JP6559384B1 - Method for producing synthetic resin skin material - Google Patents

Abstract

A step of forming a laminate for forming a skin material, having a base fabric, and an adhesive layer and a skin layer containing a resin having a softening point of 145 ° C. or higher on one surface of the base fabric in this order; With respect to the laminate for forming the skin material, an embossing roll having irregularities on the skin layer side, a backup roll on the base fabric side, and a heating temperature of the embossing roll are set to A (° C.), When the heating temperature of the backup roll is B (° C.), A and B are the conditions (I) [130 ° C. ≦ A ≦ 180 ° C.], the conditions (II) [180 ° C. ≦ B ≦ 250 ° C.] and the conditions ( III) Embossed under temperature conditions satisfying [softening point of resin contained in skin layer−15 ° C. ≦ A <softening point of resin contained in skin layer], Forming a recess having a distance of 250 μm or more from the top surface of the protrusion The manufacturing method of a synthetic resin skin material having a.

Description

  The present disclosure relates to a method for manufacturing a synthetic resin skin material.

Automotive interior parts such as instrument panels, door trims, seats, and ceilings, railroad and aircraft interior parts such as trims, seats, and ceilings, furniture, shoes, footwear, bags, interior and exterior components for construction, clothing cover materials and linings, walls Synthetic leather with excellent durability is often used as a material in place of natural leather and fiber sheets. Such synthetic leather has a concavo-convex pattern similar to natural leather on the outermost surface, that is, a grain pattern.
In recent years, as a synthetic leather used for automobile seats, chairs, etc., there is a demand for a three-dimensional skin material having deeper unevenness than a synthetic leather having shallow unevenness as a conventional leather-like texture pattern. .
In addition, for example, when used for automobile interior materials, long-term durability is required, and it is necessary to maintain a three-dimensional shape having deep irregularities for a long period of time. A synthetic resin skin material having deep irregularities is generally provided with a thick urethane foam layer as a cushion layer and a layer having deep irregularities formed by embossing the formed urethane foam layer. However, when the urethane foam layer is thickened for the purpose of forming deep irregularities, in the case of an automobile sheet or the like, the scratch resistance is inferior due to the deep irregularities, and the durability may not be sufficient.

As a skin material having deep unevenness, for example, a method of producing an uneven skin material that can form an uneven pattern deeply and clearly and does not deform unevenly even when used for a long time, has a constant load elongation of 2%. After obtaining a laminated sheet by laminating and integrating a flexible polyurethane foam material having specific physical properties on the outer surface of ˜50%, a large number of laminated sheets and embossed parts are projected between a pair of upper and lower heating plates. There has been proposed a method in which a hot pressing is performed by arranging a mold (see Japanese Patent Application Laid-Open No. 2003-326598).
In addition, the surface of the long material is pressed between the heated embossing roll and the receiving roll of the embossing roll so that the long material is allowed to pass through and is formed so as to stand from the base surface of the embossing roll. Thus, when forming an embossed pattern on the surface of the long material, a method for producing the long material is proposed in which embossing is performed under the condition that the surface of the long material convex portion does not contact the base surface of the embossing roll ( JP, 2013-59881, A).
As a method for producing a skin material that does not impair the appearance, the laminated sheet is passed between a heated embossing roll having a stamped portion protruding on the base surface and a heat roll disposed to face the heated embossing roll, The cushion material is compressed by heating to form a recess shape on the back surface of the laminated sheet, and a recess is formed at a position corresponding to the recess shape on the outer surface so as to be pulled by the compressed cushion material in the recess shape. A forming method has been proposed (Japanese Patent Laid-Open No. 2006-147432). Here, as the heating temperature condition, the heating temperature of the heat roll is higher than the softening point temperature of the synthetic resin included as a main component in the cushion material and lower than the melting temperature of the synthetic resin included as a main component in the cushion material. It is preferable to set.

However, the skin material obtained by the production method described in JP-A No. 2003-326598 is embossed on the side of the base fabric, and thus has excellent uneven shape retention, but the uneven shape is only a physical property of the base fabric. Therefore, there is a problem that it is deep and three-dimensional and the rugged R surface cannot achieve sharp design.
Moreover, in the manufacturing method described in JP2013-59881A, since the bottom surface of the embossing roll does not contact the long material, a shape defect due to heat can be prevented, but the technique described in JP2003-326598A Similarly, a skin material that is deep and three-dimensional and excellent in design has not been obtained.
In the method described in JP-A-2006-147432, it is necessary to adjust the compression conditions in order to form irregularities as designed, and the heating temperature of the heat roll is included as a main component in the cushioning material. By setting the temperature higher than the softening point temperature of the synthetic resin, the resin on the uneven shape side is softened, and it is difficult to form a sharp uneven shape.

  A problem to be solved by an embodiment of the present invention is that a synthetic resin skin material having a deep three-dimensional concavo-convex pattern, which can suppress the deformation of the concavo-convex pattern over time, and has a good durability can be obtained. It is providing the manufacturing method of a resin skin material.

Means for solving the above problems include the following embodiments.
<1> A step of forming a skin material-forming laminate having a base fabric, and an adhesive layer and a skin layer containing a resin having a softening point of 145 ° C. or higher on one surface of the base fabric in this order. And an embossing roll having irregularities on the skin layer side, a backup roll on the base fabric side, and a heating temperature of the embossing roll A (° C.). And when the heating temperature of the backup roll is B (° C.), A and B are embossed under temperature conditions satisfying the following conditions (I), (II) and (III), and the skin Forming a concave portion having a distance between the bottom surface of the concave portion and the top surface of the convex portion of 250 μm or more in the laminate for forming a material.
Condition (I): 130 ° C. ≦ A ≦ 180 ° C.
Condition (II): 180 ° C. ≦ B ≦ 250 ° C.
Condition (III): Softening point of resin contained in skin layer−15 ° C. ≦ A <Softening point of resin contained in skin layer

<2> The method for producing a synthetic resin skin material according to <1>, wherein the resin having a softening point of 145 ° C. or higher is a urethane resin.
<3> The method for producing a synthetic resin skin material according to <1> or <2>, wherein the base fabric includes synthetic fibers having a melting point of 150 ° C. or higher and 260 ° C. or lower.

<4> The surface layer further includes a step of forming a surface treatment layer containing a resin on the surface opposite to the adhesive layer side, and the resin contained in the surface treatment layer has a softening point, The manufacturing method of the synthetic resin skin material as described in any one of <1>-<3> which is resin higher than the softening point of resin contained in the said skin layer.
<5> The depth from which the bottom face of the recessed part formed by the embossing roll process reaches the inside of the base fabric laminated | stacked through the adhesive bond layer from the skin layer side of the said laminated body for skin material formation <1>- The manufacturing method of the synthetic resin skin material as described in any one of <4>.
<6> Prior to the embossing step, a step of forming a texture pattern in which the distance between the bottom surface of the concave portion and the top surface of the convex portion is 150 μm or less on the surface of the skin layer opposite to the adhesive layer side. The method for producing a synthetic resin skin material according to any one of <1> to <5>, further comprising:

<7> The method for producing a synthetic resin skin material according to any one of <1> to <6>, wherein the synthetic resin skin material is a dry resin skin material or a wet resin skin material.
<8> The method for producing a synthetic resin skin material according to <7>, wherein the synthetic resin skin material is a wet resin skin material, and further includes a step of buffing a skin layer in the wet resin skin material.
<9> In the thickness direction of the skin material forming laminate or the synthetic resin skin material, the skin material forming laminate or the synthetic resin skin with respect to the skin material forming laminate or the synthetic resin skin material. The method for producing a synthetic resin skin material composite according to any one of <1> to <8>, further comprising a step of drilling a plurality of holes penetrating the material.

