Skin material, manufacturing method thereof, and interior material

Abstract

The present invention aims to provide a skin material, a method for manufacturing the same, and an interior material, wherein the skin material comprises a base fabric layer having a structure in which an outer fabric and an inner fabric are joined and a gap is formed between the two layers, and the skin material can express a more excellent three-dimensional effect than before. The skin material (1) comprises a design layer (11) and a base fabric layer (12), the design layer (11) comprises a surface layer (111) and a foaming layer (112), the base fabric layer (12) comprises an outer fabric (121) and an inner fabric (122), and a binding yarn (123) for joining the two layers, the binding yarn (123) being arranged upright between the outer fabric (121) and the inner fabric (122) and being a thermoplastic resin fiber forming a gap (125) between the outer fabric (121) and the inner fabric (122), and the foaming layer (112) is bonded to the outer fabric (121). The interior material (5) comprises a skin material (1) and a base material (3) to which the skin material (1) is attached. The method for manufacturing the skin material (1) comprises a step of bonding a surface layer (111) to a base fabric layer (12) by means of a foaming adhesive forming a foaming layer (112).

Description

Technical Field

[0001] The present invention relates to a skin material, a method for producing the same, and an interior material. More specifically, the present invention relates to a skin material having a base fabric layer with a gap between an outer fabric layer and an inner fabric layer, a method for producing the same, and an interior material. Background Art

[0002] Interior materials are known in the past, where a surface material for imparting a design is attached to a base material. In addition to visual design, surface materials are sometimes required to have a tactile design. For example, leather-like surface materials with embossed patterns correspond to this. In addition to the surface design, leather-like surface materials with embossed patterns are also required to have a unique tactile feel similar to leather. Patent Document 1 below is a known example of such a surface material.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 2017-213865 Summary of the Invention

[0006] Problems to be solved by the invention

[0007] Patent Document 1 discloses a cover material comprising a three-dimensional knitted fabric composed of two inner and outer knitted fabric layers bound together by a binding yarn. This base fabric layer can be embossed by thermally deforming the thermoplastic resin fibers used as the binding yarn, thereby adjusting the concave heat-deformed portions to a predetermined thickness. This allows for a cover material with a three-dimensional design, including a superior three-dimensional pattern, and a high degree of design freedom.

[0008] However, in the ever-evolving industrial design, there is a constant demand for better design, and there is a real need for higher design and greater freedom.

[0009] The present invention has been made in view of the above-mentioned actual situation, and its purpose is to provide a skin material and a manufacturing method thereof, as well as an interior material, wherein the skin material has a base fabric layer having a structure in which an outer fabric layer and an inner fabric layer are connected and a gap is formed between the two layers, and the skin material can express a better three-dimensional effect than before.

[0010] Solutions for solving problems

[0011] The present invention is as follows.

[0012] [1] The main purpose of the surface material of the present invention is to have a design layer and a base fabric layer.

[0013] The aforementioned design layer comprises a surface layer and a foaming layer.

[0014] The base fabric layer comprises an outer fabric layer, an inner fabric layer, and a binding yarn for binding the two layers.

[0015] The aforementioned binding yarn is vertically arranged between the aforementioned outer fabric and the aforementioned inner fabric and is a thermoplastic resin fiber that forms a gap between the aforementioned outer fabric and the aforementioned inner fabric.

[0016] The foam layer is bonded to the outer fabric.

[0017] [2] In the skin material of the present invention, the foam layer may be thicker than the skin layer and thinner than the base fabric layer.

[0018] [3] In the skin material of the present invention, the foamed layer may have closed cells.

[0019] [4] The skin material of the present invention may have a three-dimensional design formed by narrowing the gap in the thickness direction.

[0020] [5] The gist of the interior material of the present invention is that it comprises the surface material of the present invention and a base material to which the surface material is attached.

[0021] [6] The gist of the method for producing a skin material of the present invention is to include a bonding step of bonding the skin layer and the base fabric layer with the aid of a foaming adhesive that becomes the foam layer.

[0022] Effects of the Invention

[0023] The skin material of the present invention includes a base fabric layer having a structure in which an outer fabric layer and an inner fabric layer are joined together and a gap is formed between the two layers. The skin material can express a more excellent three-dimensional effect than before.

[0024] The interior material of the present invention uses a skin material having a base fabric layer having a structure in which an outer fabric layer and an inner fabric layer are joined together with a gap formed between the two layers, thereby achieving a more excellent three-dimensional design than before. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present invention is further described in the following detailed description by way of non-limiting examples based on typical embodiments of the present invention and with reference to the accompanying drawings, wherein like reference numerals represent like parts throughout the several views.

[0026] Figure 1 This is a schematic diagram illustrating a cross section of an example of the surface material of the present invention.

