JPH02293131A - Composite sheet and preparation thereof - Google Patents

Abstract

PURPOSE:To impart a three-dimensional transfer print pattern by the uneven surface pattern of thin cloth by integrating the thin cloth having the uneven pattern and a stretched film having a heat shrinkage factor with surface of cloth to form a composite sheet. CONSTITUTION:A composite sheet 1 is molded from a thin cloth layer 2 and a stretched film layer 3 but a base material 4, pref. a flexible base material is integrated with the stretched film layer 3. The thin cloth 2 of the composite sheet 1 has an amorphous fine and deep uneven pattern, especially pref., a rubbed and wrinkled uneven pattern and becomes three-dimensional in appearance by this uneven pattern. As the fiber material constituting the thin cloth 2, one based on a polyester fiber is pref. As an embodiment of the stretched film constituting the stretched film layer, there is a film obtained from a synthetic resin such as polyolefin, polyester or polyamide.

Description

Detailed Description of the Invention [Field of Industrial Application] The present invention relates to a composite sheet in which a thin fabric layer having an uneven pattern or an uneven pattern and a printed pattern on the surface is laminated and integrated with a stretched film layer, and the production thereof. Regarding the method.

[Conventional technology]

Conventionally, thin fabrics made of woven fabrics, non-woven fabrics, etc. have a low fiber density and a small fineness of their constituent fibers, so
It has been rare to form uneven patterns on such thin fabrics because embossing or wrinkling processes easily destroy the structure and greatly disturb it, impairing its aesthetic appearance. (Shrinking fabrics and the like are those that have been specially processed and are not textured such as embossing in the present invention).

On the other hand, films, especially stretched films that are uniaxially or biaxially stretched and have many excellent physical properties such as high mechanical strength, surface smoothness, and scratch resistance, have polymer chains highly oriented in a certain direction. Since the surface of the stretched film is hard and highly elastic, it is usually difficult to impart an uneven pattern by embossing or wrinkling at a low temperature around room temperature without changing the physical properties of the stretched film itself.

This stretched film can be laminated onto other substrates with good shapeability.
After joining, the stretched film is heated to around a temperature at which it softens or melts, and then embossing or the like is performed to impart an uneven pattern. However, in this case, there are disadvantages in that the stretched film may peel off from the base layer, and the excellent physical properties of the stretched film may be impaired by embossing.

Furthermore, in order to add a dyed pattern to this stretched film layer in addition to an uneven pattern, it is necessary to perform a two-stage process in which one of the patterns is applied and then the remaining pattern is applied, making the operation complicated. However, the productivity was low and it could not be implemented industrially.

[Problem to be solved by the invention]

An object of the present invention is to provide a composite sheet in which the above-mentioned thin fabric and stretched film, both of which have hitherto been difficult to provide with an uneven pattern, are used simultaneously, and a method for producing the same.

Another purpose is to maintain the excellent physical properties of a stretched film and the delicate and soft feel and appearance of a thin fabric, and to create an uneven pattern on the surface of the thin fabric, preferably a three-dimensional transfer printed pattern due to the uneven pattern. An object of the present invention is to provide a composite sheet with a laminate and a method for producing the same.

[Means to solve the problem]

The composite sheet of the present invention is composed of a thin fabric and a stretched film having a heat shrinkage rate, and is characterized in that the surface of the thin fabric has an uneven pattern.

The figure is a schematic perspective sectional view showing one embodiment of such a composite sheet of the present invention. As shown in the figure, the composite sheet 1 of the present invention consists of a covered fabric layer 2 and a stretched film layer 3.
A base material 4, preferably a flexible base material, is preferably integrally bonded to the stretched film layer 3. The uneven pattern of the thin fabric 2 of the composite sheet 1 of the present invention is an amorphous fine and deep uneven pattern, especially a crumpled and wrinkled uneven pattern, and such an uneven pattern gives the appearance three-dimensional and It also has a three-dimensional, voluminous feel. On the surface of the composite sheet 1 of the present invention,
In addition to the above-mentioned uneven pattern, conventionally known pre-processing such as embossing or wrinkle processing may be applied in advance, or it can also be provided by post-processing. By such embossing and wrinkle processing, the uneven pattern can be made complex, and the appearance and feel of the surface can be diversified.

