JPS59157383A - Synthetic leather and production thereof - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to artificial leather using collagen fiber nonwoven fabric and a method for producing the same.

Artificial leathers with a three-dimensional nonwoven fabric as a base layer and a surface layer laminated thereon are commercially available. This artificial leather is
Although its performance is close to that of natural leather, it still
It is not as good as natural leather in terms of texture, sense of fulfillment, breathability, etc.

As a result of studying the structures of natural leather and artificial leather, the author of this application focused on the self-breathing property of collagen fibers against humidity, etc., and found that there is a gap between collagen fibers or a base layer mainly composed of collagen fibers and an epidermal layer. We thought that by providing a microcell layer with breathability, appropriate elasticity, and flexibility, we could obtain artificial leather that has the same breathability, texture, wrinkle formation, and recovery properties as natural leather. The present invention was completed through research on the layer structure and its formation method.

An object of the present invention is to provide artificial leather that has properties similar to natural leather, that is, strength 2 breathability, texture, and leather odor.

The artificial leather according to the present invention consists of a collagen fiber nonwoven needle-punched fabric impregnated with a wet polymer binder for artificial leather, and a porous cell layer with a circular cell layer as a lower layer and an upright cell layer as an upper layer. It is characterized by a structure in which a final skin layer is laminated on the upright cell layer.

That is, collagen m-fiber nonwoven needle punching is used to ensure self-breathing properties such as 1 strength, and a porous cell layer consisting of a circular cell layer and an upright cell layer is placed between the final epidermal layer and the circular cell layer is made of nonwoven needles. By providing it in contact with the punching layer, collagen fibers are provided with flexibility that follows the behavior of the non-woven needle-punched cloth, and the upright cell layer is provided with appropriate elasticity, etc., and this synergistic effect makes it similar to natural leather. It imparts the texture, that is, the tactile sensation, the ability to form wrinkles upon bending, the ability to recover from wrinkles, etc.

An example of the cross-sectional shape of the artificial leather according to the present invention is schematically shown in FIG. A porous cell layer 2 consisting of the following is laminated, and a final skin layer 4 is laminated thereon via a structural polyurethane layer 3. The surface of the collagen fiber nonwoven fabric layer 1 is a puffed layer 5 with a puff finish. As shown in the enlarged sectional view of FIG. 2, the porous cell layer includes a circular cell layer 7 made up of circular cells 6 and an upright cell layer 9 made up of upright cells 8, which are successively formed. The diameter of the open-cell circular cell is approximately 50 to 70 μm, and the thickness of the circular cell layer is:
Approximately 240 μm, and the open cell type upright cell 8 is
Height: about μm, diameter: 30/! I! The vertical cell layer has a hollow cylindrical shape of approximately 200 to 250 μm in height. In addition, as shown in Fig. 3, the collagen long fiber non-woven fabric is made of collagen long fibers 10 using a thin woven fabric (or net fabric) as a core material, and the fibers are bonded with a wet polymer binder 12 for artificial leather. Filling is combined.

Note that the porous cell layer with the above-mentioned two-layer structure is usually formed continuously in contact with the nonwoven fabric layer, but it can also be formed separately as a circular cell layer, an upright cell layer, or a two-layer continuous layer of a circular cell layer and an upright cell layer. Alternatively, a cell layer may be formed and these layers may be laminated on a nonwoven fabric so as not to impair air permeability.

Next, a method for manufacturing artificial leather according to the present invention will be explained. Collagen fiber non-woven needle-punched fabric for artificial leather is impregnated with a low modulus, low concentration polymer elastomer compounded liquid for artificial leather several times in stages depending on the solid content. After semi-solidification, high modulus, high concentration Applying a polymer elastomer compound solution for artificial leather and using a wet processing method,
A porous cell layer having a circular cell layer as a lower layer and an upright cell layer as an upper layer is continuously provided on the nonwoven fabric, and a final skin layer is laminated on the porous cell layer via a structural polyurethane layer. Its characteristic is that it forms leather.

The collagen fiber non-woven needle-punched cloth used in the present invention is made by crushing mass-produced natural leather, collecting long fibers from those completely defibrated into fibers, and using woven or net cloth as a core cloth. A collagen fiber non-woven fabric is made by making a collagen fiber non-woven fabric and then needle punching the collagen fiber non-woven fabric. Incidentally, the nonwoven fabric described in "2" is mainly composed of collagen fibers, and may be one in which natural fibers or synthetic fibers are mixed.

