CN108729243A - 一种全水性超细纤维汽车座椅及高档沙发用合成革及其制备方法 - Google Patents

一种全水性超细纤维汽车座椅及高档沙发用合成革及其制备方法 Download PDF

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CN108729243A
CN108729243A CN201810685023.9A CN201810685023A CN108729243A CN 108729243 A CN108729243 A CN 108729243A CN 201810685023 A CN201810685023 A CN 201810685023A CN 108729243 A CN108729243 A CN 108729243A
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synthetic leather
layer
slurry
aqueous
vehicle seat
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李桂军
李浩扬
倪伶俐
冯会生
张锋
刘永明
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HUAI'AN KAIYUE TECHNOLOGY DEVELOPMENT Co Ltd
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HUAI'AN KAIYUE TECHNOLOGY DEVELOPMENT Co Ltd
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Abstract

本发明公开了一种全水性超细纤维汽车座椅及高档沙发用合成革及其制备方法，在含浸全水性聚氨酯树脂的超细纤维合成革半成品表面依次涂布有打底层、发泡层、粘结层、面层，或依次涂布打底层、发泡层、面层；制备权利要求所述一种全水性超细纤维汽车座椅及高档沙发用合成革的方法。该种方法制备的合成革优点包括：1.无任何有毒有害物质残留；2.零VOC排放；3.高物性，高耐磨，耐水解3‑8年，剥离强度≥6kg；4.生产过程安全卫生环保、使用过程健康无危害；5.完全可以替代真皮；6.《中国汽车内空气质量标准》中限制物质“五苯三醛”均为零。

