JP2021041575A - Epidermis material and manufacturing method of epidermis material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an epidermis material having ventilation holes, high air permeability, less likely to cause fraying of threads constituting a base cloth even after perforation processing, and having good strength as an epidermis material, and a method for producing the same.
SOLUTION: A base fabric composed of a base fabric having a high shrinkage yarn having a hot water dimensional change rate in the range of 10% to 50% specified in JIS L 1013 (2010), and at least one surface of the base fabric. , An adhesive layer and an epidermis layer in this order, and a skin material having a plurality of vents penetrating in the thickness direction and a method for producing the same.
[Selection diagram] FIG. 1B

Description

The present disclosure relates to an epidermis material and a method for producing the epidermis material.

Automotive interior parts such as instrument panels, door trims, seats and ceilings, railway vehicle and aircraft interior parts such as trims, seats and ceilings, furniture, shoes, footwear, bags, interior and exterior parts for building, clothing exterior materials and linings, walls Instead of natural leather and textile sheets, synthetic resin skin materials with excellent durability are often used for footwear and the like. For example, with respect to automobile interior parts, it has become important to give a sense of luxury to the skin material for interiors as the vehicle becomes more sophisticated. It is also required to have breathability equal to or higher than that of natural leather.
In order to obtain moisture permeability and breathability, the laminated sheet used as synthetic leather is perforated (perforation processing), but the perforation causes a decrease in strength such as tear strength and flat surface abrasion strength of synthetic leather. In some cases.

As the skin material, a cloth is generally used as a base material, and a urethane foam layer is provided on at least one surface of the cloth to impart cushioning properties, and a skin layer for imparting design properties is provided on the outermost surface. The one provided is used.
In the case of dry synthetic leather, a polyurethane resin solution can be coated on a surface such as a paper pattern, and then the solvent in the polyurethane resin solution can be evaporated by heat drying to form a skin layer of the synthetic resin skin material. Here, by using a release paper in which a desired uneven shape (pattern) is formed in advance on the release paper or the like, an arbitrary uneven pattern is formed on the skin layer. After forming the skin layer, a polyurethane resin as an adhesive is applied and dried, and then a cloth as a base material is laminated on it and joined by a crimping means such as a roller. Dry synthetic leather can be obtained by peeling (see Patent Document 1).

Generally, when a dry synthetic leather is perforated, the cloth as a base material is cut by the perforation, so that the continuity of the threads constituting the base cloth is impaired and the strength may be lowered.
Therefore, from the viewpoint of suppressing the decrease in strength of the skin material having ventilation holes, the wet synthetic leather formed by forming an adhesive layer or the like by a wet method of impregnating the base cloth with resin is perforated instead of the dry synthetic leather. A skin material having ventilation holes has been proposed (see Patent Document 2).
Further, as the cloth constituting the base material, a base cloth composed of fibers having a synthetic resin coating layer and in which at least a part of adjacent fibers are fused to each other is used to have ventilation holes. A skin material having excellent breathability and sufficient strength as a skin material has been proposed (see Patent Document 3).

Japanese Unexamined Patent Publication No. 9-031859 International Publication No. 2014/09799 Japanese Unexamined Patent Publication No. 2016-129994

Generally, the epidermis material such as synthetic leather is a dry synthetic leather that is bonded to the epidermis without processing the base cloth, and a wet synthetic leather that is wet-processed to make a wet base and then bonded to the epidermis. It is roughly divided.
If the dry synthetic leather as described in Patent Document 1 is perforated as it is to form ventilation holes, the required strength may not be obtained due to the cutting of the base cloth.
In the wet synthetic leather in which the base cloth is impregnated with a resin as described in Patent Document 2, the strength of the base cloth is improved by the impregnated resin, and the thread fraying of the base cloth when perforated is suppressed. However, when the base fabric is impregnated with a sufficient amount of synthetic resin to improve strength and suppress fraying of threads, the punching force required for drilling and the weight of the obtained synthetic leather increase, which may be a problem depending on the application. In some cases.
It is also important that the skin material is lightweight, and for this reason, a lightweight and highly flexible dry skin material is often used for vehicle interior materials and the like.

On the other hand, the synthetic leather described in Patent Document 3 is a dry synthetic leather, which is lightweight, is melted by heat, and is fused with an adjacent thread to form a base cloth by perforation processing. Even when the yarn is cut, the yarn is less likely to fray and the decrease in strength is suppressed. However, since the fibers have a fused portion, the rigidity of the base fabric is increased, and there is still room for improvement from the viewpoint of texture and wrinkle resistance.

An object of the embodiment of the present invention is to provide a skin material having ventilation holes, high air permeability, less likely to fray the threads constituting the base cloth even after drilling, and having good strength as a skin material. To provide.
An object of another embodiment of the present invention is a skin material having ventilation holes, high air permeability, less likely to fray the threads constituting the base cloth even after drilling, and having good strength as a skin material. It is an object of the present invention to provide a method for producing an epidermis material which can be produced by a simple process.

That is, the means for solving the above problems includes the following embodiments.
<1> On at least one surface of a base fabric composed of a base fabric containing high shrinkage yarn having a hot water dimensional change rate in the range of 10% to 50% specified in JIS L 1013 (2010). , An adhesive layer and an epidermis layer in this order, and an epidermis material having a plurality of vents penetrating in the thickness direction.

<2> The skin material according to <1>, wherein the high shrinkage yarn contains at least one fiber selected from the group consisting of polyester fiber, polyamide fiber, polyurethane fiber, rayon fiber, and polyamide fiber.
<3> The skin material according to <1> or <2>, wherein the base fabric is a knitted fabric knitted including the highly shrinkable yarn.
<4> The skin material according to any one of <1> to <3>, wherein the content ratio of the highly shrinkable yarn in the base fabric is in the range of 15% to 100% with respect to all the yarns constituting the base fabric. ..

