Synthetic leather composite and method for producing synthetic leather composite

Abstract

To provide a synthetic leather composite with improved breathability, and a method for manufacturing the same.SOLUTION: There is provided a synthetic leather composite comprising: a surface layer 2 including a synthetic leather arranged on the front surface; a fabric backing layer 4 including a fabric arranged on the back surface; and an elastic layer 3 including elastic members arranged between the surface layer 2 and the fabric backing layer 4. The surface layer 2 has a protruding portion 5, and a through hole 6 that penetrates the surface layer 2, the elastic layer 3, and the fabric backing layer 4 at least at the protruding portion 5.SELECTED DRAWING: Figure 2

Description

Technical Field

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

Background Art

[0002] As a surface material used for the interiors of automobiles, railways, airplanes, furniture, building materials, etc., a synthetic leather composite having a synthetic leather as the surface is widely used. The synthetic leather composite is superior in terms of durability compared to natural leather and fiber materials that are also used as surface materials. In recent years, in addition to durability, it has been required to add functions such as design properties that can bring a sense of luxury to the interior and breathability that can bring comfort to the user to the synthetic leather composite.

[0003] JP 2022-53963 A (Patent Document 1) discloses a surface material having through holes and recesses. According to the invention described in Patent Document 1, unprecedented design properties and high breathability can be realized simultaneously.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In the invention described in Patent Document 1, although improving the breathability of the surface layer is considered, it cannot be said that improving the breathability of the cushion layer is sufficiently considered. That is, in the invention described in Patent Document 1, only the improvement of the breathability of a part of the elements constituting the synthetic leather composite is considered, and there is still room for improvement from the viewpoint of improving the breathability of the synthetic leather composite.

[0006] Therefore, it is required to realize a synthetic leather composite with further improved breathability and a method for manufacturing such a synthetic leather composite.

Means for Solving the Problem

[0007] The synthetic leather composite according to the present invention includes an epidermis layer disposed on the surface and containing synthetic leather, a back cloth layer disposed on the back surface and containing fabric, and an elastic layer disposed between the epidermis layer and the back cloth layer and containing an elastic member. The epidermis layer has convex portions, and at least in the convex portions, there are through holes penetrating the epidermis layer, the elastic layer, and the back cloth layer.

[0008] The synthetic leather composite according to this configuration has through holes penetrating from the surface to the back surface, so it has excellent air permeability. In addition, since the epidermis layer has convex portions, it has excellent design and cushioning properties. That is, according to this configuration, a synthetic leather composite having air permeability, design, and cushioning properties can be provided.

[0009] The manufacturing method of the synthetic leather composite according to the present invention is a manufacturing method of a synthetic leather composite including an epidermis layer disposed on the surface and containing synthetic leather, a back cloth layer disposed on the back surface and containing fabric, and an elastic layer disposed between the epidermis layer and the back cloth layer and containing an elastic member, and having through holes penetrating the epidermis layer, the elastic layer, and the back cloth layer. The manufacturing method includes a laminating step of laminating the epidermis layer, the elastic layer, and the back cloth layer, and a perforating step of providing the through holes in the epidermis layer, the elastic layer, and the back cloth layer laminated in the laminating step.

[0010] The synthetic leather composite obtained by the manufacturing method according to this configuration has through holes penetrating from the surface to the back surface, so it has excellent air permeability. In addition, since the epidermis layer, the elastic layer, and the back cloth layer are laminated and then the through holes penetrating them are provided, through holes penetrating the whole can be provided without requiring alignment of the through holes provided in each layer. Therefore, a synthetic leather composite with particularly excellent air permeability can be obtained by a relatively easy method. Furthermore, since the epidermis layer, the elastic layer, and the back cloth layer are laminated and then the through holes penetrating them are provided, defects such as misalignment between layers and damage to the appearance are less likely to occur when providing the through holes.

[0011] Hereinafter, preferred embodiments of the present invention will be described. However, the scope of the present invention is not limited by the preferred embodiment examples described below.

[0012] As one aspect, it is preferable that the skin layer and the elastic layer of the synthetic leather composite according to the present invention are in direct contact with each other.

[0013] According to this configuration, when providing the through holes, the relative positions of the skin layer and the elastic layer are less likely to shift, so the air permeability is likely to increase.

