JPWO2020044911A1 - 人工皮革基材、その製造方法及び立毛人工皮革 - Google Patents
人工皮革基材、その製造方法及び立毛人工皮革 Download PDFInfo
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- JPWO2020044911A1 JPWO2020044911A1 JP2020540169A JP2020540169A JPWO2020044911A1 JP WO2020044911 A1 JPWO2020044911 A1 JP WO2020044911A1 JP 2020540169 A JP2020540169 A JP 2020540169A JP 2020540169 A JP2020540169 A JP 2020540169A JP WO2020044911 A1 JPWO2020044911 A1 JP WO2020044911A1
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- fiber
- artificial leather
- base material
- fibers
- leather base
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
- D06N3/004—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using flocked webs or pile fabrics upon which a resin is applied; Teasing, raising web before resin application
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
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- B32B5/024—Woven fabric
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Abstract
Description
工程(1):互いに固有粘度の異なる2種の樹脂から形成された0.6dtex以上の長繊維の捲縮型繊維(A1)を含む第1の繊維ウェブを準備する工程。
工程(2):0.6dtex未満の極細繊維である繊維(B)を形成するための極細繊維発生型繊維(B1)の第2の繊維ウェブを準備する工程。
工程(3):第1の繊維ウェブの少なくとも1面に第2の繊維ウェブを積層して積層ウェブを形成する工程。
工程(4):積層ウェブを形成する捲縮型繊維(A1)と極細繊維発生型繊維(B1)とを絡合処理させた絡合繊維シートを形成する工程。
工程(5):絡合繊維シートを熱収縮させて熱収縮繊維シートを形成する工程。
工程(6):熱収縮繊維シートを形成する極細繊維発生型繊維(B1)に極細繊維化処理することにより、捲縮型繊維(A1)と繊維(B)との絡合体である不織布を形成させる工程。
工程(7):熱収縮繊維シートまたは不織布に高分子弾性体を含浸付与する工程。
本実施形態の人工皮革基材の製造においては、互いに固有粘度の異なる2種の樹脂から形成された、0.6dtex以上の平均繊度を有する長繊維の捲縮型繊維(A1)を含む第1の繊維ウェブを製造する。
・紡糸ドラフト=D/(A/B/C)
0.6dtex未満の極細繊維である繊維(B)を形成するための極細繊維発生型繊維(B1)を含む第2の繊維ウェブを準備する。
次に、第1の繊維ウェブと第2の繊維ウェブとを重ねて積層することにより積層ウェブを形成する。
次に、積層ウェブを形成する第1の繊維ウェブの捲縮型繊維(A1)と第2の繊維ウェブの極細繊維発生型繊維(B1)とを絡合させることにより絡合繊維シートを形成する。絡合繊維シートは、ニードルパンチや高圧水流処理等の公知の不織布製造方法を用いて、積層ウェブに絡合処理を施すことにより形成される。本実施形態では、ニードルパンチによる絡合処理について代表例として詳しく説明する。
