EP2531351A1 - Release sheet, synthetic leather and manufacturing method thereof - Google Patents

Release sheet, synthetic leather and manufacturing method thereof

Info

Publication number
EP2531351A1
EP2531351A1 EP10845015A EP10845015A EP2531351A1 EP 2531351 A1 EP2531351 A1 EP 2531351A1 EP 10845015 A EP10845015 A EP 10845015A EP 10845015 A EP10845015 A EP 10845015A EP 2531351 A1 EP2531351 A1 EP 2531351A1
Authority
EP
European Patent Office
Prior art keywords
emboss
thermoplastic resin
release sheet
resin layer
embossing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP10845015A
Other languages
German (de)
French (fr)
Other versions
EP2531351A4 (en
Inventor
Hideki Sugimoto
Daisuke Sasaki
Kenji Takaoka
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Lintec Corp
Original Assignee
Lintec Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lintec Corp filed Critical Lintec Corp
Publication of EP2531351A1 publication Critical patent/EP2531351A1/en
Publication of EP2531351A4 publication Critical patent/EP2531351A4/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
    • D06N3/0095—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by inversion technique; by transfer processes
    • D06N3/0097—Release surface, e.g. separation sheets; Silicone papers
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/001—Release paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/12—Coating on the layer surface on paper layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/028—Paper layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/408—Matt, dull surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/538—Roughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B32B2307/734—Dimensional stability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/748—Releasability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/08—Dimensions, e.g. volume
    • B32B2309/10—Dimensions, e.g. volume linear, e.g. length, distance, width
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/08—Dimensions, e.g. volume
    • B32B2309/10—Dimensions, e.g. volume linear, e.g. length, distance, width
    • B32B2309/105—Thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/08—Natural leather
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/16—Properties of the materials having other properties
    • D06N2209/1664—Releasability
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/12—Decorative or sun protection articles
    • D06N2211/28—Artificial leather
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/10—Coatings without pigments
    • D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
    • D21H19/20—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H19/22—Polyalkenes, e.g. polystyrene
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/02—Patterned paper

Definitions

  • the present invention relates to a release sheet, a manufacturing method of the release sheet and a synthetic leather.
  • a release sheet called as a casting paper has been used for manufacturing a synthetic leather made of polyurethane resin and vinyl chloride resin.
  • the release sheet is manufactured by laminating a thermoplastic resin such as polypropylene resin and polymethylpentene resin on a surface of a substrate paper (substrate sheet) and embossing the thermoplastic resin layer with an emboss roller having minute irregular form (i.e. the concave and convex shape) on a surface thereof, which is, for instance, configured as shown in Fig. 4A.
  • the release sheet is provided with the emboss pattern only on a thermoplastic resin layer 42 laminated on a substrate paper (substrate sheet) 41.
  • the synthetic leather transferred with the embossed pattern on the surface thereof is manufactured by: coating the surface of the release sheet by extruding a material such as polyurethane resin and vinyl chloride resin; drying the polyurethane resin, the vinyl chloride resin and the like to cure the release sheet; and peeling off the release sheet to transfer the emboss pattern on the release sheet.
  • a material such as polyurethane resin and vinyl chloride resin
  • drying the polyurethane resin, the vinyl chloride resin and the like to cure the release sheet
  • peeling off the release sheet to transfer the emboss pattern on the release sheet.
  • Patent Literature 1 Another example of the release sheet is disclosed in Patent Literature 1, which includes a paper layer and a thermoplastic-resin embossed layer provided on the paper layer.
  • the entirety (i.e. the paper layer and the embossed layer) of the release sheet disclosed in the Patent Literature 1 is curved in a wavy form.
  • the emboss pressure applied during manufacture reaches to the paper layer (see Fig. 4B, where reference numeral 43 denotes the paper layer and the reference numeral 44 denotes the embossed layer).
  • the Patent Literature 2 below discloses another release sheet that is used for producing a matted (i.e.
  • the release sheet including: a substrate sheet; a matted layer with minute irregular forms provided on the substrate sheet; and a release layer provided on a surface of the matted layer, the release layer being provided by a release-resin coat layer containing ultrafine particles.
  • the release layer is not embossed, but the surface thereof is provided with more minute irregular forms resulted from the minute irregular forms of the matted layer.
  • thermoplastic resin layer of the known release sheet has only one emboss pattern provided by embossing the thermoplastic resin layer or has minute irregular form of mat shape.
  • emboss patterns can be provided, which makes it difficult to manufacture synthetic leather articles having richer textures.
  • Patent Literature 2 WO2006/006713
  • An object of the invention is to provide a release sheet capable of manufacturing a synthetic leather with rich textures, a manufacturing method of the release sheet and a synthetic leather manufactured using the release sheet.
  • a release sheet includes: a substrate sheet and a thermoplastic resin layer laminated on the substrate sheet, in which two or more different emboss patterns are formed on the surface of the thermoplastic resin layer.
  • a depth of irregular form of one of the two or more different emboss patterns may be smaller than depth of irregular form of another emboss pattern.
  • the substrate sheet and the thermoplastic resin layer may be respectively embossed, and the emboss pattern formed on the substrate sheet emerges on the surface of the thermoplastic resin layer.
  • a depth of irregular form of the emboss patterns provided by embossing the thermoplastic resin layer may be smaller than a depth of the irregular form of the emboss patterns provided by embossing the substrate sheet.
  • a manufacturing method of the release sheet according to an aspect of the invention includes: a first embossing step for embossing the substrate sheet; laminating step for laminating the thermoplastic resin layer on the embossed substrate sheet; and second embossing step for embossing the laminated thermoplastic resin layer, in which the irregular forms of the embossed patterns provided in the first embossing step and the second embossing step are mutually different.
  • a synthetic leather is manufactured by using the release sheet according to any one of [l] to [4].
  • thermoplastic resin layer of the release sheet since two or more different emboss patterns are provided on the surface of the thermoplastic resin layer of the release sheet, a synthetic leather with a richer texture can be manufactured.
  • Fig. 1 is a cross section of a release sheet according to an exemplary embodiment of the invention.
  • Fig. 2 is a diagram schematically showing a manufacturing method of the release sheet according to the exemplary embodiment.
  • Figs. 3 are diagrams schematically showing a manufacturing process of the release sheet according to the exemplary embodiment, in which: Fig 3 A shows a substrate sheet before a first embossing step; Fig 3B shows the substrate sheet after the first embossing step; Fig 3C shows a laminated sheet after being subjected to a laminating step; and Fig 3D shows the release sheet obtained after the second embossing step.
  • Fig. 4A is a cross section of a release sheet according to a related art.
  • Fig. 4B is a cross section of a release sheet according to another related art.
  • Fig. 1 is a cross section of a release sheet according to an exemplary embodiment of the invention.
  • the release sheet 1 includes a substrate sheet 2 and a thermoplastic resin layer 3.
  • the thermoplastic resin layer 3 is laminated on the substrate sheet 2.
