JP6625812B2 - Cloth for skin material - Google Patents

Description

  The present invention relates to a fabric for patterning and a patterned fabric, and mainly relates to a fabric for a skin material, and is particularly suitably used as a fabric for a skin material of an automobile, such as a ceiling, a door trim, and a rear package. The present invention relates to a fabric for a skin material that can be made.

  BACKGROUND ART Conventionally, as a surface material for a vehicle such as an automobile, a cloth such as a nonwoven fabric, a woven fabric, or a knitted fabric is generally used as a surface material. As the non-woven fabric, a non-woven fabric obtained by subjecting a needle-punched non-woven fabric and a water-punched non-woven fabric to resin processing and having excellent stretchability, but having good moldability even for a complicated shape has been developed. However, a material obtained by simply applying a resin treatment to a nonwoven fabric is poor in designability for use in vehicle interiors since it has no feature on the surface. On the other hand, woven fabrics and knitted fabrics have excellent design properties, but have poor cushioning properties by themselves, and thus have a problem of poor texture. In addition, there is a problem that a woven or knitted fabric is inferior to a nonwoven fabric in terms of moldability and cost.

  As a method for improving the design of a nonwoven fabric, for example, as disclosed in Patent Documents 1 to 5, a cloth for a skin material in which a pattern is applied to a surface of the nonwoven fabric by embossing and a nonwoven fabric used for various applications are disclosed.

  Patent Literature 1 relates to an interior skin material which is formed by using a heat-fusible fiber and has a soft feel while being moldable and has a clear pattern. A large amount of heat-fusible fibers are mixed to meet the requirements for wear resistance. For this reason, such a nonwoven fabric has a hard texture, and in particular, when a complicated molding is performed by hot pressing, a problem occurs such that wrinkles occur because the molding does not follow a molding die.

  Patent Literature 2 is to form a regular embossed pattern by embossing a pressing die and pressing a material having a nonwoven fabric on the surface, but the pressing die is expensive, and each pattern is expensive. It is economically difficult to produce a press die.

  In Patent Literature 3, print processing and emboss processing are used in combination in order to enhance the designability, but the number of steps is large and it cannot be manufactured at low cost.

  Further, Patent Documents 3 and 4 disclose low-melting fibers having a melting point lower than the melting point of the main fiber / softening point so that the embossed pattern does not disappear when the embossed fabric for the skin material is thermoformed. Although embossing is performed between the temperatures using a resin or a binder resin, the effect is insufficient.

  Patent Document 5 relates to a printed nonwoven fabric which is excellent in decorativeness and can be widely felt in a vehicle interior. However, in general, it is difficult to print a pattern clearly because the nonwoven fabric surface is uneven and not smooth. The effect is not enough.

JP-A-2005-54295 JP-A-9-109797 JP-A-1-168540 JP-A-2-139481 JP 2014-51268 A

  By the way, in the field of the fabric for skin material, various kinds of original fibers such as white, gray, beige, and black are used by mixing one kind or plural kinds. In recent years, black, red, blue, etc., dark and clear colors, and pastel colors such as pink, light blue, and pale yellow are often used. In many cases, fibers of six different colors are mixed. In addition, light-colored (high-brightness) fibers are often mixed in order to make the fabric for the skin material cheaper. However, according to the study by the present inventor, when an uneven pattern is formed by embossing a fabric mixed with light-colored (high-brightness) fibers in order to enhance the design, light-colored to human eyes. It was found that the fiber and embossed concavo-convex pattern were visually recognized at the same time. If the light color of the fiber and the embossed concavo-convex pattern are visually recognized at the same time, there arises a problem that the concavo-convex pattern formed to enhance the design is blurred.

  Under such circumstances, an object of the present invention is to provide a fabric for a skin material in which an embossed pattern is clearly visible.

  The present inventor has conducted intensive studies to solve the above problems, and as a result, by performing resin processing and embossing on a fiber base material containing 70% by weight or more of dark-colored fibers having a brightness of less than 75, The inventors have found that a fabric for a skin material in which the embossed pattern becomes clear can be obtained, and completed the present invention.

That is, the fabric for a skin material according to the present invention has the following points.
[1] A fabric for a skin material, wherein a fiber base material containing 70% by weight or more of dark-colored fibers having a lightness of less than 75 is subjected to resin processing and embossing.
[2] The fabric for skin material according to [1], wherein the fiber base material is a needle-punched nonwoven fabric.
[3] The skin material according to [1] or [2], wherein the number of needles to be punched in the needle punching process is 80 to 1200 needles / cm ² , and the basis weight of the fiber base material is 50 to 400 g / m ² . Fabric.
[4] The method according to any one of [1] to [3], wherein the emboss ratio is 5 to 55%, and the emboss depth relative to the thickness of the skin material is 0.125 times or more the thickness of the skin material. The fabric for a skin material according to any one of the preceding claims.
[5] The fabric for a skin material according to any one of [1] to [4], wherein the lightness of the dark-colored fiber is 55 or less.
[6] The fabric for skin materials according to any one of [1] to [5], further including at least one or more bulky fibers selected from hollow fibers, crimped fibers, and hollow crimped fibers.
[7] The fabric for a skin material according to any one of [1] to [6], wherein the bulky fibers are included as light-colored fibers having a lightness of 75 or more.
[8] Any one of [1] to [7], further including a low-melting fiber, wherein a mixing ratio of the low-melting fiber is 1% by weight or more and 15% by weight or less in 100% by weight of the fabric for a skin material. The fabric for a skin material according to the above item.
[9] The method according to any one of [1] to [8], wherein the resin processing is performed from a surface of the cloth, and a depth of the resin processing is 1/3 to 2/3 of a cloth thickness. Cloth for skin material.
[10] The fabric for a skin material according to any one of [1] to [9], wherein a glass transition temperature (Tg) of the resin for resin processing is from −35 ° C. to 20 ° C.
[11] The fabric for skin material according to any one of [1] to [10], wherein two or more kinds of fibers having different lightness are mixed as the dark-colored fibers.
[12] The skin material according to any one of [1] to [11], wherein the modulus at 10% extension in the vertical direction is less than 90 N / 5 cm, and the modulus at 10% extension in the horizontal direction is less than 70 N / 5 cm. Fabric.

  According to the fabric for skin material of the present invention, since the fiber base material containing 70% by weight or more of the dark-colored fibers having a lightness of less than 75 is subjected to the resin processing and the embossing processing, the embossed portion and the non-embossed portion are formed. The difference becomes clear, and the embossed pattern can be clearly recognized without blurring. Thereby, a fabric having a high design property can be obtained as the fabric for the skin material.

  The fabric for a skin material of the present invention is characterized in that a fiber substrate containing 70% by weight or more of dark-colored fibers having a lightness of less than 75 is subjected to resin processing and embossing. The fabric for the skin material is, for example, after producing a fiber base material containing 70% by weight or more of dark-colored fibers having a lightness of less than 75, subjecting the obtained fiber base material to resin processing, and then embossing to form an uneven pattern. It is manufactured by forming. Hereinafter, each configuration will be described.

