TW201345727A - Resin sheet member as well as composite sheet member and method for manufacturing the same - Google Patents

Abstract

An objective of the present invention is to provide a resin sheet member having great modulus and very appropriate for processing such as pulling and bending, as well as a composite sheet member and a method for manufacturing the same. A resin sheet member for attaining this objective has a transferred shape of a fabric surface of cloth formed on at least one side thereof, said manufacturing method includes transferring the shape of the fabric surface to a resin film by attaching the fabric surface of cloth to an incurred resin film, and peeling or dissolving and removing the cloth from the resin film after the resin film is cured. Further, the composite sheet member has a substrate laminated on the resin sheet member, and the manufacturing method includes attaching the substrate to at least one side of the resin sheet member.

Description

Resin sheet material and composite sheet material and method of producing the same

The present invention relates to a resin sheet having a transfer shape in which at least one surface is formed, a method for producing the same, and a composite sheet in which a substrate is laminated on the resin sheet and a method for producing the same. Specifically, it can be suitably used for clothing, bags, shoes, automotive interior materials (central panels, door panels, sheet skins, etc.), mobile phones, notebook computer casings, partitions, and residential equipment related materials. Resin sheet material and composite sheet material and a method for producing the same.

In general, "sheet" is defined in the Japanese Industrial Standard (hereinafter referred to as "JIS") as a product which is thin and generally small in thickness and flat compared to the ratio of length to width, generally In other words, "film" refers to a thin and flat product which is extremely small in thickness and has a maximum thickness as compared with the length and width, and is usually supplied as a roll (JIS K 6900). Further, in terms of thickness, those having a thickness of 100 μm or more are referred to as sheets, and those having a thickness of less than 100 μm are referred to as films. The "sheet material" in the present invention means that both the "sheet" and the "film" are not included.

In addition, the "composite sheet material" in the present invention refers to a resin sheet material of the present invention and a sheet-like substrate such as a woven fabric, a woven fabric, a nonwoven fabric, a leather, or a paper.

In the past, there were patterns, patterns of resin sheets or imitation days. The leather-like resin sheet made of leather has (1) a embossed and printed resin sheet, and (2) a composite sheet in which a resin sheet and a substrate are bonded (for example, synthetic leather). , artificial leather, etc.). In the conventional resin sheet of (1), a coloring layer is generally formed on the surface of the resin film by a method such as printing, and a transparent layer for the purpose of protection is laminated thereon. However, such a resin sheet material is used to prevent fine cracking and tearing of the coloring layer due to elongation or deformation, and a resin which is hard and difficult to stretch is used as a material thereof, and it is difficult to perform drawing processing or bending processing ( Patent Document 1).

Moreover, the conventional composite sheet of (2) is such that the resin layer and the substrate are not The peeling method is firmly followed, but the tensile strength and modulus (stress at the time of elongation) of the resin sheet and the longitudinal direction (MD), the transverse direction (CD) of the woven fabric, the woven fabric, the non-woven fabric, and the like which become the substrate are When it is subjected to drawing processing or bending processing when it is attached to the surface of a three-dimensional object having a curved surface, there is a problem that partial wrinkles and floating occur, and there is a problem of lack of beauty when finished (Patent Document 2).

[Previous Technical Literature] [Patent Literature]

[Patent Document 1] Japanese Patent No. 2600958

[Patent Document 2] Japanese Patent Laid-Open No. Hei 11-117181

An object of the present invention is to provide an excellent conformability to a drawing process and a bending process, for example, even if it is closely attached to a complicated three-dimensional shape such as a curved surface. When the surface of the object is formed, it is still difficult to produce wrinkles and floats, and the resin sheet and the composite sheet which are excellent in appearance can be obtained, and the manufacturing method thereof can be provided.

In order to solve the above problems, the inventors of the present invention have improved the processing suitability of the resin sheet itself and the composite sheet in which the resin sheet and the substrate are laminated, and as a result of the review, it was found that the fabric was formed by at least one side of the resin sheet. The transfer shape of the cloth surface can increase the modulus of the resin sheet material, and the present invention has been completed. Further, the modulus refers to a stress at the time of constant elongation of a resin sheet or the like, that is, a tensile stress which is intended to maintain its original shape and contract when a specific elongation is given to the object in the stretching direction.

The above problems can be solved by the following invention.

That is, the resin sheet material of the present invention is a sheet material containing a synthetic resin as described in the first aspect of the patent application, and at least one of the sheet materials forms a transfer shape of the cloth surface of the fabric.

The resin sheet material according to the first aspect of the invention, wherein the fabric sheet is a non-woven fabric.

The resin sheet material according to the first or second aspect of the invention, wherein the resin sheet material contains a plurality of resin layers.

Further, the composite sheet material of the present invention is obtained by laminating a base material of the resin sheet according to any one of claims 1, 2, and 3, as described in the fourth aspect of the patent application.

