Composite skin material having uneven pattern

Abstract

To provide a composite skin material having a clear uneven pattern transferred from a mold shape and having good shape retainability of the uneven pattern and good touch feeling of the uneven pattern.SOLUTION: A composite skin material having a concavo-convex pattern according to an embodiment is a composite skin material having a concavo-convex pattern in which a skin material, a soft polyurethane foam sheet, and a lining cloth are laminated. At least one of the convex portions of the concavo-convex pattern is a convex portion having a concave portion formed on the corresponding back surface. The sum (A) of the thickness of the soft polyurethane foam sheet and the thickness of the back cloth in the convex portion (a) having the highest height among the convex portions forming the concave portions on the corresponding back surface is 250 μm or more. The height difference (B) between the convex portion (a) and the concave portion (b) adjacent to the convex portion (a) is 2500 μm or less.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a composite skin material, and more particularly to a composite skin material having a concave-convex pattern. [Background technology]

[0002] Previously, studies have been conducted to impart new designs to skin materials. For example, Patent Document 1 describes a method for embossing fabric, in which fabric is sandwiched between heated male and female plate-like dies and pressed to impart a concave-convex pattern to the fabric. It also describes that this method can impart an embossed pattern of any design and depth to the fabric. It also describes that it can impart a clear and strong (hard-to-disappear) outline to the fabric.

[0003] Patent Document 2 describes a method for manufacturing a laminated sheet that includes a synthetic resin sheet and a cushioning material laminated in this order from front to back and has irregularities on at least the front side, the method including a preparation step of attaching the cushioning material to the back side of a synthetic resin sheet to prepare a laminated sheet material, a softening step of softening the laminated sheet material, and a molding step of applying a vacuum to the front side of the laminated sheet material through a molding die made of a porous member to impart irregularities.The document also describes that this method allows a concave-convex shape pattern including fine concave-convex shapes to be faithfully formed on the surface of the laminated sheet material in which the cushioning material is attached to the back side of the synthetic resin sheet. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 6-212559 [Patent Document 2] Japanese Patent Application Publication No. 2024-074257 Summary of the Invention [Problem to be solved by the invention]

[0005] The fabric of Patent Document 1 can impart clear and strong (hard to disappear) contour lines, but the resulting embossed pattern feels hard to the touch, and the raised portions of the embossed pattern are prone to depression when pressed with a finger and are difficult to return to their original shape, i.e., the shape retention of the raised and recessed pattern is poor. The laminated sheet of Patent Document 2 can faithfully imprint a raised and recessed pattern on a molding die, but there is room for improvement in the shape retention of the raised and recessed pattern and the feel of the raised portions.

[0006] The present invention was made in view of the above-mentioned circumstances, and its object is to provide a composite skin material that has a clear uneven pattern formed by transferring the shape of a mold, and that has good shape retention and a good feel to the touch of the uneven pattern.

[0007] The present invention includes the embodiments shown below. [1] A composite skin material having a concave-convex pattern formed by laminating a skin material, a flexible polyurethane foam sheet, and a lining fabric, wherein at least one of the convex portions of the concave-convex pattern is a convex portion that forms a concave portion on the corresponding back surface, and the sum (A) of the thickness of the flexible polyurethane foam sheet and the thickness of the lining fabric at the tallest convex portion (a) among the convex portions forming a concave portion on the corresponding back surface is 250 μm or more, and the difference in height (B) between the convex portion (a) and the concave portion (b) adjacent to the convex portion (a) is 2500 μm or less. [Effects of the Invention]

[0008] According to an embodiment of the present invention, it is possible to provide a composite skin material that has a clear textured pattern formed by transferring the shape of a mold, and that has good shape retention and a good feel to the touch of the textured pattern. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 2 is a cross-sectional schematic diagram of a substrate (composite skin material). [Figure 2] 1 is a cross-sectional conceptual diagram of a composite skin material having a concave-convex pattern according to one embodiment. [Figure 3]FIG. 1 is a mold design drawing of the male and female molds used in Examples 1 to 3. [Figure 4] FIG. 10 is a mold design drawing of the male and female molds used in Example 6. DETAILED DESCRIPTION OF THE INVENTION

[0010] The composite skin material having an uneven pattern according to this embodiment is a composite skin material in which an uneven pattern is formed on the composite skin material, which is made by laminating a skin material, a soft polyurethane foam sheet, and a lining fabric.

