JP6065151B1 - Artificial leather - Google Patents

Abstract

An artificial leather having anti-pilling property, excellent durability, smooth surface, good touch, and not fluffy when touching clothing, and suitable for clothing fabrics, chair upholstery, and vehicle interior materials. An artificial leather is constituted by a fabric 12 made of an ultrafine thermoplastic synthetic fiber 11 having a surface having a single fiber fineness of less than 1 dtex. The fabric 12 is soaked with a thermoplastic resin, and at least one side of the fabric 12 is formed with a depression 32 having a height difference p of 0.3 mm or more between the flat surface 31 and the bottom 33 at least one side. The wall surface reaching the bottom 33 is the inclined wall surface 18 of the recess 32. The inclined wall surface 18 becomes a hot melt 15, and the inclined wall surface 18 is an uneven surface adjacent to a convex portion 21 and a concave portion 22 that are different in size from the hot melt 15. The unevenness difference q between the convex portion 21 and the concave portion 22 is less than 0.3 mm. [Selection] Figure 1

Description

  The present invention relates to an artificial leather excellent in air permeability, and more particularly to an artificial leather suitable for clothing fabrics, chair upholstery, and vehicle interior materials that do not give a feeling of stuffiness during use.

  As a method for imparting air permeability to the artificial leather, a heat drilling method for piercing a heated metal needle (for example, see Patent Document 1), an embossing method for generating a crack in a resin film through an embossing roll (for example, Patent Document 2,) 3), a stagnation processing method (for example, refer to Patent Document 4) for generating a crack by stagnation processing, a foreign material extraction method (for example, see Patent Document 5) for extracting soluble foreign materials mixed in the resin film, and artificial leather Solvent application method (for example, refer to Patent Document 6) for applying a solvent to the porous surface layer to open a porous film, and marking a soluble chemical on artificial leather consisting of several types of fibers with different chemical solubility. It is known as a contact printing method (for example, see Patent Document 7) or a punching method for performing a punching process (for example, see Patent Document 8). It is known.

  The present inventor has (a) a non-woven fabric containing a thermoplastic synthetic fiber having a single fiber fineness of 3 dtex or more and 50 dtex or less, and (b) via a melt produced by heating the thermoplastic synthetic fiber to a laser beam. An underlay carpet is disclosed in which melted fiber ends of a plurality of thermoplastic synthetic fibers adjacent to each other are connected to provide a mushroom-type hook fastener functionality of a mushroom-type hook-and-loop fastener to the melt (see, for example, Patent Document 9). .

Japanese Patent Publication No. 55-45670 (Japanese Patent Laid-Open No. 54-138102) Japanese Utility Model Publication No.59-031756 (Japanese Utility Model Publication No.57-180791) JP-B-02-002993 (JP 59-199874) Japanese Patent No. 4405834 (Japanese Patent Laid-Open No. 2005-264371) Japanese Examined Patent Publication No. 54-034029 (Japanese Patent Laid-Open No. 48-007957) Japanese Patent No. 4419090 (Japanese Patent Laid-Open No. 2007-039854) Japanese Patent No. 4778864 (Japanese Patent Laid-Open No. 2008-057064) Japanese Patent No. 5683353 (JP 2012-207352) Japanese Patent No. 5840808

  In the hot drilling method, the hot melt is fused to the heated metal needle during hot perforation, and the insertion resistance of the heated metal needle received from the artificial leather is increased by the hot melt, and the through holes are evenly drilled. It becomes difficult to install, and the hot melt is transferred from the heated metal needle and the artificial leather is easily contaminated.

  In the embossing method, it is difficult to ensure the required air permeability because the cracks are fine, and the embossed pattern dominates the appearance, so that a smooth plain-tone artificial leather cannot be obtained.

  In the stagnation processing method, it is difficult to ensure the required air permeability due to fine cracks, and small wrinkles are generated in the resin film, and silver-tone artificial leather cannot be obtained.

  According to the contact printing method, the generated air holes are porous traces of some types of fibers that have been dissolved and removed, and the fibers remaining around the air holes are easily removed and easily unraveled.

  In the foreign matter extraction method, the physical properties of the resin film are impaired by the mixed soluble foreign matter, and artificial leather excellent in durability cannot be obtained.

  In the solvent coating method, the generated aperture is as small as 3 to 159 μm, and even if moisture permeability is ensured, it does not provide breathability to the extent that it does not give a sense of stuffiness. It is not durable because it is clogged, and the solvent to be used is an organic solvent such as dimethylformamide, tetrahydrofuran, dioxane and the like.

  In the punching method, the peripheral edge of the through hole is easily unraveled, and durability is a problem.

The invented carpet provided with the mushroom-type hook functionality disclosed in the above-mentioned Patent Document 9 by the present inventor itself does not suggest artificial leather with excellent air permeability, but in the process of obtaining the underlay carpet, a laser beam is applied to the nonwoven fabric. When heated and heated, the thermoplastic synthetic fiber shrunk in the process of forming a melt, and the portion of the nonwoven fabric irradiated with the laser beam became thinner, and a ventilation function was felt.
Therefore, when the prototype experiment is repeated, a ventilation effect appears as the nonwoven fabric becomes low in weight, but the nonwoven fabric containing a thermoplastic synthetic fiber having a single fiber fineness of 3 dtex or more has a mushroom type that resembles a mushroom type surface fastener at a laser beam irradiation location. A hook function also appears.
As a result, the nonwoven fabric is hard and rough, making it unsuitable for clothing fabrics, chair upholstery, and vehicle interior materials.

