EP1226304A1 - Synthetic leather - Google Patents

Synthetic leather

Info

Publication number
EP1226304A1
EP1226304A1 EP00960579A EP00960579A EP1226304A1 EP 1226304 A1 EP1226304 A1 EP 1226304A1 EP 00960579 A EP00960579 A EP 00960579A EP 00960579 A EP00960579 A EP 00960579A EP 1226304 A1 EP1226304 A1 EP 1226304A1
Authority
EP
European Patent Office
Prior art keywords
synthetic leather
nonwoven fabric
continuous filaments
polymer
dtex
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP00960579A
Other languages
German (de)
French (fr)
Inventor
Rudolf Wagner
Robert Groten
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Carl Freudenberg KG
Original Assignee
Carl Freudenberg KG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Carl Freudenberg KG filed Critical Carl Freudenberg KG
Publication of EP1226304A1 publication Critical patent/EP1226304A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/016—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the fineness
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
    • A43B23/02—Uppers; Boot legs
    • A43B23/0205—Uppers; Boot legs characterised by the material
    • A43B23/0215—Plastics or artificial leather
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
    • A43B23/07—Linings therefor
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
    • A43B23/08—Heel stiffeners; Toe stiffeners
    • A43B23/16—Heel stiffeners; Toe stiffeners made of impregnated fabrics, plastics or the like
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/11—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by fluid jet
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/12—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0004—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using ultra-fine two-component fibres, e.g. island/sea, or ultra-fine one component fibres (< 1 denier)
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes

Definitions

  • the invention relates to a synthetic leather, consisting of a nonwoven fabric impregnated and / or coated with a polymer and having basis weights of 100 to 500 g / m 2 and tensile strengths in the longitudinal and transverse directions> 300 N / 5 cm
  • nonwovens made of ultrafine, entangled filaments which have a layer structure and can be processed into synthetic leather by impregnation and / or coating with polymers.
  • Those starting fibers are preferably those of the "island-in-sea" type "in which the ultrafine fibers are released by dissolving the matrix polymer.
  • the use of noticeable starting fibers is also specified
  • Document EP-A 0 624 676 discloses nonwovens made from ultra-fine fibers and processes for their production from bicomponent fibers.
  • the starting polymers of the bicomponent fibers are said to have a melting point difference of 30 to 180 ° C. and are spun as multi-segment fibers
  • Bicomponent fibers are subjected to a point calendering, in which only the fiber component with the lower melting point is melted and is solidified.
  • at least 70% of the nonwoven fabric formed from the multi-segment fibers is split into the ultrafine sub-segment fibers by mechanical action on the fibers.
  • the nonwovens obtained in this way achieve tensile strength values in the longitudinal and transverse directions of up to a maximum of 260 N / 5 cm and can be used as bed linen, scrubber for sanitary products such as handkerchiefs, diapers, padding for sleeping bags, synthetic leather, thermal insulation materials and others.
  • the invention has for its object to provide inexpensive and high tensile synthetic leather and a method for their production.
  • the object is achieved by a synthetic leather which consists of a nonwoven fabric impregnated and / or coated with a polymer and having basis weights of 100 to 500 g / m 2 and tensile strengths in the longitudinal and transverse directions> 300 N / 5 cm, the nonwoven fabric consists of melt-spun, aerodynamically stretched and immediately deposited multi-component continuous filaments with a titer ⁇ 2 dtex and the multi-component continuous filaments after pre-consolidation are at least 90% split and consolidated into super-micro continuous filaments with a titer ⁇ 0.2 dtex.
  • a synthetic leather has high tensile strengths at a comparatively low weight and is therefore inexpensive. Furthermore, it is similar to natural materials in terms of its grip.
  • the synthetic leather is preferably one in which the multicomponent continuous filament is a bicomponent continuous filament made of two incompatible polymers, in particular a polyester and a polyamide.
  • a continuous bicomponent filament has good splittability Super micro continuous filaments and creates a favorable ratio of strength to basis weight.
  • the synthetic leather is preferably one in which the multicomponent continuous filaments have a cross section with an orange-like multisegment structure, the segments alternately each containing one of the two incompatible polymers.
  • the multicomponent continuous filaments have a cross section with an orange-like multisegment structure, the segments alternately each containing one of the two incompatible polymers.
  • this orange-like multi-segment structure of the multi-component continuous filaments other arrangements of the incompatible polymers in the multi-component continuous filament, such as side-by-side or chrysanthemum leaf-like arrangements, are also possible. Such arrangements of the incompatible polymers in the multicomponent continuous filament have proven to be very easy to split.
  • the synthetic leather is preferably also one in which at least one of the incompatible polymers forming the multicomponent filament contains an additive, such as color pigments, permanently acting antistatic agents and / or additives which influence the hydrophilic or hydrophobic properties in amounts of up to 10% by weight.
