JPH04240274A - Melange-toned raised sheet-like product and production thereof - Google Patents

Abstract

PURPOSE:To obtain the title flexible leathery sheet-like product of high mechanical strength, excellent in weatherability and color variation by raising one surface of a nonwoven fabric sheet obtained by blending ultrafine fibers and pigmented fibers greater in fineness than the former fibers. CONSTITUTION:(A) Polyester conjugate fibers consisting of ultrafine fibers with a fineness of ca. 0.2 denier are blended with (B) pigmented fibers with a fineness (1-5 denier) greater than that of the former fibers at a weight ratio B/A=pref. 0.25-0.30 into a web. The web is then monolithically interlaced with a knitted fabric into a sheet followed by dissolving and removing the bound component of the conjugate fibers and then imparting a high molecular elastomer to the resultant sheet. Thence, the resulting surface is raised and the sheet is dyed, thus giving the objective leathery sheet excellent in weathering fastness and mechanical strength with natural leather-like touch and rich color tone.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a new artificial leather, and more particularly to a suede-type artificial leather having an excellent feel, weather resistance, and strong melange appearance.

0002

[Prior Art] Conventionally, as a means of obtaining suede-like artificial leather with a mélange-like appearance, a sheet is made by mixing two or more types of fibers with different dyeing behavior in an appropriate ratio, and then one type of fiber is mixed in an appropriate ratio. Alternatively, a method of dyeing with two or more different types of dyes has generally been used. For example, a fiber sheet is obtained by mixing ordinary polyester fibers such as polyethylene terephthalate with polyester fibers copolymerized with 5-sulfoisophthalic acid Na salt, and after applying a polymeric elastic material and raising the The sheet is dyed using disperse dyes and cationic dyes simultaneously or sequentially, or the sheet is made by mixing fibers that cannot be colored with ordinary dyes, such as polyolefin fibers, with polyester or polyamide fibers. This method involves dyeing only dyeable fibers.

0003

[Problems to be Solved by the Invention] However, the drawbacks of these conventional techniques include the following. In other words, when two or more different types of dyes are used, for example, disperse dyes and cationic dyes, the normal alkaline reduction washing required after disperse dyeing cannot be carried out because it dissolves the cationically dyeable fibers. Only products with very low color fastness or a very limited number of colors can be obtained. Additionally, in order to reduce damage to cationic dyeable fibers, the mixing ratio of the fibers can be increased;
As a result, there is a problem that the strength of the sheet itself decreases, and if the strength is compensated for by increasing the rate of application of the polymeric elastomer, the hand becomes hard and the product value decreases. Similar difficulties arise when using a combination of other discolored fibers, and in either case, it is extremely difficult to obtain a product with excellent weather resistance, high strength, and a soft texture.

[0004] Furthermore, when one side of the fiber is left undyed, such as a polyolefin fiber mixture, only a marbled white product can be obtained, which is a significant limitation in terms of diversification of surface appearance.

The object of the present invention is to solve the above-mentioned drawbacks of the prior art, and to provide a melange suede type that has excellent weather resistance, has a soft texture, is highly strong, and is available in a wide variety of colors. An object of the present invention is to provide an artificial leather sheet and a method for producing the same.

[0006]

[Means for Solving the Problems] A sheet-like article of the present invention that achieves the above-mentioned object has an integral structure of at least a nonwoven fabric and an elastic polymer, and has raised naps made of fibers constituting the nonwoven fabric on at least one surface thereof. A mélange-like napped sheet-like material having a mélange-like napped sheet, characterized in that the fibers constituting the nonwoven fabric are a mixture of ultrafine fibers and fibers having a fineness greater than the ultrafine fibers and colored with a pigment. It is a thing.

[0007] In the mélange-like napped sheet of the present invention, preferably, the fibers are colored with a pigment.
The weight mixing ratio with respect to the ultrafine fibers is 10% or more and 50% or less, or preferably, the knitted fabric or woven fabric is inseparable from the fibers constituting the nonwoven fabric in the inner layer portion of the nonwoven fabric and/or on at least one surface thereof. It exists as an integrated entity.

