CN115214200A - Breathable composite leather, manufacturing method thereof and automotive interior - Google Patents

Breathable composite leather, manufacturing method thereof and automotive interior Download PDF

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Publication number
CN115214200A
CN115214200A CN202210289214.XA CN202210289214A CN115214200A CN 115214200 A CN115214200 A CN 115214200A CN 202210289214 A CN202210289214 A CN 202210289214A CN 115214200 A CN115214200 A CN 115214200A
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China
Prior art keywords
layer
thickness
tpu
ratio
skin
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CN202210289214.XA
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Chinese (zh)
Inventor
宋伟锋
戴安琪
邵敏
吴艳芳
喻冬青
管世伟
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Canadian General Tower Changshu Co Ltd
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Canadian General Tower Changshu Co Ltd
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Priority to CN202210289214.XA priority Critical patent/CN115214200A/en
Publication of CN115214200A publication Critical patent/CN115214200A/en
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
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Abstract

The invention provides air-permeable composite leather, a manufacturing method thereof and an automotive interior, wherein the composite leather comprises a 3D fabric structure and a resin skin structure which are connected in a laminated manner; the resin skin structure comprises a TPU supporting layer, a skin layer and a surface treatment agent layer which are sequentially stacked on the surface of one side of the 3D fabric structure, wherein the skin layer is in composite connection with the TPU supporting layer, and the TPU supporting layer is selected from the group consisting of 70 HA-100 HA in Shore hardness and 0.3 mm-0.8 mm in thickness; wherein, the resin surface structure is provided with a plurality of air holes penetrating through the whole thickness of the resin surface structure, and the opening area of the single air hole is less than or equal to 20mm 2 And the distance between every two adjacent air holes is larger than or equal to 3mm. The open pore area of the composite leather air vent can reach 70 percent, so that the composite leather air vent has high air permeability and high tensile property and tear resistance.

Description

Breathable composite leather, manufacturing method thereof and automotive interior
Technical Field
The invention relates to the technical field of automotive interior materials, in particular to breathable composite leather, a manufacturing method thereof and automotive interior.
Background
With the rapid development of the automobile industry, people increasingly raise the requirements on the functionality and the aesthetic property of automobile interior trims. The leather punching technology can provide good air permeability and play a decorative role, and is recognized by customers consistently. However, the genuine leather cannot be widely used due to its high price and the pollution of tanning process.
The adoption of artificial leather products with higher cost performance, more environmental protection and easy obtainment to replace the traditional leather materials is becoming the development trend of automotive interior. However, current synthetic leather product is formed by the epidermis and base cloth bonding, can destroy the woven structure on synthetic leather product base cloth layer at the in-process that punches, causes the mechanical properties of whole synthetic leather product to descend, easily takes place tensile rupture or by tearing, can't satisfy the requirement of follow-up use, especially when the area of punching surpasss surperficial whole area 50%, because the woven structure and the node of base cloth suffer a large amount of destruction, make the synthetic leather overall stability after punching appear disconnected cliff formula and descend.
Disclosure of Invention
In view of the above situation, the present invention is directed to an air-permeable composite leather, a method for manufacturing the same, and an automotive interior, so as to solve the problem of poor air permeability caused by the fact that the composite leather cannot be perforated in a large area in the prior art.
In order to realize the purpose, the technical scheme adopted by the invention is as follows:
the invention provides breathable composite leather in a first aspect, which comprises a 3D fabric structure and a resin skin structure which are connected in a laminated manner;
the resin skin structure comprises a TPU supporting layer, a skin layer and a surface treatment agent layer which are sequentially stacked from inside to outside, wherein the skin layer is in composite connection with the TPU supporting layer; wherein the resin surface structure is provided with a plurality of air holes which are communicated in the thickness direction, and the opening area of each air hole is less than or equal to 20mm 2 The distance between two adjacent air holes is larger than or equal to 3mm;
the combination of hardness and thickness of the TPU support layer is selected from the following combinations: the Shore hardness is more than or equal to 70HA and less than 90HA, and the thickness is 0.4 mm-0.8 mm; or the Shore hardness is greater than or equal to 90HA and less than or equal to 100HA, and the thickness is 0.3 mm-0.6 mm;
when the open pore area percentage of the air holes reaches 50%, the ratio of transverse tensile strength to longitudinal tensile strength of the resin skin structure after opening pores and before opening pores is not lower than 70%, and the ratio of transverse tearing strength to longitudinal tearing strength is not lower than 60%;
when the ratio of the area of the open pores of the air holes reaches 70%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure after the open pores and before the open pores is not lower than 60%, and the ratio of the transverse tearing strength to the longitudinal tearing strength is not lower than 50%.
Preferably, the Shore hardness of the TPU support layer is 70 HA-80 HA, the thickness is 0.5 mm-0.6 mm,
when the open pore area percentage of the air holes reaches 50%, the ratio of transverse tensile strength to longitudinal tensile strength of the resin skin structure after opening pores and before opening pores is not lower than 75%, and the ratio of transverse tearing strength to longitudinal tearing strength is not lower than 65%;
when the open pore area percentage of the air holes reaches 75%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure after opening the pores and before opening the pores is not lower than 65%, and the ratio of the transverse tearing strength to the longitudinal tearing strength is not lower than 55%.
Preferably, the Shore hardness of the TPU support layer is 70 HA-80 HA, the thickness is 0.5 mm-0.6 mm, and the overall thickness of the resin skin structure is 1.0-1.2 mm.
Preferably, the skin layer comprises a foaming layer and a surface layer which are sequentially laminated on one side surface of the TPU support layer.
Preferably, the thickness of the TPU support layer is greater than or equal to the thickness of the foam layer and greater than the thickness of the surface layer.
Preferably, the thickness of the surface layer is 0.1 to 0.3mm; the thickness of the foaming layer is 0.1-0.4 mm, and the total thickness of the surface layer is less than or equal to 0.5mm.
Preferably, the skin layer is a non-foamed resin layer.
Preferably, the single-hole area of the mesh of the 3D fabric layer is smaller than the single-hole area of the air vent; the 3D fabric structure is darker in color than the skin layer.
The second aspect of the invention provides an automobile interior trim, wherein the fabric of the interior trim comprises the breathable composite leather.
The third aspect of the invention provides a method for manufacturing breathable composite leather, which comprises the following steps:
s100: forming the skin layer by using the raw material of the skin layer;
s200: forming a TPU support layer on one side surface of the skin layer; wherein the combination of hardness and thickness of the TPU support layer is selected from the following combinations:
the Shore hardness is more than or equal to 70HA and less than 90HA, and the thickness is 0.4 mm-0.8 mm; or
The Shore hardness is greater than or equal to 90HA and less than or equal to 100HA, and the thickness is 0.3 mm-0.6 mm;
s300: printing the slurry of the surface treatment agent layer on the other side surface of the skin layer to form the surface treatment agent layer on the skin layer to obtain a semi-finished product of the resin skin structure;
s400: forming a plurality of ventilation holes which are communicated in the thickness direction on the surface of the semi-finished product of the resin skin structure so as to form the resin skin structure; wherein the opening area of the single air hole is less than or equal to 20mm 2 The distance between two adjacent air holes is larger than or equal to 3mm;
when the open pore area percentage of the air holes reaches 50%, the ratio of transverse tensile strength to longitudinal tensile strength of the resin skin structure after opening pores and before opening pores is not lower than 70%, and the ratio of transverse tearing strength to longitudinal tearing strength is not lower than 60%;
when the ratio of the area of the open pores of the air holes reaches 70%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure after the open pores and before the open pores is not lower than 60%, and the ratio of the transverse tearing strength to the longitudinal tearing strength is not lower than 50%;
s500: and compounding the 3D fabric structure with the TPU support layer to obtain the breathable composite leather.