  According to one embodiment of the present invention, a synthetic resin skin material having a deep three-dimensional concavo-convex pattern, in which deformation of the concavo-convex over time is suppressed, and a synthetic resin skin material having good durability can be obtained. A method can be provided.

It is a schematic sectional drawing which shows an example of the synthetic resin skin material obtained by the manufacturing method of the synthetic resin skin material of this indication. It is a schematic sectional drawing which shows an example of the synthetic resin skin material which has the fine uneven | corrugated pattern further on the surface obtained by the manufacturing method of the synthetic resin skin material of this indication.

In the present specification, a numerical range described using “to” represents a numerical range including numerical values before and after “to” as a lower limit value and an upper limit value.
In the numerical ranges described stepwise in this specification, the upper limit value or the lower limit value described in a numerical range may be replaced with the upper limit value or the lower limit value of another numerical range described. Further, in the numerical ranges described in this specification, the upper limit value or the lower limit value described in a certain numerical range may be replaced with the values shown in the examples.
In the present specification, a combination of preferred embodiments is a more preferred embodiment.
In this specification, the term “process” is not only an independent process, but is included in this term if the intended purpose of the process is achieved even when it cannot be clearly distinguished from other processes.
Further, in the present specification, the amount of each component in the composition is the total amount of the plurality of substances present in the composition unless there is a specific indication when there are a plurality of substances corresponding to each component in the composition. Means.
The “base fabric” in the present specification refers to a fabric (fabric) formed using fibers and used as a base material for a synthetic resin skin material. The “base fabric” in the present specification includes woven fabric, knitted fabric, and non-woven fabric.
In the present specification, a concavo-convex pattern formed on one surface of a skin layer, represented by a leather-like pattern, having a concave portion with a distance between the bottom surface of the concave portion and the top surface of the convex portion of 150 μm or less is referred to as a “texture pattern”. This is distinguished from a “deep concavo-convex pattern” which is formed by embossing and has a concave portion with a distance between the bottom surface of the concave portion and the top surface of the convex portion of 250 μm or more.

  Hereinafter, the manufacturing method of the synthetic resin skin material of this indication is demonstrated in detail. In addition, the following description shows an example of an aspect, It is not limited to these, A various modification example can be implemented unless it exceeds the main point.

[Method for producing synthetic resin skin material]
The synthetic resin skin material manufacturing method of the present disclosure (hereinafter sometimes simply referred to as “manufacturing method”) includes a base fabric, an adhesive layer on one surface of the base fabric, and a softening point of 145 ° C. or higher. Are formed in this order to form a skin material-forming laminate (step a), and the resulting skin material-forming laminate (hereinafter referred to as “laminate”). ), An embossing roll having irregularities on the skin layer side, a backup roll on the fabric side, and a heating temperature of the embossing roll A (° C.), and a heating temperature of the backup roll B ( C.) and embossing under a temperature condition in which A and B satisfy the following condition (I), condition (II) and condition (III) (step b), In the laminate for forming the skin material obtained in step a, The distance between the protrusion top surface is formed above the recess 250μm synthetic resin skin material is obtained.
Condition (I): 130 ° C. ≦ A ≦ 180 ° C.
Condition (II): 180 ° C. ≦ B ≦ 250 ° C.
Condition (III): Softening point of resin contained in skin layer−15 ° C. ≦ A <Softening point of resin contained in skin layer

Although the mechanism of action in the manufacturing method of the present disclosure is not clear, it is considered as follows.
The synthetic resin skin material manufactured by the manufacturing method of the present disclosure (hereinafter sometimes referred to as “skin material”) contains a resin having a softening point of 145 ° C. or higher in the skin layer. Undesirable deformation due to heat is suppressed. Here, with respect to the heating temperature of the embossing roll having unevenness used for embossing, the heating temperature of the backup roll is set to a higher condition, and the heating temperature of the embossing roll is the softening point of the resin contained in the skin layer. On the other hand, the embossing of a skin layer is performed favorably by setting it lower in a predetermined range. At the time of embossing, the laminated body is sufficiently heated from the base fabric side by heating on the backup roll side. Therefore, when deep irregularities are formed on the laminated body, the temperature on the base fabric side is sufficiently increased. For this reason, when the depth of the skin material, that is, the depth of the recess is 250 μm or more, more preferably, the depth of the recess is made larger than the thickness of the skin layer and the adhesive layer, and the bottom surface of the recess is the base fabric. It is considered that when the depth reaching the inside is sufficiently heated from the base fabric side, the formability of the recesses in the vicinity of the base fabric side is improved.

By achieving the above heating conditions, a three-dimensional shape with a recess with a distance between the bottom surface of the recess and the top surface of the protrusion of 250 μm or more is formed, making it easy to emboss deep shapes with sharpness and excellent design as designed. It is estimated that the obtained skin material is unlikely to deteriorate over time.
For this reason, even in a skin material that does not have a thick foamed resin layer that is usually used to form a deep three-dimensional shape, a skin material that is easily formed in a deep three-dimensional shape and has a thick foamed resin layer Compared to the above, it is considered that there is an advantage that deformation, deterioration, etc. over time are further suppressed.

Hereinafter, an example of a method for producing the synthetic resin skin material of the present disclosure will be described in detail with reference to the drawings. In addition, the component shown using the same code | symbol in each drawing means that it is the same component.
FIG. 1: shows the schematic sectional drawing which is an example of the synthetic resin skin material 10 obtained by the manufacturing method of the synthetic resin skin material which is one Embodiment of this indication.
The synthetic resin skin material 10 has an adhesive layer 16 and a skin layer 14 in this order on one surface of the base fabric 18. In FIG. 1, the surface treatment layer 12 located on the surface of the skin layer 14 opposite to the side in contact with the adhesive layer 16 is provided to improve the durability of the skin material 10 as will be described later. Any layer.
As shown in FIG. 1, the concave portion in the skin material 10 is formed with a depth of 250 μm or more between the concave bottom surface and the convex top surface. In the preferred embodiment shown as an example in FIG. 1, the bottom surface of the recess is deeper than the total thickness of the skin layer 14 and the adhesive layer 16 of the skin material 10, and the interface between the base fabric 18 and the adhesive layer 16. And a depth reaching the inside of the base fabric 18.
As shown in FIG. 1, the skin material 10 obtained by the manufacturing method of the present disclosure can be suitably a skin material having a deep uneven solid shape that reaches the inside of the base fabric 18.
In addition, the adhesive bond layer 16 is a layer which improves the adhesiveness of the base fabric 18 and the skin layer 14, and contributes to the shape-retaining property of the formed unevenness | corrugation so that it may mention later.

<Configuration of skin material>
(1. Skin layer)
The skin material obtained by the production method of the present disclosure contains a resin having a softening point of 145 ° C. or higher. The softening point of the resin is 145 ° C. or higher, preferably 150 ° C. or higher, and more preferably 160 ° C. or higher. Although there is no restriction | limiting in particular in the upper limit of a softening point, From a viewpoint of workability, it is suitable that it is 180 degrees C or less.
The softening point of the resin can be measured by a softening temperature test method (TMA analysis) described in JIS K 7196 (2012). Moreover, when using commercially available resin for formation of a skin layer, the softening point of the resin described in the catalog of commercially available resin, ie, a catalog value, is employ | adopted.
In the present disclosure, when two or more kinds of resins are used together as the resin contained in the skin layer or the like, the softening point of the resin contained in the skin layer is the softening point of the two or more kinds of resin mixture.