<5> A step of laminating the skin layer and the adhesive layer on the surface of the release material in this order, and high shrinkage in which the hot water dimensional change rate specified in JIS L 1013 (2010) is in the range of 10% to 50%. The step of preparing a base cloth composed of threads and the adhesive layer of a release material in which the skin layer and the adhesive layer are laminated are brought into contact with at least one surface of the base cloth, and the base cloth and the adhesive layer are brought into contact with each other. The step of adhering the adhesive layer and the release material obtained by laminating the base cloth and the adhesive layer and the skin layer are heated, and the adhesive layer, the skin layer and the mold release material are formed on at least one surface of the base cloth. A step of forming in this order and peeling the release material from the surface of the skin layer to form a laminated body, and a step of drilling a plurality of ventilation holes penetrating the laminated body in the thickness direction of the laminated body are performed. Method of manufacturing the skin material including.
<6> The step of preparing the base cloth includes a step of producing a cloth using one or more kinds of threads including the highly shrinkable yarn, and a step of dyeing the produced cloth. 5> The method for producing a skin material.

According to one embodiment of the present invention, an epidermis material having ventilation holes, high air permeability, less likely to fray of threads constituting the base fabric even after drilling, and having good strength as an epidermis material. Can be provided.
According to another embodiment of the present invention, a skin material having ventilation holes, high air permeability, less likely to fray the threads constituting the base cloth even after drilling, and having good strength as a skin material. Can be provided with a method for producing an epidermis material, which can be produced by a simple process.

It is schematic cross-sectional view which shows one aspect of the laminated structure before drilling process in the skin material of this disclosure. It is the schematic sectional drawing which shows one aspect of the skin material of this disclosure. It is a partial schematic view which shows the structure of the denby knitting which is one aspect of the knitting structure of the knitted fabric used as the base cloth of the skin material of this disclosure. It is a partial schematic view which shows the structure of the cord knitting which is one aspect of the knitting structure of the knitted fabric used as the base cloth of the skin material of this disclosure. It is a partial schematic view which shows the structure of the atlas knitting which is one aspect of the knitting structure of the knitted fabric used as the base cloth of the skin material of this disclosure.

The numerical range described by using "~" in the present disclosure represents a numerical range including the numerical values before and after "~" as the lower limit value and the upper limit value.
In the present disclosure, the term "process" is included in this term as long as the intended purpose of the process is achieved, not only in an independent process but also in cases where it cannot be clearly distinguished from other processes.
In the numerical range described stepwise in the present disclosure, the upper limit value or the lower limit value described in a certain numerical range may be replaced with the upper limit value or the lower limit value of another numerical range described stepwise. Further, in the numerical range described in the present disclosure, the upper limit value or the lower limit value described in a certain numerical range may be replaced with the value shown in the examples.
Further, in the present disclosure, a combination of two or more preferred embodiments is a more preferred embodiment.

Hereinafter, the skin material of the present disclosure and the method for producing the same will be described in detail.
[Skin material]
The skin material of the present disclosure is a base fabric composed of a base fabric containing high shrinkage yarn having a hot water dimensional change rate in the range of 10% to 50% specified in JIS L 1013 (2010), and at least one of the base fabrics. The surface of the surface is provided with an adhesive layer and an epidermis layer in this order, and has a plurality of ventilation holes penetrating in the thickness direction.
Here, the hot water dimensional change rate specified in JIS L 1013 (2010) indicates the hot water dimensional change rate described in 8.18.1 of JIS L 1013, and in the present disclosure, the method A (skein size) is used. Change rate) is adopted.
The hot water dimensional change rate is determined according to the method described in JIS, and the temperature of hot water in which the fibers are immersed is 100 ° C.
A base fabric obtained by constructing a base fabric containing a high shrinkage yarn (hereinafter, may be simply referred to as "high shrinkage yarn") having a hot water dimensional change rate in the range of 10% to 50%. The density of the yarn is improved, and the decrease in strength after punching is suppressed.

Hereinafter, the skin material of the present disclosure will be described with reference to the drawings as appropriate. The components shown by the same reference numerals in the drawings in the present disclosure mean that they are the same components. The description of overlapping configurations and symbols in the drawings may be omitted.
FIG. 1A is a schematic cross-sectional view showing one aspect of the laminated body before perforation processing in the skin material of the present disclosure, and FIG. 1B is a schematic cross-sectional view showing one aspect of the skin material of the present disclosure after perforation processing. is there.
As shown in FIG. 1A, the laminate (laminate for forming the skin material) 10 for obtaining the skin material has an adhesive layer 16 and a skin layer on one surface of the base cloth 14 composed of the high shrinkage yarn. 18 and the surface treatment layer 20 are provided in this order.
The fact that the adhesive layer 16 and the skin layer 18 are provided in this order means that the adhesive layer 16 and the skin layer 18 are provided in this order on one surface of the base cloth 14, and any further provision thereof may be desired. It does not deny the existence of layers. For example, an intermediate layer, which is an arbitrary layer, may be further provided between the adhesive layer 16 and the epidermis layer 18, and the surface of the epidermis layer 18 opposite to the adhesive layer 16 side is further surface-treated. It may have a layer 20.
The skin material 12 shown in FIG. 1B can be obtained by perforating the laminate 10 shown in FIG. 1A. The skin material 12 shown in FIG. 1B has a base cloth 14 including high shrinkage yarn, and an adhesive layer 16, a skin layer 18, and a surface treatment layer 20 on at least one surface of the base cloth 14. In this order, it has a plurality of ventilation holes 22 penetrating in the thickness direction.
The surface treatment layer 20 in FIGS. 1A and 1B is an arbitrary layer provided as desired, as will be described later.

Although the action of the skin material of the present disclosure is not clear, it is considered as follows.
The skin material of the present disclosure uses a base fabric composed of a highly shrinkable yarn. By heat-treating the base fabric in any of the steps of forming the skin material, the highly shrinkable yarns contained in the base fabric are contracted, and the yarn density in the base fabric is increased. Of the threads that make up the base fabric, even if the highly shrinkable threads shrink, the elasticity of the fabric itself due to the structure is maintained.
Therefore, the base fabric having an improved yarn density has an improved strength without impairing the flexibility, and the fibers constituting the base fabric are more closely entangled due to the shrinkage of the highly shrinkable yarn.
For this reason, the laminate provided with the adhesive layer and the skin layer on the base fabric has excellent flexibility, and is caused by the improvement in the strength and the yarn density of the base fabric even after the perforation process is performed to form the ventilation holes. Therefore, it is considered that the decrease in the strength of the base fabric and, by extension, the decrease in the strength of the entire skin material are suppressed. Further, it is considered that the fraying of the base fabric during the drilling process is effectively suppressed due to the entanglement of the fibers.
In the base cloth, for example, the high shrinkage yarn contained in the base cloth is shrunk by heating by dyeing processing or by heating when the base cloth and the adhesive layer are brought into close contact with each other to cure the adhesive layer, so that the base cloth is compressed. It is considered that the constituent yarn densities are improved.
In the method for producing the skin material of the present disclosure, a skin layer is formed on the surface of the base cloth by a dry method. Therefore, the skin material obtained by the production method of the present disclosure is suppressed from a decrease in strength in the drilling step of forming through holes, is lightweight and flexible, has good breathability, and has sufficient strength as a skin material. Presumed to have.
The above is an estimation mechanism and does not limit the present disclosure in any way.

