KR100247080B1 - Method of manufacturing artificial leather with high density , high tenacity and softness - Google Patents

Abstract

Polymer arrangement is made by using two kinds of micro-capable fibers with different micro-expression states into separate webs and woven fabric reinforcement fabric (C) woven using high shrinkable fiber sole yarn having a heat shrinkage rate of 15% or more. Sieve-type ultrafine fiber (A) -woven fabric reinforcement cloth (C)-polymer brand-type ultra-fine fiber (B) in three layers in the order of needle punching, shrink processing through normal heat treatment And it relates to a method of manufacturing artificial leather excellent in high density, high strength and flexibility, characterized in that the elastic polymer is produced through the impregnation process, post-treatment process.

Description

Manufacturing method of artificial leather with high density, high strength and flexibility

The present invention relates to a method for manufacturing artificial leather having high density, high strength, and flexibility, and more particularly, a woven fabric reinforcing fabric between webs composed of two types of micronized fibers having different states of micronized expression. After inserting into a three-layer structure and needle punching and heat treatment and then raising the surface of the present invention relates to a method for producing a flexible artificial leather while maintaining high density and high strength.

Conventionally, the manufacturing technology of suede artificial leather which raised the surface using a composite sheet in which a polymer elastic body was imparted as an adhesive component to a non-woven fabric sheet made of ultrafine fibers or a grain type artificial leather which imparted a polymer elastic body to the surface It has been known. However, these artificial leather can not have the same texture and excellent physical properties as natural leather has been actively researched to improve it. For example, in order to obtain flexible artificial leather, microfiber-generating composite fibers are made into short fibers from two different polymer components having different solubilities, and made into three-dimensional sheets by needle punching, and then polyurethane is applied. However, the flexible artificial leather can be obtained by the space generated by removing one component of the used yarn, but it has a drawback that the mechanical properties such as tensile strength and frictional strength are insufficient. In order to compensate for such strong characteristics, methods for inserting reinforcing fabrics such as woven fabrics and knitted fabrics are mainly attempted. For example, according to Japanese Patent Publication No. 3-70028, an ultra-fine fiber web and After fabrication of a composite sheet by needle punching a knitted fabric treated with a water-soluble high molecular material, impregnated with polyurethane dissolved in dimethylformamide, and minimizing by removing one component of the ultrafine fiber. The present invention discloses a method of removing a water-soluble polymer treated in an inserted reinforcement cloth. However, the strength of the fabric reinforcement can be improved by inserting the fabric reinforcement, but the process is complicated by the need to process the water-soluble polymer material in the fabric reinforcement fabric to give flexibility, the needle punching workability, and the polyurethane already impregnated in the processing process The barrier effect is created by the layer, making it difficult to completely remove the water-soluble polymer material. If the removal of the water-soluble polymer material is insufficient, there is a problem such as mold caused by the water-soluble polymer material occurs over time after the manufacture of the finished product. In addition, in order to manufacture high-density artificial leather, it is necessary to increase the bonding of the fibers constituting the sheet, but to improve the bonding, the number of needle punching needs to be increased, but the fibers constituting the fabric reinforcement cloth are damaged by excessive punching. There is a problem in that the touch and appearance is poor and the density cannot be maintained because the strength is lowered.

In order to solve such a problem, Japanese Patent Publication No. Hei 1-40151 has been proposed a method of needle punching during sheet production and improving the apparent density of the sheet by several high speed emulsion treatments. By using this method, it is possible to produce a high-density artificial leather by improving the apparent density of the sheet surface, but it requires a lot of tanning treatment, the production efficiency is greatly reduced, there is a problem that it is difficult to maintain a uniform quality.

MEANS TO SOLVE THE PROBLEM The present inventors came to this invention as a result of careful study in order to solve the above problems. The present invention provides an improved manufacturing method of artificial leather having high density, high strength, and flexibility, and according to the manufacturing method, the process can be simplified, and a product of high production efficiency and uniform quality can be produced, and molds in finished products Solves the problem that occurs, and the artificial leather with excellent feel and appearance can be obtained.

1 is a schematic cross-sectional view of the artificial leather obtained by the present invention.

* Explanation of symbols for main parts of the drawings

A: ultrafine fiber of high order array type A-1: brushed layer

B: Fine blendable fiber of polymer blend C: Knitted fabric reinforcement fabric

Hereinafter, the present invention will be described in detail.