[0008] Furthermore, the method for manufacturing a sheet-like product of the present invention includes:
Forming a web by mixing composite fibers that can develop ultrafine fibers by dissolving and removing binding components and fibers colored with a pigment and having a fineness of 1 denier or more and 5 denier or less,
The web and the knitted or woven fabric are entangled and integrated to form a sheet, and then the binding components of the composite fibers in the sheet are dissolved and removed, and a polymer elastic body is added, and then,
This is a method for producing a mélange-like raised sheet material, characterized in that the surface thereof is raised.

[0009]

[Operation] The constituent elements of the sheet-like article of the present invention will be explained.

[0010] The main component of the fibers constituting the nonwoven fabric must be ultrafine fibers. In particular, in order to achieve a fine natural suede-like nap, feel, and elegant appearance, single fiber fineness of 0 is required. Preferably, the main component is ultrafine fiber with a fineness of .5 denier or less. More preferably, it is 0.2 denier or less, but from the viewpoint of weather fastness after dyeing, it is desirably 0.1 denier or more. That is, when considering use in automobile interior materials, etc., which require the product to have high weather fastness, it is most preferable to
It is 0.15 to 0.2 denier. In addition, as a method for forming ultrafine fibers, methods such as melt blowing or super draw may be used to directly obtain them, but in general, ultrafine fibers such as sea-island type composite fibers, mixed spun type composite fibers, and peelable type composite fibers that have ultrafine fiber forming properties are used. Preferably, a method is used in which the fibers are mechanically treated or bonded components are dissolved and removed. In particular, in order to give the fibers that make up the sheet an appropriate degree of freedom and achieve flexibility, it is necessary to dissolve and remove the bonding components to develop ultrafine fibers, which can be obtained from various types of composite fibers such as those mentioned above. Most preferred.

The composition of the ultrafine fibers is not particularly limited as long as it is a polymeric substance that has fiber-forming ability.
It is appropriately selected from polyester, polyamide, polyolefin, polyacrylic polymer, etc. As the bonding component for these ultrafine fibers, polymeric substances soluble in organic solvents, aqueous alkaline solutions, etc., such as polyethylene, polypropylene, polystyrene, and 5-sulfoisophthalate metal salt copolymer polyester, are used.

[0012] Fibers colored with pigments mixed with ultrafine fibers will be explained. Fibers colored with pigments (hereinafter referred to as spun-dyed fibers) are mixed with ultrafine fibers to give a mélange-like appearance to the surface of the resulting sheet, so their fineness is sufficient for the ultrafine fibers. It is necessary to have a difference in fineness, and at the same time, a sufficient mixing ratio is also required. However, when the fineness and/or mixing ratio of dyed fibers increases, the natural suede-like fine nap, feel, and elegant appearance that are characteristic of using ultrafine fibers are significantly impaired, making it difficult to obtain products with high commercial value. Can not. For this reason, spun-dyed fibers have a fineness of 1 denier or more and 5
It is preferable to use a denier or less, and more preferably a denier or more and a 3 denier or less. Also,
Its weight mixing ratio with respect to ultrafine fibers is 10% or more.
% or less, more preferably in the range of 20% to 35%. Furthermore, the relationship with the fineness of ultrafine fibers is also important for the expression of melange-like appearance and the optimization of quality and texture. is 2 to 2.5 denier,
Most preferably, the mixing ratio to the ultrafine fibers is 25 to 30%. The composition of the spun-dyed fibers is not particularly limited as long as it is a polymeric substance that has fiber-forming ability, and polyester, polyamide, polyolefin, polyacrylic polymers, etc. are mixed with inorganic or organic pigments by a conventional method. Colored ones are used as appropriate. Further, the polymer species of the dyed fibers may be the same as or different from those of the ultrafine fibers, and an appropriate combination is selected depending on the dyeing method and use.

In the sheet-like article of the present invention, in order to obtain a product with higher mechanical strength and soft texture, the inner layer of the nonwoven fabric and/or the surface of at least one thereof is coated with:
The knitted fabric or woven fabric is inserted so that it forms an inseparable integral structure with the fibers that make up the nonwoven fabric. The means for realizing such a sheet structure and the knitted fabric or woven fabric used are not particularly limited, and for example, those described in Japanese Patent Application Laid-open No. 78281/1983 can be used.

