Napped leather-like sheet-like article

Abstract

This napped leather-like sheet-like article comprises a fibrous base material that is a woven or knitted fabric and a resin applied to the fibrous base material, and has, as the front surface thereof, a napped surface having naps to which the resin has been attached. The number of design points of yarns constituting the fibrous base material per 24.5 mm square is 1,500 to 10,000 in the case where a woven fabric is used and is 3,000 to 9,000 in the case where a knitted fabric is used. The total number of fibers involved in the crossing or tangling in the design points per 25.4 mm square is 396,000 to 2,640,000 in the case where a woven fabric is used and is 912,000 to 8,208,000 in the case where a knitted fabric is used. The constant load elongation rate is 5% or more, and the constant load set rate is less than 10%.

Description

Raised leather-like sheet material

[0001] The present invention relates to a napped leather-like sheet material.

[0002] Leather-like sheets are used, for example, for vehicle interior materials such as vehicle seats and door linings, interior materials such as furniture and chairs, and fashion materials such as bags and shoes. Leather-like sheets are generally produced by imparting a polymeric elastomer to a nonwoven fabric made of ultrafine fibers. Leather-like sheets are known that use a knitted or woven fabric as a fibrous substrate and impart a resin thereto (see Patent Documents 1 and 2).

[0003] Patent Document 3 describes an artificial leather in which a polymeric elastic body is added to a fiber entangled body in which ultrafine fibers and textiles are three-dimensionally intertwined, which has raised naps with a nap length of 200 to 600 μm and a density of 0.50 to 0.85 g / cm. ３ An artificial leather is disclosed. It is disclosed that this provides artificial leather that has a dense structure, a luxurious surface appearance, and excellent mechanical properties and morphological stability.

[0004] Japanese Patent Publication No. 2022-027095 Japanese Patent Publication No. 2013-147758 Japanese Patent Publication No. 2019-112744

[0005] In the artificial leather of Patent Document 3, ultrafine fibers with short fiber lengths constituting the fiber entanglement are fixed with an elastic polymer as a binder. Therefore, it was found that there were problems such as fuzz coming off due to wear and poor surface followability.

[0006] On the other hand, when a woven or knitted fabric is used as a fibrous base material in order to solve the above problem, there is a problem that the surface appearance is slightly inferior compared to fiber entangled bodies or non-woven fabrics due to the denseness of the raised naps and the appearance of tissue lines on the surface of the woven or knitted fabric.

[0007] The present invention has been made in view of the current situation, and its purpose is to provide a napped leather-like sheet material that uses a woven or knitted fabric as a fibrous base material, has a good surface appearance, and has good fuzz resistance and surface conformability.

[0008] The present invention includes the following embodiments: [1] A napped leather-like sheet material comprising a woven or knitted fibrous substrate and a resin applied to the fibrous substrate, the sheet having a napped surface on the front side thereof, the napped surface having nap formed by fibers constituting the fibrous substrate and having the resin applied thereto, the number of weaving points of the yarns constituting the fibrous substrate per 24.5 mm square of the sheet being 1,500 to 10,000 when the fibrous substrate is a woven fabric, and 3,000 to 9,000 when the fibrous substrate is a knitted fabric. [2] A napped leather-like sheet material according to [1], wherein the number of weaving points of the yarns constituting the fibrous substrate per 24.5 mm square of the sheet-like material is 3,500 to 9,000 when the fibrous substrate is a knitted fabric, the total number of fibers involved in the intersections or entanglements at the weaving points per 24.5 mm square of the sheet-like material is 396,000 to 2,640,000 when the fibrous substrate is a woven fabric, and 912,000 to 8,208,000 when the fibrous substrate is a knitted fabric, the constant load elongation is 5% or more in both the warp and weft directions of the sheet-like material, and the constant load set ratio is less than 10% in both the warp and weft directions of the sheet-like material. [3] A napped leather-like sheet material according to [1] or [2], wherein the number of weaving points of the yarns constituting the fibrous substrate per 24.5 mm square of the sheet-like material is 3,500 to 9,000 when the fibrous substrate is a knitted fabric. [4] A napped leather-like sheet material according to [1] or [2], wherein the fibrous substrate is a circular knitted fabric. [4] The napped leather-like sheet material according to [1] or [2], wherein the fibrous substrate is a double-knitted fabric. [5] The napped leather-like sheet material according to [1] or [2], wherein the fibrous substrate is a satin weave multi-layered fabric. [6] The napped leather-like sheet material according to any one of [1] to [5], wherein the resin is present at least on the front side of the fibrous substrate in the thickness direction where the nap is present. [7] The napped leather-like sheet material according to any one of [1] to [6], wherein the resin is a polyurethane resin alone or a mixture of a silicone resin and a polyurethane resin. [8] The napped leather-like sheet material according to any one of [1] to [7], wherein the rear surface of the sheet material is free of nap and a backing is provided on the rear surface. [9] The napped leather-like sheet material according to [8], wherein the backing contains a flame retardant and a binder resin.

[10] The napped leather-like sheet material according to any one of [1] to [9], wherein the density of the fibrous substrate is, when the fibrous substrate is a woven fabric, a warp density of 200 to 500 threads / 25.4 mm and a weft density of 50 to 150 threads / 25.4 mm, and when the fibrous substrate is a knitted fabric, a warp density of 40 to 110 courses / 25.4 mm and a weft density of 30 to 70 welted threads / 25.4 mm.

[0009] Here, "weaving point" refers to a point where the yarns constituting the fibrous substrate intersect or intertwine. That is, when the fibrous substrate is a woven fabric, the weaving point means a point where the warp yarn and the weft yarn intersect. When the fibrous substrate is a knitted fabric, the weaving point means a stitch where a sinker loop and a needle loop are intertwined, and the weaving point is calculated by counting each stitch as one point.

[0010] According to an embodiment of the present invention, a napped leather-like sheet material can be provided that has a good surface appearance, good resistance to shedding, and good surface conformability, while using a woven or knitted fabric as a fibrous substrate.

[0011] FIG. 1 is a cross-sectional schematic diagram of a napped leather-like sheet material according to one embodiment. FIG. 2 is a weave structure diagram of a satin weave (7-ply satin) of Example 1. FIG. 3 is a schematic diagram showing weave points of a knitted fabric. FIG. 4 is a weave structure diagram of a brushed weave of Example 13. FIG. 5 is a conceptual diagram showing the knitting structure of the front side of a brushed weave. FIG. 6 is a weave structure diagram of a mock lody weave of Example 16. FIG. 7 is a conceptual diagram of a test piece for explaining a fatigue durability testing method. FIG. 8 is a weave structure diagram of a 5-ply satin weave of Example 10. FIG. 9 is a weave structure diagram of a 6-ply satin weave of Example 11. FIG. 10 is a weave structure diagram of an 8-ply satin weave of Example 12. FIG. 11 is a weave structure diagram of a tucked weave of Comparative Example 4. FIG. 12 is a conceptual diagram showing the knitting structure of the front side of a tucked weave.

[0012] The napped leather-like sheet material according to this embodiment (hereinafter simply referred to as "sheet material") is a napped leather-like sheet material comprising a woven or knitted fibrous substrate and a resin applied to the fibrous substrate. The sheet material has a napped surface on the front side of the sheet material, which has nap formed by the fibers constituting the fibrous substrate and to which the resin is attached. The "front side" of the sheet material refers to the side (design surface) of the front or back side of the sheet material that is visible when in use.

[0013] FIG. 1 is a cross-sectional view schematically showing one example of a napped leather-like sheet material 10. The sheet material 10 includes a fibrous substrate 12 that is a woven or knitted fabric. In this example, a resin (not shown) is applied to the entire fibrous substrate 12. A front surface 11 of the sheet material 10 is provided with naps 14 made of fibers that constitute the woven or knitted fabric of the fibrous substrate 12. Resin is adhered to the fiber surfaces of the naps 14. A napped surface 16 having naps 14 with resin adhered thereto is formed on the front surface 11 of the sheet material 10. A back surface 13 of the sheet material 10 is not provided with naps.

[0014] In this embodiment, the fibrous substrate is a woven or knitted fabric. Therefore, compared to the case where a nonwoven fabric is used, it is possible to suppress shedding due to abrasion and improve surface conformability. In one embodiment, it is preferable that the fibrous substrate consists of only a woven or knitted fabric.

[0015] Surface conformability refers to the ease with which a sheet-like material conforms to the shape of a surface when used as a covering material and attached to the surface of an object. Specifically, it refers to the ability of the sheet-like material to stretch appropriately under tension when attached to a seat, and to prevent the sheet-like material from recovering from the stretch caused by the tension after attachment, resulting in wrinkles. Therefore, a sheet-like material with good surface conformability is less likely to wrinkle when attached to the surface of an object.

[0016] Examples of woven fabrics include plain weave, twill weave, and satin weave. Among these, satin weave is preferred, and examples include 5-ply satin, 6-ply satin, 7-ply satin, 8-ply satin, and 12-ply satin. The woven fabric may be a single-ply fabric or a multi-ply fabric. Preferred are single-ply fabrics, double-ply fabrics using face yarns and back yarns as warp threads, and triple-ply fabrics using face yarns, middle yarns, and back yarns as warp threads. When the fibrous substrate is a woven fabric, a multi-ply satin weave is preferably used, and a 5-ply or 7-ply satin double-ply fabric is more preferably used.

