JP5334344B1 - Resin sheet material, composite sheet material, and production method thereof - Google Patents

Abstract

It is an object of the present invention to provide a resin sheet material and a composite sheet material having a large modulus and excellent processing suitability such as tension and bending, and methods for producing them. The resin sheet material that achieves such an object has a transfer shape of the fabric surface formed on at least one surface thereof, and the manufacturing method thereof includes the step of attaching the fabric surface of the fabric onto an uncured resin film. After the shape of the cloth surface is transferred to the film and the resin film is cured, the cloth is peeled off or dissolved away from the resin film. In addition, the composite sheet material has a base material laminated on a resin sheet material, and the manufacturing method is characterized in that the base material is attached to at least one surface of the resin sheet material.

Description

  The present invention relates to a resin sheet material having a fabric transfer shape formed on at least one side and a manufacturing method thereof, and a composite sheet material in which a base material is laminated on the resin sheet material and a manufacturing method thereof. Specifically, resin sheet materials that can be suitably used for clothing, bags, shoes, automotive interior materials (center panels, door panels, sheet skins, etc.), mobile phones, notebook PC housings, partition panels, and housing equipment-related materials. And composite sheet materials and methods for producing them.

  In general, the term “sheet” refers to a product that is thin in terms of definition in Japanese Industrial Standards (hereinafter referred to as “JIS”), and generally has a thickness that is small and small for its length and width. A “film” is a thin flat product that is extremely small compared to its length and width and whose maximum thickness is arbitrarily limited, and is usually supplied in the form of a roll ( JIS K 6900). In terms of thickness, a sheet having a thickness of 100 μm or more may be referred to as a sheet, and a sheet having a thickness of less than 100 μm may be referred to as a film. The “sheet material” in the present invention includes both the “sheet” and the “film” without distinction.

  The “composite sheet material” in the present invention is a laminate of the resin sheet material of the present invention and a sheet-like base material such as woven fabric, knitted fabric, nonwoven fabric, leather, and paper.

  Conventionally, as a resin sheet material with a pattern or pattern, or a leather-like resin sheet material imitating natural leather, (1) a resin sheet material that has been embossed or printed, (2) There are composite sheet materials (for example, synthetic leather, artificial leather, etc.) in which a resin sheet material and a base material are bonded together. As the conventional resin sheet material of (1), generally, a colored layer is formed on the surface of a resin film by a method such as printing, and a protective clear layer is further laminated thereon. However, in order to prevent fine cracks and breaks that occur in the colored layer due to elongation and deformation, such a resin sheet material is made of a hard and difficult-to-extend resin, so that it is difficult to perform tensile processing and bending processing. (Patent Document 1)

  In addition, the conventional composite sheet material (2) is firmly bonded so that the resin layer and the base material do not peel off, but the longitudinal direction (MD ) And transverse direction (CD) have different tensile strengths and moduli (stresses during constant elongation), so tensile and bending processes such as sticking in close contact with the surface of a three-dimensional object having a curved surface However, there was a problem that wrinkles and floats were partially generated when the coating was applied, and the finished product lacked elegance (Patent Document 2).

Japanese Patent No. 2600958 JP-A-11-117181

  The present invention is excellent in suitability for tensile processing and bending processing, for example, even when adhered to the surface of a complicated three-dimensional object such as a curved surface, it is difficult to cause wrinkles and floats and can be finished in a beautiful appearance. It is an object of the present invention to provide a resin sheet material and a composite sheet material that can be produced, and further to provide a manufacturing method thereof.

  In order to solve the above problems, the present inventors have repeatedly studied to improve the processability of the resin sheet material itself or a composite sheet material in which the resin sheet material and the base material are laminated. The present inventors have found that the modulus of the resin sheet material is increased by forming the transfer shape of the cloth surface on at least one side, and the present invention has been completed. The modulus is a stress at the time of constant elongation of a resin sheet or the like, that is, a tensile stress that tends to shrink in order to maintain its original shape when a specific elongation is given to the object in the tensile direction.