1. Fiber and fiber base material 1-1. Fiber The fiber substrate contains 70% by weight or more of 100% by weight of the fiber base material of a dark-colored fiber having a lightness of less than 75 (hereinafter, may be referred to as “dark fiber”). The fabric for a skin material according to the present invention is embossed in order to enhance its design, and is designed by visually checking an embossed pattern (hereinafter, sometimes referred to as an “embossed portion”). You can enjoy. However, when the cotton mixing ratio of the dark-colored fiber is low, the difference between the uneven pattern and the part that is not embossed (hereinafter, sometimes referred to as “non-embossed part”) is not clear, and the contour of the pattern (irregular pattern) is not clear. Is blurred and visible. In particular, this problem is remarkable when light-colored fibers having a lightness of about 75 to 90 and dark-colored fibers having a lightness of about 20 to 40 are mixed. Was. However, in the present invention, since the mixing ratio of the dark-colored fibers is adjusted to be 70% by weight or more, such a pattern blur phenomenon is not seen, and the embossed pattern becomes clear. The darker fiber is more preferable from the viewpoint of pattern blur, and the mixing ratio of the darker fiber is, for example, 70% by weight or more, preferably 80% by weight or more, and more preferably 85% by weight or more in 100% by weight of the fiber base material. Is more preferably 90% by weight or more, still more preferably 95% by weight or more, and particularly preferably 100% by weight.
The lightness of the fiber can be measured, for example, by the method described in Examples.

  The fiber base material may include a fiber having a lightness of 75 or more (hereinafter, may be referred to as a “light-colored fiber”) if the mixing ratio of the dark-colored fiber is 70% by weight or more. The cotton blending ratio of the dark-colored fiber and the light-colored fiber (dark-colored fiber: light-colored fiber) is preferably 100: 0 to 70:30, more preferably 95: 5 to 75:25, and 92: 8 to 100% by weight. 80:20 is more preferred.

  The lightness of the dark-colored fiber is, for example, preferably 72 or less, more preferably 70 or less, still more preferably 55 or less, particularly preferably 40 or less, and still more preferably 30 or less, and the lower limit is particularly Although not limited, for example, it is 10 or more. It is preferable that the lightness of the dark-colored fiber is lower (that is, the darker-colored fiber becomes), because the embossed pattern becomes clearer.

  On the other hand, the lightness of the light-colored fibers is generally 90 or less, more preferably 86 or less. The lower limit is 75 or more as described above, and may be 77 or more.

  When the fiber base contains both the dark-colored fiber and the light-colored fiber, the total of the dark-colored fiber and the light-colored fiber is preferably 90% by weight or more, more preferably 90% by weight, of the fibers constituting the fiber base. It is at least 95% by weight, more preferably 100% by weight.

  As the dark color fiber and the light color fiber, two or more kinds of fibers having different lightness may be mixed. In particular, in the case of a dark-colored fiber, it is preferable to include a fiber having a brightness of 55 or less. % Or more, more preferably 65% by weight or more, and the upper limit is not particularly limited, but may be 100% by weight or 90% by weight or less.

  In the case where two or more types of fibers having different lightness are mixed as the dark-colored fibers, the mixing is performed by mixing a fiber having a lightness of 10 to 55 or less and a fiber having a lightness of more than 55 to less than 75; Any of the following embodiments may be used: mixing two or more types of fibers having different lightness from the following fibers; mixing two or more types of fibers having different lightness from fibers having a lightness of more than 55 to less than 75. Further, when the cotton mixing ratio of the dark-colored fiber is 70% by weight or more, there is no problem in terms of appearance and pattern disappearance regardless of the difference in brightness.

When the fiber having a lightness of 10 to 55 or less and the fiber having a lightness of more than 55 to less than 75 are mixed, the mixing ratio (fiber of a lightness of 10 to 55 or less: a fiber of a lightness of 55 to less than 75) is 90:10 to 10:90. Is preferred, 80:20 to 20:80 is more preferred, 75:25 to 40:60 is still more preferred, and 70:30 to 55:45 is particularly preferred.
When two or more fibers having different lightnesses are mixed from fibers having a lightness of 10 to 55 or less, the mixing ratio (fibers having a lightness of 10 to 30 or less: fibers having a lightness of more than 30 to 55 or less) is 90:10 to 10:90. , Preferably 80:20 to 20:80, more preferably 60:40 to 30:70, and particularly preferably 45:55 to 35:65.
When two or more fibers having different lightness are mixed from fibers having a lightness of more than 55 to less than 75, the mixing ratio (fibers having a lightness of more than 55 to 71: fibers having a lightness of more than 71 to less than 75) is 90:10 to 10 : 90 is preferable, 80:20 to 20:80 is more preferable, 75:25 to 50:50 is further preferable, and 75:25 to 55:45 is particularly preferable.

  The dark fiber is preferably, for example, black, red, gray, yellow, light blue or the like, and the light fiber is preferably, for example, beige, light yellow, white or the like. As a post-process, before and after applying the resin processing to the fiber base material, the fiber base material may be colored in a desired color by printing or the like, and then embossing may be performed. In the present invention, it is preferable to use native fibers as the dark-colored fibers and the light-colored fibers in order to manufacture the fabric for the skin material at low cost and simply. The “dipped fiber” is a colored original yarn which is colored by mixing a coloring agent such as a pigment or a dye at the stage of the original solution before spinning.

  Examples of the fiber constituting the fiber base include natural fibers such as cotton, hemp, wool, and silk; regenerated fibers such as rayon, polynosic, cupra, and rayocell; polyamide fibers such as nylon 6 and nylon 66; polyethylene terephthalate fibers; Examples thereof include polyester fibers such as polybutylene terephthalate fiber, polylactic acid fiber, and polyarylate; polyolefin fibers such as polyethylene fiber and polypropylene fiber; and these fibers can be used alone or in combination of two or more. Among them, polyester fibers are preferably used mainly, and polyethylene terephthalate fibers are particularly preferable, because they are excellent in heat resistance, weather resistance, etc., and there are many kinds of original fibers and they are easy to handle. The amount of the polyester fiber used is preferably, for example, 80 to 100% by weight, more preferably 90 to 100% by weight, and particularly preferably 100% by weight in 100% by weight of the fibers constituting the fiber base material.

  The cross-sectional shape is not particularly limited, and any of a round cross section; an irregular cross section such as a triangle, a star, and a pentagon can be used.

