CN105350339A - 复合长纤维纺织品及用其制得的环保复合长纤维人工皮革 - Google Patents

复合长纤维纺织品及用其制得的环保复合长纤维人工皮革 Download PDF

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CN105350339A
CN105350339A CN201410638085.6A CN201410638085A CN105350339A CN 105350339 A CN105350339 A CN 105350339A CN 201410638085 A CN201410638085 A CN 201410638085A CN 105350339 A CN105350339 A CN 105350339A
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long fiber
composite long
artificial leather
core
environmental protection
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冯崇智
郑国光
林至逸
杨高隆
吴建民
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San Fang Chemical Industry Co Ltd
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San Fang Chemical Industry Co Ltd
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Priority to CN202110538598.XA priority Critical patent/CN113389056A/zh
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    • 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
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Abstract

本发明公开一种特殊的复合长纤维纺织品及用该纺织品制得的环保复合长纤维人工皮革。该环保复合长纤维人工皮革包括：一复合长纤维纺织品，其由复合长纤维制成，该复合长纤维包括至少一个芯部及一个壳部，该至少一个芯部为聚酯类聚合物、聚酰胺聚合物或聚丙烯聚合物，该壳部包覆该至少一个芯部，且该壳部为热塑性弹性体；及一弹性体薄膜，其结合于该复合长纤维纺织品。由此，可制得轻量化、耐磨耗、手感良好及尺寸稳定性佳的环保人工皮革，且无需使用溶剂即可制得人工皮革，符合环保的要求。

Description

复合长纤维纺织品及用其制得的环保复合长纤维人工皮革
技术领域
本发明涉及一种纺织品及人工皮革，特别涉及一种环保复合长纤维人工皮革及复合长纤维纺织品。
背景技术
已知的人工皮革若使用短纤维及由其制成的短纤维纺织品基材，会发生基材尺寸稳定性不佳，同时为了保持皮革的良好手感，而无法达到轻量化的目标，同时若制造过程含浸或贴合聚氨酯(PU)树酯，则会因为含有溶剂而不环保，若人工皮革使用长纤维及由其制成的长纤维纺织品基材，虽尺寸稳定性佳，但由于长纤维纺织品为薄型结构，无法给予皮革良好的手感，且制造过程含浸或贴合PU树酯，同样因为含有溶剂而不环保。
已知的人工皮革及其制造方法如对下列现有技术专利文献的分析。
1.TW201128019
做法：复合热塑性基材与异形断面纤维并熔喷于基网上，表面再进行热塑性基材热贴合并进行加热加压纹路处理。
缺点：加工较繁琐，尺寸稳定性不佳，无法轻量化，且有附加量分布不均匀的问题发生。