[0014] As one aspect, it is preferable that the synthetic leather of the synthetic leather composite according to the present invention includes a resin layer portion and a base fabric layer portion, and the thickness of the resin layer portion is 0.010 mm or more and 0.90 mm or less.

[0015] According to this configuration, the texture is likely to be good.

[0016] As one aspect, it is preferable that the fabric of the synthetic leather composite according to the present invention includes a non-woven fabric.

[0017] According to this configuration, since the processing for providing the convex portions is relatively easy, the design property is likely to increase.

[0018] As one aspect, it is preferable that the bonding step of the manufacturing method according to the present invention includes a step of at least partially melting the surface of the elastic layer and a step of bonding the skin layer to the melted elastic layer.

[0019] According to this configuration, the relative positions of the skin layer and the elastic layer are less likely to shift, so the workability when providing the through holes is good.

[0020] As one aspect, it is preferable that the manufacturing method according to the present invention further includes a cutting step of cutting the skin layer, the elastic layer, and the back fabric layer bonded in the bonding step to a predetermined size after the bonding step and before the perforating step.

[0021] According to this configuration, after laminating the skin layer, the elastic layer, and the backing layer, they are cut all at once, so that the lamination can be performed with the dimensions of the raw material. This contributes to the efficiency improvement of the lamination process.

[0022] As one aspect, the manufacturing method according to the present invention preferably further includes a decoration step of providing convex portions on the skin layer after the perforation step.

[0023] According to this configuration, a synthetic leather composite excellent in design can be obtained.

[0024] Further features and advantages of the present invention will become more apparent from the following description of exemplary and non-limiting embodiments with reference to the drawings.

Brief Description of the Drawings

[0025]

Figure 1

Figure 2

Modes for Carrying Out the Invention

[0026] Embodiments of the synthetic leather composite and the manufacturing method of the synthetic leather composite according to the present invention will be described with reference to the drawings. Hereinafter, an example in which the synthetic leather composite according to the present invention is applied to a vehicle seat material 1 (hereinafter, simply referred to as the seat material 1) will be described.

[0027] 〔Configuration of the Seat Material〕 The seat material 1 includes a skin layer 2, an elastic layer 3, and a backing layer 4 (FIGS. 1 and 2). The skin layer 2 has convex portions 5, and the convex portions 5 have through holes 6 that penetrate the skin layer 2, the elastic layer 3, and the backing layer 4. Further, the backing layer 4 has convex portions 7 on the back side. When referring to the front and back of the seat material 1, the side of the skin layer 2 that the user of the seat material 1 directly touches (the upper side in FIG. 2) is referred to as the front, and the side of the backing layer 4 arranged on the opposite side (the lower side in FIG. 2) is referred to as the back.

[0028] The skin layer 2 is a layer containing synthetic leather and forms the surface of the sheet material 1. The synthetic leather constituting the skin layer 2 includes a resin layer portion 21, a base fabric layer portion 22, and an adhesive layer portion 23 that adheres the resin layer portion 21 and the base fabric layer portion 22. When referring to the front and back of the skin layer 2, the side of the resin layer portion 21 (the upper side in FIG. 2) that the user of the sheet material 1 directly touches is referred to as the front, and the side of the base fabric layer portion 22 (the lower side in FIG. 2) disposed on the opposite side is referred to as the back. In the present application, the term "synthetic leather" means synthetic leather in a broad sense, including artificial leather and synthetic leather in a narrow sense. Further, the synthetic leather may be processed such as raised.

[0029] The resin layer portion 21 is a layer containing a resin material. The resin material can be, but is not limited to, a polyurethane resin, a polyvinyl chloride resin, etc. Further, a surface treatment may be applied to the surface of the resin layer portion 21. The surface portion formed by the surface treatment may include, but is not limited to, a polycarbonate resin, a silicone resin, etc.

[0030] The thickness of the resin layer portion 21 is preferably 0.010 mm or more and 0.90 mm or less. When the thickness of the resin layer portion 21 is within the above range, it is easy to obtain the sheet material 1 with a good surface texture.