[0011] FIG. 1 is a schematic diagram showing the cross-sectional structure of a substrate (composite skin material) 1. In this substrate (composite skin material) 1, a flexible polyurethane foam sheet 3 is provided as a lower layer on the back surface of a skin material 2, and a lining cloth 4 is further laminated on the back surface of the flexible polyurethane foam sheet 3. Therefore, the flexible polyurethane foam sheet 3 and the lining cloth 4 are laminated in this order on the back surface of the skin material 2. In this embodiment, the "back surface" refers to the side that is not visible when in use, and the "front surface" refers to the front surface of the skin material 2, i.e., the side that is visible when in use (the design surface). Note that a composite skin material formed by laminating a skin material, a flexible polyurethane foam sheet, and a lining cloth, i.e., a composite skin material before the formation of a textured pattern, will hereinafter be referred to as the "substrate" to distinguish it from a composite skin material with a textured pattern.

[0012] The skin material used in this embodiment is not particularly limited, and examples thereof include woven fabrics, knitted fabrics, nonwoven fabrics, synthetic leathers, artificial leathers, and natural leathers. From the viewpoint of the shaping ability of the concave-convex pattern, skin materials with good elongation properties that can easily follow the mold are preferred, and knitted fabrics are more preferred.

[0013] The skin material preferably contains fibers as a component. The fiber material constituting the skin material is not particularly limited, but thermoplastic fibers are preferred from the viewpoint of the ability to form a textured pattern. Examples of thermoplastic fibers include synthetic fibers such as polyester, polypropylene, and nylon, and semi-synthetic fibers such as acetate and triacetate. These can be used alone or in combination of two or more. Among these, synthetic fibers are more preferred, and polyester fibers are even more preferred, due to their excellent physical properties, particularly strength, abrasion resistance, and heat resistance. While the fiber material is preferably primarily composed of thermoplastic fibers, it may also be combined with fibers other than thermoplastic fibers, such as natural fibers and recycled fibers, by techniques such as blending, interweaving, twisting, interweaving, and interknitting, as long as the physical properties are not affected.

[0014] The form of the yarn may be either a staple fiber yarn such as a spun yarn, or a long fiber yarn such as a multifilament yarn or a monofilament yarn, or may be a long-short composite spun yarn that combines long fibers and short fibers. The multifilament yarn may be twisted as necessary, or may be subjected to processing such as false twisting or liquid disturbance treatment.

[0015] The skin material may be subjected to pretreatment such as presetting and scouring, or a coloring process, as required.

[0016] The flexible polyurethane foam sheet used in this embodiment is not particularly limited, and any conventionally known flexible polyurethane foam sheet used as a cushioning material for a surface material can be used. Examples of the flexible polyurethane foam sheet used in this embodiment include a sheet-like product of soft foamed synthetic rubber having interconnected cells, which is mainly composed of polyol and polyisocyanate, and is foamed while being resinified by mixing with a foaming agent and the like. Examples of the flexible polyurethane foam sheet include a long sheet-like product obtained by slicing a block continuously produced by soft slab foaming in the longitudinal direction.

[0017] The thickness of the flexible polyurethane foam sheet is not particularly limited, but is preferably 4 to 12 mm. When the thickness of the flexible polyurethane foam sheet is at least the lower limit, the tactile feel of the composite skin material is improved. When the thickness of the flexible polyurethane foam sheet is at most the upper limit, the formability of the textured pattern is improved. A clear textured pattern transferred from the mold shape is easily obtained. The thickness of the flexible polyurethane foam sheet refers to the thickness of the flexible polyurethane foam sheet alone. The thickness of the flexible polyurethane foam sheet in the substrate (composite skin material before the textured pattern is formed) and the thickness of the flexible polyurethane foam sheet in the composite skin material having the textured pattern may be set within the same range.

