Design Sheet and Method for Manufacturing the Same

Abstract

To provide new sheet materials with unprecedented design and texture, as well as a method of adding value to out-of-spec products generated during fabric production.SOLUTION: A design sheet made by slicing a molded product comprising a plurality of fabrics laminated and bonded with resin has; thickness of 0.1 to 3 mm; the angle between the average direction of the fabrics in the sheet and the sheet surface of less than 15°; and a pattern formed on the sheet surface, or, a design sheet made by slicing a molded product consisting of a plurality of fabrics of different colors laminated and bonded by resin has; thickness of 0.1 to 3 mm; the angle between the average direction of the fabrics included in the sheet and the sheet surface of 15 to 90°; and a pattern formed on the sheet surface.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a design sheet having a pattern formed on the surface of the sheet and a method for manufacturing the same.

Background Art

[0002] As materials for interior products, sundries, stationery, decorative items, etc., various materials such as fabrics, leathers, papers, woods, plastics, glasses, metals, etc. are used appropriately according to the application. In recent years, with the diversification of designs, new materials having unprecedented design properties and textures have been demanded.

[0003] Among the above-mentioned materials that have been conventionally used, fabrics can express a variety of colors and have a soft texture. Therefore, they are widely used not only for interior products such as wallpapers, curtains, carpets, furniture, etc., but also for sundries, stationery, decorative items, etc.

[0004] Stacking multiple fabrics to form a thick laminate is widely practiced. At that time, it is also known to laminate using an adhesive. Patent Document 1 describes a fabric molded product obtained by overlapping fabrics impregnated with an adhesive to form a plate-shaped molded product and then compressing and drying it, which is said to be usable as a substitute for building materials, etc. However, the laminate is aimed at substituting for lumber and plywood, and nothing is described about its design properties.

[0005] Patent Document 2 describes a molded product in which five or more fabrics having different color tones are laminated and adhered with a thermoplastic resin, and a stripe pattern is formed on the cut surface of the molded product. This molded product is excellent in design properties due to the pattern formed on its cross section. However, in order to utilize the design of the cross section, it must be a thick molded product.

[0006] On the other hand, in the site where the fabric is manufactured, it is inevitable that non-conforming products are produced. For example, for fabrics whose color after dyeing deviates from the product specifications or those with defects during weaving, their economic value is extremely low, and there were only uses for downcycling such as discarding them or reprocessing them into felt as rags.

Prior Art Documents

Patent Documents

[0007]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0008] The present invention has been made to solve the above problems, and aims to provide a new sheet material having unprecedented design and texture. It also aims to provide a method for adding added value to non-conforming products generated during the manufacture of fabrics.

Means for Solving the Problems

[0009] The above problems are solved by providing a design sheet formed by slicing a molded product in which a plurality of fabrics are laminated and adhered with resin; the thickness of the sheet is 0.1 to 3 mm, the angle formed by the average surface direction of the fabrics included in the sheet and the sheet surface is less than 15°, and a pattern is formed on the sheet surface. At this time, it is preferable that the color tones of the plurality of fabrics are different.

[0010] The above problem is also solved by providing a design sheet obtained by slicing a molded product formed by laminating a plurality of fabrics with different color tones and bonding them with a resin; the thickness of the sheet is 0.1 to 3 mm, the angle formed by the average surface direction of the fabric contained in the sheet and the sheet surface is 15 to 90°, and a pattern is formed on the sheet surface.

[0011] In the design sheet, the fabric is preferably a woven fabric. The fabric is also preferably a knitted fabric. The fabric is also preferably a non-standard product or a recycled product. Further, it is also preferable that an emboss is formed on the design sheet.

[0012] A preferred embodiment of the present invention is a sewn product formed by sewing the design sheet. Another preferred embodiment of the present invention is an interior product formed by attaching the design sheet to a base material.

[0013] The above problem is also solved by providing a method for manufacturing the design sheet, in which a fabric and a thermoplastic resin film are alternately stacked, then heated to melt the thermoplastic resin, and then cooled while applying pressure to solidify the thermoplastic resin impregnated in the fabric, to form a molded product having a thickness of 5 to 500 mm, and slicing the obtained molded product to obtain a sheet having a thickness of 0.1 to 3 mm. At this time, it is preferable to slice the molded product with a slicer for manufacturing a veneer.

