Skin material and method for producing the same

Abstract

To provide a new convex structure that is provided on a front surface of a base material and imparts design to a skin material.SOLUTION: A skin material includes protrusions on a front surface of a base material which is a laminate, and recesses on a back surface of the base material. The base material includes a facing material and a backing material. The facing material has a surface forming the front surface of the base material. The backing material is laminated on a back surface of the facing material, the back surface forming the back surface of the base material. The backing material is formed by a cushioning material. A concave portion is provided on a back side of the base material in a thickness direction of the convex portion. The thickness direction of the base material coincides with a direction in which the facing material and the backing material are laminated.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a skin material. [Background technology]

[0002] Technologies related to skin materials have been proposed. For example, Patent Document 1 discloses a sheet material. The sheet material is formed by laminating a surface material on a flexible polyurethane foam. The surface material may be formed by laminating a backing cloth on the back surface of the flexible polyurethane foam. A first recess and a first protrusion are formed on the surface of a laminate of the surface material and the flexible polyurethane foam, or on the surface of a laminate of the surface material, the flexible polyurethane foam, and the backing cloth. The first recess and the first protrusion give a soft impression with a blurred contour of the unevenness. The first recess and the first protrusion are formed by heat pressing. In the heat pressing, the laminate is arranged so that the surface material and the lower hot plate are in contact with each other, and the embossing part of the mold is pressed against the flexible polyurethane foam side. A clear second recess is formed on the back surface of the flexible polyurethane foam. A first recess appears on the surface material side of the portion corresponding to the second recess. A first protrusion appears on the surface material side corresponding to the second protrusion not heat pressed by the non-embossing part of the mold.

[0003] Patent Document 2 discloses a method for manufacturing a skin material. In this method, a material is hot-pressed using an embossing mold to obtain a skin material having a recess on the front side and a flat back side. In this method, the material is hot-pressed between the embossing mold and an elastic mat. A pressing rib protrudes from the surface of the embossing mold. During the hot-pressing, the pressing rib presses the front side of the material with the surface of the embossing mold separated from the surface of the material to form a recess. During the hot-pressing, the protruding end of the pressing rib is located closer to the back side than the surface height of the elastic mat in its natural state. The material includes a base fabric layer and a skin layer. The base fabric layer contains at least thermoplastic resin fibers. In the base fabric layer, the thermoplastic resin fibers are thermally deformed by the pressure from the skin layer side by the embossing mold, and a thermally deformed portion having a recess is formed. The skin layer follows the recess of the thermally deformed portion. Accordingly, a recess is formed. The base fabric layer is a knitted fabric. Examples of knitted fabrics include three-dimensional knitted fabrics, jersey, and tricot. The thickness of the base fabric layer is not particularly limited. For example, the thickness is 1 to 20 mm. The skin layer is bonded to one side of the base fabric layer by adhesion or heat welding. Examples of the skin layer include fabric, resin layer, synthetic leather, artificial leather, and natural leather. Examples of the resin layer include PU, PVC, and PP. The skin layer may be a single layer or a multi-layer. The thickness of the skin layer is not particularly limited. For example, the thickness is 0.01 to 10 mm. The embossing machine includes a lower metal receiving platform and an upper metal receiving platform. The upper receiving platform approaches and moves away from the lower receiving platform. The upper and lower receiving platforms can be heated by a heating means. An embossing mold is provided on the bottom surface of the upper receiving platform. An elastic mat made of silicone rubber is laid on the upper surface of the lower receiving platform. In this method, a material is placed on the elastic mat so that the base fabric layer faces the elastic mat, and the embossing mold is lowered.

[0004] Patent Document 3 discloses an embossed transfer printing method. In this method, a fabric is embossed by passing it between a male and female type heated embossing roll and a cushion roll. Next, in this method, the embossed fabric is passed between a cushion roll and a metal heat roll in the following state. In the above state, the surface of the fabric to be printed and the pattern-forming surface of the transfer printing paper are overlapped. A pattern is formed on the transfer printing paper by ink. The ink contains a dye that is sublimable or melt-transferable. The dye is sublimated or melt-transferred to the top surface of the embossed fabric. Then, in this method, the fabric and the transfer printing paper are peeled off. Examples of cushion rolls include a paper roll, a cotton roll, a rubber roll, and a nylon roll.

[0005] Patent Document 4 discloses an embossing device. The device includes a metal embossing roll and an elastic roll. In this device, paper before processing is passed between the embossing roll and the elastic roll to give the paper an uneven pattern. The elastic roll includes an uneven pattern on its surface. This uneven pattern corresponds to the uneven pattern of the embossing roll. The holes of the elastic roll are formed by hole processing at the portions corresponding to the convex portions of the uneven pattern of the embossing roll. The embossing roll and the elastic roll constitute male and female rolls. A rubber roll can be used as the elastic roll. This device can also process sheet materials such as metal foils, plastics, and woven and knitted fiber fabrics. This device does not necessarily need to have a clearance between the embossing roll and the elastic roll.

[0006] Patent Document 5 discloses a laminate. In this laminate, the first layer, the second layer, the third layer, the fourth layer, and the fifth layer are laminated together in this order. The first layer is a metal-deposited polyester film. The second layer is an obliquely oriented laminate film. The second layer is formed by laminating two uniaxially oriented films together in the following manner. In the above-mentioned manner, the stretching directions of the uniaxially oriented films cross each other. The third layer is a foamed polyolefin sheet. The fourth layer is a woven fabric made of plastic yarn. The fifth layer is a polyolefin film. The first layer, the second layer, the third layer, the fourth layer, and the fifth layer are embossed simultaneously. The numerous concave-convex patterns formed by embossing can be changed depending on the thickness of the laminate or the application. When the thickness of the laminate is about 0.5 to 2 mm, the interval between the convex parts is preferably about 0.5 to 5 mm, and the depth of the concave parts is preferably 0.1 to 1.5 mm. The first layer serves as a decorative layer. The second layer maintains the surface smoothness of the first layer and reinforces the laminate. The second layer helps maintain the strength of the perforations when sewing the laminate with a sewing machine. The third layer gives the laminate insulation and cushioning properties. The fourth layer contributes to preventing tension, tearing, deformation and stretching. The fifth layer prevents the cloth layer from getting dirty.

