Synthetic leather and manufacturing method

Abstract

To improve flexibility and tactile of polyvinyl chloride synthetic leather without damaging abrasion resistance thereof.SOLUTION: Flexibility and tactile of polyvinyl chloride synthetic leather are improved without damaging abrasion resistance thereof. The polyvinyl chloride synthetic leather comprises: a resin layer 2; a base fabric layer 4 including a fabric; and an adhesive layer 3 to be adhered with the resin layer 2 and the base fabric layer 4. The resin layer 2 includes a body part 5, which includes polyvinyl chloride resin as a main component, and a surface part 6, which includes polycarbonate-based urethane resin and silicone resin so that the polycarbonate-based urethane resin or the silicone resin is the main component. The body part 5 contacts with the adhesive layer 3 on one surface side and the surface part 6 on the other surface side.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to synthetic leather and a method for producing synthetic leather. [Background technology]

[0002] Synthetic leather is widely used for automobile seats and the like. A typical synthetic leather comprises a base fabric layer containing a fabric and a resin layer containing a resin material, with polyvinyl chloride resin and polyurethane resin being typical resin materials constituting the resin layer. While polyvinyl chloride resin offers cost advantages over polyurethane resin due to differences in raw material costs, it suffers from inferior mechanical properties such as abrasion resistance. Conventional polyvinyl chloride synthetic leathers typically compensate for their inferior mechanical properties by providing a thicker resin layer than polyurethane synthetic leathers, but it has sometimes been difficult to achieve satisfactory performance in all aspects, including mechanical properties, weight, flexibility, touch, and texture.

[0003] In view of the above issues, various techniques for forming a foamed resin layer as part of a resin layer in polyvinyl chloride synthetic leather have been investigated. For example, Japanese Patent Application Laid-Open No. 2020-180191 (Patent Document 1) discloses a foamed resin layer containing a polyvinyl chloride resin and a thermoplastic polyurethane elastomer, and synthetic leather containing the foamed resin layer. The technique disclosed in Patent Document 1 makes it possible to provide synthetic leather that is lightweight and has excellent abrasion resistance. Furthermore, Japanese Patent Application Laid-Open No. 2017-210703 (Patent Document 2) discloses synthetic leather that includes a foamed resin layer containing a vinyl chloride resin and a plasticizer, and a resin layer containing polyurethane. The technique disclosed in Patent Document 2 makes it possible to provide synthetic leather that has excellent abrasion resistance and is less likely to wrinkle. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 2020-180191 (or U.S. Patent Application Publication No. 2020 / 0340175) [Patent Document 2] Japanese Patent Publication No. 2017-210703 (or Chinese Patent Publication No. 107435248) Summary of the Invention [Problem to be solved by the invention]

[0005] However, the technologies of Patent Documents 1 and 2 merely improve the structure of the foamed resin layer, and the improvement effect is limited. In particular, the flexibility and feel of the products do not reach a level comparable to that of polyurethane synthetic leather.

[0006] Thus, there is a demand for improving the softness and feel of polyvinyl chloride synthetic leather without impairing its abrasion resistance. [Means for solving the problem]

[0007] The synthetic leather according to the present invention comprises a resin layer, a base fabric layer containing a material, and an adhesive layer that bonds the resin layer and the base fabric layer, wherein the resin layer has a main body portion containing polyvinyl chloride resin as a main component, and a surface portion containing polycarbonate-based urethane resin and silicone resin and having polycarbonate-based urethane resin or silicone resin as a main component, and wherein the main body portion is in contact with the adhesive layer on one side and in contact with the surface portion on the other side.

[0008] The manufacturing method of the present invention is a method for manufacturing synthetic leather having a main body portion containing a resin layer, a fabric-containing base fabric layer, and an adhesive layer bonding the resin layer and the base fabric layer, the resin layer containing a polyvinyl chloride resin as a main component, and a surface portion containing a polycarbonate-based urethane resin and a silicone resin, the surface portion being mainly composed of a polycarbonate-based urethane resin or a silicone resin, the manufacturing method comprising the steps of: forming the main body portion; forming the adhesive layer on one side of the main body portion; bonding the fabric layer to the adhesive layer; and forming the surface portion on the other side of the main body portion.

