Surface material, method for producing the same, and interior material

Abstract

To provide a skin material which forms a gap between the face fabric and the lining and has a base cloth layer having a structure in which the two layers are joined together to produce a more excellent three-dimensional effect than before, and to provide a manufacturing method thereof and an interior material.SOLUTION: A skin material 1 has a design layer 11 and a base fabric layer 12. The design layer 11 has a surface layer 111 and a foam layer 112. The base fabric layer 12 has a face fabric 121 and a lining 122, and a joining yarn 123 for joining the two layers, the joining yarn 123 is a thermoplastic resin fiber that is erected between the face fabric 121 and the lining 122 and forms a gap 125 between the face fabric 121 and the lining 122, and the foam layer 112 and the face fabric 121 are joined to each other. An interior material 5 has a skin material 1 and a base material 3 to which the skin material 1 is stuck. A method for manufacturing a skin material 1 includes a step of joining the surface layer 111 and the base fabric layer 12 through a foamable adhesive formed into a foam layer 112.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a surface material, a method for manufacturing the same, and an interior material. More specifically, the present invention relates to a surface material provided with a base fabric layer having a gap between a front layer and a back layer, a method for manufacturing the same, and an interior material.

Background Art

[0002] Conventionally, an interior material in which a surface material for imparting a design is adhered to a base material is known. In particular, in some cases, a surface material having a tactile design in addition to a visual design is required. For example, a leather-like surface material having an embossed pattern corresponds to this. A leather-like surface material having an embossed pattern requires a unique tactile sensation corresponding to leather in addition to the design on its surface. As such a surface material, the technique of Patent Document 1 below is known.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Patent Document 1 discloses a surface material having a three-dimensional knitted fabric in which front and back two-layer knitted fabrics are joined by a joining thread as a base fabric layer. In this base fabric layer, concave heat-deformed portions are adjusted to a predetermined thickness by heat deformation of thermoplastic resin fibers that are joining threads, so that an embossed pattern can be formed. As a result, it is possible to obtain a surface material having a three-dimensional design consisting of a three-dimensional pattern with excellent aesthetics and a very high degree of design freedom. However, in the continuously evolving industrial design, there is a situation where more excellent design properties are constantly required, and even higher design properties and their degrees of freedom are required.

[0005] The present invention has been made in view of the above circumstances, and in a skin material provided with a base fabric layer having a structure in which two layers are joined while forming a gap between a surface fabric and a back fabric, it is possible to provide a skin material capable of producing a more excellent three-dimensional effect than before, a manufacturing method thereof, and an interior material.

Means for Solving the Problems

[0006] The present invention is as follows. [1] The skin material of the present invention is a skin material provided with a design layer and a base fabric layer, The design layer includes a surface layer and a foamed layer, The base fabric layer includes a surface fabric and a back fabric, and a connecting thread that connects these two layers, The connecting thread is a thermoplastic resin fiber that stands between the surface fabric and the back fabric and forms a gap between the surface fabric and the back fabric, The gist is that the foamed layer and the surface fabric are joined. [2] In the skin material of the present invention, the foamed layer can be thicker than the surface layer and thinner than the base fabric layer. [3] In the skin material of the present invention, the foamed layer can have closed cells. [4] In the skin material of the present invention, it can have a three-dimensional design formed by narrowing the gap in the thickness direction. [5] The interior material of the present invention has the gist of including the skin material of the present invention and a base material to which the skin material is attached. [6] The manufacturing method of the skin material of the present invention has the gist of including a joining step of joining the surface layer and the base fabric layer via a foaming adhesive that becomes the foamed layer.

Effects of the Invention

[0007] According to the skin material of the present invention, in a skin material provided with a base fabric layer having a structure in which two layers are joined while forming a gap between a surface fabric and a back fabric, it is possible to produce a more excellent three-dimensional effect than before. According to the interior material of the present invention, by using a skin material having a base fabric layer with a structure in which a gap is formed between the front fabric and the back fabric and these two layers are connected, a three-dimensional design superior to the conventional one can be provided.

Brief Description of the Drawings

[0008] The present invention will be further described in the following detailed description by way of non-limiting examples of typical embodiments according to the present invention, with reference to the plurality of drawings mentioned, wherein like reference numerals indicate like parts throughout several views of the drawings.

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Modes for Carrying Out the Invention

[0009] Hereinafter, the present invention will be described in detail with reference to the drawings. The matters shown here are illustrative and for illustrative purposes of embodiments of the present invention, and are described for the purpose of providing an explanation that can most effectively and easily understand the principle and conceptual features of the present invention. In this regard, it is not intended to show the structural details of the present invention more than necessary for a fundamental understanding of the present invention, and it is to clarify for those skilled in the art how some forms of the present invention are actually implemented by the description in combination with the drawings.

