Light-emitting display sheet, light-emitting display component, light-emitting display device, and method for manufacturing light-emitting display component.

Abstract

The present invention relates to a light-emitting display sheet, comprising: a first fiber substrate layer, and a surface material layer stacked on the first fiber substrate layer, the first fiber substrate layer comprising: a first surface opposite to the surface material layer, and a second surface which is the opposite surface of the first surface, the light-emitting display sheet also comprising a printed portion having a contour and sandwiched between the first surface of the first fiber substrate layer and the surface material layer.

Description

Technical Field

[0001] The present invention relates to a light-emitting display sheet that transmits light from a light-emitting device to thereby perform light-emitting or non-light-emitting display of symbols such as letters and icons, patterns, and images. Background Art

[0002] In recent years, a light-emitting display device has been proposed, which covers a light-emitting device with a light-transmitting sheet to transmit light from the light-emitting device and displays symbols such as letters and icons, patterns, images, etc. on the surface.

[0003] For example, Patent Document 1 below discloses a synthetic leather, which is formed by laminating a skin layer formed of polyurethane resin on a grey cloth, and has a visible light transmittance of 0.10 to 11.90% in a wavelength range of 380 to 780 nm. Patent Document 1 also discloses that a thick paper cut into a desired shape is pasted, sewn, hooked, or welded to the back side of the grey cloth in order to locally form a light-shielding area.

[0004] In addition, the following Patent Document 2 discloses a light-transmitting artificial leather sheet using a transparent or translucent elastic sheet. Specifically, the light-transmitting artificial leather sheet is characterized in that a smoke printing layer is provided on the back or front of the elastic sheet, a mask printing layer for embodying text, graphics, patterns, or a combination thereof is provided on the back, i.e., the outermost layer, of the elastic sheet, and a leather pattern is provided on the surface of the elastic sheet.

[0005] In addition, the following patent document 3 discloses a leather-like light-emitting sheet, which comprises a light-emitting device and a light-transmitting leather-like sheet comprising a fiber substrate, wherein the light-transmitting leather-like sheet is arranged in a manner to cover the light-emitting device so that light emitted by the light-emitting device is transmitted through a light-transmitting portion formed in at least one region within the surface. Furthermore, the following is disclosed: a nonwoven fabric comprising ultrafine fibers having a fineness of 0.8 dtex or less and a polymer elastomer, and having an apparent density of 0.5 g / cm 3 The fiber base material is dense and thus has excellent dimensional stability, and is also preferred from the viewpoint of excellent precision processing when a thin-walled portion is formed by cutting and thinning in the region corresponding to the light-transmitting portion compared to the region corresponding to the non-light-transmitting portion. In addition, it is disclosed that a light-shielding layer is formed by applying a coating liquid containing a colorant to the fiber base material and drying it.

[0006] Prior art literature

[0007] Patent Literature

[0008] Patent Document 1: Japanese Patent Application Publication No. 2013-177714

[0009] Patent Document 2: Japanese Patent Application Publication No. 2014-173203

[0010] Patent Document 3: Japanese Patent Application Publication No. 2016-081817 Summary of the invention

[0011] Problems to be solved by the invention

[0012] In order to locally form a light-shielding area on a fiber substrate, a method of forming a printed portion that becomes a light-shielding portion by printing on one side of the fiber substrate using ink can be proposed. According to such a method, a light-emitting display sheet used as a member of a light-emitting display device that causes symbols, patterns, and images such as characters and icons to be displayed by light emission can be easily manufactured.

[0013] However, when such a luminous display sheet is housed in a mold and in-mold injection molding is performed to integrate it with a translucent injection-molded body, the printed portion printed on the fiber substrate contacts the molten resin of the injection molding, causing the printed portion to melt and the outline of the printed portion to be destroyed. As a result, the outline of the text, symbols, patterns, images, etc. displayed by luminescence sometimes becomes unclear.

[0014] An object of the present invention is to provide a light-emitting display sheet in which the contour of the printed portion is not easily destroyed even when the light-emitting display sheet including the printed portion is housed in a mold and subjected to in-mold injection molding.

[0015] Solutions to the problem

[0016] One aspect of the present invention is a light-emitting display sheet, which comprises: a first fiber substrate layer, and a surface material layer laminated on the first fiber substrate layer, wherein the first fiber substrate layer comprises: a first surface opposite to the surface material layer, and a second surface opposite to the first surface, and the light-emitting display sheet further comprises a printing portion having an outline and sandwiched between the first surface of the first fiber substrate layer and the surface material layer. When such a light-emitting display sheet is combined with a light-emitting device (light-emitting component) and used as a light-emitting display device, the printing portion having an outline selectively blocks the light emitted by the light-emitting device, and the non-printing portion adjacent to the printing portion selectively transmits the light, so that the shape of a symbol, pattern, or pattern is displayed in a light-emitting or non-light-emitting manner. In addition, when the light-emitting device is turned off, the surface material layer makes the first fiber substrate layer difficult to identify from the outside. Moreover, when the light-emitting display sheet is received in the mold and in-mold injection molding is performed for integration with the translucent injection-molded body, the printing part is sandwiched between the first surface and the surface material layer, so that the printing part is not easy to directly contact with the molten resin, and thus, the melting and destruction of the outline of the printing part caused by the heat and pressure of the injection molding can be suppressed. As a result, the outline of the printing part of the display pattern is maintained without being destroyed, so the outline of the light-emitting display becomes clear, and the contrast between the light-emitting part and the non-light-emitting part becomes high. In addition, secondly, when making the light-emitting display component, the first fiber substrate layer can alleviate the pressure of the injection molding resin during in-mold molding, thereby easily maintaining the touch of the surface material layer. In addition, since the injection-molded molten resin penetrates into the interior of the first fiber substrate layer, the bonding strength is improved by the anchoring effect. In addition, the first fiber substrate layer reduces the color deviation of the light by diffusing the transmitted light.

[0017] From the viewpoint of protecting the printed portion with the adhesive layer, it is preferred that the first fiber base material layer and the surface material layer are bonded together via an adhesive layer.

[0018] Furthermore, when the printed portion is formed on the first surface of the first fiber base layer, various printed portions can be formed simply by printing on the first fiber base layer, which is preferable in terms of excellent productivity.