Moreover, the method for producing a resin sheet of the present invention is a method for producing a sheet containing a synthetic resin as described in the fifth item of the patent application, The cloth surface of the fabric is attached to the uncured resin film to transfer the cloth surface shape to the resin film, and after the resin film is cured, the cloth is peeled off from the resin film.

Moreover, the method for producing a resin sheet material of the present invention is a method for producing a sheet material containing a synthetic resin as described in claim 6 of the patent application, by attaching the cloth surface of the fabric to the uncured resin film, After the resin film is transferred to the resin film and the resin film is cured, the cloth is dissolved and removed from the resin film.

Further, the method for producing a resin sheet of the present invention is the method for producing a resin sheet according to claim 5, wherein the method for producing a resin sheet according to the fifth or sixth aspect of the invention is the production of a sheet containing a synthetic resin. a method of forming a layer or a plurality of layers of a hardened or uncured resin film on a hardened or uncured resin film, at least the uppermost resin film is in an uncured state, and attaching the cloth surface to the resin On the film, the shape of the cloth is transferred.

Moreover, the manufacturing method of the composite sheet of the present invention is as described in claim 8 of the patent application, and the substrate is attached to the manufacturing method according to any one of claims 5, 6, and 7. At least one side of the manufactured resin sheet.

In the resin sheet of the present invention, the transfer shape of the cloth surface of at least one surface is formed, and the modulus is increased, and the stretch processing and the bending work are excellent in suitability. Therefore, for example, when the resin sheet of the present invention is applied to a surface on which a complicated three-dimensional object such as a curved surface is formed, the compliance with various shapes is good, and partial wrinkles and floating are less likely to occur. Therefore, it can form a straight and smooth appearance. Moreover, the transfer shape of the fabric surface of the fabric formed on the surface of the resin sheet material of the present invention has a fine uneven shape, and it is difficult to exhibit the uneven shape together with the back surface of the resin sheet material, so that it is not applied to The design of the back etc. does not cause Good influence. Therefore, the present invention is particularly suitable for a resin sheet having a small thickness.

When the resin sheet of the present invention contains a plurality of resin layers, for example, when a resin sheet containing two upper and lower resin layers is contained, when the resin film forming the upper layer is in an uncured state, the cloth surface of the fabric is crimped to make the fabric The fiber is deeply pressed into the resin film, and even if the upper layer is extremely thin, or penetrates and generates a small hole, as long as the resin film forming the lower layer is hardened in advance, the lower resin film is not crimped by the cloth surface. On the other hand, as a result, the thickness of the entire resin sheet material can be kept equal to the thickness of the lower resin film even in the thinnest portion. Therefore, it can be used as a resin sheet which is extremely thin and has a small hole and is excellent in design and functionality.

Since the composite sheet of the present invention has a large modulus of the resin sheet portion, it has high compliance with the stretching deformation of the substrate portion. Therefore, for example, even when the composite sheet of the present invention is applied to a surface on which a complicated three-dimensional object such as a curved surface is formed, it is difficult to produce partial wrinkles due to compliance with various shapes. Floating up to form a straight, smooth and beautiful appearance.

According to the method for producing a resin sheet according to the present invention, it is only necessary to attach the fabric to the uncured resin film, and after the resin film is cured, peeling off or dissolving and removing the resin film, the fabric can be easily produced. In the resin sheet material having a large modulus of the transfer shape of the cloth surface, the resin sheet material is less likely to cause an extremely thin portion or a small hole, and the resin sheet having excellent design and functionality can be produced with good yield. material.

Here, when the method of peeling and removing the fabric is employed, the manufacturing cost of the resin sheet material can be reduced by repeating the use of the fabric removed from the resin film.

Moreover, when the method of dissolving and removing the fabric is used, since it is not necessary to peel the fabric from the resin film, when the fabric is peeled off from the resin film, there is no fear that the resin film is broken or damaged, and the resin sheet is manufactured. In order to prevent the production of defective products and increase production. Therefore, it is particularly suitable for the production of a thin resin sheet.

Fig. 1 is an electron micrograph showing the state of formation of the transfer shape of the cloth surface in the surface of the resin sheet obtained in Example 1.

Fig. 2 is an electron micrograph showing a cross section of the resin sheet obtained in Example 1.

Fig. 3 is an electron micrograph showing a cross section of the resin sheet obtained in Example 5.

First, the resin sheet of the present invention will be described. The resin sheet of the present invention is increased in modulus by the transfer shape in which the fabric is formed on at least one side thereof.

Here, the transfer shape of the cloth surface of the fabric refers to a fine uneven shape in which a plurality of fiber shapes of the cloth surface forming the fabric are printed, and for example, the convex portion of the cloth surface becomes a concave portion of the resin sheet material, and the cloth surface The concave portion becomes a convex portion of the resin sheet.