2.TW438927
做法：利用非弹性体的纤维与表面配置有弹性体的纤维堆栈构成基材，再经短纤制造过程获得人工皮革。
缺点：制造过程时间长，附加量不均匀，抗张强度较低，剥离强度较差，棉网分布容易不均匀。
3.TW201040352
做法：基材是由极细长纤维及高分子弹性体组成。
缺点：尺寸稳定性不佳。
基于上述分析，有必要提供一创新且具有进步性的环保复合长纤维人工皮革及其制造方法与复合长纤维纺织品及其制造方法，以解决上述已知缺陷。
发明内容
本发明提供一种环保复合长纤维人工皮革，包括一复合长纤维纺织品及一弹性体薄膜。该复合长纤维纺织品由复合长纤维制成或由复合长纤维与其它长纤维共同制成，该复合长纤维包括至少一个芯部及一个壳部。该至少一个芯部为聚酯类聚合物、聚酰胺聚合物或聚丙烯聚合物。该壳部包覆该至少一个芯部，且该壳部为热塑性弹性体。该弹性体薄膜结合于该复合长纤维纺织品。
本发明还提供一种复合长纤维纺织品，其由复合长纤维制成或由该复合长纤维与其它长纤维共同制成，该复合长纤维包括至少一个芯部及一个壳部。该至少一个芯部为聚酯类聚合物、聚酰胺聚合物或聚丙烯聚合物。该壳部包覆该至少一个芯部，且该壳部为热塑性弹性体。
本发明以复合长纤维制成或以复合长纤维与其它长纤维共同制成复合长纤维纺织品，并利用复合长纤维纺织品与弹性体薄膜的结合，可制得轻量化、耐磨耗、手感良好及尺寸稳定性佳的环保人工皮革。而且，本发明无需使用溶剂即可制得人工皮革，符合环保的要求。
为了能够更清楚了解本发明的技术手段，从而可依照说明书的内容予以实施，并且为了让本发明所述目的、特征和优点能够更明晰易懂，以下特举优选实施例，并配合附图，详细说明如下。
附图说明
图1显示本发明环保复合长纤维人工皮革的结构示意图；
图2显示本发明复合长纤维的结构剖视图；
图3显示本发明复合长纤维的另一结构剖视图；
图4显示本发明环保复合长纤维人工皮革的制造方法的流程图；
图5A至5C显示本发明环保复合长纤维人工皮革的制造方法的示意图；
图6显示发明例1以长纤维复合纺丝机制备复合长纤维的制造过程的示意图；
图7显示发明例2以纺粘复合纤维纺丝机制备复合长纤维的制造过程的示意图；
图8显示发明例3以熔喷复合纤维纺丝机制备复合长纤维的制造过程的示意图；及
图9显示发明例4以手持式熔喷复合纤维纺丝机制备复合长纤维的制造过程的示意图。
符号说明
10环保复合长纤维人工皮革
12复合长纤维纺织品
120复合长纤维
122芯部
124壳部
14弹性体薄膜
S41～S43步骤
具体实施方式
图1显示本发明环保复合长纤维人工皮革的结构示意图。图2显示本发明复合长纤维的结构剖视图。配合参阅图1及图2，本发明的环保复合长纤维人工皮革10包括一复合长纤维纺织品12及一弹性体薄膜14。
该复合长纤维纺织品12可由复合长纤维120制成或由复合长纤维120与聚酯长纤维或聚酰胺长纤维混纺制成，且该复合长纤维纺织品12的型态可为织布型态(woven)或非织布型态(nonwoven)，其中织布可为平织或针织，且该织布可为一般纤维或高强力纤维与复合长纤维120混织的布。优选地，该复合长纤维纺织品12的厚度为0.025至10mm，而该复合长纤维纺织品12的抗张强度为1至25kg/25.4mm2。
在本实施例中，该复合长纤维120包括至少一个芯部122及一个壳部124。该至少一个芯部122占整体纤维的重量比例为10至90％，而该壳部124占整体纤维的重量比例亦可为90至10％。
该至少一个芯部122为聚酯类聚合物、聚酰胺聚合物或聚丙烯聚合物，在本实施例中，该聚酯类聚合物的特性粘度范围为0.4至1.1，而该聚酰胺聚合物的相对粘度范围为2.0至3.0，而聚丙烯聚合物的熔融指数范围为30至150(依据ASTMD1238标准，条件为2.16kg，230℃)。优选地，该至少一个芯部122可选自如下中的一种聚合物：聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸丁二醇酯(PBT)、聚对苯二甲酸丙二醇酯(PTT)、热塑性脂肪族聚酯(PLA)、聚己内酰胺(尼龙6)、聚己二酰己二胺(尼龙6,6)、聚丙烯均聚物(PolypropyleneHomopolymer)及聚丙烯无规共聚物(PolypropyleneRandomCopolymer)。