[0019] In addition, when the arithmetic mean height Sa of the first surface of the first fiber substrate layer based on ISO25178 is 3 to 20 μm, a dense surface can be formed, so a smooth surface suitable for printing can be obtained, the ink is not easy to spread, and it is easy to form a printed part with less uneven coating and a clear contour. From this aspect, it is preferred.

[0020] The first fiber base layer includes a nonwoven fabric of ultrafine fibers having an average fineness of 1.0 dtex or less, and a polymer elastic body impregnated into the nonwoven fabric and having an apparent density of 0.3 g / cm 3In the case of the above fiber substrate, a smooth surface suitable for printing can be formed, so a printed part with a clear outline can be formed, which is preferred from this point of view. In addition, since the morphological stability is excellent, the printed part is easy to maintain the shape, which is also preferred from this point of view.

[0021] In addition, when the surface material layer has a second fiber base layer and the printing part is sandwiched between the first fiber base layer and the second fiber base layer, the printing part is sandwiched and protected by the two fiber base layers having cushioning properties, thereby making it easier for the printing part to maintain its shape, which is preferred from this aspect.

[0022] In addition, from the viewpoint of providing designability to the appearance, it is preferred that the surface material layer further includes a decorative layer laminated on the outer surface side of the second fiber base material layer.

[0023] In addition, when the decorative layer is a leather-grain-like resin layer, it is preferable from the viewpoint that a light-emitting display sheet having a grain-grain leather-like surface can be obtained.

[0024] In addition, as specific examples of the surface material layer, for example, there can be mentioned a layer formed of a surface material including the following materials: the material is a textile raw material such as a non-woven fabric, a woven fabric, a knitted fabric, etc.; a wood sheet such as a thin plate obtained by slicing natural wood; a light-transmitting stone sheet such as a stone or jadeite sliced ​​into thin slices; a metal sheet such as a metal foil; a resin sheet such as a polyvinyl chloride sheet, a polyurethane sheet, a PET sheet, etc. In addition, it can be a napped leather-like sheet obtained by raising the fibers on the outer surface side of the second fiber base material layer.

[0025] Another aspect of the present invention is a light-emitting display member comprising: the light-emitting display sheet as described above, and a light-transmitting resin layer integrated with the second surface. The light-transmitting resin layer is preferably an injection-molded body.

[0026] Another aspect of the present invention is a light-emitting display device including: the light-emitting display member as described above; and a light-emitting device disposed on one side of the light-transmitting resin layer.

[0027] In addition, another aspect of the present invention is a method for manufacturing a light-emitting display component, which comprises: a process of housing the light-emitting display sheet as described above in a mold cavity of an in-mold molding mold and performing mold closing; and a process of integrating a light-transmitting resin layer with the second side of a first fiber substrate layer forming the light-emitting display sheet housed in the in-mold molding mold by injection molding.

[0028] Effects of the Invention

[0029] According to the present invention, it is possible to provide a light-emitting display sheet in which the contour of the printed portion is less likely to be destroyed even when the light-emitting display sheet including the printed portion is housed in a mold and in-mold molding is performed. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 Schematic diagram of a light-emitting display sheet 10 according to an embodiment.

[0031] Figure 2 Schematic diagram of a light-emitting display sheet 20 according to an embodiment.

[0032] Figure 3 Schematic diagram of a light-emitting display member 30 according to an embodiment.

[0033] Figure 4 This is an explanatory diagram for explaining a method of manufacturing the light-emitting display member 30 by in-mold molding.

[0034] Figure 5 Schematic diagram of a light-emitting display device 50 according to an embodiment.

[0035] Figure 6 The photographs show the evaluation results of Examples.

[0036] Figure 7 The photographs show the evaluation results of the comparative examples.

[0037] Explanation of symbols

[0038] 2. First fiber substrate layer

[0039] 3 Surface material layer

[0040] 3a Second fiber substrate layer

[0041] 4 Printing layer

[0042] 4A Printing Department

[0043] 5 Adhesive layer

[0044] 10, 20 Luminous display film

[0045] 11 Translucent resin layer

[0046] 11a Molten resin

[0047] 12 Injection molding molds

[0048] 12a Movable side mold

[0049] 12b Fixed side mold

[0050] 13 Injection molding body

[0051] 19 Light-emitting device (light-emitting component)

[0052] 19a Light Source

[0053] 19b Circuit board

[0054] 30. Light-emitting display component

[0055] 40. Luminous display device

[0056] Cavity

[0057] D Non-printing part (light transmission part)

[0058] E-light

[0059] L First side

[0060] S Second side DETAILED DESCRIPTION

[0061] The embodiments of the light emitting display sheet, light emitting display component, light emitting display device and light emitting display component manufacturing method of the present invention are described with reference to the accompanying drawings. It should be noted that each figure is a schematic diagram for describing the features of the invention and is a schematic diagram without considering the size and scale for the convenience of description.

[0062] [Luminous display sheet]

[0063] An embodiment of the light-emitting display sheet is described below. The light-emitting display sheet of this embodiment includes: a first fiber substrate layer and a surface material layer laminated on the first fiber substrate layer, and the light-emitting display sheet also includes a printing portion sandwiched between the first fiber substrate layer and the surface material layer and having an outline. Moreover, the printing portion becomes a light-shielding portion, and the non-printing portion adjacent to the printing portion becomes a light-transmitting portion.

[0064] Figure 1 FIG. 1 is a schematic diagram of a light emitting display sheet 10 which is one embodiment of the light emitting display sheet of the present embodiment. Figure 1 (a) is a schematic plan view of the light-emitting display sheet 10, Figure 1 (b) Yes Figure 1 (a) is a schematic cross-sectional view of section II' of FIG. The light-emitting display sheet 10 comprises a first fiber substrate layer 2, a surface material layer 3 having a second fiber substrate layer 3a and a decorative layer 3b, an adhesive layer 5 for bonding the first fiber substrate layer 2 and the second fiber substrate layer 3a, and a printing section 4A.

[0065] The surface material layer 3 in this embodiment is an artificial leather in which a resin layer is laminated as a decorative layer 3b on a second fiber base layer 3a. The first fiber base layer 2 and the second fiber base layer 3a are bonded together via an adhesive layer 5.

