Laminate sheet

Abstract

To propose a novel laminate sheet that, in view of a problem in that a polyurethane foam is difficult to recycle while a recyclable material is attracting attention as a part of a carbon neutral approach and the like, selects a spun lace nonwoven fabric as a member other than a polyurethane foam sheet as a base material and can ensure favorable molding smoothness when used as a skin material in press molding.SOLUTION: Provided is a laminate sheet (100) including a base material (20), an adhesive layer (30), and a skin (10). The base material (20) is a spun lace nonwoven fabric (22). The base material (20) and the skin (10) are bonded together through frame lamination with the adhesive layer (30) interposed therebetween and are laminated.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a laminated sheet comprising a substrate and a skin. [Background technology]

[0002] To improve the surface appearance of various core materials or articles (hereinafter also referred to as core materials, etc.), such as automobile interior components such as vehicle ceilings, instrument panels, and door trims, railroad car and aircraft interior components such as ceilings and trims, fabric and architectural interior components, precision instrument storage cases and bags, etc., skin materials are attached to them. Note that the term "skin material" here refers to a component that is attached to the surface of a core material, etc., whose appearance is visually inspected during use, and can be applied not only to the outside of an article such as a storage case or bag, but also to the inside (the wall surface facing the storage space).

[0003] Conventionally, a two-layer laminated sheet has been widely used, in which a polyurethane foam sheet is used as the substrate of a skin material and a skin such as fabric, leather, or synthetic leather is laminated on the polyurethane foam sheet, or a three-layer laminated sheet has been widely used, in which a fibrous backing material is laminated on one side of a polyurethane foam sheet and the above-mentioned skin is laminated on the other side. For example, Patent Document 1 proposes an invention of a laminated sheet material in which the surface slipperiness of a polyurethane foam sheet is improved and a fibrous sheet or leather sheet is laminated on at least one side of the polyurethane foam sheet.

[0004] Polyurethane foam sheets are generally produced by slicing a block of polyurethane foam, and therefore have excellent surface smoothness. Therefore, the conventional laminated sheets using polyurethane foam sheets described above have the advantage that, when pressed and bonded to the surface of various core materials, pockmarks originating from the polyurethane foam sheet are unlikely to appear on the surface of the skin, resulting in excellent smoothness after press molding. In this specification, the smoothness of the surface of the skin material after bonding the skin material to any core material by press molding may be referred to as molded smoothness. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2004-10792 Summary of the Invention [Problem to be solved by the invention]

[0006] However, while recyclable materials have been attracting attention in recent years as part of efforts to achieve carbon neutrality, polyurethane foam has the problem of being difficult to recycle, and therefore there is a demand for materials other than polyurethane foam sheets to be used as the substrate for the above-mentioned skin material.

[0007] The present invention proposes a novel laminate sheet that uses a material other than a polyurethane foam sheet as a substrate and that can ensure good molding smoothness when used as a skin material. [Means for solving the problem]

[0008] The laminated sheet of the present invention is a laminated sheet comprising a substrate, an adhesive layer, and a surface skin, characterized in that the substrate is a spunlace nonwoven fabric, and the substrate and the surface skin are bonded and laminated via the adhesive layer by frame lamination. [Effects of the Invention]

[0009] The laminate sheet of the present invention having the above-mentioned configuration can exhibit good molding smoothness when it is used as a surface material and has a member other than a polyurethane foam sheet as a substrate. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a cross-sectional view of a laminate sheet according to one embodiment of the present invention. [Figure 2]1A to 1C are explanatory diagrams illustrating various embodiments of a pre-adhesive layer provided on a pre-sheet used in the configuration of the present invention. [Figure 3] 1A to 1C are explanatory diagrams illustrating an example of a method for producing a laminate sheet of the present invention. [Figure 4] 1 is a cross-sectional view showing an example of a processed body made of a core material having a laminate sheet of the present invention pressure-bonded to its surface. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, examples of embodiments and manufacturing methods of the present invention will be described with reference to the drawings. In all drawings, similar components are given the same reference numerals, and duplicate explanations will be omitted as appropriate. In the illustrated embodiments of the present invention, certain components may be illustrated relatively large or small relative to the overall structure for ease of understanding, but neither of these is intended to limit the dimensional proportions of each component of the present invention.

