Dough and method for producing dough
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2022-09-06
- Publication Date
- 2026-03-06
AI Technical Summary
Existing leather-like fabrics lack deep embossing and high-quality texture, and are not recyclable, while those made of PVC are prone to extreme temperature variations and have poor recyclability.
A leather-like fabric comprising a polyester surface layer and a polyester back layer, bonded with an adhesive layer having a lower melting point, is embossed using a controlled process that plastically deforms the surface layer and elastically deforms the back layer, allowing for deep embossing and improved recyclability.
The fabric achieves a high-quality leather-like texture with deep embossing, reduced temperature sensitivity, and enhanced recyclability, meeting performance standards for vehicle seat covers and other applications.
Smart Images
Figure 00000000_0000_ABST
Abstract
Description
[Technical Field]
[0001] The present invention relates to a dough and a method for producing the dough. [Background technology]
[0002] Patent Document 1 discloses an embossed "leather-like nonwoven fabric." [Prior art document] [Patent documents] Patent Document 1 Japanese Patent Application Laid-Open No. 11-241277
[0003] Provides higher quality leather-like fabric. Summary of the Invention
[0004] In a first aspect of the present invention, there is provided a leather-like fabric comprising a leather-like surface layer made of at least one of polyester, nylon, acrylic, linen, cotton, silk, rayon, and wool, and a back layer adhered to the back surface of the surface layer, wherein the surface layer and the back layer are embossed.
[0005] In the above-mentioned fabric, the embossing depth of the fabric may be 50 μm or more and 400 μm or less.
[0006] In any of the above fabrics, the back layer may be a nonwoven fabric using polyester.
[0007] In any of the above fabrics, the thickness of the back layer may be greater than the thickness of the front layer.
[0008] Any of the above fabrics may include an adhesive layer for adhering the front layer and the back layer together.
[0009] In any of the above fabrics, the material of the adhesive layer may include polyester.
[0010] In any of the above fabrics, the adhesive layer may have a melting point lower than the melting points of the front layer and the back layer.
[0011] In a second aspect of the present invention, there is provided a method for manufacturing a leather-like fabric, comprising the steps of bonding a surface layer and a back layer together, and embossing the surface layer while the surface layer and the back layer are bonded together, wherein the surface layer is a leather-like layer made of polyester.
[0012] In the method for manufacturing the fabric, the embossing step may include a step of surface-heating the surface layer using an embossing machine that uses a roll-shaped or plate-shaped mold.
[0013] In any of the above methods for manufacturing a fabric, the heating temperature for the embossing may be lower than the glass transition point of the surface layer.
[0014] In any of the above methods for manufacturing a fabric, the embossing step may include a step of plastically deforming the surface layer.
[0015] In any of the above methods for manufacturing a fabric, the embossing step may include a step of elastically deforming the back surface layer.
[0016] Any of the above methods for manufacturing a fabric may include a step of expanding the back layer after embossing the front layer.
[0017] In any of the above methods for manufacturing dough, the step of expanding the back surface layer may include a step of heating the back surface layer from the back surface side.
[0018] The above summary of the invention does not list all of the features of the present invention, and subcombinations of these features may also be inventions. [Brief explanation of the drawings]
[0019] [Figure 1]1 is a photograph of the surface of fabric 100. [Figure 2A] FIG. 1 is a schematic diagram of a cross section of fabric 100 before embossing. [Figure 2B] FIG. 1 is a schematic diagram of a cross section of fabric 100 after embossing. [Figure 2C] 1 shows an example of a flow chart for producing fabric 100. [Figure 3] An example of the configuration of the warp threads 10 is shown. [Figure 4] 1 shows a modified example of the warp thread 10. [Figure 5] An example of a method for manufacturing the fabric 100 will be described. [Figure 6] A method for manufacturing the comparative fabric 500 is shown. [Figure 7] A modified method for manufacturing the fabric 100 is shown. DETAILED DESCRIPTION OF THE INVENTION
[0020] The present invention will be described below through embodiments of the invention, but the following embodiments do not limit the scope of the invention according to the claims. Furthermore, not all of the combinations of features described in the embodiments are necessarily essential to the solution of the invention.