[0009] In these structures, abrasion resistance is ensured by providing a surface containing a polycarbonate-based urethane resin and a silicone resin, instead of the foamed resin layer used in conventional polyvinyl chloride synthetic leathers, making it easier to reduce the thickness of the resin layer, thereby improving the flexibility and feel of the synthetic leather without sacrificing abrasion resistance.

[0010] Preferred embodiments of the present invention will be described below, but the scope of the present invention is not limited to the preferred embodiments described below.

[0011] In one embodiment, the synthetic leather according to the present invention has a basis weight of 150 g / m 2 More than 300g / m 2 It is preferable that:

[0012] This structure uses a thicker fabric than the fabric typically used for the base fabric layer in conventional polyvinyl chloride synthetic leather, which tends to improve the feel of the synthetic leather.

[0013] In one embodiment of the synthetic leather according to the present invention, the fabric is preferably raised.

[0014] This configuration makes it easier to improve the cushioning properties of the synthetic leather.

[0015] In one embodiment, the manufacturing method according to the present invention preferably further includes a step of shaping the resin layer by adsorbing the surface portion onto the outer peripheral surface of a support having an uneven outer peripheral surface and a negative pressure inside.

[0016] According to this configuration, the texture is less likely to be visible when the resin layer is shaped, making it easier to add decoration as intended.

[0017] Further features and advantages of the present invention will become more apparent from the following description of exemplary and non-limiting embodiments, which is given with reference to the drawings. [Brief explanation of the drawings]

[0018] [Figure 1] 1 is a cross-sectional view showing a structure of a synthetic leather according to an embodiment. [Figure 2] 1A and 1B are schematic diagrams illustrating a shaping device used in a manufacturing method according to an embodiment and a method for using the same. DETAILED DESCRIPTION OF THE INVENTION

[0019] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described in detail below with reference to the accompanying drawings, in which the present invention will be described in detail with reference to the accompanying drawings.

[0020] [Composition of synthetic leather] The synthetic leather 1 according to this embodiment includes a resin layer 2, an adhesive layer 3, and a base fabric layer 4, and the resin layer 2 has a main body portion 5 and a surface portion 6 (Fig. 1). The main body portion 5 is in contact with the adhesive layer 3 on one side and with the surface portion 6 on the other side. The synthetic leather 1 is used, for example, for automobile seats, and the surface of the resin layer 2 is decorated with irregularities. Note that Fig. 1 is a schematic illustration of the layer structure of the synthetic leather 1, and the thickness ratios of the various portions in Fig. 1 are not accurate. Furthermore, Fig. 1 does not show the irregularities on the surface of the resin layer 2.

[0021] Of the resin layer 2, the main body portion 5 contains polyvinyl chloride resin as its main component. Here, the term "main component" refers to the material that accounts for the largest weight ratio of the materials constituting the main body portion 5. The main body portion 5 is also generally referred to as a skin layer in the field of synthetic leather. The polyvinyl chloride resin contained in the main body portion 5 may have a degree of polymerization of 1300 or more and 2500 or less, for example.

[0022] Of the resin layer 2, the surface portion 6 is called the surface treatment layer and contains a polycarbonate-based urethane resin and a silicone resin. The surface portion 6 is mainly composed of a polycarbonate-based urethane resin or a silicone resin. Here, the term "main component" refers to the material that accounts for the largest weight ratio of the materials that make up the surface portion 6. The surface portion 6 is also generally called the surface treatment layer in the field of synthetic leather. However, the surface portion 6 may contain components other than the polycarbonate-based urethane resin and the silicone resin. Non-limiting examples of such other components include a crosslinking agent and a leveling agent.

