Skin material and method for manufacturing the same, and interior material

Abstract

To provide a skin material which forms a gap between the face fabric and the lining and has a base cloth layer having a structure in which the two layers are joined together to produce a more excellent three-dimensional effect than before, and to provide a manufacturing method thereof and an interior material.SOLUTION: A skin material 1 has a design layer 11 and a base fabric layer 12. The design layer 11 has a surface layer 111 and a foam layer 112. The base fabric layer 12 has a face fabric 121 and a lining 122, and a joining yarn 123 for joining the two layers, the joining yarn 123 is a thermoplastic resin fiber that is erected between the face fabric 121 and the lining 122 and forms a gap 125 between the face fabric 121 and the lining 122, and the foam layer 112 and the face fabric 121 are joined to each other. An interior material 5 has a skin material 1 and a base material 3 to which the skin material 1 is stuck. A method for manufacturing a skin material 1 includes a step of joining the surface layer 111 and the base fabric layer 12 through a foamable adhesive formed into a foam layer 112.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a skin material, a manufacturing method thereof, and an interior material. More specifically, the present invention relates to a skin material including a base fabric layer having a gap between an outer fabric and an inner fabric, a manufacturing method thereof, and an interior material. [Background technology]

[0002] Conventionally, interior materials are known in which a skin material for imparting a design is attached to a base material. In particular, there are cases where a skin material having a tactile design in addition to a visual design is required. For example, a leather-like skin material having an embossed pattern corresponds to this. A leather-like skin material having an embossed pattern is required to have a unique tactile feel equivalent to leather in addition to a design on its surface. The technology of Patent Document 1 below is known as an example of such a skin material. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2017-213865 A Summary of the Invention [Problem to be solved by the invention]

[0004] The above-mentioned Patent Document 1 discloses a skin material having a base fabric layer of a three-dimensional knit fabric in which two layers of knit fabric, front and back, are bonded with a bonding yarn. This base fabric layer can form an embossed pattern by adjusting the concave heat-deformed parts to a predetermined thickness due to the thermal deformation of the thermoplastic resin fiber that is the bonding yarn. This makes it possible to obtain a skin material that has a three-dimensional design consisting of a three-dimensional pattern with excellent aesthetics and a very high degree of design freedom. However, with industrial design constantly evolving, there is a demand for ever more excellent designs, and even greater design freedom.

[0005] The present invention has been made in view of the above-mentioned circumstances, and has an object to provide a skin material which is provided with a base fabric layer having a structure in which an outer fabric and an inner fabric are bonded together while forming a gap between these two layers, and which is capable of producing a three-dimensional effect which is superior to conventional skin materials, a manufacturing method thereof, and an interior material. [Means for solving the problem]

[0006] The present invention is as follows. [1] The skin material of the present invention is a skin material having a design layer and a base fabric layer, The design layer includes a surface layer and a foam layer, The base fabric layer includes a front layer, a back layer, and a binding yarn that binds these two layers together. The binding yarn is a thermoplastic resin fiber that is erected between the front and back fabrics and forms a gap between the front and back fabrics, The foam layer and the outer material are bonded to each other. [2] In the skin material of the present invention, the foam layer can be thicker than the surface layer and thinner than the base fabric layer. [3] In the skin material of the present invention, the foam layer may have closed cells. [4] The skin material of the present invention may have a three-dimensional design formed by narrowing the gap in the thickness direction. [5] The present invention relates to an interior material having a skin material of the present invention and a substrate to which the skin material is attached. [6] The method for producing a skin material of the present invention is characterized by comprising a bonding step of bonding the surface layer and the base fabric layer via a foamable adhesive that becomes the foam layer. Effect of the Invention

[0007] The skin material of the present invention, which is provided with a base fabric layer having a structure in which an outer fabric and an inner fabric are bonded together while forming a gap between these two layers, can produce a three-dimensional effect that is superior to that of conventional skin materials. According to the interior material of the present invention, a skin material is used which has a base fabric layer in which an outer fabric and an inner fabric are bonded together while forming a gap between them, thereby enabling the interior material to have a three-dimensional design which is superior to that of conventional materials. [Brief description of the drawings]

