CN109397824A - 一种柔软耐磨人工皮革及其制备方法 - Google Patents
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Abstract
本发明涉及一种柔软耐磨人工皮革及其制备方法,它包括高分子弹性体基体、设置于所述高分子弹性体基体内的超细纤维、形成在所述高分子弹性体基体表面且由所述超细纤维构成的绒毛层、形成在所述绒毛层中的块状熔着点以及分布在所述绒毛层上的块状树脂,所述超细纤维为中空纤维且为定岛型海岛复合短纤维的岛成分;所述超细纤维为聚酯或尼龙。这样有利于保证人工皮革的尺寸稳定、色牢度好、力学性能优良等特性,还能确保其具有柔软性好、重量轻、尺寸稳定等特性。
Description
技术领域
本发明属于人工皮革领域,具体涉及一种柔软耐磨人工皮革及其制备方法。
背景技术
以超细纤维与聚氨酯结合制造成的仿麂皮人工皮革,因其具有舒适、美观、柔软等特点在衣料、家具、鞋类以及汽车内饰材料上有着广泛应用。目前,国内外生产的超细纤维人工革大多是以海岛超细纤维为原料,通过开松、铺网工艺制成无纺布后,经浸轧聚氨酯PU涂料、碱处理、磨毛、染色、整理加工制成。为了提高皮革的强度、尺寸安定性以及耐摩擦性,通常是提高聚氨酯PU的含量而实现。但是这样会导致皮革的硬度提高,柔软性下降,在一些高档用材质上的应用受到限制;另一方面,在一些高档资材的应用上,对人工皮革的柔软性也有着严格的规定。日本专利(JP2005226213A)中公开了通过增无纺布中的纤维络合性来提高皮革的物性,降低聚氨酯的使用含量。但是该方法会造成皮革表面不平整,有凸凹状态形成,在高品质表面要求的皮革商品上应用有一定的局限。日本专利(JP201766542A)中公开了一种通过超细中空纤维制成的人工皮革,但因其所使用的超细中空纤维的中空率为30%~80%,纤维极易破损,耐磨性不高,限制了其使用范围。除此之外,在一些高端产品应用上,对带有亮面的绒毛人工皮革也有着急迫的需求。
发明内容
本发明目的是为了克服现有技术的不足而提供一种柔软耐磨人工皮革。
为解决以上技术问题,本发明采取的一种技术方案是:一种柔软耐磨人工皮革,它包括高分子弹性体基体、设置于所述高分子弹性体基体内的超细纤维、形成在所述高分子弹性体基体表面且由所述超细纤维构成的绒毛层、形成在所述绒毛层中的块状熔着点以及分布在所述绒毛层上的块状树脂,所述超细纤维为中空纤维且为定岛型海岛复合短纤维的岛成分;所述超细纤维为聚酯或尼龙。
优化地,所述超细纤维的中空率为5%~30%。
优化地,所述块状树脂为选自聚乙烯和聚碳酸酯中的一种或两种的组合,其分布含量为5~100g/m2。
优化地,所述超细纤维的直径为0.1μm~10.0μm,具体优选为0.1μm~6.0μm。
优化地,所述块状熔着点为聚酯或共聚聚酯。
优化地,所述超细纤维为平均卷曲半径0.01mm~0.2mm的三维立体卷曲结构。
本发明的又一目的在于提供一种上述柔软耐磨人工皮革的制备方法,它包括以下步骤:
(a)通过三组份纺丝设备制备定岛型海岛复合短纤维;所述定岛型海岛复合短纤维包含海成分、第一岛成分和第二岛成分,第一岛成分和第二岛成分形成皮芯结构,第一岛成分为皮成分、第二岛成分为芯成分,海成分和第二岛成分相互独立地为溶出型聚合物;
(b)将所述定岛型海岛复合短纤维与低熔点纤维混合后梳理铺网,再经针刺机抱合加工形成复合无纺布;所述低熔点纤维为聚酯、改性聚酯、聚丙烯、尼龙或聚乙烯,其在复合无纺布中的质量含量为0.1~1.0%且熔点为120℃~230℃;
(c)对所述无纺布进行高分子弹性体浸轧、脱海处理、磨毛、染色、整理和干式造面即可。
优化地,步骤(a)中,所述定岛型海岛复合短纤维中第一岛成分、第二岛成分和海成分的重量百分比分别为15%~45%、15%~45%、10%~40%。
优化地,步骤(b)中,所述无纺布的克重为50~350g/m2。
本发明带来的有益效果是:本发明柔软耐磨人工皮革,通过在高分子弹性体基体内设置中空且一定卷曲半径的超细纤维并在其表面的绒毛层中设置块状熔着点、绒毛层上均匀分布不规则平面块状树脂,这样有利于保证人工皮革的尺寸稳定、色牢度好、力学性能优良等特性,还能确保其具有柔软性好、重量轻、尺寸稳定等特性。