[0027] Figure 2This is a schematic diagram illustrating a cross section of another example of the skin material of the present invention.

[0028] Figure 3 This is a schematic diagram illustrating a cross section of an example of the interior material of the present invention.

[0029] Figure 4 This is a schematic diagram illustrating the processing of another example of the skin material of the present invention.

[0030] Figure 5 It is an enlarged view showing the appearance of the surface of the skin material according to the embodiment.

[0031] Figure 6 This is an enlarged view showing the appearance of the surface of a skin material according to a comparative example. DETAILED DESCRIPTION

[0032] Hereinafter, the present invention will be described in detail with reference to the drawings.

[0033] The items shown here are examples and are used to exemplify the embodiments of the present invention. They are described for the purpose of providing an explanation that is believed to be the most effective and easy to understand the principles and conceptual features of the present invention. This is not intended to show the structural details of the present invention beyond the level necessary for a fundamental understanding of the present invention. Instead, it is intended to enable those skilled in the art to clearly understand how some aspects of the present invention are actually implemented through the description in conjunction with the accompanying drawings.

[0034] [1]Surface material

[0035] The surface material (1) of the present invention comprises a design layer (11) and a base fabric layer (12).

[0036] The design layer (11) includes a surface layer (111) and a foaming layer (112).

[0037] Furthermore, the base fabric layer (12) comprises an outer fabric (121) and an inner fabric (122), and a binding yarn (123) for binding the two layers together. The binding yarn (123) is vertically arranged between the outer fabric (121) and the inner fabric (122), and is a thermoplastic resin fiber that forms a gap (125) between the outer fabric (121) and the inner fabric (122).

[0038] Furthermore, the feature is that the foaming layer (112) is bonded to the outer fabric (121) (refer to Figure 1 ).

[0039] In this way, when the design layer 11 and the base fabric layer 12 are bonded via the foam layer 112 and a three-dimensional design 15 (such as an embossed pattern or stitch pattern) is formed by heat pressing, it is believed that heat applied to the surface material 1 is prevented from being retained or accumulated in the design layer 11. In other words, the presence of the foam layer 112 is believed to increase the heat dissipation capacity compared to a configuration without the foam layer 112. Therefore, even when sufficient heat is applied to form the three-dimensional design, damage to the design layer 11 is suppressed, while the binder yarn 123 can be more reliably thermally deformed. In other words, even when applying higher temperatures and greater amounts of heat to thermally deform the binder yarn 123 than conventional methods, damage to the design layer 11 can be prevented. Therefore, the present surface material 1 can achieve a superior three-dimensional effect compared to conventional methods.

[0040] Furthermore, in addition to the above-mentioned effect of increasing the heat dissipation capacity, it is believed that increasing the rigidity of the design layer 11 as a whole is also conducive to embodying an excellent three-dimensional effect. It is believed that this is because the rigidity of the skin material 1 as a whole is enhanced by having the foaming layer 112. That is, when a three-dimensional design 15 is applied to a skin layer with low rigidity, wrinkles may sometimes be generated in the skin material. In contrast, in the present skin material 1 with high rigidity, wrinkles will not be generated even if a three-dimensional design is formed, and a neat and beautiful three-dimensional design can be obtained. In other words, it can be considered that if the weight per unit area is the same, the skin material 1 as a whole can obtain higher rigidity when it exists in a foamed state than when the specified material exists in a non-foamed state, and therefore, an excellent three-dimensional effect can be embodied.

[0041] Furthermore, the presence of the foamed layer 112 increases the overall thickness of the design layer 11. Specifically, for the same basis weight, the thickness of the design layer 11 increases when the specified material is in a foamed state compared to when the specified material is in a non-foamed state. Furthermore, when the three-dimensional design 15 is applied, the design layer 11 may be stretched, particularly around the three-dimensional design. However, due to the increased thickness, surface functions such as chemical resistance and friction durability can be maintained at a higher level. Furthermore, even when the design layer 11 is stretched around the three-dimensional design, the uneven shape of the base fabric layer 12 is prevented from affecting the design layer 11 in that area. This prevents the unevenness of the outer fabric 121 of the base fabric layer 12 from being reflected in the design layer 11 and becoming visible from the surface of the design layer 11.

[0042] The "design layer (11)" is a layer comprising a surface layer 111 and a foam layer 112. The surface layer 111 is the layer having a design surface in the skin material 1. Specifically, when the skin material 1 is used as an interior material (for example, an interior material for an interior room or a vehicle interior), the surface layer 111 is the layer exposed indoors or inside a vehicle.

[0043] The surface layer 111 is the layer forming the design in the design layer 11, and any layer may be used. For example, a resin layer (polyurethane, polyvinyl chloride, polypropylene, etc.), a woven fabric (designed woven fabric), synthetic leather, artificial leather, natural leather, etc. may be used. These may be used alone or in combination of two or more.