The above problems can be solved by the following present invention.
That is, the resin sheet material of the present invention is a sheet material made of synthetic resin as described in claim 1, wherein the transfer shape of the cloth surface of the fabric is formed on the surface of the sheet material. In addition, the back surface of the sheet is a resin sheet material provided with a pattern or a color to obtain a design effect .
Moreover, the resin sheet material of this invention is a resin sheet material of Claim 1 characterized by the above-mentioned.
Moreover, the resin sheet material of the present invention is the resin sheet material according to claim 1 or 2, wherein the resin sheet material is composed of a plurality of resin layers.
In addition, the composite sheet material of the present invention, as described in claim 4, is a composite comprising a base material laminated on the resin sheet material according to any one of claims 1, 2, and 3. It is a sheet material.
Moreover, the manufacturing method of the resin sheet material of this invention is a manufacturing method of the sheet material which consists of synthetic resins as described in Claim 5, Comprising: The uncured resin film formed on the release paper or the release sheet The shape of the cloth surface is transferred to the resin film by attaching the cloth surface to the upper surface, and after the resin film is cured, the cloth is peeled and removed from the resin film , and the release paper or release sheet is further removed. It is a manufacturing method of the resin sheet material characterized by peeling and removing .
Moreover, the manufacturing method of the resin sheet material of this invention is a manufacturing method of the sheet material which consists of synthetic resins as described in Claim 6, Comprising: The uncured resin film formed on the release paper or the release sheet The shape of the cloth surface is transferred to the resin film by attaching the cloth surface to the upper surface, and after the resin film is cured, the release paper or release sheet is peeled off from the resin film , and the cloth is further removed. It is a manufacturing method of the resin sheet material characterized by carrying out dissolution removal.
The method for producing a resin sheet material according to the present invention is a method for producing a sheet material made of a synthetic resin as described in claim 7, wherein the resin sheet material is cured or uncured formed on a release paper or a release sheet. One or more layers of a cured or uncured resin film are formed on the resin film, and at least the uppermost resin film is uncured, and the fabric surface of the fabric is attached to the resin film. 7. The method for producing a resin sheet material according to claim 5, wherein the shape of the cloth surface is transferred by the method.
Moreover, the manufacturing method of the composite sheet material of this invention is a manufacturing method of a composite sheet material as described in Claim 8, Comprising: Manufacture by the manufacturing method of any one of Claim 5, 6, 7 In another aspect of the present invention, there is provided a method for producing a composite sheet material, wherein a base material is attached to at least one surface of a resin sheet material.

  The resin sheet material of the present invention has an increased modulus due to the transfer shape of the fabric surface being formed on at least one surface thereof, and is excellent in suitability for tensile processing and bending processing. Therefore, for example, even when the resin sheet material of the present invention is used by sticking to the surface of a complicated three-dimensional object such as a curved surface, it can be partially wrinkled because it can follow various shapes well. It does not easily float and can be finished in a tight and smooth appearance. In addition, since the transfer shape of the cloth surface of the fabric formed on the surface of the resin sheet material of the present invention is a fine uneven shape, the uneven shape is difficult to be exposed up to the back surface of the resin sheet material, so it was applied to the back surface. It does not adversely affect the design. Therefore, the present invention is particularly suitable for a resin sheet material having a small thickness.

  Further, when the resin sheet material of the present invention is composed of a plurality of resin layers, for example, in the case of a resin sheet material composed of two upper and lower resin layers, the resin film forming the upper layer is in an uncured state. Resin film that forms the lower layer even if the fabric fibers are pressed deeply into the resin film by crimping the fabric surface of the fabric and a part with an extremely thin thickness is formed in the upper layer or a small hole is formed through it. If the resin film is cured first, the lower resin film will not be deformed by pressure bonding of the cloth surface. As a result, the thickness of the entire resin sheet material is the thickness of the lower resin film even at the thinnest part. A considerable amount can be held. Therefore, an extremely thin portion or small hole is not conspicuous in the resin sheet material, and a resin sheet material excellent in design and functionality can be obtained.

  Since the composite sheet material of the present invention has a large modulus of the resin sheet material portion, the composite sheet material has high followability to expansion / contraction deformation of the base material portion. Therefore, for example, even when the composite sheet material of the present invention is used by sticking to the surface of a complicated three-dimensional object such as a curved surface, it can be partially wrinkled because it has good followability to various shapes. It does not easily float and can be finished in a tight and smooth appearance.

According to the method for producing a resin sheet material of the present invention, the transfer shape of the fabric surface of the fabric is formed simply by attaching the fabric onto the uncured resin film and removing or dissolving after the resin film is cured. Resin sheet material with a large modulus can be easily manufactured, and resin sheet materials with excellent design and functionality can be manufactured with good yield, since defects such as extremely thin portions and small holes are unlikely to occur in the resin sheet material. .
Here, in the case of adopting the method of peeling and removing the fabric, if the fabric peeled and removed from the resin film is reused, the manufacturing cost of the resin sheet material can be reduced.

  In addition, when the method of dissolving and removing the fabric is adopted, there is no need to peel the fabric from the resin film, so there is no risk of the resin film being torn or damaged when the fabric is peeled from the resin film. In the manufacturing process of the sheet material, it is possible to prevent the generation of defective products and improve the yield. Therefore, it is particularly suitable for producing a thin resin sheet material.

Electron micrograph showing the formation state of the transfer shape of the cloth surface on the surface of the resin sheet material obtained in Example 1 Electron micrograph showing a cross section of the resin sheet material obtained in Example 1 Electron micrograph showing a cross section of the resin sheet material obtained in Example 5

  First, the resin sheet material of the present invention will be described. The resin sheet material of the present invention has an increased modulus because the transfer shape of the fabric is formed on at least one surface thereof.