Preferably, the step S200 includes the steps of:
s000: forming a TPU support layer by using a TPU elastomer;
the step S200 includes:
and compounding the skin layer with the TPU supporting layer through a direct hot-pressing compounding process or an adhesive hot-pressing compounding process to form the TPU supporting layer on the surface of the skin layer.
Preferably, the step S200 includes:
extruding, casting or calendering the TPU elastomer on the surface of the skin layer, and compounding the TPU elastomer with the skin layer through a direct hot-pressing compounding process or an adhesive hot-pressing compounding process, so as to form a TPU supporting layer on the surface of the skin layer.
Preferably, in the step S500, the 3D fabric structure is combined with the TPU support layer through a hot-pressing composite process or an adhesive composite process.
[ PROBLEMS ] the present invention
The composite leather adopts a 3D fabric structure and a resin skin structure with through air holes, wherein the resin skin structure comprises a TPU supporting layer, a skin layer and a surface treatment agent layer which are sequentially laminated, so that the TPU supporting layer is positioned at the bottommost layer of the resin skin structure and is connected with the 3D fabric structure. According to the resin skin structure, the TPU supporting layer is added to serve as the bottommost layer, and the combination of specific Shore hardness and thickness is selected for the TPU supporting layer, so that the TPU supporting layer has high transverse tensile strength, longitudinal tensile strength, high transverse tearing strength and high longitudinal tearing strength, and therefore, the TPU supporting layer has a sufficient supporting effect in the punching process of the resin skin structure, the problems of breakage or tearing of damage and arrangement and the like caused in the punching process are prevented, and even if the ratio of the area of the opening hole reaches 50% and 70%, the transverse tensile strength, the longitudinal tensile strength, the high transverse tearing strength and the high longitudinal tearing strength after the opening hole are not reduced too much, so that the high tensile property and the high tearing resistance can be still maintained; and because the percentage of open pore area can reach 50% even 70%, consequently make the gas permeability of whole resin epidermis structure improve greatly, use 3D fabric construction and resin epidermis structure complex simultaneously, because 3D fabric construction itself has porous structure, its gas permeability is also very good to make fashioned compound leather have high gas permeability, when being used for the vehicle interior, can improve driver and passenger's travelling comfort. Meanwhile, the formed composite leather has good tensile property and tear resistance, so that the coating property of the composite leather can be improved when the composite leather is applied to vehicles. Furthermore, the 3D fabric made of the composite leather has good buffering performance, so that the comfort of drivers and passengers can be further improved.
Other advantages of the present invention will be described in the detailed description, and those skilled in the art will understand the technical features and technical solutions presented in the description.
Drawings
Preferred embodiments of the breathable composite leather of the present invention will be described below with reference to the accompanying drawings. In the figure:
FIG. 1 is a schematic cross-sectional view of a preferred embodiment of the breathable composite leather of the present invention;
FIG. 2 is a schematic cross-sectional view of another preferred embodiment of the breathable composite leather of the present invention;
FIG. 3 is a flow chart of a preferred embodiment of the method for manufacturing breathable composite leather according to the present invention;
FIG. 4 is a schematic sectional view of a semi-finished product of a resin skin structure formed in a preferred embodiment of a method for manufacturing a breathable composite leather according to the present invention;
FIG. 5 is a partial cross-sectional view of a semi-finished product sample of a resin skin structure manufactured by the manufacturing method of the present invention;
FIG. 6 is a schematic sectional view of a resin skin structure formed in a preferred embodiment of the method for manufacturing breathable composite leather according to the present invention;
fig. 7 is a schematic partial surface view of a sample of a breathable resin skin structure manufactured by the manufacturing method of the present invention.
In the figure:
10. a 3D fabric structure;
20. a resin skin structure; 21. a TPU support layer; 22. a skin layer; 221. a foamed layer; 222. a PVC skin layer; 23. a surface treatment agent layer; 24. and (4) air holes.
Detailed Description
The present invention will be described below based on examples, but the present invention is not limited to only these examples. In the following detailed description of the present invention, certain specific details are set forth in order to avoid obscuring the nature of the present invention, well-known methods, procedures, and components have not been described in detail.
Furthermore, those of ordinary skill in the art will appreciate that the drawings provided herein are for illustrative purposes and are not necessarily drawn to scale.
Unless the context clearly requires otherwise, throughout the description and the claims, the words "comprise", "comprising", and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is, what is meant is "including, but not limited to".
In the description of the present invention, it is to be understood that the terms "first," "second," and the like are used for descriptive purposes only and are not to be construed as indicating or implying relative importance. In addition, in the description of the present invention, "a plurality" means two or more unless otherwise specified.
In the prior art, a TPU elastomer is added in the forming process of the composite leather, for example, in the scheme that the skin layer has only one layer, a TPU elastomer component is added in the raw material of the skin layer, or when the skin layer comprises a plurality of layers, a TPU elastomer component is added in the raw material of the PVC resin layer, which can improve the strength of the composite leather to a certain extent, but the main component of the formed skin layer is still a polyvinyl chloride material and still lacks sufficient strength, so that the phenomena of breaking or tearing and the like are easily generated in the subsequent punching process, large-area hole opening cannot be realized, and the air permeability is limited. Some waterproof composite leathers are in a resin skin structure, an independent TPU film can be arranged, if the TPU film is directly arranged on the surface layer of the surface layer, namely, one side close to the surface treatment agent layer, and the TPU film is used as the surface layer, so the TPU film must meet the performances of wear resistance, hand feeling, noise reduction, chemical resistance, aging resistance and the like, and the performance requirements can be met, the flexibility and the hardness of the formed TPU film can be greatly reduced, even if the TPU film is additionally arranged on the composite artificial leather, the composite artificial leather cannot actually play a supporting role at all in the punching process, the anti-tearing effect cannot be achieved, the tensile property is limited, the formed composite artificial leather cannot bear large-area open holes at all, and the composite leather is basically in a breaking state when the open hole area reaches 50% or even 20%, so the existing composite leathers have limited air permeability and cannot meet the requirement of high air permeability at all. Although in some waterproof composite leathers, the TPU film is located at the bottom of the PVC resin layer, the thickness of the TPU film is relatively thin, and in consideration of the waterproof property, the TPU film cannot be perforated at all, not to mention large-area perforation, and naturally, high air permeability cannot be achieved.
