Skin material for automobile interior having uneven pattern, and method for producing same

Abstract

To provide a skin material for automobile interior having an uneven pattern having sufficient unevenness and excellent in abrasion resistance without damaging the cushioning properties of the recessed parts of the uneven pattern and the touch feeling of the projected parts thereof, and a method for manufacturing the same.SOLUTION: The skin material 1 for the automobile interior comprises a base material layer 4 having projections 3 formed by a foamed resin 2 printed on the surface, a skin layer 5 laminated on the surface of the base material layer 4, and a surface treatment layer 6 laminated on the surface of the skin layer 5, and has an uneven pattern derived from the projections 3 on the surface.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a covering material for automobile interiors that can be suitably used for, for example, seats. [Background technology]

[0002] Various methods have been used to impart design features. For example, methods for forming a textured pattern on a decorative sheet having a textured surface, such as synthetic leather sheets used for automobile seats, automobile interior materials, clothing fabrics, and upholstery materials, include a method of applying a synthetic resin to a textured release paper and peeling it off to impart a textured pattern, and a method of applying a pattern by pressing an embossing roll.

[0003] It is also known that natural leather has a three-dimensional shape of a certain height and shape formed on the surface of the natural leather based on the shape of a pattern or design, in which the pattern or design is printed on the surface of the natural leather using a resin emulsion ink containing heat-expandable microcapsules, and the natural leather with the pattern or design printed on the surface of the natural leather is heated to the foaming temperature of the heat-expandable microcapsules containing gas inside, causing the heat-expandable microcapsules to foam, thereby giving the pattern or design a three-dimensional shape (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-241964 Summary of the Invention [Problem to be solved by the invention]

[0005] However, while the method using a textured release paper can create versatile textured patterns, new designs require the process of creating specialized release paper. Furthermore, there is a limit to the amount of height difference that can be achieved with release paper, making it impossible to create patterns with sufficient height difference. Furthermore, for designs with large height differences, it is difficult to apply a surface treatment layer evenly.

[0006] Furthermore, the embossing roll method had the problem that the depressions formed by heat-compressing the synthetic resin surface with the embossing roll were hard and lacked cushioning due to the reduced thickness caused by heat compression. If cushioning was to be ensured as needed, it was necessary to increase the weight per unit area by increasing the thickness of the surface material or to use chemicals, which unnecessarily increased costs. Furthermore, there were constraints, such as the fact that some desired designs were difficult to process with an embossing roll.

[0007] In addition, in the foam printing method, a print pattern using a resin containing a foaming agent as a binder is applied to the surface and exposed, and the convex parts formed by foaming have traces of small air bubbles from the binder resin scattered on the surface, making the material rough and hard to the touch.Furthermore, the abrasion resistance is not sufficient, particularly for use as a surface material for automobile interiors.

[0008] Therefore, an object of the present invention is to provide a skin material for automobile interiors having a textured pattern with sufficient texture and excellent abrasion resistance without impairing the cushioning properties of the recesses or the tactile feel of the protrusions of the textured pattern, and to provide a method for producing the same. [Means for solving the problem]

[0009] The present invention solves the above problems by taking the following measures.

[0010] The automotive interior skin material according to the present invention comprises: a base layer having a surface on which protrusions made of a foamed resin are formed; a skin layer is laminated on the surface of the base material layer, A surface treatment layer is laminated on the surface of the skin layer, and the surface has an uneven pattern derived from the convex portions.

[0011] According to the present invention, a base layer having convex portions formed on its surface by printed foam resin, a skin layer laminated on the surface of the base layer, and a surface treatment layer laminated on the surface of the skin layer, has a textured pattern derived from the convex portions on the surface; since the concave portions of the textured pattern are not formed by heat compression as in embossing, the thickness of the skin material is not initially increased, and therefore the skin material has cushioning properties that cannot be obtained by embossing, the convex portions of the textured pattern have a feel similar to that of concave portions that cannot be obtained by foam printing, and have a sufficient thickness (height) that has not been seen before, resulting in excellent design and texture that have not been seen before, and the surface of the skin material has excellent abrasion resistance.

[0012] The automotive interior skin material of the present invention having the above-mentioned configuration has the following preferred embodiments and variations.

[0013] (1) In a preferred embodiment of the present invention, the substrate layer is a fiber fabric having a permeation suppression layer laminated on part or all of its surface, and the permeation suppression layer is a layer laminated at least between the foamed resin and the fiber fabric.

[0014] According to this configuration, the base material layer is a fiber fabric with a permeation suppression layer laminated on part or all of its surface, and the permeation suppression layer is a layer laminated at least between the foamed resin and the fiber fabric. Therefore, the permeation suppression layer suppresses the permeation of the printed foamed resin into the fiber fabric and encourages the foamed resin to bulge out toward the surface rather than toward the interior of the fiber fabric, resulting in a convex portion of sufficient height.

[0015] (2) The permeation-suppressing layer contains an acrylic resin and / or a urethane resin.

[0016] According to this configuration, the permeation-suppressing layer contains an acrylic resin and / or a urethane resin, which provides good water resistance and flexibility, and provides excellent adhesion to the surface of the fiber fabric while forming a film, thereby suppressing permeation.

[0017] (3) The foamed resin contains a pigment.

[0018] According to this configuration, the foamed resin contains a pigment, so in addition to the design provided by the uneven surface pattern, color can be imparted, and the combination of the uneven surface pattern and color can further enhance the design.

[0019] (4) The surface abrasion resistance of the automotive interior covering material is grade 4 or higher.

[0020] According to this configuration, the surface has a wear resistance of grade 4 or higher, so that the design is unlikely to be lost and the surface has excellent wear resistance, even if the surface has an uneven pattern.