Effects of the Invention

[0014] The design sheet of the present invention has unprecedented design and texture, so it can provide a new sheet material for fields such as interior products, miscellaneous goods, stationery, and decorative items. Further, according to the manufacturing method of the present invention, a design sheet excellent in design can be manufactured in response to various design requirements.

[0015] When using off-spec products or recycled products as the raw material fabric, it becomes possible to add value to the low-value raw materials and provide products with excellent design. That is, so-called upcycling becomes possible, enabling the effective utilization of off-spec products and recycled products that have hitherto had to be downcycled or disposed of, and contributing to the sustainability of society as a whole.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Modes for Carrying Out the Invention

[0017] The design sheet of the present invention is obtained by slicing a molded product in which a plurality of fabrics are laminated and adhered with resin to a thickness of 0.1 to 3 mm, and a pattern is formed on the surface of the sheet.

[0018] First, the molded product before slicing will be described. The molded product is formed by laminating a plurality of fabrics and bonding them with resin.

[0019] The fabric used in the present invention is not particularly limited. Any of woven fabric, knitted fabric, and non-woven fabric can be used. The basis weight of the fabric is not particularly limited and is appropriately selected according to the application, but is usually 50 to 1000 g / m 2 2. The fiber material constituting the fabric is also not particularly limited, and natural fibers such as cotton, hemp, wool, and silk, synthetic fibers such as polyester, nylon, acrylic, and vinylon, semi-synthetic fibers such as rayon and acetate, etc. can be used. A fabric containing a plurality of types of fibers may be used. Also, a plurality of types of fabrics containing different fibers may be used and overlapped to obtain a laminate.

[0020] When bonding a fabric containing synthetic fibers using a thermoplastic resin, it is necessary that the melting point or softening point of the synthetic fiber is higher than the melting point or glass transition point of the thermoplastic resin. Specifically, the melting point or softening point of the synthetic fiber is preferably 200°C or higher, and more preferably 230°C or higher. Here, when the synthetic fiber has a clear melting point, the melting point should satisfy the above conditions, and when it does not, the softening point should satisfy the above conditions. Among synthetic fibers, polyester is preferably used because it has a high melting point and high strength.

[0021] In the case of natural fibers and semi-synthetic fibers, since they usually do not soften below 230°C, they are preferably used when bonding with a thermoplastic resin. In many cases, these fibers are decomposed by heating to a higher temperature. Among them, cellulose fibers such as cotton and hemp are preferably used when high-frequency dielectric heating or microwave heating is employed because the fibers contain moisture and have good heat resistance.

[0022] As the fabric used in the present invention, new good-quality products may be used, but it is preferable to use off-spec products or recycled products from both the cost and environmental aspects. Examples of off-spec products include those whose fabric color after dyeing deviates from the product specifications, those with defects during weaving, and those damaged or soiled during product handling. Examples of recycled products include fabric of inventory items not used for sewing, leftover fabric during cutting, inventory items after sewing, and recycled products after consumer use. Since the design sheet of the present invention can reduce waste by using off-spec products or recycled products, it can be said to be an environmentally friendly product. Moreover, since the value of the obtained design sheet is significantly improved compared to off-spec products or recycled products of raw materials, so-called upcycling is realized.

[0023] In the molded product before slicing, a plurality of fabrics are laminated and adhered with resin. Thereby, a molded product excellent in rigidity can be obtained, and a pattern excellent in design can be formed on the sliced surface. The number of fabrics to be laminated is preferably 10 or more, more preferably 20 or more, and still more preferably 50 or more. The upper limit of the number of fabrics to be laminated is not particularly limited, but considering productivity and the like, it is preferably 2000 or less, and more preferably 1000 or less.

[0024] It is preferable that the plurality of fabrics used in the present invention have different color tones. Due to the different color tones, a pattern due to the change in color is formed on the sliced surface. Here, "having different color tones" means that not all the fabrics have the same color tone. Fabrics with different color tones may be arranged randomly or regularly. The fabrics with different color tones may be stacked so that the target pattern is formed on the sliced surface. The number of color types may be 2 colors, or 3 colors, 4 colors, 5 colors or more, and can be appropriately adjusted according to the target design.