The invention provides breathable composite leather which can be widely applied to automotive interiors such as headrests, seats and the like, and can also be applied to cushions, back cushions and the like of household seats. Specifically, as shown in fig. 1 and 2, the breathable composite leather includes a 3D fabric structure 10 and a resin skin structure 20, which are connected by thermal compression bonding or adhesive bonding. The 3D fabric structure 10 is a buffer layer of the breathable composite leather, and can be formed by selecting a 3D fabric in the prior art, and the 3D fabric is also called a 3D spacer fabric, is a three-dimensional structure, has meshes thereon, can ventilate on each side, and is extremely breathable.
The resin skin structure 20 comprises a TPU support layer 21, a skin layer 22 and a surface treatment agent layer 23 which are sequentially stacked from inside to outside, wherein the skin layer 22 and the TPU support layer 21 are connected in a hot-pressing compounding or adhesive compounding manner, and the TPU support layer 21 is used as a support structure of the whole resin skin structure 20. Wherein, the inner side of the resin skin structure 20 refers to a side thereof close to the 3D fabric 10.
The resin skin structure 20 is provided with a plurality of vent holes 24 penetrating through the resin skin structure in the thickness direction thereof, that is, each vent hole 24 is a through hole and penetrates the entire resin skin structure 20, that is, penetrates the support layer 21, the skin layer 22, and the surface treatment agent layer 23. The opening area of the single air hole 24 is less than or equal to 20mm 2 E.g. 0.15mm 2 、0.2mm 2 、0.28mm 2 、0.5mm 2 、0.785mm 2 、2.0mm 2 、4.15mm 2 、7.1mm 2 、12.56mm 2 、15.9mm 2 Or 20, the distance between two adjacent air holes 24 is greater than or equal to 3mm, which means that the center distance of two adjacent air holes 24 is greater than or equal to 3mm, such as 3mm, 3.2mm, 3.5mm, 3.8mm, 4.0mm, 4.5mm, or 5.0 mm.
The TPU support layer 21 is basically a TPU elastomer and a thermoplastic polymer elastomer, and the layer is not substantially doped with other components during molding, although it is not excluded that a slight amount of modifying component may be contained for certain characteristics, and therefore, the TPU support layer 21 is also a thermoplastic polymer elastomer layer. Specifically, the combination of hardness and thickness of the TPU support layer is selected from the following combinations:
the combination mode I is that the Shore hardness is more than or equal to 70HA and less than 90HA, and the thickness is 0.4 mm-0.8 mm;
and the Shore hardness is greater than or equal to 90HA and less than or equal to 100HA, and the thickness is 0.3-0.6 mm.
That is, the TPU support layer may be in a first combination or a second combination, such as in the first combination, the shore hardness may be 70HA, 75HA, 80HA, 85HA, 88HA, etc., and the thickness may be 0.4mm, 0.5mm, 0.6mm, 0.7mm, 0.8mm, etc.; in the second combination mode, the shore hardness may be 90HA, 92HA, 95HA, 100HA, or the like, and the thickness may be 0.3mm, 0.4mm, 0.5mm, 0.6mm, or the like.
When the ratio of the open area of the air holes 24 reaches 50% or even 85%, the transverse tensile strength and the longitudinal tensile strength of the resin skin structure 20 are both greater than or equal to 350N/m 2 The transverse tear strength and the longitudinal tear strength are both greater than or equal to 40N/m 2 . Specifically, when the ratio of the open area of the vent holes 24 is 50%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure after opening and before opening is not less than 70%, such as 70%, 72%, 75%, or 80%, and the ratio of the transverse tear strength to the longitudinal tear strength is not less than 60%, such as 62%, 64%, 68%, or 72%; when the ratio of the area of the open pores of the air holes 24 reaches 70%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure after the open pores and before the open pores is not less than 60%, such as 60%,62%, 64%, 68% or 72%; the ratio of the transverse tearing strength and the ratio of the longitudinal tearing strength are not less than 50 percent, such as 50 percent, 52 percent, 54 percent, 56 percent or 60 percent, etc.
The open area ratio of the vent holes refers to the ratio of the total open area of the vent holes 24 to the surface area of the resin skin structure 20, where the surface refers to the surface of the resin skin structure 20 away from the 3D fabric structure 10, and the surface area refers to the area of the entire surface of the resin skin structure 20 before the vent holes 24 are opened, that is, the sum of the area of the vent holes 24 and the area of the remaining area after opening. The ratio of the longitudinal tensile strength refers to the ratio of the longitudinal tensile strength after the resin skin structure is perforated to the longitudinal tensile strength before the perforation, the ratio of the transverse tensile strength refers to the ratio of the transverse tensile strength after the resin skin structure is perforated to the transverse tensile strength before the perforation, the ratio of the longitudinal tear strength after the resin skin structure is perforated to the longitudinal tear strength before the perforation, and the ratio of the transverse tear strength refers to the ratio of the transverse tear strength after the resin skin structure is perforated to the transverse tear strength before the perforation.
As shown in fig. 1 and 2, the vent holes 24 penetrate through the respective layers of the resin skin structure 20, i.e., the vent holes 24 penetrate through the TPU support layer 21, the skin layer 22, and the surface treatment agent layer 23, so that when the resin skin structure 20 is combined with the 3D fabric structure 10, the air flow in the 3D fabric structure 10 can directly flow to the surface of the resin skin structure 20 through the vent holes 24. The breathable composite leather of the present invention is formed by laminating a 3D fabric structure 10 and a resin skin structure 20 having a vent hole 24 therethrough, wherein the resin skin structure 20 includes a TPU support layer 21, a skin layer 22 and a surface treatment agent layer 23 laminated in this order, that is, the 3D fabric structure 10, the TPU support layer 21, the skin layer 22 and the surface treatment agent layer 23 are laminated in this order. Because the TPU supporting layer 21 is added to the resin skin structure as the bottom layer, and the combined mode of Shore hardness greater than or equal to 70HA and less than 90HA and thickness of 0.4 mm-0.8 mm or combined mode of Shore hardness greater than or equal to 90HA and less than or equal to 100HA and thickness of 0.3 mm-0.6 mm is selected, the formed TPU supporting layer 21 HAs enough hardness and can provide enough supporting force, the supporting force is not reduced due to too small thickness, the flexibility of the layer is not lost due to too thick thickness, and the flexibility of the whole resin skin structure is not influenced, so that the TPU supporting layer 21 plays a sufficient supporting role in the punching process of the resin skin structure 20, the damages such as tearing, tensile breaking and the like in the punching process are avoided, and the test shows that when the area of the vent hole accounts for 50%, the ratio of the transverse tensile strength after the punching of the resin skin structure to the transverse tensile strength and the longitudinal tensile strength are not lower than 70%, and the ratio of the transverse tearing strength and the longitudinal tearing strength are not lower than 60%; when the ratio of the area of the open pores of the air holes reaches 70%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure after the open pores and before the open pores is not lower than 60%, and the ratio of the transverse tearing strength to the longitudinal tearing strength is not lower than 50%, namely, the resin skin structure 20 still keeps higher tensile property and tear resistance after the open pores, and after the resin skin structure is compounded with the 3D fabric structure 10 to form the composite leather, the composite leather also has good tensile property and tear resistance; meanwhile, as the air holes 24 can be formed in a large area, as can be seen from fig. 7, the air holes 24 are formed quite densely, and the area ratio of the open holes reaches more than 70%, so that the air permeability of the whole resin skin structure 20 is greatly improved, and meanwhile, the 3D fabric structure is compounded with the resin skin structure, and as the 3D fabric structure has a multi-mesh structure, the air permeability is very good, so that the formed composite leather has high air permeability, and when the composite leather is used for vehicle interiors such as vehicle seats and headrests, the composite leather can not break due to stretching in the coating process, the comfort of drivers and passengers can be improved after coating, the tensile property and the tear resistance of the resin skin structure can be continuously maintained, and the coating property of the composite leather is improved; and the 3D fabric structure is also used as a buffer structure, so that the buffer structure has good buffer performance, and the comfort of drivers and passengers can be further improved.