1-2. Bulk Fibers In order to further enhance the texture and feel of the non-embossed portion and to realize a low modulus of the fabric for the skin material, and to clarify the embossed pattern, hollow fibers, crimped fibers and hollow fibers are used for the fiber base material. It is preferable that at least one or more bulky fibers selected from crimped fibers are contained. By mixing these bulky fibers, the volume feeling of the non-embossed portion is improved, the difference in thickness from the embossed portion is increased, and the embossed pattern due to the emboss is further emphasized. In addition, since the non-embossed portion is not easily compressed during molding, the uneven pattern due to the emboss is hardly lost, and the fabric for the skin material is very excellent in design. In addition, although the texture is slightly hardened by embossing, there is also an effect that the volume is reduced by the non-embossed portion.
The bulky fiber is more preferably contained as either one of the dark-colored fiber or the light-colored fiber, or as both the dark-colored fiber and the light-colored fiber, and the light-colored fiber alone contains the bulky fiber. Preferably, the lightness when the bulky fiber is a light-colored fiber is, for example, 75 or more to 90, and more preferably 80 to 90.

The hollow fiber refers to, for example, a fiber having a hollow inside and no crimped structure. Although the hollow ratio of the hollow fiber is not particularly limited, for example, it is preferably 10% or more, more preferably 15% or more, and further preferably 20% or more. The upper limit is not particularly limited, but is preferably 60% or less, more preferably 50% or less, further preferably 35% or less in consideration of the ease of spinning with a card machine, and is easily available. Therefore, it may be 30% or less. The hollow ratio can be calculated from the cross-sectional photograph of the fiber, for example, by the following formula.
Hollow ratio (%) = (cross-sectional area of hollow part / cross-sectional area of fiber) × 100

  The crimped fiber refers to, for example, a fiber having a solid and spiral three-dimensional crimped structure. The crimp rate of the crimped fiber is, for example, preferably 16% or more, more preferably 18% or more, further preferably 19% or more, and the upper limit is, for example, preferably 30% or less, more preferably 25% or less. It is. The crimp rate can be measured, for example, according to the 8.12.2 method of JIS L1015.

  The number of crimps of the crimped fiber is, for example, preferably 3 or more, more preferably 5 or more, still more preferably 7 or more, for example, 25 or less. Is more preferably 20 pieces / inch or less, still more preferably 15 pieces / inch or less, and particularly preferably 12 pieces / inch or less. In the present invention, “inch” is 25.4 mm. The number of crimps can be measured, for example, according to the JIS L 1015 7.12 method.

  As the crimped fiber, any of a manifest type and a latent type can be used.

  The hollow crimped fiber refers to a fiber having a hollow inside and a three-dimensional spirally crimped structure. The hollow rate, crimp rate, number of crimps, and the like in the hollow crimped fiber are all as described in detail in the section of the hollow fiber and the crimped fiber.

  As the bulky fiber, a crimped fiber having a crimp or a hollow crimped fiber is preferable, and a hollow crimped fiber is more preferable.

  The bulky fibers are, for example, polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polylactic acid, and polyarylate; polyamide resins such as nylon 6, nylon 66; acrylic resins such as polyacrylonitrile, polyacrylonitrile-vinyl chloride copolymer; Various types of chemical fibers formed from synthetic fibers made from the above; regenerated fibers such as rayon and polynosic; semi-synthetic fibers such as acetate fibers and triacetate fibers; and the like can be preferably used. In particular, a composite fiber obtained by using a thermoplastic resin material as a raw material of these fibers and combining resins having different heat shrinkage rates is also preferable. In the present invention, a fiber containing a polyester resin as a raw material is preferable because the fiber is hardly deteriorated by heat or moisture, is inexpensive, and is easily available.

  As bulky fibers, composite fibers (conjugate fibers) having an eccentric structure or side-by-side structure in which resins having different heat shrinkage rates are simultaneously extruded; bicon fibers combining fibers having different heat shrinkage rates; front and back sides of fibers And various types of fibers such as crimped fibers in which the degree of treatment such as heat treatment is made different to develop a three-dimensional crimp. In the present invention, a composite fiber obtained by combining different materials is more preferable, and a composite fiber having a side-by-side structure is particularly preferable. With such a fiber, the crimped structure is firmly maintained, so that a good tactile sensation is obtained, and the collapse of the uneven pattern due to the pressure during molding can be prevented.

  The amount of the bulky fiber used is, for example, preferably 1% by weight or more, more preferably 5% by weight or more, still more preferably 10% by weight or more, and preferably 30% by weight or less in 100% by weight of the fibers constituting the fiber base material. It is preferably at most 25% by weight, more preferably at most 20% by weight.

1-3. Low melting point fiber It is desirable that the fiber base material further contains a low melting point fiber. When low-melting-point fibers are used, the low-melting-point fibers are melted by heating during embossing, so that the interface between the embossed portion and the non-embossed portion becomes sharper, and the contour of the concavo-convex pattern tends to be clear. In addition, the surface of not only the embossed portion but also the non-embossed portion is smoothened by the influence of the heat of the embossing roll, so that the tactile sensation is improved, and the scratch resistance and abrasion resistance are improved. In the case where the fiber base material is formed into a nonwoven fabric by a mechanical entanglement method such as needle punching, if a low melting point fiber is further used, the low melting point fiber partly or wholly melted by heating constitutes the fiber base material. Since it can be joined with other fibers, the entanglement of the fibers can be loosened by changing the conditions of the needle punching process, so that a low modulus can be realized, and the punch marks due to the needle punching process become less conspicuous, so that the design property is further improved. There are benefits too.
The low-melting fiber is more preferably contained as either the dark-colored fiber or the light-colored fiber, or as both the dark-colored fiber and the light-colored fiber, and only the light-colored fiber contains the low-melting fiber. Is more preferable, and the brightness when the bulky fiber is a light-colored fiber is, for example, 75 to 90, and more preferably 80 to 90.

  In the present invention, the “low-melting fiber” is defined as a fiber having a melting point lower by 30 ° C. or more than the dark-colored fiber forming the skeleton of the fiber base material. If the difference in melting point is less than 30 ° C., depending on the heating conditions, both the dark-colored fiber and the low-melting-point fiber may be melted or softened to solidify the fiber substrate, which is not preferable. The melting point of the low-melting fiber is more desirably 60 ° C. or more lower than the melting point of the dark-colored fiber. The lower limit of the melting point of the low-melting fiber is not particularly limited, but is, for example, preferably 180 ° C. or less from the melting point of the dark-colored fiber, and more preferably 160 ° C. or less from the melting point of the dark-colored fiber. The melting point of the low-melting fiber is preferably, for example, 80 to 200 ° C, and more preferably 80 to 160 ° C.

  The form of the low-melting fiber is not particularly limited. Examples of the low-melting fiber include a core-sheath structure, an eccentric structure, and a side-by-side structure composed of a plurality of resins having different melting points such as polyethylene-polypropylene, polyethylene-polyester, and polyester-modified polyester. A modified polyester fiber; a modified polyamide fiber; a modified polyolefin fiber such as a modified polypropylene fiber; and the like. Among them, a composite fiber having a core-sheath structure is preferable because of good productivity and easy availability, but there is no problem even if a low-melting fiber made of a single resin is used.