[0007] Patent Document 6 discloses an embossing system and a method for manufacturing a processed product. This system produces release paper from an original roll as a processed product. The release paper functions as a template for producing a sheet-like member to be used as synthetic leather. This system has an embossing device. The embossing device has an embossing roll and a backup roll. An embossing mold surface is formed on the outer peripheral surface of the roll body of the embossing roll. The embossing mold surface has an uneven shape. The uneven shape of the embossing mold surface is formed so as to impart a leather pattern to the original roll. The backup roll is disposed opposite the embossing roll. An uneven shape corresponding to the uneven shape of the embossing mold surface is formed on the outer peripheral surface of the backup roll. The embossing roll and the backup roll each have a heating device. The heating device heats the original roll during embossing. The original roll is made of a substrate and a synthetic resin layer. The substrate is made of paper. The synthetic resin layer is laminated on the substrate. When producing release paper using this system, a laminate is produced sequentially. The laminate consists of an original roll and a covering layer. The laminate is transported to an embossing device. The laminate is fed between an embossing roll and a backup roll, and is sandwiched and pressed between them. The embossing surface contacts the covering layer, and the outer circumferential surface of the backup roll contacts the substrate. The covering layer deforms to fit the outer contour of the embossing surface, and the substrate deforms together with the synthetic resin into the desired shape with high precision. The desired uneven pattern is formed on the laminate (original roll). The covering layer is removed from the laminate, and a release paper made of the original roll with an uneven pattern formed therein is obtained. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] JP 2012-210776 A [Patent Document 2] JP 2020-20063 A [Patent Document 3] Japanese Patent Application Publication No. 52-8190 [Patent Document 4] Japanese Patent Application Publication No. 6-143466 [Patent Document 5] Publication number 5-38934 [Patent Document 6] JP 2010-260235 A Summary of the Invention [Problem to be solved by the invention]

[0009] A skin material is provided on the front side of a given product and forms the surface of the product. For this reason, the skin material is required to have designability. The inventor thought that it would be possible to impart designability to the skin material by providing convex portions on the surface of the base material on which the skin material is formed and decorating the surface of the base material with these convex portions. In doing so, the inventor took the following points into consideration. That is, when a product formed from the skin material is used, a part of the user may come into contact with the convex portions. In this case, the inventor thought that it is important to prevent these convex portions from becoming an obstacle that causes discomfort to the user. Furthermore, the inventor thought that it is important to improve the durability and abrasion resistance of the convex portions.

[0010] An object of the present invention is to provide a new convex structure that is provided on the surface of a substrate and that imparts design properties to a skin material. [Means for solving the problem]

[0011] One aspect of the present invention is to provide a laminate on the surface of a substrate. Three-dimensional pattern and on the back surface of the substrate A three-dimensional pattern having a shape that is an inverse of the three-dimensional pattern on the surface of the substrate. The substrate includes a surface material having a surface that forms the surface of the substrate, and a backing material that is laminated on the back surface of the surface material, the back surface of the backing material forms the back surface of the substrate, and is formed by a cushion material; The three-dimensional pattern on the surface of the substrate includes a first convex portion and a second convex portion adjacent to each other in a first direction perpendicular to the thickness direction of the substrate, which coincides with the direction in which the surface material and the backing material are laminated, and a region in the first direction between the first convex portion and the second convex portion on the surface of the substrate is concave on the rear side in the thickness direction and has a curved shape connecting the tops of the two convex portions of the first convex portion and the second convex portion; the three-dimensional pattern on the rear side of the substrate includes a first recess and a second recess adjacent to each other in the first direction, and a region in the first direction between the first recess and the second recess on the rear side of the substrate is convex on the rear side in the thickness direction and has a curved shape connecting the bottoms of the two recesses of the first recess and the second recess; The above first The recess is first In front of the protrusion Record thickness On the back side of the the second recess is provided on a rear side of the second protrusion in the thickness direction, a maximum depth of the first recess from a rear surface of the base is set to a first value, a maximum depth of the second recess from a rear surface of the base is set to the first value, and a maximum distance between the first recess and the second recess in the first direction is set to a second value that is four or more times the first value. Skin material 。

[0012] The backing may be a laminate.

[0013] the first convex portion has a shape along a second direction perpendicular to both the thickness direction and the first direction, the second convex portion has the same shape as the first convex portion, the first recess portion has a shape along the second direction, the second recess portion has the same shape as the first recess, a three-dimensional pattern on the front surface of the base material is a three-dimensional horizontal stripe pattern in which the first convex portion and the second convex portion are arranged along the second direction, and a three-dimensional pattern on the back surface of the base material is a three-dimensional horizontal stripe pattern in which the first recess portion and the second recess portion are arranged along the second direction. This may be done.

[0014] The above-mentioned skin material According to this, the convex portions on the surface of the skin material can be formed in a gentle shape. In the following cases, the convex convex portion provided on the surface of the substrate can be pushed to the back side in the thickness direction by the compressive deformation of the backing material formed by the cushioning material and released. An example of the above case is that when a user of a product using a skin material uses the product, a part of the user comes into contact with the convex portion of the skin material. Furthermore, in this case, the convex portion can be pushed to the back side in the thickness direction by the concave portion on the back surface of the substrate and released. The convex portion can be easily deformed. The deformation amount of the convex portion in the thickness direction can be increased. When using a product using the skin material, the tactile sensation that the user receives from the product can be improved. The mechanical properties of the convex portion can be improved. Examples of the mechanical properties of the convex portion include elasticity, durability, and abrasion resistance.

[0015] Another aspect of the present invention is In any one of the above-mentioned methods for producing a skin material, The recess has a corresponding shape. first Embossed part and a second embossing portion having a shape corresponding to the second recess. Including Mue The processed surface of the embossed mold is brought into contact with the back surface of the base material without any gaps, and first Embossed part and the second embossing section The embossing die and the embossing receiving die are pressed into the back surface of the base material, and the elastic receiving surface of the embossing receiving die made of an elastic body is brought into contact with the front surface of the base material without any gaps, and the base material is sandwiched in the thickness direction by the embossing die and the embossing receiving die. forming a three-dimensional pattern of the front surface of the substrate on the front surface of the substrate, and forming a three-dimensional pattern of the back surface of the substrate on the back surface of the substrate; Skin material Manufacturing method It is.