[0023] The polycarbonate-based urethane resin contained in the surface portion 6 is not particularly limited. For example, the surface portion 6 can be formed using a commercially available surface treatment agent containing a polycarbonate-based urethane resin sold by Stahl, Dainichiseika Color & Chemicals Mfg. Co., Ltd., Seiko Kasei Corporation, etc. The content of the polycarbonate-based urethane resin in the surface portion 6 is, for example, 10 g / m 2 More than 30g / m 2 The surface portion 6 may contain multiple types of polycarbonate-based urethane resins, but is not limited to these. In this case, the content of the polycarbonate-based urethane resin is specified as the total content of the multiple types of polycarbonate-based urethane resins.

[0024] Polycarbonate-based urethane resins are polymers obtained by reacting, for example, a polyol compound containing a polycarbonate block with an isocyanate compound. The physical properties of polycarbonate-based urethane resins are determined by factors such as the number of polymerizations of the polycarbonate block, the number of isocyanate groups in the isocyanate compound, and the molecular structure. For example, the higher the number of polymerizations of the polycarbonate block, the smaller the proportion of urethane bonds in the polymer chain of the polycarbonate-based urethane resin. In this case, hydrogen bonds (involving urethane bond moieties) between polymer chains are less likely to form, resulting in a relatively soft polycarbonate-based urethane resin. Conversely, a low number of polymerizations of the polycarbonate block results in a relatively hard polycarbonate-based urethane resin. Furthermore, if the number of isocyanate groups in the isocyanate compound is two, the polymer chain of the polycarbonate-based urethane resin will be linear, resulting in a relatively soft polycarbonate-based urethane resin. On the other hand, if the number of isocyanate groups in the isocyanate compound is three or more, the polymer chains of the polycarbonate-based urethane resin become network-like, resulting in a relatively hard polycarbonate-based urethane resin. Thus, the physical properties of the polycarbonate-based urethane resin can be appropriately controlled by selecting the polyol compound and the isocyanate compound. This can be used to control the physical properties of the surface portion 6.

[0025] The silicone resin contained in the surface portion 6 is not particularly limited. Therefore, commercially available silicone resin-containing surface treatment agents sold by, for example, Nissin Chemical Industry Co., Ltd., Stahl, and Seiko Chemical Co., Ltd. can be used to form the surface portion 6. The surface portion 6 (surface treatment layer) containing a polycarbonate-based urethane resin and a silicone resin can be formed, for example, by applying a commercially available surface treatment agent containing a polycarbonate-based urethane resin and a commercially available surface treatment agent containing a silicone resin. Note that the surface portion 6 may contain multiple types of silicone resin. In this case, the content of the silicone resin is specified as the total content of the multiple types of silicone resin.

[0026] The silicone resin may be modified or unmodified. When the silicone resin is modified, i.e., when it is a modified silicone resin, it may be, but is not limited to, an amino-modified silicone resin, a dimethyl-modified silicone resin, a carbinol-modified silicone resin, or the like.

[0027] The composition of the surface portion 6 is not limited as long as it is primarily composed of a polycarbonate-based urethane resin or a silicone resin. Incidentally, "primarily composed of a polycarbonate-based urethane resin or a silicone resin" includes cases in which both the polycarbonate-based urethane resin and the silicone resin account for the largest weight ratios of the materials constituting the surface portion 6 (i.e., cases in which the content of the polycarbonate-based urethane resin and the content of the silicone resin are the same and greater than the content of other components). For example, when the surface portion 6 is primarily composed of a polycarbonate-based urethane resin, the surface portion 6 may contain 1 to 15 parts by weight of silicone resin per 100 parts by weight of the polycarbonate-based urethane resin.

[0028] The weight of the resin layer 2 is not particularly limited, but is, for example, 160 g / m 2 More than 300g / m 2 The surface portion 6 may have a thickness of, for example, 10 g / m 2 More than 30g / m 2 The main body 5 may be the remainder thereof.

[0029] The adhesive layer 3 may contain an adhesive commonly used in the field of synthetic leather. An example of such an adhesive is an adhesive containing polyvinyl chloride resin. In this case, the polyvinyl chloride resin may have a degree of polymerization of 1000 or more and 1700 or less. The weight of the adhesive layer 3 is not particularly limited, but may be, for example, 65 g / m 2 More than 180g / m 2 It can be the following:

[0030] The fabric layer 4 comprises a fabric, which may be, for example, but is not limited to, a woven fabric, a single jersey fabric, a double jersey fabric, a tricot fabric, a raschel fabric, a double raschel fabric, a nonwoven fabric, and the like.