[0044] The surface layer 111 may be a single layer or may comprise multiple layers. Examples of multilayered layers include a protective layer (topcoat) provided on the outermost layer of the aforementioned resin layer, woven fabric, synthetic leather, artificial leather, natural leather, or the like. The protective layer may be provided, for example, in the form of a permeable resin coating (e.g., polyurethane).

[0045] Among the above, the surface layer 111 is preferably a polyurethane layer. The polyurethane layer may be in any form, but is preferably a non-foamed polyurethane, and more preferably a polyurethane formed into a film.

[0046] The urethane raw material constituting the surface layer 111 is not limited, but generally includes a polyol component and a polyisocyanate component.

[0047] Among them, the polyol component can be exemplified by compounds having at least two hydroxyl groups in the molecule, such as polycarbonate polyols, polyether polyols, polyester polyols, alkylene glycols, and polymer polyols using polyether polyols or polyester polyols. These can be used alone or in combination of two or more. Among these, polycarbonate polyols are preferably included, and examples of the polycarbonate polyols include polycarbonate diols.

[0048] Examples of the polyisocyanate component include compounds having at least two isocyanate groups in the molecule, such as aliphatic polyisocyanates, aromatic polyisocyanates, and modified compounds thereof. These may be used alone or in combination of two or more.

[0049] Examples of aliphatic polyisocyanates include hexamethylene diisocyanate, isophorone diisocyanate, and dicyclohexamethylene diisocyanate. Examples of aromatic polyisocyanates include toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), naphthalene diisocyanate, xylene diisocyanate, and polymeric polyisocyanates (crude MDI). Furthermore, examples of modified polyisocyanate compounds include carbodiimide-modified compounds of aliphatic polyisocyanates or aromatic polyisocyanates.

[0050] The thickness of the surface layer 111 is not limited, and can be, for example, 5 mm or less. More specifically, the surface layer 111 can be 5 μm or more and 1000 μm or less, and further can be 20 μm or more and 150 μm or less.

[0051] For example, when the protective layer is provided, the protective layer may occupy, for example, 0.1 μm to 20 μm, or further 1 μm to 10 μm, of the thickness.

[0052] The above-mentioned "foaming layer (112)" is a resin layer containing bubbles formed by foaming. That is, the cell walls between the bubbles separating the foaming layer 112 are formed by resin. In addition, the bubbles constituting the foaming layer 112 can be connected bubbles, preferably independent bubbles. When they are independent bubbles, they can have a good balance of heat dissipation and heat insulation properties as the skin material 1. In addition, the type of resin constituting the foaming layer 112 is not limited, and polyurethane resins, polyolefin resins, polyvinyl chloride resins, polystyrene resins, polyamide resins, polyurethane elastomers, thermoplastic elastomers, etc. can be used. Only one of these can be used, or two or more can be used in combination.

[0053] Among these, the resin type is preferably a polyurethane resin. That is, the foam layer 112 is preferably a foam polyurethane layer. The foam polyurethane layer can be formed by any method. For example, examples of the foam polyurethane layer include a laminated polyurethane layer, a slab polyurethane layer cut from a slab-formed foam polyurethane, and a molded polyurethane layer cut from a molded foam polyurethane. In addition, injection-molded foam polyurethane layers, spray-foamed foam polyurethane layers, and hot-melt polyurethane layers can also be used.

[0054] Among these, the foam layer 112 of the skin material 1 of the present invention is preferably a foamed polyurethane layer formed by lamination, that is, a foamed polyurethane layer formed by foaming a polyurethane adhesive.

[0055] For example, among the above, the slab polyurethane layer can also be appropriately utilized. When the slab polyurethane layer is used, it is necessary to use an adhesive or the like to bond the surface layer 111 to the slab polyurethane layer serving as the foaming layer 112. Furthermore, it is also necessary to use an adhesive or the like to bond the slab polyurethane layer serving as the foaming layer 112 to the outer fabric 121 of the base fabric layer 12.

[0056] In contrast, in the laminated polyurethane layer, a foamed polyurethane raw material is applied between the surface layer 111 and the base fabric layer 12 (the outer fabric 121 of the base fabric layer 12) and reacted to form the foamed layer 112 while bonding the surface layer 111 and the base fabric layer 12. In other words, the design layer 11 and the base fabric layer 12 can be bonded together using the foamed polyurethane layer 112.

[0057] Thus, when a laminated polyurethane layer is used as the foam layer 112, there is no need to insert another adhesive inside or outside the foam layer 112, thereby preventing the adhesive from hindering flexibility. In addition, VOC problems when used as an interior material can be avoided.

[0058] It should be noted that the method for forming the laminated polyurethane layer is not limited. For example, a one-component polyurethane adhesive or a two-component polyurethane adhesive may be used, and these may be used alone or in combination.