[0016] This skin material can suppress the occurrence of gloss on the surface. It is possible to express a design on the surface of the skin material that gives a soft impression to the viewer. In addition, this skin material has the same effects as the above-mentioned skin material. Effect of the Invention

[0017] According to the present invention, it is possible to obtain a novel convex structure that is provided on the surface of a substrate and that imparts design properties to a skin material. [Brief description of the drawings]

[0018] [Figure 1] 1 is a perspective view showing an example of a schematic configuration of a skin material, the skin material being viewed obliquely from the front side. [Diagram 2] 2 is a perspective view showing an example of a schematic configuration of a skin material, which corresponds to the skin material in FIG. 1 and is shown as viewed obliquely from the back side. [Diagram 3] 1 is a perspective view showing an example of a schematic configuration of a substrate before processing, and shows the substrate as viewed obliquely from the front side. [Figure 4]4 is a perspective view showing an example of a schematic configuration of a substrate before processing. The substrate corresponds to the substrate in FIG. 3, and is shown as viewed obliquely from the back side. [Diagram 5] Fig. 3 is a perspective view showing an example of a schematic configuration of an embossing step carried out in the method for producing a skin material shown in Figs. 1 and 2. The figure shows a state in which an embossing die and an embossing receiving die sandwich a substrate therebetween. [Figure 6] 6 is a cross-sectional view taken along line II in FIG. 5. [Figure 7] 7 is a perspective view showing an example of a schematic configuration of an embossing mold, which corresponds to the embossing mold in FIGS. 5 and 6. FIG. 7 shows the processing surface of the embossing mold. [Figure 8] Fig. 7 is a perspective view showing an example of a schematic configuration of an embossing die, which corresponds to the embossing die shown in Figs. 5 and 6. Fig. 7 shows a receiving surface of the embossing die. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] The embodiments for carrying out the present invention will be described with reference to the drawings. The present invention is not limited to the configurations described below, and various configurations can be adopted within the same technical concept. For example, some of the configurations shown below may be omitted or replaced with other configurations. The present invention may include other configurations. The drawings show a specific configuration in a schematic manner. Hatching indicates a cut surface.

[0020] <Skin material 10> The skin 10 will be described with reference to Figs. 1 to 4. The skin 10 includes a convex portion 30 on the surface of the substrate 20 and a concave portion 40 on the back surface of the substrate 20 (see Figs. 1 and 2). The surface of the substrate 20 forms a design surface with the substrate 20, and is visually recognized by a viewer of the skin 10. The surface of the substrate 20 forms the surface of the skin 10, and the back surface of the substrate 20 forms the back surface of the skin 10. That is, in the state of the skin 10, the surface of the substrate 20 can be called the surface of the skin 10, and the back surface of the substrate 20 can be called the back surface of the skin 10. The substrate 20 is formed from an unprocessed state into the skin 10 through a manufacturing method for the skin 10, which is carried out using the substrate 20 as a material (see Figs. 3 and 4 to Figs. 1 and 2). The manufacturing method for the skin 10 will be described later.

[0021] In the embodiment, the skin material 10 and the base material 20 are long sheet materials. In this case, the length direction of the skin material 10 and the base material 20 is referred to as the "first direction", and the width direction of the skin material 10 and the base material 20 is referred to as the "second direction". The second direction is perpendicular to the first direction.

[0022] The substrate 20 is a laminate (see Figs. 1 to 4). The substrate 20 includes a surface material 21 and a backing material 22. The backing material 22 may be either a single layer or a laminate. In the embodiment, the backing material 22 is a single layer (single-layer sheet material) (see Figs. 1 to 4). The direction in which the surface material 21 and the backing material 22 are laminated coincides with the thickness direction of the substrate 20. The thickness direction of the substrate 20 coincides with the thickness directions of the surface material 21 and the backing material 22, and coincides with the thickness direction of the skin material 10. When the substrate 20 is a laminate in which a single-layer surface material 21 and a single-layer backing material 22 are laminated in the thickness direction of the substrate 20 (see Figs. 3 and 4), the skin material 10 is also a laminate in which a single-layer surface material 21 and a single-layer backing material 22 are laminated in the thickness direction of the skin material 10 (see Figs. 1 and 2).

[0023] In the embodiment, the thickness direction of the substrate 20 is simply referred to as the "thickness direction". One side in the thickness direction is referred to as the "front side", and the other side in the thickness direction opposite to the front side is referred to as the "back side". In the skin material 10 and the substrate 20, the surface material 21 is provided on the front side in the thickness direction, and the back material 22 is provided on the back side in the thickness direction. That is, the back material 22 is laminated on the back side of the surface material 21 (see Figs. 3 and 4). In the embodiment, the "front surface" means the front side of the sheet material in the embodiment, and the "back surface" means the back side of the sheet material in the embodiment. The sheet material in the embodiment includes the skin material 10, the substrate 20, the surface material 21, and the back material 22, and corresponds to some or all of these sheet materials.

[0024] Examples of methods for forming the substrate 20 include a method using an adhesive and a method using frame lamination. In this method, a backing material 22 is attached to the rear surface of a surface material 21 to form the substrate 20 as a laminate. The method for forming the substrate 20 is appropriately determined in consideration of various conditions. Comparing the above two methods, the inventor believes that the method using frame lamination is preferable from the standpoint of process load and weight reduction. Frame lamination is a technology that has already been put into practical use. Therefore, a description of frame lamination will be omitted.

[0025] The surface of the surface material 21 forms the surface of the substrate 20 (see FIG. 3). In this case, the surface of the surface material 21 forms the surface of the skin material 10 (see FIG. 1). The reverse surface of the backing material 22 forms the reverse surface of the substrate 20 (see FIG. 4). In this case, the reverse surface of the backing material 22 forms the reverse surface of the skin material 10 (see FIG. 2). The backing material 22 is formed of a cushion material. In the embodiment, the backing material 22 collectively refers to a sheet material laminated on the reverse surface of the surface material 21.