[0014] The sheet-like product of the present invention is produced by mixing composite fibers that can develop ultrafine fibers by dissolving and removing binding components with spun-dyed fibers to form a web, and entwining the web with knitted or woven fabrics. It can be obtained by combining the composite fibers to form a sheet, then dissolving and removing the binding components of the composite fibers in the sheet, adding a polymeric elastic body, and then raising the surface of the sheet. That is, for example, a mixture of polymer array fibers as described in Japanese Patent Publication No. 44-18369 and ordinary spun-dyed fibers in a desired ratio is prepared, and after being crimped, The cut short fibers are passed through a card and a cross wrapper to form a web, and then, as described in JP-A-62-78281, the intermediate sheet is formed into an integral structure with a fabric by needle punching. can get. When dissolving and removing the binding components of the polymer array fibers in the sheet and imparting a polymer elastic body, which of these operations should be performed first depends on the optimal order depending on the binding components and elution method used. There is, and it is not completely fixed. Further, prior to these operations, in order to control the density and texture of the surface nap of the final product, the intermediate sheet may be heat-shrinked or a water-soluble polymeric substance may be added thereto. Furthermore, there are no particular limitations on the polymeric elastomer and the method for applying it, but in order to obtain a soft feel and strength, wet coagulation of polyurethane is generally preferred. Furthermore, by grinding the surface of the sheet using sandpaper, a sheet having naps on the surface is finished, and by dyeing this by a conventional method, the sheet-like article of the present invention can be obtained.

[0015]

[Effects of the Invention] According to the present invention, the following effects can be obtained. A non-woven fabric made of finely woven fibers with excellent weather fastness mixed with ultra-fine fibers in an appropriate ratio is made into an integrated structure with a woven or knitted fabric as required, and is further added with a polymeric elastic material. By brushing and dyeing the surface of the sheet-like material, a melange suede-type leather-like material with excellent weather resistance, soft texture, and touch similar to natural leather, strong, and rich in color can be obtained. .

[0016]

[Examples] Next, the present invention will be explained in more detail with reference to Examples and Comparative Examples. Of course, the present invention is not particularly limited to these Examples.

[0017] The product was evaluated and measured by the following method. (1) Weather resistance: Sunshine Weather-Ometer 10
Discoloration due to 0 hour irradiation (black panel temperature 83°C, no spray) was evaluated and ranked as follows. ◎: 4th grade or above ○: 3rd to 4th grade △: 3rd grade ×: 3
Below grade (2) Abrasion resistance: Using a Schieffer type abrasion tester, the surface condition of the product that was abraded 50 times with a 13mm bristled nylon brush under a load of 8 pounds was compared with standard samples of each grade. . ◎: 4th grade or above ○: 3rd to 4th grade △: 3rd grade ×: 3
Below grade (3) Texture: Judgment was made based on the feel to the touch. ◎: Very good ○: Good △: Not very good
×: Poor (4) Melange effect: Judgment was made by visually observing the appearance. ◎: Clear effect ○: Effective △: Slightly effective ×: No effect Example 1 Component ratio 80/20 consisting of polyethylene terephthalate as the island component and polystyrene as the sea component, number of islands 16,
The fineness of the composite fiber is 3d (island component fineness 0.15d), the yarn is spun from 100 parts by weight of crimp tow with a number of crimps of 14 threads/inch, and polyethylene terephthalate chips to which 5% by weight of red pigment master chips are added, and the fineness is 2.1d. A mixed staple was obtained by using 24 parts by weight of crimp tow with a crimp number of 14 crimps/inch and cutting them into fibers of 51 mm length with a cutter. In this case, the weight mixing ratio of the spun-dyed fiber to the island component of the composite fiber, that is, the ultrafine fiber, is 30%. Using the staples, a web was prepared through the steps of carding and cross-wrapping, and then needle punching was performed using a pre-punching machine at a rate of 400 staples/cm 2 to produce felt having a basis weight of 210 g/m 2 .

[0018] A fabric made of polyethylene terephthalate raw silk strong twist yarn with 75 denier 72 filaments and a twist number of 2500 T/m (weaving density 90 x 80 threads/inch basis weight 75 g/m2) was evenly spread and layered on the felt to make a total of 275 filaments.
Needle punch at 0 needles/cm2, and the basis weight is 32.
A sheet material having an apparent density of 0 g/m2 and an apparent density of 0.215 g/cm3 was obtained.