[0017] The fibrous substrate is preferably a knitted fabric. From the viewpoint of surface conformability, the fibrous substrate is more preferably weft knitted, and even more preferably circular knitted. Furthermore, a knitting structure in which a connecting yarn forms a needle loop and is knitted into the front yarn and the back yarn is preferred. Such a knitting structure includes double knitting, and among double knitting, suitable examples include a brushed structure and a mock lodie structure. Such a knitting structure increases the filling rate of the yarn in the needle loop, making the needle loop less likely to deform. Therefore, the effect of improving fatigue durability and fatigue strength can be enhanced. Furthermore, an increase in the constant load set rate can be suppressed, and the effect of improving surface conformability can be enhanced.

[0018] The fibrous base material may be colored with a dye or pigment, or may be uncolored.

[0019] The fiber material constituting the fibrous substrate is not particularly limited, and conventionally known natural fibers, regenerated fibers, semi-synthetic fibers, synthetic fibers, etc. can be used. These can be used alone or in combination of two or more. Among them, from the viewpoint of durability, particularly mechanical strength, heat resistance, and light resistance, synthetic fibers are preferred, polyester fibers are more preferred, and polyethylene terephthalate fibers are particularly preferred.

[0020] As the fibrous substrate, one having nap on the surface, i.e., a fibrous substrate having a napped surface, is used. The fibrous substrate has nap formed on at least one side thereof. Preferably, nap is formed on only one side of the fibrous substrate. The nap is formed by fibers constituting the woven or knitted fabric, and is constrained by the weaving or knitting structure. Therefore, it is possible to enhance the effects of improving the fluff resistance, abrasion resistance, and surface conformability. The nap is hair (fluff) provided on the surface of the fibrous substrate, and is also called "napped." The nap can be formed, for example, by opening the knitting structure or by raising the nap.

[0021] The fineness of the fibers constituting the nap (single fiber fineness) is not particularly limited, but is preferably 0.1 to 0.5 dtex, more preferably 0.1 to 0.4 dtex. A single fiber fineness of 0.1 dtex or more provides good abrasion resistance. A single fiber fineness of 0.5 dtex or less is advantageous for improving the surface appearance and touch.

[0022] The fineness of the yarn (yarn fineness) constituting the fibrous base material is not particularly limited, but is preferably 50 to 250 dtex, more preferably 50 to 200 dtex. A yarn fineness of 50 dtex or more can enhance the effects of improving abrasion resistance, fluffing resistance, fatigue durability, and fatigue strength. A yarn fineness of 250 dtex or less can enhance the effects of improving surface appearance and texture.

[0023] The thickness of the fibrous substrate is not particularly limited and may be, for example, 600 to 1500 μm. More specifically, when the fibrous substrate is a woven fabric, the thickness of the fibrous substrate is preferably 600 to 1500 μm, more preferably 800 to 1200 μm. When the fibrous substrate is a knitted fabric, the thickness of the fibrous substrate is preferably 600 to 1400 μm, more preferably 600 to 1300 μm, and even more preferably 800 to 1200 μm. When the thickness of the fibrous substrate is equal to or greater than the lower limit, the effects of improving abrasion resistance, fluffing resistance, fatigue durability, and fatigue strength can be enhanced. When the thickness of the fibrous substrate is equal to or less than the upper limit, the effect of improving texture can be enhanced.

[0024] The thickness of the fibrous base material is a value measured using a constant pressure thickness meter (for example, Peacock Dial Gauge H-30, manufactured by Ozaki Seisakusho Co., Ltd.) in accordance with JIS L1096:2010 8.4A method (JIS method), and is a thickness measured including the napped portion.

[0025] The above-mentioned single fiber fineness, thread fineness, and thickness of the fibrous substrate are those of the fibrous substrate before the resin is applied. The single fiber fineness, thread fineness, and thickness of the fibrous substrate in the napped leather-like sheet material after the resin is applied (i.e., the thickness of the napped leather-like sheet material) may be set within the same ranges.

[0026] The resin applied to the fibrous substrate adheres to the surface of the fibers that make up the fibrous substrate. By applying the resin to the fibrous substrate, smoothness can be imparted to the front surface of the napped leather-like sheet material, resulting in a sheet material with a good texture.

[0027] The resin is present on at least the nap-like surface side (i.e., the nap-like surface side) of the fibrous substrate in the thickness direction to provide good texture and abrasion resistance. The resin may be present throughout the thickness direction of the fibrous substrate. In this case, the resin is applied to the fibrous substrate while leaving the nap, rather than covering the entire nap-like surface of the fibrous substrate in a film-like manner (i.e., not like grained leather), thereby obtaining a nap-like leather-like sheet material having a suede-like or nubuck-like appearance and feel.

[0028] Examples of resins that can be applied to the fibrous substrate include silicone resins, polyurethane resins, polyester resins, and acrylic resins. These can be used alone or as a mixture of two or more. Among these, it is preferable to use silicone resins from the viewpoint of texture, and polyurethane resins from the viewpoint of abrasion resistance, and it is more preferable to use a mixture of these. By imparting smoothness to the front surface of the sheet-like material with silicone resins, it is possible to provide a good texture and reduce the load on the texture points due to abrasion. In addition, polyurethane resins can prevent the silicone resins from falling off during the manufacturing process, allowing the above-mentioned effects of the silicone resin to be fully exerted.

[0029] The silicone resin is not particularly limited, and examples thereof include methyl hydrogen silicone resin, amino-modified silicone resin, (meth)acrylic-modified silicone resin, etc. These can be used alone or in combination of two or more. Among them, methyl hydrogen silicone resin is preferred from the viewpoints of abrasion resistance and texture. Here, the (meth)acrylic-modified silicone resin means an acrylic-modified silicone resin and / or a methacrylic-modified silicone resin.

[0030] Examples of polyurethane resins include polyether-based polyurethane resins, polyester-based polyurethane resins, and polycarbonate-based polyurethane resins. These may be used alone or in combination. Among these, polycarbonate-based polyurethane resins are preferred from the viewpoint of abrasion resistance.

[0031] The mass ratio (in terms of solid content) of the silicone resin and polyurethane resin applied to the fibrous base material is not particularly limited, and may be, for example, silicone resin: polyurethane resin = 1:2 to 1:52, or 1:2 to 1:40.

[0032] Various additives such as a catalyst, a matting agent, a smoothing agent (e.g., silicone oil), a surfactant, a filler, a leveling agent, a thickener, a crosslinking agent, a penetrating agent, etc. may be added to the resin within a range that does not impair the effects of the present embodiment.

[0033] The amount of resin attached to the fibrous base material is not particularly limited. In one embodiment, the amount of resin attached to the fibrous base material is 10 g / m in terms of solid content from the viewpoint of wear resistance and fluff resistance. ２ It is preferable that the thickness is 40 g / m or more, and from the viewpoint of texture, ２ The amount of adhesion is more preferably 15 to 25 g / m in terms of solid content. ２ Here, the amount of the resin adhered does not include the amount of the additive. Also, the amount of the resin adhered does not include the amount of the resin contained in the backing described later. That is, the resin applied to the front surface side where at least the nap exists in the thickness direction of the fibrous substrate is considered as the first resin, and is distinguished from the binder resin (second resin) contained in the backing applied only to the back surface of the sheet-like material. Therefore, the amount of the resin adhered is the amount of the first resin adhered to the fibrous substrate.

[0034] The filling rate of the resin (first resin) relative to the fibrous substrate is not particularly limited. In one embodiment, the filling rate of the resin relative to the fibrous substrate is preferably 0.5 to 2.8% in the napped portion, more preferably 0.5 to 2.5%, and preferably 3 to 9% in the ground structure portion. By being equal to or greater than the lower limit, the effect of improving abrasion resistance and shedding resistance can be enhanced. By being equal to or less than the upper limit, a good texture is easily obtained. Here, the resin filling rate is the ratio of the resin cross section per area in the cross section of the napped portion or ground structure portion of the sheet-like material. The napped portion refers to the region where naps exist in the thickness direction of the sheet-like material. The ground structure portion refers to the main body portion of the fibrous substrate that constitutes a woven or knitted structure below the napped portion.

[0035] The density of the fibrous substrate is not particularly limited. When the fibrous substrate is a woven fabric, the density of the fibrous substrate is preferably a warp density of 200 to 500 threads / 25.4 mm and a weft density of 50 to 150 threads / 25.4 mm. More preferably, the warp density is 250 to 400 threads / 25.4 mm and a weft density of 50 to 100 threads / 25.4 mm. When the fibrous substrate is a knitted fabric, the density of the fibrous substrate is preferably 40 to 110 courses / 25.4 mm and 30 to 70 welder / 25.4 mm. More preferably, the density is 60 to 90 courses / 25.4 mm and 30 to 50 welder / 25.4 mm. When the density of the fibrous substrate is equal to or greater than the lower limit, an excellent surface appearance in which the grain lines of the woven or knitted fabric are not visible is easily obtained. This is also advantageous for improving the touch, abrasion resistance, shedding resistance, fatigue durability, and fatigue strength. By setting the density of the fibrous substrate to the upper limit or less, it is easy to obtain a good texture. Note that the density of the fibrous substrate is the density of the napped leather-like sheet material to which the resin is applied. The density before applying the resin may be set within the same range as above.