[0066] The first fiber base material layer 2 has a first surface L on one side opposite to the surface material layer 3, and a second surface S on the opposite side. In addition, a printed portion 4A having an outline is formed in a manner sandwiched between the first fiber base material layer 2 and the second fiber base material layer 3a. The printed portion 4A is adjacent to a non-printed portion D that transmits light and is not printed. The printed portion 4A and the non-printed portion D form a printed layer 4. It should be noted that the outline in this embodiment refers to the boundary line between the printed portion and the non-printed portion.

[0067] Each fiber substrate layer includes a fiber structure such as a nonwoven fabric, a fabric, and a knitted fabric, and includes a fiber substrate formed by impregnating a polymer elastomer into the gaps of the fiber structure as required. The average fineness of the fibers forming the fiber structure is not particularly limited. From the perspective of easily obtaining a fiber substrate layer with a high sense of density and a smooth surface, it is preferably 1.5 dtex or less, more preferably 1.0 dtex or less, and particularly preferably 0.9 dtex or less. It should be noted that for the average fineness, for example, a scanning electron microscope (SEM) photograph of the cross section of each fiber substrate layer can be taken at 500 times, 10 fiber cross sections are randomly selected and the cross-sectional area is measured, the average value of the cross-sectional area is calculated, and the average fineness is calculated by converting according to the density of each resin.

[0068] When the macromolecular elastic body is impregnated into the gaps of the fiber structure, the type of the macromolecular elastic body to be impregnated is not particularly limited. Specific examples thereof include: polycarbonate polyurethane, polyester polyurethane, polyether polyurethane and other polyurethanes, acrylic elastomers, polyurethane acrylic composite elastomers, polyvinyl chloride, synthetic rubber, etc. Among them, polyurethane is preferred from the perspective of excellent adhesion and mechanical properties.

[0069] The thickness of the first fiber substrate layer 2 and the second fiber substrate layer 3a is not particularly limited, but is preferably 0.1 to 1 mm, and more preferably 0.35 to 0.8 mm. In addition, the apparent density of each fiber substrate layer is not particularly limited, but is preferably 0.3 g / cm2 from the perspective of being easy to carry ink during printing and forming a clear-cut printed portion. 3 More preferably, 0.50 to 0.95 g / cm 3 , particularly preferably 0.50 to 0.90 g / cm 3 .

[0070] Regarding the light transmittance of each fiber base material layer, the arithmetic mean of the transmittance in the visible light wavelength range of 380 to 780 nm is preferably 0.1% or more, more preferably 1% or more, particularly preferably 5% or more, and particularly preferably 10% or more.

[0071] The surface material layer is a light-transmitting layer used to form the outer surface of the light-emitting display sheet. Examples of the surface material layer include: leather-like sheets such as artificial leather and synthetic leather, in which a resin layer is laminated on the second fiber substrate layer as a decorative layer; a napped leather-like sheet obtained by raising the fibers on the outer surface side of the second fiber substrate layer; textile raw materials such as non-woven fabrics, fabrics, and knitted fabrics; wood sheets such as thin boards obtained by cutting natural wood into thin slices; light-transmitting stone sheets such as stone and jade cut into thin slices; metal sheets such as metal foil; resin sheets such as polyvinyl chloride sheets, polyurethane sheets, and PET sheets, etc. These materials can be used alone or in combination of two or more.

[0072] In order to make it difficult to identify the internal layers from the outside when the light-emitting device is turned off, the surface material layer preferably includes a decorative layer colored with a pigment or dye. In addition, the decorative layer may be a layer colored in a manner to present a high-grade appearance such as grain leather, wood, stone, or metal. The thickness of the decorative layer is not particularly limited, and is preferably about 20 to 500 μm, for example.

[0073] The thickness of the surface material layer is not particularly limited, but is, for example, preferably about 10 to 1000 μm, more preferably about 20 to 500 μm.

[0074] The light transmittance of the surface material layer is preferably 0.1% or more, more preferably 1.0% or more, particularly preferably 5.0% or more, and particularly preferably 10% or more, as the arithmetic mean of the transmittance in the visible light wavelength range of 380 to 780 nm. In addition, the upper limit is not particularly limited, but is preferably 90%, more preferably 80%, and particularly preferably 50%.

[0075] like Figure 1 As shown, in the light-emitting display sheet 10, a printing layer 4 is sandwiched between the first fiber base material layer 2 and the second fiber base material layer 3a, and the printing layer 4 has a printing portion 4A printed in a contoured manner and a non-printing portion D adjacent to the printing portion 4A. The printing portion 4A serves as a light-shielding portion, and the non-printing portion D serves as a light-transmitting portion. The contour shape of the printing portion 4A enables symbols, patterns, and images such as characters and icons to be displayed by light emission.

[0076] Since the printing part is a light-shielding part, the light transmittance is lower than that of the non-printing part which is a light-transmitting part. As the light transmittance of the area corresponding to the printing part of the light-emitting display sheet that blocks light, the arithmetic mean of the transmittance in the visible light wavelength range of 380 to 780 nm is preferably 0.09% or less, and more preferably 0.02% or less. In the case where the light transmittance of the area corresponding to the printing part of the light-emitting display sheet is high, there is a tendency that the symbols, patterns, and images such as characters and icons displayed by the light-emitting display become unclear. In addition, as the light transmittance of the light-emitting display sheet corresponding to the non-printing part that transmits light, the arithmetic mean of the transmittance at 380 to 780 nm is preferably 0.1 to 30%, and more preferably 0.1 to 12%. It should be noted that the light transmittance of the light-emitting display sheet is obtained by measuring the transmittance in the visible light wavelength range of 380 to 780 nm using a spectrophotometer U-4100 (Hitachi High-TechSciences), and calculating its average value.

[0077] like Figure 1 As shown in FIG. 1 , a non-printing portion D having an outline is formed adjacent to the printing portion 4A having an outline. The non-printing portion D is formed in the shape of an icon indicating the operation status of the audio device, such as stop, play, skip a song, return a song, fast forward, and rewind. The shape of the non-printing portion D is not limited to the shape of Figure 1 The shapes of the icons shown, other icons, symbols such as characters, patterns, designs, etc. are not particularly limited.