[0059] The polyurethane raw materials used are not limited, but generally include a polyol component and a polyisocyanate component.

[0060] Among them, the polyol component can be exemplified by compounds having at least two hydroxyl groups in the molecule, such as polycarbonate polyols, polyether polyols, polyester polyols, alkylene glycols, and polymer polyols using polyether polyols or polyester polyols. These can be used alone or in combination of two or more. Among these, polycarbonate polyols are preferably included. Examples of polycarbonate polyols include polycarbonate diols.

[0061] Examples of the polyether polyols include those obtained by adding alkylene oxide to polyols. Examples of polyester polyols include polyester polyol compounds obtained by polycondensing aliphatic carboxylic acids and / or aromatic carboxylic acids with polyols. Examples of alkylene glycols include polyols.

[0062] It should be noted that, regarding the polyisocyanate component, the description of the surface layer 111 described above can be applied as it is.

[0063] The polyurethane raw material used to form the foam layer 112 may contain a foaming agent in addition to a polyol component and a polyisocyanate component. Examples of the foaming agent include water, hydrocarbons (such as pentane), liquefied carbon dioxide, and alkylene chlorides (such as dichloromethane and dichloroethane). These may be used alone or in combination of two or more.

[0064] In addition to the various components mentioned above, the polyurethane raw materials may also contain various other components such as catalysts, foam stabilizers, crosslinking agents, antioxidants, ultraviolet absorbers, fillers, internal mold release agents, and flame retardants. These other components may be used alone or in combination of two or more.

[0065] Examples of the catalyst include amines (amine compounds) and organometallic compounds. Various surfactants can be used as appropriate as the foam stabilizer.

[0066] The foam layer 112 of the skin material 1 of the present invention can be formed without using a foaming agent. Specifically, it can be formed by causing the polyurethane raw material itself to contain bubbles. For example, when mixing a polyol component and a polyisocyanate component, the polyurethane raw material can be made to contain bubbles by foaming the mixed solution. In this case, a surfactant, for example, can be used as needed.

[0067] The thickness of the foam layer 112 is not limited, and can be, for example, 50 μm to 1000 μm, 80 μm to 500 μm, or 100 μm to 300 μm.

[0068] The above-mentioned "base fabric layer (12)" is a layer comprising an outer fabric 121, an inner fabric 122, and a binder yarn 123 for binding these two layers. In addition, the base fabric layer 12 is a composite layer comprising a layer comprising the outer fabric 121, a layer comprising the inner fabric 122, and a layer comprising the binder yarn 123.

[0069] The outer fabric 121 and the inner fabric 122 can each independently be a layer made of knitted fabric (double-knitted fabric), a layer made of woven fabric, a layer made of nonwoven fabric, a layer made of resin film, or other layers. Furthermore, a layer may be formed from only one of these types, or a composite layer may be formed from two or more types. When the outer fabric 121 and the inner fabric 122 are layers made of fibers, their constituent yarns may be thermoplastic resin fibers or fibers other than thermoplastic resin fibers. Furthermore, these fibers may be used singly or in combination.

[0070] Among the above, as thermoplastic resin fibers, polyester fibers, polyamide fibers, polyacrylic fibers and polyolefin fibers can be used. Among these, as polyester fibers, polyethylene terephthalate fibers, polybutylene terephthalate fibers, polypropylene terephthalate fibers, etc. can be mentioned. Furthermore, as polyamide fibers, various nylon fibers (nylon 6 fibers, nylon 66 fibers, etc.) can be mentioned. Furthermore, as polyacrylic fibers, various acrylic fibers containing polyacrylonitrile can be mentioned. Furthermore, as polyolefin fibers, polyethylene fibers, polypropylene fibers, etc. can be mentioned. Others, vinylon fibers, polyurethane fibers, etc. can also be mentioned. Only one of these can be used, or two or more can be used in combination. Among these, in addition, as fibers other than thermoplastic resin fibers, natural fibers and regenerated fibers can be mentioned. Among these, as natural fibers, cotton, linen, silk, wool, etc. can be mentioned. In addition, as regenerated fibers, cuprammonium rayon, viscose rayon, lyocell, etc. can be mentioned. These may be used alone or in combination of two or more.

[0071] The yarn is also not limited in form and may be either filament yarn or staple yarn. Furthermore, filament yarn may be either multifilament or monofilament. Furthermore, the yarn may be either non-bulky yarn or bulky yarn (plied yarn, false twist yarn, air jet yarn, etc.).