  Therefore, when a non-woven fabric made of thermoplastic synthetic fiber having a single fiber fineness of less than 3 dtex, which is not suitable for an underlay carpet, was tried, the mushroom-type hook function of the hot melt became thinner and the anti-pilling property was reduced as the single fiber fineness was reduced. It has been found that a non-woven fabric suitable for apparel fabrics, chair upholstery and vehicle interior materials can be obtained.

The artificial leather according to the present invention has been completed with such knowledge,
(1) The surface is constituted by a fabric 12 composed of an ultrafine thermoplastic synthetic fiber 11 having a single fiber fineness of less than 1 dtex, and (2) 10% by mass or more and 40% by mass or less of the fabric 12 penetrates into the fabric 12. (3) A recess having a height difference p of 0.2 mm or more on the surface between the flat surface 31 and the bottom 33 is formed on at least one side of the front and back of the fabric 12. (4) From the flat surface 31 The wall surface leading to the bottom 33 of the recess 32 is an inclined wall surface 18 of an inclined recess, and (5) the inclined wall surface 18 is formed by the hot melt 15 of the thermoplastic synthetic fiber 11, and (6) The inclined wall surface 18 is a concavo-convex surface in which a convex portion 21 and a concave portion 22 formed by different hot melts 15 are adjacent to each other, and (7) the convex portion 21 has a hemispherical shape protruding from the concave portion 22. And 8) the unevenness difference q convex portions 21 adjacent the inclined wall surface 18 and the recess 22 is a first feature that it is less than 0.4 mm.

  The second feature of the artificial leather according to the present invention is that, in addition to the first feature, (a) the depression is (1) the height difference p between the plane 31 and the surface of the bottom 33 is less than 0.3 mm. There is a shallow recess 32 (FIG. 1) in which the unevenness difference q between the convex portion 21 and the concave portion 22 adjacent to each other on the inclined wall surface 18 is less than 0.3 mm, (2) Height difference p on the surface of the plane 31 and the bottom 33 Is not less than 0.3 mm and less than 0.4 mm, and the concave and convex difference 32 between the convex portion 21 and the concave portion 22 adjacent to each other on the inclined wall surface 18 is less than 0.3 mm (FIG. 1), (3) The inner diameter (d) surrounded by the circumference is 0.3 mm or more and 2 mm or less, and the inner diameter (d) is gradually narrowed from the peripheral diameter (D) at the peripheral edge 16 toward the inner part 19, Recessed hole 24 (Fig. 2) having a height difference p of 0.4 mm or more from the surface of location 33 (4) The groove width (e) is 3 mm or more and 2 mm or less, and the inner diameter (d) gradually decreases from the peripheral diameter (D) at the peripheral edge 16 toward the inner part 19, and the height difference p between the plane 31 and the surface of the bottom 33 is 0. 4 mm or more troughs 34 (FIG. 4), (5) The enclave 30 of the same level as the surrounding flat surface 31 surrounding the depression 32 is raised from the basin 45, and the opening area is from the peripheral edge 16 toward the basin 45. The depression 44 gradually narrowing (FIG. 5), (6) the through hole 14 (FIG. 5) penetrating the front and back of the fabric 12, (b) the rim 16 of the depression is the surface of the artificial leather A point that is recessed from the plane 31 and is not square, that is, a depression extending from the plane 31 on the surface of the artificial leather beyond the peripheral edge 16 (through hole 14, depression 24, shallow depression 32, deep depression 32, valley groove 34, taper of the trumpet pipe to the bottom 33 of the depression 44) In this way, it is gently curved and intervenes in the curved surface.

  A third feature of the artificial leather according to the present invention is that, in addition to any of the first and second features, the fabric 12 is a nonwoven fabric made of thermoplastic synthetic fibers 11.

  The fourth feature of the artificial leather according to the present invention is that, in addition to any of the first, second and third features, the thermoplastic synthetic fiber 11 constituting the fabric 12 has a single fiber fineness of 0.25 dtex. It is in the point that it is less than a super extra fine fiber.

  The fifth feature of the artificial leather according to the present invention is that, in addition to any of the first, second, third and fourth features, the thermoplastic synthetic fiber 11 constituting the fabric 12 has a single fiber fineness. It is the point that it is a super extra fine fiber less than 0.1 dtex.

The sixth feature of the artificial leather according to the present invention is that in addition to any of the first, second, third, fourth and fifth features, the depression (14, 24, 32, 34, 44). The weight (M) of the total mass of the thermoplastic synthetic fibers 11 of the formed artificial leather and the mass of the thermoplastic resin is 700 g / m ² or less.