[0031] The fabric contained in the base fabric layer 4 has a basis weight of 150 g / m 2 More than 300g / m 2 It is preferable that the fabric weight is 150 g / m or less. 2 When the weight of the fabric is 300 g / m or more, the feel (cushioning, etc.) of the synthetic leather 1 tends to be good. 2 If the bending resistance is equal to or less than this range, the synthetic leather 1 tends to have a bending resistance within a range suitable for use in automobile seats.

[0032] The fabric contained in the base fabric layer 4 is preferably brushed. This is preferable because it is easy to enhance the cushioning properties of the synthetic leather. The color of the fabric contained in the base fabric layer 4 is not limited, but it is preferable to use the same color or a similar color as the resin layer 2 (main body portion 5) because this makes the base fabric layer 4 less noticeable in perforations, etc.

[0033] [Method for manufacturing synthetic leather] Next, a method for producing the synthetic leather 1 according to this embodiment will be described. In the production method according to this embodiment, the production process of the synthetic leather 1 is carried out in three stages: a first stage, a second stage, and a third stage.

[0034] In the first stage, a first semi-finished product is produced, which is composed of the main body 5, adhesive layer 3, and fabric layer 4. The first semi-finished product is produced by sequentially stacking the main body 5, adhesive layer 3, and fabric layer 4 on top of release paper, and finally removing the release paper.

[0035] First, a process for forming the main body portion 5 is carried out. Specifically, polyvinyl chloride resin is applied to release paper delivered from a release paper supply source (e.g., in roll form) and then dried, forming the main body portion 5 on the release paper. Next, a process for forming an adhesive layer 3 on one side of the main body portion 5 is carried out. Specifically, an adhesive is applied to the main body portion 5 formed on the release paper. Subsequently, a process for adhering the base fabric layer 4 to the adhesive layer 3 is carried out. Specifically, the base fabric layer 4 is bonded to the main body portion 5 formed on the release paper and the adhesive layer 3. Through these processes, a first semi-finished product with release paper is obtained. Finally, the release paper is peeled from the main body portion 5 of the first semi-finished product, and the release paper and the first semi-finished product are collected separately. There are no particular restrictions on how the release paper and the first semi-finished product are collected, but considering ease of use in the next process, it is preferable that they be collected in a rolled form.

[0036] In the second stage, the body portion 5 of the first semi-finished product is surface-treated to form the surface portion 6, thereby producing a second semi-finished product consisting of the resin layer 2 (surface portion 6 and body portion 5), the adhesive layer 3, and the fabric layer 4. That is, a step of forming a surface portion on the other side of the body portion 5 is carried out. Specifically, a surface treatment agent containing a polycarbonate-based urethane resin and a silicone resin is applied to the first semi-finished product sent out from a supply source of the first semi-finished product (for example, in a roll form), and the surface portion 6 is formed on the body portion 5.

[0037] In the third stage, a concave-convex pattern is formed on the resin layer 2 of the second semi-finished product to decorate it. That is, a process of shaping the resin layer 2 is carried out. The shaping device 10 used in this process has a heater 11 that heats the second semi-finished product 20, a ceramic roll 12 (an example of a support), and a pressure reducing device (not shown) that creates a negative pressure inside the roll 12 (FIG. 2). Note that FIG. 2 is a schematic diagram of the configuration of the shaping device 10, and the dimensional proportions of the various parts are not accurate.

[0038] The roll 12 is made of ceramic and has voids through which air can pass, so that negative pressure draws air from the outside to the inside of the roll 12. On the outer peripheral surface of the roll 12, irregularities 13 corresponding to the pattern to be transferred to the resin layer 2 are formed.

[0039] The second semi-finished product 20 is heated by the heater 11 and then introduced into the roll 12. This heating is intended to soften the vinyl chloride resin of the resin layer 2 to make it easier to shape. In the roll 12, the resin layer 2 of the second semi-finished product 20 is adsorbed onto the outer peripheral surface of the roll 12 using negative pressure from a pressure reducing device as a driving force. At this time, the irregularities 13 on the outer peripheral surface of the roll 12 are transferred to the resin layer 2, and the resin layer 2 is shaped.

