Method for producing an embossed fabric layer

Abstract

Provided is a method for producing an embossed fabric layer, including embossing a coating layer made of polyester by pressurizing a polyester fabric, the coating layer, and an embossed release paper in a layered state, and delaminating the release paper from a fabric layer in which the coating layer is formed over the polyester fabric. The method may include heating the polyester fabric, the coating layer, and the release paper.

Description

METHOD FOR PRODUCING AN EMBOSSED FABRIC LAYER

[0001] The contents of the following patent application(s) are incorporated herein by reference: NO. 2024-156892 filed in JP on September 10, 2024. The present invention relates to a method for producing an embossed fabric layer.

[0002] Patent document 1 discloses an embossed "leather-like nonwoven fabric". (Citation List) (Patent Literature) (PTL 1) Japanese Patent Application Publication No. H11-241277

[0003] There is provided a leather-like fabric with a higher quality.

[0004] (1) In a first aspect of the present invention, there is provided a method for producing an embossed fabric layer, including embossing a coating layer made of polyester by pressurizing a polyester fabric, the coating layer, and an embossed release paper in a layered state, and delaminating the release paper from a fabric layer in which the coating layer is formed over the polyester fabric.

[0005] (2) The method for producing the fabric layer according to the above (1) may include heating the polyester fabric, the coating layer, and the release paper.

[0006] (3) In the method for producing the fabric layer according to the above (1) or (2), an emboss depth of the fabric layer may be less than or equal to a thickness of the release paper.

[0007] (4) In the method for producing the fabric layer according to any of the above (1) to (3), the emboss depth of the fabric layer may be greater than or equal to 50 μm and less than or equal to 300 μm.

[0008] (5) In the method for producing the fabric layer according to any of the above (1) to (4), a thickness of the release paper may be greater than or equal to 150 μm and less than or equal to 300 μm.

[0009] (6) In the method for producing the fabric layer according to any of the above (1) to (5), the coating layer may be a polyester film. The coating layer may be laminated over the polyester fabric by applying polyester in a liquid form to the polyester fabric.

[0010] (7) In the method for producing the fabric layer according to any of the above (1) to (6), polyester may contain at least one of PET (polyethylene terephthalate), PBT (polybutylene terephthalate), or PTT (polytrimethylene terephthalate).

[0011] (8) In the method for producing the fabric layer according to any of the above (1) to (7), a heating temperature in the heating may be greater than or equal to a melting point of the coating layer and less than a melting point of the polyester fabric.

[0012] (9) In the method for producing the fabric layer according to any of the above (1) to (8), the heating temperature in the heating may be greater than or equal to the melting point of the coating layer and less than or equal to the melting point of the coating layer + 40 degrees Celsius.

[0013] (10) The method for producing the fabric layer according to any of the above (1) to (9) may include cooling the fabric layer and the release paper after the embossing.

[0014] (11) The method for producing the fabric layer according to any of the above (1) to (10) may include layering a lining layer with the polyester fabric before the coating layer made of polyester is formed over the polyester fabric.

[0015] (12) In the method for producing the fabric layer according to any of the above (1) to (11), the lining layer may be a nonwoven fabric or a double raschel.

[0016] (13) In the method for producing the fabric layer according to any of the above (1) to (12), an embossed surface of the release paper may be textured.

[0017] (14) In the method for producing the fabric layer according to any of the above (1) to (13), a color of the coating layer may be identical to a color of the polyester fabric.

[0018] (15) In the method for producing the fabric layer according to any of the above (1) to (14), the color of the coating layer may be different from the color of the polyester fabric.

[0019] Note that the summary clause of the invention does not necessarily describe all features of the present invention. In addition, the present invention may also be a sub-combination of the features described above.