In addition, the present invention can prevent the decrease of the local tensile property and the tear resistance caused by the large opening area of the single or local plurality of air holes 24 or the too dense air holes 24 in the local area by setting the opening area of the single air hole 24 and the distance between the two adjacent air holes 24, thereby further improving the tensile property and the tear resistance of the molded resin skin structure 20.
Specifically, the plurality of ventilation holes 24 may be the same or different in shape, and may each be a cylindrical hole, a tapered hole, or a through hole having another shape. In the case of cylindrical holes, the surface of the vent holes 24 (i.e., one surface of the surface-treated base layer) may be a circular hole, a square hole, a diamond hole, or a hole structure of other shape, and in the case of circular holes, the hole diameter may be 0.5mm to 5.0mm, such as 0.5mm, 0.6mm, 0.8mm, 1.0mm, 1.6mm, 2.0mm, 2.3mm, 3.0mm, 4.0mm, 4.5mm, or 5.0mm, and preferably 0.8mm to 3.0mm, and the plurality of vent holes 24 on the resin skin structure 20 may have the same hole diameter, or may have a larger part and a smaller part, or the hole diameters of the vent holes 24 may be set according to a certain rule. For other shaped apertures, the profile shape of the individual vent holes 24 may be configured according to the open area thereof. In the sample shown in fig. 7, the plurality of ventilation holes 24 are all cylindrical holes (i.e., ventilation holes with round holes on the surfaces in the prismatic holes), and the apertures of the ventilation holes 24 are not completely equal. Regardless of the arrangement of the ventilation holes 24, the total open area of the ventilation holes 24 in the composite leather of the present invention may be 50%, 60%, or 70% of the surface area of the resin skin structure 20.
The TPU support layer 21 can be formed by using a TPU elastomer, the TPU support layer 21 HAs a high requirement on the hardness as a support structure layer, and the TPU support layer 21 needs to have certain flexibility and bending resistance as a structure layer of the resin skin structure 20, so the shore hardness of the TPU elastomer serving as a raw material for forming the TPU support layer is required to be 70HA to 100HA, and the TPU support layer is specifically selected by matching with the thickness of the layer. In the above-mentioned certain combination mode, the TPU support layer may be made of TPU elastomers with different shore hardness, or may be made of TPU elastomers with the same shore hardness, and preferably, the TPU support layer 21 is formed by selecting TPU elastomers with the same shore hardness and the same grade (the TPU elastomers with the same shore hardness in the market may correspond to a plurality of grades).
Preferably, the resin skin structure 20 can provide better support, softness and strength when the shore hardness of the TPU support layer 21 is 70HA to 80 HA.
Although the hardness and strength of the formed product are better when the hardness of the TPU support layer is higher and the thickness is larger, the flexibility of the formed product is affected if the hardness and the thickness are too large, particularly, the weight of the whole product is increased due to too large thickness, the development of light weight is not facilitated, and the too thick product is limited when used at a later stage. In a preferred embodiment of the invention, the Shore hardness of the TPU supporting layer is 70 HA-80 HA, and the thickness is set to be 0.5 mm-0.6 mm, so that the mechanical strength, the flexibility, the weight of an actual product and the thickness of the product are considered, the adaptability of the product is improved, and the coating fabric is more favorable for being applied to automotive interior.
In the embodiment adopting the combination mode that the Shore hardness of the TPU support layer 21 is 70 HA-80 HA and the thickness is 0.5 mm-0.6 mm, when the ratio of the area of the open pores of the air holes 24 reaches 50%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure 20 after the open pores and before the open pores is not lower than 75%, and the ratio of the transverse tearing strength to the longitudinal tearing strength is not lower than 65%; when the ratio of the area of the open pores of the air holes 24 reaches 75%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure 20 after the open pores and before the open pores is not lower than 65%, and the ratio of the transverse tearing strength to the longitudinal tearing strength is not lower than 55%; when the ratio of the area of the open pores of the vent holes 24 is 85%, the ratio of the transverse tensile strength to the longitudinal tensile strength, the ratio of the transverse tear strength to the longitudinal tear strength of the resin skin structure 20 after the open pores and before the open pores are not less than 50%, such as 50%,52%, 54%, 56%, or 60%. It can be seen that, the composite leather of the embodiment can further reduce the influence on the transverse tensile strength, the longitudinal tensile strength, the transverse tearing strength and the longitudinal tearing strength during large-area hole opening, so that the composite leather has higher air permeability, still has stronger tensile property and tearing resistance, and has good flexibility.
In a preferred embodiment of the present invention, the overall thickness of the resin skin structure 20 is less than or equal to 1.3mm, such as 1.3mm, 1.28mm, 1.25mm, 1.2mm, 1.18mm, 1.15mm, 1.13mm, 1.1mm, 1.08mm, 1.05mm, 1.03mm, 1.0mm, or 0.8mm, and the like. Preferably, the entire thickness of the resin skin structure 20 is 1.0mm to 1.2mm. By adopting the resin skin structure 20 with the thickness, the formed composite leather still has the advantages of high tear resistance and high tensile property and ultrathin and lightweight while the formed composite leather is provided with the air holes in a large area, and is easier to coat when being applied to automotive interiors, so that the practicability of the composite leather is further improved.
The surface treatment agent layer 23 has a thickness of several micrometers, and may be a water-based coating applied to the field of automotive interior, and may be manufactured by a printing process, specifically, the surface treatment agent layer 23 may include a polymer material such as polyurethane, acrylic, silicone, and the like, and of course, a component such as a hand feeling agent, or a component such as abrasion resistance and aging resistance may be added. In an embodiment, the composition of the surface treatment agent layer 23 may further include a pigment.
