A light-transmitting surface material that maintains surface properties, and a method for manufacturing the surface material.

Abstract

In a side cross-sectional view, the upper end of the molten material adhering to the inner surface of the molten excavation section is positioned at approximately the same height as the upper end of the molten excavation section, or lower, thereby achieving both "maintenance of surface properties" and "light transmittance." [Solution] In a side cross-sectional view, the upper end of the molten material 3 attached to the inner surface of the molten excavation section 2 of the surface material 1 containing thermoplastic fibers is located at approximately the same height as or lower than the upper end of the molten excavation section 2. Alternatively, in a side cross-sectional view, the upper end of the molten material 3 may be located below the upper end of the fluff 4B of the fuzzy fabric 4, which is the upper end of the molten excavation section 2, or the base fabric 4A of the fuzzy fabric 4 may be a woven, knitted, or nonwoven fabric made of yarn with a total fineness of 30 to 500 dtex, or the molten excavation section 2 may be formed by multiple connecting holes 2A, and the connecting holes 2A may be approximately circular in shape in plan view and have a diameter of 0.1 to 3.0 mm. In the molten excavation step S1 of the manufacturing method of the surface material 1, in a side cross-sectional view, the upper end of the molten material 3 attached to the inner surface of the molten excavation section 2 is positioned at approximately the same height as or lower than the upper end of the molten excavation section 2.

Description

[Technical Field]

[0001] The present invention relates to a surface material containing thermoplastic fibers, and a method for producing the surface material. [Background technology]

[0002] Conventionally, pinhole-processed, full-grain-finish artificial leather has been known as a surface material for covering interior parts of automobiles (Patent Document 1). This pinhole-processed, full-grain-like artificial leather comprises a leather-like sheet made of a fine long-fiber nonwoven fabric containing an intertwined web structure of ultrafine long fiber bundles and a polymer elastic material impregnated inside it, and a full-grain layer formed on at least one side of the leather-like sheet, wherein 10 to 100 pinholes / cm² with a major axis of 30 to 100 μm and a minor axis of 3 to 5 μm are formed by piercing the full-grain layer and the leather-like sheet with a needle, on the surface of the full-grain layer. 2 It is used on the back panel of backpacks. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2011-214196 [Overview of the Initiative] [Problems that the invention aims to solve]

[0004] In the pinhole-processed, full-grain-like artificial leather described in Patent Document 1, it can be said that it has light transmittance such that when a light source is placed on the back surface and observed from the front surface, the light source is visible. However, as shown in Figure 4 of Patent Document 1, the pinhole-processed full-grain-finish artificial leather has a problem in that the surface side of the pinhole-processed full-grain-finish artificial leather melts and bulges due to the formation of the pinholes, which impairs the surface properties, texture, and feel of the pinhole-processed full-grain-finish artificial leather. Furthermore, on the surface side of the silver-coated artificial leather with needle hole processing in Patent Document 1, it can be said that the melted and raised portion inhibits the oblique transmission of light from the back side with a light source to the surface side (so-called oblique light transmissibility).

[0005] In view of such points, the present invention aims to provide a skin material that realizes the compatibility of "maintaining surface properties" and "light transmissibility" by positioning the upper end of the melt adhered to the inner surface of the melt excavation part at substantially the same height as the upper end of the melt excavation part or lower than the upper end of the melt excavation part in a side cross-sectional view, and a method for manufacturing the skin material.

Means for Solving the Problems

[0006] The skin material 1 according to the present invention is a skin material containing thermoplastic fibers, and a melt excavation part is formed by melting the skin material from the surface and excavating at least a part of the skin material. In a side cross-sectional view of the skin material of the melt excavation part, the upper end of the melt adhered to the inner surface of the melt excavation part is located at substantially the same height as the upper end of the melt excavation part or lower than the upper end of the melt excavation part, which is the first feature.

[0007] The second feature of the skin material 1 according to the present invention is that, in addition to the first feature, the skin material includes a base fabric composed of the thermoplastic fibers and hairy fabric provided on the base fabric and composed of the thermoplastic fibers. In a side cross-sectional view of the skin material of the melt excavation part, the upper end of the hairy part becomes the upper end of the melt excavation part, and in a side cross-sectional view of the skin material of the melt excavation part, the upper end of the melt is located below the upper end of the hairy part.

[0008] The third feature of the skin material 1 according to the present invention is that, in addition to the second feature, the base fabric is a woven fabric, a knitted fabric or a non-woven fabric, and the base fabric is composed of yarns with a total fineness of 30 dtex or more and 500 dtex or less.

[0009] The fourth feature of the skin material 1 according to the present invention is that, in addition to the above first feature, the melt-excavated portion is a communication hole portion that communicates from the front surface to the back surface of the skin material, and a plurality of the communication hole portions are formed in a predetermined range in the plan view of the skin material.

[0010] The fifth feature of the skin material 1 according to the present invention is that, in addition to the above fourth feature, the shape of the communication hole portion in the plan view is substantially circular, and the diameter of the communication hole portion is 0.1 mm or more and 3.0 mm or less.

[0011] Due to these features, in a side cross-sectional view, by positioning the upper end of the melt 3 adhering to the inner surface of the melt-excavated portion 2 at substantially the same height as the upper end of the melt-excavated portion 2 or at a lower position, unlike Patent Document 1, the front surface side of the skin material 1 does not melt and swell, and the surface properties, texture, touch, etc. of the skin material 1 can be maintained ("maintenance of surface properties", etc.). At the same time, the melt-excavated portion 2 is at least a thin portion by the amount of the skin material 1 containing thermoplastic fibers excavated, including the case where it communicates from the front surface to the back surface of the skin material 1. Therefore, if a light source is placed on the back surface side of the melt-excavated portion 2 and observed from the front surface side, it can be said that it has light transmissibility such that the light source on the back surface side can be seen, and both "maintenance of surface properties" and "light transmissibility" can be achieved. In addition, it can be said that the skin material 1 is a "light-transmissive skin material with surface property maintenance".

[0012] Also, in a side cross-sectional view, by positioning the upper end of the melt 3 below the upper end of the fiber tufts 4B of the hairy fabric 4, which is the upper end of the melt-excavated portion 2, "maintenance of surface properties" and the like can also be achieved in the hairy fabric 4.

[0013] Furthermore, by forming the base fabric 4A of the hairy fabric 4 into a woven fabric, knitted fabric or non-woven fabric composed of yarns with a total fineness of 30 dtex or more and 500 dtex or less, not only "maintenance of surface properties" but also improvement in texture and the like becomes possible.

[0014] Furthermore, by forming multiple communication holes 2A, which are molten drilling sections 2, within a predetermined range, light transmittance can be improved within that predetermined range. Additionally, by setting the diameter of the approximately circular communication holes 2A in plan view to be between 0.1 mm and 3.0 mm, it is possible to achieve both "maintenance of surface properties" and "light transmittance."

[0015] The present invention relates to a method for manufacturing a surface material 1, which is a method for manufacturing a surface material containing thermoplastic fibers, and comprises a melting and drilling step of melting the surface material from the surface to form a melting and drilling section in which at least a part of the surface material is excavated, wherein in the melting and drilling step, in a side cross-sectional view of the surface material of the melting and drilling section, the upper end of the molten material adhering to the inner surface of the melting and drilling section is positioned at approximately the same height as the upper end of the melting and drilling section, or below the upper end of the melting and drilling section.

[0016] Due to this feature, in the melting and drilling process S1, when viewed in a side cross-section, the upper end of the molten material 3 adhering to the inner surface of the melting and drilling section 2 is positioned at approximately the same height as or lower than the upper end of the melting and drilling section 2. Unlike Patent Document 1, the surface side of the skin material 1 does not melt and bulge, and the surface properties, texture, and feel of the skin material 1 can be maintained (e.g., "maintenance of surface properties"). At the same time, the molten excavation section 2 is at least thin-walled or penetrates through the surface material 1 containing thermoplastic fibers, so if a light source is placed on the back side of the molten excavation section 2 and observed from the front side, the light source on the back side can be seen, indicating that it has light transmittance, thus achieving both "maintenance of surface properties" and "light transmittance". Furthermore, the method for manufacturing the surface material 1 can also be described as "a method for manufacturing a light-transmitting surface material that maintains its surface properties." [Effects of the Invention]

[0017] According to the surface material and its manufacturing method of the present invention, by positioning the upper end of the molten material adhering to the inner surface of the molten excavation section at approximately the same height as, or lower than, the upper end of the molten excavation section in a side cross-sectional view, it is possible to achieve both "maintenance of surface properties" and "light transmittance." [Brief explanation of the drawing]

[0018] [Figure 1] This is a schematic diagram showing a surface material of the first embodiment according to the present invention, where (a) shows a side cross-sectional view and (b) shows a plan view. [Figure 2] This is a schematic diagram showing a skin material of a second embodiment according to the present invention, where (a) shows a side cross-sectional view and (b) shows a plan view. [Figure 3] This is a schematic diagram showing a surface material of a third embodiment according to the present invention, where (a) shows a side cross-sectional view and (b) shows a plan view. [Figure 4] This is a schematic diagram showing a surface material of a fourth embodiment according to the present invention, where (a) shows a side cross-sectional view and (b) shows a plan view. [Figure 5] This is a perspective view photograph showing the surface side of Example 1-1 of the surface material according to the present invention (base fabric is knitted, light colored, and melted and cut by irradiation with an ultraviolet laser). [Figure 6] This is a photograph used as a substitute for a drawing, showing a side cross-sectional view of molten material adhering to the inner surface of the molten excavation section in Example 1-1. [Figure 7] This is a perspective view photograph showing the surface side of Example 1-2 of the surface material according to the present invention (the base fabric is woven, black, and melted by irradiation with an ultraviolet laser). [Figure 8] This is a photograph used as a substitute for a drawing, showing a side cross-sectional view of molten material adhering to the inner surface of the molten excavation section in Example 1-2. [Figure 9] This is a perspective view photograph showing the surface side of Example 2 of the surface material according to the present invention (the base fabric is woven, black, and melt cutting is performed by irradiation with an infrared laser and without a melt-preventing agent). [Figure 10] This is a photograph used as a substitute for a drawing, showing a side cross-sectional view of molten material adhering to the inner surface of the molten excavation section in Example 2. [Figure 11] This is a perspective view photograph showing the surface side of Example 3 of the surface material according to the present invention (the base fabric is woven, black, and melt drilling is performed by irradiation with an infrared laser and with a melt-preventing agent). [Figure 12]In Example 3, the image is a photograph used as a substitute for a drawing, showing a side cross-sectional view of molten material adhering to the inner surface of the molten excavation section. Figure 12 shows a side cross-sectional view of molten material adhering to the inner surface of a roughly circular molten excavation section (communication hole section), among the roughly circular and roughly linear molten excavation sections. [Figure 13] This is a photograph serving as a perspective view showing the surface side of Example 4 of the surface material according to the present invention (base fabric is knitted, light color, and melt excavation is performed by a punching machine). [Figure 14] This is a photograph used as a substitute for a drawing, showing a side cross-sectional view of molten material adhering to the inner surface of the molten excavation section in Example 4. [Figure 15] A flowchart illustrating a method for manufacturing a surface material according to the present invention, wherein (a) shows the first embodiment, (b) shows the second embodiment, (c) shows the third embodiment, (d) shows the fourth embodiment, and (e) shows the fifth embodiment. [Modes for carrying out the invention]

[0019] <Overall composition of surface material 1> Hereinafter, embodiments of the present invention will be described with reference to the drawings. Figures 1 to 14 show the surface material 1 according to the present invention, which is a sheet-like material containing thermoplastic fibers 1A.

