Decorative skin material

Abstract

To provide a decorative skin material capable of giving a high-grade feeling.SOLUTION: A decorative skin material 11 has a woven fabric 14, which is formed by weaving warp 12 and weft 13 formed of untwisted multifilament yarn made of synthetic resin and impregnated with an impregnation resin 16 having visible light permeability. The warp 12 and the weft 13 include a lustrous material that reflects visible light.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a decorative skin material used for, for example, vehicles and buildings. [Background technology]

[0002] Generally, carbon cloth is used as a decorative item because of its luxurious and sporty appearance. One known example of such a decorative item is a panel made of carbon cloth solidified with epoxy resin or acrylic resin. However, because the carbon fibers that make up the carbon cloth are easily broken, it is difficult to bend the decorative item to conform to a three-dimensional curved surface.

[0003] Therefore, decorative materials have been proposed that do not use carbon fibers but instead express designs with the texture and feel of carbon cloth patterns (see, for example, Patent Document 1). These decorative materials are manufactured by embossing a black resin sheet to form a woven, uneven pattern. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2001-113894 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the decorative materials described above express a woven textured pattern without using fibers because it is difficult to reproduce each individual fiber, which makes it difficult to create a luxurious feel like carbon cloth. [Means for solving the problem]

[0006] Various aspects of decorative skin materials for solving the above problems will be described below. [Embodiment 1] A decorative skin material comprising a woven fabric woven with warp and weft threads, both of which are untwisted multifilament yarns made of synthetic resin, and impregnated with an impregnating resin that is transparent to visible light, wherein the warp and weft threads contain a lustrous material that reflects visible light.

[0007] According to the above configuration, the woven fabric contains a lustrous material that reflects visible light in the warp and weft yarns that make up the woven fabric, imparting a gloss to the woven fabric. Therefore, even if the woven fabric is covered with an impregnated resin that forms its outer shape, the gloss imparted to the woven fabric makes the weave of the woven fabric easily visible through the impregnated resin. This creates a luxurious feel.

[0008] [Aspect 2] The decorative skin material according to [Aspect 1], wherein the size of the lustrous material is smaller than the fiber diameter of the monofilaments that make up the warp and weft threads. According to the above configuration, the lustrous material can be contained inside the monofilaments that make up each of the warp and weft yarns.

[0009] [Aspect 3] A decorative covering material according to [Aspect 1] or [Aspect 2], characterized in that the woven fabric is coated with a coating agent made of a synthetic resin that is transparent to visible light.

[0010] According to the above-mentioned configuration, the coating agent can restrain the warp and weft yarns, thereby improving the slippage resistance of the woven fabric. [Effects of the Invention]

[0011] The present invention has the effect of creating a sense of luxury. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a schematic plan view of a decorative skin material according to one embodiment. [Figure 2] FIG. 2 is an enlarged cross-sectional view of FIG. [Figure 3] FIG. 2 is a cross-sectional view showing the inside of the warp and weft yarns. [Figure 4] FIG. 10 is a cross-sectional view of a decorative skin material according to a modified example. [Figure 5] FIG. 10 is a cross-sectional view of a decorative skin material according to a modified example. [Figure 6] FIG. 2 is a cross-sectional view of a laminate. [Figure 7] FIG. 2 is a cross-sectional view of a laminate. [Figure 8] FIG. 2 is a cross-sectional view of a laminate. [Figure 9] FIG. 2 is a cross-sectional view of a laminate. DETAILED DESCRIPTION OF THE INVENTION

[0013] An embodiment will be described below with reference to the drawings. <Decorative skin material 11> 1 and 2, decorative skin material 11 is used, for example, to decorate the interior and exterior of vehicles, the interior and exterior walls of buildings, and the surfaces of furniture and home appliances. Decorative skin material 11 has a flexible woven fabric 14 woven with warp yarns 12 and weft yarns 13, both of which are untwisted multifilament yarns made of synthetic resin. Woven fabric 14 is entirely coated with a synthetic resin coating agent 15. Furthermore, woven fabric 14 is impregnated with an impregnating resin 16 that forms the outer shape of decorative skin material 11. In other words, woven fabric 14 is entirely covered with impregnating resin 16 as well as coating agent 15.

[0014] <Woven fabric 14> As shown in Figures 1 and 2, the woven fabric 14 is formed by plain weaving a plurality of aligned warp threads 12 (three in this example) and a plurality of aligned weft threads 13 (three in this example). In this case, the width A of the roving is set, for example, in the range of 2.3 mm to 4.3 mm. This range of the roving width A corresponds to a 6K carbon cloth. In this case, 6K refers to the number of filaments, meaning that 6,000 carbon fibers are used per bundle.