[0026] The skin material 10 may be made of a known laminated sheet material as the base material 20. In this case, the surface material 21 and the backing material 22 may also be made of known sheet materials.

[0027] For example, the surface material 21 may be a fibrous sheet material. Examples of the surface material 21 include fabrics and leathers. Examples of fabrics include woven fabrics, knitted fabrics, and nonwoven fabrics. Examples of leathers include artificial leather, synthetic leather, and natural leather. Synthetic leathers include polyurethane leather and polyvinyl chloride leather. Natural leathers include split leather. The surface material 21 may be a composite of two or more of these materials. The fibers forming the surface material 21 are not particularly limited. For example, the fibers may be thermoplastic fibers. Examples of thermoplastic fibers include synthetic fibers and semi-synthetic fibers. Examples of synthetic fibers include polyester fibers, polypropylene fibers, and nylon fibers. Examples of semi-synthetic fibers include acetate fibers and triacetate fibers. The fibers forming the surface material 21 may be one type, or a combination of two or more types.

[0028] Besides, the surface material 21 may be made of a known film material. For example, the film material may be made of a synthetic resin. Examples of the synthetic resin include polyvinyl chloride resin, polyurethane resin, polyester resin, and polyamide resin. The synthetic resin forming the film material may be one type, or may be a mixed composition of two or more types.

[0029] Examples of the backing material 22 include synthetic resin foam, woven fabric, and knitted fabric. An example of a synthetic resin foam is polyurethane foam. When a woven fabric is used as the backing material 22, the backing material 22 is preferably a three-dimensional woven fabric. When a knitted fabric is used as the backing material 22, the backing material 22 is preferably a three-dimensional knitted fabric.

[0030] The thickness of the substrate 20 is set to 1.01 to 12.5 mm. The thickness of the backing material 22 is set to 1 to 10 mm. In this case, the thickness of the surface material 21 is set to 0.01 to 2.5 mm. However, such thicknesses of the substrate 20, the surface material 21, and the backing material 22 are merely examples. The thicknesses of the substrate 20, the surface material 21, and the backing material 22 are appropriately determined in consideration of various conditions. As described above, in the skin material 10, a known laminated sheet material can be used as the substrate 20 including the surface material 21 and the backing material 22. Therefore, further explanation regarding the substrate 20 as a material will be omitted.

[0031] The recess 40 is provided on the back surface of the base material 20 and on the back side of the protrusion 30 in the thickness direction (see FIGS. 1 and 2). The recess 40 has a concave shape corresponding to the convex shape of the protrusion 30 provided on the front side of the recess 40 in the thickness direction. In other words, the protrusion 30 has a convex shape corresponding to the concave shape of the recess 40 provided on the back side of the protrusion 30 in the thickness direction.

[0032] The protrusions 30 and the recesses 40 are provided along the second direction and traverse the base material 20 in the second direction (see Figs. 1 and 2). The skin material 10 includes a plurality of protrusions 30 on the surface of the base material 20, and includes an equal number of recesses 40 as the plurality of protrusions 30 on the back surface of the base material 20. The plurality of protrusions 30 have the same shape, and the plurality of recesses 40 have the same shape. Both the plurality of protrusions 30 and the plurality of recesses 40 are repeated at equal intervals in the first direction. That is, in the skin material 10, the surface of the base material 20, which is the design surface, has a three-dimensional horizontal striped pattern, and the back surface of the base material 20 has a three-dimensional horizontal striped pattern that is the inverse of the three-dimensional pattern on the surface.

[0033] However, the three-dimensional pattern on the surface of the substrate 20 may be in a form other than a three-dimensional horizontal stripe pattern. The three-dimensional pattern on the surface of the substrate 20 is appropriately determined in consideration of various conditions. Examples of matters to be considered when determining the three-dimensional pattern include the design required for the skin material 10 and the design to be expressed by the skin material 10. The three-dimensional pattern on the back surface of the substrate 20 has a shape that is the inverse of the three-dimensional pattern on the surface of the substrate 20.

[0034] Region R1 on the front surface of the substrate 20 has a gently curved shape that is concave on the rear side in the thickness direction (see FIG. 1). Region R1 is between two adjacent protrusions 30 on the front surface of the substrate 20. Region R1 connects the tops of two adjacent protrusions 30 with a concave curved shape. Region R2 on the rear surface of the substrate 20 has a gently curved shape that is convex on the rear side in the thickness direction (see FIG. 2). Region R2 is between two adjacent recesses 40 on the rear surface of the substrate 20. Region R2 is provided on the rear side of region R1 in the thickness direction. Region R2 connects the bottoms of two adjacent recesses 40 with a concave curved shape.

[0035] The maximum depth of the recess 40 from the back surface of the base material 20 is set to a first value N1 (see FIG. 2). The maximum distance between the first recess and the second recess is set to a second value N2 (see FIG. 2). The first recess and the second recess are two adjacent recesses 40 among the multiple recesses 40. In this case, the second value N2 is preferably set to four times or more the first value N1 (4.0×N1≦N2). The relationship between the first value N1 and the second value N2 is more preferably set to "4.5×N1≦N2≦100×N1", and even more preferably set to "8.3×N1≦N2≦50×N1". In other words, the relationship between the first value N1 and the second value N2 is preferably set to "N1≦0.25×N2", more preferably set to "0.010×N2≦N1≦0.22×N2", and even more preferably set to "0.020×N2≦N1≦0.12×N2".

[0036] The first recess and the second recess in the skin 10 are both arranged along the second direction and are spaced apart at a constant interval in the first direction (see FIGS. 1 and 2). That is, the interval between the first recess and the second recess in the skin 10 is a second value N2 (maximum interval) at any position in the second direction.