[0025] The plurality of fabrics used in the present invention may have the same color tone. Even in this case, in the case of "parallel slicing" described later, since the distance between the fabrics appearing on the slice surface is several millimeters or more, a pattern can be observed with the naked eye. The present inventor confirmed that when using a dark-colored fabric, the difference in color tone between the fabric and the resin can be recognized. Also, even when using a white fabric, it was confirmed that a pattern can be recognized as a difference in glossiness on the slice surface. In interior products and the like, patterns due to such slight differences in color tone and texture are often preferred.

[0026] The resin for adhering the plurality of fabrics to each other is not particularly limited, but a thermoplastic resin is preferable. When using a thermoplastic resin, the fabrics can be easily adhered to each other by heating and melting the resin, impregnating the fabric therewith, and then cooling. Also, since an inexpensive resin can be used, it is advantageous in terms of cost.

[0027] Examples of the thermoplastic resin used at this time include polyolefin, polyvinyl chloride, polycarbonate, acrylic resin, polyester, nylon, polystyrene, ABS resin, AS resin, etc. Among them, polyolefin with a relatively low melting point and low cost is preferably used. Polyolefin generally does not have good adhesiveness to other resins, but in the present invention, since the molten thermoplastic resin heated is impregnated into the fiber aggregate in the fabric by applying pressure, the fabrics can be adhered to each other sufficiently firmly. As the polyolefin, polyethylene such as low-density polyethylene and high-density polyethylene, and polypropylene can be used. An ethylene-propylene copolymer can also be used. Among them, low-density polyethylene is preferably used because of its low melting point and low cost. Here, the low-density polyethylene includes not only high-pressure method low-density polyethylene but also linear low-density polyethylene (LLDPE). Also, if it is used for interior applications such as wallpaper, it is preferable to use polyvinyl chloride. Thereby, the design sheet can be made flame-retardant. Also, a flame retardant may be blended in the resin, or a flame retardant may be attached to the fabric and then adhered using the resin.

[0028] The method of heating and melting a thermoplastic resin, impregnating a fabric therewith, and then cooling and adhering is not particularly limited. However, a method in which a fabric and a thermoplastic resin film are alternately stacked, then the thermoplastic resin is melted by heating, and then the thermoplastic resin impregnated in the fabric is solidified by cooling while applying pressure is preferred. By doing so, a molded article in which the fiber aggregate in the fabric is uniformly impregnated with the thermoplastic resin and the fabrics are firmly adhered to each other can be obtained.

[0029] The thermoplastic resin film to be stacked with the fabric has a melting point or glass transition point lower than the melting point or softening point of the fibers contained in the fabric. Here, when the thermoplastic resin film has a clear melting point, the melting point may satisfy the above conditions, and when it does not, the glass transition point may satisfy the above conditions. In order not to reduce the strength of the fibers during heating, it is preferable that the melting point or glass transition point of the thermoplastic resin film is 40 °C or more lower than the melting point or softening point of the fibers contained in the fabric, and more preferably 80 °C or more lower. The melting point or glass transition point of the thermoplastic resin contained in the film is preferably 60 to 180 °C, and more preferably 80 to 160 °C. By including the melting point or glass transition point of the thermoplastic resin within the above range, the fabric can be adhered while suppressing a decrease in fiber strength, and the heat resistance of the molded article can be ensured.

[0030] The thickness of the thermoplastic resin film disposed between the fabrics is not particularly limited and is usually 10 to 500 μm, preferably 20 to 300 μm. The thickness of the film is adjusted according to the basis weight and thickness of the fabric to be stacked. There may be only one film sandwiched between the fabrics, or there may be a plurality of films. When composed of a plurality of films, it is sufficient that the total thickness is within the above thickness range.