As an example of a specific means for achieving the present invention, by producing two kinds of microfine fiber (A and B) webs having different forms of micronized expression, weaving a knitted fabric reinforcement (C) between the webs After the three-layer structure, the needle punched to produce a composite sheet. The use ratio of (A), (B), (C) layer which forms this three-layer sheet is weight ratio in a nonwoven fabric state (A): (B): (C) = 30-60%: 60-30% : It is preferable to set it as 40 to 10%. In the three-layer sheet, the surface is exposed to the microarrayable fiber (A) of the polymer array type, so that the writing effect is excellent when brushing, and the backside is smooth to expose the fiber (B) of the polymer blend type. Improves touch, flexibility and fit.

The micronized fiber having different micronized expression forms used in the present invention refers to a fiber produced due to a difference in distribution route and mixing method of the molten polymer polymer when the two polymer polymers are melted and composite spun. As described above, the micronized fiber (A) of the polymer array system in which the two components are continuously and continuously supplied and formed into fibers and the two components are mixed in an arbitrary weight ratio before or after melting, thereby forming a matrix. It is composed of ultrafine fibers (B) of a polymer blend type in which fibrils are discontinuously mixed in a). As the polymer used in the ultrafine fiber, fibers known incompatibility can be used, and the two polymers used in the ultrafine fiber (A) and (B) may be the same or different, but the ultrafine fiber may be used. Among the two polymers used for the combustible fibers (A) and (B), the components to be removed are preferably the same to be extracted and removed for the purpose of miniaturization. In addition, the microfiber polymer remaining after the micronization of the microfiber of the present invention is not particularly limited, but polyethylene terephthalate (hereinafter referred to as PET), polybutylene terephthalate (hereinafter referred to as PBT), and polyether The polymer which has fiber forming ability, such as ester type elastomer, nylon 6, nylon 66, polyurethane type, polyolefin type, polyacrylonitrile type, is preferable. Among them, PET, nylon 6 and the like are particularly preferable in terms of appearance and practicality of the finished product. It is also possible to use, for example, polystyrene and its copolymer, PVA, polyethylene, copolymerized polyester, copolymerized polyamide, and the like to be removed to be removed during the ultrafine treatment of the ultrafine fiber.

The single yarn fineness after the micronization treatment of the micronized fiber used in the present invention is preferably 0.1 denier or less.

Knitted fabric reinforcement used in the present invention is an important means of improving strength and making high density sheets. The yarn constituting the reinforcement fabric can be used in the same way without distinction to the warp yarn, and the polymer can be used without particular limitation to the polymer having a fiber forming ability, but the high shrinkage of 15% or more heat shrinkage in the yarn state for the production of high-density sheet It is preferable to use a sole yarn of the fiber. The polymer of the high-shrinkable fiber does not need to be particularly limited, but a polymer having a fiber forming ability such as PET or its copolymer, PBT, polyester-based elastomer, nylon 6 and its copolymer, nylon 66 and its copolymer, and polyurethane-based is preferable. . Among them, PET or its copolymer, PBT, nylon 6 and its copolymer, polyether ester elastomer, and the like are particularly preferable. In addition, the component of the fiber fused with the high-shrinkable fiber is not particularly limited and all known fibers can be used. In the case of weaving, the method may include a known air entanglement treatment, coalescing and covering. Plywood composite yarn may be used as a non-twisted yarn or in a twisted state, and the number of twists or arrangements is not particularly limited and may be the same as that used in ordinary knitted fabrics. In the present invention, the structure of the reinforcement fabric also need not be particularly limited, but in the case of woven fabrics such as plain weave or Twill (Twill) is good, it is not necessary to limit the density.

In the present invention, the method for producing a composite sheet may be in accordance with a conventional process of needle punching through carding and a cross wrapper. Since the density of the punching needle is different depending on the thickness of the desired sheet, the punching needle can not be collectively limited, but is preferably in the range of 1000-5000 minutes / cm 2.

The heat treatment of the composite sheet produced in the present invention may be dry heat or wet heat, and may be continuous or discontinuous. Although the treatment temperature does not need to be particularly limited, it is preferable that the temperature of the moist heat 50 degrees to 100 degrees and the dry heat 80 degrees to 130 degrees is a condition that can completely bleed the shrinkage characteristics of the constituent yarn of the reinforcing fabric used.

The nonwoven fabric sheet, which has been subjected to shrinkage, is impregnated with polyurethane mainly with a polymer elastomer, but in addition to polyurethane, various kinds of materials such as natural rubber, chlorprene rubber, SBR, NBR, acrylic rubber material, fluorine rubber material and silicone rubber material You may mix rubbery materials. In addition, anti-inflammatory agents, pigments, dyes, lubricants, leveling agents, plasticizers, antioxidants, ultraviolet absorbers, hydrolysis agents, fragrances, and the like may be mixed and used in the polymer elastomers within a range not impairing the object of the present invention.