[0018] The density of the flexible polyurethane foam sheet (JIS K7277 apparent density) is not particularly limited, but is preferably 16 to 60 kg / m 3 When the density of the flexible polyurethane foam sheet is in this range, the cushioning properties and durability thereof can be maintained.

[0019] The hardness (JIS K6400-2 D method) of the flexible polyurethane foam sheet is not particularly limited, but is preferably 36 to 360 N. When the hardness of the flexible polyurethane foam sheet is equal to or greater than the lower limit, cushioning properties and durability can be maintained. When the hardness of the flexible polyurethane foam sheet is equal to or less than the upper limit, cushioning properties can be maintained.

[0020] The impact resilience (JIS K6400-3) of the flexible polyurethane foam sheet is not particularly limited, but is preferably 20% or more. When the impact resilience of the flexible polyurethane foam sheet is equal to or greater than the lower limit, cushioning properties can be maintained. The upper limit of the impact resilience is also not particularly limited, and may be, for example, 70% or less.

[0021] The method for laminating the skin material and the flexible polyurethane foam sheet together is not particularly limited, and examples thereof include a method using an adhesive, a flame lamination method, a stitching method, etc. Among these, the frame lamination method is preferred from the viewpoints of process load and weight reduction.

[0022] The lining used in this embodiment is not particularly limited, and may be a fabric made of synthetic fiber such as polyester. By laminating a lining on the surface of the flexible polyurethane foam sheet opposite the surface material side, it is possible to prevent contamination of the mold during pressing, to allow the substrate to slide smoothly during sewing work, and to suppress damage to the flexible polyurethane foam sheet.

[0023] The method for laminating and integrating the backing fabric can be the same as the method for integrating the surface material and the flexible polyurethane foam sheet, but from the viewpoints of process load and weight reduction, a method using frame lamination is preferred.

[0024] Thus, the substrate (composite skin material before the formation of the textured pattern) is obtained.

[0025] The thickness (T1) of the obtained substrate is not particularly limited, but is preferably 3.1 to 13 mm. When the thickness (T1) of the substrate is equal to or greater than the lower limit, the tactile feel of the composite skin material having a concave-convex pattern is improved. In addition, the skin material is less likely to be broken by the mold when forming the recesses. When the thickness (T1) of the substrate is equal to or less than the upper limit, the formability of the concave-convex pattern is improved. A clear concave-convex pattern that is a transfer of the mold shape is easily obtained.

[0026] The obtained substrate is subjected to a pressing process. Examples of pressing processes include embossing and welding, which use a mold. From the viewpoint of the ability to form a concave-convex pattern, it is preferable to perform embossing using a male and female mold. That is, a heated mold (preferably a male and female mold) is pressed against the substrate to form the concave-convex pattern. This results in a composite skin material with a concave-convex pattern.

[0027] By using male and female molds for pressing, a clear uneven pattern that transfers the mold shape can be obtained. It is also possible to form convex and concave portions with different heights and depths, enhancing the design. To form more complex uneven patterns, a single mold may contain both male and female portions and non-male and female portions.

[0028] The uneven pattern is not particularly limited, and may be, for example, a geometric pattern consisting of lines, circles, polygons, etc., either alone or in combination of two or more.

[0029] The surface temperature of the mold (i.e., the heat treatment temperature during hot pressing) can be set appropriately depending on the materials of the skin material and the flexible polyurethane foam sheet. For example, when the skin material is polyethylene terephthalate (melting point: 260°C), the surface temperature is preferably 100 to 210°C, and more preferably 120 to 180°C. By keeping the temperature at or above the lower limit, the durability, particularly heat resistance, of the formed textured pattern can be maintained. By keeping the temperature at or below the upper limit, it is possible to prevent the surface of the skin material from becoming too glossy and the texture of the composite skin material from becoming too hard.

