JP2016164316A - Manufacturing method of sewn product including elastic synthetic leather - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a sewn product which is capable of supplying a synthetic leather having excellent elasticity in a stable shape, has excellent elasticity, and has a high commodity value, and to provide a manufacturing method of the sewn product.SOLUTION: The sewn product is manufactured by: cutting a laminate of an elastic synthetic leather and a reinforcement fabric in various shapes of members of a sewn product as a target; peeling the reinforcement fabric from the laminate; and sewing the elastic synthetic leather in various shapes.SELECTED DRAWING: None

Description

The present invention relates to a method for manufacturing a sewn product using synthetic leather (artificial leather). As a sewing product, it is suitably used for golf, baseball gloves, elbow and knee supporters.

  Golf and baseball gloves and elbow and knee supporters are required to expand and contract according to the movement of bending the joints. In general, synthetic leather uses a warp knitted fabric as a base fabric, but the warp knitted fabric is excellent in the stretchability in the horizontal direction but is poor in the stretchability in the vertical direction. By using a knitted fabric containing polyurethane fibers as a base fabric, it is possible to produce a synthetic leather having stretchability in the longitudinal and lateral directions. However, knitted fabrics, particularly knitted fabrics containing polyurethane fibers, are likely to undergo dimensional fluctuations. Therefore, when processing synthetic leather, it is possible to use a substrate bonded with a reinforcing fabric in order to impart processing stability. It is general (patent document 1).

  As the reinforcing fabric, a fabric made of synthetic fiber or natural fiber is used. Those having a small elongation rate when immersed in water in the coagulation treatment step are preferred. Specific examples include polyester taffeta, rayon chillers, and the like.

  In general, after finishing processing such as coating and surface treatment, the reinforcing fabric is peeled off and wound up. As a manufacturing method of a sewn product, it is common to cut a synthetic leather from which a reinforcing fabric is peeled into the shape of each member of a sewn product, and sew each member to produce a sewn product.

  In order to prevent the reinforcing fabric from peeling off during the production process of the synthetic leather, the adhesive strength between the synthetic leather substrate and the reinforcing fabric needs to have a certain level or more. Therefore, in order to peel off the reinforcing fabric in a mass production machine, a certain amount of strong tension is applied in the vertical direction. Therefore, synthetic leather with excellent longitudinal stretchability is large in the vertical direction when peeling the reinforcing fabric. extend. Thereafter, dry heat setting is performed in the tentering process. However, due to the fact that the heat is stretched greatly in the vertical direction, large stretch distortion in the vertical direction remains after setting.

  Although it is possible to reverse the longitudinal elongation to restore the original state in order to suppress the longitudinal elongation before the dry heat setting, the lateral curl occurs due to the strong tension in the longitudinal direction. Or after the reinforcing fabric is peeled off, such as resin or fiber crystallization, mass production is very difficult.

Before sewing gloves, supporters, etc., the synthetic leather is cut into individual parts, but if large stretch distortion remains, each part is small, making the sewing work very difficult and inefficient. Is. Even if it can be sewn, a large strain remains. As a result, wrinkles and distortion are conspicuous in the sewn product, and it is difficult to finish the sewn product with a quality that can be marketed.
Patent Document 2 describes that as a method for producing stretchable synthetic leather, a cotton cloth is attached to a base material in order to ensure the dimensional stability of the base material, and the cotton cloth is peeled off after coating processing. There is no description about the processing steps and processing stability.

  Accordingly, if the reinforcing fabric is peeled off if the longitudinal elongation is small, subsequent processing is possible, but usable base fabrics are limited. In addition, the range in which troubles can be solved by adjusting the tension during processing is narrow, and the base materials that can be used are limited. In this case, the processing speed decreases, and it is impossible to manufacture quickly. Moreover, if it cannot be manufactured quickly, the price of the synthetic leather obtained will increase and its practicality will be diminished.

  Prior art documents relating to synthetic leather having stretchability can be cited, for example, as in Patent Document 3 and Patent Document 4, but a simple and efficient method for producing sewn products such as gloves and supporters having stretchable synthetic leather is as follows. Not disclosed.