该壳部124包覆该至少一个芯部122，且该壳部124为热塑性弹性体。在本实施例中，该壳部124的原料熔融指数范围为1至100g/10min，依据ASTMD1238标准，条件为2.16kg，190℃。优选地，该壳部124可选自如下中的一种聚合物：热塑性聚氨酯(TPU)、热塑性聚酯弹性体(TPEE)及热塑性聚烯烃(TPO)。
参阅图3，其显示本发明复合长纤维的另一结构剖视图。如图3所示，在另一实施例中，该复合长纤维120可包括复数个(多个)芯部122及一个壳部124，各该芯部122呈间隔设置，且该壳部124包覆这些芯部122。
另外，为达到轻量化及提高尺寸稳定性的目的，优选地，该复合长纤维120的单根纤维旦数、密度及强度应分别满足以下条件：旦数为0.001至20dpf；密度为0.8至1.4g/cm3；及强度为0.5至8.0g/den(旦)。
再参阅图1，该弹性体薄膜14结合于该复合长纤维纺织品12。在本实施例中，该弹性体薄膜14与该复合长纤维纺织品12的结合方式可选自如下中的一种：使用固形份为5～55％的水性糊剂粘着或直接以90～180℃的温度进行热压粘着。
此外，该弹性体薄膜14可为发泡薄膜或未发泡薄膜，其中发泡薄膜的密度为0.3至0.9g/cm3及厚度为0.2至2.0mm，而未发泡薄膜的厚度为0.1至2.0mm。且优选地，该弹性体薄膜14可由如下中的一种材料制成：热塑性聚氨酯(TPU)、热塑性聚酯弹性体(TPEE)及热塑性聚烯烃(TPO)。
图4显示本发明环保复合长纤维人工皮革的制造方法的流程图。图5A至5C显示本发明环保复合长纤维人工皮革的制造方法的示意图。配合参阅图4的步骤S41及图5A，制备复合长纤维120。在此步骤中，该复合长纤维120包括至少一个芯部122及一个壳部124。该至少一个芯部122占整体纤维的重量比例为10至90％，而该壳部124占整体纤维的重量比例为90至10％。
该至少一个芯部122为聚酯类聚合物、聚酰胺聚合物或聚丙烯聚合物。优选地，该至少一个芯部122可选自如下中的一种聚合物：聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸丁二醇酯(PBT)、聚对苯二甲酸丙二醇酯(PTT)、热塑性脂肪族聚酯(PLA)、聚己内酰胺(尼龙6)、聚己二酰己二胺(尼龙6,6)、聚丙烯均聚物(PolypropyleneHomopolymer)及聚丙烯无规共聚物(PolypropyleneRandomCopolymer)。
该壳部124包覆该至少一个芯部122，且该壳部124为热塑性弹性体。优选地，该壳部124可选自如下中的一种聚合物：热塑性聚氨酯(TPU)、热塑性聚酯弹性体(TPEE)及热塑性聚烯烃(TPO)。
另外，在此步骤中，制备该复合长纤维120的方法可选自如下中的一种：融熔纺丝法、纺粘法及熔喷法。且优选地，该至少一个芯部122的挤出(押出)温度为180至250℃，而该壳部124的挤出温度为150至250℃。
配合参阅图4的步骤S42及图5B，以该复合长纤维120制成或以该复合长纤维120与聚酯长纤维或聚酰胺长纤维混纺制成一复合长纤维纺织品12。在此步骤中，制成该复合长纤维纺织品12的方法可选自如下中的一种：融熔纺丝法、纺粘法、熔喷法及纤维织布法。在本实施例中，纤维织布法包括以平织喷水织机、平织喷气织机、圆编织机、经编织机、提花织机、横编织机等中的一种设备织造所构成的织物。此外，该复合长纤维纺织品12的型态可为织布型态(woven)或非织布型态(nonwoven)。再者，该复合长纤维纺织品12可与一般纤维或高强力纤维交织或混纺，且该复合长纤维纺织品12可经热塑形成鞋面材料。