Description

一种全水性超细纤维汽车座椅及高档沙发用合成革及其制备 方法
技术领域
本发明涉及一种超细纤维合成革，特别是涉及一种全水性超细纤维汽车座椅及高档沙发用合成革及其制备方法。
背景技术
聚氨酯合成革是目前替代天然皮革制品最为理想的材料之一，其中的超细纤维合成革则是汽车座椅、高档沙发等领域真皮革最为理想的替代材料。随着经济的调整发展，人们的生活水平不断提高，对生活质量的要求也越来越高，因此皮革制品的需求量也不断增大，档次也逐渐提高。
目前相对高端的座椅面料产品主要是真皮革和溶剂型超细纤维革，其中真皮革存在众多问题：1.由于动物保护组织的限制数量受限；2.成品中甲醛、重金属超标；3.加工过程污染严重；4.由于受动物个体大小及生产过程会有受伤等的影响，其优质皮大小受限等。而溶剂型超细纤维合成革同样存在很多问题，诸如：1.使用含有大量溶剂的聚氨酯浆料，存在安全隐患、污染环境；2.造成甲苯、二甲基甲酰胺等VOC严重超标，其中二甲基甲酰胺被联合国癌症研究机构列为2A类致癌物质；3、另外目前市场上少量的水性超细纤维合成革其剥离强度不高（普遍低于4kg），剥离强度低，胶层容易脱落，不耐用，不能满足特殊场合/用途的较高要求。所有上述产品都很难通过我国2017年1月1日实施的《中国汽车内空气质量标准》中关于五苯三醛的限量要求。
发明内容
本发明要解决的技术问题是提供一种全水性超细纤维汽车座椅及高档沙发用合成革，既可克服水性超细纤维合成革污染问题，还可克服水性超细纤维合成革剥离强度低的问题，真正成为替代天然皮革制品的理想材料，本发明同时提供所述合成革的制备方法。
本发明是通过以下技术方案实现的：
一种全水性超细纤维汽车座椅及高档沙发用合成革，在含浸全水性聚氨酯树脂的超细纤维合成革半成品表面依次涂布有打底层、发泡层、粘结层、面层，或依次涂布打底层、发泡层、面层。
所述打底层浆料由以下质量份的原料经混合而成：水性聚氨酯粘接层树脂70-90，水溶性粉5-10，填料5-10，补强剂0.1-1，水0-10。
制备全水性超细纤维汽车座椅及高档沙发用合成革方法，包括如下步骤：
步骤一：用打底层浆料涂布经过含浸全水性聚氨酯树脂的超细纤维合成革半成品表面，烘干制得带有打底层的超细纤维合成革半成品；
步骤二： 在步骤一制得的合成革半成品的打底层表面涂布发泡浆料，经烘干后制得带有发泡层的超细纤维合成革半成品备用；
步骤三：在离型纸上用面层浆料涂布形成面层，再用粘结层浆料涂布在面层上形成粘结层，所述粘结层与步骤二超细纤维合成革半成品的发泡层贴合后烘干分离收卷，或直接在步骤二超细纤维合成革半成品的发泡层上涂面层后烘干压花收卷。
进一步地，所述步骤一中打底层浆料的涂布量为1-100g/m2，涂膜厚度为1-10微米，涂布次数为1次。
进一步地，步骤一中所述烘干是将涂布好打底层浆料的半成品以8-20m/min的速度进入烘箱进行烘干处理，烘箱内温度按由前向后的顺序逐渐增加。
进一步地，所述烘箱内温度前段为50-100℃，后段为120-150℃。
进一步地，所述的补强剂为双端羟丙基聚二甲基硅氧烷、γ-氨丙基三乙氧基硅烷、γ-氨丙基三甲氧基硅烷中的一种或两种以上混合。
进一步地，步骤一所述的含浸全水性聚氨酯树脂的超细纤维合成革半成品，是将定岛超纤无纺布匀速经过带有水性PU浆料的含浸槽，经轧辊轧出后经烘干，再将半成品在减碱量机中进行碱减量处理，最后水洗烘干得。
进一步地，所述碱为氢氧化钠，浓度为3-5%，水温为90℃，时间为30-50分钟。
进一步地，所述面层浆料由以下质量份原料经混合制得，水性聚氨酯面层树脂50-80，有机硅手感剂0-1，有机硅润湿流平剂0-1，水性色浆2-4，消光粉2-6，分散剂0-1；面层浆料粘度为2000-3000mpa.s。
进一步地，所述粘接层浆料由以下质量份原料经混合制得，水性聚氨酯粘接层树脂100，有机硅润湿流平剂0-1，水性色浆2-10，消泡剂0-1，分散剂0-1；粘接层浆料粘度为3000-4000mpa.s。
本发明的有益效果是：
本发明通过采用全水性聚氨酯树脂含浸定岛纤维基布，采用氢氧化钠而不用甲苯进行减量，得到半成品后待用，在经过特殊打底处理的半成品上制成表面致密的水性发泡层，再通过离型纸贴面水性面底层或辊涂水性面层后压花处理，从而制成高物性、表面花纹立体感强的沙发或汽车座椅用全水性聚氨酯超细纤维合成革产品；
本发明产品的剥离强度≥6kg，采用打底工艺处理，特别是打底料中的补强剂含有羟基，可与超细纤维基布纤维形成化学共价键，从而实现牢固结合,又因为该打底层没有发泡，因此成膜后具有较高的强度，且可与带有较好手感的发泡层形成极其牢固的结合，从而提高了产品的剥离强度。
本发明产品的优点包括：1.无任何有毒有害物质残留；2.零VOC排放；3.高物性，高耐磨，耐水解3-8年，剥离强度≥6kg；4.生产过程安全卫生环保、使用过程健康无危害；5.完全可以替代真皮；6.《中国汽车内空气质量标准》中限制物质“五苯三醛”均为零。
具体实施例
下面结合具体实施例对本发明进行详细的介绍。
实施例1
一种全水性超细纤维汽车座椅及高档沙发用合成革，在含浸全水性聚氨酯树脂的超细纤维合成革半成品表面依次涂布有打底层、发泡层、粘结层、面层。
制备方法，包括如下步骤：
步骤一：用打底层浆料涂布经过含浸全水性聚氨酯树脂的超细纤维合成革半成品表面，烘干制得带有打底层的超细纤维合成革半成品。
a.制备含浸水性PU浆料：称取水性PU树脂70质量份，水溶性粉15质量份，水性增稠剂0.4质量份，有机硅手感剂0.7质量份，有机硅柔软剂3质量份，填料15质量份，水性消泡剂0.4质量份混合制备成乳白色均一粘稠液体待用；