Examples of the resin having a softening point of 145 ° C. or higher included in the skin layer include a urethane resin, a vinyl chloride resin, an acrylic resin, a polyester, and a thermoplastic elastomer.
Since the skin layer is present on the surface opposite to the base material of the skin material, that is, in the vicinity of the surface that affects the appearance of the skin material, it is preferable that the touch, appearance, etc. are good in addition to workability. .
From such a viewpoint, urethane resin is preferable as the resin contained in the skin layer.
The urethane resin in the skin layer is not particularly limited except that the softening point is 145 ° C. or higher, and a known urethane resin can be used.

Examples of the urethane resin contained in the skin layer include polycarbonate polyurethane, polyether polyurethane, polyester polyurethane, and modified products thereof. Among these, when the skin layer obtained by the production method of the present disclosure is used for applications that require long-term durability, such as automobile interior materials and chairs, polycarbonate-based polyurethane is preferable.
A commercially available product may be used as the polyurethane. For example, Crisbon (registered trademark, hereinafter the same) NY-324 manufactured by DIC Corporation is preferably used.

The urethane resin contained in the skin layer has a hardness measured according to JIS K 6672 (1994) of 49 N / cm ^{2 to} 980 N / cm ² at 100% modulus and 196 N / cm ² at 100% modulus. A urethane resin of ˜588 N / cm ² is preferred.
In addition, as a method of adjusting the hardness (100% modulus) of the urethane resin, for example, in the case of softening, a method of increasing a polyol component ratio that becomes a soft segment or a method of increasing a molecular weight of the polyol can be given. It is done. Also, when making the urethane resin harder, increase the urethane bond and urea bond, which are hard segments, or hexamethylene diisocyanate (HDI), hydrogenated xylylene diisocyanate (hydrogenated XDI), isophorone diisocyanate (IPDI). And a method of adding a crosslinking agent such as dicyclohexylmethane diisocyanate (hydrogenated MDI) to impart energy to form a crosslinked structure.
The urethane resin can be appropriately selected from water-based polyurethane, solventless polyurethane, and solvent-based polyurethane.

The skin layer may contain only one type of resin or may contain two or more types.
For example, it may include only one type of urethane resin, may include a plurality of different urethane resins, or may include a urethane resin and another resin, such as a vinyl chloride resin, an acrylic resin, or a polyester.

  If desired, on the surface of the skin layer opposite to the adhesive layer side, an arbitrary fine uneven pattern such as leather can be provided in advance, a so-called squeezed pattern. The texture pattern in this specification refers to a concavo-convex pattern in which the depth of the concave portion is 150 μm or less.

FIG. 2 is a schematic cross-sectional view showing an example of a skin material in which a fine concavo-convex pattern, that is, a texture pattern, is provided in advance on the skin layer. In the example shown in FIG. 2, the synthetic resin skin material 20 has the adhesive layer 16 and the skin layer 24 in this order on one surface of the base fabric 18, and is in contact with the adhesive layer 16 of the skin layer 24. The surface opposite to the side has a fine uneven pattern. That is, the synthetic resin skin material 20 includes a skin layer 24 having a texture pattern. In the example of the skin material 20 shown in FIG. 2, the surface treatment layer 22 which is an arbitrary layer is provided on the surface of the skin layer 24 opposite to the side in contact with the adhesive layer 16. The surface treatment layer 22 in the synthetic resin skin material 20 shown in FIG. 2 has an appearance reflecting a texture pattern formed in advance on the skin layer 24.
When the skin material 20 shown in FIG. 2 is manufactured, a texture pattern which is a fine concavo-convex pattern is formed in advance on the skin layer 24 of the skin material 20, and then a deep concavo-convex pattern is formed by embossing as described later. Here, since the softening point of the resin contained in the skin layer 24 is 145 ° C. or higher, the retention of the texture pattern formed on the skin layer is improved, and the skin material having a deep uneven pattern formed by embossing The fine texture pattern formed on the 20 skin layers 24 is maintained after embossing. The deep concave portion in the skin material 20 has a distance between the bottom surface of the concave portion and the top surface of the convex portion of 250 μm or more, and preferably exceeds the interface between the adhesive layer 16 and the base fabric 18 as shown in FIG. It is formed with a depth reaching the inside of 18.
The skin material 20 obtained by the manufacturing method of the present disclosure in the example shown in FIG. 2 has a three-dimensional shape in which deep unevenness reaching the inside of the base fabric 18 is formed, and the surface treatment formed on the skin layer 24 A fine concavo-convex pattern, that is, a textured pattern, is observed through the layer 22, and the skin material is complicated and excellent in design.

To the skin layer, in addition to the resin as the main agent, known additives used for synthetic resin skin materials are added for the purpose of imparting various functions such as designability, touch improvement, and strength improvement, as long as the effect is not impaired. May be.
Examples of the additive that can be contained in the skin layer include a crosslinking agent, a crosslinking accelerator, a colorant, a feel improver, a film forming aid, a flame retardant, and a foaming agent.
For example, the design property of the obtained skin material improves because a skin layer contains a coloring agent. Moreover, the flame retardance improvement of a skin material can be aimed at by adding well-known flame retardants, such as phosphorus type | system | group, a halogen type | system | group, and an inorganic metal type, to a skin layer.

The thickness of the skin layer is appropriately selected according to the intended use of the synthetic resin skin material. Since the synthetic resin skin material of the present disclosure has deep recesses, the thickness of the skin layer is preferably in the range of 20 μm to 300 μm, more preferably in the range of 30 μm to 200 μm, from the viewpoint of workability when forming the recesses.
In addition, since the distance between the bottom surface of the concave portion and the top surface of the convex portion is 150 μm or less, the depth of the concave portion in the above-described grain pattern retains the grain pattern even when forming a three-dimensional shape having the above-described deep irregularities. Becomes better.

In addition, when forming a skin layer using a urethane resin, it may be formed by a dry method or a wet method.
The dry method in the present disclosure refers to a method in which a base fabric is not processed and is bonded to a skin layer containing a urethane resin, and the wet method is a method in which a wet base is formed after subjecting the base fabric to wet processing described below. , Refers to the method of bonding to the skin layer.
That is, the skin material obtained by the production method of the present disclosure may be a dry resin skin material or a wet resin skin material.
A skin material (that is, a dry resin skin material) in which a skin layer is formed by a dry method is lightweight and excellent in flexibility.
On the other hand, after the base fabric is impregnated with the resin, the skin material in which the skin layer is formed by a wet method in which the skin layer is bonded (that is, the wet resin skin material), the strength of the base fabric is improved by the impregnated resin, and When the through-hole described later is drilled, fraying of the base fabric is suppressed, and a soft tactile sensation is obtained by the porous layer formed by the resin impregnated in the base fabric.

