JP6186405B2 - Patterned sheet, patterned sheet manufacturing method, and manufacturing apparatus - Google Patents

Description

  The present invention relates to a patterned sheet, a method for manufacturing a patterned sheet, and a manufacturing apparatus.

  Patterned sheets (synthetic leather) are used, for example, in clothing, furniture, automobile interior sheets, and the like. The patterned sheet generally has a configuration in which a resin film layer made of urethane resin or the like is formed on a fiber base layer. In order to give the patterned sheet an appearance close to natural leather, a wrinkle pattern is usually formed on the surface of the film layer of the patterned sheet.

  As a method for producing a patterned sheet, Patent Document 1 (Japanese Patent Laid-Open No. 63-50580) discloses that a film layer is formed by applying urethane resin or the like to the surface of a fiber base layer, and then the surface of the film layer. Discloses a method of performing a process for forming irregularities.

  Further, in Patent Document 2 (Japanese Patent Laid-Open No. 4-110985), as a method for producing a patterned sheet, a resin layer serving as a film layer is formed on a transfer release paper provided with a textured pattern, and this is used as a fiber. A method of transferring to the surface of the substrate layer is disclosed.

JP-A-63-50580 Japanese Patent Laid-Open No. 4-100985

  However, neither Patent Document 1 nor Patent Document 2 discloses a patterned sheet in which a texture such as a texture pattern on the surface is designed in an arbitrary pattern.

  An object of the present invention is to provide a patterned sheet having an excellent design property that can arbitrarily design not only a pattern but also a surface texture.

  Another object of the present invention is to provide a method for producing a patterned sheet having an excellent design property that can arbitrarily design not only the pattern but also the texture of the surface.

  Furthermore, another object of the present invention is to provide an apparatus for manufacturing a patterned sheet having an excellent design property that can arbitrarily design not only the pattern but also the texture of the surface.

The patterned sheet of the present invention that solves the above problem includes a first region and a second region. The first region is exposed on the surface of the patterned sheet in the upper surface of the fiber base layer. The second region is disposed on a region different from the first region in the upper surface of the fiber base layer, and a film layer on which irregularities for expressing a texture pattern are formed on the surface of the patterned sheet Exposed. At the boundary between the first region and the second region, a contact surface is formed in which the film layer is in contact with the fiber base layer in the first region. The contact surface extends in a direction in which the film layer is viewed from the fiber base layer in the second region.

In the patterned sheet of the present invention, the film layer may have a thickness of 20 μm to 400 μm.

In the patterned sheet of the present invention, the fiber base layer may be a woven fabric, a knitted fabric, or a non-woven fabric.

  According to the present invention, it is possible to provide a textured sheet having excellent design properties, a textured sheet manufacturing method, and a textured sheet manufacturing apparatus that can arbitrarily design not only the pattern but also the surface texture. it can.

FIG. 1 is a plan view of a patterned sheet according to the first embodiment. FIG. 2 is a cross-sectional view of the patterned sheet according to the first embodiment. FIG. 3 shows an apparatus used for manufacturing the patterned sheet of the first embodiment. FIG. 4 shows an apparatus used for manufacturing the patterned sheet of the first embodiment. FIG. 5 shows an apparatus used for manufacturing the patterned sheet of the first embodiment. FIG. 6 is a flowchart of the manufacturing process of the patterned sheet according to the first embodiment. FIG. 7 is a cross-sectional view showing a release paper in the manufacturing process of the patterned sheet according to the first embodiment. FIG. 8 is a plan view of the patterned sheet of the second embodiment. FIG. 9 is a cross-sectional view of the patterned sheet according to the second embodiment. FIG. 10 is a plan view of the patterned sheet according to the third embodiment. FIG. 11 is a cross-sectional view of the patterned sheet of the third embodiment. FIG. 12 shows an apparatus used for manufacturing the patterned sheet of the third embodiment. FIG. 13 is a flowchart of the manufacturing process of the patterned sheet according to the third embodiment. FIG. 14 shows an apparatus used for manufacturing a patterned sheet according to a modification of the third embodiment. FIG. 15 shows a screen plate according to a modification. FIG. 16 is a plan view showing a pattern formed by a screen plate according to a modification. FIG. 17 shows a screen plate making unit in a manufacturing apparatus according to a modification of the third embodiment. FIG. 18 is a plan view of the patterned sheet of the fourth embodiment. FIG. 19 is a cross-sectional view of the patterned sheet according to the fourth embodiment. FIG. 20 is a plan view of the patterned sheet according to the fifth embodiment. 21 is a cross-sectional view taken along line XXI-XXI in FIG. FIG. 22 is a plan view of the patterned sheet according to the sixth embodiment. FIG. 23 is a cross-sectional view of the patterned sheet of the sixth embodiment. FIG. 24 is a cross-sectional view of a patterned sheet according to a modification of the sixth embodiment. 25 is a plan view of the patterned sheet of Example 1. FIG. FIG. 26 is a cross-sectional photograph of the patterned sheet of Example 1. FIG. 27 is a cross-sectional photograph of the patterned sheet of Example 2. FIG. 28 is a cross-sectional photograph of the patterned sheet of Example 3.

  Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings. For convenience of explanation, the drawings referred to in the following description show only the main members necessary for explaining the present invention in a simplified manner among the constituent members of the embodiment of the present invention. Therefore, the present invention can include arbitrary components not shown in the following drawings. In addition, the dimensions of the members in the following drawings do not faithfully represent actual dimensions, dimensional ratios of the members, or the like.

<Embodiment 1>
FIG. 1 shows a patterned sheet 10 according to the first embodiment. The patterned sheet 10 of the present embodiment has a fiber base layer 11. The patterned sheet 10 has a first region 10A in which no film layer is provided on the fiber base layer 11, and a second region 10B in which one film layer is provided on the fiber base layer 11. . As an example, the patterned sheet 10 includes a plurality of first regions 10A and a plurality of second regions 10B, and each of the first region 10A and the second region 10B has a square shape. Each of the plurality of first regions 10A and the plurality of second regions 10B is arranged in a lattice pattern, and has a checkered pattern as a whole.

  Note that the first area 10A and the second area 10B form a checkered pattern as an example. For example, the first area 10A and the second area 10B have a striped pattern or a check pattern. A polka dot pattern, an animal pattern (leopard pattern, giraffe pattern, zebra pattern, etc.), a logo mark, an illustration, or the like may be configured. The same applies to the following embodiments.

  As shown in FIG. 2, the first region 10 </ b> A includes a fiber base layer 11. Moreover, the 2nd area | region 10B has the structure by which the fiber base material layer 11 and the film layer 12 were laminated | stacked, as shown in FIG.

(Fiber base layer 11)
Examples of the fiber base layer 11 include woven fabric, knitted fabric, and non-woven fabric. Examples of the woven fabric include plain weave, twill weave, satin weave, leopard weave, imitation weave, oblique pattern weave, double weave and the like. Examples of the knitted fabric include circular knitting, tricot, and russell. Examples of the nonwoven fabric include short fiber nonwoven fabric (dry nonwoven fabric, wet nonwoven fabric), long fiber nonwoven fabric, needle punch nonwoven fabric, papermaking nonwoven fabric, spunbond nonwoven fabric, melt blown nonwoven fabric, and electrospun nonwoven fabric.

  The material of the fiber constituting the fiber base layer 11 includes cotton, wool, hemp, silk, polyester fiber, polyamide fiber, polypropylene fiber, polyethylene fiber, polyaramid fiber, polyether ester fiber, and polyurethane fiber. Examples thereof include fiber, glass fiber, and carbon fiber. Examples of the polyester fiber include polyethylene terephthalate, polytrimethylene terephthalate, polytetramethylene terephthalate, polycyclohexylene dimethylene terephthalate, polyethylene-2,6-naphthalenedicarboxylate, polyethylene-1,2-bis (2 -Chlorophenoxy) ethane-4,4'-dicarboxylate and the like. Examples of the polyamide fiber include nylon 6, nylon 66, nylon 610, nylon 12, and the like.