Here, the transfer shape of the cloth surface is a fine uneven shape obtained by copying the shape of many fibers forming the cloth surface. For example, the convex portion of the cloth surface becomes a concave portion of the resin sheet material. The concave portion of the surface becomes a convex portion of the resin sheet material.
When such a concavo-convex shape is formed on the surface of the resin sheet material, the resin sheet material has a thin concave portion and a thick convex portion. When a tensile force is applied from the outside to such a resin sheet material, the thin concave portion is relatively easily deformed, so it is considered that the tensile force is deformed by deformation, while the thick convex portion is Since it is relatively difficult to deform, it is considered that a stress is generated to resist the tensile force and return the resin sheet material to the original shape. It is considered that both of these actions combine to increase the modulus of the resin sheet material.
In addition, since the unevenness of the transfer shape on the fabric surface is fine, the uneven shape is difficult to appear on the surface (back surface) of the resin sheet material on which the transfer shape is not formed, which adversely affects the design applied to the back surface, etc. Will not affect.

  The synthetic resin forming the resin sheet material of the present invention may be any thermoplastic soft synthetic resin that is generally used, and is particularly limited as long as it can be properly used according to the properties required for each application. Is not to be done. Examples of the synthetic resin include vinyl chloride resin, olefin resin, polyurethane resin, and the like. When forming a leather-like sheet material that places emphasis on patterns, flexibility, texture, etc., such as clothing and shoes, polyurethane resin is used. When forming a leather-like sheet material that requires flame resistance, vinyl chloride resin is used. It may be selected depending on the application, for example.

  In addition, pigments, various additives, and stabilizers can be added to the synthetic resin as necessary, and coloring agents, slimming agents, and the like can be added to improve the appearance.

  Further, a transfer shape of the cloth surface can be formed only on the surface of the resin sheet material, and the back surface of the resin sheet material can be used as a design surface to give patterns and colors in order to obtain various design effects. In order to give such a pattern or color, a known method may be used. For example, to give a pattern, the release paper has irregularities such as a leather pattern, a geometric pattern pattern, a woven pattern, and a wood grain pattern. What is necessary is just to use what is necessary, or you may use a smooth thing without an unevenness | corrugation in a release paper. Moreover, what is necessary is just to provide the desired color by dye and a pigment by methods, such as various printing, in order to provide a color.

  Further, when a material containing a large number of microbubbles made of polyurethane resin or the like is used as the material of the resin sheet material, air permeability can be imparted in the thin portion of the resin sheet material. Thus, the resin sheet material to which air permeability was given can be used suitably as materials, such as clothing and shoes.

  In the present invention, the fabric used for forming the transfer shape of the fabric surface of the fabric may be any of a woven fabric, a knitted fabric, a non-woven fabric, and the like, and is not particularly limited. In general, a non-woven fabric is less expensive than a woven fabric. Therefore, it is preferable.

  Examples of fibers constituting the fabric include ordinary fibers such as fibers made of synthetic resins such as polyester, polyamide, polyacrylonitrile, polyolefin, and polyvinyl alcohol, artificial fibers such as regenerated cellulose, and natural fibers such as cotton, hemp, and wool. Is mentioned. What is necessary is just to select arbitrarily from the textile fabric manufactured using those fibers, a knitted fabric, a nonwoven fabric, or the laminated fabric which combined them etc. according to the material and use of a resin sheet material. Further, in the case of a synthetic fiber, not only a fiber composed of a single polymer, but also a fiber obtained by mixing or spinning two or more polymers may be used.

  When the fabric is a woven fabric, the texture is not particularly limited, such as plain weave, twill weave, satin weave, etc., but if the fabric surface is finished so smooth, the fiber shape of the fabric surface is transferred to the resin sheet material. It becomes difficult to be done.

  When the fabric is a nonwoven fabric, all nonwoven fabrics expressed in various categories such as a short fiber nonwoven fabric, a long fiber nonwoven fabric, a needle punch nonwoven fabric, a papermaking nonwoven fabric, a spunbond nonwoven fabric, a melt blown nonwoven fabric, and an electrospun nonwoven fabric can be applied.

  As the short fiber nonwoven fabric, a nonwoven fabric manufactured by a chemical bond method, a thermal bond method, a spunlace method, a needle punch method, or the like can be used. Moreover, as a long fiber nonwoven fabric, the nonwoven fabric obtained by a spun bond system can be used conveniently.

  About the fineness (dtex) of a fabric, when the fabric is a woven fabric, it may be an ordinary fineness that can be woven as a woven yarn.

  Moreover, when a fabric is a nonwoven fabric, is preferably 0.5 to 25 dtex. When the thickness is smaller than 0.5 dtex, when the cloth surface is attached to the uncured resin film, the liquid resin penetrates deeply between the fine fibers, and the cloth tends to be difficult to remove. On the other hand, if the fineness is larger than 25 dtex, the bulk of the non-woven fabric increases, and the operability when contacting the resin film tends to deteriorate. A more preferable fineness is 1 to 20 dtex.