The skin layer 22 may be a skin layer commonly used for artificial leathers in the prior art, and may have a single-layer structure, as shown in fig. 1, which is a non-foamed resin layer that can be formed by coating, casting, calendering, and the like (described in detail below). In another embodiment, the skin layer 22 is a multi-layer structure, as shown in fig. 2, comprising a foaming layer 221 and a surface layer 222 sequentially laminated on one side surface of the TPU support layer 21, i.e., in this embodiment, the resin skin structure 20 comprises the TPU support layer 21, the foaming layer 221, the surface layer 222, and the surface treatment agent layer 23 sequentially laminated.
Regardless of the layer structure of the skin layer 22, the main component may include one or more thermoplastic or thermosetting materials such as PVC, PU, silicone, TPO, etc., and when the skin layer 22 includes the foaming layer 221, the main component of the skin layer 22 may further include a foaming agent, an expanding agent, etc. Of course, the skin layer 22 may also include other materials commonly used in resin skin structures. Further, in order to achieve better visual effects, the present invention preferably adds a pigment to the skin layer 22.
In the embodiment where the skin layer 22 has a multi-layer structure, the foaming layer 221 and the surface layer 222 may be formed by coating, casting, calendering, etc. respectively, but the foaming layer 221 is formed directly on one side surface of the surface layer 222 (described in detail below), and the two layers may be bonded without an adhesive, so as to increase the reliability of the connection of the layers of the entire resin skin structure 20 and reduce the thickness of the entire resin skin structure 20 and the composite leather.
The thickness of the surface layer 222 and the foaming layer 221, if too thick, also affects the flexibility of the resin skin structure 20 and the formed composite leather, and therefore, in a preferred embodiment of the present invention, the thickness of the surface layer 222 is preferably 0.1mm to 0.3mm, such as 0.1mm, 0.12mm, 0.15mm, 0.18mm, 0.2mm, 0.25mm, 0.28mm, or 0.3mm, etc. The thickness of the foamed layer 221 is preferably 0.1 to 0.4mm, such as 0.1mm, 0.15mm, 0.2mm, 0.22mm, 0.25mm, 0.27mm, 0.3mm, 0.35mm, 0.38mm, or 0.4mm, and the like. Further preferably, the thickness of the surface layer 222 is 0.1mm to 0.2mm; the thickness of the foaming layer 221 is 0.2mm to 0.3mm. By adopting the layer structure with the thickness range, the whole thickness of the molded resin skin structure 20 and the molded product composite leather can be well controlled, the product can show better flexibility and tensile property, and the coating is easier to carry out when the layer structure is applied to automotive interiors.
Further, regardless of the thickness of the surface layer 222 and the foaming layer 221, in a preferred embodiment of the present invention, the thickness of the skin layer 22 is less than or equal to 0.5mm, i.e. regardless of whether the skin layer 22 is a single-layer structure or a multi-layer structure, the total thickness of the skin layer 22 is preferably less than or equal to 0.5mm, such as 0.5mm, 0.48mm, 0.45mm, 0.43mm, 0.4mm, 0.38mm, 0.35mm or 0.3mm, etc., so as to better control the thickness of the resin skin structure 20 and further improve the flexibility and tensile property of the molded product.
In the embodiment in which the skin layer 22 has a multi-layer structure, in order to better improve the air permeability and flexibility of the composite leather, the thickness of the TPU support layer 21 is greater than or equal to the thickness of the foaming layer 221 and greater than the thickness of the surface layer 222. Further preferably, the thickness of the TPU support layer 21 is greater than or equal to the entire thickness of the skin layer 22, so that the thickness of the resin skin structure 20 is not necessarily too large, and the ratio of the thickness between the resin skin structure 20 and the TPU support layer 21 can be controlled, so as to improve the mechanical properties of the resin skin structure 20, such as tear resistance, tensile property, flexibility, and the like, and further enable the resin skin structure 20 and the formed composite leather to have better air permeability and mechanical properties. In the embodiment of the skin layer 22 having a single-layer structure, the thickness of the TPU support layer 21 is preferably equal to or greater than the thickness of the skin layer 22.
Wherein, 3D fabric construction 10 and resin epidermis structure 20 can be connected through hot pressing complex or the compound technology of gluing agent, when using the gluing agent complex, the gluing agent can be located 3D fabric construction 10's mesh, consequently, compare in the mode that bonds 3D fabric construction 10 and resin epidermis structure 20 through the bonding glue film, can increase the reliability that 3D fabric construction 10 and resin epidermis structure 20 are connected, and because the mesh that 3D fabric construction 10 can be infiltrated into basically to liquid, there is not the glue solution between 3D fabric layer and resin epidermis structure 20 basically, consequently, can also reduce the thickness of whole compound leather. In a preferred embodiment, the 3D fabric structure 10 has a greater thickness than the resin skin structure 20 to improve the cushioning properties of the composite leather.
In one embodiment, the 3D fabric structure 10 has a thickness of 1mm to 5mm, such as 1mm, 1.3mm, 1.5mm, 1.8mm, 2.0mm, 2.2mm, 2.5mm, 2.8mm, 3.0mm, 3.2mm, 3.5mm, 3.7mm, 4.0mm, 4.3mm, 4.6mm, 4.8mm, or 5.0, etc., preferably, the 3D fabric structure 10 has a thickness of 3mm to 5mm. By adopting the thickness, the thickness of the whole composite leather is not too thick, the airflow channel is not too long, and the comfort of drivers and passengers can be improved when the composite leather is applied to automotive interiors.
The color of the 3D fabric structure 10 may be the same as that of the resin skin structure 20 or only the skin layer 22, and thus, after selecting the color, the composite leather of the present invention has the ventilation holes 24 penetrating through the whole resin skin structure 20, so that when observing the composite leather, especially when observing through the ventilation holes 24, if the color of the 3D fabric structure 10 is lighter, a significant color difference may be generated, which affects the visual effect. To solve this problem, in a preferred embodiment of the present invention, the 3D fabric structure 10 has a darker color than the skin layer 22, so that there is substantially no visual color difference even when viewed through the ventilation holes 24, thereby improving the visual effect of the product. Alternatively, the surface treatment layer 23 and the skin layer 22 may both be the same color, may both be light or dark, or the skin layer 22 may be light or dark and the surface treatment layer 23 may be a clear layer, but in either case the 3D fabric structure 10 may be darker so that there is substantially no color difference from the surface of the composite leather. In particular, the darker colors may include black, dark blue or dark curry, and the like.
Further, the area of the single mesh of the 3D fabric structure 10 is smaller than the open area of the single airing hole 24, so that the resin skin structure 20 is not substantially exposed from the mesh when the composite leather is viewed from the surface of the 3D fabric structure 10, and thus, in this embodiment, no color difference is visually generated regardless of which surface of the composite leather is viewed.
In another embodiment, when the 3D fabric structure 10 is selected to have a light color, the single-hole area of the mesh of the 3D fabric structure 10 is smaller than the single-hole area of the airing holes 24.
The invention also provides a manufacturing method of the breathable composite leather, which can be used for manufacturing the breathable composite leather, and as shown in figure 3, the manufacturing method comprises the following steps:
s100: the skin layer 22 is formed using the raw material of the skin layer 22.
