JPH06312485A - Composite sheetlike material - Google Patents

Abstract

PURPOSE:To improve hand and design properties by adding a resin/adhesive/ fiber cloth composite layer having a grain pattern at least on one side surface to a composite sheetlike material in which a resin layer having orientated crystal is integrated with fiber cloth through an adhesive layer. CONSTITUTION:A composite sheetlike material comprises a resin with the layer 2 through an adhesive layer 3. In this case, a resin/adhesive/fiber cloth composite layer 4 having a grain pattern is added to at least one side surface of the material. Incidentally, a thickness of the layer 2 is specified to 10mum or less. The layer 3 is formed of thermoplastic resin having a lower melting point than those of the layer 2 and the cloth 1. Further, the cloth 1 is formed of woven knitted fabric using ultrafine fiber having 0.5 denier or less, and the knitted fabric is formed by entangling yarns both therebetween and in the yarn at least at ultrafine fibers or formed of yarns in which a plurality of ultrafine fibers having different shrinkage factors are dispersively arranged at random.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite sheet material having excellent texture and design, and more particularly to a high touch composite sheet material having a very good feel and texture.

The composite sheet material of the present invention has a design and texture that make people feel uncomfortable touching it, and has a very good feel when actually touched by hands, and therefore, it is a book cover, a table cloth, a curtain. , Bags, purses, accessory cases, makeup bags, purses, gloves, clothing, coats, aprons, umbrellas, rain gear, hats, cushions, seats for chairs and sofas, building interior materials, automobile seats and interior materials, furniture skin materials It can be suitably used as a material such as.

[0003]

2. Description of the Related Art Conventionally, as a composite sheet of this type, a fiber sheet having a surface of a fiber cloth coated with a polyurethane resin or a polyvinyl chloride resin has been provided as so-called synthetic leather.

[0004]

In the conventional synthetic leather in which the surface of the fiber cloth is coated with the above-mentioned polyurethane resin, the dye of the fiber cloth bleeds out through the polyurethane resin during long-term use. There was a drawback that it would end up. In particular, when superposed on another material, there is a fatal defect that the bleed-out dye is transferred to the superposed other material and is contaminated. Furthermore, since the synthetic leather coated with a polyurethane resin is inferior in scratch resistance, it has a drawback that the surface is easily scratched. Also, when coated with polyvinyl chloride resin, the bleed-out plasticizer takes in dirt on the surface, so the surface is easily soiled,
Moreover, it has a fatal drawback that once it is contaminated, it cannot be removed. Further, when the contaminated surface comes into contact with another material, there is a problem that the other material is contaminated.

Further, in terms of texture and feel, conventional fiber sheets coated with a polyurethane resin or a polyvinyl chloride resin cannot generally take full advantage of the supple texture of the fiber cloth as the base fabric, The texture became hard, and in terms of feel, it was not satisfactory because the so-called rubber-like or vinyl-like feel could not be completely wiped off.

Furthermore, when the polyurethane resin is coated on the fiber cloth, it is necessary to use an organic solvent such as toluene or methyl ethyl ketone at a high concentration. Therefore, in terms of equipment, special auxiliary equipment for drying and recovering these solvents is required, which not only increases the manufacturing cost, but also deteriorates the working environment and the health of workers. It wasn't even desirable. In addition, from the viewpoint of global environment protection, there is a strong demand for fiber sheets that do not use this type of organic solvent. Similarly, polyvinyl chloride resin has a problem that a large amount of plasticizer is mixed and chlorine gas is generated during waste incineration, and its use is restricted as much as possible from the viewpoint of global environment protection. .

The present invention has been made to improve the above-mentioned drawbacks of conventional fiber sheets coated with a polyurethane resin or a polyvinyl chloride resin.
It is an object of the present invention to provide a high-touch composite sheet material having an excellent feel.

[0008]

According to the present invention, there is provided a high-touch composite sheet-like article excellent in texture, design and touch, wherein the resin layer having oriented crystals is an adhesive layer. In the composite sheet-like material that is integrated with the fiber cloth via the resin / adhesive /
This is achieved by a composite sheet having a fiber cloth composite layer on at least one side.