b.定岛超纤无纺布含浸：将a制备的含浸浆料加入含浸槽中，将定岛超纤无纺布以300-600m/h的速度匀速经过含浸槽，使其充分浸润水性PU浆料；
c.轧出：将浸透了水性PU浆料的超纤基布通过一对轧辊，挤出其中的部分浸渍液，通过调整轧辊间隙为基布厚度的三分之二，保证基布中含浸水性PU浆料的质量为基布质量的60%- 120%；
d.烘箱烘干：经挤压好的含浸水性PU浆料的基布以300-600m/h的速度进入温度为100-150℃的烘箱进行干燥固化得半成品一；
e.碱减量：将半成品一在碱减量机中进行碱减量处理，其中碱为氢氧化钠，溶液百分浓度为3-5%，水温为90℃，时间为30-50分钟；
f.水洗及烘干：经碱减量好的半成品一用清水清洗后，再用20%的柠檬酸溶液常温浸泡20分钟进行中和，再用清水洗至PH为7后进入温度为100-150℃的烘箱进行干燥得半成品二。
涂布打底层：
g、制备打底层浆料：称取水性聚氨酯粘接层树脂80质量份，水溶性粉7质量份，填料8质量份，双端羟丙基聚二甲基硅氧烷0.7质量份，水5质量份，混合均匀备用。
h、涂布：涂布量为80g/ m2，涂膜厚度为8微米，涂布次数为1次。
i、烘干：将涂布好打底层浆料的布料以5-20m/min的速度进入烘箱进行烘干，烘箱内温度按由前向后的顺序逐渐增加，其中前段的温度为50-100℃，后段的温度为120-150℃。布料经过烘箱的时候由传动链传送，烘干后经过压平、检验收卷，制得带有打底层的超细纤维合成革半成品。
步骤二： 在步骤一制得的合成革半成品的打底层表面涂布发泡浆料，经烘干后制得带有发泡层的超细纤维合成革半成品备用；
具体如下：
a.浆料配制：称取水性聚氨酯发泡树脂80质量份，水溶性粉8质量份，有机硅手感剂0.5质量份，有机硅润湿流平剂0.5质量份，填料20质量份，水性色浆3质量份，水性分散剂0.5质量份，水5质量份，制备成粘度在2000-8000mpa.s的发泡层混合浆料待用；
b.机械发泡：用发泡机对上述浆料进行发泡处理，其中发泡倍率为2倍，发泡时间为2-15秒，待从发泡机中放出的浆料泡沫均匀时即可进入涂布工序；
c.涂布：涂布量为300-500g/m2，涂膜厚度为10-70微米，涂布次数为3次；
d.烘干：将涂布好浆料的布料以3-12m/min的速度进入烘箱进行烘干处理，烘箱内温度按由前向后的顺序逐渐增加，其中前段的温度为50-100℃，后段的温度为120-150℃。布料经过烘箱的时候由传动链传送，烘干后经过压平、检验收卷，制得带有发泡层的超细纤维合成革半成品。
步骤三：在离型纸上用面层浆料涂布形成面层，再用粘结层浆料涂布在面层上形成粘结层，所述粘结层与步骤二超细纤维合成革半成品的发泡层贴合后烘干分离收卷，具体如下
a.配料：称取水性聚氨酯面层树脂70质量份，有机硅手感剂0.5质量份，有机硅润湿流平剂0.5质量份，水性色浆3质量份，消光粉4质量份，分散剂0.5质量份，制备成粘度在2000-3000mpa.s的面层浆料待用；
称取水性聚氨酯粘接层树脂100质量份，有机硅润湿流平剂0.5质量份，水性色浆7质量份，消泡剂0.5质量份，分散剂0.5质量份，制备成粘度在3000-4000mpa.s的粘接层浆料待用；
b.在离型纸上涂面层：涂布量为100g/ m2，涂膜厚度为12微米，涂布次数为1次；
c.烘干：烘箱烘干；
d.涂粘接层：在面层上涂布粘接层混合浆料，涂布量为120g/ m2，涂膜厚度为15微米，涂布次数为1次；
e.贴合：在生产线贴合工段把步骤二制得的半成品的发泡层面，贴合在步骤三制得的半成品的粘接层面上；
f.烘干：将贴合好的布料以10-20m/min的速度进入烘箱进行烘干，烘箱内温度按由前向后的顺序逐渐增加，其中烘箱前段的温度为70 -100℃，后段的温度为100-140℃；
g.分离、收卷：对离型纸和成品进行分离，分别收卷。检验合格后包装入库。
实施例2
一种全水性超细纤维汽车座椅及高档沙发用合成革，在含浸全水性聚氨酯树脂的超细纤维合成革半成品表面依次涂布打底层、发泡层、面层。
步骤三、用面层浆料涂布步骤二制得带有发泡层的超细纤维合成革半成品，经烘干、压花处理收卷。
具体方法包括配制面层浆料、辊涂布面层、烘干、压花处理和检验收卷工序，得成品。具体如下：
a.配料：称取水性聚氨酯面层树脂70质量份，有机硅手感剂0.5质量份，有机硅润湿流平剂0.5质量份，水性色浆3质量份，消光粉4质量份，分散剂0.5质量份，制备成粘度在2000-3000mpa.s的面层浆料待用；
b.涂面层：涂布量为100g/ m2，涂膜厚度为12微米，涂布次数为1次；
c.烘箱烘干；
d.压花处理：根据需要选择压花轮，将涂布好的布料以5-20m/min的速度，以3-4kg的压力，在140-190℃的温度下进行压花处理；
e.收卷、检验合格后包装入库。
其余实施如实施例1。
实施例3
制备打底用浆料：称取水性聚氨酯粘接层树脂70质量份，水溶性粉5质量份，填料5质量份，γ-氨丙基三乙氧基硅烷0.1质量份，水1质量份，制备成打底用混合浆料待用。
其余实施如实施例1。
实施例4
制备打底用浆料：称取水性聚氨酯粘接层树脂90质量份，水溶性粉10质量份，填料10质量份，γ-氨丙基三甲氧基硅烷1质量份，水10质量份，混合均匀得打底用混合浆料待用。
其余实施如实施例1。
实施例5
步骤二： 在步骤一制得的半成品二表面涂布发泡浆料，经烘干后制得带有发泡层的超细纤维合成革半成品。未涂布打底层浆料，用于对比剥离强度。
其余实施如实施例1。
下表是实施例1-5制得的产品，经检测各项指标均达到或优于目前的行业、地方标准的规定要求，具体见表1、表2：
表1 实施例1-5得到的合成革性能指标
表2 国标及行业标准

