Synthetic leather and synthetic leather manufacturing method

Abstract

To provide a synthetic leather that has sufficient bulky feeling on a surface, no shininess (gloss) on concavity, and fine irregular pattern making use of texture of woven fabric as a base layer, and also to provide a manufacturing method thereof.SOLUTION: A synthetic leather 1 has a base layer 2 and a skin layer 3 integrally laminated on a surface of the base layer 2. The base layer 2 consists of a stacked texture woven fabric. The surface of the skin layer 3 has an irregular design with texture feeling formed by a heating treatment. Either one of following (1) and (2) is satisfied on two-series warp and two-series weft constituting the stacked texture woven fabric: (1) the warp or the weft of a front surface on a side contacting with convex formed on the skin layer 3 includes a yarn having dry heat shrinkage percentage lower than the other series yarn; and (2) the warp and the weft on the side contacting with convex formed on the skin layer 3 include the yarn having dry heat shrinkage percentage lower than the other series yarn.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to synthetic leather and a method for manufacturing the same.

Background Art

[0002] Synthetic leather is widely used in bags, clothing, seats, and the like. On the surface of such synthetic leather, fine embossed patterns and uneven shapes are formed, enhancing the design. To form an embossed pattern on the surface of synthetic leather, there are methods such as applying a synthetic resin to a release paper having an embossed pattern in advance and transferring the embossed pattern of the release paper (for example, Patent Document 1), or forming an embossed pattern on the surface of the synthetic resin by pressing (embossing) with an embossing roll having an embossed pattern applied to its surface by engraving or the like (for example, Patent Document 2). In embossing, an embossing roll with an uneven pattern having a greater height difference than the embossed pattern is used to form a deep embossed pattern. In addition to the methods using release paper and embossing rolls, uneven wrinkles are generated on the surface of a synthetic leather-like material due to the thermal shrinkage of yarns to form a pattern (for example, Patent Document 3).

[0003] Citation Document 1 discloses a method for manufacturing synthetic leather with a natural embossed pattern by applying a synthetic resin solution on a release paper, heating and drying it, then laminating a base fabric through an adhesive, drying, peeling off the release paper. Citation Document 2 discloses a method of forming recesses on the surface fabric by passing a laminated sheet in which the surface fabric of artificial leather and a cushion material are laminated and integrated between a heating embossing roll and a heat roll arranged opposite to each other. Citation Document 3 discloses a synthetic leather-like material in which a film having dyeability is laminated on a fabric in which a portion not containing yarns with a large thermal shrinkage is made to appear on the patterned front side in a double fabric woven with yarns having a large thermal shrinkage, and then the fabric is shrunk to have a pattern with extremely large uneven wrinkles, and the convex portions are dyed dark and the concave portions are dyed light.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0005] By the way, in the method for manufacturing synthetic leather of Patent Document 1, a texture pattern can be imparted to the surface using a release paper having a general-purpose texture pattern. However, in order to newly form a unique texture pattern on the surface of the synthetic leather, a dedicated release paper with the texture pattern needs to be newly created. Furthermore, due to the method of transferring the texture pattern of the release paper, there is a limit to increasing the height difference of the unevenness on the surface of the synthetic leather, and it is difficult to further improve the designability. In addition, the method using an embossing roll of Patent Document 2 can impart a new design by changing the concavo-convex pattern, but of course, an expensive embossing roll must be prepared. Moreover, generally, the portion heated and pressed by the convex portion of the embossing roll is likely to generate glare, and there is a risk of an undesirable gloss difference between the portion where the convex portion does not contact. In addition, due to the relationship between the strength of the convex portion and the pressing, it is difficult to impart a delicate pattern. Further, the synthetic leather-like material of Patent Document 3 was a synthetic leather-like material in which a portion with large uneven wrinkles was dotted with a polka dot pattern, and the convex portions were dyed dark and the concave portions were dyed light, but there was room for improvement in designability.

[0006] The present invention has been made in view of such a technical background, and it is an object of the present invention to provide a synthetic leather having an uneven pattern on the surface without using the technologies of Patent Document 1 and Patent Document 2, and to provide a synthetic leather having a sufficient swelling feeling on the surface and an uneven pattern utilizing the texture of the fabric serving as the base layer as a design that cannot be obtained only by the extremely large wrinkle pattern with unevenness according to the technology of Patent Document 3 without the glare (luster) in the concave portions, and a method for manufacturing the same.

Means for Solving the Problems

[0007] To achieve the above object, the present invention provides the following means.