The seventh feature of the artificial leather according to the present invention is that, in addition to any of the first, second, third, fourth, fifth and sixth features, a depression (14, 24, 32, 34, 44) The weight per unit area (M) of the total mass of the thermoplastic synthetic fiber 11 of the artificial leather and the mass of the thermoplastic resin formed in the artificial leather is 300 g / m ² or less.

  In addition to any of the first, second, third, fourth, fifth, sixth and seventh features, the eighth feature of the artificial leather according to the present invention is that it penetrates into the interior of the fabric 12. The thermoplastic resin is urethane resin.

  A ninth feature of the artificial leather according to the present invention is that the fabric 12 is constituted in addition to any of the first, second, third, fourth, fifth, sixth, seventh and eighth features. The thermoplastic synthetic fiber 11 is polyester fiber.

  The tenth feature of the artificial leather according to the present invention is that in addition to any of the first, second, third, fourth, fifth, sixth, eighth, eighth and ninth features, 14, 24, 32, 34, 44), the pattern 47 is drawn on the surface.

Since the thermoplastic synthetic fiber 11 constituting the fabric 12 is an ultrafine fiber having a single fiber fineness of less than 1 dtex, it melts instantaneously when heated by irradiation with a laser beam, and is adjacent to the surface of the fabric 12. The hot melt 15 is instantly formed on the surface of the fabric 12 when the ultrafine fibers come into contact with each other.
The hot melt 15 is harder than the ultra-thin thermoplastic synthetic fiber 11 because it is a molded product in which adjacent ultra-fine fibers are brought into contact with each other, and the hard hot melt 15 is interposed on the surface. Therefore, the fabric 12 has anti-pilling properties, is excellent in abrasion resistance, and is rich in durability.

  A convex portion 21 adjacent to the concave portion 22 and having a concave-convex difference q of less than 0.4 mm and intervening in the hot melt 15 protrudes from the tip of a pile fiber having a single fiber fineness of 3 dtex or more protruding from the base fabric like a mushroom-shaped hook. It is not formed, but is raised less than 0.3 mm from the concave portion 22 adjacent to the convex portion 21 to form a hemispherical shape. Therefore, the surface is smooth and the touch is good, and the fibers of the clothing are not easily caught. Does not fluff even if touched.

  The thermoplastic synthetic fiber 11 and the thermoplastic resin constituting the artificial leather of the present invention are cured by cooling in depressions such as the through hole 14, the depression 24, the shallow or deep depression 32, the trough 34, and the depression 44. Then, through the hot melt 15 constituting the peripheral edges 16 and 17 and the inclined wall surface 18, the eyelids are firmly joined as if they were bound together by eyelets, so that the through holes 14, the recessed holes 24, the shallow bottom and deep bottom depressions The synthetic synthetic fiber 11 and the thermoplastic resin are not unraveled in the depressions such as 32, the troughs 34, and the depressions 44, and an artificial leather excellent in durability is obtained.

According to the present invention, artificial leather excellent in durability, rich in elasticity, soft, flexible and soft to the touch, well adapted to the skin as a clothing fabric, and well adapted to curved surfaces as a chair upholstery or vehicle interior material and easy to stretch Is obtained.
That is, any fabric of woven fabric, knitted fabric and non-woven fabric can be used as the base material of the artificial leather as long as the thermoplastic synthetic fiber 11 is used as the raw material. Double knitted fabrics (double jerseys), multiple woven fabrics such as triple woven fabrics and triple knitted fabrics can also be used.
However, in woven fabrics and knitted fabrics, the quality changes depending on the woven and knitted structure, the woven and knitted density, the material and fineness of the mixed woven yarn and knitting yarn, and is difficult to handle.
Therefore, the use of non-woven fabric is recommended as the base material for artificial leather.

The nonwoven fabric used for the base material of artificial leather is a kind of paper or Japanese paper, so that it becomes hard cardboard when a resin film is laminated on paper or Japanese paper, and shape stability and dimensions are obtained by laminating a resin film on the nonwoven fabric. Even if the stability is improved, a soft and flexible artificial leather cannot be obtained.
Therefore, when using a nonwoven fabric for the base material of artificial leather, it is recommended that the nonwoven fabric is simply impregnated with a thermoplastic resin and not laminated so that a thermoplastic resin film is bonded.
In that case, it is recommended to use a polyurethane resin as the thermoplastic resin soaked into the nonwoven fabric from the viewpoint of softness and flexibility of the artificial leather.

When finely pulverizing the fiber aggregate that is the plastic synthetic fiber 11, the internal voids are crushed and the fiber aggregate is reduced in size and becomes dense. Similarly, as the single fiber fineness of the plastic synthetic fiber 11 becomes fine, the internal voids decrease and the fabric 12 becomes dense.
Also, as the single fiber fineness of the plastic synthetic fiber 11 becomes finer, the heat capacity also decreases and the flammability increases, so when it is heated, it softens instantly and heat shrinks and heat melts.
And since the plastic synthetic fiber 11 is in the close contact state in the dense fabric 12 with few internal voids, when it is heated, it is thin and flexible and does not stimulate the skin, and between the adjacent convex portions 21 and concave portions 22. A film-like hot melt 15 having a small unevenness q is instantaneously generated.
Therefore, it is desirable that the single fiber fineness of the plastic synthetic fiber 11 is finer and is less than 0.25 dtex, preferably less than 0.2 dtex, more preferably less than 0.1 dtex.