Claims (10)

1.一种全水性超细纤维汽车座椅及高档沙发用合成革，其特征在于：在含浸全水性聚氨酯树脂的超细纤维合成革半成品表面依次涂布有打底层、发泡层、粘结层、面层，或依次涂布打底层、发泡层、面层。
2.根据权利要求1所述的一种全水性超细纤维汽车座椅及高档沙发用合成革，其特征在于：所述打底层浆料由以下质量份的原料经混合而成：水性聚氨酯粘接层树脂70-90，水溶性粉5-10，填料5-10，补强剂0.1-1，水0-10。
3.制备权利要求1所述一种全水性超细纤维汽车座椅及高档沙发用合成革的方法，其特征在于：包括如下步骤：
步骤一：用打底层浆料涂布经过含浸全水性聚氨酯树脂的超细纤维合成革半成品表面，烘干制得带有打底层的超细纤维合成革半成品；
步骤二： 在步骤一制得的合成革半成品的打底层表面涂布发泡浆料，经烘干后制得带有发泡层的超细纤维合成革半成品备用；
步骤三：在离型纸上用面层浆料涂布形成面层，再用粘结层浆料涂布在面层上形成粘结层，所述粘结层与步骤二超细纤维合成革半成品的发泡层贴合后、烘干、分离收卷；或直接在步骤二超细纤维合成革半成品的发泡层上涂面层后烘干压花收卷。
4.根据权利要求3所述的一种全水性超细纤维汽车座椅及高档沙发用合成革制备方法，其特征在于：所述步骤一中打底层浆料的涂布量为1-100g/m2，涂膜厚度为1-10微米，涂布次数为1次。
5.根据权利要求3所述的一种全水性超细纤维汽车座椅及高档沙发用合成革制备方法，其特征在于：步骤一中所述烘干是将涂布好打底层浆料的半成品以5-20m/min的速度进入烘箱进行烘干处理，烘箱内温度按由前向后的顺序逐渐增加。
6.根据权利要求5所述的一种全水性超细纤维汽车座椅及高档沙发用合成革制备方法，其特征在于：所述烘箱内温度前段为50-100℃，后段为120-150℃。
7.根据权利要求2所述的一种全水性超细纤维汽车座椅及高档沙发用合成革，其特征在于：所述的补强剂为双端羟丙基聚二甲基硅氧烷、γ-氨丙基三乙氧基硅烷、γ-氨丙基三甲氧基硅烷中的一种或两种以上混合。
8.根据权利要求3所述的一种全水性超细纤维汽车座椅及高档沙发用合成革制备方法，其特征在于：步骤一所述的含浸全水性聚氨酯树脂的超细纤维合成革半成品，是将定岛超纤无纺布匀速经过带有水性PU浆料的含浸槽，经轧辊轧出后经烘干，再将半成品在减碱量机中进行碱减量处理，最后水洗烘干得。
9.根据权利要求3所述的一种全水性超细纤维汽车座椅及高档沙发用合成革制备方法，其特征在于：所述面层浆料由以下质量份原料经混合制得，水性聚氨酯面层树脂50-80，有机硅手感剂0-1，有机硅润湿流平剂0-1，水性色浆2-4，消光粉2-6，分散剂0-1；面层浆料粘度为2000-3000mpa.s。
10.根据权利要求3所述的一种全水性超细纤维汽车座椅及高档沙发用合成革制备方法，其特征在于：所述粘接层浆料由以下质量份原料经混合制得，水性聚氨酯粘接层树脂100，有机硅润湿流平剂0-1，水性色浆2-10，消泡剂0-1，分散剂0-1；粘接层浆料粘度为3000-4000mpa.s。
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