CA2418841A1 - Coated, flexible fabric - Google Patents
Coated, flexible fabric Download PDFInfo
- Publication number
- CA2418841A1 CA2418841A1 CA002418841A CA2418841A CA2418841A1 CA 2418841 A1 CA2418841 A1 CA 2418841A1 CA 002418841 A CA002418841 A CA 002418841A CA 2418841 A CA2418841 A CA 2418841A CA 2418841 A1 CA2418841 A1 CA 2418841A1
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- Prior art keywords
- fabrics
- coated
- coating
- textile
- process according
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
- D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
- D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
- D06N3/0025—Rubber threads; Elastomeric fibres; Stretchable, bulked or crimped fibres; Retractable, crimpable fibres; Shrinking or stretching of fibres during manufacture; Obliquely threaded fabrics
- D06N3/0031—Retractable fibres; Shrinking of fibres during manufacture
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
- D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
- D06N3/145—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes two or more layers of polyurethanes
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T428/24438—Artificial wood or leather grain surface
Abstract
The invention relates to an embossed, PUR system-coated textile fabric, to a method for producing the same and to the use of a fabric of this type as a decorative starting material. The inventive fabrics, which have a residual shrinkage, are coated with PUR and then post-treated using heat.
Description
Le A 34 641-Foreign countries Coated flexible fabrics This invention relates to grained PU-coated textile fabrics, a process for producing them and the use of such fabrics as a decorative starting material.
It has long been known to produce coated textile fabrics, as for producing synthetic leather for example. The coating is applied to the substrate in one or more layers directly or by the transfer process. The coated textile fabrics are useful, inter alia, for producing outerwear, shoe uppers and liners, bagmakers' material and upholstery material and also for automotive interiors.
Coated textiles or other fabrics are grained or embossed by the following methods known to one skilled in the art, but which all have disadvantages:
~ The action of heat and pressure on embossing calenders, embossing plates or else transfer papers is used to impress a predetermined pattern on a coated base material. This embossing produces a grain, but local compaction is responsible for undesirable harshening. This relatively costly and inconvenient process exclusively utilizes thermoplastic PU solutions which in some instances still contain solvent residues which are evaporated off by the heat action.
~ The treatment of materials which have been coated by means of two component PU solutions can be used to produce uncontrolled grain patterns when these materials are for a certain time agitated in an axial spin dryer with alternating direction of rotation at temperatures of for example 20 to 100°C (eg DE-A 1 760 260). The disadvantages with this process are not only the use of organic solvents, but also the need for exact compliance with the timing of the processing sequences, the consequence being that grain formation has to take place before the actual crosslinking of the system.
~ The transfer process creates embossed surfaces by utilizing grained release materials, especially release papers or silicone stencils. However, the embossings Le A 34 641-Foreign countries produced using release papers are comparatively flat and have to be predetermined during the actual coating step. The use of silicone stencils is very cost intensive and no longer acceptable but for specialty effects.
S It is an object of the present invention to provide a process for producing a deep grain profile on textile fabrics without the above-described disadvantages whereby high-quality products are obtained in a simple operation.
It has been found that, surprisingly, coated fabrics having grain formation are obtained when textile fabrics having residual shrinkage are initially coated with PU
dispersions or solutions by the direct or transfer process and then aftertreated with the application of heat.
The present invention accordingly provides a process for producing grained textile . fabrics, characterized in that fabrics having residual shrinkage are coated with PU dispersions or solutions and then a$ertreated with the application of heat.
The present invention further provides grained coated textile fabrics obtainable by the process of the present invention.
Textile fabrics for the purposes of the present invention include, for example, wovens and formed-loop knits and bound and unbound fibrous webs, including microfiber webs. These can be constructed of synthetic, natural fibers and/or blends thereof. All other flexible fabrics are useful for the process of the present invention in principle as well as textiles composed of any fiber, provided they possess residual shrinkage.
The residual shrinkage of textile materials composed of fiber blends having a polyester fiber portion can be increased by splitting, since this reduces the portion of polyester fibers and hence of the harder portion of the fabric.
Le A 34 641-Foreign countries To form a very deep grain profile it has been determined to be advantageous to fill and consolidate the textile fabrics by PU coagulation before the polyurethane coating, which is why this is a preferred embodiment of the present invention.
Particularly useful systems for pretreating the fabrics by coagulation are reactive or postcrosslinking PU dispersions as described for example in WO 00/34352. The PU
dispersion, consisting of blocked isocyanate groups and at least one polyamine, is precipitated by thermal treatment to form a stable, partially crosslinked polyurethane or gel.