[0021] The present invention also provides a method for producing an automobile interior skin material, comprising: a base layer having a surface on which protrusions made of a foamed resin are formed by printing; a skin layer is laminated on the surface of the base material layer, a surface treatment layer is laminated on the surface of the skin layer, A method for producing an automobile interior skin material having a textured pattern derived from the convex portions on its surface, comprising: a printing step of applying the foaming resin to a surface of the base material layer; a drying step of drying the base material layer after the printing step at a temperature lower than the foaming temperature of the foaming resin; a surface layer lamination step of laminating a surface layer on the entire surface of the base layer after the drying step; a surface treatment layer laminating step of laminating a surface treatment layer on the surface of the skin layer after the skin layer laminating step; a foaming step of heating the surface-treated layer at a temperature equal to or higher than the foaming temperature of the foaming resin after the surface-treated layer laminating step, The surface is characterized by having an uneven pattern derived from the convex portions.

[0022] The above-described method for producing an automobile interior skin material of the present invention includes the following preferred embodiments and variations.

[0023] The method further includes a step of laminating a permeation suppression layer on a part or the whole of the surface of the fiber fabric before applying the foaming resin in the printing step, thereby partially laminating the permeation suppression layer.

[0024] According to this configuration, by using a base layer in which a permeation suppression layer is laminated on part or all of the surface of the fiber fabric, the applied foaming resin is prevented from permeating into the fiber fabric in the subsequent printing process, and in the subsequent foaming process, the foaming resin expands more toward the surface of the fiber fabric rather than toward the interior.

[0025] The method further includes a step of blending a pigment into the foamed resin before the printing step.

[0026] According to this configuration, the foamed resin contains a pigment before the printing process, so that in addition to the design provided by the uneven surface pattern, color can be imparted, and the combination of the uneven surface pattern and color can further enhance the design. [Effects of the Invention]

[0027] According to the present invention, there are provided a surface material for automobile interiors having a textured pattern with sufficient texture and excellent abrasion resistance without impairing the cushioning properties of the recesses of the textured pattern or the tactile feel of the protrusions, and a method for producing the same. [Brief explanation of the drawings]

[0028] [Figure 1] 1 is a cross-sectional view showing a skin material for an automobile interior according to an embodiment of the present invention; [Figure 2] FIG. 2 is a cross-sectional view illustrating an example of a substrate layer. [Figure 3] FIG. 10 is a cross-sectional view showing an example of a structure in which a foamed resin is applied to the surface of a base material layer. [Figure 4] FIG. 2 is a schematic plan view showing an example of a pattern in which a foamed resin is applied to the surface of a base material layer. [Figure 5] 2A to 2C are cross-sectional views illustrating the steps in the method for producing an automobile interior skin material shown in FIG. 1. [Figure 6]FIG. 2 is a cross-sectional view showing a skin material for automobile interiors according to another embodiment. [Figure 7] FIG. 10 is a cross-sectional view showing a skin material for automobile interiors according to yet another embodiment. [Figure 8] FIG. 10 is a cross-sectional view showing a skin material for automobile interiors according to yet another embodiment. [Figure 9] 1 is a cross-sectional view showing a laminated material according to the prior art; DETAILED DESCRIPTION OF THE INVENTION

[0029] Next, an embodiment of an automobile interior skin material and a method for manufacturing the same according to the present invention will be described with reference to the drawings.

[0030] As shown in FIG. 1, the automotive interior skin material 1 is characterized by comprising a base layer 4 having convex portions 3 formed on its surface by printed resin foam 2, a skin layer 5 laminated on the surface of the base layer 4, and a surface treatment layer 6 laminated on the surface of the skin layer 5, with the surface having an uneven pattern derived from the convex portions 3.

[0031] In the present invention, the foamed resin 2 refers to a resin to which a foaming agent has been added, and examples of the resin include, but are not limited to, acrylic resin, polyvinyl chloride resin, polyurethane resin, and the like.

[0032] The foaming agent is not particularly limited as long as it is an agent that foams in a specific temperature range, and examples thereof include thermally expandable microballoons.

[0033] As shown in Fig. 2(a), the substrate layer 4 is made of a fiber fabric 4-1 without a permeation-suppressing layer 4-2 laminated thereon. Fig. 1 shows a cross-sectional view of an automobile interior covering material 1 using the substrate layer 4 shown in Fig. 2(a). As shown in Fig. 2(b), the substrate layer 4 is preferably a fiber fabric 4-1 having a permeation-suppressing layer 4-2 laminated on at least a portion of the surface of the fiber fabric 4-1. Fig. 6 shows a cross-sectional view of an automobile interior covering material 1 using the substrate layer 4 shown in Fig. 2(b).

[0034] The protrusions 3 are formed by the expansion at a specific temperature of a foaming agent blended in foamed resin 2 printed on the surface of the base layer 4. FIG. 3(a) is a cross-sectional schematic diagram showing a structure in which foamed resin 2 is printed on the surface of a base layer 4 made of a fiber fabric 4-1. FIG. 3(b) is a cross-sectional schematic diagram showing a structure in which foamed resin 2 is printed on the permeation-suppressing layer 4-2 of a base layer 4, which has a permeation-suppressing layer 4-2 laminated on at least a portion of the surface of the fiber fabric 4-1. The height of the protrusions 3 formed by the foamed resin 2 printed on the permeation-suppressing layer 4-2 of the base layer 4 is higher than the protrusions 3 of the foamed resin 2 that do not overlap the permeation-suppressing layer 4-2.