[0020] Furthermore, thermoplastic fiber 1A is not particularly limited as long as it is a thermoplastic fiber, but may include, for example, polyester fibers such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), and polybutylene terephthalate (PBT), nylon (polyamide) fibers, polyacrylic fibers (acrylic fibers) mainly composed of polyacrylonitrile (PAN), polyolefin fibers such as polyethylene (PE) and polypropylene (PP), acetate fibers, polyurethane (PU) fibers, polyvinylidene chloride (PVDC) fibers, and polyvinyl alcohol (PVA) fibers (vinylon fibers), and other synthetic fibers, and these may be used individually or in combination.

[0021] In the present invention, "the surface material 1 contains thermoplastic fiber 1A" means that the surface material 1 contains only one thermoplastic fiber 1A, or contains multiple thermoplastic fibers 1A. Furthermore, even if the surface material 1 contains only one thermoplastic fiber 1A, if, for example, the single thermoplastic fiber 1A is meandering and overlapping and the material is a nonwoven fabric composed of a single thermoplastic fiber 1A (for example, a spunbond nonwoven fabric composed of a single filament (long fiber)), then multiple thermoplastic fibers 1A will be exposed on the inner surface 2a of the molten excavation section 2. Hereafter, the surface material 1 will be described assuming that it contains multiple thermoplastic fibers 1A. The yarn constituting the surface material 1 may be any of the following: multifilament (a yarn composed of multiple long thermoplastic fibers 1A), monofilament (a yarn composed of one long thermoplastic fiber 1A), or spun yarn (a spun yarn composed of multiple short thermoplastic fibers 1A).

[0022] The surface material 1 has a molten excavation section 2, which will be described later, and molten material 3 is attached to the inner surface 2a of the molten excavation section 2. Here, the "surface 1a" of the surface material 1 refers to one of the surfaces of the sheet-like surface material 1 excluding the end faces. If the surface material 1 includes a fuzzy fabric 4, it may also be the side with the fluff 4B. It can also be said to be the side that is exposed when used to cover car interior parts or in textile products such as shoes. Conversely, the "back surface 1b" of the surface material 1 is the other surface of the sheet-like surface material 1 excluding the end surface, and if the surface material 1 is equipped with a fuzzy fabric 4, it may be the side that does not have fuzzy fibers 4B, and can also be said to be the side that is not exposed when used to cover the interior parts of an automobile, etc.

[0023] The surface material 1 may include a fuzzy fabric 4 having a base fabric 4A (so to speak, a base fabric layer 4A') and a fluff 4B (so to speak, a fluff layer 4B'), and the base fabric 4A may be any of the woven, knitted, or nonwoven fabrics described later. In addition, a backing resin 10 may be applied to the back surface 1b side of the skin material 1 to form a backing layer 10'.

[0024] The basis weight of the skin material 1 is not particularly limited. For example, it may be 50 g / m 2 or more and 1000 g / m 2 or less. More specifically, the lower limit value may be 50 g / m 2 or more, preferably 70 g / m 2 or more, more preferably 100 g / m 2 or more, and the upper limit value may be 1000 g / m 2 or less, preferably 800 g / m 2 or less, more preferably 500 g / m 2 or less. Incidentally, each lower limit value of this basis weight may be combined with any of the upper limit values. The thickness T of the skin material 1 may also be any value. For example, it may be 0.1 mm or more and 3.0 mm or less. More specifically, the lower limit value may be 0.1 mm or more, preferably 0.2 mm or more, more preferably 0.3 mm or more, and the upper limit value may be 3.0 mm or less, preferably 2.7 mm or less, more preferably 2.5 mm or less. Incidentally, each lower limit value of this thickness T may be combined with any of the upper limit values. Incidentally, for the measurement of the thickness T of the skin material 1 in the present invention and the thicknesses of the base fabric layer 4A', the fluff layer 4B', the backing layer 10', etc. described later, visual determination at a predetermined magnification in an electron microscope may also be used.

[0025] <Melting and excavation part 2> As shown in FIGS. 1 to 14, the melting and excavation part 2 is a part that is melted from the surface 1a of the above-described skin material 1 and excavates at least a part of the skin material 1. The melting and excavation part 2 may communicate from the surface 1a to the back surface 1b of the skin material 1 (the surface 1a side and the back surface 1b side of the skin material 1 may be connected by the melting and excavation part 2 so that gas or the like can freely flow). Conversely, it may not communicate (that is, it may be in a thin-walled shape with a thickness thinner than the part other than the melting and excavation part 2 and may also be said to be bottomed). Furthermore, there are no particular limitations on the plan view shape of the molten drilling section 2; for example, it may be roughly hole-shaped, or it may be any other shape besides roughly hole-shaped. Therefore, the molten excavation section 2 has communication and a plan view shape, <1> In the first embodiment, which is interconnected and substantially perforated (i.e., the connecting hole portion 2A described later, see Figure 1, etc.), <2> A second embodiment (see Figure 2, etc.) has a shape that is in communication and not substantially perforated, <3> A third embodiment (see Figure 3, etc.) that is not connected and is substantially perforated, <4> This includes four embodiments of the fourth embodiment (see Figure 4, etc.) which are not interconnected and have a shape other than a substantially perforated shape.

[0026] In a side cross-sectional view of the surface material 1 of the molten excavation section 2, the upper end 3J of the molten material 3 adhering to the inner surface 2a of the molten excavation section 2 is located at approximately the same height as the upper end 2J of the molten excavation section 2, or below the upper end 2J of the molten excavation section 2. Here, the term "upper end" in this invention refers to the end portion on the surface 1a side of the skin material 1 that is furthest from the back surface 1b of the skin material 1. This "upper end" may also be determined by cutting the portion of the skin material 1 that includes the molten excavation portion 2 to expose the side cross-section, and then using a photograph (such as a photograph taken with a scanning electron microscope, SEM) to show the exposed side cross-section. Furthermore, in this invention, "approximately the same height" means that the distance from the back surface 1b of the surface material 1 is approximately the same. This "approximately the same height" can also be determined by cutting the portion of the surface material 1 that includes the molten excavation section 2 to expose the side cross-section, and judging from a photograph that serves as a substitute for a drawing of the exposed side cross-section. In this judgment, the photograph that serves as a substitute for a drawing of the side cross-section will be used to compare multiple "upper ends" and will not only include cases where the distance from the back surface 1b of the surface material 1 is exactly the same, but will also include cases where the difference in the distance from the back surface 1b of the surface material 1 is less than or equal to a predetermined unit (such as 10 μm or 1 μm). Furthermore, in this invention, "below" means being closer to the back surface 1b of the surface material 1. This "below" can also be determined by cutting the portion of the surface material 1 that includes the molten excavation section 2 to expose the side cross-section, and using a photograph that serves as a substitute for a drawing of the exposed side cross-section. In this determination, taking into account the "approximately the same height" in this invention described above, it can also be said that in the photograph that serves as a substitute for a drawing of the side cross-section, the difference in the distance from the back surface 1b of the surface material 1 when comparing multiple "upper ends" is greater than a predetermined unit. Based on these, the statement in the present invention that "in a side cross-sectional view of the surface material 1 of the molten excavation section 2, the upper end 3J of the molten material 3 attached to the inner surface 2a of the molten excavation section 2 is located at approximately the same height as the upper end 2J of the molten excavation section 2, or below the upper end 2J of the molten excavation section 2" means that when the portion of the surface material 1 including the molten excavation section 2 is cut to expose the side cross-section, and when the exposed side cross-section is viewed from the side of the side cross-section, the upper end 3J of the molten material 3 is located at approximately the same height as the upper end 2J of the molten excavation section 2, or the upper end 3J of the molten material 3 is located below the upper end 2J of the molten excavation section 2. Conversely, it can also be said that when the portion including the molten excavation section 2 is cut and the exposed side cross-section is viewed from the side of the side cross-section, the upper end 3J of the molten material 3 is not located above the upper end 2J of the molten excavation section 2. Furthermore, in a single molten excavation section 2, the statement that "the upper end 3J of the molten material 3 is located at approximately the same height as the upper end 2J of the molten excavation section 2, or below the upper end 2J of the molten excavation section 2" means that at any point in the circumferential direction of a plan view of the single molten excavation section 2, "the upper end 3J of the molten material 3 is located at approximately the same height as the upper end 2J of the molten excavation section 2, or below the upper end 2J of the molten excavation section 2."

[0027] Furthermore, if the surface material 1 is equipped with a fuzzy fabric 4 as described later, in a side cross-sectional view of the surface material 1 of the molten excavation section 2, the upper end 4BJ of the fluff 4B of the fuzzy fabric 4 can be said to be the upper end 2J of the molten excavation section 2, and in a side cross-sectional view of the surface material 1 of the molten excavation section 2, the upper end 3J of the molten material 3 adhering to the inner surface 2a of the molten excavation section 2 may be located below the upper end 4BJ of the fluff 4B. Furthermore, in the present invention, "when the surface material 1 is equipped with a fuzzy fabric 4, in a side cross-sectional view of the surface material 1 of the molten excavation section 2, the upper end 3J of the molten material 3 attached to the inner surface 2a of the molten excavation section 2 is located below the upper end 4BJ of the fluff 4B" means that when the portion of the surface material 1 including the molten excavation section 2 is cut to expose the side cross-section, and when the exposed side cross-section is viewed from the side of the side cross-section, the upper end 3J of the molten material 3 is located below the upper end 2J of the molten excavation section 2, which is the upper end 4BJ of the fluff 4B. Conversely, when the portion including the molten excavation section 2 is cut and the exposed side cross-section is viewed from the side of the side cross-section, the upper end 3J of the molten material 3 is not at approximately the same height as the upper end 4BJ of the fluff 4B, and the upper end 3J of the molten material 3 is not located above the upper end 4BJ of the fluff 4B. Here, in this invention, "upper end 4BJ of the fluff 4B" can also be said to mean the upper end (the uppermost point in a side cross-sectional view) of the fluff layer 4B' of the fluffed fabric 4 described later. In addition, in the fluffed fabric 4, the angle (vertical angle) formed by the surface of the base fabric 4A and the length direction of the fluff 4B is 0° or more and 90° or less. For example, if the vertical angle is 90° (45° or more and 90° or less), then the upper end 4BJ of the fluff 4B can mean the tip (fiber end) of the fluff 4B. Alternatively, the vertical angle may be 0° or more and less than 45°, or 10° or more and less than 45°, and if the vertical angle is 0° (0° or more and less than 45°), the tip of the fluff 4B may be drooping. Therefore, the upper end 4BJ of the fluff 4B can also be said to mean the uppermost point in a side cross-sectional view of a predetermined number of fluff 4B.