Coagulation is particularly useful for producing films, for coating a wide range of materials and for partial or complete impregnation of fibrous webs, formed-loop knits or other fabrics for consolidation.
The reactive, postcrosslinkable PU dispersions are applied for example by casting, spraying, dipping, squirting, slopping, using knife, roll or pad-mangle, and the dispersions can be used in the liquid or foamed state.
In general, application by one of the methods mentioned is followed by coagulation by dipping in hot water at 50°C to 100°C and preferably 75°C to 95°C or using hot water vapor or in an oven by means of radiative or high-frequency dryers and subsequent drying at 60°C to 180°C, preferably 100°C to 140°C and curing at 140°C
to 165°C.
The fabrics are tentered during the crosslinking and drying in order that premature shrinkage of the fabric may be avoided.
The coagulate formed is so durable that the precipitating operation following application can even be carned out in the saponification and splitting bath (3%
NaOH), and in the case of, for example, microfiber webs having a polyester portion this portion can be simultaneously saponified and dissolved out. This leads to particularly soft fabrics having a pleasant hand.
Le A 34 641-Foreign countries The coated or filled fabrics can also be subsequently peached and are then particularly soft. Softness is also increased by a mechanical treatment in a tumbler.
It is also possible for the process of the present invention to be preceded by other aqueous coagulation processes for consolidation, such as for example the electrolytic or thermal coagulation of dispersions.
Electrolytic coagulation is effected by dipping the coated substrate into a concentrated salt solution or into acidulated water or the like, and the binder will be coagulated by the high electrolyte content.
In thermal coagulation, nonpostcrosslinkable binders which have been formulated to be heat sensitive can be made to coagulate by raising the temperature.
The precleaned and optionally consolidated textile fabrics are then coated with the polyurethane systems in a known manner by the direct or transfer process.
Coatings useful for the process of the present invention include for example the one-component and two-component polyurethane systems which are known in the textile and leather industries and which consist of isocyanate prepolymers and crosslinkers and which are commercially available as solutions.
Useful coatings for the process of the present invention further include the aqueous polyurethane one-component dispersions which are described in DE-A 4 236 569 and which additionally contain hydrophilisizing structures.
Particularly useful are solvent-free two-component polyurethane systems consisting of a blocked isocyanate prepolymer and polyamine, which are described for example in EP-A 0 784 097. These possess good wet adhesion and an excellent water resistance. Mixtures of various PU systems are also suitable.
Le A 34 641-Foreign countries Coatings based on PU dispersions known from DE-A 42 36 569 are capable of increasing the wear comfort of the coated fabrics, since coatings produced using these PU dispersions are water vapor pervious.
In the direct process, the PU coatings are applied by direct coating on the substrate using doctor blades, rolls or wire-wound bars.
In general, plural but preferably two coats are applied in succession so that the overall thickness of the coating made up of base and topcoats is in the range from 10 to 100 wm and preferably in the range from 20 to 60 Vim. The base coat can also be a paste which dries to form a microporous layer and which is described in DE-A 2 020 153. The subsequently applied topcoat protects the entire ensemble against mechanical wear and tear.
The coating ensemble of basecoat and topcoat can also be applied by the transfer process.
The transfer process is advantageous when using very flexible substrates such as formed-loop knits, fibrous webs or other discontinuous fabrics.
In the transfer process, the initial step is for the topcoat to be doctor coated onto a grained_or else ungrained transfer paper and dried. This is followed optionally by a preferably foamed intercoat. After a second base or adhesive coat has been applied, the substrate is lightly pressed into the still moist layer. On drying there is a firmly bonded ensemble of coating and substrate and this ensemble is detached from the transfer base and in its construction substantially corresponds to the previously described direct coating. The article obtained after the crosslinking step is coated and optionally, depending on the transfer paper, surficially grained.
In this state, the coated fabric can be stored dry before later being subjected to an aftertreatment in which the article can then have the desired graining and coloring conferred on it.
Le A 34 641-Foreign countries A simple pre-embossing of the fabrics coated according to the present invention can be used to create a grain pattern in a specific manner, since a corresponding, but substantially deeper graining will form in the aftertreatment by the action of heat in the depressions resulting from the preembossing. Without this pre-embossing, the aftertreatment would produce a rather adventitiously grained product.
The direct-coated fabrics can optionally be subjected to slight pre-embossing by means of embossing or goffering calenders.