  The mixing ratio of the low-melting fiber is preferably 1% by weight or more, more preferably 2% by weight or more, still more preferably 3% by weight or more, particularly preferably 4% by weight or more in 100% by weight of the fiber base material. It is. The upper limit is, for example, preferably 15% by weight or less, more preferably 10% by weight or less, and further preferably 8% by weight or less. If the blending ratio of the low melting point fiber exceeds the upper limit, the fiber base material may be undesirably hardened.

  The low-melting fiber is a composite fiber or a single resin having a core-in-sheath structure or a side-by-side structure composed of a plurality of resins having different melting points such as polyester-modified polyester, nylon-modified nylon, and olefin resin such as polyethylene-polypropylene. Although there is a low melting point fiber or the like, a composite fiber having a core-sheath structure made of a polyester-modified polyester resin has a wide selection range of the melting point and is suitably used. The melting point of the low melting point resin depends on the type of fiber used and the manufacturing conditions such as the temperature of embossing and molding. If the melting point of the resin is lower by about 30 to 100 ° C. than the melting point of the dark-colored fiber, the embossed portion becomes sharper. It is preferable because it has excellent heat resistance. In particular, when the low-melting resin is a low-melting fiber made of a crystalline resin, it is possible to prevent the pattern from disappearing more without re-melting when molding.

The fineness of the fibers used for the fiber base material (such as the above-described dark-colored fibers, light-colored fibers, bulky fibers, and low-melting fibers) is preferably, for example, 0.8 to 8 dtex, more preferably 1.1 to 7 dtex, and Preferably it is 1.4-3.3 dtex. If the fineness is less than 1.0 dtex, the air permeability is lowered, so that not only the sound absorbing property is deteriorated, but also the spinning property in a card machine is unfavorably poor. If it is larger than 8 dtex, the embossed portion is particularly thin, so that the adhesive is exuded during molding or smoothed by consolidation. It is not preferable because it becomes too strong.
Among them, the fineness of the bulky fibers described above is, for example, preferably 4 to 8 dtex, and more preferably 5.5 to 7.5 dtex.
The fineness of the low-melting fiber is preferably 0.8 to 6 dtex, and more preferably 1.5 to 5 dtex. When the fineness of the low melting point fiber is within the above range, the low melting point fiber can be easily melted, and the heat treatment time can be shortened.

  The fiber length of the fiber used for the fiber base is preferably 15 to 152 mm, more preferably 30 to 100 mm.

1-4. Fiber Substrate The fiber substrate used for the fabric for the skin material may be any of a nonwoven fabric, a woven fabric and a knitted fabric, but a nonwoven fabric is desirable because of its excellent moldability. As the nonwoven fabric, any of a long-fiber nonwoven fabric and a short-fiber nonwoven fabric can be used, and a short-fiber nonwoven fabric is particularly preferable.

  As the nonwoven fabric, a spunbonded nonwoven fabric; a dry nonwoven fabric obtained by various bonding methods such as a thermal bond method, a chemical bond method, a needle punch method, a hydroentanglement method, a stitch bond method; a thermal bond method, a chemical bond method, a spunlace method And other wet bonding methods. In the present invention, in order to realize a low modulus, a mechanical entanglement method such as a needle punch method and a water entanglement method is preferable, and the needle punch method is more preferable.

  When the fiber base is a non-woven fabric, the fiber base can be manufactured by a known method. For example, the fibers are weighed and then mixed, then carded using a card machine, wrapped with a cross wrapper, and laminated using a cross layer machine or the like. Needle punching may be performed with the number and needle depth of 3 to 12 mm (more preferably 4 to 9 mm).

The skin material for the skin material is likely to have a high modulus by fixing (consolidating) a part of the fibers of the skin material for the skin material by the embossing process, as compared with a conventional product that is not embossed. When the skin material has a high modulus, wrinkles are likely to occur during molding. Therefore, it is desirable to reduce the mechanical entanglement of the fiber and reduce the modulus by weakening the manufacturing conditions of the mechanical entanglement treatment such as needle punching. From such a viewpoint, when the number of needles for needle punching is set to 80 to 1200 needles / cm ² , which is equivalent to about 10 to 20% of the normal (the fiber base of a normal non-embossed fabric for skin material). 100-1500 present / cm ² approximately in wood), it is subjected to embossing to obtain a interior material of a low modulus. For this reason, there is obtained a great merit that it can be molded with a molding die currently used while having excellent design properties. The number of driving needles is more preferably 200 to 1200 needles / cm ² , further preferably 500 to 1100 needles / cm ² , particularly preferably 700 to 1000 needles / cm ² , and still more preferably 800 to 1000 needles / cm ^2. 1000 lines / cm ² .

  In the needle punching, any of a method in which one of the upper and lower surfaces of the web is pierced with a needle and a method in which both the upper and lower surfaces of the web are pierced with a needle can be adopted.

  Further, as another method, when fibers treated with a silicone oil agent are mixed in an amount of about 1 to 30%, friction between fibers is reduced and fibers are not excessively entangled, so that a low modulus can be realized.

The basis weight and thickness of the fiber base material may be appropriately adjusted according to the usage mode. Basis weight is preferably from 50 to 400 g / m ^2, more preferably from 100 to 300 g / m ^2, more preferably from 150 to 250 g / m ^2. Further, the thickness is preferably 0.3 to 5 mm, more preferably 1 to 4 mm.

2. Resin processing By performing resin processing on the fiber base material, gloss (shininess) is likely to be generated in the embossed portion due to heating and pressing during embossing. Due to this luster, the difference between the embossed portion and the non-embossed portion becomes clear, and the visual effect that the uneven pattern looks more three-dimensional is exhibited. In particular, when a dark color or a pastel color is used for the fiber base material, it is difficult to exhibit such a visual effect by a method such as printing, but the present invention makes it possible.

  The type of resin used may be a general-purpose resin, for example, an acrylic binder containing a structural unit derived from acrylic acid and / or an acrylate ester; a vinyl acetate-based binder containing a structural unit derived from vinyl acetate; Vinyl chloride binders containing structural units derived therefrom; butadiene-styrene based, butadiene-acrylonitrile-based, chloroprene-based synthetic rubber-based binders; polyester-based binders; urethane-based binders; and the like are preferable. These resins can be used alone or in combination of two or more. Among them, an acrylic binder is preferable because the embossed pattern is clear and easily available.

  Examples of the acrylate include methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, isobutyl acrylate, sec-butyl acrylate, tert-butyl acrylate, and 2,2-dimethyl acrylate. Propyl, cyclohexyl acrylate, 2-tert-butyl acrylate, 2-naphthyl acrylate, phenyl acrylate, methyl methacrylate, ethyl methacrylate, propyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, sec methacrylate -Butyl, tert-butyl methacrylate, 2,2-dimethylpropyl methacrylate, cyclohexyl methacrylate, 2-tert-butylphenyl methacrylate, 2-naphthyl methacrylate, phenyl methacrylate and the like Radical polymerizable monomers can be exemplified.