[0035] The size of the protrusions 3 depends on the amount of foamed resin 2 printed and the type and amount of foaming agent in the foamed resin 2. As for the type and amount of foaming agent, for example, it is preferable to mix 5% to 20% by mass of thermally expandable microballoons into the acrylic resin, and more preferably 8% to 16% by mass.

[0036] Alternatively, the foamed resin 2 may be printed two or more times, overlapping the foamed resin 2, resulting in a higher convex portion 3 in the overlapping area. In this case, Figures 3(c) and 3(d) show a substrate layer 4 without a permeation-suppressing layer 4-2 and a substrate layer 4 with a permeation-suppressing layer 4-2, respectively. In the figures, the foamed resin printed in the initial (first) printing is shown as foamed resin 2, and the foamed resin printed in the second printing is shown as foamed resin 2'. While these figures show an example in which the foamed resin 2 is printed in layers, resulting in a double layer, more than two layers may be used. In conventional resin printing, printing a second or third printing to increase the resin thickness can result in problems such as poor abrasion resistance and bleeding. For this reason, overlapping printing is not typically performed, but this is not a problem in the present invention due to the configuration of the surface treatment layer 6 described below.

[0037] Figure 4 is a plan view schematic diagram showing an example of a pattern in which foamed resin is applied to the surface of the base layer 4, and plan views of foamed resin 2 and / or foamed resin 2' printed are shown in Figures 4(a) to (d), respectively.

[0038] FIG. 4(a) shows an example of printing a foamed resin once. The base layer 4 is made of a fiber fabric 4-1, and two strips of foamed resin 2 are printed on the surface of the base layer 4. The cross-sectional view taken along line aa in FIG. 4(a) is similar to FIG. 1. FIG. 4(b) shows an example of printing a foamed resin once on a base layer 4 having a permeation-suppressing layer 4-2. The base layer 4 is made of a fiber fabric 4-1 with a permeation-suppressing layer 4-2 (three rectangular (dashed) areas) laminated on its surface. Two strips of foamed resin 2 are printed on the surface of the base layer 4. One of the strips of foamed resin 2 is applied so that it overlaps a portion of the permeation-suppressing layer 4-2 and almost the entire area of ​​the other permeation-suppressing layer 4-2. The other strip of foamed resin 2 is applied so that it overlaps the end of the permeation-suppressing layer 4-2 and almost the entire area of ​​the other permeation-suppressing layer 4-2. The height of the protrusions 3 of the foamed resin 2 printed on the permeation-suppressing layer 4-2 is higher than the protrusions 3 of the foamed resin 2 that do not overlap the permeation-suppressing layer 4-2. The cross-sectional view taken along line bb in Figure 4(b) is as shown in Figure 6.

[0039] FIG. 4(c) shows an example of printing foam resin twice. In addition to the two foam resin 2 (first plate) printed in strips on the surface of the base layer 4 shown in FIG. 4(a), foam resin 2' is applied by the second plate printing, and there is a region where the foam resin 2 and the foam resin 2' intersect. In this region, foam resin 2' is applied on top of the foam resin 2 by the second plate printing. Therefore, in this overlapping region, the convex portion 3 is higher than the region where only foam resin 2 is applied. Also, FIG. 4(d) shows an example of printing foam resin twice on a base layer 4 having a permeation suppression layer 4-2. In addition to the two foam resin 2 (first plate) printed in strips on the surface of the base layer 4 having a permeation suppression layer 4-2 laminated thereon shown in FIG. 4(b), foam resin 2' is applied by the second plate printing, and there is a region where the foam resin 2 and the foam resin 2' intersect. In this region, foam resin 2' is applied on top of the foam resin 2 by the second plate printing. Therefore, in this overlapping area, the convex portion 3 is higher than in the area where only the foamed resin 2 is present, but this is added to the difference in height of the convex portion 3 in Figure 4(b) already explained, and the convex portion 3 in the area where it overlaps the permeation suppression layer 4-2 and where the foamed resin 2 and the foamed resin 2' overlap is the highest.

[0040] As described above, the foamed resin 2 applied to and overlapping the permeation-suppressing layer 4-2 inhibits the foamed resin 2 from permeating into the fiber fabric 4-1 more effectively than the foamed resin 2 in areas where the permeation-suppressing layer 4-2 is not present, resulting in a higher height of the protrusions 3 after the foaming process. Furthermore, the regions where the foamed resin 2 and the foamed resin 2' overlap are higher than the non-overlapping regions. Fig. 8 shows a schematic cross-sectional view of an automotive interior skin material 1 in which the foamed resin 2 and the foamed resin 2' are applied to and overlapped on the permeation-suppressing layer 4-2 as shown in Fig. 4(d).

[0041] Examples of the fiber fabric 4-1 include knitted fabrics such as circular knitted, warp knitted, and weft knitted fabrics, multi-layered fabrics such as double woven fabrics, and nonwoven fabrics such as needle punched fabrics. The types of fibers constituting the fiber fabric 4-1 include synthetic fibers, natural fibers, recycled fibers, etc. Among these, synthetic polyester fibers and recycled polyester fibers are preferred.

[0042] The basis weight of the fiber fabric 4-1 is 180 g / m 2 ~550g / m 2 The weight per unit area is preferably in the range of 180 g / m 2 If it is less than this, the resin may penetrate too much, making the paper hard and prone to wrinkling. 2 If the amount exceeds this, it is not preferable because it will unnecessarily increase costs.

[0043] The thickness of the fiber fabric 4-1 is preferably in the range of 0.5 mm to 2.0 mm. If the thickness is less than 0.5 mm, the resin may penetrate too much, causing the fabric to become hard and prone to wrinkling, while if the thickness is more than 2.0 mm, it is undesirable because it will unnecessarily increase costs.