[0010] [1] Skin material The skin material (1) of the present invention is a skin material provided with a design layer (11) and a base fabric layer (12), The design layer (11) includes a surface layer (111) and a foam layer (112). The base fabric layer (12) includes a face fabric (121) and a back fabric (122), and a connecting thread (123) that connects these two layers. This connecting thread (123) stands between the face fabric (121) and the back fabric (122) and is a thermoplastic resin fiber that forms a gap (125) between the face fabric (121) and the back fabric (122). Furthermore, the foam layer (112) and the face fabric (121) are joined together (see Fig. 1).

[0011] In this way, by joining the design layer 11 and the base fabric layer 12 via the foam layer 112, when forming a three-dimensional design 15 (such as an embossed pattern or a stitch pattern) by hot pressing, it is considered that the heat applied to the skin material 1 can be prevented from staying or accumulating in the design layer 11. That is, due to the presence of the foam layer 112, it can be said that the heat dispersion capacity is increased compared to the mode without the foam layer 112. Therefore, even if sufficient heat is applied for forming the three-dimensional design, damage to the design layer 11 is suppressed, while the connecting thread 123 can be more surely thermally deformed. That is, in order to thermally deform the connecting thread 123, it is considered that damage to the design layer 11 can be prevented even if a higher temperature or a larger amount of heat is applied compared to the prior art. For this reason, according to this skin material 1, a more excellent three-dimensional effect can be produced compared to the prior art.

[0012] Furthermore, in addition to the above-described effect of increasing the heat dispersion capacity, it is considered that an increase in the rigidity of the entire design layer 11 also contributes advantageously to the production of an excellent three-dimensional effect. This is presumably because the rigidity of the entire skin material 1 increases by providing the foamed layer 112. That is, when a three-dimensional design 15 is applied to a skin layer with low rigidity, the skin material may become wavy. On the other hand, in this skin material 1 with high rigidity, even when a three-dimensional design is formed, no waviness occurs, and the three-dimensional design can have a clear and beautiful appearance. That is, it can be said that when the same basis weight is present in a foamed state rather than in a non-foamed state, the entire skin material 1 can obtain high rigidity, and thus an excellent three-dimensional effect can be produced.

[0013] In addition, due to the presence of the foamed layer 112, the thickness of the entire design layer 11 increases. That is, when the same basis weight is present, the thickness of the design layer 11 increases when the predetermined material is present in a foamed state rather than in a non-foamed state. When the three-dimensional design 15 is applied, especially when the design layer 11 around the three-dimensional design is extended, even in such a case, since the thickness is increased, skin functions such as chemical resistance and friction durability can be maintained at a high level. Also, when the design layer 11 around the three-dimensional design is extended, it is possible to prevent the uneven shape of the base fabric layer 12 from affecting the design layer 11 at that location. That is, it is possible to prevent the unevenness of the surface fabric 121 of the base fabric layer 12 from being reflected in the design layer 11 and being recognized as the uneven shape from the surface of the design layer 11.

[0014] The above-mentioned "design layer (11)" is a layer including a surface layer 111 and a foamed layer 112. The surface layer 111 is a layer having a design surface in the skin material 1. That is, for example, when the skin material 1 is used as an interior material (interior material for a room, interior material for a vehicle, etc.), it is the layer on the side exposed in the room or in the vehicle.

[0015] The surface layer 111 is a layer that forms the design in the design layer 11, and any layer can be used. For example, a resin layer (polyurethane, polyvinyl chloride, polypropylene, etc.), a woven fabric (design fabric), synthetic leather, artificial leather, natural leather, etc. can be used. These may be used alone or in combination of two or more. Further, the surface layer 111 may be composed of a single layer or multiple layers. As an example of the multi-layer embodiment, there is an embodiment in which a protective layer (top coat layer) is provided on the outermost layer of layers such as the resin layer, woven fabric, synthetic leather, artificial leather, and natural leather described above. The protective layer can be provided, for example, as a permeable resin coat layer (such as polyurethane).

[0016] Among the above, the surface layer 111 is preferably a polyurethane layer. This polyurethane layer may be in any form, but non-foamed polyurethane is preferred, and more preferably, polyurethane shaped into a film form. Also, the urethane raw material constituting the surface layer 111 is not limited and usually contains a polyol component and a polyisocyanate component. Among these, the polyol component is exemplified as a compound having at least two hydroxyl groups in the molecule, and examples include polycarbonate polyols, polyether polyols, polyester polyols, alkylene glycols, and polymer polyols using polyether polyols or polyester polyols. These may be used alone or in combination of two or more. Among these, it is preferable to contain a polycarbonate polyol, and examples of the polycarbonate polyol include polycarbonate diol.