[0040] By using negative pressure as a driving force to shape the resin layer 2, the texture of the fabric layer 4 is less likely to be visible on the surface of the resin layer 2, making it easier to achieve the intended decoration. The problem of the texture of the fabric layer 4 being visible on the surface of the resin layer 2 is more likely to occur when the resin layer 2 is thin (i.e., when the resin layer 2 is light in weight). On the other hand, if the contact force between the roll and the resin layer 2 is reduced to avoid the problem of the texture of the fabric layer 4 being visible on the surface of the resin layer 2, the intended decoration may not be achieved. Therefore, when the resin layer 2 is thin, it is difficult to determine the shaping conditions that prevent the texture of the fabric layer 4 from being visible and allow for sufficient decoration. Using a method using negative pressure as a driving force to shape the resin layer 2 makes it easier to both avoid the texture being visible and achieve sufficient decoration, compared to using a method in which synthetic leather 1 is pressed against a roll. Therefore, when the weight of the resin layer 2 is relatively small, using negative pressure as a driving force to shape the resin layer 2 is particularly advantageous compared to using a method in which synthetic leather 1 is pressed against a roll. In the synthetic leather 1 according to this embodiment, the weight of the resin layer 2 is 160 g / m 2 More than 300g / m 2However, this preferred range of basis weight is smaller than the weight of a typical resin layer in conventional polyvinyl chloride synthetic leather. In other words, since the weight of the resin layer 2 in the preferred embodiment of the synthetic leather 1 according to the present embodiment is smaller than the weight of the resin layer in conventional polyvinyl chloride synthetic leather, it is advantageous to shape the resin layer 2 using a method that uses negative pressure as a driving force.

[0041] Other Embodiments Finally, other embodiments of the synthetic leather and manufacturing method according to the present invention will be described. Note that the configurations disclosed in the following embodiments can be applied in combination with the configurations disclosed in other embodiments, provided that no contradictions arise.

[0042] In the above embodiment, synthetic leather 1 including a resin layer 2, an adhesive layer 3, and a fabric layer 4 has been described as an example. However, in the synthetic leather according to the present invention, the presence of other layers is not excluded as long as the resin layer and the fabric layer are bonded together by an adhesive layer. Similarly, the presence of other parts is not excluded as long as the resin layer has a main body containing polyvinyl chloride resin and a surface containing polycarbonate-based urethane resin and silicone resin.

[0043] In the above embodiment, an example has been described in which the resin layer 2 is shaped using a ceramic roll 12. However, in the manufacturing method according to the present invention, the step of shaping the resin layer may or may not be included. Furthermore, the method of shaping the resin layer is not limited to the above configuration. For example, a method of forming a main body on embossed release paper and transferring the irregularities of the release paper to the main body, or a method of pressing the main body against a roll made of a material other than ceramic (such as iron) and transferring the irregularities of the roll, may be employed. Note that if the irregularities of the release paper are transferred to the main body, the third step of the manufacturing method according to the above embodiment may be omitted.

[0044] Among these methods, when using a roll (regardless of material), a desired pattern can be formed in the resin layer 2 by installing a roll with concaves and convexes corresponding to the desired pattern in equipment available to the user. In contrast, when using release paper, unless the user manufactures the release paper in their own equipment, the patterns that can be formed in the resin layer 2 are limited to those that can be selected from commercially available release papers. Since it is not common for manufacturers of synthetic leather 1 to manufacture release paper, using a roll has the advantage of allowing greater freedom in shaping and easier design changes than using release paper. Therefore, shaping the resin layer 2 using a method using negative pressure as a driving force is particularly advantageous in a preferred embodiment of the synthetic leather 1 according to this embodiment, in that it allows for both the addition of the intended decoration and the degree of freedom in decoration.