[0030] When male and female molds are used, the surface temperatures of the molds (i.e., corresponding to the heat treatment temperature during hot pressing) are preferably 150 to 190°C for the male mold and 170 to 230°C for the female mold. When the surface temperature of the male mold is equal to or higher than the lower limit, the ability to form a concave-convex pattern is improved. A clear concave-convex pattern formed by transferring the mold shape is easily obtained. When the surface temperature of the male mold is equal to or lower than the upper limit, the tactile feel of the composite skin material is improved. When the surface temperature of the female mold is equal to or higher than the lower limit, the ability to form a concave-convex pattern is improved. A clear concave-convex pattern formed by transferring the mold shape is easily obtained. When the surface temperature of the female mold is equal to or lower than the upper limit, melting of the flexible polyurethane foam sheet is prevented. A decrease in processability is suppressed.

[0031] When male and female dies are used as the dies, the pressing conditions are preferably a pressing pressure of 2 to 15 MPa, a pressing time of 1 to 30 seconds, and a clearance of 0 to 1000 μm. When the pressing pressure and pressing time are at or above the lower limit values, the ability to form the textured pattern is improved. A clear textured pattern formed by transferring the shape of the die is easily obtained. When the pressing pressure and pressing time are at or below the upper limit values, the feel of the composite skin material having the textured pattern is good. When the clearance is within the above range, the ability to form the textured pattern is improved. A clear textured pattern formed by transferring the shape of the die is easily obtained.

[0032] Thus, a textured pattern is formed on the substrate.

[0033] The uneven pattern consists of recesses and protrusions. In this embodiment, at least one of the protrusions is a protrusion that forms a recess on the corresponding back surface. By forming such protrusions, a clear uneven pattern that transfers the mold shape is obtained. If the shape of the back surface does not follow the shape of the protrusions on the front surface, tension is generated on the front surface, which is thought to affect the shape of the protrusions formed on the front surface. In other words, if there is no male mold, the shape of the protrusions on the front surface will be distorted by the pull of the back surface, and therefore clear protrusions that transfer the mold shape will not be formed.

[0034] FIG. 2 is a schematic diagram showing a cross section of the composite skin material 10 having the resulting textured pattern. In FIG. 2, two of the convex portions 11 of the textured pattern are convex portions that form concave portions on the corresponding back surface. Of the convex portions that form concave portions on the corresponding back surface, the tallest convex portion is convex portion 11a. Also in FIG. 2, convex portion 11a has two concave portions formed adjacent to it. Of the concave portions adjacent to convex portion 11a, the concave portion with the greatest height difference from convex portion 11a is concave portion 12b. Note that in FIG. 2, convex portion 11c is also formed. Convex portion 11c is a portion that has not been shaped by pressing, i.e., a non-pressed portion, and no concave portion is formed on the corresponding back surface.

[0035] When multiple protrusions each having a recess formed on the corresponding back surface are formed, the protrusion with the highest height is designated as protrusion (a) (protrusion 11a in FIG. 2). In this embodiment, the sum (A) of the thickness of the flexible polyurethane foam sheet and the thickness of the backing fabric in protrusion (a) is 250 μm or more. When the thickness (A) is equal to or greater than the lower limit, the protrusions have cushioning properties, the shape of the protrusions is well maintained, and the tactile feel of the protrusions and the composite skin material having the protrusions and recesses is excellent. The upper limit of the thickness (A) is not particularly limited, but is preferably 700 μm or less. When the thickness (A) is equal to or less than the upper limit, the formability of the recess and projection pattern is improved. A clear recess and projection pattern that transfers the shape of the mold is easily obtained.