[0031] A laminate obtained by alternately stacking a fabric and a thermoplastic resin film is heated to melt the thermoplastic resin. The heating temperature is preferably higher than the melting point or glass transition point of the thermoplastic resin film and lower than the melting point or softening point of the fibers contained in the fabric. Examples of the heating method include heating in an oven, heating by heat transfer from the hot plate of a hot press, high-frequency dielectric heating, and microwave heating. When heating using an oven or a hot press device, the laminate must be heated by heat transfer. However, since the fabric contains air inside, the heat transfer coefficient is small. Therefore, a method using high-frequency dielectric heating or microwave heating is desirable. In particular, high-frequency induction heating is more preferable in terms of efficiently heating a thick molded body with a low heat transfer coefficient. Furthermore, it is particularly preferable to use a combination of high-frequency dielectric heating or microwave heating and heating with a heater to efficiently heat both the central part and the outer part. In order to efficiently heat by high-frequency dielectric heating or microwave heating, it is preferable that the fabric contains polar molecules such as moisture. Therefore, it is preferable that the fabric contains fibers with a high moisture content such as cellulose fibers, wool, silk, and nylon, and it is particularly preferable that the fabric contains cellulose fibers. At this time, the content of cellulose fibers in the fabric is preferably 10% by mass or more, and more preferably 20% by mass or more.

[0032] The laminated body heated in this way is cooled while being pressed to solidify the thermoplastic resin impregnated in the fabric. The method of solidifying the thermoplastic resin is not particularly limited, but it is preferable to use a cooling press. At this time, a method in which the laminated body preheated to melt the thermoplastic resin is pressed while being cooled to solidify while impregnating the fabric with the thermoplastic resin is preferable. Also, a method can be adopted in which the thermoplastic resin is melted while being impregnated into the fabric by pressing while heating using a hot press or the like, and then the thermoplastic resin is solidified by pressing while cooling. By solidifying the molten thermoplastic resin under pressure, the molten thermoplastic resin solidifies in a state where it is sufficiently impregnated into the gaps between the fibers in the fabric, and the fabrics are firmly adhered to each other. The pressure applied to the laminated body during cooling may be appropriately adjusted according to the use of the molded product. In order to adhere so that it does not peel off even when sliced, the pressure is preferably 1 N / cm 2 or more. In order to adhere more firmly, the press pressure is preferably 5 N / cm 2 or more, and more preferably 10 N / cm 2 or more. The upper limit value of the press pressure is not particularly limited, but considering the cost of equipment and energy, etc., it is realistic to set it to 10000 N / cm 2 or less. After the thermoplastic resin has solidified, the pressure is released to obtain a molded product.

[0033] The resin for adhering a plurality of fabrics to each other is not limited to the above thermoplastic resin. It is also possible to solidify an adhesive that is liquid at normal temperature to adhere the fabrics to each other and obtain a molded article. As such an adhesive, various adhesives can be used. For example, a reaction-type adhesive that solidifies by a chemical reaction, such as an epoxy resin, a urethane resin, or a silicone resin, can be used, or an emulsion adhesive such as an acrylic resin emulsion or a polyvinyl acetate emulsion can be used, or a water-soluble adhesive such as PVA paste or a solvent-type adhesive dissolved in an organic solvent such as a rubber-based adhesive can be used. However, when a dispersion medium or a solvent is included, a large amount of energy and time are required for drying, so it is preferable to use a reaction-type adhesive. Note that the adhesive here only needs to be able to adhere the fabrics to each other in the present invention, and it does not have to be one generally used as an adhesive.

[0034] The method of impregnating and then solidifying an adhesive that is liquid at normal temperature is not particularly limited. A laminate may be produced by stacking fabrics impregnated with an adhesive in advance, or the operation of stacking and coating the fabrics one by one may be repeated, or the stacked fabrics may be impregnated with an adhesive all at once. It is preferable to solidify the laminate impregnated with the adhesive while applying pressure from a direction perpendicular to the fabric. If it is a room-temperature reaction-type adhesive, the above operation will be performed within the time from the start of the curing reaction to solidification. If it is a heat-curing type adhesive, it is preferable to heat the laminate while applying pressure. Among these, from the viewpoints of ease of operation and productivity, it is preferable to use a heat-curing type adhesive. A molded article can be obtained by solidifying the laminate while applying pressure.