When such a concavo-convex shape is formed on the surface of the resin sheet, the thickness of the resin sheet is reduced in thickness and the convex portion is thick. When a tensile force is applied to the resin sheet from the outside, it is considered that the concave portion having a small thickness is relatively easily deformed, so that the tensile force is missed due to the deformation, and on the other hand, it is considered that the convex portion having a large thickness is relatively opposed. It is difficult to deform, so it will resist the tensile force and cause stress to restore the resin sheet to its original shape. It is considered that the two effects are multiplied to increase the modulus of the resin sheet.

In addition, since the unevenness of the transfer shape of the cloth surface is fine, it is difficult for the surface (back surface) on the side of the transfer shape where the surface of the resin sheet is not formed to be uneven, and the design is not applied to the back surface. influences.

The synthetic resin forming the resin sheet of the present invention is not particularly limited as long as it is a thermoplastic soft synthetic resin generally used, and can be suitably used depending on the properties required for the application. The synthetic resin may, for example, be a vinyl chloride resin, an olefin resin or a polyurethane resin. When a leather-like sheet material such as a garment, a shoe, or the like, which is attached to a pattern, a softness, or a texture, is selected, a polyurethane resin is selected, and a vinyl-like resin which is required to have a flame resistance is selected, and a vinyl chloride resin or the like is selected for use. And you can choose.

Further, in the above synthetic resin, a pigment, various additives, and a stabilizer may be added as needed to enhance the appearance, and a coloring agent, a slime agent, or the like may be added.

Moreover, the transfer shape of the cloth surface is formed only on the surface of the resin sheet, and the back surface of the resin sheet material is an design surface, and the pattern and color can be imparted to obtain various design effects. The pattern and the color can be imparted according to a known method. For example, if the pattern is to be imparted, the release paper can be used as a leather pattern, a geometric pattern, a fabric pattern, a wood pattern, or the like, or can be used. The mold paper is smooth and smooth. Further, in order to impart color, it is only necessary to impart a desired color to a dye or a pigment by various methods such as printing.

In addition, when a material containing a large number of fine bubbles made of a polyurethane resin or the like is used as the material of the resin sheet, the thin portion of the resin sheet can impart gas permeability. Such a breathable resin sheet can be suitably used as a material for clothes, shoes, and the like.

In the present invention, the fabric for forming the transfer shape of the cloth surface may be any one of a woven fabric, a woven fabric, a non-woven fabric, and the like, and is not particularly limited, but generally, since the nonwoven fabric is cheaper than the fabric, Preferably.

The fiber constituting the fabric may, for example, be a fiber made of a synthetic resin such as polyester, polyamide, polyacrylonitrile, polyolefin or polyvinyl alcohol; rayon such as regenerated cellulose; cotton. Natural fibers such as hemp and wool. A woven fabric, a woven fabric, a non-woven fabric, or a laminated fabric which is produced by using these fibers can be arbitrarily selected depending on the material and use of the resin sheet. Further, in the case of a synthetic fiber, it may of course be a fiber made of a single polymer or a fiber obtained by mixing two or more kinds of polymers into a mixed spun yarn or a composite spun yarn.

When the fabric is a woven fabric, there are plain weave, twill weave, satin weave, etc., and the structure is not particularly limited. However, if the fabric surface is too smooth, the fiber shape of the fabric is difficult to transfer and form on the resin sheet.

When the fabric is non-woven, it can be applied to all kinds of short-fiber non-woven fabrics or long-fiber non-woven fabrics, needle-punched non-woven fabrics or paper-laid non-woven fabrics, spunbonded non-woven fabrics, melt-blown (Melt-blow) non-woven fabrics, and electrospinning non-woven fabrics. Not woven.

For the short fiber nonwoven fabric, a non-woven fabric produced by chemical bonding, thermal bonding, spunlace, needle rolling, or the like can be used. Further, in the case of a long-fiber nonwoven fabric, a nonwoven fabric obtained by a spunbonding method can be suitably used.

Regarding the fineness (unit of dtex) of the fabric, when the fabric is a fabric, it can be woven into a general fineness of the woven yarn.

Further, when the fabric is a non-woven fabric, it is preferably 0.5 to 25 dtex. If you become When it is finer than 0.5 dtex, when the cloth surface is attached to the uncured resin film, the liquid resin is deeply dyed between the fine fibers, and it tends to be difficult to remove the cloth. In addition, when the fineness is thicker than 25 dtex, the volume of the non-woven fabric becomes high, and the workability when attached to the resin film tends to be deteriorated. More fineness is 1 to 20 dtex.

Next, a method of producing the resin sheet of the present invention will be described. According to the method for producing a resin sheet of the present invention, the cloth surface of the fabric can be attached to the uncured resin film, the cloth surface shape can be transferred to the resin film, and the resin film can be cured. The resin film is a simple step of peeling off or dissolving and removing the cloth, and is easy to manufacture a resin sheet having a large modulus of a transfer shape in which the cloth surface of the fabric is formed.