次に、絡合繊維シートを熱収縮させることにより、絡合繊維シートの繊維密度および絡合度合を高めるとともに、繊維(A1)にクリンプを発現させたり、既に発現しているクリンプを強めたりする。熱収縮処理の具体例としては、例えば、絡合繊維シートを水蒸気に連続的に接触させる方法や、絡合繊維シートに水を付与した後、加熱エアーや赤外線などの電磁波で水を加熱する方法等が挙げられる。また、熱収縮処理により緻密化された絡合繊維シートをさらに緻密化するとともに形態を固定化したり、表面を平滑化したりすることを目的として、必要に応じて、さらに熱プレス処理を行ってもよい。
本工程では、熱収縮繊維シート中の極細繊維発生型繊維を極細繊維化処理することにより、互いに固有粘度の異なる2種の樹脂から形成された0.6dtex以上の長繊維の捲縮型繊維(A1)と、0.6dtex未満の平均繊度を有する極細繊維である繊維(B)、との絡合体である不織布を形成させる。本実施形態では、極細繊維発生型繊維が海島型複合繊維である場合について、代表例として詳しく説明する。
人工皮革基材の製造においては、人工皮革基材に形態安定性を付与し、また、充実感を高めるために、工程(5)で得られた熱収縮繊維シートまたは工程(6)で得られた不織布に高分子弾性体を含浸付与する。工程(5)で得られた熱収縮繊維シートに高分子弾性体を含浸付与した場合、高分子弾性体が付与された後に、工程(6)において極細繊維発生型繊維に極細繊維化処理するために、形成される極細繊維の繊維(B)が高分子弾性体で拘束されず、ストレッチ性のより高い人工皮革基材が得られる点から好ましい。
平均繊度は以下のように測定した。人工皮革基材の断面の走査型電子顕微鏡(SEM)写真を3000倍で撮影した。そして、SEM写真から繊維の断面をランダムに10個選んで断面積を測定し、その断面積の平均値を算出した。そして、断面積の平均値を各樹脂の密度を用いて平均繊度に換算した。なお、SEM写真においては、サイドバイサイド型のポリエステル繊維を繊維(A)とし、それ以外のものを繊維(B)として区別して測定した。
溶媒としてフェノール/テトラクロロエタン(体積比1/1)混合溶媒を用い30℃でウベローデ型粘度計(林製作所製HRK−3型)を用いて測定した。
人工皮革基材の厚み方向の中央部分をスライスした後、下層側表面を100倍の倍率で電子顕微鏡観察を行った。そして、図1に示すように、繊維1の湾曲部における100μmの長さの弦から垂線を下して交わる繊維までの距離Aを測定し、以下の式で湾曲率を算出した。そして、ランダムに10ヶ所で測定した湾曲率の平均を平均湾曲率とした。
平均湾曲率(%)=A(μm)/100(μm)×100
積層する繊維(A1)と繊維(B1)の目付けを測定し、その合計目付け量W(g/m2)とその中の繊維(A)と繊維(B)との各割合から繊維(A)と繊維(B)の目付けX(g/m2)を算出した。次に、水系ポリウレタン液濃度Y(%)、不織布へ含浸した時のピックアップZ(%)とした時、以下の式から水系ポリウレタンの割合を求めた。
水系ポリウレタン割合(%)=
[W×Z/100×Y/100]/[W×Z/100×Y/100+X]×100
JIS L1913に準じて、厚さ(mm)および目付け(g/cm2)を測定し、これらの値から見掛け密度(g/cm3)を算出した。
伸長率は、定荷重で伸張した際の伸び率を示す。また、伸長回復率は、定荷重で伸張し、荷重を除いた後の回復率を示す。人工皮革基材を2.5cm幅に切出し、長さ5cm間に3cm間隔の基準線を入れ、荷重1kgを5分間付加した後の基準線が伸びた長さL1を測定し、以下の式で伸長率を測定した。
・伸長率(%)=[L1(cm)−3(cm)]/3(cm)×100
また、荷重解放して5分間後、基準線間の長さL2を測定し、以下の式で伸長回復率を測定した。
・伸長回復率(%)=[L1(cm)−L2(cm)]/[L1(cm)−3(cm)]/×100
目視及び触感により、得られた立毛人工皮革の外観を以下の基準で判定した。
A:繊維が細かくばらけた均一な長さを有し、やわらかくスムースな感触の立毛面であった。
B:繊維が粗くばらけて不均一な長さを有し、粗い感触でライティングのない立毛感であった。
得られた立毛人工皮革を折り曲げて、腰や柔軟性の感触を以下の基準で判定した。
A:充実感があり、ボキ折れすることなく、柔軟性に優れた風合いであった。
B:充実感に欠ける、ボキ折れする、硬い、のいずれか1つ以上に該当する風合いであった。
得られた立毛人工皮革を引っ張り、その時の力の程度や戻りやすさの感触を以下の基準で判定した。
A:弱い力で伸びやすく力を解放した後の伸びの戻りが早い。