[0072] Furthermore, the fineness of the constituent yarns is not limited, and can be, for example, 50 dtex or more and 1500 dtex or less. In particular, constituent yarns of 70 dtex or more and 1200 dtex or less, 150 dtex or more and 1200 dtex or less, 70 dtex or more and 500 dtex or less, or 150 dtex or more and 500 dtex or less can be used. The fineness of the constituent yarns of the outer layer fabric 121 and the inner layer fabric 122 can be the same or different.

[0073] In the various combinations described above, it is preferable that both the outer fabric 121 and the inner fabric 122 are layers using knitted fabric (knitted fabric layer, knitted fabric).

[0074] When both the outer fabric 121 and the inner fabric 122 are knitted fabrics, their yarn densities are not limited. The yarn density in the course direction can be set to 10 yarns / inch or more and 100 yarns / inch or less, preferably 15 yarns / inch or more and 70 yarns / inch or less. Furthermore, the yarn density in the wale direction can be set to 5 yarns / inch or more and 50 yarns / inch or less. The yarn density in the wale direction is more preferably 15 yarns / inch or more and 50 yarns / inch or less, more preferably 8 yarns / inch or more and 40 yarns / inch or less, and particularly preferably 15 yarns / inch or more and 40 yarns / inch or less. The yarn densities of the outer fabric 121 and the inner fabric 122 may be the same or different.

[0075] The aforementioned fineness and yarn density can reduce the number of stitches, thereby making the stitches smaller. Consequently, a knitted fabric with virtually no stitches can be obtained. Thus, when knitted fabrics with few and small stitches are used as the outer fabric 121 and the inner fabric 122, the binding yarn 123 can be prevented from protruding from the knitted fabric when forming the three-dimensional design 15.

[0076] The binding yarn 123 is a thermoplastic resin fiber that is vertically arranged between the outer fabric 121 and the inner fabric 122 and forms a gap 125 between the outer fabric 121 and the inner fabric 122. The binding yarn 123 can bind the outer fabric 121 and the inner fabric 122 in any manner. For example, the binding yarn 123 can be interwoven by interweaving the outer fabric-side binding yarn woven into the outer fabric 121 with the inner fabric-side binding yarn woven into the inner fabric 122.

[0077] Furthermore, during heat pressing for providing the three-dimensional design 15 (embossed pattern, stitch pattern), the binder yarn 123 can have the function of narrowing the gap 125 formed between the outer fabric 121 and the inner fabric 122 in the thickness direction and maintaining the thickness thereof by thermal deformation.

[0078] As the binding yarn, thermoplastic resin fibers such as polyester fibers, polyamide fibers, polyacrylic fibers, and polyolefin fibers can be used. Among these, polyester fibers include polyethylene terephthalate fibers, polybutylene terephthalate fibers, and polypropylene terephthalate fibers. Furthermore, polyamide fibers include various nylon fibers (nylon 6 fibers, nylon 66 fibers, etc.). Furthermore, polyacrylic fibers include various acrylic fibers including polyacrylonitrile. Furthermore, polyolefin fibers include polyethylene fibers and polypropylene fibers. These may be used alone or in combination of two or more.

[0079] It should be noted that, in addition to the binding yarn 123, the base fabric layer 12 may also include other non-thermoplastic binding yarns for binding the outer fabric 121 and the inner fabric 122, as long as the binding yarns 123 used to form the three-dimensional design 15 are not hindered by thermal deformation. Specifically, these include natural fibers such as cotton, linen, silk, and wool. By including such fibers in the binding yarns, the base fabric layer 12 can achieve sufficient shape retention and impart softness.

[0080] The type of binder yarn is not limited, but filament yarn is preferred. Filament yarns can be either multifilament or monofilament, with monofilament being more preferred. Monofilament yarns can have the rigidity of a thread and are therefore preferred from the perspectives of thickness retention, cushioning properties, and shaping properties for the three-dimensional design 15. Furthermore, the binder yarn can be either a non-bulky yarn or a bulky yarn (such as a plied yarn, a false twist yarn, or an air jet yarn).

[0081] Furthermore, the binding yarn 123 can utilize yarn partially containing a low-melting-point material (hereinafter also referred to as "fusion yarn"). More specifically, a fusion yarn having a lower melting point than the constituent yarns of the outer fabric 121 and the inner fabric 122 can be utilized. The fusion yarn can be a single yarn, a combination of a fusion yarn and a non-fusion yarn (a yarn with a higher melting point than the fusion yarn), a monofilament yarn formed by laminating the fusion yarn and the non-fusion yarn, either alone or by twisting these yarns together, or a core-sheath monofilament yarn alone or by twisting these yarns together. Using this fusion yarn facilitates heat deformation during hot pressing for forming the three-dimensional design 15 (such as an embossed pattern or a stitch pattern).

[0082] Furthermore, highly crimped yarns may be used as all or part of the binding yarn 123. When highly crimped yarns are used, more excellent cushioning properties and shape retention properties can be obtained.