  • an additive such as color pigments, permanently acting antistatic agents and / or additives which influence the hydrophilic or hydrophobic properties in amounts of up to 10% by weight.
  • the synthetic leather consisting of spun-dyed fibers has a very high high-temperature light fastness. Furthermore, the additives can reduce or avoid static charges and improve the moisture transport properties.
  • a synthetic leather in which the nonwoven is impregnated with 10 to 45 percent by weight of a polymer, based on the starting weight of the nonwoven, is particularly preferred. With the same or even superior strength properties of the synthetic leather, less impregnation of the starting nonwoven is necessary according to the invention than with previously known products.
  • the process according to the invention for the production of a synthetic leather consists in that multicomponent continuous filaments are spun from the melt, aerodynamically stretched and immediately deposited into a nonwoven fabric, pre-consolidation takes place and the nonwoven fabric is solidified by high-pressure fluid jets as in supermicro continuous filaments with a titer ⁇ 0.2 dtex split and then impregnated and / or coated with a polymer.
  • the synthetic leathers thus obtained are very uniform in terms of their thickness, they have an isotropic thread distribution, have no tendency to delaminate and are distinguished by high modulus values.
  • the process for producing the synthetic leather is advantageously carried out in such a way that the solidification and splitting of the multicomponent continuous filaments takes place in that the pre-consolidated nonwoven fabric is subjected to high pressure water jets alternately on both sides.
  • the starting nonwoven fabric for the synthetic leather therefore has a good surface and a degree of splitting of the multi-component continuous filaments> 90%.
  • the process for splitting and solidifying the multicomponent continuous filament is advantageously carried out on an aggregate with rotating sieve drums. Such a unit allows the construction of very compact systems.
  • the non-woven fabric split into super-micro continuous filaments and consolidated with high-pressure fluid jets is impregnated with a polyurethane dissolved in dimethylformamide and the polymer is coagulated in a known manner. It is particularly preferred in the production of the synthetic leather according to the invention that the impregnation with a polymer is carried out with the aid of an aqueous polyurethane latex dispersion and then coagulated. This form of impregnation of the starting nonwoven does not leave any residues on solvents and is therefore environmentally friendly.
  • a method is particularly preferred in which the multicomponent continuous filaments are spin-dyed.
  • the integration of the dyes in the polymer fibers leads to excellent hot light fastness.
  • Writing effect is understood to mean the exposure of microfiber ends on the surface of the synthetic leather, which can be oriented in a visible manner.
  • the synthetic leathers produced according to the invention are particularly suitable for use in the shoe industry as upper material, inner lining, trimming or heel lining. They are still suitable as clothing materials. Because of their good mechanical strength and in the case of spun-dyed products because of their high fastness to hot light, the synthetic leathers according to the invention are suitable for use in automotive interior fittings for the production of dashboards, side panels, hat racks, headlining linings or trunk linings and for the manufacture of upholstered furniture, in particular as upholstery materials suitable for armchairs, sofas or chairs.
  • a filament pile with a basis weight of 160 g / m 2 is produced from a polyester-polyamide (PES-PA) bicomponent filament and subjected to water jet needling at pressures of up to 250 bar on both sides.
  • the bicomponent continuous filaments have a titer of ⁇ 0.2 dtex after the water jet needling, which leads to a simultaneous splitting of the starting filaments.
  • the consolidated nonwoven is subjected to an impregnation with a polyurethane (PUR) dissolved in dimethylformamide (DMF), about 12% by weight of PUR being applied based on the initial weight of the nonwoven.
  • PUR polyurethane
  • DMF dimethylformamide
  • the polymer-impregnated nonwoven fabric obtained is sanded on the surface and, for example, equipped with special silicones to improve the grip.
  • a synthetic leather with a nubuck-like surface is obtained.
  • a filament pile with a basis weight of 110 g / m 2 is produced from a PES-PA bicomponent continuous filament and subjected to water jet needling at pressures of up to 250 bar on both sides.
  • the bicomponent continuous filaments have a titer of ⁇ 0.2 dtex after the water jet needling, which leads to a simultaneous splitting of the starting filaments.
  • the consolidated nonwoven fabric is subjected to an impregnation with an aqueous polyurethane latex dispersion, about 10% by weight of PUR being applied based on the starting weight of the nonwoven fabric.
  • the polyurethane is coagulated by treatment with hot water or saturated steam and then dried and crosslinked at approx. 150 to 160 ° C.
  • the polymer impregnated nonwoven obtained is sanded on the surface and equipped with special silicones to improve the grip, for example.