[0021] 1 is a photograph of the surface of fabric 100. Fabric 100 is an embossed leather-like fabric made of at least one of polyester, nylon, acrylic, linen, cotton, silk, rayon, and wool. Fabric 100 may have texture and gloss like genuine leather or synthetic leather.
[0022] The leather-like fabric 100 made of polyester can reduce the mass by 50% or more compared to fabrics made of genuine leather or polyvinyl chloride (PVC). Furthermore, unlike fabrics made of genuine leather or PVC, the fabric 100 is less likely to become too hot in the summer or too cold in the winter. The finish of the fabric 100 can be improved by using a steam iron. The recyclability of the fabric 100 can be improved by using only polyester.
[0023] The fabric 100 may be used for vehicle seat covers that require high strength, wrinkle resistance, flame retardancy, etc. The fabric 100 may meet at least one of the evaluation standards of JIS L1096, L1093, L1092, L1076, L0860, L0849, L0844, or L0842. However, the use of the fabric 100 is not particularly limited.
[0024] 2A is a schematic diagram of a cross section of fabric 100 before embossing. Fabric 100 includes a surface layer 110, an adhesive layer 120, and a back layer .
[0025] The surface layer 110 is a leather-like layer made of polyester. The surface layer 110 has a leather-like design achieved by embossing. The surface layer 110 may be a woven fabric made of polyester, as described below. The surface layer 110 is bonded to the back layer 130. The thickness of the surface layer 110 may be 0.3 mm or more and 1.5 mm or less. For example, the thickness of the surface layer 110 is 0.8 mm.
[0026] The adhesive layer 120 bonds the front layer 110 and the back layer 130 together. The material of the adhesive layer 120 may include polyester. However, the adhesive layer 120 may include polyester with a different composition from the front layer 110 and the back layer 130. The melting point of the adhesive layer 120 may be lower than the melting points of the front layer 110 and the back layer 130. The front layer 110 and the back layer 130 can be bonded together by heating the fabric 100 to melt the adhesive layer 120. The melting points of the front layer 110 and the back layer 130 may be the same or different. In one example, the melting points of the front layer 110 and the back layer 130 are 220°C, and the melting point of the adhesive layer 120 is 110°C. Note that the method of bonding the front layer 110 and the back layer 130 is not limited to the method using the adhesive layer 120.
[0027] The back layer 130 is adhered to the back surface of the front layer 110. In this example, the back layer 130 is attached to the back surface of the front layer 110 using an adhesive layer 120. The back layer 130 may be a nonwoven fabric made of polyester. The front layer 110 and the back layer 130 may be made of the same material. By making each layer of the fabric 100 out of the same material, recyclability is improved. The thickness of the back layer 130 may be 1.0 mm or more and 20.0 mm or less. The thickness of the back layer 130 may be thicker than the thickness of the front layer 110. By forming the back layer 130 thick, a deep embossing can be formed on the front layer 110.
[0028] 2B is a schematic diagram of a cross section of the fabric 100 after embossing. In this example, the adhesive layer 120 is not shown for simplicity. In this example, the fabric 100 has the front layer 110 and the back layer 130 embossed.
[0029] The fabric 100 has unevenness formed by embossing. In this example, the back layer 130 is bonded to the back surface of the surface layer 110, and the embossing of the surface layer 110 penetrates into the back layer 130, thereby achieving deep embossing. The embossing depth De of the fabric 100 may be 50 μm or more and 400 μm or less. The embossing depth De may be the maximum value of the difference between the convex portions and concave portions in the embossed surface layer 110.
[0030] Here, the surface layer 110 may have a single yarn having a decitex of 0.05 or more and 0.7 or less. By thinning the single yarn in this way, the rigidity of the single yarn is weakened, allowing for a deeper embossing. Furthermore, by thinning the single yarn, it is possible to eliminate stitches and achieve a high-quality leather-like fabric with improved texture expression.
