JP5901468B2 - Elastic flame retardant artificial leather - Google Patents

Description

  The present invention relates to a stretchable flame retardant artificial leather that has flame retardancy, has an appropriate stretchability in the vertical direction, has a feeling of non-elongation, and is excellent in flexibility, molding processability, and wearing feeling. Is.

  Since leather-like sheets such as artificial leather have flexibility and functionality not found in natural leather, they are used in various applications such as clothing and materials. Stretchability has attracted attention as an important function from the viewpoints of wearing feeling in clothing, molding processability in materials, and ease of sewing and tailoring.

  From the above background, various leather-like sheets having elasticity have been studied. For example, an elastic sheet obtained by stretching 15% or more in the vertical and / or horizontal direction on an artificial leather base mainly composed of a fiber entangled body including ultrafine fibers having a single fiber fineness of 0.9 dtex or less and a polymer elastic body Has been proposed, a method for producing artificial leather excellent in elasticity, characterized in that the artificial leather is contracted by relaxing the extension of the elastic sheet and then the elastic sheet is removed (for example, Patent Document 1). However, in this method, when the artificial leather substrate is contracted, the artificial leather substrate may be curled on the elastic sheet side. Further, since the artificial leather substrate is contracted only by the contraction force of the elastic sheet, it is difficult to forcibly contract the high-density artificial leather substrate with a high contraction rate. Furthermore, the use of adhesives degrades the quality of the artificial leather surface.

  Therefore, a manufacturing method that does not use an elastic sheet has been proposed. For example, Patent Document 2 discloses that an artificial leather mainly composed of a fiber entangled body mainly containing ultrafine fibers having a single yarn fineness of 1.1 dtex or less and a polyurethane resin, after applying a softener to the artificial leather, A method for producing artificial leather excellent in stretchability in the width direction is disclosed, wherein the agent is applied and simultaneously stretched in the length direction and contracted in the width direction in a heated state. However, since it elongates in the length direction, spotted spots and thickness spots of artificial leather are promoted. Moreover, since it extended | stretched by providing a softening agent, when it used as a suede-like artificial leather, the surface uniformity and abrasion resistance were inadequate. Furthermore, the proposed manufacturing method is intended to improve the extensibility of the artificial leather in the width direction, and since it extends in the length direction in the heated state, the length of the obtained artificial leather The extensibility in the direction is low, and therefore, the artificial leather in Patent Document 2 has no improvement in the extensibility in the vertical direction.

  A method in which the fabric is forcibly compressed in the vertical direction using a shrinkage processing apparatus having a configuration in which the endless rubber belt runs while contacting a part of the peripheral surface of the thermal cylinder roll, thereby forming a wrinkle on a part of the fabric, or A method for softening a high-density fabric has been proposed (Patent Documents 3 and 4). However, Patent Documents 3 and 4 do not describe anything about artificial leather having an entangled body of ultrafine fibers, and do not disclose anything about artificial leather with improved vertical stretchability.

  As described above, the above-mentioned prior art documents do not disclose a base material for artificial leather that has improved the stretchability and stretchability in the vertical direction while increasing the density and improving the mechanical properties.

  Further, when the flame retardant fine particles are applied to the base material for artificial leather disclosed in the prior art document using a binder resin represented by a polymer elastic body, a large amount for preventing the fine particles from falling off. With this binder resin, there was a problem that the fiber structure was excessively restrained and the extensibility and stretchability were remarkably lowered. And it became possible to provide the artificial leather which has the elasticity and the flame retardance by utilizing the invention of Patent Document 5 filed by the present applicant.

JP 2004-197282 A Japanese Patent Laying-Open No. 2005-0761151 Japanese Patent Laid-Open No. 5-44153 JP 9-31832 A Japanese Patent Application No. 2012-059384

  The present invention provides a stretchable flame retardant artificial leather that has flame retardancy, has moderate stretchability in the vertical direction, has high density and good mechanical properties, and has a moderate feeling of elongation. For the purpose.

This invention solves the said subject with the stretchable flame-retardant artificial leather which has the following structures. That is, the stretchable flame retardant artificial leather of the present invention is a stretchable flame retardant artificial leather containing a polymer elastic body and flame retardant fine particles in a fiber entanglement made of ultrafine fibers having an average single fiber fineness of 0.9 dtex or less. In addition, the apparent density is 0.40 g / cm ³ or more, and in the cross section parallel to both the thickness direction and the vertical direction, a micro waviness structure composed of ultrafine fibers is provided in the vertical direction. The number of pitches present in 1 mm in the vertical direction is 2.2 or more, and the average height of the undulation structure is 50 to 350 μm.

  In a preferred embodiment of the present invention, the flame retardant fine particles have an average particle size of 10 μm or less, are flame retardants made of a metal salt of dialkylphosphinic acid, and the polymer elastic body is a solidified product of polyurethane water-based emulsion. is there. The ultrafine fiber is preferably an inelastic fiber, and is preferably a polyester fiber. The micro waviness structure is preferably formed by shrinking in the vertical direction and heat setting.

  The stretchable flame-retardant artificial leather of the present invention has a high apparent density and a predetermined waviness structure, while containing flame-retardant fine particles, it has moderate stretchability in the vertical direction and good mechanical properties. It can also give a moderate feeling of elongation stoppage.

It is the schematic which shows an example of the shrinkage processing apparatus for enforcing the manufacturing method of this invention. It is the schematic which shows the other example of the shrinkage processing apparatus for enforcing the manufacturing method of this invention. It is a figure which shows the load elongation curve of the elastic | stretch flame-retardant artificial leather obtained in Example 1, and the non-shrink processed artificial leather of Comparative Example 1. It is a scanning electron micrograph of the cross section parallel to the thickness direction and the length direction of the stretchable flame-retardant artificial leather obtained in Example 1. FIG. 5 is a scanning electron micrograph of a cross section parallel to the thickness direction and the vertical direction of the stretchable flame-retardant artificial leather obtained in Example 1, and showing the magnification larger than that in FIG. 4. 4 is a scanning electron micrograph of a cross section parallel to the thickness direction and the vertical direction of the unshrink-processed artificial leather of Comparative Example 1. FIG. 7 is a scanning electron micrograph of a cross section parallel to the thickness direction and the vertical direction of the non-shrink-processed artificial leather of Comparative Example 1, which is a photograph showing the magnification larger than that in FIG. 6. It is the schematic for demonstrating the measuring method of 5% circular modulus.

The stretchable flame retardant artificial leather of the present invention is a stretchable flame retardant artificial leather containing a polymer elastic body and flame retardant fine particles in a fiber entanglement made of ultrafine fibers, and has an apparent density of 0.40 g / cm. with a ³ or higher, as shown in FIGS. 4 and 5, in both cross section parallel to the thickness direction and longitudinal direction, and has a micro waveform structure composed of ultrafine fibers along the longitudinal direction. The stretchable flame-retardant artificial leather of the present invention has a good mechanical property while having an appropriate stretchability and a feeling of non-elongation in the vertical direction due to a high apparent density and a micro waviness structure.

  The elastic flame retardant artificial leather of the present invention will be described in detail later. By artificially shrinking the base body for artificial leather, that is, the artificial leather before mechanical shrinkage processing in the vertical direction, and heat setting in the contracted state. As a result, a micro waviness structure is formed along the vertical direction by mechanical shrinkage, and the micro waviness structure is maintained by heat setting.

Hereinafter, the present invention will be described in more detail.
[Ultra fine fiber]
The average single fiber fineness of the ultrafine fibers constituting the fiber entangled body in the stretchable flame retardant artificial leather is preferably 0.9 dtex or less, more preferably 0.0001 to 0.9 dtex, more preferably 0.0001 to 0. .5 dtex, particularly preferably 0.005 to 0.3 dtex. If the average single fiber fineness is less than 0.0001 dtex, the strength of the stretchable flame-retardant artificial leather may be lowered. If the average single fiber fineness exceeds 0.9 dtex, the texture of the stretchable flame retardant artificial leather becomes stiff, and the fiber entanglement becomes insufficient, resulting in a decrease in the surface quality of the stretchable flame retardant artificial leather. Or problems such as reduced wear resistance may occur.
In addition, a limited amount of fibers having a single fiber fineness of less than 0.0001 dtex or fibers having a single fiber fineness of more than 0.9 dtex may be included as long as the effects of the present invention are not impaired. The content of fibers having a single fiber fineness of less than 0.0001 dtex and fibers having a single fiber fineness of more than 0.9 dtex is preferably 30% or less (several standards) of the total fibers constituting the elastic flame-retardant artificial leather, 10% or less (number basis) is more preferable, and it is further preferable that it is not included at all.