[0017] The polyisocyanate component is exemplified as a compound having at least two isocyanate groups in the molecule, and examples include aliphatic polyisocyanates, aromatic polyisocyanates, and modified compounds thereof. These may be used alone or in combination of two or more. Examples of the aliphatic polyisocyanate include hexamethylene diisocyanate, isophorone diisocyanate, dicyclohexane methane diisocyanate and the like. Examples of the aromatic polyisocyanate include toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), naphthalene diisocyanate, xylylene diisocyanate, polymeric polyisocyanate (crude MDI) and the like. Further, examples of the modified polyisocyanate compound include carbodiimide-modified compounds of aliphatic polyisocyanate or aromatic polyisocyanate.

[0018] The thickness of the surface layer 111 is not limited, but for example, it can be 5 mm or less. More specifically, the surface layer 111 can be 5 μm or more and 1000 μm or less, and further can be 20 μm or more and 150 μm or less. Also, for example, when the above-mentioned protective layer is provided, the protective layer can occupy, for example, 0.1 μm or more and 20 μm or less, and further 1 μm or more and 10 μm or less of the above thickness.

[0019] The above-mentioned "foam layer (112)" is a resin layer that encloses bubbles formed by foaming. That is, the cell walls separating the bubbles in the foam layer 112 are formed of resin. Further, the bubbles constituting the foam layer 112 may be connected bubbles, but are preferably closed cells. In the case of closed cells, the heat dispersibility and heat insulation property as the skin material 1 can be provided in good balance. Further, the resin type constituting the foam layer 112 is not limited, and polyurethane resins, polyolefin resins, polyvinyl chloride resins, polystyrene resins, polyamide resins, urethane elastomers, thermoplastic elastomers and the like can be used. These may be used alone or in combination of two or more.

[0020] Among these, as the resin type, a polyurethane-based resin is preferable. That is, the foam layer 112 is preferably a foamed polyurethane layer. The foamed polyurethane layer may be any foamed polyurethane layer formed in any manner. That is, for example, as the foamed polyurethane layer, a laminated urethane layer formed by laminate molding, a slab urethane layer cut out from foamed polyurethane formed by slab molding, a mold urethane layer cut out from foamed polyurethane formed by mold molding, etc. can be mentioned. In addition, an injection-molded foamed polyurethane layer, a spray-foamed foamed polyurethane layer, a hot-melt type urethane layer, etc. can also be used.

[0021] Among these, the foam layer 112 of the skin material 1 of the present invention is preferably a foamed polyurethane layer formed by laminate molding. That is, it is preferably a foamed polyurethane layer formed by foaming a urethane adhesive. For example, among the above, the slab urethane layer can also be suitably used. However, when using the slab urethane layer, it is necessary to join the surface layer 111 and the slab urethane layer which is the foam layer 112 via an adhesive or the like. Further, it is also necessary to join the slab urethane layer which is the foam layer 112 and the fabric 121 of the base fabric layer 12 via an adhesive or the like.

[0022] On the other hand, for the laminated urethane layer, a foamed urethane raw material is applied between the surface layer 111 and the base fabric layer 12 (the fabric 121 of the base fabric layer 12) and reacted, so that while forming the foam layer 112, the surface layer 111 and the base fabric layer 12 can be joined. That is, the design layer 11 and the base fabric layer 12 can be joined by the foamed urethane layer 112. Thus, when using a laminated urethane layer as the foam layer 112, since there is no need to interpose another adhesive on the front and back of the foam layer 112, it is possible to prevent the inhibition of flexibility by the adhesive. In addition, it is possible to prevent the VOC problem when used as an interior material. Note that the method for forming this laminated urethane layer is not limited. For example, a one-component type urethane adhesive or a two-component type urethane adhesive may be used, and these may be used alone or in combination.

[0023] Also, the urethane raw materials used are not limited, and usually include a polyol component and a polyisocyanate component. Among these, the polyol component is exemplified as a compound having at least two hydroxyl groups in the molecule. For example, polycarbonate polyols, polyether polyols, polyester polyols, alkylene glycols, and polymer polyols using polyether polyols or polyester polyols can be mentioned. These may be used alone or in combination of two or more. Among these, it is preferable to contain a polycarbonate polyol. Examples of the polycarbonate polyol include polycarbonate diol. Examples of the above-mentioned polyether polyol include polyether polyols obtained by adding alkylene oxide to a polyhydric alcohol. Examples of the polyester polyol include polyester polyol compounds obtained by polycondensing aliphatic carboxylic acids and / or aromatic carboxylic acids with polyhydric alcohols. Further, examples of the alkylene glycol include polyhydric alcohols. In addition, regarding the polyisocyanate component, the description in the above-mentioned surface layer 111 can be applied as it is.