  Next, the manufacturing method of the resin sheet material of this invention is demonstrated. According to the method for producing a resin sheet material of the present invention, the cloth surface of the cloth is attached to an uncured resin film, the shape of the cloth surface is transferred to the resin film, and the resin film is cured, and then the resin A resin sheet material having a high modulus in which the transfer shape of the cloth surface is formed can be easily manufactured by a simple process of peeling or dissolving the cloth from the film.

  Moreover, in the method for producing a resin sheet material of the present invention, when transferring the shape of the cloth surface to the resin film, the cloth surface is pressure-bonded onto the resin film using a pressure-bonding roll or the like as necessary. Since the fabric has cushioning properties, it is possible to uniformly disperse the pressing force applied at the time of pressure bonding, and to prevent a problem that a large pressing force is applied only to a specific portion on the resin film. Therefore, the resin sheet material is less prone to defects such as extremely thin portions and small holes, and a resin sheet material excellent in design and functionality can be manufactured with high yield.

In addition, in the manufacturing process of the resin sheet material of the present invention, when forming the transfer shape of the cloth surface, the depth of the depth to which the cloth surface is attached and pressed onto the uncured resin film is determined. What is necessary is just to adjust suitably according to the use etc. of. However, if the cloth surface is pushed too deeply into the resin film, the resulting resin sheet material may be partially extremely thin or may have small holes.
When the cloth surface is attached to the uncured resin film, the liquid resin is pushed and moved by the fibers of the cloth and enters the gaps between the fibers of the cloth, or the liquid resin is absorbed by the capillary force of the fibers of the cloth. Although it penetrates between the fibers, if the fabric is peeled or dissolved and then removed by curing the resin film as it is, a transferred shape of the fibers appears on the resin film. This transfer shape is formed of a portion where the resin is depressed by being pushed out by the fibers of the fabric and a portion where the resin is soaked and raised between the fibers of the fabric. Therefore, the thickness of the obtained resin sheet material is thicker than the resin film having a smooth surface before being attached to the cloth surface by the amount of protrusion.

  Since the surface of the resin sheet material of the present invention exhibits such a complicated uneven state, it is difficult to accurately measure the depth of the unevenness. Therefore, the depth of the transfer shape of the cloth surface formed on the resin sheet material of the present invention is conveniently defined indirectly by the height of the height of the resin film raised by the attachment of the cloth surface. It is. In the present application, the difference between the thickness of the obtained resin sheet material and the thickness of the resin film cured without contacting the cloth surface is defined as the height of the resin film raised, that is, the “bump height”. Define that there is.

Then, about the resin sheet material obtained in Example 1 of the present invention to be described later, from the thickness of 0.22 mm, Comparative Example 1 obtained by curing without attaching the cloth surface to the resin film. The raised height is 0.13 mm obtained by subtracting 0.09 mm which is the thickness of the resin sheet material.
In the resin sheet material of the present invention, when the raised height is 0.01 to 0.13 mm, the degree of the transfer shape depth of the formed fabric surface is appropriate, and the modulus is large and various shapes can be obtained. Since it can be set as the resin sheet material with favorable followability, it is preferable.

  The first manufacturing method of the resin sheet material according to the present invention includes the step of transferring the shape of the cloth surface to the resin film by attaching the cloth surface to the uncured resin film, and curing the resin film. The cloth is peeled off from the resin film.

  There are a dry method and a wet method for forming the resin film, and either method can be adopted. In the dry method, a synthetic resin solution mainly composed of polyurethane, polyvinyl chloride, or the like suitable for the dry method is applied onto a release paper or a release sheet, and is thermally dried and aged to cure the resin film. In the wet method, a synthetic resin solution mainly composed of polyurethane suitable for the wet method is applied on a release sheet, and this is solidified in a coagulation tank to form a resin film.

  Further, if necessary, the resin sheet material can be multi-layered to increase the durability of the resin sheet material or to give the resin sheet material a certain thickness. Also, different types of resins can be combined, and various properties can be imparted to the resin sheet material.

  As a method for applying the above synthetic resin solution, any coating method such as knife coating, knife over roll coating, reverse roll coating and the like can be employed.

  Next, before the resin film is cured, the resin film and the fabric formed by any one of the above methods are attached to the resin film so that the transfer shape of the cloth surface of the fabric is formed. As a method of attachment, it is only necessary to place the fabric on the uncured resin film, but it is also possible to apply pressure by applying a pressing force using a calendar roll or a pressure roll.

  Next, after the resin film is cured while the cloth is attached, the cloth is peeled off from the resin film. In this case, the cloth may be impregnated with a water-repellent solution made of silicon or fluorine in advance, or the water-repellent may be applied to the cloth so that the cloth is easily peeled off from the resin film. it can.

  The fabric for peeling and removing is preferably made of inelastic fibers. This is because in the case of a fabric made of elastic fibers, it may be difficult to peel off from the resin film, and there is a risk of damaging the resin film if it is forcibly peeled off. Specifically, fibers made of polyester, polyamide, polypropylene, polyethylene or the like are preferable. In the case of peeling and removing, some fiber pieces of the fabric may remain on the resin film.