B:弱い力で伸びにくく力を解放した後の伸びの戻りが遅い、あるいは弱い力で伸びやすいが力を解放した後の伸びの戻りが遅い、あるいは弱い力で伸びにくく力を解放した後の伸びの戻りは早い、のいずれかに該当する。
人工皮革の原反から、たて10cm×よこ4cmの試験片を切りだした。そして、試験片の短辺の中央に、長辺に平行に5cmの切れ目を入れた。そして、引張試験機を用い、各切片を治具のチャックに挟み、10cm/minの引張速度でs−s曲線を測定した。原反の縦方向と縦方向に垂直な横方向について各試験片3個を測定し、それぞれ平均値を求めた。
固有粘度[η]=1.025(dl/g)のポリブチレンテレフタレート(PBT)と固有粘度[η]=0.585(dl/g)のポリエチレンテレフタレート(PET)とを用い、275℃で溶融複合紡糸用口金より吐出し、紡糸速度が4000m/minとなるようにエジェクター圧力を調整し、長繊維をネット上に捕集し、平均繊度1.5dtexのサイドバイサイド型のポリエステル繊維を含む第1の繊維ウェブを得た。
表1に示したように、実施例1において、固有粘度[η]=1.025(dl/g)のPBTの代わりに、固有粘度[η]=0.775(dl/g)のPETを用い、固有粘度[η]=0.585(dl/g)のPETの代わりに、固有粘度[η]=0.52(dl/g)のPETを用いた以外は同様にして立毛人工皮革を得、評価した。結果を表1に示す。
表1に示したように、実施例1において、固有粘度[η]=0.585(dl/g)のPETの代わりに、固有粘度[η]=0.52(dl/g)のPETを用い、さらに、水系ポリウレタンの含有割合を変更した以外は同様にして立毛人工皮革を得、評価した。結果を表1に示す。
表1に示したように、実施例1において、平均繊度0.3dtexのPETの極細繊維を形成させた代わりに、平均繊度0.5dtexのPETの極細繊維を形成させ、さらに、水系ポリウレタンの含有割合を変更した以外は同様にして立毛人工皮革を得、評価した。結果を表1に示す。
実施例3の第2の繊維ウェブを、次のようにして製造された第2の繊維ウェブに変更し、表1に示したような長繊維の極細繊維に変更した以外は実施例1と同様にして立毛人工皮革を得、評価した。結果を表1に示す。
(第2の繊維ウェブの製造)
水溶性熱可塑性ポリビニルアルコール系樹脂(PVA;海成分)と変性度6モル%のイソフタル酸変性ポリエチレンテレフタレ−ト(島成分)とを、海成分/島成分が25/25(質量比)となるように260℃で溶融複合紡糸用口金(島数:12島/繊維)より吐出し、紡糸速度が3500m/minとなるようにエジェクター圧力を調整し、長繊維をネット上に捕集し、長繊維の平均繊度3.0dtexの海島型複合繊維を含む第2の繊維ウェブを得た。
表1に示したように、実施例3において、平均繊度1.5dtexのサイドバイサイド型のポリエステル繊維を含む第1の繊維ウェブの代わりに、平均繊度0.6dtexのサイドバイサイド型のポリエステル繊維を含む第1の繊維ウェブを用いた以外は同様にして立毛人工皮革を得、評価した。結果を表1に示す。
表1に示したように、実施例2において、固有粘度[η]=0.775(dl/g)のPETの代わりに、固有粘度[η]=1.025(dl/g)のPBTを用い、第2の繊維ウェブ/第1の繊維ウェブ/第2の繊維ウェブ=1/2/1の重量比で積層して積重ウェブを形成した代わりに、第1の繊維ウェブのみで同じ目付の積重ウェブを形成し、さらに、水系ポリウレタンの含有割合を変更した以外は同様にして立毛人工皮革を得、評価した。結果を表1に示す。
表1に示したように、比較例1において、積重ウェブを1840パンチ/cm2でニードルパンチングする代わりに、2760パンチ/cm2でニードルパンチングした等の変更をした以外は同様にして立毛人工皮革を得、評価した。結果を表1に示す。
表1に示したように、実施例1において、平均繊度1.5dtexのサイドバイサイド型のポリエステル繊維を含む第1の繊維ウェブの代わりに、固有粘度[η]=0.615(dl/g)のPETからなるポリエステル繊維を含む第1の繊維ウェブを用い、積重ウェブを1840パンチ/cm2でニードルパンチングする代わりに、3680パンチ/cm2でニードルパンチングし、さらに、水系ポリウレタンの含有割合を変更した以外は同様にして立毛人工皮革を得、評価した。結果を表1に示す。