  • Two different emboss patterns i.e. a first emboss pattern and a second emboss pattern
  • a first emboss pattern and a second emboss pattern are provided on the surface of the thermoplastic resin layer 3. Detailed description of the emboss patterns will be mentioned below.
  • the substrate sheet 2 of this exemplary embodiment may be provided by any paper or film base that is adapted to support the thermoplastic resin layer 3.
  • the substrate sheet 2 are: paper base such as tissue paper, kraft paper, linter paper, wood containing paper, woodfree paper, impregnated paper, coat paper, art paper, vegetable paper and glassine paper; film of polyolefin resin such as polyethylene and polypropylene; film of vinyl resin such as polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, ethylene- vinyl acetate copolymer and ethylene- vinylalcohol copolymer; film of polyester resin such as polyethylene terephthalate, polybutylene terephthalate and polyethylene naphthalate; and film of the other synthetic resin such as polystyrene, acrylonitrile butadiene styrene copolymer, triacetyl cellulose, cellophane and polycarbonate.
  • paper bases are favorable in terms of heat resistance and thermoformability
  • the thickness and size of the substrate sheet 2 is not specifically limited, but can be selected in any manner in accordance with the usage of the release sheet 1, the type of the substrate sheet 2 and the like.
  • the basis weight of the substrate sheet is preferably in a range of 30 to 200 g/m 2 , more preferably 80 to 140 g/m 2 .
  • the thickness of the substrate sheet is preferably in a range of 5 to 500 ⁇ , more preferably 15 to 300 ⁇ .
  • the substrate sheet 2 may be a continuous belt shape or a roll shape of paper or film.
  • the substrate sheet 2 When the basis weight of the substrate sheet 2 is less than 30 g/m 2 or the thickness of the synthetic resin film is less than 5 ⁇ , because a substrate sheet 2 is thin and a stiffness of a substrate sheet is weak, the substrate sheet 2 may be inferior in handling and heat resistance during the subsequent process.
  • the basis weight of the substrate sheet 2 exceeds 200 g/m 2 or the thickness of the substrate sheet 2 exceeds 500 ⁇ , because the weight per area of the substrate sheet 2 increases, the release sheet 1 may cause the problem of wound meters per a roll or in weight restriction during transportation. Specifically, when the weight per a roll is limited and the sheet is wound in compliance with the weight restriction, a problem of decrease in the wound meters per a roll arises. Further, when there is no restriction in the roll diameter and a desired wound meters per a roll is wound, a problem of increase in the weight per a roll arises.
  • the paper base may preferably be provided with an anti curling treatment on the backside thereof (i.e. a side opposite to the side coated with the thermoplastic resin layer).
  • the anticurling treatment prevents the substrate sheet 2 from being curled to deform the release sheet 1 on account of heat, water absorption or drying.
  • the anticurling treatment is applied by, for instance, coating a synthetic resin such as acrylic resin, polystyrene resin and styrene-butadiene copolymer or laminating film of polyolefin resin and the like on the backside of the paper base.
  • a base emboss pattern is provided on the substrate sheet 2 of this exemplary embodiment (see Fig. 3B).
  • a depth (i.e. a distance between a top of a convex portion and a bottom of a concave portion) hi of the base emboss pattern is preferably larger than a depth h3 of the second emboss pattern (see Figs. 3B and 3D).
  • the thermoplastic resin layer 3 is provided by a resin that exhibits excellent releasability and coatability against a resin forming a synthetic leather, example of which is a polyolefin polymer.
  • a resin that exhibits excellent releasability and coatability against a resin forming a synthetic leather example of which is a polyolefin polymer.
  • the polyolefin polymer is a homopolymer and copolymer of a-olefin.
  • Examples of the a-olefin are ethylene, propylene, 1-butene, 2-methyl-l-butene, 1-pentene, 2-methyl-l-pentene, 1-hexene, 2,2-dimethyl- 1-butene, 2-methyl-l-hexene, 4-methyl- 1-pentene, 1-heptene, 2-methyl- 1-hexene,
  • the thickness and size of the thermoplastic resin layer 3 is not specifically limited, but can be selected in any manner in accordance with the usage of the release sheet 1 and the type of the thermoplastic resin layer 3.
  • the thickness of the thermoplastic resin layer 3 is preferably in a range of 5 to 200 ⁇ , more preferably 10 to 100 ⁇ .
  • the thickness of the thermoplastic resin layer 3 is less than 5 ⁇ , less number of design is available for the second emboss pattern and the thermoplastic resin layer may not be formed into a membrane of uniform thickness on account of the thinness.
  • the productivity may be lowered on account of the long time required for solidifying the molten resin and the first emboss pattern may be buried.
  • the first emboss pattern is provided by the irregular form conforming to the base emboss pattern.
  • the depth h2 of the irregular form of the first emboss pattern is approximately the same as the depth hi of the irregular form of the base emboss pattern.
  • the second emboss pattern provides more minute irregular form than that of the first emboss pattern and conforms to the irregular form of the first emboss pattern within an area provided with the first emboss pattern.
  • the depth h2 of the irregular form of the first emboss pattern is preferably larger than the depth h3 of the irregular form of the second emboss pattern (see Figs. 3C and 3D).
  • Fig. 2 schematically shows a release-sheet producing apparatus 10.
  • the release-sheet producing apparatus 10 includes a first embossing unit 11, an extruder 12 and a second embossing unit 13.
  • the first embossing unit 11 embosses the substrate sheet 2.
  • the first embossing unit 11 includes a first emboss roller 11a and a first pressure roller l ib.
  • the first emboss roller 11a is made of metal and an outer circumference thereof is provided with irregular form corresponding to the first emboss pattern (the irregular form of the first emboss pattern not shown in Fig. 2).
  • the first pressure roller l ib is made of rubber, of which outer surface is substantially flat.
  • the extruder 12 extrudes a thermoplastic resin to coat the thermoplastic resin on the substrate sheet 2.
  • the extruder 12 includes a T-die.
  • the thermoplastic resin is extruded through the T-die on the substrate sheet 2 to be laminated thereon.
  • the second embossing unit 13 embosses the thermoplastic resin layer 3.
  • the second embossing unit 13 includes a second emboss roller 13a and a second pressure roller 13b.
  • the second emboss roller 13a is made of metal and an outer surface thereof is provided with irregular form corresponding to the second emboss pattern. Coolant water is supplied to the inside of the second emboss roller 13a.
  • the second emboss roller 13a also works as a cooling roller for cooling and solidifying the thermoplastic resin layer 3 laminated on the substrate sheet 2.
  • the second pressure roller 13b is made of rubber, of which outer surface is substantially flat.
  • the first emboss roller 11a and the first pressure roller l ib of the first embossing unit 11 are disposed vertically opposed.
  • the substrate sheet 2 (see Fig. 3 A) supplied to the release-sheet producing apparatus 10 is substantially horizontally fed, and is nipped between the first emboss roller 11a and the first pressure roller l ib.
  • the embossing condition such as applied pressure and temperature is determined according to the material of the substrate sheet 2 and the irregular form on the first emboss roller 11a.