[0044] The permeation suppression layer 4-2 is not particularly limited as long as it suppresses the permeation of foamed resins and the like into the fiber fabric 4-1, i.e., the permeation into the gaps between the threads and the fibers that make up the threads of the fiber fabric 4-1. For example, a thin-film resin is preferred, and among them, those containing acrylic resin and / or urethane resin are preferred because they have good water resistance and flexibility, form a film on the surface of the fiber fabric, and have excellent adhesion, and can suppress permeation. In addition, the acrylic resin and / or urethane resin may be blended with, for example, a crosslinking agent, wax, silicone, etc., which is preferred for further suppressing permeation. In addition, the basis weight of the permeation suppression layer 4-2 is 3 g / m 2 ~80g / m 2 The weight is preferably in the range of 3 g / m 2 If it is less than 80g / m, the effect of suppressing penetration may be weakened. 2 If the thickness exceeds this range, it is not preferable because it will unnecessarily increase the material cost.

[0045] The permeation-suppressing layer 4-2 can be laminated on the surface of the fiber fabric 4-1 by, for example, a printing method using a flat screen or a rotary screen or a coating method using a gravure roll, and then dried to form an integrated laminate. The permeation-suppressing layer 4-2 can be applied to the entire surface of the fiber fabric 4-1, or to a predetermined position in a predetermined shape.

[0046] The surface layer 5 is a layer containing a resin, and is laminated on the entire surface of the base layer 4. The resin is preferably one or more selected from the group consisting of polyurethane resin and polyvinyl chloride. The surface layer 5 may have multiple layers. The surface layer 5 is formed by appropriately blending carbon black or pigments of various colors with the resin. The surface layer 5 has a basis weight of 20 g / m 2 ~400g / m 2 The range is preferred.

[0047] The surface treatment layer 6 contains a polycarbonate-based urethane resin and a silicone resin, and the weight of the surface treatment agent 6 is 2 g / m 2 ~40g / m 2 The weight is preferably in the range of 2 g / m 2 If it is less than 40 g / m, the abrasion resistance may be insufficient. 2 If the thickness exceeds this range, the unevenness caused by the foaming of the foaming agent may become less noticeable, which is undesirable.

[0048] In the present invention, the uneven pattern resulting from the protrusions 3 is formed by foaming the foamed resin 2 printed on the surface of the base material layer 4, and the protrusions 3 form relative depressions 7, resulting in the automotive interior skin material 1 having an uneven pattern on its surface.

[0049] The foamed resin 2 may also be printed in layers, in which case there may be some non-overlapping areas, and the overlapping areas will have higher protrusions 3 than the other areas. This increases the variety of designs for the automotive interior skin material 1 having a textured surface, further enhancing its design potential.

[0050] Although an adhesive layer between the base layer 4 and the skin layer 5 is not shown in Fig. 1, it is preferable to provide an adhesive layer. The adhesive layer is preferably an adhesive containing, for example, polyvinyl chloride resin and / or polyurethane resin, and the basis weight of the adhesive layer is 50 g / m 2 ~250g / m 2 The range is preferred.

[0051] The foamed resin 2 preferably contains a pigment, and the pigment is not particularly limited, but examples thereof include natural mineral pigments, synthetic inorganic pigments, and organic pigments.

[0052] Furthermore, the surface abrasion resistance of the automotive interior covering material 1 is preferably grade 4 or higher, and in the present invention, this is determined by testing using a Taber tester as specified in ASTM D38846.1, which will be described later.

[0053] Next, a manufacturing method of an automotive interior skin material 1 according to the present invention will be described. The manufacturing method of an automotive interior skin material 1 according to the present invention includes a printing step of applying a foaming resin 2 (2') to the surface of a base layer 4, a drying step of drying the base layer 4 after the printing step at a temperature lower than the foaming temperature of the foaming resin 2 (2'), a skin layer laminating step of laminating a skin layer 5 over the entire surface of the base layer 4 after the drying step, a surface treatment layer laminating step of laminating a surface treatment layer 6 on the surface of the skin layer 5 after the skin layer laminating step, and a foaming step of heating at a temperature equal to or higher than the foaming temperature of the foaming resin 2 (2'), and is characterized by forming an uneven pattern derived from the convex portions 3 on the surface.

[0054] 5 shows a cross-sectional view illustrating the state of each step in the manufacturing method of the automotive interior skin material 1. The automotive interior skin material 1 can be manufactured by carrying out the printing step, drying step, skin layer lamination step, and surface treatment layer lamination step shown in the figure in this order, and then finally carrying out the foaming step.

[0055] (printing process, drying process) A fiber fabric 4-1 is prepared in advance as the base material layer 4, as shown in FIG. 2(a) or FIG. 5(1), for example. A printing process is performed to apply a foaming resin 2 containing a foaming agent to the base material layer 4, followed by a drying process at a temperature at which the foaming resin 2 does not foam. This temperature is preferably in the range of 70°C or higher and lower than 140°C. A schematic cross-sectional view after the drying process is shown in FIG. 5(2). By applying the foaming resin 2 to the base material layer 4 in the desired pattern, a rugged pattern is obtained after the foaming process.

[0056] If the drying step is performed at a temperature that causes the foaming resin 2 to foam, the foaming agent will foam before the skin layer 5 is laminated, causing the convex portions to appear first, making it impossible to laminate the base layer 4 and the skin layer 5 without any gaps, which may result in an insufficient uneven pattern being formed on the surface. The printing step may be performed by screen printing using a panel-shaped screen, or by rotary printing using a cylindrical cylinder.