[0035] The suitable thickness of the molded product obtained as described above is 5 to 500 mm. The thicker the molded product, the larger the area of the design sheet that can be manufactured and the better the productivity. The thickness of the molded product is more preferably 10 mm or more, and even more preferably 20 mm or more. On the other hand, if the molded product is too thick, it may take a long time for heating and cooling, which may instead reduce the production efficiency, and the cost of the manufacturing equipment may also increase. The thickness of the molded product is more preferably 300 mm or less, and even more preferably 200 mm or less. Before slicing the obtained molded product, it is preferable to cut the periphery of the molded product with a saw or the like and adjust the shape into a rectangular parallelepiped shape as needed, and further, polishing and deburring may be performed as needed.

[0036] The design sheet of the present invention is manufactured by slicing the molded product to a thickness of 0.1 to 3 mm. As a result of intensive studies by the present inventor, it has been clarified that slicing can be performed thinly and smoothly using a slicer. The molded product contains a hard and anisotropic component derived from the fabric and a relatively soft and isotropic component that adheres the fabric, and it was expected that slicing them together would be difficult, but it has been clarified that slicing can be performed neatly by selecting an appropriate slicer. For example, it has been found that slicing can be performed by a slicer for veneer production for slicing natural wood in wood processing to obtain veneer. In particular, it is preferable to slice using a vertical thrust slicer with a large cutting force. Patterns derived from a plurality of fabrics appear on the sliced surface of the sheet.

[0037] The thickness of the design sheet of the present invention is 0.1 to 3 mm. It is preferable to slice thinly because the cost per unit area of the design sheet is reduced. The inventor has confirmed that in the case of using a woven fabric with a relatively large basis weight as described in Example 1, it can be sliced neatly when the thickness is 0.25 mm, and it can be sliced somehow even when the thickness is 0.2 mm. Considering that it is easier to slice thinly as the basis weight of the fabric included in the design sheet is smaller, the practical limit value of the slicable thickness is considered to be about 0.1 mm. Considering the stability of the slicing process and the strength of the obtained sheet, etc., the thickness of the sheet is preferably 0.15 mm or more, more preferably 0.2 mm or more. When sewing in a single layer or in cases where particular strength is required, it is preferably 0.3 mm or more. On the other hand, if the thickness of the design sheet exceeds 3 mm, the cost per unit area becomes too high and it cannot be used for applications that require flexibility. The thickness of the design sheet is preferably 2 mm or less, more preferably 1.5 mm or less, and even more preferably 1 mm or less.

[0038] One of the preferred embodiments of the design sheet of the present invention is a design sheet in which the angle formed between the average surface direction of the fabric contained in the sheet and the sheet surface is less than 15°, and a pattern is formed on the sheet surface. This embodiment is hereinafter referred to as "parallel slice". As described in Examples 1 and 3 below, even when slicing in a direction parallel to the stacked fabrics, due to the slight inclination during press molding, the slight inclination during cutting, and the deflection of the fabric within the molded product, etc., even if not intentionally inclined, an irregular and curved pattern is formed on the slice surface (FIG. 2, FIG. 9). A typical pattern formed at this time is a wave pattern. Of course, the pattern can also be adjusted by intentionally tilting or bending. From the viewpoints of workability and yield improvement, it is preferable to slice parallel to the fabric. In addition, since the patterns formed on the surface of the design sheet thus obtained are different for each sheet, it is natural when arranging the sheets for use. When the angle formed between the average surface direction of the fabric and the sheet surface is 15° or more, the pitch of the pattern becomes fine, so when using a single-color fabric, it becomes difficult to visually recognize the pattern. The angle is more preferably 10° or less, and even more preferably 5° or less. The pitch of the wave pattern in the parallel slice is preferably 3 to 450 mm. Since the pitch of the pattern is relatively large, the visibility is good.