  Further, from the viewpoint of the soft flexibility of the artificial leather, the nonwoven fabric has an ultrafine thermoplastic synthetic fiber 11 having a single fiber fineness of less than 0.25 dtex, preferably less than 0.20 dtex, more preferably less than 0.10 dtex, In particular, it is recommended to use extra fine polyester fibers.

  When the single fiber fineness of the thermoplastic synthetic fiber 11 used for the base material of the artificial leather is increased, the particle size of the molten mass of the hot melt 15 generated at the tip of the broken fiber which is heated and melted and broken is also increased. The clothes that come into contact with are caught and easily unraveled. In order to avoid the unraveling of the garment, it is recommended to use thermoplastic synthetic fibers 11 having a single fiber fineness of less than 0.25 dtex, preferably less than 0.20 dtex, more preferably less than 0.10 dtex, for the base material of artificial leather. The

The real thickness of the artificial leather is a value obtained by dividing the weight per unit area of the artificial leather (Mg / m ² ) by the density (ρg / cm ³ ) derived from the specific gravity (ρ) of the artificial leather, that is, the quotient (Mg / m ² ÷ ρg / cm ³ = M / ρμm) The specific gravity of the polyester used as the raw material for the artificial leather is 1.38, the density is 1.38 g / cm ³ , the specific gravity of the polyacrylate is 1.15, the density is 1.15 g / cm ³ , and the specific gravity of the acrylate copolymer 1.28, density 1.28 g / cm ³ , polyamide (nylon) specific gravity 1.14, density 1.14 g / cm ³ , vinylon specific gravity 1.30, density 1.30 g / cm ³ The specific gravity of polyvinyl chloride is 1.39 and the density is 1.39 g / cm ^3. The specific gravity (ρ) of these synthetic fibers and synthetic resins is generally around 1.3 and the density is 1.3 g / cm ³ . Become. Therefore, the substantial thickness of artificial leather having a basis weight (M) of 700 g / m ² should be generally 538 μm.
Here, “the real thickness of the artificial leather” means the thickness of the raw material without the internal voids composed of the raw material synthetic fiber and the raw material synthetic resin excluding the internal voids of the artificial leather, ie, the raw material synthetic fiber and the raw material synthesis It means the thickness calculated from the basis weight (Mg / m ² ) which is the mass per unit area of the artificial leather which is the total mass with the resin.
The characteristics of the artificial leather according to the present invention can be defined by the “substantial thickness of the artificial leather” for the following reasons.

That is, heat melting occurs when an artificial leather having a basis weight (M) of 700 g / m ² is heated without generating decomposition gas and a circular through hole 14 having an internal diameter (d) of 2 mm is formed as a heating mark. The mass of the object is equal to the mass of a circular punched piece having a diameter of 2 mm generated by punching a through hole having an internal diameter (d) of 2 mm.
The area of the circular punched piece with a diameter of 2 mm is a circular area with a radius of 1 mm, which is 0.0314 cm ² .
The volume of the hot melt corresponds to the volume of a circular punched piece with a diameter of 2 mm. The volume is 0.0314 cm ² of the circular punched piece with a radius of 1 mm and the real thickness of the artificial leather is 538 μm (= 0.0538 cm). Product (1.193 mm) ³ (≈0.00168932 cm ³ ).

That is, the total mass (Q) of the dent-forming layer of the artificial leather to which the present invention is applied is 700 g / m ² , and the through hole, the depression hole, the shallow bottom or the deep bottom formed in the artificial leather to which the present invention is applied. Since the maximum diameter of the depressions such as depressions, valley grooves, depressions, etc. is 2 mm, the hot melt generated in the artificial leather to which the present invention is applied is equivalent to a cube having a dimension of 1.193 mm (≈1.2 mm). Become a shape.
The total mass (Q) of the dent forming layer is 700 g / m ² and the actual thickness is 538 μm (= 0.538 mm). The maximum diameter is the dent such as through holes, recessed holes, shallow and deep pits, valley grooves, and pits. In the case of a 2 mm cylindrical shape, the height (538 mm) of the cylinder having a diameter of 2 mm and the thickness (tmm) of 0.6 mm is 0.6 mm, and the cylindrical shape is one third of the diameter of the diameter. Even if it touches the inclined wall surface 18 of the depression such as the through hole 14, the depression 24, the shallow or deep depression 32, the trough 34, or the depression 44, it does not give a sense of incongruity.