  In addition, when the ultrafine fiber is obtained from, for example, an ultrathinnable fiber as described in detail below and is entangled in a fiber bundle state to form a fiber entanglement, the fineness of the fiber bundle of the ultrafine fiber is preferably 1 0.0 to 4.0 dtex, and the number of ultrafine fibers in one fiber bundle is preferably 9 to 500. Within the above range, the appearance of the artificial leather substrate or the suede-like artificial leather obtained from the substrate and the balance between color development and wear resistance are good.

  The ultrafine fibers may be short fibers or long fibers. Short fibers are preferable because they can produce artificial leather having a high-grade surface, but long fibers are preferable because they can simplify the manufacturing process and are excellent in physical properties such as strength. In addition, it is generally difficult to produce artificial leather having elasticity in the vertical direction using non-elastic long fibers, but according to the present invention, it has elasticity in the vertical direction even when using non-elastic long fibers. Elastic flame retardant artificial leather can be obtained.

  In the present invention, the long fiber is a fiber having a fiber length longer than a short fiber having a fiber length of usually about 3 to 80 mm, and means a fiber that is not intentionally cut like a short fiber. For example, the fiber length of the long fiber is preferably 100 mm or more, and may be several m, several hundreds m, several km or more as long as it is technically manufacturable and physically cut. .

  The ultrafine fibers are preferably inelastic fibers. Specifically, fibers made of polyester, polyamide, polypropylene, polyethylene or the like are used. Among these, polyester is preferable because the waviness structure is easily retained by heat setting described later. Further, elastic fibers such as polyether ester fibers and polyurethane fibers such as so-called spandex are not preferable.

  The polyester is not particularly limited as long as it can be fiberized. Specifically, for example, polyethylene terephthalate, polytrimethylene terephthalate, polytetramethylene terephthalate, polycyclohexylene dimethylene terephthalate, polyethylene- Examples include 2,6-naphthalene dicarboxylate, polyethylene-1,2-bis (2-chlorophenoxy) ethane-4,4′-dicarboxylate, and the like. Among them, polyethylene terephthalate that is most commonly used or a modified polyester mainly composed of ethylene terephthalate units (for example, isophthalic acid-modified polyethylene terephthalate) is preferably used.

  Examples of the polyamide include polymers having an amide bond such as nylon 6, nylon 66, nylon 610, nylon 12, and the like.

  To these polymers, inorganic particles such as titanium oxide particles may be added to the polymer in order to improve the concealing properties, lubricants, pigments, heat stabilizers, ultraviolet absorbers, conductive agents, heat storage materials, It can also be added according to various purposes such as antibacterial agents.

[Fiber entangled body]
The fiber entangled body in the present invention is, for example, a short fiber or long fiber ultrafine fiber or ultrathinnable fiber is formed into a web, and the resulting web is entangled to form an entangled nonwoven fabric, and then the ultrathinnable fiber. Is formed by a method such as performing ultrafine processing.

  In the case of short fibers, the ultrafine fibers or fibers that can be refined to form the fiber entanglement are made into a web by a dry method or a wet method such as carding or papermaking, but it is better to make a web by a dry method. It is preferable because an artificial leather having a surface can be obtained.

  In addition, in the case of a long fiber, an ultrafine fiber or an ultrathinnable fiber for forming a fiber entangled body can be formed into a web by a spunbond method, and if it is collected in a continuous filament state to form a web In addition, a part of the long fiber may be cut in a later step of making the artificial leather. In the case of a web using ultrathinnable continuous fibers, the surface fibers may be temporarily fused by hot pressing. When temporarily fused, the form of the web is stabilized and the handling property in the subsequent process is improved.

Basis weight of the webs web of microfine fibers or microfine possible fibers, 10 to 100 g / ^{m 2} is preferred. Further, the web is entangled by a method such as needle punching or water jet to form an entangled nonwoven fabric. For example, after a plurality of layers of the web are laminated using a cross wrapper or the like as necessary, needle punching is performed under the condition that at least one barb penetrates from both sides simultaneously or alternately. The punching density is preferably in the range of 200 to 5000 punches / cm ² . When it is within the above range, sufficient entanglement is obtained, and there is little damage caused by the needle of the ultrafine fiber or ultrafine fiber. By the entanglement treatment, the ultrafine fibers or the finely tunable fibers are entangled three-dimensionally to obtain an entangled nonwoven fabric in which the ultrafine fibers or the finely tunable fibers are gathered very densely.
The web may be provided with a silicone oil agent or a mineral oil agent such as a needle breakage preventing oil agent, an antistatic oil agent, or an entanglement improving oil agent at any stage from the production to the entanglement treatment. If necessary, the entangled state of the entangled nonwoven fabric may be made denser by a shrinking treatment such as immersing in warm water of 70 to 100 ° C. Further, the finely woven fibers or the fibers that can be made finer may be gathered more densely by performing a heat press treatment to stabilize the form of the entangled nonwoven fabric. The basis weight of the entangled nonwoven fabric is preferably 100 to 2000 g / m ² .

  When using an ultrafine fiber, the ultrafine fiber is converted into an ultrafine fiber bundle by ultrafine treatment, and a fiber entangled body composed of the ultrafine fiber bundle is formed. This ultrathinning treatment is performed on an entangled nonwoven fabric formed by entanglement of a web of ultrathinnable fibers. The ultrafine treatment may be performed on an entangled nonwoven fabric that does not contain a polymer elastic body described later, or may be performed on a polymer elastic body-containing nonwoven fabric.

  The ultrathinnable fiber is a multicomponent composite fiber composed of at least two types of polymers. The ultrathinnable fiber is not particularly limited, and can be appropriately selected from sea-island fiber, multilayer laminated fiber, and the like obtained by a method such as a mixed spinning method or a composite spinning method. The sea-island type fiber has a cross section in which a different kind of island component polymer is dispersed in the sea component polymer. The ultra-thinnable fiber is formed on an entangled nonwoven fabric and, if necessary, contains a polymer elastic body as described later, and then extracts or decomposes and removes one component (removal component) of the polymer. Then, the remaining polymer (fiber forming component) is converted into a fiber bundle in which a plurality of ultrafine fibers are gathered to be ultrafine.

  In the case of a sea-island type fiber, the ultra-thinnable fiber is converted into a fiber bundle in which a plurality of ultra-fine fibers composed of the remaining island component polymer are collected by extracting or decomposing and removing the sea component polymer. That is, in the case of sea-island type fibers, ultrafine fibers are formed from the island component polymer. Therefore, the above-mentioned polyester, polyamide, polypropylene, polyethylene or the like is used as the island component polymer. Hereinafter, although the case where a sea-island type fiber is used as the ultra-thinnable fiber will be described, the present invention can be similarly carried out when an ultra-thinnable fiber other than the sea-island type fiber is used.

The ultrafine fibers are converted into a fiber bundle of ultrafine fibers by removing the sea component polymer with a soluble or decomposing agent. Accordingly, the sea component polymer needs to be more soluble in a solvent or decomposable by a decomposing agent than the island component polymer. As a method of removing the sea component polymer, a polymer elastic body which does not dissolve the island component polymer but dissolves the sea component polymer or a decomposing agent which does not decompose the island component polymer but decomposes the sea component polymer is described below. A method of treating the containing nonwoven fabric is preferred.
It is preferable that the sea component polymer has a low affinity with the island component polymer from the viewpoint of the spinning stability of the sea-island fiber, and that the melt viscosity and / or surface tension is lower than the island component polymer under the spinning conditions. As long as these conditions are satisfied, the sea component polymer is not particularly limited. For example, polyethylene, polypropylene, polystyrene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, styrene-ethylene copolymer, styrene-acrylic copolymer are used. Polymers, polyvinyl alcohol resins and the like are preferably used.
When the island component polymer is a polyamide resin or a polyester resin, if the sea component polymer is polyethylene, an organic solvent such as toluene, trichloroethylene, or tetrachloroethylene is used, and the sea component polymer is water-soluble thermoplastic polyvinyl alcohol (PVA) or water-soluble. If thermoplastic modified polyvinyl alcohol (modified PVA), warm water is used, and if the sea component polymer is an easily alkali-degradable modified polyester, an alkaline decomposing agent such as an aqueous sodium hydroxide solution is used. The removal of the sea component polymer may be performed according to methods and conditions conventionally employed in the artificial leather field, and is not particularly limited. When a method with a low environmental load is desired, water-soluble thermoplastic PVA or modified PVA such as ethylene-modified PVA is used as the sea component polymer, and this is used at 85 to 100 ° C. without using an organic solvent. It is treated in hot water for 100 to 600 seconds, extracted and removed until the removal rate is 95% by mass or more (including 100%), and the ultrafine fiber is converted into a fiber bundle of ultrafine fibers made of island component polymer. Is preferred.

