JP4385199B2 - Artificial leather and vehicle chair upholstery - Google Patents

Description

  The present invention relates to an artificial leather obtained by impregnating a raised fabric with an elastic elastomer.

A raw fabric made of sea-island composite fibers composed of sea-component polymers and island-component polymers is treated with a solution in which the sea-component polymers can be dissolved, and the sea-component polymers are dissolved and removed to form sea-island composite fibers into island-component polymers. It is known to make ultrafine multifilaments, brushed, impregnated with elastic elastomer to give artificial leather, and the elastic elastomer to be given is polyurethane elastomer, acrylonitrile butadiene rubber, butadiene rubber, natural rubber, polychlorinated Vinyl, polyamide, etc. are used, and the raw fabric is prepared as a nonwoven fabric with needle punching on a sea-island composite fiber web, or the web is needle punched into a woven fabric or knitted fabric (for example, a nonwoven fabric with an interlining) (for example, , See Patent Document 1).
Japanese Patent No. 3430852 (Japanese Patent Laid-Open No. 10-280283)

  As for the raising treatment of the fabric, Japanese Patent No. 3435957 (Japanese Patent Laid-Open No. 9-217265), Japanese Patent No. 3244173 (Japanese Patent Laid-Open No. 2000-34617), Japanese Patent No. 3300955 (Japanese Patent Laid-Open No. 11-21760), As described in Japanese Patent No. 3200373 (Japanese Patent Laid-Open No. 11-110376), Japanese Patent No. 2646635 (Japanese Patent Laid-Open No. 1-250463), Japanese Patent Publication No. 62-56261 (Japanese Patent Laid-Open No. 56-123467) The cloth or sandpaper is wound around the peripheral surface, and the cloth is passed through a rotating raising roll.

  Artificial leather raw fabrics include Japanese Patent No. 3410577 (Japanese Patent Laid-Open No. 8-246357), Japanese Patent No. 3280302 (Japanese Patent Laid-Open No. 11-269975), Japanese Patent No. 3155135 (Japanese Patent Laid-Open No. 7-126986), Japanese Patent No. 3128375 (Japanese Patent Laid-Open No. 6-240584), Japanese Patent No. 3128333 (Japanese Patent Laid-Open No. 5-339864), Japanese Patent No. 3126566 (Japanese Patent Laid-Open No. 7-126985), Japanese Patent No. 3109793 (Japanese Patent Laid-Open No. 7). No. 173778), Japanese Patent No. 3109764 (Japanese Unexamined Patent Publication No. 5-279965), Japanese Patent No. 3109761 (Japanese Unexamined Patent Publication No. Hei 5-272669), Japanese Patent No. 3090749 (Japanese Unexamined Patent Publication No. Hei 5-156579), Japanese Patent No. No. 3043131 (Japanese Patent Laid-Open No. 5-51881), Japanese Patent No. 3008414 (Japanese Patent Laid-Open No. 5-51881) No. 137281), Japanese Patent Publication No. 6-55999 (Japanese Patent Laid-Open No. Sho 62-62991), Japanese Patent Publication No. 6-2984 (Japanese Patent Publication No. Sho 61-207664), Nonwoven fabrics that are easy to do are widely used.

Raising treatment can also be applied to the surface of the fabric, and most of the fluffed fluff is composed of weft fibers of the fabric perpendicular to the direction of rotation of the raising roll (for example, see Patent Document 2).
Artificial leather made by impregnating and applying a polyurethane resin emulsion as a raw fabric of a woven fabric and a raised fabric is known, and the raw fabric is woven by a double satin double-sided weft double woven structure and has a warp density of 150. The main yarn / 吋, the weft density is 224 / 吋, or the warp density is 147 / 吋, the weft density is 192 / 吋, and the polyester false twist bulky processed yarn (82.5 dtex / 36f) is used as the warp. The weft yarn is a polyester filament yarn (121.1 dtex / 366f or 60.5 dtex / 196f) which has a single fiber fineness and is easy to be raised as compared with the warp, and the weft density is higher than the warp density. The base fabric is made dense and easily raised, for example (see Patent Document 3).
Japanese Examined Patent Publication No. 3-73662 (column 4, lines 28 and 36-37, column 10, lines 24-32, FIGS. 1 and 2) Japanese Patent Publication No. 7-72393 (Japanese Patent Laid-Open No. 63-135570, Examples 1 and 2)

  Artificial leather (for example, refer to Patent Document 1) using a nonwoven fabric made of a fiber web as a base fabric is easy to stretch and lacks shape retention, and is liable to sag.