[0012] A laminated sheet (100) according to one embodiment of the present invention will be described below with reference to FIGS. FIG. 1 is a cross-sectional view of a laminated sheet (100) according to one embodiment of the present invention. FIG. 2 is an explanatory diagram illustrating several aspects (32a, 32b, 32c) of the pre-adhesive layer (32) provided on a pre-sheet (110) used in the construction of the present invention. FIG. 3 is an explanatory diagram illustrating an example of a manufacturing method for the laminated sheet (100) of the present invention. FIG. 4 is a cross-sectional view showing an example of a processed body (200) comprising a core material (210) having a laminated sheet (100) of the present invention pressure-bonded to its surface.

[0013] As shown in Figure 1, the laminated sheet (100) comprises a surface skin (10) and a substrate (20) with an adhesive layer (30) interposed therebetween. The substrate (20) comprises a spunlace nonwoven fabric (22). In the present invention, the substrate (20) and the surface skin (10) are laminated and bonded together via the adhesive layer (30) by frame lamination. Here, the term "frame lamination" in the present invention refers to a process in which a pre-adhesive layer (32) (see FIG. 3) provided on at least one side of the substrate (20) and the skin (10) is melted with a flame to form an adhesive layer (30), and the substrate (20) and the skin (10) are laminated and bonded together via the adhesive layer (30). Conventionally, frame lamination is a technique in which one side of a flexible urethane foam is melted to prepare a molten surface, and any sheet-like member is laminated and bonded to the molten surface. However, the laminated sheet (100) of the present invention does not use a flexible urethane foam, and is constructed by laminating and bonding the skin (10) and substrate (20) together by melting a pre-prepared pre-adhesive layer (32) with a flame.

[0014] As described above, the present invention provides a spunlace nonwoven fabric (22) as the substrate (20). When using a spunlace nonwoven fabric as the substrate of a laminate sheet, it is generally easier to adjust the basis weight of the spunlace nonwoven fabric (22) compared to other nonwoven fabrics, making it easier to achieve a lighter weight. However, the substantial reduction in the bulk of the nonwoven fabric raises concerns about a decrease in the flexibility of the laminate sheet. In contrast, the present invention uses frame lamination to laminate and bond the spunlace nonwoven fabric (22) to the surface skin (10), which allows the flexibility of the laminate sheet (100) to be maintained compared to when conventional lamination and bonding techniques such as thermal lamination are used. As a result, molding smoothness during press molding can be ensured.

[0015] The use of the laminate sheet (100) is not particularly limited, but due to the above-mentioned effects, the laminate sheet (100) is suitably used as a sheet to be laminated by hot press processing onto the surface of a core material, etc. More specifically, the laminate sheet (100) of the present invention used for hot press processing is suitably used as a skin material for automobile interior components such as vehicle ceilings, instrument panels, and door trims, and for railway vehicle and aircraft interior components such as ceilings and trims. The laminated sheet (100) will be described in more detail below.

[0016] <Eidermis> The surface skin 10 forms the front side of the laminated sheet 100. The sheet material used as the surface skin 10 is not particularly limited, but examples thereof include woven fabric, knitted fabric, nonwoven fabric, synthetic leather, and resin sheet.

[0017] The basis weight or thickness of the surface skin 10 is not particularly limited, but when a woven fabric, knitted fabric, or nonwoven fabric is used as the surface skin 10, the basis weight is, for example, 100 g / m 2 More than 1000g / m 2 From the viewpoint of reducing the weight of the laminated sheet (100), the basis weight is 100 g / m or less. 2 More than 500g / m 2 It is preferable that the weight is less than 100 g / m 2 More than 400g / m 2 It is more preferable that the surface skin (10) is not more than 100%. The surface skin (10) may be a single layer made of woven fabric, knitted fabric, or nonwoven fabric, or may be a multi-layer made by laminating two or more layers of the same or different sheets. When the surface skin (10) is multi-layered, it is preferable that the total basis weight of the multi-layered surface skin (10) is within the above range.

[0018] When synthetic leather is used as the skin 10, the average thickness of the synthetic leather is preferably, for example, 0.5 mm or more and 2.0 mm or less, and more preferably 0.5 mm or more and 1.3 mm or less. When a resin sheet is used as the skin 10, the average thickness of the resin sheet is preferably 20 μm or more and 100 μm or less.