(2. Adhesive layer)
The synthetic resin skin material obtained by the production method of the present disclosure has an adhesive layer between the base fabric and the skin layer. The adhesive layer improves the adhesion between the base fabric and the skin layer.
There is no restriction | limiting in particular in resin contained in an adhesive bond layer, ie, resin used as the main material of an adhesive agent or an adhesive, The resin for well-known adhesive agents or an adhesive can be used.
Especially, as resin contained in an adhesive bond layer, it is preferable that it is resin with a heat melting temperature of 160 degreeC or more, and it is more preferable that it is resin with a heat melting temperature of 180 degreeC or more.
Although there is no restriction | limiting in particular in the upper limit of the heat melting temperature of resin contained in an adhesive bond layer, It is preferable that it is 200 degrees C or less from a viewpoint of embossing property.
When the heat melting temperature of the resin contained in the adhesive layer is 160 ° C. or higher, when the laminate for forming the skin material is heated and embossed, the adhesive layer melts and penetrates into the base fabric. Reduction in texture of the material is suppressed. Moreover, the retention property of the formed deep uneven | corrugated pattern becomes more favorable because the heat melting temperature of resin contained in an adhesive bond layer is high.
The heat melting temperature is determined from the storage elastic modulus (E ′) in the dynamic viscoelasticity measurement of JIS K7244-4 (1999). Using a dynamic viscoelasticity measuring device, the storage elastic modulus of the sample resin is measured while changing the temperature. When the sample is heated above the softening point of the resin, the value of the storage elastic modulus (E ′) is large. The temperature at which the temperature drops is the heat melting temperature.

Examples of the resin that can be used for forming the adhesive layer include resins used for adhesives such as polyurethane, vinyl chloride resin, and acrylic resin.
More specifically, the adhesive layer is, for example, an adhesive such as (1) a two-component curable polyester adhesive, (2) a two-component curable polyurethane adhesive, and (3) a two-component curable acrylic adhesive. It is preferable to contain.
In addition, the adhesive agent used for formation of an adhesive bond layer is also available as a commercial item, for example, adhesive No. 3660 (trade name) [two-component curable polyurethane adhesive: No Tape Industry Co., Ltd.], Daikarak (registered trademark) 7250NT [two-component curable polyester adhesive: Daido Kasei Kogyo Co., Ltd.], Crisbon TA265 [two-component curing] Type polyether adhesive: DIC Corporation, Crisbon TA205 [polycarbonate polyurethane adhesive: DIC Corporation] and the like are suitable.

  The thickness of the adhesive layer is preferably in the range of 40 μm to 100 μm, and more preferably in the range of 50 μm to 90 μm. When the thickness of the adhesive layer is within the above range, the adhesion between the base fabric and the skin layer and the retention of the uneven pattern in the skin layer become better.

[3. Foundation)
There is no restriction | limiting in particular in the base fabric used for the skin material obtained by the manufacturing method of this indication, The base fabric used for a well-known synthetic resin skin material can be selected suitably, and can be used.
Examples of the base fabric include woven fabric, knitted fabric, and non-woven fabric. By using a base fabric as the base material of the skin material, the flexibility and strength of the obtained skin material are improved. Especially, when using a skin material for a vehicle interior material, a knitted fabric is suitable.
The knitted fabric may be a single-sided knitted fabric, a double-sided knitted fabric, or a pile fabric. Further, the knitted fabric that can be used for the base fabric may be subjected to raising.

The base fabric preferably contains fibers.
The fiber contained in the base fabric is not particularly limited as long as it has necessary strength and flexibility.
The fiber used for the base fabric can be appropriately selected depending on the purpose of use of the synthetic resin skin material. For example, the stretchability of the base fabric is further improved by including polyurethane fibers as part of the fibers used for the knitted fabric of the base fabric. Moreover, the intensity | strength of a base fabric improves more by including a polyester fiber, Kevlar fiber, etc.
From the viewpoint of good flexibility and strength, the fibers contained in the base fabric include polyester, rayon, hemp, cotton, vinyl chloride, vinylidene chloride, aramid, acrylic, phenol, polyurethane, carbon-based fibers, etc. , And blended fibers obtained by combining two or more of the above fibers.
Especially, it is preferable that a polyester fiber is included as a fiber from a viewpoint that durability, a softness | flexibility, and embossing workability are favorable and it is low-cost.

From the viewpoint of better embossability and retainability of deep concavo-convex patterns formed by embossing, the base fabric preferably contains synthetic fibers having a melting point of 150 ° C. or higher and 260 ° C. or lower.
As the polyester fiber when the base fabric includes polyester fiber, for example, any of general-purpose type polyester fiber having a melting point of 255 ° C. to 260 ° C. and low-melting type polyester fiber having a melting point of 150 ° C. to 200 ° C. is preferably used. it can.

  The thickness of the base fabric is appropriately selected according to the intended use of the skin material. The skin material obtained by the production method of the present disclosure preferably has a deep recess reaching the inside of the base fabric, and therefore the thickness of the base fabric is preferably in the range of 0.5 mm to 2.0 mm. A range of 0.8 mm to 1.5 mm is more preferable.

When forming a wet resin skin material, first, impregnate the base fabric with the resin solution, replace the solvent and water in the resin solution, and dry to form a wet skin material with a porous structure. Can be obtained.
As the resin used for impregnating the base fabric in the wet method, polyurethane is preferable. Examples of the polyurethane include polycarbonate polyurethane, polyether polyurethane, and polyester polyurethane. As the resin used for impregnation of the base fabric in the wet method, polycarbonate-based polyurethane is preferred from the viewpoint of hydrolysis resistance, heat deterioration resistance, and the like.

The resin solution to be impregnated into the base fabric can contain various components as required in addition to the resin and solvent as the main agent.
For example, the flame retardance of a skin material improves because a resin solution contains a flame retardant.
Examples of the flame retardant include organic flame retardants, such as phosphorus flame retardants, nitrogen-phosphorus flame retardants, and halogen flame retardants.
The resin solution may contain a colorant, a leveling agent, and the like, for example.

[4. Other layers]
In addition to the skin layer, the adhesive layer and the base fabric, the skin material obtained by the production method of the present disclosure may further include other layers as long as the effects are not impaired.
Examples of the other layer include a layer having a function of controlling at least one of surface physical properties and appearance of the skin layer, such as a surface treatment layer, an intermediate layer, and an intermediate foam layer.

(Surface treatment layer)
The surface treatment layer is a layer provided on the surface of the skin layer opposite to the base fabric side (sometimes referred to as the surface of the skin layer). The surface treatment layer preferably includes a urethane resin, an acrylic resin, a fluororesin, and the like, more preferably includes a urethane resin, from the viewpoint that the strength, durability, and unevenness retention of the skin layer can be further improved. .
The resin contained in the surface treatment layer is preferably a resin having a heat melting temperature of 180 ° C. or higher, and a heat melting temperature of 185 ° C. or higher, from the viewpoint that deterioration of appearance due to gloss change during heat embossing is suppressed. It is more preferable that the resin. Although there is no restriction | limiting in particular in the upper limit of heat melting temperature, It is preferable that it is 200 degrees C or less from a viewpoint of embossing property.
By forming the surface treatment layer on the surface of the skin layer, the appearance is further improved.
In addition to the resin, the surface treatment layer can contain a crosslinking agent, an organic filler, silica, a lubricant, a flame retardant, and the like. For example, when the surface treatment layer contains an organic filler, a lubricant, etc., a smooth feel is imparted to the skin material, and the abrasion resistance of the skin material is further improved.
When the skin material has a surface treatment layer, the thickness of the surface treatment layer is preferably 2 μm to 10 μm, and more preferably 3 μm to 8 μm.