[0045] Regarding other configurations, it should be understood that the embodiments disclosed in this specification are illustrative in all respects and that the scope of the present invention is not limited thereby. Those skilled in the art will easily understand that appropriate modifications are possible without departing from the spirit of the present invention. Therefore, other embodiments modified without departing from the spirit of the present invention are naturally included in the scope of the present invention. [Example]

[0046] The present invention will be further described below with reference to examples, but the present invention is not limited to these examples.

[0047] [Production of test specimens] The methods for producing synthetic resins in the examples and comparative examples will be described below. Unless otherwise specified, the above-mentioned embodiments will be followed.

[0048] Example 1 The resin layer is made of polyvinyl chloride resin and has a basis weight of 300 g / m 2 The base fabric layer is a double jersey fabric with a basis weight of 250 g / m 2The surface was formed using a surface treatment agent containing 100 parts by mass of a polycarbonate-based urethane resin, 9 parts by mass of a first silicone resin, and 3 parts by mass of a second silicone resin (referred to as "PC,Si" in Table 1). The first silicone resin was a dimethyl-modified silicone resin, and the second silicone resin was an amino-modified silicone resin, which also applies to the following examples and comparative examples. The fabric of the base fabric layer was a black, unbrushed fabric. The resin layer was shaped by adsorbing it onto a ceramic roll (referred to as "adsorption" in Table 1).

[0049] Example 2 The resin layer is made of polyvinyl chloride resin and has a basis weight of 300 g / m 2 The base fabric layer is made of a single jersey fabric with a basis weight of 150 g / m 2 The surface was formed using a surface treatment agent containing 100 parts by mass of polycarbonate-based urethane resin, 9 parts by mass of a first silicone resin, and 3 parts by mass of a second silicone resin. The base fabric layer was made of white, unbrushed fabric. The resin layer was shaped by transferring the unevenness of the release paper to the main body (referred to as "release paper" in Table 1).

[0050] Example 3 The resin layer is made of polyvinyl chloride resin and has a basis weight of 300 g / m 2 The base fabric layer is made of a single jersey fabric with a basis weight of 150 g / m 2 The surface was formed using a surface treatment agent containing 100 parts by mass of polycarbonate-based urethane resin, 9 parts by mass of a first silicone resin, and 3 parts by mass of a second silicone resin. The base fabric layer was an unbrushed white fabric. The resin layer was shaped using a method in which the unevenness of an iron roll was transferred to the main body (listed as "iron" in Table 1), and the pressing force when pressing the synthetic leather against the iron roll was adjusted so that the texture of the base fabric layer would not appear on the surface of the resin layer.

[0051] Example 4 The resin layer is made of polyvinyl chloride resin and has a basis weight of 300 g / m 2The base fabric layer is a double jersey fabric with a basis weight of 300 g / m 2 The surface was formed using a surface treatment agent containing 100 parts by mass of polycarbonate-based urethane resin, 9 parts by mass of a first silicone resin, and 3 parts by mass of a second silicone resin. The fabric of the base fabric layer was a black, brushed fabric. The resin layer was formed by adsorbing it onto a ceramic roll.

[0052] Example 5 The resin layer is made of polyvinyl chloride resin and has a basis weight of 300 g / m 2 The base fabric layer is a single-woven fabric with a basis weight of 200 g / m 2 The surface was formed using a surface treatment agent containing 100 parts by mass of polycarbonate-based urethane resin, 9 parts by mass of a first silicone resin, and 3 parts by mass of a second silicone resin. The fabric of the base fabric layer was a white, brushed fabric. The resin layer was formed by adsorption onto a ceramic roll.

[0053] (Comparative Example 1) This is an example of conventional polyvinyl chloride synthetic leather. The resin layer is made of polyvinyl chloride resin, and the basis weight is 600 g / m. 2 The base fabric layer is a single-woven fabric with a basis weight of 150 g / m 2 The resin layer was configured to have a surface layer, a main body, and an intermediate layer made of foamed polyvinyl chloride resin, with the intermediate layer in contact with the adhesive layer. The surface was formed using a surface treatment agent containing polyurethane resin (listed as "PU" in Table 1). The base fabric layer was made of white, unbrushed fabric. The resin layer was shaped by transferring the unevenness of the release paper to the main body.