[0031] The base fabric layer portion 22 is a layer containing a fabric. The fabric can be, but is not limited to, a woven fabric, a single jersey, a double jersey, a tricot, a raschel, a double raschel, a non-woven fabric, etc. The fabric constituting the base fabric layer portion 22 may be impregnated.

[0032] As described above, from the perspective of the texture of the surface of the sheet material 1, it is preferable that the thickness of the resin layer portion 21 is 0.010 mm or more and 0.90 mm or less. This range is in a relatively small region as the thickness of the resin layer portion 21 constituting the synthetic leather. Since the thickness of the resin layer portion 21 has a positive correlation with the elastic modulus, the elastic modulus of the resin layer portion 21 in a preferable configuration from the perspective of texture is generally in a small category among the synthetic leathers distributed in the market. The relatively low elastic modulus of the resin layer portion 21 becomes a factor that makes it easier for the perforating member that penetrates the sheet material 1 when forming the through holes 6 to get caught, and there is a possibility of impairing the workability during perforation. In the configuration including the fabric impregnated with the base fabric layer portion 22, a certain level of elastic modulus can be ensured for the entire surface layer 2, and the catching of the perforating member can be suppressed. That is, when the thickness of the resin layer portion 21 is 0.010 mm or more and 0.90 mm or less and includes the fabric impregnated with the base fabric layer portion 22, it is easy to balance the good texture of the surface of the sheet material 1 and the workability during perforation.

[0033] The thickness of the base fabric layer portion 22 is not particularly limited, and for example, it can be 0.050 mm or more and 1.5 mm or less. Also, the thickness of the base fabric layer portion 22 may be 1.0 mm or less.

[0034] The adhesive layer portion 23 may contain an adhesive generally used in the field of synthetic leather. Examples of such adhesives include adhesives containing, for example, polyvinyl chloride resin and polyurethane resin. The adhesive can be selected in consideration of the resin material constituting the resin layer portion 21, the fabric constituting the base fabric layer portion 22, and combinations thereof.

[0035] The elastic layer 3 is a layer containing an elastic member and is disposed between the surface layer 2 and the back fabric layer 4. The elastic member can be, for example, urethane foam, fiber cushion material, etc., but is not limited thereto. From the perspective of improving the breathability of the sheet material 1, it is preferable to use an elastic member subjected to a process for improving breathability. As an example of a particularly suitable elastic member, a high-breathability urethane foam with relatively large bubble sizes to improve breathability can be mentioned.

[0036] In this embodiment, the skin layer 2 (base fabric layer portion 22) and the elastic layer 3 are in direct contact. That is, there is no adhesive or the like for bonding the two between the skin layer 2 (base fabric layer portion 22) and the elastic layer 3. More specifically, a part of the elastic material constituting the elastic layer 3 has entered the gaps between the fibers of the base fabric layer portion 22, and the two are bonded by a so-called anchor effect. Such an adhesive structure can be formed, for example, by frame lamination (described later).

[0037] The back fabric layer 4 is a layer including a fabric and forms the back surface of the sheet material 1. The fabric can be any type of fabric such as a non-woven fabric, a knitted fabric, or a woven fabric. Examples of the non-woven fabric include, but are not limited to, spunbond and spunlace. Examples of the knitted fabric include, but are not limited to, single jersey, double jersey, tricot, raschel, and double raschel. When the fabric constituting the back fabric layer 4 includes a non-woven fabric, it is preferable because the processability when providing the convex portion 5 is improved. The details will be described later in conjunction with the method of forming the convex portion 5.

[0038] In this embodiment, the elastic layer 3 and the back fabric layer 4 are in direct contact. That is, there is no adhesive or the like for bonding the two between the elastic layer 3 and the back fabric layer 4. More specifically, a part of the elastic material constituting the elastic layer 3 has entered the gaps between the fibers constituting the fabric of the back fabric layer 4, and the two are bonded by a so-called anchor effect. Such an adhesive structure can be formed, for example, by frame lamination (described later). However, in the present invention, an adhesive may be used for the adhesion between layers, and in this case, an adhesive layer will be interposed between the layers. Examples of such an adhesive include adhesives containing, for example, polyvinyl chloride resin and polyurethane resin.