JP-A-4-214473 JP-A-10-60782 JP 2001-164477 A JP2010-111989

  The problem to be solved by the present invention is to supply a synthetic leather excellent in stretchability in a stable shape and to provide a sewn product excellent in stretchability and high in commercial value and a method for producing the same.

  In order to solve the above-mentioned problems, the present invention cuts a laminate of stretchable synthetic leather and reinforcing fabric into various shapes of members of a desired sewing product, and peels the reinforcing fabric from the laminate. The purpose is to sew elastic synthetic leather of various shapes to produce a sewn product.

  According to the present invention, a sewn product having desired shape stability and excellent stretchability is provided, and the efficiency of the sewing work of the sewn product can be realized.

  First, the elastic synthetic leather which concerns on embodiment of this invention is demonstrated in detail. In addition, the unit of fineness and 1 denier in this specification means 10/9 dtex.

<Base fabric>
As the base fabric used in the synthetic leather of the present invention, an appropriate fabric can be used depending on the purpose of use, but synthetic fibers such as nylon fibers, polyester fibers and polyamide fibers, and semi-synthetic fibers such as acetate fibers. Natural fibers such as cotton, hemp, and wool can be used alone or in admixture of two or more without being limited to woven fabrics, knitted fabrics, non-woven fabrics, and the like. Preferably, it contains polyurethane fibers. For example, it is a thread in which a polyurethane fiber is cored and a nylon processed thread is wound around in one direction in either the S or Z direction when the thread is stretched, and the polyurethane fiber content in the base fabric is arbitrary. However, it is preferably 5 to 40% by mass, more preferably 10 to 20% by mass.

<Resin layer>
Examples of the material for forming the resin layer include vinyl chloride, acrylic resin, and polyurethane resin. In order to realize a synthetic leather excellent in flexibility and stretchability, polyurethane resin is preferable. Examples of polyurethane resins include polyester copolymer, polyether copolymer, or polycarbonate copolymer polyurethanes, polyurethanes copolymerized with castor oil-derived materials, polyurethane resins copolymerized with silicone, fluorine, amino acids, and the like. . In addition to the polyurethane resin, acrylic resins, polyester resins, polytetrafluoroethylene resins, polyamide resins and the like can be used, and these can be used alone or in combination.

  As a method for forming the coating layer, the polyurethane resin formed by coating directly on the base fabric or by coating on the release substrate is bonded to the coating layer by using an adhesive and then released onto the coating layer. Although there is a method of peeling the base material, etc., it is not limited to any of them. As a coating method, various coating methods such as knife coating, knife over roll coating, and reverse roll coating can be employed.

<Manufacture of synthetic leather>
The synthetic leather according to the present invention employs a synthetic leather in which a polyurethane solution obtained by dissolving a polyurethane resin in a water-soluble solvent is coated on a base fabric and a porous layer is formed by wet coagulation of the polyurethane. preferable.

  In the coating method, various coating methods such as knife coating, knife over roll coating, and reverse roll coating can be used.

  When laminating a non-porous film on the porous layer, the non-porous film of the surface layer is coated with a polyurethane resin solution on the release substrate, and the solvent is dried to adhere the entire surface with an adhesive. Although there is a method, or a method in which the release paper is peeled after being laminated on the base material after the porous layer is formed in a semi-dry state when the nonporous film is formed, it is not limited thereto. As the stretchability of the stretchable synthetic leather in the present invention, the constant load elongation (JIS-L1096, method C) when a load of 1.96 N / cm is applied is 30 to 150% in length and width, and the elongation recovery rate. (JIS-L1096, Method B-1) is preferably 80% or more in both length and width.

<Reinforcing fabric>
As the reinforcing fabric, a fabric using synthetic fibers or natural fibers is used. The reinforcing fabric is preferably laminated on the base fabric side of the synthetic leather. It is preferable that the elongation rate when a tensile load of 0.5 N / cm is applied in the vertical direction is 0 to 5%, and the shrinkage rate when immersed in water in the coagulation treatment step is 0 to 10%. Specifically, a polyester taffeta, a rayon fabric, etc. are illustrated.