[0083] The fineness of the binding yarn 123 is not limited and can be set to 10 dtex or more and 1500 dtex or less. Furthermore, the fineness is preferably 20 dtex or more and 1000 dtex or less, and more preferably 20 dtex or more and 350 dtex or less.

[0084] Furthermore, the yarn density of the binding yarn 123 is not limited. However, the yarn density in the course direction can be set to 10 yarns / inch or more and 100 yarns / inch or less, and preferably 15 yarns / inch or more and 70 yarns / inch or less. Furthermore, the yarn density in the wale direction can be set to 5 yarns / inch or more and 50 yarns / inch or less, and preferably 8 yarns / inch or more and 30 yarns / inch or less.

[0085] When the base fabric layer 12 having the outer fabric 121, inner fabric 122, and binding yarn 123 is a knitted fabric, the type of knit or weave is not particularly limited, and may be warp knitting or weft knitting. More specifically, examples include double raschel knitting, raschel knitting, chain stitch, interlining stitch, plain weave (single bar plain weave), warp pile stitch, warp satin weave (satin weave), double plain weave, half knit weave, satin weave, velvet weave, warp pile chain stitch, rib weave (double plain weave), double purl weave (double purl weave), plain stitch (Tianzi weave), double face weave, circular rib weave, leno weave, perforated weave, triple perforated weave, Milano rib weave, single embossed weave, double embossed weave, triple embossed weave, cross stitch, and long pile interlock weave. One of these may be used alone, or two or more may be used in combination.

[0086] Among these, bulky knitted fabrics are preferred, and thus three-dimensional knitted fabrics, plain knitted fabrics, and tricot knitted fabrics are preferred. Among these, three-dimensional knitted fabrics are preferred, and double Raschel knitting is more preferred. The structure of these structures is preferably a plain weave.

[0087] The thickness of the base fabric layer 12 (normal thickness at locations where the three-dimensional design 15 is not formed) is not limited and can be, for example, 1 mm to 20 mm, more preferably 2 mm to 10 mm.

[0088] Furthermore, the overall thickness of the skin material 1 (normal thickness at locations where the three-dimensional design 15 is not formed) is not limited and can be, for example, 2 mm to 25 mm, and more preferably 3 mm to 10 mm.

[0089] As described above, the skin material 1 of the present invention is excellent in the embodiment having the three-dimensional design 15 (see Figure 2Specifically, the presence of the three-dimensional design 15 can create an excellent three-dimensional effect. Specifically, the surface layer 111 has a three-dimensional design 15. That is, the three-dimensional design 15 is visually discernible from the surface layer 111. Furthermore, this three-dimensional design 15 can be formed by narrowing the gaps 125 in the thickness direction using the binder yarn 123. For example, the three-dimensional design 15 (an embossed pattern, a simulated stitch pattern formed by thermal deformation, etc.) can be formed by thermally deforming the binder yarn 123 to narrow the gaps 125 in the thickness direction. Alternatively, the three-dimensional design 15 (stitch pattern) can be formed by narrowing the gaps 125 in the thickness direction using sewing thread that passes through the inside and outside of the surface material 1. In this stitch pattern, the binder yarn 123 is not thermally deformed. Furthermore, the three-dimensional design 15 formed by narrowing the gaps 125 in the thickness direction, in other words, the design layer 11, is formed by stretching the gaps between the outer fabric 121 and inner fabric 122 of the base fabric layer 12. That is, in the skin material 1 of the present invention, not only the concavities and convexities are formed within the relatively thin thickness range of the design layer 11, but also a dynamic design can be provided (see FIG. Figure 2 ), which is formed by being stretched to the gap between the outer fabric 121 and the inner fabric 122 of the base layer 12.

[0090] In particular, in the three-dimensional design 15 based on thermal deformation, the ratio of the gap 125 to be narrowed in the thickness direction by the binding yarn 123 is not limited. The average thickness of the position where the three-dimensional shaping (embossing) is not performed is D0 (mm), and the depth of the concave portion of the embossed pattern 15 is D 15 (mm), preferably D0 / D 15 ≥1.1, more preferably 1.1≤D0 / D 15 ≤8.0, more preferably 1.2≤D0 / D 15 ≤6.0, more preferably 1.4≤D0 / D 15 ≤5.0, particularly preferably 1.6≤D0 / D 15 ≤3.5. In the embossed pattern 15 of such a form, the effects of the present invention can be more effectively obtained.

[0091] However, in the concave portion of this three-dimensional design (embossed pattern), the concave shape is formed by narrowing the gap 125 in the thickness direction through the heat-deformed binder yarn 123. Generally, the thickness of the foam layer 112 is substantially the same as the thickness of the foam layer 112 in the area without the embossed pattern. With this type of embossed pattern 15, the effects of the present invention can be more effectively achieved.