[0036] In this embodiment, the number of weaving points of the yarns constituting the fibrous substrate per unit area of ​​the sheet-like material is set as follows. That is, when the fibrous substrate is a woven fabric, the number of weaving points per 24.5 mm square of the sheet-like material is 1,500 to 10,000, preferably 1,800 to 7,000, more preferably 2,000 to 4,500, or even 3,000 to 7,000. Furthermore, when the fibrous substrate is a knitted fabric, the number of weaving points per 24.5 mm square of the sheet-like material is 3,000 to 9,000, preferably 3,500 to 9,000, more preferably 3,500 to 7,700, even more preferably 4,000 to 6,000, particularly preferably 4,500 to 5,500, or even 3,500 to 5,500. When the number of texture points is equal to or greater than the lower limit, the density of the fibrous substrate increases, resulting in an excellent surface appearance with no visible texture lines of the woven or knitted fabric, a good feel, and excellent abrasion resistance, resistance to shedding, fatigue durability, fatigue strength, and surface conformability. When the number of texture points is equal to or less than the upper limit, a good texture is obtained. The number of texture points mentioned above is the number of texture points in the napped leather-like sheet material to which the resin has been applied. The number of texture points before the resin is applied may be set within the same range as above.

[0037] In this specification, "per 24.5 mm square of the sheet" refers to a square area of ​​25.4 mm in the warp direction and 25.4 mm in the weft direction of the sheet (25.4 × 25.4 mm ２ The warp direction and weft direction of a sheet-like material refer to the directions in which the warp and weft threads run for woven fabrics, and to the length direction and width direction at the time of knitting for knitted fabrics.

[0038] When the fibrous substrate is a woven fabric, the weaving points are the points at which the warp and weft yarns intersect, as described above. For example, in the complete weave of a seven-ply satin double-weave fabric shown in Figure 2, the weaving points are the white points in the warp (front) row labeled "front" and the black points in the warp (back) row labeled "back."

[0039] In the case of a woven fabric, the number of weaving points per 24.5 mm square is calculated by the following formula (1). In the formula, n represents the number of weaves in the n-ply weave, and is, for example, an integer from 1 to 3. In the case of a single weave, n=1, in the case of a double weave, n=2, and in the case of a triple weave, n=3.

[0040] A ｋ represents the warp density of the k-th warp (counts / 25.4 mm). ｋ In the case of a single-ply fabric, the k-th warp thread represents the warp density of the fabric. In the case of a double-ply fabric, the k-th warp thread represents the face thread or the back thread, and A １ represents the warp density of the face yarn (first warp), and A ２ represents the warp density of the rear yarn (second warp). In the case of a triple weave, the kth warp represents the front yarn, middle yarn or rear yarn, and A １ represents the warp density of the face yarn (first warp), and A ２ represents the warp density of the middle thread (second warp thread), and A ３ represents the warp density of the rear yarn (third warp yarn).

[0041] B ｋ represents the number of intersections (pieces / piece) between the k-th warp thread and the weft thread in the weft repeat unit, and can be obtained from the weave structure diagram. Here, the weft repeat unit refers to the number of weft threads that form a complete weft structure, and can be obtained from the weave structure diagram. For example, in the weave structure diagram shown in Figure 2, the weft repeat unit is 14, and B １ and B ２ Each is two pieces per bottle.

[0042] C represents the weft density (counts / 25.4 mm), and D represents the repeat unit (counts) of the weft.

[0043] When the fibrous base material is a knitted fabric, the weaving points refer to stitches where sinker loops and needle loops are intertwined, as described above. That is, the areas surrounded by dotted lines in Fig. 3 are stitches (weaving points) where sinker loops and needle loops are intertwined, and the weaving points are calculated by counting each stitch as one point.

[0044] In the case of knitted fabrics, the formula for calculating the weaving points differs depending on the knitting structure, so the formula for calculating the weaving points is derived from each structure diagram, and the number of weaving points can be calculated from the obtained formula. For example, in the case of double knitting, the number of weaving points per 24.5 mm square is calculated using the following formula (2). In the formula, G Ｆ represents the course density (pieces / 25.4 mm) on the front surface. Ｆ represents the probability of existence of a texture point in the longitudinal direction (length direction) of the front surface. Ｆ represents the well density (wells / 25.4 mm) on the front surface. Ｆ represents the probability of existence of a texture point in the weft direction (width direction) of the front surface. Ｒ represents the course density (pieces / 25.4 mm) on the back surface. Ｒ represents the probability of existence of a texture point in the radial direction on the back surface. Ｒ represents the well density (wells / 25.4 mm) on the back surface. Ｒ represents the probability of existence of texture points in the latitude direction on the back surface.

[0045] For example, in the case of a brushed weave, the weave diagram is shown in Figure 4, and the knitting structure as viewed from the front side is simply shown in Figure 5. In this case, the existence probability H Ｆ As shown in FIG. 5, in the warp direction, there are texture points in three out of three courses, that is, G Ｆ Of which G Ｆ Since there is a tissue point at minute, H Ｆ = G Ｆ / G Ｆ The probability of existence of texture points in the radial direction on the back surface H Ｒ Similarly, for H Ｒ = G Ｒ / G Ｒ The probability of existence of texture points in the weft direction on the front surface, J Ｆ As shown in FIG. 5, in the horizontal direction, there are texture points in three out of three wells, that is, I Ｆ Among I Ｆ Since there is a tissue point at J Ｆ =I Ｆ / I Ｆ The probability of existence of texture points in the lattice direction on the back surface, J Ｒ Similarly, for J Ｒ =I Ｒ / I Ｒ Therefore, the number of texture points in the case of brushed texture is expressed by the following formula (2-1):

[0046] In the case of mock rody weave, the weave diagram is shown in Figure 6. From this weave diagram, on the front side, the face yarns and connecting yarns alternately form courses or welds. On the back side, the back yarns and connecting yarns alternately form courses or welds. From this weave diagram, the existence probability H Ｆ , J Ｆ , H Ｒ , J Ｒ is the same as in the case of brush tissue, i.e., H Ｆ = G Ｆ / G Ｆ , J Ｆ =I Ｆ / I Ｆ , H Ｒ = G Ｒ / G Ｒ , and J Ｒ =I Ｒ / I Ｒ Therefore, the number of tissue points in the case of mock Rody tissue is expressed by the above formula (2-1).

[0047] In this embodiment, the total number of fibers involved in the intersections or entanglements at the weaving points per unit area of ​​the sheet-like material (hereinafter also referred to as the "weaving point fiber number") is set as follows: That is, when the fibrous base material is a woven fabric, the total number of fibers involved in the intersections at the weaving points per 24.5 mm square of the sheet-like material is 396,000 to 2,640,000, preferably 500,000 to 1,848,000, more preferably 700,000 to 1,500,000, and even more preferably 800,000 to 1,300,000. Furthermore, when the fibrous substrate is a knitted fabric, the total number of fibers involved in entanglement at the weaving points per 24.5 mm square of the sheet-like material is 912,000 to 8,208,000, preferably 1,050,000 to 7,022,400, more preferably 1,500,000 to 4,000,000, and even more preferably 1,800,000 to 3,000,000. When the number of weaving point fibers is equal to or greater than the lower limit, the nap density increases, resulting in an excellent surface appearance with no visible weaving lines, a good feel, and excellent surface conformability. Furthermore, when the number of weaving point fibers is equal to or less than the upper limit, the texture is good (no core remains). The above number of weaving point fibers is the number in a napped leather-like sheet-like material to which a resin has been applied. The number of weaving point fibers before the resin is applied may be set within the same range as above.

[0048] Here, the number of fibers at a weaving point is the number of fibers obtained by calculating the number of fibers (also called single fibers) that make up the threads that intersect or intertwine at each weaving point present in a 24.5 mm square of the sheet-like material, and then adding up these numbers for all weaving points present in a 24.5 mm square.

[0049] When the fibrous base material is a woven fabric, the number of fibers at the weaving point is calculated by the following formula (3). In the formula, n, A ｋ , B ｋ , C and D are the same as in formula (1). ｋ represents the number of single fibers (pieces) of the kth warp yarn. ｋ In the case of a single-ply fabric, E represents the number of single fibers in the warp. １represents the number of single fibers in the surface yarn (first warp yarn), and E ２ represents the number of single fibers in the back yarn (second warp yarn). In the case of a triple-ply fabric, E １ represents the number of single fibers in the surface yarn (first warp yarn), and E ２ represents the number of single fibers in the middle yarn (second warp yarn), and E ３ represents the number of single fibers in the back yarn (third warp yarn), and F represents the number of single fibers in the weft yarn.

[0050] When the fibrous base material is a knitted fabric, the formula for calculating the number of fibers at a weaving point differs depending on the knitting structure, so a calculation formula can be derived from each weaving diagram, and the number of fibers at a weaving point can be calculated from the resulting formula. For example, in the case of a brushed weave, as shown in the weaving diagram in FIG. 4, on the front side, both the sinker loop and the needle loop are looped by the front yarn and the connecting yarn. Therefore, at the weaving point on the front side, a total of four fibers are involved in the entanglement: the front yarn and the connecting yarn that form the sinker loop, and the front yarn and the connecting yarn that form the needle loop. Therefore, the number of fibers involved in the entanglement at the weaving point on the front side is the sum of the number of single fibers of these four yarns. On the back side, both the sinker loop and the needle loop are looped by the back yarn and the connecting yarn. Therefore, at the weaving point on the back side, a total of four fibers are involved in the entanglement: the back yarn and the connecting yarn that form the sinker loop, and the back yarn and the connecting yarn that form the needle loop. Therefore, the number of fibers involved in the entanglement at the weaving point on the back surface is the sum of the number of single fibers of these four yarns.