[0036] The sum (A) of the thickness of the flexible polyurethane foam sheet and the thickness of the lining fabric at the convex portion (a) is a value obtained by observing a vertical cross section of the composite skin material having concaves and convexes with a microscope (for example, Digital Microscope VHX-5000 manufactured by Keyence Corporation) and measuring the thickness of the flexible polyurethane foam sheet and the thickness of the lining fabric at the highest part of the convex portion (a).

[0037] When multiple recesses are formed adjacent to a convex portion (a), the recess with the largest height difference from the convex portion (a) is designated as recess (b) (recess 12b in FIG. 2). In this embodiment, the height difference (B) between the convex portion (a) and the recess (b) adjacent to the convex portion (a) is 2500 μm or less. When the height difference (B) between the recess (b) adjacent to the convex portion (a) is equal to or less than the upper limit, the formability of the concave-convex pattern is improved. A clear concave-convex pattern transferred from the mold shape is easily obtained. In addition, when the convex portion is pressed, the convex portion sinks less and is easy to restore, so the shape of the convex portion is well maintained. Shape retention can be improved. The lower limit of the height difference (B) between the convex portion (a) and the recess (b) adjacent to the convex portion (a) is not particularly limited, but it is preferably 300 μm or more. When the height difference (B) is equal to or greater than the lower limit, a clear concave-convex pattern is easily obtained.

[0038] The height difference (B) between the convex part (a) and the concave part (b) adjacent to the convex part (a) is a value obtained by observing a vertical cross-section of the composite skin material having unevenness with a microscope (for example, manufactured by Keyence Corporation, digital microscope VHX-5000) and measuring the height difference between the highest part of the convex part (a) and the lowest part of the concave part (b).

[0039] The distance (D) obtained by translating parallel from the highest part of the convex part (a) to the lowest part of the concave part (b) and the distance (E) obtained by moving along the surface shape of the composite skin material from the highest part of the convex part (a) to the lowest part of the concave part (b) preferably satisfy 1.05 < E / D < 1.5. When E / D is greater than the lower limit value, it is easy to obtain a distinct uneven pattern. When E / D is smaller than the upper limit value, the elongation characteristics of the composite skin material are not impaired, so the shape retention of the convex part is good. The shape retention can be improved. Here, the highest part of the convex part (a) refers to the vertex of the convex part (a) or the center point of the top surface when the convex part (a) has a top surface, and the lowest part of the concave part (b) refers to the bottom point of the concave part (b) or the center point of the bottom surface when the concave part (b) has a bottom surface.

[0040] The distance (D) obtained by translating parallel from the highest part of the convex part (a) to the lowest part of the concave part (b) and the distance (E) obtained by moving along the surface shape of the composite skin material from the highest part of the convex part (a) to the lowest part of the concave part (b) are values obtained by observing and measuring a vertical cross-section of the composite skin material having unevenness with a microscope (for example, manufactured by Keyence Corporation, digital microscope VHX-5000).

[0041] In the present embodiment, a convex part (c) may be formed on the convex part of the uneven pattern (the convex part 11c in FIG. 2). The convex part (c) is a non-pressed part, that is, a part that has not been shaped by pressing, and is a convex part in which a concave part is not formed on the corresponding back surface.

[0042] The sum (C) of the thickness of the flexible polyurethane foam sheet and the thickness of the backing fabric in the convex portion (c) is not particularly limited, but is preferably 3 to 10 mm. When the thickness (C) is equal to or greater than the lower limit, the composite skin material has a good feel to the touch. When the thickness (C) is equal to or less than the upper limit, the composite skin material has excellent handleability, and is easy to sew and wind.

[0043] In this embodiment, the thickness of each layer (i.e., the skin material, the flexible polyurethane foam sheet, and the lining) changes before and after pressing at the pressed portion of the mold. The thickness (T2) of the composite skin material having a concave-convex pattern is not particularly limited, but is preferably 0.2 to 13 mm. When the thickness (T2) of the composite skin material having a concave-convex pattern is equal to or greater than the lower limit, the tactile feel of the composite skin material having a concave-convex pattern is improved. When the thickness (T2) of the composite skin material having a concave-convex pattern is equal to or less than the upper limit, the handleability is excellent. The sewing properties and winding properties are improved. It is preferable that the thickness of all parts (all concave portions, convex portions, and non-pressed portions) of the composite skin material having a concave-convex pattern be within the above numerical range.