  After the polyurethane resin is coated on the synthetic leather base material, the adhesive strength between the synthetic leather base material and the reinforcing fabric has a certain or higher adhesive strength in order to prevent the reinforcing fabric from peeling off during the solidification process. There is a need. Thereafter, it is preferable to have an adhesive strength of a certain level or less in order not to reduce the workability of cutting the laminated body of the synthetic leather and the reinforcing fabric before sewing and peeling the reinforcing fabric by hand. Therefore, the adhesive strength between the synthetic leather substrate and the reinforcing fabric is preferably 0.1 to 2.0 N / cm. More preferably, it is 0.5 to 1.3 N / cm. The measuring method of adhesive strength is as follows.

  Three test pieces each having a width of 30 mm and a length of 150 mm are collected from the vertical direction and the horizontal direction. The reinforcing fabric is peeled 40 mm from both ends of the test piece. Under the conditions of room temperature 25 ± 5 ° C. and humidity 65% ± 10% RH, using “Tensilon” (registered trademark) universal material testing machine RTC-1250A manufactured by Orientec, grasp the synthetic leather base material and the reinforcing fabric, The reinforcing fabric was peeled off at a gripping distance of 30 mm and a measurement speed of 1000 mm / min. The average value of the maximum value and the average value of the minimum values at the time of peeling was taken as the measurement value, and the average value of the measurement values in the forward and reverse directions was taken as the result.

  EXAMPLES Hereinafter, although an Example demonstrates this invention further more concretely, this invention is not limited by a following example. Moreover, each evaluation followed the following method. In addition, about the synthetic leather with which the reinforcing fabric shown in the Example was attached, various evaluation was performed after peeling the reinforcing fabric by hand.

[Constant load elongation]
Conforms to JIS-L1096, method C. Three pieces of synthetic leather specimens having a width of 50 mm and a length of 300 mm are taken from the longitudinal direction and the transverse direction, respectively, and marked lines are provided at intervals of 200 mm in length. The upper part of the test piece is fixed to the jig of the apparatus at the position of the marked line. A jig with a load of 1.0 kgf is fixed at the position of the marked line at the bottom of the test piece. Measure the mark interval (L) after applying the load and leaving it to stand for 1 minute. The constant load elongation (%) is obtained by the following equation. Results are expressed as average values.
Constant load elongation (%) = (L−200) / 200 × 100
In this measurement method, 30% or more felt that there was elasticity when the elasticity was evaluated with human hands.

[Elongation recovery rate]
Conforms to JIS-L1096B-1 method. Three pieces of synthetic leather specimens having a width of 50 mm and a length of 300 mm are taken from the longitudinal direction and the transverse direction, respectively, and marked lines are provided at intervals of 200 mm in length. The upper part of the test piece is fixed to the jig of the apparatus at the position of the marked line. A jig with a load of 1.0 kgf is fixed at the position of the marked line at the bottom of the test piece. Add the load and leave it for 1 minute, then remove the load and leave it for 3 minutes. After repeating this 10 times, the marked line interval (L ₁₀ ) in a state where a load is applied and the marked line interval (L ′ ₁₀ ) after removing the load and leaving it for 3 minutes are measured.
The elongation recovery rate (%) is obtained by the following equation. Results were expressed as average values.
Elongation recovery rate (%) = (L ₁₀ −L ′ ₁₀ ) / (L ₁₀ −200) × 100.

[Tensile breaking strength]
Measurement was performed in accordance with JIS-L1096A method. As a tester, “Tensilon” (registered trademark) universal material tester RTC-1250A was used. Results are expressed as average values.

[Tensile breaking elongation]
It measured based on JIS-L1096A method similarly to the tensile breaking strength. As a tester, “Tensilon” (registered trademark) universal material tester RTC-1250A was used. Results are expressed as average values.

[Evaluation of curling properties of synthetic leather]
A test piece having a length of 10 cm and a width of 10 cm was taken from the synthetic leather from which the reinforcing fabric was peeled off from the obtained laminate, and the presence or absence of curling was observed when left on a flat surface.