In the case of the transfer process, pre-embossing for grain design can be produced by means of a grained transfer paper. Unstructured release papers or simple matting calenders will produce an adventitious graining in the aftertreatment.
The aftertreatment of the coated textile fabrics consists in a subsequent dyeing 1 S operation or in a tensionless treatment with boiling water. In the case of the treatment with boiling water there is also the possibility of directly adding suitable pigments to the coating compositions.
Depending on the composition of the base material, acid, disperse or metallized dyes are used to color the coating and the base material. Low-tension dyeing processes at a long liquor ratio, as provided using a reel beck for example, are particularly useful.
Metallized dyes, used directly or else laked, produce the best wetfastnesses for the PU coating.
After the dyeing operation has ended, the fabric is neutralized where appropriate and then thoroughly rinsed. Additions to the last rinse baths are a way to employ finishes to improve the hand before the material is dried tensionlessly. When cellulosic base materials are used, it is advisable to pass them through a tumbler to remove any wet-rigidity.
The fabrics of the present invention can be used as a decorative starting material, for example as an outerwear material, as a shoe upper material and liner, as bagmakers' and upholstery material and also as an automotive interior material.
Le A 34 641-Foreign countries _7.
Examples I. Pretreatment of the cleaned textile fabric:
Example 1 (inventive):
Consolidation by aqueous coagulation with reactive dispersion.
Batch: 90 - 180 parts by weight of Impranil~ VP LS 2333 (Bayer AG, Leverkusen) 1 - 2.7 parts by weight of Imprafix~ VP LS 2330/isopropanol (1:1) (Bayer AG, Leverkusen) 910-820 parts by weight of demineralized water.
The solids content of the dispersion batch is 4 to 8%.
The textile fabric is treated with the dispersion batch on a pad-mangle (100%
wet pick-up) and subsequently coagulated in a steamer at 98°C.
Complete curing and drying takes place on a tenter at 165°C.
If desired, a fibrous web, for example composed of polyester and polyamide fiber blends, can be split during or after coagulation has taken place in order that a softer hand may be obtained. To this end, the fibrous web is treated for example for about 1 hour in 3% sodium hydroxide solution at the boil, the polyester portion being dissolved out.
Prior peaching of the substrate surface enhances the effect.
Le A 34 641-Foreign countries _g_ Example 2 (inventive):
Consolidation by coagulation with conventional dispersion.
Batch: 200 parts by weight of Impranil~ DLV Dispersion (Bayer AG, Leverkusen) 4 parts by weight of Koagulant~ WS (20%) (Bayer AG, Leverkusen) 16 parts by weight of aqueous sodium chloride solution (10%) 4 parts by weight of Euderm~ Driver DE (Bayer AG, Leverkusen) 2 parts by weight of Bayderm~ Fix CIN (Bayer AG, Leverkusen 774 parts by weight of water S
The textile is treated with the dispersion batch on a pad-mangle (100% wet pick-up) and subsequently dried on a tenter.
Splitting of a polyester/polyamide web can be carned out similarly to Example 1.
Example 3 (inventive) Where no coagulation is carned out to consolidate the textile fabric, it is advisable for the cleaned, scoured textile to be dried on the tenter.
II. Coating Example 1 (inventive):
T- opcoat: 650 parts by weight of Impranil~ DLN Dispersion (Bayer AG, Leverkusen) Le A 34 641-Foreign countries 350 parts by weight of Impranil~ DLF Dispersion (Bayer AG, Leverkusen) thickened with Mirox~ AM (Stockhausen, Duisburg) in the presence of ammonia Intercoat: 500 parts by weight of Impranil~ DLN Dispersion (Bayer AG, Leverkusen) 500 parts by weight of Impranil~ VP LS 2333 (Bayer AG, Leverkusen) 7.5 parts by weight of Imprafix~ VP LS 2330 (Bayer AG, Leverkusen)/isopropanol (1:1) 20 parts by weight of Stockal~ STA (Stockhausen, Krefeld) 30 parts by weight of Stockal~ SR (Stockhausen, Krefeld) are mechanically foamed to 500 g/1 and thickened with Mirox~ AM (Stockhausen, Krefeld) in the presence of ammonia.
Adhesive coat: 1000 parts by weight of Impranil~ VP LS 2333 (Bayer AG, Leverkusen) 15 parts by weight of Imprafix~ VP LS 2330 (Bayer AG, Leverkusen)/isopropanol (1:1) are thickened with Mirox~ AM (Stockhausen, Krefeld) in the presence of ammonia.
Coating can be effected not only by the direct process but also by the transfer process.