The present invention will be described in detail below with reference to the drawings. FIG. 1 is a schematic view showing an example of a cross section of the composite sheet material of the present invention. As shown in FIG. 1, the composite sheet material according to the present invention comprises a fiber cloth 1, a resin layer 2 having oriented crystals and an adhesive layer 3 laminated on the surface thereof. The fiber cloth 1 and the resin layer 2 are integrated by an adhesive layer 3. A part of the adhesive layer 3 is partially impregnated between and within the fiber bundles of the fiber cloth 1,
The resin / adhesive / fiber cloth composite layer 4 is formed. The resin / adhesive / fiber cloth composite layer 4 has an uneven grain pattern by embossing or the like.

The fiber cloth 1 used in the present invention is composed of one or more composite fibers of polyamide fibers such as nylon 6 and nylon 66, polyacrylonitrile fibers, polypropylene fibers and polyester fibers. Although the denier of the fibers constituting the cloth is not particularly limited, it is preferably composed of ultrafine fibers having a single yarn denier of 0.5 denier or less. Either one of the warp yarn and the weft yarn of the fabric may be made of ultrafine fibers, or both the warp yarn and the weft yarn may be made of ultrafine fibers.

Further, as another preferred embodiment of the fiber cloth, a cloth made of at least two kinds of ultrafine fibers of polyester and polyamide can be mentioned.

The ultrafine fibers having a denier of 0.5 or less may be produced by a method using a polymer mutual array fiber commonly called a sea-island type composite fiber, and the island component is a polymer called a sea-island type composite fiber. You may make it from the thing which is a mutual array fiber. In this case, the sea component may be separated with a solvent or a decomposing agent, or may be separated like a peelable split fiber composed of A and B2 components. Further, in the method of spinning directly, the spinning conditions may be made strict. Further, it may be thinned by using a superdraw phenomenon.
You may make by methods other than these. Furthermore,
Fibers having a denier of 0.5 or less may be obtained by using peelable split fibers composed of components A and B2.

As the form of the fiber cloth, a so-called woven fabric,
Although it may take any form such as knitting or non-woven fabric, woven fabric or knitting is preferably used in terms of texture and dimensional stability. The weave structure may be a plain weave, a satin weave, a twill weave, or the like. Various knitting structures such as horizontal knitting and vertical knitting can be applied as the knitting structure. The unit weight and the thickness of the fiber cloth are not particularly limited, but the unit weight is preferably 50 to 300 g / m ² , and the thickness is preferably 0.1 to 1 mm. In addition, the surface of the fabric is subjected to treatment such as raising,
It may have naps.

Further, in the woven and knitted fabric, the product of the woven and knitted densities of the warp yarn and the weft yarn is 1000 fibers / cm ² or more, and the product of the number of constituent fibers in the warp yarn and the weft yarn is 5000.
A woven or knitted fabric having a dense surface of 000 fibers / cm ² or more is preferable because the composite integration with the resin layer becomes good and the texture becomes more excellent.

Furthermore, by subjecting a woven fabric made of ultrafine fibers of 0.5 denier or less to water jet punching, the fibers are opened, a fine space is formed in the fiber bundle, and the fibers are bundled. It is more preferable that the fibers are entangled not only inside but also between the fiber bundles, and the woven fabric can have a sufficient bulge, resulting in a dense and flexible fabric. Further, in this case, since the adhesive layer enters the fine space in the formed fiber bundle, the composite integration becomes more excellent.

Another preferred embodiment of the woven or knitted fabric is a woven or knitted fabric formed by using two or more kinds of ultrafine fibers having different shrinkage ratios, and subjected to shrinkage treatment to obtain a dense and soft woven fabric with a bulge. Knitting can be mentioned. Here, in the case where the ultrafine fibers are randomly dispersed and arranged without forming a group, fine unevenness is generated on the surface of the woven or knitted fabric, and a woven or knitted fabric excellent in texture is obtained, which is more preferable. .