[0015] The warp threads 12 and weft threads 13 that make up the woven fabric 14 are both made of a thermoplastic resin. In this case, polyester, polyamide, polyurethane, polypropylene, etc. can be used as the thermoplastic resin. From the viewpoint of improving the durability of the woven fabric 14, it is preferable that the warp threads 12 and weft threads 13 be made of polyester or polyamide. Furthermore, from the viewpoint of recyclability, it is preferable that the warp threads 12 and weft threads 13 be made of polyester.

[0016] As an example, both the warp threads 12 and the weft threads 13 are colored black. In this case, the warp threads 12 and the weft threads 13 are colored by dope dyeing. That is, the warp threads 12 and the weft threads 13 are dope-dyed yarns. In other words, the warp threads 12 and the weft threads 13 are colored by mixing a colorant such as a pigment into the raw material itself. Coloring by dope dyeing is more resistant to fading than coloring by dyeing, and is therefore advantageous in terms of durability.

[0017] The warp yarns 12 and weft yarns 13 have a fineness in the range of 200 decitex to 5000 decitex. Furthermore, the fiber diameter of the single fibers constituting the warp yarns 12 and weft yarns 13 made of multifilament yarns is preferably in the range of 5 μm to 60 μm, more preferably in the range of 20 μm to 60 μm. This allows the woven fabric 14 to have a high-quality appearance with a gloss like carbon cloth, while ensuring the abrasion resistance of the woven fabric 14.

[0018] Incidentally, if the fiber diameter of the single fibers constituting the warp threads 12 and weft threads 13 is less than 5 μm, the single fibers will be too thin, resulting in reduced abrasion resistance. On the other hand, if the fiber diameter of the single fibers constituting the warp threads 12 and weft threads 13 is greater than 60 μm, it will be difficult to achieve a glossy, luxurious appearance like that of carbon cloth using the woven fabric 14. The basis weight of the woven fabric 14 is set to, for example, about 400 grams per square meter.

[0019] As shown in Fig. 3, a large number of luminous materials 17 that reflect visible light are dispersed in the warp yarns 12 and the weft yarns 13. The luminous materials 17 are made of, for example, mica or aluminum flakes. The size (average particle diameter) of the luminous materials 17 is set to be smaller than the fiber diameter of the single fibers that make up the warp yarns 12 and the weft yarns 13, respectively.

[0020] <Coating Agent 15> As shown in Figures 1 and 2, coating agent 15 is made of a synthetic resin that is transparent to visible light. That is, a colorless and transparent emulsion-type coating agent is used for coating agent 15. Because coating agent 15 is colorless and transparent, it is possible to make the most of the appearance of woven fabric 14. Using an emulsion-type coating agent for coating agent 15 eliminates the need for organic solvents, which contributes to reducing the environmental impact.

[0021] For example, polyester-based, acrylic-based, or polyamide-based coating agents can be used as the coating agent 15. The pencil hardness of the coating agent 15, as defined in JIS K5600-5-4, is preferably in the range of HB to 6B, and more preferably B. This can improve the slippage resistance and durability (abrasion resistance) of the woven fabric 14 without impairing the texture of the woven fabric 14. Examples of methods for applying (applying) the coating agent 15 to the woven fabric 14 include impregnation and a gravure coater (roll coater).

[0022] <Impregnating resin 16> 1 and 2, the impregnating resin 16 makes the surface of the decorative skin material 11 flat and gives the outer shape of the decorative skin material 11, for example, a plate or block shape. The impregnating resin 16 is made of a synthetic resin that is transparent to visible light. That is, a colorless and transparent synthetic resin is used for the impregnating resin 16.

[0023] The impregnating resin 16 is colorless and transparent, which allows the appearance of the woven fabric 14 to be utilized. For example, epoxy-based, acrylic-based, or polyester-based resins can be used as the impregnating resin 16. Methods for applying the impregnating resin 16 include spray painting, brush painting, casting, and filling. The impregnating resin 16 may be made of the same synthetic resin as the coating agent 15.

[0024] <Function of decorative skin material 11> As described above, the decorative skin material 11 is configured such that the lustrous material 17 that reflects visible light is contained within the warp threads 12 and weft threads 13 of the synthetic resin woven fabric 14, thereby imparting gloss to the woven fabric 14. Therefore, even though the woven fabric 14 is covered with the impregnating resin 16 that forms the outer shape of the decorative skin material 11, the gloss imparted to the woven fabric 14 makes the weave of the woven fabric 14 easily visible through the impregnating resin 16. Therefore, the decorative skin material 11 can create a luxurious feel.

[0025] In addition, the decorative skin material 11 has an appearance very similar to that of high-quality carbon cloth without using fragile and expensive carbon fiber, and because it is flexible, it has good conformability to three-dimensional curved surfaces. Therefore, the decorative skin material 11 can be produced more cheaply than carbon cloth and is suitable for use on three-dimensional curved surfaces where carbon cloth cannot be used.