[Sew products are distorted]
The presence or absence of distortion of the sewn product was confirmed.

[Example 1]
As a base fabric, 12% by mass of polyurethane fiber and 88% by mass of nylon fiber, and a circular knitted fabric with single-side raised treatment (density: 52 wells / 92 courses / in, front; nylon 70 denier / 52 filament, Back: 30 denier polyurethane) was prepared. For the purpose of imparting passability and dimensional stability during processing to this knitted fabric, a woven fabric made of rayon (number of driven 90 / 2.54 cm) is used as a reinforcing fabric on the surface opposite to the raised surface, and acrylic / vinyl acetate. A composite material obtained by laminating a system emulsion resin as a binder was used as a base fabric (hereinafter referred to as “base fabric A”).

  As a pretreatment for coating, the base fabric A was immersed in water, and the mangle was adjusted so that 80 to 90% of water adhered to the mass of the base fabric A.

  Next, 100.0 parts by mass of a polyurethane resin “Leocoat U-2410H (manufactured by Toray Cortex Co., Ltd.)”, 120 parts by mass of N, N-dimethylformamide (hereinafter referred to as “DMF”), a nonionic surfactant (large) Nissei Kagaku Kogyo Co., Ltd., CUT-101) 2.0 parts by mass, Pigment (DIC Co., Ltd., DIRAC WHITE L-6626D) 6.5 parts by mass were added and stirred to obtain a polyurethane resin blended solution. (Hereinafter referred to as “Solution 1”).

The prefabricated base fabric A was coated on the surface of the circular knitted fabric at a coating amount of 800 g / m ^{2 with} a knife over roll coater, and immersed in a 30 ° C. bath containing an aqueous solution containing 10% by mass of DMF for 10 minutes. Then, the polyurethane resin compounded solution was precipitated and solidified, then immersed and washed in hot water at 80 ° C. for 30 minutes, and dried with hot air at 120 ° C. to obtain an intermediate.

  Next, embossing was performed on the resin-coated surface to give pore-like uneven portions. For the embossing, a concave and convex mold roller was used. A synthetic leather provided with irregularities was obtained by heat compression with a mold roll heated to 150 ° C.

  In order to make the length in the width direction constant with the reinforcing cloth attached to the rayon woven fabric, dry heat setting was performed to obtain a laminate of synthetic leather and reinforcing fabric.

Table 1 shows the evaluation results of the stretchable synthetic leather obtained by peeling the reinforcing fabric from the obtained laminate.
Moreover, after cutting this laminated body into the shape of each member of the glove which is a target sewing product and peeling the reinforcing fabric from the laminated body, each member was sewn to produce a sewn product. Table 1 shows the presence or absence of distortion of the sewn product.

[Example 2]
As a base fabric, 10% by mass of polyurethane fiber and 90% by mass of nylon fiber, and a circular knitted fabric with single-side raised treatment (density: 40 wells / 59 in course / in, front; nylon 70 denier / 52 filament, For the purpose of imparting passability and dimensional stability at the time of processing to polyurethane (30 denier), a rayon fabric (90 pieces / in) is used as a reinforcing fabric on the surface opposite to the raised surface with acrylic / acetic acid A composite material laminated with a vinyl emulsion resin as a binder was used as a base fabric (hereinafter referred to as “base fabric B”).

  As a pretreatment for coating, the base fabric B was immersed in water, and the mangle was adjusted so that 80 to 90% of water adhered to the weight of the base fabric B.

The surface of the circular knitted fabric is coated with the solution 1 at a coating amount of 800 g / m ^{2 on} the pretreated base fabric B with a knife over roll coater, and the aqueous solution containing 10% by mass of DMF is solidified in a bath at 30 ° C. for 10 minutes. The polyurethane resin compounded liquid was precipitated and solidified by immersion, and then immersed and washed in hot water at 80 ° C. for 30 minutes and dried with hot air at 120 ° C. to obtain an intermediate.