  • a synthetic leather with a nubuck-like surface is obtained.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • General Chemical & Material Sciences (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

The invention relates to a synthetic leather comprising a polymer-impregnated and/or coated non-woven with a surface area weight of 150 to 500 g/m2 and a tensile strength of ⊃ 300 N/5 cm in the longitudinal and perpendicular direction. The non-woven is made of melt-spun, aerodynamically stretched multi-component endless filaments indirectly arranged to form a non-woven. Said non-woven has a titer of < 2 dtex. The multi-component endless filaments are split and hardened when said filaments have attained a strength of 90 % of the supermicro-endless filaments, i.e. a titer of < 0.2 dtex.

Description

Synthetisches Leder Synthetic leather
Beschreibungdescription
Die Erfindung betrifft ein synthetisches Leder, bestehend aus einem mit einem Polymer imprägnierten und/oder beschichteten Vliesstoff mit Flachengewichten von 100 bis 500 g/m2 und Zugfestigkeiten in Längs- sowie in Querrichtung > 300 N/5 cmThe invention relates to a synthetic leather, consisting of a nonwoven fabric impregnated and / or coated with a polymer and having basis weights of 100 to 500 g / m 2 and tensile strengths in the longitudinal and transverse directions> 300 N / 5 cm
Aus dem Dokument EP-A 0 090 397 sind Vliesstoffe aus ultrafeinen, verknaulten Filamenten bekannt, die eine Schichtstruktur aufweisen und durch Imprägnieren und/oder Beschichten mit Polymeren zu synthetischem Leder verarbeitet werden können Als Ausgangsfasern werden vorzugsweise solche vom Typ "Inseln-im-Meer" eingesetzt, bei denen die ultrafeinen Fasern durch Auflosung des Matrixpolymeren freigesetzt werden Weiterhin wird auch die Verwendung sp ttbarer Ausgangsfasern angegebenFrom document EP-A 0 090 397, nonwovens made of ultrafine, entangled filaments are known which have a layer structure and can be processed into synthetic leather by impregnation and / or coating with polymers. Those starting fibers are preferably those of the "island-in-sea" type "in which the ultrafine fibers are released by dissolving the matrix polymer. Furthermore, the use of noticeable starting fibers is also specified
Dokument EP-A 0 624 676 offenbart Vliesstoffe aus ultrafeinen Fasern und Verfahren zu deren Herstellung aus Bikomponenten-Fasern Die Ausgangspolymere der Bikomponenten-Fasern sollen dabei einen Schmelzpunkt-Unterschied von 30 bis 180°C aufweisen und werden als Mehrsegmentfasern ersponnen Die zu einem Faserflor abgelegten Bikomponenten-Fasern werden einer Punktkalandπerung unterzogen, bei der nur die Faserkomponente mit dem niedrigeren Schmelzpunkt aufgeschmolzen und verfestigt wird. In einem nachfolgenden Schritt wird der aus den Mehrsegmentfasern gebildete Vliesstoff durch mechanische Einwirkung auf die Fasern zumindest zu 70 % in die ultrafeinen Teilsegmentfasem gesplittet. Die so erhaltenen Vliesstoffe erreichen Zugfestigkeitswerte in Längs- und Querrichtung bis maximal 260 N/5 cm und können als Bettwäsche, Abscrbent für Sanitärprodukte, wie Taschentücher, Windeln, Wattierungen für Schlafsäcke, Kunstleder, Thermoisolationsmaterialien und anderes verwendet werden.Document EP-A 0 624 676 discloses nonwovens made from ultra-fine fibers and processes for their production from bicomponent fibers. The starting polymers of the bicomponent fibers are said to have a melting point difference of 30 to 180 ° C. and are spun as multi-segment fibers Bicomponent fibers are subjected to a point calendering, in which only the fiber component with the lower melting point is melted and is solidified. In a subsequent step, at least 70% of the nonwoven fabric formed from the multi-segment fibers is split into the ultrafine sub-segment fibers by mechanical action on the fibers. The nonwovens obtained in this way achieve tensile strength values in the longitudinal and transverse directions of up to a maximum of 260 N / 5 cm and can be used as bed linen, scrubber for sanitary products such as handkerchiefs, diapers, padding for sleeping bags, synthetic leather, thermal insulation materials and others.
Die Erfindung hat sich die Aufgabe gestellt, preiswerte und hochzugfeste synthetische Leder sowie ein Verfahren zu deren Herstellung anzugeben.The invention has for its object to provide inexpensive and high tensile synthetic leather and a method for their production.