[0057] (Skin layer lamination process) A laminate is obtained by laminating a substrate layer 4 coated with a foamed resin 2 and a skin layer 5 containing one or two resins selected from the group consisting of polyurethane resins and polyvinyl chloride resins, prepared in advance, over the entire surface of the substrate layer 4 so as to sandwich the foamed resin 2. It is preferable to provide an adhesive layer between the layers of this laminate. The provision of an adhesive layer can further increase the peel strength between the layers. After laminating the skin layer 5 on the substrate layer 4, it is more preferable to press the layers together by passing them between two opposing rotating rolls, i.e., by nip rolls. Figure 5(3) shows a schematic cross-sectional view of the surface of the substrate layer 4 after the drying process and laminating the skin layer 5.

[0058] (Surface treatment layer lamination process) Next, a surface treatment layer 6 is laminated by applying a surface treatment agent to the surface of the skin layer 5 of the laminate obtained in the previous step. The surface treatment agent can be applied by a known method such as a roll method or a spray method. After application, it is preferable to dry the surface, preferably at a temperature at which the foamed resin 2 does not foam. This temperature is preferably in the range of, for example, 80°C or higher and lower than 150°C. Figure 5(4) shows a schematic cross-sectional view of the surface treatment layer 6 laminated on the surface of the skin layer 5 after the skin layer lamination step.

[0059] (Foaming process) Next, a heat treatment is performed at a temperature at which the foaming resin 2 foams. The foaming resin 2 printed on the base layer 4 foams and expands, causing it to bulge toward the skin layer 5 and increase in thickness (height), resulting in an automotive interior skin material 1 having protrusions 3 formed thereon. The heat treatment temperature is preferably between 150°C and 190°C. A cross-sectional view of the automotive interior skin material 1 after the foaming step is shown in FIG. 5(5). As shown in FIG. 5(5), the total height of the skin layer 5 and the surface treatment layer 6 at recesses 7 that are not protrusions 3 of the automotive interior skin material 1 is represented as t1, and the total height of the foaming resin 2, the skin layer 5, and the surface treatment layer 6 at the positions of the protrusions 3 is represented as t2, where t2 > t1.

[0060] Thus, the skin material 1 for automobile interiors, on which the uneven pattern derived from the convex portions 3 is formed, has cushioning (cushioning that maintains the thickness of the original base material layer 4) and sufficient thickness (height) that cannot be obtained by embossing, even in the concave portions 7 of the uneven pattern, and also has a tactile feel similar to that of the convex portions of the uneven pattern (tactile feel derived from the skin layer 5), resulting in an unprecedentedly excellent design and texture. For example, as shown in Figure 5 (5), the surface of the skin material 1 for automobile interiors has an uneven pattern derived from foamed resin 2 printed in stripes (two lines) on the surface of fiber fabric 4-1 as the base material layer 4.

[0061] As another method, it is preferable to laminate the permeation suppression layer 4-2 on part or all of the surface of the fiber fabric 4-1 before applying the foamed resin 2. For example, in FIG. 2(b), the permeation suppression layer 4-2 is laminated on at least part of the surface of the fiber fabric 4-1. Specifically, for example, an acrylic resin, a urethane resin, or the like may be applied to the fiber fabric 4-1 as the permeation suppression layer 4-2 by a printing method using a flat screen or a rotary screen, or an application method using a gravure roll, etc. This type of application is preferable to suppress permeation into the gaps between the yarns and the fibers that make up the fiber fabric 4-1.

[0062] Next, a printing process is carried out in which the foaming resin 2 is applied to the base material layer 4 so as to have a portion overlapping with the permeation-suppressing layer 4-2, followed by a drying process at a temperature that does not foam the foaming resin 2. In this printing process, the portion where the applied foaming resin 2 overlaps with the permeation-suppressing layer 4-2 suppresses the foaming resin 2 from permeating into the fiber fabric 4-1.

[0063] Subsequently, the skin material for automotive interiors 1 is obtained by the same processes as described above for the skin layer lamination step, the surface treatment layer lamination step, and the subsequent foaming step. A cross-sectional schematic diagram of the skin material for automotive interiors 1 in this case is shown in FIG. 6. As shown in FIG. 6, the total height of the skin layer 5 and the surface treatment layer 6 at the recesses 7, not the protrusions 3, of the skin material for automotive interiors 1 is represented as t1, and the total height of the permeation-suppressing layer 4-2, the foamed resin 2, the skin layer 5, and the surface treatment layer 6 at the position of the protrusions 3 is represented as t2, where t2 > t1. This height t2 is larger due to the suppression of permeation of the foamed resin 2 into the fiber fabric 4-1. The height t2 increases (is higher) by rising further toward the skin layer 5 rather than toward the base layer 4 than toward the substrate layer 4, compared to t2 shown in FIG. 5(5). Furthermore, the resulting skin material for automotive interiors 1 has no rough texture and no reduction in cushioning properties, as occurs with embossing.

[0064] Furthermore, in the printing process, by applying the foamed resin 2 multiple times and providing overlapping portions of the foamed resin, it is possible to form convex portions 3 with different heights and an uneven pattern resulting from the different heights of the convex portions 3. For example, as shown in Figure 7, if the total height of the foamed resin 2, foamed resin 2', skin layer 5, and surface treatment layer 6 at the position of the convex portion 3 where the foamed resin is overlapped twice is represented as t3, then t3 > t2 > t1.