[0026] That is, the decorative skin material 11 can be used, for example, in the interior of a vehicle on the surfaces of the instrument panel, console box, door trim, ceiling panel, seats, etc., which are seen and touched by the occupants. This allows the occupants (users) to visually enjoy the luxurious appearance that closely resembles carbon cloth and the textured feel that is unique to the woven fabric 14.

[0027] <Effects of the embodiment> According to the embodiment described above in detail, the following effects are achieved. (1) The decorative skin material 11 has a woven fabric 14 made of warp threads 12 and weft threads 13, both of which are made of untwisted multifilament yarns made of synthetic resin. The woven fabric 14 is impregnated with an impregnating resin 16 that is transparent to visible light. The warp threads 12 and weft threads 13 contain a reflective material 17 that reflects visible light.

[0028] According to the above configuration, the lustrous material 17 that reflects visible light is contained in the warp yarns 12 and weft yarns 13 that make up the woven fabric 14, thereby imparting a gloss to the woven fabric 14. Therefore, even if the woven fabric 14 is covered with the impregnating resin 16 that forms the outer shape, the gloss imparted to the woven fabric 14 makes the weave of the woven fabric 14 easily visible through the impregnating resin 16. This allows for a luxurious feel to be created.

[0029] (2) In the decorative skin material 11, the size of the glittering material 17 is smaller than the fiber diameter of the single fibers that make up the warp threads 12 and the weft threads 13, respectively. According to the above-mentioned configuration, the glittering material 17 can be contained inside the monofilaments that make up the warp threads 12 and the weft threads 13, respectively.

[0030] (3) In the decorative skin material 11, the woven fabric 14 is coated with a coating agent 15 made of synthetic resin that is transparent to visible light. According to the above-mentioned configuration, the coating agent 15 can restrain the warp yarns 12 and the weft yarns 13, thereby improving the slippage resistance of the woven fabric 14.

[0031] <Example of change> The above embodiment can be modified as follows: Furthermore, the above embodiment and the following modifications can be combined with each other within the scope of technical compatibility.

[0032] 4, a plate-shaped base substrate 18 may be provided on the back surface opposite to the design surface (front side) of the decorative skin material 11. The base substrate 18 is made of, for example, polypropylene, ABS, or acrylic resin.

[0033] As shown in Fig. 5, in the case of Fig. 4, a plate-shaped backing material 19 may be provided between the decorative skin material 11 and the base substrate 18. In this case, if the backing material 19 is made of, for example, urethane foam, it is possible to impart cushioning properties to the decorative skin material 11. The backing material 19 may also be made of nonwoven fabric, a resin sheet (film), or the like.

[0034] The coating agent 15 may be omitted. The coating agent 15 does not necessarily have to be an emulsion-type coating agent, but may be, for example, a solvent-type coating agent.

[0035] The size of the glittering material 17 does not necessarily have to be smaller than the fiber diameter of the single fibers that make up the warp threads 12 and the weft threads 13 . The woven fabric 14 may be formed by weaving one, two, or four or more warp threads 12 and weft threads 13. In this case, the number of warp threads 12 and weft threads 13 constituting the woven fabric 14 may be set according to the number of filaments per bundle of carbon fibers in the carbon cloth to be simulated.

[0036] The warp threads 12 and weft threads 13 may be colored in a color other than black. That is, the warp threads 12 and weft threads 13 may be colored, for example, red, blue, or green. In this way, for example, by setting the color of the warp threads 12 and weft threads 13 to match the external appearance color of the area where the decorative skin material 11 is used, it is possible to achieve a sense of color unity between the external appearance of the decorative skin material 11 and the external appearance of the area around the decorative skin material 11.

[0037] The colors of the warp threads 12 and weft threads 13 may be changed individually. For example, the warp threads 12 may be black and the weft threads 13 may be red, or one of the three warp threads 12 or weft threads 13 may be blue and the remaining two may be red. In other words, the multiple warp threads 12 and the multiple weft threads 13 may each be a different color. In this way, various patterns and colors can be expressed by weaving the warp threads 12 and weft threads 13 not only in plain weave but also in twill or satin weave, which contributes to improving the design of the decorative covering material 11.

[0038] The woven fabric 14 may be formed by weaving the warp threads 12 and the weft threads 13 in a twill or satin weave. The woven fabric 14, i.e., the warp threads 12 and the weft threads 13, may be colored by dyeing.

[0039] After forming the woven fabric 14 by weaving the warp threads 12 and weft threads 13, both of which are colorless or light-colored, letters and patterns of various colors may be printed on the woven fabric 14 using a color inkjet printer. This increases the degree of freedom in design expression using the decorative skin material 11.