[0020] Fig. 1 illustrates a photograph of a front surface of a fabric layer 100 that has been embossed in the present example.Fig. 2A is a schematic diagram of a cross section of the fabric layer 100 before being embossed.Fig. 2B is a schematic diagram of the cross section of the fabric layer 100 after being embossed.Fig. 3 illustrates a modification example of the cross section of the fabric layer 100 after being embossed.Fig. 4 illustrates an outline of a method for producing the fabric layer 100.Fig. 5A illustrates an example of a flowchart for producing the fabric layer 100.Fig. 5B illustrates an example of the flowchart for producing the fabric layer 100.Fig. 5C illustrates an example of the flowchart for producing the fabric layer 100.Fig. 6 illustrates an example of an appearance of an embossing machine 300 used to produce the fabric layer 100.Fig. 7 illustrates an example of a method for producing the fabric layer 100.Fig. 8 illustrates an example of the method for producing the fabric layer 100.Fig. 9 illustrates a photograph of a front surface of a fabric layer 500 that has been embossed in a comparative example.Fig. 10 illustrates a modification example of a release paper 200 used for the embossing.

[0021] The present invention will be described below through embodiments of the invention, but the following embodiments do not limit the invention according to the claims. In addition, not all of the combinations of features described in the embodiments are essential to the solving means of the invention.

[0022] Fig. 1 illustrates a photograph of a front surface of a fabric layer 100 that has been embossed in the present example. The fabric layer 100 is a fabric of a woven fabric or a knitted fabric provided with a pattern represented by embosses. The fabric layer 100 in the present example has a leather-like design achieved through embossing.

[0023] The fabric layer 100 may be a fabric using at least one of polyester, nylon, acrylic, linen, cotton, silk, rayon, or wool. The fabric layer 100 may have gloss like genuine leather or synthetic leather. The fabric layer 100 in the present example can achieve a leather-like texture without providing a backing fabric such as a nonwoven fabric on a back side. It is however noted that a back surface of the fabric layer 100 may be provided with a lining fabric such as polyurethane or a nonwoven fabric.

[0024] The leather-like fabric layer 100 using polyester can reduce a mass by 50% or more as compared to genuine leather or a fabric using polyvinyl chloride (PVC). In addition, as being different from genuine leather or the fabric using PVC, the fabric layer 100 is less likely to have a high temperature in a summer period and a low temperature in a winter period. The fabric layer 100 can improve finish properties by finishing using a steam iron. Recyclability improves when the fabric layer 100 is made of only polyester.

[0025] The fabric layer 100 may be used for a seat cover for a vehicle which demands high strength, wrinkle resistance, flame retardancy, and the like. The fabric layer 100 may have water repellency and may have flame retardancy. The fabric layer 100 may meet an evaluation criterion of at least one of JIS L1091, JIS L1092, JIS L1093, JIS L1096, JIS L1076, JIS L0860, JIS L0849, JIS L0844, or JIS L0842. It is however noted that a use of the fabric layer 100 is not particularly limited.

[0026] Fig. 2A is a schematic diagram of a cross section of the fabric layer 100 before being embossed. The fabric layer 100 includes a polyester fabric 110 and a coating layer 120.

[0027] The polyester fabric 110 may be a woven fabric composed of warp yarns and weft yarns. A material of the polyester fabric 110 may contain at least one of polyester, nylon, acrylic, linen, cotton, silk, rayon, or wool. The material of the polyester fabric 110 in the present example is polyester. The polyester fabric 110 in the present example does not have a lining fabric but may have a lining fabric. A board thickness of the polyester fabric 110 may be greater than or equal to 0.3 mm and less than or equal to 2.0 mm. For example, the board thickness of the polyester fabric 110 is 0.8 mm.

[0028] The coating layer 120 is laminated over the polyester fabric 110. The coating layer 120 in the present example is provided on a front surface of the polyester fabric 110 but may be provided on a back surface side of the polyester fabric 110. The coating layer 120 may be bonded to the polyester fabric 110. The coating layer 120 may be laminated over the polyester fabric 110 by affixing a previously molded polyester film to the polyester fabric 110 or may be laminated over the polyester fabric 110 by applying polyester in a liquid form to the polyester fabric 110.

[0029] A material of the coating layer 120 may contain at least one of polyester, polyurethane, olefin-based resin, EVA (ethylene vinyl acetate) resin, or polyamide. The material of the coating layer 120 may contain polyester, or the entire material may be polyester. The coating layer 120 in the present example is a polyester film.