  Artificial leather made of a non-woven fabric with a cored fabric that is needle punched by layering the fiber web on the base fabric lacks stretchability (elastic expansion and contraction), while retaining its shape. Since it has a multi-layer structure, it is hard and difficult to sew, and it is difficult to ensure the quality required for the vehicle chair upholstery in terms of feel and sitting comfort.

  In artificial leather made of woven fabric (for example, see Patent Document 3), shape retention is ensured in the same manner as artificial leather made of nonwoven fabric with interlining. When raised fluffs are generated and the hair is raised strongly, the strength is reduced, and the fluffed fluff that is scraped out becomes too long and thick as a whole. is there.

  And in the conventional artificial leather to which polyurethane resin is applied as an elastic elastomer to be impregnated, it is difficult to ensure high light resistance that is strongly required for vehicle chair upholstery.

  Therefore, the present invention has an object of obtaining artificial leather that is excellent in shape retention, stretchability, light resistance, soft touch, thin and breathable, easy to sew, and particularly suitable for vehicle chair upholstery. .

The present invention relates to (a) artificial leather formed by impregnating a raised fabric with an elastic elastomer, (b) the raised fabric is obtained by raising the surface of a woven fabric, and (c) the warp of the woven fabric is made of polyester. A polyester-based ultrafine multifilament mixed yarn using a polyester-based heat-shrinkable multifilament and a polyester-based ultrafine multifilament of 0.05 to 0.40 dtex whose single fiber fineness is smaller than that of the polyester-based heat-shrinkable multifilament, Polyester-based crimped multifilament yarn is applied to the weft, and (d) the warp surface area occupied ratio in the woven structure appearing in a unit area (1 mm ² ) of 1 mm each of the weft of the raised surface is 0.75. -0.92 (75-92%), (e) The warp density is 5-12 / mm, (f) Impregnation of elastic elastomer Is polished after it is given by the first feature that the brushed surface is fluffed.

  The second feature of the present invention is that, in addition to the first feature, (g) a silicone elastomer is impregnated as an elastic elastomer.

  A third feature of the present invention is that, in addition to any of the first and second features, (b1) the woven structure on the raised surface of the woven fabric constituting the raised fabric is a five-ply satin weave texture. is there.

  The fourth feature of the present invention is that, in addition to any of the first and second features, (b2) the woven fabric constituting the raised fabric is a double woven fabric.

  According to a fifth feature of the present invention, in addition to any of the first and second features described above, (b3) the woven structure of the woven fabric constituting the raised fabric is a double woven structure, and the surface woven structure on the raised surface Is in the point that it is made from 5 to 8 sheets.

  The sixth feature of the present invention is that, in addition to any of the first, second, third, fourth and fifth features, (c1) the ultrafine multifilament is composed of a sea component polymer and an island component polymer. The sea-island type composite fiber is formed, and after weaving, the sea component polymer is dissolved and removed, and is made into ultrafine filaments having a single fiber fineness of 0.05 to 0.40 dtex.

According to a seventh aspect of the present invention, in addition to any of the first, second, third, fourth, fifth and sixth characteristics, (h) before and after impregnation of the elastic elastomer (before or after) In addition, the raised surface is embossed, the depth of the recess formed by the embossed treatment is 0.3 mm or more, and the unit area of the background of the embossed raised surface is 1 cm each. In (1 cm ² ), the area occupation ratio occupied by the recesses is 0.1 to 0.3 (10 to 30%).

  The eighth feature of the present invention is that, in addition to any of the first, second, third, fourth, fifth, sixth and seventh features, (i) an elastic yarn is mixed with the warp. There is in point.