[0008] The present invention will be further described in the following detailed description by way of non-limiting examples of exemplary embodiments according to the invention and with reference to the several drawings mentioned, in which like reference numerals refer to like parts throughout the several views of the drawings. [Figure 1] FIG. 2 is a schematic diagram illustrating a cross section of an example of a skin material of the present invention. [Diagram 2] FIG. 4 is a schematic diagram illustrating a cross section of another example of a skin material of the present invention. [Diagram 3] 1 is a schematic diagram illustrating a cross section of an example of an interior material of the present invention. [Figure 4] 5A to 5C are schematic diagrams illustrating the processing steps of another example of the skin material of the present invention. [Diagram 5] FIG. 4 is an enlarged view showing the appearance of the surface of a skin material according to an embodiment. [Figure 6] FIG. 4 is an enlarged view showing the appearance of the surface of a skin material according to a comparative example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] The present invention will now be described in detail with reference to the drawings. The matters shown herein are illustrative and are intended to exemplify the embodiments of the present invention, and are described for the purpose of providing what is believed to be the most effective and easily understandable explanation of the principles and conceptual features of the present invention. In this respect, it is not intended to show structural details of the present invention beyond the extent necessary for a fundamental understanding of the present invention, and the description in conjunction with the drawings will make it clear to those skilled in the art how some forms of the present invention can be actually embodied.

[0010] [1]Skin material The skin material (1) of the present invention is a skin material having a design layer (11) and a base fabric layer (12), The decorative layer (11) includes a surface layer (111) and a foam layer (112). The base fabric layer (12) comprises a front fabric (121), a back fabric (122), and a binding yarn (123) that binds these two layers together. The binding yarn (123) is a thermoplastic resin fiber that stands between the front fabric (121) and the back fabric (122) and forms a gap (125) between the front fabric (121) and the back fabric (122). Further, the foam layer (112) and the outer material (121) are bonded together (see FIG. 1).

[0011] In this way, the design layer 11 and the base fabric layer 12 are joined via the foam layer 112, so that it is possible to prevent the heat applied to the skin material 1 from staying or accumulating in the design layer 11 when forming the three-dimensional design 15 (embossed pattern, stitch pattern, etc.) by heat pressing. That is, it can be said that the presence of the foam layer 112 increases the heat dispersion capacity compared to a mode in which the foam layer 112 is not present. Therefore, even if sufficient heat is applied to form the three-dimensional design, damage to the design layer 11 is suppressed, while the binding yarn 123 can be thermally deformed more reliably. That is, it is thought that damage to the design layer 11 can be prevented even if a higher temperature or a larger amount of heat is applied to thermally deform the binding yarn 123 compared to the conventional method. Therefore, the skin material 1 can produce a three-dimensional effect that is superior to the conventional method.

[0012] Furthermore, in addition to the above-mentioned effect of increasing the heat dissipation capacity, the increased rigidity of the entire design layer 11 is also considered to contribute advantageously to the production of an excellent three-dimensional effect. This is considered to be because the provision of the foam layer 112 increases the overall rigidity of the skin material 1. That is, when a three-dimensional design 15 is applied to a skin layer with low rigidity, waving may occur in the skin material. In contrast, with the present skin material 1 having high rigidity, even if a three-dimensional design is formed, waving does not occur, and the three-dimensional design can be made to look neat and beautiful. That is, if a given material has the same basis weight, it can be said that the skin material 1 can obtain a higher rigidity as a whole when it exists in a foamed state than when it exists in a non-foamed state, and therefore an excellent three-dimensional effect can be produced.

[0013] In addition, the presence of the foamed layer 112 increases the overall thickness of the design layer 11. That is, if the specified material has the same basis weight, the thickness of the design layer 11 will be greater when the specified material is in a foamed state than when the specified material is in a non-foamed state. When the three-dimensional design 15 is applied, the design layer 11 around the three-dimensional design may be stretched, but even in such a case, the thickness is increased, so that the surface functions such as chemical resistance and friction durability can be maintained at a high level. Even if the design layer 11 around the three-dimensional design is stretched, the uneven shape of the base fabric layer 12 can be prevented from affecting the design layer 11 at that point. That is, the unevenness of the outer fabric 121 of the base fabric layer 12 is reflected in the design layer 11, and the uneven shape can be prevented from being recognized from the surface of the design layer 11.

[0014] The "design layer (11)" is a layer including a surface layer 111 and a foam layer 112. The surface layer 111 is a layer having a design surface in the skin material 1. That is, for example, when the skin material 1 is used as an interior material (an interior material for an interior room, an interior material for a vehicle, etc.), the surface layer 111 is the layer exposed to the interior of the room or the vehicle.