[0030] The polyester fabric 110 and the coating layer 120 may be made of an identical material. Recyclability improves by forming each layer of the fabric layer 100 using the identical material. The polyester fabric 110 and the coating layer 120 may be the identical material or may have different compositions. For example, the polyester fabric 110 and the coating layer 120 are made of polyester with different compositions. The polyester fabric 110 and the coating layer 120 may have different melting points due to different compositions. Polyester may contain at least one of PET (polyethylene terephthalate), PBT (polybutylene terephthalate), or PTT (polytrimethylene terephthalate).

[0031] The melting point of the coating layer 120 may be lower than the melting point of the polyester fabric 110. The coating layer 120 can be bonded onto the polyester fabric 110 by heating the fabric layer 100 and melting the coating layer 120.

[0032] A film thickness of the coating layer 120 may be thinner than a film thickness of the polyester fabric 110. The film thickness of the coating layer 120 may be greater than or equal to 10 μm and less than or equal to 150 μm.

[0033] The coating layer 120 may be transparent or may be colored. A color of the coating layer 120 may be identical to a color of the polyester fabric 110, or the color of the coating layer 120 may be different from the color of the polyester fabric 110. A color of the fabric layer 100 can be adjusted by coloring the coating layer 120. As an example, a depth of black of the fabric layer 100 can be increased by laminating, on the black polyester fabric 110, the same black coating layer 120. The coating layer 120 may have water repellency and may have flame retardancy.

[0034] The fabric layer 100 can achieve a genuine leather like design with added glossiness by providing the coating layer 120. The coating layer 120 can coat dense fibers of the polyester fabric 110 and can therefore improve scratch resistance. The coating layer 120 can further improve the unevenness of the emboss texture by filling gaps between the fibers of the polyester fabric 110 as compared with the polyester fabric 110 alone.

[0035] Fig. 2B is a schematic diagram of the cross section of the fabric layer 100 after being embossed. In the fabric layer 100 in the present example, the polyester fabric 110 and the coating layer 120 are embossed.

[0036] The polyester fabric 110 and the coating layer 120 have unevenness formed through embossing. In the present example, the polyester fabric 110 and the coating layer 120 are affixed to each other, and both the polyester fabric 110 and the coating layer 120 are embossed, so that deep unevenness can be achieved. An emboss depth De of the fabric layer 100 may be greater than or equal to 50 μm and less than or equal to 300 μm. The emboss depth De may be a maximum value of a difference between a convex portion and a concave portion in the embossed coating layer 120.

[0037] A total board thickness T of the polyester fabric 110 and the coating layer 120 may be a thickness of the embossed convex portion and a back surface of the polyester fabric 110. The total board thickness T of the polyester fabric 110 and the coating layer 120 may be greater than or equal to 0.5 mm and less than or equal to 2.5 mm.

[0038] Since the embossing is carried out after the coating layer 120 is laminated over the polyester fabric 110 composed of a woven fabric or a knitted fabric, the fabric layer 100 in the present example can obtain more stable physical properties as compared with a nonwoven fabric or the like that has a varying density. With this arrangement, the fabric layer 100 having uniform tensile strength and elasticity can be obtained. Since the uniform embossing is achieved, the higher quality leather-like fabric layer 100 can be obtained.

[0039] Fig. 3 illustrates a modification example of the cross section of the fabric layer 100 after being embossed. The example illustrated in Fig. 3 is different from the example illustrated in Fig. 2B in that a lining layer 130 is provided.

[0040] In the polyester fabric 110, the lining layer 130 is provided to a surface opposite to a surface where the coating layer 120 is provided. The lining layer 130 may be a nonwoven fabric or may be a double raschel. By providing the lining layer 130, a softer feel can be attained overall as compared to a case where the fabric layer 100 alone is used.

[0041] In the example illustrated in Fig. 3, the polyester fabric 110 and the coating layer 120 are embossed, but the lining layer 130 is not embossed. However, the lining layer 130 may be embossed. With this arrangement, a texture of the front surface of the fabric layer 100 can be finely adjusted.