Specifically, the skin layer 22 may be manufactured by a coating process or a calendering process, such as coating a slurry of the skin layer 22 on a release paper, then heating for plasticizing, and then peeling the release paper to form the skin layer 22; or directly calendered by calendering rolls to form the skin layer 22.
S200: the TPU support layer 21 is formed on one surface of the skin layer, that is, the TPU support layer 21 is formed on one surface of the skin layer 22, and may be manufactured by a heat and pressure compounding process or an adhesive compounding process. Wherein the combination of hardness and thickness of the TPU support layer 21 is selected from the following combinations, specific combinations of which are described above with reference to:
the Shore hardness is more than or equal to 70HA and less than 90HA, and the thickness is 0.4 mm-0.8 mm; or alternatively
The Shore hardness is greater than or equal to 90HA and less than or equal to 100HA, and the thickness is 0.3 mm-0.6 mm;
s300: the slurry of the surface treatment agent layer is printed on the other surface of the skin layer 22 to form the surface treatment agent layer 23 on the skin layer 22 to obtain a semi-finished product of the resin skin structure, and specifically, the slurry of the surface treatment agent layer may be printed on the other surface of the skin layer 22 and then heat-cured to form the surface treatment agent layer 23.
As shown in fig. 4 and 5. Fig. 4 is a schematic sectional view of a semi-finished product of a resin skin structure, fig. 5 is a photograph of a sample of the semi-finished product of a resin skin structure obtained in the process of manufacturing a composite leather by using the manufacturing method of the present invention, which is observed under a microscope, wherein a TPU support layer 21, a foaming layer 221, a surface layer 222 and a surface treatment agent layer 23 are arranged in this order from bottom to top, and the thickness of the surface treatment agent layer 23 is only a few micrometers, so that it is not obvious in the drawing.
S400: a plurality of ventilation holes 24 penetrating the whole thickness are opened on the surface of the semi-finished product of the resin skin structure to form the resin skin structure 20,wherein the opening area of the single air hole 24 is less than or equal to 20mm 2 The distance between two adjacent air holes 24 is more than or equal to 3mm;
when the ratio of the area of the open pores of the air holes 24 reaches 50%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure 20 after the open pores and before the open pores is not lower than 70%, and the ratio of the transverse tearing strength to the longitudinal tearing strength is not lower than 60%;
when the ratio of the open area of the vent holes 24 is 70%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure 20 after opening the holes and before opening the holes is not less than 60%, and the ratio of the transverse tear strength to the longitudinal tear strength is not less than 50%.
As shown in fig. 6 and 7, the open area of the airing holes 24 accounts for 70% or more of the surface area of the resin skin structure 20. Wherein fig. 7 shows a sample view of a resin skin structure in which the airing holes 24 are opened.
S500: and (3) compounding the 3D fabric structure with the TPU support layer to obtain the breathable composite leather, as shown in figure 2.
Specifically, the 3D fabric structure is attached to the surface of the TPU support layer 21 away from the surface treatment agent layer 23, and then the 3D fabric structure is compounded by a hot-press compounding process or an adhesive. The adhesive can be formed through a hot-pressing compounding process or an adhesive compounding process.
The manufacturing method of the high-permeability leather comprises the steps of compounding the skin layer 22 and the TPU support layer 21, then printing the surface treatment agent layer to form a semi-finished product of the resin skin structure, then punching the air holes 24, and then compounding the semi-finished product with the 3D fabric structure. Thus, in the punching process, the TPU supporting layer 21 can provide enough supporting effect to prevent the problems of tearing and tensile fracture in the punching process, and by adding the supporting layer, the air holes 24 can be formed in the whole resin skin structure 20 in a large area; simultaneously, firstly, the air holes 24 are formed and then are compounded with the 3D fabric structure 10, the problem of punching depth does not need to be considered during punching, compared with the process of punching after being compounded with the 3D fabric structure 10, the punching process is easier to control, and the 3D fabric structure 10 cannot be damaged, so that high air permeability is realized, the integrity of the 3D fabric structure 10 can be ensured, the reliability of the formed composite leather is further improved, and the tear resistance and better stretching property can be ensured. For the beneficial effects of the composite leather formed by the method, reference is made to the foregoing description, and the description is omitted here.
When the skin layer 22 includes a multilayer structure, the step S100 may specifically include the steps of:
s110: molding the surface layer 222 using the raw material of the surface layer;
s120: the skin layer 22 is obtained by forming the foamed layer 221 on one surface of the surface layer 222 using a raw material of the foamed layer.
That is, even if the skin layer 22 includes a multi-layer structure, the layers thereof are directly molded without being bonded by a bonding adhesive layer, so that the reliability of the connection between the layers of the entire resin skin structure 20 can be improved, and the thickness of the entire structure, and thus the thickness of the composite leather, can be reduced.
The surface layer 222 may be a PVC surface layer, a PU surface layer, or a TPO surface layer, i.e., the layer has PVC, PU, or TPO as its main component. The surface layer 222 may be formed by a coating, casting or calendaring process, and when the coating or casting process is used for forming, the slurry of the surface layer 222 is coated or cast on the release paper, and is cured to form the surface layer 222. When the forming process is a rolling process, the surface layer 222 may be directly formed by a coating process or a rolling process through a rolling roller, and in this embodiment, the raw material of the surface layer is a block formed by each component of the dense layer.
The material component of the foamed layer 221 may be a PVC foamed layer, a PU foamed layer, or a TPO foamed layer, that is, the main component of the layer is PVC, PU, or TPO. The foam layer 221 may be formed by coating, casting, or calendaring processes. Specifically, when a coating or casting process is used, the raw material coated or cast on one surface of the surface layer 222 with the foam layer 221 is cured and foamed to form the foam layer 221, and the skin layer 22 is obtained. In use
In the rolling process, the material of the foam layer 221 is rolled on one surface of the surface layer 222 by a rolling roll, and the foam layer 221 is formed after curing and foaming, thereby obtaining the skin layer 22. In any of these processes, when the surface layer 222 is formed by a coating or casting process, the release paper needs to be peeled off after the foam layer is formed, and the skin layer 22 is obtained.
In a preferred embodiment, the surface layer and the foamed layer are formed by the same process, such as coating process, casting process, or calendering process.
In one embodiment, the TPU support layer 21 can be formed in step S200, and then the skin layer 22 is combined with the TPU support layer 21, that is, step S200 is preceded by the steps of:
s000: the TPU support layer 21 is formed using a TPU elastomer. Specifically, the support layer can be formed by an extrusion, casting or calendaring process, when the extrusion or casting process is used for forming, the slurry of the TPU elastomer needs to be coated or cast on release paper, the TPU support layer 21 is formed by curing, and then the release paper needs to be peeled off, so that the TPU support layer 21 is obtained; when formed using a calendering process, a block of TPU elastomer may be used and rolled by a calender roll to provide the TPU support layer 21.