  The average fineness of the sea-island fiber is preferably 1.0 to 6.0 dtex. In the cross section of the sea-island fiber, the mass ratio of the sea component polymer to the island component polymer is preferably 5/95 to 70/30, and the number of islands is preferably 5 or more.

[Polymer elastic body]
In the stretchable flame retardant artificial leather of the present invention, the fiber entangled body contains a polymer elastic body as a binder of flame retardant fine particles, and the micro waviness structure is a polymer contained in the ultrafine fibers and fiber entangled body. It is composed of an elastic body.

The polymer elastic body is contained in the fiber entangled body by the polymer elastic body application treatment. The polymer elastic body imparting treatment is performed, for example, by impregnating an entangled nonwoven fabric formed by entanglement of a web with an aqueous dispersion or organic solvent solution of a polymer elastic body and solidifying it. The polymer elastic body applying treatment may be performed before or after the above-described fiber ultrafine processing.
When applying the flame retardant fine particles to the fiber entangled body, the fiber entangled body is impregnated with a dispersion obtained by dispersing the flame retardant fine particles in an aqueous dispersion of an elastic polymer or an organic solvent solution and solidified.

  Examples of the polymer elastic body include polyurethane elastomers, polyurea elastomers, polyurethane-polyurea elastomers, polyacrylic acid resins, acrylonitrile-butadiene elastomers, styrene-butadiene elastomers, among others, polyurethane elastomers, polyurea elastomers, polyurethane- Polyurethane elastomers such as polyurea elastomers are preferred. For example, a polyurethane-based elastomer obtained by using at least one selected from polymer diols having an average molecular weight of 500 to 3500 such as polyester diol, polyether diol, polyester polyether diol, polylactone diol, and polycarbonate diol is preferable. From the viewpoint of product durability, a polyurethane obtained by using a polymer diol containing 30% by weight or more of a polycarbonate diol is more preferable. When the polycarbonate diol is less than 30% by weight, the durability may be lowered.

Polycarbonate diol is one in which diol skeletons are linked via a carbonate bond to form a polymer chain and have hydroxyl groups at both ends. The diol skeleton is determined by the glycol used as a raw material, but the type thereof is not particularly limited. For example, 1,6-hexanediol, 1,5-pentanediol, neopentyl glycol, 3-methyl- 1,5-pentanediol can be used. In addition, a copolymer polycarbonate diol using at least two or more kinds of glycols selected from these glycol groups as raw materials is particularly preferable because an artificial leather excellent in flexibility and appearance can be obtained. In addition, when obtaining artificial leather with particularly excellent flexibility, it is preferable to introduce chemical bonds other than carbonate bonds, such as ester bonds and ether bonds, into the polymer diol within a range that does not impair durability.
As a method for introducing such a chemical bond, a method in which polycarbonate diol and other polymer diols are individually polymerized, and these are mixed and used in an appropriate ratio at the time of polyurethane production can be employed.

  The polyurethane elastomer can be obtained by reacting a polymer diol, an organic polyisocyanate, and a chain extender in a predetermined molar ratio. The reaction conditions are not particularly limited, and a polyurethane elastomer can be produced by a conventionally known method.

  Examples of the polymer diol include polyether polyols such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol, and poly (methyltetramethylene glycol) and copolymers thereof; polybutylene adipate diol, polybutylene sebacate diol, polyhexamethylene Polyester polyols such as adipate diol, poly (3-methyl-1,5-pentylene adipate) diol, poly (3-methyl-1,5-pentylene sebacate) diol, polycaprolactone diol and copolymers thereof; Hexamethylene carbonate diol, poly (3-methyl-1,5-pentylene carbonate) diol, polypentamethylene carbonate diol, polytetramethylene carbonate diol Polycarbonate polyols and their copolymers such as Le; polyester carbonate polyols and the like. Moreover, you may use together polyfunctional alcohols, such as a trifunctional alcohol and a tetrafunctional alcohol, or short chain alcohols, such as ethylene glycol, as needed. These may be used alone or in combination of two or more. In particular, amorphous polycarbonate polyols, alicyclic polycarbonate polyols, linear polycarbonate polyol copolymers, polyether polyols, and the like are preferable from the viewpoint of obtaining artificial leather excellent in the balance between flexibility and fullness. .

Examples of the organic polyisocyanate include non-yellowing diisocyanates such as aliphatic or alicyclic diisocyanates such as hexamethylene diisocyanate, isophorone diisocyanate, norbornene diisocyanate, and 4,4′-dicyclohexylmethane diisocyanate; 2,4-tolylene diisocyanate, Examples include aromatic diisocyanates such as 2,6-tolylene diisocyanate, 4,4′-diphenylmethane diisocyanate, and xylylene diisocyanate polyurethane. Moreover, you may use together polyfunctional isocyanates, such as trifunctional isocyanate and tetrafunctional isocyanate, as needed. These may be used alone or in combination of two or more.
Among these, 4,4′-dicyclohexylmethane diisocyanate, isophorone diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, 4,4′-diphenylmethane diisocyanate, and xylylene diisocyanate have mechanical properties. It is preferable because it is excellent.

Examples of chain extenders include hydrazine, ethylenediamine, propylenediamine, hexamethylenediamine, nonamethylenediamine, xylylenediamine, isophoronediamine, piperazine and derivatives thereof, diamines such as adipic acid dihydrazide and isophthalic acid dihydrazide; and diethylenetriamine. Triamines; tetramines such as triethylenetetramine; ethylene glycol, propylene glycol, 1,4-butanediol, 1,6-hexanediol, 1,4-bis (β-hydroxyethoxy) benzene, 1,4-cyclohexanediol Diols such as: Triols such as trimethylolpropane; Pentaols such as pentaerythritol; Aminoethyl alcohol, aminopropyl alcohol, etc. Roh alcohol, and the like. These may be used alone or in combination of two or more.
Among these, it is preferable from the viewpoint of mechanical performance to use a combination of two or more of hydrazine, piperazine, ethylenediamine, hexamethylenediamine, isophoronediamine and derivatives thereof, and triamines such as diethylenetriamine. In addition, during the chain extension reaction, together with the chain extender, monoamines such as ethylamine, propylamine, and butylamine; carboxyl group-containing monoamine compounds such as 4-aminobutanoic acid and 6-aminohexanoic acid; methanol, ethanol, propanol, butanol, etc. Monools may be used in combination.

The polymer elastic body is impregnated into the entangled nonwoven fabric as an aqueous solution, an aqueous dispersion, or an organic solvent solution (for example, a solution of an organic solvent such as dimethylformamide, methyl ethyl ketone, acetone, toluene). The impregnation method is not particularly limited, and examples thereof include a method of uniformly impregnating the entangled nonwoven fabric by dipping and the like, and a method of applying to the front and back surfaces. The impregnated polymer elastic body aqueous solution, aqueous dispersion, or organic solvent solution may be solidified by conditions and methods conventionally employed in artificial leather production (for example, a wet method or a dry method).
The concentration of the polymer elastic body aqueous solution, aqueous dispersion (for example, aqueous emulsion), or organic solvent solution is preferably 5 to 50% by weight.

  The polymer elastic body is preferably impregnated into the entangled non-woven fabric as an aqueous dispersion, whereby the fiber entangled body contains the solidified product of the water-based emulsion of the polymer elastic body. In the present invention, by incorporating a solidified product of an aqueous emulsion into the fiber entangled body, it is possible to easily form and maintain a swell structure by mechanical shrinkage treatment and heat setting treatment described later. In addition, for example, when polyamide that is difficult to heat set is used as an ultrafine fiber, an entangled nonwoven fabric is impregnated with a polymer elastic body as an organic solvent solution to form a swell structure by mechanical shrinkage and heat setting treatment. It is not preferable because it is difficult to hold.

  The application amount of the polymer elastic body varies depending on the fiber length (short fiber or long fiber) and the application method (aqueous solution, aqueous dispersion, organic solvent solution). From the product flexibility, surface touch, dyeing uniformity, The solid content is preferably in the range of 5 to 70% by weight of the ultrafine fiber weight. In particular, when short fibers are used and applied using an organic solvent solution of a polymer elastic body, the solid content is preferably 10 to 70% by weight of the ultrafine fiber weight. If the application amount is less than 10% by weight, the wear resistance tends to be lowered, and if the application amount exceeds 70% by weight, the texture tends to become hard, which is not preferable. Moreover, you may mix | blend additives, such as a coloring agent, antioxidant, an antistatic agent, a dispersing agent, a softening agent, and a coagulation regulator, in a polymeric elastic body as needed.