[0024] The above-mentioned urethane raw materials for forming the foam layer 112 can contain a foaming agent in addition to the polyol component and the polyisocyanate component. Examples of the foaming agent include water, hydrocarbons (such as pentane), liquefied carbon dioxide gas, alkylene chlorides (such as methylene chloride and ethylene chloride), and the like. These may be used alone or in combination of two or more. In addition to the above various components, various components such as catalysts, foam stabilizers, crosslinking agents, antioxidants, ultraviolet absorbers, fillers, internal mold release agents, and flame retardants can be blended into the above-mentioned urethane raw materials. These other components may be used alone or in combination of two or more. Examples of the catalyst include amines (amine compounds) and organometallic compounds. Also, as the foam stabilizer, various surfactants can be appropriately used.

[0025] The foam layer 112 of the skin material 1 of the present invention can be formed without using a foaming agent. Specifically, it can be formed by including air bubbles in the urethane raw material itself. For example, when mixing the polyol component and the polyisocyanate component, air bubbles can be included in the urethane raw material by foaming the mixed solution. At this time, if necessary, for example, a surfactant or the like can be utilized.

[0026] The thickness of the foam layer 112 is not limited, and for example, it can be 50 μm or more and 1000 μm or less. This foam layer 112 can further be 80 μm or more and 500 μm or less, and can be 100 μm or more and 300 μm or less.

[0027] The above-mentioned "base fabric layer (12)" is a layer including a face fabric 121 and a back fabric 122, and a connecting thread 123 that connects these two layers. Further, the base fabric layer 12 is a composite layer having a layer including the face fabric 121, a layer including the back fabric 122, and a layer including the connecting thread 123. The face fabric 121 and the back fabric 122 may each independently be a layer using a knitted fabric (double knitted fabric), a layer using a woven fabric, a layer using a non-woven fabric, a layer using a resin film, or a layer other than these. Further, it may be a layer composed of only one of these, or a composite layer using two or more types of layers. When the face fabric 121 and the back fabric 122 are layers using fibers, the constituent yarns thereof may be thermoplastic resin fibers or fibers other than thermoplastic resin fibers. Also, only one type of these fibers may be used, or two or more types may be used in combination.

[0028] Among the above, as the thermoplastic resin fiber, polyester fiber, polyamide fiber, polyacrylic fiber, polyolefin fiber, etc. can be used. Among these, as the polyester fiber, polyethylene terephthalate fiber, polybutylene terephthalate fiber, polytrimethylene terephthalate fiber, etc. can be mentioned. Further, as the polyamide fiber, various nylon fibers (nylon 6 fiber, nylon 66 fiber, etc.) can be mentioned. Further, as the polyacrylic fiber, various acrylic fibers containing polyacrylonitrile, etc. can be mentioned. Further, as the polyolefin fiber, polyethylene fiber, polypropylene fiber, etc. can be mentioned. In addition, vinylon fiber, polyurethane fiber, etc. can also be mentioned. These may be used alone or in combination of two or more. Among these, also, as the fiber other than the thermoplastic resin fiber, natural fiber and regenerated fiber, etc. can be mentioned. Among these, as the natural fiber, cotton, hemp, silk, wool, etc. can be mentioned. Also, as the regenerated fiber, cupra rayon, viscose rayon, lyocell, etc. can be mentioned. These may be used alone or in combination of two or more.

[0029] The form of the constituent yarn is not limited either, and it may be a filament yarn or a spun yarn. Also, in the case of a filament yarn, it may be a multifilament or a monofilament. Further, the constituent yarn may be a non-bulky processed yarn or a bulky processed yarn (twisted yarn, false-twisted processed yarn, fluid jet processed yarn, etc.). Furthermore, the fineness of the constituent yarn is not limited, and for example, it can be 50 dtex or more and 1500 dtex or less. In particular, constituent yarns such as 70 dtex or more and 1200 dtex or less, 150 dtex or more and 1200 dtex or less, 70 dtex or more and 500 dtex or less, 150 dtex or more and 500 dtex or less can be utilized. The fineness of each constituent yarn of the face fabric 121 and the back fabric 122 may be the same or different.