  • a mechanism for heating the roller surface by steam or hot air is favorably provided in the roller inside of the first emboss roller 11a.
  • the irregular form provided in advance on the surface of the first emboss roller 11a is transferred on the surface of the substrate sheet 2 that is in contact with the first emboss roller 11a (see Fig 3B).
  • the irregular form provides the base emboss pattern of the first emboss pattern provided on the surface of the thermoplastic resin layer 3.
  • the surface of the first emboss roller 11a is preferably heated to apply heat to the substrate sheet 2.
  • the manufacturing step of the substrate sheet 2 and the embossing step may be combined (i.e. in an inline equipment).
  • the first embossing step in the release-sheet producing apparatus 10 may be preceded by a manufacturing unit of the substrate sheet 2 to provide an inline release-sheet producing apparatus. With such an inline equipment, the production efficiency of the release sheet 1 can be enhanced.
  • a paper form step and the embossing step may be conducted together in an inline process.
  • paper form method is not limited, but paper material (pulp slurry) in which pulp is evenly dispersed in water may be, for instance, supplied in a single one or a combination (multiply forming) of a cylinder paper machine, a Fourdrinier paper machine, twin-wire paper machine and single-layer inclined wire paper machine.
  • the embossing may be applied, for instance, while heating the paper base after subjecting the paper base to a dryer, or alternatively, before being subjected to the dryer while the paper base is semi-dried. In the latter instance, a drying step has to be provided after the embossing.
  • the paper base is resin-impregnated paper
  • the paper may be impregnated with the resin by a size press and the like during the paper form step and the embossing may be applied while the resin is impregnated, followed by a heat-drying.
  • the resin to be impregnated is not limited but a single one of or a combination of SBR (styrene-butadiene rubber), BR (acrylonitrile-butadiene rubber), MBR (methylmethacrylate-butadiene rubber), vinyl chloride resin, acrylic resin, vinyl acetate resin, EVA (ethylene-vinyl acetate) resin, polyvinyl alcohol, starch and the like may be suitably used.
  • Such a resin may be impregnated in the form of water-based emulsion, water solution or solution of organic solvent.
  • water-based emulsion or water solution is preferable in terms of workability and safety.
  • the resin solution used for impregnation may be further added with a size agent, wax, cross-linking agent, coloring agent and antifoaming agent.
  • the paper form step and the first embossing step may be simultaneously conducted in a single step and the laminating step of the thermoplastic resin and the second embossing step may be conducted in a separate process.
  • the extrusion step of the resin sheet (film material) and the first embossing step may be conducted together in an inline process.
  • a cooling mechanism may preferably be provided in the first emboss roller 11a, so that the molten thermoplastic resin (i.e. the material of the film base) extruded from an extruder is cooled while transferring the irregular form.
  • thermoplastic resin layer 3 is laminated conforming to the irregular form provided on the surface of the substrate sheet 2, and the first embossing pattern is provided (see Fig. 3C)
  • the condition of the extruder 12 such as heating temperature is set according to the melting point and melt flow rate of the thermoplastic resin of the thermoplastic resin layer 3.
  • the second emboss roller 13a and the second pressure roller 13b of the second embossing unit 13 are disposed horizontally opposed.
  • the substrate sheet 2 (see Fig. 3C) after experiencing the lamination step is substantially downwardly fed, and is nipped between the second emboss roller 13a and the second pressure roller 13b.
  • the embossing condition such as applied pressure and temperature is determined according to the material of the thermoplastic resin and the irregular form on the second emboss roller 13 a.
  • the irregular form provided in advance on the surface of the second emboss roller 13a are transferred onto the thermoplastic resin layer 3 that is in contact with the second emboss roller 13a, during which the thermoplastic resin layer 3 is cooled.
  • the transfer and cooling provide the second emboss pattern (see Fig. 3D).
  • the second emboss pattern is formed along the irregular form of the first emboss pattern.
  • the release sheet 1 is manufactured.
  • the release sheet manufactured after experiencing the second embossing step is wound by a winding machine (not shown) in a roll.
  • the wound release sheet 1 is cut in a size corresponding to the application thereof before being in use.
  • Synthetic-leather resin such as polyurethane resin and vinyl chloride resin is coated on the surface of the thermoplastic resin layer 3 of the release sheet 1. After drying and curing the coated synthetic-leather resin, a ground fabric is attached on the surface synthetic-leather resin via an adhesive, which is dried and aged. Subsequently, the release sheet 1 is peeled off, then a synthetic leather is provided. The synthetic leather after being peeled off from the release sheet 1 is transferred the first emboss pattern and the second emboss pattern on the thermoplastic resin layer 3.
  • the ground fabric may not be attached, but the manufactured layer of the synthetic-leather resin may be independently used.
  • the release sheet can provide a pattern more close to textures of natural leather and wood grain than manufacturing by conventional release sheet.
  • the base emboss pattern is provided on the substrate sheet 2 of the release sheet 1, the first emboss pattern emerging on the surface of the thermoplastic resin layer 3 is supported by the irregular form of the base emboss pattern. Accordingly, the first emboss pattern is prevented from being blurred even whereby heat and pressure are applied on the first emboss pattern when the second emboss pattern is formed.
  • the first emboss pattern corresponding to the base emboss pattern on the substrate sheet 2 is formed on the thermoplastic resin layer 3 via the substrate sheet 2
  • the first emboss pattern and the second emboss pattern may be directly formed on the thermoplastic resin layer 3 without forming the base emboss pattern on the substrate sheet 2.
  • the above direct formation can be achieved by, for instance, using an emboss roller provided in advance with different first and second emboss patterns during the embossing after the thermoplastic resin layer 3 is laminated.
  • the number of the emboss pattern on the surface of the release sheet 1 is not limited to two, but may be three or more. With a more number of emboss patterns provided on the thermoplastic resin layer 3, the textures of natural leather and the like can be more closely imitated than those provided by two emboss patterns.
  • a base emboss pattern of a first emboss pattern may be provided on the substrate sheet 2 and a second and a third emboss patterns may be applied on the thermoplastic resin layer 3.
  • the thermoplastic resin layer 3 may be a lamination of an intermediate layer and a surface layer, a base emboss pattern of the first emboss pattern may be formed on the substrate sheet 2, a base emboss pattern of the second emboss pattern may be formed on the intermediate layer and the third emboss pattern may be formed on the surface layer.
  • the depth of the each of the irregular form may preferably be (depth of the first emboss pattern) > (depth of the second emboss pattern) > (depth of the third emboss pattern).
  • the irregular form i.e. the concave and convex shape
  • the first and the second emboss patterns may be randomly provided.
  • the interval and shape of the irregular form may be changed in order to more closely simulate the configuration of natural leather and the like.
  • the embossing may be performed using, for instance, a flat press machine having a flat plate provided with irregular form corresponding to the emboss pattern without using an emboss roller.
  • the second emboss roller 13a and the second pressure roller 13b are disposed horizontally (i.e. in right-and-left direction) opposed in the exemplary embodiment, the second emboss roller 13a and the second pressure roller 13b may be disposed vertically opposed as in the first emboss roller 11a and the first pressure roller l ib.