[0078] The printed portion is formed by printing with a pigment ink containing a pigment with high shielding properties such as carbon black and titanium oxide and a binder, or with a dye ink containing a dark dye with light shielding properties. Specifically, it is formed by printing with ink on the surface of the first fiber base material layer 2 and the second fiber base material layer 3a. From the perspective of productivity, the printed portion is preferably formed by printing with ink on the first fiber base material layer 2.

[0079] The softening temperature of the resin forming the printing portion is preferably 80° C. or higher, more preferably 100° C. or higher.

[0080] The thickness of the printed portion is preferably about 5 to 80 μm, more preferably about 20 to 50 μm.

[0081] In addition, in the light-emitting display sheet 10, the first fiber substrate layer 2 and the surface material layer 3 that clamp the printing part 4A are bonded together by the adhesive layer 5. According to this mode, it is preferable from the aspect that the printing part 4A is protected by the adhesive layer 5. The thickness of the adhesive layer is not particularly limited, for example, it is preferably about 50 to 200 μm. In order to form the adhesive layer, for example, a hot melt adhesive is preferably used. It should be noted that when the first fiber substrate layer 2 and the surface material layer 3 are bonded, since the first fiber substrate layer 2 has gaps between fibers, it is not easy for bubbles to remain in the bonding part.

[0082] Alternatively, the first fiber base material layer 2 and the surface material layer 3 may be bonded together by thermocompression bonding without interposing an adhesive layer therebetween. Figure 2 Schematic diagram of a light-emitting display sheet 20 obtained by thermocompression bonding a first fiber base material layer 2 and a second fiber base material layer 3 a forming a surface material layer 3 . Figure 2 (a) shows a schematic plan view of the light-emitting display sheet 20, Figure 2 (b) shows Figure 2 (a) is a schematic cross-sectional view of the II-II' section.

[0083] The light-emitting display sheet described above is used for production of a light-emitting display member in which a light-transmitting resin molded body and the second surface S of the first fiber base material layer 2 are integrated as described below.

[0084] [Luminous display member]

[0085] An embodiment of a light emitting display member is described below. The light emitting display member of this embodiment includes the light emitting display sheet described above and a light transmissive resin layer integrated with the second surface of the first fiber base material layer of the light emitting display sheet.

[0086] Figure 3 It is used Figure 1 Schematic diagram of the light-emitting display member 30 of the light-emitting display sheet 10 shown in FIG. Figure 3 (a) shows a schematic plan view of the light-emitting display member 30, Figure 3 (b) shows Figure 3 (a) is a schematic cross-sectional view of the III-III' section.

[0087] like Figure 3 As shown, the light-emitting display member 30 includes: a light-emitting display sheet 10, and a light-transmitting resin layer 11 integrated with the second surface S of the first fiber substrate layer 2 of the light-emitting display sheet 10. That is, in the light-emitting display member 30, the light-transmitting resin layer 11 is integrated with the second surface S side of the first fiber substrate layer 2 forming the light-emitting display sheet 10. In addition, the surface layer of the light-transmitting resin layer 11 is impregnated with the surface layer of the second surface S of the first fiber substrate layer 2.

[0088] The light-transmitting resin layer 11 is preferably formed by in-mold molding using injection molding. The resin forming the light-transmitting resin layer can be used without particular limitation as long as it is a light-transmitting resin. Specific examples of the resin forming the light-transmitting resin layer include: acrylic resins such as MBS resins (methyl methacrylate-butadiene-styrene copolymer resins), ABS resins, and PMMA resins; polystyrene resins; polycarbonate resins; polyolefin resins such as polypropylene; polyester resins such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT); various polyamide resins; cycloolefin polymer (COP) resins, etc. In addition, these resins may be composite products with fillers or the like, or mixed products obtained by alloying or blending a plurality of resins. The thickness of the light-transmitting resin layer is not particularly limited, and is preferably 0.3 to 3.0 mm, and more preferably 0.5 to 2.0 mm.

[0089] Regarding the light transmittance of the light-transmitting resin layer, the arithmetic mean of the transmittance in the visible light wavelength range of 380 to 780 nm is preferably 10% or more, more preferably 50% or more, and particularly preferably 90% or more.

[0090] The following is a detailed description of a method for manufacturing a light-emitting display component based on in-mold molding. In the manufacture of the light-emitting display component, the following steps are included: a step of housing the light-emitting display sheet in a mold cavity of an in-mold molding mold and performing mold closing; and a step of integrating the light-transmitting resin layer with the second surface side of the first fiber base material layer forming the light-emitting display sheet housed in the in-mold molding mold by injection molding.

[0091] Below, refer to Figure 4 , a method for manufacturing the light-emitting display component 30 is described in detail. The light-emitting display component 30 is formed by integrating the translucent resin layer 11 to be injection molded and the second surface S of the first fiber substrate layer 2 forming the light-emitting display sheet 10 through in-mold molding using the above-mentioned light-emitting display sheet 10.

[0092] exist Figure 4 10 is a light-emitting display sheet, 12a is a movable side mold, 12b is a fixed side mold, 13 is an injection molding part body of an injection molding machine, 13a is a nozzle, 13b is a barrel, 13c is a coaxial screw, 14 is a resin injection port, 11 is a light-transmitting resin layer, 11a is a molten resin, and 30 is a light-emitting display component. The movable side mold 12a and the fixed side mold 12b form a pair to form an injection molding mold 12 that forms a mold cavity c. It should be noted that in this embodiment, the movable side mold 12a is a female mold of the injection molding mold, and the fixed side mold 12b is a male mold of the injection molding mold.

[0093] First, if Figure 4 As shown in (a), the light-emitting display sheet 10 is accommodated in the concave portion of the cavity for forming the movable side mold 12a. At this time, the second surface S side of the first fiber base material layer 2 is arranged along the direction of filling the molten resin 11a. It should be noted that in this embodiment, an example of using the light-emitting display sheet 1 that is pre-formed by deep drawing in advance in the shape of the cavity c of the injection molding mold 12 is described, but the light-emitting display sheet 10 can also be provided for in-mold molding without pre-forming.

[0094] Next, if Figure 4 As shown in (b), the movable side mold 12a and the fixed side mold 12b are molded together. Figure 4 As shown in (c), the molten resin 11a is filled into the cavity c formed in the state where the movable side mold 12a and the fixed side mold 12b are clamped. Specifically, the injection unit main body 13 of the injection molding machine is moved forward, the nozzle 13a is brought into contact with the resin injection port 14 formed in the fixed side mold 12b, and the molten resin 11a is injected into the barrel 13b by the coaxial screw 13c, thereby filling the cavity c with the molten resin 11a at a given pressure.