[0092] More specifically, the thickness of the foam layer 112 in the portion without the embossed pattern 15 (the region not heated and pressed) is defined as D. 112A The thickness of the base fabric layer 12 is D 12AFurthermore, in the concave portion of the embossed pattern 15, the thickness of the foam layer 112 in the portion where the thickness of the skin material 1 is the smallest is D 112B , the thickness of the base fabric layer 12 is D 12B When D 12B / D 12A ≤0.6, and 0.8≤D 112B / D 112A ≤1.2. This value can be further set to 0.3≤D 12B / D 12A ≤0.5, and 0.9≤D 112B / D 112A ≤1.1.

[0093] It should be noted that the specific shape (shape when viewed from above) of the three-dimensional design 15 (embossed pattern, etc.) is not limited. For example, it can be linear (straight or curved), a shape formed by depressing a predetermined area, or a shape formed by drawing a pattern. Furthermore, the pattern is also not limited.

[0094] The surface material 1 of the present invention may consist solely of the aforementioned design layer 11 and base fabric layer 12, or may include additional layers. Examples of the additional layers include woven fabric layers and resin sheet layers. These layers may be used singly or in combination. The woven fabric layer may have a printed pattern, a woven pattern, or a color. Similarly, the resin sheet may have a printed pattern or a color.

[0095] [2] Interior materials

[0096] The interior material 5 of the present invention comprises a skin material 1 and a base material 3 to which the skin material 1 is attached (see Figure 3 ).

[0097] The shape of the substrate 3 is not limited, and it may be a solid body or a hollow body.

[0098] The material constituting the substrate 3 is not limited and may be an organic material or an inorganic material, or a composite material containing these. Examples of organic materials include thermoplastic resins and cured resins. Inorganic materials include metals, alloys, and ceramics. In particular, the substrate 3 may be made into a vehicle interior material.

[0099] The method for disposing the skin material 1 on the base material 3 is not particularly limited, and examples thereof include known methods such as attachment with an adhesive or the like and thermal fusion.

[0100] In addition, other functional layers such as a sound absorbing layer and an elastic layer may be inserted between the base material 3 and the skin material 1 .

[0101] The surface material 1 and interior material 5 of the present invention can be used in various technical fields. Specifically, they can be suitably used in various industries involving surface materials, such as automobiles and railway vehicles (especially vehicle interior materials), aircraft, ships, construction, and clothing.

[0102] Specifically, it is useful in technical fields such as surface materials for vehicle interior materials such as door trims, roof trims, and seats, surface materials for furniture such as sofas, and surface materials for daily necessities such as bags, wallets, and clothes.

[0103] [3] Method for manufacturing surface material

[0104] The method for producing a skin material of the present invention includes a bonding step of bonding the surface layer 111 and the base fabric layer 12 via a foaming adhesive to form the foam layer 112 .

[0105] More specifically, the method for producing a skin material of the present invention may include a step of forming a foamed polyurethane layer (foamed layer 112 ) by lamination molding.

[0106] The laminated polyurethane layer can be formed by applying a foamed polyurethane raw material between the surface layer 111 and the base fabric layer 12 (the outer fabric 121 of the base fabric layer 12) and reacting them, thereby bonding the surface layer 111 and the base fabric layer 12 while forming the foamed layer 112. In other words, the design layer 11 and the base fabric layer 12 can be bonded together using the foamed polyurethane layer 112.

[0107] Thus, when forming the laminated polyurethane layer as the foam layer 112, there is no need to insert another adhesive inside or outside the foam layer 112, thereby preventing the adhesive from hindering the flexibility. In addition, VOC problems when used as an interior material can be avoided.

[0108] It should be noted that the method for forming the laminated polyurethane layer is not limited. For example, a one-component polyurethane adhesive or a two-component polyurethane adhesive may be used, and these may be used alone or in combination.

[0109] Furthermore, this method may include a three-dimensional shaping step of forming the embossed pattern 15 .

[0110] The heating temperature during the three-dimensional shaping is not limited and can be appropriately selected according to the raw materials. For example, the heating temperature can be set to 100 to 200°C (particularly 120 to 180°C).

[0111] The heating time is not limited and can be set to, for example, 0.1 to 600 seconds.

[0112] Furthermore, after the three-dimensional shaping is performed, a cooling step may be provided for cooling the shaping position. The cooling method at this time is not particularly limited, and known methods may be cited. It should be noted that natural cooling (letting cool) may also be performed.

[0113] It should be noted that the symbols in parentheses of the various configurations described in the above embodiments indicate corresponding relationships with specific configurations described in the examples described later.

[0114] Example

[0115] Hereinafter, the present invention will be described in detail using examples.