In the composite sheet of the present invention, it is desirable that a transfer print pattern is provided on the surface of the thin fabric in addition to the uneven pattern. Here, the transfer print pattern refers to a transfer paper printed with a plain color or various patterns using dyes or pigments, which is superimposed on the thin fabric layer constituting the composite sheet of the present invention, and heated from the transfer paper side. A printed pattern formed by transferring the printed pattern of In the case of a plain pattern, plain transfer paper of various colors without a printed pattern may be used, and the stretched film may be heat-shrinked under the same conditions as above to develop an uneven pattern.

The uneven pattern and printed pattern of such thin fabrics are irregular, fine and deep uneven patterns, especially the colors of the printed pattern overlap with the crumpled and wrinkled pattern, giving a complex appearance. In some cases, the pattern is made three-dimensional.

Moreover, the texture is rich in volume due to the uneven pattern.

The fiber material constituting the thin fabric that forms the surface layer of the composite sheet of the present invention is not particularly limited as long as it has only irregularities, but in the case of the transfer printing, the durability of the printed colored pattern From above, it is preferable to use a thin fabric mainly composed of polyester fibers. Thin fabrics containing polyester fibers as a main component include blended or inter-knitted fabrics of polyester fibers having a weight of at least 50 χ and cotton, rayon, wool, etc. having a weight of not more than 50 χ, or non-woven fabrics. Preferably, JIS L-1096
It is preferable that the drape coefficient is within the range of 5 to 70 as defined in (General Textile Testing Methods).

On the other hand, examples of the stretched film laminated on the thin fabric include films made from polyolefins such as polybrobylene and ethylene-propylene copolymers, and synthetic resins such as polyester, polyamide, and polyvinyl chloride.

It is preferable to use a film formed by blending inorganic fine particles (hereinafter referred to as filler) with these resins and forming a large number of voids inside by uniaxial or biaxial stretching, that is, a stretched void film. ．． The fillers include inorganic particles such as calcium carbonate, magnesium carbonate, alumina, aluminum silicate, kaolin, kaolinite, talc, clay, diatomaceous earth, dolomite, titanium oxide, magnesium oxide, and zeolite, or synthetic resin components forming the film. Examples include fine particles made of different synthetic resins. These fine particles may be either a single substance or a mixture, but preferably they are mainly composed of calcium carbonate. The blending amount of the filler is 10 to 40 weight χ, preferably 15 to
If the range of 35 weight χ is less than 10 weight χ, then
The shrinkability of the stretched void film is insufficient, making it difficult to cause sufficient shrinkage during transfer printing, resulting in insufficient unevenness formation of thin fabrics, and when the weight exceeds 40 weight tχ, the resin compound becomes brittle and cannot be stretched. Sometimes they tend to tear easily, making it difficult to make into a film.

It is desirable that this stretched void film has a void ratio of 25x to 7oz, preferably 30x to 55x.

Here, the void ratio (χ) refers to the density of the stretched voided film having voids. This stretched void film is thermocompression bonded near the melting point of its component synthetic resin, and when the density of the film with the voids filled is ρ, it is a value defined by the following equation.

Note that the density of a stretched void film is determined by its weight and volume (
Calculated from thickness x area).

Void ratio (χ) = [(ρ - ρ.) / ρ) Although formation is possible, the stretched void film becomes brittle and has insufficient strength. In addition, the above void rate is
This is the value before forming an uneven pattern on the composite sheet of the present invention. In order to obtain a stretched voided film having the above-mentioned predetermined void ratio, increasing the film forming conditions such as the stretching ratio and stretching temperature will increase the void ratio, and increasing the amount of filler will also increase the void ratio. be able to.