  Next, in the second method for producing the resin sheet material, after the cloth surface is transferred onto the uncured resin film, the shape of the cloth surface is transferred to the resin film, and the resin film is cured. In this method, the fabric is dissolved and removed from the resin film.

  First, a resin film is formed. As described above, the resin film forming method includes a dry method and a wet method. In the second manufacturing method, it is preferable to employ the dry method. Next, before the resin film is cured, the resin film and the cloth are attached to the resin film so that the transfer shape of the cloth surface of the cloth is formed. The attachment method may be in accordance with the first manufacturing method described above.

  Next, after the resin film is cured while the cloth is attached, the cloth is dissolved and removed. When the fabric is dissolved, the solvent may be appropriately selected according to the material of the fabric. For example, when a nonwoven fabric made of polyvinyl alcohol (hereinafter also referred to as “PVA”) resin is used, water is used as the solvent. It is convenient because it can. Furthermore, it is preferable to use a PVA resin that dissolves at a low temperature of about 20 ° C. to 90 ° C. because energy costs for raising the water temperature can be suppressed. Moreover, when using a spunbond nonwoven fabric, it is preferable to use a melt-moldable PVA resin because the nonwoven fabric can be easily manufactured.

  In the case of dissolving and removing, the fiber pieces of the cloth may not be completely dissolved in the resin film and may remain somewhat. The method of dissolving and removing the fabric has an advantage that the resin film is hardly damaged during the removal. Therefore, the manufacturing method is particularly suitable when the thickness of the resin film is thin.

  Next, the composite sheet material of the present invention will be described. As for the composite sheet material of this invention, the resin sheet material of this invention and a base material are laminated | stacked. Examples of the base material used for the composite sheet material of the present invention include woven fabric, knitted fabric, non-woven fabric, film, resin plate, wood, natural leather, artificial leather and the like. The substrate can be selected according to the target product. Since the resin sheet material portion of the composite sheet material follows the expansion and contraction of the base material portion well, for example, the composite sheet material of the present invention is pasted on the surface of a complicated three-dimensional object such as a curved surface. Even when worn and used, it has good followability to all shapes, so that it is difficult for wrinkles and floats to occur in part, and it can be finished in a tight and smooth appearance.

  In addition, what is necessary is just to use adhesive agents, such as a hot-melt-adhesive agent, for bonding a resin sheet material and a base material. At that time, the unevenness of the transfer shape of the fabric surface of the resin sheet material increases the adhesion to the base material due to the anchor effect, so that the amount of adhesive used is reduced, and further, the workability is impaired by the adhesive. hard.

  EXAMPLES Hereinafter, although an Example demonstrates this invention further more concretely, this invention is not limited by a following example. In addition, the following method was used for the measuring method of each physical-property value in an Example.

(1) Weight per unit weight (g / m ² ) was obtained by collecting five test pieces, measuring each mass (g) and area (m ² ), and determining the mass per 1 m ² (g / m ² ). .

(2) Thickness Thickness (mm) was measured randomly at five points with a thickness measuring instrument (H type manufactured by Ozaki Seisakusho Co., Ltd.) with a 0.5 kPa load applied to the test piece. The average value was obtained.

(3) Tensile strength (N / 50mm width)
Using a testing machine (manufactured by Shimadzu Corporation, Autograph AGS-J type), a test piece having a width of 50 mm and a length of 200 mm was measured under the conditions of a gripping interval of 100 mm and a tensile speed of 100 mm / min. The strength was measured. The average value of five test pieces was determined and used as the tensile strength. In addition, about tensile strength, it calculated | required both the MD direction (machine direction) and CD direction (direction orthogonal to MD direction) of a test piece.

(4) 5% modulus (5% elongation stress (N / 5cm width))
The stress at 5% elongation was determined according to the above-described tensile strength measurement method. In addition, the stress at the time of 5% elongation was obtained by obtaining an average value of five test pieces, and was obtained for both the MD direction (machine direction) and the CD direction (direction perpendicular to the MD direction) of the test piece.

(5) 10% modulus (stress at 10% elongation (N / 50 mm width))
The stress at 10% elongation was determined according to the above tensile strength measurement method. In addition, the stress at the time of 10% expansion | strain was also calculated | required about the average value of five test pieces, and was calculated | required about both MD direction (machine direction) and CD direction (direction orthogonal to MD direction) of a test piece.

(6) Ventilation rate Five test pieces with a size of 100 mm × 100 mm were collected, and using a breathability tester (KES-F8-AP1 manufactured by Kato Tech Co., Ltd.), the piston speed of the breathability tester was set to 0. The airflow resistance R (KPa · s / m) was measured after adjusting to 2 cm / sec. From the measured ventilation resistance R, the average value of the ventilation amount V (cm ³ / m ² · s) per unit area of five test pieces was obtained using the following equation. The air of the breathability tester flows from the lower surface to the upper surface of the test piece.
(Formula) V = 1.2455 / R
In this example, the measurement was performed with the surface (front surface) on which the transfer shape of the nonwoven fabric cloth surface of the test piece was formed and the surface on the release paper side (back surface) as the lower surface.