In this embodiment, step S200 includes:
the skin layer 22 and the TPU support layer 21 are compounded through a direct hot-press compounding process or an adhesive hot-press compounding process to form the TPU support layer 21 on the surface of the skin layer 22. The direct hot-press compounding process is to compound the TPU support layer 21 and the skin layer 22 by hot pressing, the two layers are directly attached, and no other structure exists between the two layers. When the adhesive is used for compounding, the adhesive is coated on one surface of the skin layer 22, and then the skin layer and the TPU support layer 21 are subjected to hot-pressing compounding.
In another embodiment, the TPU support layer 21 is formed simultaneously with the skin layer 22 in step S200, that is, step S200 includes:
the TPU elastomer is extruded, cast or calendered on the surface of the skin layer 22 and is compounded with the skin layer 22 through a hot press compounding process or an adhesive compounding process, thereby forming the TPU support layer 21 on the surface of the skin layer 22. When compounding with adhesives, one side of the skin layer 22 is coated with a layer of glue before extruding, casting or calendering the TPU elastomer.
Wherein, above-mentioned extrusion, curtain coating or calendering can choose for use current technique, specifically, can choose for use to be in liquid or gelatinous TPU elastomer as the raw materials during extrusion, curtain coating, can choose for use to be in massive TPU elastomer as the raw materials during the calendering. The raw materials in various states can be obtained by the methods in the prior art, for example, the raw materials in liquid state or gel state can be obtained by heating TPU elastomer.
By adopting the mode, the TPU supporting layer 21 does not need to be formed independently, so that the steps of a forming process are reduced, and the production efficiency of the composite leather can be improved.
The slurry for the surface treatment agent layer, the slurry for the skin layer, the slurry for the foam layer, and the slurry for the surface layer may be prepared according to the materials included in the above-described layers, and the specific preparation method may be the one in the prior art, and will not be described in detail here. The thickness and color of the TPU support layer 21, the thickness and color of the surface treatment agent layer, the thickness and color of the skin layer, the thickness and color of the foam layer, the thickness and color of the surface layer, and the shape and pore size of the vent holes 24, which are formed by the manufacturing method, can be referred to the above documents, and will not be described herein again.
In step S500, when an adhesive is used for compounding, step S500 includes the steps of:
s510: coating an adhesive on one surface of the resin skin structure, which is far away from the surface treating agent layer (namely one surface of the TPU supporting layer, which is far away from the surface treating agent layer), so as to form an adhesive layer;
s520: and (3) placing the 3D fabric structure in the adhesive layer for pressurizing and compounding, enabling the glue solution of the adhesive layer to permeate into meshes of the 3D fabric layer, and curing to form the composite leather. The pressure of the pressurization compounding is small, and the buffering performance of the 3D fabric structure cannot be affected.
By adopting the mode, even if the adhesive is compounded, a thicker adhesive layer is basically not formed between the 3D fabric structure and the TPU supporting layer, so that the thickness of the whole composite leather is not too large, and the reliability of the connection between the 3D fabric structure and the resin skin structure can be still ensured.
The samples of the resin skin structure 20 were manufactured using the above manufacturing method, and the transverse tensile strength, the longitudinal tensile strength, the transverse tear strength and the longitudinal tear strength were measured at the same time when the samples were subjected to the tests before the punching and at the different open area ratios, in which the TPU support layer 21 of each example in table 1 was molded using the same hardness and the same brand of TPU elastomer, corresponding to the shore hardness and the thickness of the TPU support layer 21 of each example, the shore hardness of the TPU support layer 21 in example 1 was 70HA, and the thickness was 0.5mm, with reference to the first column of table 1.
Also, the results of the tests were performed on the comparison 1, the comparison 2 and the comparison 3, and are shown in the following Table 2. Wherein, the ratio 1, the ratio 2 and the ratio 3 are shown in table 2, the ratio 1 is also a sample of the resin skin structure manufactured by the manufacturing method of the invention, but the Shore hardness of the TPU supporting layer 21 is 80HA, and the thickness is 0.2mm; the contrast ratio 2 is the artificial leather formed by bonding the common skin layer and the base cloth in the prior art, and the contrast ratio 3 is the composite leather formed by bonding the common skin layer and the improved base cloth, wherein the improved base cloth refers to the base cloth formed by a mode of an improved weaving process, such as the base cloth in patent CN209010829U, and the contrast ratio 3 can be the artificial leather in the patent; the improved base cloth can also be the base cloth of patent CN212375618U, and the ratio 3 can be the artificial leather of the patent.
In tables 1 and 2 below, the open area ratio of 0 indicates no opening.
TABLE 1
Figure BDA0003561029500000171
Figure BDA0003561029500000181
TABLE 2
Figure BDA0003561029500000182
In the field of automotive interior, for a resin skin structure or artificial leather (including base fabric), the transverse direction tensile strength and the machine direction tensile strength are required to be 350N/m or more 2 The transverse tear strength and the longitudinal tear strength need to be greater than or equal to 40N/m 2 As is apparent from the data in table 1, the resin skin structure 20 of the present invention has performance before and after punching greater than the industry standard, and meets the requirements of the industry; and the reduction of each physical property after punching relative to that before punching is not less than 50 percent.
It can be seen from tables 1 and 2 that when the open area of the vent holes 24 reaches 75%, the resin skin structure of the present invention still satisfies the industrial requirements in terms of transverse tensile strength, longitudinal tensile strength, transverse tear strength, and longitudinal tear strength, and the numerical value is much higher than each pair of proportions, which are actually all lower than the industrial standard and cannot be used at all. Therefore, the resin skin structure can ensure good mechanical property while having high air permeability, the composite leather formed by the resin skin structure and the 3D fabric structure also has good mechanical property, the ratio of the area of the open pores is far greater than that of the artificial leather in the prior art, and the air permeability can be greatly improved.
Although the present application has been described in many cases with the ratio of the open area of the ventilation holes 24 being 20%, 50%, 70%, 75%, or 85%, the present invention is not limited to these ratios of the open area, and actually, the ratio of the open area may be set to any one of the following ranges according to the demand for air permeability: less than 20%, 20% -50%, 50% -70%, 70% -75%, 75% -85%, and even more than 85%.
The invention also provides an automobile interior, such as a seat and a headrest, and the fabric of the interior comprises the breathable composite leather in any embodiment.
When the composite leather is used as an automotive interior, the air holes 24 can avoid the edges and corners of the covered body such as a seat, a headrest and the like as much as possible, and are provided with areas with larger areas, preferably surface areas directly used for contacting with a human body, such as central areas of a cushion and a backrest of the seat, so as to further reduce the stretching and tearing risks caused in the covering process and prolong the service life of the interior.
It will be appreciated by those skilled in the art that the above-described preferred embodiments may be freely combined, superimposed, without conflict.
It will be understood that the embodiments described above are illustrative only and not restrictive, and that various obvious and equivalent modifications and substitutions for details described herein may be made by those skilled in the art without departing from the basic principles of the invention.