Whether the depressions such as the through hole 14, the depression hole 24, the shallow bottom or deep depression 32, the valley groove 34, and the depression 44 influence the tactile texture of the artificial leather is determined by whether the through hole 14, the depression hole 24, or the shallow depression. The hot melt 15 constituting the bottom or deep bottom depression 32, valley groove 34, depression 44, or the like is composed of the thermoplastic synthetic fiber 11 and the thermoplastic resin, which are raw materials of artificial leather, and the heat melting thereof. The volume of the object 15 is not due to the thickness or bulkiness of the artificial leather including the internal gap as described above, but to the depressions such as the through hole 14, the depression hole 24, the shallow or deep depression 32, the valley groove 34, and the depression 44. Is defined by the total mass (Q) of the total mass of the thermoplastic synthetic fiber 11 and the thermoplastic resin constituting the dent forming layer.
Therefore, the artificial leather of the present invention is characterized by the raw material synthetic fiber and the raw material synthetic resin, and the depressions such as the through hole 14, the depression hole 24, the shallow or deep depression 32, the trough 34, and the depression 44 are formed. It can be defined by the “substantial thickness” of the formed dent forming layer.

  In the artificial leather in which the through holes 14 are formed, the thickness of the dent forming layer is the actual thickness of the artificial leather. However, in the artificial leather in which the recessed hole 24 is formed instead of the through hole 14, the substantial thickness of the dent forming layer is a part of the thickness (t) of the entire artificial leather, and the apparent thickness of the entire artificial leather. It is calculated as a ratio (t / T) between (T) and the apparent thickness (t) of the depression forming layer (FIG. 6).

Similarly, the total mass (Q) of the dent-forming layer of the artificial leather in which the depressions 24 are formed is the basis weight (M) of the entire artificial leather, the apparent thickness (T) of the entire artificial leather, and the appearance of the dent-forming layer. It is calculated as the product (M × t / T) with the ratio (t / T) to the thickness (t) of the film (FIG. 6).
This is because the texture of the artificial leather in which the depressed hole 24 is formed is lower than the bottom (25) of the depressed hole 24 and is not formed in the lower layer thermoplastic synthetic fiber or thermoplastic resin that does not constitute the hot melt 15. Because it is not influenced.

If the inner diameter (d) of the through hole, depression hole, shallow or deep depression, valley groove, depression or the like is less than 1 mm, the volume of the hot melt becomes finer and gentle to the skin Artificial leather will be obtained.
That is, as described above, the substantial thickness of the depression forming layer of the recessed hole 24 of the artificial leather having a total mass (Q) of 700 g / m ² is generally 538 μm. The area of the circular punched piece having a diameter of 1 mm is a circular area having a radius of 0.5 mm, which is 0.0078 cm ² .
The volume of the hot melt in this case corresponds to the volume of a circular punched piece having a diameter of 1 mm, and the volume is the area (0.0078 cm ² ) of the circular punched piece having a radius of 05 mm and the substantial thickness (0. 0538 cm) (0.74 mm) ³ and further smaller. Therefore, even if it touches the slanted wall surface 18 of the artificial leather of the present invention, such as a through hole, a depression hole, a shallow or deep depression, a trough, or a depression, it does not give a sense of incongruity.

In addition, in the artificial leather of the present invention, the peripheral edge 16 of the depression such as the through hole 14, the depression hole 24, the shallow or deep depression 32, the trough 34, or the depression 44 is in a position recessed from the surface of the artificial leather, The inner diameter (d) of the inner diameter (d) from the peripheral diameter (D) at the peripheral edge 16 extends from the inner periphery 19 of the depression such as the through hole 14, the depression 24, the shallow or deep depression 32, the valley groove 34, and the depression 44. As the skin gradually narrows, the skin directly touches the hot melt 15 that constitutes the interior of the through hole 14, the depressed hole 24, the shallow or deep recess 32, the trough 34, or the recess 44. Therefore, artificial leather suitable for clothing fabrics, chair upholstery, and vehicle interior materials can be obtained.
Further, in order to make the hot melt 15 minute, the total mass (Q) of the dent forming layer is reduced to 600 g / m ² or less, more preferably 600 g / m ² or less, and the substantial thickness of the artificial leather is generally 460 μm or less. To be.

  The reason why polyester fibers are recommended is that, first of all, the hot melt 15 of polyester fiber is harder and hotter than the hot melt of other synthetic fibers such as polyamide (nylon), polypropylene and polyethylene. The effect of stitching the artificial skin front and back by the melt 15 is enhanced, and secondly, the melting point is higher than that of polyamide, polypropylene, polyethylene, etc., and the through hole 14, the depression hole 24, the shallow bottom or deep bottom depression This is because the temperature management of the melting point when forming the depressions such as 32, troughs 34, depressions 44, etc. becomes easy.

  When a pattern is plotted on the surface by depressions such as through holes 14, depressions 24, shallow or deep depressions 32, troughs 34, depressions 44, etc., it seems that depressions or vents are drilled. You can get artificial leather that does not give a stiff impression and is excellent in design.

It is a principal part expanded sectional perspective view of the artificial leather which concerns on this invention. It is a principal part expanded sectional view of the artificial leather which concerns on this invention. It is a principal part expanded sectional view of the artificial leather which concerns on this invention. It is a top view of the artificial leather which concerns on this invention. It is a principal part expanded sectional perspective view of the artificial leather which concerns on this invention. 1 is a plan view of an artificial leather according to the present invention. 1 is a plan view of an artificial leather according to the present invention. It is a principal part expanded sectional view of the artificial leather which concerns on this invention. It is a principal part expanded sectional view of the artificial leather which concerns on this invention. It is a perspective view of the jacket which becomes the artificial leather concerning the present invention. It is a perspective view of the jacket which becomes the artificial leather concerning the present invention. It is a perspective view of the curtain which becomes the artificial leather which concerns on this invention. It is a perspective view of the chair cover which consists of artificial leather which concerns on this invention.