[0051] From the above, in the case of a brushed texture, the number of texture point fibers is calculated by the following formula (4-1). In the formula, G Ｆ , I Ｆ , G Ｒ , and I Ｒ is the same as formula (2). K represents the number of single fibers in the face yarn. L represents the number of single fibers in the connecting yarn. M represents the number of single fibers in the back yarn.

[0052] In the case of a mock rody structure, as shown in the structure diagram in Figure 6, at a weaving point on the front side, a total of two fibers, the face yarn and the connecting yarn, are involved in the entanglement. Therefore, the number of fibers involved in the entanglement at the weaving point on the front side is the sum of the number of single fibers of these two yarns. At a weaving point on the back side, a total of two fibers, the back yarn and the connecting yarn, are involved in the entanglement. Therefore, the number of fibers involved in the entanglement at the weaving point on the back side is the sum of the number of single fibers of these two yarns. From the above, in the case of a mock rody structure, the number of fibers at a weaving point is calculated using the following formula (4-2).

[0053] In the formula, G Ｆ , I Ｆ , G Ｒ , and I Ｒ is the same as formula (2). K represents the number of single fibers in the face yarn. L represents the number of single fibers in the connecting yarn. M represents the number of single fibers in the back yarn.

[0054] The above-mentioned "number of single fibers" refers to the number of single fibers constituting the yarn, and for example, in the case of a multifilament yarn, it refers to the number of filaments constituting the multifilament yarn. When the yarn is a split yarn, the number of single fibers refers to the number of single fibers after splitting.

[0055] In the napped leather-like sheet material according to this embodiment, the nap length on the napped surface is preferably set to 200 to 500 μm. That is, the nap length when the resin is attached is preferably 200 to 500 μm. By setting the nap length to 200 μm or more, the surface appearance, abrasion resistance, and tactile feel can be improved. Furthermore, by setting the nap length to 500 μm or less, the abrasion resistance can be improved. The nap length is more preferably 250 μm or more, even more preferably 300 μm or more, and preferably 400 μm or less.

[0056] More specifically, when the fibrous substrate is a woven fabric, the nap length is more preferably 200 to 400 μm. When the fibrous substrate is a knitted fabric, the nap length is more preferably 200 to 500 μm, even more preferably 250 to 500 μm, still more preferably 250 to 400 μm, and particularly preferably 300 to 400 μm.

[0057] The above-mentioned napped length is the napped length of the napped leather-like sheet material to which the resin has been applied. The length of the nap before applying the resin may be set within the same range as above.

[0058] The length of the raised nap is measured as follows. That is, before measurement, the napped surface is stroked three times with a hand in the direction against the grain to make the nap stand up, and then the length of the raised nap (the length from the base to the tip of the nap) is measured. For the measurement, a vertical cross section of the napped leather-like sheet material is observed at 100x magnification with a microscope (for example, VHX-200 / 100F, manufactured by Keyence Corporation), the lengths of any 10 raised naps are measured, and the average value is calculated. Here, the "against the grain" direction is the direction opposite to the "with the grain" direction, and the "with the grain" direction is the direction in which the raised naps lie.

[0059] The napped leather-like sheet material according to this embodiment has a constant-load elongation of 5% or more in both the warp and weft directions. That is, the constant-load elongation of the sheet material in the warp direction is 5% or more, and the constant-load elongation of the sheet material in the weft direction is 5% or more. This gives the sheet material excellent surface conformability. Specifically, when stretched, the sheet material can be stretched appropriately. The constant-load elongation is affected by the number of weaving points and the number of weaving point fibers; the fewer the weaving points, the easier it is to stretch, and the more the weaving point fibers, the harder it is to stretch.

[0060] The constant load elongation of the sheet-like material is preferably 6 to 40% in both the warp and weft directions. Specifically, when the fibrous substrate is a woven fabric, the constant load elongation is preferably 5 to 20%, more preferably 5.5 to 15%. When the fibrous substrate is a knitted fabric, the constant load elongation is preferably 10 to 40%, more preferably 15 to 35%.

[0061] In this specification, the constant load elongation rate refers to the elongation rate when using a test piece with a width of 80 mm, gripping both ends of the test piece with a grip interval of 150 mm in the length direction and applying a load of 98.1 N for 10 minutes. The detailed measurement method is as described in Examples.

[0062] The napped leather-like sheet material according to this embodiment has a constant-load set ratio of less than 10% in both the warp and weft directions. That is, the constant-load set ratio in the warp direction of the sheet material is less than 10%, and the constant-load set ratio in the weft direction is less than 10%. This provides the sheet material with excellent surface conformability. Specifically, when the sheet material is stretched and attached, it can be prevented from remaining stretched and unable to return to its original shape. Therefore, it can conform to surfaces of various shapes. The constant-load set ratio is affected by the number of weaving points and the number of weaving point fibers; the more weaving points there are, the lower the constant-load set ratio. Furthermore, the greater the number of weaving point fibers, the less likely the yarns are to move at the weaving points, resulting in a lower constant-load set ratio.

[0063] The constant load setting ratio of the sheet-like material is preferably 0 to 8.5% and may be 0.5 to 8.5% in both the warp and weft directions. Specifically, when the fibrous substrate is a woven fabric, the constant load setting ratio is preferably 6% or less and may be 0.5 to 6%. When the fibrous substrate is a knitted fabric, the constant load setting ratio is preferably 8.5% or less and may be 0.5 to 8.5%.

[0064] In this specification, the constant load set rate refers to the residual elongation rate after a test piece having a width of 80 mm is gripped at both ends of the test piece at a gripping distance of 150 mm in the longitudinal direction, a load of 98.1 N is applied for 10 minutes, the load is released, and the test piece is left for 10 minutes. The detailed measurement method is as described in the Examples.

[0065] In one embodiment, the napped leather-like sheet may have a backing on its back surface. In a preferred embodiment, the back surface of the sheet may not have nap, and a backing that is a resin layer may be provided on the back surface where napped leather-like sheet is not formed.

[0066] When the fibrous substrate is a woven fabric, the backing is provided, for example, to impart flame retardancy and prevent fraying, and when the fibrous substrate is a knitted fabric, the backing is provided, for example, to impart flame retardancy. The backing can be formed by applying a backing agent containing a flame retardant and a binder resin to the back surface of the fibrous substrate. In addition to the flame retardant and binder resin, the backing agent may also contain various additives such as a solvent and a thickener.

[0067] The flame retardant is not particularly limited, and for example, a phosphorus-based flame retardant can be used. Examples of phosphorus-based flame retardants include ammonium polyphosphate, aluminum phosphate, phosphate ester, guanidine phosphate, and organic phosphine oxide. These can be used alone or in combination of two or more.

[0068] The binder resin may be a resin that functions as a binder for adhering the flame retardant to the fibrous substrate, such as polyurethane resin, acrylic resin, silicone resin, or vinyl chloride resin. Polyurethane resin is preferred. The mass ratio (solids equivalent) of the flame retardant to the binder resin is not particularly limited, and may be, for example, flame retardant:binder resin = 5:5 to 9:1, or 6:4 to 8:2.

[0069] The amount of backing agent applied to the sheet-like material is not particularly limited, and is preferably 10 to 100 g / m as the amount of solid content (i.e., the amount of backing). ２ Or 40 to 80 g / m ２ That's fine too.

[0070] The method for producing the napped leather-like sheet material according to this embodiment is not particularly limited. The production method according to one embodiment includes, in this order: (1) forming nap on at least one surface of a fibrous substrate, which is a woven or knitted fabric, using fibers constituting the woven or knitted fabric; and (2) applying a resin to the napped fibrous substrate. The method may further include (3) subjecting the resin-applied fibrous substrate to at least one bath treatment selected from the group consisting of dyeing, scouring, and soaping. The method may also include (4) applying a backing to the back surface of the fibrous substrate. Since the resin is applied to the fibrous substrate in (2) before the bath treatment in (3), the abrasion resistance can be improved.

[0071] In the step (1) of forming the raised nap, the method of forming the raised nap is not particularly limited, and known methods can be used. For example, a method of opening a knitted fabric such as a double woven fabric, a sinker pile circular knitted fabric, or a double knitted fabric, and a method using a raising machine such as a card cloth raising machine or an emery raising machine can be used. Among these, a method using a raising machine is preferred from the viewpoint of appearance and feel. Methods using a raising machine include full-cut raising, semi-cut raising, and loop raising, with semi-cut raising being more preferred. Here, full-cut raising is raising in which all of the fibers constituting the loop-shaped raised yarn are cut. Semi-cut raising is raising in which some of the fibers constituting the loop-shaped raised yarn are cut. Loop raising is raising in which the loop-shaped raised yarn is not cut.

[0072] In the resin application step (2), a resin composition liquid is applied to a fibrous substrate. The resin composition liquid may contain a solvent such as a highly polar solvent, if necessary. From the viewpoint of environmental load, water is preferably used as the solvent.

[0073] The method for applying the resin composition liquid to the fibrous substrate can be any of various conventionally known methods, and is not particularly limited. For example, dipping, coating, spraying, printing, and the like can be used. Among these, dipping is preferred because it allows the resin to be applied uniformly to the fibrous substrate.

[0074] When dipping is used as a method for applying the resin composition liquid to the fibrous substrate, the pickup rate is not particularly limited, but is preferably 20 to 80 mass %. By having the pickup rate in this range, the desired amount can be applied evenly.