[0039] In the case of parallel slice, since the fabrics in the design sheet exist at an angle close to parallel, the peel strength between adjacent fabrics is high, and the tensile strength of the entire sheet is also high. Therefore, it can be used for applications that utilize the strength and flexibility with a single layer of the design sheet. For example, it can also be applied to applications where leather is used. Moreover, since it is hardened with resin, as shown in FIG. 3, it is also excellent in water resistance, so it can also be used in places where leather cannot be used due to water resistance problems. Sewing and embossing can also be performed, and wallets as shown in FIGS. 4 to 6 can be manufactured. Also, even if it is thin, it has high rigidity, so it can be made into a firm cylindrical shape and used as a trash can (FIG. 7).

[0040] In the case of parallel slicing, by using woven fabric, the strength and rigidity can be improved compared to knitted fabric or non-woven fabric. On the other hand, since knitted fabric is less stiff than woven fabric, the fabric in the molded product is more likely to bend, and the pattern is more likely to be irregular. When a wave pattern is formed using woven fabric (Figure 2), a more irregular pattern can be obtained compared to this, and a design sheet (Figure 9) with a unique texture can be obtained.

[0041] Another preferred embodiment of the design sheet of the present invention is a design sheet in which a plurality of fabrics with different color tones are laminated, and the angle formed by the average surface direction of the fabric included in the sheet and the sheet surface is 15 to 90°, and a pattern is formed on the sheet surface. This embodiment will be hereinafter referred to as "non-parallel slicing". When the angle formed by the average surface direction and the sheet surface is 15° or more, the pitch of the fabric on the sheet surface becomes small, and in the case of a single color, the pattern is difficult to visually recognize. Therefore, in this case, a plurality of fabrics with different color tones are laminated. As described in Example 2 below, when sliced in a direction perpendicular to the stacked fabrics, a linear stripe pattern like a geological layer was formed, and a fine gradation was observed from a slightly distant position (Figure 8). By adjusting the inclination, the pitch of the stripe pattern can be adjusted. From the viewpoints of workability and reduction of waste amount, it is preferable to slice perpendicular to the fabric (i.e., 90°). The angle formed by the average surface direction of the fabric and the sheet surface is preferably 45° or more, more preferably 70° or more, and even more preferably 80° or more. Note that this angle refers to the acute angle among the angles formed by the average surface direction of the fabric and the sheet surface, and the maximum value is 90°. In the case of non-parallel slicing, since the area sliced at one time is narrower than that in parallel slicing, it is preferable from the viewpoint of productivity to stack a plurality of molded products in advance, bond them using an adhesive, and then slice them together. The pitch of the wave pattern in non-parallel slicing is preferably 0.1 to 3 mm. Since the pitch of the pattern is small, a gradation of the stripe pattern is observed.

[0042] In the case of non-parallel slices, since the fabric contained in the design sheet is not long and continuous in the plane direction of the sheet, the tensile strength is low. Therefore, it is preferably used by attaching it to a base material. For example, it is preferably used by attaching it to the surface of paper, cloth, wood, plastic, metal, etc. Of course, in the case of horizontal slices, it can be similarly used by attaching it to a base material.

[0043] As described above, the design sheet of the present invention is a new sheet material having unprecedented design and texture. It is suitable for interior products such as wallpaper, furniture, and household appliances and the decoration of their surfaces. Furthermore, it can be used for various purposes such as miscellaneous goods, stationery, and decorative items, and can exhibit excellent design.

Example

[0044] Example 1 [Parallel slice using woven fabric] As the fabric, a twill woven fabric made of 100% by mass of cotton and having a basis weight of 368 g / m 2 was used. As the thermoplastic resin film, a low-density polyethylene film with a thickness of 100 μm was used. The woven fabric and the film were each cut into a size of 50 cm × 50 cm, and 123 sheets of woven fabric and 122 sheets of film were alternately stacked so that the woven fabric was arranged on the lowermost and uppermost surfaces. The woven fabric used here contains two colors with different color tones, and they were arranged and stacked according to the desired surface design. The obtained laminate was heated for 16 minutes with a high-frequency dielectric heating device (13.56 MHz) equipped with a heater to melt the film. The temperature of the heater was set to 170°C.