[0042] Fig. 4 illustrates an outline of a method for producing the embossed fabric layer 100 in Fig. 2B. A flowchart in the present example is an example of the method for producing the fabric layer 100 but is not limited to this.

[0043] In step S100, the coating layer 120 is embossed by pressurizing the polyester fabric 110, the coating layer 120, and a release paper 200 in a layered state. The polyester fabric 110, the coating layer 120, and the release paper 200 may be laminated in this order. In the present example, the release paper 200 is embossed.

[0044] In step S200, the release paper 200 is delaminated from the fabric layer 100. By delaminating the release paper 200 from the fabric layer 100, the embossed fabric layer 100 is obtained. The coating layer 120 is separated from the release paper 200, and an emboss shape following the polyester fabric 110 can be maintained.

[0045] Fig. 5A illustrates an example of a flowchart for producing the embossed fabric layer 100 in Fig. 2B. The flowchart in the present example is an example of the method for producing the fabric layer 100 and is not limited to this. By using Fig. 5A, the outline of the producing method described in Fig. 4 will be described in detail.

[0046] In step S110, the polyester fabric 110 of a woven fabric or a knitted fabric is prepared. Preparation of the polyester fabric 110 may be producing the polyester fabric 110 or may be purchasing the polyester fabric 110 produced by a third party.

[0047] In step S120, the fabric layer 100 is formed in which the coating layer 120 made of polyester is formed over the polyester fabric 110. In step S120, the coating layer 120 is laminated over the polyester fabric 110. The coating layer 120 may be affixed or may be applied to the polyester fabric 110. The coating layer 120 may be affixed to the front surface of the polyester fabric 110 or may be affixed to the back surface.

[0048] In step S130, the fabric layer 100 and the embossed release paper 200 are layered. The release paper 200 may be layered with the front surface of the fabric layer 100 or may be layered with the back surface thereof. The release paper 200 in the present example is embossed. In the producing method in the present example, since the release paper 200 is embossed, the fabric layer 100 can be embossed while a mold release effect is attained.

[0049] In step S140, the fabric layer 100 and the release paper 200 are heated. The coating layer 120 may be bonded to the polyester fabric 110 by heating. A heating temperature in the heating in step S140 may be greater than or equal to the melting point of the coating layer 120 and may be less than the melting point of the polyester fabric 110. The heating temperature in the heating in step S140 may be greater than or equal to the melting point of the coating layer 120, may be less than or equal to the melting point of the coating layer 120 + 15 degrees Celsius, may be less than or equal to the melting point of the coating layer 120 + 30 degrees Celsius, or may be less than or equal to the melting point of the coating layer 120 + 40 degrees Celsius. In an example, the heating temperature in the heating in step S140 is greater than or equal to the melting point of the coating layer 120 and less than or equal to the melting point of the coating layer 120 + 40 degrees Celsius. Since the heating reaches a temperature greater than or equal to the melting point of the coating layer 120, the coating layer 120 is easily embossed.

[0050] The heating in step S140 in the present example is executed after the fabric layer 100 and the release paper 200 are layered in step S130 and before the coating layer 120 is embossed in step S150 but is not limited to the present example. Timing of the heating may be any timing. The heating in step S140 may be executed after the coating layer 120 is formed in the polyester fabric 110 in step S120 and before the coating layer 120 is embossed in step S150. The heating in step S140 may be executed when the polyester fabric 110 and the coating layer 120 are embossed. A time when the polyester fabric 110 and the coating layer 120 are embossed may be at a same time as the embossing.

[0051] In step S150, the coating layer 120 is embossed. In step S150, the coating layer 120 is embossed by pressurizing the fabric layer 100 and the release paper 200. In step S150, the polyester fabric 110 may be embossed. Herein, the embossing on the polyester fabric 110 and the coating layer 120 refers to formation of unevenness in both the polyester fabric 110 and the coating layer 120. In the present example, the polyester fabric 110 and the coating layer 120 are embossed in a state in which the polyester fabric 110, the coating layer 120, and the release paper 200 are laminated.