[0116] [1] Preparation of skin material (Examples 1-2 and Comparative Example 1)

[0117] <Example 1>

[0118] The skin material 1 of Example 1 was prepared.

[0119] Skin material 1: Overall thickness is about 4mm.

[0120] Design layer 11: formed by a surface layer 111 and a foam layer 112.

[0121] The surface layer 111 is formed of a protective layer made of polyurethane with a thickness of about 5 μm and a resin layer made of polyurethane with a thickness of about 30 μm.

[0122] Foam layer 112: A polyurethane foam layer foamed to a thickness of about 190 μm, a layer formed by foaming a polyurethane adhesive.

[0123] Base fabric layer 12: Double Raschel knitted fabric (thickness: about 3.5 mm)

[0124] More specifically, the outer fabric 121 (constituent yarn: polyester resin fiber, thickness: approximately 0.6 mm) and the inner fabric 122 (constituent yarn: polyester resin fiber, thickness: approximately 0.6 mm) are connected by a binder yarn 123 (polyester resin fiber, height: approximately 2.3 mm). The knitted fabric has 45 courses and 30 wales. The denier of the constituent yarns of the outer and inner fabrics is 84 dtex, and the binder yarn 123 is 33 dtex.

[0125] The skin material of Example 1 was placed on the base of a heated press, and heated and pressed from the design layer 11 side using a press die under the conditions of a heating time of 20 seconds, a base temperature of 200°C, and a press die temperature of 150°C. Then, the skin material 1 of Example 1 having a concave embossed pattern 15 formed thereon was obtained (see Figure 4 ). The appearance of its surface is shown in Figure 5 .

[0126] In the skin material 1 of Example 1, the foam layer 112 is thicker than the surface layer 111. The thickness D of the foam layer 112 is 112 (μm) and the thickness D of the surface layer 111 111 (μm) is D 112 / D 111 =5.4. Furthermore, the foam layer 112 is thinner than the base fabric layer 12. The thickness D of the foam layer 112 is 112 (μm) and the thickness D of the base fabric layer 12 12 (μm) is D 12 / D 112 =184.

[0127] Comparative Example 1

[0128] The skin material 9 of Comparative Example 1 was prepared.

[0129] A skin material 9 was obtained in the same manner as in Example 1 except that the foamed layer 112 in the skin material 1 of Example 1 was not foamed but a non-foamed polyurethane layer having a thickness of 35 μm was formed.

[0130] Then, an embossed pattern was formed in the same manner as in Example 1 to obtain a surface material 9 of Comparative Example 1. The appearance of the surface is shown in FIG. Figure 6 .

[0131] The present invention is not limited to the above-described detailed embodiments, and various modifications and changes can be made within the scope of the claims of the present invention.

[0132] Industrial applicability

[0133] The surface material and structure of the present invention can be used in various technical fields. Specifically, they can be suitably used in the field of surface materials in various industries such as vehicles (automobiles and railway vehicles), aircraft, ships, construction, and clothing.

[0134] Description of Reference Numerals

[0135] 1. Surface material,

[0136] 11; Design layer,

[0137] 111; surface layer, 112; foaming layer,

[0138] 12; base fabric layer,

[0139] 121; outer fabric, 122; inner fabric, 123; binding yarn, 125; gap,

[0140] 15; embossed pattern,

[0141] 3. Base material,

[0142] 5. Interior materials.

Claims

1. A skin material, characterized in that: With design layer and base fabric layer, The design layer comprises a surface layer and a foaming layer, The base fabric layer comprises an outer fabric layer, an inner fabric layer, and a binding yarn for binding the two layers. The binding yarn is vertically arranged between the outer fabric and the inner fabric, and is a thermoplastic resin fiber forming a gap between the outer fabric and the inner fabric. The foaming layer is bonded to the outer fabric. The skin material has an embossed pattern as a three-dimensional design formed by narrowing the gap in the thickness direction. The thickness of the foamed layer in the portion without the embossed pattern is D 112A The thickness of the base fabric layer is D 12A In the concave portion having the embossed pattern, the thickness of the foam layer in the portion with the smallest thickness of the skin material is D 112B The thickness of the base fabric layer is D 12B hour, 0.3≤D 12B / D 12A ≤0.5, and 0.9≤D 112B / D 112A ≤1.

1.

2. The skin material according to claim 1, wherein The foam layer is thicker than the surface layer and thinner than the base fabric layer.

3. The surface material according to claim 1 or 2, wherein The foamed layer has independent cells.

4. An interior material, characterized in that: have: The surface material according to any one of claims 1 to 3, and A substrate to which the skin material is attached.

5. A method for manufacturing a skin material, characterized in that: The method for producing a surface material according to any one of claims 1 to 3 comprises: A bonding step of bonding the surface layer and the base fabric layer via a foaming adhesive that becomes the foam layer.

Images