配合参阅图4的步骤S43及图5C，将弹性体薄膜14结合于该复合长纤维纺织品12。在此步骤中，该弹性体薄膜14可由如下中的一种材料制成：热塑性聚氨酯(TPU)、热塑性聚酯弹性体(TPEE)及热塑性聚烯烃(TPO)。
在本实施例中，该弹性体薄膜14热压贴合于该复合长纤维纺织品12。或者，在另一实施例中，该弹性体薄膜14可以涂布或喷涂方式结合于该复合长纤维纺织品12，例如将水溶性聚氨酯(PU)涂布或喷涂于该复合长纤维纺织品12，而该水溶性聚氨酯(PU)干燥后可形成该弹性体薄膜14。
本发明以复合长纤维120制成复合长纤维纺织品12，并利用复合长纤维纺织品12与弹性体薄膜14的结合，可制得轻量化、手感良好及尺寸稳定性佳的人工皮革。而且，本发明无需使用溶剂即可制得人工皮革，符合环保的要求。此外，本发明使用热粘加工即可制得人工皮革，与传统人工皮革中需要冗长的烘箱干燥制造过程相比亦可缩短加工制造过程时间，减少能源排放，并可有效降低制造成本及提高生产效能。
此外，本发明环保复合长纤维人工皮革具有透湿性，可直接成型为鞋面。例如，该复合长纤维纺织品12可呈鞋型，而该弹性体薄膜14经热压可形成鞋面。
另外，本发明复合长纤维纺织品亦可直接热压成型为具有凹凸的鞋面。例如，该复合长纤维纺织品12可呈鞋型。
兹以下列实例详细说明本发明，但并不意味着本发明仅局限于这些实例所公开的内容。
[发明例1]
以PBT(聚对苯二甲酸丁二醇酯,IV＝0.74)当芯部成分，搭配TPU(热塑性聚氨酯,MI＝4,190℃,2.16kg)当壳部成分，PBT与TPU的重量比为6：4。参阅图6，其显示发明例1的以长纤维复合纺丝机制备复合长纤维的制造过程的示意图。如图6所示，利用长纤维复合纺丝机制成芯壳断面复合长纤维，PBT纺丝箱温度为250℃，TPU纺丝箱温度为220℃，卷取速度为2500m/min，可得复合长纤维的规格为100den/24f，单根纤维强度为4g/den。
将复合长纤维整齐排列后，经织布机织成经纱密度每英寸17条及纬纱密度每英寸17条的0.15mm厚的织造网布。
使用厚度为0.1mm的TPU膜与该织造网布，以热压机在120℃的温度、20kg/cm2的压力下进行热压贴合，TPU薄膜与纤维壳部的TPU同时因热而软化熔融并完成热贴合，即可制得厚度为0.25mm，且柔软又赋有弹性的环保复合长纤维人工皮革半成品。
以离型纸的PU干式涂布制造过程，在离型纸上依序涂布水溶性聚氨酯面层及糊剂，再与上述半成品表面进行贴合，即可制得具各种表面纹路的环保复合长纤维人工皮革。
[发明例2]
以PET(聚对苯二甲酸乙二醇酯,IV＝0.5)当芯部成分，搭配TPU(热塑性聚氨酯,MI＝50,190℃,2.16kg)当壳部成分，PBT与TPU的重量比为6：4。参阅图7，其显示发明例2的以纺粘复合纤维纺丝机制备复合长纤维的制造过程的示意图。如图7所示，利用纺粘复合纤维纺丝机制成芯壳断面复合长纤维，PET纺丝箱温度为260℃，TPU纺丝箱温度为220℃，经纺粘制造过程进行纺丝，其中风压为9kg/cm2，风引拉伸丝速度为4000m/min，输送带速度为4m/min，因此，可制得直径20μm的复合长纤维及厚度0.22mm的纺粘不织布纺织品，再以热压机(温度110℃、压力5kg/cm2)热压该纺粘不织布纺织品，热压后的该纺粘不织布纺织品的厚度为0.2mm，并具有良好的尺寸稳定性。
使用厚度为0.1mm的TPU发泡膜与该纺粘不织布纺织品，以热压机在110℃的温度、10kg/cm2的压力下进行热压贴合，TPU薄膜与纤维壳部的TPU同时因热而软化熔融并完成热贴合，故可制得柔软的、弹性的且厚度为0.3mm的环保复合长纤维人工皮革半成品。
以离型纸的PU干式涂布制造过程，在离型纸上依序涂布水溶性聚氨酯面层及糊剂，再与上述半成品表面进行贴合，即可制得具各种表面纹路的环保复合长纤维人工皮革。