表1に示したように、実施例1において、平均繊度0.3dtexのPETの極細繊維を形成させた代わりに、平均繊度0.6dtexのPETの繊維を形成させた以外は同様にして立毛人工皮革を得、評価した。結果を表1に示す。
固有粘度[η]=1.025(dl/g)のポリブチレンテレフタレート(PBT)と固有粘度[η]=0.52(dl/g)のポリエチレンテレフタレート(PET)とを50/50の比率で用い、275℃で1ホールの面積Cが0.08mm2である溶融複合紡糸用口金より、吐出速度A0.25(g/min)で吐出した。なお、このとき、樹脂の溶融密度Bは、1.21(g/cm3)であった。そして、紡糸速度Dが3987m/minとなるようにエジェクター圧力を調整し、紡糸ドラフトが1544になるように紡糸して長繊維をネット上に捕集することにより、平均繊度0.63dtexのサイドバイサイド型のポリエステル繊維を含む第1の繊維ウェブを得た。
また、ポリウレタン含有割合は10質量%であった。
捲縮型繊維(A1)の溶融紡糸の際に、紡糸ノズル1ホールから吐出されるポリマーの吐出速度をA(g/min)、ポリマーの溶融密度をB(g/cm3)、1ホールの面積をC(mm2)、紡糸速度をD(m/min)として、以下の式により紡糸ドラフトを算出した。
・紡糸ドラフト=D/(A/B/C×104)
なお、樹脂の溶融密度B(g/cm3)は、溶融紡糸の際に固有粘度の異なる2種の樹脂がそれぞれ吐出されるときの吐出体積(cc/rpm)E1,E2とし、それらを吐出するときの各ギアポンプの回転数(rpm)をそれぞれF1とF2とし、吐出される1分間のポリマー吐出量(g/min)G1とG2を測定し、以下の式から算出した。
・溶融密度(g/cm3)=G1/E1/F1×G1/(G1+G2)+G2/E2/F2×G2/(G1+G2)
厚さ方向の断面の空隙の平均面積は以下のようにして測定した。
人工皮革基材の厚み方向の断面の全層を40倍の倍率で走査型電子顕微鏡で観察し、その画像を撮影した。そして、得られた画像を画像解析ソフトPopimaging(Digital being kids. Co製)を用い、動的閾値法で画像を二値化した。そして、二値化した画像をimage pro premier (日本ローパー社製)で読み込み、カウントツールで面積が5ドット以上の空隙部を抽出した。計測は万遍なく選択した3箇所の断面で行った。そして、計測ツールで抽出した各空隙部の面積を測定して平均値を求めた。図2に実施例1で得られた画像の一例を示す。黒い箇所のそれぞれが空隙部である。
実施例7において、次のように製造された第1の繊維ウェブを用いた以外は同様にして立毛人工皮革を得、評価した。
固有粘度[η]=1.025(dl/g)のポリブチレンテレフタレート(PBT)と固有粘度[η]=0.52(dl/g)のポリエチレンテレフタレート(PET)とを50/50の比率で用い、275℃で1ホールの面積Cが0.08mm2である溶融複合紡糸用口金より、吐出速度A0.51(g/min)で吐出した。そして、紡糸速度Dが4048m/minとなるようにエジェクター圧力を調整し、紡糸ドラフトが768になるように紡糸して長繊維をネット上に捕集することにより、平均繊度1.18dtexのサイドバイサイド型のポリエステル繊維を含む第1の繊維ウェブを得た。
結果を表2に示す。
実施例7において、次のように製造された第1の繊維ウェブを用いた以外は同様にして立毛人工皮革を得、評価した。
固有粘度[η]=1.025(dl/g)のポリブチレンテレフタレート(PBT)と固有粘度[η]=0.52(dl/g)のポリエチレンテレフタレート(PET)とを50/50の比率で用い、275℃で1ホールの面積Cが0.08mm2である溶融複合紡糸用口金より、吐出速度A1.0(g/min)で吐出した。そして、紡糸速度Dが4132m/minとなるようにエジェクター圧力を調整し、紡糸ドラフトが400になるように紡糸して長繊維をネット上に捕集することにより、平均繊度2.42dtexのサイドバイサイド型のポリエステル繊維を含む第1の繊維ウェブを得た。
結果を表2に示す。
実施例7において、次のように製造された第2の繊維ウェブを用いて、平均繊度0.3dtexのPETの極細繊維を形成させた代わりに、平均繊度0.5dtexのPETの極細繊維を形成させた以外は同様にして立毛人工皮革を得、評価した。