[0065] A pigment may also be blended into the foamed resin 2. Depending on the type and amount of pigment blended into the resin of the skin layer 5, the skin layer 5 can be made light in color to increase transparency, or no pigment can be blended into the skin layer 5 to make it colorless and thereby impart transparency, thereby allowing the hue of the blended pigment to be visible in the convex portions of the uneven pattern of the skin material for automobile interiors 1. By blending pigments of different colors into the foamed resin 2, the skin material for automobile interiors 1 can be made multicolored by using foamed resins 2 of different colors.

[0066] Furthermore, when applying the foamed resin 2, for example, by repeatedly applying the foamed resin 2 using a printing plate, it is possible to create a multi-level pattern in which the heights of the convex portions differ in stages, or a multi-color, multi-level pattern that combines multiple colors and multiple levels, thereby providing an automotive interior skin material 1 and a method for manufacturing the same that have even more advanced and diverse design expressions.

[0067] In addition, by preparing foam resin 2 that produces different hues depending on the combination of pigments to be blended, and applying different hues to each printing plate, patterns can be created. By combining this pattern with the uneven pattern created by foaming, a variety of patterns can be expressed. In other words, it is possible to create uneven patterns that give a variety of colors and patterns. [Example]

[0068] Next, specific examples of the present invention will be described, but the present invention is not particularly limited to these examples. Table 1 shows the details of each example and comparative example, and Table 2 shows the evaluation results.

[0069] [Table 1]

[0070] Example 1 As a fiber fabric, a circular knit fabric made of polyester fiber (weight 280 g / m 2 In addition, a foamed resin was prepared by blending 100 parts by mass of acrylic resin with 10% by mass of a foaming agent (thermally expandable microballoons).

[0071] The circular knit fabric of the base layer was coated with a foamed resin in a striped pattern using a screen (see Figure 4(a)) and then dried at 110°C. Next, a polyurethane resin-containing liquid blend was applied to release paper (without grain) and dried at 80°C to form a skin layer on the release paper. The polyurethane resin liquid blend was then applied as an adhesive to the skin layer, and immediately after drying at 90°C, the foamed resin side of the base layer was placed on the adhesive-coated surface and passed through two pressure rolls to form a laminate. After aging for 24 hours, the release paper was peeled off, and a surface treatment agent containing a polycarbonate-based urethane resin and a silicone resin was applied to the surface of the skin layer and dried at 120°C to form a surface treatment layer. The resulting synthetic leather sheet was then heat-treated at 170°C, causing the foamed resin to foam and form convex portions, resulting in an automotive interior skin material with a textured surface (Figure 1). The resulting car interior skin material has a textured pattern with sufficient height differences, and the recessed parts of the textured pattern are also sufficiently thick, so even though the recessed parts have a large area, it has excellent cushioning properties, a pleasant feel on the raised parts, and excellent abrasion resistance. The cushioning evaluation result showed a WC value of 1.0 gf·cm / cm 2 The evaluation result for unevenness was "Good" with a height difference of 100 μm, and the evaluation result for abrasion resistance was "Good" with a grade of 4-5, meaning that all evaluations were acceptable.

[0072] <Example 2> An automobile interior skin material was obtained in the same manner as in Example 1 (FIG. 6), except that in Example 1, an acrylic resin was applied to a portion of the surface of the circular knit fabric to partially laminate a permeation-suppressing layer, and then a foamed resin was applied in a striped pattern so as to partially overlap this permeation-suppressing layer (see FIG. 4(b)). The obtained automobile interior skin material had a textured pattern with significantly greater differences in elevation than in Example 1 due to the presence of the permeation-suppressing layer. The cushioning evaluation result showed a WC value of 1.0 gf·cm / cm 2 The evaluation result for unevenness was "Excellent" with a height difference of 282 μm, and the evaluation result for abrasion resistance was "Excellent" with a grade of 4-5, meaning that all evaluations were acceptable.

[0073] Example 3 An automotive interior skin material was obtained in the same manner as in Example 1, except that in Example 1, a screen was used to apply the foamed resin to the circular knit fabric in a striped pattern on the first plate, and the foamed resin was applied to the second plate in a border pattern that was approximately perpendicular to the striped pattern of the first plate, resulting in a roughly checkered pattern (see Figure 4(c)). The height difference between the convex and concave portions where the foamed resin stripe and border patterns did not intersect was 178 μm (see Figure 7, t2-t1), and the height difference between the convex and concave portions where they intersected was 257 μm (see Figure 7, t3-t1). The resulting automotive interior skin material had a multi-level concave-convex pattern with significantly more visible height differences than Example 1. Furthermore, since the convex portions had two or more different thicknesses, it had excellent design properties, and the tactile feel and cushioning of the convex portions were also significantly better. The cushioning evaluation results showed a WC value of 1.1 gf·cm / cm 2 The evaluation result for unevenness was "Excellent" with a height difference of 257 μm (see Figure 7, t3-t1), and the evaluation result for abrasion resistance was "Excellent" with a grade of 4-5. All evaluations were acceptable.