[Flame retardant fine particles]
The present invention is a stretchable flame retardant artificial leather containing a polymer elastic body and flame retardant fine particles in a fiber entangled body, and the average particle diameter of the flame retardant fine particles is 10 μm or less. It is preferable in terms of excellent flammability. And the flame retardant which consists of a metal salt of a dialkylphosphinic acid is preferable at the point by which transfer to the surface of a flame retardant is suppressed. As the metal salt of dialkylphosphinic acid, those generally proposed as flame retardants can be used.
Metal salts of dialkylphosphinic acids proposed as flame retardants have properties such as the following (1) to (3).
(1) The phosphorus content is 20% by mass or more.
(2) It is a fine white powder that is hardly soluble in water and solvents.
(3) The melting point and the thermal decomposition temperature are high (normally, the thermal decomposition temperature is about 300 ° C.).
Such a metal salt of dialkylphosphinic acid has excellent flame retardancy because the phosphorus content is as high as 20% by mass or more.
In addition, since it is in the form of fine powder, problems such as aggregation are less likely to occur when blended with an aqueous solution, aqueous dispersion, or organic solvent solution of the polymer elastic body forming the polymer elastic body. Can be easily included.
And since it is sparingly soluble in water and solvents, it has excellent water resistance and solvent resistance. It is difficult to bleed out from silvered surfaces such as surface layers. Moreover, since the melting point and the thermal decomposition temperature are high, the heat resistance is also good. Therefore, it is considered highly durable against washing treatment such as washing with water, dry cleaning, and accelerated tests such as a jungle test and a heat aging test, and is unlikely to deteriorate the appearance and touch.
Furthermore, since it is white, there is no restriction | limiting in color when the adhesive bond layer and skin layer which further comprise a silvered layer are colored with a pigment etc., and it can color in arbitrary colors.

The dialkylphosphinic acid ion constituting the metal salt of the dialkylphosphinic acid is an ion in which two hydrogen atoms of the phosphinic acid ion are each substituted with an alkyl group. The alkyl group in the dialkylphosphinate ion may be linear, branched or cyclic, preferably has 1 to 5 carbon atoms, and more preferably has 1 to 2 carbon atoms. Specific examples of the alkyl group include a methyl group and an ethyl group. The two alkyl groups in the dialkylphosphinic acid may be the same or different.
Examples of the metal constituting the metal salt of dialkylphosphinic acid include magnesium, calcium, aluminum, antimony, tin, germanium, titanium, zinc, iron, zirconium, cerium, bismuth, strontium, manganese, lithium, sodium, potassium, and the like. . In the present invention, the metal salt of dialkylphosphinic acid is particularly preferably a salt of a polyvalent metal such as aluminum, calcium, titanium, or zinc, and particularly preferably an aluminum salt. Such a polyvalent metal salt is a poorly soluble salt having very low solubility in water or a solvent, and is excellent in the effect of the present invention.

  Specific examples of the metal salt of dialkylphosphinic acid include, for example, those described in JP-T-2001-525327, JP-A-2001-525329, JP-A-2004-346325, etc., for example, dialkylphosphinic acid (or an alkali metal thereof) Salt) and metal compounds containing metals such as magnesium, calcium, aluminum, antimony, tin, germanium, titanium, iron, zirconium, cerium, bismuth, strontium, manganese, lithium, sodium, potassium, etc. A compound etc. can be used. Among these, the metal is preferably a polyvalent metal as described above.

The content of the metal salt of dialkylphosphinic acid in the fiber entanglement is different in the method of flame retardancy evaluation depending on the application and purpose of use, and the fiber type and basis weight of the fiber entanglement used, and the polymer elasticity Since the required amount varies depending on the type and amount of the body, it may be set in advance in consideration of them.
In the case of car seat applications, a relatively small amount of flame retardant can pass the horizontal method, which is the flame retardant performance test standard.

When the stretchable flame retardant artificial leather of the present invention is used for car seat applications, in order to ensure sufficient flame retardancy, the content of the metal salt of dialkylphosphinic acid is the fiber entangled body and the polymer elastic body. The total weight is preferably 10% by mass or more. When the content of the metal salt of dialkylphosphinic acid is 10% by mass or more based on the total weight of the fiber entangled body and the polymer elastic body, excellent flame retardancy is obtained, and the stretchable flame retardant artificial leather is It can be used for various flame retardant articles.
As a preferable configuration of the stretchable flame-retardant artificial leather in the present invention, the fiber entangled body is polyester fiber, the polymer elastic body is polyurethane resin, and flame-retardant fine particles are blended in the urethane resin.
In the case of such a composite material, the polyester fiber is melted and dripped to exhibit flame retardancy, but the urethane resin is difficult to melt, and the combustion behavior of the two is completely different. Therefore, for example, in order to pass the flame retardant performance test standard for car seat applications, the amount of the flame retardant fine particles to be blended in the urethane resin is set to be equal to or greater than the amount of the urethane resin, so that the difficulty per unit area. It is necessary to make the urethane resin highly flame retardant by increasing the amount of the flame retardant, and to make the melting behavior of the polyester fiber and the urethane resin to the same level. In particular, when the urethane resin layer has a structure three-dimensionally cross-linked with a cross-linking agent, the urethane resin layer is very difficult to melt, so it is considered necessary to make it extremely flame-retardant.
Therefore, in the present invention, the amount of the metal salt of dialkylphosphinic acid in the urethane resin is set to 100% by mass or more based on the weight of the urethane resin, and the flame retardant of the urethane resin is made highly flame retardant, so The flame retardancy that passes the flame retardant performance test standard for articles can be sufficiently achieved.

  In order to make the polyurethane resin highly flame-retardant, it is necessary to apply a flame retardant having a large particle diameter using a small amount of polyurethane resin. Generally, when impregnation and back coating are carried out by such a method, In addition, the flame retardant and the polyurethane resin restrain the fiber entanglement, so that the decrease in stretchability and the curing of the texture are unavoidable, and even if the flame retardant performance test standard is passed, there is a problem that the sewability becomes poor. In the present invention, even if the flame-retardant fine particles are added to increase the density, the above problem can be solved by providing a micro waviness structure in the vertical direction. Furthermore, by using flame retardant fine particles having an average particle size of 10 μm or less, the texture is good despite the flame retardancy, sewing properties, and high apparent density, and appropriate stretchability in the vertical direction is achieved. It is possible to improve the physical properties and give a moderate feeling of elongation stoppage.

  The upper limit of the content of the metal salt of dialkylphosphinic acid in the polyurethane resin is not particularly limited, but is preferably such that the proportion of the metal salt of dialkylphosphinic acid in the polyurethane resin is 800% by mass or less. When the ratio of the metal salt of dialkylphosphinic acid in the adhesive layer is 800% by mass or less, sufficient adhesion to the fiber entanglement of the flame retardant fine particles can be ensured.

The polyurethane resin may contain optional components other than the flame retardant fine particles represented by the metal salt of dialkylphosphinic acid and the urethane resin. Examples of such optional components include black pigments for imparting light shielding properties and aluminum pigments for imparting concealing properties.
Further, in the present invention, flame retardancy represented by flame retardant fine particles other than metal salt of dialkylphosphinic acid, such as conventionally proposed aluminum hydroxide other than metal salt of dialkylphosphinic acid, in the polyurethane resin in the present invention. Fine particles may be contained.

[Silver surface / napping]
The stretchable flame-retardant artificial leather of the present invention is provided with a silver surface on at least one surface, or at least one surface is raised by a napping treatment, and a silver-tone artificial leather, semi-silver-tone artificial leather, It is preferable to use napped-tone artificial leather or nubuck-like artificial leather. The method for providing the silver surface layer and the napping treatment may be a method conventionally used for the production of artificial leather, and is not particularly limited in the present invention. For example, a dry surface forming method in which a surface layer formed on a release paper is bonded to at least one surface of an artificial leather substrate via an adhesive layer, and a polymer elastic body on at least one surface of the artificial leather substrate The silver surface layer can be formed by a method of applying a dispersion or solution of the above and then drying and solidifying it. Further, a raised surface can be formed by a method of raising at least one surface of the artificial leather substrate with a needle cloth, sandpaper or the like, and then performing a hair treatment.

[Substrate for artificial leather]
As described above, the artificial leather substrate of the present invention, that is, the artificial leather before the heat shrinking treatment, is preferably formed by web-forming short fibers or long ultrafine fibers or ultrathinnable fibers, and entangle the resulting web. Thus, an entangled nonwoven fabric is obtained, and thereafter, a polymer elastic body applying treatment, an ultrafine treatment, and a silver surface / napped processing are performed as necessary.