[0030] Among the various combinations described above, it is preferable that both the face fabric 121 and the back fabric 122 are layers (knitted fabric layer, knitted fabric) using a knitted fabric. Also, when both the face fabric 121 and the back fabric 122 are knitted fabrics, their thread densities are not limited, but the thread density in the course direction can be 10 threads / inch or more and 100 threads / inch or less, preferably 15 threads / inch or more and 70 threads / inch or less. Also, the thread density in the wale direction can be 5 threads / inch or more and 50 threads / inch or less. The thread density in the wale direction is more preferably 15 threads / inch or more and 50 threads / inch or less, even more preferably 8 threads / inch or more and 40 threads / inch or less, and particularly preferably 15 threads / inch or more and 40 threads / inch or less. The thread densities of the face fabric 121 and the back fabric 122 may be the same or different.

[0031] With the above-described fineness and thread density, the number of stitches can be reduced, and further, the size of the stitches can be reduced. For this reason, it is also possible to obtain a fabric with almost no stitches. Thus, when using a fabric with few and small stitches as the face fabric 121 and the back fabric 122, it is possible to suppress the connecting thread 123 from protruding from the fabric when forming the three-dimensional design 15.

[0032] The connecting thread 123 is a thermoplastic resin fiber that stands between the face fabric 121 and the back fabric 122 and forms a gap 125 between the face fabric 121 and the back fabric 122. The connecting thread 123 may connect the face fabric 121 and the back fabric 122 in any manner. For example, it can be connected by entangling the connecting thread on the face fabric side knitted into the face fabric 121 and the connecting thread on the back fabric side knitted into the back fabric 122. Also, the connecting thread 123 can have a function of narrowing the gap 125 formed between the face fabric 121 and the back fabric 122 in the thickness direction and maintaining its thickness by thermally deforming during the hot press for providing the three-dimensional design 15 (embossed pattern, stitch pattern).

[0033] As the connecting thread, thermoplastic resin fibers such as polyester fibers, polyamide fibers, polyacrylic fibers, and polyolefin fibers can be used. Among these, examples of polyester fibers include polyethylene terephthalate fibers, polybutylene terephthalate fibers, polytrimethylene terephthalate fibers, etc. Further, examples of polyamide fibers include various nylon fibers (nylon 6 fibers, nylon 66 fibers, etc.). Further, examples of polyacrylic fibers include various acrylic fibers containing polyacrylonitrile, etc. Further, examples of polyolefin fibers include polyethylene fibers, polypropylene fibers, etc. These may be used alone or in combination of two or more. Among these, In addition, the base fabric layer 12 can include other non-thermoplastic connecting threads while connecting the surface fabric 121 and the back fabric 122, as long as it does not inhibit the thermal deformation of the connecting thread 123 for forming the three-dimensional design 15. Specifically, fibers made of natural fibers such as cotton, hemp, silk, wool, etc. can be mentioned. By including such fibers in the connecting thread, softness can be imparted to the base fabric layer 12 while obtaining sufficient shape retention.

[0034] Also, the form of the connecting thread is not limited, but a filament yarn is preferred. In the case of a filament yarn, it may be a multifilament or a monofilament, but a monofilament is more preferred. A monofilament is preferred from the viewpoints of having the rigidity as a yarn, thickness retention, cushioning property, formability in the three-dimensional design 15, etc. Further, the connecting thread may be a non-bulky processed yarn or a bulky processed yarn (twisted yarn, false-twisted processed yarn, fluid injection processed yarn, etc.).

[0035] Furthermore, as the connecting thread 123, a thread containing a low-melting-point material in part thereof (hereinafter, also simply referred to as "fusible thread") can be used. More specifically, a fusible thread having a melting point lower than that of the constituent threads of the face fabric 121 and the back fabric 122 can be used. The fusible thread may be a single thread, or may be a twisted combination of a fusible thread and a non-fusible thread (a thread having a melting point higher than that of the fusible thread), or may be a monofilament thread obtained by laminating a fusible thread and a non-fusible thread alone or a twisted combination thereof, or may be a core-sheath monofilament thread alone, or may be a twisted combination thereof, etc. When this fusible thread is used, heat deformation can be made easier during hot pressing for providing the three-dimensional design 15 (embossed pattern, stitch pattern, etc.). Also, as the connecting thread 123, all or part of it can use a high-crimp thread. When using a high-crimp thread, even better cushioning properties and shape retention can be obtained.

[0036] Also, although the fineness of the connecting thread 123 is not limited, it can be 10 dtex or more and 1500 dtex or less. Further, this fineness is preferably 20 dtex or more and 1000 dtex or less, and more preferably 20 dtex or more and 350 dtex or less. Furthermore, although the thread density of the connecting thread 123 is not limited, the thread density in the course direction can be 10 threads / inch or more and 100 threads / inch or less, and preferably 15 threads / inch or more and 70 threads / inch or less. Also, the thread density in the wale direction can be 5 threads / inch or more and 50 threads / inch or less, and preferably 8 threads / inch or more and 30 threads / inch or less.