[0044] The thickness (T2) of the composite skin material having a textured pattern is determined by observing the vertical cross section of the composite skin material with a microscope (for example, Keyence Corporation's Digital Microscope VHX-5000), measuring the thickness at any 10 points, and calculating the average of these values. The thickness (T1) of the substrate can also be determined in a similar manner.

[0045] The applications of the composite skin material having a concave-convex pattern according to this embodiment are not particularly limited, and specific examples of applications include interior materials for various vehicles, such as automobile seats and door linings, interior applications such as coverings for sofas and chairs, and fashion applications such as bags and shoes.

[0046] The various numerical ranges described in this specification can be arbitrarily combined with their upper and lower limits, and all such combinations are considered to be preferred numerical ranges described in this specification. Furthermore, a numerical range described as "X to Y" means from X to Y. [Example]

[0047] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to the following examples.

[0048] Each evaluation item was performed according to the following method.

[0049] [Design (clear uneven pattern transferred from mold shape)] The composite skin material having the uneven pattern and the mold were visually inspected and evaluated according to the following evaluation criteria. Grade 2 or higher was considered to be acceptable. (Evaluation criteria) Grade 3: The pattern on the mold is faithfully transferred, and the contours and sharpness are clearly expressed. Grade 2: The pattern on the mold is faithfully transferred, and the contours and sharpness are expressed, but there are some areas that are not expressed. Grade 1: The pattern on the mold is not faithfully transferred, and the outline of the pattern cannot be expressed.

[0050] [Tactile feel (hardness)] The protruding portion (a) of the composite skin material having the uneven pattern was touched and evaluated according to the following evaluation criteria. Grade 2 or higher was considered to be acceptable. (Evaluation criteria) Grade 3: Soft (not hard). Grade 2: Feels slightly hard. Grade 1: Hard.

[0051] [Shape retention (retaining the shape of the uneven pattern)] The protruding portion (a) of the composite skin material having a concave-convex pattern was pressed down with the entire index finger, kept in that state for 10 seconds, and then the index finger was removed. The time from when the index finger was removed until the protruding portion (a) returned to its original state was measured and evaluated according to the following evaluation criteria. The change in state was judged visually. Grade 3 was considered a pass. (Evaluation criteria) Level 3: Return to original state within 5 seconds. Level 2: Return to original state within 5 to 10 seconds. Level 1: Does not return to its original state after 10 seconds.

[0052] [Composite skin material] A 28-gauge, three-reed tricot knitting machine was used to knit a tricot fabric. A full set of 84 dtex / 36 f / cm polyester raw silk was used as the front yarn in the front reed L1 to form a two-needle swing cord knit (1-0 / 2-3). A full set of 84 dtex / 36 f / cm polyester raw silk was used as the middle yarn in the middle reed L2 to form a Denbigh knit (0-1 / 2-1). A full set of 112 dtex / 84 f / cm polyester false-twist textured yarn was used as the back yarn in the back reed L3 to form a three-needle swing cord knit (1-0 / 3-4). The resulting tricot fabric was dyed beige using a disperse dye in a jet dyeing machine at 130°C for 30 minutes. It was then raised using a clothed raising machine equipped with a clothed roll with 12 pile rollers and 12 counter-pile rollers. Specifically, the fabric was raised six times alternately from the knitting end direction and the knitting start direction at a clothed roller torque of 10 MPa and a fabric speed of 17 m / min, to give semi-cut raising to the sinker loop surface. The fabric was then heat-treated at 150°C for one minute in a heat setter to obtain a skin material (tricot knit fabric, knit density 60 courses / 25.4 mm, 40 wales / 25.4 mm, thickness 1 mm (raised portion: 0.2 mm, ground weave portion: 0.8 mm)). A soft polyurethane foam sheet (manufactured by Inoac Corporation, EL-67F, thickness 6 mm, density 20 kg / m) was applied to the back of the obtained skin material. 3) and a backing fabric (polyester nonwoven fabric, E01012, manufactured by Tsubakimoto Kogyo Co., Ltd.) were laminated together by frame lamination to obtain a substrate having a thickness of 5.8 mm.