Further, in the method for producing a resin sheet material of the present invention, when the cloth surface shape of the fabric is transferred to the resin film, it is necessary to press the cloth surface against the resin film by using a pressure roller or the like, and the cloth is cushioned. Therefore, even when the pressure is applied, the applied pressing force is uniformly dispersed, and it is possible to prevent a large pressing force from being applied only at a specific portion on the resin film. Therefore, it is difficult to produce a very thin portion or a small hole in the resin sheet material, and a resin sheet having excellent design properties and excellent functionality can be produced with high yield.

Further, in the manufacturing step of the resin sheet of the present invention, when the transfer shape of the cloth surface is formed, the resin sheet to be produced is applied to the extent that the cloth surface is attached to the uncured resin film and then pressed. The use of the material may be appropriately adjusted. However, if the cloth surface is pressed too deeply into the resin film, the resulting resin sheet material may be partially thinned or a small hole may be formed.

When the cloth surface is pressure-bonded to the uncured resin film, the liquid resin is pushed by the fibers of the cloth and enters the space between the fibers of the cloth, or the liquid resin is dyed into the cloth fiber by the capillary force of the cloth fibers. Indirectly, the resin film is directly After the hardening, the fabric is peeled off or dissolved and removed, and the transfer shape of the fiber is exhibited in the resin film. The transfer shape is formed by a portion where the resin is recessed by extrusion of the fabric fibers, and a portion where the resin is dyed between the fabric fibers and raised. Therefore, the thickness of the obtained resin sheet material becomes thicker than the resin film which is smooth on the surface before the cloth surface is formed by the amount of the ridge formed.

Since the surface of the resin sheet of the present invention exhibits such a complicated uneven state, it is difficult to accurately measure the depth of the unevenness. Therefore, the degree of the depth of the transfer shape of the cloth surface formed by the resin sheet of the present invention is preferably set to the extent that the height of the resin film is indirectly inferred from the subsequent surface of the cloth. In the present invention, the difference between the thickness of the resin sheet thus obtained and the thickness of the resin film which is directly cured without the surface of the cloth is defined as the height of the resin film ridge, that is, the "height height".

In the resin sheet obtained in Example 1 of the present invention to be described later, the resin sheet of Comparative Example 1 obtained by directly hardening the resin sheet obtained by directly coating the resin film with a thickness of 0.22 mm was used. The thickness is 0.09 mm, and the obtained 0.13 mm is the bulging height.

In the resin sheet of the present invention, when the embossing height is 0.01 to 0.13 mm, the degree of depth of the transfer shape of the formed cloth surface is appropriate and the modulus is large, and the resin sheet having good conformability to various shapes can be obtained. It is better.

In the first manufacturing method of the resin sheet of the present invention, the cloth surface is transferred onto the uncured resin film, and the cloth surface shape is transferred to the resin film to cure the resin film, and then the resin is removed from the resin. The film peeled off the aforementioned fabric.

The method of forming the resin film may be a dry method or a wet method, and any method may be employed. Dry method, which is suitable for dry method, such as polyurethane, polyvinyl chloride, etc. The synthetic resin solution as a main component is applied onto a release paper or a release sheet, and is thermally dried and cooked to cure the resin film. In the wet method, a synthetic resin solution containing a polyurethane as a main component in a suitable wet method is applied onto a release sheet, and solidified in a coagulation bath to form a resin film.

Moreover, if the resin layer of the resin sheet material is made into a plurality of layers, the durability of the resin sheet material can be improved, and the resin sheet material can have a certain thickness or more. Further, a combination of resins of different types can be imparted to various properties of the resin sheet.

The coating method of the synthetic resin solution may be any coating method such as knife coating, knife over roll coating, or reverse roll coating.

Then, before the resin film is cured, the resin film formed by any of the above methods is applied to the fabric so that the transfer shape of the cloth surface can be formed in the form of a resin film. Next, as long as the cloth is placed on the uncured resin film, a calender roll, a pressure roller or the like may be repeatedly used to apply pressure by pressure.

Then, after the resin film is cured in a state where the cloth is next, the fabric is peeled off from the resin film. At this time, in order to facilitate the peeling of the fabric from the resin film, the cloth is previously impregnated with the solution containing the hydrazine or the fluorine-containing water repellent, and the water repellent may be applied to the fabric in advance.

The fabric at the time of peeling removal is preferably made of inelastic fibers. When the fabric is made of an elastic fiber, it is difficult to peel off from the resin film, and if it is forcibly pulled apart, the resin film may be damaged. Specifically, it is preferably a fiber made of polyester, polyamide, polypropylene, polyethylene or the like. Furthermore, when peeling and removing is performed, even It is also uncomfortable that the fiber sheet of the cloth remains slightly on the resin film.

Then, in the second manufacturing method of the resin sheet, the cloth surface is transferred to the uncured resin film, and the cloth surface shape is transferred to the resin film to cure the resin film, and then the resin is removed from the resin. A method in which the film dissolves and removes the aforementioned cloth.