[0008] [1] A base layer, and an epidermis layer laminated and integrated on the surface of the base layer, wherein the base layer is made of a double cloth fabric, and the surface of the epidermis layer has a textured uneven design formed by heat treatment, The synthetic leather is characterized in that any one of the following (1) to (2) is satisfied in two series of warp threads (lengthwise threads) and two series of weft threads (crosswise threads) constituting the double cloth fabric. (1) The surface warp thread (lengthwise thread) or weft thread (crosswise thread) of the fabric in contact with the convex portion formed on the epidermis layer contains a thread having a lower dry heat shrinkage rate than the thread of the other series. (2) The surface warp thread (lengthwise thread) and weft thread (crosswise thread) of the fabric in contact with the convex portion formed on the epidermis layer contain a thread having a lower dry heat shrinkage rate than the thread of the other series.

[0009] [2] The synthetic leather according to claim 1, which has an anchor thread between the face fabric and the back fabric of the double cloth fabric.

[0010] [3] The synthetic leather according to claim 1 or 2, wherein the epidermis layer contains one or two resins selected from the group consisting of polyurethane-based resins and polyvinyl chloride-based resins.

[0011] [4] A method for manufacturing synthetic leather comprising a base layer, and an epidermis layer laminated and integrated on the surface of the base layer, comprising a lamination step of laminating a surface layer on the base layer via the adhesive layer, and a heating step of heating the laminate obtained by the lamination step, having a textured uneven design formed by heat treatment, The method for manufacturing synthetic leather is characterized in that any one of the following (1) to (2) is satisfied in two series of warp threads (lengthwise threads) and two series of weft threads (crosswise threads) constituting the double cloth fabric. (1) The surface fabric warp (lengthwise yarn) or weft (crosswise yarn) on the side in contact with the convex portions formed on the skin layer contains a yarn having a lower dry heat shrinkage rate than the yarn of the other series. (2) The surface fabric warp (lengthwise yarn) and weft (crosswise yarn) on the side in contact with the convex portions formed on the skin layer contain a yarn having a lower dry heat shrinkage rate than the yarn of the other series.

[0012] [5] The method for manufacturing synthetic leather according to claim 4, further comprising a presetting step of presetting the base layer before the laminating step.

[0013] [6] The base layer comprises synthetic fibers, and in the presetting step, the temperature is in the range of 110°C to 160°C, and in the heating step, it is processed in a temperature range higher than the temperature of the presetting step. The method for manufacturing synthetic leather according to claim 4 or 5.

Advantages of the Invention

[0014] [1] In the invention of [1], it is possible to provide synthetic leather having an uneven pattern on the surface without using the conventional techniques of embossed paper with a textured pattern and embossing. As a design that does not have the glare (luster) in the concave portions and cannot be obtained only by the extremely large crease pattern of the unevenness due to the shrinkage of the fabric, it is possible to provide synthetic leather having an uneven pattern that makes use of the texture of the fabric serving as the base layer.

[0015] [2] In the invention of [2], it is easier to form unevenness more reliably.

[0016] [3] In the invention of [3], improvement in durability and texture can be expected.

[0017] [4] In the invention of [4], it is possible to provide a method for manufacturing synthetic leather that has no glare (luster) in the concave portions of the uneven design, is more likely to form an uneven pattern that makes use of the texture of the fabric serving as the base layer, and has a large height difference in the uneven pattern of the skin layer.

[0018] In the invention of [5], when laminating the surface layer on the base layer via the adhesive layer, it is easy to flatten the surface of the base layer and suppress the generation of unintended wrinkles. By presetting, it is possible to suppress the occurrence of wrinkles in the base layer during the lamination process and make the surface of the base layer smooth. Even if the base layer has a texture, the surface layer and the adhesive layer can be laminated uniformly, and the uneven pattern can be further obtained by the heating process.

[0019] In the invention of [6], it is easy to form an uneven pattern on the skin layer by the thermal shrinkage of a part of the warp and / or weft that make up the base layer.

Brief Description of the Drawings

[0020]

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Mode for Carrying Out the Invention

[0021] Embodiments of the synthetic leather and manufacturing method according to the present invention will be described with reference to the drawings. Hereinafter, examples in which the synthetic leather and manufacturing method according to the present invention are applied to the synthetic leather and its manufacturing method will be described.

[0022] 〔Configuration of Synthetic Leather〕 The synthetic leather 1 according to the present embodiment includes a base layer 2 and a skin layer 3, and the skin layer 3 has a surface layer 4 and an adhesive layer 5 (Fig. 1). The adhesive layer 5 is in contact with the base layer 2 on one side and in contact with the surface layer 4 on the other side. The synthetic leather 1 is, for example, used for automobile seats, and the surface of the skin layer 3 is provided with an uneven pattern. Note that Fig. 1 schematically shows the layer structure of the synthetic leather 1, and the ratio of the thicknesses of each part in Fig. 1 is not accurate.

[0023] The base layer 2 includes a fabric. Such a fabric can be, for example, a woven fabric, double jersey, tricot, double raschel, etc., but is not limited thereto.