[0054] (Comparative Example 2) The synthetic leather of Comparative Example 2 was obtained in the same manner as Comparative Example 1, except that the resin layer was shaped by transferring the irregularities of an iron roll to the main body. The pressing force used to press the synthetic leather against the iron roll was adjusted so that the texture of the base fabric layer would not appear on the surface of the resin layer.

[0055] (Comparative Example 3) This is an example of conventional polyvinyl chloride synthetic leather without an intermediate layer. The resin layer is made of polyvinyl chloride resin and has a basis weight of 300 g / m. 2 The base fabric layer is a single-woven fabric with a basis weight of 150 g / m 2 The surface was formed using a surface treatment agent containing polyurethane resin. The base fabric layer was made of white, unbrushed fabric. The resin layer was formed by adsorbing it onto a ceramic roll.

[0056] Comparative Example 4 This is an example of a conventional polyvinyl chloride synthetic leather with a modified surface treatment method. The resin layer is made of polyvinyl chloride resin, and the basis weight is 600 g / m. 2 The base fabric layer is a single-woven fabric with a basis weight of 150 g / m 2 The surface was formed using a surface treatment agent containing 100 parts by mass of polycarbonate-based urethane resin, 9 parts by mass of a first silicone resin, and 3 parts by mass of a second silicone resin. The fabric of the base fabric layer was unbrushed white. The resin layer was formed by adsorption onto a ceramic roll.

[0057] (Comparative Example 5) This is an example of conventional polyurethane synthetic leather. The resin layer is made of polyurethane resin, and the basis weight is 150 g / m. 2 The base fabric layer is a double jersey fabric with a basis weight of 300 g / m 2 The surface was formed using a surface treatment agent containing polyurethane resin. The base fabric layer was made of a black, brushed fabric. The resin layer was shaped by transferring the unevenness of the release paper to the main body.

[0058] (Comparative Example 6) This is an example of conventional polyurethane synthetic leather. The resin layer is made of polyurethane resin, and the basis weight is 100 g / m. 2 The base fabric layer was made of tricot fabric with a basis weight of 200 g / m 2The surface was formed using a surface treatment agent containing polyurethane resin. The base fabric layer was a black, unbrushed fabric. The resin layer was shaped by transferring the unevenness of the release paper to the main body.

[0059] [Evaluation of test specimens] (Bending hardness test) A sensory evaluation of bending hardness was performed on each of the Examples and Comparative Examples. A 22 cm × 17 cm test piece was prepared for each example and placed on a desk with the surface 6 facing up. The tester then placed their hand on top of the test piece. With the thumb spread and the other four fingers clasped, the tester removed the palm from the test piece while keeping the fingertips in contact with the test piece, and then gripped the test piece. The bending hardness of the test piece was evaluated based on the resistance felt by the palm and fingers. The tester subjectively selected the bending hardness of the test piece from five levels, A to E, with Comparative Example 6 (conventional polyurethane synthetic leather) as the standard for the highest rating of "A" and Comparative Example 2 (conventional polyvinyl chloride synthetic leather) as the standard for the lowest rating of "E."

[0060] (Slipperiness test) A sensory evaluation of the slipperiness of each example of the Examples and Comparative Examples was conducted. A 22 cm × 17 cm test piece was prepared for each example, placed on a platform balance with the surface portion 6 facing up, and the tester contacted the test piece with the tips of their index, middle, and ring fingers (above the first joint). The tester pressed the test piece with three fingers, maintaining a reading of 300 g on the platform balance, and moved their fingertips back and forth. The slipperiness of the test piece was evaluated based on the resistance felt at the fingertips. Comparative Example 6 (conventional polyurethane-based synthetic leather) was used as the standard for the highest rating of "A," and Comparative Example 2 (conventional polyvinyl chloride-based synthetic leather) was used as the standard for the lowest rating of "E." The tester then subjectively ranked the slipperiness of the test piece from five levels, A to E.