  The glass transition temperature (Tg) of the resin for resin processing is preferably −35 ° C. or higher, and more preferably −20 ° C. or higher, from the viewpoints of clarifying the embossed uneven pattern, improving the texture of the surface of the skin material for the skin material, and improving workability. , More preferably -10 ° C or higher, and the upper limit is preferably 20 ° C or lower, more preferably 15 ° C or lower, still more preferably 10 ° C or lower, and particularly preferably 5 ° C or lower. When the Tg of the resin is lower than −35 ° C., a cloth for a skin material having a soft texture and a low modulus can be obtained, but the resin adheres to an embossing mold or a molding die, and the abrasion resistance of the cloth for the skin material is low. It is not preferable because the surface of the skin material for the skin material is deteriorated, and the surface feel of the fabric for the skin material is deteriorated and the touch feeling is deteriorated. On the other hand, if the temperature is higher than 20 ° C., it is not preferable because it has poor followability to a mold during molding and causes wrinkles.

  The form of the binder at the time of resin processing is not particularly limited, but may be a foamable binder that is mechanically and / or chemically foamed. The binder is foamed, the foamed foamed binder is applied to the fiber base material, and then a part or all of the foam in the foamable binder is broken on the fiber base material, thereby forming the binder fiber base material. Can be controlled in the thickness direction.

  The foamable binder preferably contains a foaming agent, a foam stabilizer, a thickener, and the like, in addition to the resin described above.

  As the foaming agent, various surfactants can be preferably used. In particular, nonionic surfactants such as polyoxyethylene alkyl ether, fatty acid sorbitan ester, alkyl polyglucoside, fatty acid diethanolamide, and alkyl monoglyceryl ether; monoalkyl sulfate And anionic surfactants such as alkyl polyoxyethylene sulfates, alkyl benzene sulfonates and monoalkyl phosphates; and the like.

  The amount of the foaming agent added is preferably 0.1 to 6% by weight, more preferably 0.2 to 5.5% by weight, and still more preferably 0.5 to 5% by weight, based on 100% by weight of the foamable binder. It is. If the amount of the foaming agent is less than 0.1% by weight, the binder may not be foamed to a desired expansion ratio, which is not preferable. On the other hand, if the amount of the foaming agent exceeds 6% by weight, the foaming property of the foamable binder after coating becomes poor, and the foamable binder becomes difficult to penetrate in the thickness direction of the fiber base material. .

  As the foam stabilizer, silicone compounds such as polydimethylsiloxane; ammonium salt compounds of fatty acids such as ammonium stearate; and the like can be preferably used.

  The amount of the foam stabilizer added is preferably 0.05 to 20% by weight, more preferably 0.1 to 16% by weight, and still more preferably 0.3 to 14% by weight based on 100% by weight of the foaming binder. It is. If the amount of the foam stabilizer is less than 0.05% by weight, the foam may not be formed uniformly. Further, if the amount exceeds 20% by weight, the foam cannot be made more uniform with the increase in the amount of the foam stabilizer added. Therefore, the foam stabilizer may be wasted, which is not economical.

  Examples of the thickener include thickeners derived from natural products such as sodium alginate; association thickeners such as polyurethane resins; ammonia thickeners such as polyacrylate resins; carboxymethyl cellulose (CMC); Cellulosic thickeners; and the like. Among them, an association thickener such as a polyurethane resin is preferable.

  The amount of the thickener to be added is preferably 0.05 to 5% by weight, more preferably 0.1 to 4.5% by weight, and further preferably 0.1 to 4.5% by weight, based on 100% by weight of the foamable binder. 5 to 3% by weight. If the amount of the thickener is less than 0.05% by weight, the foamable binder cannot have an appropriate viscosity, and when the foamable binder is applied, the foamable binder is immersed in the back surface of the fiber base material. It is not preferable because there is a possibility that it will come out. On the other hand, if the amount of the thickener exceeds 5% by weight, the viscosity of the foamable binder becomes too high, and the foamable binder may not be sufficiently foamed, which is not preferable.

  The expansion ratio of the expandable binder is, for example, preferably from 3 to 11.5 times, more preferably from 4 to 10.5 times, and still more preferably from 5 to 9.5 times. When the expansion ratio is less than 3 times, the amount of air contained in the expandable binder decreases, and the expandable binder easily passes through the fiber base material. This is not preferable because the foamable binder may penetrate to the back side of the fiber base material. On the other hand, if the expansion ratio exceeds 11.5 times, it is not preferable because the expandable binder hardly penetrates the fiber base material deeply. The details of a specific method using a foamable binder may be referred to, for example, JP-A-2015-003445.

  The resin may be mixed with a functional agent such as a pigment, a dye, a deodorant, a flame retardant, an antifouling agent, and an aromatic for the purpose of improving the function as an interior material. A water repellent or a waterproofing agent may be added for the purpose of preventing the adhesive applied during molding from seeping out. As the water repellent and the waterproofing agent, non-fluorinated ones are preferable. For example, “Sybinol (registered trademark)” series manufactured by Seiden Chemical Co., Ltd., “TH-44” manufactured by Nikka Chemical Co., Ltd., manufactured by Nikka Chemical Co., Ltd. "Neoseed (registered trademark)" series and the like.

  As a method of resin processing, a method of applying to a fiber base material by a spray method, a coating method, a printing method, a transfer method, or the like; a method of impregnating a binder into the fiber base material; and the like are preferable. In the present invention, impregnation is also possible, but since a certain amount or more of resin is required to improve abrasion resistance, the texture of the fabric for the skin material is hard and the moldability is inferior. Spray coating is more preferred.

  In the spray method, the orifice diameter is not particularly limited, and for example, is preferably about 0.3 to 1 mm, and more preferably 0.4 to 0.8 mm.

  When applying the foamable binder described above, a coating method is preferable so as not to break bubbles, and a doctor coating method is more preferable.

The purpose of resin processing is mainly to improve abrasion resistance and give gloss to the embossed portion. Therefore, in order to finish the fabric for the skin material with a low modulus, the spray pressure is adjusted by a spray method (for example, 1 〜5 kg / cm ² ), and the binder may be fixed only to the surface layer portion of the fabric for the skin material by using a foaming binder. In the cloth for skin material, the resin processing is preferably performed from the surface of the cloth, and the depth thereof is preferably １ ／ to ／ of the thickness of the cloth.