  The formation of depressions such as through holes 14, depressions 24, shallow or deep depressions 32, troughs 34, depressions 44, etc., uses a laser beam irradiator, irradiates the surface of artificial leather with a laser beam, and heats the laser beam. This is performed by heating the plastic synthetic fiber 11 and the thermoplastic resin.

By the way, when a flame is radiated to the thermoplastic synthetic fiber deposition layer, a depressed hole is instantly generated, and if radiated as it is, the bottom of the hole also burns and the depressed hole becomes a through hole. The tunnel is wide and the difference between the entrance and exit is very small.
The same applies to the case where a laser beam is applied to the thermoplastic synthetic fiber deposition layer. If the laser beam is continuously applied for a long time, the distance between the peripheral diameter (D) of the through-hole 14 and the internal diameter (d). However, the wide and narrow gap disappears, making it difficult to obtain the artificial leather expected by the present invention.

  Therefore, in the present invention, a laser beam is irradiated to form a through hole 14 having a wide difference between the peripheral diameter (D) of the peripheral edge 16 and the internal diameter (d), the recessed hole 24, a shallow or deep recess 32, and a valley. In order to drill a recess such as the groove 34 and the depression 44, the outline of the through hole 14, the depression hole 24, the shallow or deep depression 32, the trough 34, the depression 44 and the like is fine. Even so, the laser beam is instantaneously moved and irradiated along the fine contour so as to trace the fine contour.

  In artificial leather used for chair upholstery and vehicle interior materials, there is a wide difference between the peripheral diameter (D) of the peripheral edge 16 on the laminated surface side of the thermoplastic resin film and the internal diameter (d) of the interior 19 of the through hole 14. When it is desired to increase the water-soluble resin composition or emulsion resin composition on the back side of the artificial leather or the back side of the base fabric 12 of the artificial leather that is heated by the laser beam later than the laminated surface of the thermoplastic resin film A backing adhesive such as an object may be lined up.

Artificial leather used for chair upholstery and vehicle interior materials is preferably backed with a backing adhesive to make it easier to apply to a base material.
In order to back the backing adhesive as described above or to make it easy to apply to the base material, it is preferable to raise the back of the artificial leather.

  When the surface of the synthetic leather or the artificial leather is irradiated with a laser beam, a thermal melt 15 in which the thermoplastic synthetic fiber 11 and the thermoplastic resin are integrated is generated at the irradiated portion, and the peripheral edge 16 is bordered on the integrated thermal melt 15. The peripheral edge 16 is recessed from the surface, and the diameter d is gradually narrowed from the peripheral edge 16 toward the interior 19, so-called tapered through hole 14, depression hole 24, shallow or deep recess 32, trough groove 34. This is because depressions such as depressions 44 are generated.

  Artificial leather impregnated with a thermoplastic resin can be prepared as a synthetic leather having a thermoplastic resin laminated on its surface and used for the artificial leather of the present invention.

  Thermoplastic resins include polyester, polyacrylate ester, acrylate copolymer, polyamide (nylon), vinylon, polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, ethylene vinyl acetate copolymer, ethylene chloride Vinyl copolymer, ethylene vinyl acetate vinyl chloride terpolymer, polyurethane, polyamino acid, polyamino acid polyurethane copolymer, and other synthetic rubber and natural rubber can also be used.

The pattern to be stipulated on the surface of the artificial leather has through-holes distributed in the unit areas 20a, 20b, 20c, 20d,... Of the unit area (4 cm ² ) in which the vertical dimension m and the horizontal dimension n of the artificial leather are 2 cm. 14. Opening areas Sa, Sb, Sc, Sd of the depressions 24 to 14a, 14b, 14c, 14d, etc., such as the depression 24, the shallow or deep depression 32, the trough 34, the depression 44, etc. The opening area occupancy in the unit area (4 cm ² ) can be partially changed, and can be depicted by the difference (difference) in the opening area occupancy of the unit regions 20a, 20b, 20c, 20d,. (FIG. 6).

  The pattern to be stipulated on the surface of the artificial leather includes through holes 14, depressions 24, shallow or deep depressions 32, valley grooves 34, depressions 44, etc. distributed in the unit areas 20 a, 20 b, 20 c, 20 d. Of the depressions 24 to 14a, 14b, 14c, 14d,... Are partially changed, and the opening areas Sa, Sb, Sc, Sd,. (Difference).