First, a resin film is formed. As described above, the method of forming the resin film includes a dry method and a wet method, and in the second method, a dry method is preferably employed. Then, before the resin film is cured, the resin film and the cloth are formed in a transfer film shape of the cloth to form a resin film. Next, the method may be based on the above first production method.

Then, after the resin film is cured in a state where the cloth is next, the cloth is dissolved and removed. When the cloth is dissolved, the solvent may be appropriately selected depending on the material of the fabric. For example, if a non-woven fabric made of a polyvinyl alcohol (hereinafter also referred to as "PVA") resin is used, the solvent can be easily used with water. . Further, if it is used in a PVA resin which is dissolved at a low temperature of about 20 ° C to 90 ° C, the energy cost for increasing the water temperature can be lowered, which is preferable. Further, when a spunbonded nonwoven fabric is used, it is preferable to use a melt-formable PVA resin to easily produce a nonwoven fabric.

Further, when the dissolution is carried out, the fiber sheet of the fabric is not completely dissolved and remains slightly on the resin film. The method of dissolving and removing the fabric has the advantage that the resin film is damaged in the case of removal. Therefore, it is especially suitable for the manufacturing method of the thinness of a resin film.

Next, the composite sheet of the present invention will be described. The composite sheet of the present invention is laminated with the resin sheet of the present invention and a substrate. The substrate used in the composite sheet of the present invention is a woven fabric, a woven fabric, a non-woven fabric, a film, a resin sheet, a wood, Natural leather, artificial leather, etc. The substrate can be selected in response to the target product. The resin sheet portion of the composite sheet material conforms to the stretching deformation of the substrate portion in a good manner. For example, when the composite sheet of the present invention is attached to the surface of a complicated three-dimensional shape formed such as a curved surface, it is used for all shapes. The compliance is good, and it is difficult to produce partial wrinkles and floats, so that a straight and smooth appearance can be formed.

Further, when the resin sheet material is bonded to the substrate, for example, an adhesive such as a hot melt adhesive may be used. At this time, since the unevenness of the transfer shape of the cloth surface of the fabric of the resin sheet material is improved by the anchor effect, the adhesion to the substrate is improved, so that the amount of the adhesive used is small, and then The processing suitability of the adhesive is difficult to damage.

(Example)

Hereinafter, the present invention will be specifically described by way of examples, but the present invention is not limited by the following examples. In addition, the method of measuring each physical property value in the Example uses the following method.

(1) Quality per unit area

The mass per unit area (g/m ² ) was determined by taking five test pieces and measuring individual mass (g) and area (m ² ) to obtain mass per 1 m ² (g/m ² ).

(2) Thickness

The thickness (mm) was measured by a thickness measuring device (manufactured by Ozaki Seisakusho Co., Ltd., H Type), and five random portions were measured in a state in which a load of 0.5 kPa was applied to the test piece, and the average value was obtained.

(3) Tensile strength (N/50mm width)

Using a testing machine (manufactured by Shimadzu Corporation, AUTOGRAPH AGS-J) with a clamping interval of 100 mm and a tensile speed of 100 mm/ A test piece having a width of 50 mm and a length of 200 mm was measured under the conditions of minute, and the strength at the time of fracture was measured. The average of the five test pieces was taken as the tensile strength. Further, the MD direction (mechanical direction) and the CD direction (direction orthogonal to the MD direction) of the test piece were simultaneously determined for the tensile strength.

(4) 5% modulus (stress at 5% elongation (N/5cm width))

According to the above tensile strength measurement method, the stress at 5% elongation was obtained. Further, the stress at 5% elongation was also obtained by taking the average of five test pieces, and both the MD direction (mechanical direction) and the CD direction (direction orthogonal to the MD direction) of the test piece were obtained.

(5) 10% modulus (stress at 10% elongation (N/50 mm width))

According to the above tensile strength measurement method, the stress at 10% elongation was obtained. Further, the stress at 10% elongation was also obtained by taking the average of five test pieces, and both the MD direction (mechanical direction) and the CD direction (direction orthogonal to the MD direction) of the test piece were obtained.

(6) Air permeability

Five test pieces of a size of 100 mm × 100 mm were used, and a gas permeability tester (KES-F8-AP1, manufactured by KATO TECH Co., Ltd.) was used to adjust the piston rate of the gas permeability tester to 0.2 cm/sec. R (KPa.s/m). From the measured gas permeability resistance R, the average value of the gas permeability V (cm ³ /m ² .s) per unit area of the five test pieces was determined using the following formula. The air system of the gas permeability tester flows from the lower side of the test piece to the upper side.

(Formula) V=1.2455/R

In the present embodiment, the surface (surface) on which the transfer surface of the test cloth is formed with the non-woven fabric surface and the surface (back surface) on the release paper side are respectively placed under the test. set.