[0052] The method for producing the fabric layer 100 may include cooling the fabric layer 100 and the release paper 200 in step S160 after the embossing in step S150. In step S160, the fabric layer 100 and the release paper 200 may be cooled to become a temperature less than or equal to the melting point of the coating layer 120. With this arrangement, the embossing carried out onto the fabric layer 100 can be stabilized.

[0053] In the cooling in step S160, the fabric layer 100 and the release paper 200 may be cured. Herein, curing of the fabric layer 100 and the release paper 200 may be resting the fabric layer 100 and the release paper 200 during a period until the coating layer 120 heated to a temperature greater than or equal to the melting point and melted is cooled down to a temperature less than or equal to the melting point and sufficiently solidified.

[0054] Note that the producing method may include adding functionality such as water repellency or flame retardancy to the fabric layer 100. The polyester fabric 110 may be added with functionality, the coating layer 120 may be added with functionality, or both the polyester fabric 110 and the coating layer 120 may be added with functionality. The polyester fabric 110 and the coating layer 120 may be added with separate functions. For example, the fabric layer 100 may be added with functionality such as water repellency through dipping using a functional agent such as a water repellent. The functional agent may have any function such as flame retardancy. The fabric layer 100 may be immersed at once by using a plurality of functional agents in combination.

[0055] Fig. 5B illustrates an example of the flowchart for producing the embossed fabric layer 100 in Fig. 2B. The difference from Fig. 5A will be described by using Fig. 5B.

[0056] The example of Fig. 5B includes forming the coating layer 120 over the release paper 200 in step S125. Thereafter, in step S135, the release paper 200 over which the coating layer 120 is formed is layered with the polyester fabric 110. In accordance with such a method too, through step S140 to step S200, the embossed fabric layer 100 in the present example can be obtained.

[0057] Fig. 5C illustrates an example of the flowchart for producing the embossed fabric layer 100 in Fig. 3. The flowchart of Fig. 5C is different from the flowchart of Fig. 5A in that layering the lining layer 130 with the polyester fabric 110 in step S115 is included. Other than the aspect in which step S115 is included may be identical to the producing method described by using Fig. 5A.

[0058] The method for producing the fabric layer 100 may include layering the lining layer 130 with the polyester fabric 110 in step S115 before the coating layer 120 made of polyester over the polyester fabric 110 is formed in step S120. The lining layer 130 such as a nonwoven fabric or a double raschel may be affixed to the back surface of the polyester fabric 110. Even when the lining layer 130 is affixed to the back surface of the polyester fabric 110, the polyester fabric 110 and the coating layer 120 can be easily recycled by delaminating the lining layer 130.

[0059] Step S115 and step S120 may be executed in the reverse order. That is, after execution of formation of the coating layer 120 made of polyester over the polyester fabric 110 in step S120, layering the lining layer 130 with the polyester fabric 110 in step S115 may be executed.

[0060] In step S130, the coating layer 120 is formed on the polyester fabric 110 provided with the lining layer 130. Thereafter, through step S140 to step S200, the embossed fabric layer 100 having the lining layer 130 can be produced.

[0061] Fig. 6 illustrates an example of an appearance of an embossing machine 300 used to produce the fabric layer 100 in the present example. The embossing machine 300 includes a pressurizing roll 310, a stand 320, a heating part 330, and a cooling part 340. In the example of Fig. 6, the fabric layer 100 and the release paper 200 are respectively described as wound up rolls.

[0062] The pressurizing roll 310 pressurizes the fabric layer 100 and the release paper 200 to emboss the fabric layer 100. In the producing method in the present example, since the release paper 200 is embossed, a front surface of the pressurizing roll 310 is flat. The pressurizing roll 310 may be heated to emboss the fabric layer 100. The embossing machine 300 in the present example may control the emboss depth De by adjusting conditions such as a temperature and a pressure of the pressurizing roll 310 and a conveyor speed. As an example, when the temperature of the pressurizing roll 310 is increased, the emboss depth De can be made shallow by speeding up the conveyor speed, and the emboss depth De can be made deep by slowing down the conveyor speed.

