JP2605917Y2 - Thermoplastic synthetic leather - Google Patents

Description

[Detailed description of the invention]

[0001]

[Industrial applications] This invention is applied to automotive interior materials, furniture,
The present invention relates to a thermoplastic resin leather used for shoes and the like.

[0002]

2. Description of the Related Art In conventional thermoplastic resin leather, a cotton or rayon fabric or a knitted fabric is used as a backing cloth, and a flexible thermoplastic resin layer is formed on the surface of the leather via an adhesive. Things are mostly. Therefore, since the adhesive is used, the texture is hard and the whole becomes heavy,
As a fabric for handbags, golf bags, and the like, it is heavy and burdensome to carry. On the other hand, it is inevitable for flexibility and feel for chair covering of automobiles and furniture.
In addition, a separate process for gluing the backing cloth is required, which causes an increase in product cost.

[0003]

The object of the present invention is to strengthen the bond between the backing cloth and the thermoplastic resin layer having a soft surface, and to improve the texture and flexibility of the cloth. The object of the present invention is to reduce the manufacturing cost by omitting the drawing step. Another object is to reduce the specific gravity of the fabric, reduce the weight of the fabric product, and make it easier to carry a secondary product using the fabric.

[0004]

In order to achieve the above-mentioned object, the present invention provides a lining, a knitting cloth and a backing cloth made of a kind of non-woven fabric containing 50% to 100% of thermoplastic resin fibers.
The thermoplastic resin fiber and a thermoplastic resin layer having a heat-welding property are formed, and at these mating surfaces, the thermoplastic resin fiber and the flexible thermoplastic resin layer contained in the backing layer are directly heat-welded. A thermoplastic synthetic resin leather characterized by the above.

In order to achieve the above object, the flexible thermoplastic resin layer of the thermoplastic synthetic resin leather of the present invention comprises a non-foamed layer, a foamed layer, and a composite layer in which a non-foamed layer is formed on the surface of the foamed layer. It is preferable that the feature is one of the above.

In order to achieve the above object, the thermoplastic resin layer of the thermoplastic synthetic resin leather of the present invention is a foamed layer, and a surface cloth of the same material as the backing cloth is formed on the surface in the same manner as the backing cloth. Preferably, it is characterized by being thermally welded.

In order to achieve the above object, the thermoplastic resin fiber and the flexible thermoplastic resin layer contained in the backing cloth of the thermoplastic synthetic resin leather of the present invention are both made of olefin resin. Is preferred.

In order to achieve the above object, the backing cloth containing the thermoplastic resin fibers of the thermoplastic synthetic resin leather of the present invention is characterized by including at least one of the following. a. What was formed with the thread consisting only of the thermoplastic resin fiber. b. Each of the fibers of the backing cloth is formed of fibers obtained by coating the flexible thermoplastic resin layer and the non-heat-welding fiber with the thermoplastic resin having the heat-welding property, respectively. c. What was formed with the blended yarn of the thermoplastic resin fiber and other fibers. d. A yarn made of one of mixed weaving, mixed knitting, cross-weaving, cross-knitting, and mixing with a yarn made of only the thermoplastic resin fiber and a yarn made of another fiber.

In this specification, the term "olefin resin" means not only olefin resins such as polyethylene, polypropylene and polybutylene, but also ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer,
Includes butylene-propylene copolymer thermoplastic elastomer (TPO).

[0010]

According to the first and second aspects of the present invention, 50% to 100% of the fibers forming the backing cloth are provided.
Is a resin of the same system as the flexible thermoplastic resin layer, and therefore does not require any adhesive for bonding, and is firmly bonded by heat welding.

That is, when the content is less than 50%, the heat welding with the flexible thermoplastic resin layer becomes insufficient, and there is a possibility that the two may be separated from the bonding surface. Further, since both the soft thermoplastic resin layer and the backing cloth are flexible, even if they are repeatedly bent, they are not separated from the bonded surfaces.

Particularly, in the invention according to claim 2, when the soft thermoplastic resin layer is a foamed layer, the ratio of the apparent thickness is as follows:
Light specific gravity, rich in cushioning and heat insulation.