[Base cloth]
(High shrinkage yarn)
The base fabric in the skin material of the present disclosure is composed of a highly shrinkable yarn.
The high shrinkage yarn is a high shrinkage yarn having a hot water dimensional change rate in the range of 10% to 50% specified in JIS L 1013 (2010), and has a hot water dimensional change rate in the range of 20% to 40%. It is preferable to have.
The highly shrinkable yarn may be a monofilament yarn or a twisted yarn as long as the above conditions for the rate of change in hot water dimension are satisfied.
The high shrinkage yarn preferably contains at least one fiber selected from the group consisting of polyester fiber, polyamide fiber, polyurethane fiber, rayon fiber, and polyamide fiber from the viewpoint of having strength and flexibility, and polyester. More preferably, it contains fibers.
The thickness of the highly shrinkable yarn is not particularly limited, but from the viewpoint of achieving both strength and flexibility, 40 dtex to 222 dtex is preferable, and 56 dtex to 167 dtex is more preferable.
Further, in the case of twisted yarn, it is preferable that the high shrinkage yarn is in the range of 10 filaments to 144 filaments.
The yarns constituting the base fabric may be all high-shrink yarns, but may include yarns other than the high-shrink yarns in addition to the high-shrink yarns.
From the viewpoint of achieving both strength and flexibility, the content ratio of the highly shrinkable yarn in the base fabric is preferably in the range of 15% to 100% with respect to all the yarns constituting the base fabric, and is preferably in the range of 15% to 100%. More preferably, it is in the range of 80%.

(Structure of base cloth)
The base fabric may be a woven fabric, a knitted fabric, or a non-woven fabric, but a knitted fabric is preferable from the viewpoint of more preferably utilizing the characteristics of flexibility and high shrinkage yarn.
As the knitted fabric, a tricot knitted fabric which is a warp knit, a knit knitted fabric which is a weft knit, and the like are preferable, and a tricot knitted fabric is more preferable.

Representative examples of the tricot knitting structure suitable for knitting the base fabric are shown in FIGS. 2A to 2C.
FIG. 2A shows the Denby knitting structure, which is the most common structure of tricot knitting. In FIG. 2A, the colored yarn indicates a highly shrinkable yarn 24, and the yarn shown in white indicates a yarn 26 that is not a highly shrinkable yarn.
As shown in FIG. 2A, the base fabric may include the high shrinkage yarn 24 as a part of the knitting. For example, when the base fabric is a 3-bar tricot knit, one of the three yarns constituting the base fabric may be a high-shrink yarn.
Of course, all the yarns used for knitting the knitted fabric may be high shrinkage yarns.

FIG. 2B shows a cord knitting structure which is an example of another structure of tricot knitting, and FIG. 2C shows an atlas knitting structure which is an example of another structure of tricot knitting.
In FIGS. 2B and 2C, the colored yarn indicates a highly shrinkable yarn 24, and the yarn shown in white indicates a yarn 26 that is not a highly shrinkable yarn.
As described above, the base cloth may include the high shrinkage yarn 24 and the yarn 26 other than the high shrinkage yarn.
The structure of the base fabric is not limited to the above-mentioned tricot knitting, and can be selected according to the purpose.

To give a preferable example of the yarn density, when the yarn thickness is 56 dtex and the type of the base fabric is tricot knitting, the yarn density is wale (W) / course (C) = 30 to 40 [lines / inch (= 2.54 cm). )] / 60 to 70 [books / inch].

(Thickness of base cloth)
The thickness of the base cloth can be appropriately selected according to the purpose of use of the skin material.
For example, when the skin material of the present disclosure is used as the skin material of a seat seat, the base cloth is used from the viewpoint of having sufficient strength as the skin material, excellent appearance of ventilation holes, light weight and flexibility. The thickness is preferably 0.8 mm to 1.4 mm, more preferably 0.9 mm to 1.1 mm.

[Epidermis layer]
The skin material of the present disclosure has a skin layer on at least one surface of the above-mentioned base cloth via an adhesive layer.
The epidermis layer can be provided with a design property according to the purpose of use of the epidermis material. The method for forming the epidermis layer is not particularly limited, and the epidermis layer can be provided by applying a known synthetic leather and a method for forming the epidermis layer used for the epidermis material.

The synthetic resin used for forming the epidermis layer is not particularly limited and may be appropriately selected depending on the intended purpose.
Examples of the synthetic resin used for forming the epidermis layer include polyurethane, acrylic resin, polyester and the like. Of these, polyurethane is preferable from the viewpoint of good durability and elasticity.
Examples of the polyurethane used for forming the epidermis layer include polycarbonate-based polyurethane, polyether-based polyurethane, polyester-based polyurethane, and modified products thereof. From the viewpoint that the skin material of the present disclosure is used for applications requiring long-term durability such as automobile seats and chairs, polycarbonate-based polyurethane is preferable as the polyurethane used for the skin material.

When using the polyurethane for forming the skin layer, the polyurethane, the hardness was measured in accordance with JIS K 6253 (1997 years) is preferably 98N / ^{cm 2} ~3500N / ^cm 2 at 100% modulus, 196 N / cm ^{2 to} 588 N / cm ² is more preferable.
As a method of adjusting the hardness (100% modulus) of polyurethane, for example, when it is desired to soften it, the ratio of the polyol component to be a soft segment is increased, or when it is desired to increase the molecular weight of the polyol and make it harder. Crosslinking agents such as hexamethylene diisocyanate (HDI), hydrogenated xylylene diisocyanate (hydrogenated XDI), isophorone diisocyanate (IPDI), dicyclohexylmethane diisocyanate (hydrogenated MDI), etc. A method of forming a crosslinked structure by adding energy to the material can be mentioned.