[0024] The fabric included in the base layer 2 has, for example, a basis weight of 100 g / m 2 or more and 500 g / m 2 or less. Further, it is more preferable that the basis weight is 150 g / m 2 or more and 350 g / m 2 or less. When the basis weight of the fabric is 150 g / m 2 or more, the touch (such as cushioning property) of the synthetic leather 1 is likely to be good. Also, when the basis weight of the fabric is 350 g / m 2 or less, the hardness and softness of the synthetic leather 1 are likely to be within a range suitable for use in an automobile seat.

[0025] The surface layer 4 contains one or two resins selected from the group consisting of polyurethane-based resins and polyvinyl chloride-based resins. The weight of the surface layer 4 is not particularly limited, but in the case of a polyurethane-based resin, for example, it can be 20 g / m 2 or more and 300 g / m 2 or less. Further, it is more preferable that the weight is 30 g / m 2 or more and 150 g / m 2 or less. In the case of a polyvinyl chloride-based resin, for example, the weight can be 100 g / m 2 or more and 400 g / m 2 or less. Further, it is more preferable that the weight is 150 g / m 2 or more and 250 g / m 2 or less. Also, the surface layer may be two or more layers. Note that the resin constituting the surface layer 4 may contain a foaming agent, but it is preferably not contained.

[0026] The adhesive layer 5 may contain an adhesive generally used in the field of synthetic leather. Examples of such an adhesive include an adhesive containing a polyurethane-based resin or a polyvinyl chloride-based resin. The weight of the adhesive layer 5 is not particularly limited, but for example, the weight can be 60 g / m 2 or more and 250 g / m 2 or less. Further, the weight is 70 g / m2 It is more preferable that it is 150 g / m or less. 2 below.

[0027] 〔Method for manufacturing synthetic leather〕 Next, a method for manufacturing the synthetic leather 1 according to the present embodiment will be described. In the manufacturing method according to the present embodiment, the manufacturing process of the synthetic leather 1 is carried out in three steps: the first step, the second step, and the third step.

[0028] In the first step, after weaving with a dobby loom or a jacquard loom to create a raw fabric, a preset (heat treatment) is performed in the preset process to obtain a base layer.

[0029] In the second step, a process of forming the synthetic leather 1 in which the surface layer 3 and the base layer 2 are laminated and integrated is carried out. Specifically, with respect to the release paper fed from a supply source of the release paper (for example, in a roll shape), application and heat treatment of a polyurethane resin or a polyvinyl chloride resin are performed to form a surface layer 4 on the release paper. Next, a process of forming an adhesive layer 5 on the opposite side of the release paper of the surface layer 4 is carried out. Specifically, an adhesive is applied and heat treatment is performed on the surface layer 4 formed on the release paper on the opposite side of the release paper, and then a process of adhering the base layer 2 to the adhesive layer 5 is carried out. Specifically, the base layer 2 is bonded onto the surface layer 4 and the adhesive layer 5 formed on the release paper. Finally, the release paper is peeled off from the laminate in which the surface layer 3 composed of the surface layer 4 and the adhesive layer 5 and the base layer 2 are integrated, and the synthetic leather 1 is obtained.

[0030] In the third step, a process of forming a concavo-convex design on the synthetic leather 1 in which the surface layer 3 having the surface layer 4 and the adhesive layer 5 and the base layer 2 are laminated and integrated is carried out. Specifically, a concavo-convex pattern is formed by performing heat treatment on the synthetic leather 1 in which the surface layer 3 having the surface layer 4 and the adhesive layer 5 obtained in the second step and the base layer 2 are laminated and integrated.

Example

[0031] Next, specific embodiments of the present invention will be described, but the present invention is not particularly limited to these embodiments. Table 1 shows the contents and evaluation results of each example and comparative example. There are two types of fabric looms, dobby looms and jacquard looms, depending on the difference in the pattern-making device. A dobby loom is a device equipped with a harness frame that can express relatively small and simple patterns, and a jacquard loom is a device equipped with a harness that can express large and complex patterns. Both are looms equipped with a mechanism capable of expressing a double weave. In each of the following examples and comparative examples, a jacquard loom with a warp density of 180 threads / inch is used to create a double weave or triple weave, which is a double weave. In a double weave fabric, both the warp (lengthwise yarn) and the weft (crosswise yarn) are each composed of two series of yarns excluding the ancillary yarn. For example, in the warp of Example 1 below, it is composed of Series 6 and Series 7 in Figure 3, and in the weft, it is composed of Series 8 and Series 9 in Figure 3. The ancillary yarn refers to the warp (lengthwise yarn) or weft (crosswise yarn) arranged in the space (pocket part) between the front and back fabrics, or the yarn arranged on both the warp (lengthwise yarn) and weft (crosswise yarn). The created double weave or triple weave will develop an uneven pattern after being heated in a subsequent process, but at the green stage after weaving, it has less of a plain swelling feeling compared to after heating. In the description of the double weave of each of the following examples and comparative examples, the side in contact with the skin layer 3 of the base layer 2 is the front fabric, the side opposite to the front fabric is the back fabric, the number of times the warp continuously entangles with the weft in the front fabric is represented by F, and the number of times the warp continuously entangles with the weft in the back fabric is represented by R. For example, when the warp continuously entangles with 8 wefts in the front fabric in each series, it is represented by F8, and when the warp continuously entangles with 3 wefts in the back fabric, it is represented by R3. The dry heat shrinkage rate represents the shrinkage rate at 130°C for 3 minutes of dry heat.