Erfindungsgemäß wird die Aufgabe durch ein synthetisches Leder gelöst, welches aus einem mit einem Polymer imprägnierten und/oder beschichteten Vliesstoff mit Flächengewichten von 100 bis 500 g/m2 sowie Zugfestigkeiten in Längs- und Querrichtung > 300 N/5 cm besteht, wobei der Vliesstoff aus schmelzgesponnenen, aerodynamisch verstreckten und unmittelbar zu einem Vlies abgelegten Mehrkomponenten-Endlosfilamenten mit einem Titer < 2 dtex besteht und die Mehrkomponenten-Endlosfilamente nach einer Vorverfestigung zumindest zu 90 % zu Supermikro-Endlosfilamenten mit einem Titer < 0,2 dtex gesplittet und verfestigt sind. Ein solches synthetisches Leder weist bei einem vergleichsweise geringen Gewicht hohe Zugfestigkeiten auf und ist daher preiswert. Weiterhin ähnelt es im Hinblick auf seinen Griff natürlichen Materialien.According to the invention, the object is achieved by a synthetic leather which consists of a nonwoven fabric impregnated and / or coated with a polymer and having basis weights of 100 to 500 g / m 2 and tensile strengths in the longitudinal and transverse directions> 300 N / 5 cm, the nonwoven fabric consists of melt-spun, aerodynamically stretched and immediately deposited multi-component continuous filaments with a titer <2 dtex and the multi-component continuous filaments after pre-consolidation are at least 90% split and consolidated into super-micro continuous filaments with a titer <0.2 dtex. Such a synthetic leather has high tensile strengths at a comparatively low weight and is therefore inexpensive. Furthermore, it is similar to natural materials in terms of its grip.
Vorzugsweise ist das synthetische Leder eines, bei dem das Mehrkomponenten-Endlosfilament ein Bikomponenten-Endlosfiiament aus zwei inkompatiblen Polymeren, insbesondere einem Polyester und einem Polyamid, ist. Ein solches Bikomponenten-Endlosfiiament weist eine gute Spaltbarkeit in Supermikro-Endlosfilamenten auf und bewirkt ein günstiges Verhältnis von Festigkeit zu Flächengewicht auf.The synthetic leather is preferably one in which the multicomponent continuous filament is a bicomponent continuous filament made of two incompatible polymers, in particular a polyester and a polyamide. Such a continuous bicomponent filament has good splittability Super micro continuous filaments and creates a favorable ratio of strength to basis weight.
Vorzugsweise ist das synthetische Leder eines, bei dem die Mehrkomponenten-Endlosfilamente einen Querschnitt mit orangenartiger Multisegment-Struktur aufweisen, wobei die Segmente alternierend jeweils eines der beiden inkompatiblen Polymeren enthalten. Neben dieser orangenartigen Multisegment-Struktur der Mehrkomponenten-Endlosfilamente sind auch andere Anordnungen der inkompatiblen Polymeren im Mehrkomponenten-Endlosfilament wie side-by-side oder chrysanthemenblattähnlicher Anordnungen möglich. Solche Anordnungen der inkompatiblen Polymeren im Mehrkomponenten-Endlosfilament haben sich als sehr gut spaltbar erwiesen.The synthetic leather is preferably one in which the multicomponent continuous filaments have a cross section with an orange-like multisegment structure, the segments alternately each containing one of the two incompatible polymers. In addition to this orange-like multi-segment structure of the multi-component continuous filaments, other arrangements of the incompatible polymers in the multi-component continuous filament, such as side-by-side or chrysanthemum leaf-like arrangements, are also possible. Such arrangements of the incompatible polymers in the multicomponent continuous filament have proven to be very easy to split.
Vorzugsweise ist das synthetische Leder weiterhin eines, bei dem mindestens eines der das Mehrkomponenten-Endlosfilament bildenden inkompatiblen Polymeren ein Additiv, wie Farbpigmente, permanent wirkende Antistatika und/oder die hydrophilen oder hydrophoben Eigenschaften beeinflussende Zusätze in Mengen bis zu 10 Gewichtsprozent, enthält. Das aus spinngefärbten Fasern bestehende synthetische Leder weist eine sehr hohe Hochtemperatur- Lichtechtheit auf. Weiterhin können durch die Zusätze statische Aufladungen vermindert bzw. vermieden und die Feuchtigkeits-Transporteigenschaften verbessert werden.The synthetic leather is preferably also one in which at least one of the incompatible polymers forming the multicomponent filament contains an additive, such as color pigments, permanently acting antistatic agents and / or additives which influence the hydrophilic or hydrophobic properties in amounts of up to 10% by weight. The synthetic leather consisting of spun-dyed fibers has a very high high-temperature light fastness. Furthermore, the additives can reduce or avoid static charges and improve the moisture transport properties.