[0037] The skin material 10 can be used as the outer material of various products. The aforementioned products include parts. Examples of products in which the skin material 10 can be used include transportation equipment interior parts, interior goods, shoes, bags, and clothing. Transportation equipment includes automobiles, trains, aircraft, and ships. When the skin material 10 is used as a transportation equipment interior part, the skin material 10 becomes a material that forms the following parts of the transportation equipment. Examples of the aforementioned parts include the ceiling, seats, dashboard, door lining, and handles. Interior goods include furniture. Examples of furniture include sofas and chairs.

[0038] <Method of manufacturing the skin material 10 and embossing device 50> The manufacturing method of the skin material 10 and the embossing device 50 will be described with reference to Figs. 5 to 8. In the embodiment, the manufacturing method of the skin material 10 is simply referred to as the "manufacturing method". The manufacturing method includes an embossing step. The embossing step is performed by the embossing device 50. The embossing device 50 embosses the base material 20 as a material in the embossing step.

[0039] The embossing device 50 includes an embossing die 60 and an embossing receiving die 70 (see Figs. 5 and 6). The embossing die 60 and the embossing receiving die 70 are arranged side by side in the thickness direction. The embossing die 60 is arranged on the back side in the thickness direction of the substrate 20 to be processed. The embossing receiving die 70 is arranged on the front side in the thickness direction of the substrate 20 to be processed.

[0040] When the substrate 20 is a long sheet material, the embossing apparatus 50 includes a supply device and a recovery device. However, in the embodiment, the supply device and the recovery device are not illustrated. The supply device supplies the substrate 20 to the embossing die 60 and the embossing receiving die 70. The recovery device recovers the skin material 10 formed by the embossing die 60 and the embossing receiving die 70. The embossing apparatus 50 can employ supply devices and recovery devices similar to those of known embossing apparatuses. Therefore, further explanation of the supply devices and recovery devices employed by the embossing apparatus 50 will be omitted.

[0041] The substrate 20 and the skin material 10 are in the form of a continuous long sheet material from the supply device to the recovery device, and are transported from the supply device to the recovery device. The substrate 20 is shaped into the skin material 10 by the embossing die 60 and the embossing receiving die 70 during the transport from the supply device to the recovery device.

[0042] In the embodiment, the first direction, second direction, and thickness direction (front side and back side) defined for identifying the skin material 10 and the substrate 20 are used as the directions for identifying the embossing device 50 (the embossing die 60 and the embossing receiving die 70) (see Figs. 5 to 8). In this case, the first direction corresponds to both the conveying direction and the opposite direction thereto (see Figs. 5 and 6). When the manufacturing method is carried out, the substrate 20 and the skin material 10 are conveyed in the conveying direction.

[0043] The embossing die 60 is made of metal. Known mold materials can be used as the metal material for forming the embossing die 60. Examples of the metal material for forming the embossing die 60 include steel and aluminum alloy. Steel includes alloy steel.

[0044] The embossing die 60 includes a plurality of embossed portions 62 on a processing surface 61 (see Figs. 6 and 7). The processing surface 61 of the embossing die 60 faces the back surface of the substrate 20 (see Fig. 6). The embossed portions 62 have a convex shape corresponding to the concave portions 40. The arrangement of the plurality of embossed portions 62 is determined according to the arrangement of the plurality of convex portions 30 to be expressed on the surface of the substrate 20 in the skin material 10. That is, the surface of the substrate 20 in the skin material 10 is provided with a plurality of convex portions 30 in a manner corresponding to the arrangement of the plurality of embossed portions 62 in the embossing die 60.

[0045] In an embodiment, the plurality of protrusions 30 and the plurality of recesses 40 are repeated at equal intervals in the first direction (see FIGS. 1 and 2). Thus, the plurality of embossed portions 62 are provided at equal intervals in the first direction in a manner similar to the plurality of protrusions 30 and the plurality of recesses 40 (see FIG. 7). Furthermore, in an embodiment, the plurality of protrusions 30 and the plurality of recesses 40 traverse the substrate 20 in the second direction. The embossed portions 62 correspond to such an arrangement of the protrusions 30 and the recesses 40 and traverse the embossing die 60 in the second direction.

[0046] In the embodiment, the number of embossing sections 62 in one embossing die 60 is six (see Figs. 5 to 7). The number of embossing sections 62 in one embossing die 60 may be two or more and five or less, or seven or more. Furthermore, the number of embossing sections 62 in one embossing die 60 may be one. The number of embossing sections 62 in one embossing die 60 is appropriately determined in consideration of various conditions.

[0047] Region R3 of the processed surface 61 has a gently curved shape that is concave on the back side in the thickness direction (see FIG. 7). Region R3 is between two adjacent embossed portions 62 on the processed surface 61. Region R3 has a shape corresponding to region R2 of the recess 40.

[0048] The maximum height of the embossed portion 62 from the bottom position of the region R3 is set to a third value N3 (see FIG. 7). That is, the maximum height of the embossed portion 62 can also be said to be the height of the top of the embossed portion 62 based on the bottom position of the region R3. The maximum distance between the first embossed portion and the second embossed portion is set to a fourth value N4 (see FIG. 7). The first embossed portion and the second embossed portion are two adjacent embossed portions 62 among the multiple embossed portions 62. In this case, it is preferable to set the fourth value N4 to be four times or more the third value N3 (4.0×N3≦N4). The relationship between the third value N3 and the fourth value N4 is more preferably set to "4.5×N3≦N4≦50×N3", and even more preferably set to "8.3×N3≦N4≦25×N3". In other words, the relationship between the third value N3 and the fourth value N4 is preferably set to "N3≦0.25×N4", more preferably set to "0.020×N4≦N3≦0.22×N4", and even more preferably set to "0.040×N4≦N3≦0.12×N4". Accordingly, it becomes possible for the skin material 10 to realize the relationship between the first value N1 and the second value N2 described above.

[0049] The inventors have found from various studies and past experiences that the following phenomenon is likely to occur: The maximum depth of the recess 40 formed by embossing in the embossing step is smaller than the maximum height of the embossed portion 62. Taking into consideration the occurrence of such an event, the inventor considers it preferable to set the third value N3 and the fourth value N4 to "4.5×N3≦N4≦50×N3" and "0.020×N4≦N3≦0.22×N4" for the first value N1 and the second value N2 of "4.5×N1≦N2≦100×N1" and "0.010×N2≦N1≦0.22×N2", and to set the third value N3 and the fourth value N4 to "8.3×N3≦N4≦25×N3" and "0.040×N4≦N3≦0.12×N4" for the first value N1 and the second value N2 of "8.3×N1≦N2≦50×N1" and "0.020×N2≦N1≦0.12×N2".