[发明例3]
以PTT(聚对苯二甲酸丙二醇酯,IV＝0.55)当芯部成分，搭配TPU(热塑性聚氨酯,MI＝80,190℃,2.16kg)当壳部成分，PTT与TPU的重量比为6：4。参阅图8，其显示发明例3的以熔喷复合纤维纺丝机制备复合长纤维的制造过程的示意图。如图8所示，利用熔喷复合纤维纺丝机制成芯壳断面复合长纤维，PTT纺丝箱温度为250℃，TPU纺丝箱温度为200℃，经熔喷制造过程进行纺丝，其中高压空气压力为3000psi，高压空气温度为180℃，输送带速度为2m/min，因此，可制得直径20μm的复合长纤维及厚度0.27mm的熔喷不织布纺织品，再以热压机(温度100℃、压力5kg/cm2)热压该熔喷不织布纺织品，热压后的该熔喷不织布纺织品的厚度为0.25mm，并具有良好的尺寸稳定性。
使用厚度为0.1mm的TPU发泡膜与该熔喷不织布纺织品，以热压机在110℃的温度、10kg/cm2的压力下进行热压贴合，TPU薄膜与纤维壳部的TPU同时因热而软化熔融并完成热贴合，故可制得柔软的、弹性的且厚度为0.35mm的环保复合长纤维人工皮革半成品。
以离型纸的PU干式涂布制造过程，在离型纸上依序涂布水溶性聚氨酯面层及糊剂，再与上述半成品表面进行贴合，即可制得具各种表面纹路的环保复合长纤维人工皮革。
[发明例4]
以PBT(聚对苯二甲酸丁二醇酯,IV＝0.74)当芯部成分，搭配TPU(热塑性聚氨酯,MI＝80,190℃,2.16kg)当壳部成分，PBT与TPU的重量比为7：3。参阅图9，其显示发明例4的以手持式熔喷复合纤维纺丝机制备复合长纤维的制造过程的示意图。如图9所示，利用手持式熔喷复合纤维纺丝机制成芯壳断面复合长纤维，PBT纺丝箱温度为250℃，TPU纺丝箱温度为200℃，经熔喷制造过程进行纺丝，并利用喷枪将丝喷在鞋体上，使其形成鞋面，其中高压空气压力为2800psi，高压空气温度为170℃，因此，可制得直径20μm的复合长纤维及厚度0.2mm的鞋材，并可在TPU加色，赋予鞋子色彩。
[发明例5]
以PET(聚对苯二甲酸乙二醇酯,IV＝0.5)当芯部成分，搭配TPU(热塑性聚氨酯,MI＝50,190℃,2.16kg)当壳部成分，PBT与TPU的重量比为6：4。利用纺粘复合纤维纺丝机(图7)制成芯壳断面复合长纤维，PET纺丝箱温度为260℃，TPU纺丝箱温度为220℃，经纺粘制造过程进行纺丝，其中风压为9kg/cm2，风引拉伸丝速度为4000m/min，输送带速度为4m/min，因此，可制得直径20μm的复合长纤维及厚度0.22mm的纺粘不织布纺织品，再以热压机(温度110℃、压力5kg/cm2)热压该纺粘不织布纺织品，热压后的该纺粘不织布纺织品的厚度为0.2mm，并具有良好的尺寸稳定性。
涂布水溶性聚氨酯(PU)于该纺粘不织布纺织品，该水溶性聚氨酯(PU)干燥后可形成弹性体薄膜，以制得环保复合长纤维人工皮革。
[发明例6]
以发明例1中经熔融纺丝制得的规格为100d/24f的复合纤维为经纱，以单位强度大于6g/den、规格为75d/24f的高强力聚酯长纤维为纬纱，这两种长纤维经织布机以经密120根/2.54cm、纬密90根/2.54cm制得一厚度为0.12mm的平织纺织品。使用厚度为0.12mm、发泡倍率为1.59倍、密度为0.755g/cm3的CO2发泡TPU膜与该织造网布，以热压机在125℃的温度、25kg/cm2的压力下进行热压贴合，TPU发泡薄膜与纤维壳部的TPU同时因热而软化熔融并完成热贴合，故可制得柔软的、弹性的且厚度为0.24mm的环保复合长纤维人工皮革半成品。以离型纸的PU干式涂布制造过程，在离型纸上依序涂布水溶性聚氨酯面层及糊剂，再与上述半成品表面进行贴合，即可制得具各种表面纹路，且抗张强度为55kg/cm2的高物性环保复合长纤维人工皮革。
[发明例7]