Next, it is essential that the resin layer 2 constituting the outer layer of the present invention has oriented crystals. As such a resin, a thermoplastic resin such as a polyester resin typified by polyethylene terephthalate resin, a polypropylene resin, a polyamide resin, a polyphenylene sulfide resin, an aromatic polyamide resin, a polyimide resin or the like is mainly used. A polyethylene terephthalate resin or a copolymer resin thereof, a polyphenylene sulfide resin, or an aromatic polyamide resin is particularly preferably used in terms of strength, rigidity, heat resistance and the like of the resin.

The resin layer 2 having oriented crystals is a so-called biaxial sheet in which a sheet obtained by usual T-die melt extrusion in a thermoplastic resin is stretched in the vertical direction under heating and then in the horizontal direction. It can be made by stretching.
In addition, an aromatic polyamide or the like can have an oriented crystal structure by subjecting it to stretching treatment after solution casting. It is possible to prevent the dye of the fabric from bleeding out by making the molecules that make up the resin layer as an ultrathin film oriented and crystallized, and it is also possible to obtain the surface strength and abrasion resistance required for the composite sheet. In addition to imparting the property, the dry touch feeling which is a feature of the present invention can be exhibited.

Here, the crystallinity of the resin layer is 20%.
The above is required, and it is preferably 40% or more.

The thickness of the resin layer 2 is preferably 10 μm or less from the viewpoint of the texture and feel of the composite sheet material. More preferably, it is 1 μm or more and 5 μm or less. When the thickness is less than 1 μm, there is a problem in surface strength and scratch resistance, and when it is more than 10 μm, the surface strength and scratch resistance are improved, but the texture and feel of the composite sheet material are improved. Tend to be inferior.

As the adhesive layer 3 used in the present invention,
A polyester resin, a copolyester resin, a polyamide resin, a polyurethane resin or the like having a melting point lower than that of the resin layer 2 and the fiber cloth 1 is used. In particular, in the case of a cloth made of polyester fiber, a polyester resin or a copolyester resin is preferable in terms of adhesiveness with the cloth. Here, in the case of a resin such as an aromatic polyamide which does not have a melting point, the melting point or the thermal decomposition point of the resin is regarded as the melting point.

The thickness of the adhesive layer 3 is preferably thin from the viewpoint of the texture and the feeling of touch, but if it is too thin, the strength required for adhesion to the fabric cannot be obtained.
It is preferably 0 μm or less. When the thickness is more than 10 μm, the adhesive layer 3 melted in the step of laminating and integrating penetrates too much into the inside of the fiber cloth 1 and as a result, the supple texture of the cloth is impaired, so that it is preferable to appropriately adjust.

For laminating and integrating the fiber cloth 1 and the resin layer 2, an ordinary apparatus such as a heating flat plate press or a heating roll can be used, but the heating roll is preferably used from the viewpoint of productivity, and particularly steel is used. It is more preferable to use a combination of a heating roll made of rubber and a nip roll made of heat resistant rubber or heat resistant resin such as chloroprene.

When the layers are integrated, the adhesive layer 3 formed in advance in the form of a film is sandwiched between the resin layer 2 and the fiber cloth 1 and is inserted between the heating roll and the nip roll. At this time, the resin layer 2 is placed on the heating roll surface side, and the fiber cloth 1
Insert so that it contacts the nip roll surface side. If it is inserted in the opposite direction, the fiber cloth 1 comes into contact with the surface of the steel heating roll, and the bulge and suppleness of the fiber cloth 1 are likely to be impaired. The temperature of the heating roll is set higher than the melting point of the adhesive layer 3 and lower than the melting points of the resin layer 2 and the fiber cloth 1, but it is preferably set higher than the melting point of the adhesive layer 3 by 20 ° C. or more.

The adhesive layer 3 which is heated and melted by the heating rolls is partially impregnated between the fiber bundles of the fiber cloth 1 and in the fiber bundles by an appropriate pressing force of the nip rolls, so that the resin / adhesive By forming the fiber cloth composite layer 4, the resin layer 2 and the fiber cloth 1 can be appropriately combined and integrated. At this time, the linear pressure and the feeding speed of the nip roll are appropriately adjusted so that the melted adhesive layer 3 is not excessively impregnated into the fiber cloth 1.