[0031] The thickness T of the fabric 100 after embossing may be the thickness between the embossed convex portions and the back surface of the back surface layer 130. The thickness T of the fabric 100 may be 0.3 mm or more and 20.0 mm or less. As will be described later, the thickness of the fabric 100 can be increased by including a shrinkage yarn, which gives the yarn swelling.
[0032] The thickness of the front layer 110 and the back layer 130 may be the same as or different from their respective thicknesses before embossing. The thickness of the front layer 110 may be 0.3 mm or more and 1.5 mm or less. The thickness of the back layer 130 may be 1.0 mm or more and 20.0 mm or less.
[0033] 2C shows an example of a flowchart for manufacturing the fabric 100. The flowchart in this example is an example of, and is not limited to, a manufacturing method for the fabric 100. In step S100, a surface layer 110 is prepared.
[0034] In step S110, functionality such as water repellency or flame retardancy is imparted to the surface layer 110. For example, the surface layer 110 may be imparted with functionality such as water repellency by dipping it with a functional agent such as a water repellent. The functional agent may have any function, such as flame retardancy. The surface layer 110 may be immersed in a combination of multiple functional agents at once. Step S110 may be omitted.
[0035] In step S120, the back layer 130 is attached to the back surface of the front layer 110. The front layer 110 may be attached to the back layer 130 by an adhesive layer 120. The front layer 110 and the back layer 130 are attached to each other before the front layer 110 is embossed.
[0036] In step S130, the surface layer 110 is embossed while the surface layer 110 and the back layer 130 are bonded together. By embossing the surface layer 110 and the back layer 130 while they are bonded together, a deeper embossing depth De can be achieved while preventing breakage of the surface layer 110. Furthermore, the embossing depth De of the fabric 100 can be controlled by adjusting the density and thickness of the back layer 130. By decreasing the density and increasing the thickness of the back layer 130, it becomes easier to increase the embossing depth De of the fabric 100. Conversely, by increasing the density and decreasing the thickness of the back layer 130, it becomes easier to decrease the embossing depth De of the fabric 100.
[0037] In step S140, any backing material may be attached to the back surface of the back surface layer 130. For example, a cushioning material such as polyurethane may be attached to the back surface of the back surface layer 130. The attachment of the backing material may be omitted. Even if a backing material is attached to the back surface of the back surface layer 130, the fabric 100 can be easily recycled by peeling off the backing material.
[0038] The surface layer 110 may include warp threads and weft threads. Increasing the thread density of the warp threads reduces the gaps in the fabric 100, making the weft threads less visible. This makes the surface layer 110 flatter, making it easier to achieve a high-quality leather-like fabric. Thread density refers to the number of single threads per inch. The thread density of the warp threads may be 200 or more and 300 or less. For example, skipping five or more surface threads of the weft threads causes shrinkage in the horizontal direction, allowing the thread density of the warp threads to be increased.
[0039] Here, if the single yarn of the surface layer 110 is thinned, there is a risk of thread breakage due to embossing. In this example, by increasing the thread density of the warp yarns and increasing the total number of threads, it is possible to provide a surface layer 110 that is less susceptible to thread breakage by dispersing the embossing pressure, even when the single yarn of the surface layer 110 is thinned.
[0040] FIG. 3 shows an example of the configuration of the warp yarns 10. The warp yarns 10 of this example have a predetermined first shrinkage yarn 11 and a second shrinkage yarn 12 that is different from the first shrinkage yarn 11. In the warp yarns 10 of this example, the first shrinkage yarn 11 and the second shrinkage yarn 12 are mixed. That is, the first shrinkage yarn 11 and the second shrinkage yarn 12 are mixed to form one warp yarn 10. The first shrinkage yarn 11 and the second shrinkage yarn 12 may have different heat shrinkage properties. In this example, a case where the warp yarns 10 include a shrinkage yarn will be described, but they may not include a shrinkage yarn.