[0075] After applying the resin composition liquid to the fibrous substrate, heat treatment is performed as needed. The heat treatment is performed to evaporate the solvent in the resin composition liquid and dry the resin. Furthermore, when using a catalyst or crosslinking agent that causes a crosslinking reaction by heat treatment or when using a two-component curing resin, the heat treatment is performed to promote the reaction and form a coating with sufficient strength. The heat treatment temperature may be, for example, 130 to 190°C or 150 to 170°C. The heat treatment time may be 1 to 3 minutes or 2 to 3 minutes.

[0076] The bath treatment step (3) is not particularly limited, and any desired step can be adopted. Examples include a dyeing step, a scouring step, a soaping step, etc. These steps are conventionally known steps, and conventionally known methods can be used.

[0077] The backing treatment step (4) is not particularly limited, and involves applying a backing agent to the back surface (i.e., the surface opposite to the napped surface) of a fibrous substrate to which a resin has been applied or a fibrous substrate that has been further dyed, etc. After application, a heat treatment is performed to form a backing layer on the back surface of the fibrous substrate.

[0078] The napped leather-like sheet material of this embodiment uses a woven or knitted fabric as the fibrous substrate, and its density (number of weaving points and number of fibers at weaving points) is specified, which allows it to achieve a surface appearance and texture comparable to artificial leathers using nonwoven fabric as the fibrous substrate, as well as excellent shedding resistance, fatigue durability, fatigue strength, and surface conformability.

[0079] The applications of the napped leather-like sheet material according to this embodiment are not particularly limited. Specific examples of applications include interior materials for various vehicles, such as automobile seats, ceiling materials, dashboards, door linings, and steering wheels. Other applications include interior applications such as sofa and chair coverings, and fashion applications such as bags and shoes.

[0080] The various numerical ranges described in this specification can be arbitrarily combined with their respective upper and lower limit values, and all such combinations are considered to be preferred numerical ranges described in this specification. Furthermore, a numerical range described as "X to Y" means from X to Y.

[0081] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to the following examples.

[0082] Each evaluation item was performed according to the following method.

[0083] [Constant Load Elongation] Three test pieces measuring 80 mm wide and 250 mm long were taken from the sheet material in each of the warp and weft directions. Each test piece was marked with a 100 mm interval in the center of the length direction. The test piece was attached to the grips of a constant load elongation tester (Martens type) (manufactured by Daiei Scientific Instruments Manufacturing Co., Ltd.) with a grip spacing of 150 mm and no slack, under an atmosphere of room temperature 23±2°C and humidity 50±5% RH. A load of 98.1 N, including the weight of the grip, was applied to the lower grip. After leaving the specimen for 10 minutes, the distance L (mm) between the gauge lines was measured, and the constant load elongation (%) was calculated using the following formula: Constant Load Elongation (%) = {(L - 100) / 100} × 100. The constant load elongation was calculated by averaging the measurements of three test pieces in each of the warp and weft directions. If the constant load elongation percentages in both the warp and weft directions are 5% or more, the surface conformability is excellent.

[0084] [Constant Load Set Rate] Three test pieces measuring 80 mm wide and 250 mm long were taken from the sheet material in both the warp and weft directions. Each test piece was marked with a 100 mm interval in the center of the length direction. The test piece was attached to the grips of a constant load elongation tester (Martens type) (manufactured by Daiei Scientific Instruments Manufacturing Co., Ltd.) at a room temperature of 23±2°C and a humidity of 50±5% RH with a grip spacing of 150 mm so as not to slacken. A load of 98.1 N, including the weight of the grip, was applied to the lower grip. After leaving the test piece for 10 minutes, the test piece was removed from the tester and left on a horizontal table for 10 minutes. After leaving the test piece for 10 minutes, the distance L1 (mm) between the gauge lines was measured. The constant load set rate was calculated using the following formula: Constant load set rate (%) = {(L1 - 100) / 100} x 100 The constant load set rate was determined by calculating the average of the measurements of three test pieces in each of the warp and weft directions. If the constant load set rates in both the warp and weft directions are less than 10%, the surface followability is excellent.

[0085] [Fatigue durability (seam fatigue)] Two sets of test pieces, each 100 mm wide and 100 mm long, were taken from the sheet material in the warp and weft directions, with two pieces in each set. The two test pieces were overlapped with their front surfaces facing each other and sewn together at a position 6 mm from the edge of one side. The sewing conditions were as follows: knitting needle: No. 21-S (manufactured by Organ Needle Co., Ltd.), sewing thread: polyester #8, stitch type: lock stitch, stitch pitch: 25±2 stitches / 100 mm. A total of four 92 mm straight cuts were made perpendicular to the sewn edges, 25 mm from both ends of each of the two edges opposite the sewn edges, to prepare test pieces (see FIG. 7).

[0086] Using a TTD-type seam fatigue tester (TTD-100, manufactured by Daiei Scientific Instruments Manufacturing Co., Ltd.), the clamp was set in the center of the three sections divided by the above-mentioned notches. The test piece was placed horizontally and fixed to the left and right chucks at a distance of 120 mm so that the seam was centered. Each side was repeatedly pulled 2,500 times with a load of 29.4 N, a stroke of 150 mm, and a speed of 30 times / min. After 2,500 pulls, the maximum value of seam slippage (hole dimensions) was measured in a stationary state with the load applied. Fatigue durability was expressed as the larger value of the two sets of test pieces for each of the warp and weft directions. A result of 2.2 mm or less can be considered to have excellent fatigue durability.

[0087] [Fatigue Strength (Seam Strength)] Three sets of 100 mm wide and 100 mm long test pieces were taken from the sheet material in the warp and weft directions, with two pieces in each set. The two test pieces were overlapped face-to-face and sewn together at a position 6 mm from the edge of one side. The stitching conditions were: knitting needle: No. 21-S (Organ Needle Co., Ltd.), sewing thread: polyester #8, stitch type: lockstitch, stitch pitch: 25±2 stitches / 100 mm. Using a tensile tester (Autograph AG-1, Shimadzu Corporation), the test pieces were gripped at a 76 mm interval with a gripping jig (sizes: front side: 25.4 mm vertical x 25.4 mm horizontal, back side: 25.4 mm vertical x 50.8 mm horizontal) (see Figure 8). The load (N) required to break the test piece when pulled from this state at a rate of 200 mm / min was measured. The fatigue strength was expressed as the minimum value of three sets of test pieces for each of the warp and weft directions. If the result was 300 N or more, it could be said that the fatigue strength was excellent.

[0088] [Abrasion Resistance / Peeling] A test piece measuring 70 mm wide and 300 mm long was taken from the weft direction of the sheet material, and a urethane foam sheet measuring 70 mm wide, 300 mm long, and 10 mm thick was attached to the backside and fixed to a T-TYPE flat abrasion tester (manufactured by Daiei Kagaku Seiki Seisakusho Co., Ltd.). A load of 9.8 N was applied to a friction element covered with cotton cloth (cotton canvas), and the front surface (napped surface) of the test piece was rubbed. The friction element was rubbed 10,000 times at a speed of 60 reciprocations / minute over a distance of 140 mm on the front surface of the test piece. The front surface of the test piece was observed before and after friction, and the abrasion resistance was evaluated according to the following criteria. In addition, the table indicates that there was peeling and indicates that there was no peeling. <Evaluation Criteria> Grade 5: No change in the condition of the worn area. Grade 4: The surface fibers are slightly tangled along the worn surface, but are barely noticeable. Grade 3: The surface fibers are tangled along the worn surface, but are barely noticeable. Grade 2: The surface fibers are tangled along the worn surface and are extremely noticeable. Some shedding has occurred. Grade 1: The tangled fibers and threads have come off (shedding has occurred), and the base thread is visible.

[0089] [Handle (Bending Resistance)] Measurement was performed in accordance with JIS L 1096:2010 Method A (45° cantilever method) with the front surface of the test piece facing upward. If the result was 130 mm or less in both the warp and weft directions, it can be said that the hand is excellent.

[0090] [Feel (sensory evaluation)] The napped leather-like sheet material was gripped by hand and evaluated according to the following evaluation criteria. <Evaluation criteria> Grade 5: The hardness (hardness with a core) of the fibrous substrate is not felt. Grade 4: The hardness (hardness with a core) of the fibrous substrate is barely felt. Grade 3: The hardness (hardness with a core) of the fibrous substrate is felt, but is not bothersome. Grade 2: The hardness (hardness with a core) of the fibrous substrate is felt. Grade 1: The hardness (hardness with a core) of the fibrous substrate is strongly felt.

[0091] [Surface appearance] The front surface of the napped leather-like sheet material was stroked five times with the hand in the direction of the grain, and then the front surface was visually inspected and rated according to the following evaluation criteria. <Evaluation criteria> Grade 5: No visible tissue lines. Grade 4: Slightly visible tissue lines, but barely noticeable. Grade 3: Visible tissue lines, but not noticeable. Grade 2: Visible tissue lines, but slightly noticeable. Grade 1: Visible tissue lines, but very noticeable.

[0092] [Method for calculating filling rate] The cross sections perpendicular and parallel to the warp direction of the knitted or woven structure were photographed at a magnification of 1000 times using a scanning electron microscope (S-3000N, manufactured by Hitachi High-Technologies Corporation), showing the napped portion and the ground structure portion. The photographed image was enlarged and printed on A4 size paper. In the printed image, the cut surface of the resin was painted red. The red portion was then cut out, and the mass (Ma) of the paper in the entire observation area and the mass (Mb) of the paper in the cut-out resin portion were measured, and the resin filling rate per area was calculated as (Mb / Ma) x 100 (%). The filling rate was determined by measuring any five points on each of the perpendicular cross section and the parallel cross section, excluding the maximum and minimum values, and calculating the average value of the remaining three points, a total of six points.