Example 1
Preparation of non-woven fabric for forming transfer shape of cloth surface of fabric A long-fiber non-woven fabric was prepared by a spunbond method using a melt-moldable PVA resin.
First, a melt-moldable PVA resin chip is introduced into a melt extruder and melted, and then introduced into a spinneret having a spinning hole, and the spinneret of the spinneret is adjusted so that the fineness becomes 4 dtex. And melt spun. Then, the spun long fiber group was continuously collected while sucking from the back side of the net to obtain a long fiber web. From this PVA resin having a fineness of 4 dtex, a thickness of 0.3 mm, and a basis weight of 40 g / m ² , in which the long fiber web is passed through an embossing device comprising a heated uneven roll and a flat roll, and the long fibers are partially fused to each other. A long fiber nonwoven fabric was obtained.

Preparation of urethane resin film Polyurethane resin made of aliphatic polyurethane with 100% modulus of 89 kgf / cm against 69 parts of N, N-dimethylformamide (DMF) on drawn release paper (manufactured by Sappi, Ultracast Verona) (Stahl: SU9202) 25 parts, Silicone resin (Stahl, HM145) 3 parts, Pigment dispersion (Stahl, black) 3 parts The solution after drying becomes 0.03 mm The surface was coated with a knife coater, and the surface was dried with hot air at 90 ° C. for 2 minutes. On top of that, for 57 parts of N, N-dimethylformamide (DMF), 40 parts of a polyurethane resin made of aliphatic polyurethane having a 100% modulus of 4 kgf / cm (manufactured by Stahl: SU5089), silicon resin (manufactured by Stahl, A solution containing 3 parts of HM145) was applied with a knife coater so that the thickness after drying was 0.03 mm, and the surface was dried with hot air at 90 ° C. for 3 minutes. Further, 40 parts of an N, N-dimethylformamide (DMF) and 40 parts of a polyurethane resin (SU5089, manufactured by Stahl) having a 100% modulus of 4 kgf / cm, and a crosslinking agent (STAhl) A solution containing 5 parts of XR40-102) and 15 parts of a pigment dispersion (made by Stahl, black) was applied with a knife coater so that the thickness after drying was 0.03 mm, and the surface was 90 ° C. After being dried with hot air for 1 minute, a laminated film (three layers) made of three kinds of polyurethane resins having a thickness of 0.09 mm was obtained.

Manufacture of resin sheet material
On the urethane resin laminated film obtained above, the long fiber nonwoven fabric made of the above PVA resin is placed, and the clearance of the pair of laminate rolls is 0.39 mm (the total thickness of the urethane resin laminated film and the long fiber nonwoven fabric) And was attached at a roll temperature of 150 ° C. After the contact, the urethane resin laminate film was stored for 48 hours to age, and the urethane resin was cured. Thereafter, the urethane resin laminate film was peeled from the release paper, the PVA long fiber nonwoven fabric was dissolved in water at a temperature of 25 ° C., and the urethane resin laminate film was dried to obtain a sheet material.
The resulting resin sheet material had a thickness of 0.22 mm, and a transfer shape of the nonwoven fabric was formed on the surface (FIGS. 1 and 2). 1 and 2 were taken using an electron microscope (manufactured by JEOL Ltd.).
Moreover, the pattern by the release paper was beautifully formed in the back surface of the resin sheet material.

(Example 2)
Production of Resin Sheet Material A plain woven fabric (manufactured by Nichibi Co., Ltd., GTS970, thickness 0.095 mm) made of PVA fibers is placed on the same urethane resin laminated film as in Example 1, and the clearance between the pair of laminate rolls Was adjusted to 0.185 mm (substantially the same as the total thickness of the urethane resin laminated film and the plain weave fabric), and was attached at a roll temperature of 150 ° C. After the contact, the urethane resin laminate film was stored for 48 hours to age, and the urethane resin was cured. Thereafter, the urethane resin laminated film was peeled off from the release paper, a plain woven fabric made of PVA fibers was dissolved in water at a temperature of 90 ° C., and the urethane resin laminated film was dried to obtain a sheet material.
The thickness of the obtained resin sheet material was 0.12 mm, and the transfer shape of the fabric surface was formed on the surface. Moreover, the pattern by the release paper was beautifully formed in the back surface of the resin sheet material.

(Example 3)
Preparation of Nonwoven Fabric for Forming Transfer Shape on Fabric Surface A short fiber nonwoven fabric was prepared by a thermal bond method using PVA fibers.
A fiber made of PVA resin having a fineness of 2.2 dtex and a fiber length of 51 mm was prepared. And the fiber which consists of this PVA resin was mixed uniformly, and it opened and accumulated with the card machine, and obtained the fiber web. By passing the fiber web through an embossing roll at 185 ° C., the fibers were bonded to each other to obtain a PVA short fiber nonwoven fabric having a thickness of 0.33 mm and a basis weight of 40 g / m ² .