The fixed amount of resin (resin basis weight), a solid content is preferably 2 to 30 g / m ^2, more preferably from 5 to 20 g / m ^2, more preferably from 8~15g / m ^2. When the resin basis weight is within the above range, a fabric for skin material having excellent abrasion resistance and low modulus can be obtained while maintaining the embossed pattern. On the other hand, when the resin basis weight is large, the fabric is excellent in abrasion resistance, but tends to be a hard texture and a high modulus skin material for a skin material. Even in such a case, for example, in the case of spray processing, the diameter of the resin is reduced by reducing the diameter of the orifice of the spray tip, or if the fiber base is a needle-punched nonwoven fabric, the number of shots is reduced. For example, if the entanglement of the fibers is loosened, the texture and the modulus can be improved.

  The resin processing may be performed on at least one surface of the fiber base material, and may be performed on both surfaces.

  Also, before and after resin processing, if the fiber base material is passed between a heating plate and a heating roll to smooth the surface of the fiber base material, the unevenness of the fiber base surface is reduced, and the unevenness due to the emboss due to the pressure during the molding process. Blurring of the pattern can be suppressed.

3. Embossing In the present invention, a fabric for skin material excellent in design, moldability and abrasion resistance is obtained by further embossing the resin-processed fiber base material obtained by the method described above. In the embossing process, a concave portion serving as a pattern is formed in a resin-processed fiber base material under conditions of heat and pressure.

  The conditions for embossing may be appropriately determined according to the type, depth, area of the pattern, the configuration of the fiber base material, etc., but the temperature is 130 to 240 ° C. (more preferably 180 to 210 ° C.), and the pressure is 30. It is preferably about 200 to 150 kg / cm (more preferably 80 to 150 kg / cm).

  The pattern of the emboss is not particularly limited, and it is preferable to form a shape such as a carbon cloth tone, a texture tone, a grained tone, a diamond pattern, a dot, a polygon, a waveform, a stripe, and a heart as the embossed projection. It is not necessary that all the embossed projections have the same shape and height. A variety of shapes and heights change the degree of shine, and further improve the design.

  The emboss ratio is preferably from 5 to 55%, more preferably from 20 to 45%, and still more preferably from 25 to 40%, from the viewpoints of designability, texture, and followability to a molding die.

  The depth of the embossment relative to the thickness of the skin material cloth is preferably 0.125 times or more, more preferably 0.2 times or more, and even more preferably 0.25 times or more the thickness of the skin material cloth. . The upper limit is not particularly limited, but is preferably 0.5 times or less, and may be 0.4 times or less. In particular, when embossing is performed on a fiber base material having a dark fiber mixing ratio of 70% by weight or more so that the embossing ratio and the depth from the surface fall within the above ranges, the embossed pattern becomes clear. Moreover, the illusion of the embossed portion tends to cause a spatial illusion that bright colors are near and dark colors are far away, which is very effective for making the interior of the vehicle compartment wide.

  The depth of the embossed portion is 0.15 to 0.8 times the thickness of the fiber base material of the embossed portion (that is, a length obtained by subtracting the depth of the embossed portion from the thickness of the fiber base material). It is preferably within the range, more preferably 0.3 to 0.6 times.

  The fabric for skin material according to the present invention is excellent in elongation characteristics because of ease of molding. For example, the modulus at 10% elongation in the vertical direction of the skin material for skin material is preferably less than 90 N / 5 cm, more preferably 70 N / 5 cm or less, further preferably 50 N / 5 cm or less, and the lower limit is not particularly limited. , For example, 40 N / 5 cm or more. Further, the modulus at the time of 10% elongation in the horizontal direction of the fabric for the skin material is preferably less than 70 N / 5 cm, more preferably 36 N / 5 cm or less, further more preferably 25 N / 5 cm or less, and the lower limit is not particularly limited. , For example, 15 N / 5 cm or more.

  Further, the fabric for a skin material according to the present invention is also excellent in abrasion resistance. For example, in the abrasion resistance measured according to JIS L1913 6.6.1a), the cloth can exhibit class 3 or higher, and furthermore, it is possible to exhibit a resistance of 4 or more. Grade or higher, more preferably 4 to 5 grade, still more preferably 5 grade.

4. Interior material When molded as an interior material for a car, a molding material obtained by laminating an adhesive layer and a skin of the present invention on a base material may be placed between upper and lower molding dies and heated and pressed. . The base material is appropriately selected depending on the purpose and application of the molded product, but in the molding process, it is preferable that the base material be shaped into a predetermined shape only by heat and pressure, or pressure alone. Body, rigid or semi-rigid synthetic resin material, or a foam or a fiber reinforced synthetic resin reinforced with glass fiber or the like is used. Among them, a polyurethane resin foam and a polystyrene resin foam having a thickness of about 3 to 5 mm are used. Or, a fiber-reinforced synthetic resin plate is suitable.

  As the adhesive layer, films, sheets, and pellets can be used as an isocyanate-based, acrylic-based, synthetic rubber-based emulsion adhesive, or a synthetic resin-based hot melt adhesive, and particularly have a low melting point (80 ° C to 160 ° C). ) Spunbond nonwoven fabric (spider web hot melt sheet: Dynac (registered trademark)) made of polyamide resin is preferable.

  The molding method may be performed by applying pressure by a known press method. A cold press method in which the molding material is heated in advance and then pressed at room temperature; at least the lower mold of the upper and lower molds is heated, and the molding material is heated. A known means such as a hot press method in which pressure is applied;

  The molding conditions may be determined as appropriate according to the type and shape of the skin and the base material. For example, in the case of hot pressing, the temperature is preferably 50 to 170 ° C, more preferably 80 to 150 ° C, and the pressing time. Is preferably about 10 to 60 seconds.

  Generally, the heating and pressurizing conditions in the molding process are gentler than in the embossing process. Therefore, when the fabric for a skin material of the present invention is used, the embossed pattern can be maintained. The fabric for a skin material according to the present invention is particularly preferably used as a fabric for a skin material for a vehicle such as a ceiling, a door trim, and a rear package (that is, a design outer surface material for a skin material).

  Hereinafter, the present invention will be described more specifically with reference to Examples. However, the present invention is not limited to the following Examples, and may be appropriately modified within a range that can be adapted to the purpose of the preceding and the following. It is of course possible to carry out them, and all of them are included in the technical scope of the present invention.

  The measuring methods used in the examples and comparative examples are as follows.

(Emboss rate)
The ratio of the area (S ₁ ) of the convex portion on the embossing roll having a constant area (S ₀ ) is calculated as the emboss ratio by the following equation.
Emboss ratio (%) = S ₁ / S ₀ × 100

(Emboss depth)
A sample is taken from the embossed non-woven fabric, cut with a sharp cutter, and the cut cross section is observed under magnification to determine the thickness of the non-embossed portion (T ₀ : equivalent to the thickness of the non-woven fabric) and the surface. Of the embossed portion (T ₁ ) is measured. The emboss depth from the surface is calculated by the following equation.
Embossing depth = T ₁ / T ₀

(Weight)
According to JIS L1913 6.2.