<Each process of manufacturing method of skin material>
Next, the manufacturing method of the present disclosure that can form the skin layer as described above will be described in the order of steps.
[Step a]
Step a includes a base fabric, an adhesive layer on one surface of the base fabric, and a skin layer containing a resin having a softening point of 145 ° C. or higher and preferably a softening point of 180 ° C. or lower in this order. It is the process of forming and forming the laminated body for skin material formation.
Here, the material used for forming each layer and the thickness of each layer are as described above.
There is no restriction | limiting in particular in the formation method of a skin layer. For example, a composition layer for forming a skin layer can be formed by applying the composition for forming a skin layer to a release-treated surface of a release material that has been subjected to a release treatment on at least one side. The composition layer for forming a skin layer thus obtained is laminated on a base fabric coated with an adhesive, whereby a skin layer is formed on the base fabric via an adhesive layer. A laminate can be obtained.
As the base fabric, one manufactured in advance in a separate step may be used, or a commercially available product may be used.

The process a will be described in more detail by taking as an example the case of using a urethane resin for the formation of the skin layer.
The polyurethane in the composition for forming a skin layer may be used alone or in combination of two or more. For example, a polycarbonate-based polyurethane, which is a preferred polyurethane, and a polyurethane other than the polycarbonate-based polyurethane may be used in combination.

As the water-based polyurethane, a polyether- or polycarbonate-based water-based polyurethane homopolymer or a mixture or copolymer of a polyether-based polyurethane and a polycarbonate-based polyurethane may be used as a part of the molecular chain of the urethane main agent. Polyurethane into which carboxyl groups of 0.01% to 10%, preferably 0.05% to 5%, more preferably 0.1% to 2% are introduced by mass ratio with respect to the main agent. When a carboxyl group is introduced in the mass ratio range described above, the water-based polyurethane can have sufficient water dispersibility and dry film formability due to the presence of the carboxyl group.
Examples of the solvent-based polyurethane include at least one solvent-based polyurethane selected from the group consisting of polycarbonate-based polyurethane, polyether-based polyurethane, polyester-based polyurethane, and modified products thereof that are soluble in an organic solvent. The solvent-based polyurethane may be a one-component system or a two-component system.

From the viewpoint that the film strength of the formed skin layer becomes better, the cured polyurethane preferably has a crosslinked structure.
For example, an embodiment in which a crosslinked structure is introduced into an aqueous polyurethane includes, for example, a composition for forming a skin layer, in which the composition for forming a skin layer includes a resin in which a carboxyl group is introduced into a main polyurethane agent and a crosslinking agent. In the skin layer obtained by using a carboxylic acid, the carboxyl group and the crosslinking agent react to form a crosslinked structure, whereby a skin layer having a crosslinked structure can be obtained.
Examples of the crosslinking agent that can be used in the composition for forming the skin layer in order to form a crosslinked structure include conventionally known crosslinking agents. Examples of the crosslinking agent include an isocyanate crosslinking agent, an epoxy crosslinking agent, an aziridine crosslinking agent, a carbodiimide crosslinking agent, and an oxazoline-based crosslinking agent. Especially, it is preferable from a viewpoint of suppressing hydrolysis of a polyurethane to use a carbodiimide crosslinking agent for the composition for skin layer formation.

  Moreover, if the aspect which introduce | transduces a crosslinked structure into solvent-type polyurethane is mentioned as an example, the aspect which uses together polyisocyanate as a crosslinking component will be mentioned, for example using solvent-type polyurethane as a main ingredient. By using a polyisocyanate in combination, a crosslinked structure can be formed in the polyurethane during the heat curing of the polyurethane.

The composition for forming the skin layer may further contain other components in addition to the resin as the main agent and the solvent.
Examples of other components that can be included in the composition for forming a skin layer include a crosslinking agent, a colorant, and a feel improver.

The composition for forming a skin layer may contain a colorant.
Examples of the colorant include colored organic resin particles in which a colorant is contained in organic resin fine particles selected from urethane resin particles, acrylic resin particles, silicone resin particles, and the like. From the viewpoints of affinity and uniform dispersibility with respect to the polyurethane-based resin, it is preferable to contain polycarbonate-based colored resin particles.
In general, the average particle diameter of such organic resin fine particles is preferably in the range of 0.10 μm to 1.50 μm, and more preferably in the range of 0.15 μm to 1.00 μm.

There is no restriction | limiting in particular in the method of providing a skin layer forming composition to a mold release material surface, A well-known providing method is applicable. Examples of the application method include a method of applying with a hermetic or open coating head.
There is no restriction | limiting in particular in the application quantity of the composition for skin layer formation, and the film thickness of the formed skin layer, According to the objective, it selects suitably.
In general, strength and in terms of appearance, as the coating amount before drying of the skin layer forming composition is ^preferably in the range of ^{50g / m 2 ~300g / m 2} , 150g / m 2 ~300g / and more preferably in the range of m ^2.

The skin layer-forming composition can be dried by a known method.
As drying conditions, a temperature of 80 ° C. to 150 ° C. is preferable, and 90 ° C. to 120 ° C. is more preferable. The drying time under this temperature condition can be 1 minute to 5 minutes, and preferably 2 minutes to 3 minutes.
As described above, the thickness of the skin layer after drying is preferably in the range of 20 μm to 300 μm, and more preferably in the range of 30 μm to 200 μm.

The mold release material may be one having a smooth surface to which the composition for forming the skin layer is applied, or one having a fine texture pattern formed thereon.
The step of having a texture pattern on the skin layer, which is performed as desired, will be described later.
The method of applying the resin composition for forming the skin layer to the surface of the release material that has been subjected to the release treatment may be a method in which the resin composition for forming the skin layer is applied to the surface of the release material and then drying, and there is no hindrance to transfer. In some cases, a transfer method may be used.

  Here, the formation of the skin layer by the dry method has been described. However, as described above, the skin layer can also be formed by the wet method. The method for impregnating the base fabric with the resin in the wet method is as described above.

[Step b]
In step b, the embossing roll having irregularities on the skin layer side and the backup roll on the base fabric side are brought into contact with the laminate obtained in step a, respectively, and the heating temperature of the embossing roll is set to A (° C.), When the heating temperature of the backup roll is B (° C.), the embossing is performed under a temperature condition in which A and B satisfy the following conditions (I), (II), and (III).
Condition (I): 130 ° C. ≦ A ≦ 180 ° C.
Condition (II): 180 ° C. ≦ B ≦ 250 ° C.
Condition (III): Softening point of resin contained in skin layer−15 ° C. ≦ A <Softening point of resin contained in skin layer

Embossing is performed by heating a pair of rolls of an embossing roll and a backup roll independently, adjusting the distance between the rolls, that is, the clearance, and passing the laminate between the pair of rolls. Heat embossing.
The clearance between the embossing roll and the backup roll is preferably set to be 0.1 mm to 1.5 mm narrower than the thickness of the skin material to be manufactured from the viewpoint of the formation of the uneven pattern.

In step b, the embossing roll is heated under the condition of 130 ° C. to 180 ° C. [Condition (I)], and the backup roll is heated within the range of 180 ° C. to 250 ° C. [Condition (II)]. At this time, the heating temperature of the embossing roll is adjusted to a temperature range lower than the softening point (softening temperature) of the resin contained in the skin layer and at a softening point of −15 ° C. or more [Condition (III)].
By embossing under the above temperature conditions, a three-dimensional concavo-convex pattern is formed on the skin material, and the formed concavo-convex pattern has a sharp shape and excellent shape retention.
In addition, it is preferable that the heating temperature of the embossing roll in embossing is lower than the heating temperature of a backup roll.
What is necessary is just to adjust suitably the temperature of an embossing roll and a backup roll to the temperature which satisfy | fills the said conditions (I), conditions (II), and conditions (III) according to the softening point (softening temperature) of resin contained in a skin layer. .