(Example 1) Modulation of a non-woven fabric for forming a transfer shape of a fabric

The long-fiber nonwoven fabric was prepared by a spunbonding method using a melt-formable PVA resin.

First, a chip of a melt-formable PVA resin is put into a melt extruder and melted, and then introduced into a spinning nozzle having a spinning hole to adjust the spinning opening of the spinning nozzle so that the fineness becomes 4 dtex. , made into melt spinning. Then, the spun long fiber group is continuously collected while being sucked from the back side of the net to form a growth fiber woven fabric. The long fiber fabric was passed through an embossing device formed by a heated uneven roller and a flat roller, and partially long fibers were fused to each other to obtain a PVA resin having a fineness of 4 dtex, a thickness of 0.3 mm, and a mass per unit area of 40 g/m ² . The long fiber is not woven.

Modification of urethane resin film

The following solution was applied to a press-off release paper (U.S., Ultracast Verona, manufactured by Sappi Co., Ltd.) by knife coating so as to have a thickness of 0.03 mm after drying, and the surface was dried by hot air at 90 ° C for 2 minutes. The solution contains: a polyurethane resin composed of an aliphatic polyurethane having a 100% modulus of 89 kgf/cm relative to 69 parts of N,N-dimethylformamide (DMF). 25 parts of (Stahl company: SU9202), 3 parts of an anthraquinone resin (HM145 by Stahl company), and 3 parts of a pigment dispersion (manufactured by Stahl Co., Ltd., black). The following solution was applied by blade coating in such a manner that the thickness after drying became 0.03 mm, and the surface was dried by hot air at 90 ° C for 3 minutes, and the solution contained: relative to N,N-dimethyl 57 parts of methotrexate (DMF), 40 parts of a polyurethane resin (manufactured by Stahl Co., Ltd.: SU5089) made of 100% of an aliphatic polyurethane having a modulus of 4 kgf/cm, and a resin (Stahl) System, HM145) 3 parts. Reappear The following solution was applied by blade coating in such a manner that the thickness after drying became 0.03 mm, and the surface was dried by hot air at 90 ° C for 1 minute, and the solution contained: relative to N,N-dimethylformamidine 40 parts of a polyamide (DMF), 40 parts of a polyurethane resin (SU5089, manufactured by Stahl Co., Ltd.) made of an aliphatic polyurethane having a modulus of 4 kgf/cm, and a crosslinking agent (manufactured by Stahl Co., Ltd.) , XR40-102) 5 parts, pigment dispersion (manufactured by Stahl, black) 15 parts. Then, a laminated film (three layers) made of three kinds of polyurethane resins having a thickness of 0.09 mm was obtained.

Manufacturing of resin sheet

The long-fiber nonwoven fabric made of the PVA resin was placed on the urethane resin laminated film obtained above, and the clearance of the pair of laminated rolls was adjusted to 0.39 mm (with a urethane resin laminated film). The thickness of the long-fiber non-woven fabric was almost the same, and the temperature was 150 ° C. After that, the urethane resin laminated resin was aged for 48 hours to cure the urethane resin. Then, the urethane resin laminated film was peeled off from the release paper, and the PVA long fiber nonwoven fabric was dissolved in water at a temperature of 25 ° C to dry the urethane resin laminated film to obtain a sheet material.

The obtained resin sheet had a thickness of 0.22 mm, and a transfer shape of a non-woven fabric surface was formed on the surface (Figs. 1 and 2). In addition, the photographs of Fig. 1 and Fig. 2 were taken using an electron microscope (manufactured by JEOL Ltd.). Moreover, the back surface of the resin sheet material forms a texture pattern of a good release paper.

(Example 2) Manufacturing of resin sheet

A plain woven fabric made of PVA fibers (GTS970, manufactured by NITIVY Co., Ltd., thickness: 0.095 mm) was placed on the same urethane resin laminated film as in Example 1, and the gap between the pair of laminated rolls was adjusted. 0.185mm (with urethane) The thickness of the ester resin laminate film and the woven fabric were almost the same in total, and the temperature was 150 ° C at the roll. After that, the urethane resin laminated resin was aged for 48 hours to cure the urethane resin. Then, the urethane resin laminated film was peeled off from the release paper, and the plain woven fabric made of the PVA fiber was dissolved in water at a temperature of 90 ° C to dry the urethane resin laminated film to obtain a sheet material.

The obtained resin sheet had a thickness of 0.12 mm, and a transfer shape of a fabric surface was formed on the surface. Moreover, the back surface of the resin sheet material forms a texture pattern of a good release paper.

(Example 3) Modulation of a non-woven fabric for forming a transfer shape of a surface of a fabric

The short fiber non-woven fabric was prepared by a hot press method using PVA fibers.