In transfer coating with the aid of an embossed transfer paper, the graining of the coating can be structurally predetermined and deepened or augmented by the aftertreatment.
Le A 34 641-Foreign countries When a smooth transfer paper is chosen, the graining produced by the aftertreatment as well as by the direct coating is adventitious.
III. Aftertreatment of coated textile fabric When the coated textile is aftertreated with hot water only, it is also possible for suitable pigments to be added directly to the coating pastes.
Polyurethane is generally dyed with metallized dyes (eg complexing azo dyes, porphyrins or phthalocyanines) and selected acid and disperse dyes (eg azo, triarylmethane or anthraquinone dyes). In the case of on-tone dyeings with the substrate, these can also be combined with other classes of dye, depending on the dyeing method and substrate.
The following particulars represent one possible way of performing a simple dyeing, in a reel beck for example:
Example (inventive):
Dyes used:
Telon~ (Dystar, Leverkusen) monosulfonic acid dye Isolan S~ (Dystar, Leverkusen) 1:2 metallized dyes Liquor ratio: 40:1 demineralized water Dye concentration: 2 to 4% on weight of fiber Temperature profile during dyeing:
40°C ~ 30 min. ~ 100°C ~ 60 min. ~ 100°C
The pH is adjusted to 5 with acetic acid for dyeing with acid dyes.
Le A 34 641-Foreign countries The fabric is subsequently neutralized with aqueous sodium hydroxide solution and rinsed with demineralized water and finally dried tensionlessly, for example on a festoon dryer.
It has long been known to produce coated textile fabrics, as for producing synthetic leather for example. The coating is applied to the substrate in one or more layers directly or by the transfer process. The coated textile fabrics are useful, inter alia, for producing outerwear, shoe uppers and liners, bagmakers' material and upholstery material and also for automotive interiors.
Coated textiles or other fabrics are grained or embossed by the following methods known to one skilled in the art, but which all have disadvantages:
~ The action of heat and pressure on embossing calenders, embossing plates or else transfer papers is used to impress a predetermined pattern on a coated base material. This embossing produces a grain, but local compaction is responsible for undesirable harshening. This relatively costly and inconvenient process exclusively utilizes thermoplastic PU solutions which in some instances still contain solvent residues which are evaporated off by the heat action.
~ The treatment of materials which have been coated by means of two component PU solutions can be used to produce uncontrolled grain patterns when these materials are for a certain time agitated in an axial spin dryer with alternating direction of rotation at temperatures of for example 20 to 100°C (eg DE-A 1 760 260). The disadvantages with this process are not only the use of organic solvents, but also the need for exact compliance with the timing of the processing sequences, the consequence being that grain formation has to take place before the actual crosslinking of the system.
~ The transfer process creates embossed surfaces by utilizing grained release materials, especially release papers or silicone stencils. However, the embossings Le A 34 641-Foreign countries produced using release papers are comparatively flat and have to be predetermined during the actual coating step. The use of silicone stencils is very cost intensive and no longer acceptable but for specialty effects.
S It is an object of the present invention to provide a process for producing a deep grain profile on textile fabrics without the above-described disadvantages whereby high-quality products are obtained in a simple operation.
It has been found that, surprisingly, coated fabrics having grain formation are obtained when textile fabrics having residual shrinkage are initially coated with PU
dispersions or solutions by the direct or transfer process and then aftertreated with the application of heat.
The present invention accordingly provides a process for producing grained textile . fabrics, characterized in that fabrics having residual shrinkage are coated with PU dispersions or solutions and then a$ertreated with the application of heat.
The present invention further provides grained coated textile fabrics obtainable by the process of the present invention.
Textile fabrics for the purposes of the present invention include, for example, wovens and formed-loop knits and bound and unbound fibrous webs, including microfiber webs. These can be constructed of synthetic, natural fibers and/or blends thereof. All other flexible fabrics are useful for the process of the present invention in principle as well as textiles composed of any fiber, provided they possess residual shrinkage.
The residual shrinkage of textile materials composed of fiber blends having a polyester fiber portion can be increased by splitting, since this reduces the portion of polyester fibers and hence of the harder portion of the fabric.
Le A 34 641-Foreign countries To form a very deep grain profile it has been determined to be advantageous to fill and consolidate the textile fabrics by PU coagulation before the polyurethane coating, which is why this is a preferred embodiment of the present invention.
Particularly useful systems for pretreating the fabrics by coagulation are reactive or postcrosslinking PU dispersions as described for example in WO 00/34352. The PU
dispersion, consisting of blocked isocyanate groups and at least one polyamine, is precipitated by thermal treatment to form a stable, partially crosslinked polyurethane or gel.