  According to a ninth feature of the present invention, in addition to any of the first, second, third, fourth, fifth, sixth, seventh and eighth features, (j) a conductive yarn is used for the weft. It is in the point where it is mixed.

  A vehicle chair upholstery according to the present invention is provided on the back surface of artificial leather having any of the first, second, third, fourth, fifth, sixth, seventh, eighth, and ninth features. A lining process is performed.

In the present invention, the “occupied area ratio of warp yarn in a woven structure appearing in a unit area (1 mm ² ) each having a background of a raised surface of 1 mm ² ” is a woven fabric or a raised fabric, It does not mean the area occupancy ratio of the warp woven fabric, the raised fabric, or the artificial leather that appears on the entire surface of the artificial leather. It means the ratio of the area of the warp structure point displayed by the eyes to the total area of the woven structure diagram (drawing).
Specifically, the exposed area occupancy ratio of the warp is 50%, the exposed area occupancy ratio of the warp in the plain weave structure is 67%, and the exposed area occupancy ratio of the warp in the 2/1 twill structure is 67%. The warp surface area occupancy ratio of the structure and four-ply warp satin weave structure is 75%, the warp surface area occupancy ratio of the five-ply warp satin weave structure is 80%, and the warp display of the eight-ply warp satin weave structure The area occupancy ratio is 85%, and the exposed area occupancy ratio of the twelve warp satin weave is 92%.
Therefore, in a narrow sense, the “occupied area ratio of warp display area” means that the woven fabric of the artificial leather of the present invention is divided into four woven fabrics from twelve warp woven fabrics to twelve warp woven fabrics. It means that it is a series of sutra textures.
Therefore, to say that the exposed area occupation ratio of the warp is 0.75 to 0.92 (75 to 92%), specifically, the weft is almost exposed on the surface of the woven fabric, the raised fabric or the artificial leather. It can also be said that it means not.

As described above, the weft 11 is hardly exposed on the raised surface of the woven fabric of the present invention, and the warp yarn 12 constituting the raised surface is made of short fibers and is not a spun yarn that is easily fluffed. Since it is a multifilament yarn and the length direction of the warp 12 and the direction of rotation of the raising roll are parallel, the raising surface is difficult to fluff in the raising treatment.
However, in the present invention, the warp density is 5 to 12 yarns / mm, which is extremely dense, and the exposed area occupation ratio of the warp per 1 mm ^{2 of} the raised surface is 0.75 to 0.92. Almost all the warp yarns 12 occupy ultrafine filaments having a single fiber fineness of 0.05 to 0.40 dtex, the boundary 13 between the adjacent warp yarns 12 and the warp yarns 12 is hardly noticeable, and it is difficult to fluff by raising. The warp yarn 12 swells in bulk and, in addition, due to the shrinkage difference from the heat-shrinkable multifilament mixed together with the ultrafine filament, the ultrafine filament is raised on the raised surface. When mixed, the ultrafine filament tends to rise, and a portion thereof is shaved off to give a fluffy view, and the raised surface becomes nubuck.
In particular, when polishing after impregnation of the elastic elastomer, the ultrafine filaments wrapped and reinforced by the elastic elastomer are raised on the raised surface, so that the elastic elastomer film surrounding the ultrafine filaments is broken and Since the filament is cut and the cut surface 14 becomes fuzzy, the elastic elastomer film cracks and the moisture permeability of the raw fabric is regained. At the same time, the elastic elastomer gives wet feeling and stretchability. , Artificial leather with shape retention as a raw fabric is obtained, and by applying a silicone elastomer as an elastic elastomer, it has a slimy feeling, excellent light resistance, water repellency and antifouling properties (soil release), and anti-melting It has the characteristics (cigarette fire resistance) and becomes an artificial leather suitable for vehicle chair upholstery.