As another method of laminating and integrating the resin layer 2 and the fiber cloth 1, a lamination device or the like is used in advance to form a composite film in which the resin layer 2 and the adhesive layer 3 are integrated, and then, The composite film and the fiber cloth 1 may be laminated and integrated by using the above heating roll / nip roll. At this time, in the composite film heated by the heating roll, only the adhesive layer 3 is melted and partially impregnated between the fiber bundles of the fiber cloth 1 and in the fiber bundles, so that the resin / adhesive / fiber cloth The composite layer 4 is formed.

As another method, the resin layer 2 is extrusion-coated with the adhesive layer 3, and while the adhesive layer 3 is in a molten state, the fiber cloth 1 is laminated and integrated under pressure. Good. At this time, the adhesive layer 3 in the molten state is pressed to partially impregnate the fiber cloth 1 between the fiber bundles and in the fiber bundles, thereby forming the resin / adhesive / fiber cloth composite layer 4.

As another method, the resin layer 2 and the adhesive layer 3 are previously formed into a composite film by a coextrusion method,
The adhesive layer 3 of the composite film and the fiber cloth 1 may be laminated and integrated by using a heating roll / nip roll. At this time, in the composite film heated by the heating roll, only the adhesive layer 3 is melted and partially impregnated between the fiber bundles of the fiber cloth 1 and in the fiber bundles, so that the resin / adhesive / fiber cloth The composite layer 4 is formed.

The composite sheet-like material laminated and integrated by the above method is further processed by using an embossing roll, resin, adhesive,
The fibrous-fabric composite layer 4 is provided with a desired embossed texture pattern.
By arbitrarily selecting the uneven textured pattern, it is possible to produce a composite sheet material having a variety of design properties.

Further, it is particularly preferable in terms of the process that the resin layer 2 and the fiber cloth 1 are integrally laminated and the embossing roll is used to simultaneously form the resin / adhesive / fiber cloth composite layer 4 with a grain pattern.

The composite sheet-like material obtained in this manner has a better texture, better design, and better texture than conventional fiber sheets coated with polyurethane resin or polyvinyl chloride resin.
It is a high-touch composite sheet that excels in all touch feelings.

[0032]

【Example】

Example 1 A woven fabric was prepared by using a polymer mutual array fiber having a total denier of 50 d × 10 f in which the island component is polyethylene terephthalate (superfine fiber single yarn denier 0.06 d after sea removal) as warps and wefts. The weave design was plain weave, and the weaving density was 148 warps / inch and 110 wefts / inch.
The fabric thickness after sea removal is 0.11 mm, and the basis weight is 75 g / m ^2.
Met. Water pressure 50 kg / cm once from one side of the fabric
Water-jet punch processing was performed in ² . As a result, the woven fabric was contracted in both the vertical direction and the horizontal direction, and was a fine ultrafine fiber woven fabric having a thickness of 0.16 mm, a dense weight of 100 g / m ^{2 and} a sense of thickness, which was not easily frayed and which was flexible. The melting point of the fabric was 260 ° C. The thus obtained fiber cloth was subjected to a floral pattern print processing.

On the other hand, a sheet melt-extruded with a T-die was biaxially stretched to prepare a polyethylene terephthalate resin film having a thickness of 2 μm. The melting point of the resin film is 26.
It was 3 ° C.

Similarly, an isophthalic acid copolymerized polybutylene terephthalate resin film having a thickness of 3 μm was produced by T-die extrusion and biaxial stretching. The melting point of the resin film was 160 ° C.

Next, a superfine fiber woven fabric, an isophthalic acid-copolymerized polybutylene terephthalate resin film, and a polyethylene terephthalate resin film are superposed in this order and supplied between a heating roll and a nip roll. Layers are integrated under a condition of 3 kg / cm and a roll speed of 1.5 m / min, and have a thickness of 0.16.
A mm ultrafine fiber composite sheet was prepared.

Next, the ultrafine fiber composite sheet is fed between an embossing roll and a rubber roll, and is embossed under the conditions of an embossing roll temperature of 140 ° C., a roll linear pressure of 100 kg / cm, and a roll speed of 1 m / min, and a fine surface is formed. A composite sheet material having a rough kerf-like grain pattern was obtained.