  The fiber base layer 11 may have a configuration in which a plurality of knitted fabrics, woven fabrics, and nonwoven fabrics are laminated. For example, the form stability of the fiber base material layer 11 can be improved by laminating a nonwoven fabric and a woven fabric, or a nonwoven fabric and a knitted fabric.

  The fiber base layer 11 may be fluffed on the surface. Further, the fiber base layer 11 may be subjected to treatment such as water repellent finishing.

(Film layer 12)
The film layer 12 is composed of two layers of an adhesive layer 12a and a surface layer 12b.

  The adhesive layer 12a is made of, for example, a melt-adhesive resin such as a polyester-based, polyether-based, or polycarbonate-based thermoplastic polyurethane resin. Alternatively, the adhesive layer 12a is made of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), ethylene propylene terpolymer (EPDM), polyacrylonitrile butadiene styrene (ABS) resin, acrylic resin, polyvinylidene chloride (PVDC). It is formed of a resin obtained by mixing a resin such as a modified nylon resin and a melt-adhesive resin such as a thermoplastic polyurethane resin. The thickness of the adhesive layer 12a is preferably larger than the diameter of the fibers constituting the fiber base layer 11. For example, when microfiber or the like is used as the fiber base layer 11, the thickness of the adhesive layer 12a is preferably 0.1 μm or more. Further, from the viewpoint that the film layer 12 may be peeled off when the adhesive layer 12a becomes too thick, the thickness of the adhesive layer 12a is preferably 390 μm or less.

  The surface layer 12b is made of, for example, polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS), acrylonitrile butadiene styrene (ABS) resin, acrylonitrile styrene (AS) resin, acrylic resin, polymethacrylic acid. Methyl, polyvinyl alcohol (PVA), polyvinylidene chloride (PVDC), polyethylene terephthalate (PET), polycarbonate (PC), polysulfone (PSF), polyethersulfone (PES), polyarylate (PAR), polyetherimide (PEI) , Polyurethane (PU), polyether ether ketone (PEEK) and the like. The surface layer 12b may be formed of one kind among these, or may be formed using two or more kinds in combination. Among these, polyurethane is preferable as the resin constituting the surface layer 12b from the viewpoint of excellent properties such as flexibility. As the polyurethane, polyether polyurethane, polyester polyurethane, polycarbonate polyurethane, polymer polyol polyurethane and the like can be used. The surface layer 12b may be a single layer or may have a configuration in which a plurality of layers are laminated. The thickness of the surface layer 12b is, for example, 10 to 350 μm.

  The material constituting the surface layer 12b may be nonporous or porous. From the viewpoint that the texture of the patterned sheet 10 becomes flexible, the material constituting the surface layer 12b is preferably porous.

  The thickness of the film layer 12 is, for example, 20 μm to 400 μm. The thickness of the film layer 12 is preferably 20 μm or more, more preferably 40 μm or more, and further preferably 60 μm or more. When the thickness of the film layer 12 is less than 20 μm, the wear resistance of the film layer 12 is low, and the appearance may be deteriorated due to wear. Moreover, when the thickness of the film layer 12 is less than 10 μm, the film layer 12 may be buried between the fibers of the fiber base layer 11 and a desired appearance may not be obtained. On the other hand, the thickness of the film layer 12 is preferably 400 μm or less, and more preferably 350 μm or less. When the thickness of the surface layer 12b is larger than 400 μm, the flexibility of the patterned sheet 10 as a whole may be impaired. When the thickness of the film layer 12 is larger than 400 μm, the difference in thickness between the region where the film layer 12 does not exist (first region 10A) and the region where the film layer 12 exists (second region 10B) becomes large. The film layer 12 may be easily peeled off.

  The film layer 12 contains a crosslinking agent, a protein (collagen, fibroin, etc.), an antioxidant, a weathering agent (ultraviolet absorber, etc.), a pigment, a dye, a flame retardant, a water repellent as necessary. May be.

  A textured pattern 12c is formed on the surface of the surface layer 12b. The wrinkle pattern 12c is a pattern formed by unevenness as seen on the surface of natural leather, for example. The size of the unevenness of the embossed pattern 12c (projection height of the convex portion when the concave portion is used as a reference) is, for example, 0.01 to 100 μm. Since the textured pattern 12c is formed on the surface of the film layer 12, the textured sheet 10 has a three-dimensional appearance, and can have a high-class feeling by approaching the appearance of natural leather. As will be described later, the embossed pattern 12 c is formed using a textured release paper.

  In FIG. 2, for convenience, the concave and convex portions constituting the embossed pattern are indicated by reference numerals 12 c in the concave portions, but in actuality, the pattern configured as the entire irregularities is referred to as the embossed pattern.

  The patterned sheet 10 having the above-described configuration is suitably used for, for example, clothing, furniture, automobile interior sheets, miscellaneous goods, and the like.

(Method for producing patterned sheet)
Prior to the description of the manufacturing method, a manufacturing apparatus used for manufacturing a patterned sheet will be described. The manufacturing apparatus 100A shown in FIG. 3 is a roll-to-roll apparatus including a release paper supply roller 141 and a release paper take-up roller 142. The manufacturing apparatus 100A includes a resin coating unit 143, a coater 144, a drying unit 145, a resin coating unit 146, a coater 147, and a drying unit 148 from the upstream side.

  A manufacturing apparatus 100B illustrated in FIG. 4 includes a release paper supply roller 151, an intermediate roller 152, a release paper take-up roller 153, and a plotter 154. The manufacturing apparatus 100B is a roll-to-roll system apparatus. The plotter 154 is provided above the intermediate roller 152. The plotter 154 is, for example, a device used to make a sticker by cutting a cutting sheet based on computer data. The plotter 154 has a cutter 155. The cutter 155 is disposed so that the blade faces the intermediate roll 152.

(Step S4)
A manufacturing apparatus 100C shown in FIG. 5 includes a fiber base layer supply unit 101, a film layer supply unit 102, a pair of pressure rollers 103, a heating roller 104, a pressure roller 105, a release paper recovery unit 106, and a winding unit 107. including. The fiber base layer 11 prepared in step S1 is wound around the fiber base layer supply unit 101. Further, the release paper R3 with the film layer 12 produced in step S3 is wound around the film layer supply unit 102.

  Next, a method for manufacturing the patterned sheet 10 will be described. As shown in FIG. 6, the manufacturing process of the patterned sheet 10 includes a step of preparing the fiber base layer 11 (step S1), a step of preparing the resin solution (step S21), and a step of preparing the release paper R (step). S22), the process (step S3) of producing the film layer 12, and the process of bonding the film layer 12 (step S4) are included.

(Step S1)
First, in step S1, the fiber base material layer 11 is prepared. As described above, the fiber base layer 11 may be a woven fabric, a knitted fabric, or a non-woven fabric. If necessary, the fiber base layer 11 is subjected to fluffing, water repellent processing, pressing, and the like.

(Steps S21 and S22)
Independently of step S1, in step S21, an adhesive layer resin solution to be the adhesive layer 12a and a surface layer resin solution to be the surface layer 12b are prepared.

  In addition, independent from step S1 and step S21, in step S22, a release paper R having a texture pattern on the surface is prepared. The release paper R only needs to have a texture pattern on at least one surface (first surface). The embossed pattern formed on the surface of the release paper R has a pattern opposite to the embossed pattern 12 c to be formed on the surface of the patterned sheet 10.