[0039] In addition, in the sheet material 1, as long as the skin layer 2 is disposed on the front surface and the back cloth layer 4 is disposed on the back surface, the provision of other layers in addition to the skin layer 2, the elastic layer 3, and the back cloth layer 4 is not hindered. Examples of such other layers include an adhesive layer, a foamed layer, and the like. For example, even when the sheet material 1 has another layer between the skin layer 2 and the elastic layer 3 and the skin layer 2 and the elastic layer 3 are not in direct contact with each other, it can be said that the elastic layer 3 exists between the skin layer 2 and the back cloth layer 4. That is, the mode in which the elastic layer 3 is disposed between the skin layer 2 and the back cloth layer 4 does not depend on whether the elastic layer 3 is in direct contact with each of the skin layer 2 and the back cloth layer 4 or not.

[0040] The convex portion 5 is a portion that protrudes from the periphery on the front surface side of the skin layer 2, and a plurality of convex portions 5 are arranged in parallel. In the present embodiment, the convex portion 5 is formed by quilting, and a seam (stitch) with a sewing thread 51 is provided in parallel with the convex portion 5. The number and arrangement of the seams are arbitrary and can be appropriately selected according to the intended design. In FIGS. 1 and 2, as an example, an example is shown in which one convex portion 5 (which may be referred to as a ridge from its mode) is provided between two seams.

[0041] The back convex portion 7 is a portion that protrudes from the periphery on the back surface side (the lower side in FIG. 2) of the back cloth layer 4. The back convex portion 7 is disposed on the back side of the front convex portion 5.

[0042] As described above, it is preferable in terms of workability when providing the convex portion 5 by quilting that the fabric constituting the back cloth layer 4 includes a non-woven fabric, particularly spunbond. When providing the convex portion 5 by quilting, the skin layer 2, the elastic layer 3, and the back cloth layer 4 are sewn together with a sewing thread 51 to form a seam. At this time, the tension of the sewing thread 51 forming the seam causes deformation on the front surface side of the skin layer 2 and the back surface side of the back cloth layer 4. The deformation on the front surface side of the skin layer 2 forms the convex portion 5, and the deformation on the back surface side of the back cloth layer 4 forms the back convex portion 7. Here, since the fabric including the non-woven fabric has a relatively high elastic modulus, when the fabric constituting the back cloth layer 4 includes a non-woven fabric, the back surface side of the back cloth layer 4 is less likely to deform compared to the case of using other fabrics. Then, the tension of the sewing thread 51 is mainly borne by the skin layer 2, and the deformation on the front surface side of the skin layer 2 is likely to increase. As a result, the convex portion 5 is likely to be prominent.

[0043] When using a relatively soft (low elastic modulus) synthetic leather as the synthetic leather constituting the skin layer 2, since the deformation on the front surface side of the skin layer 2 tends to increase, even if a relatively soft (low elastic modulus) fabric is used as the fabric constituting the back cloth layer 4, the convex portion 5 is likely to appear. That is, the range of choice of the fabric is widened. On the contrary, if a relatively hard (high elastic modulus) fabric is used as the fabric constituting the back cloth layer 4, it is easy to suppress the deformation on the back surface side of the back cloth layer 4. As a result, since the deformation on the front surface side of the skin layer 2 is likely to increase, the convex portion 5 is likely to appear regardless of the elastic modulus of the synthetic leather constituting the skin layer 2. Therefore, the range of choice of the synthetic leather is widened. That is, based on the relative elastic moduli of the skin layer 2 and the back cloth layer 4, the combination of the materials of each layer can be selected.

[0044] When the height by which the convex portion 5 protrudes from the surroundings is 0.8 times or more the height by which the back convex portion 7 protrudes from the surroundings, the visibility of the convex portion 5 is enhanced, which is preferable from the viewpoint of design. The height by which the convex portion 5 protrudes from the surroundings is specified, for example, as the height difference between the apex portion of the convex portion 5 and the sewing thread 51 in the thickness direction (front-back direction) of the sheet material 1 (FIG. 2). The height of the back convex portion 7 is also specified in the same manner.