(Brightness of fiber)
A fiber web obtained by carding fibers with a carding machine is laminated, and the number of needles is 60 / cm ² , the needle depth is 8 mm from the front side, and the back side is from the back side using a needle (manufactured by Organ: part number 1-40). A high-speed spectrophotometer was used to measure the lightness of the surface of a nonwoven fabric having a basis weight of 100 g / m ² , which had been punched with a number of needles of 90 / cm ² and a needle depth of 8 mm, and a number of needles of 120 / cm ² and a needle depth of 8 mm. (Manufactured by Murakami Color Research Laboratory Co., Ltd .: model number CMS-500: sample window size 15.5 mm × 24 mm, observation size 8 mm × 16 mm).

(Modulus)
According to JIS L1913 6.3, a sample of 5 cm × 20 cm was collected from the fabric for the skin material prepared in the Examples and Comparative Examples, and the vertical direction (the flow direction of the nonwoven fabric in the manufacturing process; the MD direction) and the horizontal direction (the MD direction) In the direction perpendicular to the direction; CD direction), the film is pulled at a grip interval of 10 cm and a speed of 20 cm / min, and the modulus at 10% extension (1 cm extension) is measured. The modulus was evaluated according to the following items.
◎: very low modulus (vertical: <50 N / 5 cm, horizontal: both satisfy <25 N / 5 cm), very suitable for molding ：: low modulus (vertical: 50 N / 5 cm or more and less than 70 N / 5 cm) , Horizontal: satisfy any of 25 N / 5 cm or more and less than 36 N / 5 cm), but suitable for molding △: slightly higher modulus (vertical: 70 N / 5 cm or more but less than 90 N / 5 cm, horizontal: 36 N / 5 cm or more and 70 N / ×: high modulus (vertical: ≧ 90 N / 5 cm, horizontal: ≧ 70 N / 5 cm), not suitable for molding

(Wear resistance)
According to JIS L1913 6.6.1a), a load of 500 g is applied to the worn wheel CS-10, and the surface state after 50 rotations is visually checked. Grade 3 or higher is evaluated as good.

(Moldability)
It is molded with the molding die currently used, and it is visually checked whether wrinkles occur in the deep drawing part.
：: No wrinkles at all, as in the case without embossing
：: Can be used as a product, although there are wrinkles
△: Although it has small wrinkles, it can be used as a product
×: Many large wrinkles are generated and cannot be used as a product.

(Surface design)
The design before and after molding is evaluated as follows.
Before molding: appearance / tactile feel, after molding: appearance / disappearance / feel of the pattern / appearance (pattern) Visually check whether the pattern is clear.
◎: The pattern can be confirmed very clearly
：: The pattern can be clearly confirmed
×: The pattern is not clear and is blurred.-Disappearance of the pattern Visually check whether the pattern of the deep drawing portion has disappeared.
：: Very good design without loss of pattern
：: The design is excellent although the pattern is slightly lost.
×: The pattern has disappeared and the design is not excellent. ・ Tactile sensation Check the tactile sensation when touching the surface by hand.
◎: Very good tactile sensation
：: Excellent touch feeling
Δ: Surface condition is poor and touch feeling is not excellent

  The fibers and binders used in the examples and comparative examples of the present application are summarized below.

Example 1
90% by weight of a dark gray-colored original polyester fiber (lightness 43) having a fineness of 3.3 dtex and a fiber length of 51 mm, and 10% by weight of a white original polyester fiber (lightness 80) having a fineness of 2.2 dtex and a fiber length of 51 mm. The fiber web which has been blended, carded, and wrapped is needle-punched from both sides of the fiber web at 950 needles / cm ² and a needle depth of 6 mm to form a 190 g / m ² non-woven fabric. Then, a polyacrylate binder (glass transition temperature: Tg-10 ° C.) was applied to a dry conversion of 10 g / m ² by spraying (spray tip orifice diameter 0.66 mm) and dried, and the total was 200 g / m ^2. to obtain a pattern with a non-woven fabric made with m ^2.
Embossing is performed under the conditions of a temperature of 200 ° C. and a pressure of 120 kg / cm using an embossing roll formed so that the embossing ratio becomes 35% using the diamond pattern as a convex portion, and the diamond pattern is patterned on the surface. A skin material for a skin material was obtained. A base material (urethane foam), an adhesive (isocyanate-based), and a skin material were laminated in this order, and molded using a molding die for an automobile ceiling at a temperature of 150 ° C. and a press time of 30 sec.

Examples 2 to 14, Comparative Examples 1 to 6
A fabric for a skin material was obtained and molded in the same manner as in Example 1, except that the fiber configuration, needle punch conditions, basis weight, resin Tg and resin processing method, and emboss ratio were changed as shown in the table.

  In Example 5, a composition for a foamable binder was prepared by the following method, and the prepared foamable binder composition was foamed with a general-purpose mechanical foaming machine to obtain a foamable binder. After forming the nonwoven fabric in the same manner as in Example 1, instead of resin processing by spraying, a foaming binder having an expansion ratio of 6 to 7 times produced by the above method is applied to one surface of the nonwoven fabric by a doctor coating method. Then, a part of the foamable binder was impregnated into one side of the obtained nonwoven fabric. Thereafter, the nonwoven fabric after the application of the foamable binder was introduced into a hot air dryer heated to 150 ° C., and dried for 1 minute to obtain a nonwoven fabric for patterning. The embossing process and the molding process applied to the obtained nonwoven fabric for patterning were performed in the same manner as in Example 1 to obtain a fabric for a skin material.

(Composition for foamable binder)
・ Polyacrylate ester binder (Tg: -10 ° C.): 20 parts ・ Foaming agent (Mayforma F210): 1 part ・ Foam stabilizer (33% ammonium stearate-containing foam stabilizer, “DC-100A” manufactured by San Nopco) "): 3 parts ・ Thickener (associative thickener for polyurethane resin," Neo Sticker N "manufactured by Nikka Chemical Co., Ltd .: 0.8 part)

In Comparative Examples 1 and 2, after the fibers shown in the table were weighed, and the fiber webs mixed, carded and wrapped were subjected to needle punching based on the conditions shown in the table to form a 180 g / m ² nonwoven fabric. In place of the resin processing, a nonwoven fabric prepared so as to have a residence time of 20 seconds in a heat treatment machine at a temperature of 150 ° C. was introduced, and subjected to a heat treatment to obtain a nonwoven fabric for patterning. The embossing process and the molding process applied to the obtained nonwoven fabric for patterning were performed in the same manner as in Example 1 to obtain a fabric for a skin material.

  In Comparative Example 3, an interior was obtained in the same manner as in Example 1 except that embossing was not performed.

  In Tables 3 to 5 below, “NP” means needle punching, and “NP / TB” means that after performing needle punching, thermal bonding is further performed.