[0095] The injection molding of the above-mentioned molten resin 11a is carried out under high temperature and high pressure. Therefore, when the printing part formed on the light-emitting display sheet contacts with the molten resin during the injection molding process, the printing part will melt due to the heat and pressure of the molten resin, and its outline will be easily destroyed and become unclear. According to the light-emitting display sheet of this embodiment, a printing layer including the printing part is formed between the first surface of the first fiber substrate layer and the surface material layer. Therefore, when injection molding is performed for integration with the injection-molded body, the printing part is protected by the first fiber substrate layer with low thermal conductivity, thereby making it difficult for the printing part to contact with the molten resin, and it is not easy for the outline to be destroyed or the printing part to be blurred.

[0096] In addition, after cooling for a given time, the light-transmitting resin layer 11 formed in the cavity c formed by combining the movable side mold 12a and the fixed side mold 12b and the light-emitting display sheet 10 laminated on the light-transmitting resin layer 11 are integrated. Figure 4 As shown in (d), the movable mold 12a and the fixed mold 12b are opened, and the light-emitting display member 30 in which the molded light-transmitting resin layer 11 and the light-emitting display sheet 1 laminated on the light-transmitting resin layer 11 are integrated is taken out.

[0097] The light-emitting display member described above is used as a member for forming a light-emitting display device described next in which a light-emitting device is arranged on one side of a light-transmitting resin layer.

[0098] [Luminous display device]

[0099] Next, an embodiment of a light emitting display device is described. The light emitting display device of this embodiment includes the light emitting display member described above and a light emitting device disposed on one side of the light transmissive resin layer.

[0100] Figure 5 It is used in Figure 3 Schematic diagram of a light-emitting display device 50 of a light-emitting display member 30 shown in FIG. Figure 5 (a) shows a schematic plan view of a light-emitting display device 50, Figure 5 (b) shows Figure 5 (a) Schematic cross-sectional view of the V-V' section.

[0101] Reference Figure 5 (b) The light-emitting display device 50 includes: a light-emitting display member 30, and a light-emitting device 19 disposed on one side of the light-transmitting resin layer 11 of the light-emitting display member 30. The light-emitting device 19 is formed by mounting a light source 19a such as an LED device on a circuit substrate 19b, and power is supplied from a power source (not shown) so that the light source 19a emits light. As a light-emitting device, in addition to a light-emitting device formed by a mounting substrate on which a light source is mounted, an image display device such as a light-emitting display device can also be used.

[0102] When the light source 19a of the light emitting device 19 is turned on, light is incident from the translucent resin layer 11 of the light emitting display member 30. Then, the light incident on the translucent resin layer 11 is incident on the first fiber base material layer 2 from the surface of the light emitting display sheet 10 on the side integrated with the translucent resin layer 11, that is, the second surface S of the first fiber base material layer 2. Then, the light incident on the first fiber base material layer 2 is reflected and diffused on the fiber surface inside the first fiber base material layer 2, and then emitted from the light transmission part formed in the printing layer 4, that is, the non-printing part D. On the other hand, the printing part 4A blocks the transmission of light.

[0103] Then, the light emitted from the non-printing portion D further passes through the surface material layer 3 and is emitted from the outer surface of the surface material layer 3. In this way, the light E emitted from the light emitting device 19 is led out from the outer surface of the surface material layer 3. The arrow shows the light E emitted from the outer surface of the surface material layer 3. In this case, the light led out from the outer surface of the surface material layer 3 emits in a shape consistent with the shape of the non-printing portion D formed on the printing layer 4. For example, Figure 5 As shown in (a), on the outer surface side of the surface material layer 3, the shape of the icon indicating the operation state of the audio device emerges on the outer surface side.

[0104] Furthermore, when the surface material layer 3 is appropriately colored, the surface material layer 3 makes the first fiber base material layer 2 less visible from the outside when the light source 19a is turned off.

[0105] The brightness of the light emitted by the light emitting device 19 can be appropriately selected according to the application, and is preferably 20 to 200 lumens, more preferably 30 to 100 lumens, for example, from the perspective of ensuring a sufficient light intensity for visualizing the light display.

[0106] Embodiments of the light emitting display sheet, the light emitting display member, and the light emitting display device have been described above. Next, as a representative example of the light emitting display sheet, a light emitting display sheet having an artificial leather surface material layer will be described in more detail according to a manufacturing method.

[0107] The fiber substrate used as the first fiber substrate layer or the second fiber substrate layer of the light-emitting display sheet is a fiber structure including non-woven fabric, fabric, knitted fabric, etc., and a sheet material in which a polymer elastic body is impregnated in the gaps of the fiber structure as required. From the perspective of easily increasing the fiber density, increasing the apparent density, and easily reducing the uneven density of the fibers to make the surface smooth, non-woven fabrics are preferred among the fiber structures, and non-woven fabrics of ultrafine fibers with an average fineness of less than 1.0 dtex are particularly preferred. As a representative example, the case of using a fiber substrate including a non-woven fabric of ultrafine fibers is described in detail below.

[0108] The nonwoven fabric of ultrafine fibers is obtained by entangling ultrafine fiber-generating type fibers such as island-type (matrix-microdomain) composite fibers and performing an ultrafine fiberization treatment. It should be noted that in the present embodiment, the case of using island-type composite fibers is described in detail. It should be noted that ultrafine fiber-generating type fibers other than island-type composite fibers can also be used to replace the island-type composite fibers. In addition, ultrafine fiber-generating type fibers can also be directly spun without using ultrafine fiber-generating type fibers. As specific examples of ultrafine fiber-generating type fibers other than island-type composite fibers, there can be cited peelable split type fibers, petal type fibers, etc. The peelable split type fibers are formed by lightly bonding a plurality of ultrafine fibers immediately after spinning, and can be untied by mechanical operation to form a plurality of ultrafine fibers. The petal type fibers are formed by alternately aggregating a plurality of resins into petal shapes in the melt spinning process.