The thickness of the epidermis layer is appropriately selected according to the purpose of use of the epidermis material. In general, the thickness of the epidermis layer before drying (hereinafter, may be referred to as Wet application amount) is about 20 μm to 300 μm, and the Wet application amount is preferably 100 μm to 250 μm.
The film thickness of the epidermis layer after drying is preferably 5 μm to 200 μm, more preferably 20 μm to 150 μm.

Further, in the composition for forming the epidermis layer, in addition to the resin as the main agent, known additives are used for the purpose of imparting various functions such as improving the feel to the epidermis layer as long as the effects of the present disclosure are not impaired. May be added.
Examples of the additive that can be used in the composition for forming the epidermis layer include a cross-linking agent, a cross-linking accelerator, a colorant, a film-forming aid, a flame retardant, and a foaming agent.
For example, by incorporating a colorant in the epidermis layer, the designability is improved. Further, by adding a known flame retardant such as phosphorus-based, halogen-based, or inorganic metal-based to the epidermis layer, the flame retardancy of the epidermis material can be improved.
The method of applying the composition for forming the epidermis layer on the surface of the release material for drawing transfer or the smooth release material is to apply the composition for forming the epidermis layer on the surface of the release material for drawing transfer. , A method of drying may be used, and a transfer method may be used if there is no problem in the hanged transfer.

[Adhesive layer]
The epidermis layer is a layer adhered to the base fabric via an adhesive layer.
The adhesive constituting the adhesive layer is not particularly limited, and examples thereof include a polyurethane-based adhesive, a vinyl chloride resin-based adhesive, and an adhesive containing an acrylic resin.
More specifically, for example, (1) a two-component curable polyester adhesive, (2) a two-component curable polyurethane adhesive, and (3) a two-component curable acrylic pressure-sensitive adhesive are preferable.
(2) The two-component curable polyurethane adhesive may be any of a two-component curable polyether polyurethane adhesive, a two-component curable polyester polyurethane adhesive, and a two-component curable polycarbonate polyurethane adhesive.

The composition used for forming the adhesive layer may contain various additives in addition to the above-mentioned adhesive, depending on the purpose, as long as the effects of the present disclosure are not impaired.
Examples of the additive include a colorant, a flame retardant, a foaming agent and the like.

When the adhesive layer contains a flame retardant such as phosphorus, the flame retardancy of the skin material is improved. However, if the content of the flame retardant is too large, the flexibility of the obtained adhesive layer may decrease. Therefore, when the flame retardant is used, the content of the flame retardant should be 5% by mass or less with respect to the adhesive. Is preferable.

[Other layers]
The skin material of the present disclosure may have, in addition to the base fabric, the adhesive layer, and the skin layer, any other layer as long as the effects of the present disclosure are not impaired.
Examples of other layers include an intermediate layer and a surface treatment layer.

(Surface treatment layer)
As shown in FIG. 1B, the skin material of the present disclosure may have a surface treatment layer on the side opposite to the adhesive layer side of the skin layer.
The surface treatment layer is formed by applying a surface treatment agent composition containing an aqueous emulsion resin or a dispersion resin to the surface of the epidermis layer.
As the resin contained in the aqueous emulsion resin or dispersion resin used for forming the surface treatment layer, any resin can be used as long as a uniform emulsion can be formed with respect to an aqueous medium or a non-aqueous organic solvent. May be good. As the resin that can be used, for example, polyurethane, acrylic resin, elastomer and the like are preferable, and polyurethane is more preferable.
Examples of the aqueous medium include water, alcohol, and a mixed medium in which two or more of these are mixed. As the aqueous solvent, water and a mixed solvent containing 90% by mass to 99% by mass of water and 10% by mass to 1% by mass of alcohol are preferable.
Examples of the non-aqueous organic solvent include dimethylformamide (DMF), methylethylketone (MEK), isopropyl alcohol (IPA), toluene and the like, and a mixed solvent obtained by mixing two or more of these.
By forming a surface treatment layer on the surface of the epidermis layer, the appearance and wear resistance are further improved.
The surface treatment layer can contain a cross-linking agent, an organic filler, a lubricant, a flame retardant and the like. For example, by containing an organic filler, a lubricant, or the like in the surface treatment layer, a smooth feel is imparted to the skin material, and wear resistance is further improved.

(Middle layer)
In the skin material of the present disclosure, an intermediate layer may be provided between the adhesive layer and the skin layer. The resin used for forming the intermediate layer is not particularly limited, and examples thereof include polyurethane and acrylic resin, and polyurethane is preferable.
Examples of the polyurethane used for the intermediate layer include polycarbonate-based polyurethane, polyether-based polyurethane, polyester-based polyurethane and modified products thereof, and polycarbonate-based polyurethane is suitable when long-term durability is required.
The thickness of the polyurethane intermediate layer can be in the range of 10 μm to 200 μm. The thickness is preferably in the range of 10 μm to 100 μm, more preferably in the range of 30 μm to 60 μm.
Hardness of the polyurethane used as the intermediate ^{layer, 98N / cm 2 ~1176N / cm} 2 is suitable in the 100% modulus.

The skin material of the present disclosure uses a base cloth composed of high-shrink yarns, and has ventilation holes formed by perforating a laminate having an adhesive layer and a skin layer on the surface of the base cloth. ..
Therefore, due to its breathability, it does not get stuffy even when used in contact with the human body, and is excellent in comfort. Further, even if it has a vent, it has sufficient strength.
Therefore, the skin material of the present disclosure can be used as a synthetic leather suitable for automobile interior parts, railway vehicle and aircraft interior parts, footwear materials mainly for shoes, chair upholstery seats, and interior materials. It is suitable as a leather material for seats such as automobile seats and chairs, and its application range is wide.