具体实施方式
本发明柔软耐磨人工皮革,它包括高分子弹性体基体、设置于所述高分子弹性体基体内的超细纤维、形成在所述高分子弹性体基体表面且由所述超细纤维构成的绒毛层、形成在所述绒毛层中的块状熔着点以及分布在所述绒毛层上的块状树脂,所述超细纤维为中空纤维且为定岛型海岛复合短纤维的岛成分;所述超细纤维为聚酯或尼龙(优选为聚对苯二甲酸乙二醇)。这样有利于保证人工皮革的尺寸稳定、色牢度好、力学性能优良等特性,还能确保其具有柔软性好、重量轻、尺寸稳定等特性。
上述超细纤维的中空率为5%~30%,优选为20%~30%;当纤维的中空率低于5%时,所制造的人工皮革的柔软性没有较大改变;当纤维的中空率高于30%时,所制成的人工皮革上的绒毛易破损,耐磨性差。所述块状树脂为选自聚乙烯和聚碳酸酯中的一种或两种的组合,其分布含量为5~100g/m2。所述超细纤维的直径为0.1μm~10.0μm,具体优选为0.1μm~6.0μm。所述块状熔着点为聚酯或共聚聚酯。所述超细纤维为平均卷曲半径0.01mm~0.2mm、直径为0.01μm~10μm的三维立体卷曲结构。当纤维直径低于0.01μm时,纤维的强度较弱,人工皮革的耐磨耗性显著下降;当纤维直径高于10μm时,制成的人工皮革手感较差,影响其在制品上的应用。所述块状树脂(不规则平面块状树脂)为选自聚乙烯和聚碳酸酯中的一种或两种的组合,其分布含量为5~100g/m2,低于5g/m2时,由绒毛层表面上的块状平面树脂所来带的亮面不明显,高于100g/m2时,由于绒毛层表面上的块状平面树脂含量过多,手感差。所述高分子弹性体基体为聚氨酯。超细纤维为三维卷曲结构。
上述柔软耐磨人工皮革的制备方法,它包括以下步骤:(a)通过三组份纺丝设备制备定岛型海岛复合短纤维;所述定岛型海岛复合短纤维包含海成分、第一岛成分和第二岛成分,第一岛成分和第二岛成分形成皮芯结构,第一岛成分为皮成分、第二岛成分为芯成分,海成分和第二岛成分相互独立地为溶出型聚合物;(b)将所述定岛型海岛复合短纤维与低熔点纤维混合后梳理铺网,再经针刺机抱合加工形成复合无纺布;所述低熔点纤维为聚酯、改性聚酯、聚丙烯、尼龙或聚乙烯,其在复合无纺布中的质量含量为0.1~1.0%且熔点为120℃~230℃;(c)对所述无纺布进行高分子弹性体浸轧、脱海处理、磨毛、染色、整理和干式造面即可。
步骤(a)中,定岛型海岛复合短纤维是将第一岛成分、第二岛成分和海成分分别通过三组分复合纺丝机熔融、进入海岛型纺丝组件(第一岛成分、第二岛成分分别通过各自的路径在喷丝孔的出口汇合形成皮芯结构后,再与海成分在喷丝板出口汇合)喷出形成,因此其岛相(即第一岛成分、第二岛成分)和海相(即海成分)在纤维的长度方向是连续、均匀分布的;岛数固定,一般在8岛及以上。海成分通常为碱溶性聚酯或聚烯烃类易溶出型聚合物,优选为碱溶性聚酯(COPET)。所述定岛型海岛复合短纤维中第一岛成分、第二岛成分和海成分的重量百分比分别为15%~45%、15%~45%、10%~40%;海成分含量高于40%时,会造成海成分溶出困难,同时也会使海成分使用量过多,在后道加工工序中造成的溶出部分的聚合物较多,对环境污染较重;第二岛成分成分重量百分比高于35%时,会造成中空纤维中空率高,易破损,耐磨性差。步骤(b)中,所述无纺布的克重为50~350g/m2。步骤(b)中,所述低熔点纤维为聚酯(通常指PET)或改性聚酯(绍兴喜能纺织)。低熔点纤维的添加量低于0.1wt%时,低熔点纤维经加热工序中形成的熔着粘合点较少,不利于提高皮革的耐磨性;低熔点纤维添加量高于1.0wt%时,形成的熔着粘合点较大,并且分布不均与,造成手感较差,不利于产品的应用。低熔点纤维的熔点低于120℃时,人工皮革的耐热性较差;高于230℃时,不易形成熔着粘合点。上述干式造面的具体方法为:在已经涂上聚乙烯与聚碳酸酯(聚乙烯:聚碳酸=50:50)混合树脂的离型纸上喷上粘结剂(粘结剂为市售的聚氨酯类,如PU-7510型号),然后在已经形成的人工皮基布的绒毛层上进行贴合加工,加热固化。
下面将对本发明优选实施方案进行详细说明:
实施例1