(Step S3)
Next, in step S3, the film layer 12 (surface layer 12b and adhesive layer 12a) is formed on the surface of the release paper R. Step S3 for forming the film layer 12 includes a step of applying a surface layer resin solution (step S31), a step of drying it (step S32), a step of applying an adhesive layer resin solution (step S33), It includes a step of drying (step S34), a step of cutting into the film layer (step S35), and a step of removing unnecessary portions of the film layer (step S36). In steps S31 to S34, the manufacturing apparatus 100A shown in FIG. 3 is used. In step S35, the manufacturing apparatus 100B shown in FIG. 4 is used.

  The step S3 will be described in detail. First, the release paper R is wound around the release paper supply roller 141 and the release paper take-up roller 142 of the manufacturing apparatus 100A. In step S31, the coating unit 143 applies the prepared surface layer resin solution to the surface of the release paper R. When the release paper R has a texture pattern only on the first surface of the release paper R, a resin solution is applied to the first surface of the release paper R. At this time, for example, the resin solution for the surface layer is applied using an inkjet method. The surface layer resin solution applied in the application unit 143 is adjusted in the coater 144 so as to have a uniform thickness. In step S32, in the drying unit 145, the applied surface layer resin solution is heated and dried for a predetermined time to form the surface layer 12b.

  Subsequently, in step S33, the application unit 146 applies an adhesive layer resin solution to be the adhesive layer 12a to the surface of the surface layer 12b. At this time, the resin material is applied using, for example, an inkjet method. The adhesive layer resin solution applied in the application unit 146 is adjusted in the coater 147 so as to have a uniform thickness. In step S34, the applied resin solution for the adhesive layer is dried by heating for a predetermined time in the drying unit 148 to form the adhesive layer 12a. As a result, as shown in FIG. 7, the film layer 12 is formed on the entire surface of the release paper R (the release paper R in this state will be described with reference to “release paper R1”). As shown in FIG. 3, the release paper R <b> 1 is taken up by the release paper take-up roller 142.

  Next, as shown in FIG. 4, the release paper R1 is wound around the release paper supply roller 151, the intermediate roller 152, and the release paper take-up roller 153 of the manufacturing apparatus 100B. In step S35, the film layer 12 of the release paper R1 passing through the intermediate roller 152 is cut along the pattern frame by the plotter 154 so that the film layer 12 has a desired pattern. In step S35, the film layer 12 may be manually cut using a cutter knife without using the manufacturing apparatus 100B.

  After passing through the intermediate roller 152, the film layer 12 on the release paper R1 is in a state of being cut along a frame of an arbitrary pattern. The release paper R after passing through the intermediate roller 152 will be described with reference to “release paper R2”. In the intermediate portion 156 of the intermediate roller 152 and the release paper take-up roller 153, unnecessary portions (regions corresponding to the first region 10A of the patterned sheet 10) of the release paper R2 are removed (step S36). As a result, the film layer 12 is formed on the release paper R only in the second region 10B of the patterned sheet 10 (the release paper R in this state is described by the sign “release paper R3”). To do.) The release paper R3 is taken up by a release paper take-up roller 153 as shown in FIG.

  Hereinafter, bonding of the fiber base layer 11 and the film layer 12 using the manufacturing apparatus 100C will be described. The fiber base layer 11 fed from the fiber base layer supply unit 101 and the release paper R3 with the film layer 12 sent from the film layer supply unit 102 are, as shown in FIG. Sandwiched between. At this time, the surface of the release paper R3 on which the film layer 12 is formed contacts the fiber base layer 11. And both are crimped | bonded by a pair of crimping roller 103, and are united.

  Next, the fiber base layer 11 and the release paper R3 with the film layer 12 which are pressed and integrated with the pair of press rollers 103 are sent to the heating roller 104 and heated. The heating temperature at this time should just be the temperature which does not inhibit the texture of the surface of the fiber base material layer 11 to be used, and the texture of the fiber base material layer 11 itself, for example, 50-250 degreeC. Thereby, the adhesive layer 12a is melted and bonded to the fiber base layer 11, and the fiber base layer 11 and the film layer 12 are completely integrated.

  The fiber base layer 11 and the film layer 12 heated and bonded by the heating roller 104 are separated from the release paper R, the fiber base layer 11 and the film layer 12 through the pressure roller 105. The released release paper R is collected by the release paper collection unit 106. It is the sheet | seat 10 with a pattern which the laminated body of the remaining fiber base material layers 11 and the film layer 12 produced, and the sheet | seat 10 with a pattern is sent to the winding-up part 107 and wound up, as shown in FIG.

  In addition, in step S4, you may adhere | attach the fiber base material layer 11 and the film layer 12 using a press machine other than the manufacturing method demonstrated above, for example.

(Effect of Embodiment 1)
According to the patterned sheet 10 of the present embodiment, since the film layer 12 can be adhered to a predetermined portion of the fiber base layer 11 and an arbitrary design can be applied, the patterned sheet 10 having a high degree of freedom is provided. Can be obtained. In addition, since the texture layer 12c is formed on the surface of the film layer 12 that adheres to the second region 10B, the texture of the surface of the second region 10B can be designed to be an arbitrary texture. .

  Moreover, according to the sheet | seat 10 with a pattern of Embodiment 1, while the 2nd area | region 10B is covered with the film layer 12, the 1st area | region 10A is not covered with a film layer, but the fiber base material layer 11 is covered. Is exposed. Therefore, good breathability is obtained as the patterned sheet 10 as a whole. Since the patterned sheet 10 has good air permeability, it is suitable for use as, for example, an automobile seat cover.

  Furthermore, according to the patterned sheet 10 of Embodiment 1, since the second region 10B is formed by adhering the film layer 12 to the fiber base layer 11, two types of materials are present in the patterned sheet 10. In spite of the presence, the design can be seamless between the first region 10A and the second region 10B.

(Modification of Embodiment 1)
In the present embodiment, it has been described that the first region 10A of the patterned sheet 10 is not covered with the film layer and the second region 10B is covered with the film layer 12, but the second region 10B has two or more layers. It may be covered with a film layer. Even in this case, the effect of the present embodiment can be obtained.

  Moreover, two types of film layers may be adhere | attached as the film layer 12 adhere | attached on the 2nd area | region 10B of the patterned sheet | seat 10 of this embodiment. That is, a film layer may be provided in a part of the second region 10B, and another type of film layer may be provided in the remaining part of the second region 10B. In this case, a patterned sheet having a more complicated design than that of the present embodiment can be obtained.

<Embodiment 2>
Next, the patterned sheet 20 according to the second embodiment will be described. As an example, as shown in FIG. 8, the patterned sheet 20 includes a first area 20 </ b> A and a second area 20 </ b> B arranged in a lattice pattern, as in the patterned sheet 10 of the first embodiment. It has become.

  Similar to the first embodiment, the first region 20 </ b> A includes a fiber base layer 21 as shown in FIG. 9. Moreover, the 2nd area | region 20B has the structure by which the fiber base material layer 21 and the film layer 22 were laminated | stacked, as shown in FIG. The fiber base layer 21 has the same configuration as the fiber base layer 11 of the first embodiment.

(Film layer 22)
The film layer 22 is composed of a resin layer containing an adhesive component. Specifically, the film layer 22 is formed of a melt-adhesive resin such as a polyester-based, polyether-based, or polycarbonate-based thermoplastic polyurethane resin. Alternatively, the film layer 22 is made of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS), acrylonitrile butadiene styrene (ABS) resin, acrylonitrile styrene (AS) resin, acrylic resin, polymethacrylic acid. Methyl, polyvinyl alcohol (PVA), polyvinylidene chloride (PVDC), polyethylene terephthalate (PET), polycarbonate (PC), polysulfone (PSF), polyethersulfone (PES), polyarylate (PAR), polyetherimide (PEI) , Polyurethane (PU), polyether ether ketone (PEEK) and other resins and thermoplastic polyurethane resins and other melt-adhesive resins. In addition, from the point which has the outstanding softness | flexibility, it is preferable that the film layer 22 is formed with the polyurethane. The thickness of the film layer 22 is, for example, 10 to 350 μm.