The sheet-like material was shrink-processed in hot water at 98° C., a PVA solution was applied to the island component at a solid content of 5% and dried, and then the sea component was dissolved and extracted with trichlorethylene. This sheet was coated with a polyurethane DMF solution (concentration 11%).
) was impregnated in a solid content of 30% to the island component, dyed fibers, and total polyester component of the fabric, and then the polyurethane was coagulated in water. This sheet was further dipped in hot water and squeezed repeatedly to remove PVA and DMF and dried.
The non-textured side was ground with sandpaper and raised. This raised sheet was made using red disperse dye 0.5% OWF.
Jet dyed at 120°C for 1 hour, finished and finished to a thickness of 0.
A suede-like leather-like sheet with a diameter of 9 mm and a basis weight of 390 g/m2 was obtained.

The leather-like material thus obtained has an elegant and uniform appearance with a reddish melange effect, has excellent texture and feel, and has excellent physical properties such as weather resistance and abrasion resistance as listed in Table 1. It had a

Example 2 In obtaining a mixed staple, composite fiber crimp tow 1
A suede-like leather-like sheet was obtained in the same manner as in Example 1, except that the amount of spun-dyed fiber crimp tow was 12 parts by weight relative to 00 parts by weight. In this case, the weight mixing ratio of dyed fibers to ultrafine fibers was 15%, but as shown in Table 1, the melange effect of the obtained leather-like product was smaller than in Example 1.

Example 3 When obtaining a mixed staple, composite fiber crimp tow 1
A suede-like leather-like sheet was obtained in the same manner as in Example 1, except that the amount of spun-dyed fiber crimp tow was changed to 64 parts by weight relative to 00 parts by weight. In this case, the weight mixing ratio of the dyed fibers to the ultrafine fibers is 80%, and as shown in Table 1, the melange effect of the obtained leather-like product is sufficient, but the texture is slightly different from that of Example 1. It had a strong sense of roughness.

Example 4 A suede-like leather-like material was obtained in exactly the same manner as in Example 1, except that the fineness of the dyed fibers was changed to 5d in obtaining a mixed staple. It had a slightly rough texture, similar to the one obtained in the previous example, but the melange effect was sufficient.

[0024] When obtaining a comparative mixed staple, 8 mo of 5-sodium sulfoisophthalic acid was added as an island component instead of the dyed fiber.
Example 1 except that a composite fiber consisting of polyethylene terephthalate copolymerized with 1% copolymerized and polystyrene as the sea component, a component ratio of 80/20, a number of Shimamotos of 16, and a fineness of 3.8d (the fineness of the island component was 0.19d) was used. A raised sheet material was obtained in the same manner. Add 0.5% owf of red disperse dye to the sheet-like material.
The product was finished by dyeing in the same bath with 7% OWF of a red cationic dye to obtain a suede-like leather-like material with a red melange of shading. Although this product had excellent texture, touch, and abrasion resistance, it was significantly inferior to products using dyed yarn in terms of weather resistance.

[0025]

[Table 1]

Claims (4)

[Claims] Claims: 1. A sheet-like article consisting of an integral structure of at least a nonwoven fabric and a polymeric elastic material, and having raised naps made of fibers constituting the nonwoven fabric on at least one surface thereof, wherein the fibers constituting the nonwoven fabric are ultrafine fibers. and fibers having a fineness greater than that of the ultrafine fibers and colored with a pigment are mixed therein. 2. The mélange-like raised sheet material according to claim 1, wherein the weight mixing ratio of the pigment-colored fibers to the ultrafine fibers is 10% to 50%. 3. The nonwoven fabric according to claim 1 or 2, characterized in that the knitted fabric or woven fabric exists inseparably and integrally with the fibers constituting the nonwoven fabric on the inner layer portion of the nonwoven fabric and/or on the surface of at least one thereof. Melange-like raised sheet material. 4. A web is formed by mixing composite fibers capable of forming ultrafine fibers by dissolving and removing binding components and fibers colored with a pigment and having a fineness of 1 denier or more and 5 denier or less. The knitted or woven fabric is entangled and integrated to form a sheet, and then the bonding components of the composite fibers in the sheet are dissolved and removed, and a polymeric elastic body is added.
A method for producing a melange-like napped sheet material, which comprises subsequently raising the surface of the product.