水溶性熱可塑性ポリビニルアルコール系樹脂(PVA;海成分)と変性度6モル%のイソフタル酸変性ポリエチレンテレフタレ−ト(島成分)とを、海成分/島成分が50/50(質量比)となるように260℃で溶融複合紡糸用口金(島数:12島/繊維)より吐出し、紡糸速度800m/minで紡糸を行った。次に、延伸し平均繊度11.8dtexの繊維を得た後、捲縮を付与した。得られた捲縮後繊維を51mmにカットし、カード機を通して第2の繊維ウェブを得た。
結果を表2に示す。
実施例7において、第2の繊維ウェブ/第1の繊維ウェブ/第2の繊維ウェブ=1/2/1の質量比で積層し、積層ウェブを形成した代わりに、1/8.5/1の質量比で積層し、積層ウェブを得た以外は同様にして立毛人工皮革を得、評価した。結果を表2に示す。
実施例7において、第2の繊維ウェブ/第1の繊維ウェブ/第2の繊維ウェブ=1/2/1の質量比で積層し、積層ウェブを形成した代わりに、0.7/1/0.7の質量比で積層し、積層ウェブを得た以外は同様にして立毛人工皮革を得、評価した。結果を表2に示す。
実施例8において、熱収縮繊維シートに、水系ポリウレタンのエマルジョン(固形分10%)をpick up50%で含浸させた代わりに、水系ポリウレタンのエマルジョン(固形分11%)をpick up50%で含浸させて、ポリウレタン含有割合を10質量%の代わりに8.5質量%に変更した以外は同様にして立毛人工皮革を得、評価した。
結果を表2に示す。
実施例8において、熱収縮繊維シートに、水系ポリウレタンのエマルジョン(固形分10%)をpick up50%で含浸させた代わりに、水系ポリウレタンのエマルジョン(固形分18.8%)をpick up50%で含浸させて、ポリウレタン含有割合を10質量%の代わりに13質量%に変更した以外は同様にして立毛人工皮革を得、評価した。結果を表2に示す。
実施例13において、次のように製造された第1の繊維ウェブを用いた以外は同様にして立毛人工皮革を得、評価した。
固有粘度[η]=1.025(dl/g)のポリブチレンテレフタレート(PBT)と固有粘度[η]=0.52(dl/g)のポリエチレンテレフタレート(PET)とを50/50の比率で用い、275℃で1ホールの面積Cが0.08mm2である溶融複合紡糸用口金より、吐出速度A1.0(g/min)で吐出した。そして、紡糸速度Dが4065m/minとなるようにエジェクター圧力を調整し、紡糸ドラフトが393になるように紡糸して長繊維をネット上に捕集することにより、平均繊度2.46dtexのサイドバイサイド型のポリエステル繊維を含む第1の繊維ウェブを得た。
結果を下記表3に示す。
実施例7において、次のように製造された第1の繊維ウェブのみで積層ウェブを形成した、さらに、水系ポリウレタン含有割合を10質量%の代わりに6質量%に変更した以外は同様にして立毛人工皮革を得、評価した。
固有粘度[η]=1.025(dl/g)のポリブチレンテレフタレート(PBT)と固有粘度[η]=0.52(dl/g)のポリエチレンテレフタレート(PET)とを50/50の比率で用い、275℃で1ホールの面積Cが0.08mm2である溶融複合紡糸用口金より、吐出速度A0.51(g/min)で吐出した。そして、紡糸速度Dが3643m/minとなるようにエジェクター圧力を調整し、紡糸ドラフトが691になるように紡糸して長繊維をネット上に捕集することにより、平均繊度1.4dtexのサイドバイサイド型のポリエステル繊維を含む第1の繊維ウェブを得た。
結果を表3に示す。
実施例7において、サイドバイサイド型のポリエステル繊維を含む第1の繊維ウェブの代わりに、平均繊度1.32dtexのレギュラー型のポリエステル繊維を含む第1の繊維ウェブを用い、第1の繊維ウェブのみで積層ウェブを形成し、さらに、水系ポリウレタン含有割合を10質量%の代わりに6質量%に変更した以外は同様にして立毛人工皮革を得、評価した。結果を表3に示す。
実施例8において、熱収縮繊維シートに、水系ポリウレタンのエマルジョン(固形分10%)をpick up50%で含浸させた代わりに、水系ポリウレタンのエマルジョン(固形分6.6%)をpick up50%で含浸させて、ポリウレタン含有割合を10質量%の代わりに5質量%に変更した以外は同様にして立毛人工皮革を得、評価した。結果を表3に示す。