[Manufacturing method of skin material]
Next, a method for producing the skin material of the present disclosure will be described.
The skin material of the present disclosure is preferably produced by the method for producing the skin material of the present disclosure described in detail below.
The skin material of the present disclosure has a step of providing a skin layer and an adhesive layer on the surface of the release material, and the hot water dimensional change rate specified in JIS L 1013 (2010) is in the range of 10% to 50%. The step of preparing a base cloth composed of a high shrinkage yarn (high shrinkage yarn) and the adhesive layer of a release material in which the skin layer and the adhesive layer are laminated are brought into contact with at least one surface of the base cloth. In the step of bringing the base cloth and the adhesive layer into close contact with each other, the base cloth, the adhesive layer, the skin layer and the release material are heated, and the adhesive layer and the skin layer are applied to at least one surface of the base cloth. And the release material are formed in this order, and the release material is peeled off from the surface of the skin layer to form a laminate, and a plurality of ventilation holes penetrating the laminate in the thickness direction are formed in the laminate. Including the process.
In the manufacturing method of the present disclosure, the steps of preparing the base cloth are a step of preparing a cloth using one or more kinds of threads including the highly shrinkable yarn and a step of dyeing the prepared cloth. And can be included.

(Step of providing a skin layer and an adhesive layer on the surface of the release material)
First, a skin layer is formed on the surface of the release material.
As the release material, a known release material can be appropriately selected and used according to the purpose. As the release material, a release material for drawing transfer may be used, or a smooth release material may be used.
As a method for forming the skin layer on the surface of the release material, a known method can be applied. In general, as a method of forming the epidermis layer, a method of applying the composition for forming the above-mentioned epidermis material to the surface of the release material and drying to form the epidermis layer can be mentioned. Further, if there is no problem in the hanged transfer, the skin layer may be provided on the surface of the release material by the transfer method.

An arbitrary uneven pattern (squeeze) such as leather can be provided on the surface of the epidermis layer.
The squeezing is performed after forming a skin layer on the base cloth via an adhesive layer, or by pressurizing and adhering the laminate including the skin layer to the base cloth and heating to cure the adhesive layer, and then squeezing. It may be formed by heat-bonding a draw-type transfer roll having the above. Further, a skin layer and an adhesive layer are formed on the surface of the release material for transfer, which has been drawn in advance, and the formed adhesive layer and the base cloth are arranged so as to be in contact with each other, and are brought into close contact with each other and heated. After that, it may be formed by peeling off the release material for drawing transfer.

As the release material for drawing transfer, any one may be used as long as the desired drawing shape is formed, for example, a commercially available product may be used, or the release material may be obtained by computer graphics or the like. A one having a desired drawing pattern formed on the surface may be used.

The adhesive layer is formed by applying the composition for forming the above-mentioned adhesive layer to the surface of the epidermis layer. The method of applying the composition for forming the adhesive layer on the surface of the epidermis layer may be a coating method or a transfer method.
In this way, a laminate having a skin layer and an adhesive layer in this order is formed on the surface of the release material.

(Step of preparing a base fabric composed of highly shrinkable yarn)
In this step, in order to prepare the base cloth according to the skin material of the present disclosure, a base cloth composed of high shrinkage yarn is prepared.
The preparation of the base fabric may be a step of producing a base fabric using a yarn other than the high shrinkage yarn and, if desired, a high shrinkage yarn, and a step of preparing a base fabric composed of a commercially available high shrinkage yarn. It may be.
The details of the highly shrinkable yarn are as described in the description of the skin material, and the same applies to preferred examples.

In the step of producing the base fabric, a woven fabric, a knitted fabric, or a non-woven fabric may be produced by using a highly shrinkable yarn and, if desired, a yarn other than the highly shrinkable yarn. Weaving of yarn, knitting of yarn, and production of non-woven fabric using yarn can be performed by a conventional method.
Among them, it is preferable to prepare a base fabric by tricot knitting using a high shrinkage yarn and, if desired, a yarn other than the high shrinkage yarn.
The content of the highly shrinkable yarn in the base fabric is as described in the section of the skin material, and the same applies to preferable examples.

This step may include a step of preparing a cloth using one kind or two or more kinds of yarns including a highly shrinkable yarn, and further a step of dyeing the prepared cloth.
In this step, by dyeing the cloth, the highly shrinkable yarn is heat-shrinked by the heating during the dyeing process, the yarn density of the base cloth is further improved, and in addition to the improvement of the appearance by dyeing the base cloth, the base cloth is dyed. The strength of the cloth is further improved.

Either the step of providing the skin layer and the adhesive layer on the surface of the release material and the step of preparing the base cloth may be performed first. Further, it may be performed in parallel as another step.
A laminate obtained by these steps in advance, which is provided with a skin layer and an adhesive layer on the surface of the release material, and a base cloth are brought into close contact with each other in the next step, and the adhesive layer and the skin are brought into close contact with each other on the base cloth by a dry method. Form a layer.

(A step of bringing the adhesive layer of the release material having the skin layer and the adhesive layer on at least one surface of the base cloth into contact with each other to bring the base cloth and the adhesive layer into close contact with each other)
In this step, the adhesive layer side of the laminate obtained as described above is brought into contact with the surface of the base cloth formed in advance, and is brought into close contact with pressure.
At the time of pressure consolidation, heat treatment may be performed, or heat treatment may be performed after pressure consolidation.
The pressure when pressurizing the laminate and the base cloth is preferably 10 MPa to 50 MPa, more preferably 15 MPa to 30 MPa. It is preferable to pressurize after forming the adhesive layer on the epidermis layer and before the adhesive layer is cured from the viewpoint of further improving the peel strength between the base cloth and the epidermis layer in the epidermis material.

Heating of the base cloth, the laminated body including the adhesive layer and the skin layer can be performed by a known method. The heating means is not particularly limited, and known heating means such as heating using a hot roll, heating with warm air, and heating in a heating / drying furnace may be used.
The heating temperature is preferably a temperature at which the base fabric and the laminate are surely adhered to each other and do not affect the adhesive layer and the skin layer.

The heating temperature for heating the base cloth and the laminate including the adhesive layer and the skin layer to cure the adhesive layer and the like is preferably in the range of 40 ° C. to 70 ° C., preferably 40 ° C. to 60 ° C. The range is more preferred. The heating time is preferably 24 hours or more under the above temperature conditions.
Appropriate conditions may be selected for the temperature condition and heating time of the heat treatment depending on the type of synthetic resin used for forming the skin layer and the adhesive layer, the type of the highly shrinkable yarn used for the base fabric, and the like.
The heat treatment in this step sufficiently cures the resin contained in the adhesive layer. The epidermis layer may be cured before the composition for forming the adhesive layer is applied, but this heating step may further cure the resin contained in the epidermis layer.
The heat treatment forms an adhesive layer on the epidermis layer.