[0063] The stand 320 supports the fabric layer 100 when the fabric layer 100 is embossed. The stand 320 may include a low density material with a density lower than that of the fabric layer 100. The low density material of the stand 320 may be polyurethane. The stand 320 may include, below the low density material, a material with a higher density than that of the low density material.

[0064] The heating part 330 heats the fabric layer 100 and the release paper 200. The heating part 330 may be a known component such as an infrared heater, an electric heating wire, an oil heater, or a steam heater as long as the fabric layer 100 and the release paper 200 can be heated.

[0065] The cooling part 340 cools the embossed fabric layer 100 and the release paper 200. The cooling part 340 may include a blower. The cooling part 340 may perform the cooling based on a water cooling system. A specific configuration of the cooling part 340 is not particularly limited as long as a mode is adopted in which the fabric layer 100 and the release paper 200 can be cooled.

[0066] Fig. 7 illustrates an example of the method for producing the fabric layer 100. In the present example, step S152 and step S154 for generating the fabric layer 100 by using the embossing machine 300 will be described. Step S152 and step S154 in the present example are examples of step S150 in Fig. 5A, Fig. 5B, and Fig. 5C.

[0067] In step S152, the fabric layer 100 and the release paper 200 are placed on the stand 320 of the embossing machine 300 in a layered state. In the present example, the release paper 200 is arranged between the fabric layer 100 and the pressurizing roll 310. The release paper 200 may be arranged between the fabric layer 100 and the stand 320. When the release paper 200 is arranged between the fabric layer 100 and the stand 320, the release paper 200 may interpose between the coating layer 120 and the stand 320.

[0068] The release paper 200 prevents bonding of the coating layer 120 to the embossing machine 300. The release paper 200 in the present example has an identical size to the fabric layer 100 but may be larger than the fabric layer 100. A material of the release paper 200 may contain at least one of paper, polyethylene, polypropylene, or epoxy resin. A thickness Dr of the release paper 200 may be any thickness as long as embossing of the fabric layer 100 is not disturbed. The thickness Dr of the release paper 200 may be greater than or equal to 150 μm or may be less than or equal to 300 μm.

[0069] The release paper 200 has unevenness according to an embossing mold applied to the fabric layer 100. The release paper 200 may have various shapes or depths according to emboss dimensions of convex portions and concave portions and the like.

[0070] In step S154, the polyester fabric 110 and the coating layer 120 are embossed from above the release paper 200. That is, the fabric layer 100 is embossed in a state in which the release paper 200 is sandwiched between the fabric layer 100 and the pressurizing roll 310. The fabric layer 100 may be embossed in a state in which the stand 320 is arranged under the fabric layer 100. The embossing machine 300 may perform surface heating of the fabric layer 100 by using the pressurizing roll 310. Here, the surface heating refers to heating a surface in a wider range, rather than applying a high frequency wave to a fabric to process a part of the fabric as in using a high frequency welder. The coating layer 120 may be bonded to the polyester fabric 110 by the heating at the time of embossing.

[0071] In step S200, the embossed fabric layer 100 is taken out from the embossing machine 300, and the release paper 200 is delaminated from the fabric layer 100. By using the release paper 200, the coating layer 120 can be prevented from adhering to the pressurizing roll 310. In this manner, by devising the embossing method, the fabric layer 100 having a high quality leather-like texture with an improved expression of unevenness is obtained.

[0072] In the producing method in the present example, by using the release paper 200 embossed, the embossed fabric layer 100 is produced. The emboss depth De of the fabric layer 100 is less than or equal to the thickness Dr of the release paper 200. The emboss depth De of the fabric layer 100 may be greater than or equal to 50 μm and less than or equal to 300 μm.