A fiber made of PVA resin having a fiber length of 2.2 dtex and a length of 51 mm was prepared. Then, the fibers made of the PVA resin were uniformly mixed, and the carded fibers and the fibers were collected using a card to obtain a fiber fabric. The fibers were brought into contact with each other by passing the fiber woven fabric through an embossing roll at 185 ° C to obtain a PVA short fiber non-woven fabric having a thickness of 0.33 mm and a mass per unit area of 40 g/m ² .

Modification of urethane resin film

It was prepared in the same manner as in Example 1.

Manufacturing of resin sheet

The PVA short fiber nonwoven fabric was placed on the urethane resin laminated film, and the gap between the pair of laminated rolls was adjusted to 0.42 mm (the total thickness of the urethane resin laminated film and the short fiber non-woven fabric was almost the same). The roll temperature was 150 ° C followed by. After that, the urethane resin laminated resin was aged for 48 hours to cure the urethane resin. Then, the urethane resin laminated film is peeled off from the release paper, The PVA short fiber nonwoven fabric was dissolved in water at a temperature of 25 ° C, and the urethane resin laminated film was dried to obtain a resin sheet. The obtained resin sheet had a thickness of 0.17 mm and a transfer shape of a non-woven fabric surface was formed on the surface.

(Example 4) Modulation of a non-woven fabric for forming a transfer shape of a surface of a fabric

The long fiber nonwoven fabric was prepared by a spunbonding method using a polypropylene resin.

First, a piece of a polypropylene resin (melting point: 163 ° C) was placed in a melt extruder and melted, and then introduced into a spinning nozzle having a spinning hole to adjust the spinning opening of the spinning nozzle so that the fineness became 2.5 dtex. , made into melt spinning. Then, the spun filament group is continuously collected on the web while being sucked from the back side to form a growth fiber woven fabric. The long fiber fabric was passed through an embossing device formed by a heated uneven roll and a flat roll, and partially long fibers were fused to each other to obtain a polypropylene long fiber nonwoven fabric having a thickness of 0.30 mm and a mass per unit area of 40 g/m ² . Then, the polypropylene long-fiber non-woven fabric is passed between the heated flat roll and the flat roll so that the embossing (convex) does not disappear (the surface of the long-fiber non-woven fabric is not smoothed), and peeling-removing is obtained. The polypropylene long fiber is not woven.

Manufacture of urethane resin film

It was prepared in the same manner as in Example 1.

Manufacturing of resin sheet

The polypropylene long fiber nonwoven fabric was placed on the urethane resin laminated film obtained above, and the gap between the pair of laminated rolls was adjusted to 0.47 mm (total thickness with the urethane resin laminated film and the long fiber non-woven fabric) Almost the same), followed by 120 °C. After that, the urethane resin laminated resin was aged for 48 hours to cure the urethane resin. The polypropylene non-woven fabric is peeled off and the release paper is peeled off. A resin sheet material was obtained. The obtained resin sheet had a thickness of 0.10 mm, and a transfer shape of a non-woven fabric surface was formed on the surface.

(Example 5) Manufacture of a non-woven fabric for forming a transfer shape of a surface of a fabric

The short fiber non-woven fabric was prepared by a water needle method using PVA fibers.

A fiber made of PVA resin having a fiber length of 1.9 dtex and a length of 47 mm was prepared. Then, the fibers made of the PVA resin were uniformly mixed, and the carded fibers and the fibers were collected using a card to obtain a fiber fabric. The fiber fabric was subjected to water flow interlacing treatment and dried to obtain a PVA short fiber nonwoven fabric having a thickness of 0.45 mm and a mass per unit area of 100 g/m ² .

Modification of urethane resin film

Three types of urethane resin were prepared in the same manner as in Example 1, and each urethane resin was applied, and the thickness after drying was set to 0.06 mm to obtain a urethane resin film having a thickness of 0.18 mm.

Manufacturing of resin sheet

A PVA short fiber nonwoven fabric was laminated on the urethane resin laminated film obtained above, and the gap between the pair of laminated rolls was adjusted to 0.63 mm (the total thickness of the urethane resin laminated film and the short fiber non-woven fabric was almost the same). The roll temperature was 150 ° C followed by. After that, the urethane resin laminated resin was aged for 48 hours to cure the urethane resin. Then, the urethane resin laminated film was peeled off from the release paper, and the PVA short fiber non-woven fabric was dissolved in water at a temperature of 90 ° C to dry the urethane resin laminated film to obtain a resin sheet. The obtained resin sheet had a thickness of 0.21 mm and a transfer shape of a non-woven fabric surface was formed on the surface (Fig. 3). Furthermore, the photograph of Fig. 3 is the same as that of Figs. 1 and 2, using an electron microscope (Japan Electronics Co., Ltd. has Photographed by company system).

(Comparative Example 1)

Three kinds of urethane resin laminated films made of a urethane resin were prepared in the same manner as in Example 1, and the mixture was directly aged for 48 hours without a cloth to obtain a resin sheet having a smooth surface (thickness: 0.09 mm).