[0019] From the viewpoint of weight reduction, it is preferable that the surface layer 10 is thin. Specifically, from the viewpoint of weight reduction, it is preferable that the surface layer 10 has a basis weight of 100 g / m 2 More than 400g / m 2 It is preferable to use the following woven fabric, knitted fabric, nonwoven fabric, etc., or synthetic leather with an average thickness of 0.5 mm to 1.3 mm, or a resin sheet with an average thickness of 20 μm to 100 μm. Generally, when a laminate sheet is formed by laminating a thin surface and a nonwoven fabric used as a substrate using a thermal lamination method or the like, the surface irregularities of the substrate (nonwoven fabric) tend to affect the surface of the surface of the surface. As a result, when the laminate sheet is bonded to a core material or the like by thermal processing and pressing, there is a risk that pockmarks originating from the nonwoven fabric will be clearly visible on the surface of the surface of the surface. However, in the present invention, the surface of the surface of the substrate (spunlace nonwoven fabric) is laminated and bonded by frame lamination, so that the surface irregularities of the spunlace nonwoven fabric constituting the substrate are less likely to appear on the surface of ...

[0020] <Base material> The spunlace nonwoven fabric (22) used as the substrate of the laminated sheet (100) refers to a nonwoven fabric formed by entangling fibers using a high-pressure water jet. More specifically, the spunlace nonwoven fabric (22) is produced by forming fibers into a sheet using a carding machine, and then applying a high-pressure water jet to the card to entangle the fibers. The spunlace nonwoven fabric (22) can be adjusted to have a small basis weight to reduce its weight, and can adequately support the surface as a substrate.

[0021] According to the study of the present inventors, it has been found that the surface of a spunlace nonwoven fabric is smoother than that of other commonly used nonwoven fabrics (such as nonwoven fabrics produced by spunbond processing), and is therefore suitable as a substrate for a laminate sheet. The surface roughness of the spunlace nonwoven fabric (22) is not particularly limited, but from the viewpoint of exhibiting superior smoothness, the maximum height difference of the surface of the spunlace nonwoven fabric (22) is preferably 200 μm or less, and more preferably 180 μm or less. If the laminated sheet (100) has a maximum height difference of 200 μm or less on the surface of the substrate (20), the unevenness of the substrate (20) is exposed on the surface of the skin (10), and the reduction in molding smoothness can be sufficiently prevented.

[0022] The maximum height difference on the surface of the substrate (20) is measured by taking a depth composite image using a microscope and measuring the cross-sectional shape of the taken 3D image.

[0023] Generally, spunlace nonwoven fabrics are known as parallel web, cross web, and random web fabrics depending on the manufacturing method. The parallel web refers to a spunlace nonwoven fabric produced so that the fibers are aligned in the direction of travel of the carding machine, the cross web refers to a spunlace nonwoven fabric produced by cross-laid parallel webs, and the random web refers to a spunlace nonwoven fabric in which the fibers are not oriented. It is preferable to use a cross-web as the spunlace nonwoven fabric (22) of the laminated sheet (100) from the viewpoint that the longitudinal and lateral stretches of the substrate (20) are similar and it is easy to conform to the surface of an uneven core material or the like during press molding.

[0024] The basis weight of the spunlace nonwoven fabric (22) is not particularly limited, but from the viewpoint of more sufficiently reducing the weight of the laminated sheet (100), the basis weight of the spunlace nonwoven fabric (22) is preferably 50 g / m 2 More than 200g / m 2 Preferably, it is 50 g / m or less. 2 More than 100g / m 2 From the viewpoint of providing the laminated sheet (100) with better feel and flexibility, the basis weight of the spunlace nonwoven fabric (22) is preferably 100 g / m or less. 2 More than 400g / m 2 It is preferable that:

[0025] Unlike conventional laminate sheets that use a polyurethane foam sheet as a substrate, the laminate sheet 100 uses a spunlace nonwoven fabric 22 as a substrate. Specific examples of fibers that make up the spunlace nonwoven fabric 22 include thermoplastic resins such as polyolefin resins and polyester resins. Examples of the polyolefin resin include polypropylene resin and polyethylene resin. Examples of the polyester resin include polyethylene terephthalate resin, polytrimethylene terephthalate resin, and polybutylene terephthalate resin.