[0015] The surface layer 111 is a layer that forms 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 fabric), synthetic leather, artificial leather, natural leather, etc. may be used. These may be used alone or in combination of two or more types. Moreover, the surface layer 111 may be a single layer or may be a multi-layer. An example of a multi-layer embodiment is one in which a protective layer (top coat layer) is provided on the outermost layer of the above-mentioned resin layer, woven fabric, synthetic leather, artificial leather, natural leather, etc. The protective layer can be provided, for example, as a permeable resin coat layer (polyurethane, etc.).

[0016] Among the above, it is preferable that the surface layer 111 is a polyurethane layer. This polyurethane layer may be in any form, but is preferably a non-foamed polyurethane, and more preferably a polyurethane shaped into a film. The urethane raw material constituting the surface layer 111 is not limited, and typically contains a polyol component and a polyisocyanate component. Among these, the polyol component is exemplified as a compound having at least two hydroxyl groups in the molecule, and examples thereof include polycarbonate-based polyols, polyether-based polyols, polyester-based polyols, alkylene glycols, and polymer polyols using polyether-based polyols or polyester-based polyols. These may be used alone or in combination of two or more. Among these, it is preferable to include a polycarbonate-based polyol, and examples of the polycarbonate-based polyol include polycarbonate diols.

[0017] The polyisocyanate component is exemplified as a compound 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. Examples of the aliphatic polyisocyanate include hexamethylene diisocyanate, isophorone diisocyanate, dicyclohexamethane diisocyanate, etc. Examples of the aromatic polyisocyanate include toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), naphthalene diisocyanate, xylylene diisocyanate, polymeric polyisocyanate (crude MDI), etc. Examples of the modified polyisocyanate compound include carbodiimide modified compounds of aliphatic polyisocyanate or aromatic polyisocyanate.

[0018] The thickness of the surface layer 111 is not limited, but can be, for example, 5 mm or less. More specifically, the thickness of 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. Furthermore, for example, when the above-mentioned protective layer is provided, the protective layer can occupy, for example, 0.1 μm or more and 20 μm or less of the above-mentioned thickness, and further can occupy 1 μm or more and 10 μm or less.

[0019] The "foamed layer (112)" is a resin layer containing bubbles formed by foaming. That is, the cell walls separating the bubbles of the foamed layer 112 are formed of resin. The bubbles constituting the foamed layer 112 may be interconnected bubbles, but are preferably closed bubbles. When the bubbles are closed bubbles, the skin material 1 can have a good balance between heat dispersibility and heat insulation. The type of resin constituting the foamed layer 112 is not limited, and polyurethane resin, polyolefin resin, polyvinyl chloride resin, polystyrene resin, polyamide resin, urethane elastomer, thermoplastic elastomer, etc. can be used. These may be used alone or in combination of two or more.

[0020] Among these, the resin type is preferably a polyurethane resin. That is, the foam layer 112 is preferably a foamed polyurethane layer. The foamed polyurethane layer may be a foamed polyurethane layer formed in any manner. That is, for example, the foamed polyurethane layer may be a laminated urethane layer formed by lamination molding, a slab urethane layer cut out from a slab-molded foamed polyurethane, a molded urethane layer cut out from a molded foamed polyurethane, etc. In addition, a foamed polyurethane layer formed by injection molding, a foamed polyurethane layer formed by spray foam molding, a hot melt type urethane layer, etc. may also be used.

[0021] Among these, the foam layer 112 of the skin material 1 of the present invention is preferably a foamed polyurethane layer formed by lamination molding, that is, a foamed polyurethane layer formed by foaming a urethane adhesive. For example, among the above, a slab urethane layer can also be suitably used, but when a slab urethane layer is used, it is necessary to bond the surface layer 111 and the slab urethane layer, which is the foam layer 112, via an adhesive or the like, and further, it is necessary to bond the slab urethane layer, which is the foam layer 112, and the surface 121 of the base fabric layer 12 also via an adhesive or the like.