[0028] Furthermore, the "inner surface 2a" of the molten excavation section 2 refers to the surface exposed on the side of the excavated (disappeared) portion (so to speak, the inside) in the molten excavation section 2 (in other words, the part of the skin material 1 that has disappeared) where the skin material 1 has been melted from the surface 1a and excavated to at least a part of the skin material 1, and it can be said to be a surface that extends in the thickness T direction of the skin material 1. In particular, as mentioned above <1> or <3> As shown above, if the plan view shape of the molten excavation section 2 is roughly hole-like, then the "inner surface 2a" is the surface along the circumferential direction of the roughly hole-like molten excavation section 2 in a plan view of the surface material 1. Therefore, the "inner surface 2a" of the molten excavation section 2 can also be said to be the "inner circumferential surface 2a". Also, as mentioned above <3> or <4> As shown above, if the molten drilling section 2 does not connect the surface 1a to the back surface 1b of the skin material 1 (i.e., the molten drilling section 2 has a bottom surface 2b), then the "inner surface 2a" of the molten drilling section 2 is the surface between the bottom surface 2b of the molten drilling section 2 and the surface 1a of the skin material 1 other than the molten drilling section 2, and can also be said to be the surface that surrounds the bottom surface 2b of the molten drilling section 2 when viewed from the surface 1a of the skin material 1. In other words, if the molten drilling section 2 does not connect, the "inner surface 2a" of the molten drilling section 2 does not include the bottom surface 2b of the molten drilling section 2.

[0029] <Molten hole-shaped molten excavation section 2> The plan view shape of the molten excavation section 2 described above is as follows: <1> or <3> In the case of a roughly perforated hole, the specific plan view shape of the roughly perforated molten excavation section 2 is not particularly limited, but may be, for example, roughly circular or roughly elliptical, or it may be roughly square, roughly rectangular, roughly trapezoidal, roughly triangular, roughly pentagonal, roughly hexagonal, etc. The size of the roughly perforated molten drilling section 2 is not particularly limited, but for example, the longest opening distance in any of the roughly perforated molten drilling section 2 openings may be 0.10 mm or more and 20.00 mm or less. More specifically, the lower limit may be 0.10 mm or more, preferably 0.15 mm or more, and even more preferably 0.20 mm or more, and the upper limit may be 20.00 mm or less, preferably 10.00 mm or less, even more preferably 5.00 mm or less, and even more preferably 3.00 mm or less. Note that each of these lower limits of the opening distance may be combined with any of the upper limits. Hereafter, the plan view shape of the roughly bore-shaped molten drilling section 2 will be described assuming that it is mainly a roughly circular bore. The diameter of the roughly circular molten drilling section 2 is not particularly limited, but may be, for example, 0.10 mm or more and 20.00 mm or less. More specifically, the lower limit may be 0.10 mm or more, preferably 0.15 mm or more, and even more preferably 0.20 mm or more, and the upper limit may be 20.00 mm or less, preferably 10.00 mm or less, even more preferably 5.00 mm or less, and even more preferably 3.00 mm or less. Note that each of these lower limits of diameter may be combined with any of the upper limits.

[0030] These molten excavation sections 2, which are roughly circular in shape, are formed in multiple or just one manner for each surface material 1. Furthermore, if multiple molten excavation sections 2 are formed on a single surface material 1, the statement "the upper end 3J of the molten material 3 is located at approximately the same height as the upper end 2J of the molten excavation section 2, or below the upper end 2J of the molten excavation section 2" means that in at least one of the multiple molten excavation sections 2, "the upper end 3J of the molten material 3 is located at approximately the same height as the upper end 2J of the molten excavation section 2, or below the upper end 2J of the molten excavation section 2." Hereinafter, it will be described that the molten excavation sections 2, which are generally circular in shape, are mainly formed in multiples for each surface material 1. The molten excavation section 2, which is roughly circular in shape, may be formed in multiples only within a predetermined range in a plan view of the surface material 1, and this predetermined range may be formed in only one or multiple locations within the surface material 1. Furthermore, as shown in Figures 1 and 3, if a light-emitting device (not shown) is placed on the back surface 1b of the surface material 1, which covers a predetermined area in a plan view where multiple roughly circular holes or the like molten excavation sections 2 are formed, the light from the light-emitting device will pass through the multiple molten excavation sections 2 and will be easily visible from the surface surface 1a of the surface material 1. Therefore, the predetermined area can also be said to be a light-transmitting section 2X. On the other hand, in a single surface material 1, since the parts other than the light-transmitting parts 2X do not have molten drilled parts 2 which are roughly circular holes or the like formed thereon, even if a light-emitting device is placed on the back surface 1b side of the surface material 1, it can be said that the light from the light-emitting device does not pass through the surface material 1, and it is difficult to see from the front surface 1a side of the surface material 1, so the parts other than the light-transmitting parts 2X can also be said to be non-light-transmitting parts 2Y. Hereafter, we will assume that mainly only one light-transmitting portion 2X is formed per surface material 1.

[0031] The light-transmitting portion 2X may be formed over substantially the entire surface material 1 (i.e., the non-light-transmitting portion 2Y may not be formed), or it may be formed on a part of the surface material 1 (i.e., both the light-transmitting portion 2X and the non-light-transmitting portion 2Y may be formed). The planar shape of the light-transmitting portion 2X can be any shape, for example, it may be roughly rectangular, roughly square, roughly elliptical, roughly circular, roughly triangular, roughly pentagonal, or roughly hexagonal. When the planar shape of the light-transmitting portion 2X is substantially rectangular, there are no particular limitations on the size of its long and short sides. For example, the long side may be 50 mm or more and 500 mm or less, and more specifically, the lower limit may be 50 mm or more, preferably 100 mm or more, and even more preferably 150 mm or more, and the upper limit may be 500 mm or less, preferably 450 mm or less, even more preferably 400 mm or less, and even more preferably 350 mm or less. The short side may be 10 mm or more and 100 mm or less, and more specifically, the lower limit may be 10 mm or more, preferably 15 mm or more, even more preferably 20 mm or more, and the upper limit may be 100 mm or less, preferably 90 mm or less, even more preferably 80 mm or less, and even more preferably 70 mm or less. Note that these lower limits for the long and short sides may be combined with any of the upper limits. The arrangement of the multiple approximately circular holes or the like within the light-transmitting section 2X is not particularly limited, but for example, they may be formed at predetermined intervals (predetermined pitches) intersecting approximately orthogonally (i.e., in a grid pattern) vertically and horizontally (i.e., approximately along the long and short sides of the approximately rectangular light-transmitting section 2X), or they may be formed at predetermined intervals intersecting approximately orthogonally (i.e., in a staggered pattern) diagonally (i.e., diagonally to the long and short sides of the approximately rectangular light-transmitting section 2X). The spacing between adjacent molten drilling sections 2, which are roughly circular holes or the like, within the light-transmitting section 2X is not particularly limited, but may be, for example, 0.3 mm or more and 10.0 mm or less. More specifically, the lower limit may be 0.3 mm or more, preferably 0.5 mm or more, and even more preferably 0.7 mm or more, and the upper limit may be 10.0 mm or less, preferably 5.0 mm or less, even more preferably 4.0 mm or less, and even more preferably 3.0 mm or less. Note that each of these lower limits may be combined with any of the upper limits.

[0032] <Molten drilling section 2, which has a shape other than a roughly hollow hole> On the other hand, the plan view shape of the molten excavation section 2 is as described above. <2> or <4> There are no particular limitations on shapes other than the roughly perforated shape, but for example, they may be roughly linear (see parts of Figures 4 and 11), roughly L-shaped or other letter-like shapes (see Figure 4), or roughly rectangular (see parts of Figures 2 and 11), or they may be characters (such as kanji, hiragana, katakana, English letters (European letters, alphabet), or characters from other countries), numbers, symbols, or patterns (for example, instruments and meters installed on the instrument panel, control panel, console box, ornament (door trim), dashboard, glove box, etc. in automobiles, or warning lights, scales, marks, etc. that indicate the status and function of the automobile). The planar area of ​​the molten drilling section 2, which has a shape other than a roughly hole-like shape, is not particularly limited, but for example, 10 mm 2 5000mm or more 2 The following is also acceptable, and to elaborate further, the lower limit is 10 mm 2 Preferably 20 mm 2 More preferably 30 mm2 The value is greater than or equal to 5000mm. 2 Preferably 4000mm 2 More preferably 3000mm 2 More preferably, 2000 mm 2 The following are also acceptable. Furthermore, each of these lower limits for the planar area may be combined with any of the upper limits. There are no particular limitations on the number of molten excavation sections 2 that have a shape other than a roughly perforated hole; for example, there may be one or multiple sections in a single surface material 1. If there are multiple molten drilling sections 2 that have a shape other than a roughly hollow hole, these multiple molten drilling sections 2 that have a shape other than a roughly hollow hole may be adjacent to each other (as a single unit) to represent a single word (English word), a single kanji, hiragana, katakana, symbol, or pattern.

[0033] <Side cross-sectional view of molten excavation section 2, etc.> The side cross-sectional shape of the molten excavation section 2 described above is as follows: <1> ~ <4> Regardless of which case it is, there are no particular limitations, but for example, the size of the molten excavation section 2 in a plan view may change as it moves from the surface 1a to the back 1b of the skin material 1, such as being roughly linear (the size of the molten excavation section 2 in a plan view is roughly constant from the surface 1a to the back 1b of the skin material 1), or being roughly tapered (the size of the molten excavation section 2 in a plan view gradually increases from the surface 1a to the back 1b of the skin material 1). Furthermore, the molten excavation section 2 may have the same side cross-sectional shape on one side (such as the left side in the substitute photograph for the side view drawing) and the same side cross-sectional shape on the other side (such as the right side in the substitute photograph for the side view drawing), but it may also be different (in other words, asymmetrical).

[0034] In particular, the molten drilling section 2 is as described above. <3> or <4> In cases where there is no communication, the thickness T' of the area where the non-communicating (having a bottom surface 2b) molten excavation section 2 exists (also called a bottomed section or thin-walled section 2') will naturally be thinner than the thickness T of the surface material 1 described above, by the amount that has been excavated. There are no particular limitations on the specific value of the thickness T' of the thin-walled section 2', but for example, it may be 0.1 mm or more and 0.5 mm or less. More specifically, the lower limit may be 0.1 mm or more, preferably 0.2 mm or more, and the upper limit may be 0.5 mm or less, preferably 0.4 mm or less. Note that each of these lower limits of thickness T' may be combined with any of the upper limits. Furthermore, the thickness T' of the thin-walled section 2' may be a constant value (constant thickness) in one molten excavation section 2, but conversely, it does not have to be a constant value (constant thickness); for example, it may be a partially different thickness T'. In the case of partially different thicknesses T', the side cross-sectional shape of the non-connecting molten excavation sections 2 can be said to be a stepped (stepped) shape that tapers approximately towards the back surface 1a from the back surface 1b in one non-connecting molten excavation section 2. On the other hand, the thickness T" of the areas where there are no non-communicating molten excavation sections 2 (also called non-thin-walled sections 2") is not particularly limited, but may be, for example, 1.0 mm or more and 3.0 mm or less. More specifically, the lower limit may be 0.1 mm or more, preferably 0.2 mm or more, and even more preferably 0.3 mm or more, and the upper limit may be 3.0 mm or less, preferably 2.7 mm or less, and even more preferably 2.5 mm or less. Note that each lower limit of this thickness T" may be combined with any of the upper limits. Here, the thickness T" of this non-thin-walled section 2" can also be said to be the thickness T of the surface material 1 described above. Furthermore, the difference ΔT between the thickness T' of the thin-walled section 2' and the thickness T' of the non-thin-walled section 2'' is not particularly limited, but may be, for example, 0.5 mm or more and 2.9 mm or less. More specifically, the lower limit may be 0.5 mm or more, preferably 0.7 mm or more, and even more preferably 0.9 mm or more, and the upper limit may be 2.9 mm or less, preferably 2.6 mm or less, and even more preferably 2.3 mm or less. Note that each lower limit of this difference ΔT may be combined with any of the upper limits. In addition, the thickness T' of the thin-walled section 2' may be expressed as a ratio to the thickness T' of the non-thin-walled section 2''. There are no particular limitations on this ratio, but for example, the thickness T' of the thin-walled section 2' may be greater than 0% and 50% or less of the thickness T' of the non-thin-walled section 2''. More specifically, the lower limit may be greater than 0%, preferably 5% or more, more preferably 10% or more, and even more preferably 15% or more, while the upper limit may be 50% or less, preferably 40% or less, even more preferably 30% or less, and even more preferably 20% or less. Note that each lower limit of this ratio may be combined with any of the upper limits. The following describes the melting and excavation section 2, mainly: <1> This will be described as the first embodiment, which is a connecting and substantially perforated hole (i.e., the connecting hole portion 2A described later).