Besonders bevorzugt ist ein synthetisches Leder, bei dem der Vliesstoff mit 10 bis 45 Gewichtsprozent eines Polymeren, bezogen auf das Ausgangsgewicht des Vliesstoffes, imprägniert ist. Bei gleichen oder sogar überlegenen Festigkeitseigenschaften des synthetischen Leders ist erfindungsgemäß eine geringere Imprägnierung des Ausgangsvliesstoffes notwendig als bei bisher bekannten Produkten. Das erfindungsgemäße Verfahren zur Herstellung eines synthetischen Leders besteht darin, daß Mehrkomponenten-Endlosfilamente aus der Schmelze ersponnen, aerodynamisch verstreckt und unmittelbar zu einem Vlies abgelegt werden, eine Vorverfestigung erfolgt und der Vliesstoff durch Hochdruck- Fluidstrahlen verfestigt wie gleichzeitig in Supermikro-Endlosfilamente mit einem Titer < 0,2 dtex gesplittet sowie anschließend mit einem Polymer imprägniert und/oder beschichtet wird. Die so erhaltenen synthetischen Leder sind sehr gleichmäßig hinsichtlich ihrer Dicke, sie weisen eine isotrope Fadenverteilung auf, besitzen keine Neigung zum Delaminieren und sind durch hohe Modulwerte ausgezeichnet.A synthetic leather in which the nonwoven is impregnated with 10 to 45 percent by weight of a polymer, based on the starting weight of the nonwoven, is particularly preferred. With the same or even superior strength properties of the synthetic leather, less impregnation of the starting nonwoven is necessary according to the invention than with previously known products. The process according to the invention for the production of a synthetic leather consists in that multicomponent continuous filaments are spun from the melt, aerodynamically stretched and immediately deposited into a nonwoven fabric, pre-consolidation takes place and the nonwoven fabric is solidified by high-pressure fluid jets as in supermicro continuous filaments with a titer <0.2 dtex split and then impregnated and / or coated with a polymer. The synthetic leathers thus obtained are very uniform in terms of their thickness, they have an isotropic thread distribution, have no tendency to delaminate and are distinguished by high modulus values.
Vorteilhafterweise wird das Verfahren zur Herstellung des synthetischen Leders in der Weise durchgeführt, daß die Verfestigung und Splittung der Mehrkomponenten-Endlosfilamente dadurch erfolgt, daß der vorverfestigte Vliesstoff mehrfach abwechselnd auf beiden Seiten mit Hochdruck- Wasserstrahlen beaufschlagt wird. Der Ausgangsvliesstoff für das synthetische Leder weist dadurch eine gute Oberfläche und einen Splittungsgrad der Mehrkomponenten-Endlosfilamente > 90 % auf.The process for producing the synthetic leather is advantageously carried out in such a way that the solidification and splitting of the multicomponent continuous filaments takes place in that the pre-consolidated nonwoven fabric is subjected to high pressure water jets alternately on both sides. The starting nonwoven fabric for the synthetic leather therefore has a good surface and a degree of splitting of the multi-component continuous filaments> 90%.
Vorteilhafterweise wird das Verfahren zur Splittung und Verfestigung des Mehrkomponenten-Endlosfilaments auf einem Aggregat mit rotierenden Siebtrommeln durchgeführt. Ein solches Aggregat gestattet den Bau sehr kompakter Anlagen.The process for splitting and solidifying the multicomponent continuous filament is advantageously carried out on an aggregate with rotating sieve drums. Such a unit allows the construction of very compact systems.
Vorteilhafterweise wird der in Supermikro-Endlosfilamente gesplitte und mit Hochdruck-Fluidstrahlen verfestigte Vliesstoff mit einem in Dimethylformamid gelösten Polyurethan imprägniert und das Polymer in bekannter Weise koaguliert. Besonders bevorzugt bei der Herstellung des erfindungsgemäßen synthetische Leders ist, daß die Imprägnierung mit einem Polymer mit Hilfe einer wäßrigen Polyurethan-Latexdispersion vorgenommen und anschließend koaguliert wird. Diese Form der Imprägnierung des Ausgangsvliesstoffes führt zu keinen Rückständen an Lösemitteln und ist somit umweltfreundlich.Advantageously, the non-woven fabric split into super-micro continuous filaments and consolidated with high-pressure fluid jets is impregnated with a polyurethane dissolved in dimethylformamide and the polymer is coagulated in a known manner. It is particularly preferred in the production of the synthetic leather according to the invention that the impregnation with a polymer is carried out with the aid of an aqueous polyurethane latex dispersion and then coagulated. This form of impregnation of the starting nonwoven does not leave any residues on solvents and is therefore environmentally friendly.
Besonders bevorzugt ist ein Verfahren, bei dem die Mehrkomponenten- Endlosfilamente spinngefärbt werden. Die Einbindung des Farbstoffe in die Polymerfasern führt zu hervorragenden Heißlichtechtheiten.A method is particularly preferred in which the multicomponent continuous filaments are spin-dyed. The integration of the dyes in the polymer fibers leads to excellent hot light fastness.