[0022] In contrast, the laminated urethane layer can bond the surface layer 111 and the fabric layer 12 (surface material 121 of the fabric layer 12) while forming the foamed layer 112 by applying and reacting a foamed urethane raw material between the surface layer 111 and the fabric layer 12. That is, the design layer 11 and the fabric layer 12 can be bonded by the foamed urethane layer 112. In this way, when a laminated urethane layer is used as the foam layer 112, it is not necessary to apply other adhesives to the front and back of the foam layer 112, which prevents the adhesive from impairing flexibility. Also, it prevents VOC problems when used as an interior material. The method for forming this laminated urethane layer is not limited, and for example, a one-liquid type urethane adhesive or a two-liquid type urethane adhesive may be used, and these may be used alone or in combination.

[0023] The urethane raw material used is not limited, and typically contains a polyol component and a polyisocyanate component. Among these, the polyol component is exemplified as a compound having at least two hydroxyl groups in the molecule, and examples thereof include polycarbonate-based polyols, polyether-based polyols, polyester-based polyols, alkylene glycols, and polymer polyols using polyether-based polyols or polyester-based polyols. These may be used alone or in combination of two or more. Among these, it is preferable to include a polycarbonate-based polyol. Examples of polycarbonate-based polyols include polycarbonate diols. The above-mentioned polyether polyols include polyether polyols obtained by adding alkylene oxide to polyhydric alcohols. The polyester polyols include polyester polyol compounds obtained by polycondensation of aliphatic carboxylic acid and / or aromatic carboxylic acid with polyhydric alcohols. The alkylene glycols include polyhydric alcohols. Incidentally, for the polyisocyanate component, the description of the surface layer 111 can be applied as is.

[0024] The above-mentioned urethane raw material for forming the foam layer 112 may contain a foaming agent in addition to the polyol component and the polyisocyanate component. Examples of the foaming agent include water, hydrocarbons (pentane, etc.), liquefied carbon dioxide gas, and alkylene chlorides (methylene chloride, ethylene chloride, etc.). These may be used alone or in combination of two or more. In addition to the various components described above, the above-mentioned urethane raw material may contain various components such as a catalyst, a foam stabilizer, a crosslinking agent, an antioxidant, an ultraviolet absorber, a filler, an internal mold release agent, a flame retardant, etc. These other components may be used alone or in combination of two or more. Examples of the catalyst include amines (amine compounds) and organometallic compounds. As the foam stabilizer, various surfactants can be appropriately used.

[0025] 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 incorporating air bubbles into the urethane raw material itself. For example, when mixing the polyol component and the polyisocyanate component, air bubbles can be incorporated into the urethane raw material by foaming the mixed liquid. In this case, for example, a surfactant or the like can be used as necessary.

[0026] The thickness of the foam layer 112 is not limited, and may be, for example, 50 μm or more and 1000 μm or less. The thickness of the foam layer 112 may further be 80 μm or more and 500 μm or less, or 100 μm or more and 300 μm or less.

[0027] The "fabric layer (12)" is a layer including a front material 121, a back material 122, and a binding yarn 123 that binds these two layers together. The fabric layer 12 is a composite layer including a layer including the front material 121, a layer including the back material 122, and a layer including the binding yarn 123. The outer fabric 121 and the inner fabric 122 may each independently be a layer using a knitted fabric (double knitted fabric), a layer using a woven fabric, a layer using a nonwoven fabric, a layer using a resin film, or a layer other than these. Furthermore, it may be a layer consisting of only one of these, or a composite layer consisting of two or more layers. When the outer fabric 121 and the inner fabric 122 are layers using fibers, the constituent yarns may be thermoplastic resin fibers or fibers other than thermoplastic resin fibers. Moreover, only one type of these fibers may be used, or two or more types may be used in combination.

[0028] Among the above, the thermoplastic resin fibers may be polyester fibers, polyamide fibers, polyacrylic fibers, polyolefin fibers, etc. Among these, the polyester fibers may be polyethylene terephthalate fibers, polybutylene terephthalate fibers, polytrimethylene terephthalate fibers, etc. Furthermore, the polyamide fibers may be various nylon fibers (nylon 6 fibers, nylon 66 fibers, etc.). Furthermore, the polyacrylic fibers may be various acrylic fibers containing polyacrylonitrile, etc. Furthermore, the polyolefin fibers may be polyethylene fibers, polypropylene fibers, etc. Other examples include vinylon fibers and polyurethane fibers. These may be used alone or in combination of two or more. Among these, fibers other than the thermoplastic resin fibers may be natural fibers and regenerated fibers, etc. Among these, natural fibers may be cotton, hemp, silk, wool, etc. Furthermore, regenerated fibers may be cupra rayon, viscose rayon, lyocell, etc. These may be used alone or in combination of two or more.