  Since the fabric for the skin material of Example 1 contained 70% by weight or more of the dark-colored fibers having a lightness of less than 75, the embossed concavo-convex pattern was clear.

In Example 2, the resin weight was reduced to 5 g / m ² as compared with Example 1, and embossing was performed over a wide area with a shallower emboss. In this case, a low modulus could be realized because the amount of the resin fixed was small, but the abrasion resistance was reduced from the fourth grade to the third grade.

In Example 3, the fibers to be used were changed from dark gray to light gray, and the mixing ratio of white fibers was increased to 30% to prepare a light-tone skin material fabric. In addition, the resin basis weight was increased to 20 g / m ² . Even in the case of a skin material for a skin material having a relatively bright tone, the appearance was good when the cotton mixing ratio of the dark-colored fibers was 70% by weight or more. On the other hand, the modulus was inferior to that of Example 1 due to a large resin basis weight, but at a level satisfactory as a product.

  In Example 4, resin processing was performed using a binder having a high Tg. Although the modulus was inferior to that of Example 1 due to the high Tg, it was at a satisfactory level as a product. Good results were also obtained for other items.

  In Example 5, resin processing was performed using a foamable binder. In this case, since the binder is partially impregnated and solidified in the thickness direction of the skin material cloth, it is slightly inferior in modulus in comparison with Example 1 in which resin processing is performed by spraying. Was satisfactory, and good results were obtained in other items.

  In Example 6, a fabric for skin material containing hollow crimped polyester was produced. Because of containing the crimped fiber, the fabric for the skin material was able to realize a low modulus, and the pattern was hard to disappear due to the spring effect of the crimped fiber, and the feel was excellent.

In Example 7, the resin basis weight was also 20 g / m ² , but the diameter of the spray was reduced and the conditions of needle punching were changed to loosen the entanglement of the fibers. Even if it was applied, a low modulus could be realized. In addition, the abrasion resistance was good due to the large resin weight.

  In Example 8, a fabric for a skin material containing a low-melting fiber was produced. Since part or all of the low-melting fiber is melted by heating, it can be bonded to other fibers contained in the nonwoven fabric. Therefore, since the fiber entanglement can be loosened by changing the conditions of the needle punching, a low modulus can be realized. In addition, since the low-melting fiber was melted by heating during embossing, the contour of the concavo-convex pattern became clear. Further, the followability to the mold was improved, so that the moldability was also excellent.

In Example 9, a fabric for a skin material was obtained in the same manner as in Example 3, except that the emboss ratio was increased and the resin basis weight was changed to 10 g / m ² . Since the amount of the resin used was small, the fabric for the skin material had a lower modulus than that of Example 3 and was excellent in moldability.

  In Examples 10 to 13, the types of fibers included in the nonwoven fabric were variously changed from those in Example 1. In Example 10, 40% by weight of a fiber having a lightness of 72 was used as the fiber contained in the nonwoven fabric. However, if the lightness of the fiber was lower than 75, even if the cotton mixing ratio exceeded 30% by weight, the appearance was reduced. There was no problem with the disappearance of the handle. In Example 11, a fabric for a skin material composed of 100% by weight of a fiber having a lightness of 21 was produced. However, the higher the cotton mixing ratio of the dark-colored fiber, the more the concavo-convex pattern became very clear, and the appearance was the best. In Example 12, a fabric for a skin material was produced by combining fibers having a large difference in lightness, such as a fiber having a lightness of 21, a fiber having a lightness of 36, and a fiber having a lightness of 86. On the other hand, in Example 13, a fabric for a skin material was produced by combining fibers having a small difference in brightness, such as brightness 70, brightness 72, and brightness 76. As is clear from the results of Example 12 and Example 13, there is no problem in terms of appearance and pattern disappearance if the cotton mixing ratio of the dark-colored fiber is 70% by weight or more regardless of the difference in brightness. I understood.

  In Example 14, resin processing was performed using a resin binder having a Tg of −30 ° C. Since the Tg was low, the abrasion resistance was good and the followability to the mold was excellent, so that no wrinkles occurred during molding. However, the stickiness was felt due to the low Tg, and the evaluation was “評 価” in the tactile sensation.

  On the other hand, in Comparative Examples 1 and 2, resin processing was not performed, so that after embossing the fabric for the skin material, the embossed uneven pattern disappeared, and satisfactory design properties could not be exhibited. In Comparative Example 1, the mixing ratio of the low-melting fiber was increased, so that the modulus was high and the feel was hard. In addition, wrinkles were easily generated, and the moldability was poor. In Comparative Example 2, since no resin processing was performed, the abrasion resistance was poor as “second class”.

  In Comparative Example 3, since the embossing was not performed, the modulus was high, but the design was inferior.

  In Comparative Examples 4 to 6, a fabric for a skin material having a cotton blending ratio of dark fiber of 60% by weight was produced. In any of the examples, since the cotton mixing ratio of the dark-colored fiber was low, the uneven pattern formed by the embossing was blurred in appearance, and was inferior in design.

Claims (11)

A fiber base material containing 70% by weight or more of dark-colored fibers having a lightness of less than 75 has been subjected to resin processing and embossing processing and has not been subjected to printing processing, and has a modulus of 90 N / 5 cm at 10% elongation in the vertical direction. A modulus at 10% elongation in the transverse direction of less than 70 N / 5 cm .   The fabric for a skin material according to claim 1, wherein the fiber base material is a needle punched nonwoven fabric. Needle punching number of implanted machining needle is 80-1200 present / cm ^2, surface material cloth of claim 1 or 2 basis weight of said fibrous substrate is 50 to 400 g / m ^2.   The embossing ratio is 5 to 55%, and the emboss depth relative to the thickness of the skin material is 0.125 times or more the thickness of the skin material. A fabric for a skin material as described in the above.   The fabric for a skin material according to any one of claims 1 to 4, wherein the lightness of the dark-colored fiber is 55 or less.   The fabric for skin material according to any one of claims 1 to 5, further comprising at least one or more bulky fibers selected from hollow fibers, crimped fibers, and hollow crimped fibers.   The fabric for a skin material according to any one of claims 1 to 6, wherein the bulky fiber is contained as a light-colored fiber having a lightness of 75 or more.   The skin according to any one of claims 1 to 7, further comprising a low-melting fiber, wherein a mixing ratio of the low-melting fiber is 1% by weight or more and 15% by weight or less in 100% by weight of the fabric for a skin material. Material fabric.   The cloth for skin materials according to any one of claims 1 to 8, wherein the resin processing is performed from a surface of the cloth, and a depth of the resin processing is 1/3 to 2/3 of a cloth thickness.   The cloth for skin materials according to any one of claims 1 to 9, wherein a glass transition temperature (Tg) of the resin for resin processing is from -35 ° C to 20 ° C.   The cloth for skin materials according to any one of claims 1 to 10, wherein two or more kinds of fibers having different lightness are mixed as the dark-colored fibers.