When a squeeze transfer release material is used to form a squeeze in the epidermis layer, the squeeze transfer release material is peeled off after heat treatment to squeeze the surface on the base cloth via an adhesive layer. An epidermis layer with a mold is formed.
As another method of forming a squeeze on the surface of the epidermis layer, a smooth release material having no squeeze is used instead of the release material for transfer of the squeeze, and the skin layer and the adhesive are adhered to the smooth release material surface. After peeling off the smooth release material using the layered laminate, the epidermis layer and the release material for squeezing transfer (embossing roll for squeezing) are brought into contact with each other to perform heat embossing and squeeze on the surface of the epidermis layer. There is a method of forming.

It is preferable that the heat treatment performed in this step of bringing the base cloth and the adhesive layer into close contact with each other is performed immediately after forming the skin layer and the adhesive layer on the release material.
Specifically, it can be said that one of the preferred embodiments is that the base cloth and the adhesive layer are brought into close contact with each other and heat-treated while the adhesive layer is uncured. While the adhesive layer formed on the surface of the epidermis layer is uncured, it is brought into contact with the base cloth and brought into close contact with pressure, so that some of the fibers contained in the base cloth easily penetrate into the adhesive layer, and the adhesive layer is formed. Adhesion with the base cloth is further improved. Further, the subsequent heat treatment promotes the curing of the adhesive layer, so that the adhesiveness with the base cloth is improved, and the peel strength between the base cloth and the skin layer becomes better in the obtained skin material.
After the adhesive layer and the epidermis layer are cured by the heat treatment, the release material is peeled off from the surface of the epidermis layer to obtain a laminate (laminate for forming the epidermis material).

(Step of drilling a plurality of ventilation holes penetrating the laminate in the thickness direction of the laminate)
Next, a plurality of ventilation holes penetrating in the thickness direction of the laminated body are perforated in the obtained laminated body. For example, a punching roll, a flat plate punch type, or the like is used to punch vent holes having a desired diameter in the laminated body at desired intervals. As a result, a skin material having an adhesive layer and a skin layer on the base cloth and having a large number of vents penetrating in the thickness direction is manufactured.

According to the above method, in the base cloth serving as a support, at least a part of the threads (fibers) constituting the base cloth is a high shrinkage thread, and the high shrinkage thread is heat-shrinked in the process of manufacturing the skin material. Since the yarn density is higher than that of the known base fabric and the strength and yarn density of the base fabric are improved without impairing the flexibility, the laminate formed by the wet method during the drilling process. With less stress than this, it is possible to easily form a vent hole that is close to a perfect circle in a plan view.
Further, the yarns constituting the base fabric are cut by perforation, but at least a part of the yarns constituting the base fabric is high shrinkage yarns, and the yarn density of the base fabric itself is high, so that the strength of the base fabric is lowered. Is suppressed.
Further, it is one of the advantages of the present disclosure that the inclusion of the highly shrinkable yarn suppresses the cut yarn from stretching completely after cutting and prevents the cut yarn from jumping out into the ventilation holes and spoiling the appearance. is there.

Since the adhesion in the laminate and the skin layer are formed by the dry method, the cloth is not impregnated with resin due to the wet method, so that the obtained skin material is lighter than the skin material formed by the wet method. It also has the secondary advantage that the stress required for drilling is also smaller.

Therefore, the skin material of the present disclosure manufactured by the manufacturing method of the present disclosure described above has ventilation holes, is highly breathable, and is less likely to fray the threads constituting the base fabric even after the perforation process, and is the skin material. According to the production method of the present invention, such an epidermis material can be efficiently produced.

Hereinafter, the skin material of the present disclosure and the method for producing the same will be specifically described with reference to examples, but the present disclosure is not limited thereto.

[Example 1]
(1. Formation of laminated body A)
Polyurethane (trade name: Chrisbon NY-324, DIC Co., Ltd.) diluted with a mixed solvent of dimethylformamide (DMF) / methylethylketone (MEK) 1: 1 (mass ratio) on the surface of the release material to a solid content of 15% by mass. Was coated with a knife coater to an amount of 200 g / m ² , and dried in a heating and drying furnace at 100 ° C. for 2 minutes to form a skin layer on the surface of the release material.
5 parts by mass of dimethylformamide (DMF) is added to 100 parts by mass of polyurethane (trade name: TA205, manufactured by DIC Corporation), and 10 parts by mass of a cross-linking agent (product name: Bernock DN950, manufactured by DIC Corporation) is added. To prepare a composition for forming an adhesive layer. The obtained composition for forming an adhesive layer ^{was laminated and coated at an amount of 150 g / m 2} , and an adhesive layer was formed on the epidermis layer to obtain a laminated body A.

(2. Preparation of base cloth)
Tricot knitting obtained by tricot knitting with a knitting density: wales / course: 34/65 [books / inch] using polyester fibers of high shrinkage yarn (thread thickness 56dtex) and non-high shrinkage polyester fibers. The cloth was heat-dyed at 100 ° C. for 60 minutes to prepare a base cloth. By this heat dyeing step, the highly shrinkable yarn contained in the base fabric was shrunk, and the density of the yarn constituting the base fabric was improved.
The proportion of highly shrinkable yarn contained in the base fabric is 15%.
The rate of change in hydrothermal dimension measured with hot water at 100 ° C., as defined by JIS L 1013 (2010) of the highly shrinkable yarn contained in the base fabric, is 30%.

(3. Formation of laminated body B)
The base cloth obtained above and the adhesive layer of the laminate A obtained above were brought into contact with each other, laminated at a pressure of 0.24 MPa, and consolidated under pressure. Then, it was left to stand in an atmosphere of 50 ° C. for 48 hours to cure the adhesive layer, then the release material was peeled off, and the laminate B having the epidermis layer on the surface of the base cloth via the adhesive layer (lamination for forming the epidermis material). Body) got. By the step of forming the laminated body B, the highly shrinkable yarn contained in the base fabric was contracted, and the yarn density constituting the base fabric was further improved.