Adjustment of urethane resin film The same adjustment as in Example 1 was performed.

Manufacture of resin sheet material A PVA short fiber nonwoven fabric is placed on the above-mentioned urethane resin laminate film, and the clearance between the pair of laminate rolls is 0.42 mm (approximately the same as the total thickness of the urethane resin laminate film and the short fiber nonwoven fabric). ) And attached at a roll temperature of 150 ° C. After the contact, the urethane resin laminate film was stored for 48 hours to age, and the urethane resin was cured. Then, the urethane resin laminated film was peeled from the release paper, the PVA short fiber nonwoven fabric was dissolved in water at a temperature of 25 ° C., and the urethane resin laminated film was dried to obtain a resin sheet material. The obtained resin sheet material had a thickness of 0.17 mm, and a transfer shape of the nonwoven fabric was formed on the surface.

Example 4
Preparation of non-woven fabric for forming a transfer shape on the surface of the fabric A long-fiber non-woven fabric was prepared by using a polypropylene resin by a spunbond method. First, a chip of polypropylene resin (melting point: 163 ° C.) was put into a melt extruder. After melting, it was introduced into a spinneret having a spinning hole, the spinneret of the spinneret was adjusted so that the fineness was 2.5 dtex, and melt spinning was performed. Then, the spun long fiber group was continuously collected on the net while sucking from the back side to obtain a long fiber web. This long fiber web is passed through an embossing device comprising a heated uneven roll and a flat roll, and a polypropylene long fiber nonwoven fabric having a thickness of 0.30 mm and a basis weight of 40 g / m ² partially fused between the long fibers. Obtained. After that, the polypropylene long fiber nonwoven fabric is passed between the heated flat roll and the flat roll so as not to erase the emboss (unevenness) (the surface of the long fiber nonwoven fabric is not smoothed). A long fiber nonwoven fabric was obtained.

Preparation in the same manner as in Production Example 1 of urethane resin film .

Production of Resin Sheet Material The above-mentioned polypropylene long fiber nonwoven fabric is placed on the urethane resin laminated film obtained above, and the clearance between the pair of laminate rolls is 0.47 mm (the thickness of the urethane resin laminated film and the long fiber nonwoven fabric). And was attached at 120 ° C. After the contact, the urethane resin laminate film was stored for 48 hours to age, and the urethane resin was cured. The polypropylene nonwoven fabric was peeled off and the release paper was peeled off to obtain a resin sheet material. The thickness of the obtained resin sheet material was 0.10 mm, and the transfer shape of the nonwoven fabric was formed on the surface.

(Example 5)
Production of Nonwoven Fabric for Forming Transfer Shape on Fabric Surface A short fiber nonwoven fabric was prepared by a spunlace method using PVA fibers.
A fiber made of PVA resin having a fineness of 1.9 dtex and a fiber length of 47 mm was prepared. And the fiber which consists of this PVA resin was mixed uniformly, and it opened and accumulated with the card machine, and obtained the fiber web. The fiber web was hydroentangled and dried to obtain a PVA short fiber nonwoven fabric having a thickness of 0.45 mm and a basis weight of 100 g / m ² .

Adjustment of Urethane Resin Film Three types of urethane resins were prepared in the same manner as in Example 1, each urethane resin was applied, and the thickness after drying was set to 0.06 mm, and a urethane resin film having a thickness of 0.18 mm was formed. Obtained.

Production of resin sheet material On the urethane resin laminate film obtained above, a PVA short fiber nonwoven fabric is laminated, and the clearance between the pair of laminate rolls is 0.63 mm (the total thickness of the urethane resin laminate film and the short fiber nonwoven fabric). Adjusted to approximately the same) and attached at a roll temperature of 150 ° C. After the contact, the urethane resin laminate film was stored for 48 hours to age, and the urethane resin was cured. Then, the urethane resin laminated film was peeled from the release paper, the PVA short fiber nonwoven fabric was dissolved in water at a temperature of 90 ° C., and the urethane resin laminated film was dried to obtain a resin sheet material. The thickness of the obtained resin sheet material was 0.21 mm, and the transfer shape of the nonwoven fabric was formed on the surface (FIG. 3). In addition, the photograph of FIG. 3 was image | photographed using the electron microscope (made by JEOL Ltd.) similarly to FIG.1 and FIG.2.

(Comparative Example 1)
In the same manner as in Example 1, a urethane resin laminated film composed of three types of urethane resins was prepared and aged for 48 hours without attaching the fabric, and the resin sheet material having a smooth surface (thickness 0. 09 mm).

(Comparative Example 2)
Preparation of Urethane Resin Film A resin sheet material having a smooth surface prepared by adjusting a urethane resin laminated film composed of three types of urethane resins in the same manner as in Example 5 and aged for 48 hours without touching the fabric. (Thickness 0.18 mm) was obtained.