[0029] The form of the constituent yarn is not limited, and may be a filament yarn or a spun yarn. In addition, the filament yarn may be a multifilament or a monofilament. Furthermore, the constituent yarn may be a non-bulky textured yarn or a bulky textured yarn (twisted yarn, false twist textured yarn, fluid jet textured yarn, etc.). Furthermore, the fineness of the constituent yarns is not limited and can be, for example, 50 dtex or more and 1500 dtex or less, and 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, 150 dtex or more and 500 dtex or less, etc. The fineness of each constituent yarn of the outer fabric 121 and the lining fabric 122 may be the same or different.

[0030] Among the various combinations mentioned above, it is preferable that both the outer layer 121 and the inner layer 122 are layers using knitted fabric (knitted fabric layer, knitted fabric). Furthermore, when both the front fabric 121 and the back fabric 122 are knitted fabrics, their thread densities are not limited, but the thread density in the course direction can be 10 threads / inch to 100 threads / inch, and preferably 15 threads / inch to 70 threads / inch. The thread density in the wale direction can be 5 threads / inch to 50 threads / inch. The thread density in the wale direction is further preferably 15 threads / inch to 50 threads / inch, more preferably 8 threads / inch to 40 threads / inch, and particularly preferably 15 threads / inch to 40 threads / inch. The thread densities of the front fabric 121 and the back fabric 122 may be the same or different.

[0031] The above-mentioned fineness and yarn density allow the number of stitches to be reduced, and even the stitches to be made small. Therefore, a knitted fabric with almost no stitches can be obtained. In this way, when knitted fabrics with fewer and smaller stitches are used as the front fabric 121 and the back fabric 122, it is possible to prevent the binding yarn 123 from protruding from the knitted fabric when the three-dimensional design 15 is formed.

[0032] The binding yarn 123 is a thermoplastic resin fiber that stands between the front fabric 121 and the back fabric 122 and forms a gap 125 between the front fabric 121 and the back fabric 122. The binding yarn 123 may bind the front fabric 121 and the back fabric 122 in any manner, but for example, the binding yarn on the front fabric side knitted into the front fabric 121 and the binding yarn on the back fabric side knitted into the back fabric 122 can be intertwined to bind them. In addition, the binding thread 123 undergoes thermal deformation during heat pressing to create the three-dimensional design 15 (embossed pattern, stitch pattern), thereby narrowing the gap 125 formed between the outer fabric 121 and the lining fabric 122 in the thickness direction while also having the function of maintaining that thickness.

[0033] Thermoplastic resin fibers such as polyester fibers, polyamide fibers, polyacrylic fibers, and polyolefin fibers can be used as the binding yarn. Of these, examples of polyester fibers include polyethylene terephthalate fibers, polybutylene terephthalate fibers, and polytrimethylene terephthalate fibers. Examples of polyamide fibers include various nylon fibers (nylon 6 fibers, nylon 66 fibers, etc.). Examples of polyacrylic fibers include various acrylic fibers containing polyacrylonitrile. Examples of polyolefin fibers include polyethylene fibers and polypropylene fibers. These may be used alone or in combination of two or more. Of these, In addition, the fabric layer 12 may contain, in addition to the binding yarn 123, other non-thermoplastic binding yarns that bind the front fabric 121 and the back fabric 122 together, as long as the thermal deformation of the binding yarn 123 for forming the three-dimensional design 15 is not hindered. Specific examples of such fibers include natural fibers such as cotton, linen, silk, and wool. By including such fibers in the binding yarns, the fabric layer 12 can be given softness while still having sufficient shape retention.

[0034] The form of the binding yarn is not limited, but a filament yarn is preferable. The filament yarn may be a multifilament or a monofilament, but a monofilament is more preferable. Since the monofilament can have the rigidity as a yarn, it is preferable from the viewpoints of thickness retention, cushioning properties, and shaping properties in the three-dimensional design 15. Furthermore, the binding yarn may be a non-bulky textured yarn or a bulky textured yarn (twisted yarn, false twist textured yarn, fluid jet textured yarn, etc.).