[0041] By including shrinkage yarns in the warp yarns 10, the crimps can be spread laterally, making the stitches disappear. In this example, by using different shrinkage yarns, such as the first shrinkage yarn 11 and the second shrinkage yarn 12, for the warp yarns 10, the stitches can be made even less visible. Three or more shrinkage yarns may be used for the warp yarns 10. By including shrinkage yarns in the fabric 100, the yarns can be made bulging, increasing its thickness. By including shrinkage yarns, the voids in the fabric 100 can be increased, making it easier to press the fabric 100 with a mold and creating the unevenness of the embossing process.
[0042] The surface gloss of the fabric 100 can be adjusted as desired by adjusting the crimp of the first shrinkage yarn 11 and the second shrinkage yarn 12. In this way, warp yarns 10 containing any shrinkage yarn may be selected from the viewpoints of the surface gloss and embossing of the fabric 100. Similarly, a plurality of different shrinkage yarns may be used for the weft yarn.
[0043] Fig. 4 shows a modified example of the warp yarn 10. Unlike the warp yarn 10 in Fig. 3, the warp yarn 10 does not include multiple shrinkage yarns. The warp yarn 10 may not include shrinkage yarns, or may include only a single type of shrinkage yarn.
[0044] 5 shows an example of a method for manufacturing the fabric 100. This example shows an example of the embossing step in step S130 of FIG. 2C. In this example, the fabric 100 is embossed using an embossing machine 200. The embossing machine 200 includes a mold 210 and a stand 220.
[0045] In step S132, a leather-like fabric 100 is prepared. The prepared fabric 100 is placed on a stand 220. A mold 210 may be placed above the stand 220. The mold 210 may be a roll- or plate-shaped mold having projections and depressions corresponding to the embossing pattern to be applied to the fabric 100. The mold 210 may be heated to emboss the fabric 100. The heating temperature for embossing using the mold 210 may be lower than the glass transition point of the front layer 110. The glass transition points of the front layer 110 and the back layer 130 may be the same. The mold 210 may have various shapes or depths depending on the dimensions of the embossed projections and depressions. When a roll-shaped mold 210 is used, the embossing depth De may be controlled by adjusting conditions such as the temperature, pressure, and conveyor speed of the mold 210. When a plate-shaped mold 210 is used, the embossing depth De may be controlled by adjusting conditions such as the temperature, pressure, and holding time of the mold 210.
[0046] In step S134, the fabric 100 is embossed using a mold 210. In this example, the fabric 100 is embossed with the back layer 130 adhered to the back surface of the front layer 110. This may result in an embossing depth De of the fabric 100 of 50 μm or more and 400 μm or less. The back layer 130 may be elastically deformed when the fabric 100 is embossed. By elastically deforming the back layer 130 without plastically deforming it, the back layer 130 can be expanded in a process after the embossing. The front layer 110 may be plastically deformed by the embossing.
[0047] The embossing machine 200 uses a mold 210 to perform surface heating on the surface layer 110. Here, surface heating refers to heating a wider surface area, rather than processing only a part of the material by applying high frequency waves to the material as in a high frequency welder.
[0048] In step S136, the embossed fabric 100 is removed from the embossing machine 200. In this example, the fabric 100 is embossed while the back layer 130 is adhered to the back surface of the front layer 110, thereby achieving a high-quality leather-like texture with improved relief expression.
[0049] 6 shows a manufacturing method of fabric 500 of the comparative example. In step S500, fabric 500 is prepared. In step S502, fabric 500 is embossed. In step S504, fabric 500 is removed. Unlike fabric 100, fabric 500 of this example does not have back layer 130 adhered to front layer 110, and therefore it is not easy to apply deep embossing to fabric 500.
[0050] Figure 7 shows a modified example of the method for manufacturing the fabric 100. This example differs from the manufacturing method in Figure 5 in that it includes step S135. In this example, the differences from the manufacturing method in Figure 5 will be particularly described.