[0032] <Example 1> In the vertical yarns (F8, R3) at 6 in FIG. 3, an 84T / 36 / 2 polyester dyed yarn with a dry heat shrinkage rate of 3% is used; in the vertical yarns (F3, R8) at 7 in FIG. 3, an 84T / 36 / 2 polyester undyed yarn with a dry heat shrinkage rate of 38% is used; in the horizontal yarn at 8 in FIG. 3, a 167T / 48 / 3 polyester dyed yarn with a dry heat shrinkage rate of 3% is used; in the horizontal yarn at 9 in FIG. 3, an 84T / 36 / 3 polyester undyed yarn with a dry heat shrinkage rate of 39% is used. After weaving on a jacquard loom in the double weave shown in FIG. 3 to create a grey fabric, a preset process is carried out at 120°C to obtain a base layer 2. Subsequently, on a release paper, a polyurethane resin compound solution is applied to a dry weight of 72 g / m 2 and dried at 80°C to create a surface layer 4 on the release paper. Further, a polyurethane resin adhesive compound solution is applied on the surface layer 4 to a dry weight of 123 g / m 2 and dried at 90°C to create an adhesive layer 5. Immediately after creating the skin layer 3 in which the surface layer 4 and the adhesive layer 5 are laminated and integrated, the surface of the base layer 2 is overlapped and pressure-bonded to the surface of the adhesive layer 5 on the release paper, aged for 24 hours, and then the release paper is peeled off to obtain a synthetic leather in which the base layer 2 and the skin layer 3 are laminated and integrated. Thereafter, by performing a heat treatment on the synthetic leather at 130°C, a temperature higher than the preset temperature, heat shrinkage of the base layer 2 occurs, and a synthetic leather of 418 g / m with an uneven design appearing on the skin layer 3 is obtained. The evaluation results were a height difference expressing a swelling feeling of "Grade 4 - 5", a texture feeling expressing a dense texture of the fabric of "Grade 4", and the overall evaluation (texture feeling uneven design) was "Grade 4 - 5". 2 <Example 2>

[0033] ​For the vertical yarns (F8, R3) at 6 in Fig. 4, 84T / 36 / 2 polyester textured yarn with a dry heat shrinkage rate of 30% was used. For the vertical yarns (F3, R8) at 7 in Fig. 4, 84T / 36 / 2 polyester raw yarn with a dry heat shrinkage rate of 38% was used. For the horizontal yarn at 8 in Fig. 4, 84T / 36 / 3 polyester raw yarn with a dry heat shrinkage rate of 39% was used. For the horizontal yarn at 9 in Fig. 4, 84T / 36 / 3 polyester raw yarn with a dry heat shrinkage rate of 39% was used. Using a Jacquard loom, unlike Fig. 3 as shown in Fig. 4, a dobby weave with a connection (11 in Fig. 4) where the vertical yarn at 7 in Fig. 4 is wound around the horizontal yarn at 8 in Fig. 4 was woven to create a green fabric. After that, preset processing was performed at 120°C to obtain Base Layer 2. Subsequently, the same processing as in Example 1 was carried out to obtain a synthetic leather of 412 g / m 2 The evaluation results showed a height difference "4 - 5 grades" expressing a swelling feeling and a texture feeling "4 grades" expressing a dense texture of the fabric. The comprehensive evaluation (texture feeling uneven design) was "4 - 5 grades".

[0034] <Example 3> To the same combination of yarn materials as in Example 1, an 84T / 36 / 3 polyester textured yarn with a dry heat shrinkage rate of 31% as an anchor yarn was further added to the horizontal yarn at 10 in Fig. 5. After weaving on a Jacquard loom in a triple weave as shown in Fig. 5 to create a green fabric, preset processing was performed at 120°C to obtain Base Layer 2. Subsequently, the same processing as in Example 1 was carried out to obtain a synthetic leather of 472 g / m 2 The evaluation results showed a height difference "5 grades" expressing a swelling feeling and a texture feeling "5 grades" expressing a dense texture of the fabric. The comprehensive evaluation (texture feeling uneven design) was "5 grades".