In the present invention, the raised fluff is not scraped out for a long time by the raising process, but the raised ultrafine multifilaments are raised according to the shrinkage difference from the heat-shrinkable multifilament, so that the fluffy feel is brought about. In the subsequent polishing process, the ultrafine filaments are cut to finish the raised surface with a fluffy texture, so that no thick raised fluff layer is formed on the raised surface.
Therefore, in the present invention, the surface unevenness by the embossing process gives a sense of thickness, but the unevenness increases the specific surface area of the artificial leather (area that touches the outside air), and the concave portion exhibits a moisture retention function, Since the thickness of the artificial leather is thin at the bottom of the recess (valley bottom), it increases moisture permeability and flexibility, is excellent in shape retention, stretchability, light resistance, soft touch, thin and moisture permeable, Artificial leather that is easy to sew and that is particularly suitable for vehicle chair upholstery can be obtained.

According to the present invention, the weft 11 is not exposed on the raised surface of the raw fabric, and therefore the weft 11 is not damaged by the raising process, and the weft acts on the warp during the weaving process. Strong tension does not work.
For this reason, even if a conductive yarn is applied to the weft, the electrical continuity in which the conductive yarn can be energized is maintained in the weaving process and the raising process, and the aesthetic appearance (coloring) of the raised surface is not impaired by the conductive yarn. Antistatic artificial leather suitable for the material can be obtained.

In the present invention, a warp is mixed with a polyester-based heat-shrinkable multifilament and a polyester-based ultrafine multifilament having a fineness of 0.05 to 0.40 dtex, which is smaller than that of the polyester-based heat-shrinkable multifilament (mixed fiber and / or Or, twisted polyester-based ultra-fine multifilament mixed yarn is to make the ultra-fine multifilament bulge due to the shrinkage difference from the heat-shrinkable multifilament, as described above, and to make it easily bulky in the raising process. .
For that purpose, a polyester-based heat shrinkage in which the heat shrinkage rate in boiling water is at least 10%, preferably 15% or more, more preferably 20% or more, so that the shrinkage difference with the ultrafine multifilament is 8% or more. The heat-shrinkable multifilament is mixed with the warp yarn, the mixing ratio of the heat-shrinkable multifilament and the ultrafine multifilament is set to the latter 2-5, the latter 8-5, that is, the heat-shrinkable multifilament mixing ratio is 20- 50 mass%, preferably 25 to 40 mass%, and generally about 28 mass%, to increase the mixing ratio of ultrafine multifilaments that will constitute the fluff cut in the polishing process.
The mixing of the elastic yarn with the warp is also for the same reason as the mixing of the heat-shrinkable multifilament, and the mixing ratio is preferably 5 to 25% by mass, generally about 10% by mass.
Polyester ultra-fine multifilament mixed yarn used for warp is a polyester ultra-fine multifilament mixed filament made by twisting polyester heat-shrinkable multifilament and 0.055-0.22 dtex polyester ultrafine multifilament. A twisted yarn is recommended.

In the present invention, the unit area for setting the exposed area occupation ratio of the warp is 1 mm ² and the exposed area occupation ratio of the warp is 0.75 to 0.92. This is because the long raised fluff is not formed, but it is raised finely and uniformly to give the appearance of a raised fabric.
In order to make the raised surface densely covered with such fine multifilaments that are raised and opened, the warp cover factor calculated as K = (total denier of warp) × (warp density) ^1/2 (K) The total fineness and warp density of the warp are set so that the warp density is set as the number of warps per inch (w / w) is 1200 to 5000, preferably 2400 to 4500. Good.
The weft density is preferably 1.9 to 7.9 yarns / mm.
When the base fabric is made of a double weave, the back weave may be a satin weave having a larger number than the front.