  Next, the embossed pore-shaped irregularities by embossing were provided on the resin-coated surface. For the embossing, a concave and convex mold roller was used. A synthetic leather provided with irregularities was obtained by heat compression with a mold roll heated to 150 ° C.

  In order to make the length in the width direction constant with the reinforcing cloth attached to the rayon woven fabric, dry heat setting was performed to obtain a laminate of synthetic leather and reinforcing fabric.

Table 1 shows the evaluation results of the stretchable synthetic leather obtained by peeling the reinforcing fabric from the obtained laminate.
Moreover, this laminated body was cut into the shape of each member of a glove which is a target sewing product, and after the reinforcing fabric was peeled from the laminated body, each member was sewn to produce a sewing product. Table 1 shows the presence or absence of distortion of the sewn product.

[Example 3]
As a base fabric, 12% by mass of polyurethane fiber and 88% by mass of nylon fiber, and a circular knitted fabric with single-side raised treatment (density: 74 wells / 92 courses / in, front; nylon 70 denier / 52 filament, Back: Polyurethane (30 denier) for the purpose of imparting passability and dimensional stability during processing, a rayon woven fabric (number of drives 90 / in) as a reinforcing fabric, acrylic / vinyl acetate on the surface opposite to the raised surface A composite material laminated with a system emulsion resin as a binder was used as a base fabric (hereinafter referred to as “base fabric C”).

  As a pretreatment for coating, the base fabric C was immersed in water, and the mangle was adjusted so that 80 to 90% of water adhered to the weight of the base fabric C.

The circular knitted fabric surface is coated with the solution 1 at a coating amount of 800 g / m ^{2 on} the pretreated base fabric with a knife over roll coater, and immersed in a bath containing an aqueous solution containing 10% by mass of DMF at 30 ° C. for 10 minutes. Then, the polyurethane resin compounded liquid was precipitated and solidified, and then immersed and washed in hot water at 80 ° C. for 30 minutes and dried with hot air at 120 ° C. to obtain an intermediate.

  Next, the embossed pore-shaped irregularities by embossing were provided on the resin-coated surface. For the embossing, a concave and convex mold roller was used. A synthetic leather provided with irregularities was obtained by heat compression with a mold roll heated to 150 ° C.

  In order to make the length in the width direction constant with the reinforcing cloth attached to the rayon woven fabric, dry heat setting was performed to obtain a laminate of synthetic leather and reinforcing fabric.

  Table 1 shows the evaluation results of the stretchable synthetic leather obtained by peeling the reinforcing fabric from the obtained laminate.

  Moreover, this laminated body was cut into the shape of each member of a glove which is a target sewing product, and after the reinforcing fabric was peeled from the laminated body, each member was sewn to produce a sewing product. Table 1 shows the presence or absence of distortion of the sewing product.

[Comparative Example 1]
Base fabric A was used as the base fabric.

  As a pretreatment for coating, the base fabric A was immersed in water, and the mangle was adjusted so that 80 to 90% of water adhered to the weight of the base fabric A.

The surface of the circular knitted fabric is coated on the surface of the circular knitted fabric with a coating amount of 800 g / m ^{2 on} a pre-treated base fabric with a knife over roll coater, and 10% in a 30 ° C. bath using an aqueous solution containing 10% by mass of DMF as a coagulation bath. The polyurethane resin compounded solution was precipitated and solidified by dipping for 30 minutes, then immersed and washed in hot water at 80 ° C. for 30 minutes, and dried with hot air at 120 ° C. to obtain an intermediate.
Next, the embossed pores were provided on the resin-coated surface. For the embossing, a concave and convex mold roller was used. A synthetic leather provided with irregularities was obtained by heat compression with a mold roll heated to 150 ° C.

  The rayon woven fabric used as the reinforcing fabric was peeled off by a dedicated machine, wound up, and then subjected to dry heat setting to make the length in the width direction constant, thereby obtaining a synthetic leather. Table 1 shows the evaluation results of the obtained synthetic leather.

  Although this synthetic leather was cut into the shape of each member of a glove, which is a sewing product for the purpose, and each member was sewn to produce a sewing product, a stable form could not be maintained.