[0035] Furthermore, the binding yarn 123 may be a yarn containing a low melting point material in part (hereinafter, simply referred to as "fusion yarn"). More specifically, a fusion yarn having a melting point lower than that of the constituent yarns of the front fabric 121 and the back fabric 122 may be used. The fusion yarn may be a single yarn, or may be a twisted combination of a fusion yarn and a non-fusion yarn (a yarn having a melting point higher than that of the fusion yarn), or may be a monofilament yarn alone or a twisted combination of a fusion yarn and a non-fusion yarn bonded together, or may be a core-sheath monofilament yarn alone or a twisted combination of these. When this fusion yarn is used, it is possible to make it easier to thermally deform the yarn during heat pressing to provide the three-dimensional design 15 (embossed pattern, stitch pattern, etc.). Moreover, highly crimped yarn can be used as all or part of the binding yarn 123. When highly crimped yarn is used, even better cushioning properties and shape retention can be obtained.

[0036] The fineness of the binding yarn 123 is not limited, but may be 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. Furthermore, the yarn density of the binding yarns 123 is not limited, but the yarn density in the course direction can be 10 pieces / inch or more and 100 pieces / inch or less, and preferably 15 pieces / inch or more and 70 pieces / inch or less. The yarn density in the wale direction can be 5 pieces / inch or more and 50 pieces / inch or less, and preferably 8 pieces / inch or more and 30 pieces / inch or less.

[0037] When the fabric layer 12 having such a front fabric 121, back fabric 122 and binding yarn 123 is a knitted fabric, the type of knitting or structure is not particularly limited, and may be, for example, warp knitting or weft knitting. More specifically, double raschel knitting, raschel knitting, chain knitting, insert knitting, denby knitting (single tricot knitting), cord knitting, atlas knitting (Vandyke knitting), double denby knitting, half knitting, satin knitting, velvet knitting, queens cord knitting, rubber knitting (rib knitting), pearl knitting (garter knitting), plain knitting (plain knitting), double-sided knitting, milling knitting, mock rody knitting, punch knitting, three-mouth punch knitting, Milano rib knitting, single pique knitting, double pique knitting, triple pique knitting, cross miss knitting, brush interlock knitting, etc. These may be used alone or in combination of two or more types. Among these, bulky knits (bulky knit fabrics) are preferred, and thus three-dimensional knit fabrics, jersey and tricot are preferred, among which three-dimensional knit fabrics are preferred, and double raschel knit is more preferred. These structures are preferably plain structures.

[0038] The thickness of the base fabric layer 12 (the normal thickness of the portion where the three-dimensional design 15 is not formed) is not limited, but may be, for example, 1 mm or more and 20 mm or less. This thickness is further preferably 2 mm or more and 10 mm or less. Furthermore, the overall thickness of the skin material 1 (the normal thickness of the portion where the three-dimensional design 15 is not formed) is not limited, but may be, for example, 2 mm or more and 25 mm or less. This thickness is further preferably 3 mm or more and 10 mm or less.

[0039] As described above, the skin material 1 of the present invention is excellent in the aspect having the three-dimensional design 15 (see FIG. 2). That is, when the three-dimensional design 15 is present, an excellent three-dimensional effect can be created. Specifically, the surface layer 111 has the three-dimensional design 15. That is, the three-dimensional design 15 is visible from the surface layer 111. The three-dimensional design 15 can be formed by the binding thread 123 narrowing the gap 125 in the thickness direction. That is, for example, the binding thread 123 can be thermally deformed to narrow the gap 125 in the thickness direction to form the three-dimensional design 15 (embossed pattern, pseudo stitch pattern formed by thermal deformation, etc.). Also, the gap 125 can be narrowed in the thickness direction by a sewing thread that penetrates the front and back of the skin material 1 to form the three-dimensional design 15 (stitch pattern). In the stitch pattern in this case, the binding thread 123 is not thermally deformed.

[0040] In particular, in the three-dimensional design 15 due to thermal deformation, the ratio by which the binding yarn 123 narrows the gap 125 in the thickness direction is not limited, but the average thickness in the area where the three-dimensional shaping (embossing) is not performed is defined as D0 (mm), and the depth of the recess of the embossed pattern 15 is defined as D 15 (mm), D0 / D 15 ≧1.1, and 1.1≦D0 / D 15 ≦8.0 is more preferable, and 1.2≦D0 / D 15 ≦6.0 is more preferable, and 1.4≦D0 / D 15 ≦5.0 is more preferable, and 1.6≦D0 / D 15 It is particularly preferable that the ratio is ≦3.5. In the embossed pattern 15 having such a configuration, the effects of the present invention can be more effectively obtained.