[0050] In the embossing die 60, the first embossing portion and the second embossing portion are both arranged along the second direction and are spaced apart at a constant interval in the first direction (see FIG. 7). That is, the interval between the first embossing portion and the second embossing portion in the embossing die 60 is a fourth value N4 (maximum interval) at any position in the second direction.

[0051] The embossing die 70 is made of an elastic material. Examples of the elastic material forming the embossing die 70 include rubber, thermoplastic elastomer, and plastic. Examples of the rubber forming the embossing die 70 include silicone rubber, nitrile rubber, chloroprene rubber, ethylene-propylene rubber, butyl rubber, urethane rubber, fluororubber, and natural rubber. Examples of the thermoplastic elastomer include polyurethane elastomer, nylon elastomer, and polyvinyl chloride elastomer. Examples of the plastic include acrylic resin, polyvinyl chloride resin, polypropylene resin, polystyrene resin, polyethylene resin, and polyethylene terephthalate resin.

[0052] The hardness of the elastic body forming the embossing mold 70 is preferably A90 or less, more preferably A70 or less, and even more preferably A60 or less. The above-mentioned hardness is an average value of hardness obtained by the following hardness test method. This hardness test method is performed in accordance with JIS K6253-3:2012 (Vulcanized rubber and thermoplastic rubber - Determination of hardness - Part 3: Durometer hardness).

[0053] By making the embossing receiving die 70 from an elastic material, the receiving surface 71 of the embossing receiving die 70 has elasticity. The receiving surface 71 faces the surface of the base material 20 (see FIG. 6). The receiving surface 71 has a smooth shape when no force is applied thereto (see FIG. 8). In the embodiment, "smooth" means a state without any elevations or irregularities. The receiving surface 71 is deformed by the pressing force from the embossing die 60 acting through the base material 20.

[0054] When the manufacturing method is carried out, the base material 20 is transported intermittently in the transport direction. For example, the transport amount per time is set to the dimension of the processing surface 61 in the transport direction (first direction) (see FIG. 6). In the embossing process, embossing is performed on a portion of the base material 20 that has been newly transported between the embossing die 60 and the embossing receiving die 70. In the embossing process, the embossing die 60 approaches the embossing receiving die 70 relatively. The embossing die 60 and the embossing receiving die 70 sandwich the base material 20 from the thickness direction (see FIGS. 5 and 6).

[0055] In the embossing die 60, the embossing portion 62 bites into the substrate 20 from the back side in the thickness direction, and region R3 comes into surface contact with the back surface of the substrate 20 (see FIG. 6). In the embossing receiving die 70, the receiving surface 71 comes into surface contact with the front surface of the substrate 20 (see FIG. 6). That is, in the embossing die 60, the processing surface 61 and the back surface of the substrate 20 come into contact with no gaps, and in the embossing receiving die 70, the receiving surface 71 and the front surface of the substrate 20 come into contact with no gaps. The receiving surface 71 is deformed into a shape that conforms to the processing surface 61 by the pressing force from the embossing die 60 acting through the substrate 20 (see FIG. 6).

[0056] The processing conditions of the embossing performed in the embossing step are appropriately determined in consideration of various conditions. Examples of the processing conditions of the embossing include the pressure on the substrate 20, the pressing time, and the processing temperature. The embossing device 50 may include a heater. The heater is provided in the embossing mold 60 and heats the embossing mold 60. This adjusts the processing temperature. The processing conditions of the embossing in the embossing step can be determined by referring to the processing conditions of embossing that has already been put into practical use.

[0057] Thereafter, the embossing die 60 moves away from the embossing receiving die 70 relative to each other. In the embossing step, the relative approaching and separating motions of the embossing die 60 and the embossing receiving die 70 are performed by moving one or both of the embossing die 60 and the embossing receiving die 70 in the thickness direction. The intermittent transport of the substrate 20 is performed in a state in which the embossing die 60 and the embossing receiving die 70 are separated from each other. The embossing device 50 repeatedly performs the embossing step while transporting the substrate 20 intermittently.

[0058] <Effects of the embodiment> According to the embodiment, the following effects can be obtained.

[0059] (1) The skin material 10 includes protrusions 30 on the surface of the substrate 20 and recesses 40 on the back surface of the substrate 20 (see Figs. 1 and 2). The substrate 20 is a laminate, and includes a surface material 21 and a backing material 22 (see Figs. 1 to 4). The surface of the surface material 21 forms the surface of the substrate 20 (see Figs. 1 and 3). The backing material 22 is laminated on the back surface of the surface material 21 (see Figs. 1 to 4). The back surface of the backing material 22 forms the back surface of the substrate 20 (see Figs. 2 and 4). The backing material 22 is made of a cushioning material. The recesses 40 are provided on the back side of the protrusions 30 in the thickness direction (see Figs. 1 and 2).

[0060] According to the skin material 10, in the following cases, the convex protrusions 30 provided on the surface of the substrate 20 can be pushed to the back side in the thickness direction by the compressive deformation of the backing material 22 formed by the cushioning material, and can be released. An example of the above case is that when a user of a product using the skin material 10 uses the product, a part of the user comes into contact with the protrusions 30 of the skin material 10. Furthermore, in this case, the protrusions 30 can be pushed to the back side in the thickness direction by the recesses 40 on the back side of the substrate 20, and can be released. The protrusions 30 can be easily deformed. The deformation amount of the protrusions 30 in the thickness direction can be increased. When using a product using the skin material 10, the tactile sensation that the user receives from the product can be improved. The mechanical properties of the protrusions 30 can be improved. Examples of the mechanical properties of the protrusions 30 include elasticity, durability, and abrasion resistance. The protrusions 30 are provided on the surface of the substrate 20 to impart design to the skin material 10. The protrusions 30 can have a new protrusion structure.