In the invention according to the third aspect, the surface of the soft thermoplastic resin layer is formed by heat-welding a cloth of the same material as that of the backing cloth. There is no difference from the above, and the appearance is woven or knitted, but since the resin layer is formed in the middle, it is rich in cushioning and heat insulation.

In the invention according to the fourth aspect, since 50% to 100% of the backing cloth and the flexible thermoplastic resin layer are both olefin-based resins, the bonding between the two is completely welded and integrated, and the bonding is performed. The force is strong, and the specific gravity of this resin is 1 or less, approximately 0.89 to 0.97.

In the invention according to claim 5, since the backing cloth satisfies one of the above requirements, 50% to 100% of the fibers are combined with the flexible thermoplastic resin layer at the mating surface. It is heat-welded and integrated, and its laminating force is extremely strong and repeatable, so that it retains sufficient flexibility even with bending.

Embodiment 1 This is shown in FIG.
And the invention according to claim 5. In the drawings, reference numeral 10 denotes a backing cloth. In this embodiment, a knitted knitted cloth is used. In each course, rayon swoof yarn and a yarn made of polyethylene fiber (hereinafter, referred to as polyethylene yarn), which is a kind of olefin resin, are alternately formed. It is knitted using. The ratio of the course of the rayon swoof yarn to the polyethylene yarn is 1: 2, 1: 3, 1: 4 or 100% polyethylene yarn is also included in this embodiment. The knitted knitting is appropriately selected and used according to the intended use, such as a flat knitted knit, a pearl knitted, a rubber knitted, or an inset knitted with substantially equal elongation in the length and width.

The knitted yarn composed of olefin-based resin fibers includes, in addition to the polyethylene yarn, a polypropylene yarn and a yarn composed of these copolymer resin fibers. On the other hand, the non-olefin-based resin fibers include, in addition to the rayon suff yarn, natural fibers such as cotton yarn and hemp yarn, synthetic fibers such as polyester fiber, nylon fiber, and acrylic fiber, or a blended yarn thereof. In the case where the backing fabric 10 is a knitted fabric having a double-sided structure, if the surface in contact with the flexible thermoplastic resin layer is knitted so as to meet the above-described conditions, this embodiment is included in the present invention.

Reference numeral 11 denotes a flexible thermoplastic resin layer, which is formed from a polyethylene resin, which is a kind of olefin resin, and the resin layer 11 and the backing cloth 10 They are directly welded to each other and integrated. Reference numeral 12 denotes an aperture formed on the surface of the resin layer 11.

Embodiment 2 This is shown in FIG. 2 and includes the inventions described in all claims. The difference from the first embodiment is that the resin layer 1
1a is a crosslinked polypropylene foam (for example, Toray Industries, Inc., registered trademark Trepef (PPSM15030); resin layer 11b is a type of olefin resin TPO (for example, Mitsui Petrochemical Industries, Ltd., registered trademark Mirastomer 80)
30N), the thickness of the non-foamed layer 11b is 0.35 mm, the expansion ratio of the foam is 15 times, and the thickness is 3 mm. Having a foaming ratio of about 15 to 30 times,
Alternatively, a communication bubble may be used.

Also in this embodiment, the mating surfaces of the backing cloth 10 containing polyethylene yarn, the foamed layer 11a, and the foamed layer 11a and the non-foamed layer 11b are integrated by direct heat welding. The above-mentioned foam layer 11a also includes a foam layer using a crosslinked polyethylene foam or polybutadiene foam.

The non-foamed layer 11b is provided with a squeezer 12 on its surface, the printed pattern is formed,
This embodiment also includes the one in which the foamed layer 11a is formed on the surface without forming 1b. In this embodiment, the apparent specific gravity is as very light as about 0.1 to 0.2.

Third Embodiment FIG. 3 shows a third embodiment of the present invention.
And the invention according to claim 5. Backing cloth 1
A value of 0 was a plain weave mixed woven fabric, and the content of polyethylene yarn was 75%.

The difference from the second embodiment is that the foam layer 12a
A surface layer cloth 13 made of a woven cloth further containing 75% of polyethylene yarn is directly heat-welded to the surface of the foam layer 12a in the same manner as the backing cloth 10. As the surface cloth 13,
Patterned, printed, or patterned weaves using two or more colors of yarn
It is appropriately selected and used for the pattern knitting.