Here, the temperature (A) of the embossing roll at the time of embossing refers to the heating temperature of the top of the convex portion of the embossing roll, that is, the surface temperature of the embossing roll that enters and contacts the side having the skin layer of the laminate. . The temperature of the bottom surface of the concave portion of the laminate depends on the heating temperature of the convex top portion of the embossing roll.
Moreover, the temperature (B) of a backup roll points out the heating temperature of the surface which contacts the base fabric of a laminated body.

The depth of the concave portion formed in the skin material is set such that the distance between the concave bottom surface and the convex top surface is 250 μm or more. Preferably, the depth is such that the embossed convex portion enters the base fabric side from the interface between the adhesive layer adjacent to the skin layer and the base fabric.
In the above preferred embodiment, when embossing, the top surface of the convex portion of the embossing roll penetrates into the skin layer, and reaches the depth from the skin layer side of the laminate to the base fabric laminated through the adhesive layer. Embossing is performed to penetrate and form deep recesses.
Here, the height of the convex portion of the embossing roll may be set higher than the depth of the concave portion formed in the skin material in consideration of the clearance with the backup roll.
The embossing pressure is preferably in the range of 30 kN / m to 150 kN / m, and more preferably in the range of 50 kN / m to 120 kN / m.
In addition, from the viewpoint of the appearance of the deep three-dimensional shape to be formed, the distance between the concave bottom surface and the convex top surface of the embossing roll unevenness is preferably larger than 250 μm.
The height of the convex portion of the embossing roll, that is, the depth of the concave portion formed in the skin material is larger than 250 μm, so that the concave portion formed in the skin material has a concave bottom surface and a convex top surface as designed. Becomes a three-dimensional shape having a sufficient depth of 250 μm or more.

[Optional process]
The manufacturing method of this indication may have other processes in addition to the above-mentioned process a and process b.
As other steps (arbitrary steps) optionally performed, for example, a step of forming a texture pattern on the skin layer, a step of forming a surface treatment layer on the surface of the skin layer, and the skin material is a wet resin skin material Examples thereof include a step of buffing the surface of the wet resin skin material with sandpaper or the like, a step of drilling through holes in the laminate or the skin material, and the like.

[Step of forming a wrinkle pattern on the skin layer (step c)]
In the manufacturing method of the present disclosure, prior to the embossing step (step b), on the surface of the skin layer opposite to the adhesive layer side, the distance between the concave bottom surface and the convex top surface is 150 μm or less. You may further have the process of forming a pattern. By including the step c, the skin material obtained by the production method of the present disclosure has a texture pattern which is a fine uneven pattern on the surface of the skin layer opposite to the base fabric side.
Examples of the method for forming a wrinkle pattern include a method for transferring a wrinkle pattern to the surface of the skin layer using a wrinkle-type transfer release material having a wrinkle pattern that is a fine uneven pattern in advance.
A skin layer in which a skin layer forming composition layer is formed on the surface of the surface of the release material for a surface texture transfer pattern on which a surface texture has been formed in advance by a coating method, etc., and dried by heating and drying. Get. Thereafter, the obtained skin layer is adhered to the base fabric through an adhesive layer and dried by heating, and then the release material is peeled off to form a skin material forming laminate having a fine texture pattern on the surface of the skin layer. You can get a body.

There are no particular restrictions on the embossed mold release material as long as the desired fine uneven pattern is formed. As the release material for embossing type transfer, for example, a commercially available product may be used, or one having a desired pattern formed on the surface of the release material by computer graphics or the like may be used.
The method of applying the skin layer forming resin composition to the embossed mold release material surface may be a method in which the skin layer forming resin composition is applied to the mold release material surface and then dried. Alternatively, a transfer method may be used.
In addition, as a method of forming a texture pattern without using a textured mold release material, when a skin layer is laminated to a base fabric through an adhesive layer, a textured roll is formed as a laminating roll that contacts the skin layer side. For example, a method using a modified sivolol. When laminating the skin layer on the base fabric through the adhesive layer, a grain pattern is formed on the surface of the skin layer by heat laminating with a grain roll and a backup roll.

  According to the manufacturing method of the present disclosure, after forming a texture pattern on the surface of the skin layer in the step c, the embossing is performed under the embossing process even when embossing for forming a deep uneven shape is performed in the step b. Since it is appropriately controlled, the texture pattern formed on the skin layer after the formation of the deep concavo-convex pattern is maintained. The skin material obtained in this way is a skin material excellent in design with a characteristic appearance having a fine texture pattern on the surface and a deep three-dimensional uneven pattern.

  Note that, as described above, the skin material obtained by the manufacturing method of the present disclosure has a deep concavo-convex pattern and is excellent in appearance due to a three-dimensional shape, and thus it is not always necessary to form a texture pattern on the skin material.

[Step of forming a surface treatment layer containing a resin on the surface of the skin layer opposite to the adhesive layer side (step d)]
The manufacturing method of the present disclosure includes a step [step d] of forming a surface treatment layer containing a resin on the surface of the skin layer opposite to the adhesive layer side after step a and prior to step b. You may do it.
The surface treatment layer is a layer provided on the surface of the skin layer in the skin material. Usually, when a surface treatment layer is provided, the surface treatment layer is located on the outermost surface of the skin material, and the protection of the skin layer, improvement of the durability of the skin material, improvement of the formation of the uneven pattern, improvement of the retainability of the uneven pattern Various functions can be imparted to the skin material.
The surface treatment layer preferably includes a urethane resin, an acrylic resin, a fluororesin, and the like, more preferably includes a urethane resin, from the viewpoint that the strength, durability, and unevenness retention of the skin layer can be further improved. .
The resin contained in the surface treatment layer is preferably a resin whose softening point is higher than the softening point of the resin contained in the skin layer. Furthermore, from the viewpoint of suppressing deterioration in appearance due to gloss change during hot embossing, a resin having a heat melting temperature of 180 ° C. or higher is more preferable, and a resin having a heat melting temperature of 185 ° C. or higher is preferable. preferable.
Although there is no restriction | limiting in particular in the upper limit of heat melting temperature, It is preferable that it is 200 degrees C or less from a viewpoint of embossing property.

  In addition to the resin, the surface treatment layer may contain a crosslinking agent, an organic filler, a lubricant, a flame retardant, and the like depending on the purpose. For example, when the surface treatment layer contains an organic filler, a lubricant, etc., a smooth feel is imparted to the skin material, and the abrasion resistance of the skin material is further improved.

The thickness of the surface treatment layer is preferably 2 μm to 10 μm, and more preferably 3 μm to 8 μm.
The function with which a surface treatment layer is provided is fully expressed because the thickness of a surface treatment layer exists in the said range.