[0051] In step S135, after the front surface layer 110 is embossed, the back surface layer 130 is expanded. For example, the back surface layer 130 is expanded by heating it from the back surface side. The expansion of the back surface layer 130 allows the thickness of the back surface layer 130, which was compressed during the embossing process, to be restored.
[0052] For example, by plastically deforming the surface layer 110 by embossing and elastically deforming the back surface layer 130 by embossing, it becomes easier to expand only the back surface layer 130. By heating the back surface layer 130 in a manner that the surface layer 110 is less affected by heat than the back surface layer 130, it is possible to expand the back surface layer 130 while maintaining the embossing depth De of the surface layer 110. This allows the back surface layer 130, which was compressed during embossing, to be restored. Even if embossing marks remain on the back surface of the back surface layer 130, they can be flattened by the expansion of the back surface layer 130.
[0053] Although the present invention has been described above using embodiments, the technical scope of the present invention is not limited to the scope described in the above embodiments. It will be apparent to those skilled in the art that various modifications and improvements can be made to the above embodiments. It is clear from the claims that such modifications and improvements can also be included within the technical scope of the present invention.
[0054] It should be noted that the execution order of each process, such as operations, procedures, steps, and stages, in the devices, systems, programs, and methods shown in the claims, specifications, and drawings is not specifically stated as "before," "prior to," etc., and that the processes can be performed in any order unless the output of a previous process is used in a subsequent process. Even if the operational flow in the claims, specifications, and drawings is described using "first," "next," etc. for convenience, this does not mean that the processes must be performed in this order. [Explanation of symbols]
[0055] 10...warp thread, 11...first shrinkage thread, 12...second shrinkage thread, 100...fabric, 110...surface layer, 120...adhesive layer, 130...back layer, 200...embossing machine, 210...mold, 220...frame, 500...fabric
Claims
1. With a leather-like surface layer, a back surface layer adhered to the back surface side of the front surface layer; an adhesive layer for adhering the front surface layer and the back surface layer; Equipped with the front layer and the back layer are embossed; the surface layer, the back layer, and the adhesive layer are made of polyester; The thickness of the surface layer is 0.3 mm or more and 1.5 mm or less. Leather-like fabric.
2. The embossing depth of the fabric is 50 μm or more and 400 μm or less. The leather-like fabric according to claim 1.
3. The back surface layer is a nonwoven fabric made of polyester. The leather-like fabric according to claim 1.
4. The thickness of the back surface layer is greater than the thickness of the front surface layer. The leather-like fabric according to claim 1.
5. The adhesive layer has a melting point lower than that of the front layer and the back layer. The leather-like fabric according to any one of claims 1 to 4.
6. bonding the front surface layer and the back surface layer together using an adhesive layer; embossing the surface layer while the surface layer and the back layer are attached to each other; Equipped with the surface layer is a leather-like layer, the surface layer, the back layer, and the adhesive layer are made of polyester; The thickness of the surface layer is 0.3 mm or more and 1.5 mm or less. How to make leather-like fabric.
7. The embossing step includes a step of heating the surface layer by using an embossing machine using a roll-shaped or plate-shaped mold. A method for producing the leather-like fabric according to claim 6.
8. The heating temperature for the embossing is lower than the glass transition temperature of the surface layer. A method for producing the leather-like fabric according to claim 6.
9. The embossing step includes plastically deforming the surface layer. A method for producing the leather-like fabric according to claim 6.
10. The embossing step includes elastically deforming the backing layer. A method for producing the leather-like fabric according to claim 6.
11. After embossing the front surface layer, the back surface layer is expanded. A method for producing the leather-like fabric according to any one of claims 6 to 10.
12. A step of bonding a front surface layer and a back surface layer together; embossing the surface layer while the surface layer and the back layer are attached to each other; After embossing the front surface layer, heating the back surface layer from the back surface side to expand the back surface layer; Equipped with The surface layer is a leather-like layer made of polyester. How to make leather-like fabric.