[0035] <Communication hole 2A> As shown in Figures 1 to 14, the communication hole portion 2A is a portion that connects the surface 1a to the back surface 1b of the surface material 1 described above, and its plan view shape is roughly that of a hole. Multiple communication holes 2A may be formed in a predetermined area (so to speak, the light-transmitting portion 2X described above) in a plan view of the surface material 1. Furthermore, if the surface material 1 has a backing layer 10' described later, the communication hole 2A will also penetrate the backing layer 10', and if the surface material 1 has a fuzzy fabric 4 described later, the communication hole 2A will also penetrate the base fabric layer 4A' and the fuzzy layer 4B'. Furthermore, the plan view shape of the communication hole 2A may be approximately circular, and in this case, the diameter of the communication hole 2A may be 0.1 mm or more and 3.0 mm or less. Further details regarding the communication hole 2A are as described above. <1> This is similar to the first embodiment, which is interconnected and has a substantially perforated shape.

[0036] <Molten material 3> As shown in Figures 1 to 14, the molten material 3 is attached to the inner surface 2a of the molten excavation section 2 described above, and may also be attached across multiple thermoplastic fibers 1A exposed on the inner surface 2a. In addition, the molten material 3 may be attached to the bottom surface 2b of the molten excavation section 2, or it may be attached across multiple thermoplastic fibers 1A exposed on the bottom surface 2b, or it may be attached from the inner surface 2a to the bottom surface 2b of the molten excavation section 2. In the present invention, "molten material 3" can be said to be a substance formed when multiple thermoplastic fibers 1A are melted and then solidified. As a result, the cross-sectional area of ​​the molten material 3 (the area in the side view direction of the molten excavation section 2) is larger than the cross-sectional area of ​​the thermoplastic fibers 1A themselves (such as the cross-sectional area of ​​the thermoplastic fibers 1A in the part where the molten excavation section 2 is not formed), and therefore it can be said that it adheres across multiple thermoplastic fibers 1A (adjacent thermoplastic fibers 1A). The molten material 3 may include molten lumps (molten material that has taken on a lumpy shape (such as a roughly spherical or ellipsoidal shape)) 3A, molten surfaces (molten material 3 that has spread in a planar manner over a predetermined area along the inner surface 2a or bottom surface 2b of the molten excavation section 2, etc., in a planar or side view of the molten excavation section 2) 3B, etc. Furthermore, when molten material 3 adheres across multiple thermoplastic fibers 1A on the inner surface 2a or bottom surface 2b of the molten excavation section 2, it can be said that the molten material 3 suppresses the unraveling or scattering of the multiple thermoplastic fibers 1A (i.e., the molten excavation section 2 and the surface material 1 become stronger).

[0037] The size of the molten mass 3A may be such that it covers the cross-sectional area of ​​at least two single thermoplastic fibers 1A, or, if large enough, it may cover the cross-sectional area of ​​a yarn composed of two or more thermoplastic fibers 1A (for example, a yarn composed of multiple long thermoplastic fibers 1A). If the molten mass 3A is approximately spherical, its diameter is not particularly limited, and if it is approximately ellipsoidal, its major axis is not particularly limited, but for example, it may be 5 μm or more and 100 μm or less. More specifically, the lower limit may be 5 μm or more, preferably 10 μm or more, and even more preferably 15 μm or more, and the upper limit may be 100 μm or less, preferably 80 μm or less, and even more preferably 60 μm or less. Note that each of these lower limits for the major axis may be combined with any of the upper limits. The area of ​​the molten facet 3B (the area viewed from the side if it is attached to the inner surface 2a, and the area viewed from the top if it is attached to the bottom surface 2b) is at most the size of substantially the entire inner surface 2a and bottom surface 2b of the molten excavation section 2, and it can be said that the area of ​​the molten facet 3B is at least greater than the thickness of the molten facet 3B (thickness in a side view). The area of ​​the molten facet 3B is not particularly limited, but for example, it is 10 mm², similar to the planar area of ​​the molten excavation section 2 described above. 2 5000mm or more 2 The following is also acceptable, and to elaborate further, the lower limit is 10 mm 2 Preferably 20 mm 2 More preferably 30 mm 2 The value is greater than or equal to 5000mm. 2 Preferably 4000mm 2 More preferably 3000mm 2 More preferably, 2000 mm 2 The following are also acceptable. Furthermore, each of these lower limits for area may be combined with any of the upper limits. The thickness of the molten facet 3B is not particularly limited, but for example, it may be between 5 μm and 300 μm. More specifically, the lower limit may be 5 μm or more, preferably 10 μm or more, and even more preferably 15 μm or more, while the upper limit may be 300 μm or less, preferably 200 μm or less, and even more preferably 100 μm or less. Note that each of these lower limits of thickness may be combined with any of the upper limits. There is no particular limit to the number of molten materials 3 (such as molten lumps 3A and molten faces 3B) described above; for example, there may be one or multiple molten excavation sections 2.

[0038] <Aribori fabric 4> As shown in Figures 1-14, the fuzzy fabric 4 comprises a base fabric 4A (described later) and a pile 4B (described later). Here, the "side of the fuzzy fabric 4 where the fluff 4B is provided (so to speak, the fuzzy side)" can also be said to be the side that is closer to the surface 1a that is exposed when the surface material 1 is used to cover the interior parts of an automobile, etc. Conversely, the "back side (so to speak, the reverse side)" of the fuzzy fabric 4 can be said to be the side that is close to the back side 1b that is not exposed when the surface material 1 is used to cover the interior parts of an automobile, etc., and can also be said to be the back side of the base fabric 4A in the fuzzy fabric 4, which will be described later. The thickness of the fuzzy fabric 4 (which can also be said to be the sum of the thickness of the base fabric 4A and the height of the fluff 4B (the length of the perpendicular line drawn from the tip of the fluff 4B to the surface of the base fabric 4A)) is not particularly limited, but for example it may be 40 μm or more and 9000 μm or less (0.04 mm or more and 9.00 mm or less), and to elaborate further, the lower limit may be 40 μm or more, preferably 80 μm or more, and even more preferably 250 μm or more, and the upper limit may be 9000 μm or less, preferably 4500 μm or less, and even more preferably 1800 μm or less. Note that each of these lower limits of thickness may be combined with any of the upper limits.

[0039] The fibers that make up the fuzzy fabric 4 (the base fabric 4A and fluff 4B described later) are also thermoplastic fibers 1A. As mentioned above, the yarn used to make up the woolen fabric 4 can be any of the following: multifilament, monofilament, spun yarn, etc. There are no particular limitations on the fineness of the fibers constituting the woolen fabric 4 (base fabric 4A and / or fluff 4B), but for example, the total fineness may be 30 dtex or more and 500 dtex or less. More specifically, the lower limit may be 30 dtex or more, preferably 40 dtex or more, and even more preferably 50 dtex or more, and the upper limit may be 500 dtex or less, preferably 400 dtex or less, and even more preferably 350 dtex or less. Note that each of these lower limits of total fineness may be combined with any of the upper limits. Furthermore, if the yarn constituting the woolen fabric 4 (base fabric 4A and / or fluff 4B) is multifilament, there are no particular limitations on the fineness of each filament, but for example, it may be 0.1 dtex or more and 50.0 dtex or less. More specifically, the lower limit may be 0.1 dtex or more, preferably 0.5 dtex or more, and even more preferably 1.0 dtex or more, and the upper limit may be 50.0 dtex or less, preferably 30.0 dtex or less, and even more preferably 20.0 dtex or less. Note that each of these lower limits of fineness may be combined with any of the upper limits.

[0040] <Base fabric 4A> As shown in Figures 1-14, the base fabric 4A is a sheet-like material composed of thermoplastic fibers 1A in the aforementioned fuzzy fabric 4, and is also called the base fabric layer 4A'. Here, the "surface" of the base fabric 4A can also be said to be the surface close to the surface 1a that is exposed when the surface material 1 is used to cover the interior parts of an automobile, and this surface is provided with nap 4B. Conversely, the "back side" of the base fabric 4A can be said to be the side close to the back side 1b that is not exposed when the surface material 1 is used to cover the interior parts of an automobile, etc. (if the surface material 1 does not have a backing layer 10', then it is, so to speak, the back side 1b of the surface material 1 itself), and can also be said to be the back side of the aforementioned fuzzy fabric 4 itself. The thickness of the base fabric 4A is not particularly limited, but for example, it may be between 30 μm and 8500 μm (0.03 mm and 8.50 mm). More specifically, the lower limit may be 30 μm or more, preferably 60 μm or more, and even more preferably 200 μm or more, while the upper limit may be 8500 μm or less, preferably 4100 μm or less, and even more preferably 1500 μm or less. Note that each of these lower limits of thickness may be combined with any of the upper limits. The fibers constituting the base fabric 4A can be said to be the same in terms of material, composition, and fineness as those of the aforementioned fuzzy fabric 4, but they may be the same as or different from the material, composition, and fineness of the fluff 4B described later.

[0041] The base fabric 4A may be woven fabric, knitted fabric, nonwoven fabric, or a combination thereof. If the base fabric 4A is a woven fabric, there are no particular limitations on its weave structure, but it may be plain weave, twill weave, satin weave (such as five-ply satin weave or warp-shifted satin weave), double weave, or multi-layered weave (double weave or more). Furthermore, if the base fabric 4A is a knitted fabric, there are no particular limitations on the knitting structure, but it may be a warp knit such as tricot knit or a weft knit such as circular knit. Furthermore, if the base fabric 4A is a nonwoven fabric, its composition is not particularly limited, but it may be a needle-punched nonwoven fabric in which fibers are caught on reciprocating needles and intertwined with each other, a spunbond nonwoven fabric in which long fibers (filaments) spun from a nozzle are laminated and bonded on a moving screen, a thermal-bonded nonwoven fabric containing heat-fusible fibers and formed by heating, a stitch-bonded nonwoven fabric, etc., bonded by a needle-punching method. Furthermore, the base fabric 4A may be the base fabric portion (the fabric portion that supports the base end of the provided nap 4B) of a napped fabric 4 equipped with nap 4B by means other than napping, such as the moquette fabric (moquette weave) described later, or it may be suede, velour, or other materials.