The void structure of this stretched voided film does not necessarily have to be uniform in the thickness direction of the film; for example, the void ratio near the surface may be lower than in the center of the film or there may be no voids. On the contrary, if voids exist on the surface, the toughness of the surface decreases, the adhesion to thin fabrics also decreases, and this is unfavorable in terms of durability such as peeling during or after the formation of irregularities. It is preferable that at least the surface of the void film that is bonded to the thin fabric has no voids. The method for manufacturing this stretched void film that does not have voids on at least one surface is to coextrude two or more synthetic resins with different filler amounts into a film, or to blend a filler-containing synthetic resin with a filler. It can be obtained by co-extruding a non-containing resin into a film and then stretching it. In addition, separate films are made from two or more types of synthetic resins with different amounts of filler added, or a synthetic resin containing filler and a resin containing no filler, and one of these resin film layers is vertically stacked. It can be obtained by stretching in the transverse direction, then laminating other layers and stretching in the transverse direction. To explain the manufacturing method more specifically, a synthetic resin such as polypropylene mixed with a filler such as calcium carbonate, and a synthetic resin such as an ethylene propylene block copolymer that does not contain this filler are mixed together. The resin layer is coextruded to a thickness ratio of about 0.01 to 0.2, which is the thickness ratio of the resin layer not containing filler to the resin layer, and stretched in both the vertical and horizontal directions, and the stretching ratio (length x width) is about 50 to It is stretched 50 times and then heat set.

In addition to the above fillers, heat stabilizers, antioxidants,
Various additives such as weathering agents, antistatic agents, and nucleating agents can be appropriately blended.

The stretched film used in the present invention is subjected to a corona discharge treatment in air or an inert gas atmosphere on the joint surface, that is, on the surface of the ethylene propylene prosoc copolymer film layer, so that the surface wetting tension becomes 40 dynes/cI1 or more. It is preferable.

The ratio of the thickness of the thin fabric to this stretched film is 1.0
Below, it is preferably 0.05 to 0.6, more preferably 0.1 to 0.3. If this thickness ratio becomes too large, it becomes difficult to form unevenness. Note that as long as the thickness ratio is within the above range, the thickness of each of the stretched film and thin fabric is not particularly limited, but the thickness of the stretched film is
The thickness of the thin fabric is preferably 6 to 50 μm, preferably 10 to 40 μm, and the thickness of the thin fabric is 30 to 150 μm, preferably 60 to 1
20 μm is good.

When commercializing the composite sheet of the present invention comprising the above-mentioned thin fabric and stretched film, it is desirable to laminate and integrate a base material, preferably a flexible base material, on the stretched film surface of the composite sheet. The base material is appropriately selected from ordinary knitted fabrics, nonwoven fabrics, papers, foams, synthetic leathers, artificial leathers, and the like.

Hereinafter, a method for manufacturing a composite sheet according to the present invention will be explained.

The composite sheet of the present invention is produced by laminating the thin fabric, such as a polyester fiber fabric, and a stretched film, such as a stretched poid film made of polypropylene, bonding and integrating them using an adhesive, and then applying a desired base material to the stretched film surface. Join them to create a composite sheet. Next, a transfer printing paper is superimposed on the thin fabric surface of this composite sheet, and the thin fabric surface is heated under temperature conditions such that the stretched film shrinks but the thin fabric layer does not shrink, thereby performing transfer printing. By this transfer printing, the stretched film layer of the composite sheet is selectively heat-shrinked, and the composite sheet of the present invention can be manufactured by forming irregularities on the surface of the thin fabric. The conditions for the thermal transfer printing are not particularly limited, but usually the stretched film has an areal shrinkage rate of at least 1.
Preferably, conditions are selected that result in % shrinkage.

Note that the adhesive used for bonding the thin fabric and stretched film constituting the composite sheet of the present invention and for bonding this stretched film and the flexible base material is not particularly limited. , are appropriately selected and used depending on the type of stretched film and base material. Preferred adhesives include synthetic resin adhesives such as reactive or self-crosslinking polyacrylic acid ester adhesives, urethane adhesives, and epoxy adhesives, and rubber adhesives.

In the composite sheet of the present invention, transfer printing is applied to the entire surface of the thin fabric layer, or by partially transfer printing (heating), the transfer print pattern and unevenness H
Also included are those provided with a portion where no ffi is formed.