Next, the nonwoven fabric is impregnated and coated with a wet polyurethane elastomer for artificial leather several times in stages.
Impregnation is carried out in a first impregnating tank filled with a mixed solution of No. 796 dimethylformamide (hereinafter abbreviated as M and F). It is preferable that the basis weight at this time is 150 to 200 g/m'' wet.Next, in the second impregnation tank, using the same type of elastomer, a glue, S, and F solution with a solid content of 8 to 10% is mixed. , Wet basis weight: 200-250g/IT'+2
Impregnate it so that

In addition to the polyurethane elastomer, a solid nylon compound liquid or the like can be used as the above-mentioned compound liquid.

After impregnation, semi-coagulation is performed in a semi-coagulation tank (water or salt water at 20-40°G), and the weight is 3-5 kg/cm using nip rolls.
Nip treatment is performed with a press pressure of 1. Next, a highly concentrated wet polyurethane for artificial leather with high modulus is applied using a banked doctor with adjusted hydraulic pressure.

Mixed melting (solid content concentration 12-20%) wet basis weight W
r 700 g/m ” -1000 g/m ” After confirming that the surface is smooth, the main coagulation tank (
D, M, F in warm water (20-40°G) (soak for 4-10 minutes).

After confirming the coagulation state through metabolism with water, transfer to the washing tank. For example, there are three washing tanks: 60°C, 70°G, and 80°G.
D.

Wash and dry to completely remove M and F.

Through this treatment, the wet polyurethane porous layer has a two-tiered cell structure, with the surface layer having an upright cell structure, the bottom layer having a circular or oval cell structure, and the top layer having a circular or oval cell structure. The layers form a microscopic cell layer that is breathable.

The composition, opening amount and coagulation of the above elastomer mixture,
Washing conditions and the like can be selected within a range that does not depart from the purpose of the present invention.

Next, a top layer is laminated with a cross-linking polyurethane liquid on the cell layer obtained as described above, and a cured urethane layer for dyeing is laminated by a conventional method, and various patterns and patterns are printed on the surface. After dyeing the material, the material is dyed using the same dyeing method as natural leather to obtain artificial leather based on the collagen-woven nonwoven fabric.

Hereinafter, the present invention will be defined in more detail by Examples.

EXAMPLE A collagen fiber non-woven needle-punched cloth produced by the method described above was immersed in an impregnating bath filled with a wet polyurethane elastomer compounded solution of Formulation 1, and wet for 180 min.
g/m 2 (= set so that it can be worn.

Process: j 1 parts by weight Wet polyurethane distomer 1 solution (100% modulus 35 kg/cm 2)
100.0 Affinity surfactant 21.5 Hydrophobic surfactant 32.0 Marbosol PO' 5.0 Cell adjustment *t15'1.0 Pigment
5.0D, M, F・
220.0 Note 1) Manufactured by Sanyo Chemical Industries, Ltd.
Sunburen L Q 33342) Manufactured by Nippon Zeon Co., Ltd.
Zeon P Sodium dioctyl sulfosuccinate 3) Made by Dainippon Ink Chemical Co., Ltd. Crisbon Asyster 5D-7 Nonionic polymer activator 4) Polyethylene emulsion made by Matsumoto Yushi Pharmaceutical Co., Ltd. 5) Made by Dainippon Ink Chemical Co., Ltd. lisbon assistant
The 5D-8i nonionic polymer activator was then impregnated into a wet polyurethane elastomer solution bath of Formulation 2 to give a wet coating weight of 200 g/m 2 .

Affinity surfactant 21.0 Hydrophobic surfactant 32.0 Marbosol P○45.0 Cell conditioner α5 pigment
Shiod,
M, F・20α
0 Note 1), 2), 3) +4) +51 After impregnating each with the same formulation 1, the resin layer of the impregnated collagen fiber nonwoven needle punched cloth was semi-solidified in a 5 m coagulation tank (wet with water at 20°G). After soaking in water for about 40 seconds, the roll interval is set to 0 in a free state using nip rolls, and water is squeezed out with a squeezing pressure of 6 kg/cm 2 to make the surface to be coated as smooth as possible.

Next, apply the wet E-polyurethane elastomer solution of Formulation 3 to a wet basis weight of approximately 700 to 100 using a doctor with a bank.
0 g//m'' and a coating thickness of 0.3 mm.