[0042] <Fuzz 4B> As shown in Figures 1-14, the fluff 4B is a fiber provided on the base fabric 4A described above. Here, "provided on the base fabric 4A" means that the base end of the fluff 4B is connected to (or fixed to) the surface of the base fabric 4A, and in particular, it includes not only the case where the angle between the surface of the base fabric 4A and the length direction of the fluff 4B is approximately 90° (so to speak, this angle can also be called the vertical angle), but also the case where the length direction of the fluff 4B is oblique to the surface of the base fabric 4A, and in the case where it is oblique, the vertical angle may be, for example, 45° or more and 90° or less, preferably 60° or more and 90° or less, and even more preferably 80° or more and 90° or less. In particular, if the vertical angle is, for example, 45° or more (i.e., if the fluff 4B is erected from the base fabric 4A), the fabric with fluff 4 can also be said to be a fabric with raised fluff. Furthermore, the vertical angle may be less than 45° (i.e., 0° or more but less than 45°), or it may be 0° or more but 30° or less, 0° or more but 20° or less, 0° or more but 10° or less, or even approximately 0° (in other words, even if the fluff 4B is roughly aligned with the surface of the base fabric 4A).

[0043] The length of the fluff 4B (which can be said to be approximately the same as the height of the fluff 4B (i.e., the vertical height) when the vertical angle is approximately 90°; however, when the vertical angle is not approximately 90°, as mentioned above, the length of the perpendicular line drawn from the tip of the fluff 4B to the surface of the base fabric 4A can be said to be the height of the fluff 4B) is not particularly limited, but for example, it may be 10 μm or more and 5000 μm or less (0.010 mm or more and 5.000 mm or less), and to elaborate further, the lower limit may be 10 μm or more, preferably 15 μm or more, and even more preferably 20 μm or more, and the upper limit may be 5000 μm or less, preferably 1000 μm or less, and even more preferably 500 μm or less. Note that each of these lower limits of length may be combined with any of the upper limits. The fibers constituting the fluff 4B can be said to be the same in terms of material, composition, and fineness as those of the aforementioned fluffed fabric 4, but they may also be the same as, or different from, those of, the base fabric 4A (for example, in the moquette fabric and double raschel knit fabric described later, the outer fabric and the connecting yarn may be made of different materials).

[0044] The fluff 4B is not particularly limited as long as it is present on the base fabric 4A as described above, but it may also be the fibers of a napped fluff that is provided (erected) by raising the nap of at least one of the surface and back surface of the base fabric 4A (for example, if the base fabric 4A is a tricot knit fabric, at least one of the sinker loop surface and the needle loop surface). The napping of the base fabric 4A may be performed, for example, using a needle cloth with napping needles or an emery material such as sandpaper, or it may also be performed using a needle punch needle, a brush needle, or the like. In addition, the fuzzy fabric 4 may be a fabric that has loops, such as a sinker loop circular knit fabric, in which the loops have been cut off. This is because, instead of the aforementioned napping, the fuzzy fabric 4 has fluff 4B on the surface of the base fabric 4A (i.e., it originally has fluff 4B without napping). In this case, the cut loops are the fluff 4B, and the fabric portion that supports the base end of the cut loops is the base fabric 4A. Furthermore, the napped fabric 4 may be a moquette fabric in which the connecting threads that link the front and back fabrics are cut (center cut) instead of the napped fabric described above, or a double raschel knit fabric in which the connecting threads that link the front and back fabrics are cut. In this case, the cut connecting threads are the nap 4B, and the front or back fabric that supports the base end of the cut connecting threads is the base fabric 4A. If multiple such fluffs 4B gather together to form a layer, it can be said to be a fluff layer 4B'. In particular, when the base fabric 4A is napped to form fluff 4B in the napping process S0-2 described later, the napped fluff 4B can be said to be layered, and the value of the vertical angle of the fluff 4B is irrelevant.

[0045] <Backing resin 10> As shown in Figures 1 to 14, the backing resin 10 is a resin that covers the back surface 1b of the surface material 1 described above (in particular, the back surface of the woolen fabric 4). In other words, the backing resin 10 is attached to the back surface of the fuzzy fabric 4. The material of the backing resin 10 is not particularly limited, but may be a thermoplastic resin, such as polyacrylic resin (acrylic resin) mainly composed of polyacrylonitrile (PAN), polyurethane (PU) resin, silicone (Si) resin, or other materials such as polyvinylidene chloride (PVDC) resin, polyvinyl chloride (PVC) resin, polyethylene terephthalate (PET), polyester resins such as polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), nylon (polyamide) resin, polyolefin resins such as polyethylene (PE) and polypropylene (PP), acetate resin, polyvinyl alcohol (PVA) resin (vinylon resin), and these may be used individually or in combination. There are no particular limitations on the amount of backing resin 10 applied (adhered), but for example, 30 g / m² by dry weight. 2 More than 180g / m 2 The following is also acceptable, and to elaborate further, the lower limit is 30g / m 2 Preferably 40 g / m² 2 More preferably 50 g / m 2 If it is above that, or if the upper limit is 180g / m² 2 Preferably 170 g / m² 2 More preferably 160 g / m 2 The following are also acceptable. Furthermore, each of these lower limits for application amount may be combined with any of the upper limits.

[0046] <Backing layer 10'> As shown in Figures 1 to 14, the backing layer 10' is a layer formed of backing resin 10 that covers the back surface 1b of the surface material 1 described above (particularly the back surface of the woolen fabric 4). Here, the "surface" of the backing layer 10' can be said to be the surface close to the surface 1a that is exposed when the skin material 1 is used in textile products such as seat covers for seats (chairs) in automobiles, and conversely, the "back surface" of the backing layer 10' can be said to be the surface close to the back surface 1b that is not exposed when the skin material 1 is used in textile products such as seat covers (in other words, the back surface 1b of the skin material 1 itself). The thickness of the backing layer 10' is not particularly limited, but for example, it may be between 10 μm and 500 μm (0.01 mm and 0.50 mm). More specifically, the lower limit may be 10 μm or more, preferably 15 μm or more, and even more preferably 20 μm or more, while the upper limit may be 500 μm or less, preferably 400 μm or less, and even more preferably 300 μm or less. Note that each of these lower limits of thickness may be combined with any of the upper limits. The method for manufacturing the surface material 1 described above will now be explained in detail.

[0047] <Method for manufacturing surface material 1> As shown in Figure 15, the method for manufacturing the surface material 1 described above (hereinafter also referred to as "the manufacturing method") includes at least the melting and drilling step S1 described later. The manufacturing method may include a fabric forming process S0-1, a napping process S0-2, a cutting process S0-2', a backing process S0-3, and the like, as described later. Furthermore, in the said manufacturing method, if only the melting and drilling step S1 is included, it shall be the first embodiment; if the fabric forming step S0-1, the napping step S0-2, and the melting and drilling step S1 are included, it shall be the second embodiment; if the fabric forming step S0-1, the cutting step S0-2', and the melting and drilling step S1 are included, it shall be the third embodiment; if the fabric forming step S0-1, the napping step S0-2, the backing step S0-3, and the melting and drilling step S1 are included, it shall be the fourth embodiment; and if the fabric forming step S0-1, the cutting step S0-2', the backing step S0-3, and the melting and drilling step S1 are included, it shall be the fifth embodiment.

[0048] <Melting and drilling process S1> As shown in Figure 15, the melting and drilling process S1 is a process in which the above-mentioned surface material 1 is melted from the surface 1a to form a melting and drilling section 2 in which at least a part of the surface material 1 has been drilled. In this melting and drilling process S1, in a side cross-sectional view of the surface material 1 of the melting and drilling section 2, the upper end 3J of the molten material 3 adhering to the inner surface 2a of the melting and drilling section 2 is positioned at approximately the same height as the upper end 2J of the melting and drilling section 2, or below the upper end 2J of the melting and drilling section 2. The specific means for forming the molten excavation section 2 are not particularly limited. As a means of forming the molten excavation section 2, for example, a predetermined area of ​​the surface material 1 (so to speak, a part of the plurality of thermoplastic fibers 1A) may be melted from the surface 1a by irradiation with a laser (laser beam) to form a molten excavation section 2 in which at least a part of the surface material 1 has been excavated, or at least a part of the surface material 1 may be excavated by melting a part of the surface material 1 from the surface 1a side with a cutting tool. Furthermore, regardless of the method used, a molten excavation section 2 is formed, and at least some molten material 3 is deposited on the inner surface 2a of the molten excavation section 2. In particular, if the aforementioned molten material 3, such as "spanning multiple thermoplastic fibers 1A," is deposited on the inner surface 2a of the molten excavation section 2, it can be said that the molten excavation section 2 was formed by laser irradiation. Conversely, if the molten excavation section 2 is formed by means other than laser irradiation, it can be said that the aforementioned molten material 3 spanning multiple thermoplastic fibers 1A is not formed.

[0049] When forming the molten excavation section 2 by laser irradiation, the energy density (energy per unit area on the fabric) applied to the surface material 1, the laser output (wattage), the beam spot movement speed, the beam spot diameter, and other parameters such as the oscillation frequency and focal length may be set to predetermined values. The wavelength of the laser beam (wavelength of the emitted light) is not particularly limited, but it may be an ultraviolet (UV) laser, or any other type of laser, such as an infrared laser (carbon dioxide (CO2) laser), a visible light laser, or an X-ray laser. In particular, the mechanisms of melting and drilling into the surface material 1 differ between ultraviolet laser irradiation and infrared laser irradiation. Since the energy of laser light is inversely proportional to the wavelength of the laser, ultraviolet lasers impart more energy to the surface material 1 than other lasers, and when irradiated onto organic materials such as thermoplastic fibers 1A in the surface material 1, they directly dissociate the molecular bonds. Therefore, unlike infrared lasers, which vibrate the molecules in the thermoplastic fibers 1A of the surface material 1 and melt the surface material 1 through frictional heat, ultraviolet lasers have less thermal impact on the surface material 1. Furthermore, when laser light is focused by a lens, it is possible to narrow the beam spot diameter to approximately the wavelength of the laser light. Therefore, it can be said that lasers using ultraviolet light, which has a shorter wavelength than infrared light, can narrow the beam spot diameter even further, enabling finer melting and drilling. In this invention, "beam spot diameter" refers to the diameter of the laser beam near the focal point (near a point separated from the lens by the focal length) where the laser beam is focused by a lens with a predetermined focal length. This focal point region has a high energy density and is suitable for efficient melting processes. There are no particular limitations on the values ​​of the laser used for irradiation, but for example, an energy density of 0.20 J / cm² is acceptable. 2 More than 1.00J / cm 2 The following is also acceptable, and to elaborate further, the lower limit is 0.20 J / cm². 2 Preferably, 0.30 J / cm² 2 More preferably 0.35 J / cm² 2 If it is above that, or if the upper limit is 1.00 J / cm² 2 Preferably, 0.80 J / cm² 2 More preferably, 0.70 J / cm² 2 The following conditions may be met, and the laser output may be between 1 watt and 400 watts. More specifically, the lower limit may be 1 watt or more, preferably 5 watts or more, and even more preferably 10 watts or more, while the upper limit may be 400 watts or less, preferably 350 watts or less, and even more preferably 300 watts or less. These lower limits for energy density and laser output may be combined with any of the upper limits. Here, the laser output of the ultraviolet laser may be between 1W and 100W, and more specifically, the lower limit may be between 1W and 2W, more preferably between 3W and 100W, and the upper limit may be between 100W and 50W, more preferably between 30W and 100W. Note that each of these lower limits of the ultraviolet laser output may be combined with any of the upper limits. On the other hand, the laser output of the infrared laser may be between 10W and 400W, and more specifically, the lower limit may be between 10W and 20W, more preferably between 30W and 100W, and the upper limit may be between 400W and 400W, more preferably between 350W and 300W. Note that each of these lower limits of the infrared laser output may be combined with any of the upper limits. Furthermore, the laser beam spot may have a movement speed of 10 mm / second or more and 100 mm / second or less. More specifically, the lower limit may be 10 mm / second or more, preferably 15 mm / second or more, and more preferably 20 mm / second or more, and the upper limit may be 100 mm / second or less, preferably 80 mm / second or less, and more preferably 60 mm / second or less. The beam spot diameter may be 0.1 mm or more and 2.0 mm or less. More specifically, the lower limit may be 0.1 mm or more, preferably 0.2 mm or more, and more preferably 0.3 mm or more, and the upper limit may be 2.0 mm or less, preferably 1.5 mm or less, and more preferably 1.0 mm or less. Note that these lower limits for beam spot movement speed and beam spot diameter may be combined with any of the upper limits. In addition, the laser may form one molten drilling section 2 with a single irradiation of the surface material 1, or it may form one molten drilling section 2 with multiple irradiations. There is no particular limit to the number of laser irradiations when forming one molten drilling section 2 in the surface material 1, but for example it may be between 1 and 200 times, and more specifically, the lower limit may be between 1 and 5 times, more preferably between 10 and 10 times, and the upper limit may be between 200 and 100 times, more preferably between 50 and 50 times. Note that each of these lower limits for the number of laser irradiations may be combined with any of the upper limits. In addition, when forming the communication hole portion 2A in the molten drilling section 2, depending on the relationship between the diameter of the communication hole portion 2A and the beam spot diameter described above, the communication hole portion 2A may be formed by irradiating only the outer shape of the approximately circular hole with the laser multiple times or once to create a communication, and then hollowing out the part inside the outer shape, or by irradiating the through hole portion 2A with the laser multiple times or once over a very short distance to form the diameter of the through hole portion 2A to be almost the same size as the beam spot diameter.