Fourth Embodiment FIG. 4 shows a fourth embodiment of the present invention, which includes the first, second, fourth, and fifth aspects of the present invention. The difference from the second embodiment is that the surface layer 14 made of a vinyl chloride resin is bonded to the surface of the foamed layer 11a via the adhesive 15. Vinyl chloride resin is a type of resin that does not thermally fuse with polyethylene resin.

The surface layer 14 is generally formed as a separate sheet, and may be provided with a printed pattern or the like as necessary.
When the surface layer 14 is an olefin-based resin such as a polyethylene sheet, the surface layer 14 and the foam layer 11a are directly heat-welded without using the adhesive 15 (Example 2).

Embodiment 5 This is shown in FIG. 5 and includes the invention described in all claims. The difference from Example 2 is that the foam layer 1
Short fibers 16 are implanted on the entire surface or in a pattern of the surface 1a through an adhesive 15 by an electrostatic flocking method.

As described above, in all the embodiments, the backing cloth 10 may be other woven cloth, knitted cloth or non-woven cloth instead of the one shown in the embodiment.
% To 100% is selected and used as needed.

The polyethylene fiber is 50% to 100%.
As described above, as the backing cloth containing%, mixed weave, mixed knit as well as mixed weave, blended yarn, or cotton, rayon, vinyl resin polyester resin, acrylic resin, nylon resin, etc. Woven fabrics, knitted fabrics, and nonwoven fabrics using yarns coated with the same are also included.

Further, in the above-described Embodiments 2, 3 and 4, the surface of which the same short fibers as in Embodiment 5 are planted again is also included in the embodiment of the present invention.

Next, the manufacturing method of each embodiment will be briefly described. FIG. 6 shows an apparatus for manufacturing the product of the first embodiment. The material to be the surface resin layer 11 is manufactured in advance as a sheet 11A, which is fitted to the heating drum 20 and brought into contact with the surface side. Outside the first infrared lamp group 2
1, and the sheet 11A is heated from both sides.
On the other hand, the backing cloth 10 is heated on the bonding surface side by the second infrared lamp group 22. When the sheet is polyethylene, the surface temperature of the backing cloth 10 and the sheet 11A is heated to about 130 ° C.

The sheet 11A is then pressed between the squeezing roller 23 and the backup roll 24 to apply pressure to the sheet 11A.
0 and at the same time, squeeze 12 on the surface of the surface resin layer 11.
To obtain the product.

FIG. 7 shows Embodiment 2 and Embodiment 4.
This is an apparatus for manufacturing T
The side of the foam layer 11a of the PO sheet or the sheet 11B on which the surface layer 14 as the vinyl chloride resin layer is bonded is attached to the outer peripheral surface of the heating drum 20 in the same manner as described above, while the bonding surface of the backing cloth 10 is heated by the infrared lamp group 22a. Then, these are pressed by a pair of pinch rolls 25 to obtain a product.

The manufacturing method of Example 3 is performed by performing the method of Example 2 twice on the front and back sides. In the manufacturing method of the fifth embodiment, short fibers are implanted on the surface of the foamed layer 11a or the non-foamed layer 11b by the electrostatic flocking method in the next step of the backing cloth laminating step.

[0034]

According to the first to third aspects of the present invention, 50% to 100% of the fibers constituting the backing cloth are provided.
% Of the material of the flexible thermoplastic resin layer bonded to the surface is formed of the same resin material, and the two are directly heat-welded at the mating surface, so that the bond is strong and Because there is no adhesive on the bonding surface, the leather fabric is rich in flexibility and texture. Therefore, it is suitable for an automobile inner layer leather which is subjected to severe repeated loads. In the invention according to claim 2, in the case where the flexible thermoplastic resin layer is a foamed layer, the apparent specific gravity is extremely small, the cushioning property is excellent, and the heat insulating effect is exhibited, and the door, the instrument panel, and the ceiling of the automobile are provided. Ideal for golf bags, Boston bags, interior decoration materials and other skin materials for furniture.