  • thermoplastic resin is laminated on the substrate sheet 2 after experiencing the first embossing by the extruder 12 to form the thermoplastic resin layer 3, which is then nipped between the second emboss roller 13a and the second pressure roller 13b while substantially horizontally feeding the substrate sheet 2.
  • pressure rollers l ib, 13b respectively paired with the emboss rollers 11a, 13a are made of rubber in the above exemplary embodiment, a metal roller, a synthetic resin roller or a metal flat table may alternatively be used according to the material of the substrate sheet and the thermoplastic resin sheet. Examples
  • the depth of the irregular form was measured by a surface roughness gauge (manufactured by Accretech (China) Co., Ltd, model No. : SURCOM480A).
  • Resin-impregnated paper having 120 g/m 2 basis weight (manufactured by LINTEC Corporation, model No. : FLEX- A) was used as the substrate sheet.
  • the resin-impregnated paper was supplied to the release-sheet producing apparatus described in the above exemplary embodiment.
  • a base emboss pattern was formed on the surface of the resin-impregnated paper while the temperature of the first emboss roller (manufactured by LINTEC Corporation, model No. : R-101 having a so-called "kipskin” pattern imitating a kind of cow's skin) was set at 130 degrees C.
  • the depth of the irregular form formed on the surface of the first emboss roller was 60 ⁇ .
  • the depth of irregular form of the base emboss pattern formed on the resin-impregnated paper was 60 ⁇ .
  • a mixed resin of polypropylene (manufactured by SunAllomer Ltd., PHA03A) and low-density polyethylene (manufactured by SunAllomer Ltd., PH800C) was laminated on the resin-impregnated paper provided with the base emboss pattern.
  • the temperature of the extruder was 290 degrees C and the thickness of the thermoplastic resin layer was 35 ⁇ .
  • a first emboss pattern corresponding to the irregular form of the base emboss pattern was formed on the surface of the thermoplastic resin layer.
  • the depth of the irregular form of the first emboss pattern was 60 ⁇ .
  • a second emboss pattern was formed while cooling the thermoplastic resin layer formed by the above mixed resin with the temperature of the second emboss roller (manufactured by LINTEC Corporation, model No. : R-70-1 having a "calfskin” pattern imitating a kind of cow's skin) being set at 290 degrees C.
  • a release sheet having two emboss patterns i.e. kipskin pattern and calfskin pattern
  • the depth of the irregular form formed on the surface of the second emboss roller was 30 ⁇ .
  • the depth of irregular form of the second emboss pattern was 30 ⁇ .
  • a synthetic leather was manufactured using thus manufactured release sheet.
  • a polyurethane resin manufactured by Suzhou finechemical ind. co., ltd, model No. : FB930
  • a ground fabric manufactured by Zhejiang Hexin ind. co., ltd, thickness: 0.55 mm
  • an adhesive manufactured by Suzhou finechemical ind. co., ltd, model No. FB7500
  • the release sheet was peeled off to obtain a synthetic leather.
  • the first emboss pattern (kipskin pattern) and the second emboss pattern (calfskin pattern) of the thermoplastic resin layer was transferred on the synthetic leather after peeling off the release sheet.
  • a release sheet and a synthetic leather were manufactured in the same manner as
  • Example 1 except that: the thermoplastic resin in Example 1 was changed to polymethyl pentene (manufactured by Mitsui Chemicals, Inc. TPX (registered trademark), model No. : DX231); the temperature of the extruder was set as 290 degrees C; and the emboss roller used in the second embossing step was changed to another second emboss roller (manufactured by LINTEC Corporation, Model No. : R-135 having "kidskin” pattern imitating cow's skin that imitates goat's skin).
  • a release sheet and a synthetic leather having two emboss patterns i.e. kipskin pattern and kidskin pattern
  • the depth of the irregular form formed on the surface of the first emboss roller was 60 ⁇ .
  • the depth of irregular form of the base emboss pattern formed on the resin-impregnated paper was 60 ⁇ .
  • the depth of the irregular form of the first emboss pattern was 60 ⁇ .
  • the depth of the irregular form formed on the surface of the second emboss roller was 30 ⁇ .
  • the depth of the irregular form of the second emboss pattern was 30 ⁇ .
  • a release sheet was manufactured in the same manner as Example 1 except that the first embossing step was not performed.
  • the depth of the second emboss pattern was 30 ⁇ .
  • the synthetic leather was manufactured in the same manner as Example 1.
  • Thus manufactured release sheet and the synthetic leather had only one calfskin emboss pattern.
  • the first and the second emboss patterns were formed on the surface of the release sheet of the Examples 1 and 2. Further, the second emboss pattern was provided conforming to the irregular form of the first emboss pattern within an area on which the first emboss pattern was formed.
  • the present invention is applicable to a release sheet, a manufacturing method of the release sheet and a synthetic leather.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Abstract

A release sheet (1) has a substrate sheet (2) and a thermoplastic resin layer (3) laminated on the substrate sheet (2), in which two or more different emboss patterns are formed on a surface of the thermoplastic resin layer (3). A manufacturing method of the release sheet (1) includes: the first embossing step for embossing the substrate sheet (2); laminating step for laminating the thermoplastic resin layer (3) on the embossed substrate sheet (2); and the second embossing step for embossing the laminated thermoplastic resin layer (3), in which the irregular form of the embossed patterns provided in the first embossing step and the second embossing step are different from each other. Synthetic leather is manufactured by using the release sheet.

Description

RELEASE SHEET, MANUFACTURING METHOD OF THE RELEASE SHEET
AND SYNTHETIC LEATHER
Technical Field
The present invention relates to a release sheet, a manufacturing method of the release sheet and a synthetic leather.
Background Art
A release sheet called as a casting paper has been used for manufacturing a synthetic leather made of polyurethane resin and vinyl chloride resin.
The release sheet is manufactured by laminating a thermoplastic resin such as polypropylene resin and polymethylpentene resin on a surface of a substrate paper (substrate sheet) and embossing the thermoplastic resin layer with an emboss roller having minute irregular form (i.e. the concave and convex shape) on a surface thereof, which is, for instance, configured as shown in Fig. 4A. The release sheet is provided with the emboss pattern only on a thermoplastic resin layer 42 laminated on a substrate paper (substrate sheet) 41.
The synthetic leather transferred with the embossed pattern on the surface thereof is manufactured by: coating the surface of the release sheet by extruding a material such as polyurethane resin and vinyl chloride resin; drying the polyurethane resin, the vinyl chloride resin and the like to cure the release sheet; and peeling off the release sheet to transfer the emboss pattern on the release sheet.