実施例8において、熱収縮繊維シートに、水系ポリウレタンのエマルジョン(固形分10%)をpick up50%で含浸させた代わりに、水系ポリウレタンのエマルジョン(固形分10.2%)をpick up50%で含浸させて、ポリウレタン含有割合を10質量%の代わりに7.5質量%に変更した以外は同様にして立毛人工皮革を得、評価した。結果を表3に示す。
実施例8において、熱収縮繊維シートに、水系ポリウレタンのエマルジョン(固形分10%)をpick up50%で含浸させた代わりに、水系ポリウレタンのエマルジョン(固形分24%)をpick up50%で含浸させて、ポリウレタン含有割合を10質量%の代わりに16質量%に変更した以外は同様にして立毛人工皮革を得、評価した。結果を表3に示す。
Claims (15)
- 繊維(A)と繊維(B)との絡合体である不織布と、前記不織布の内部に付与された高分子弾性体と、を含み、
前記繊維(A)は、互いに固有粘度の異なる2種の樹脂から形成された捲縮繊維であって、0.6dtex以上の平均繊度を有する長繊維であり、
前記繊維(B)は、0.6dtex未満の平均繊度を有する極細繊維である人工皮革基材。 - 前記繊維(A)は、平均湾曲率が10%以上である請求項1に記載の人工皮革基材。
- 前記繊維(A)は、平均湾曲率が15%以上である請求項1に記載の人工皮革基材。
- 前記繊維(B)は、平均湾曲率が15%未満である請求項3に記載の人工皮革基材。
- 前記繊維(B)は、平均繊維長100mm未満の短繊維である請求項1〜4の何れか1項に記載の人工皮革基材。
- 前記繊維(A)は、前記2種の樹脂の前記固有粘度の差が0.05(dl/g)以上であるサイドバイサイド型繊維または偏芯芯鞘型繊維である請求項1〜5の何れか1項に記載の人工皮革基材。
- 前記2種の樹脂はポリエステルである請求項1〜6の何れか1項に記載の人工皮革基材。
- 前記繊維(A)と前記繊維(B)との配合割合((A)/(B))が、10/90〜90/10である請求項1〜7の何れか1項に記載の人工皮革基材。
- 荷重1kgを5分間付加したときの平均伸長率が10%以上である請求項1〜8の何れか1項に記載の人工皮革基材。
- 前記高分子弾性体は水系ポリウレタンであり、
前記水系ポリウレタンの含有割合が8〜15質量%であり、
厚さ方向の断面の空隙の平均面積が300〜1000μm2である請求項1〜9の何れか1項に記載の人工皮革基材。 - 請求項1〜10の何れか1項に記載の人工皮革基材を含み、その一面が立毛処理されていることを特徴とする立毛人工皮革。
- 請求項1に記載の人工皮革基材の製造方法であって、
前記繊維(A)を形成するための、互いに固有粘度の異なる2種の樹脂から形成された0.6dtex以上の長繊維の捲縮型繊維(A1)を含む第1の繊維ウェブを準備する工程と、
前記繊維(B)を形成するための、極細繊維発生型繊維(B1)の第2の繊維ウェブを準備する工程と、
前記第1の繊維ウェブの少なくとも1面に前記第2の繊維ウェブを積層して積層ウェブを形成する工程と、
前記積重ウェブを形成する前記捲縮型繊維(A1)と前記極細繊維発生型繊維(B1)とを絡合処理させた絡合繊維シートを形成する工程と、
前記絡合繊維シートを熱収縮させて熱収縮繊維シートを形成する工程と、
前記熱収縮繊維シートを形成する前記極細繊維発生型繊維(B1)に極細繊維化処理することにより、前記捲縮型繊維(A1)と前記繊維(B)との絡合体である不織布を形成させる工程と、
前記熱収縮繊維シートまたは前記不織布に高分子弾性体を含浸付与する工程と、を少なくとも備える人工皮革基材の製造方法。 - 前記積層ウェブは、前記第1の繊維ウェブの両面に前記第2の繊維ウェブを積層した積層体である請求項12に記載の人工皮革基材の製造方法。
- 前記高分子弾性体を含浸付与する工程が、前記熱収縮繊維シートまたは前記不織布に、ポリウレタン水系エマルジョンを含浸させた後、乾燥させることにより水系ポリウレタンを生成させる工程である請求項12または13に記載の人工皮革基材の製造方法。
- 前記捲縮型繊維(A1)が、紡糸ドラフト400以上で紡糸された繊度0.6dtex以上の捲縮型繊維であり、
前記水系ポリウレタンの含有割合が8〜15質量%で、厚さ方向の断面の空隙の平均面積が300〜1000μm2である人工皮革基材を製造する請求項14に記載の人工皮革基材の製造方法。
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