[0073] With regard to embossing by using a conventional embossing machine, a fabric layer is embossed by using a pressurizing roll having unevenness according to an embossing mold. For this reason, the emboss pattern obtained through conventional embossing has a cycle having one rotation of a length of a circumference of the pressurizing roll as a maximum value. In addition, there is a risk that an insertion angle formed by the fabric layer and the release paper that are to be inserted into the embossing machine is shifted, the applied emboss pattern is also shifted.

[0074] On the other hand, in the embossing using the embossing machine 300 in the present example, the pressurizing roll 310 is flat, and the release paper 200 is embossed. With this arrangement, by changing the emboss pattern of the release paper 200, it is possible to carry out embossing with a more complex pattern that does not have a fixed cycle. In addition, by overlapping the fabric layer 100 with the release paper 200, even when an insertion angle formed by the fabric layer 100 and the release paper 200 which are to be inserted into the embossing machine 300 is shifted, a desired emboss pattern can be obtained.

[0075] Fig. 8 illustrates an example of the method for producing the fabric layer 100. In the example of Fig. 8, a mode of the embossing machine 300 used to produce the fabric layer 100 is different. The embossing machine 300 includes a core 350 and a cavity 360. Although illustrations are omitted, in the example of Fig. 8 too, similarly as in the example of Fig. 6, the fabric layer 100 and the release paper 200 may be respectively wound up rolls. By using Fig. 8, step S156 and step S158 for generating the fabric layer 100 will be described. Step S156 and step S158 in the present example are examples of step S150 in Fig. 5A, Fig. 5B, and Fig. 5C.

[0076] In step S156, the fabric layer 100 and the embossed release paper 200 are placed in the embossing machine 300 in a layered state. The fabric layer 100 and the release paper 200 may be placed on the core 350 of the embossing machine 300. In step S156, the fabric layer 100 and the release paper 200 may be heated by a heater or the like which is not illustrated in the drawing. With this arrangement, the coating layer 120 is easily embossed in a subsequent pressing step.

[0077] In step S158, the fabric layer 100 and the release paper 200 are pressed. Since the release paper 200 is provided with unevenness according to the embossing mold applied to the fabric layer 100, the coating layer 120 can be embossed upon pressing.

[0078] Fig. 9 illustrates a photograph of a front surface of an embossed fabric layer 500 in a comparative example. The difference from Fig. 1 will be described by using Fig. 9.

[0079] With regard to the fabric layer 500 in the comparative example, the fabric layer 500 is embossed by using a pressurizing roll onto which unevenness according to the emboss pattern is transferred. When the fabric layer 500 in the comparative example is embossed, a release paper is caused to interpose between the fabric layer 500 and the pressurizing roll. With this arrangement, polyester coating over the front surface of the fabric layer 500 avoids direct contact with the pressurizing roll, and the embossed polyester coating can be retained over the front surface of the fabric layer 500.

[0080] Since the release paper used for the method for producing the fabric layer 500 in the comparative example has a high smoothness of a surface in contact with the fabric layer 500, a gloss value of the front surface of the fabric layer 500 after the embossing becomes high. On the other hand, with regard to the fabric layer 100 in the present example, the fabric layer 100 is embossed by using the release paper 200 onto which the unevenness according to the emboss pattern is transferred. The release paper 200 onto which the emboss pattern is transferred in the present example has a smoothness lower than that of the release paper used for the method for producing the fabric layer 500 in the comparative example. With this arrangement, the fabric layer 100 in the present example can achieve a gloss value lower than that of the fabric layer 500 in the comparative example.

[0081] Fig. 10 illustrates a modification example of the release paper 200 used for the embossing. The difference from Fig. 7 will be described by using Fig. 10.

[0082] In the release paper 200 of Fig. 10, an embossed surface of the release paper 200 has an area S that has been textured. The area S is an area indicated by a bolded line in Fig. 10. Since the release paper 200 is textured, a front surface of the coating layer 120 is scratched to diffuse light, so that the glossiness can be reduced. By adjusting a degree of the texturing of the coating layer 120, the glossiness of the fabric layer 100 can be adjusted.