  The patterned sheet 20 can be formed by the same method as the patterned sheet 10 of Embodiment 1 except that the film layer 22 is formed of a resin layer containing an adhesive component.

(Effect of Embodiment 2)
As described above, the thickness of the film layer 22 is composed of a resin layer containing an adhesive component. For this reason, the film layer 22 does not include an independent adhesive layer as in the first embodiment, and the total thickness of the film layer 22 can be formed smaller than the thickness of the film layer 12 in the first embodiment. Become. Therefore, the difference in thickness between the first region 20A and the second region 20B is smaller than that in the first embodiment. As a result, the step on the surface of the patterned sheet 20 at the boundary between the first region 20A and the second region 20B is small, and a natural tactile sensation is obtained.

  Other effects obtained by the patterned sheet 20 are the same as those of the first embodiment.

<Embodiment 3>
Next, the patterned sheet 120 according to the third embodiment will be described. The patterned sheet 120 has the same configuration as the patterned sheet 20 of the second embodiment. That is, as an example, as shown in FIG. 10, the patterned sheet 120 has the first region 120 </ b> A and the second region 120 </ b> B arranged in a lattice pattern as in the patterned sheet 10 of the first embodiment. It is a checkered pattern.

  In addition, as in the first embodiment, the first region 120A includes a fiber base layer 121 as shown in FIG. In addition, the second region 120B has a configuration in which a fiber base layer 121 and a film layer 122 are laminated as shown in FIG. The fiber base layer 121 and the film layer 122 have the same configuration as the fiber base layer 21 and the film layer 22 of the second embodiment.

(Method for producing patterned sheet 120)
Prior to the description of the method for manufacturing the patterned sheet 120, a manufacturing apparatus used for manufacturing the patterned sheet 120 will be described. FIG. 12 shows a manufacturing apparatus 200 used for forming the film layer 122 in the manufacturing process of the patterned sheet 120. A manufacturing apparatus 200 illustrated in FIG. 12 includes a release paper supply roller 201, a screen plate installation unit 202, a resin coating unit 203, a drying unit 204, and a release paper take-up roller 205. The release paper R prepared in step S22 is wound around the release paper supply roller 201 and the release paper take-up roller 205. In the screen plate setting unit 202, the screen plate P1 prepared in step S23 is set. The resin coating unit 203 is provided in the vicinity of the screen plate P1 installed in the screen plate installation unit 202. The process of forming the film layer 122 using the manufacturing apparatus 200 includes a process of screen printing a resin solution (Step S301) and a drying process (Step S302).

  Next, a method for manufacturing the patterned sheet 120 will be described. As shown in FIG. 13, the manufacturing process of the patterned sheet 120 includes a step of preparing the fiber base layer 121 (step S1), a step of preparing the resin solution (step S21), and a step of preparing the release paper R (step). S22), a step of preparing a screen plate (step S23), a step of producing the film layer 122 (step S30), and a step of bonding the film layer 122 (step S4).

(Step S1)
First, in step S1, the fiber base material layer 121 is prepared. As described above, the fiber base layer 121 may be a woven fabric, a knitted fabric, or a non-woven fabric. If necessary, the fiber base layer 121 is subjected to fluffing, water repellent processing, pressing, or the like.

(Steps S21, S22, S23)
Independently of step S1, a resin solution is prepared in step S21. This resin solution constitutes the film layer 122. The resin solution contains an adhesive component. The viscosity of the resin solution prepared here is, for example, 2 to 70 Pa · s. Further, the Ti value (thixotropic index) of the resin solution is preferably 1.5 or more. Here, the Ti value is a parameter including the time dependency of the viscosity of the substance. Specifically, the Ti value is measured by using a rotational viscometer to measure the viscosity at a predetermined speed and 1/10 of the predetermined speed using the same rotor, and the measured value at the speed of 1/10 is measured at the predetermined speed. The value divided by the measured value. When the Ti value of the resin solution is lower than 1.5, the applied resin solution flows, and the film layer may not be formed into a desired pattern. Further, when the concentration of the resin solution at a predetermined speed is higher than 70 Pa · s, there is a possibility that bubbles are generated in the coating film.

  In addition, independent from step S1 and step S21, in step S22, a release paper R having a texture pattern on the surface is prepared. The release paper R only needs to have a texture pattern on at least one surface (first surface). The embossed pattern formed on the surface of the release paper R has a pattern opposite to that of the embossed pattern 122 c to be formed on the surface of the patterned sheet 120.

(Step S23)
In addition, independently of step S1, step S21 and step S22, a screen plate P1 is prepared in step S23. As the screen plate, for example, a flat screen plate P1 is prepared. The screen plate P1 is provided with a region where the resin can permeate from one surface to the opposite surface and a region where the resin cannot permeate. The region where the resin can permeate is arranged so as to coincide with an arbitrary pattern forming the resin.

  The structure of the screen plate P1 will be described. The screen plate P1 includes a screen plate body and a coating layer. A plurality of holes are formed on the entire surface of the screen plate body to form a mesh structure. The coating layer is formed on the surface of the mesh structure of the screen plate body. The coating layer is formed on a part of the surface of the screen plate body. The region where the coating layer is formed on the surface of the screen plate main body constitutes a region where the mesh holes of the screen plate main body are blocked and the resin cannot penetrate. The coating layer is formed of, for example, a photocurable resin.

  An example of a method for producing the screen plate P1 will be described. First, a portion of the surface of the screen plate body having a plurality of mesh holes on the surface is covered with a mask. Here, the region covered with the mask corresponds to an arbitrary pattern to be formed. And a photocurable resin is apply | coated to the area | region which was not covered with the mask. After applying the photocurable resin, the photocurable resin is irradiated with ultraviolet rays. As a result, a coating layer having a pattern opposite to an arbitrary pattern to be formed is formed. Finally, by removing the mask, a resin permeation region corresponding to an arbitrary pattern to be formed appears. In this way, the screen plate P1 is obtained.

  The resin permeation region of the screen plate P1 can be automatically formed in an arbitrary design using a computer.

  It is also possible to peel the coating layer from the once produced screen plate P1 and reuse the screen plate body.

(Step S30)
In step S301, the resin application unit 203 applies a resin solution to the release paper R via the screen plate P1. That is, the resin solution is screen-printed on the release paper R. As a result, the resin solution can be applied so that the resin reaches the release paper R only from the region where the resin can permeate in the screen plate P1, and forms an arbitrary pattern.

  The release paper R on which the resin solution is screen-printed in step S301 is sent to the drying unit 204 of the manufacturing apparatus 200. In step S302, the applied resin solution is heated and dried for a predetermined time. Thereby, the film layer 122 is formed in a partial region of the release paper R (a region corresponding to the second region 120B of the patterned sheet 120). Finally, the release paper R on which the film layer 122 is formed is collected by the release paper take-up roller 205.

(Step S4)
Subsequently, in step S <b> 4, the film layer 122 is transferred from the release paper R to the surface of the fiber base layer 121. Here, an apparatus similar to the manufacturing apparatus 100C described in the first embodiment can be used.

  Hereinafter, bonding of the fiber base layer 121 and the film layer 122 using the manufacturing apparatus 100C will be described. First, the fiber base layer 121 is set in the fiber base layer supply unit 101. Further, the release paper R collected by the release paper take-up roller 205 in step S30 is set in the film layer supply unit 102. The fiber base layer 121 sent out from the fiber base layer supply unit 101 and the release paper R with the film layer 122 sent out from the film layer supply unit 102 are sandwiched between a pair of pressure rollers 103. At this time, the surface of the release paper R on which the film layer 122 is formed contacts the fiber base layer 121. And both are crimped | bonded by a pair of crimping roller 103, and are united.