Affinity surfactant 31.5 Hydrophobic surfactant 42.0 Cell conditioner 51.0 Disparon 1970 0.5 Sodium bicarbonate 10.0 KOV130
0 2CLO Face Li
7.OD, M, F,
70.03) Same as 2) of Recipe 1 4) Same as 3) of Recipe 1 5) Same as 4) of Recipe 1 After exiting the coagulation tank, the water is squeezed out using nip rolls, and the water is washed in the first tank (warm water 60°G) and the second tank (warm water 60°G).
℃), completely rinsed with water in the third tank (hot water 70℃), and then transferred to the impregnated wet polyurethane porous cell layer.
Wash with water to the extent that it does not contain . After washing with water, the water is squeezed out using a nip roll, and the air volume is increased using a drying machine, and the hot air temperature is kept as low as possible (furnace temperature: 90°C) to dry.

Next, apply the cured urethane solution of Formulation 4 over a dry film onto a release paper to a thickness of 0.2 mm (0.2 mm) to form a dry film.

Cured urethane solution for dyeing 110αO Dyeing accelerator additive 20.3 Swelling inhibitor 3&O D, M, F, 25.0 Methyl ethyl ketone 35.0 Matting agent 45
．． 0 Finishing viscosity 8000-10000 cpis Note 1) Petal 4002 G polyurethane elastomer manufactured by Toyo Polymer Co., Ltd. 2) Sulfated oil manufactured by NOF C) 3) Protin AD-105 10% special in toluene solution manufactured by Toyo Polymer Co., Ltd. The resulting dry film containing metal compounds (
The structural polyurethane solution of this formulation 5 has a basis weight of 90 to 10.
0 g/m was applied in seven layers and immediately laminated with a wet polyurethane porous layer.

Prescription 5 parts by weight Elevated polyurethane solution 110α0 Diphenylmethane diisocyanate 5.0 Elevation accelerator Q7.0 D, M, F, 1F Ethyl acetate for viscosity adjustment Adjust as needed - Viscosity
6000-7000 cpis Note 1) Dainippon Ink & Chemicals Co., Ltd. Chrisbon 62082) Same as above Chrisbon Axel HM The bonded materials were pressed at a press pressure of 1-2 kg/cm 2 to 110°0.1206C, 140° G.1
Dry sequentially at a temperature of 50°C, and then dry in a ripening room (room temperature 30-40°C).
After aging at 5° C. for 8 to 12 hours, the release paper was peeled off to complete a matrix of collagen nonwoven artificial leather. The surface was subjected to PjlA, tying, etc., then dyed, and finally dried to obtain artificial leather containing collagen W and fiber nonwoven fabric as main phases.

The comparison results of the characteristics of this artificial leather and natural leather are shown in Table 1 below.

As shown in this table, properties similar to natural leather can be obtained.

The artificial leather obtained in this way has the following characteristics.

1. It has excellent absorbency as it is mainly composed of collagen fibers.

2. It is lighter than natural leather and has appropriate elasticity and drapability.

3. Dimensional stability. That is, the die can be cut freely without any direction.

4. It is breathable and has an odor similar to real leather.

This artificial leather is used for shoe uppers and bags.

It can be widely used for camera cases, belts, industrial materials, etc.

[Brief explanation of the drawing]

FIG. 1 is a sectional view of the artificial leather according to the present invention, and FIGS. 2 and 3 are an enlarged sectional view of a conceptually illustrated porous cell layer and a collagen fiber base material layer, respectively. . 1... Collagen 'a-cone nonwoven fabric. 2...Porous cell layer. 4...Final epidermal layer, 6...Circular cell. 8... Upright cell, 11... Woven fabric. Patent applicant Asahi Chemical Industry Co., Ltd. Patent attorney Keiji Matsunaga

Claims (1)

[Claims] 1. A porous cell layer consisting of a circular cell layer as a lower layer and an upright cell layer as an upper layer is continuously formed on a collagen fiber non-woven needle punched cloth impregnated with a wet polymer binder for artificial leather. 1. An artificial leather, characterized in that the artificial leather is provided in one piece, and a final skin layer is laminated on the upright cell layer. 2. Add a low modulus, low concentration polymer elastomer compounded liquid for artificial leather to the non-woven needle punching machine for artificial leather in stages depending on the solid content (after impregnating it several times and semi-solidifying it, high modulus and high concentration A porous cell layer having a circular cell layer as a lower layer and an upright cell layer as an upper layer is continuously formed on the nonwoven fabric by applying a liquid polymer elastomer compounded solution for artificial leather and using a wet processing method. A method for producing artificial leather, which comprises laminating a final skin layer on F.