[0026] The resin constituting the spunlace nonwoven fabric (22) may be one type of resin selected from the resins exemplified above, or may be a mixed resin of two or more types. From the viewpoint of recyclability, when the spunlace nonwoven fabric (22) is made from a combination of two or more types of fibers, it is preferable that the fibers be made of the same type of resin. Here, "made of the same type of resin" refers to the fact that the resins constituting the multiple fibers constituting the spunlace nonwoven fabric (22) are all made of an olefin-based resin or a polyester-based resin. In particular, it is preferable that the resins be made of any one type selected from the group consisting of polypropylene-based resin, polyethylene-based resin, polyethylene terephthalate-based resin, polytrimethylene terephthalate-based resin, and polybutylene terephthalate-based resin, and more preferably polyethylene terephthalate-based resin. With such a laminated sheet (100), the surface layer (10) and the spunlace nonwoven fabric (22) can be peeled and separated, facilitating material recycling of the spunlace nonwoven fabric (22). In particular, from the viewpoint of industrially established recycling technology and the ability to effectively promote material recycling, it is preferable that the resin constituting the fibers constituting the spunlace nonwoven fabric (22) be a polyester-based resin, and more preferably a polyethylene terephthalate-based resin.

[0027] In order to improve the recyclability of the laminated sheet (100), it is preferable that the resin constituting the skin (10) and the resin constituting the spunlace nonwoven fabric are the same type of resin. Furthermore, from the viewpoint of exhibiting better recyclability of the laminated sheet (100), it is more preferable that the resin constituting the skin (10), the resin constituting the spunlace nonwoven fabric, and the resin constituting the adhesive layer (30) are the same type of resin. The term "uniformly made of the same type of resin" used here refers to the explanation of "uniformly made of the same type of resin" given above in relation to the spunlace nonwoven fabric (22).

[0028] The melting point of the fibers constituting the spunlace nonwoven fabric (22) is not particularly limited, but for example, fibers having a melting point of 190°C or higher and 230°C or lower can be used, and in particular, one or more types of fibers made of polyester resins having a melting point of 190°C or higher and 230°C or lower can be used.

[0029] <Adhesive layer> Next, the adhesive layer (30) will be described. The present invention is characterized in that the substrate (20) and the skin (10) are bonded and laminated via the adhesive layer (30) by frame lamination. More specifically, a pre-adhesive layer (32) is provided in advance on one side of the substrate (20) and / or the skin (10), and the pre-adhesive layer (32) is melted by flame to laminate and bond the substrate (20) and the skin (10), thereby forming the laminated sheet (100). Here, an embodiment in which the pre-adhesive layer (32) is provided on the substrate (20) will be described as an example.

[0030] The pre-adhesive layer (32) may be any layer that provides adhesion through frame lamination, and may be, for example, preferably formed using any one or a combination of the pre-adhesive layers (32) of the following first to third embodiments. An example of a pre-sheet (110) provided with the pre-adhesive layers (32a, 32b, 32c) of the first to third embodiments is shown in Figure 2. In the descriptions of the first and second embodiments described below, the term "adhesive sheet" refers to a sheet-like material made from a flame-soluble resin, and includes, for example, a sheet-like material formed into a film (adhesive film) and adhesive woven fabrics, adhesive knitted fabrics, and adhesive nonwoven fabrics made from fibers made from a flame-soluble resin. Here, the resin making up the adhesive sheet can be, for example, a resin with a melting point of 100°C or higher and 200°C or lower. In the description of the third embodiment described below, the term "adhesive nonwoven fabric" refers to a meltblown nonwoven fabric made from fibers made from a flame-soluble resin. In the present invention, the terms "sheet" and "film" both refer to sheet-like materials, and are not limited in thickness, etc.