  Next, the fiber base layer 121 and the release paper R with the film layer 122 which are pressed and united by the pair of press rollers 103 are sent to the heating roller 104 and heated. The heating temperature at this time may be a temperature that does not hinder the texture of the fiber base layer 121 to be used or the texture of the fiber base layer 121 itself, and is, for example, 50 to 250 ° C. Thereby, the adhesive component contained in the film layer 122 melts and adheres to the fiber base layer 121, and the fiber base layer 121 and the film layer 122 become completely integrated.

  The fiber base layer 121 and the film layer 122 that are heated and bonded by the heating roller 104 are separated from the release paper R through the pressure roller 105. The released release paper R is collected by the release paper collection unit 106. It is the sheet | seat 120 with a pattern which the laminated body of the remaining fiber base material layer 121 and the film layer 122 produced, and the sheet | seat 120 with a pattern is sent to the winding-up part 107, and is wound up.

(Effect of Embodiment 3)
According to the present embodiment, since the film layer 122 is formed to have an arbitrary pattern by screen printing, the film layer corresponding to the unnecessary portion (first region 120A) is peeled off from the release paper R. Work can be omitted. Therefore, when producing a patterned sheet, the yield can be improved.

(Modification of Embodiment 3)
In the third embodiment, it has been described that the release paper R having the film layer 122 formed on the surface thereof in the manufacturing apparatus 200 is collected by the release paper take-up roller 205 and set in the film layer supply unit 102 of the manufacturing apparatus 100C. As shown in FIG. 14, a manufacturing apparatus 300 in which the manufacturing apparatus 200 and the manufacturing apparatus 100C are integrated may be used. That is, the film layer 122 may be transferred to the fiber base layer 121 without the release paper R sent from the drying unit 204 being temporarily collected by a roller.

  In the third embodiment, it has been described that the manufacturing apparatus 200 includes one set of the screen plate installation unit 202 and the resin coating unit 203. However, the manufacturing apparatus 200 may include a plurality of sets of the screen plate installation unit 202 and the resin coating unit 203. Good. In this case, the plurality of screen plate installation parts 202 and the resin application part 203 are arranged in series. For example, when the manufacturing apparatus 200 includes three sets of the screen plate installation unit 202 and the resin coating unit 203, the red film layer 12 is formed on the release paper R in the first resin coating unit 203, and the second The yellow film layer 12 can be formed on the release paper R in the resin application portion 203, and the green film layer 12 can be formed on the release paper R in the third resin application portion 203. Thereby, the film layer 12 of a different color or a different material can be formed on the release paper R.

  Although the manufacturing apparatus 200 used in Embodiment 3 has been described as including the flat screen plate P1, the screen plate may have a shape other than the flat plate shape. For example, as shown in FIG. 15, it may be a cylindrical screen plate P2. In the example of the screen plate P2 shown in FIG. 15, the screen plate P2 has a flower pattern. The mesh of the screen plate body P2a is exposed at the petal portion of the floral pattern. In the region other than the petal portion of the floral pattern, the screen plate body P2a is covered with the coating layer P2b. Therefore, the screen plate P2 in FIG. 16 can transmit the resin solution from the inside of the cylinder to the outside in the petal portion of the flower pattern. As a result, the resin solution can be applied only to the petals of the floral pattern so as to obtain a pattern as shown in FIG. In addition, the broken line in FIG. 16 has shown the width | variety when the screen plate P2 makes one rotation.

  In addition, when the cylindrical diameter of the cylindrical screen plate is large, the pitch of the pattern to which the resin solution is to be applied (the distance between the broken lines shown in FIG. 16) can be increased.

  The manufacturing apparatus 200 described in the present embodiment may further include a screen plate making unit that makes a screen plate. FIG. 17 shows an example of the screen plate making unit 210. The screen plate making unit 210 includes an image reading unit 211, a mask forming unit 212, a mask fixing unit 213, a screen plate main body fixing unit 214, and a coating unit 215.

  The image reading unit 211 reads an arbitrary pattern to be formed on the patterned sheet into the computer. The mask forming unit 212 forms a corresponding mask based on the image data read by the image reading unit 211. The mask formed here has an opening having a shape corresponding to the pattern to be formed. The mask fixing unit 213 fixes the mask formed by the mask forming unit 212. The screen plate main body fixing unit 214 fixes the screen plate main body. The mask fixing unit 213 and the screen plate main body fixing unit 214 are arranged so that the mask fixed to the mask fixing unit 213 covers the screen plate main body fixed to the screen plate main body fixing unit 214. The coating unit 215 forms a coating layer on the surface of the screen plate main body fixed to the screen plate main body fixing unit 214 through the mask fixed to the mask fixing unit 213.

<Embodiment 4>
Next, the patterned sheet 30 according to the fourth embodiment will be described. As an example, as shown in FIG. 18, the patterned sheet 30 includes a first area 30 </ b> A and a second area 30 </ b> B arranged in a lattice pattern, as in the patterned sheet 10 of the first embodiment. It has become.

  As shown in FIG. 19, the first region 30 </ b> A includes a fiber base layer 31 and a first film layer 32. Further, as shown in FIG. 19, the second region 30 </ b> B has a configuration in which a fiber base layer 31, a first film layer 32, and a second film layer 33 are laminated. In other words, the patterned sheet 30 has a configuration in which the second film layer 33 is provided only in the second region 30 </ b> B on the sheet member 34 including the fiber base layer 31 and the first film layer 32.

(Sheet material)
As described above, the sheet member 34 has a configuration in which the fiber base layer 31 and the first film layer 32 are laminated. The fiber base layer 31 has the same configuration as the fiber base layer 11 of the first embodiment.

  As shown in FIG. 19, the first film layer 32 is formed of an adhesive layer 32a and a surface layer 32b. The adhesive layer 32a is made of the same material as the adhesive layer 12a of the film layer 12 of the first embodiment. The thickness of the adhesive layer 32a is, for example, 0.1 to 1000 μm. Moreover, the surface layer 32b is comprised with the material similar to the surface layer 12b of the film layer 12 of Embodiment 1. FIG. The thickness of the surface layer 32b is, for example, 10 to 400 μm. Moreover, as the 1st film layer 32 whole, it is 20-1400 micrometers, for example.

  A textured pattern 32c is formed on the surface of the surface layer 32b. In FIG. 19, for the sake of convenience, among the irregularities constituting the embossed pattern, the recesses are indicated by reference numeral 32c, but actually, the pattern constructed as the entire irregularities is referred to as an embossed pattern.

  Similar to the film layer 12 of the first embodiment, the second film layer 33 has a configuration in which an adhesive layer 33a and a surface layer 33b are laminated. The configurations of the adhesive layer 33a and the surface layer 33b are the same as those of the adhesive layer 13a and the surface layer 13b of the first embodiment. The thickness of the second film layer 33 is, for example, 20 to 400 μm.

  A texture pattern 33c is formed on the surface of the surface layer 33b. In FIG. 19, for the sake of convenience, among the unevenness constituting the texture pattern, the recess is denoted by reference numeral 33c, but in actuality, the pattern configured as the entire unevenness is referred to as a texture pattern. Since the wrinkle pattern 33c is formed on the surface layer 33b, a high-class feeling like natural leather can be obtained in both appearance and texture.

  The wrinkle pattern 33 c may be the same as or different from the wrinkle pattern 32 c formed on the surface layer 32 b of the first film layer 32. When the pattern of the texture pattern 33c of the second film layer 33 is different from the pattern of the texture pattern 32c of the first film layer 32, the texture pattern 32c and the texture pattern 33c are naturally discontinuous patterns. Even when the pattern of the texture pattern 33c of the second film layer 33 is the same as the pattern of the texture pattern 32c of the first film layer 32, when the second film layer 33 is adhered on the first film layer 32, the texture pattern Unless the alignment is performed so that 33c exactly overlaps the texture pattern 32c, the texture pattern 32c and the texture pattern 33c are discontinuous patterns.