[0093] [Example 1] A different shrinkage blend yarn of 83 dtex / 24 f polyester textured yarn (16-split yarn) and 33 dtex / 12 f polyester high shrinkage yarn was used as the warp yarn, and an 83 dtex / 36 f polyester textured yarn was used as the back yarn. A 167 dtex / 48 f polyester textured yarn was used as the weft. A seven-ply satin fabric was woven with the weave shown in the weave diagram of Figure 2.

[0094] The resulting woven fabric was washed with water and dried. The surface of the woven fabric was then subjected to a nap raising treatment using a clothed nap raising machine equipped with a clothed roll having 12 pile rollers and 12 counter pile rollers. The nap raising treatment was performed three times, alternating between raising from the weaving start direction and the weaving end direction, at a clothed roll torque of 10 MPa and a fabric speed of 15 m / min.

[0095] Next, the fabric was heat-treated at 150°C for 3 minutes in a heat setter, and then semi-cut raised using an emery raising machine with sandpaper (#320). Specifically, the surface (raised surface) of the fabric was ground at a sandpaper surface rotation speed of 1000 rpm, a clearance of 0.8 mm, and a fabric speed of 8 m / min to produce a raised fabric (basis weight 250 g / m ２ The fabric had a thickness of 1050 μm, a single fiber fineness of the raised portion of 0.22 dtex, a raised length of 300 μm, a warp density of the fibrous base material of 366 yarns / 25.4 mm, and a weft density of 60 yarns / 25.4 mm.

[0096] The resulting napped fabric was dipped into the resin composition liquid of Formulation 1 shown in Table 1 using a mangle at a pickup rate of 50% by mass. It was then heat-treated at 170°C for 3 minutes using a heat setter. This resulted in a sheet-like material in which the napped fabric, a fibrous substrate, was impregnated with a silicone resin and a polyurethane resin. The resulting sheet-like material was dyed with a disperse dye at 130°C for 50 minutes using a jet dyeing machine, and then heat-treated at 130°C for 3 minutes using a heat setter.

[0097] The following backing agent was applied to the back of the obtained woven fabric using a knife coater in a dry coating amount of 60 g / m ２ The solution was then applied so that the resultant was a napped leather-like sheet material of Example 1. The napped leather-like sheet material had a fibrous base material warp density of 366 threads / 25.4 mm, a weft density of 60 threads / 25.4 mm, a number of weaving points per 25.4 mm square of 3,137, a total number of fibers involved in the intersections at the weaving points per 25.4 mm square of 828,206, a constant-load elongation rate of 5% or more in both the warp and weft directions, and a constant-load set rate of less than 10% in both the warp and weft directions.

[0098] [Backing Agent] A flame retardant and a binder resin were mixed in a mass ratio of 7:3 in terms of solid content, and water was added to obtain a mixed liquid with a solid content of 50 mass %. ４ P.O. ３ ) ｎA polyurethane resin (HYDRAN WLS-201, manufactured by DIC Corporation, solid content 33 to 37% by mass) was used as the binder resin. The resulting mixture was adjusted to a viscosity of 15,000 mPa s using a thickener (ADEKA Corporation, ADEKA NOL UH-540, solid content 30% by mass) to form a backing agent.

[0099] [Example 3] A triple-ply yarn formed by twisting three 83 dtex / 36 f polyester yarns together was used as the back yarn and weft yarn of the warp, and the basis weight, thickness, and density were changed as shown in Table 2. A napped leather-like sheet material of Example 3 was produced in the same manner as in Example 1, except that Formulation 2 shown in Table 1 was used as the resin composition liquid to be applied to the fibrous substrate.

[0100] Examples 4 and 5 The basis weight or density of the fibrous base material was changed as shown in Tables 2 and 3, and the other procedures were the same as in Example 1 to obtain napped leather-like sheet materials of Examples 4 and 5.

[0101] [Examples 2, 6 to 9] As the resin composition liquid to be applied to the fibrous substrate, formulations 2, 3, and 6 to 8 shown in Table 1 were used as shown in Tables 2 to 4, respectively, and the same procedures as in Example 1 were otherwise carried out to obtain napped leather-like sheet materials of Examples 2, 6 to 9.

[0102] [Examples 10 to 12] The weave of the fibrous substrate was changed to a 5-ply satin weave as shown in Figure 9 in Example 10, a 6-ply satin weave as shown in Figure 10 in Example 11, and an 8-ply satin weave as shown in Figure 11 in Example 12, and the rest of the procedures were the same as in Example 1 to obtain napped leather-like sheet materials of Examples 10 to 12.

[0103] [Comparative Example 1] A nonwoven fabric (manufactured by Asahi Kasei Corporation, 3007B, basis weight 280 g / m) in which 8.9% by mass of polycarbonate-based polyurethane resin was attached to the fibers was used. ２ The nonwoven fabric was subjected to the same raising treatment as in Example 1 to obtain a raised nonwoven fabric. The raised nonwoven fabric thus obtained had a total basis weight of the fibrous base material and polyurethane resin of 280 g / m ２ , the basis weight of the fibrous base material is 257 g / m ２The thickness was 900 μm, the single fiber fineness of the napped portion was 0.15 dtex and 0.3 dtex, and the nap length was 130 μm. The resin composition liquid was applied to the raised nonwoven fabric in the same manner as in Example 1, except that Formulation 3 shown in Table 1 was used as the resin composition liquid to treat the raised nonwoven fabric, and dyeing and heat treatment were carried out. Thereafter, a backing agent was applied in a dry coating amount of 70 g / m ２ The backing treatment was carried out in the same manner as in Example 1, except that the coating was carried out so that the napped leather-like sheet material of Comparative Example 1 was obtained.

[0104] Comparative Examples 2 and 3 The basis weight and density of the fibrous base material were changed as shown in Table 5, and the other procedures were the same as in Example 1 to obtain napped leather-like sheet materials of Comparative Examples 2 and 3.

[0105] Details and evaluation of the obtained napped leather-like sheet material are shown in Tables 2 to 5. Regarding "resin" in Tables 2 to 5, "resin adhesion amount" refers to the amount of resin (in solids content) applied to the fibrous substrate by the resin composition liquid shown in Table 1 (the same applies to Tables 6 to 8 below). When two or more resins are used in combination in the resin composition liquid shown in Table 1, for example, in Example 1, it refers to the total adhesion amount (in solids content) of the silicone resin and polyurethane resin. When a resin is used alone in the resin composition liquid, for example, in Examples 6, 7, and 9, it refers to the adhesion amount (in solids content) of that resin.

[0106] In the "napped leather-like sheet material" in Tables 2 to 5, the "thickness (μm)", "napped length (μm)", "single fiber fineness of the napped portion", "density of the fibrous substrate", "number of weaving points", "number of fibers at weaving points", "constant load elongation (%)", and "constant load setting rate (%)" are values ​​for the napped leather-like sheet material (the same applies to Tables 6 to 8 below).

[0107] In Example 1, the number of texture points is calculated as follows by the above formula (1): From the texture diagram of FIG. 2 and the density of the fibrous base material in Table 2, in formula (1), n ​​= 2, A １ = 183 pieces / 25.4 mm, A ２ = 183 pieces / 25.4 mm, B １ =2 pieces / piece, B ２ = 2 / piece, C = 60 pieces / 25.4 mm, D = 14 pieces. Therefore, the number of tissue points can be calculated by the following formula. The same procedure was repeated for Examples 3 to 5 and Comparative Examples 2 and 3, which have different fibrous base material configurations, and the value was calculated using formula (1).

[0108] For Example 10, the repeating unit of the weft yarn is D=10, and B １ =2 pieces / piece, B ２ In Example 11, the repeating unit of the weft yarn is D = 6, and B １ =1 piece / piece, B ２ In Example 12, the repeating unit of the weft yarn is D = 16, and B １ =2 pieces / piece, B ２ = 2 pieces / piece. １ , A ２ , C are the same as in Example 1. Using these, the number of texture points in Examples 10 to 12 is calculated from equation (1).

[0109] In Example 1, the number of fibers at the weaving point is calculated as follows according to the above (3). １ = 24 x 16 + 12 (books), E ２ = 36 (pieces), F = 48 (pieces). Therefore, the number of fibers at a tissue point can be calculated using the following formula: The same procedure was repeated for Examples 3 to 5, 10 to 12 and Comparative Examples 2 and 3, which have different fibrous base material configurations, and the value was calculated using formula (3).