Coagulation is particularly useful for producing films, for coating a wide range of materials and for partial or complete impregnation of fibrous webs, formed-loop knits or other fabrics for consolidation.
The reactive, postcrosslinkable PU dispersions are applied for example by casting, spraying, dipping, squirting, slopping, using knife, roll or pad-mangle, and the dispersions can be used in the liquid or foamed state.
In general, application by one of the methods mentioned is followed by coagulation by dipping in hot water at 50°C to 100°C and preferably 75°C to 95°C or using hot water vapor or in an oven by means of radiative or high-frequency dryers and subsequent drying at 60°C to 180°C, preferably 100°C to 140°C and curing at 140°C
to 165°C.
The fabrics are tentered during the crosslinking and drying in order that premature shrinkage of the fabric may be avoided.
The coagulate formed is so durable that the precipitating operation following application can even be carned out in the saponification and splitting bath (3%
NaOH), and in the case of, for example, microfiber webs having a polyester portion this portion can be simultaneously saponified and dissolved out. This leads to particularly soft fabrics having a pleasant hand.
Le A 34 641-Foreign countries The coated or filled fabrics can also be subsequently peached and are then particularly soft. Softness is also increased by a mechanical treatment in a tumbler.
It is also possible for the process of the present invention to be preceded by other aqueous coagulation processes for consolidation, such as for example the electrolytic or thermal coagulation of dispersions.
Electrolytic coagulation is effected by dipping the coated substrate into a concentrated salt solution or into acidulated water or the like, and the binder will be coagulated by the high electrolyte content.
In thermal coagulation, nonpostcrosslinkable binders which have been formulated to be heat sensitive can be made to coagulate by raising the temperature.
The precleaned and optionally consolidated textile fabrics are then coated with the polyurethane systems in a known manner by the direct or transfer process.
Coatings useful for the process of the present invention include for example the one-component and two-component polyurethane systems which are known in the textile and leather industries and which consist of isocyanate prepolymers and crosslinkers and which are commercially available as solutions.
Useful coatings for the process of the present invention further include the aqueous polyurethane one-component dispersions which are described in DE-A 4 236 569 and which additionally contain hydrophilisizing structures.
Particularly useful are solvent-free two-component polyurethane systems consisting of a blocked isocyanate prepolymer and polyamine, which are described for example in EP-A 0 784 097. These possess good wet adhesion and an excellent water resistance. Mixtures of various PU systems are also suitable.
Le A 34 641-Foreign countries Coatings based on PU dispersions known from DE-A 42 36 569 are capable of increasing the wear comfort of the coated fabrics, since coatings produced using these PU dispersions are water vapor pervious.
In the direct process, the PU coatings are applied by direct coating on the substrate using doctor blades, rolls or wire-wound bars.
In general, plural but preferably two coats are applied in succession so that the overall thickness of the coating made up of base and topcoats is in the range from 10 to 100 wm and preferably in the range from 20 to 60 Vim. The base coat can also be a paste which dries to form a microporous layer and which is described in DE-A 2 020 153. The subsequently applied topcoat protects the entire ensemble against mechanical wear and tear.
The coating ensemble of basecoat and topcoat can also be applied by the transfer process.
The transfer process is advantageous when using very flexible substrates such as formed-loop knits, fibrous webs or other discontinuous fabrics.
In the transfer process, the initial step is for the topcoat to be doctor coated onto a grained_or else ungrained transfer paper and dried. This is followed optionally by a preferably foamed intercoat. After a second base or adhesive coat has been applied, the substrate is lightly pressed into the still moist layer. On drying there is a firmly bonded ensemble of coating and substrate and this ensemble is detached from the transfer base and in its construction substantially corresponds to the previously described direct coating. The article obtained after the crosslinking step is coated and optionally, depending on the transfer paper, surficially grained.
In this state, the coated fabric can be stored dry before later being subjected to an aftertreatment in which the article can then have the desired graining and coloring conferred on it.
Le A 34 641-Foreign countries A simple pre-embossing of the fabrics coated according to the present invention can be used to create a grain pattern in a specific manner, since a corresponding, but substantially deeper graining will form in the aftertreatment by the action of heat in the depressions resulting from the preembossing. Without this pre-embossing, the aftertreatment would produce a rather adventitiously grained product.
The direct-coated fabrics can optionally be subjected to slight pre-embossing by means of embossing or goffering calenders.