[0109] In the manufacture of ultrafine fiber nonwoven fabrics, first, a thermoplastic resin that constitutes a sea component (matrix component) of the island-in-sea type composite fiber and a thermoplastic resin that constitutes an island component (micro-region component) of the island-in-sea type composite fiber, which can be selectively removed, are melt-spun and stretched to produce an island-in-sea type composite fiber, wherein the island component of the island-in-sea type composite fiber is a resin component that forms the ultrafine fibers.

[0110] As the thermoplastic resin of the sea component, a thermoplastic resin having different solubility in a solvent or decomposition in a decomposing agent from the resin of the island component can be selected. Specific examples of the thermoplastic resin constituting the sea component include water-soluble polyvinyl alcohol resins, polyethylene, polypropylene, polystyrene, ethylene-propylene resins, ethylene-vinyl acetate resins, styrene-ethylene resins, styrene-acrylic resins, and the like.

[0111] As the resin component that forms the island component and forms the ultrafine fiber, that is, the thermoplastic resin, there is no particular limitation as long as it is a resin that can form the island-type composite fiber and the ultrafine fiber. Specifically, for example, aromatic polyesters such as polyethylene terephthalate (PET), isophthalic acid-modified PET, sulfoisophthalic acid-modified PET, polybutylene terephthalate, and polyhexamethylene terephthalate; aliphatic polyesters such as polylactic acid, polyethylene succinate, polybutylene succinate, polybutylene succinate adipate, and polyhydroxybutyrate-polyhydroxyvalerate resins; polyamides such as polyamide 6, polyamide 66, polyamide 10, polyamide 11, polyamide 12, and polyamide 6-12; polyolefins such as polypropylene, polyethylene, polybutene, polymethylpentene, and chlorinated polyolefins, etc. These can be used alone or in combination of two or more.

[0112] As a method for manufacturing an ultrafine fiber nonwoven fabric, for example, a method of melt-spinning sea-island type composite fibers to manufacture a web, subjecting the web to an entanglement treatment, and then selectively removing the sea component from the sea-island type composite fibers to form ultrafine fibers can be cited. As a method for manufacturing a web, a method of forming a long fiber web by capturing long fiber sea-island type composite fibers spun by a spunbond method or the like on a web without cutting them, a method of forming a short fiber web by cutting long fibers into short fibers, etc. Among them, a long fiber web is particularly preferred from the perspective of easily increasing the fiber density and increasing the apparent density, and easily reducing the uneven density of the fibers and making the surface smooth. In addition, in order to impart morphological stability, the formed web may also be subjected to a fusion treatment.

[0113] It should be noted that long fibers do not refer to short fibers that are intentionally cut after spinning, but to continuous fibers. More specifically, for example, they refer to fibers that are not intentionally cut into short fibers with a fiber length of about 3 to 80 mm. The fiber length of the island-in-the-sea composite fiber before ultrafine fiberization is preferably 100 mm or more, which is technically possible to manufacture, and as long as it is not inevitably cut during the manufacturing process, it can also reach a fiber length of several meters, hundreds of meters, thousands of meters or longer. It should be noted that due to the needle punching and surface polishing during the entangling process described later, sometimes a part of the long fiber is inevitably cut to form short fibers during the manufacturing process.

[0114] In any process until the sea component of the island-in-sea composite fiber is removed to form ultrafine fibers, the island-in-sea composite fiber can be made dense by performing fiber shrinkage treatment such as entanglement treatment and heat shrinkage treatment using water vapor. As an example of the entanglement treatment, there can be mentioned a method of stacking about 5 to 100 webs and performing needle punching or high-pressure water jet treatment.

[0115] The sea component of the sea-island composite fiber is dissolved or decomposed and removed at an appropriate stage after forming the web. By such decomposition removal or dissolution extraction removal, the sea-island composite fiber is ultrafinely fibrous to form a nonwoven fabric of ultrafine fibers in the form of fiber bundles. The apparent density of the nonwoven fabric of ultrafine fibers in the form of fiber bundles can also be further increased by heat shrinking treatment, heating rollers or heating pressing.

[0116] The fiber structure can be provided with the polymeric elastic body by impregnating the fiber structure with a solution or an emulsion of the polymeric elastic body and thereby coagulating the polymeric elastic body.

[0117] As a method for imparting a polymer elastomer to a fiber structure such as a nonwoven fabric, there can be cited a method of impregnating a fiber structure with a solution or emulsion of a polymer elastomer and then coagulating the polymer elastomer. As a method for impregnating a fiber structure with a solution or emulsion of a polymer elastomer, it is preferred to adopt an immersion and clamping method in which a solution or emulsion is impregnated once or multiple times in a manner such that the fiber structure becomes a given impregnation state and then squeezed using a pressure roller or the like. In addition, as other methods, a rod coating method, a knife coating method, a roller coating method, a notched wheel coating method, a spray coating method, etc. can also be adopted.

[0118] The content ratio of the polymer elastomer in the fiber base material is preferably 3 to 40% by mass, more preferably 8 to 35% by mass, and particularly preferably 12 to 30% by mass, from the perspective of increasing the apparent density of the fiber base material by increasing the fiber density and allowing the ink used for printing the printing part to easily penetrate and be carried by capillary action.

[0119] Thus, a fiber substrate can be obtained. The obtained fiber substrate can be subjected to thickness adjustment based on slicing treatment, grinding treatment, etc. as needed. In addition, the fiber substrate can be further pressed to adjust the apparent density. Specifically, by hot pressing the fiber substrate by pressing or heating at room temperature, the voids in the substrate of the fiber substrate layer can be reduced, and the fiber density of the fiber structure can be increased. The pressing device is not particularly limited, and for example, a manual press, a roller press, etc. can be used.

[0120] When pressing is performed, the pressing pressure is preferably 5 to 20 MPa, more preferably 8 to 15 MPa, from the perspective of maintaining the appearance quality. In addition, when hot pressing is used, the set temperature of the pressing plate is preferably 100 to 150° C., more preferably 110 to 120° C., from the perspective of maintaining the appearance quality. In this way, the apparent density of the fiber base material can be adjusted.