[0061] (Indentation test) A sensory evaluation of the indentation property was conducted for each of the Examples and Comparative Examples. A 22 cm × 17 cm test piece was prepared for each example, placed on a table with the surface 6 facing up, and the tester pressed the test piece with his or her index finger. The indentation property of the test piece was evaluated based on the rebound sensation felt at the fingertip. Comparative Example 5 (a conventional polyurethane synthetic leather with a raised base fabric layer 4) was used as the standard for the highest rating of "A," and Comparative Example 1 (a conventional polyvinyl chloride synthetic leather) was used as the standard for the lowest rating of "E." The indentation property of the test piece was subjectively selected from five levels, A to E, by the tester.

[0062] (visual test) Each example of the examples and comparative examples was visually observed to check the state of the pattern on the surface. The state of the pattern in each example was evaluated on the following two levels of A or E. A: The pattern can be seen even when observed from a distance of 30 cm or more from the test piece. E: The pattern can only be seen when approaching within 30 cm of the test piece.

[0063] (Bending resistance test) For each of the examples and comparative examples, a bending test was carried out based on JIS L 1096:2020 (bending resistance test method A (45° cantilever method)). The test results for each example are shown in Table 1.

[0064] (Wear resistance test) Abrasion resistance tests were conducted for each of the examples and comparative examples in accordance with JASO M403-88 (friction strength method B). However, the load was changed to 3 kg. The number of abrasion cycles until damage was observed on the surface of the test specimen was recorded as the test result for each example. For test specimens that showed no damage after 28,000 abrasion cycles, the test was terminated at that point. The test results for each example are shown in Table 1.

[0065] (KES exam) For each of the examples and comparative examples, a bending hardness test and a bending recovery test were carried out using KES-FB2-A. The test results for each example are shown in Table 1.

[0066] 〔result〕 The evaluation results for each example of the Examples and Comparative Examples are shown in Table 1. As shown in Table 1, in Examples 1 to 5, synthetic leathers were obtained that had higher abrasion resistance and were superior in flexibility and tactile feel compared to Comparative Examples 1 and 2, which were conventional polyvinyl chloride synthetic leathers. In terms of abrasion resistance and slipperiness, Examples 1 to 5 were comparable to Comparative Examples 5 and 6, which were polyurethane synthetic leathers. Furthermore, Examples 4 and 5, which used brushed fabric, exhibited pressability comparable to Comparative Examples 5 and 6.

[0067] Table 1: Examples and Comparative Examples [Table 1] [Industrial Applicability]

[0068] The present invention can be used, for example, in car seats. [Explanation of symbols]

[0069] 1: Synthetic leather 2: Resin layer 3: Adhesive layer 4: Base fabric layer 5: Main body 6: Surface part 10:Excipient device 11: Heater 12: Roll 13: Unevenness 20:Second semi-finished product

Claims

1. The present invention includes a resin layer, a fabric layer including a material, and an adhesive layer that bonds the resin layer and the fabric layer, the resin layer has a main body portion containing polyvinyl chloride resin as a main component, and a surface portion containing polycarbonate-based urethane resin and silicone resin and containing polycarbonate-based urethane resin or silicone resin as a main component; The synthetic leather has a main body portion that is in contact with the adhesive layer on one side and in contact with the surface portion on the other side.

2. The fabric has a basis weight of 150 g / m ２ More than 300g / m ２ The synthetic leather according to claim 1, wherein:

3. 3. The synthetic leather according to claim 1, wherein the fabric is brushed.

4. The present invention includes a resin layer, a fabric layer including a material, and an adhesive layer that bonds the resin layer and the fabric layer, A method for producing synthetic leather, wherein the resin layer has a main body portion containing polyvinyl chloride resin as a main component, and a surface portion containing polycarbonate-based urethane resin and silicone resin and containing polycarbonate-based urethane resin or silicone resin as a main component, forming the body portion; forming the adhesive layer on one surface of the main body; bonding the fabric layer to the adhesive layer; and forming the surface portion on the other side of the main body portion.

5. The manufacturing method according to claim 4, further comprising the step of shaping the resin layer by adsorbing the surface portion onto the outer peripheral surface of a support having an uneven outer peripheral surface and a negative pressure inside.

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