Claims (13)

1. The breathable composite leather is characterized by comprising a 3D fabric structure and a resin skin structure which are connected in a laminated mode;
the resin skin structure comprises a TPU supporting layer, a skin layer and a surface treatment agent layer which are sequentially stacked from inside to outside, wherein the skin layer is in composite connection with the TPU supporting layer;
wherein the resin surface structure is provided with a plurality of air holes which are communicated in the thickness direction, and the opening area of each air hole is less than or equal to 20mm 2 The distance between two adjacent air holes is larger than or equal to 3mm;
the combination of hardness and thickness of the TPU support layer is selected from the following combinations: the Shore hardness is more than or equal to 70HA and less than 90HA, and the thickness is 0.4 mm-0.8 mm; or the Shore hardness is greater than or equal to 90HA and less than or equal to 100HA, and the thickness is 0.3 mm-0.6 mm;
when the open pore area percentage of the air holes reaches 50%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure after opening the pores and before opening the pores is not lower than 70%, and the ratio of the transverse tearing strength to the longitudinal tearing strength is not lower than 60%; when the ratio of the area of the open pores of the air holes reaches 70%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure after the open pores and before the open pores is not lower than 60%, and the ratio of the transverse tearing strength to the longitudinal tearing strength is not lower than 50%.
2. The breathable composite leather of claim 1, wherein the TPU support layer HAs a Shore hardness of 70HA to 80HA and a thickness of 0.5mm to 0.6mm;
when the open pore area percentage of the air holes reaches 50%, the ratio of transverse tensile strength to longitudinal tensile strength of the resin skin structure after opening pores and before opening pores is not lower than 75%, and the ratio of transverse tearing strength to longitudinal tearing strength is not lower than 65%;
when the open pore area percentage of the air holes reaches 75%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure after opening the pores and before opening the pores is not lower than 65%, and the ratio of the transverse tearing strength to the longitudinal tearing strength is not lower than 55%;
when the open area of the air holes is 85%, the ratio of the transverse tensile strength to the longitudinal tensile strength, the ratio of the transverse tearing strength to the longitudinal tearing strength of the resin skin structure after opening the holes and before opening the holes is not lower than 50%.
3. The breathable composite leather of claim 2, wherein the TPU support layer HAs a Shore hardness of 70HA to 80HA and a thickness of 0.5mm to 0.6mm, and the overall thickness of the resin skin structure is 1.0mm to 1.2mm.
4. The breathable composite leather of any one of claims 1 to 3, wherein the skin layer comprises a foaming layer and a surface layer laminated in this order on one side surface of the TPU support layer.
5. The breathable composite leather of claim 4, wherein the thickness of the TPU support layer is greater than or equal to the thickness of the foam layer and greater than the thickness of the surface layer.
6. The breathable composite leather of claim 4, wherein the surface layer has a thickness of 0.1 to 0.3mm; the thickness of the foaming layer is 0.1-0.4 mm, and the total thickness of the surface layer is less than or equal to 0.5mm.
7. The breathable composite leather of claim 4, wherein the skin layer is a non-foamed resin layer.
8. The breathable composite leather of any one of claims 1 to 7, wherein the area of the single mesh of the 3D fabric layer is smaller than the open area of the single breathable hole; the 3D fabric structure is darker in color than the skin layer.
9. An automotive interior, characterized in that the facing of the interior comprises the breathable composite leather according to any one of claims 1 to 8.
10. The manufacturing method of the breathable composite leather is characterized by comprising the following steps:
s100: forming the skin layer by using the raw material of the skin layer;
s200: forming a TPU support layer on one side surface of the skin layer; wherein the combination of hardness and thickness of the TPU support layer is selected from the following combinations:
the Shore hardness is more than or equal to 70HA and less than 90HA, and the thickness is 0.4 mm-0.8 mm; or alternatively
The Shore hardness is greater than or equal to 90HA and less than or equal to 100HA, and the thickness is 0.3 mm-0.6 mm;
s300: printing the slurry of the surface treatment agent layer on the other side surface of the skin layer to form the surface treatment agent layer on the skin layer to obtain a semi-finished product of the resin skin structure;
s400: forming a plurality of air holes which are communicated in the thickness direction on the surface of the semi-finished product of the resin skin structure so as to form the resin skin structure; wherein the opening area of the single air hole is less than or equal to 20mm 2 The distance between two adjacent air holes is larger than or equal to 3mm;
when the ratio of the area of the open pores of the air holes reaches 50%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure after the open pores and before the open pores is not lower than 70%, and the ratio of the transverse tearing strength to the longitudinal tearing strength is not lower than 60%;
when the ratio of the area of the open pores of the air holes reaches 70%, the ratio of the transverse tensile strength to the longitudinal tensile strength of the resin skin structure after the open pores and before the open pores is not lower than 60%, and the ratio of the transverse tearing strength to the longitudinal tearing strength is not lower than 50%;
s500: and compounding the 3D fabric structure with the TPU support layer to obtain the breathable composite leather.
11. The manufacturing method according to claim 10, wherein the step S200 is preceded by the steps of:
s000: forming a TPU support layer by using a TPU elastomer;
the step S200 includes:
and compounding the skin layer and the TPU support layer through a direct hot-pressing compounding process or an adhesive hot-pressing compounding process to form the TPU support layer on the surface of the skin layer.
12. The manufacturing method according to claim 10, wherein the step S200 includes:
extruding, casting or calendering the TPU elastomer on the surface of the skin layer, and compounding the TPU elastomer with the skin layer through a direct hot-pressing compounding process or an adhesive hot-pressing compounding process, so as to form a TPU supporting layer on the surface of the skin layer.
13. The manufacturing method according to any one of claims 10 to 12, wherein in step S500, the 3D fabric structure is composited with the TPU support layer by a hot press composite process or an adhesive composite process.
CN202210289214.XA 2022-03-23 2022-03-23 Breathable composite leather, manufacturing method thereof and automotive interior Pending CN115214200A (en)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002085608A1 (en) * 2001-04-20 2002-10-31 Basf Aktiengesellschaft Shaped body from leather and thermoplastic material that has an improved soft touch
KR20180045544A (en) * 2016-10-26 2018-05-04 주식회사 서연이화 Altificial leather for use as vehicle interior material and method for manufacturing same
KR20200141842A (en) * 2019-06-11 2020-12-21 (주)엘지하우시스 Artificial leather for vehicle interior material and method for manufacturing the same
CN113235309A (en) * 2020-03-30 2021-08-10 加通汽车内饰(常熟)有限公司 Light-transmitting artificial leather and preparation method thereof, composite leather and automotive interior

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002085608A1 (en) * 2001-04-20 2002-10-31 Basf Aktiengesellschaft Shaped body from leather and thermoplastic material that has an improved soft touch
KR20180045544A (en) * 2016-10-26 2018-05-04 주식회사 서연이화 Altificial leather for use as vehicle interior material and method for manufacturing same
KR20200141842A (en) * 2019-06-11 2020-12-21 (주)엘지하우시스 Artificial leather for vehicle interior material and method for manufacturing the same
CN113235309A (en) * 2020-03-30 2021-08-10 加通汽车内饰(常熟)有限公司 Light-transmitting artificial leather and preparation method thereof, composite leather and automotive interior

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