[0040] <Technology Disclosure> The following describes techniques that deviate from the spirit of the present invention. In the decorative skin material 11, the coating agent 15 may contain a lustrous material 17. In this case, the warp threads 12 and weft threads 13 that make up the woven fabric 14 may or may not contain the lustrous material 17. If the warp threads 12 and weft threads 13 do not contain the lustrous material 17, the warp threads 12 and weft threads 13 may be made of, for example, black dope-dyed yarns.

[0041] The laminate 30 shown in FIG. 6 can be used as a decorative skin material. The laminate 30 has a five-layer structure, in which a resin film 31, an adhesive layer 32, a decorative textile 33, another adhesive layer 32, and a base substrate 18 are laminated in this order from the front side to the back side. The resin film 31 is made of, for example, a general-purpose resin or an engineering plastic. The adhesive layer 32 is made of, for example, an acrylic, silicone, or urethane resin. The decorative textile 33 is the decorative skin material 11 without the impregnated resin 16. The laminate 30 is manufactured by, for example, vacuum forming, pressure forming, or hot press molding. When manufacturing the laminate 30 by vacuum forming or pressure forming, a resin film 31 is required to withstand the pressure caused by the molding. The resin film 31 may be peeled off after the laminate 30 is molded. For example, if the adhesive layer 32 is a hot melt adhesive, the resin film 31 can be omitted if the adhesive layer 32 can withstand the pressure caused by the molding during vacuum forming or pressure forming.

[0042] In the laminate 30 shown in FIG. 6, the base substrate 18 may be omitted. 6, the adhesive layer 32 is made of, for example, a solvent-drying adhesive such as vinyl acetate resin, a two-component reactive adhesive such as epoxy resin, a moisture-curing adhesive such as urethane resin, a heat-curing adhesive such as epoxy resin or phenol resin, a hot-melt adhesive such as polyamide resin or vinyl acetate resin, a pressure-sensitive adhesive such as acrylic resin or rubber resin, a re-moistening adhesive such as glue or dextrin, a UV-curing adhesive such as acrylic resin or epoxy resin, etc. The adhesive layer 32 may also be a pressure-sensitive adhesive made of, for example, an acrylic, silicone, or urethane resin.

[0043] The laminate 34 shown in Fig. 7 can be used as a decorative skin material. The laminate 34 shown in Fig. 7 is the laminate 30 shown in Fig. 6, with a backing material 19 placed between the adhesive layer 32 on the back side and the decorative fabric 33. The laminate 34 shown in Fig. 7 is manufactured in the same manner as the laminate 30 shown in Fig. 6 described above.

[0044] The laminate 35 shown in Fig. 8 can be used as a decorative skin material. The laminate 35 has a five-layer structure in which a decorative fabric 33, an adhesive layer 32, a resin film 31, another adhesive layer 32, and a base substrate 18 are laminated in this order from the front side to the back side. The laminate 35 shown in Fig. 8 is manufactured in the same manner as the laminate 30 shown in Fig. 6 described above. In this case, the resin film 31 cannot be removed after the laminate 35 is formed.

[0045] The laminate 36 shown in Fig. 9 can be used as a decorative skin material. The laminate 36 shown in Fig. 9 is the laminate 35 shown in Fig. 8, with a backing material 19 placed between the adhesive layer 32 on the base substrate 18 side and the resin film 31. The laminate 36 shown in Fig. 9 is manufactured in the same manner as the laminate 30 shown in Fig. 6 described above. In this case, the resin film 31 cannot be removed after the laminate 36 is formed.

[0046] In the laminate 30 shown in FIG. 6, the laminate 34 shown in FIG. 7, the laminate 35 shown in FIG. 8, and the laminate 36 shown in FIG. 9, the coating agent 15 may be omitted from the decorated textile 33. [Explanation of symbols]

[0047] 11...Decorative skin material 12...warp threads 13...Weft 14…Woven fabric 15...Coating agent 16...Impregnated resin 17…Shining material 18...Base material 19...Backing material 30, 34, 35, 36...Laminate 31...Resin film 32...adhesive layer 33...Decorative textiles A…Roving width

Claims

1. The fabric is woven with warp and weft yarns, both of which are made of untwisted multifilament yarns made of synthetic resin, and is impregnated with an impregnation resin that is transparent to visible light. The decorative skin material is characterized in that the warp threads and the weft threads contain a glittering material that reflects visible light.

2. 2. The decorative skin material according to claim 1, wherein the size of the glittering material is smaller than the fiber diameter of the single fibers constituting the warp threads and the weft threads.

3. 3. The decorative skin material according to claim 1, wherein the woven fabric is coated with a coating agent made of a synthetic resin that is transparent to visible light.

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