  In the second region 30 </ b> B, even if the first film layer 32 is covered with the second film layer 33, the textured pattern 32 c of the first film layer 32 is formed in the lower layer of the second film layer 33. It has become. Accordingly, as shown in FIG. 19, in the cross-sectional view of the patterned sheet 30, the texture pattern 32c of the first film layer 32 can be observed also in the second region 30B.

(Method for producing patterned sheet 30)
Next, the manufacturing method of the patterned sheet 30 of Embodiment 4 is demonstrated. This manufacturing method is different in that the sheet member 34 is prepared instead of the fiber base layer 11 in step S1 of the manufacturing method of the patterned sheet 10 of the first embodiment. In step S <b> 1, a sheet member 34 in which the first film layer 32 is provided on the fiber base layer 31 is prepared. The sheet member 34 can be produced according to a conventionally known synthetic leather manufacturing method.

  Steps S2 to S4 are the same as those in the first embodiment. Thereby, the patterned sheet 30 is obtained.

(Effect of Embodiment 4)
According to the patterned sheet 30 of the present embodiment, the second film layer 33 can be adhered to a predetermined portion of the sheet member 34 and an arbitrary design can be applied. Therefore, the patterned sheet 30 having a high degree of freedom is provided. Can be obtained. Since the texture pattern 32c of the first film layer 32 and the texture pattern 33c of the second film layer 33c may be the same pattern or different from each other, the textured sheet 30 is formed by the method of this embodiment. By forming, the texture of the surface of the second region 30B can be arbitrarily designed independently of the first region 30A.

(Modification of Embodiment 4)
Although it has been described that the second film layer 33 includes the adhesive layer 33a and the surface layer 33b, the second film layer 33 is formed of a resin layer containing an adhesive component, like the film layer 22 of the second embodiment. Also good. In this case, the thickness of the adhesive layer 33a and the surface layer 33b can be made smaller than that of the second film layer 33, and a natural tactile sensation is also provided at the boundary between the first region 30A and the second region 30B. The patterned sheet 30 can be obtained.

  In the present embodiment, it has been described that the first region 30A of the patterned sheet 30 is covered with the first film layer 32 and the second region 30B is covered with the first film layer 32 and the second film layer 33. The first region 30 </ b> A may be covered with the first film layer 32, and the second region 30 </ b> B may be covered with three or more film layers including the first film layer 32 and the second film layer 33. Even in this case, the same effect as in the fourth embodiment can be obtained. However, by laminating two or more film layers on the first film layer 32 in the second region 30B, the difference in thickness between the first region 30A and the second region 30B increases. The second region 30B is preferably composed of two film layers.

  In the present embodiment, the first region 30A and the second region 30B of the patterned sheet 30 have been described as being covered with the common first film layer 32. However, the first region 30A and the second region 30B have been described. The film layer that covers the region 30 </ b> B in common may be two or more film layers including the first film layer 32. That is, in this case, the first region 30A is covered with two film layers, and the second region 30B is covered with three film layers.

<Embodiment 5>
In the first to third embodiments, the case where zero film layers are formed in the first regions 10A and 20A and one film layer 11 and 21 is formed in the second regions 10B and 20B is described in the fourth embodiment. Then, one film layer (first film layer 32) is formed in the first region 30A, and two film layers (first film layer 32 and second film layer 33) are formed in the second region 30B. Although cases have been described, the present invention is not particularly limited thereto. For example, the patterned sheet of the present invention may include a third region in which three or more film layers are laminated. Hereinafter, the patterned sheet 40 according to the fifth embodiment will be described. FIG. 20 is a plan view of the patterned sheet 40. FIG. 21 is a cross-sectional view of the patterned sheet 40 taken along the line XXI-XXI in FIG.

  The patterned sheet 40 has a fiber base layer 41. The patterned sheet 40 includes a first region 40A in which one film layer is provided on the fiber base layer 41, a second region 40B in which two film layers are provided on the fiber base layer 41, and And a third region 40C in which three film layers are provided on the fiber base layer 41.

  As shown in FIG. 21, the first region 40 </ b> A includes a fiber base layer 41 and a first film layer 42. In addition, as shown in FIG. 21, the second region 40B has a configuration in which the fiber base layer 41, the first film layer 42, and the second film layer 43 are laminated, or the fiber base layer 41, the first The film layer 42 and the third film layer 44 are stacked. Furthermore, as shown in FIG. 21, the third region 40C has a configuration in which a fiber base layer 41, a first film layer 42, a second film layer 43, and a third film layer 44 are laminated. In other words, the patterned sheet 40 is provided with the second film layer 43 or the third film layer 44 on the sheet member 45 including the fiber base layer 41 and the first film layer 42 in the second region 40B. It has a configuration. The patterned sheet 40 has a configuration in which the second film layer 43 and the third film layer 44 are provided on the sheet member 45 including the fiber base layer 41 and the first film layer 42 in the third region 40C. Have

  The sheet member 45 has the same configuration as the sheet member 34 of the fourth embodiment. Further, the second film layer 43 and the third film layer 44 have the same configuration as the second film layer 33 of the fourth embodiment. On the surfaces of the first film layer 42, the second film layer 43, and the third film layer 44, texture patterns 42c, 43c, and 44c are formed, respectively. The effects obtained by the patterned sheet 40 are the same as those of the patterned sheet 30 of the fourth embodiment.

<Embodiment 6>
In the modification of the third embodiment, a plurality of color resin solutions are applied to one release paper R by performing screen printing a plurality of times, thereby forming a plurality of color film layers 122 on the fiber base layer 121. Although it has been described that it can be formed, it is also possible to form a multi-color film layer on the fiber base layer by other methods.

  Hereinafter, the patterned sheet 140 according to the sixth embodiment will be described. The patterned sheet 140 includes a first area 140A and a second area 140B as shown in FIG. The second region 140B includes, for example, a red region 140Br, a yellow region 140By, and a green region 140Bg. Each of the red region 140Br, the yellow region 140By, and the green region 140Bg is formed in a rectangular shape, for example. Further, each of the red region 140Br, the yellow region 140By, and the green region 140Bg is disposed adjacent to each other. Note that the shape, color scheme, and arrangement of the second region 140B shown in FIG. 22 are examples of the present invention, and the present invention is not limited to these.

  As shown in FIG. 23, the patterned sheet 140 has a configuration in which a fiber base layer 141 and a film layer 142 are laminated. The film layer 142 has a configuration in which an adhesive layer 142a and a surface layer 142b are laminated. The film layer 142 is formed only in the second region 140B. That is, the fiber base layer 141 is not covered with the film layer 142 in the first region 140A. In the second region 140B, the fiber base layer 141 is covered with the film layer 142. The fiber base layer 141 and the adhesive layer 142a have the same configuration as that of the first embodiment.

  The surface layer 142b includes a red surface layer 142br, a yellow surface layer 142by, and a green surface layer 142bg. The red surface layer 142br is formed in the red region 140Br. The yellow surface layer 142by is formed in the yellow region 140By. The green surface layer 142bg is formed in the green region 140Bg. A texture pattern 142c is formed on the surface of each of the red surface layer 142br, the yellow surface layer 142by, and the green surface layer 142bg. The embossed pattern 142c formed on the surface of each of the red surface layer 142br, the yellow surface layer 142by, and the green surface layer 142bg is the same pattern. The texture pattern 142c formed on the surface of each of the red surface layer 142br, the yellow surface layer 142by, and the green surface layer 142bg is a continuous pattern.

  The patterned sheet 140 can be produced in the same manner as in Embodiment 1 except that three types of resin solutions, red, yellow, and green, are used as the resin solution applied onto the release paper R. Application | coating of each resin to the release paper R can be performed using the inkjet method, for example.

  According to this embodiment, the embossed pattern 142c has a shape according to the embossed pattern of one release sheet. Therefore, the texture pattern 142c formed on each color film layer 142 can have the same shape and a continuous shape despite having the plurality of color film layers 142. That is, it is possible to obtain a design with an increased degree of color freedom while maintaining the tactile sensation as if the surface of the patterned sheet 140 is a single material.