[0045] In addition, it is also preferable that the height at which the convex portion 5 protrudes from the surroundings is 0.3 times or more the thickness of the sheet material 1, because the visibility of the convex portion 5 is enhanced. That is, it is preferable to satisfy at least one of the conditions that the height at which the convex portion 5 protrudes from the surroundings is 0.8 times or more the height at which the back convex portion 7 protrudes from the surroundings, and the condition that it is 0.3 times or more the thickness of the sheet material 1, and it is more preferable to satisfy both conditions.

[0046] The through-hole 6 is a hole that penetrates the skin layer 2, the elastic layer 3, and the back cloth layer 4, and opens to the convex portion 5 on the skin layer 2 side. In the present embodiment, the through-hole 6 is a round hole with a diameter of 1 mm. As in this example, when the equivalent circle diameter of the through-hole 6 is 0.40 mm or more, it is preferable in terms of easily ensuring the air permeability of the sheet material 1. The equivalent circle diameter of the through-hole 6 is more preferably 0.80 mm or more. The upper limit of the equivalent circle diameter of the through-hole 6 is not particularly limited, but it can be, for example, 2.5 mm or less. In the present embodiment, they are provided at intervals of 4 mm in an arrangement forming the vertices of an equilateral triangle with each other in a plan view (FIG. 1). However, the arrangement of the through-holes 6 is not limited.

[0047] 〔Function and effect of the sheet material〕 Since the sheet material 1 according to the present embodiment has the through-holes 6 that penetrate the skin layer 2, the elastic layer 3, and the back cloth layer 4, it has excellent air permeability. Therefore, the sheet material 1 is suitable as the skin material of a ventilation seat. In addition, since the sheet material 1 has the convex portions 5, a desired design can be added to the surface that touches the user's eyes. Therefore, when the sheet material 1 is used as the skin material of an automobile seat, a seat with excellent design can be realized.

[0048] 〔Manufacturing method of the sheet material〕 Next, the manufacturing method of the sheet material 1 according to the present embodiment will be described. The manufacturing method of the sheet material 1 includes a laminating step of laminating the skin layer 2, the elastic layer 3, and the back cloth layer 4 to obtain a composite raw fabric, a cutting step of cutting the composite raw fabric, a punching step of providing the through-holes 6 in the cut composite raw fabric, and a decorating step of providing the convex portions 5 on the skin layer 2.

[0049] (1) Laminating step In the laminating process, a composite fabric web in which the skin layer 2, the elastic layer 3, and the backing layer 4 are laminated is obtained. The composite fabric web has the skin layer 2, the elastic layer 3, and the backing layer 4 in this order, and is a synthetic leather composite that is finally larger in area than the sheet material 1 to be obtained. The dimensions of the composite fabric web are determined by, for example, the dimensions of any of the webs of the skin layer 2, the elastic layer 3, and the backing layer 4 used as raw materials.

[0050] The procedure for laminating the skin layer 2, the elastic layer 3, and the backing layer 4 in the laminating process is not particularly limited. For example, a procedure in which the backing layer 4 is laminated on one side of the elastic layer 3 and then the skin layer 2 is laminated on the other side of the elastic layer 3 can be adopted. In the laminating process according to the present embodiment, the skin layer 2, the elastic layer 3, and the backing layer 4 are each handled in the dimensions of the web, and each layer is supplied as a web roll wound around an axis. First, the elastic layer 3 and the backing layer 4 are each pulled out from the web roll, and a secondary web in which the two are laminated is obtained, and the secondary web is wound around another axis to form a secondary web roll. Next, a composite fabric web in which the skin layer 2 pulled out from the web roll and the secondary web pulled out from the secondary web roll are laminated is obtained, and the composite fabric web is wound around another axis.

[0051] The method of bonding the skin layer 2 to the elastic layer 3 is not particularly limited. For example, it includes the step of at least partially melting the surface of the elastic layer 3 and the step of bonding the skin layer 2 to the melted surface of the elastic layer 3. Among the above methods, the processing method of melting the surface of the elastic layer 3 by heating using a burner is called frame lamination. When a part of the elastic material constituting the elastic layer 3 is melted by heating to have fluidity and is pressed against the skin layer 2 (the base fabric layer portion 22), the elastic material enters the gaps between the fibers of the base fabric layer portion 22. Then, when the temperature of the elastic material drops and solidifies, the state where a part of the elastic layer 3 enters the gaps between the fibers of the base fabric layer portion 22 is fixed. Through the above mechanism, adhesion by the so-called anchor effect is realized. When the elastic layer 3 and the skin layer 2 are bonded by this method, no adhesive is required to bond the two. This is because the elastic material itself constituting the elastic layer 3 serves as an adhesive. However, using an adhesive to bond the elastic layer 3 and the skin layer 2 is not excluded.