[0037] When the base fabric layer 12 having such a face fabric 121, a back fabric 122, and a connecting yarn 123 is a knitted fabric, the type of knitting or weave is not particularly limited. For example, it may be warp knitting or weft knitting. More specifically, double raschel knitting, raschel knitting, chain knitting, insert knitting, denim knitting (single tricot knitting), cord knitting, atlas knitting (bandage knitting), double denim knitting, half knitting, satin knitting, velvet knitting, queens cord knitting, rubber knitting (rib knitting), pearl knitting (garter knitting), plain knitting (calico knitting), double-sided knitting, milling knitting, mock roddy knitting, punch knitting, 3-hole punch knitting, milano rib knitting, single pique knitting, double pique knitting, triple pique knitting, crossmith knitting, brushed interlock knitting, etc. may be mentioned. These may be used alone or in combination of two or more kinds. Among these, it is preferably a thick knitted fabric (thick knitted fabric), and therefore, a three-dimensional knitted fabric, jersey, tricot, etc. are preferable, and among them, a three-dimensional knitted fabric is preferable, and double raschel knitting is more preferable. These structures preferably have a plain structure.

[0038] The thickness of the base fabric layer 12 (the normal thickness at the location where the three-dimensional design 15 is not formed) is not limited, but for example, it can be set to 1 mm or more and 20 mm or less. This thickness is more preferably 2 mm or more and 10 mm or less. Furthermore, the overall thickness of the skin material 1 (the normal thickness at the location where the three-dimensional design 15 is not formed) is not limited, but for example, it can be set to 2 mm or more and 25 mm or less. This thickness is more preferably 3 mm or more and 10 mm or less.

[0039] As described above, the skin material 1 of the present invention is excellent in the aspect having the three-dimensional design 15 (see Fig. 2). That is, when having the three-dimensional design 15, an excellent three-dimensional effect can be produced. Specifically, the surface layer 111 has the three-dimensional design 15. That is, it has the three-dimensional design 15 visually recognized from the surface layer 111. And this three-dimensional design 15 can be formed by the connecting yarn 123 narrowing the gap 125 in the thickness direction. That is, for example, by thermally deforming the connecting yarn 123, the gap 125 can be narrowed in the thickness direction to form the three-dimensional design 15 (embossed pattern, pseudo stitch pattern formed by thermal deformation, etc.). Also, the gap 125 can be narrowed in the thickness direction by the sewing thread penetrating the front and back of the skin material 1 to form the three-dimensional design 15 (stitch pattern). In the case of the stitch pattern in this case, the connecting yarn 123 is not thermally deformed.

[0040] Among the above, particularly in the three-dimensional design 15 by thermal deformation, the ratio at which the connecting yarn 123 narrows the gap 125 in the thickness direction is not limited, but the average thickness at the location where three-dimensional shaping (embossing) is not performed is D 0 (mm), and the depth of the concave portion of the embossed pattern 15 is D 15 (mm), when D 0 / D 15 ≧1.1 is preferable, 1.1≦D 0 / D 15 ≦8.0 is more preferable, 1.2≦D 0 / D 15 ≦6.0 is more preferable, 1.4≦D 0 / D 15 ≦5.0 is more preferable, 1.6≦D 0 / D 15 ≦3.5 is particularly preferable. In the embossed pattern 15 in such an aspect, the effects of the present invention can be obtained more effectively.

[0041] However, in the concave portion of this three-dimensional design (embossed pattern), the concave shape is formed by the thermally deformed connecting thread 123 narrowing the gap 125 in the thickness direction. Usually, the thickness of the foam layer 112 is substantially the same as the thickness of the foam layer 112 in the region without the embossed pattern. In the embossed pattern 15 in such a mode, the effects of the present invention can be obtained more effectively. More specifically, let the thickness of the foam layer 112 in the portion without the embossed pattern 15 (the region not heated and pressed) be D 112A and the thickness of the base fabric layer 12 be D 12A Furthermore, in the concave portion of the embossed pattern 15, let the thickness of the foam layer 112 at the portion where the thickness of the skin material 1 is the smallest be D 112B and the thickness of the base fabric layer 12 be D 12B In the case where it is set like this, 0 < D 12B / D 12A ≦ 0.6, and 0.8 ≦ D 112B / D 112A ≦ 1.2 can be set. This value can further be 0.3 ≦ D 12B / D 12A ≦ 0.5, and 0.9 ≦ D 112B / D 112A ≦ 1.1 can be set.