[0035] <Example 4> For the vertical yarns (F8, R3) at No. 6 in Fig. 6, 84T / 36 / 2 polyester textured yarn with a dry heat shrinkage rate of 30% is used; for the vertical yarns (F3, R8) at No. 7 in Fig. 6, 84T / 36 / 2 polyester original yarn with a dry heat shrinkage rate of 38% is used; for the horizontal yarn at No. 8 in Fig. 6, 167T / 48 / 3 polyester textured yarn with a dry heat shrinkage rate of 30% is used; for the horizontal yarn at No. 9 in Fig. 6, 84T / 36 / 3 polyester original yarn with a dry heat shrinkage rate of 39% is used. Furthermore, for the horizontal yarn at No. 10 in Fig. 6, 84T / 36 / 3 polyester textured yarn with a dry heat shrinkage rate of 31% is added as an anchor yarn. After weaving in a triple weave shown in Fig. 6 on a jacquard loom to create a greige fabric, a preset process is carried out at 120°C to obtain Base Layer 2. Subsequently, the same processing as in Example 1 is carried out to obtain a synthetic leather of 490 g / m 2 as shown in Fig. 16. The evaluation results showed a height difference of "Grade 5" expressing a swelling feeling and a texture feeling of "Grade 5" expressing a dense texture of the fabric, and the overall evaluation (texture feeling uneven design) was "Grade 5".

[0036] <Example 5> Using the same combination of yarn materials as in Example 4, on a jacquard loom, as shown in Fig. 7, different from Fig. 6, after weaving in a triple weave where the vertical yarn at No. 7 in Fig. 7 is intertwined with the horizontal yarn at No. 8 in Fig. 7 (No. 11 in Fig. 7) to create a greige fabric, a preset process is carried out at 120°C to obtain Base Layer 2. Subsequently, the same processing as in Example 1 is carried out to obtain a synthetic leather of 482 g / m 2 as shown in Fig. 7. The evaluation results showed a height difference of "Grade 5" expressing a swelling feeling, a texture feeling of "Grade 4" expressing a dense texture of the fabric, and the overall evaluation (texture feeling uneven design) was "Grade 5".

[0037] <Example 6> For the vertical yarns (F8, R3) at 6 in FIG. 8, 84T / 36 / 2 polyester dyed yarn with a dry heat shrinkage rate of 3% is used; for the vertical yarns (F3, R8) at 7 in FIG. 8, 84T / 36 / 2 polyester processed yarn with a dry heat shrinkage rate of 30% is used; for the horizontal yarn at 8 in FIG. 8, 167T / 48 / 3 polyester dyed yarn with a dry heat shrinkage rate of 3% is used; for the horizontal yarn at 9 in FIG. 8, 84T / 36 / 3 polyester processed yarn with a dry heat shrinkage rate of 31% is used. Further, for the horizontal yarn at 10 in FIG. 8, as the anchor yarn, 84T / 36 / 3 polyester processed yarn with a dry heat shrinkage rate of 31% is added. After weaving on a Jacquard loom to create a green fabric in a triple weave with the same connection as in Example 5 as shown in FIG. 8, a preset treatment is performed at 120°C to obtain the base layer 2. Subsequently, the same processing as in Example 1 is carried out to obtain a synthetic leather of 465 g / m 2 The evaluation results showed a height difference of "Grade 5" expressing a swelling feeling and a texture feeling of "Grade 4" expressing a dense texture of the fabric, and the overall evaluation (texture feeling uneven design) was "Grade 5".

[0038] <Example 7> Using the same combination of yarn materials as in Example 4, after weaving on a Jacquard loom to create a green fabric in a triple weave with a connection (11 in FIG. 9) where the vertical yarn at 7 in FIG. 9 is intertwined with the horizontal yarn at 8 in FIG. 9 as shown in FIG. 9, a preset treatment is performed at 120°C to obtain the base layer 2. Subsequently, the same processing as in Example 1 is carried out to obtain a synthetic leather of 475 g / m 2 The evaluation results showed a height difference of "Grade 4" expressing a swelling feeling and a texture feeling of "Grade 4" expressing a dense texture of the fabric, and the overall evaluation (texture feeling uneven design) was "Grade 4".

[0039] <Example 8> Using the same base layer 2 as in Example 4, on the release paper, a polyvinyl chloride resin compound solution is applied so that the weight after heat treatment is 170 g / m 2 and heat treatment is carried out at 180°C to create the surface layer 4 on the release paper. On top of the surface layer 4, a polyurethane resin adhesive compound solution is further applied with a dry weight of 123 g / m 2Apply it so as to form, and dry at 90 ° C to create the adhesive layer 5. Immediately after creating the skin layer 3 in which the surface layer 4 and the adhesive layer 5 are laminated and integrated, the surface of the base layer 2 is superposed and pressure-bonded to the surface of the adhesive layer 5 on the release paper, and after aging for 24 hours, the release paper is peeled off. Thus, a synthetic leather in which the base layer 2 and the skin layer 3 are laminated and integrated was obtained. Then, by performing heat treatment on the synthetic leather at 130 ° C, which is a temperature higher than the preset temperature, heat shrinkage of the base layer 2 occurs, and uneven patterns are developed on the skin layer 3. A synthetic leather of 588 g / m 2 was obtained. The evaluation results were "Grade 4" for the height difference expressing the swelling feeling, "Grade 4" for the texture feeling expressing the dense texture of the fabric, and the overall evaluation (texture feeling uneven pattern) was "Grade 4".