The composite sheet material has a soft and supple texture, a dry touch to the touch, and a printed floral pattern stand out, with a mild luster and a high-class feeling. there were. The surface of the sheet was rubbed with a notched portion of a 10 yen copper coin, but it was not scratched. In addition, the plain composite sheet prepared in the same manner and the composite surface of the composite sheet of the print pattern were overlapped and left under pressure at high temperature for a long time, but the dye of the print pattern migrated to the plain sheet surface. It was never polluted.

Example 2 Similar to Example 1, an ultrafine fiber fabric having a basis weight of 100 g / m ² , a polyethylene terephthalate resin film having a thickness of 2 μm, and an isophthalic acid copolymerized polybutylene terephthalate resin film having a thickness of 3 μm were prepared.

Next, the ultrafine fiber woven fabric, the isophthalic acid copolymerized polybutylene terephthalate resin film, and the polyethylene terephthalate resin film are laminated in this order, and the ultrafine fiber woven fabric is fed along the rubber roll and supplied between the embossing roll and the rubber roll. , Emboss roll temperature 175
° C, roll linear pressure 100 kg / cm, roll speed 1 m / m
Under the condition of in, the layers were integrally integrated, and at the same time, a grain pattern was formed on the outer layer to obtain a composite sheet-shaped article having a thickness of 0.15 mm.

Similar to the composite sheet material obtained in Example 1, the composite sheet material had a supple texture and a dry touch feeling, and was a high-quality leather-like sheet. The resin layer on the surface was not peeled off even when the composite sheet material was strongly rubbed by hand, and the composite sheet material was not broken or scratched even when scratched with a nail.

Example 3 By using 40 filaments of 150 deniers of split-release composite fiber containing polyethylene terephthalate and nylon 6 in a ratio of 8: 2, ultrafine fibers (polyethylene terephthalate single yarn denier 0.38d, nylon single yarn denier 0.
A plain weave consisting of 75d) was prepared. The weaving density was 118 warp threads / inch and 73 weft threads / inch. After the split peeling process, heat setting was performed at 180 ° C. for 30 seconds, a two-step dyeing process was performed for amphoteric dyeing, and a fixing process was performed.

On the other hand, an aromatic polyamide resin film having a thickness of 1.8 μm was produced by the solution casting method. The resin film has substantially no melting point.

An isophthalic acid-copolymerized polyethylene terephthalate resin film having a thickness of 2 μm was prepared by T-die melt extrusion biaxial stretching method. The melting point of the resin film was 190 ° C.

Next, a split peelable composite fiber fabric, an isophthalic acid copolymerized polyethylene terephthalate resin film,
Aromatic polyamide resin films are superposed in this order, supplied between heating rolls / nip rolls, laminated under the conditions of heating roll temperature 210 ° C., roll linear pressure 3 kg / cm, roll speed 1.5 m / min, and thickness 0.25
mm fiber composite sheet was prepared.

Next, the fiber composite sheet is fed to an embossing roll / rubber roll, and the embossing roll temperature 175.
° C, roll linear pressure 100 kg / cm, roll speed 1 m / m
Embossing was performed under the condition of in to obtain a composite sheet material having a fine grain pattern on the surface.

The composite sheet material was a glittering material having a supple texture, a dry touch feeling, and a metallic luster. When the cigarette was applied to the surface of the sheet-like material and immediately blown off, the resin layer was not scorched at all. For comparison, when a conventional synthetic leather coated with a polyurethane resin was exposed to a cigarette fire, a hole was immediately formed.

[0047]

EFFECT OF THE INVENTION The composite sheet material of the present invention has a copolyester resin film as an adhesive layer on one side of a superfine fiber woven fabric, and a polyethylene terephthalate resin layer or aromatic polyamide resin layer having oriented crystals is laminated and integrated. Since it is configured as described above, the dye of the fabric does not exude to the surface through the polyurethane resin layer, which was a drawback of the conventional fiber sheet coated with polyurethane resin. Therefore, the dye of the fabric is transferred to other materials. It has a novel characteristic that it does not become contaminated. In addition, there is no defect that the plasticizer bleeds out and takes in dirt on the surface as seen in the conventional fiber sheet coated with polyvinyl chloride resin, and therefore,
It has excellent stain resistance.