(Test Example 1)
The measurement results of thickness, tensile strength, modulus (tensile strength, 5% modulus, 10% modulus) and air flow rate of the resin sheet materials obtained in Examples 1 to 5, Comparative Example 1 and Comparative Example 2 are shown. It was shown in 1.

  Although Examples 1-4 were resin films comprised from the same raw material as Comparative Example 1, it was confirmed that the modulus was improved by forming the transfer shape of the fabric surface of the fabric. Similarly, from Example 5 and Comparative Example 2, it was confirmed that the modulus was improved by forming the transfer shape of the fabric surface of the fabric.

  Further, in the resin sheet materials of Examples 1 and 2, it was confirmed that the air permeability was generated by forming the transfer shape of the cloth surface of the fabric as compared with the urethane resin film of Comparative Example 1. . In addition, since the ventilation resistance (R) was too large, the resin sheet material of the comparative example 1 and the comparative example 2 was not able to be measured with the air permeability tester.

(Example 6)
A resin sheet obtained in Example 1 using a urethane-based heat-sensitive nonwoven fabric (manufactured by KB Selen Co., Ltd., Espancione FF UEO100, basis weight 100 g / m ² ) as an adhesive for producing a composite sheet material The material and the base material were laminated, the clearance of the pair of laminate rolls was adjusted to the same width as the total thickness of each, and pressure-bonded at 130 ° C. to obtain a composite sheet material. In addition, artificial leather (manufactured by San Fang, thickness 0.75 mm, basis weight 250 g / m ² ) made of a long-fiber nonwoven fabric was used as the base material.

(Example 7)
A composite sheet material was produced in the same manner as in Example 6 except that the resin sheet material obtained in Example 3 was used instead of the resin sheet material obtained in Example 1.

(Comparative Example 3)
A composite sheet material was produced in the same manner as in Example 6 except that the resin sheet material obtained in Comparative Example 1 was used instead of the resin sheet material obtained in Example 1.

(Test Example 2)
From the composite sheet material obtained in Examples 6 and 7 and Comparative Example 3, a test piece having a width of 50 mm and a length of 200 mm was cut out and used with a testing machine (manufactured by Shimadzu Corporation, Autograph AGS-J type). After applying a stress at the time of 5% elongation to each test piece with a gripping interval of 100 mm, the appearance of the composite sheet material removed from the tester was visually observed. The results are shown in Table 2.

  As shown in Table 2, it was confirmed that the composite sheet materials of Examples 6 and 7 were excellent in adhesion between the resin sheet material and the base material. On the other hand, it was confirmed that the composite sheet material of Comparative Example 3 had weak adhesion between the resin sheet material and the substrate. That is, the resin sheet materials of Example 1 and Example 3 of the present invention have a larger modulus than that of Comparative Example 1, and therefore, even when a base material is bonded to these to form a composite sheet material It is excellent in the ability to follow the expansion and contraction of the base material and can maintain the appearance beautifully.

INDUSTRIAL APPLICABILITY The present invention can be suitably used for clothes, bags, shoes, automobile interior materials (center panels, door panels, seat skins, etc.), mobile phones, notebook computer casings, partition panels, housing equipment-related materials, and the like. It is useful for providing a resin sheet material, a composite sheet material, and a method for producing them.

Claims (8)

A sheet material made of a synthetic resin, in which a transfer shape of the cloth surface of the fabric is formed on the surface of the sheet material, and a pattern or color is applied to the back surface of the sheet to obtain a design effect . A resin sheet material characterized by that. The resin sheet material according to claim 1, wherein the fabric is a nonwoven fabric. The resin sheet material according to claim 1, wherein the resin sheet material includes a plurality of resin layers. A composite sheet material comprising a base material laminated on the resin sheet material according to claim 1. A method for producing a sheet material made of a synthetic resin, wherein the cloth surface is transferred to a resin film by attaching the cloth surface to an uncured resin film formed on a release paper or a release sheet. A method for producing a resin sheet material, comprising: curing the resin film, peeling and removing the fabric from the resin film, and peeling and removing the release paper or release sheet. A method for producing a sheet material made of a synthetic resin, wherein the cloth surface is transferred to a resin film by attaching the cloth surface to an uncured resin film formed on a release paper or a release sheet. A method for producing a resin sheet material, comprising: curing the resin film, removing the release paper or release sheet from the resin film, and further dissolving and removing the fabric. A method for producing a sheet material made of a synthetic resin, wherein one or more layers of a cured or uncured resin film are formed on a cured or uncured resin film formed on a release paper or a release sheet. 7. The shape of the cloth surface is transferred by forming and attaching at least the uppermost resin film in an uncured state and attaching the cloth surface of the cloth onto the resin film. Manufacturing method of resin sheet material. It is a manufacturing method of a composite sheet material, Comprising: A base material is stuck on at least one side of the resin sheet material manufactured by the manufacturing method according to any one of claims 5, 6, and 7. Manufacturing method of sheet material.

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