(Modification of Embodiment 6)
In Embodiment 6, as shown in FIG. 22, the patterned sheet 140 on which a plurality of color film layers 142 are formed may have the configuration shown in FIG. 24. That is, the film layer 142 may be composed of an adhesive layer 142a, a surface layer 142b, and a color layer 142d. The color layer 142d is provided in the upper layer of the surface layer 142b. The color layer 142d includes a red layer 142dr, a yellow layer 142dy, and a green layer 142dg. The color layer 142d can be formed, for example, by printing on the surface of the release paper R by an inkjet method or the like.

  In the sixth embodiment, the film layer 142 has been described as including the adhesive layer 142a and the surface layer 142b. However, the film layer 142 may be formed of a resin including an adhesive component as a single layer. That is, the film layer 142 may not have the adhesive layer 142a.

(Other variations)
In Embodiment 1 to Embodiment 6 described above, the wrinkle pattern is a pattern formed by unevenness as seen on the surface of natural leather, but the “wrinkle pattern” in the present invention is a film layer. This includes the case where the surface is not uneven, that is, the surface of the film layer is flat. For example, the “texture pattern” of the present invention also includes a pattern that represents a pattern formed by the unevenness seen on the surface of natural leather by processing the surface of the film layer with colored shading or surface texture. Therefore, it is not an essential requirement that the surface of the film layer has irregularities as described in the above embodiment, and the surface of the film layer may be flat. When the surface of the film layer is flat, a wrinkle pattern is formed on the surface of the film layer by, for example, processing of colored shading or surface texture.

  Further, in the above embodiment, the case where the wrinkle pattern is a pattern formed by unevenness as seen on the surface of natural leather has been described, but the “wrinkle pattern” in the present invention is a satin, geometric pattern, fine pattern It may represent a pattern, logo design, line, cloth pattern, wood grain, or the like.

  As mentioned above, embodiment mentioned above is only the illustration for implementing this invention. Therefore, the present invention is not limited to the above-described embodiment, and can be implemented by appropriately modifying the above-described embodiment without departing from the spirit thereof.

  The patterned sheet of the present invention includes a first region in which zero or more film layers having a wrinkle pattern on the surface are provided on the fiber base layer, and a film having a wrinkle pattern on the surface of the fiber base layer. A second region provided with one or more layers, and when two or more film layers are stacked among the first region and the second region, a texture pattern is formed on the surface of each layer. Is formed.

  The first region of the patterned sheet of the present invention may have zero film layers.

  When the film layer is 0 layer in the first region, the thickness of the film layer in the second region is preferably 20 to 400 μm.

  In the patterned sheet of the present invention, the first region may have one film layer, and the second region may have two film layers.

  When the first region has one film layer and the second region has two film layers, the thickness of the film layer in the first region is 20 to 1400 μm, and the second region Of the two film layers in the region, the thickness of the film layer provided on the surface is preferably 20 to 400 μm.

  The texture pattern formed on the surface of the first region of the patterned sheet of the present invention may be different from the texture pattern formed on the surface of the second region.

  The textile base layer of the patterned sheet of the present invention may be a woven fabric, a knitted fabric, or a nonwoven fabric.

  The method for producing a patterned sheet according to the present invention includes a first step of forming zero or more first film layers having a texture pattern on one surface of a fiber base layer, and a fiber base layer. A second step of forming one or more second film layers having a wrinkle pattern on a part of one surface or a part of the surface of the first film layer.

  The second step of the method for producing a patterned sheet according to the present invention includes a wrinkle pattern forming step of forming a wrinkle pattern on the surface of the second film layer, and one surface of the fiber base layer or the first film layer. It is preferable to include a bonding step of bonding the second film layer to a part of the surface.

  The embossed pattern forming step of the method for producing a patterned sheet of the present invention is preferably performed prior to the bonding step.

  In this case, in the method for producing a patterned sheet of the present invention, the second film layer having an arbitrary pattern is provided on the first surface of the release paper on which the texture pattern is formed in the texture pattern forming step. Thus, a texture pattern is formed on the surface of the release film side of the second film layer, and in the bonding step, the release of the second film layer is performed on one surface of the fiber base layer or the surface of the first film layer. It is preferable to adhere the second film layer by superimposing the surface opposite to the pattern paper side and transferring the second film layer to the fiber base layer or the first film layer.

  When the release paper is used in the embossed pattern forming process, the patterned sheet manufacturing method of the present invention includes the step of forming one or more second film layers on the first surface in the embossed pattern forming process; The second film layer may be formed on the release paper through a step of making the second film layer into an arbitrary pattern by removing a part of the second film layer formed in the above.

  Moreover, when using a release paper in a wrinkle pattern formation process, the manufacturing method of the sheet | seat with a pattern of this invention is by applying resin to the area | region used as arbitrary patterns among 1st surfaces in a wrinkle pattern formation process. The second film layer may be formed on the release paper.

  In this case, in the method for producing a patterned sheet of the present invention, it is preferable that the resin is applied to the first surface by using a screen printing method using a screen plate in the texture pattern forming step.

  When the screen printing method is used in the wrinkle pattern forming step, the screen plate used in the method for producing a patterned sheet of the present invention is intended to apply a resin to the screen plate body having a plurality of mesh holes and the surface of the screen plate body. It is preferable to have a coating layer formed so as to be a pattern opposite to an arbitrary pattern.

  In the wrinkle pattern forming step, when the second film layer is formed on the release paper by applying a resin to a region that becomes an arbitrary pattern in the first surface, in the method for producing a patterned sheet of the present invention The resin to be used preferably contains an adhesive component.

  An apparatus for producing a patterned sheet according to an embodiment of the present invention includes: a film layer forming unit that forms a film layer having a texture pattern by applying a resin to a part of the surface of a release paper having a texture pattern on the surface; And a film layer transfer section for adhering the film layer formed in the film layer forming section to the fiber base layer or the film layer formed on the fiber base layer and peeling the release paper.

  The apparatus for producing a patterned sheet according to another embodiment of the present invention includes a film layer forming part for forming a film layer on a part of a fiber base layer, and a texture pattern on the surface of the film layer formed by the film layer forming part. And a wrinkle pattern forming portion for forming

  Hereinafter, the patterned sheets (Examples 1 to 4) produced as examples of the present invention will be described in detail.

Example 1
A patterned sheet 50 was produced according to the method for producing the patterned sheet 10 of the first embodiment described above (see the flowchart of FIG. 6), and this was designated as Example 1. The formed patterned sheet 50 had a design in which a plurality of first regions 50A and second regions 50B were alternately arranged in stripes, as shown in FIG. FIG. 26 is a cross-sectional photograph of the patterned sheet 50.

Specifically, the fiber base layer 51 was prepared. As the cloth to be the fiber base layer 51, a raised composite short fiber nonwoven fabric having a length of 100 m and a width of 150 cm was prepared (corresponding to step S1 shown in FIG. 6). The fiber apparent density of this composite short fiber nonwoven fabric (apparent density measured according to the artificial leather test method for shoe uppers of JIS K 6550) was 0.23 g / cm ³ . The composite short fiber nonwoven fabric was padded with a silicone-based water repellent. Thereafter, the composite short fiber nonwoven fabric was dried using a dryer (manufactured by Ichikin Kogyo Co., Ltd., model number: IFT415) to obtain a fiber base layer 51. The obtained fiber base layer 51 had a water repellency evaluated by a water repellency test conducted according to JIS L 1092 as grade 2.