The application of ultra-fine multifilament yarn as sea-island type composite fiber composed of sea component polymer and island component polymer is such that the shape of ultra-fine multifilament is maintained without being damaged by sea component polymer during the weaving process. It is to make it.
In the warp yarn from which the sea component polymer has been dissolved and removed, the ultrafine filaments of the ultrafine multifilament are in close contact.
The raising process is performed in order to release the ultrafine filaments from the close contact state and open the ultrafine multifilaments in a bulky manner, and the raising process is performed along the boundary 13 between the adjacent warps 12 and the warps 12. It only needs to be light enough to remove the texture of the tissue.
Thus, in the present invention, it is sufficient to lightly raise the nap, and the length direction of the warp 12 and the rotation direction of the nap roll are parallel, and the warp density is 5.9 to 11.8 / mm. In general, when the exposed area occupation ratio of the warp per unit area (1 mm ² ) is 5 to 12 yarns / mm and is 0.75 to 0.92, in a plain weave (single woven) or multi-woven surface weave structure The weft density is 5.9 to 11.8 strands / mm, which is equivalent to the warp density, and generally 5 to 12 strands / mm, and the length of the warp that emerges between the binding points is less than about 1 mm. Although the raised warp 12 (ultrafine filament) is scraped up by the raising roll and is hardly broken, and the weft 11 (heat-shrinkable multi-filament) can be said to be long in the direction perpendicular to the rotation direction of the raising roll. Filament) is almost exposed on the raised surface Because no, not almost damaged from brushed roll.
Thus, since the weft 11 and the warp 12 are hardly damaged by the raising process, the artificial leather of the present invention is excellent in strength and suitable for a vehicle chair upholstery.

When forming a concave portion by embossing on the brushed surface in a linear shape, the minimum dimension between the adjacent linear concave portions, that is, the width of the convex portion that can be formed between the adjacent linear concave portion and the linear concave portion Is 3 mm or less, preferably 1 mm or less.
When the raised surface is embossed with a recess (dot), the size (area) of the recess (dot) is 1 mm ² or less, and the adjacent recess (dot) mold and recess (dot) mold The minimum dimension in between is set to 3 mm or less, preferably 1 mm or less.
The elastic elastomer impregnated and imparted to the raised fabric may be an emulsion type or an organic solvent solution type.
In impregnation applied amount of elastic elastomer impregnated applied to napped fabric (dry weight) is, 60 g / m ² or less, in particular, if not subjected to embossing treatment is 10 to 30 g / m ² (generally 25 g / m ² front and back) However, when embossing is performed, the amount is preferably 20 g / m ² or more (20 to 60 g / m ² ).
Artificial leather backing processing for application to a vehicle chair upholstery is performed by applying a backing agent (backing adhesive) to the back surface. In the backing processing, the back surface may be raised in advance.
In that case, the back side is covered with wefts on the opposite side to the raised surface, so it is easy to fluff, and the raised fluffs are intertwined, so the amount of backing agent applied is small, and the artificial leather has flexibility and breathability. Kept.

Example 1
75 dtex / 50f / 17 split polyester sea-island composite multifilament, 75 dtex / 12f polyester high heat shrinkable multifilament (heat shrinkage in boiling water 20%) and 20 dtex / 1f polyurethane elastic yarn are mixed by air cover method and twisted The actual twisted yarn is used as warp yarn 12, 100 dtex / 2 × 36f polyester high crimped false twisted yarn 12a as front weft yarn, 100 dtex / 2 × 36f polyester high crimped false twisted yarn 11b and 150 dtex / 30f polyester medium crimped temporary A conductive weft yarn 11c obtained by twisting a twisted yarn and a 20 dtex / 6f conductive yarn is used as a back weft, and in a woven fabric structure (FIG. 2-b), a 150 dtex / 30f polyester crimped false twisted yarn 11b and a conductive twisted yarn 11c are used. Fig. 2 which is woven by driving the former four at the ratio of the latter one The weft double weave of the five-ply warp weave weave shown in Fig. 1 is subjected to alkali weight reduction treatment to divide the sea-island composite multifilament into 17 ultrafine multifilaments, and polyester high heat shrinkable multifilaments (warp 12 ) Is thermally shrunk, impregnated with 30 g / m ² (dry mass) of silicone elastomer (organic solvent solution type), and the polished surface is polished to give a warp density of 6.7 yarns / mm and a weft density of 7. 1 piece / mm of artificial leather was obtained.
In FIG. 2, (a) is a five-sheet warp weave texture chart of a weft double woven fabric, (b) is a five-sheet warp satin texture chart of a weft double woven fabric, and (c) is ten sheets of a weft double woven fabric. Shows the organization chart of suzuki lining.