[0110]

[0111] The details of each component in Table 1 are as follows. Silicone resin 1: A resin solution (solid content 50% by mass) containing 50 parts by mass of methyl hydrogen silicone oil (KF99 manufactured by Shin-Etsu Chemical Co., Ltd., 100% by mass solids, formed by heat treatment in combination with a catalyst) and 2 parts by mass of polyoxyethylene polyoxypropylene glycol (dispersant manufactured by Fujifilm Wako Pure Chemical Industries, Ltd., 100% by mass solids), and 48 parts by mass of water. Silicone resin 2: Nikka Silicon AMZ-3 manufactured by Nicca Chemical Co., Ltd., amino-modified silicone resin, solid content 36% by mass. Silicone oil 1: Dimethyl silicone oil, Elasfinish S-65 manufactured by Dai-ichi Kogyo Seiyaku Co., Ltd., active ingredient 42% by mass. Polyurethane resin 1: Evaphanol APC-66 manufactured by Nicca Chemical Co., Ltd., polycarbonate-based polyurethane resin (water-based one-component type, forced emulsification type, solid content 36% by mass). Catalyst solution 1: A crosslinking catalyst solution (solid content 18% by mass) prepared by blending 14 parts by mass of zinc stearate (catalyst, manufactured by FUJIFILM Wako Pure Chemical Industries, Ltd., solid content 100% by mass), 4 parts by mass of polyoxyethylene polyoxypropylene glycol (dispersant, manufactured by FUJIFILM Wako Pure Chemical Industries, Ltd., solid content 100% by mass), and 82 parts by mass of water.

[0112]

[0113]

[0114]

[0115]

[0116] The results are shown in Tables 2 to 5. The napped leather-like sheet material of Comparative Example 1, which used a nonwoven fabric as the fibrous substrate, suffered from shedding. Furthermore, the scrim was exposed, resulting in poor surface appearance. Furthermore, the constant load elongation was low, and surface conformability was also poor.

[0117] In the napped leather-like sheet material of Comparative Example 2, a woven fabric was used as the fibrous substrate, but the number of texture points per 25.4 mm square was less than 1,500 and the number of texture point fibers was less than 396,000, resulting in poor fatigue durability, fatigue strength, and surface appearance. In Comparative Example 2, the constant load setting rate in the weft direction was also 10% or more, resulting in poor surface conformability. In the napped leather-like sheet material of Comparative Example 3, the number of texture points per 25.4 mm square exceeded 10,000 and the number of texture point fibers exceeded 2,640,000, resulting in poor texture.

[0118] In contrast, the napped leather-like sheet materials of Examples 1 to 12 had a surface appearance and texture comparable to that of artificial leather using a nonwoven fabric as a fibrous substrate, and exhibited no shedding due to abrasion, excellent fatigue durability, and excellent fatigue strength. Furthermore, since the constant-load elongation percentage of Examples 1 to 12 was 5% or more and the constant-load set rate was less than 10%, the sheet materials could be stretched appropriately under tension when attached to a seat. Furthermore, by releasing the tension after attachment, excessive stretching could be restored, preventing the sheet materials from wrinkling. Therefore, the sheet materials of Examples 1 to 12 had excellent surface conformability.

[0119] [Example 13] Using a 24G circular knitting machine, a circular knitted fabric was knitted with a brushed knitting structure as shown in Figure 4, using 83 dtex / 24 f polyester textured yarn (16-split yarn) as the face yarn, 83 dtex / 12 f polyester textured yarn as the connecting yarn, and 167 dtex / 48 f polyester textured yarn as the back yarn.

[0120] The resulting circular knitted fabric was washed with water and dried. The surface of the circular knitted fabric was then subjected to a nap raising treatment using a clothed cardboard roll equipped with 12 pile rollers and 12 counter pile rollers. The nap raising treatment was carried out three times, alternating between raising from the knitting start direction and the knitting end direction, at a clothed cardboard roll torque of 10 MPa and a fabric speed of 15 m / min.

[0121] Next, the circular knitted fabric was heat-treated at 150°C for 3 minutes in a heat setter, and then semi-cut raised using an emery raising machine with sandpaper (#320). Specifically, the surface (raised surface) of the circular knitted fabric was ground at a sandpaper surface rotation speed of 1000 rpm, a clearance of 0.8 mm, and a fabric speed of 8 m / min. Next, the circular knitted fabric was heat-treated at 150°C for 3 minutes in a heat setter, and then tentered to achieve the desired density. This resulted in a raised circular knitted fabric (basis weight 400 g / m ２ The fiber substrate had a thickness of 1100 μm, a single fiber fineness of the napped portion of 0.22 dtex, a nap length of 300 μm, and a density of 73 courses / 25.4 mm and 33 wells / 25.4 mm.

[0122] The resulting raised circular knit fabric was dipped into the resin composition liquid of Formulation 1 shown in Table 1 using a mangle at a pickup rate of 50% by mass. It was then heat-treated at 170°C for 3 minutes using a heat setter. This resulted in a sheet-like material in which the raised circular knit fabric, a fibrous substrate, was impregnated with a silicone resin and a polyurethane resin. The resulting sheet-like material was dyed with a disperse dye at 130°C for 50 minutes using a jet dyeing machine, and then heat-treated at 130°C for 3 minutes using a heat setter.

[0123] The backing agent was applied to the back surface of the obtained circular knitted fabric using a knife coater in a dry coating amount of 65 g / m ２ The fabric was then heat-treated in a heat setter at 130°C for 3 minutes to obtain a napped leather-like sheet material of Example 13. The napped leather-like sheet material obtained had 4,818 weaving points per 25.4 mm square, a total of 2,197,008 fibers involved in entanglement at the weaving points per 25.4 mm square, a constant load elongation of 5% or more in both the warp and weft directions, and a constant load set ratio of less than 10% in both the warp and weft directions.

[0124] [Examples 14 and 15] As the resin composition liquid to be applied to the fibrous substrate, formulations 4 and 5 shown in Table 1 were used, respectively, as shown in Table 6. The same procedures as in Example 13 were otherwise carried out to obtain napped leather-like sheet materials of Examples 14 and 15.

[0125] Example 16 A napped leather-like sheet material of Example 16 was obtained in the same manner as in Example 1, except that the knitting structure of the fibrous base material was changed to the mock lody structure shown in FIG.

[0126] [Example 17] By changing the tentering conditions in the heat treatment at 150°C for 3 minutes using a heat setter after semi-cut raising, it was possible to obtain a circular knitted fabric with a raised nap (basis weight 280 g / m ２ A napped leather-like sheet material of Example 17 was obtained in the same manner as in Example 13, except that the napped leather-like sheet material of Example 17 had a thickness of 900 μm, a single fiber fineness of the raised portion of 0.22 dtex, a nap length of 200 μm, and a fibrous substrate density of 50 courses / 25.4 mm and 30 wells / 25.4 mm. The pickup rate of the resulting napped circular knit fabric by dipping was 54% by mass.

[0127] [Example 18] In the heat treatment using a heat setter after semi-cut raising, instead of setting the width, heat treatment was performed at 150°C for 3 minutes to achieve the desired density, thereby obtaining a raised circular knit fabric (basis weight 480 g / m ２ A napped leather-like sheet material of Example 18 was obtained in the same manner as in Example 13, except that the napped leather-like sheet material of Example 18 had a thickness of 1200 μm, a single fiber fineness of the napped portion of 0.22 dtex, a nap length of 400 μm, and a fibrous base material density of 90 courses / 25.4 mm and 45 wells / 25.4 mm. The pickup rate of the resulting napped circular knit fabric by dipping was 49% by mass.

[0128] [Example 19] A polyester textured yarn (8-split yarn) of 83 dtex / 24 f was used as the face yarn. After semi-cut raising, the tentering conditions were changed during heat treatment at 150°C for 3 minutes using a heat setter, resulting in a raised circular knit fabric (basis weight 300 g / m ２ A fibrous base material having a thickness of 1000 μm, a single fiber fineness of the napped portion of 0.44 dtex, a nap length of 200 μm, and a density of 55 courses / 25.4 mm and 33 wells / 25.4 mm was obtained. The pickup rate of the resulting napped circular knit fabric by dipping was 57% by mass. Otherwise, the same procedure as in Example 13 was repeated to obtain a napped leather-like sheet material of Example 19.

[0129] Example 20: A two-ply yarn consisting of two 83 dtex / 24 f polyester textured yarns (16-split yarns) twisted together was used as the face yarn. The pickup rate of the napped circular knit fabric during dipping was set to 51% by mass. A napped leather-like sheet material of Example 20 was obtained in the same manner as in Example 13.

[0130] [Example 21] A triple-ply yarn made by twisting together three 83 dtex / 24 f polyester textured yarns (16-split yarns) was used as the face yarn. In the heat treatment using a heat setter after semi-cut raising, instead of width setting, width setting was performed by heat treatment at 150°C for 3 minutes to achieve the desired density, thereby producing a raised circular knit fabric (basis weight 460 g / m ２ A fibrous base material having a thickness of 1,400 μm, a single fiber fineness of the napped portion of 0.22 dtex, a nap length of 400 μm, and a density of 73 courses / 25.4 mm and 45 wells / 25.4 mm was obtained. The pickup rate of the resulting napped circular knit fabric by dipping was 49% by mass. Otherwise, the same procedure as in Example 13 was repeated to obtain a napped leather-like sheet material of Example 21.

[0131] A napped leather-like sheet material of Comparative Example 4 was obtained in the same manner as in Example 13, except that a 24G circular knitting machine was used to knit a circular knitted fabric with the tuck structure shown in Figure 12, using 77 dtex / 216 f polyester textured yarn as the face yarn and connecting yarn, and 121 dtex / 36 f polyester textured yarn as the back yarn. A simplified representation of the knitting structure of the tuck structure viewed from the front side is shown in Figure 13.

[0132] [Comparative Example 5] By changing the tentering conditions in the heat treatment at 150°C for 3 minutes using a heat setter after semi-cut raising, a raised circular knit fabric (basis weight 270 g / m ２ A napped leather-like sheet material of Comparative Example 5 was obtained in the same manner as in Example 13, except that the napped leather-like sheet material of Comparative Example 5 had a thickness of 900 μm, a single fiber fineness of the napped portion of 0.22 dtex, a nap length of 200 μm, and a fibrous substrate density of 40 courses / 25.4 mm and 28 wells / 25.4 mm. The pickup rate of the resulting napped circular knit fabric by dipping was 53% by mass.