[0041] However, in the recesses of this three-dimensional design (embossed pattern), the recesses are formed by the thermally deformed binding yarns 123 narrowing the gaps 125 in the thickness direction, and usually the thickness of the foamed layer 112 is substantially the same as the thickness of the foamed layer 112 in the area not having the embossed pattern. In the embossed pattern 15 of this type, the effect of the present invention can be obtained more effectively. More specifically, the thickness of the foam layer 112 in the portion not having the embossed pattern 15 (the area not heated and pressed) is set to D. 112A The thickness of the base fabric layer 12 is D 12A Furthermore, the thickness of the foam layer 112 at the recess of the embossed pattern 15 where the thickness of the skin material 1 is the smallest is set to D 112B The thickness of the base fabric layer 12 is D 12B If you set it to 0 <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 It can be ≦1.1.

[0042] The specific shape of the three-dimensional design 15 (embossed pattern, etc.) is not limited. That is, for example, it may be linear (straight line, curved line), may be a shape with a predetermined area widely recessed, or may be formed to draw a pattern. Furthermore, the pattern is not limited.

[0043] The skin material 1 of the present invention may be composed of only the design layer 11 and the base fabric layer 12 described above, or may have other layers. Examples of the other layers include a woven fabric layer, a resin sheet layer, etc. These may be used alone or in combination of two or more layers. The woven fabric layer may have a printed pattern, a woven pattern, a color, etc. Similarly, the resin sheet may have a printed pattern, a color, etc.

[0044] [2] Interior materials The interior material 5 of the present invention has a skin material 1 and a base material 3 to which the skin material 1 is attached (see FIG. 3).

[0045] The shape of the substrate 3 is not limited, and it may be a solid body or a hollow body. Furthermore, the material constituting the base material 3 is not limited, and may be either an organic material or an inorganic material, or may be a composite material containing these. Examples of organic materials include thermoplastic resins and cured resins. Examples of inorganic materials that can be used include metals, alloys, ceramics, and the like. In particular, the base material 3 may be used as a vehicle interior material.

[0046] The method of attaching the skin material 1 to the base material 3 is not particularly limited, and examples thereof include known methods such as attachment via an adhesive or heat fusion. Between the substrate 3 and the skin material 1, other functional layers such as a sound absorbing layer, an elastic layer, etc. may be interposed.

[0047] The skin material 1 and the interior material 5 of the present invention can be used in various technical fields. Specifically, they can be suitably used in fields related to skin materials in various industries, such as vehicles (particularly interior materials for vehicles) such as automobiles and railroad cars, aircraft, ships, construction, and apparel. Specifically, it is useful in technical fields such as covering materials for vehicle interior materials such as door trims, roof trims, and seats, covering materials for furniture such as sofas, and covering materials for daily necessities such as bags, wallets, and clothes.

[0048] [3] Manufacturing method of skin material 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 with a foamable adhesive that becomes the foam layer 112. More specifically, the method for producing a skin material of the present invention can include a step of forming a urethane foam layer (foam layer 112) by lamination molding. The laminated urethane layer can bond the surface layer 111 and the fabric layer 12 (surface material 121 of the fabric layer 12) while forming the foamed layer 112 by applying and reacting a urethane foam raw material between the surface layer 111 and the fabric layer 12. That is, the design layer 11 and the fabric layer 12 can be bonded by the urethane foam layer 112. In this way, when a laminated urethane layer is formed as foam layer 112, it is not necessary to apply other adhesives to the front and back of foam layer 112, which prevents the adhesive from impairing flexibility. Also, it prevents VOC problems when used as an interior material. The method for forming this laminated urethane layer is not limited, and for example, a one-liquid type urethane adhesive or a two-liquid type urethane adhesive may be used, and these may be used alone or in combination.

[0049] Furthermore, the method may include a three-dimensional shaping step for forming the embossed pattern 15 . The heating temperature during three-dimensional shaping is not limited and is appropriately selected depending on the material. For example, the heating temperature can be 100 to 200° C. (particularly, 120 to 180° C.). Furthermore, the heating time is not limited and can be, for example, 0.1 to 600 seconds. Furthermore, after three-dimensional shaping, a cooling step of cooling the shaped portion can be provided. The cooling method is not particularly limited, and known methods can be used. Natural cooling (cooling) is also possible.