[0050] Furthermore, when forming the molten excavation section 2 by laser irradiation, regardless of the type of laser (whether it is an ultraviolet laser, an infrared laser, etc.), it is also possible to apply an anti-melting agent that prevents the melting of thermoplastic fibers 1A to the surface material 1 before irradiating it with the laser beam, without having to adjust the laser output of the laser beam. The aforementioned anti-melting agent may be water, which vaporizes and evaporates upon receiving a laser beam, and cools the thermoplastic fiber 1A, which is heated by the laser beam, by absorbing the heat of vaporization. It may also contain surfactants such as sodium fatty acid salts or water-soluble organic solvents such as methanol. Furthermore, if the surface material 1 that is the target of forming the molten excavation section 2 by laser irradiation has the above-mentioned base fabric 4A and fluff 4B (it is a fluffed fabric 4), then if the vertical angle of some or all of the fluff 4B is 0° or more and less than 45° or 10° or more and less than 45° (in other words, if the fluff 4B is lying flat, bent, or slanted), it can be said that the surface properties will be easier to maintain regardless of the type of laser. In order to maintain the state in which the fluff 4B is lying flat, etc., the fluff 4B (at least a part of it from the tip side to the base end side) and the base fabric 4A may be connected with resin (so to speak, a connecting resin). In this case, the connecting resin is not particularly limited, but may include, for example, polyurethane (PU) resin, polyvinylidene chloride (PVDC) resin, acetate resin, polyvinyl alcohol (PVA) resin (vinylon resin), polyester resins such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), and polybutylene terephthalate (PBT), nylon (polyamide) resin, polyacrylic resin (acrylic resin) mainly composed of polyacrylonitrile (PAN), polyethylene (PE), polypropylene (PP), and other polyolefin resins. When forming the molten excavation section 2 by laser irradiation as described above, the laser beam may be directed at one location on the surface 1a of the skin material 1, or the location on the surface 1a of the skin material 1 may be moved in a vertical, horizontal, diagonal direction, etc. (and in a direction substantially aligned with the back surface 1b of the skin material 1) to form the molten excavation section 2 having a predetermined planar shape (such as a substantially circular hole as described above, or a substantially linear or rectangular shape, or a shape other than a substantially hole such as letters, numbers, symbols, or patterns). On the other hand, when forming the molten excavation section 2 with a cutting tool, the cutting tool may be one or more needles (for example, a needle cloth with napped needles as described later) and their tips may be applied to one location on the surface 1a side of the skin material 1, or one or more needles may be pressed against the surface 1a of the skin material 1 and finely vibrated in the vertical, horizontal, diagonal, etc. direction (and in a direction substantially along the back surface 1b of the skin material 1) to tear off a part of the skin material 1 (a part of the multiple thermoplastic fibers 1A) that is in contact with the tips of the one or more needles, thereby forming the molten excavation section 2. In this case, the location where the vibrating one or more needles touch the surface 1a side of the skin material 1 may be moved in the vertical, horizontal, diagonal, etc. direction to form the molten excavation section 2 having a predetermined planar shape. Alternatively, as the cutting tool, the tip of a blade such as a knife or an emery member described later may be applied to one spot on the surface 1a side of the surface material 1, or the tip of the blade or emery member may be pressed against the surface 1a of the surface material 1 and vibrated finely in the vertical, horizontal, or diagonal directions to tear off a part of the surface material 1 that is in contact with the tip of the blade, etc., thereby forming the molten excavation section 2. In particular, in the melting and drilling process S1, <1> or <2> When forming a molten drilled section 2 that connects the surface 1a to the back surface 1b of the outer material 1, it is also possible to form the molten drilled section 2 by connecting only the outer shape in plan view of the molten drilled section 2 and hollowing out the part inside the outer shape. In addition to the laser irradiation and cutting tools described above, if the molten drilled section 2 can be formed by means other than these, such as using a punching machine to connect the surface 1a to the back surface 1b of the outer material 1 and form the molten drilled section 2.

[0051] <Fabric forming process S0-1> As shown in Figure 15, the fabric formation process S0-1 is a process in which the aforementioned fuzzy fabric 4 is formed before the melting and excavation process S1 described above. As mentioned above, the fuzzy fabric 4 (base fabric 4A as the surface material 1 after manufacturing) may be a woven fabric, a knitted fabric, or a nonwoven fabric. If the fuzzy fabric 4 is a woven fabric, the fabric formation process S0-1 can be said to be the woven fabric weaving process S0-1. If the fuzzy fabric 4 is a knitted fabric, the fabric formation process S0-1 can be said to be the knitted fabric knitting process S0-1. If the fuzzy fabric 4 is a nonwoven fabric, the fabric formation process S0-1 can be said to be the nonwoven fabric formation process S0-1.

[0052] In the case of the weaving process S0-1, there are no particular limitations on the loom used in this process, but it may be a dobby loom, a jacquard loom, a velvet loom, a wire velvet loom, etc., and there are no particular limitations on the number of reeds in a dobby loom, for example it may be 24 dents or 27.5 dents. Furthermore, in the case of the knitting process S0-1, there are no particular limitations on the knitting machine used in this process. For example, it may be a warp knitting machine such as a tricot knitting machine or a double raschel knitting machine, or a weft knitting machine such as a circular knitting machine. There are also no particular limitations on the gauge of these warp and weft knitting machines. For example, it may be 28 gauge (28G) or 26 gauge (26G). In addition, there are no particular limitations on the speed of the warp knitting machine in the knitting process S0-1. For example, it may be 1500 rpm or higher. Furthermore, in the case of the nonwoven fabric formation process S0-1, there are no particular limitations on the manufacturing equipment used in this process. For example, it could be a needle punching machine that catches fibers with reciprocating needles to entangle them with each other, a spunbonding machine that laminates and bonds long fibers (filaments) spun from a nozzle onto a moving screen, a thermal bonding machine that forms heat-fusible fibers by heating, or equipment that bonds stitch-bonded nonwoven fabrics, etc., using the needle punching method.

[0053] If the fuzzy fabric 4 formed in the fabric formation process S0-1 does not have fluff 4B, the manufacturing method proceeds to perform a napping process S0-2, which will be described later, after the fabric formation process S0-1. Furthermore, if the fuzzy fabric 4 formed in the fabric formation process S0-1 is a moquette fabric in which the outer and inner layers are connected by connecting threads, or a double raschel knit fabric or sinker loop circular knit fabric in which the outer and inner layers are connected by connecting threads, and has nap 4B on the surface of the base fabric 4A even without being brushed, then the manufacturing method involves performing the cutting process S0-2' described later after the fabric formation process S0-1.

[0054] <Nursing process S0-2> As shown in Figure 15, the napping process S0-2 is a process in which the base fabric 4A of the napped fabric 4, which was formed in the above-described fabric forming process S0-1, is napped when the napped fabric 4 does not have fluff 4B. In the napping process S0-2, a napping process using a napping cloth (or a napping roll if it is in roll form) with napping needles may be used. In the case of napping with a napping cloth, the napping state can be adjusted by changing the density, length, angle, and tip shape of the napping cloth, as well as the number of rotations of the napping cloth, the contact pressure with the base fabric 4A, and the number of contacts. In the napping process S0-2, emery napping may be performed, and the napping state can be adjusted by changing whether it is wet or dry (wet or dry state), the emery material (sandpaper, emery roll, etc.), the processing speed, and the number of times the emery material comes into contact with the base fabric 4A. Furthermore, in the napping process S0-2, the raised fibers created by napping may be cut, and a finishing process may be performed to straighten the pile after napping. In addition, napping of the base fabric 4A may be performed using a buffing machine, a needle punch machine with needle punching needles, a brush needle, etc.

[0055] <Cutting process S0-2'> As shown in Figure 15, the cutting process S0-2' is a process in which, if the fuzzy fabric 4 formed in the fabric formation process S0-1 described above has connecting threads in a moquette fabric that can become fluff 4B, connecting threads in a double raschel knit fabric, or loops in a sinker loop circular knit fabric, the loops or connecting threads are cut. In the cutting process S0-2', when cutting loops in a sinker loop circular knit fabric, the loops may be sheared (sheared) using a shearing machine or the like to make them the desired length. Furthermore, in the cutting process S0-2', when cutting connecting threads in moquette fabric or double raschel knit fabric, the connecting threads may be center-cut using a shearing machine or the like midway between the outer fabric and the lining (for example, approximately in the middle), forming the base fabric 4A on the outer fabric and the fluff 4B with one of the center-cut connecting threads, while forming another base fabric 4A on the lining and the fluff 4B with the other center-cut connecting thread. Furthermore, the cutting of the loops and connecting threads described above, and the construction of the woolen fabric 4 described above, may be performed in a single process. In this case, the process can also be called the fabric formation and cutting process.

[0056] <Backing Process S0-3> As shown in Figure 15, the backing process S0-3 is a process of applying the backing resin 10 to the back surface 1b of the surface material 1 (the back surface of the woolen fabric 4) as described above. There are no particular restrictions on the backing process S0-3, but for example, the backing resin 10 may be applied (adhered) to the back surface of the woolen fabric 4 in an emulsion state. Here, in the backing process S0-3 as well, solvents such as organic solvents may or may not be used as the solvent in the emulsion state. The specific means of application are not particularly limited, but in addition to application by brush or spray application, methods such as the comma direct method, gravure direct method, gravure reverse method, reverse roll coating method, air knife coating method, and kiss coating method may be used, or other methods such as thin film coaters, roll printing machines, inkjet printing machines, and rotor dampening may be used. Furthermore, when applying the backing resin 10 in emulsion form, the solvent is not particularly limited as long as it is not an organic solvent or other solvent, but water may be used. In this case, the backing resin 10 to be applied will be a water-based polyacrylic resin emulsion or a water-based polyurethane resin emulsion, etc., using water as the solvent. Furthermore, if the backing process S0-3 is performed on the back surface of the woolen fabric 4, the backing resin 10 can be applied to the back surface. Therefore, the process may be performed immediately after the fabric forming process S0-1 (i.e., before the napping process S0-2 or the cutting process S0-2'), in which case it can be said that this is a different embodiment from the first to fifth embodiments described above. [Examples]

[0057] From here, we will refer to Examples 1-1 to 1-4 of the surface material 1 according to the present invention.