[Step of buffing the surface of the wet resin skin material (step e)]
The manufacturing method of the present disclosure may further include a step [step e] of buffing the surface of the wet resin skin material after step a and prior to step b.
When the synthetic resin skin material of the present disclosure is a wet resin skin material, by performing step e, the surface of the wet resin skin material opposite to the base fabric side of the skin layer, that is, the silver leather surface in natural leather It can be set as the skin material which has the fine raising | fluff which gives the texture like nubuck to the surface equivalent to.
The buffing can be performed by a known method, for example, a buffing wheel having a fine abrasive grain on the surface, a sandpaper or the like that is pressed against the surface of the skin layer and raised. Processing is preferred.
Sandpaper used for buffing can be appropriately selected from No. 200 to No. 1000 and used. As a specific method of buffing, for example, a buffing wheel attached with sandpaper with a buffing machine is brought into contact with the surface of the skin layer of the wet resin skin material at a rotation speed of 500 rpm to 1000 rpm (rotation / min). And buffing by cutting. By buffing, a nubuck-like texture and a raised feeling can be provided on the surface of the skin layer of the wet resin skin material.
Note that the buffing may be performed only once as necessary, or may be repeatedly performed a plurality of times in order to obtain a target texture.

[Step of drilling a plurality of holes penetrating in the thickness direction of the laminate or skin material (step f)]
The manufacturing method of the present disclosure may further include a step of drilling a plurality of holes penetrating in the thickness direction of the laminate or the skin material.
The plurality of holes are holes penetrating in the thickness direction of the laminate or the skin material from the skin layer in the laminate or the skin material to the base fabric that is the bottom surface of the skin material.
By having a large number of holes penetrating the laminate or skin material in the thickness direction of the laminate or skin material, the skin material obtained by the production method of the present disclosure has good air permeability, moisture permeability, and the like. Also, the appearance is better.
In the step of drilling a plurality of holes penetrating the laminate or skin material in the thickness direction of the laminate or skin material, the method of forming the through-hole can be generally arbitrarily applied to the method of drilling a resin sheet. it can. The step f may be a step of punching holes having a desired diameter at a desired interval in the laminate or the skin material with a punching roll, for example.
The diameter of the through holes in a plan view, the interval between adjacent through holes, and the like can be appropriately determined according to the purpose. Usually, the diameter of the through hole in plan view is preferably 2 mm or less from the viewpoint that the strength of the skin layer is hardly lowered due to the presence of the through hole. Further, from the viewpoint of easily obtaining the desired air permeability, the diameter of the through hole in a plan view is preferably 0.5 mm or more.
The step of punching a plurality of holes [step f] may be performed after manufacturing the laminate, that is, after step a and prior to step b, and after forming the skin material, that is, after step b. Also good.

According to the method for producing a synthetic resin skin material of the present disclosure, the solid resin having a deeper concavo-convex pattern than the conventional synthetic resin skin material, the shape retention of the formed three-dimensional shape is good, and durability It is possible to produce a synthetic resin skin material excellent in the above.
According to the manufacturing method of the present disclosure, it is possible to obtain a synthetic resin skin material having a deep three-dimensional concavo-convex pattern, suppressing deformation of the concavo-convex over time, and having excellent durability. Since the obtained skin material can maintain a good appearance due to deep recesses for a long period of time and has excellent durability, it is suitably used for applications requiring durability such as automobile interior materials.

Hereinafter, the production method of the present disclosure will be specifically described with reference to examples. The following examples are merely examples of embodiments, and the present disclosure is not limited to the following examples.
Unless otherwise specified, the following “%” and “part” are based on mass.

[Example 1]
(Preparation of the skin layer)
Crisbon (registered trademark) NY-373 (manufactured by DIC Corporation, heat softening temperature (softening point): 160 ° C., polycarbonate based polyurethane having a heat melting temperature: 180 ° C.) in an amount of a solvent (dimethyl) having a solid content of 16% Formamide: DMF) was diluted to prepare a composition for forming the epidermis layer. The obtained composition for forming the skin layer was coated on the surface of the release paper ARX196M (trade name, manufactured by Asahi Roll Co., Ltd.) with a knife coater at a coating amount of 250 g / m ² , and the composition for forming the skin layer on the surface of the release paper A layer was formed.

(Formation of adhesive layer and production of laminate)
The adhesive layer has 150 g of adhesive for forming an adhesive layer (polycarbonate urethane adhesive: heat melting temperature: 190 ° C., manufactured by DIC Corporation, Crisbon TA-205FT) on one surface of the skin layer. / M ² was applied and formed by heating at 100 ° C. for 2 minutes and drying.
Thereafter, a base fabric (a knitted fabric of 220 dtex / 48 f polyester yarn (melting point: 254 ° C.), thickness: 1.1 mm: manufactured by Hayashi Telemp Co., Ltd., GHS009) was formed on one surface of the skin layer. The layers were bonded in the direction in contact with the agent layer, and then aged at 50 ° C. for 48 hours to be cured.
The surface treatment layer forming composition containing an aqueous dispersion of urethane resin (heat melting temperature: 180 ° C., softening temperature: 175 ° C.) on the surface of the skin layer opposite to the base fabric has a thickness after drying. It apply | coated with the quantity used as 5 micrometers, and it dried and formed the surface treatment layer, and obtained the laminated body of thickness 1.2mm. [Step (a)]

(Forming uneven patterns)
The resulting laminate was embossed. The embossing roll temperature of the embossing machine is a temperature (155 ° C) that is 5 ° C lower than the thermal softening point of the resin contained in the skin layer at the surface temperature of the top of the convex portion of the embossing roll that contacts the skin layer side of the laminate. The temperature of the surface in contact with the base fabric on the backup roll side was set to 200 ° C. The clearance between the rolls was 0.9 mm, and embossing was performed at a pressure of 80 kN / m [step b] to obtain a synthetic resin skin material in which a deep three-dimensional shape (recess depth: 800 μm) was formed.

  The skin material obtained by the manufacturing method of Example 1 obtained has a thickness of 1.2 mm, the thickness of the surface treatment layer is 5 μm, the thickness of the skin layer is 40 μm, and the thickness of the adhesive layer is The depth of the concave portion formed in the skin material is 60 μm, and the distance between the top surface of the convex portion and the bottom surface of the concave portion is 800 μm on the surface of the region where the concave portion of the skin material is not formed. It was a skin material in which deep recesses reaching the inside of the base fabric were formed and had a three-dimensional uneven pattern.

[Example 2]
A laminate was formed in the same manner as in the method for producing the synthetic resin skin material of Example 1.
In the formation of the concavo-convex pattern on the laminate, the embossing roll temperature of the embossing machine is the surface temperature of the top of the convex portion of the embossing roll that contacts the skin layer side of the laminate, from the heat softening point of the resin contained in the skin layer. A recess was formed in the same manner as in Example 1 except that the temperature was lowered to 15 ° C. (145 ° C.), and a synthetic resin skin material was obtained by the production method of Example 2.

Example 3
A laminate was formed in the same manner as in the method for producing the synthetic resin skin material of Example 1.
In the formation of the concavo-convex pattern on the laminate, the embossing roll temperature of the embossing machine is the surface temperature of the top of the convex portion of the embossing roll that contacts the skin layer side of the laminate, from the heat softening point of the resin contained in the skin layer. A recess was formed in the same manner as in Example 1 except that the temperature was lowered to 10 ° C. (150 ° C.), and a synthetic resin skin material was obtained by the production method of Example 3.

Example 4
A laminate was formed in the same manner as in the method for producing the synthetic resin skin material of Example 1.
In the formation of the concavo-convex pattern on the laminate, the embossing roll temperature of the embossing machine is the surface temperature of the top of the convex portion of the embossing roll that contacts the skin layer side of the laminate, and the heat softening point of the resin contained in the skin layer A recess was formed in the same manner as in Example 1 except that the temperature was set to the same temperature (160 ° C.), and a synthetic resin skin material was obtained by the production method of Example 4.