[0040] <Comparative Example 1> For the warp yarn 6 in FIG. 10, 84T / 36 / 2 polyester textured yarn with a dry heat shrinkage rate of 30% was used, and for the weft yarn 8 in FIG. 10, 167T / 48 / 3 polyester textured yarn with a dry heat shrinkage rate of 30% was used. After weaving with a jacquard loom in the single weave shown in FIG. 10 to create a greige fabric, preset processing was performed at 120 ° C to obtain the base layer 2. Subsequently, the same processing as in Example 1 was performed to obtain a synthetic leather of 421 g / m 2 was obtained. The evaluation results were "Grade 1-2" for the height difference expressing the swelling feeling, "Grade 3" for the texture feeling expressing the dense texture of the fabric, and the overall evaluation (texture feeling uneven pattern) was "Grade 2".

[0041] <Comparative Example 2> For the warp yarn 6 (F8, R3) in FIG. 11, 84T / 36 / 2 polyester raw yarn with a dry heat shrinkage rate of 38% was used, for the warp yarn 7 (F3, R8) in FIG. 11, 84T / 36 / 2 polyester textured yarn with a dry heat shrinkage rate of 30% was used, for the weft yarn 8 in FIG. 11, 84T / 36 / 3 polyester raw yarn with a dry heat shrinkage rate of 39% was used, and for the weft yarn 9 in FIG. 11, 167T / 48 / 3 polyester textured yarn with a dry heat shrinkage rate of 30% was used. After weaving with a jacquard loom in the double weave shown in FIG. 11 to create a greige fabric, preset processing was performed at 120 ° C to obtain the base layer 2. Subsequently, the same processing as in Example 1 was performed to obtain a 410 g / m as shown in FIG. 17 2Synthetic leather was obtained. The evaluation results were a height difference "Grade 1" expressing a swelling feeling and a texture feeling "Grade 3" expressing a dense texture of the fabric, and the overall evaluation (texture feeling uneven design) was "Grade 2".

[0042] <Comparative Example 3> For the 6 warp yarns (F8, R3) in Fig. 12, 84T / 36 / 2 polyester raw yarn with a dry heat shrinkage rate of 38% was used; for the 7 warp yarns (F3, R8) in Fig. 12, 84T / 36 / 2 polyester raw yarn with a dry heat shrinkage rate of 38% was used; for the weft yarns in Fig. 12 at 8, 84T / 36 / 3 polyester raw yarn with a dry heat shrinkage rate of 39% was used; for the weft yarns in Fig. 12 at 9, 167T / 48 / 3 polyester raw yarn with a dry heat shrinkage rate of 37% was used. Furthermore, for the weft yarns, 84T / 36 / 3 polyester raw yarn with a dry heat shrinkage rate of 39% was added as the anchor yarn in Fig. 12 at 10. After weaving into a triple weave shown in Fig. 12 on a jacquard loom to create a green fabric, preset processing was carried out at 120°C to obtain Base Layer 2. Subsequently, the same processing as in Example 1 was carried out to obtain synthetic leather of 471 g / m as shown in Fig. 17. 2 Synthetic leather was obtained. The evaluation results were a height difference "Grade 3 - 4" expressing a swelling feeling and a texture feeling "Grade 2" expressing a dense texture of the fabric, and the overall evaluation (texture feeling uneven design) was "Grade 2".

[0043] <Comparative Example 4> For the 6 warp yarns (F8, R3) in Fig. 13, 84T / 36 / 2 polyester processed yarn with a dry heat shrinkage rate of 30% was used; for the 7 warp yarns (F3, R8) in Fig. 13, 84T / 36 / 2 polyester processed yarn with a dry heat shrinkage rate of 30% was used; for the weft yarns in Fig. 13 at 8, 84T / 36 / 3 polyester processed yarn with a dry heat shrinkage rate of 31% was used; for the weft yarns in Fig. 13 at 9, 167T / 48 / 3 polyester processed yarn with a dry heat shrinkage rate of 30% was used. Furthermore, for the weft yarns in Fig. 13 at 10, 84T / 36 / 2 polyester processed yarn with a heat shrinkage rate of 31% was added as the anchor yarn. After weaving into a triple weave shown in Fig. 13 on a jacquard loom to create a green fabric, preset processing was carried out at 120°C to obtain Base Layer 2. Subsequently, the same processing as in Example 1 was carried out to obtain 477 g / m. 2Synthetic leather was obtained. The evaluation results were as follows: the height difference representing a swelling feeling was "Grade 2", the texture feeling representing the dense texture of the fabric was "Grade 2 - 3", and the comprehensive evaluation (texture feeling uneven pattern) was "Grade 2 - 3".