(Example 2)
75dtex / 50f · 17 split type polyester sea-island composite multifilament and 30 dtex / 12f polyester high heat shrinkable multifilament (heat shrinkage rate in boiling water 20%) are interlaced and twisted, and the actual twisted yarn is used as warp 12. 100 dtex / 2 × 36f polyester high crimped false twisted yarn 12a is used as a front weft, 100dtex / 2 × 36f polyester high crimped false twisted yarn 11b and 150 dtex / 30f polyester medium crimped false twisted yarn and 20 dtex / 6f conductive Conductive plied yarn 11c obtained by twisting the yarn is used as the back weft, and in the woven fabric structure (FIG. 2-b), 150 dtex / 30f polyester medium crimped false twisted yarn 11b and conductive plied yarn 11c are used for the former four. Weft double weave of five-ply satin weave texture (Fig. 2-a) The material is subjected to alkali weight loss treatment, and the sea-island composite multifilament is divided into 17 ultrafine multifilaments. In the heating process after dyeing, the polyester high heat-shrinkable multifilament (warp 12) is heat-shrinked to produce a silicone elastomer (organic solvent). Solution type) was impregnated with 30 g / m ² (dry mass), and the raised surface was polished to obtain an artificial leather having a warp density of 6.7 yarns / mm and a weft density of 7.1 yarns / mm.

It is a perspective view of the artificial leather which concerns on this invention. It is a woven organization chart of artificial leather concerning the example of the present invention.

Explanation of symbols

11: Weft 12: Warp 13: Boundary 14: Cutting surface

Claims (10)

(A) In artificial leather formed by impregnating a raised fabric with an elastic elastomer,
(B) A raised fabric is obtained by raising a surface of a woven fabric,
(C) For the warp of the woven fabric, a polyester-based heat-shrinkable multifilament and a polyester-based ultrafine multifilament with a single fiber fineness of 0.05 to 0.40 dtex, which is finer than the polyester-based heat-shrinkable multifilament, were mixed. Polyester-based ultra-fine multifilament mixed yarn is applied, and weft yarn is applied with polyester-based crimped multifilament yarn,
(D) The exposed area occupation ratio of the warp in the woven structure appearing in the unit area (1 mm ² ) of 1 mm each of the background of the raised surface is 0.75 to 0.92 (75 to 92%),
(E) The warp density is 5 to 12 yarns / mm,
(F) Artificial leather with a raised surface that is polished after impregnation with an elastic elastomer. (G) The artificial leather according to claim 1, wherein a silicone elastomer is impregnated as an elastic elastomer. (B1) The artificial leather according to any one of claims 1 and 2, wherein the woven structure on the raised surface of the woven fabric constituting the raised fabric is a five-ply warp woven structure. (B2) The artificial leather according to any one of claims 1 and 2, wherein the woven structure of the raised fabric is a double woven structure. (B3) The artificial structure according to any one of claims 1 and 2, wherein the woven structure of the woven fabric constituting the raised fabric is a double woven structure, and the surface woven structure on the raised surface is a five to eight-ply warp woven structure. leather. (C1) The ultra-fine multifilament is a sea-island type composite fiber composed of a sea component polymer and an island component polymer, and the sea component polymer is dissolved and removed after weaving to make an ultrafine filament with a single fiber fineness of 0.05 to 0.40 dtex. The artificial leather according to any one of claims 1, 2, 3, 4, and 5, wherein (H) Before and after impregnation of the elastic elastomer (before or after), the raised surface is embossed, and the depth of the recess formed by the embossing is 0.3 mm or more. Claims 1, 2, 3, wherein the area occupancy of the recesses is 0.1 to 0.3 (10 to 30%) in a unit area (1 cm ² ) of 1 cm each of the background of the raised surface The artificial leather according to any one of 4, 5, and 6. (I) The artificial leather according to any one of claims 1, 2, 3, 4, 5, 6, and 7, wherein an elastic yarn is mixed with the warp. (J) The artificial leather according to any one of claims 1, 2, 3, 4, 5, 6, 7, and 8, wherein a conductive yarn is mixed with the weft. (K) A vehicle chair upholstery fabric obtained by performing a backing treatment on the back surface of the artificial leather according to any one of claims 1, 2, 3, 4, 5, 6, 7, 8, and 9.

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