Since the composite sheet material of the present invention mainly uses the ultrafine fiber woven fabric as the fiber cloth, it has the supple and swelling texture of the ultrafine fiber woven fabric,
Moreover, since the thickness of the resin layer is an extremely thin layer of 10 μm or less,
It does not impair the supple and swelling texture of these ultrafine fiber fabrics. Further, since the resin layer has oriented crystals, an extremely dry touch feeling is exhibited, and it has a novel feature that cannot be achieved by the conventional fiber sheet coated with polyurethane resin or polyvinyl chloride resin. Furthermore, because of its high strength, it will not be easily broken or scratched even if the surface is scratched with a nail. Further, it has excellent stain resistance and can be easily wiped off even if dirt is attached. Since it is also excellent in airtightness, when used as a table cloth, for example, water does not soak into the fiber cloth even if milk, coffee, water or the like is spilled. Furthermore, since it has better heat resistance than polyurethane resin and polyvinyl chloride resin, it will not easily melt or burn even if the ash of cigarette is accidentally dropped or it comes into contact with the stove. .

Furthermore, since the embossing is applied to the resin / adhesive / fiber cloth composite layer to impart the embossed pattern, the embossed pattern is maintained permanently. By selecting an arbitrary embossed pattern, it is possible to obtain a high-touch composite sheet-like material with extremely excellent design.

Further, when the composite sheet material of the present invention was manufactured, the adhesive layer between the resin layer and the fiber cloth was heat-bonded with a copolyester resin film having a melting point lower than those of these base materials. No pretreatment of the fiber fabric is required as is the case with conventional adhesives. In addition, since the lamination integration and the embossing can be performed at the same time, the manufacturing process can be simplified, which is advantageous in terms of cost. Further, since the melted adhesive layer is impregnated between the fiber bundles of the fiber cloth or in the fiber bundles to be composite-integrated with the resin layer, the ears of the composite sheet-like material can be cut even when cut into various shapes. It does not cause fraying and has excellent post-processability.

Furthermore, the composite sheet material of the present invention is
Since no organic solvent such as toluene or methyl ethyl ketone is used like when coating a polyurethane resin, no special equipment for drying or recovering the solvent is required. Therefore, the manufacturing facility can be simplified, which is not only advantageous in terms of cost, but also extremely desirable from the viewpoint of working environment and global environment protection.

Since the composite sheet material of the present invention has the above-mentioned excellent properties, it is not limited to the above table cloths, but book covers, curtains, bags, wallets, accessory cases,
It can be suitably used as a material for makeup bags, purses, gloves, clothing, coats, umbrellas, rain gear, aprons, hats, cushions, seats for chairs and sofas, building interior materials, automobile seats and interior materials, and furniture skin materials. It is a thing.

[Brief description of drawings]

FIG. 1 is a schematic view showing an example of a cross section of a composite sheet material of the present invention.

[Explanation of symbols]

 1: fiber cloth 2: resin layer 3: adhesive layer 4: resin / adhesive / fiber cloth composite layer

Claims (6)

[Claims] 1. A composite sheet material in which a resin layer having oriented crystals is integrated with a fiber cloth via an adhesive layer, wherein at least one surface of the resin / adhesive / fiber cloth composite layer having a grain pattern is formed. A composite sheet-like material having the above-mentioned. 2. The composite sheet material according to claim 1, wherein the resin layer has a thickness of 10 μm or less. 3. The composite sheet material according to claim 1, wherein the adhesive layer is made of a thermoplastic resin having a melting point lower than that of the resin layer and the fiber cloth. 4. The fiber fabric is a woven or knitted fabric made of ultrafine fibers having a denier of 0.5 or less.
The composite sheet material according to 1. 5. A woven or knitted fabric, both between yarns and within yarns,
At least the ultrafine fibers are entwined with each other, and the composite sheet material according to claim 4. 6. The woven or knitted fabric is composed of yarns in which two or more kinds of ultrafine fibers having different shrinkage rates are randomly dispersed and arranged without forming a group, respectively. The composite sheet material according to claim 5.