  Next, a surface layer resin solution to be the surface layer 12b and an adhesive layer resin solution to be the adhesive layer 12a were prepared (corresponding to step S21 shown in FIG. 6). As the resin solution for the surface layer, polycarbonate polyurethane (manufactured by DIC Corporation, trade name: Crisbon MP-865PS, solid content 30% by weight) 100 parts by weight, brown pigment (manufactured by DIC Corporation, trade name: Dirac brown, 30 parts by weight of solid content (70% by weight) and 210 parts by weight of dimethylformamide (DMF) were charged, and these were stirred and mixed to prepare a polymer elastic body solution (20 Pa · S) having a solid content concentration of 15% by weight. As the resin solution for the adhesive layer, 20 parts by weight of heat-bonding nonwoven fabric (manufactured by Toyobo STC Co., Ltd., trade name: LNS3010, melting point 100 ° C.) is dissolved in 80 parts by weight of methyl ethyl ketone (MEK), and the solid content is 20% by weight. An adhesive solution was prepared.

  Next, a release paper having a width of 155 cm (trade name: AR-64, manufactured by Lintec Corporation) was prepared. Of these, 200 m was taken and loaded into a film coating dryer (manufactured by Hirano Techseed Co., Ltd., type: PD-RF) (corresponding to step S22 shown in FIG. 6). The release paper had a textured pattern formed on the surface (the difference in thickness between the concave portion and the convex portion in the rough surface of the textured pattern was about 40 to 60 μm).

Next, the surface layer resin solution and the adhesive layer resin solution were applied while the film coating dryer was running at a running speed of 2 m / min (corresponding to step S3 shown in FIG. 6). The drying temperature of the film coating dryer at this time was 130 ° C. First, the resin solution for the surface layer was applied onto the release paper so as to have a solid content of 50 g / m ² to form a resin layer to be the surface layer 52b. Further, an adhesive solution of a hot-melt acrylic resin (melting temperature: 90 ° C.) was applied to form a resin layer to be the adhesive layer 52a.

  Next, a release paper on which a surface layer 52b and an adhesive layer 52a (film layer 52) were formed was attached to a cutting plotter (Mimaki Engineering Co., Ltd., model number: CG-160FXII). At this time, the surface layer 52b and the adhesive layer 52a (film layer 52) formed on the surface of the release paper were mounted so as to be a cut surface. Then, a slit-like pattern was cut along the roll axis direction of the release paper. The slit pattern had a slit width of 5 mm and a pitch of 20 mm. That is, the film layer 52 after being cut was divided into a state in which long portions having a width of 5 mm and a width of 15 mm were alternately arranged. Thereafter, a 5 mm wide portion was removed from the plurality of divided film layers 52. As a result, the film layers 52 having a width of 15 mm were arranged in a striped pattern at a pitch of 20 mm.

  Next, the fiber base layer 51 and the release paper were superposed using a thermo printer (Inoue Metal Industry Co., Ltd., type 1001), and the film layer 52 was transferred to the fiber base layer 51 (shown in FIG. 6). Equivalent to step S4). The running conditions at this time were felt tension: 0.6 MPa, heating temperature: 150 ° C., and running speed: 1 m / min.

  When the release paper was peeled off after the fiber base layer 51 was cooled, artificial leather was obtained in a striped pattern on the fiber base layer 51 in the region where the film layer 52 was adhered (second region 50B). On the surface of the region that is the artificial leather, a textured pattern 52c (the thickness difference between the recessed portion and the protruding portion in the textured unevenness is about 40 to 60 μm) was formed. On the other hand, in the area | region (1st area | region 50A) where the film layer 52 is not adhere | attached, the raising | fluff of the fiber base material layer 51 was exposed as it is.

  According to FIG. 26, it can be confirmed that the patterned sheet 50 has the first region 50A where the fiber base layer 51 is exposed on the surface and the second region 50B where the film layer 52 is exposed on the surface. Moreover, since the thickness in d1 and the thickness in d2 differ in the 2nd area | region 50B, it can also confirm that the film layer 52 has the embossed pattern 52c.

(Example 2)
The fiber base layer used in Example 1 was cut into a 40 cm × 30 cm rectangle. Moreover, the release paper (the one on which the resin laminate was formed) used in Example 1 was cut into a 40 cm × 30 cm rectangle. Then, these are laminated so that the surface on which the resin laminate of the release paper is formed is in contact with the fiber base material layer, and heated with an automatic press (Okuno Denki Sangyo Co., Ltd., model number: Oxan press AF-43T) Pressurized. The conditions at this time were heating temperature: 160 ° C. and heating time: 40 seconds.

  Also in Example 2 in which the resin laminate (film layer) and the fiber base layer were superposed using an automatic press machine, the fiber base layer (first region 50A) was striped as in Example 1. ) And synthetic leather (second region 50B) could be obtained in a patterned sheet.

(Example 3)
FIG. 27 is a cross-sectional photograph of the patterned sheet 60 of Example 3 of the present invention. The patterned sheet 60 includes a fiber base layer 61 and a film layer 62. The fiber base layer 61 is a woven fabric. The patterned sheet 60 of Example 3 was produced according to the same process as the patterned sheet 40 of Example 2.

  Even when the fiber base layer 61 is a woven fabric, the fiber base layer 61 (first region 60A) and the film layer 62 (second region 60B) are striped like the first embodiment. The patterned sheets 61 arranged alternately could be obtained.

Example 4
FIG. 28 is a cross-sectional photograph of the patterned sheet 70 of Example 4 of the present invention. The patterned sheet 70 includes a fiber base layer 71, a first film layer 72, and a second film layer 73. The fiber base layer 71 is a nonwoven fabric. The first film layer 72 is formed by laminating an adhesive layer 72a and a surface layer 72b, and a texture pattern 72c (pitch of the texture pattern 72c: about 400 μm) is formed on the surface of the surface layer 72b. The 2nd film layer 73 is formed with the resin layer containing an adhesive agent, and the wrinkle pattern 73c (pitch of the wrinkle pattern 73c: about 600-800 micrometers) is formed in the surface. The first film layer 72 was provided so as to cover the entire surface of the fiber base layer 71. The second film layer 73 was provided so as to cover only the second region 70B. The patterned sheet 70 of Example 4 was produced according to the same process as the patterned sheet 40 of Example 2.

  In Example 4, the patterned sheet 70 including the region where the first film layer 72 is exposed (first region 70A) and the region where the second film layer 73 is provided (second region 70B) is obtained. I was able to. That is, in one sheet 70 with a pattern, it was possible to obtain a sheet 70 with two different kinds of wrinkle patterns 72c and 73c formed on the surface. In FIG. 28, the thickness of the first film layer 72 is different between the thickness indicated by d3 and the thickness indicated by d4. From this, it was confirmed that the textured pattern 72c of the first film layer 72 was also present on the surface of the first film layer 72 below the second film layer 73 in the second region 70B.

  The present invention can be used for a patterned sheet, a method for manufacturing a patterned sheet, and a manufacturing apparatus.

10, 20, 30 Patterned sheet 11, 21, 31 Fiber substrate layer 12, 22 Film layer 32 First film layer 33 Second film layer 12c, 22c, 32c, 33c Wrinkle pattern 10A, 20A, 30A First region 10B, 20B, 30B second area

Claims (3)

A sheet with a pattern,
A first region exposed on the surface of the patterned sheet of the upper surface of the fiber base layer;
A film layer that is disposed on a region different from the first region in the upper surface of the fiber base layer and that has irregularities for expressing a texture pattern on the surface of the patterned sheet is exposed. A second region,
Including
At the boundary between the first region and the second region, a contact surface is formed in which the film layer and the fiber base layer in the first region are in contact with each other,
The said contact surface is a sheet | seat with a pattern extended in the direction which looked at the said film layer from the said fiber base material layer in the said 2nd area | region. In the patterned sheet according to claim 1 ,
The patterned sheet having a thickness of the film layer of 20 μm to 400 μm. In the patterned sheet according to claim 1 ,
The patterned sheet | seat whose said fiber base material layer is a textile fabric, a knitted fabric, or a nonwoven fabric.