(4. Formation of ventilation holes)
The skin material of Example 1 having a through hole is formed by punching a hole in the laminated body B in which the base cloth, the adhesive layer, and the skin layer obtained through each of the above steps are laminated. Obtained.
The diameter, spacing, and aperture ratio of the vent holes in the skin material are as follows.
Hole diameter: 1.4 mm
Pitch: 5.0 mm
Aperture ratio: 12%
The mass of the obtained skin material of Example 1 was measured and found to be 537 g / m ² .

[Example 2]
The skin material of Example 2 was obtained in the same manner as in Example 1 except that the proportion of the highly shrinkable yarn contained in the base cloth was 45%.

[Comparative Example 1]
The skin material of Comparative Example 1 was obtained in the same manner as in Example 1 except that the proportion of the highly shrinkable yarn contained in the base cloth was set to 0%.

[Comparative Example 2]
Instead of the base fabric used in Example 1, a polyester fiber yarn other than the high-shrink yarn was used, and a base fabric of Kanoko knitted fabric knitted at a knitting density: wales / course: 35/40 [books / inch] was used. A skin material of Comparative Example 2 was obtained in the same manner as in Example 1 except for the above.

[Comparative Example 3]
Instead of the base cloth used in Example 1, polyester fibers having a resin coating layer described in JP-A-2016-129994 were used, and knitted at a knitting density: wale / course: 35/84 [books / inch]. A skin material of Comparative Example 3 was obtained in the same manner as in Example 1 except that the base fabric was changed to a denby knitted fabric in which at least a part of adjacent fibers was fused by heating.

[Comparative Example 4]
(1. Preparation of wet base)
30 parts by mass of flame retardant (trade name: Pecoframe ATC, manufactured by Arcroma) and 600 parts by mass of dimethylformamide (DMF) with respect to 350 parts by mass of polyurethane (trade name: Chrisbon MP-865PS, manufactured by DIC Corporation). A resin solution for impregnation was prepared by adding a part.
A twill woven fabric using a polyester / rayon blended fiber is immersed in the above-mentioned impregnated resin solution, the twill woven fabric is impregnated with the impregnating resin solution, and then immersed in water for 10 minutes to remove the solvent and solidify the polyurethane. I let you.
Then, it was dried under hot air at 120 ° C. for 10 minutes to form a base cloth layer (wet base cloth, thickness: 1.1 mm) having a porous structure. Next, using a buffing machine (manufactured by Meinan Seisakusho Co., Ltd., trade name: A-5), one side of the base fabric layer was buffed to roughen it to obtain a raised surface.

(2. Formation of laminated body A)
Polyurethane (trade name: Chrisbon NY-324, DIC Co., Ltd.) diluted with a mixed solvent of dimethylformamide (DMF) / methylethylketone (MEK) 1: 1 (mass ratio) on the surface of the mold with a solid content of 15% by mass. Was coated with a knife coater to an amount of 200 g / m ² , and dried in a heating and drying furnace at 100 ° C. for 2 minutes to form a skin layer on the surface of the release material.
5 parts by mass of dimethylformamide (DMF) is added to 100 parts by mass of polyurethane (trade name: TA205, manufactured by DIC Corporation), and 10 parts by mass of a cross-linking agent (product name: Bernock DN950, manufactured by DIC Corporation) is added. To prepare a composition for forming an adhesive layer. The obtained composition for forming an adhesive layer ^{was laminated and coated at an amount of 150 g / m 2} , and an adhesive layer was formed on the epidermis layer to obtain a laminated body A.

(3. Preparation of laminated body B)
The base cloth obtained above and the adhesive layer in the laminated body A of the skin layer and the adhesive layer were brought into contact with each other, laminated at a pressure of 0.24 MPa, and consolidated under pressure.
Then, it was left to stand in an atmosphere of 50 ° C. for 48 hours to cure the adhesive layer, and then the release material was peeled off to obtain a laminate B having a skin layer on the surface of the base cloth via the adhesive layer.

(4. Formation of ventilation holes)
A skin material of Comparative Example 3 having ventilation holes was obtained by punching holes in the laminate B in which the base cloth, the adhesive layer, and the skin layer were laminated, which were obtained through each of the above steps. The diameter, spacing, and aperture ratio of the vent holes in the skin material are as follows.
Hole diameter: 1.4 mm
Pitch: 5.0 mm
Aperture ratio: 12%

(Mass of knitted fabric used to make the base fabric)
In the skin materials of Example 1, Example 2, and Comparative Examples 1 to 4, the mass per unit area of each knitted fabric used for producing the base fabric was measured. The mass per unit area is the mass before the knitted fabric is heat-shrinked to form a base fabric. The results are also shown in Table 1 below.

(Evaluation of skin material)
Compared to the obtained skin materials of Examples 1 and 2, and Comparative Examples 1 to 4, each item of the hardness, breathability, tear strength, tensile strength, wear resistance, and vent hole appearance of the skin material. Was evaluated by the following methods and criteria.
According to the following evaluation criteria, 4 points and 5 points are evaluated as having no problem in practical use, and 5 points are excellent levels.

(1. Rigidity and softness)
The rigidity and softness of the skin material was measured by JIS L1096 (2010) 8.21.1 A method (45 ° cantilever method) and evaluated according to the following criteria.
The length of movement of the test piece indicates the moving distance of the test piece until the tip of the test piece hangs below the cantilever by moving the test piece on the flat surface portion of the top of the 45 ° cantilever, and the moved length is short. The more flexible it is, the better it is evaluated.
Since the skin material is flexible, the effect of suppressing the occurrence of wrinkles can be expected.
(Evaluation criteria)
5 points: The length of movement of the test piece is less than 90 mm 4 points: The length of movement of the test piece is 90 mm or more and less than 100 mm 3 points: The length of movement of the test piece is 100 mm or more and less than 110 mm 2 points: The length of movement of the test piece is less than 110 mm Length of 110 mm or more and less than 120 mm 1 point: The length of movement of the test piece is 120 mm or more

(2. Breathability)
The air permeability of the skin material was measured by JIS L1096 (2010) 8.26.1 A method (Frazier method), and evaluated on a scale of 1 to 5 based on the following criteria. The results are shown in Table 1 below.
(Evaluation criteria)
5 points: 120cm ³ / cm ² · s or more 4 points: 100cm ³ / cm ² · s or more 120 cm ³ / cm ² · s less than 3 points: 80cm ³ / cm ² · s or more 100 cm ³ / cm ² · s less than 2 Point: 60 cm ³ / cm ² · s or more 80 cm ³ / cm ^{less than 2} · s 1 point: 60 cm ³ / cm less than ^{2 · s}