[Comparative Example 2]
Base fabric B was used as the base fabric.

  As a pretreatment for coating, the base fabric B was immersed in water, and the mangle was adjusted so that 80 to 90% of water adhered to the weight of the base fabric B.

The surface of the circular knitted fabric is coated on the surface of the circular knitted fabric with a coating amount of 800 g / m ^{2 on} a pre-treated base fabric with a knife over roll coater, and 10% in a 30 ° C. bath using an aqueous solution containing 10% by mass of DMF as a coagulation bath. The polyurethane resin compounded solution was precipitated and solidified by dipping for 30 minutes, then immersed and washed in hot water at 80 ° C. for 30 minutes, and dried with hot air at 120 ° C. to obtain an intermediate.

  Next, the embossed pores were provided on the resin-coated surface. For the embossing, a concave and convex mold roller was used. A synthetic leather provided with irregularities was obtained by heat compression with a mold roll heated to 150 ° C.

  The rayon woven fabric used as the reinforcing fabric was peeled off by a dedicated machine, wound up, and then subjected to dry heat setting to make the length in the width direction constant, thereby obtaining a synthetic leather. Table 1 shows the evaluation results of the obtained synthetic leather.

  Although this synthetic leather was cut into the shape of each member of a glove, which is a sewing product for the purpose, and each member was sewn to produce a sewing product, a stable form could not be maintained.

[Comparative Example 3]
Base fabric C was used as the base fabric.

  As a pretreatment for coating, the base fabric C was immersed in water, and the mangle was adjusted so that 80 to 90% of water adhered to the weight of the base fabric C.

The surface of the circular knitted fabric is coated on the surface of the circular knitted fabric with a coating amount of 800 g / m ^{2 on} a pre-treated base fabric with a knife over roll coater, and 10% in a 30 ° C. bath using an aqueous solution containing 10% by mass of DMF as a coagulation bath. The polyurethane resin compounded solution was precipitated and solidified by dipping for 30 minutes, then immersed and washed in hot water at 80 ° C. for 30 minutes, and dried with hot air at 120 ° C. to obtain an intermediate.
Next, the embossed pores were provided on the resin-coated surface. For the embossing, a concave and convex mold roller was used. A synthetic leather provided with irregularities was obtained by heat compression with a mold roll heated to 150 ° C.

  The rayon woven fabric used as the reinforcing fabric was peeled off by a dedicated machine, wound up, and then subjected to dry heat setting to make the length in the width direction constant, thereby obtaining a synthetic leather. Table 1 shows the evaluation results of the obtained synthetic leather.

  Although this synthetic leather was cut into the shape of each member of a glove, which is a sewing product for the purpose, and each member was sewn to produce a sewing product, a stable form could not be maintained.

The synthetic leather of the present invention can be used for sports gloves such as golf and baseball, and supporters that support joints of elbows and knees.

Claims (7)

After the laminate of the stretch synthetic leather having a base fabric and one or more resin layers and the reinforcing fabric is cut into various shapes of members of the target sewing product, and the reinforcing fabric is peeled from the laminate, A method for producing a sewn product having a stretchable synthetic leather, which sews stretchable synthetic leather of various shapes. The method for manufacturing a sewn product according to claim 1, wherein the sewn product is a glove. The manufacturing method of the sewing product of Claim 1 or 2 whose base fabric of the said elastic synthetic leather is a base fabric containing a polyurethane fiber. The manufacturing method of the sewn product in any one of Claims 1-3 whose constant load elongation of the said elastic synthetic leather is 30 to 150% of each length and width. The method for manufacturing a sewn product according to any one of claims 1 to 4, wherein the stretch recovery rate of the stretchable synthetic leather is 80% or more in each of length and width. The method for manufacturing a sewn product according to any one of claims 1 to 5, wherein an adhesive strength between the base fabric of the stretchable synthetic leather and the reinforcing fabric is 0.1 to 2.0 N / cm. The sewing product obtained by the manufacturing method of Claims 1-6.