[0074] Example 4 In Example 2, a foamed resin (0.5 wt % blue pigment per 100 parts by mass of acrylic resin) was applied to the permeation-suppressing layer in a striped pattern so that the foamed resin partially overlapped the permeation-suppressing layer. Subsequently, a second plate was applied with a foamed resin (0.5 wt % red pigment per 100 parts by mass of acrylic resin) in a border pattern that intersected the striped pattern of the first plate at right angles, resulting in a roughly checkered pattern (see FIG. 4(d)). An automotive interior skin material was obtained in the same manner as in Example 2 (FIG. 8). The resulting textured pattern of the automotive interior skin material had a multi-level textured pattern that allowed for significantly more visible height differences than in Example 1. The color difference ΔE* calculated from color measurement results at a viewing angle of 10 degrees using a D65 light source in the CIE (International Commission on Illumination) L*a*b* color system was as follows: The color difference between the convex and concave portions that did not overlap with the foamed resin containing 0.5 wt% blue pigment and the permeation-suppressing layer was ΔE* = 5.8, and the color difference between the convex and concave portions that overlap with the permeation-suppressing layer was ΔE* = 15.5. The color difference between the convex and concave portions that did not overlap with the foamed resin containing 0.5 wt% red pigment and the permeation-suppressing layer was ΔE* = 5.9, and the color difference between the convex and concave portions that overlap with the permeation-suppressing layer was ΔE* = 13.1. The color difference between the convex and concave portions that overlap with the foamed resin containing 0.5 wt% blue pigment and the permeation-suppressing layer and the foamed resin containing 0.5 wt% red pigment and the permeation-suppressing layer was ΔE* = 18.0. Thus, all ΔE* values ​​were 5.0 or greater, demonstrating that the automotive interior skin material had a multicolored textured pattern with clearly visible color differences. In other words, the color of the raised portions of the uneven pattern is different from the color of the recessed portions in two or more areas, and the thickness of the raised portions is different in two or more areas, so not only does it have an excellent design, but the tactile feel and cushioning of the raised portions are also much better. The evaluation result of the cushioning property showed a WC value of 1.1 gf cm / cm 2 The evaluation results for unevenness were "Excellent" with a height difference of 289 μm (see Figure 8, t3-t1), and the evaluation results for abrasion resistance were "Excellent" with a grade of 4-5. All evaluations were acceptable.

[0075] <Example 5> In Example 1, a woven fabric made of polyester fiber (basis weight 465 g / m) was used instead of the circular knitted fabric. 2A skin material for automobile interiors was obtained in the same manner as in Example 1, except that a WC value of 0.8 gf cm / cm was used (Fig. 1). 2 The evaluation result for unevenness was "Good" with a height difference of 158 μm, and the evaluation result for abrasion resistance was "Good" with a grade of 4-5, meaning that all evaluations were acceptable.

[0076] Example 6 An automotive interior skin material was obtained in the same manner as in Example 1, except that a compound liquid containing polyvinyl chloride resin was applied to release paper and dried at a temperature of 80°C to form a skin layer on the release paper (Fig. 1). The cushioning evaluation result showed a WC value of 1.8 gf cm / cm. 2 The evaluation result for unevenness was "Excellent" with a height difference of 249 μm, and the evaluation result for abrasion resistance was "Excellent" with a grade of 4-5, meaning that all evaluations were acceptable.

[0077] [Table 2]

[0078] <Comparative Example 1> A synthetic leather sheet was obtained in the same manner as in Example 1, except that a release paper with a embossed texture (50 μm depth) was used instead of the unembossed release paper, and no foam resin was applied to the circular knit fabric of the base layer (FIG. 9(1)). The evaluation results for cushioning showed a WC value of 1.8 gf cm / cm. 2 The evaluation result for unevenness was "Good" with a height difference of 27 μm, and the evaluation result for abrasion resistance was "Good" with a grade of 4-5.

[0079] <Comparative Example 2> The synthetic leather sheet obtained in Comparative Example 1 was heat-pressed at 180°C using a flat embossing mold with a concave-convex pattern (5 mm deep) to obtain a synthetic leather sheet with a concave-convex pattern (Figure 9(2)). The concave portions of the concave-convex pattern had poor cushioning properties because the base layer (fiber fabric) was compressed. The evaluation result of cushioning properties showed a WC value of 0.4 gf cm / cm. 2The evaluation result for unevenness was "○" with a height difference of 180 μm, and the evaluation result for abrasion resistance was grade 4 with a "○".

[0080] <Comparative Example 3> The surface of the synthetic leather sheet obtained in Comparative Example 1 was coated with a foamed resin in a striped pattern in the same manner as in Example 1, and then dried at a temperature of 110°C. The synthetic leather sheet was then dried at a temperature of 170°C, causing the foamed resin to foam and form convex portions, resulting in a synthetic leather sheet with an uneven pattern on the surface (Figure 9(3)). Furthermore, the convex portions of the uneven pattern had a rough resin surface exposed due to foaming, which gave it a poor feel. The cushioning evaluation result showed a WC value of 1.0 gf·cm / cm 2 The evaluation result for unevenness was "Good" with a height difference of 290 μm, and the evaluation result for abrasion resistance was "Poor" with a grade 1-2.

[0081] <Comparative Example 4> In Example 1, a surface treatment layer containing a polycarbonate-based urethane resin and a silicone resin was not formed on the surface of the skin layer (FIG. 9(4)). The evaluation result of cushioning property was a WC value of 1.0 gf cm / cm. 2 The evaluation result for unevenness was "○" with a height difference of 95 μm, and the evaluation result for abrasion resistance was "×" with a grade 1-2.

[0082] As can be seen from the evaluation results of Examples 1 to 6 and Comparative Examples 1 to 4, the automotive interior covering materials of the present invention had a textured pattern with sufficient unevenness and excellent abrasion resistance without compromising the cushioning properties of the recessed portions or the tactile feel of the protruding portions of the textured pattern. That is, the protruding portions of the textured pattern had the same tactile feel as the recessed portions, and the textured patterns had a sufficient thickness (height) that had not been achieved before, resulting in unprecedentedly excellent design and texture. Furthermore, the provision of a surface treatment layer provided a textured pattern with excellent abrasion resistance. Specifically, the automotive interior covering materials of Examples 2, 3, and 4 had overlapping between the permeation-suppressing layer and the foamed resin, or between the foamed resins themselves, which inhibited the permeation of the foamed resin into the fiber fabric, resulting in a much higher height of the protruding portions and a large difference in height in the textured pattern, resulting in sufficient unevenness. Furthermore, the automotive interior skin material of Example 4 had improved pigment color development, as can be seen from the color difference between the convex and concave portions of the textured pattern, and the convex portions of the textured pattern had a multi-step and multi-colored textured pattern not previously seen. On the other hand, the synthetic leather sheet using conventional release paper in Comparative Example 1 passed the test in terms of cushioning and abrasion resistance in the recessed areas, but the uneven pattern (uneven feel) was quite poor. Also, the synthetic leather sheet using conventional embossing in Comparative Example 2 passed the test in terms of uneven pattern (uneven feel) and abrasion resistance, but the cushioning in the recessed areas was quite poor.