[0121] In addition, in the fiber substrate, in order to make one side of the light-shielding layer to be printed smooth, the side of the fiber substrate to be printed can be smoothed by grinding. As the surface roughness of the first surface L, the arithmetic mean height Sa based on ISO25178 is preferably 3 to 20 μm. It should be noted that the arithmetic mean height (Sa) based on ISO25178 is a parameter representing the average value of the absolute value of the difference between the height of each point and the average surface of the surface. When the arithmetic mean height Sa of the first surface L is too high, one side of the printed printing part is too fuzzy and lacks smoothness, the ink spreads, and there is a tendency that it is difficult to correctly carry on the printed surface. In addition, when the arithmetic mean height Sa of the first surface L is too low, after the ink is applied, the anchoring effect becomes difficult to work, and there is a tendency that the fixation of the ink is reduced. In addition, in order to make the surface smooth, a coating with a thickness of about 5 to 80 μm can also be provided on the first surface L.

[0122] Thus, a fiber substrate can be obtained. Then, a printing part is printed on one side of the obtained fiber substrate using ink. The printing part is formed by printing symbols, patterns, images such as text and icons to be displayed luminously on one side of the fiber substrate using ink, or a non-printing part is formed without printing. The printing method used for printing is not particularly limited, and screen printing, gravure printing, inkjet printing, etc. can be cited. Among them, screen printing is preferred from the perspective of mass production because it can stably apply ink with a relatively low-cost process.

[0123] The viscosity of the ink used for printing is designed to a preferred range depending on the printing method. In the case of screen printing, the viscosity of the applied ink after dilution with a solvent is preferably about 10 to 100 Pa·sec from the perspective of appropriate penetration into the fiber substrate.

[0124] Thus, a fiber base material having a printed layer can be formed, wherein the printed layer includes a printed portion that serves as a light shielding layer and a non-printed portion that transmits light. Then, a surface material is laminated on the surface of the fiber base material having the printed layer formed thereon.

[0125] As a method for laminating a surface material on the surface of a fiber base material on which a printed layer is formed, there can be cited a method of bonding the fiber base material and the surface material with an adhesive by heat pressing a stack having an adhesive sandwiched between the surface material and the surface of the fiber base material on which a printed layer is formed.

[0126] As representative examples of artificial leathers of surface materials, there can be mentioned, for example, grained artificial leathers having a surface resin layer laminated on one side of the above-mentioned fiber base material, and suede-like and nubuck-like raised-hair artificial leathers having raised-hair fibers formed on one side of the fiber base material.

[0127] Grained artificial leather is obtained by forming a surface resin layer containing a light-transmitting polymer elastic body such as polyurethane on one side of a fiber base material by a dry surface forming method, a direct coating method, etc. In addition, raised nap artificial leather is formed by performing a nap treatment on one side of a fiber base material by grinding with sandpaper, emery paper, etc.

[0128] As the resin for forming the surface resin layer of the grain artificial leather, various polyurethanes such as polycarbonate polyurethane, polyester polyurethane, polyether polyurethane, acrylic elastomer, polyurethane acrylic composite elastomer, polyvinyl chloride elastomer, synthetic rubbers such as silicone rubber, etc. with light transmittance can be cited. These resins can be used alone or in combination of two or more. Among them, polyurethane is preferably used from the aspect of excellent mechanical properties such as wear resistance and bending resistance.

[0129] The dry coating method is a method in which a resin film containing a polymer elastic body is formed on a supporting substrate such as release paper, an adhesive is applied to the surface of the resin film, and the film is attached to the side of the fiber substrate on which the printed layer is formed, and the film is pressed and bonded as needed, and the release paper is peeled off to form a surface resin layer having light transmittance. In addition, the direct coating method is a method in which a liquid resin or resin liquid containing a polymer elastic body is directly applied to the side of the fiber substrate on which the printed layer is formed, and the resin layer is cured to form a surface resin layer.

[0130] The adhesive used to form the adhesive layer in the dry surfacing method is not particularly limited. For example, in the case of polyurethane, a polyurethane adhesive is preferably used. The thickness of the adhesive layer is not particularly limited, but is preferably 0.03 to 0.3 mm, and more preferably 0.05 to 0.2 mm.

[0131] In addition, when the surface layer material has thermal softening properties, bonding can be performed by thermocompression bonding without using an adhesive.

[0132] In the light-emitting display sheet thus obtained, since the printed layer including the printed portion that serves as a light-shielding layer and the unprinted non-printed portion that transmits light is sandwiched by the first fiber base material layer and the surface material layer, the printed portion is not easily melted and destroyed even when injection molding is performed for integration with the injection-molded body. The light-emitting display sheet or light-emitting device using the light-emitting display sheet of this embodiment can form a surface for light-emitting display in the interior decoration of household appliances, automobiles, airplanes, ships, buildings, etc.

[0133] Example

[0134] The present invention will be described in more detail below by way of examples. It should be noted that the scope of the present invention is not limited by these examples.

[0135] [Example]

[0136] As a fiber substrate for the first fiber substrate layer, a fiber substrate with a thickness of 0.35 mm and an apparent density of 0.50 g / cm 3 A fiber substrate A is provided, the fiber substrate A comprising ultrafine fibers of modified PET having an average fineness of 0.9 dtex and a Tg of 100° C. and polyurethane. The arithmetic mean height Sa of the first surface of the fiber substrate A is 7.6 μm, and the arithmetic mean height Sa of the second surface is 10.0 μm. Then, a printing layer is printed on the first surface of the fiber substrate A by screen printing. The printing is performed in a manner that a printed portion having an outline of a black grid pattern is formed.

[0137] On the other hand, as a fiber base material used for forming the second fiber base material layer of the artificial leather, a fiber base material with a thickness of 0.35 mm and an apparent density of 0.50 g / cm 3 A fiber base material B comprising ultrafine fibers of modified PET having an average fineness of 0.9 dtex and a Tg of 100° C. and polyurethane.

[0138] In addition, a 30 μm thick film of a silicone-modified polycarbonate polyurethane resin was formed as a grainy surface resin layer on the surface of the wrinkled release paper, and then a 70 μm thick adhesive layer of a polyurethane adhesive was laminated on the surface of the silicone-modified polycarbonate polyurethane resin film.

[0139] Then, a deposited body in which the film of the silicone-modified polycarbonate-based polyurethane resin was superimposed on the fiber substrate B was formed so that the adhesive layer faced one surface of the fiber substrate B. Then, the deposited body was heated at 80° C. for 2 minutes. Then, the release paper was peeled off, thereby manufacturing an artificial leather in which the fiber substrate B and the film of the silicone-modified polycarbonate-based polyurethane resin were bonded together by the polyurethane adhesive.