(Comparative Example 2) Modification of urethane resin film

Three kinds of urethane resin laminated films made of a urethane resin were prepared in the same manner as in Example 5, and the mixture was directly aged for 48 hours without a cloth to obtain a resin sheet having a smooth surface (thickness: 0.18 mm).

(Test Example 1)

The measurement results of the thickness, tensile strength, modulus (tensile strength, 5% modulus, 10% modulus) and air permeability of the resin sheets obtained in the above Examples 1 to 5, Comparative Example 1, and Comparative Example 2 Shown in Table 1.

Even when the resin films composed of the same materials as those of Comparative Example 1 were used in Examples 1 to 4, it was confirmed that the mold was formed by the transfer shape of the cloth surface on which the fabric was formed. The situation of number increase. In the same manner as in Comparative Example 2, in the same manner as in Comparative Example 2, it was confirmed that the modulus was increased by the transfer shape of the cloth surface on which the fabric was formed.

Further, in the resin sheets of Examples 1 and 2, compared with the urethane resin film of Comparative Example 1, it was confirmed that the transfer shape of the cloth surface on which the cloth was formed was generated to cause gas permeability. Further, the resin sheets of Comparative Examples 1 and 2 were too large to be measured by a gas permeability tester because the gas permeability resistance (R) was too large.

(Example 6) Manufacturing of composite sheets

Using a urethane-based thermosensitive nonwoven fabric (manufactured by KB SEIREN Co., Ltd., Espansione FF UEO100, unit mass: 100 g/m ² ) as an adhesive, the resin sheet obtained in Example 1 was laminated with a substrate, and one was laminated. The gap of the pair of laminated rolls was adjusted to have almost the same width as the total thickness of the individual layers, and crimped at 130 ° C to obtain a composite sheet. Further, as the substrate, artificial leather (manufactured by San Fang Co., Ltd., thickness: 0.75 mm, mass per unit area: 250 g/m ² ) was used.

(Example 7)

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

(Comparative Example 3)

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

(Test Example 2)

The composite sheets obtained in Examples 6, 7 and Comparative Example 3 were cut out. A test piece having a width of 50 mm and a length of 200 mm was subjected to a test machine (AUTOGRAPH AGS-J type manufactured by Shimadzu Corporation) with a clamping interval of 100 mm, and a stress of 5% elongation was applied to each test piece, and the test was visually observed. The appearance of the composite sheet taken off by the machine. The results are shown in Table 2.

As shown in Table 2, it was confirmed that the composite sheet-based resin sheets of Examples 6 and 7 were excellent in adhesion to the substrate. On the other hand, it was confirmed that the composite sheet-based resin sheet of Comparative Example 3 was weak in adhesion to the substrate. That is, the resin sheets of the first embodiment and the third embodiment of the present invention have a larger modulus than those of the comparative example 1, and therefore, when the composite sheet is formed next to the substrate, the substrate is stretched and stretched. Excellent compliance and good looks.

(industrial availability)

The invention provides a resin sheet material and a composite sheet material and a manufacturing method thereof, which are suitable for use in clothing, bags, shoes, automotive interior materials (central panel, door panel, sheet skin, etc.), mobile phones, notebook computers Cases, partitions, materials related to residential equipment, etc.

Since the picture in this case is a photo, it is not a representative figure of this case. Therefore, there is no designated representative map in this case.

Claims (8)

A resin sheet material comprising a sheet of synthetic resin having a transfer surface of a fabric surface formed on a surface thereof, and a back surface of the sheet material as an design surface. The resin sheet material according to claim 1, wherein the fabric is a non-woven fabric. The resin sheet according to claim 1 or 2, wherein the resin sheet contains a plurality of resin layers. A composite sheet material obtained by laminating a base material to a resin sheet material according to any one of claims 1, 2, and 3. A method for producing a resin sheet material, which is a method for producing a sheet material containing a synthetic resin, which is obtained by attaching a cloth surface of a fabric to an uncured resin film formed on a release paper or a release sheet After the surface shape is transferred to the resin film and the resin film is cured, the cloth is peeled off from the resin film, and the release paper or the release sheet is peeled off. A method for producing a resin sheet material, which is a method for producing a sheet material containing a synthetic resin, which is obtained by attaching a cloth surface of a fabric to an uncured resin film formed on a release paper or a release sheet After the surface shape is transferred to the resin film and the resin film is cured, the release paper or the release sheet is peeled off from the resin film, and the cloth is dissolved and removed. The method for producing a resin sheet according to claim 5 or 6, which is a method for producing a sheet containing a synthetic resin, which is formed on a hardened or uncured resin film formed on a release paper or a release sheet Forming one or more layers of a hardened or uncured resin film, and at least making the uppermost resin film unhardened In the state, the cloth surface of the fabric is attached to the resin film, whereby the cloth surface shape is transferred. A method of producing a composite sheet material, wherein the substrate is attached to at least one side of a resin sheet material produced by the production method according to any one of claims 5, 6, and 7.