[0045] The laminate heated in this way was sandwiched between cooling presses with a pressing pressure of 50 N / cm 2 , the polyethylene was solidified, and then the load was removed to obtain a molded product with a thickness of 50 mm with the woven fabric exposed on both surfaces. The obtained molded product was hard and had sufficient rigidity. Here, since the basis weight of the low-density polyethylene (density 0.92 / cm 3 ) film with a thickness of 100 μm is 92 g / m 2 , it contains 20% by mass of low-density polyethylene with respect to the total weight of the molded product.

[0046] After vertically cutting the periphery of the obtained molded product with a panel saw and then dividing it into two, a rectangular parallelepiped molded product with a length of 46 cm, a width of 23 cm, and a thickness of 4.7 cm was obtained. The appearance of the obtained molded product is shown in Fig. 1. This molded product was set on the stage of a vertical slicer so that the fabric was horizontal, and sliced in a direction parallel to the fabric, and a total of 30 design sheets with a thickness of 0.56 mm were obtained. The angle formed between the average surface direction of the fabric contained in the sheet and the sheet surface was less than 5°.

[0047] The appearance when the design sheet thus obtained was bent is shown in Fig. 2. Wave patterns were formed on the surface of the sheet, and the average pitch of the wave patterns was in the range of 10 mm to 200 mm, and a pattern with a pitch that was easy to observe visually was formed. Due to the influence of a slight inclination during press forming, a slight inclination during cutting, and the deflection of the fabric within the molded product, etc., an appropriate wave pattern was obtained even without intentionally inclining.

[0048] The obtained design sheet had sufficient toughness while having flexibility. Also, since it was impregnated with polyethylene, it could repel water and was excellent in water resistance (Fig. 3). Also, it could be cut and subjected to sewing or embossing, and photographs of wallets processed in such a way are shown in Figs. 4 to 6. Also, taking advantage of the fact that it was thin but had high rigidity, a cut was made at one end of the design sheet, it was rolled into a cylindrical shape, and the other end was inserted into the cut to form a cylindrical shape, and a photograph of attaching a bottom to make a trash can is shown in Fig. 7 (Fig. 7). Note that Figs. 3, 6, and 7 are photographs of examples of different colors created in the same way.

[0049] Reference Example 1 [Vertical Slicing Using Woven Fabric] As the fabric, a twill woven fabric containing 65% by mass of polyester and 35% by mass of cotton and having a basis weight of 160 to 260 g / m 2 was used. The average basis weight of the woven fabric used was 220 g / m 2It was. As the thermoplastic resin film, a low-density polyethylene film with a thickness of 100 μm was used. The woven fabric and the film were each cut into a size of 50 cm × 50 cm, and 207 woven fabrics and 206 films were alternately stacked so that the woven fabric was arranged on the lowermost and uppermost surfaces. The woven fabrics used here included 6 types with different color tones, and they were arranged and stacked according to the desired surface design. The obtained laminate was heated for 16 minutes with a high-frequency dielectric heating device (13.56 MHz) equipped with a heater to melt the film. The temperature of the heater was set at 170°C.

[0050] The laminate heated in this way was sandwiched between cooling presses with a pressing pressure of 50 N / cm 2 to solidify the polyethylene, and then the load was removed to obtain a molded product with a thickness of 55 mm and the woven fabric exposed on both surfaces. The obtained molded product was hard and had sufficient rigidity. Here, since the basis weight of the low-density polyethylene (density 0.92 / cm 3 ) film with a thickness of 100 μm is 92 g / m 2 , it contains 29 mass% of low-density polyethylene with respect to the total weight of the molded product.

[0051] The periphery of the obtained molded product was vertically cut with a panel saw and then divided into two to obtain a rectangular parallelepiped molded product with a length of 46 cm, a width of 23 cm, and a thickness of 5.5 cm. The obtained molded product was set on the stage of a vertical slicer so that the fabric was vertical, and sheets were cut out in a direction perpendicular to the fabric to obtain a total of 30 decorative sheets with a thickness of 0.68 mm. The angle formed between the average surface direction of the fabric contained in the sheet and the sheet surface was 85 to 90°.

[0052] The appearance of the thus obtained design sheet is shown in FIG. 8. Linear stripe patterns like a geological layer were formed on the surface of the sheet. The pitch between the fabrics laminated in contact with and separated from each other was within the range of 0.17 to 0.36 mm, and when observed from a slightly distant position, a fine gradation was observed. The obtained design sheet had flexibility and excellent water resistance.