(3. Tear strength)
The tear strength of the epidermis was measured by the JIS L1096 (2010) 8.17.3 C method (Travezoid method), and was evaluated on a scale of 1 to 5 based on the criteria shown below. The results are shown in Table 1 below.
(Evaluation criteria)
5 points: tear strength of 100N or more and 4 points: tear strength of 80N or more and less than 100N 3 points: tear strength of 60N or more and less than 80N 2 points: tear strength of 40N or more and less than 60N 1 point: tear strength of less than 40N

(4. Tensile strength)
The tensile strength of the skin material was measured by JIS L1096 (2010) 8.14.1 A method (label strip method) and evaluated according to the following criteria.
(Evaluation criteria)
5 points: Tensile strength is 150N or more and less than 150N 4 points: Tensile strength is 130N or more and less than 150N 3 points: Tensile strength is 110N or more and less than 130N 2 points: Tensile strength is 90N or more and less than 110N 1 point: Tensile strength is less than 90N

(5. Flat surface wear resistance)
The obtained skin material is cut, and one test piece having a width of 70 mm and a length of 300 mm is collected along the length (MD) direction and the width (CD) direction of the skin material, and the width is on the back surface. A urethane foam having a size of 70 mm, a length of 300 mm, and a thickness of 10 mm is attached and fixed to a flat wear tester T-TYPE (manufactured by Daiei Kagaku Seiki Seisakusho Co., Ltd.).
A load of 9.8 N was applied to a friction element covered with a cotton cloth (No. 6 canvas) to wear the surface of the test piece (the side on which the epidermis layer was formed). The friction element was reciprocally worn 10,000 times at a speed of 60 reciprocations / minute between 140 mm on the surface of the test piece. The No. 6 canvas covered with the friction element was worn back and forth a total of 10,000 times by exchanging the No. 6 canvas every 2500 round trips. The test piece after wear was observed and judged according to the following criteria.
(Evaluation criteria)
5 points: No change in appearance (no cracks or tears)
4 points: Slight wear but inconspicuous 3 points: Wear is clearly observed and the fibrous substrate is exposed (cracks are observed)
2 points: Slightly exposed fibrous base material 1 point: Significantly exposed fibrous base material (tear is observed)

(6. Appearance of ventilation holes)
For 10 of the vents (1.4 mm in diameter) formed in the skin material, the frayed threads in the vents were visually evaluated using a magnifying glass, and the number of frayed threads exposed in the holes was counted. The average number of the results of the individual vents was calculated and used as the number of frayed yarns. The results were evaluated on a scale of 1 to 5 based on the criteria shown below. The results are shown in Table 1 below.
(Evaluation criteria)
5 points: Frayed threads cannot be visually confirmed 4 points: 1 to 2 frayed threads that can be visually confirmed 3 points: 3 to 5 frayed threads that can be visually confirmed 2 points: Visually confirmed 6 to 9 frayed threads that can be made 1 point: 10 or more frayed threads that can be visually confirmed

As is clear from Table 1, the skin materials of Examples 1 and 2 have good rigidity, that is, flexibility, strength, and abrasion resistance, and are equivalent to the skin materials of each comparative example. It was breathable and the appearance of the vents was good.
On the other hand, it can be seen that Comparative Example 1 using the base cloth not containing the highly shrinkable yarn is inferior in strength, and Comparative Example 2 is inferior in strength and abrasion resistance. Further, Comparative Example 3 using a base cloth in which at least a part of adjacent threads are fused to each other has good strength and abrasion resistance, but there is still room for improvement in rigidity and softness, and wrinkles are generated. It turns out that it may not be suitable for applications of concern.
The skin material of Comparative Example 4, which is a wet skin material, had good rigidity and softness and wear resistance, but was heavy in weight and inferior in tear strength and tensile strength.
From the above results, it was confirmed that the skin material of the present disclosure has ventilation holes and has good air permeability, and at the same time, has sufficient strength and abrasion resistance as the skin material and is flexible.

10 Laminated body (Laminated body for forming skin material)
12 Skin material 14 Base cloth 16 Adhesive layer 18 Skin layer 20 Surface treatment layer 22 Vent holes 24 High shrinkage yarn 26 Threads other than high shrinkage yarn

Claims (6)

An adhesive layer is formed on at least one surface of a base fabric and a base fabric having a high shrinkage yarn having a hot water dimensional change rate in the range of 10% to 50% specified in JIS L 1013 (2010). A skin material having a skin layer and a skin layer in this order, and having a plurality of vents penetrating in the thickness direction. The skin material according to claim 1, wherein the highly shrinkable yarn contains at least one fiber selected from the group consisting of polyester fiber, polyamide fiber, polyurethane fiber, rayon fiber, and polyamide fiber. The skin material according to claim 1 or 2, wherein the base fabric is a knitted fabric knitted including the highly shrinkable yarn. The skin material according to any one of claims 1 to 3, wherein the content ratio of the highly shrinkable yarn in the base fabric is in the range of 15% to 100% with respect to all the yarns constituting the base fabric. A process of laminating the skin layer and the adhesive layer on the surface of the release material in this order,
A process of preparing a base fabric composed of high-shrink yarn having a hot water dimensional change rate in the range of 10% to 50% specified in JIS L 1013 (2010), and a process of preparing a base fabric.
A step of bringing the adhesive layer of the release material, in which the skin layer and the adhesive layer are laminated, into contact with at least one surface of the base cloth to bring the base cloth and the adhesive layer into close contact with each other.
The mold release material obtained by laminating the base cloth and the adhesive layer and the skin layer is heated to form an adhesive layer, a skin layer and a mold release material on at least one surface of the base cloth in this order, and the surface of the skin layer is formed. The process of peeling off the release material to form a laminate,
A method for producing a skin material, which comprises a step of perforating a plurality of ventilation holes penetrating the laminated body in the thickness direction of the laminated body. The fifth aspect of claim 5, wherein the step of preparing the base cloth includes a step of preparing a cloth using one or more kinds of yarns including the highly shrinkable yarn and a step of dyeing the produced cloth. Manufacturing method of skin material.

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