According to the third aspect of the present invention, since the surface cloth is also made of the same material as the backing cloth, there is no adhesive in the bonding between the surface cloth and the foam layer, and the heat bonding is as strong as the backing cloth. The surface is made of woven or knitted fabric in accordance with the cushioning properties and heat insulating effect described above. It is effective and suitable for many fabrics mentioned above. In particular, it has an excellent effect of preventing dew condensation as an interior decoration material.

In the invention according to the fourth aspect, since the thermoplastic resin fibers and the flexible thermoplastic resin layer contained in the backing cloth are both made of olefin resin, the welding force on the bonding surface is strong. In addition, since both materials are easily available, the product cost is low and the specific gravity is small. Also, no harmful gas is generated when used secondary products or chips are burned as waste.

In the invention of claim 5, since the thermoplastic resin fibers contained in the backing cloth are contained in the form as described above, when bonding with the thermoplastic resin layer, be sure to cover the entire surface of the mating surface. It is in uniform contact and is thermally welded to it, and its bonding strength is strong.

Effects of the Embodiments The effects of the respective embodiments exhibit the effects of the inventions described in the respective claims included in this embodiment, and overlapping descriptions are omitted. Example 4 has a smooth surface. In the case of Example 5, the surface is brushed and is velvet-like.

[Brief description of the drawings]

FIG. 1 is an enlarged longitudinal sectional view of a first embodiment.

FIG. 2 is an enlarged longitudinal sectional view of a second embodiment.

FIG. 3 is an enlarged longitudinal sectional view of a third embodiment.

FIG. 4 is an enlarged longitudinal sectional view of a fourth embodiment.

FIG. 5 is an enlarged longitudinal sectional view of a fifth embodiment.

FIG. 6 is a principle explanatory view showing an example of an apparatus for manufacturing the product of the first embodiment.

FIG. 7 is a principle explanatory view showing an example of an apparatus for manufacturing a product according to a fourth embodiment.

[Explanation of symbols]

 Reference Signs List 10 backing cloth 11 flexible thermoplastic resin layer 11a foam layer 12 squeezing 13 surface cloth 14 surface layer 15 adhesive 16 short fiber flocking

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) D06N 3/00-3/18 B32B 27/00 B32B 27/12

Claims (5)

(57) [Scope of request for utility model registration] 1. A flexible thermoplastic resin having a heat-sealing property with the thermoplastic resin fiber on the surface of a backing cloth made of a kind of knitted cloth containing thermoplastic resin fibers of 50% to 100% and having substantially the same longitudinal and lateral elongation. This flexible thermoplastic resin layer is a kind of a foamed layer, a composite layer in which a non-foamed layer is formed on the surface of the foamed layer, and is a combination of the backing cloth and the flexible thermoplastic resin layer. The thermoplastic synthetic resin leather is characterized in that the thermoplastic resin fibers and the thermoplastic resin layer contained in the backing fabric are directly heat-welded. 2. The flexible thermoplastic resin layer comprises a non-foamed layer, a foamed layer,
The thermoplastic synthetic resin leather according to claim 1, which is one of composite layers in which a non-foamed layer is formed on the surface of the foamed layer. 3. The flexible thermoplastic resin layer is a foamed layer,
The thermoplastic synthetic resin leather according to claim 2, wherein a surface cloth of the same material as the backing cloth is heat-welded to the surface similarly to the backing cloth. 4. The thermoplastic resin according to claim 1, wherein both the thermoplastic resin fibers and the flexible thermoplastic resin layer contained in the backing cloth are made of an olefin resin. Synthetic resin leather. 5. The thermoplastic synthetic resin leather according to claim 1, wherein the backing cloth containing the thermoplastic resin fibers includes at least one of the following. a. What was formed with the thread consisting only of the thermoplastic resin fiber. b. Each of the fibers of the backing cloth is formed of fibers obtained by coating the flexible thermoplastic resin layer and the non-heat-welding fiber with the thermoplastic resin having the heat-welding property, respectively. c. What was formed with the blended yarn of the thermoplastic resin fiber and other fibers. d. A yarn made of one of mixed weaving, mixed knitting, cross-weaving, cross-knitting, and a mixture of the yarn made of only the thermoplastic resin fiber and the yarn made of another fiber.