[0053] Example 3 [Parallel Slicing Using Knitted Fabric] As the fabric, a knitted fabric containing 100% by mass of cotton and having a basis weight of 212 g / m 2 was used. As the thermoplastic resin film, a low-density polyethylene film with a thickness of 100 μm was used. The knitted fabric and the film were each cut into a size of 50 cm × 50 cm, and 139 knitted fabrics and 138 films were alternately stacked so that the knitted fabric was arranged on the lowermost and uppermost surfaces. The knitted fabrics used here included 5 types with different color tones, and were arranged and stacked according to the desired surface design. The obtained laminate was heated for 16 minutes with a high-frequency dielectric heating device (13.56 MHz) incorporating a heater to melt the film. The heater temperature was 170°C.

[0054] The laminate heated in this way was sandwiched between cooling presses with a pressing pressure of 50 N / cm 2 to solidify the polyethylene, and then the load was removed to obtain a molded product with a thickness of 40 mm and the woven fabric exposed on both surfaces. The obtained molded product was hard and had sufficient rigidity. Here, since the basis weight of the low-density polyethylene (density 0.92 / cm 3 ) film with a thickness of 100 μm is 92 g / m 2 , it contains about 30% by mass of low-density polyethylene with respect to the total weight of the molded product.

[0055] The periphery of the obtained molded product was vertically cut with a panel saw and then divided into two to obtain a rectangular parallelepiped molded product with a length of 46 cm, a width of 23 cm, and a thickness of 3.5 cm. This molded product was set on the stage of a vertical slicer so that the fabric was horizontal, and sliced in a direction parallel to the fabric to obtain a total of 5 decorative sheets with a thickness of 0.6 mm.

[0056] The appearance of the thus obtained design sheet is shown in Fig. 9. On the surface of the sheet, irregularly curved patterns are formed, and the average pitch of the patterns falls within the range of 10 mm to 400 mm, and patterns with a pitch that is easy to observe visually are formed. Due to the influence of a slight inclination during press forming, a slight inclination during cutting, and the deflection of the fabric within the molded product, irregular patterns are formed even without intentionally tilting. Compared to the design sheet obtained using woven fabric in Example 1, more irregular patterns are formed and it has a unique texture, presumably because the fabric has no stiffness.

Claims

1. A design sheet obtained by slicing a molded product formed by laminating a plurality of fabrics and bonding them with a resin, wherein; The resin is a thermoplastic resin selected from polyolefin or polyvinyl chloride, and the thermoplastic resin is impregnated in the fabric. The thickness of the sheet is 0.1 to 1.5 mm. The angle formed between the average surface direction of the fabric contained in the sheet and the sheet surface is 10° or less, and A design sheet having a pattern formed on the sheet surface.

2. The design sheet according to claim 1, wherein the color tones of the plurality of fabrics are different.

3. The design sheet according to claim 1 or 2, wherein the fabric is a woven fabric.

4. The design sheet according to claim 1 or 2, wherein the fabric is a knitted fabric.

5. The design sheet according to any one of claims 1 to 4, wherein the fabric is an off-spec product or a recycled product.

6. The design sheet according to any one of claims 1 to 5, on which an emboss is formed.

7. A sewn product obtained by sewing the design sheet according to any one of claims 1 to 6.

8. An interior product obtained by attaching the design sheet according to any one of claims 1 to 6 to a base material.

9. A method for manufacturing a design sheet according to any one of claims 1 to 6, comprising alternately stacking a fabric and a film of a thermoplastic resin selected from polyolefin or polyvinyl chloride, then heating to melt the thermoplastic resin, and then solidifying the thermoplastic resin impregnated in the fabric by cooling while applying pressure to form a molded product having a thickness of 5 to 500 mm, and slicing the obtained molded product to obtain a sheet having a thickness of 0.1 to 1.5 mm.

10. The method for manufacturing a design sheet according to claim 9, wherein the molded article is sliced by a slicer for manufacturing a veneer.

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