Weiterhin bevorzugt ist bei verschiedenen Anwendungen eine Nachbehandlung durch Schleifen oder Buffen. Dadurch kann der Griff bzw. die Oberflächeneigenschaften verbessert werden, außerdem kann ein sogenannter "Schreibeffekt" erreicht werden. Unter "Schreibeffekt" wird dabei die Freilegung von Mikrofaserenden an der Oberfläche des synthetischen Leders verstanden, die in sichtbarer Weise orientiert werden können.Aftertreatment by grinding or buffing is also preferred in various applications. The grip or surface properties can be improved as a result, and a so-called "writing effect" can also be achieved. "Writing effect" is understood to mean the exposure of microfiber ends on the surface of the synthetic leather, which can be oriented in a visible manner.
Die erfindungsgemäß hergestellten synthetischen Leder sind insbesondere geeignet für die Anwendung in der Schuhindustrie als Obermaterial, Innenfutter, Besatz oder Fersenfutter. Sie sind weiterhin geeignet als Bekleidungsmaterialen. Aufgrund ihrer guten mechanischen Festigkeit und bei spinngefärbten Produkten wegen ihrer hohen Heißlichtechtheit sind die erfindungsgemäßen synthetischen Leder für die Verwendung im Automobil- Innenausbau für die Herstellung von Armaturenbretter, Seitenverkleidungen, Hutablagen, Dachhimmelauskleidung oder Kofferraum-Auskleidungen und für die Herstellung von Polstermöbeln, insbesondere als Bezugstoffe für Sessel, Sofas oder Stühle geeignet. Beispiel 1The synthetic leathers produced according to the invention are particularly suitable for use in the shoe industry as upper material, inner lining, trimming or heel lining. They are still suitable as clothing materials. Because of their good mechanical strength and in the case of spun-dyed products because of their high fastness to hot light, the synthetic leathers according to the invention are suitable for use in automotive interior fittings for the production of dashboards, side panels, hat racks, headlining linings or trunk linings and for the manufacture of upholstered furniture, in particular as upholstery materials suitable for armchairs, sofas or chairs. example 1
Aus einem Polyester-Polyamid (PES-PA)-Bikomponenten-Endlosfilament wird ein Filamentflor mit einem Flächengewicht von 160 g/m2 erzeugt und einer Wasserstrahlvernadelung mit Drücken bis 250 bar beidseitig unterzogen. Die Bikomponenten-Endlosfilamente weisen nach der Wasserstrahlvernadelung, die zu einer gleichzeitigen Splittung der Ausgangsfilamente führt, einen Titer < 0,2 dtex auf. Der verfestigte Vliesstoff wird einer Imprägnierung mit einem in Dimethylformamid (DMF) gelösten Polyurethan (PUR) unterzogen, wobei ca. 12 Gew.% PUR bezogen auf das Ausgangsgewicht des Vliesstoffes aufgebracht werden. Der erhaltene, polymerimprägnierte Vliesstoff wird oberfiächig angeschliffen und zur Griffverbesserung beispielsweise mit speziellen Silikonen ausgerüstet. Es wird ein synthetisches Leder mit einer nubukartigen Oberfläche erhalten.A filament pile with a basis weight of 160 g / m 2 is produced from a polyester-polyamide (PES-PA) bicomponent filament and subjected to water jet needling at pressures of up to 250 bar on both sides. The bicomponent continuous filaments have a titer of <0.2 dtex after the water jet needling, which leads to a simultaneous splitting of the starting filaments. The consolidated nonwoven is subjected to an impregnation with a polyurethane (PUR) dissolved in dimethylformamide (DMF), about 12% by weight of PUR being applied based on the initial weight of the nonwoven. The polymer-impregnated nonwoven fabric obtained is sanded on the surface and, for example, equipped with special silicones to improve the grip. A synthetic leather with a nubuck-like surface is obtained.