本实施例提供一种柔软耐磨人工皮革,它包括高分子弹性体基体(聚氨酯)、设置在高分子弹性体基体内的超细纤维(直径约为5μm;其为中空纤维,皮成分为PET;它为定岛型海岛复合短纤维的岛成分)、形成在高分子弹性体基体表面且由超细纤维构成的绒毛层以及形成在绒毛层中的块状熔着点;
具体制备方法包括以下步骤:
(a)通过三组份纺丝设备按第一岛成分(PET)、第二岛成分(COPET)和海成分(COPET)的重量百分比为28%、42%、30%进行三组份纺丝(纺丝参数:纺丝箱体温度为290℃;采用侧吹风方式进行纺丝冷却、丝条固化,冷却风速度为20m/min、温度为20℃;纺丝速度为1200m/min、拉伸倍率为3.0,复合纺丝机的单孔吐出量为1.20g/min、岛数为8岛)得定岛型海岛复合短纤维,随后将定岛型海岛复合短纤维切断成长度为51mm的短纤维,其中第一岛成分和第二岛成分形成皮芯结构,第一岛成分为皮成分、第二岛成分为芯成分;
(b)将定岛型海岛复合短纤维(即步骤a中的短纤维)与低熔点聚酯纤维(熔点为200℃)混合后梳理铺网(复合短纤维与低熔点纤维的重量比为99.9:0.1),形成网状纤维薄层,再经针刺机或水刺机抱合加工形成复合无纺布(克重为300g/m2);
(c)将制成的无纺布浸入聚氨酯的DMF溶液后(聚氨酯的浓度约为30wt%),经115~130℃干燥定型形成仿麂皮基布(无纺布与聚氨酯的重量比为85:15),再将基布浸入质量浓度5~10%的NaOH或KOH溶液中进行脱海处理(脱海后的单纤维的直径为5.0μm,纤维的中空率为30%),然后再浸入去离子水中进行超音波清洗并调节至pH至中性,进行干燥;将干燥后的基布采用带式磨皮机进行预磨皮处理,达到所要面料的表皮绒感,然后进行染色加工而成,从而得到所需人工皮革基布;在涂布聚乙烯与聚碳酸酯(树脂a为聚乙烯:聚碳酸按质量比50:50混合)混合树脂的离型纸纸上喷上粘结剂(PU-7510型号),然后在人工皮革基布的绒毛层上进行贴合加工,经加热固化而成(混合树脂的分布含量约为20g/m2,形成不规则平面块状树脂)。
实施例2
本实施例提供一种柔软耐磨人工皮革,它与实施例1中的基本一致,不同的是:步骤(b)中,获得的无纺布克重150g/m2。
实施例3
本实施例提供一种柔软耐磨人工皮革,它与实施例1中的基本一致,不同的是:步骤(b)中,获得的无纺布克重200g/m2。
实施例4
本实施例提供一种柔软耐磨人工皮革,它与实施例1中的基本一致,不同的是:步骤(b)中,获得的无纺布克重50g/m2。
实施例5
本实施例提供一种柔软人工皮革,它与实施例1中的基本一致,不同的是:制得的定岛型海岛复合短纤维岛数为16岛。
实施例6
本实施例提供一种柔软耐磨人工皮革,它与实施例1中的基本一致,不同的是:第一岛成分为PA。
实施例7
本实施例提供一种柔软耐磨人工皮革,它与实施例1中的基本一致,不同的是:第一岛成分(PET)、第二岛成分(COPET)和海成分(COPET)的重量百分比为30:40:30。
实施例8
本实施例提供一种柔软耐磨人工皮革,它与实施例1中的基本一致,不同的是:第一岛成分(PET)、第二岛成分(COPET)和海成分(COPET)的重量百分比为40:40:20。
对比例1
本例提供一种人工皮革,它与实施例1中的基本一致,不同的是:它直接使用二组分复合纺丝机制备的复合短纤维,其中岛成分为PET,海成分为COPET,无纺布的克重为300g/m2。
实施例1-8、对比例1中制得的人工皮革中海岛短纤维的性能测试数据见表1。
表1实施例1-8、对比例1中人工皮革的原料配比和耐磨等级数据表
将实施例1-8、对比例1中制得的人工皮革进行测试,其结果列于表2中。
表2实施例1-8、对比例1中人工皮革的性能测试数据表
※亮面树脂种类
树脂a:聚乙烯:聚碳酸酯=50:50
注:克重:根据GB/T24218的规定,测定人造皮革的克重;
(1)单丝纤维中空率:
脱海后的单丝纤维通过显微镜进行截面拍照,取大小均匀的十个拍照样品进行测试计算,计算方法定义:纤维截面(包括纤维壁和中空部分)重量为M1,中空部面积重量为M2,中空率为M2/M1x100%。
(2)单丝纤维卷曲半径:
脱海后的单丝纤维通过显微镜进行拍照,纤维具有螺旋状的形态时,判定该并列复合纤维有三维立体卷曲结构;随机选择50根纤维,对其半径进行测定,取其平均值为该纤维的卷曲半径。
(3)柔软性试验:
人工皮革制成直径250mm的圆形样品,让20健康的男性、女性按照以下标准进行触感测试,取其平均值,评价结果4级以上为柔软性良好。
5:柔软性有,触感反应强;
4:柔软性有,触感反应稍微弱一点;
3:柔软性稍微弱一点,触感反应少;
2:柔软性差,触感反应没有;
1:柔软性没有,皮革硬,触感反应没有;
(4)耐磨耗性试验:
根据GB/T21196-2007法的规定,测定人造皮革的耐磨耗性,摩擦次数设为20000次,以摩擦后的重量减少率为基准分为5等级进行判定。以重量减少率(%)={(原布重量-摩擦后重量)/(原布重量)}×100表示,重量减少率为4%以上时评价为3等级以下,2%以上且小于4%时评价为4等级,小于2%时评价为5等级。
上述实施例只为说明本发明的技术构思及特点,其目的在于让熟悉此项技术的人士能够了解本发明的内容并据以实施,并不能以此限制本发明的保护范围。凡根据本发明精神实质所作的等效变化或修饰,都应涵盖在本发明的保护范围之内。
Claims (10)
1.一种柔软耐磨人工皮革,它包括高分子弹性体基体、设置于所述高分子弹性体基体内的超细纤维、形成在所述高分子弹性体基体表面且由所述超细纤维构成的绒毛层、形成在所述绒毛层中的块状熔着点以及分布在所述绒毛层上的块状树脂,其特征在于:所述超细纤维为中空纤维且为定岛型海岛复合短纤维的岛成分;所述超细纤维为聚酯或尼龙。
2.根据权利要求1所述的柔软耐磨人工皮革,其特征在于:所述超细纤维的中空率为5%~30%。
3.根据权利要求1所述的柔软耐磨人工皮革,其特征在于:所述块状树脂为选自聚乙烯和聚碳酸酯中的一种或两种的组合,其分布含量为5~100g/m2。
4.根据权利要求1所述的柔软耐磨人工皮革,其特征在于:所述超细纤维的直径为0.1μm~10.0μm。
5.根据权利要求1所述的柔软耐磨人工皮革,其特征在于:所述块状熔着点为聚酯或共聚聚酯。
6.根据权利要求1所述的柔软耐磨人工皮革,其特征在于:所述超细纤维为平均卷曲半径0.01mm~0.2mm的三维立体卷曲结构。
7.根据权利要求1所述的柔软耐磨人工皮革,其特征在于:所述高分子弹性体基体为聚氨酯。
8.权利要求1至7中任一所述柔软耐磨人工皮革的制备方法,其特征在于:它包括以下步骤:
(a)通过三组份纺丝设备制备定岛型海岛复合短纤维;所述定岛型海岛复合短纤维包含海成分、第一岛成分和第二岛成分,第一岛成分和第二岛成分形成皮芯结构,第一岛成分为皮成分、第二岛成分为芯成分,海成分和第二岛成分相互独立地为溶出型聚合物;
(b)将所述定岛型海岛复合短纤维与低熔点纤维混合后梳理铺网,再经针刺机抱合加工形成复合无纺布;所述低熔点纤维为聚酯、改性聚酯、聚丙烯、尼龙或聚乙烯,其在复合无纺布中的质量含量为0.1~1.0%且熔点为120℃~230℃;
(c)对所述无纺布进行高分子弹性体浸轧、脱海处理、磨毛、染色、整理和干式造面即可。
9.根据权利要求8所述柔软耐磨人工皮革的制备方法,其特征在于:步骤(a)中,所述定岛型海岛复合短纤维中第一岛成分、第二岛成分和海成分的重量百分比分别为15%~45%、15%~45%、10%~40%。
10.根据权利要求8所述柔软人工皮革的制备方法,其特征在于:步骤(b)中,所述无纺布的克重为50~350 g/m2。
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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CN111501205A (zh) * | 2020-04-15 | 2020-08-07 | 江苏尚科聚合新材料有限公司 | 一种高耐久人工皮革抛光垫及其制备方法 |
CN111501205B (zh) * | 2020-04-15 | 2021-03-26 | 江苏尚科聚合新材料有限公司 | 一种高耐久人工皮革抛光垫的制备方法 |
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