The apparent density of the artificial leather base for is preferably a 0.25~0.80g / cm ^3, and more preferably 0.30~0.70g / cm ^3. By making the apparent density of the artificial leather before heat shrink treatment in these ranges, voids in the fiber entangled body of the artificial leather substrate are reduced, and it becomes easier to form a wavy structure by the heat shrink treatment described later, and processability Can also be good. Also, the basis weight is preferably from 130~1600g / ^{m 2,} more preferably from 150~1400g / ^{m 2,} thickness is preferably 0.5 to 2.0 mm.

[Swell structure]
The micro wave structure in the stretchable flame-retardant artificial leather of the present invention is composed of ultrafine fibers by mechanically shrinking the artificial leather substrate in the vertical direction (MD of the production line) and heat-setting the shrinkage state. The fiber entangled body or the fiber entangled body and the polymer elastic body contained in the fiber entangled body are bent along the vertical direction and molded. The stretchable flame-retardant artificial leather has a flexible texture and a fine folded fold due to this undulation structure (bending structure) even if its apparent density is high. The waviness structure does not need to be continuous and may be discontinuous in the vertical direction.

  The undulation structure is characterized in that the number of pitches existing in a vertical direction of 1 mm is 2.2 or more, the average height (height difference between peaks and valleys) is 50 to 350 μm, and the average pitch is 450 μm or less. To do. Here, the average pitch means the average distance of one pitch of the undulation structure (between the valley and the next mountain, and between the mountain and the next valley), and the number of pitches means the pitch existing in 1 mm. Numbers. The stretchable flame-retardant artificial leather of the present invention is not stretchable of the fiber itself, but has a moderate stretch in the vertical direction and a sense of stopping stretching due to such a change (elongation) in the wavy structure. Stretch flame retardant artificial leather has a moderate stretch in the vertical direction, so it has a good feeling of wear and processability to the product, and it has a moderate stop feeling to prevent it from collapsing or losing its shape. it can.

The pitch number is preferably 2.2 to 6.7, more preferably 2.5 to 5.0. Moreover, it is preferable that the said average pitch is 150-450 micrometers, and it is more preferable that it is 200-400 micrometers. By making the number of pitches within the above-mentioned range, a higher feeling of elongation stoppage is obtained, and it becomes difficult to lose shape due to wearing, and the elongation in the vertical direction becomes good, and the wearing feeling and moldability become better.
The average height is more preferably 80 to 300 μm. By setting the average height to 80 to 300 μm, it is possible to improve the vertical direction and the feeling of stopping the elongation, and at the same time, the surface irregularities are suppressed, and an artificial leather substrate having excellent smoothness and appearance is obtained. It becomes possible.

  When the artificial leather base of the present invention is mechanically shrunk in the vertical direction, it is shrunk smaller than the vertical direction in the horizontal direction or is not substantially shrunk. Therefore, the micro waviness structure along the horizontal direction is not formed in a cross section parallel to the horizontal direction. Alternatively, even if formed, the undulation amount of the undulation structure in the cross section parallel to the horizontal direction is smaller than the undulation amount of the undulation structure in the cross section parallel to the vertical direction. That is, the pitch number (per 1 mm) of the undulation structure along the vertical direction of the stretchable flame-retardant artificial leather and the average height are respectively from the pitch number (per 1 mm) of the undulation structure along the horizontal direction and the average height. Also grows.

Since the stretchable flame-retardant artificial leather of the present invention has a micro waviness structure in the vertical direction and has an appropriate stretchability, it has a good feeling of wear and processability to products, and also has a feeling of non-stretching. Loss of wear, loss of shape and the like can be prevented. The stretchability in the vertical direction and the feeling of stoppage of elongation can be evaluated by a load elongation curve in the vertical direction (vertical axis: load, horizontal axis: elongation) and a 5% circular modulus in the vertical direction. For example, the stretchable flame-retardant artificial leather of the present invention can exhibit a stretch rate of 10 to 40% ((stretched length / length before stretching) × 100) at a load of 40 N / cm. The 5% circular modulus in the vertical direction is an index indicating the extensibility at the time of low elongation, and in the present invention, for example, it can be set to 40 N or less, preferably 10 to 30 N by forming a wavy structure.
The feeling of non-elongation does not mean that it does not elongate at all, but it means that when the elongation exceeds a certain value, the resistance to elongation becomes remarkably large, and it is not easy to elongate. It is influenced by the load change at the time. In the present invention, the feeling of elongation stoppage is expressed by the ratio of the load at the time of 30% extension and the load at the time of 5% extension (at the time of 30% extension / 5% extension) in the load elongation curve in the vertical direction (see FIG. 3). The load at 5% elongation greatly affects the sewability, workability and wearing feeling. When the artificial leather is stretched by more than 30%, the structure of the nonwoven fabric that usually constitutes the artificial leather is greatly changed, and such artificial leather cannot exhibit the effect of preventing the loss of shape and shape as intended by the present invention. . For this reason, the load at 30% elongation was adopted. The load ratio of the stretchable flame-retardant artificial leather of the present invention is preferably 5 or more, more preferably 5 to 40, and particularly preferably 8 to 40. When it is within the above range, there is a feeling of stoppage of elongation in the vertical direction, there is little loss of shape due to wearing, and the feeling of wearing and workability for various uses is good.

[Apparent density and basis weight of stretchable flame-retardant artificial leather]
The apparent density of the stretchable flame-retardant artificial leather of the present invention is 0.40 g / cm ³ or more. By setting the apparent density to 0.40 g / cm ³ or more, voids inside the artificial leather are reduced, and a wavy structure is easily formed by mechanical shrinkage treatment. In addition, the tear strength, peel strength, etc. can be improved, and in particular, the feeling of stopping elongation can be improved, so that high-strength artificial leather can be obtained while ensuring the stretchability in the vertical direction by the undulation structure. Apparent density is more preferably 0.45 g / cm ³ or more, further preferably 0.50 g / cm ³ or more. Further, it is preferably 0.80 g / cm ³ or less, more preferably 0.70 g / cm ³ or less, still more preferably 0.65 g / cm ³ or less. By making the apparent density 0.80 g / cm ³ or less, workability for various applications can be improved.

The basis weight of the stretchable flame-retardant artificial leather is preferably 150 g / m ² or more, more preferably 200 g / m ² or more, and further preferably 250 g / m ² or more. Moreover, Preferably it is 1500 g / m < ² > or less, More preferably, it is 1200 g / m < ² > or less, More preferably, it is 1000 g / m < ² > or less. It is preferable for the elastic flame-retardant artificial leather to have a basis weight of 150 g / m ² or more because good repulsion can be easily obtained. Moreover, when the fabric weight of a stretchable flame-retardant artificial leather is 1500 g / m < ² > or less, the workability for various uses tends to be good, which is preferable. Moreover, although thickness is chosen according to a use, it is 0.35-2.00 mm, Preferably it is 0.40-1.50 mm. In the present invention, when the mechanical shrinkage treatment / heat set treatment is performed, the apparent density and the basis weight are larger than the apparent density and the basis weight of the artificial leather substrate, that is, the artificial leather before the mechanical shrinkage treatment. .

[Formation of swell structure]
The micro waviness structure along the vertical direction is obtained by mechanically contracting the artificial leather substrate in the vertical direction and heat setting in the contracted state.