The pattern 47 to be stipulated on the surface of the artificial leather has through holes 14, depressions 24, shallow or deep depressions 32, valley grooves 34, depressions 44 distributed in the unit areas 20 a, 20 b, 20 c, 20 d. The distribution intervals of the depressions 24 to 14a, 14b, 14c, 14d,... Can be partially changed, and can be drawn by the difference (difference) in the distribution intervals (FIG. 7).
The pattern can be a geometrical figure, a realistic picture, or an abstract pattern, and can be drawn on the entire surface of the artificial leather. The inner diameter (d) of depressions such as through holes 14, depression holes 24, shallow or deep depressions 32, valley grooves 34, depressions 44, etc., which are the pixels of the pattern should be 2 mm or less. Depending on the composition, the through hole 14, the depressed hole 24, the shallow hole or the depressed hole 24, preferably within a range not exceeding half of the number of depressions such as the shallow bottom or deep depression 32, the valley groove 34, the depression 44, etc. In a range that is 20% or less of the number of depressions such as the bottom and deep depressions 32, valley grooves 34, depressions 44, etc., the internal diameter (d) is 2 mm or more and 4 mm or less, preferably 2 mm or more and 3 mm or less. It is also possible to form depressions such as holes, shallow or deep depressions, troughs, depressions and the like.

  The pattern 47 to be stipulated on the surface of the artificial leather has through holes 14, depressions 24, shallow or deep depressions 32, valley grooves 34, depressions 44 distributed in the unit areas 20 a, 20 b, 20 c, 20 d. The shape of the peripheral edges 16a, 16b, 16c, 16d,... Bordering the depressions 24 to 14a, 14b, 14c, 14d, etc. is partially changed, and the peripheral edges 16a, 16b, 16c, 16d,. It can also be depicted by the difference in shape (difference) (FIG. 6).

In the present invention, the inner diameter (d) of the depressions such as the through hole 14, the depression hole 24, the shallow or deep depression 32, the valley groove 34, the depression 44, etc. is assumed to be a perfect circle having the diameter d. The relational expression S = π × (d / d) between the opening area S of the depressions such as the through hole 14, the depression hole 24, the shallow or deep depression 32, the valley groove 34, the depression 44, and the inner diameter (d). 2) Calculated by ² .
Here, the opening area S means the area of the void inside the through hole seen through the hole bottom 25 of the recessed hole and the inside of the through hole when the artificial leather supported horizontally is viewed in plan view. The area of the air gap is obtained by actually measuring the area of the air gap obtained by copying the air gap.

In order to make the hot melt 15 fine as described above, the total mass (Q) of the dent forming layer, which is the sum of the mass of the fabric 12 and the mass of the thermoplastic resin film, is preferably 600 g / m ² or less. It is desirable to make it 500 g / m ² or less.

Artificial leather can also be used with the laser beam irradiation side facing up (Fig. 10). It can also be used with the irradiation surface facing the back side (FIGS. 11 to 13).
A surface material 41 such as a cosmetic material, an antifouling material, or a waterproof material is bonded or applied to the surface used toward the front side in use (FIG. 8), and on the back surface used toward the back side in use. Can also be laminated or backed with a backing material 42 such as a cushioning material, a soundproofing heat insulating material or a reinforcing material (FIG. 9).

  In the artificial leather that uses the laser beam irradiation surface facing the front side without bonding the surface material (41), the artificial leather is dyed and left unmelted thermoplastic synthetic fiber 11 without being irradiated with the laser beam. A shading pattern due to the difference in dyeing property generated with the hot melt 15 generated by the laser beam irradiation can be revealed on the laser beam irradiation surface (FIG. 10).

  In artificial leather obtained by irradiating a laser beam without penetrating to the back side of the irradiated surface, it is used as a light shielding material like a lamp shade or curtain 40 with the irradiated surface of the laser beam facing the back side. A watermark pattern 46 corresponding to the depth (f) of the depression such as the depression 24, the depression 32, the valley groove 34, and the depression 44 can be revealed on the back side (FIG. 12).

  In an artificial leather that requires strong breathability and wear resistance, such as a chair upholstery 39, a through hole 14 is formed in the leather, and the surface of the surface 41 is placed on the back side of the laser light irradiation surface. They are used together (FIG. 13).

Apparent thickness measured with a dial thickness gauge in which 57.5 g / m ² (dry weight) of urethane resin is impregnated into a polyester fiber non-woven fabric with a basis weight of 172.5 g / m ² consisting of polyester fiber having a single fiber fineness of 0.04 dtex. Is a commercially available non-woven fabric (synthetic fiber felt) having a total weight of 230 g / m ² and a “substantial thickness” of 177 μm (= 230 g / m ² ÷ 1.3 g / cm ³ ). Through the apparatus, the artificial fabric is irradiated with a laser beam so as to trace a fine circular outline, and the through hole distribution density is 4 / cm ² (the number of through hole distribution in the unit region is 16/4 cm ² ). A circular through hole having an internal diameter (d) of 0.86 mm and a through hole opening area of 0.58 mm ² was drilled to finish artificial leather.

  The carbon dioxide laser beam irradiation device has a maximum output of 600 W to 1000 W, an average output of 10 W to 330 W, a laser beam wavelength of 10.6 μm, an oscillation frequency of 25 kHz or less, an operating speed of 4000 mm / min, a beam size of 12 ± 0.5 mm, and a marking line thickness of 0. A laser beam irradiation device “Biade RF-333” manufactured by Italy High-Tech Co., Ltd. having a diameter of 4/2 mm was used.