In the case of the transfer process, pre-embossing for grain design can be produced by means of a grained transfer paper. Unstructured release papers or simple matting calenders will produce an adventitious graining in the aftertreatment.
The aftertreatment of the coated textile fabrics consists in a subsequent dyeing 1 S operation or in a tensionless treatment with boiling water. In the case of the treatment with boiling water there is also the possibility of directly adding suitable pigments to the coating compositions.
Depending on the composition of the base material, acid, disperse or metallized dyes are used to color the coating and the base material. Low-tension dyeing processes at a long liquor ratio, as provided using a reel beck for example, are particularly useful.
Metallized dyes, used directly or else laked, produce the best wetfastnesses for the PU coating.
After the dyeing operation has ended, the fabric is neutralized where appropriate and then thoroughly rinsed. Additions to the last rinse baths are a way to employ finishes to improve the hand before the material is dried tensionlessly. When cellulosic base materials are used, it is advisable to pass them through a tumbler to remove any wet-rigidity.
The fabrics of the present invention can be used as a decorative starting material, for example as an outerwear material, as a shoe upper material and liner, as bagmakers' and upholstery material and also as an automotive interior material.
Le A 34 641-Foreign countries _7.
Examples I. Pretreatment of the cleaned textile fabric:
Example 1 (inventive):
Consolidation by aqueous coagulation with reactive dispersion.
Batch: 90 - 180 parts by weight of Impranil~ VP LS 2333 (Bayer AG, Leverkusen) 1 - 2.7 parts by weight of Imprafix~ VP LS 2330/isopropanol (1:1) (Bayer AG, Leverkusen) 910-820 parts by weight of demineralized water.
The solids content of the dispersion batch is 4 to 8%.
The textile fabric is treated with the dispersion batch on a pad-mangle (100%
wet pick-up) and subsequently coagulated in a steamer at 98°C.
Complete curing and drying takes place on a tenter at 165°C.
If desired, a fibrous web, for example composed of polyester and polyamide fiber blends, can be split during or after coagulation has taken place in order that a softer hand may be obtained. To this end, the fibrous web is treated for example for about 1 hour in 3% sodium hydroxide solution at the boil, the polyester portion being dissolved out.
Prior peaching of the substrate surface enhances the effect.
Le A 34 641-Foreign countries _g_ Example 2 (inventive):
Consolidation by coagulation with conventional dispersion.
Batch: 200 parts by weight of Impranil~ DLV Dispersion (Bayer AG, Leverkusen) 4 parts by weight of Koagulant~ WS (20%) (Bayer AG, Leverkusen) 16 parts by weight of aqueous sodium chloride solution (10%) 4 parts by weight of Euderm~ Driver DE (Bayer AG, Leverkusen) 2 parts by weight of Bayderm~ Fix CIN (Bayer AG, Leverkusen 774 parts by weight of water S
The textile is treated with the dispersion batch on a pad-mangle (100% wet pick-up) and subsequently dried on a tenter.
Splitting of a polyester/polyamide web can be carned out similarly to Example 1.
Example 3 (inventive) Where no coagulation is carned out to consolidate the textile fabric, it is advisable for the cleaned, scoured textile to be dried on the tenter.
II. Coating Example 1 (inventive):
T- opcoat: 650 parts by weight of Impranil~ DLN Dispersion (Bayer AG, Leverkusen) Le A 34 641-Foreign countries 350 parts by weight of Impranil~ DLF Dispersion (Bayer AG, Leverkusen) thickened with Mirox~ AM (Stockhausen, Duisburg) in the presence of ammonia Intercoat: 500 parts by weight of Impranil~ DLN Dispersion (Bayer AG, Leverkusen) 500 parts by weight of Impranil~ VP LS 2333 (Bayer AG, Leverkusen) 7.5 parts by weight of Imprafix~ VP LS 2330 (Bayer AG, Leverkusen)/isopropanol (1:1) 20 parts by weight of Stockal~ STA (Stockhausen, Krefeld) 30 parts by weight of Stockal~ SR (Stockhausen, Krefeld) are mechanically foamed to 500 g/1 and thickened with Mirox~ AM (Stockhausen, Krefeld) in the presence of ammonia.
Adhesive coat: 1000 parts by weight of Impranil~ VP LS 2333 (Bayer AG, Leverkusen) 15 parts by weight of Imprafix~ VP LS 2330 (Bayer AG, Leverkusen)/isopropanol (1:1) are thickened with Mirox~ AM (Stockhausen, Krefeld) in the presence of ammonia.