[0044] <Comparative Example 5> For the warp yarns (F8, R3) at 6 in Fig. 14, 84T / 36 / 2 polyester raw yarn with a dry heat shrinkage rate of 38% was used; for the warp yarns (F3, R8) at 7 in Fig. 14, 84T / 36 / 2 polyester processed yarn with a dry heat shrinkage rate of 30% was used; for the weft yarn at 8 in Fig. 14, 84T / 36 / 3 polyester raw yarn with a dry heat shrinkage rate of 39% was used; for the weft yarn at 9 in Fig. 14, 167T / 48 / 3 polyester processed yarn with a dry heat shrinkage rate of 30% was used. Further, for the weft yarn at 10 in Fig. 14, 84T / 36 / 3 polyester raw yarn with a dry heat shrinkage rate of 39% was added as an anchor yarn. After weaving into a triple weave shown in Fig. 14 using a jacquard loom to create a green fabric, preset processing was performed at 120°C to obtain Base Layer 2. Subsequently, the same processing as in Example 1 was carried out to obtain synthetic leather of 479 g / m 2 Synthetic leather was obtained. The evaluation results were as follows: the height difference representing a swelling feeling was "Grade 1", the texture feeling representing the dense texture of the fabric was "Grade 2 - 3", and the comprehensive evaluation (texture feeling uneven pattern) was "Grade 2".

[0045]

Table 1

[0046] As can be seen from Table 1, in Examples 1 to 8, the base layer is a double-layer fabric, and in the two series of warp threads (lengthwise threads) and the two series of weft threads (crosswise threads) constituting the double-layer fabric, the warp thread (lengthwise thread) or the weft thread (crosswise thread) of the surface fabric on the side in contact with the convex portion H formed on the skin layer contains a thread having a smaller dry heat shrinkage rate at a temperature of 130 °C for 3 minutes than the thread of the other series, or the warp thread (lengthwise thread) and the weft thread (crosswise thread) of the surface fabric on the side in contact with the convex portion H formed on the skin layer contain a thread having a smaller dry heat shrinkage rate at a temperature of 130 °C for 3 minutes than the thread of the other series, and an uneven design with a large swelling feeling (height difference) where the uneven feeling derived from the texture of the base layer fabric as shown in FIG. 1 can be sufficiently felt was obtained. Furthermore, in those having an anchor thread between the surface fabric and the back fabric of the double-layer fabric, the uneven feeling derived from the texture of the base layer fabric was more clearly felt, and an uneven design with a larger swelling feeling (height difference) was obtained. In the examples, the texture of the lengthwise threads was shown in cross-sectional views in the weaving direction as shown in FIGS. 3 to 15, but it can be similarly shown by changing only the viewing direction in a cross-sectional view seen from the width direction of the fabric in which the warp threads (lengthwise threads) and the weft threads (crosswise threads) are interchanged so that the texture of the lengthwise threads can be understood. On the other hand, in a single-layer fabric such as Comparative Example 1 or in the two series of warp threads (lengthwise threads) constituting the double-layer fabric as in Comparative Examples 3 and 4, where there is no difference in the dry heat shrinkage rate at a temperature of 130 °C for 3 minutes between the warp threads (lengthwise threads) and the threads of the other series, or in Comparative Examples 2 and 5, when the series of warp threads (lengthwise threads) that are continuously wound around the weft threads (crosswise threads) in the surface fabric contain threads having a larger dry heat shrinkage rate at a temperature of 130 °C for 3 minutes than the threads of the other series, an uneven design with a large swelling feeling (height difference) where the texture feeling as shown in FIG. 1 can be felt was not obtained. In the present invention, the uneven design with a texture feeling refers to a level of 3 or higher in the comprehensive evaluation (texture uneven design).

[0047] <Regarding the evaluation of the swelling feeling and the texture feeling> Regarding the swelling feeling (height difference), it was measured using a VR-5000 (manufactured by Keyence Corporation) and judged based on the judgment criteria for the swelling feeling (height difference). Regarding the texture, the sample was placed on a flat table, and the examiner visually observed it from a position 45 degrees obliquely above the sample at a separation distance of 30 cm, and made judgments based on the judgment criteria for the texture. In addition, when the evaluation is between, for example, Grade 4 and Grade 5, it is expressed as 4 - 5 grades. (Judgment Criteria for Swelling (Height Difference)) Grade 5: The height difference is 310 μm or more Grade 4 - 5: The height difference is 270 μm or more and less than 310 μm Grade 4: The height difference is 230 μm or more and less than 270 μm Grade 3 - 4: The height difference is 190 μm or more and less than 230 μm Grade 3: The height difference is 150 μm or more and less than 190 μm Grade 2 - 3: The height difference is 110 μm or more and less than 150 μm Grade 2: The height difference is 70 μm or more and less than 110 μm Grade 1 - 2: The height difference is 30 μm or more and less than 70 μm Grade 1: The height difference is less than 30 μm (Judgment Criteria for Texture) Grade 5: The unevenness derived from the texture of the base fabric is significantly felt Grade 4: The unevenness derived from the texture of the base fabric is sufficiently felt Grade 3: The unevenness derived from the texture of the base fabric is felt Grade 2: The unevenness derived from the texture of the base fabric is slightly felt Grade 1: The unevenness derived from the texture of the base fabric is not felt at all