As one specific example of the mechanical shrinkage treatment of the present invention, an artificial leather substrate is brought into close contact with the surface of a thick elastic sheet (rubber sheet, felt, etc.) having a thickness of several centimeters or more and extended in the vertical direction, There is a method in which the surface of the artificial leather base is contracted in the vertical direction by elastically restoring the surface from the stretched state to the state before stretching.
FIG. 1 is a schematic view showing an example of an apparatus for shrinking an artificial leather substrate by this method. The belt 3 made of a thick elastic sheet advances while contacting the surface of the pressure roller 4 (surface material: metal). During this time, the outer surface of the belt 3 is elongated in the vertical direction due to the difference between the inner and outer circumferences of the belt. The artificial leather substrate 1 sent from the turn rollers 5 a and 5 b is brought into close contact with the extended outer surface of the belt 3. The belt 3 and the base 1 for artificial leather that is in close contact with the belt 3 pass through the gap between the pressure roller 4 and the drum 2 (surface material: metal), and run while contacting the surface of the drum 2. After passing through this gap, the surface of the belt 3 on the artificial leather substrate 1 side contracts to be driven in the direction of travel (vertical direction) by elastic recovery from the stretched state in the vertical direction to the state before stretching.
Corresponding to the change from the stretched state of the belt 3 to the elastic recovery state, the artificial leather base 1 is shrunk so as to be driven in the advancing direction (vertical direction), and then taken up as a shrunk artificial leather base 6. . The outer diameter of the pressure roller 4 is preferably 10 to 50 cm in order to extend the outer surface of the elastic sheet by using the difference between the inner and outer circumferences at an elongation rate in the range described later. In addition, by relaxing the stretched state of the outer surface of the elastic sheet and restoring the state before stretching, the elastic sheet is shrunk in the vertical direction (traveling direction) and at the same time the shrinkage of the artificial leather substrate is within the range described below. In order to contract in the vertical direction (traveling direction) at a rate, the outer diameter of the drum 2 is preferably larger than the outer diameter of the pressure roller 4 and is 20 to 80 cm. The diameter of the drum 2 is preferably as large as possible in order to lengthen the heat setting time and efficiently perform the heat setting. Therefore, the outer diameters of the drum 2 and the roller 4 are determined in consideration of these. Usually, it is preferable to prioritize the heat setting time. In general, the pressure roller 4 is not directly heated, and the raw material (substrate for artificial leather) before shrinking is preheated, but the surface temperature of the roller 4 in a steady operation state is 40 to 90 ° C. The surface temperature of the drum 2 is preferably heated to 70 to 150 ° C.
The belt 3 is preferably a thick belt such as rubber or felt, and the thickness is usually 20 mm or more. Further, when the conveyance speed of the artificial leather substrate 1 by the turn rollers 5a and 5b in FIG. 1 is higher than the conveyance speed of the belt 3, the artificial leather substrate 1 is folded in the vertical direction on the surface of the belt 3, and this folding is performed. Further, since the artificial leather substrate 1 is contracted by a change from the stretched state of the surface of the thick belt 3 to the elastic recovery state, the contraction effect of the artificial leather substrate 1 can be increased.

As another mechanical shrinkage treatment method, the artificial leather substrate is shrunk in the vertical direction (traveling direction) by using the action of elastically recovering the elastic sheet from the stretched state by nip-deforming between the pressure rollers. There is also a method.
FIG. 2 is a schematic view showing an example of an apparatus for shrinking an artificial leather substrate by this method. A belt 3 made of an elastic sheet circulates along the surface of a rubber roller 13 having a metal roller 11 and a thick rubber portion 12. The outer surface of the belt 3 extends in the vertical direction due to the difference between the inner and outer circumferences when traveling on the surface of the rubber roller 13. The artificial leather substrate 1 is supplied to the extended outer surface of the belt 3. The belt 3 and the artificial leather substrate 1 are guided to the nip portion between the metal roller 11 and the rubber roller 13. The thick rubber portion 12 is deformed toward the center of the rubber roller 13 by the pressure of the nip. Due to this deformation, the belt 3 is elastically restored from the stretched state to the original state, and accordingly, the artificial leather substrate 1 contracts in the vertical direction (traveling direction) under compression. The contracted artificial leather substrate 14 travels along the surface of the metal roller 11 being heated, and is heat-treated during this time and taken off. The surface temperature of the metal roller 11 is preferably 70 to 150 ° C. Generally, the rubber roller 13 is not directly heated, and a method of preheating the raw fabric (artificial leather substrate) before shrinking is generally used, but the surface temperature of the rubber roller 13 in a steady operation state is 40 to 90 ° C. Preferably there is.

The method of forming a wavy structure using the mechanical shrinkage treatment is to closely adhere the artificial leather substrate to the surface without using an adhesive means such as an adhesive while extending the surface of the elastic sheet in the vertical direction. Next, the stretched state is relaxed to elastically recover the surface of the elastic sheet to the state before stretching, and the artificial leather substrate is contracted so as to be driven in the traveling direction (vertical direction). The elastic sheet surface stretch rate ((length stretched / length before stretch) × 100) when the artificial leather substrate is in close contact is 5 to 40%, preferably 7 to 25%, more preferably 10 to 20 %. If it is 5% or more, a wavy structure can be formed by this method even when a base for artificial leather that hardly extends in the vertical direction is adhered. For example, a base for artificial leather made of short fibers having a basis weight of 250 g / m ² or less is stretched by the tension applied in the production process, and as a result, hardly stretches in the vertical direction. However, according to this method, even when short fibers are used, it is possible to obtain a stretchable flame retardant artificial leather that easily extends in the vertical direction due to the undulation structure. In addition, when a web by a spunbond method is used, filaments are generally arranged in the vertical direction, and a substrate for artificial leather that is difficult to extend in the vertical direction can be obtained. However, according to this method, the elastic structure extends in the vertical direction. Elastic flame retardant artificial leather can be obtained.

The shrinkage treatment is preferably performed at 70 to 150 ° C., more preferably 90 to 130 ° C., preferably 2 to 20%, more preferably 4 to 15%, and the artificial leather substrate shrinks in the vertical direction. Let
Shrinkage rate = [(length before shrinkage) − (length after shrinkage)] / length before shrinkage × 100

  The elastic sheet used in the mechanical shrinkage treatment is not particularly limited as long as it is a sheet-like material having the above-described elastic characteristics, but it is preferable to use a sheet of natural rubber or synthetic rubber. If an elastic sheet made of natural rubber or synthetic rubber is used, the elastic recovery force is particularly high. Therefore, when shrinking together with the base material for artificial leather, the base material for artificial leather is still sufficiently against the resistance of the base material for artificial leather. The effect of contracting can be obtained. In order to prevent the structural change of the surface of the artificial leather substrate due to heating and pressurization during the shrinking treatment, it is preferable to control the tension of the elastic sheet low and use an elastic sheet having low hardness.

  The thickness of the elastic sheet is preferably 20 to 100 mm, and more preferably 30 to 70 mm. Within the above range, the elastic sheet can be effectively extended and contracted in the vertical direction using the difference between the inner and outer circumferences.

As the natural rubber, rubber mainly composed of cis-1,4-polyisoprene collected from bark such as Hevea tree can be used.
Synthetic rubber includes styrene-butadiene rubber, butadiene rubber, isoprene rubber, butyl rubber, ethylene propylene rubber, chloroprene rubber, nitrile rubber, silicone rubber, acrylic rubber, epichlorohydrin rubber, fluorine rubber, urethane rubber, ethylene-vinyl acetate rubber, chlorinated Polyethylene rubber or the like can be used.

  In this method, since the shrinkage state of the artificial leather substrate is heat-set by heating before separating the artificial leather substrate from the elastic sheet, the elastic sheet is preferably excellent in heat resistance and has heat resistance. Silicone rubber, fluorine rubber or ethylene propylene rubber is preferred.

  In this method, after the artificial leather substrate is shrunk in the vertical direction, the artificial leather substrate is heated before being separated from the elastic sheet, and the contracted state is heat set. Thereby, an appropriate swell structure is formed, and an elastic flame-retardant artificial leather with improved elasticity can be obtained. The heating temperature for the heat setting is preferably selected from the range of 100 to 150 ° C. in consideration of the thermal history received by the fibers contained in the artificial leather substrate in the production process. For example, in the case of an artificial leather substrate treated with wet heat 120 ° C. with a liquid dyeing machine or the like, the temperature for heat setting is preferably 120 ° C. or higher for wet heat treatment and 140 ° C. or higher for dry heat treatment. The heat set treatment time varies depending on the polymer type of the fiber contained in the artificial leather substrate and the heat set temperature, and is usually selected from the range of 0.1 to 5 minutes. For example, in the case of polyethylene terephthalate fiber, 1 to 3 minutes is preferable in terms of heat setting and processing stability. When one heat set is insufficient, it is preferable to heat set again after the artificial leather substrate is pulled away from the elastic sheet.

  The heat setting method uses a known method such as a method in which hot air is blown onto a substrate for artificial leather to heat, a method in which heating is performed using an infrared heater, a method in which heat treatment is performed by sandwiching between a heating cylinder and an elastic sheet or nonwoven fabric sheet. However, from the viewpoint of being able to process with low tension, a method of using the ironing effect of the heating cylinder by heat treatment between the heating cylinder and the sheet is preferably used. The heat-set artificial leather substrate is usually taken up at a speed of 2 to 15 m / min.

In order to effectively form a waviness structure in this method, it is preferable to perform a preheat treatment and / or a humidification treatment for softening the artificial leather substrate before the artificial leather substrate is brought into close contact with the elastic sheet. .
As a preheating method, a known heating method such as a method of heating while humidifying by spraying steam or water, a method of heating hot air by spraying on a base for artificial leather, a method of heating using an infrared heater, etc. may be used. it can. Although the optimum conditions for the preheat treatment are different depending on the substrate for artificial leather to be used, the preheat temperature is preferably 40 to 100 ° C. In order to prevent the artificial leather substrate from being excessively heated during the shrinking treatment, it is preferable to apply moisture to the artificial leather substrate by spraying steam or water and performing a humidification treatment. The moisture content is preferably 1 to 5% by weight with respect to the amount of ultrafine fibers of the artificial leather substrate. Thereby, the temperature of the base material for artificial leather can be easily controlled to 100 ° C. or lower. In addition, when it is desired to effectively shrink the substrate by raising the temperature of the artificial leather substrate to 100 ° C. or higher, it is preferable to use hot air or an infrared heater. The preheat treatment and the humidification treatment may be combined.