In addition, the fabric surface on which the uneven pattern, the uneven pattern, and the transfer print pattern are formed can be coated with a resin, preferably a transparent resin, to improve its durability. After that, by simple operations such as creasing or hand-rubbing, a finer uneven pattern can be added to the uneven pattern formed by transfer printing, and the surface gloss and texture can be changed.

〔Example〕

Hereinafter, the present invention will be explained in more detail with reference to Examples.

Example 8 Menoret index based on STM-01238 (
M. 1) Particle size is 1.7 in polypropylene resin with 1.0.
A resin composition containing 20 weight x of calcium carbonate of μ was melted and formed into a film by a known method, and 3.
A stretched void film having a thickness of about 60 μm and an area shrinkage rate (120° C., 30 minutes) of 5% was prepared by biaxially stretching 5 times and 9 times in the transverse direction and heat setting.

Using urethane adhesive "Seiriki Bond" E260/C26 manufactured by Dainichiseika Kagyo ■ on this stretched void film,
A 50/50 blended plain fabric of polyester fibers and rayon having a drape coefficient of 50 was joined together, and a felt-like polyester fiber nonwoven fabric was laminated on the stretched void film surface as a base material to obtain a composite sheet.

A transfer paper was placed on the stretched void film surface of the obtained composite sheet, and thermal transfer printing was performed while heating at 200° C. for 30 seconds.

On the plain weave surface of the thin fabric of the thermally transfer printed composite sheet, a three-dimensional transfer print pattern was formed with a textured uneven pattern, but the texture was not damaged at all.

〔Effect of the invention〕

According to the present invention, a thin fabric and a stretched film, which have conventionally been difficult to form an uneven pattern on the surface, have a monotonous appearance and feel, and lack functionality, are laminated to form an integrated composite sheet, By forming an uneven pattern, preferably a transfer print pattern, on the surface of the thin fabric, it is possible to give the surface a three-dimensional effect and make its appearance and feel, as well as its color and gloss, complex and diverse. .

Moreover, the uneven pattern of this thin fabric is created by a simple crumpling process.
For example, by rubbing it with your hands, the shape and form of the unevenness changes, so the degree of unevenness can be changed to a unique one according to your preference at or after the product is manufactured.

Therefore, the composite sheet of the present invention can be used in a variety of products that can be used in a wide range of applications by combining thin fabrics, stretched films, types of substrates, embossing before or after thermal transfer printing, etc. , building materials such as wall materials and flooring materials, books, stationery, binding, furniture,
It can be applied alone or in combination with existing materials in many fields such as automobile interior materials, bags, and bags.

[Brief explanation of drawings]

FIG. 1 is a schematic perspective sectional view showing one example of the composite sheet of the present invention. DESCRIPTION OF SYMBOLS 1... Composite sheet, 2... Thin fabric layer, 3... Stretched film layer. Figure 7 Agent: Patent Attorney Shinichi Ogawa

Claims (4)

[Claims] (1) A composite sheet consisting of a thin fabric and a stretched film having a heat shrinkage rate, and the surface of the thin fabric has an uneven pattern. (2) A composite sheet consisting of a thin fabric mainly made of polyester fibers and a stretched film having a higher heat shrinkage rate than the thin fabric, the surface of the thin fabric having an uneven pattern and a printed pattern. (3) A composite sheet is created by laminating and integrating a stretched film with a heat shrinkage rate on a thin fabric, a transfer sheet is laminated on the thin fabric surface of this composite sheet, and thermal transfer printing is performed under temperature conditions that cause the stretched film to shrink. A method for producing a composite sheet, which comprises shrinking the stretched film layer by shrinking the stretched film layer. (4) A composite sheet is created by laminating and integrating a stretched film having a higher heat shrinkage rate than the thin fabric onto a thin fabric mainly made of polyester fibers, and a transfer sheet is laminated on the thin fabric surface of this composite sheet, A method for producing a composite sheet, characterized in that thermal transfer printing is performed under temperature conditions where the thin fabric does not shrink but the stretched film shrinks, thereby causing the stretched film layer to shrink.