Coating can be effected not only by the direct process but also by the transfer process.
In transfer coating with the aid of an embossed transfer paper, the graining of the coating can be structurally predetermined and deepened or augmented by the aftertreatment.
Le A 34 641-Foreign countries When a smooth transfer paper is chosen, the graining produced by the aftertreatment as well as by the direct coating is adventitious.
III. Aftertreatment of coated textile fabric When the coated textile is aftertreated with hot water only, it is also possible for suitable pigments to be added directly to the coating pastes.
Polyurethane is generally dyed with metallized dyes (eg complexing azo dyes, porphyrins or phthalocyanines) and selected acid and disperse dyes (eg azo, triarylmethane or anthraquinone dyes). In the case of on-tone dyeings with the substrate, these can also be combined with other classes of dye, depending on the dyeing method and substrate.
The following particulars represent one possible way of performing a simple dyeing, in a reel beck for example:
Example (inventive):
Dyes used:
Telon~ (Dystar, Leverkusen) monosulfonic acid dye Isolan S~ (Dystar, Leverkusen) 1:2 metallized dyes Liquor ratio: 40:1 demineralized water Dye concentration: 2 to 4% on weight of fiber Temperature profile during dyeing:
40°C ~ 30 min. ~ 100°C ~ 60 min. ~ 100°C
The pH is adjusted to 5 with acetic acid for dyeing with acid dyes.
Le A 34 641-Foreign countries The fabric is subsequently neutralized with aqueous sodium hydroxide solution and rinsed with demineralized water and finally dried tensionlessly, for example on a festoon dryer.
Claims (8)
1. A process for producing grained fabrics, characterized in that textile fabrics having residual shrinkage are initially coated with PU dispersions or solutions and then aftertreated with the application of heat.
2. A process according to claim 1, characterized in that the coating of the textile fabrics is effected by the direct process or by the transfer process.
3. A process according to claim 1, characterized in that the textile fabrics are consolidated by aqueous coagulation with reactive and postcrosslinkable PU
dispersions before the PU coating.
dispersions before the PU coating.
4. A process according to claim 1, characterized in that the textile fabrics are subjected to a pre-embossing step after the PU coating.
5. A process according to claim 1, characterized in that the aftertreatment of the coated textile fabrics is effected in a dyeing operation or in a tensionless treatment with hot water.
6. Grained coated fabrics obtainable by a process according to claim 1.
7. A method of using the fabrics of claim 6 as a decorative starting material.
8. A method of using the fabrics of claim 6 as an outerwear material, as a shoe upper material and liner, as a bagmakers' and upholstery material and also as an automotive interior material.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE10039249A DE10039249A1 (en) | 2000-08-11 | 2000-08-11 | Coated, flexible fabrics |
| DE10039249.0 | 2000-08-11 | ||
| PCT/EP2001/008790 WO2002014596A1 (en) | 2000-08-11 | 2001-07-30 | Coated, flexible fabric |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2418841A1 true CA2418841A1 (en) | 2003-02-07 |
Family
ID=7652102
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002418841A Abandoned CA2418841A1 (en) | 2000-08-11 | 2001-07-30 | Coated, flexible fabric |
Country Status (15)
| Country | Link |
|---|---|
| US (1) | US20020114925A1 (en) |
| EP (1) | EP1311720A1 (en) |
| JP (1) | JP2004506817A (en) |
| KR (1) | KR20030029817A (en) |
| CN (1) | CN1446281A (en) |
| AU (1) | AU2001279791A1 (en) |
| BR (1) | BR0113172A (en) |
| CA (1) | CA2418841A1 (en) |
| CZ (1) | CZ2003404A3 (en) |
| DE (1) | DE10039249A1 (en) |
| HU (1) | HUP0303752A2 (en) |
| IL (1) | IL154145A0 (en) |
| MX (1) | MXPA03001244A (en) |
| PL (1) | PL359851A1 (en) |
| WO (1) | WO2002014596A1 (en) |