Another example of the release sheet is disclosed in Patent Literature 1, which includes a paper layer and a thermoplastic-resin embossed layer provided on the paper layer. The entirety (i.e. the paper layer and the embossed layer) of the release sheet disclosed in the Patent Literature 1 is curved in a wavy form. In such a release sheet, the emboss pressure applied during manufacture reaches to the paper layer (see Fig. 4B, where reference numeral 43 denotes the paper layer and the reference numeral 44 denotes the embossed layer). The Patent Literature 2 below discloses another release sheet that is used for producing a matted (i.e. gloss-restrained) article, the release sheet including: a substrate sheet; a matted layer with minute irregular forms provided on the substrate sheet; and a release layer provided on a surface of the matted layer, the release layer being provided by a release-resin coat layer containing ultrafine particles. The release layer is not embossed, but the surface thereof is provided with more minute irregular forms resulted from the minute irregular forms of the matted layer.
However, the thermoplastic resin layer of the known release sheet has only one emboss pattern provided by embossing the thermoplastic resin layer or has minute irregular form of mat shape. Thus, only a small variety of emboss patterns can be provided, which makes it difficult to manufacture synthetic leather articles having richer textures.
[Patent Literature 1] JP-A-2007-296672
[Patent Literature 2] WO2006/006713
Summary of Invention
An object of the invention is to provide a release sheet capable of manufacturing a synthetic leather with rich textures, a manufacturing method of the release sheet and a synthetic leather manufactured using the release sheet.
Summary of the invention is listed as follows. :
[1] A release sheet according to an aspect of the invention includes: a substrate sheet and a thermoplastic resin layer laminated on the substrate sheet, in which two or more different emboss patterns are formed on the surface of the thermoplastic resin layer.
[2] In the release sheet according to the above aspect [1], a depth of irregular form of one of the two or more different emboss patterns may be smaller than depth of irregular form of another emboss pattern.
[3] In the release sheet according to [1] or [2], the substrate sheet and the thermoplastic resin layer may be respectively embossed, and the emboss pattern formed on the substrate sheet emerges on the surface of the thermoplastic resin layer. [4] In the release sheet according to [3], a depth of irregular form of the emboss patterns provided by embossing the thermoplastic resin layer may be smaller than a depth of the irregular form of the emboss patterns provided by embossing the substrate sheet.
[5] A manufacturing method of the release sheet according to an aspect of the invention includes: a first embossing step for embossing the substrate sheet; laminating step for laminating the thermoplastic resin layer on the embossed substrate sheet; and second embossing step for embossing the laminated thermoplastic resin layer, in which the irregular forms of the embossed patterns provided in the first embossing step and the second embossing step are mutually different.
[6] A synthetic leather is manufactured by using the release sheet according to any one of [l] to [4].
According to the present invention, since two or more different emboss patterns are provided on the surface of the thermoplastic resin layer of the release sheet, a synthetic leather with a richer texture can be manufactured.
Brief Description of Drawings
Fig. 1 is a cross section of a release sheet according to an exemplary embodiment of the invention.
Fig. 2 is a diagram schematically showing a manufacturing method of the release sheet according to the exemplary embodiment.
Figs. 3 are diagrams schematically showing a manufacturing process of the release sheet according to the exemplary embodiment, in which: Fig 3 A shows a substrate sheet before a first embossing step; Fig 3B shows the substrate sheet after the first embossing step; Fig 3C shows a laminated sheet after being subjected to a laminating step; and Fig 3D shows the release sheet obtained after the second embossing step.
Fig. 4A is a cross section of a release sheet according to a related art.
Fig. 4B is a cross section of a release sheet according to another related art.
Reference Signs List
1 Release sheet
2 Substrate sheet 3 Thermoplastic resin layer
10 Release- sheet producing apparatus
11 First embossing unit
11a First emboss roller
l ib First pressure roller
12 Extruder
13 Second embossing unit
13a Second emboss roller
13b Second pressure roller
hi Depth of irregular form of base emboss pattern
h2 Depth of irregular form of first emboss pattern
h3 Depth of irregular form of second emboss pattern
Description of Embodiments
An exemplary embodiment of the invention will be described below with reference to the attached drawings.
Fig. 1 is a cross section of a release sheet according to an exemplary embodiment of the invention.
The release sheet 1 includes a substrate sheet 2 and a thermoplastic resin layer 3. The thermoplastic resin layer 3 is laminated on the substrate sheet 2. Two different emboss patterns (i.e. a first emboss pattern and a second emboss pattern) are provided on the surface of the thermoplastic resin layer 3. Detailed description of the emboss patterns will be mentioned below.
Substrate Sheet
The substrate sheet 2 of this exemplary embodiment may be provided by any paper or film base that is adapted to support the thermoplastic resin layer 3. Specific examples of the substrate sheet 2 are: paper base such as tissue paper, kraft paper, linter paper, wood containing paper, woodfree paper, impregnated paper, coat paper, art paper, vegetable paper and glassine paper; film of polyolefin resin such as polyethylene and polypropylene; film of vinyl resin such as polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, ethylene- vinyl acetate copolymer and ethylene- vinylalcohol copolymer; film of polyester resin such as polyethylene terephthalate, polybutylene terephthalate and polyethylene naphthalate; and film of the other synthetic resin such as polystyrene, acrylonitrile butadiene styrene copolymer, triacetyl cellulose, cellophane and polycarbonate. Incidentally, paper bases are favorable in terms of heat resistance and thermoformability. Among them, kraft paper, wood containing paper, woodfree paper and impregnated paper are favorable in view of excellent heat resistance and dimension stability.
The thickness and size of the substrate sheet 2 is not specifically limited, but can be selected in any manner in accordance with the usage of the release sheet 1, the type of the substrate sheet 2 and the like. For instance, when the substrate sheet 2 is a paper base, the basis weight of the substrate sheet is preferably in a range of 30 to 200 g/m2, more preferably 80 to 140 g/m2. When the substrate sheet 2 is a synthetic resin film, the thickness of the substrate sheet is preferably in a range of 5 to 500 μπι, more preferably 15 to 300 μπι. The substrate sheet 2 may be a continuous belt shape or a roll shape of paper or film.
When the basis weight of the substrate sheet 2 is less than 30 g/m2 or the thickness of the synthetic resin film is less than 5 μπι, because a substrate sheet 2 is thin and a stiffness of a substrate sheet is weak, the substrate sheet 2 may be inferior in handling and heat resistance during the subsequent process. On the other hand, when the basis weight of the substrate sheet 2 exceeds 200 g/m2 or the thickness of the substrate sheet 2 exceeds 500 μπι, because the weight per area of the substrate sheet 2 increases, the release sheet 1 may cause the problem of wound meters per a roll or in weight restriction during transportation. Specifically, when the weight per a roll is limited and the sheet is wound in compliance with the weight restriction, a problem of decrease in the wound meters per a roll arises. Further, when there is no restriction in the roll diameter and a desired wound meters per a roll is wound, a problem of increase in the weight per a roll arises.
When a paper base is used as the substrate sheet 2, the paper base may preferably be provided with an anti curling treatment on the backside thereof (i.e. a side opposite to the side coated with the thermoplastic resin layer). The anticurling treatment prevents the substrate sheet 2 from being curled to deform the release sheet 1 on account of heat, water absorption or drying. The anticurling treatment is applied by, for instance, coating a synthetic resin such as acrylic resin, polystyrene resin and styrene-butadiene copolymer or laminating film of polyolefin resin and the like on the backside of the paper base.
A base emboss pattern is provided on the substrate sheet 2 of this exemplary embodiment (see Fig. 3B). A depth (i.e. a distance between a top of a convex portion and a bottom of a concave portion) hi of the base emboss pattern is preferably larger than a depth h3 of the second emboss pattern (see Figs. 3B and 3D). When the thermoplastic resin layer 3 is laminated on the irregular form of the base emboss pattern provided on the substrate sheet 2, the base emboss pattern emerges on the surface of the thermoplastic resin layer 3 to provide the first emboss pattern. Accordingly, a base emboss pattern corresponding to the form of the first emboss pattern is provided on the substrate sheet 2 in advance.
Thermoplastic Resin Layer
The thermoplastic resin layer 3 is provided by a resin that exhibits excellent releasability and coatability against a resin forming a synthetic leather, example of which is a polyolefin polymer. Examples of the polyolefin polymer is a homopolymer and copolymer of a-olefin. Examples of the a-olefin are ethylene, propylene, 1-butene, 2-methyl-l-butene, 1-pentene, 2-methyl-l-pentene, 1-hexene, 2,2-dimethyl- 1-butene, 2-methyl-l-hexene, 4-methyl- 1-pentene, 1-heptene, 2-methyl- 1-hexene,
3 -methyl- 1 -hexene, 2,2-dimethyl- 1 -pentene, 3 , 3 -dimethyl- 1 -pentene,
2, 3 -dimethyl- 1-pentene, 3 -ethyl- 1-pentene, 2,2,3-trimethyl-l-butene, 1-octene, and 2,2,4-trimethyl- 1-octene. Among them, a polymer of ethylene, propylene and 4-methl- 1-pentene is especially favorable.
The thickness and size of the thermoplastic resin layer 3 is not specifically limited, but can be selected in any manner in accordance with the usage of the release sheet 1 and the type of the thermoplastic resin layer 3. The thickness of the thermoplastic resin layer 3 is preferably in a range of 5 to 200 μπι, more preferably 10 to 100 μιη. When the thickness of the thermoplastic resin layer 3 is less than 5 μπι, less number of design is available for the second emboss pattern and the thermoplastic resin layer may not be formed into a membrane of uniform thickness on account of the thinness. On the other hand, when the thickness of the thermoplastic resin layer 3 exceeds 200 μπι, the productivity may be lowered on account of the long time required for solidifying the molten resin and the first emboss pattern may be buried.
First Emboss Pattern, Second Emboss Pattern
Since the thermoplastic resin layer 3 is provided on the base emboss pattern of the substrate sheet 2, the first emboss pattern is provided by the irregular form conforming to the base emboss pattern. At this time, the depth h2 of the irregular form of the first emboss pattern is approximately the same as the depth hi of the irregular form of the base emboss pattern.
The second emboss pattern provides more minute irregular form than that of the first emboss pattern and conforms to the irregular form of the first emboss pattern within an area provided with the first emboss pattern.
The depth h2 of the irregular form of the first emboss pattern is preferably larger than the depth h3 of the irregular form of the second emboss pattern (see Figs. 3C and 3D).
Manufacturing Method of Release Sheet
Next, a manufacturing method of the release sheet 1 will be described below with reference to the attached drawings.
Fig. 2 schematically shows a release-sheet producing apparatus 10.
The release-sheet producing apparatus 10 includes a first embossing unit 11, an extruder 12 and a second embossing unit 13.
The first embossing unit 11 embosses the substrate sheet 2. The first embossing unit 11 includes a first emboss roller 11a and a first pressure roller l ib. The first emboss roller 11a is made of metal and an outer circumference thereof is provided with irregular form corresponding to the first emboss pattern (the irregular form of the first emboss pattern not shown in Fig. 2). The first pressure roller l ib is made of rubber, of which outer surface is substantially flat.
The extruder 12 extrudes a thermoplastic resin to coat the thermoplastic resin on the substrate sheet 2. The extruder 12 includes a T-die. The thermoplastic resin is extruded through the T-die on the substrate sheet 2 to be laminated thereon.
The second embossing unit 13 embosses the thermoplastic resin layer 3. The second embossing unit 13 includes a second emboss roller 13a and a second pressure roller 13b. The second emboss roller 13a is made of metal and an outer surface thereof is provided with irregular form corresponding to the second emboss pattern. Coolant water is supplied to the inside of the second emboss roller 13a. Thus, the second emboss roller 13a also works as a cooling roller for cooling and solidifying the thermoplastic resin layer 3 laminated on the substrate sheet 2. The second pressure roller 13b is made of rubber, of which outer surface is substantially flat.
Manufacturing steps of the release sheet 1 are shown in Figs. 3 A to 3D with reference to the cross sections of the substrate sheet 2 and the thermoplastic resin layer 3 in the respective steps.
First Embossing Step
The first emboss roller 11a and the first pressure roller l ib of the first embossing unit 11 are disposed vertically opposed. The substrate sheet 2 (see Fig. 3 A) supplied to the release-sheet producing apparatus 10 is substantially horizontally fed, and is nipped between the first emboss roller 11a and the first pressure roller l ib. The embossing condition such as applied pressure and temperature is determined according to the material of the substrate sheet 2 and the irregular form on the first emboss roller 11a. A mechanism for heating the roller surface by steam or hot air is favorably provided in the roller inside of the first emboss roller 11a.
The irregular form provided in advance on the surface of the first emboss roller 11a is transferred on the surface of the substrate sheet 2 that is in contact with the first emboss roller 11a (see Fig 3B). The irregular form provides the base emboss pattern of the first emboss pattern provided on the surface of the thermoplastic resin layer 3. When the base emboss pattern is provided, the surface of the first emboss roller 11a is preferably heated to apply heat to the substrate sheet 2. By forming the base emboss pattern while heating the substrate sheet 2, the irregular form of the base emboss pattern can be more clearly transferred onto the substrate sheet 2.
The manufacturing step of the substrate sheet 2 and the embossing step may be combined (i.e. in an inline equipment). Specifically, the first embossing step in the release-sheet producing apparatus 10 may be preceded by a manufacturing unit of the substrate sheet 2 to provide an inline release-sheet producing apparatus. With such an inline equipment, the production efficiency of the release sheet 1 can be enhanced.
For instance, when the substrate sheet 2 is made of paper base, a paper form step and the embossing step may be conducted together in an inline process.
At this time, the paper form method is not limited, but paper material (pulp slurry) in which pulp is evenly dispersed in water may be, for instance, supplied in a single one or a combination (multiply forming) of a cylinder paper machine, a Fourdrinier paper machine, twin-wire paper machine and single-layer inclined wire paper machine.
The embossing may be applied, for instance, while heating the paper base after subjecting the paper base to a dryer, or alternatively, before being subjected to the dryer while the paper base is semi-dried. In the latter instance, a drying step has to be provided after the embossing.
When the paper base is resin-impregnated paper, the paper may be impregnated with the resin by a size press and the like during the paper form step and the embossing may be applied while the resin is impregnated, followed by a heat-drying. The resin to be impregnated is not limited but a single one of or a combination of SBR (styrene-butadiene rubber), BR (acrylonitrile-butadiene rubber), MBR (methylmethacrylate-butadiene rubber), vinyl chloride resin, acrylic resin, vinyl acetate resin, EVA (ethylene-vinyl acetate) resin, polyvinyl alcohol, starch and the like may be suitably used. Such a resin may be impregnated in the form of water-based emulsion, water solution or solution of organic solvent. However, water-based emulsion or water solution is preferable in terms of workability and safety. The resin solution used for impregnation may be further added with a size agent, wax, cross-linking agent, coloring agent and antifoaming agent.
The paper form step and the first embossing step may be simultaneously conducted in a single step and the laminating step of the thermoplastic resin and the second embossing step may be conducted in a separate process.
When the substrate sheet 2 is a resin film material, the extrusion step of the resin sheet (film material) and the first embossing step may be conducted together in an inline process. At this time, a cooling mechanism may preferably be provided in the first emboss roller 11a, so that the molten thermoplastic resin (i.e. the material of the film base) extruded from an extruder is cooled while transferring the irregular form.
Laminating Step
The molten thermoplastic resin is extruded from the die of the extruder 12 to be laminated on the substrate sheet 2 having been subjected to the first embossing step, and the thermoplastic resin layer 3 is formed. The thermoplastic resin layer 3 is laminated conforming to the irregular form provided on the surface of the substrate sheet 2, and the first embossing pattern is provided (see Fig. 3C)
The condition of the extruder 12 such as heating temperature is set according to the melting point and melt flow rate of the thermoplastic resin of the thermoplastic resin layer 3.
Second Embossing Step
The second emboss roller 13a and the second pressure roller 13b of the second embossing unit 13 are disposed horizontally opposed. The substrate sheet 2 (see Fig. 3C) after experiencing the lamination step is substantially downwardly fed, and is nipped between the second emboss roller 13a and the second pressure roller 13b. The embossing condition such as applied pressure and temperature is determined according to the material of the thermoplastic resin and the irregular form on the second emboss roller 13 a.
The irregular form provided in advance on the surface of the second emboss roller 13a are transferred onto the thermoplastic resin layer 3 that is in contact with the second emboss roller 13a, during which the thermoplastic resin layer 3 is cooled. The transfer and cooling provide the second emboss pattern (see Fig. 3D). The second emboss pattern is formed along the irregular form of the first emboss pattern.
Thus, the release sheet 1 is manufactured.
The Other Steps
The release sheet manufactured after experiencing the second embossing step is wound by a winding machine (not shown) in a roll. The wound release sheet 1 is cut in a size corresponding to the application thereof before being in use.
Manufacturing Method of Synthetic Leather
Synthetic-leather resin such as polyurethane resin and vinyl chloride resin is coated on the surface of the thermoplastic resin layer 3 of the release sheet 1. After drying and curing the coated synthetic-leather resin, a ground fabric is attached on the surface synthetic-leather resin via an adhesive, which is dried and aged. Subsequently, the release sheet 1 is peeled off, then a synthetic leather is provided. The synthetic leather after being peeled off from the release sheet 1 is transferred the first emboss pattern and the second emboss pattern on the thermoplastic resin layer 3.
Incidentally, the ground fabric may not be attached, but the manufactured layer of the synthetic-leather resin may be independently used.
Advantage of Exemplary Embodiment
According to the above-described exemplary embodiment, the following advantages can be obtained.
(1) Since two different emboss patterns (i.e. the first emboss pattern and the second emboss pattern) are provided on the surface of the thermoplastic resin layer 3 of the release sheet 1, a rich-textured synthetic leather with a plurality of patterns that cannot be provided by a conventional release sheet can be manufactured with the use of the release sheet 1.
(2) Since the depth of the irregular form of the first emboss pattern of the release sheet 1 is larger than the depth of the irregular form of the second emboss pattern, two emboss patterns can be clearly engraved.
(3) Since the second emboss pattern is provided conforming to the irregular form of the first emboss pattern within the area provided with the first emboss pattern, the release sheet can provide a pattern more close to textures of natural leather and wood grain than manufacturing by conventional release sheet.
(4) Since the base emboss pattern is provided on the substrate sheet 2 of the release sheet 1, the first emboss pattern emerging on the surface of the thermoplastic resin layer 3 is supported by the irregular form of the base emboss pattern. Accordingly, the first emboss pattern is prevented from being blurred even whereby heat and pressure are applied on the first emboss pattern when the second emboss pattern is formed.
Modification of Embodiment
The scope of the present invention is not limited to the above-described exemplary embodiments but includes modifications as follows.
Though the first emboss pattern corresponding to the base emboss pattern on the substrate sheet 2 is formed on the thermoplastic resin layer 3 via the substrate sheet 2, the first emboss pattern and the second emboss pattern may be directly formed on the thermoplastic resin layer 3 without forming the base emboss pattern on the substrate sheet 2. The above direct formation can be achieved by, for instance, using an emboss roller provided in advance with different first and second emboss patterns during the embossing after the thermoplastic resin layer 3 is laminated.
The number of the emboss pattern on the surface of the release sheet 1 is not limited to two, but may be three or more. With a more number of emboss patterns provided on the thermoplastic resin layer 3, the textures of natural leather and the like can be more closely imitated than those provided by two emboss patterns. When, for instance, three emboss patterns are to be provided, a base emboss pattern of a first emboss pattern may be provided on the substrate sheet 2 and a second and a third emboss patterns may be applied on the thermoplastic resin layer 3. Alternatively, the thermoplastic resin layer 3 may be a lamination of an intermediate layer and a surface layer, a base emboss pattern of the first emboss pattern may be formed on the substrate sheet 2, a base emboss pattern of the second emboss pattern may be formed on the intermediate layer and the third emboss pattern may be formed on the surface layer. At this time, the depth of the each of the irregular form may preferably be (depth of the first emboss pattern) > (depth of the second emboss pattern) > (depth of the third emboss pattern).
Though the irregular form (i.e. the concave and convex shape) of the first and the second emboss patterns are regularly provided substantially at a regular interval in the above exemplary embodiment, other arrangement is possible. The first and the second emboss patterns may be randomly provided. The interval and shape of the irregular form may be changed in order to more closely simulate the configuration of natural leather and the like.
The embossing may be performed using, for instance, a flat press machine having a flat plate provided with irregular form corresponding to the emboss pattern without using an emboss roller.
Though the second emboss roller 13a and the second pressure roller 13b are disposed horizontally (i.e. in right-and-left direction) opposed in the exemplary embodiment, the second emboss roller 13a and the second pressure roller 13b may be disposed vertically opposed as in the first emboss roller 11a and the first pressure roller l ib. In this arrangement, thermoplastic resin is laminated on the substrate sheet 2 after experiencing the first embossing by the extruder 12 to form the thermoplastic resin layer 3, which is then nipped between the second emboss roller 13a and the second pressure roller 13b while substantially horizontally feeding the substrate sheet 2.
Further, though the pressure rollers l ib, 13b respectively paired with the emboss rollers 11a, 13a are made of rubber in the above exemplary embodiment, a metal roller, a synthetic resin roller or a metal flat table may alternatively be used according to the material of the substrate sheet and the thermoplastic resin sheet. Examples
Though the invention will be described in detail below with reference to Examples, it should be understood that the scope of the invention is by no means restricted by the Examples.
Incidentally, the depth of the irregular form was measured by a surface roughness gauge (manufactured by Accretech (China) Co., Ltd, model No. : SURCOM480A).
Example 1
Resin-impregnated paper having 120 g/m2 basis weight (manufactured by LINTEC Corporation, model No. : FLEX- A) was used as the substrate sheet. The resin-impregnated paper was supplied to the release-sheet producing apparatus described in the above exemplary embodiment. In the first embossing step, a base emboss pattern was formed on the surface of the resin-impregnated paper while the temperature of the first emboss roller (manufactured by LINTEC Corporation, model No. : R-101 having a so-called "kipskin" pattern imitating a kind of cow's skin) was set at 130 degrees C. The depth of the irregular form formed on the surface of the first emboss roller was 60 μπι. The depth of irregular form of the base emboss pattern formed on the resin-impregnated paper was 60 μπι.
Next, with the use of an extruder, a mixed resin of polypropylene (manufactured by SunAllomer Ltd., PHA03A) and low-density polyethylene (manufactured by SunAllomer Ltd., PH800C) was laminated on the resin-impregnated paper provided with the base emboss pattern. The temperature of the extruder was 290 degrees C and the thickness of the thermoplastic resin layer was 35 μπι. At this time, a first emboss pattern corresponding to the irregular form of the base emboss pattern was formed on the surface of the thermoplastic resin layer. The depth of the irregular form of the first emboss pattern was 60 μπι.
In the second embossing step, a second emboss pattern was formed while cooling the thermoplastic resin layer formed by the above mixed resin with the temperature of the second emboss roller (manufactured by LINTEC Corporation, model No. : R-70-1 having a "calfskin" pattern imitating a kind of cow's skin) being set at 290 degrees C. Thus, a release sheet having two emboss patterns (i.e. kipskin pattern and calfskin pattern) was obtained. The depth of the irregular form formed on the surface of the second emboss roller was 30 μπι. The depth of irregular form of the second emboss pattern was 30 μπι.
A synthetic leather was manufactured using thus manufactured release sheet. A polyurethane resin (manufactured by Suzhou finechemical ind. co., ltd, model No. : FB930) was coated on the surface of the thermoplastic resin layer of the release sheet. After drying the coated polyurethane resin, a ground fabric (manufactured by Zhejiang Hexin ind. co., ltd, thickness: 0.55 mm) was attached on the surface of the polyurethane resin via an adhesive (manufactured by Suzhou finechemical ind. co., ltd, model No. FB7500), which was dried and aged. Subsequently, the release sheet was peeled off to obtain a synthetic leather. The first emboss pattern (kipskin pattern) and the second emboss pattern (calfskin pattern) of the thermoplastic resin layer was transferred on the synthetic leather after peeling off the release sheet.
Example 2
A release sheet and a synthetic leather were manufactured in the same manner as
Example 1 except that: the thermoplastic resin in Example 1 was changed to polymethyl pentene (manufactured by Mitsui Chemicals, Inc. TPX (registered trademark), model No. : DX231); the temperature of the extruder was set as 290 degrees C; and the emboss roller used in the second embossing step was changed to another second emboss roller (manufactured by LINTEC Corporation, Model No. : R-135 having "kidskin" pattern imitating cow's skin that imitates goat's skin). Thus, a release sheet and a synthetic leather having two emboss patterns (i.e. kipskin pattern and kidskin pattern) on the surface thereof was obtained.
The depth of the irregular form formed on the surface of the first emboss roller was 60 μπι. The depth of irregular form of the base emboss pattern formed on the resin-impregnated paper was 60 μπι. The depth of the irregular form of the first emboss pattern was 60 μπι. The depth of the irregular form formed on the surface of the second emboss roller was 30 μπι. The depth of the irregular form of the second emboss pattern was 30 μπι.
Comparative Example 1
A release sheet was manufactured in the same manner as Example 1 except that the first embossing step was not performed. The depth of the second emboss pattern was 30 μπι. The synthetic leather was manufactured in the same manner as Example 1. Thus manufactured release sheet and the synthetic leather had only one calfskin emboss pattern. The first and the second emboss patterns were formed on the surface of the release sheet of the Examples 1 and 2. Further, the second emboss pattern was provided conforming to the irregular form of the first emboss pattern within an area on which the first emboss pattern was formed. In other words, since a pattern with a small depth was formed in another pattern with a large depth, a release sheet that could manufacture a synthetic leather with a richer texture than that produced using a release sheet provided with a single emboss pattern as in the Comparative Example 1 could be obtained. In fact, a highly textured pattern was formed on the surface of the synthetic leather manufactured by the release sheet of the Examples 1 and 2.
Industrial Applicability
The present invention is applicable to a release sheet, a manufacturing method of the release sheet and a synthetic leather.

Claims

1. A release sheet, comprising:
a substrate sheet; and
a thermoplastic resin layer laminated on the substrate sheet, wherein
two or more different emboss patterns are formed on the surface of the thermoplastic resin layer.
2. The release sheet according to claim 1, wherein a depth of irregular form of at least one of the two or more different emboss patterns is smaller than the depth of irregular form of another emboss pattern.
3. The release sheet according to claim 1 or 2, wherein the substrate sheet and the thermoplastic resin layer are respectively embossed, and
an emboss pattern formed on the substrate sheet emerges on a surface of the thermoplastic resin layer.
4. The release sheet according to claim 3, wherein a depth of the irregular form of the emboss pattern provided by embossing the thermoplastic resin layer is smaller than a depth of the irregular form of the emboss pattern provided by embossing the substrate sheet.
5. A method for manufacturing a release sheet with an emboss pattern, the method comprising:
first embossing step for embossing a substrate sheet;
laminating step for laminating a thermoplastic resin layer on the embossed substrate sheet; and
second embossing step for embossing the laminated thermoplastic resin layer, wherein irregular form of emboss patterns provided by the first embossing step and the second embossing step are different with each other.
6. A synthetic leather manufactured by using the release sheet according to claim 1 or 2.
7. A synthetic leather manufactured by using the release sheet according to claim 3.
8. A synthetic leather manufactured by using the release sheet according to claim 4.
EP10845015.6A 2010-02-02 2010-02-02 Release sheet, synthetic leather and manufacturing method thereof Withdrawn EP2531351A4 (en)

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KR20120124472A (en) 2012-11-13
CN102985254B (en) 2015-09-02
JP5627141B2 (en) 2014-11-19
TWI507290B (en) 2015-11-11
EP2531351A4 (en) 2014-01-22
WO2011094930A1 (en) 2011-08-11
TW201134658A (en) 2011-10-16
JP2013518738A (en) 2013-05-23

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