[0083] <Cushioning evaluation method> Tests were conducted under the following conditions using a KES compression tester (KES-G5, manufactured by Kato Tech Co., Ltd.) to measure the compression energy (WC) of the compression characteristics of the recesses in the uneven pattern on the surface of the automotive interior skin material. The higher the WC value, the easier it is to compress and the better the cushioning properties, so the results were judged based on the following criteria, with a "○" being considered a pass. (Test conditions) Compression ball type: φ10mm, Maximum compression load: 100gf, Variable compression speed: 0.02mm / sec (Judgment criteria) "○": WC value is 0.7 gf·cm / cm 2 End "×": WC value is 0.7gf·cm / cm 2 less than

[0084] <Method for evaluating unevenness> Using a VR-5000 (manufactured by Keyence Corporation), the thickness of the concave and convex parts of the textured pattern on the car interior skin material was measured, and since the difference in thickness (= height difference) can be evaluated as the sense of texture (bulge), the height difference between the concave and convex parts was calculated and judged based on the following criteria, with a rating of "○" or higher being considered a pass. (Judgment criteria) "◎": 200μm or more "〇": 60μm or more and less than 200μm "×": Less than 60 μm

[0085] <Abrasion resistance evaluation method> Tests were conducted using a Taber tester specified in ASTM D38846.1 under the following conditions to evaluate the degree of loss of the texture pattern due to surface abrasion of automotive interior covering materials. Specifically, the materials were placed face up on a table and visually observed from an angle of 45 to 60 degrees. The results were rated based on the following criteria, with grades 3 and above being considered pass (○) and grades below 3 being considered fail (×). Grades between the criteria, for example, between grades 4 and 5, were designated grades 4-5. (Test conditions) Wheel No.: CS#10, Load: 9.8N, Test rotation speed: 2,000 times, Rotational friction speed: 60 rpm / min (Judgment criteria) Grade 5: No change in the uneven pattern is observed. Grade 4: Wear marks are visible on the uneven pattern. Grade 3: Fading of the uneven pattern is observed. Grade 2: Part of the uneven pattern is recognized to have disappeared. Grade 1: It is recognized that all of the uneven pattern has disappeared. [Industrial Applicability]

[0086] The present invention can be used as an automobile interior covering material for automobile seats. [Explanation of symbols]

[0087] 1. Automotive interior skin materials 2. Foam resin 2'...Foam resin 3. Convex part 4...Base material layer 4-1 Fiber fabric 4-2... Penetration suppression layer 5... Epidermal layer 6. Surface treatment layer 7. Recess t1: Total height of the skin layer and surface treatment layer t2: Total height of the foam resin, skin layer, and surface treatment layer at the position of the convex part t3: Total height of the two layers of foam resin, skin layer, and surface treatment layer at the convex part

Claims

1. a base layer having a surface on which protrusions made of a foamed resin are formed; a skin layer is laminated on the surface of the base material layer, a surface treatment layer is laminated on the surface of the skin layer, A surface material for automobile interiors, characterized in that the surface has an uneven pattern resulting from the convex portions.

2. the substrate layer is a fiber fabric having a permeation-suppressing layer laminated on a part or all of its surface, 2. The automotive interior skin material according to claim 1, wherein the permeation suppression layer is a layer laminated at least between the foamed resin and the fiber fabric.

3. 3. The automotive interior skin material according to claim 2, wherein the permeation-suppressing layer contains an acrylic resin and / or a urethane resin.

4. 2. The automotive interior skin material according to claim 1, wherein the foamed resin contains a pigment.

5. 5. The automotive interior covering material according to claim 1, wherein the surface has a wear resistance of grade 4 or higher.

6. a base layer having a surface on which protrusions made of a foamed resin are formed; a skin layer is laminated on the surface of the base material layer, a surface treatment layer is laminated on the surface of the skin layer, A method for producing an automobile interior skin material having a textured pattern derived from the convex portions on its surface, comprising: a printing step of applying the foaming resin to a surface of the base material layer; a drying step of drying the base material layer after the printing step at a temperature lower than the foaming temperature of the foaming resin; a surface layer lamination step of laminating a surface layer on the entire surface of the base layer after the drying step; a surface treatment layer laminating step of laminating a surface treatment layer on the surface of the skin layer after the skin layer laminating step; a foaming step of heating the surface-treated layer at a temperature equal to or higher than the foaming temperature of the foaming resin after the surface-treated layer laminating step, A method for producing a surface material for automobile interiors, comprising forming a textured pattern derived from the convex portions on the surface.

7. Before applying the foam resin in the printing process, 7. The method for producing an automobile interior skin material according to claim 6, further comprising the step of laminating a permeation-suppressing layer on a part or all of the surface of the fiber fabric.

8. Before the printing step, 8. The method for producing an automobile interior skin material according to claim 6, further comprising the step of blending a pigment into the foamed resin.

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