[0061] The backing material 22 may be softer than the surface material 21. The backing material 22 may be less resilient than the surface material 21. This makes it easier for the protrusions 30 to be pushed to the back side in the thickness direction and then released.

[0062] (2) The maximum depth of the recesses 40 from the rear surface of the base material 20 is set to a first value N1 (see FIG. 2). The base material 20 includes a plurality of protrusions 30, and includes the same number of recesses 40 as the plurality of protrusions 30 (see FIGS. 1 and 2). The maximum distance between two adjacent recesses 40 is set to a second value N2 (see FIG. 2). The relationship between the first value N1 and the second value N2 is set to "4.0×N1≦N2". With this configuration, the protrusions 30 can be made to have a gentle shape on the surface of the skin material 10.

[0063] (3) The convex portions 30 and concave portions 40 of the skin material 10 are formed by the embossing process of the manufacturing method. In the embossing process, the substrate 20 is sandwiched between the embossing die 60 and the embossing receiving die 70 in the thickness direction in the following state. In the above state, the processing surface 61 of the embossing die 60 and the back surface of the substrate 20 are in contact with each other without any gaps, and the embossing portion 62 is pressed into the back surface of the substrate 20. Furthermore, in the above state, the receiving surface 71 of the embossing receiving die 70 and the surface of the substrate 20 are in contact with each other without any gaps. The embossing receiving die 70 is made of an elastic body. The receiving surface 71 has elasticity.

[0064] The skin material 10 can suppress the generation of gloss on the surface. A design that can give a soft impression to the viewer of the skin material 10 can be expressed on the surface of the skin material 10. In addition, the skin material 10 has the same effects as those described above.

[0065] <Modification> The embodiment can also be as follows. Some of the configurations of the modified examples shown below can be appropriately combined and adopted. Below, we will explain the points that are different from the above, and will appropriately omit explanations of similar points.

[0066] (1) In the skin material 10, the substrate 20 is a two-layer laminate, and the backing material 22 is a single layer made of a cushioning material. The substrate 20 may be a laminate of three or more layers. For example, the substrate 20 is a three-layer laminate including the surface material 21, and the backing material is a two-layer laminate. In this case, the two-layer backing material includes an intermediate material and a backing material. The backing material is laminated on the back surface of the intermediate material. An example of the intermediate material is a cushioning material used as the backing material 22. As a result, the backing material has cushioning properties similar to the backing material 22. The backing material forms the back surface of the substrate 20. The recessed portion 40 is formed on the back surface of the substrate 20 formed by the backing material and on the back side of the protruding portion 30.

[0067] As the surface material 21, known sheet materials such as fibrous sheet materials and known film materials such as synthetic resin film materials are exemplified. As the fibrous sheet materials, sheet materials such as artificial leather and synthetic leather are exemplified. For example, synthetic leather is a fibrous sheet material with a synthetic resin film material on the surface. That is, the sheet material or film material forming the surface material 21 may be a single layer body or a laminate. When the fibrous sheet material has cushioning properties, the fibrous sheet material functions as a cushioning material. Taking synthetic leather as an example, when the fibrous sheet material on the back side of the resin film in the synthetic leather has cushioning properties and no cushioning material corresponding to the backing material 22 is provided for this synthetic leather, this synthetic leather can also be regarded as the substrate 20 in the next embodiment. In the above embodiment, the resin film functions as the surface material 21. Furthermore, in the above embodiment, the fibrous sheet material having cushioning properties becomes a cushioning material and functions as the backing material 22. The case where the substrate 20 has a form in which the backing material 22 made of a cushioning material is provided on the back surface of the surface material 21 made of synthetic leather is as described above. Although a detailed explanation is omitted, these points are similar to those of laminates other than synthetic leather.

[0068] (2) The protrusions 30 and the recesses 40 are provided along the second direction and traverse the base material 20 in the second direction (see Figs. 1 and 2). The skin material 10 includes a plurality of protrusions 30 on the surface of the base material 20, and includes an equal number of recesses 40 as the plurality of protrusions 30 on the back surface of the base material 20. The plurality of protrusions 30 have the same shape, and the plurality of recesses 40 have the same shape. Both the plurality of protrusions 30 and the plurality of recesses 40 are repeated at equal intervals in the first direction. That is, in the skin material 10, the surface of the base material 20, which is the design surface, has a three-dimensional horizontal stripe pattern, and the back surface of the base material 20 has a three-dimensional horizontal stripe pattern that is the inverse of the three-dimensional pattern on the surface.

[0069] In the skin material, the three-dimensional pattern formed by the multiple protrusions on the surface of the substrate can be made different by changing either or both of the shape of the protrusions and the arrangement of the multiple protrusions. The three-dimensional pattern formed by the multiple protrusions on the surface of the substrate may be made different from the three-dimensional pattern shown in FIG.

[0070] That is, the shape of the convex portion does not have to be linear. Examples of shapes different from linear include curved and dotted shapes. Furthermore, the shape of the convex portion may be arbitrary. The shape of the convex portion may be the same for all of the multiple convex portions, or may be different for some of the multiple convex portions. The arrangement of the multiple convex portions does not have to be horizontal striped. Examples of arrangements different from horizontal stripes include vertical stripes and lattice shapes. The arrangement of the multiple convex portions may be regular or irregular. The shape of the convex portions and the arrangement of the multiple convex portions are appropriately determined in consideration of various conditions. However, the skin material includes the same number of recesses as the multiple convex portions on the back side of the substrate and on the back side of the convex portions on the front surface of the substrate in the thickness direction. The recesses have a recessed shape corresponding to the convex shape of the convex portions provided on the front side of the recesses in the thickness direction, similar to the convex portions 30 and the recessed portions 40.

[0071] In the embossing mold, the shape of the embossed portion on the processing surface is appropriately determined according to the shape of the concave portion corresponding to the convex portion on the surface of the base material. In this case, the shape of the embossed portion is determined taking into consideration the relationship between the first value N1 and the second value N2 and the third value N3 and the fourth value N4 described above.