Example 5
A laminate was formed in the same manner as in the method for producing the synthetic resin skin material of Example 1.
In the formation of the concavo-convex pattern on the laminate, a concave portion was formed in the same manner as in Example 5 except that the temperature of the surface in contact with the base fabric on the backup roll side of the embossing machine was set to 180 ° C. A synthetic resin skin material was obtained by the production method.

Example 6
A laminate was formed in the same manner as in the method for producing the synthetic resin skin material of Example 1.
In the formation of the concavo-convex pattern on the laminate, a concave portion was formed in the same manner as in Example 6 except that the temperature of the surface in contact with the base fabric on the backup roll side of the embossing machine was set to 250 ° C. A synthetic resin skin material was obtained by the production method.

[Comparative Example 1]
A laminate was formed in the same manner as in the method for producing the synthetic resin skin material of Example 1.
In the formation of the concavo-convex pattern on the laminate, the embossing roll temperature of the embossing machine is 20 from the softening point of the resin contained in the skin layer at the surface temperature of the convex top of the embossing roll that contacts the skin layer side of the laminate. A concave portion was formed in the same manner as in Example 1 except that the temperature was increased to 180 ° C. (180 ° C.), and a synthetic resin skin material was obtained by the production method of Comparative Example 1.

[Comparative Example 2]
A laminate was formed in the same manner as in the method for producing the synthetic resin skin material of Example 1.
In the formation of the concavo-convex pattern on the laminate, the embossing roll temperature of the embossing machine is 20 from the softening point of the resin contained in the skin layer at the surface temperature of the convex top of the embossing roll that contacts the skin layer side of the laminate. A recess was formed in the same manner as in Example 1 except that the temperature was lowered to 140 ° C. (140 ° C.), and a synthetic resin skin material was obtained by the production method of Comparative Example 2.

<Evaluation of synthetic resin skin material>
(1. Appearance evaluation related to three-dimensionality)
The shape of the recessed part of the obtained synthetic resin skin material was observed visually, and the embossed transfer state used for embossing was evaluated according to the following evaluation criteria. The results are shown in Table 1 below. In Table 1, the evaluation item is described as “stericity”.
-Evaluation criteria-
A: The corner of the recess has a sharp embossed corner R shape and is clearly transferred B: The shape of the embossed shape is transferred, but the shape of the corner R of the recess is gentle C: Embossed type The shape of is almost not transferred

(durability)
A surface abrasion test with a load of 2 kg was performed on the obtained synthetic resin skin material by the following method, and the durability of the synthetic resin skin material was evaluated according to the following evaluation criteria. The results are shown in Table 1 below. In Table 1, the evaluation item is described as “2 kg plane wear”.
The test was conducted with reference to a plane abrasion tester (Method B) of the fabric material for JASO M 403/88 / sheet skin.
The test conditions were the same except that the standard conditions in the JASO method were the main test conditions and the pressing load in the JASO method was changed from 9.8N to 19.6N.
-Evaluation criteria-
A: The shape of the recess is maintained even when the surface wear is 10,000 times or more. B: The shape of the recess is destroyed when the surface wear is 7500 times or more and less than 10,000 times.

  From the results shown in Table 1, the skin material obtained by the method for producing the synthetic resin skin material of Example 1 to Example 6 is deep and has a three-dimensional shape having recesses as designed, and the formed three-dimensional shape is The shape was maintained even after 10,000 wear tests. From this, it can be seen that the synthetic resin skin material obtained by the production method of Example 1 has a sharp three-dimensional shape and good shape retention, that is, durability.

  On the other hand, the synthetic resin skin material obtained by the production method of Comparative Example 1 where the heating temperature of the embossing roll during embossing is higher than the softening point of the urethane resin has good transferability of the shape of the recesses. It was inferior in durability. Further, the synthetic resin skin material obtained by the production method of Comparative Example 2 in which the temperature of the embossing roll at the time of embossing is 20 ° C. lower than the softening point of the urethane resin is the production of Examples 1 to 6. Compared to the skin material obtained by the method, the shape transferability of the recess was inferior.

(Explanation of symbols)
10, 20 Synthetic resin skin material 12 Surface treatment layer 14 Skin layer 16 Adhesive layer 18 Base fabric 22 Surface treatment layer 24 Skin layer (skin layer having a wrinkle pattern)

The disclosure of Japanese Patent Application No. 2018-020513 filed on Feb. 7, 2018 is incorporated herein by reference.
All documents, patent applications, and technical standards mentioned in this specification are to the same extent as if each individual document, patent application, and technical standard were specifically and individually stated to be incorporated by reference, Incorporated herein by reference.

Claims (9)

A step of forming a laminate for forming a skin material, having a base fabric and an adhesive layer on one surface of the base fabric, and a skin layer containing a resin having a softening point of 145 ° C. or higher in this order;
With respect to the obtained laminate for forming a skin material, an embossing roll having irregularities on the skin layer side and a backup roll on the base fabric side are brought into contact with each other, and the heating temperature of the embossing roll is set to A (° C.). When the heating temperature of the backup roll is B (° C.), A and B are embossed under temperature conditions satisfying the following conditions (I), (II) and (III), and the skin material is formed. Forming a concave portion having a distance between the bottom surface of the concave portion and the top surface of the convex portion of 250 μm or more in the laminated body for manufacturing the synthetic resin skin material.
Condition (I): 130 ° C. ≦ A ≦ 180 ° C.
Condition (II): 180 ° C. ≦ B ≦ 250 ° C.
Condition (III): Softening point of resin contained in skin layer−15 ° C. ≦ A <Softening point of resin contained in skin layer   The method for producing a synthetic resin skin material according to claim 1, wherein the resin having a softening point of 145 ° C or higher is a urethane resin.   The manufacturing method of the synthetic resin skin material of Claim 1 or Claim 2 in which the said base fabric contains the synthetic fiber whose melting | fusing point is 150 to 260 degreeC. A step of forming a surface treatment layer containing a resin on a surface of the skin layer opposite to the adhesive layer side;
4. The synthetic resin skin material according to claim 1, wherein the resin contained in the surface treatment layer has a softening point higher than that of the resin contained in the skin layer. 5. Method.   The bottom surface of the recess formed by the embossing is a depth reaching from the skin layer side of the skin material forming laminate to the base fabric laminated through the adhesive layer. The manufacturing method of the synthetic resin skin material of any one of Claims 1.   Prior to the embossing step, the method further includes a step of forming a texture pattern in which the distance between the bottom surface of the concave portion and the top surface of the convex portion is 150 μm or less on the surface of the skin layer opposite to the adhesive layer side. The manufacturing method of the synthetic resin skin material of any one of Claims 1-5.   The method for producing a synthetic resin skin material according to any one of claims 1 to 6, wherein the synthetic resin skin material is a dry resin skin material or a wet resin skin material.   The said synthetic resin skin material is a wet resin skin material, The manufacturing method of the synthetic resin skin material of Claim 7 which further includes the process of buffing the skin layer in the said wet resin skin material.   In the thickness direction of the skin material forming laminate or the synthetic resin skin material, the skin material forming laminate or the synthetic resin skin material penetrates the skin material forming laminate or the synthetic resin skin material. The manufacturing method of the synthetic resin skin material of any one of Claims 1-8 which further has the process of drilling the several hole to do.