  In the present invention, the base body for artificial leather is shrunk so as to drive in the traveling direction (vertical direction), and thus the resulting stretchable flame-retardant artificial leather has a micro-bending structure (swell structure) as described above. . Further, in the present invention, since the artificial leather has a non-woven structure composed of high density and ultrafine fibers, a micro waviness structure is easily formed.

  In the present invention, the vertical direction is the flow direction (MD) of the artificial leather production line, and the direction orthogonal thereto is the horizontal direction. The vertical direction of the artificial leather in the product can generally be determined from a plurality of factors such as the orientation direction of the fiber bundle of ultrafine fibers, streak traces by needle punching or high-speed fluid treatment, and treatment traces. If the vertical direction cannot be determined because the vertical direction determined by these multiple elements is different, there is no clear orientation, or there are no streak marks, the vertical direction in which the tensile strength is maximized is determined. The direction and the direction perpendicular to the direction are the horizontal direction.

[Other additives]
The stretchable flame-retardant artificial leather of the present invention includes other dyes, softeners, texture modifiers, anti-pilling agents, antibacterial agents, and deodorants, in addition to the additives described above, without departing from the effects of the present invention. , Functional agents such as water repellents, light proofing agents, and antifungal agents may be included.

  As described above, since the stretchable flame-retardant artificial leather of the present invention has a high apparent density and a wavy structure, it contains mechanically fine particles in the vertical direction while containing flame-retardant fine particles. It has strength and feels like it stops growing, resulting in excellent surface quality. Therefore, it can be used for a wide range of applications such as clothing, furniture, car seats, and miscellaneous goods. Further, the undulation structure in the stretchable flame-retardant artificial leather can be easily formed by shrinking and heat-setting the artificial leather substrate in the vertical direction.

  EXAMPLES Hereinafter, although an Example demonstrates this invention in detail, this invention is not limited to a following example. Each physical property value in the examples was measured by the following method.

(1) Weight per unit area, apparent density per unit area is JIS L 1096
It was measured by the method described in 8.4.2 (1999). Further, the thickness was measured with a dial thickness gauge (manufactured by Ozaki Mfg. Co., Ltd., trade name “Peacock H”), and the apparent density was determined by dividing the basis weight value by the thickness value.

(2) Sense of staying stopped JIS L 1096 (1999) 8.14.1
Measurement was performed by the method described in Method A. A test piece having a width of 2.5 cm was fixed to a chuck having a holding interval of 20 cm, and the test piece was pulled at a constant speed to obtain elongation and load. From the results, a load elongation curve was created in which the horizontal axis represents the elongation rate (%) and the vertical axis represents the load per 2.5 cm width of the test piece (Kg / 2.5 cm). From this curve, the load at the time of 30% elongation and the load at the time of 5% elongation were obtained, and the ratio (at the time of 30% elongation / 5% elongation) was obtained. Measurement was performed three times, and the average value was rounded to one decimal place. When the feeling of stretch stop is good (the ratio is 8 or more), “A” is set, when the feel of stretch stop is slightly good (the ratio is 5 or more and less than 8), “B” is set, and other cases are set as “C”. evaluated.

(3) Elongation rate The vertical direction elongation rate at a load of 40 N / cm was determined from the load elongation curve.

(4) Average single fiber fineness The cross-sectional area of 100 fibers randomly selected with an optical microscope was measured, and the number average was obtained. From the average value of the fiber cross-sectional area and the specific gravity of the fiber, the fineness was calculated. The specific gravity of the fiber is JIS
L 1015
It was measured based on 8.14.2 (1999).

(5) 5% circular modulus (N)
As shown in FIG. 8, a 200 mm-diameter mark is written in the vertical direction at the center of the straight line extending in the vertical direction on one 300 mmφ circular test piece, and the gripping interval is 200 mm with an Instron type tensile tester, and the tensile speed is 200 mm / The modulus at 5% elongation in minutes is measured.

(6) Waviness structure evaluation A cross section parallel to both the thickness direction and the vertical direction of the stretchable flame-retardant artificial leather was photographed with a scanning electron microscope, and undulation was observed at 5.0 mm along the vertical direction at an arbitrary position in the thickness direction. The pitch of the structure (that is, the next peak from the valley and the next valley from the peak) was counted, and the average was obtained to determine the number of pitches existing in 1 mm. Moreover, in the undulation structure seen in 5.0 mm above, the average height of the undulation structure is obtained by calculating the average height difference between adjacent peaks and valleys, and the average length along the vertical direction of the pitch is averaged. The pitch. The height difference between adjacent peaks and valleys was determined as the height difference between peaks and valleys along the thickness direction.

(7) Evaluation of flame retardancy of car seat A sample having a size of 100 mm x 356 mm randomly cut from a base for stretchable flame retardant artificial leather was used to measure the burning rate using the FMVSS 302 method. The standard of flame retardancy varies depending on the automobile manufacturer, but if it is self-extinguishing (combustion rate is 0), it passes without any problem. In the case of combustion, generally, for example, it is determined to pass if the combustion speed is 10 mm / min or less.

Example 1
Water-soluble thermoplastic ethylene-modified polyvinyl alcohol (modified PVA, sea component, modified degree 10 mol%) and isophthalic acid-modified polyethylene terephthalate (modified PET, island component) having a modified degree 6 mol% It was discharged from a die for melt composite spinning (number of islands: 25 islands / fiber) at 260 ° C. so that the island component was 25/75 (mass ratio). The ejector pressure was adjusted so that the spinning speed was 3700 m / min, and sea-island long fibers having an average fineness of 2.1 dtex were collected on the net. Next, a sheet of sea-island long fibers on the net is lightly pressed with a metal roll with a surface temperature of 42 ° C, peeled off from the net while suppressing fuzz on the surface, and between the metal roll (lattice pattern) with a surface temperature of 75 ° C and the back roll To obtain a long fiber web having a basis weight of 34 g / m ² in which the surface fibers were temporarily fused in a lattice shape.

An oil agent and an antistatic agent were applied to the long fiber web, 10 sheets were overlapped by cross-wrapping to produce a laminated web having a total basis weight of 340 g / m ² , and sprayed with a needle breakage preventing oil agent. Next, using a 6 barb needle with a distance of 3.2 mm from the tip of the needle to the first barb, needle punching was alternately performed at 3300 punch / cm ² from both sides at a needle depth of 8.3 mm. The area retention before and after the needle punching was 77%, and the basis weight of the entangled nonwoven fabric after the needle punching was 440 g / m ² .

Water is applied in an amount of 10% by mass to the entangled nonwoven fabric, causing shrinkage by heat treatment in an atmosphere of relative humidity of 95% and 70 ° C., improving the apparent density of the nonwoven fabric and densifying. A non-woven fabric was obtained. The area shrinkage rate by this densification treatment was 50%, the basis weight of the nonwoven fabric was 880 g / m ² , and the apparent density was 0.52 g / cm ³ . Next, the densified nonwoven fabric was dry-heated and roll-pressed, impregnated with a water-based polyurethane emulsion, dried and cured at 150 ° C. to obtain a nonwoven fabric sheet containing a polymer elastic body. Subsequently, PVA was dissolved and removed in hot water at 95 ° C. to obtain a base for artificial leather having a resin fiber ratio R / F = 12/88.

The obtained base for artificial leather was sliced parallel to the main surface and divided into two (thickness: 0.67 mm). Next, as flame retardant processing, 38 parts of Pekoflam S-ST1 (metal salt of dialkylphosphinic acid, average particle size 3.5 μm, maximum particle size of about 10 μm, solid content 40%, manufactured by Clariant Japan Co., Ltd.), self-emulsifying water-based polyurethane 5 parts emulsion (polycarbonate, 40% solids, 100% modulus: 27 MPa), 15 parts Lastex LB (30% solids), 5 parts Nikka silicon AM202 (26.4% solids), 37 parts water After 90% of the treatment liquid was applied to the weight of the artificial leather substrate, it was dried at 120 ° C. to obtain a flame-retardant artificial leather substrate (thickness 0.64 mm, basis weight 369 / m ² , apparent density 0. 577 g / cm ³ ). FIG. 3 shows a load elongation curve in the vertical direction of this flame-retardant artificial leather substrate, and FIGS. 6 and 7 show scanning electron micrographs of cross sections parallel to the thickness direction and the vertical direction.