[0058] <Example 1-1> As shown in Figures 5 and 6, in the surface material 1 of Example 1-1, the fuzzy fabric 4 is a tricot knit fabric that has been brushed (i.e., the base fabric 4A is a knit fabric), and it is equipped with a backing layer 10' made of polyurethane resin backing resin 10. In this Example 1-1, in the melting drilling process S1, an ultraviolet (UV) laser is irradiated, melting the surface material 1 so that it is connected from the surface 1a to the back surface 1b, forming multiple molten drilled sections 2, and it can be said that molten material 3 (molten mass 3A, molten facet 3B, etc.) spanning multiple thermoplastic fibers 1A is attached to at least the inner surface 2a of each molten drilled section 2. In other words, the molten drilled sections 2 in Example 1-1 are <1> This can be described as the first embodiment, which is interconnected and has a substantially perforated shape. In the surface material 1 of Example 1-1, in a side cross-sectional view of the surface material 1 of Example 1-1 including the molten excavation section 2, the upper end 3J of the molten material 3 is located below the upper end 2J of the molten excavation section 2 (furthermore, the upper end 4BJ of the fluff 4B of the fuzzy fabric 4 is the upper end 2J of the molten excavation section 2, and in a side cross-sectional view of the surface material 1 of Example 1-1 including the molten excavation section 2, the upper end 3J of the molten material 3 is located below the upper end 4BJ of the fluff 4B). Furthermore, the surface material 1 in Example 1-1 has an overall light color (beige), a thickness of approximately 1.00 mm, and a basis weight of approximately 516 g / m². 2 (The basis weight, excluding the 10' backing layer described later, is approximately 456g / m²) 2 ) The plan view shape of the molten drilling section 2 is such that multiple roughly circular holes (communication holes 2A) with a diameter of approximately 1.00 mm intersect roughly orthogonally (in a staggered pattern), with intervals of approximately 5.00 mm along each side of the square and approximately 8.00 mm along the diagonal of the square (more precisely, the interval corresponding to each side of a square formed by four adjacent communication holes 2A is approximately 5.00 mm, and the interval corresponding to the diagonal of the square is approximately 8.00 mm). Each communication hole 2A in Example 1-1 is formed by irradiating only the roughly circular outer shape with an ultraviolet laser multiple times (for example, 25 times) to create communication, and then hollowing out the part inside the outer shape. The laser output of the ultraviolet laser is 5 W (watts). In this example, the tricot knit fabric that becomes the woolen fabric 4 in Example 1-1 is knitted in the fabric formation (knitting) process S0-1 by repeatedly operating the first reed in the order of 1-0 / 1-2 on a 28 gauge, three-reed warp knitting machine to knit polyester multifilament yarn (total fineness 84 dtex, single fiber fineness approximately 7.00 dtex), repeatedly operating the second reed in the order of 1-0 / 3-4 to knit polyester multifilament yarn (total fineness 33 dtex, single fiber fineness approximately 2.75 dtex), and repeatedly operating the third reed in the order of 1-0 / 3-4 to knit polyester multifilament yarn (a yarn made by combining yarn with a total fineness of 80 dtex and a single fiber fineness of approximately 0.185 dtex and yarn with a total fineness of 30 dtex and a single fiber fineness of approximately 2.50 dtex). Furthermore, the tricot knit fabric that becomes the woolen fabric 4 in Example 1-1 has a wale density (warp density) of approximately 25 wales (threads) / inch and a course density (weft density) of approximately 80 courses (threads) / inch on the machine. In Example 1-1, after the fabric formation process S0-1, the sinker loop surface of the tricot knit fabric is brushed in the napping process S0-2 to create a napped fabric 4 with nap 4B provided on the base fabric 4A, and the backing layer 10' is formed in the backing process S0-3.

[0059] <Examples 1-2> As shown in Figures 7 and 8, the surface material 1 of Example 1-2 was obtained by changing the overall color to black, making the fuzzy fabric 4 a napped satin weave fabric (i.e., the base fabric 4A is a woven fabric), and adding a backing layer 10' composed of a polyacrylic resin backing resin 10, and creating a shape in which multiple roughly circular holes (communicating holes 2A) with a diameter of approximately 10.00 mm are formed at intervals of approximately 15.00 mm. In other words, the molten excavation section 2 in Example 1-2 was also <1> This can be described as the first embodiment, which is interconnected and has a substantially perforated shape. In the surface material 1 of Example 1-2, as seen in a side cross-sectional view of the surface material 1 of Example 1-2 including the molten excavation section 2, the upper end 3J of the molten material 3 is located below the upper end 2J of the molten excavation section 2 (furthermore, the upper end 4BJ of the fluff 4B of the fuzzy fabric 4 is the upper end 2J of the molten excavation section 2, and as seen in a side cross-sectional view of the surface material 1 of Example 1-2 including the molten excavation section 2, the upper end 3J of the molten material 3 is located below the upper end 4BJ of the fluff 4B). Furthermore, the surface material 1 in Examples 1-2 has a basis weight of approximately 395 g / m². 2 (The basis weight, excluding the 10' backing layer described later, is approximately 345g / m²) 2 ) In this example, the satin weave fabric that becomes the woolen cloth 4 in Example 1-2 is woven in the fabric formation (weaving) process S0-1 on a dobby loom using polyester multifilament yarn (total fineness 117 dtex with single fiber fineness of approximately 0.20 dtex) as the warp threads and polyester multifilament yarn (total fineness 167 dtex with single fiber fineness of approximately 3.50 dtex) as the weft threads. Furthermore, the satin weave fabric that becomes the woolen cloth 4 in Examples 1-2 has a warp density of approximately 130 threads / inch and a weft density of approximately 55 threads / inch on the loom.

[0060] <Example 2> As shown in Figures 9 and 10, the surface material 1 of Example 2 was obtained by changing the overall color to black, changing the irradiation of the ultraviolet (UV) laser in the melting and drilling process S1 to the irradiation of an infrared laser (CO2 laser), and further changing the fluffy fabric 4 to a satin weave fabric (i.e., the base fabric 4A is a woven fabric) and providing a backing layer 10' composed of a polyacrylic resin backing resin 10, and changing the plan view shape of the melting and drilling section 2 to a shape in which multiple substantially circular holes (communicating holes 2A) with a diameter of approximately 0.35 mm are formed in a grid pattern at intervals of approximately 1.00 mm. In other words, the melting and drilling section 2 in Example 2 is also <1> This can be described as the first embodiment, which is interconnected and has a substantially perforated shape. In the skin material 1 of Example 2, as seen in a side cross-sectional view of the skin material 1 of Example 2 including the molten excavation section 2, the upper end 3J of the molten material 3 is located below the upper end 2J of the molten excavation section 2 (furthermore, the upper end 4BJ of the fluff 4B of the fuzzy fabric 4 is the upper end 2J of the molten excavation section 2, and as seen in a side cross-sectional view of the skin material 1 of Example 2 including the molten excavation section 2, the upper end 3J of the molten material 3 is located below the upper end 4BJ of the fluff 4B). Furthermore, the surface material 1 in Example 2 has a basis weight of approximately 395 g / m². 2 (The basis weight, excluding the 10' backing layer described later, is approximately 345g / m²) 2 In Example 2, each communication hole 2A is formed by irradiating a 0.10 mm line segment with an infrared laser having a beam spot diameter of 0.30 mm once, and the laser output of the infrared laser is 28 W. In this example, the satin weave fabric that becomes the woolen cloth 4 in Example 2 is woven in the fabric formation (weaving) process S0-1 on a dobby loom using polyester multifilament yarn (total fineness 117 dtex with single fiber fineness of approximately 0.20 dtex) as the warp threads and polyester multifilament yarn (total fineness 167 dtex with single fiber fineness of approximately 3.50 dtex) as the weft threads. Furthermore, the satin weave fabric that becomes the woolen cloth 4 in Example 2 has a warp density of approximately 130 threads / inch and a weft density of approximately 55 threads / inch on the loom.

[0061] <Example 3> As shown in Figures 11 and 12, the surface material 1 of Example 3 was obtained by changing the irradiation of the ultraviolet (UV) laser in the melting and drilling process S1 to the irradiation of an infrared laser (CO2 laser) after applying water, which is a melt-resistant agent, to the surface material 1 of Example 1-2, and by changing the plan view shape of the melting and drilling section 2 to a shape in which multiple substantially circular holes (connecting holes 2A) with diameters gradually increasing from approximately 0.80 mm to approximately 1.50 mm are intersected in a staggered pattern, with intervals of approximately 5.00 mm on each side of the square and approximately 8.00 mm on the diagonal of the square, and by surrounding these multiple staggered connecting holes in a substantially rectangular shape with substantially linear shapes that do not connect to each other. In other words, the melting and drilling section 2 in Example 3 is a melting and drilling section 2 with substantially circular holes. <1> This is the first embodiment, which is connected and substantially hole-shaped, and the substantially linear molten excavation section 2 <3> This can be described as a third embodiment, which is a substantially perforated shape used without communication. In the surface material 1 of Example 3, as seen in a side cross-sectional view of the surface material 1 of Example 3 including the molten excavation section 2, the upper end 3J of the molten material 3 is located below the upper end 2J of the molten excavation section 2. (Furthermore, the upper end 4BJ of the fluff 4B of the fuzzy fabric 4 is the upper end 2J of the molten excavation section 2, and as seen in a side cross-sectional view of the surface material 1 of Example 3 including the molten excavation section 2, the upper end 3J of the molten material 3 is located below the upper end 4BJ of the fluff 4B.) In Example 3, each communication hole 2A is formed by gradually changing the beam spot diameter of the infrared laser to be approximately equal to the diameter of the communication hole 2A, from approximately 0.80 mm to approximately 1.50 mm, and connecting only the outer, approximately circular shape of each communication hole 2A by irradiating it once with the infrared laser, then hollowing out the part inside the outer shape. The laser output of the infrared laser is 36 W.

[0062] <Example 4> As shown in Figures 13 and 14, the surface material 1 of Example 4 was obtained by changing the irradiation of the ultraviolet (UV) laser in the melting and drilling process S1 to the use of a punching machine (punching) for the surface material 1 of Example 1-1, and by making the plan view shape of the melting and drilling section 2 such that multiple roughly circular holes (communicating holes 2A) with a diameter of approximately 1.00 mm intersect in a staggered pattern, with spacing of approximately 2.00 mm on each side of the square and approximately 4.00 mm on the diagonal of the square. In other words, the melting and drilling section 2 in Example 4 is also <1> This can be described as the first embodiment, which is interconnected and has a substantially perforated shape. In the surface material 1 of Example 4, a punching machine was used, and as shown in Figure 15, it can be seen that molten material 3 is adhering to the inner surface 2a of the molten excavation section 2. Furthermore, in the surface material 1 of Example 4, in a side cross-sectional view of the surface material 1 of Example 4 including the molten excavation section 2, the upper end 3J of the molten material 3 is located below the upper end 2J of the molten excavation section 2 (and furthermore, the upper end 4BJ of the fluff 4B of the fuzzy fabric 4 is the upper end 2J of the molten excavation section 2, so in a side cross-sectional view of the surface material 1 of Example 4 including the molten excavation section 2, the upper end 3J of the molten material 3 is located below the upper end 4BJ of the fluff 4B).