[0048] Furthermore, based on the judgment results of the swelling (height difference) and the texture, a comprehensive evaluation (texture unevenness design) was carried out according to the following evaluation criteria. (Comprehensive Evaluation (Texture Unevenness Design) Criteria) Grade 5: The swelling (height difference) is significantly felt, and the unevenness derived from the texture of the base fabric is sufficiently felt Grade 4: The swelling (height difference) is sufficiently felt, and the unevenness derived from the texture of the base fabric is sufficiently felt Grade 3: The swelling (height difference) is felt, and the unevenness derived from the texture of the base fabric is felt Grade 2: Either the swelling (height difference) or the unevenness derived from the texture of the base fabric is felt Level 1: Neither the swelling feeling (height difference) nor the unevenness derived from the texture of the base fabric can be felt.

Industrial Applicability

[0049] It is suitable as an interior fabric and as an interior skin material for vehicles.

Explanation of Signs

[0050] 1 ··· Synthetic leather 2 ··· Base layer 3 ··· Epidermal layer 4 ··· Surface layer 5 ··· Adhesive layer 6 ··· In FIGS. 3 to 15, the warp yarns of each base layer 7 ··· In FIGS. 3 to 9 and FIGS. 11 to 15, the other warp yarns of each base layer 8 ··· In FIGS. 3 to 15, the weft yarns of each base layer 9 ··· In FIGS. 3 to 9 and FIGS. 11 to 15, the other weft yarns of each base layer 10 ··· In FIGS. 5, 6, 7, 8, 9, 12, 13, 14, the anchor yarns of each base layer 11 ··· In FIGS. 4, 7, 8, 9, the connecting parts of each base layer H ··· Convex part of the uneven pattern (convex part with a height difference of 150 μm or more (level 3 or higher)) L ··· Concave part of the uneven pattern (concave part with a height difference of 150 μm or more (level 3 or higher))

Claims

1. a base layer, and a skin layer laminated and integrated on the surface of the base layer, characterized in that: the base layer is made of a double-layer woven fabric, the surface of the skin layer has a textured uneven design formed by heat treatment, in two series of warp threads (lengthwise threads) and two series of weft threads (crosswise threads) constituting the double-layer woven fabric, the synthetic leather is characterized by satisfying any one of the following (1) to (2): (1) The warp thread (lengthwise thread) or weft thread (crosswise thread) of the fabric on the side in contact with the convex portion formed on the skin layer contains a thread having a lower dry heat shrinkage rate than the threads of the other series. (2) The warp thread (lengthwise thread) and weft thread (crosswise thread) of the fabric on the side in contact with the convex portion formed on the skin layer contain a thread having a lower dry heat shrinkage rate than the threads of the other series.

2. The synthetic leather according to claim 1, having an anchor thread between the front and back of the double-layer woven fabric.

3. The synthetic leather according to claim 1 or 2, wherein the skin layer contains one or two resins selected from the group consisting of polyurethane-based resins and polyvinyl chloride-based resins.

4. A method for manufacturing synthetic leather comprising a base layer and a skin layer laminated and integrated on the surface of the base layer, characterized in that: a lamination step of laminating a surface layer on the base layer via the adhesive layer; a heating step of heating the laminate obtained by the lamination step; and in two series of warp threads (lengthwise threads) and two series of weft threads (crosswise threads) constituting the double-layer woven fabric, the method for manufacturing synthetic leather is characterized by satisfying any one of the following (1) to (2), having a textured uneven design formed by heat treatment: (1) The warp thread (lengthwise thread) or weft thread (crosswise thread) of the fabric on the side in contact with the convex portion formed on the skin layer contains a thread having a lower dry heat shrinkage rate than the threads of the other series. (2) The warp thread (lengthwise thread) and weft thread (crosswise thread) of the fabric on the side in contact with the convex portion formed on the skin layer contain a thread having a lower dry heat shrinkage rate than the threads of the other series.

5. The method for manufacturing synthetic leather according to claim 4, further comprising a presetting step of presetting the base layer before the lamination step.

6. The base layer comprises synthetic fibers, in the presetting step, the temperature range is 110°C to 160°C, in the heating step, the treatment is performed in a temperature range higher than the temperature of the presetting step. The method for manufacturing synthetic leather according to claim 4 or 5.

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