[0052] Regarding the bonding of the elastic layer 3 and the back fabric layer 4, it is the same as the bonding of the elastic layer 3 and the skin layer 2. That is, a method including the step of at least partially melting the surface of the elastic layer 3 and the step of bonding the back fabric layer 4 to the melted surface of the elastic layer 3 can be adopted. However, using an adhesive for bonding the elastic layer 3 and the back fabric layer 4 is not excluded. Also, the bonding method of the elastic layer 3 and the skin layer 2 and the bonding method of the elastic layer 3 and the back fabric layer 4 can be selected independently.

[0053] (2) Cutting process The cutting process is a process of cutting the composite fabric (the bonded skin layer 2, elastic layer 3, and back fabric layer 4) obtained in the bonding process into a predetermined size. The predetermined size mentioned here is the size required for the final product and the size required for the sheet material 1. For convenience, the semi-finished product after the cutting process is called the cut composite.

[0054] Conventional highly breathable sheet materials were generally produced by a procedure in which through-holes were provided in synthetic leather cut to a predetermined size of the sheet material, and then an elastic material cut to the same size was bonded to the perforated synthetic leather. That is, the bonding of the synthetic leather and the elastic material was performed in units of the size of the sheet material. In contrast, in this embodiment, since the skin layer 2, the elastic layer 3, and the back cloth layer 4 are bonded together and then cut all at once, the bonding can be performed in the size of the raw fabric. This contributes to the efficiency of the bonding process.

[0055] (3) Punching process The punching process is a process of providing through-holes 6 in the composite raw fabric (the bonded skin layer 2, elastic layer 3, and back cloth layer 4) obtained in the bonding process. In this embodiment, the punching process is performed after the cutting process (that is, on the cut composite). As a method for providing the through-holes 6, a known method such as punching can be used. For convenience, the semi-finished product after punching is referred to as a punched composite.

[0056] (4) Decoration process The decoration process is a process of providing convex portions 5 on the skin layer 2. By providing the convex portions 5, a desired design can be added to the surface of the sheet material 1.

[0057] In this embodiment, the decoration process is realized by quilting. That is, stitches (stitches) with sewing threads 51 are provided around the portions that become the convex portions 5 in the punched composite, and the portions between the sewing threads 51 are made to protrude. Note that through-holes 6 are not provided in the portions where stitches are provided in the decoration process.

[0058] However, the method for providing the convex portions 5 in the decoration process is not limited to quilting. For example, pressing, hot embossing, cold embossing, welder embossing, vacuum embossing, embroidery, etc. are also effective as methods for providing the convex portions 5. Also, the decoration method does not have to be uniform, and the convex portions 5 may be provided by different decoration methods for each part of the sheet material 1.

[0059] 〔Other Embodiments〕 Finally, other embodiments of the synthetic leather composite and the method for manufacturing the synthetic leather composite according to the present invention will be described. Note that the configurations disclosed in the following respective embodiments can be applied in combination with the configurations disclosed in other embodiments as long as no contradiction occurs.

[0060] In the above embodiment, the configuration in which the through holes 6 are provided only in the convex portions 5 has been described as an example. However, in the present invention, it is not prohibited to provide through holes in portions other than the convex portions.

[0061] In the above embodiment, the configuration in which a plurality of convex portions 5 are arranged in parallel has been described as an example. However, in the present invention, the shape of the convex portions is not limited. That is, the convex portions can be provided in any form such as ridges or protrusions.

[0062] Regarding other configurations as well, it should be understood that all the embodiments disclosed in this specification are illustrative in all respects, and the scope of the present invention is not limited thereby. Those skilled in the art will easily understand that appropriate modifications can be made without departing from the gist of the present invention. Therefore, other embodiments modified without departing from the gist of the present invention are naturally included in the scope of the present invention.