[0140] Then, a sheet of a polyurethane adhesive as a hot melt adhesive with a thickness of 50 μm was arranged on the first surface of the fiber substrate A on which the printed layer was formed, and the fiber substrate B of the artificial leather was stacked thereon to form a deposited body. Then, the deposited body was pressed by a hot press machine with a surface temperature of 100° C., thereby manufacturing a light-emitting display sheet in which the fiber substrate A as the first fiber substrate layer and the artificial leather were bonded together by the polyurethane adhesive.

[0141] Then, the light emitting display sheet was hot-pressed at a mold temperature of 100° C. and a press pressure of 4 MPa using a press mold for imparting a shape corresponding to an injection molding mold described later, thereby forming a preform.

[0142] Then, in-mold molding was performed using a preform of the light-emitting display sheet trimmed into a given shape. Specifically, in the state where the movable side mold and the fixed side mold of the injection molding mold mounted on an electric injection molding machine (SE-100 manufactured by Sumitomo Heavy Industries, Ltd.) are opened, the preform and the cavity forming surface of the movable side mold are positioned and configured. It should be noted that the preform is configured so that the artificial leather and the cavity forming surface are opposite. Then, the movable side mold and the fixed side mold are molded together. It should be noted that the shape of the cavity of the injection molding mold is a circular shape with a thickness of 3 mm, a diameter of 80 mm, a height of 10 mm, and a trapezoidal cross-section.

[0143] Then, the MBS resin was injected and filled into the mold cavity under the conditions of a resin temperature of 240°C and a mold temperature of 40°C. After the filling was completed, the mold was opened after cooling. Thus, a light-emitting display component was obtained in which the surface layer of the fiber substrate A as the first fiber substrate layer of the light-emitting display sheet was integrated with the surface of the MBS resin molded body.

[0144] The printed layer was observed with the naked eye from one side of the MBS resin molded body of the obtained light-emitting display component. As a result, no deformation of the outline of the printed portion that forms the boundary between the printed portion and the non-printed portion was confirmed. In addition, a circular LED device with a brightness of 40 lumens and a diameter of 3.5 mm was arranged opposite to one side of the MBS resin molded body of the obtained light-emitting display component, and a light-emitting device with a distance of 20 mm from the sample was arranged. The light from the light-emitting device was passed through the light-emitting display component, and the lattice pattern formed by the light emission that appeared on the surface resin layer of the surface material layer was observed with the naked eye. The photograph at this time is shown in Figure 6 .

[0145] [Comparative Example]

[0146] In the embodiment, a stacked body in which one side of the fiber substrate B of the artificial leather is overlapped is formed in a manner opposite to the second side of the fiber substrate A on which the printed layer is not formed, instead of forming a stacked body in which one side of the fiber substrate B of the artificial leather is overlapped in a manner opposite to the first side of the fiber substrate A on which the printed layer is formed, and otherwise, a luminous display sheet and a luminous display component are manufactured in the same manner.

[0147] Then, the printed layer was observed with the naked eye from one side of the MBS resin molded body of the obtained light-emitting display component. As a result, the outlines of the grid pattern of the printed parts were observed and the parts with significant deformation were confirmed. In addition, the light from the light-emitting device was transmitted through the light-emitting display component in the same way as in the embodiment, and the light emission of the grid pattern formed by the light emission on the surface of the surface material layer was observed with the naked eye. The photograph at this time is shown in FIG. Figure 7 .

[0148] like Figure 6 As shown in FIG. 1 , in the light-emitting device using the light-emitting display member obtained in the embodiment of the present invention, the outline of the grid of the printed part is not destroyed and the outline is clear. As a result, the contrast of the light-emitting display is increased. On the other hand, Figure 7 As shown, in the light-emitting device using the light-emitting display member obtained in the comparative example, the outline of the grid of the printed part was destroyed, and a large number of unclear portions were confirmed.

Claims

1. A light-emitting display sheet, comprising: a first fiber substrate layer, and a surface material layer laminated on the first fiber substrate layer, wherein the first fiber substrate layer comprises a nonwoven fabric of ultrafine fibers having an average fineness of 1.0 dtex or less and a polymer elastomer impregnated into the nonwoven fabric, and comprises a surface material layer having an apparent density of 0.3 g / cm 3 The above fiber base materials, The first fiber base material layer includes a first surface facing the surface material layer and a second surface opposite to the first surface. The light-emitting display sheet further includes a printed portion having an outline and sandwiched between the first surface of the first fiber base material layer and the surface material layer, wherein the printed portion is formed on the first surface by printing.

2. The light-emitting display sheet according to claim 1, wherein: The first fiber base material layer and the surface material layer are bonded together via an adhesive layer.

3. The light-emitting display sheet according to claim 1, wherein: The arithmetic mean height Sa of the first surface according to ISO 25178 is 3 to 20 μm.

4. The light-emitting display sheet according to claim 1, wherein: The surface material layer comprises a second fiber base material layer, The printing section is sandwiched between the first fiber base material layer and the second fiber base material layer.

5. The light-emitting display sheet according to claim 4, wherein: The surface material layer further includes a decorative layer laminated on the outer surface side of the second fiber base material layer.

6. The light-emitting display sheet according to claim 5, wherein: The decorative layer is a leather grain-like resin layer.

7. The light-emitting display sheet according to claim 1, wherein: The surface material layer includes at least one selected from a textile raw material, a wood sheet, a stone sheet, a metal sheet and a resin sheet. 8 . A light-emitting display member comprising: the light-emitting display sheet according to claim 1 , and a light-transmitting resin layer integrated with the second surface.

9. The light-emitting display member according to claim 8, wherein: The light-transmitting resin layer is an injection-molded body. 10 . A light-emitting display device comprising: the light-emitting display member according to claim 8 or 9 , and a light-emitting device disposed on one side of the light-transmitting resin layer.

11. A method for manufacturing a light-emitting display component, the method comprising: A step of placing the light-emitting display sheet according to any one of claims 1 to 7 in a cavity of an in-mold molding die and performing mold closing; and A step of integrating a light-transmitting resin layer with the second surface of the first fiber base material layer forming the light-emitting display sheet accommodated in the in-mold molding die by injection molding.

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