Families Citing this family (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6874256B2 (en) * | 2003-04-04 | 2005-04-05 | Vans, Inc. | Shoe with removable vamp |
| DE10330099A1 (en) * | 2003-07-03 | 2005-01-27 | Benecke-Kaliko Ag | Composite material with plastic composite matrix, process for their preparation and their use |
| US7401843B2 (en) * | 2003-07-24 | 2008-07-22 | Tremco Incorporated | Recreational vehicle roofing coating |
| DE102007013163B4 (en) | 2007-03-20 | 2013-04-04 | Benecke-Kaliko Ag | Process for the production of multilayer plastic films |
| CN101798763B (en) * | 2009-12-21 | 2014-01-22 | 厦门泓信超细纤维材料有限公司 | Superfine fiber polyurethane synthesis leather and preparation method thereof |
| CN101798764B (en) * | 2009-12-21 | 2012-10-10 | 厦门泓信超细纤维材料有限公司 | Dyeing method of artificial leather |
| CN102409553B (en) * | 2011-09-16 | 2013-06-19 | 东台市富安合成材料有限公司 | Method for preparing solvent-free vehicle interior leather based on in-situ polymerization |
| CN102505529A (en) * | 2011-10-13 | 2012-06-20 | 上海华峰超纤材料股份有限公司 | Method for manufacturing embossed and dyed ultrafine fiber synthetic leather |
| NL2022904B1 (en) * | 2019-04-09 | 2020-10-20 | Stahl Int B V | Method for upgrading and embossing leather |
Family Cites Families (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| BE463530A (en) * | 1944-06-19 | 1947-02-28 | ||
| FR1266408A (en) * | 1959-09-03 | 1961-07-07 | Weinsheim Gmbh Chem Werke | Process for the manufacture of materials, preferably fibrous materials, provided with layers of synthetic material |
| US3837983A (en) * | 1969-02-20 | 1974-09-24 | Koracorp Ind Inc | Simulated leather fabric |
| JPS4985204A (en) * | 1972-12-20 | 1974-08-15 | ||
| US4053669A (en) * | 1974-04-11 | 1977-10-11 | Pandel-Bradford, Inc. | Imitation sheet material with surface grain appearance |
| JPS6021980A (en) * | 1983-07-12 | 1985-02-04 | Toray Ind Inc | Composite material |
| JP2592452B2 (en) * | 1987-05-29 | 1997-03-19 | 旭化成工業株式会社 | Moldable nonwoven sheet having three-dimensional texture and method for producing the same |
| JP2941821B2 (en) * | 1988-11-07 | 1999-08-30 | アキレス株式会社 | Manufacturing method of synthetic leather |
| JPH093783A (en) * | 1995-06-20 | 1997-01-07 | Daiyu Shoji:Kk | Grained synthetic leather having excellent steric surface appearance and its production |
-
2000
- 2000-08-11 DE DE10039249A patent/DE10039249A1/en not_active Withdrawn
-
2001
- 2001-07-30 MX MXPA03001244A patent/MXPA03001244A/en not_active Application Discontinuation
- 2001-07-30 CA CA002418841A patent/CA2418841A1/en not_active Abandoned
- 2001-07-30 AU AU2001279791A patent/AU2001279791A1/en not_active Abandoned
- 2001-07-30 CZ CZ2003404A patent/CZ2003404A3/en unknown
- 2001-07-30 BR BR0113172-9A patent/BR0113172A/en not_active Application Discontinuation
- 2001-07-30 PL PL35985101A patent/PL359851A1/en not_active Application Discontinuation
- 2001-07-30 HU HU0303752A patent/HUP0303752A2/en unknown
- 2001-07-30 JP JP2002519715A patent/JP2004506817A/en active Pending
- 2001-07-30 KR KR10-2003-7001906A patent/KR20030029817A/en not_active Application Discontinuation
- 2001-07-30 IL IL15414501A patent/IL154145A0/en unknown
- 2001-07-30 WO PCT/EP2001/008790 patent/WO2002014596A1/en not_active Application Discontinuation
- 2001-07-30 CN CN01814011A patent/CN1446281A/en active Pending
- 2001-07-30 EP EP01958034A patent/EP1311720A1/en not_active Withdrawn
- 2001-08-09 US US09/925,661 patent/US20020114925A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| KR20030029817A (en) | 2003-04-16 |
| HUP0303752A2 (en) | 2007-09-28 |
| JP2004506817A (en) | 2004-03-04 |
| EP1311720A1 (en) | 2003-05-21 |
| DE10039249A1 (en) | 2002-02-28 |
| CN1446281A (en) | 2003-10-01 |
| WO2002014596A1 (en) | 2002-02-21 |
| IL154145A0 (en) | 2003-07-31 |
| CZ2003404A3 (en) | 2003-05-14 |
| BR0113172A (en) | 2003-06-24 |
| AU2001279791A1 (en) | 2002-02-25 |
| US20020114925A1 (en) | 2002-08-22 |
| MXPA03001244A (en) | 2004-03-10 |
| PL359851A1 (en) | 2004-09-06 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |