10, 10A Interior material

Claims (2)

It consists of a laminate with a woven fabric on top of the backing layer, at least via an adhesive layer.
The woven fabric is fixed by the adhesive layer and is fixed.
The woven fabric has a woven structure having a plurality of warps arranged in the weft direction and a plurality of wefts arranged in the warp direction.
The warp and weft are coated yarns in which a core yarn made of a monofilament made of synthetic resin is coated with a coating material containing vinyl chloride resin as a main component.
The woven fabric has a cut edge and has a cut edge.
The cut edge is formed at least substantially parallel to the warp.
The coating layer made of the coating material of the coating yarn has a plurality of colors by having a plurality of different color portions in the circumferential direction when viewed in a cross section.
The warp is twisted around an axis and extends along the cut edge so that each color is alternately exhibited at a distance larger than the distance between adjacent wefts in the warp direction .
The wefts are twisted around an axis and extend along the cut edge so that each color is alternately exhibited at intervals larger than the spacing between adjacent warps in the weft direction .
Interior material that is characterized by that. The thickness of the core yarn made of the monofilament is 100 decitex or more and less than 500 decitex .
The interior material according to claim 1.

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