The open leather area occupying the unit area (4 cm ² ) of the obtained artificial leather is 2.32%, the air permeability according to JIS-L-1096 (Fragile A method) is 25.37 cc / cm ² / sec, JIS- The bending resistance by L-1096 (cantilever A method) is 6.4 cm, and the hot melt 15 generated by heating with a laser beam protrudes from the peripheral edge 16 of the through-hole 14 and does not protrude to the surface. The diameter d of the hole 14 is gradually narrowed from the peripheral edge 16 of the surface of the artificial leather toward the inside 19 of the recessed hole 24, and is soft and flexible, has a good touch, is well-familiar to the skin, and has high quality as a clothing fabric. It was.

  The artificial leather of the present invention can be used for clothing materials, chair upholstery materials, vehicle interior materials, as well as decorative materials such as wall upholstery materials, furniture surface materials, cover materials.

d: internal diameter e: groove width f: depth m: vertical dimension n: weft dimension p: elevation difference q: unevenness difference D: peripheral diameter 11: thermoplastic synthetic fiber 12: fabric 13: thermoplastic resin 14: through hole 15: hot melt 16: peripheral edge 17: peripheral edge 18: inclined wall surface 19: inside 20: unit area 21: convex part 22: concave part 24: depression hole 25: hole bottom 30: enclave 31: plane 32: depression 33: low part 34: Tanizo 35: Valley bottom 39: Chair upholstery 40: Curtain 41: Surface material 42: Backing 44: Recess 45: Basin 46: Watermark 47: Picture

Claims (5)

(1) The surface is constituted by a fabric (12) consisting of an ultrafine thermoplastic synthetic fiber (11) having a single fiber fineness of less than 1 dtex,
(2) 10% by mass or more and 40% by mass or less of the thermoplastic resin of the fabric (12) is infiltrated into the fabric (12);
(3) At least one side of the fabric (12) is formed with a depression in which the height difference (p) between the surface of the flat surface (31) and the bottom (33) is depressed by 0.2 mm or more on one side,
(4) The wall surface from the plane (31) to the bottom (33) of the depression (32) is an inclined wall surface (18) of the depression,
(5) The inclined wall surface (18) is formed of a hot melt (15) of the thermoplastic synthetic fiber (11),
(6) The inclined wall surface (18) is a concavo-convex surface in which the convex portion (21) and the concave portion (22) formed by the hot melts (15) of different sizes are adjacent to each other,
(7) The convex part (21) has a hemispherical shape raised from the concave part (22),
(8) Artificial leather in which the unevenness difference q between the convex portion (21) and the concave portion (22) adjacent to each other on the inclined wall surface (18) is less than 0.4 mm. (A) The dent is
(1) The height difference p between the surface of the flat surface (31) and the bottom (33) is less than 0.3 mm, and the unevenness difference between the convex portion (21) and the concave portion (22) adjacent to each other on the inclined wall surface (18) ( a shallow recess (32) with q) less than 0.3 mm,
(2) The height difference (p) on the surface of the plane (31) and the bottom (33) is not less than 0.3 mm and less than 0.4 mm, and the convex portion (21) and the concave portion adjacent to each other on the inclined wall surface (18). (22) Deep recess (32) having an unevenness difference q of less than 0.3 mm,
(3) The inner diameter (d) surrounded by the inclined wall surface (18) is 0.3 mm or more and 2 mm or less, and the inner diameter (d) is changed from the peripheral diameter (D) to the inner side (19 ) And a depression (24) having a height difference (p) between the plane (31) and the bottom (33) of 0.4 mm or more,
(4) The groove width (e) is not less than 0.3 mm and not more than 2 mm, and the inner diameter (d) is gradually narrowed from the peripheral diameter (D) at the peripheral edge (16) toward the internal (19), 31) and a trough (34) having a height difference (p) between the surface of the bottom (33) of 0.4 mm or more,
(5) The enclave (30) of the same level as the surrounding plane (31) surrounding the depression (32) is raised from the basin (45), and the opening area is from the periphery (16) to the basin (45) A depression (44) that is gradually narrowed,
(6) A through hole (14) penetrating the front and back of the fabric (12),
Either
(B) The artificial leather according to claim 1, wherein a peripheral edge (16) of the recess is in a position recessed from the plane (31) of the surface of the artificial leather and is not angular.   The artificial leather according to any one of claims 1 and 2, wherein the fabric (12) is a nonwoven fabric comprising thermoplastic synthetic fibers (11).   The artificial leather according to any one of claims 1, 2 and 3, wherein the thermoplastic synthetic fiber (11) constituting the fabric (12) is an ultrafine fiber having a single fiber fineness of less than 0.25 dtex. The weight per unit area (M) of the total mass of the thermoplastic synthetic fiber (11) of the artificial leather in which the depressions (14, 24, 32, 34, 44) are formed and the mass of the thermoplastic resin is 700 g / m ² or less. The artificial leather according to any one of claims 1, 2, 3, and 4.

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