[0031] (First aspect) The pre-adhesive layer (32a) of the first embodiment is formed by laminating and integrating the adhesive sheet (34) onto the substrate (20) with the intertwining yarns (44) by needle punching, with the adhesive sheet (34) superimposed on the spunlace nonwoven fabric (22). In the first embodiment, the pre-adhesive layer (32a) can be formed by laminating and integrating the adhesive sheet (34) onto the substrate (22) of spunlace nonwoven fabric (22) without heating by needle punching. This effectively prevents thermal denaturation of the spunlace nonwoven fabric (22) during the preparation of the pre-adhesive layer (32a). Furthermore, because the pre-adhesive layer (32a) is formed without heating, there is no risk of some of the molten resin in the pre-adhesive layer (32a) impregnating the spunlace nonwoven fabric (22) and degrading the texture of the pre-sheet (110) or laminated sheet (100). As a more specific example, FIG. 2A shows a cross section of a pre-sheet (110) formed by stacking an adhesive sheet (34), which is an adhesive nonwoven fabric, on a spunlace nonwoven fabric (22) and then entangling the intertwining yarns (44) by needle punching to form an integrated laminate. The intertwining yarns (44) are shown schematically in FIG. 2A. In the pre-sheet (110) having the pre-adhesive layer (32a) of the first embodiment, some of the fibers of the spunlace nonwoven fabric (22) are sheared by needle punching, resulting in a laminated sheet (100) having a substrate (20) with good elongation. Having a substrate (20) with good elongation allows the laminated sheet (100) to easily conform to a core material or the like during press molding, resulting in a processed product with a good appearance.

[0032] (Second aspect) The pre-adhesive layer (32b) of the second embodiment is formed by thermally bonding an adhesive sheet (35) to the spunlace nonwoven fabric (22) by thermal lamination. For example, a pre-sheet (110) having a pre-adhesive layer (32b) can be obtained by feeding a spunlace nonwoven fabric (22) from a rotating roll and feeding an adhesive sheet (35) from another rotating roll, laminating and pressing these together, and then applying heat from the spunlace nonwoven fabric (22) side to melt and bond the surface of the adhesive sheet (35) facing the spunlace nonwoven fabric (22). The above-mentioned thermal lamination process includes a mode in which the entire surface of the adhesive sheet (35) is melted and adhered to the spunlace nonwoven fabric (22) to form a continuous pre-adhesive layer (32b), and a mode in which the adhesive sheet (35) and the spunlace nonwoven fabric (22) are pressed together by roll embossing, and the adhesive sheet (35) is melted in a dot pattern to form a scattered pre-adhesive layer (32b). A continuously formed pre-adhesive layer (32b) is preferred because it can form an adhesive layer (30) with higher adhesiveness. A scattered pre-adhesive layer (32b) is also preferred because it improves the texture and flexibility of the laminated sheet (100). As a more specific example, Figure 2B shows a cross section of a pre-sheet (110) having a continuous layer of pre-adhesive layer (32b) formed by pressing an adhesive sheet (35), which is an adhesive film, against a spunlace nonwoven fabric (22) and applying heat from the spunlace nonwoven fabric (22) side, thereby melting and bonding the surface of the adhesive sheet (35) facing the spunlace nonwoven fabric (22).

[0033] (Third aspect) The pre-adhesive layer (32c) of the third embodiment is made of an adhesive nonwoven fabric (36) formed by meltblown processing on one side of the spunlace nonwoven fabric (22). Here, meltblown processing refers to a processing method in which molten resin is discharged from a spinning nozzle and blown with hot air to stretch and accumulate fibers. In this embodiment, the molten and stretched fibers are accumulated on the surface of the spunlace nonwoven fabric (22) to form the adhesive nonwoven fabric (36). As a more specific example, Figure 2C shows a cross section of a pre-sheet (110) formed by forming adhesive nonwoven fabric (36) by meltblown processing on one surface of spunlace nonwoven fabric (22). In this way, when adhesive nonwoven fabric (36) is further formed on the surface of spunlace nonwoven fabric (22) by meltblown processing, it can be manufactured in the same series of steps as in the nonwoven fabric manufacturing process, and it is possible to reduce the manufacturing process by one step compared to the first and second embodiments.

[0034] As described above, the pre-adhesive layer (32) of the present invention can be provided on the spunlace nonwoven fabric (22) or the surface skin (10). The pre-adhesive layer (32) can be provided on either the spunlace nonwoven fabric (22) or the surface skin (10), the pre-adhesive layer (32) is melted by flame, and the spunlace nonwoven fabric (22) or the surface skin (10) is laminated to form a laminated sheet (100). Note that, because the design of the surface skin (10) is not limited (i.e., a single pre-sheet (110) can be combined with various surface skins (10)), and the surface skin (10) is less susceptible to the heat of frame lamination, a preferred embodiment is to provide the pre-adhesive layer (32) on the spunlace nonwoven fabric (22), then melt the pre-adhesive layer (32) by flame, and then laminate the surface skin (10).