[0083] In the release paper 200 of Fig. 10, the texturing applied to the release paper 200 may be pear skin treatment. By performing the pear skin treatment on the embossed surface of the release paper 200, when the fabric layer 100 is delaminated from the release paper 200, the coating layer 120 is partially delaminated, so that breathability of the fabric layer 100 can be improved. The texturing may be pore treatment or sand treatment.

[0084] The area S may exist only in a part of the embossed surface of the release paper 200. The area S may be textured at different strengths depending on locations. With this arrangement, texture and breathability in one part of the fabric layer 100 can be adjusted.

[0085] While the present invention has been described above by way of the embodiments, the technical scope of the present invention is not limited to the scope described in the above-described embodiments. It is apparent to persons skilled in the art that various alterations or improvements can be made to the above-described embodiments. It is also apparent from the description of the claims that the embodiments to which such alterations or improvements are made can fall within the technical scope of the present invention.

[0086] Each process of the operations, procedures, steps, stages, and the like performed by a device, system, program, and method shown in the claims, the specification, and the drawings can be performed in any order as long as the order is not indicated by "prior to," "before," and the like and as long as the output from a previous process is not used in a later process. Even if the operational flow is described using phrases such as "first" or "next" for convenience in the claims, the specification, and the drawings, it does not necessarily mean that the process must be performed in this order.

[0087] 100: fabric layer; 110: polyester fabric; 120: coating layer; 130: lining layer; 200: release paper; 300: embossing machine; 310: pressurizing roll; 320: stand; 330: heating part; 340: cooling part; 350: core; 360: cavity; and 500: fabric layer.

Claims

1. A method for producing an embossed fabric layer, comprising: 　　embossing a coating layer made of polyester by pressurizing a polyester fabric, the coating layer, and an embossed release paper in a layered state; and 　　delaminating the release paper from a fabric layer in which the coating layer is formed over the polyester fabric.

2. The method for producing the fabric layer according to claim 1, comprising: 　　heating the polyester fabric, the coating layer, and the release paper.

3. The method for producing the fabric layer according to claim 1, wherein 　　an emboss depth of the fabric layer is less than or equal to a thickness of the release paper.

4. The method for producing the fabric layer according to claim 1, wherein 　　an emboss depth of the fabric layer is greater than or equal to 50 μm and less than or equal to 300 μm.

5. The method for producing the fabric layer according to claim 1, wherein 　　a thickness of the release paper is greater than or equal to 150 μm and less than or equal to 300 μm.

6. The method for producing the fabric layer according to claim 1, wherein 　　the coating layer is a polyester film.

7. The method for producing the fabric layer according to claim 1, wherein 　　the coating layer is laminated over the polyester fabric by applying polyester in a liquid form to the polyester fabric.

8. The method for producing the fabric layer according to claim 1, wherein 　　polyester contains at least one of PET (polyethylene terephthalate), PBT (polybutylene terephthalate), or PTT (polytrimethylene terephthalate).

9. The method for producing the fabric layer according to claim 2, wherein 　　a heating temperature in the heating is greater than or equal to a melting point of the coating layer and less than a melting point of the polyester fabric.

10. The method for producing the fabric layer according to claim 9, wherein 　　the heating temperature in the heating is greater than or equal to the melting point of the coating layer and less than or equal to the melting point of the coating layer + 40 degrees Celsius.

11. The method for producing the fabric layer according to claim 2, comprising: 　　cooling the fabric layer and the release paper after the embossing.

12. The method for producing the fabric layer according to any one of claims 1 to 11, comprising: 　　layering a lining layer with the polyester fabric before the coating layer made of polyester is formed over the polyester fabric.

13. The method for producing the fabric layer according to claim 12, wherein 　　the lining layer is a nonwoven fabric or a double raschel.

14. The method for producing the fabric layer according to any one of claims 1 to 11, wherein 　　an embossed surface of the release paper is textured.

15. The method for producing the fabric layer according to any one of claims 1 to 11, wherein 　　a color of the coating layer is identical to a color of the polyester fabric.

16. The method for producing the fabric layer according to any one of claims 1 to 11, wherein 　　a color of the coating layer is different from a color of the polyester fabric.

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