Beispiel 2Example 2
Aus einem PES-PA-Bikomponenten-Endlosfilament wird ein Filamentflor mit einem Flächengewicht von 110 g/m2 erzeugt und einer Wasserstrahlvernadelung mit Drücken bis 250 bar beidseitig unterzogen. Die Bikomponenten-Endlosfilamente weisen nach der Wasserstrahlvernadelung, die zu einer gleichzeitigen Splittung der Ausgangsfilamente führt, einen Titer < 0,2 dtex auf. Der verfestigte Vliesstoff wird einer Imprägnierung mit einer wäßrigen Polyurethan-Latexdispersion unterzogen, wobei ca. 10 Gew.% PUR bezogen auf das Ausgangsgewicht des Vliesstoffes aufgebracht werden. Das Polyurethan wird durch Behandlung mit heißem Wasser oder Sattdampf koaguliert und nachfolgend bei ca. 150 bis 160°C getrocknet und vernetzt. Der erhaltene, polymerimprägnierte Vliesstoff wird oberflächig angeschliffen und zur Griffverbesserung beispielsweise mit speziellen Silikonen ausgerüstet. Es wird ein synthetisches Leder mit einer nubukartigen Oberfläche erhalten. A filament pile with a basis weight of 110 g / m 2 is produced from a PES-PA bicomponent continuous filament and subjected to water jet needling at pressures of up to 250 bar on both sides. The bicomponent continuous filaments have a titer of <0.2 dtex after the water jet needling, which leads to a simultaneous splitting of the starting filaments. The consolidated nonwoven fabric is subjected to an impregnation with an aqueous polyurethane latex dispersion, about 10% by weight of PUR being applied based on the starting weight of the nonwoven fabric. The polyurethane is coagulated by treatment with hot water or saturated steam and then dried and crosslinked at approx. 150 to 160 ° C. The polymer impregnated nonwoven obtained is sanded on the surface and equipped with special silicones to improve the grip, for example. A synthetic leather with a nubuck-like surface is obtained.

Claims

Patentansprüche claims
1. Synthetisches Leder bestehend aus einem mit einem Polymer imprägnierten und/oder beschichteten Vliesstoff mit Flächengewichten von 100 bis 500 g/m2 und Zugfestigkeiten sowohl in Längs- als auch in1. Synthetic leather consisting of a nonwoven fabric impregnated and / or coated with a polymer and having basis weights of 100 to 500 g / m 2 and tensile strengths both in longitudinal and in
Querrichtung > 300 N/5 cm wobei der Vliesstoff aus schmelzgesponnenen, aerodynamisch verstreckten und unmittelbar zu einem Vlies abgelegten Mehrkomponenten-Endlosfilamenten mit einem Titer < 2 dtex besteht und die Mehrkomponenten-Endlosfilamente nach einer Vorverfestigung zumindest zu 90 % zu Supermikro-Transverse direction> 300 N / 5 cm whereby the nonwoven fabric consists of melt-spun, aerodynamically stretched and immediately deposited multi-component continuous filaments with a titer of <2 dtex and the multi-component continuous filaments after pre-consolidation are at least 90% super-micro
Endlosfilamenten mit einem Titer < 0,2 dtex gesplittet und verfestigt sind.Continuous filaments with a titer of <0.2 dtex are split and solidified.
2. Synthetisches Leder nach Anspruch 1 , dadurch gekennzeichnet, daß das Mehrkomponenten-Endlosfilament ein Bikomponenten- Endlosfilament aus zwei inkompatiblen Polymeren, insbesondere einem2. Synthetic leather according to claim 1, characterized in that the multi-component continuous filament is a bicomponent continuous filament made of two incompatible polymers, in particular one
Polyester und einem Polyamid, ist.Polyester and a polyamide.
3. Synthetisches Leder nach Anspruch 1 oder 2, dadurch gekennzeichnet, daß die Mehrkomponenten-Endlosfilamente einen Querschnitt mit orangenartiger Multisegment-Struktur aufweisen, wobei die Segmente alternierend jeweils eines der beiden inkompatiblen Polymeren enthalten.3. Synthetic leather according to claim 1 or 2, characterized in that the multicomponent continuous filaments have a cross section with an orange-like multisegment structure, the segments alternately each containing one of the two incompatible polymers.
4. Synthetisches Leder nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß mindestens eines der das Mehrkomponenten- Endlosfilament bildenden inkompatiblen Polymere ein Additiv, wie Farbpigmente, permanent wirkende Antistatika und/oder die hydrophilen oder hydrophoben Eigenschaften beeinflussenden Zusätzen in Mengen bis zu 10 Gewichtsprozent, enthält. 4. Synthetic leather according to one of claims 1 to 3, characterized in that at least one of the multicomponent continuous filament-forming incompatible polymers is an additive, such as color pigments, permanently acting antistatic agents and / or additives which influence the hydrophilic or hydrophobic properties in amounts of up to 10 Percent by weight.
5. Synthetisches Leder nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, daß der Vliesstoff mit 10 bis 45 Gewichtsprozent eines Polymeren, bezogen auf das Ausgangsgewicht des Vliesstoffes, imprägniert ist.5. Synthetic leather according to one of claims 1 to 4, characterized in that the nonwoven fabric is impregnated with 10 to 45 percent by weight of a polymer, based on the starting weight of the nonwoven fabric.