[0035] The resin constituting the adhesive layer (30) may be any resin capable of forming the pre-adhesive layer (32) and exhibiting adhesive properties upon melting during frame lamination. From the perspective of strengthening the stiffness of the laminate sheet (100), the resin constituting the adhesive layer (30) is preferably a polypropylene-based resin. From the perspective of recycling, it is preferable that the resin constituting the adhesive layer (30) is the same as the resin constituting the skin (10) and / or the resin constituting the substrate (20). It is even more preferable that the resin constituting the adhesive layer (30), the resin constituting the skin (10), and the resin constituting the substrate (20) are the same. In other words, by using the same type of resin for all of the resins constituting the laminate sheet (100), the laminate sheet (100) can be fully mono-materialized. The mono-material laminate sheet (100) can be recycled without the need for a separation process to separate the skin (10) and the spunlace nonwoven fabric (22). Among these, it is more preferable that the surface skin (10), the spunlace nonwoven fabric (22), and the adhesive part (30) are all made of a polyester-based resin, and it is even more preferable that the surface skin (10), the spunlace nonwoven fabric (22), and the adhesive part (30) are all made of a polyethylene terephthalate-based resin.

[0036] The basis weight of the pre-adhesive layer (32) is not particularly limited, but from the viewpoint of good adhesion between the surface layer (10) and the pre-sheet (110), it is 10 g / m 2 More than 50g / m 2 Preferably, it is 15 g / m or less. 2 More than 30g / m 2 More preferably, it is:

[0037] [Laminated sheet manufacturing method] An example of a method for producing the laminate sheet 100 of the present invention will be described below. However, the method for producing the laminate sheet 100 of the present invention will not be limited to the method for producing the laminate sheet 100 of the present invention. In explaining the method for producing the laminate sheet 100, reference will be made to FIG. 3 as appropriate.

[0038] The manufacturing method of the laminated sheet (100) described below is an example in which a pre-sheet (110) including a spunlace nonwoven fabric (22) and a pre-adhesive layer (32) formed on one side of the spunlace nonwoven fabric (22) is used to laminate and bond the spunlace nonwoven fabric (22) and the surface skin (10) by frame lamination. More specifically, as shown in FIG. 3, the pre-sheet (110) is set on a roll (410) and conveyed at an appropriate speed, and the surface skin (10) is set on a roll (420) and conveyed at an appropriate speed. A melting step is performed upstream of the lamination of the pre-sheet (110) and the surface skin (10), in which the pre-adhesive layer (32) is melted by a flame (440). Multiple nozzles from which the flame (440) is emitted may be arranged at appropriate intervals across the width of the pre-sheet (110) (into the plane of the drawing in FIG. 3). Then, a lamination step is performed in which the surface skin (10) is laminated onto the spunlace nonwoven fabric (22) via the pre-adhesive layer (32) melted in the melting step, and an adhesive part forming step is performed in which an adhesive part (30) is formed between the spunlace nonwoven fabric (22) and the surface skin (10), thereby producing a laminated sheet (100). The laminated laminated sheet (100) is suitably wound up on a third roll (430) as shown in Figure 3. The lamination step and adhesive part forming step described above may be performed in part or in whole overlapping with each other.

[0039] In this manufacturing method, one or more of the following conditions can be adjusted: the conveying speed of the pre-sheet (110) and the skin (10), the number and spacing of the nozzles of the flame (440), the distance between the flame (440) and the pre-sheet (110), etc. In the above-described manufacturing method, the conveying speed of the pre-sheet (110) and the skin (10) is not particularly limited, but may be adjusted, for example, in the range of 20 m / min to 40 m / min. The temperature of the flame (440) is not particularly limited, but may be adjusted approximately in the range of 600°C to 800°C. The distance between the surface of the pre-sheet (110) facing the pre-bonded portion (32) and the flame (440) may be appropriately adjusted taking into consideration the type and melting point of the resin constituting the pre-sheet (110).