[0063] <Other> The present invention is not limited to the embodiments described above. The structure, shape, dimensions, and other components of the surface material 1, the method for manufacturing the surface material 1, and the overall structure can be modified as appropriate in accordance with the spirit of the present invention. The surface material 1 may contain non-thermoplastic fibers (such as thermosetting fibers, glass fibers, wool, silk, rayon fibers, or cupro fibers) in addition to thermoplastic fibers 1A. The surface material 1 does not necessarily have to be a fuzzy fabric 4 (i.e., it does not have to be a fluffy surface 4B) (see Figure 4). In that case, the upper end 2J of the molten excavation section 2 can be said to be the upper end (i.e., the upper end 4AJ) of the surface material 1 itself (i.e., the base fabric 4A itself). In a side cross-sectional view of the surface material 1 of the molten excavation section 2, it is not particularly necessary for the upper end 3J of the molten material 3 attached to the inner surface 2a of the molten excavation section 2 to be at approximately the same height as the upper end 2J of the molten excavation section 2. Furthermore, if the surface material 1 is equipped with a fuzzy fabric 4, in a side cross-sectional view of the surface material 1 of the molten excavation section 2, the upper end 4BJ of the fluff 4B becomes the upper end 2J of the molten excavation section 2. However, in a side cross-sectional view of the surface material 1 including the molten excavation section 2, "the upper end 3J of the molten material 3 is located below the upper end 4BJ of the fluff 4B" means not only that the upper end 3J of the molten material 3 is at approximately the same height as the upper end 4AJ of the base fabric 4A, or located below the upper end 4AJ of the base fabric 4A, but also that the upper end 3J of the molten material 3 is located above the upper end 4AJ of the base fabric 4A and below the upper end 4BJ of the fluff 4B. Furthermore, at least one of the molten materials 3 may be located at a distance from the other molten materials 3. For example, one molten material 3 (molten mass 3A, etc.) may be located away from the other molten materials 3 (molten facet 3B, etc.) and attached to the inner surface 2a of the molten excavation section 2, specifically the inner surface 4A' of the base fabric layer 4A'. In this case, if the height of the upper end of the molten material 3 (the distance from the back surface 1b of the surface material 1) is higher than the height of the upper end of the other molten materials 3 (i.e., the upper end of the molten material 3 is located above the upper end of the other molten materials 3), then the upper end 3J of the molten material 3 becomes the upper end of the molten material 3 (see Figures 2, 3, and 8).

[0064] The molten material 3 adhering to the inner surface 2a of the molten excavation section 2 does not necessarily have to span across multiple thermoplastic fibers 1A. This is because the molten drilling section 2 is as described above. <3> or <4> The same applies to the bottom surface 2b of the molten excavation section 2 when there is no communication between them; the molten material 3 does not need to span across multiple thermoplastic fibers 1A on the bottom surface 2b, and the molten material 3 itself does not need to be attached to the bottom surface 2b. If the surface material 1 includes a woolen fabric 4, the base fabric 4A may be made of a material other than woven, knitted, or nonwoven fabric (for example, a plate-like body or laminate made of synthetic resin, or a film made of synthetic resin). When the outer layer material 1 includes a woolen fabric 4, even if the base fabric 4A is a woven, knitted, or nonwoven fabric, the base fabric 4A may be composed of yarns with a total fineness of less than 30 dtex or yarns thicker than 500 dtex. As described above, the molten drilling section 2 does not have to be a communication hole section 2A. Also, multiple communication holes 2A are not required to be formed in a predetermined range in a plan view of the surface material 1, and it is acceptable for only one communication hole section 2A to be formed for each surface material 1. The plan view shape of the communication hole 2A does not have to be approximately circular, and even if the plan view shape of the communication hole 2A is approximately circular, its diameter may be less than 0.1 mm or greater than 3.0 mm.

[0065] The molten material 3 may be present in only one location on the inner surface 2a or bottom surface 2b of the molten excavation section 2, and may also be mixed with molten material 3 that spans multiple thermoplastic fibers 1A and molten material 3 that does not span multiple thermoplastic fibers 1A (i.e., attached to only one thermoplastic fiber 1A). The molten material 3 may consist of one or more molten lumps 3A or one or more molten facets 3B on the inner surface 2a or bottom surface 2b of the molten excavation section 2, or it may consist of one or more molten lumps 3A and molten facets 3B mixed together. Furthermore, if a part of the molten facet 3B is attached to the inner surface 2a or bottom surface 2b of the molten excavation section 2, the other part may be floating away from the inner surface 2a or bottom surface 2b (separated from the inner surface 2a or bottom surface 2b). Furthermore, on the inner surface 2a and bottom surface 2b of the molten excavation section 2, there may be areas where the molten material 3 is not attached and the end face (cross-section) of the thermoplastic fiber 1A is exposed.

[0066] In addition to the above, the fuzzy fabric 4 may also be made by tufting (implanting) pile yarn made of fluff 4B onto a base fabric 4A made of a predetermined fiber, and then cutting the pile yarn. If the woolen fabric 4 is a circular knitted fabric that has been brushed, the circular knitted fabric is roughly tubular with or without a bottom, but when it is brushed and used as woolen fabric 4, the tubular portion may be cut off and used as a roughly sheet-like material. A resin fiber layer may be formed by the fluff 4B of the woolen fabric 4 and the resin applied to the fluff 4B (not shown), or a resin fiber layer may not be formed (no resin may be applied). The outer layer 1 does not necessarily have to be a fuzzy fabric 4 (in other words, it may be a fabric consisting only of a base fabric without fluff), and in this case the base fabric may have the same configuration as the base fabric 4A described above. The surface material 1 does not necessarily have a backing resin 10 covering the back surface 1b (especially the back surface of the woolen fabric 4) or a backing layer 10' (see Figure 2), nor does it necessarily have to have a backing resin 10 covering at least a portion of the back surface 1b of the surface material 1.

[0067] The surface material 1 may optionally contain extender pigments or fillers such as titanium dioxide and calcium carbonate, or it may be a material to which deodorants, antibacterial agents, antifungal agents, flame retardants, water repellents, stain repellents, colorants, fragrances, foaming agents, etc., have been added. The surface material 1 may be any color, such as black, brown, blue, white, red, orange, yellow, green, or purple, and its saturation may also be any value. The pattern of the surface material 1 may also be any, such as a solid color, a plant pattern such as flowers or plants, an animal pattern, a geometric pattern, or a pattern created by surface irregularities. The light-emitting device (not shown), which may be placed on the back surface 1b of the surface material 1, can have any configuration as long as it emits light, but for example, it may emit light to display information such as characters or patterns. The light-emitting device may be, for example, a liquid crystal display device (a device that displays information such as characters and patterns on a screen by irradiating a backlight from the back of a liquid crystal screen and transmitting light), or a display device (a device that displays a pattern by partially blocking the light emitted from the light guide plate with the light-shielding layer by printing a pattern on the surface of a light guide plate), or an LED display, liquid crystal display, organic EL display, or plasma display. In addition, a light source (such as a light bulb or fluorescent lamp) in the case where the light source is placed on the back surface 1b of the surface material 1 and observed from a planar viewing direction on the surface 1a side may also be included as a light-emitting device.

[0068] The manufacturing method for the surface material 1 may include the melting and drilling step S1, the fabric forming step S0-1, the napping step S0-2, the cutting step S0-2', the backing step S0-3 described above, as well as steps other than the fabric forming and cutting steps (for example, a resin coating step in which resin is applied to the nap 4B of the napped fabric 4 to form a resin fiber layer). In the melting drilling process S1, if the means for forming the melting drilled section 2 is laser irradiation, the laser beam may be irradiated onto the surface material 1 without applying a melt-inhibiting agent. In addition, the surface material 1 may be subjected to a post-processing treatment at predetermined steps (timings), such as between the napping process S0-2 and the melting and drilling process S1, or between the cutting process S0-2' and the melting and drilling process S1, by dipping it with a synthetic resin such as polyurethane (PU) resin and / or silicone (Si) resin. [Industrial applicability]

[0069] The surface material according to the present invention, and the surface material manufactured by the method for manufacturing the surface material according to the present invention, can be used to cover interior materials (interior wall materials, ceiling materials, floor materials, etc.) and seats in the interior (room) of vehicles such as automobiles (passenger cars), railway vehicles, aircraft, and ships. In particular, in the case of automobiles, it can be used to cover interior materials (interior wall materials, ceiling materials, floor materials) such as instrument panels, control panels, console boxes, ornaments (door trims), dashboards, and glove boxes, as well as car seats (seats) and steering wheel covers. In addition, the surface material according to the present invention, and the surface material manufactured by the method for manufacturing the surface material according to the present invention, can be used not only inside vehicles such as automobiles as described above, but also as interior materials such as wall materials, ceiling materials, and floor materials inside buildings such as houses and office buildings, as well as furniture such as chairs and beds, and lighting fixtures. Furthermore, they may also be used for industrial materials, and for everyday materials such as shoes and clothing. [Explanation of Symbols]

[0070] 1 Skin material 2. Molten excavation section 2A Communication hole 3. Molten material 4 Blanket fabric 4A Base fabric 4B Fluff S1 Melting and drilling process

Claims

1. A surface material containing thermoplastic fibers, The surface material is melted from the surface, forming a molten excavation section in which at least a portion of the surface material has been excavated. A surface material characterized in that, in a side cross-sectional view of the surface material of the molten excavation portion, the upper end of the molten material adhering to the inner surface of the molten excavation portion is located at approximately the same height as the upper end of the molten excavation portion, or below the upper end of the molten excavation portion.

2. The surface material comprises a base fabric made of the thermoplastic fibers and a fuzzy fabric having fibers provided on the base fabric and made of the thermoplastic fibers. In a side cross-sectional view of the surface material of the molten excavation section, the upper end of the fluff becomes the upper end of the molten excavation section. The surface material according to claim 1, characterized in that, in a side cross-sectional view of the surface material of the molten excavation section, the upper end of the molten material is located below the upper end of the fluff.

3. The base fabric is a woven, knitted, or nonwoven fabric. The surface material according to claim 2, characterized in that the base fabric is composed of yarn with a total fineness of 30 dtex or more and 500 dtex or less.

4. The aforementioned molten drilling section is a connecting hole that extends from the surface to the back of the surface material. The surface material according to claim 1, characterized in that a plurality of communication holes are formed within a predetermined range in a plan view of the surface material.

5. The plan view shape of the aforementioned communication hole is approximately circular. The surface material according to claim 4, characterized in that the diameter of the communication hole portion is 0.1 mm or more and 3.0 mm or less.

6. A method for producing a surface material containing thermoplastic fibers, The process includes a melting and drilling step in which the surface material is melted from the surface to form a melted and drilled section in which at least a part of the surface material is excavated, A method for manufacturing a surface material, characterized in that, in the melting and drilling process, the upper end of the molten material adhering to the inner surface of the surface material of the melting and drilling portion is positioned at approximately the same height as the upper end of the melting and drilling portion, or below the upper end of the melting and drilling portion, in a side cross-sectional view of the surface material of the melting and drilling portion.

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