以发明例1中经熔融纺丝制得的规格为100d/24f的复合纤维与单位强度大于6g/den、规格为50d/24f的高强力聚酯长纤维进行S型假捻，制得150/48/2的假捻纱，该假捻纱使用针织机制得一厚度为0.08mm的针织纺织品。使用厚度为0.1mm、发泡倍率为1.57倍、密度为0.763g/cm3的CO2发泡TPU膜与该针织布，以热压机在120℃的温度、15kg/cm2的压力下进行热压贴合，TPU发泡薄膜与纤维壳部的TPU同时因热而软化熔融并完成热贴合，故可制得柔软的、弹性的且厚度为0.18mm的环保复合长纤维人工皮革半成品。以离型纸的PU干式涂布制造过程，在离型纸上依序涂布水溶性聚氨酯面层及糊剂，再与上述半成品表面进行贴合，即可制得具各种表面纹路的环保复合长纤维人工皮革。
上述实施例仅为说明本发明的原理及其功效，并非限制本发明，因此本领域技术人员可对上述实施例进行修改及变化而仍不脱离本发明的精神。本发明所要求保护的范围应如所附的权利要求所列。

Claims (13)

1.一种环保复合长纤维人工皮革，包括：
一复合长纤维纺织品，其由复合长纤维制成，该复合长纤维包括至少一个芯部及一个壳部，该至少一个芯部为聚酯类聚合物、聚酰胺聚合物或聚丙烯聚合物，该壳部包覆该至少一个芯部，且该壳部为热塑性弹性体；及
一弹性体薄膜，其结合于该复合长纤维纺织品，该弹性体薄膜由如下中的一种材料制成：热塑性聚氨酯(TPU)、热塑性聚酯弹性体(TPEE)及热塑性聚烯烃(TPO)。
2.如权利要求1的环保复合长纤维人工皮革，
其中该复合长纤维纺织品的型态为织布型态或非织布型态。
3.如权利要求1的环保复合长纤维人工皮革，
其中该弹性体薄膜与该复合长纤维纺织品的结合方式选自如下中的一种：使用固形份为5～55％的水性糊剂粘着或以90～180℃的温度进行热压粘着。
4.如权利要求1的环保复合长纤维人工皮革，
其中该弹性体薄膜为未发泡薄膜，厚度为0.1至2.0mm。
5.如权利要求1的环保复合长纤维人工皮革，
其中该弹性体薄膜为发泡薄膜，密度为0.3至0.9g/cm3，厚度为0.2至2.0mm。
6.如权利要求1的环保复合长纤维人工皮革，
其中该复合长纤维纺织品由复合长纤维与聚酯长纤维或聚酰胺长纤维混纺制成。
7.如权利要求1的环保复合长纤维人工皮革，
其中该至少一个芯部占整体纤维的重量比例为10至90％，该壳部占整体纤维的重量比例为90至10％。
8.如权利要求1的环保复合长纤维人工皮革，
其中该至少一个芯部选自如下中的一种聚合物：聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸丁二醇酯(PBT)、聚对苯二甲酸丙二醇酯(PTT)、热塑性脂肪族聚酯(PLA)、聚己内酰胺(尼龙6)、聚己二酰己二胺(尼龙6,6)、聚丙烯均聚物及聚丙烯无规共聚物。
9.一种复合长纤维纺织品，其由复合长纤维制成，该复合长纤维包括至少一个芯部及一个壳部，该至少一个芯部为聚酯类聚合物、聚酰胺聚合物或聚丙烯聚合物，该壳部包覆该至少一个芯部，且该壳部为热塑性弹性体。
10.如权利要求9的复合长纤维纺织品，
其由复合长纤维与聚酯长纤维或聚酰胺长纤维混纺制成。
11.如权利要求9的复合长纤维纺织品，
其中该至少一个芯部占整体纤维的重量比例为10至90％，该壳部占整体纤维的重量比例为90至10％。
12.如权利要求9的复合长纤维纺织品，
其中该至少一个芯部选自如下中的一种聚合物：聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸丁二醇酯(PBT)、聚对苯二甲酸丙二醇酯(PTT)、热塑性脂肪族聚酯(PLA)、聚己内酰胺(尼龙6)、聚己二酰己二胺(尼龙6,6)、聚丙烯均聚物及聚丙烯无规共聚物。
13.如权利要求9的复合长纤维纺织品，
其中该壳部选自如下中的一种聚合物：热塑性聚氨酯(TPU)、热塑性聚酯弹性体(TPEE)及热塑性聚烯烃(TPO)。
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