[0040] As described above, in the laminated sheet (100) of the present invention, the surface layer (10) and the spunlace nonwoven fabric (22) are laminated and bonded by frame lamination, unlike conventional lamination methods such as paste lamination using an adhesive, hot lamination, or heat lamination. Unlike the conventional lamination methods described above, the laminated sheet (100) does not directly heat the spunlace nonwoven fabric (22) or the surface layer (10) used in the pre-sheet (110). Therefore, the laminated sheet (100) can well maintain the soft texture of the spunlace nonwoven fabric (22) or the surface layer (10). By adopting frame lamination, deterioration of texture due to adhesives can be reduced, and a laminated sheet (100) with excellent molding smoothness can be provided. Furthermore, compared to the conventional lamination means described above, frame lamination has a faster production speed for lamination, and curing after lamination is either unnecessary or can be completed in a short time, so it can be said that the laminated sheet (100) of the present invention has a configuration with excellent productivity.

[0041] [Heat-pressed body] The laminated sheet (100) described above is suitable for use as a skin material for a core material or the like. For example, as shown in FIG. 4, a processed body (200) can be produced by heat-pressing the laminated sheet (100) against one side of a core material (210) of a desired shape. The laminated sheet (100) in the processed body (200) uses a spunlace nonwoven fabric (22) as a base material, and the spunlace nonwoven fabric (22) and the skin (10) are laminated and bonded together by frame lamination, preventing the appearance of scars caused by the spunlace nonwoven fabric (22) on the surface of the skin (10). Therefore, when visually observed from the laminated sheet (100) side, the processed body (200) has a smooth, smooth appearance and is excellent in appearance. Furthermore, the laminated sheet (100) side of the processed body (200) has an excellent appearance and can be endowed with the good feel and flexibility of the spunlace nonwoven fabric (22). [Example]

[0042] The present invention will be described in more detail below with reference to examples of the laminate sheet of the present invention. Specifically, the examples show examples in which a pre-sheet was produced by laminating an adhesive nonwoven fabric or adhesive film as a pre-adhesive layer on a spunlace nonwoven fabric, and the pre-sheet was then laminated on a surface by frame lamination to produce a laminate sheet. First, the pre-sheets used in the examples were prepared as follows. [Pre-sheet for Example 1] Fiber (melting point 150℃) spun from polypropylene resin (PP resin) is used, and the weight is 15g / m2 by the spunbond method. 2 An adhesive nonwoven fabric was prepared. In addition, polyester resin spun fibers (melting point 210°C) were used to make a spun lace fabric with a basis weight of 80 g / m 2 A cross-web spunlace nonwoven fabric (for substrate) was prepared. The maximum height difference on the surface of the spunlace nonwoven fabric was 150 μm. The adhesive nonwoven fabric was placed on one side of a spunlace nonwoven fabric, and the two were needle-punched to form an integrated laminate pre-sheet. [Pre-sheet for Example 2] A pre-sheet was prepared in the same manner as in Example 1, except that the basis weight of the spunlace nonwoven fabric was changed to that shown in Table 1. The maximum height difference on the surface of the spunlace nonwoven fabric was 160 μm. [Pre-sheet for Example 3] A pre-sheet was prepared in the same manner as in Example 1, except that the basis weight of the pre-adhesive layer was changed to that shown in Table 1. [Pre-sheet for Example 4] A pre-sheet was prepared in the same manner as in Example 2, except that the basis weight of the pre-adhesive layer was changed to that shown in Table 1. [Pre-sheet for Example 5] An adhesive film (hot melt sheet, melting point 120° C.) made of polyester resin was prepared. The adhesive film was placed on one side of a spunlace nonwoven fabric similar to that in Example 2, and the spunlace nonwoven fabric and the adhesive film were thermally laminated to prepare a pre-sheet. [Pre-sheet for Example 6] A spunlace nonwoven fabric (for substrate) similar to that in Example 3 was prepared. Next, a molten polyester resin was extruded from a spinning nozzle onto one side of the spunlace nonwoven fabric by meltblowing to form a meltblown adhesive nonwoven fabric bonded to the spunlace nonwoven fabric, with a basis weight of 100 g / m. 2 A pre-sheet was prepared.

[0043] A laminated sheet was prepared by frame lamination using the pre-sheets for each example prepared as described above and the surface skin described below. That is, the surface is a knitted fabric (basis weight 100 g / m) made of polyester fiber spun using polyester resin. 2 ) was prepared. As shown in FIG. 3, the skin was set on one roll, and a pre-sheet was set on the other roll, and the pre-adhesive layer on the delivered pre-sheet was melted by flame. The skin and the spunlace nonwoven fabric were quickly laminated together via the molten pre-adhesive layer, thereby obtaining a laminated sheet. The laminated sheets obtained in Examples 1 to 6 had good surface smoothness and could be used as skin materials for press molding.