6. Verfahren zur Herstellung eines synthetischen Leders nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, daß Mehrkomponenten- Endlosfilamente aus der Schmelze ersponnen, aerodynamisch verstreckt und unmittelbar zu einem Vlies abgelegt werden, eine Vorverfestigung erfolgt und der Vliesstoff durch Hochdruck-Fluidstrahlen verfestigt sowie gleichzeitig in Supermikro-Endlosfilamente mit einem Titer < 0,2 dtex gesplittet sowie anschließend mit einem Polymer imprägniert und/oder beschichtet wird.6. A process for producing a synthetic leather according to one of claims 1 to 5, characterized in that multicomponent continuous filaments are spun from the melt, aerodynamically stretched and deposited immediately to form a nonwoven fabric, pre-consolidation takes place and the nonwoven fabric is consolidated by high pressure fluid jets and is simultaneously split into super micro continuous filaments with a titer of <0.2 dtex and then impregnated and / or coated with a polymer.
7. Verfahren nach Anspruch 6, dadurch gekennzeichnet, daß die Verfestigung und Splittung der Mehrkomponenten-Endlosfilamente dadurch erfolgt, daß der vorverfestigte Vliesstoff mehrfach abwechselnd von beiden Seiten mit Hochdruck-Fluidstrahlen beaufschlagt wird.7. The method according to claim 6, characterized in that the solidification and splitting of the multi-component continuous filaments takes place in that the pre-consolidated nonwoven fabric is acted upon alternately from both sides with high pressure fluid jets.
8. Verfahren nach Anspruch 7, dadurch gekennzeichnet, daß das Verfestigen und Splitten des Mehrkomponenten-Endlosfilaments auf einem Aggregat mit rotierenden Siebtrommeln durchgeführt wird.8. The method according to claim 7, characterized in that the solidification and splitting of the multi-component continuous filament is carried out on an aggregate with rotating sieve drums.
9. Verfahren nach einem der Ansprüche 6 bis 8, dadurch gekennzeichnet, daß die Imprägnierung mit einem Polymer mit einem im9. The method according to any one of claims 6 to 8, characterized in that the impregnation with a polymer with an im
Dimethylformamid gelösten Polyurethan vorgenommen und das Polymer koaguliert wird. Dimethylformamide dissolved polyurethane made and the polymer is coagulated.
10. Verfahren nach einem der Ansprüche 6 bis 8, dadurch gekennzeichnet, daß die Imprägnierung mit einem Polymer mit einer wäßrigen Polyurethan-Latexdispersion vorgenommen wird.10. The method according to any one of claims 6 to 8, characterized in that the impregnation is carried out with a polymer with an aqueous polyurethane latex dispersion.
11. Verfahren nach einem der Ansprüche 7 bis 10, dadurch gekennzeichnet, daß die Färbung der Mehrkomponenten-Endlosfilamente durch Spinnfärben vorgenommen wird.11. The method according to any one of claims 7 to 10, characterized in that the dyeing of the multi-component continuous filaments is carried out by spin dyeing.
12. Verfahren nach einem der Ansprüche 7 bis 11 , dadurch gekennzeichnet, daß eine Nachbehandlung durch Schleifen oder Buffen vorgenommen wird.12. The method according to any one of claims 7 to 11, characterized in that an aftertreatment is carried out by grinding or buffing.
13. Verwendung eines synthetischen Leders hergestellt nach einem der Ansprüche 7 bis 12, dadurch gekennzeichnet, daß das synthetische Leder in der Schuhindustrie als Obermaterial, Innenfutter, Besatz oder13. Use of a synthetic leather produced according to one of claims 7 to 12, characterized in that the synthetic leather in the shoe industry as an upper material, inner lining, trimmings or
Fersenfutter eingesetzt wird.Heel lining is used.
14. Verwendung eines synthetischen Leders hergestellt nach einem der Ansprüche 7 bis 12, dadurch gekennzeichnet, daß das synthetische Leder im Automobil-Innenbereich für die Herstellung von14. Use of a synthetic leather produced according to one of claims 7 to 12, characterized in that the synthetic leather in the automotive interior for the production of
Armaturenbrettern, Seitenverkleidungen, Hutablagen,Dashboards, side panels, parcel shelves,
Dachauskleidungen oder Kofferraum-Auskleidungen eingesetzt wird.Roof linings or trunk linings are used.
15. Verwendung eines synthetischen Leders hergestellt nach einem der Ansprüche 7 bis 12, dadurch gekennzeichnet, daß das synthetische15. Use of a synthetic leather produced according to one of claims 7 to 12, characterized in that the synthetic
Leder in der Bekleidungs- oder Polstermöbelindustrie insbesondere als Bezugsstoff für Sessel, Sofas oder Stühle eingesetzt wird. Leather is used in the clothing or upholstered furniture industry in particular as a covering material for armchairs, sofas or chairs.
EP00960579A 1999-10-05 2000-09-01 Synthetic leather Withdrawn EP1226304A1 (en)

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