[0042] In addition, the specific shape of the three-dimensional design 15 (embossed pattern, etc.) is not limited. That is, for example, it may be linear (straight or curved), may be a shape with a wide concave in a predetermined region, or may be formed so as to draw a pattern. Also, the pattern is not limited.

[0043] The skin material 1 of the present invention may consist only of the above-described design layer 11 and base fabric layer 12, or may include other layers. Examples of other layers include a woven fabric layer, a resin sheet layer, etc. These may use only one layer or may use two or more layers in combination. The woven fabric layer can have a printed pattern, a woven pattern, coloring, etc. Similarly, the resin sheet can have a printed pattern, coloring, etc.

[0044] [2] Interior material The interior material 5 of the present invention has a skin material 1 and a base material 3 to which the skin material 1 is adhered (see Fig. 3).

[0045] The shape of the base material 3 is not limited, and it may be a solid body or a hollow body. Also, the material constituting the base material 3 is not limited, and it may be either an organic material or an inorganic material, or a composite material containing these. Examples of the organic material include thermoplastic resins and cured resins. As the inorganic material, metals, alloys, ceramics, etc. can be used. In particular, the base material 3 can be used as a vehicle interior material.

[0046] The method of disposing the skin material 1 on the base material 3 is not particularly limited, and examples include adhesion via an adhesive or the like, and known methods such as heat fusion. Also, other functional layers such as a sound absorption layer and an elastic layer may be interposed between the base material 3 and the skin material 1.

[0047] The skin material 1 and the interior material 5 in the present invention can be used in various technical fields. Specifically, they can be preferably used in fields related to skin materials in various industries such as vehicles (especially vehicle interior materials) such as automobiles and railway vehicles, airplanes, ships, buildings, and apparel. Specifically, it is useful in technical fields such as skin materials for vehicle interior materials such as door trims, roof trims, and seat covers, skin materials for furniture such as sofas, and skin materials for daily necessities such as bags, wallets, and clothes.

[0048] [3] Method for manufacturing the skin material The method for manufacturing the skin material of the present invention includes a joining step of joining a surface layer 111 and a base fabric layer 12 via a foaming adhesive that becomes a foaming layer 112. More specifically, the method for manufacturing the skin material of the present invention can include a step of forming a foamed urethane layer (foaming layer 112) by laminate molding. The laminated urethane layer can bond the surface layer 111 and the base fabric layer 12 (the outer fabric 121 of the base fabric layer 12) by applying a foaming urethane raw material between them and reacting, while forming the foamed layer 112. That is, the design layer 11 and the base fabric layer 12 can be bonded by the foamed urethane layer 112. In this way, when forming the laminated urethane layer as the foamed layer 112, there is no need to use other adhesives on the front and back of the foamed layer 112, so it is possible to prevent the inhibition of flexibility by the adhesive. In addition, it is possible to prevent the VOC problem when used as an interior material. In addition, the method for forming this laminated urethane layer is not limited. For example, a one-component urethane adhesive or a two-component urethane adhesive may be used, and these may be used alone or in combination.

[0049] Furthermore, this method can include a three-dimensional shaping step of forming the embossed pattern 15. The heating temperature during three-dimensional shaping is not limited and is appropriately selected according to each material. For example, this heating temperature can be 100 to 200 °C (especially 120 to 180 °C). Also, the heating time is not limited and can be, for example, 0.1 to 600 seconds. Furthermore, after performing three-dimensional shaping, a cooling step of cooling the shaped portion can be provided. The cooling method at this time is not particularly limited, and known methods can be mentioned. In addition, natural cooling (air cooling) may be used.

[0050] In addition, the reference numerals in parentheses for each configuration described in the above embodiment indicate the correspondence with the specific configurations described in the examples below.

Examples

[0051] Hereinafter, the present invention will be specifically described by way of examples. [1] Preparation of the skin material (Examples 1 to 2 and Comparative Example 1) <Example 1> The skin material 1 of Example 1 was prepared. Skin material 1: The overall thickness is about 4 mm. The design layer 11 consists of a surface layer 111 and a foamed layer 112. The surface layer 111 consists of a protective layer made of polyurethane with a thickness of about 5 μm and a resin layer made of polyurethane with a thickness of about 30 μm. The foamed layer 112 is a foamed polyurethane layer foamed to a thickness of about 190 μm, which is a layer formed by foaming a polyurethane adhesive. The base fabric layer 12 is a double raschel knitted fabric (thickness: about 3.5 mm) More specifically, it is a knitted fabric with a structure in which a face fabric 121 (constituent yarn: polyester-based resin fiber, thickness: about 0.6 mm) and a back fabric 122 (constituent yarn: polyester-based resin fiber, thickness: about 0.6 mm) are connected by a connecting yarn 123 (polyester-based resin fiber, height about 2.3 mm). The constituent yarns of the face fabric and the back fabric are 84 dtex in course 45, wale 30, and fineness, and the connecting yarn 123 is 33 dtex.