Examples

[0063] Hereinafter, the present invention will be further described with reference to examples. However, the following examples do not limit the present invention.

[0064] (1) Sensory Evaluation 〔Preparation of Test Specimens〕 (Example 1) As a test piece according to Example 1, a test piece having the same layer structure as the sheet material 1 according to the above embodiment was created. The resin material constituting the resin layer portion 21 of the skin layer 2 was a polyurethane resin, and the fabric constituting the base fabric layer portion 22 was impregnated tricot. The thickness of the resin layer portion 21 was set to 0.1 mm, and the thickness of the base fabric layer portion 22 was set to 0.70 mm. The elastic material constituting the elastic layer 3 was a high-ventilation urethane foam with a thickness of 10 mm. The fabric constituting the back cloth layer 4 was spunbond with a thickness of 0.50 mm. The height of the convex portion 5 was 0.94 times the height of the back convex portion 7. The diameter of the through hole 6 was set to 1.0 mm.

[0065] The manufacturing method of the test piece according to Example 1 was made to conform to the manufacturing method of the sheet material 1 according to the above embodiment. That is, the bonding process, the cutting process, the punching process, and the decorating process were carried out in this order. In the bonding process, after bonding the elastic layer 3 and the back cloth layer 4 by frame lamination, the elastic layer 3 and the skin layer 2 were bonded by frame lamination.

[0066] (Comparative Example 1-1) The test piece according to Comparative Example 1-1 was obtained by processing the same materials as in Example 1 by a method different from that of Example 1. However, the fabric constituting the back cloth layer 4 was spunbond with a thickness of 0.25 mm. In Comparative Example 1-1, the cutting process, the punching process, and the decorating process were carried out in this order, and the bonding process was not carried out. In the cutting process, the elastic layer 3 and the back cloth layer 4 that were previously bonded together and the skin layer 2 were cut separately. The height of the convex portion 5 was 1.04 times the height of the back convex portion 7.

[0067] (Comparative Example 1-2) The same materials as in Example 1 were used except that the fabric constituting the back cloth layer 4 was 15d nylon half tricot (thickness 0.05 mm). In Comparative Example 1-2, the cutting process, the punching process, the bonding process, and the decorating process were carried out in this order to obtain a test piece. In the cutting process, the elastic layer 3 and the back cloth layer 4 that were previously bonded together and the skin layer 2 were cut separately. In the bonding process, the elastic layer 3 and the skin layer 2 were bonded using an adhesive. The height of the convex portion 5 was 0.72 times the height of the back convex portion 7.

[0068] (Comparative Examples 1-3) Test pieces of Comparative Examples 1-3 were obtained in the same manner as in Example 1, except that the perforation process was not performed. The height of the convex portion 5 was 0.94 times the height of the back-side convex portion 7.

[0069] 〔Evaluation of Test Pieces〕 (Air Permeability) A test piece was attached to one end of the cylinder, and air was blown in from the other end to check for the presence or absence of air outflow from the surface of the test piece. Air circulation was confirmed in Example 1, Comparative Example 1-1, and Comparative Example 1-2. Air circulation could not be confirmed in Comparative Example 1-3. Regarding air permeability, it can be said that the test pieces of Example 1, Comparative Example 1-1, and Comparative Example 1-2 are at a practical level.

[0070] (Appearance) In Example 1, no problems were observed in the appearance of the test piece. In Comparative Example 1-1, wrinkles occurred in the skin layer 2 during the decoration process. These wrinkles are likely to be unacceptable in view of the general quality standards of automobile manufacturers. In Comparative Example 1-2, the convex portion 5 formed during the decoration process was less prominent compared to other examples. Comparative Example 1-2 was inferior to the example in terms of imparting a characteristic design.

[0071] (2) Quantitative Evaluation 〔Preparation of Test Pieces〕 (Example 2) As a test piece according to Example 2, a test piece having the same layer structure as the sheet material 1 according to the above embodiment was prepared. The resin material constituting the resin layer portion 21 of the skin layer 2 was a polyurethane resin, and the fabric constituting the base fabric layer portion 22 was an impregnated tricot. The thickness of the resin layer portion 21 was 0.1 mm, and the thickness of the base fabric layer portion 22 was 0.70 mm. The elastic material constituting the elastic layer 3 was a normal urethane foam with a thickness of 5 mm. The fabric constituting the back fabric layer 4 was a jersey with a thickness of 0.05 mm. The height of the convex portion 5 was 2.91 times the height of the back-side convex portion 7. The diameter of the through hole 6 was 1.6 mm.