[0053] [Example 1] Using an NSF-type single-action compression molding machine (ANSF-30H, manufactured by Shinto Metal Industry Co., Ltd.), the following settings were made: surface temperature of the male mold (skin material side) 180°C, surface temperature of the female mold (flexible polyurethane foam sheet side) 230°C, clearance between the male and female molds 100 μm, pressure 4.5 MPa, and pressing time 6 seconds. Mold I, one of the molds shown in Figure 3, was used for the male and female molds, and pressing was performed on the substrate to obtain a composite skin material with a textured pattern.

[0054] [Example 2] A composite skin material having a concave-convex pattern was obtained in the same manner as in Example 1, except that mold II of the molds shown in FIG. 3 was used.

[0055] [Example 3] A composite skin material having a concave-convex pattern was obtained in the same manner as in Example 1, except that mold III of the molds shown in FIG. 3 was used.

[0056] [Example 4] A composite skin material having a concave-convex pattern was obtained in the same manner as in Example 3, except that the surface temperature of the male mold (skin side) was changed to 190°C.

[0057] [Example 5] A composite skin material having a concave-convex pattern was obtained in the same manner as in Example 1, except that the surface temperature of the male mold (skin side) was changed to 190°C.

[0058] [Example 6] A composite skin material having a concave-convex pattern was obtained in the same manner as in Example 1, except that mold IV shown in FIG. 4 was used.

[0059] [Comparative Example 1] A composite skin material having a concave-convex pattern was obtained in the same manner as in Example 3, except that the surface temperature of the male mold (skin side) was changed to 190° C. and the clearance between the male and female molds was changed to 50 μm.

[0060] Comparative Example 2 A composite skin material having a concave-convex pattern was obtained in the same manner as in Example 2, except that the surface temperature of the male mold (skin side) was changed to 190°C.

[0061] Table 1 shows the details and evaluation of the composite skin materials having irregularities obtained for Examples 1 to 6 and Comparative Examples 1 and 2.

[0062] [Table 1]

[0063] In Comparative Example 1, the sum (A) of the thickness of the flexible polyurethane foam sheet and the thickness of the backing fabric at the convex portions (a) was less than the lower limit, and therefore the touch and shape retention were poor. In Comparative Example 2, the height difference (B) between the convex portions (a) and the concave portions (b) exceeded the upper limit, and therefore a clear uneven pattern formed by transferring the mold shape was not formed, and therefore the design and shape retention were poor. In contrast, in Examples 1 to 6, a clear uneven pattern formed by transferring the mold shape was formed, and therefore the design was excellent, as well as the touch and shape retention were excellent. [Explanation of symbols]

[0064] 1: Base material, 2: Skin material, 3: Soft polyurethane foam sheet, 4: Lining fabric 10: composite skin material having irregularities; 11, 11a, 11c: convex portions; 12, 12b: concave portions

Claims

[Claim 1] A composite skin material having a concave-convex pattern, which is formed by laminating a skin material, a soft polyurethane foam sheet, and a backing fabric, At least one of the convex portions of the concave-convex pattern is a convex portion that forms a concave portion on the corresponding back surface, the sum (A) of the thickness of the flexible polyurethane foam sheet and the thickness of the backing fabric at the highest convex portion (a) among the convex portions forming a concave portion on the corresponding back surface is 250 μm or more; a height difference (B) between the convex portion (a) and the concave portion (b) adjacent to the convex portion (a) is 2500 μm or less; A composite skin material with a textured pattern.

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