  Heat-setting the above-mentioned flame retardant artificial leather substrate, a humidifying portion, a shrinking portion for shrinking the artificial leather substrate continuously sent from the humidifying portion, and a fabric shrink-processed by the shrinking portion Using a shrinkage processing device (manufactured by Komatsubara Tekko Co., Ltd., Sun Foraging Machine) equipped with a heat set part, the drum temperature of the shrink part is 120 ° C, the drum temperature of the heat set part is 120 ° C, and the conveyance speed is 10 m / min This was treated to shrink 5.5% in the vertical direction (length direction) to obtain a stretchable flame-retardant artificial leather. FIG. 3 shows a load elongation curve in the vertical direction of the stretchable flame-retardant artificial leather, and FIGS. 4 and 5 show scanning electron micrographs of a cross section parallel to the thickness direction and the vertical direction.

Example 2
Water-soluble thermoplastic ethylene-modified polyvinyl alcohol (modified PVA, sea component, modified degree 10 mol%) and isophthalic acid-modified polyethylene terephthalate (modified PET, island component) having a modified degree 6 mol% It was discharged from a die for melt composite spinning (number of islands: 25 islands / fiber) at 260 ° C. so that the island component was 25/75 (mass ratio). The ejector pressure was adjusted so that the spinning speed was 3700 m / min, and sea-island long fibers having an average fineness of 2.1 dtex were collected on the net. Next, a sheet of sea-island long fibers on the net is lightly pressed with a metal roll with a surface temperature of 42 ° C, peeled off from the net while suppressing fuzz on the surface, and between the metal roll (lattice pattern) with a surface temperature of 75 ° C and the back roll To obtain a long fiber web having a basis weight of 34 g / m ² in which the surface fibers were temporarily fused in a lattice shape.

An oil agent and an antistatic agent were applied to the long fiber web, and eight sheets were overlapped by cross-wrapping to produce an overlap web having a total basis weight of 272 g / m ² , and sprayed with a needle breakage prevention oil agent. Next, using a 6 barb needle with a distance of 3.2 mm from the tip of the needle to the first barb, needle punching was alternately performed at 3300 punch / cm ² from both sides at a needle depth of 8.3 mm. The area retention before and after the needle punching was 77%, and the basis weight of the entangled nonwoven fabric after the needle punching was 350 g / m ² .

Water is applied in an amount of 10% by mass to the entangled nonwoven fabric, causing shrinkage by heat treatment in an atmosphere of relative humidity of 95% and 70 ° C., improving the apparent density of the nonwoven fabric and densifying. A non-woven fabric was obtained. The area shrinkage due to this densification treatment was 47%, the basis weight of the nonwoven fabric was 630 g / m ² , and the apparent density was 0.45 g / cm ³ . Next, the densified nonwoven fabric was dry-heated and roll-pressed, impregnated with a water-based polyurethane emulsion, dried and cured at 150 ° C. to obtain a nonwoven fabric sheet containing a polymer elastic body. Subsequently, PVA was dissolved and removed in hot water at 95 ° C. to obtain a base for artificial leather having a resin fiber ratio R / F = 12/88.

The obtained base for artificial leather was sliced parallel to the main surface and divided into two (thickness: 0.54 mm). Next, flame retardant processing was performed in the same manner as in Example 1 to obtain a flame retardant artificial leather base (thickness 0.61 mm, basis weight 296 / m ² , apparent density 0.485 g / cm ³ ). The flame retardant artificial leather substrate was treated using a shrinkage processing apparatus in the same manner as in Example 1 and contracted 7.9% in the vertical direction to obtain a stretchable flame retardant artificial leather.

Example 3
Sea-island-type composite fiber staple with an isophthalic acid-modified polyethylene terephthalate having a degree of modification of 6 mol% and a sea component of polyethylene (island component: sea component = 60: 40 (mass ratio); fineness 4.0 decitex; fiber A web was prepared by carding and cross-wrapping a length of 51 mm; a crimp number of 12 crimps / inch).
The web was entangled with a 1200 punch / cm ² needle punch and then contracted in hot water at 90 ° C. to obtain an entangled nonwoven fabric with a basis weight of 750 g / m ² .

The entangled nonwoven fabric obtained was impregnated with a 15% dimethylformamide (DMF) solution of polyether polyurethane, and then immersed in a mixed liquid bath of DMF and water to wet-coagulate the polyurethane. After removing the remaining DMF by washing with water, the sea component polyethylene was extracted and removed in a 85 ° C. toluene bath, and the remaining toluene was removed azeotropically in a 100 ° C. hot water bath, followed by drying. A substrate for artificial leather having m ² and a thickness of 1.5 mm was obtained.

The surface of the obtained artificial leather substrate was buffed twice with No. 180 sandpaper to make the surface smooth and the thickness was 0.65 mm. The surface was then buffed twice with sandpaper No. 240 and twice with sandpaper No. 400 to obtain a napped artificial leather with a raised surface composed of ultrafine polyethylene terephthalate fibers (thickness 0.65 mm, basis weight) 304 / m ² , apparent density 0.468 g / cm ³ ).

Next, flame retardant processing was performed in the same manner as in Example 1 to obtain a flame retardant artificial leather base (thickness 0.64 mm, basis weight 325 / m ² , apparent density 0.508 g / cm ³ ). The flame retardant artificial leather substrate was treated using a shrinkage processing apparatus in the same manner as in Example 1, and contracted 3.5% in the vertical direction to obtain a stretchable flame retardant artificial leather.

The evaluation results of the stretchable flame-retardant artificial leather obtained in Examples 1 to 3 are shown in the table.
The stretchable flame retardant artificial leather substrate obtained in Examples 1 to 3 has a micro waviness structure along the vertical direction, and contains the flame retardant fine particles, but also stretchable and stretchable in the vertical direction. The feeling of stopping was excellent. In addition, it has a soft texture, high density and excellent mechanical properties, but the texture is full and flexible, and when bent, fine wrinkles are uniformly generated, and the base for artificial leather for car seats It was an extremely excellent material.

Comparative Examples 1-3
A substrate for artificial leather was obtained in the same manner as in Examples 1 to 3 except that the shrinkage processing was not performed. The evaluation results are shown in Table 1. See FIGS. 6 and 7 for the vertical direction load elongation curve and the scanning electron micrograph of the cross section parallel to the thickness direction and the vertical direction of the substrate for artificial leather not subjected to the shrinking process of Comparative Example 1.

  As is clear from Table 1, the base materials for artificial leather of Comparative Examples 1 to 3 were poor in extensibility in the vertical direction and a feeling of non-stretching and had a hard texture.

  According to the present invention, the stretchable flame retardant artificial leather has moderate stretchability in the vertical direction and a feeling of non-stretching while maintaining high mechanical strength and containing flame retardant fine particles. In addition, since it is excellent in moldability, it can be suitably used for furniture, car seats, and other leather products that require flame retardancy.

DESCRIPTION OF SYMBOLS 1 Substrate for artificial leather 2 Drum 3 Belt 4 Pressure roller 5a, 5b Turn roller 6 Shrinked artificial leather 11 Metal roller 12 Thick rubber part 13 Rubber roller 14 Shrinked artificial leather

Claims (7)

Stretch flame retardant artificial leather containing a polymer elastic body and flame retardant fine particles in a fiber entanglement composed of ultrafine fibers with an average single fiber fineness of 0.9 dtex or less, and an apparent density of 0.40 g / cm ^The number of pitches of the waviness structure having a micro waviness structure composed of the ultrafine fibers in the vertical direction in a cross section parallel to both the thickness direction and the vertical direction, and existing in 1 mm in the vertical direction. Is a stretchable flame-retardant artificial leather having an average height of the waviness structure of 50 to 350 μm.   The stretchable flame-retardant artificial leather according to claim 1, wherein the flame-retardant fine particles have an average particle size of 10 μm or less.   The stretchable flame-retardant artificial leather according to claim 1 or 2, wherein the flame-retardant fine particles are a flame retardant comprising a metal salt of a dialkylphosphinic acid.   The stretchable flame-retardant artificial leather according to any one of claims 1 to 3, wherein the polymer elastic body is a solidified product of a polyurethane water-based emulsion.   The stretchable flame-retardant artificial leather according to any one of claims 1 to 4, wherein the ultrafine fiber is an inelastic fiber.   The stretchable flame-retardant artificial leather according to claim 5, wherein the non-elastic fiber is a polyester fiber. The stretchable flame-retardant artificial leather according to any one of claims 1 to 6, wherein the micro waviness structure is formed by shrinking in a vertical direction and heat setting.