[0133] [Comparative Example 6] In the heat treatment using a heat setter after semi-cut raising, instead of setting the width, heat treatment was performed at 150°C for 3 minutes to achieve the desired density, thereby obtaining a raised circular knitted fabric (basis weight 490 g / m ２ A fibrous base material having a thickness of 1200 μm, a single fiber fineness of the napped portion of 0.22 dtex, a nap length of 410 μm, and a density of 95 courses / 25.4 mm and 50 wells / 25.4 mm was obtained. The pickup rate of the resulting napped circular knit fabric by dipping was 49% by mass. Otherwise, a napped leather-like sheet material of Comparative Example 6 was obtained in the same manner as in Example 13.

[0134] [Comparative Example 7] A polyester textured yarn (8-split yarn) of 83 dtex / 24 f was used as the face yarn. After semi-cut raising, the tentering conditions were changed in the heat treatment at 150°C for 3 minutes using a heat setter, resulting in a raised circular knit fabric (basis weight 290 g / m ２ A fibrous base material having a thickness of 1000 μm, a single fiber fineness of the napped portion of 0.44 dtex, a nap length of 200 μm, and a density of 50 courses / 25.4 mm and 33 wells / 25.4 mm was obtained. The pickup rate of the resulting napped circular knit fabric by dipping was 56% by mass. A napped leather-like sheet material of Comparative Example 7 was obtained in the same manner as in Example 13.

[0135] [Comparative Example 8] A triple-ply yarn made by twisting together three 83 dtex / 24 f polyester textured yarns (16-split yarns) was used as the face yarn. In the heat treatment using a heat setter after semi-cut raising, instead of width setting, width setting was performed by heat treatment at 150°C for 3 minutes to achieve the desired density, thereby producing a raised circular knit fabric (basis weight 470 g / m ２ A napped leather-like sheet material of Comparative Example 8 was obtained in the same manner as in Example 13, except that the napped leather-like sheet material of Comparative Example 8 had a thickness of 1,400 μm, a single fiber fineness of the napped portion of 0.22 dtex, a nap length of 400 μm, and a fibrous substrate density of 73 courses / 25.4 mm and 50 wells / 25.4 mm. The pickup rate of the resulting napped circular knit fabric by dipping was 49% by mass.

[0136] Details and evaluation of the napped leather-like sheet materials obtained are shown in Tables 6 to 8.

[0137] In Examples 13 to 15, the number of texture points is calculated as follows using the above formula (2-1): Ｆ = G Ｒ = 73 courses / 25.4 mm, I Ｆ =I Ｒ = 33 wells / 25.4 mm. Therefore, the number of tissue points can be calculated using the following formula:

[0138] In Examples 13 to 15, the number of fibers at the weaving point is calculated as follows using the above formula (4-1): From the yarn usage of the fibrous base material in Table 6, K = 24 x 16 (pieces), L = 12 (pieces), and M = 48 (pieces). Therefore, the number of fibers at the weaving point can be calculated using the following formula:

[0139] For Examples 17 to 21 and Comparative Examples 5 to 8, the number of tissue points is calculated by formula (2-1), and the number of tissue point fibers is calculated by formula (4-1).

[0140] In Example 16, the number of tissue points was calculated using the above formula (2-1) as in Example 13, and was 4818 points per 25.4 mm square. The number of tissue point fibers was calculated as follows using the above formula (4-2).

[0141] In Comparative Example 4, the number of weaving points is calculated as follows. In a tucked structure (double knit), tucks exist on the front side, but no tucks exist on the back side. Therefore, the weaving points are calculated separately for the front and back sides, and then added together. The back side, where no tucks exist, can be considered the same as a brushed structure. On the other hand, for the front side, as shown in Figures 12 and 13, one tuck exists every four courses in the warp direction, and one tuck exists every two wells in the weft direction. Therefore, the number of weaving points on the front side is the number of weaving points calculated in the same way as for a brushed structure minus the number of tucks. Therefore, the number of weaving points is calculated using the following formula (G in the formula) Ｒ , I Ｒ is the same as the above formula (2).

[0142] In Comparative Example 4, the number of fibers at the weaving points was calculated separately for the front and back surfaces, and the two were added together, just like the number of weaving points. On the front surface, as shown in Figures 12 and 13 , the number of intertwined yarns differs between weaving points without tucks (non-tuck weaving points) and weaving points with tucks (tuck weaving points). At a non-tuck weaving point, a total of two yarns, one front yarn and one front yarn, are intertwined. At a tuck weaving point, a total of three yarns, two front yarns and one connecting yarn, are intertwined. Of the 2,133.25 weaving points on the front surface, the number of tuck weaving points was 304.75 (= 53 / 4 × 46 / 2), and the number of non-tuck weaving points was 1,828.5 (= 2,133.25 - 304.75). On the other hand, on the back side, the number of weaving points is 2,438, and at each weaving point, a total of two yarns, the back yarn and the connecting yarn, are entangled. Therefore, the number of fibers at a weaving point is calculated using the following formula.

[0143]

[0144]

[0145]

[0146] The results are shown in Tables 6 to 8. In the napped leather-like sheet material of Comparative Example 4, a knitted fabric was used as the fibrous substrate, but the knitting structure was a tuck structure. In a tuck structure, needle loops are formed by skipping one or more courses, so the filling rate of the needle loops is low and the needle loops are prone to deformation, which is thought to result in a high constant-load set rate. In Comparative Example 4, because the constant-load set rate was so high, when the sheet material was attached to a seat under tension, the stretch due to the tension did not fully return, and the sheet material was prone to wrinkles, resulting in poor surface conformability.

[0147] In the napped leather-like sheet material of Comparative Example 5, a knitted fabric was used as the fibrous substrate, but the number of texture points in a 25.4 mm square was small, so the fatigue durability, fatigue strength, and surface appearance were poor. In the napped leather-like sheet material of Comparative Example 6, the number of texture points in a 25.4 mm square was too large, so the texture was poor. In the napped leather-like sheet material of Comparative Example 7, the number of texture point fibers in a 25.4 mm square was too small, so the touch and surface appearance were poor. In the napped leather-like sheet material of Comparative Example 8, the number of texture point fibers in a 25.4 mm square was too large, so the texture was poor.

[0148] In contrast, the napped leather-like sheet materials of Examples 13 to 21 had a surface appearance and texture comparable to that of artificial leather, were free of fluff shedding due to abrasion, and had excellent fatigue durability, fatigue strength, and abrasion resistance. Furthermore, Examples 13 to 21 had high constant-load elongation and low constant-load setting, and therefore had excellent surface conformability.

[0149] 10... Raised leather-like sheet material, 11... Front surface, 12... Fibrous base material, 13... Back surface, 14... Raised nap, 16... Raised surface

Claims

1. A napped leather-like sheet-like material comprising a woven or knitted fibrous base material and a resin applied to the fibrous base material, The sheet-like material has a nap-like surface on a front surface thereof, the nap being formed by fibers constituting the fibrous base material and having the resin attached thereto; The number of weaving points of the yarn constituting the fibrous base material per 25.4 mm square of the sheet-like material is 1,500 to 10,000 when the fibrous base material is a woven fabric, and 3,000 to 9,000 when the fibrous base material is a knitted fabric; The total number of fibers involved in the intersection or entanglement at the weaving points per 25.4 mm square of the sheet-like material is 396,000 to 2,640,000 when the fibrous base material is a woven fabric, and 912,000 to 8,208,000 when the fibrous base material is a knitted fabric; A napped leather-like sheet material having a constant load elongation rate of 5% or more in both the warp and weft directions of the sheet material, and a constant load set rate of less than 10% in both the warp and weft directions of the sheet material.

2. The napped leather-like sheet material according to claim 1, wherein the number of weaving points of the yarn constituting the fibrous base material per 25.4 mm square of the sheet material is 3,500 to 9,000 when the fibrous base material is a knitted fabric.

3. 2. The napped leather-like sheet material according to claim 1, wherein the fibrous base material is a circular knitted fabric.

4. 2. The napped leather-like sheet material according to claim 1, wherein the fibrous base material is a double-knitted fabric.

5. 2. The napped leather-like sheet material according to claim 1, wherein the fibrous base material is a multi-layered woven fabric of satin weave.

6. 2. The napped leather-like sheet material according to claim 1, wherein the resin is present at least on the front surface side on which the nap is present in the thickness direction of the fibrous base material.

7. 2. The napped leather-like sheet material according to claim 1, wherein the resin is a polyurethane resin alone or a mixture of a silicone resin and a polyurethane resin.

8. 2. The napped leather-like sheet material according to claim 1, wherein the rear surface of the sheet material is not napped and a backing is provided on the rear surface.

9. 9. The napped leather-like sheet material according to claim 8, wherein the backing comprises a flame retardant and a binder resin.

10. The napped leather-like sheet material according to claim 1, wherein the density of the fibrous substrate is, when the fibrous substrate is a woven fabric, a warp density of 200 to 500 threads / 25.4 mm and a weft density of 50 to 150 threads / 25.4 mm, and when the fibrous substrate is a knitted fabric, a warp density of 40 to 110 courses / 25.4 mm and a weft density of 30 to 70 welds / 25.4 mm.

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