[0052] The skin material of Example 1 was placed on the receiving table of a heat press machine, and using a press mold, heat pressing was performed from the design layer 11 side under the conditions of a heating time of 20 seconds, a receiving table temperature of 200 °C, and a press mold temperature of 150 °C. Then, it was naturally cooled and demolded to obtain the skin material 1 of Example 1 in which the embossed pattern 15 formed in a concave shape was formed (see Figure 4). The appearance of its surface is shown in Figure 5.

[0053] In this skin material 1 of Example 1, the foamed layer 112 is a layer thicker than the surface layer 111, and the thickness D 112 (μm) of the foamed layer 112 and the thickness D 111 (μm) of the surface layer 111, the ratio is D 112 / D 111 = 5.4. Furthermore, the foamed layer 112 is a layer thinner than the base fabric layer 12, and the thickness D 112 (μm) of the foamed layer 112 and the thickness D 12 (μm) of the base fabric layer 12, the ratio is D 12 / D 112 = 184.

[0054] <Comparative Example 1> The skin material 9 of Comparative Example 1 was prepared. An epidermis material 9 identical to that of Example 1 was obtained, except that the foam layer 112 in the epidermis material 1 of Example 1 was not foamed and a non-foamed polyurethane layer with a thickness of 35 μm was used. Thereafter, an embossed pattern was formed in the same manner as in Example 1 to obtain the epidermis material 9 of Comparative Example 1. The appearance of its surface is shown in FIG. 6.

[0055] The present invention is not limited to the embodiments described in detail above, and various modifications or changes are possible within the scope shown in the claims of the present invention.

Industrial Applicability

[0056] The epidermis material and the structure of the present invention can be used in various technical fields. Specifically, it can be suitably used in fields related to epidermis materials in various industries such as vehicles (automobiles, railway vehicles, etc.), aircraft, ships, buildings, and apparel.

Explanation of Reference Numerals

[0057] 1; Epidermis material 11; Design layer 111; Surface layer, 112; Foam layer 12; Base fabric layer 121; Outer fabric, 122; Lining, 123; Connecting yarn, 125; Gap 15; Embossed pattern 3; Base material 5; Interior material

Claims

1. A skin material having a design layer and a base fabric layer, The design layer includes a surface layer and a foam layer, The base fabric layer includes a front layer, a back layer, and a binding yarn that binds these two layers together. The binding yarn is a thermoplastic resin fiber that is erected between the front and back fabrics and forms a gap between the front and back fabrics, The foam layer and the outer material are bonded to each other, The foam layer is a laminated urethane layer formed by reacting a urethane foam raw material, The gap is narrowed in the thickness direction by embossing to form a three-dimensional design, a thickness of the foam layer in the non-embossed portion is substantially the same as a thickness of the foam layer in the embossed recessed portion; a ratio D 12B / D 12A of a thickness D 12A of the base fabric layer in the portion not subjected to the embossing to a thickness D 12B of the base fabric layer in the portion where the thickness of the skin material in the recess is the thinnest, and a ratio D 112B / D 112A of a thickness D 112A of the foam layer in the portion not subjected to the embossing to a thickness D 112B of the foam layer in the portion where the thickness of the skin material in the recess is the thinnest are 0<D 12B / D 12A ≦0.6 and 0.8≦D 112B / D 112A ≦1.2 (however, this does not include synthetic leather which is provided with a fibrous base material and a polyurethane resin layer formed on the fibrous base material and has a grain pattern on its front surface, and in which the bending resistance of the front surface of the synthetic leather is 65 to 95 mm and the bending resistance of the back surface is 55 to 85 mm).

2. The skin material according to claim 1 , wherein the foam layer is thicker than the surface layer and thinner than the base fabric layer.

3. The skin material according to claim 1 or 2, wherein the foam layer has closed cells.

4. The average thickness D in the area where the embossing is not performed ０ (mm) and the depth D of the recess １５ (mm) D ０ / D １５ However, 1.1≦D ０ / D １５ 3. The skin material according to claim 1, wherein the viscosity is ≦8.

0.

5. The skin material according to claim 1 ; and a substrate having the skin material attached thereto.

6. A method for producing the skin material according to claim 1, comprising the steps of: A method for producing a skin material, comprising: a bonding step of bonding the surface layer and the base fabric layer via a foamable adhesive that becomes the foam layer.

Images