[0072] (Comparative Example 2) The test piece according to Comparative Example 2 was obtained by processing the same material as in Example 2 in a method different from that of the example. In Comparative Example 2, after providing holes with a diameter of 1.6 mm in the skin layer 2, the skin layer 2 and the elastic layer 3 were bonded together by frame lamination. Subsequently, the bonded skin layer 2 and elastic layer 3 were cut to a predetermined size. Finally, decoration by quilting was performed. That is, in Comparative Example 2, each process was carried out in the order of the perforation process, the bonding process, the cutting process, and the decoration process. The height of the convex portion 5 was 2.91 times the height of the back convex portion 7. As is clear from the above manufacturing method, Comparative Example 2 does not have the through hole 6.

[0073] 〔Evaluation of test piece〕 According to Method A (Frazee method) of the air permeability test described in JIS L 1096:2020, the air permeabilities of Example 2 and Comparative Example 2 were evaluated. Five measurements were made for each sample, and the average value was taken as the air volume. In the test where air was supplied from the side of the skin layer 2 and passed through to the side of the backing layer 4, the air volume of Example 2 was 113 cm 3 / (cm 2 ·sec), and the air volume of Comparative Example 2 was 47.3 cm 3 / (cm 2 ·sec). In the test where air was supplied from the side of the backing layer 4 and passed through to the side of the skin layer 2, the air volume of Example 2 was 112 cm 3 / (cm 2 ·sec), and the air volume of Comparative Example 2 was 47.6 cm 3 / (cm 2 ·sec). It was found that in Example 2 having the through hole 6 penetrating the skin layer 2, the elastic layer 3, and the backing layer 4, the air volume was significantly larger than that of Comparative Example 2 which did not have it.

Industrial applicability

[0074] The present invention can be used, for example, as a seat material for automobiles.

Explanation of reference numerals

[0075] 1: Seat material for automobiles 2: Skin layer 21: Resin layer portion 22: Base fabric layer part 23: Adhesive layer part 3: Elastic layer 4: Lining layer 5: Protrusion 51: Sewing thread 6: Through hole 7: Inner protrusion

Claims

1. An outer skin layer disposed on the surface and including synthetic leather, A back cloth layer disposed on the back surface and including a fabric, An elastic layer disposed between the outer skin layer and the back cloth layer and including an elastic member, and comprising: The outer skin layer has convex portions, and A synthetic leather composite having through holes penetrating the outer skin layer, the elastic layer, and the back cloth layer, at least in the convex portions.

2. The synthetic leather composite according to claim 1, wherein the outer skin layer and the elastic layer are in direct contact.

3. The synthetic leather includes a resin layer portion, The synthetic leather composite according to claim 1, wherein the thickness of the resin layer portion is 0.010 mm or more and 0.90 mm or less.

4. The synthetic leather composite according to claim 1, wherein the fabric includes a non-woven fabric.

5. An outer skin layer disposed on the surface and including synthetic leather, A back cloth layer disposed on the back surface and including a fabric, An elastic layer disposed between the outer skin layer and the back cloth layer and including an elastic member, and comprising: A method for manufacturing a synthetic leather composite having through holes penetrating the outer skin layer, the elastic layer, and the back cloth layer, comprising: A laminating step of laminating the outer skin layer, the elastic layer, and the back cloth layer; and A punching step of providing the through holes in the outer skin layer, the elastic layer, and the back cloth layer laminated in the laminating step.

6. The laminating step includes: A step of at least partially melting the surface of the elastic layer; and A step of laminating the outer skin layer to the melted elastic layer. The manufacturing method according to claim 5.

7. The manufacturing method according to claim 5, further comprising a cutting step of cutting the outer skin layer, the elastic layer, and the back cloth layer laminated in the laminating step into a predetermined size after the laminating step and before the punching step.

8. The manufacturing method according to claim 5, further comprising a decorating step of providing convex portions on the outer skin layer after the punching step.

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