[0050] The reference characters in parentheses for each component described in the above embodiment indicate the corresponding relationship with the specific components described in the examples described later. EXAMPLES

[0051] The present invention will now be described in detail with reference to examples. [1] Preparation of skin material (Examples 1-2 and Comparative Example 1) <Example 1> A skin material 1 of Example 1 was prepared. Skin material 1: Overall thickness is approximately 4 mm. Design layer 11 : Consists of a surface layer 111 and a foam layer 112 . Surface layer 111: Consists 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. Foam layer 112: A foamed polyurethane layer foamed to a thickness of about 190 μm, formed by foaming a polyurethane adhesive. Base fabric layer 12: Double raschel knitted fabric (thickness: approx. 3.5 mm) More specifically, the knitted fabric has a structure in which an outer fabric 121 (constituent yarn: polyester-based resin fiber, thickness: approximately 0.6 mm) and a lining fabric 122 (constituent yarn: polyester-based resin fiber, thickness: approximately 0.6 mm) are connected by a binding yarn 123 (polyester-based resin fiber, height approximately 2.3 mm), and has 45 courses, 30 wales, and the constituent yarns of the outer fabric and lining have a fineness of 84 dtex, and the binding yarn 123 has a fineness of 33 dtex.

[0052] The skin material of Example 1 was placed on a table of a hot press machine and hot pressed using a press mold from the side of the design layer 11 under the conditions of a heating time of 20 seconds, a table temperature of 200° C., and a press mold temperature of 150° C. The material was then naturally cooled and removed from the mold to obtain the skin material 1 of Example 1 having the embossed pattern 15 formed in a concave shape (see FIG. 4). The appearance of the surface is shown in FIG.

[0053] In the skin material 1 of Example 1, the foam layer 112 is thicker than the surface layer 111, and the thickness D of the foam layer 112 is 112 (μm) and thickness D of surface layer 111 111 The ratio of D 112 / D 111 Further, the foam layer 112 is a layer thinner than the base fabric layer 12, and the thickness D 112 (μm) and the thickness D of the base fabric layer 12 12 The ratio of D 12 / D 112 =184.

[0054] <Comparative Example 1> A skin material 9 of Comparative Example 1 was prepared. A skin material 9 was obtained that was the same as that of Example 1, except that the foamed layer 112 in the skin material 1 of Example 1 was not foamed but was a non-foamed polyurethane layer having a thickness of 35 μm. Thereafter, an embossed pattern was formed in the same manner as in Example 1 to obtain a skin material 9 of Comparative Example 1. The appearance of the surface is shown in FIG.

[0055] The present invention is not limited to the above-described embodiments, and various modifications and variations are possible within the scope of the claims of the present invention. [Industrial Applicability]

[0056] The skin material and structure of the present invention can be used in various technical fields. Specifically, the skin material can be suitably used in fields related to skin materials in various industries, such as vehicles (automobiles, railway cars, etc.), aircraft, ships, construction, and apparel. [Explanation of symbols]

[0057] 1;Skin material, 11; Design layer, 111; surface layer, 112; foam layer, 12; base fabric layer, 121; outer fabric, 122; lining, 123; bonding thread, 125; gap, 15; embossed pattern, 3; base material, 5;Interior materials.

Claims

1. A skin material having a design layer and a base fabric layer, The design layer includes a surface layer and a foam layer, The base fabric layer includes a front layer, a back layer, and a binding yarn that binds these two layers together. The binding yarn is a thermoplastic resin fiber that is erected between the front and back fabrics and forms a gap between the front and back fabrics, A skin material, characterized in that the foam layer and the surface material are bonded together.

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 skin material according to claim 1 or 2, wherein the foam layer has closed cells.

4. 4. The skin material according to claim 1, further comprising a three-dimensional design formed by narrowing the gap in the thickness direction.

5. A skin material according to any one of claims 1 to 4, and a substrate having the skin material attached thereto.

6. A method for producing a skin material according to any one of claims 1 to 4, comprising the steps of: A method for producing a skin material, comprising: a bonding step of bonding the surface layer and the base fabric layer via a foamable adhesive that becomes the foam layer.

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