[0072] (3) The embossing mold 60 and the embossing receiving mold 70 have a flat plate shape (see Figs. 5 to 8). The embossing mold and the embossing receiving mold may be in the form of a roll. An embossing mold in the form of a roll may be called an embossing roll. An embossing receiving mold in the form of a roll may be called a receiving roll or a backup roll. The shapes of the embossing mold and the embossing receiving mold are appropriately determined in consideration of various conditions.

[0073] When the embossing mold and the embossing receiving mold have a roll shape, the first direction, the second direction, and the thickness direction used in the above-mentioned embodiment correspond to the circumferential direction, the axial direction, and the radial direction that specify the roll shape. That is, the first direction corresponds to the circumferential direction of the roll-shaped embossing mold and the embossing receiving mold. The second direction corresponds to the axial direction of the roll-shaped embossing mold and the embossing receiving mold. The above-mentioned axial direction coincides with the width direction of the roll-shaped embossing mold and the embossing receiving mold. The thickness direction corresponds to the radial direction of the roll-shaped embossing mold and the embossing receiving mold. When the position of the outer peripheral surface of the roll-shaped embossing mold facing the back surface of the substrate 20 is taken as a reference, the radial direction of the roll-shaped embossing mold coincides with the thickness direction. When the position of the outer peripheral surface of the roll-shaped embossing receiving mold facing the front surface of the substrate 20 is taken as a reference, the radial direction of the roll-shaped embossing receiving mold coincides with the thickness direction. The roll-shaped embossing mold and the embossing receiving mold sandwich the substrate 20 at the above-mentioned reference position.

[0074] In the flat embossing die 60, the region R3 of the processing surface 61 has a gently curved shape that is concave toward the back side in the thickness direction (see FIG. 7). In the roll-shaped embossing die, the region between the two embossed portions has a gently curved shape that is concave toward the center in the radial direction. In the roll-shaped embossing die, the center side in the radial direction coincides with the back side in the thickness direction at the next position. In the above-mentioned position, the region between the two embossed portions faces the back side of the substrate 20. In other words, when the above-mentioned position is used as a reference, it can be said that even in the roll-shaped embossing die, the region between the two embossed portions on the processing surface has a gently curved shape that is concave toward the back side in the thickness direction.

[0075] The embossing die is made of an elastic body and has a roll shape. In this case, the elastic body forming the embossing die forms the outer peripheral surface of the embossing die, and this outer peripheral surface becomes a receiving surface having elasticity. The embossing die made of an elastic body and having a roll shape may have a composite structure of a metal rod-shaped member and an elastic body. That is, the elastic part may be provided on the outer peripheral surface of the metal rod-shaped member. Such a composite structure can also be adopted for an embossing die made of an elastic body and having a flat plate shape. That is, the embossing die may include a metal plate-shaped member and a flat plate-shaped elastic body. The elastic body may be provided on the outer surface of the metal plate-shaped member that is the front side in the thickness direction. [Explanation of symbols]

[0076] 10 skin material, 20 substrate, 21 surface material, 22 backing material, 30 protruding portion 40 recess, 50 embossing device, 60 embossing die, 61 processing surface 62 embossing portion, 70 embossing receiving mold, 71 receiving surface, N1 first value N2 second value, N3 third value, N4 fourth value, R1,R2,R3 area

Claims

1. The surface of the substrate, which is a laminate, includes a three-dimensional pattern, A three-dimensional pattern having a shape obtained by inverting the three-dimensional pattern on the front surface of the substrate is included on the rear surface of the substrate, The substrate is A surface material having a surface that forms a surface of the substrate; A backing material is laminated on the back surface of the surface material, the back surface forming the back surface of the base material and being formed by a cushioning material, The three-dimensional pattern on the surface of the substrate is The first convex portion and the second convex portion are adjacent to each other in a first direction perpendicular to the thickness direction of the substrate, the first convex portion and the second convex portion being aligned in a direction in which the surface material and the backing material are laminated together; a region in the first direction between the first convex portion and the second convex portion on the surface of the base material is formed to have a concave shape on the back side in the thickness direction and a curved shape connecting the apexes of the two convex portions of the first convex portion and the second convex portion; The three-dimensional pattern on the back surface of the substrate is a first recess and a second recess adjacent to each other in the first direction; a region in the first direction between the first recess and the second recess on the back surface of the base material is formed into a curved shape that is convex toward the back surface in the thickness direction and connects bottoms of the first recess and the second recess; The first recess is provided on a rear side of the first protrusion in the thickness direction, The second recess is provided on a rear side of the second protrusion in the thickness direction, A maximum depth of the first recess from a back surface of the base is set to a first value; A maximum depth of the second recess from a rear surface of the base material is set to the first value; a maximum distance in the first direction between the first recess and the second recess is set to a second value that is four or more times larger than the first value.

2. The covering material of claim 1 , wherein the backing material is a laminate.

3. The first convex portion has a shape along a second direction perpendicular to both the thickness direction and the first direction, The second convex portion has the same shape as the first convex portion, The first recess has a shape along the second direction, the second recess has the same shape as the first recess, the three-dimensional pattern on the surface of the base material is a three-dimensional horizontal stripe pattern in which the first convex portions and the second convex portions are arranged along the second direction, 3. The skin material according to claim 1, wherein the three-dimensional pattern on the rear surface of the base material is a three-dimensional horizontal stripe pattern in which the first recesses and the second recesses are arranged along the second direction.

4. A method for producing a skin material according to any one of claims 1 to 3, comprising: a processing surface of an embossing mold including a first embossed portion having a shape corresponding to the first recess and a second embossed portion having a shape corresponding to the second recess is brought into contact with the back surface of the substrate without any gaps, the first embossed portion and the second embossed portion are pressed into the back surface of the substrate, and an elastic receiving surface of an embossing receiving mold made of an elastic body is brought into contact with the front surface of the substrate without any gaps, and the substrate is sandwiched between the embossing mold and the embossing receiving mold in the thickness direction, thereby forming a three-dimensional pattern of the front surface of the substrate on the front surface of the substrate and forming a three-dimensional pattern of the back surface of the substrate on the back surface of the substrate.

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