[0044] In the above-described Examples 1 to 6, examples in which a knitted fabric was used as the surface were shown, but instead of a knitted fabric, a woven fabric, a nonwoven fabric, a resin sheet, synthetic leather, etc. may be used as the surface. For example, when synthetic leather having a resin layer such as a vinyl chloride resin layer formed on one side of a base fabric is used as the surface, the base fabric and the spunlace nonwoven fabric may be laminated and bonded to each other in opposing directions via an adhesive layer to produce a laminated sheet.

[0045] [Table 1]

[0046] The present invention described above encompasses the following technical ideas. (1) A laminated sheet comprising a substrate, an adhesive layer, and a surface layer, The substrate is a spunlace nonwoven fabric, A laminated sheet, characterized in that the substrate and the surface are bonded and laminated via the adhesive layer by frame lamination. (2) The laminate sheet according to (1) above, wherein the maximum height difference on the surface of the substrate is 200 μm or less. (3) The basis weight of the spunlace nonwoven fabric is 50 g / m 2 More than 200g / m 2 The laminate sheet according to (1) or (2) above, which is: (4) A laminate sheet according to any one of (1) to (3) above, wherein the spunlace nonwoven fabric is a cross-web. (5) The laminate sheet according to any one of (1) to (4) above, wherein the adhesive layer is formed using any one or a combination of the pre-adhesive layers of the following first to third embodiments: (First aspect) a pre-adhesive layer formed by laminating and integrating an adhesive sheet onto the spunlace nonwoven fabric or the surface layer by needle punching; (Second aspect) a pre-adhesive layer in which an adhesive sheet is thermally bonded to the spunlace nonwoven fabric or the surface layer by thermal lamination; (Third aspect) A pre-adhesive layer made of an adhesive nonwoven fabric formed by meltblown processing on the spunlace nonwoven fabric or the surface layer. (6) A pre-sheet for constructing a laminated sheet having a substrate, an adhesive layer, and a surface layer made of a spunlace nonwoven fabric, A pre-sheet characterized in that the spunlace nonwoven fabric or the surface layer is provided with any one or a combination of the pre-adhesive layers of the following first to third aspects: (First aspect) a pre-adhesive layer formed by laminating and integrating an adhesive sheet onto the spunlace nonwoven fabric or the surface layer by needle punching; (Second aspect) a pre-adhesive layer in which an adhesive sheet is thermally bonded to the spunlace nonwoven fabric or the surface layer by thermal lamination; (Third aspect) A pre-adhesive layer made of an adhesive nonwoven fabric formed by meltblown processing on the spunlace nonwoven fabric or the surface layer. [Explanation of symbols]

[0047] 10...epidermis 20...Base material 22. Spunlace nonwoven fabric 30...adhesive layer 32 Pre-adhesive layer 32a First aspect 32b...Second embodiment 32c Third aspect 33. Meltblown 34, 35... Adhesive sheet 36...adhesive nonwoven fabric 40. Intertwined fibers 100···Laminated sheet 110···Pre-sheet 200...processed body 210···Core material 410 First roll 420...Second Row 430···Third roll 440...Flame

Claims

1. A laminated sheet comprising a substrate, an adhesive layer, and a surface layer, The substrate is a spunlace nonwoven fabric, A laminated sheet, characterized in that the substrate and the surface are bonded and laminated via the adhesive layer by frame lamination.

2. The laminate sheet according to claim 1, wherein the spunlace nonwoven fabric is a cross-web.

3. The laminate sheet according to claim 1 or 2, wherein the adhesive layer is formed using any one or a combination of pre-adhesive layers of the following first to third embodiments: (First Aspect) a pre-adhesive layer formed by laminating and integrating an adhesive sheet onto the spunlace nonwoven fabric or the surface layer by needle punching; (Second Aspect) a pre-adhesive layer in which an adhesive sheet is thermally bonded to the spunlace nonwoven fabric or the surface layer by thermal lamination; (Third Aspect) A pre-adhesive layer made of an adhesive nonwoven fabric formed by meltblown processing on the spunlace nonwoven fabric or the surface layer.

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