The proportion of the elastomeric polymer in the artificial leather of the present invention is preferably 10 to 70% of the total weight, and more preferably 20 to 50%.

In the present invention, the elastomer polymer is usually solidified in water, and thus, the media that requires the elastomer polymer are materials that are compatible with water. As such examples, in addition to known dimethylformamide (DMF), dimethylacetamide (DMAC), diethylformamide (DEF), dimethylsulfoxide (DMSO), tetrahydrofuran, dioxane diethylformamide, hexamethylphosphor Amides and the like can be used.

In the present invention, the method for miniaturizing the ultrafine fiber can use a remover for removing the matrix component (or sea component in island-in-sea fiber). As such an example, PET may be listed in the order of fibrill component (or island component in islands-in-the-sea fiber)-matrix component (or sea component in island-in-sea fiber)-matrix component remover (or sea component remover in island-in-sea fiber). -Isophthalic acid sulfonate copolymer or PET-sodium hydroxide, PET or its copolymers-polystyrene-trichlorethylene, PET or its copolymers-nylon 6 or nylon 66-formic acid, polyetherester elastomer-polyethylene-toluene Or trichlorethylene, polyurethane-polyethylene-toluene, trichlorethylene, or the like.

The artificial leather of the present invention can be brushed and dyed by a known method, and in order to increase the added value, the artificial leather can be brushed after the partial fusion treatment, or a special processing such as a flexible process or a flame retardant process may be performed in parallel.

Artificial leather of the present invention is widely used for applications such as clothing, furniture, interior bags.

Hereinafter, the present invention will be described in detail by way of examples.

EXAMPLE

Performance evaluation of the product in the present invention was evaluated according to the following method.

(1) Tensile strength, elongation: 5 and 12.1 of JIS-L1079

(2) Flexibility: JIS-L1079-5.17B method

(3) Lecture degree: A method of 5.17 of JIS-L1079

(4) Appearance evaluation: Visual inspection of 5 artificial leather experts

Example 1

PET with intrinsic viscosity 0.72 and sea component with polyethylene of MI 16, spinning with component ratio 60:40, 37 number of bones, stretched, crimped, cut at 2.8 times, 3 denier, 51mm, 15 crimps / An ultrafine fiber (or island-in-the-sea fiber) (A) having a polymer array type of in was obtained.

Separately, the april component is a PET-matrix component with an inherent viscosity of 0.70 as a polyethylene of MI 14, and is spun at a component ratio of 55:45. The fine blendable fiber (or fibril connection type fiber) (B) of the polymer blend method of was obtained. These microfine fibers have a single yarn fineness of 0.05 denier after the microfine treatment. Each of these ultrafine fibers was made into a uniform web through a card and a cross wrapper.

In order to prepare the fabric reinforcement fabric (C), 50 denier 24 filament long fibers were melt-spun and spin-spun into a 180 degree high-stretch PET having an intrinsic viscosity of 0.60, copolymerized with isophthalic acid (IPA). Got. Using the long fibers as warp and weft yarns, a plain fabric having a weight of 80 g / m 2, and a warp and weft density of 74 bones / in and 48 bones / in was produced, respectively.

Next, a 90 g / m 2 ultrafine fiber (A) web is exposed to the surface, and a 90 g / m 2 ultrafine fiber (B) is located on the back side, and the weight is between (A) and (B). 50g / m2 of fabric reinforcement cloth (C) was inserted and laminated to form a three-layered sheet, and needle punching was carried out at a needle depth of 7 mm and 3,000 sheets / cm 3 to produce a three-layer composite having a weight of 200 g / m 2 and an apparent density of 0.245 g / cm 3. Sheets were prepared.

The composite sheet was immersed in hot water at 90 degrees for 3 minutes so that the area shrinkage of the sheet was 45% to obtain a high density sheet having a weight of 290 g / m 2 and an apparent density of 0.355 g / cm 3. The high density sheet was impregnated in a 15% polyurethane (hereinafter referred to as PU) -dimethylformamide (hereinafter referred to as DMF) solution and coagulated in a 10% aqueous solution of DMF maintained at 50 degrees, and passed through toluene maintained at 85 degrees to obtain polyethylene. After removal, the resultant was washed with hot water at 95 degrees to remove DMF in the sheet, thereby obtaining an elastomer-impregnated microfiber composite sheet having a PU adhesion of 40% of the total fiber. The sheet thus obtained had a weight of 285 g / m 2 and an apparent density of 0.383 g / cm 3.

The sheet was brushed with sandpaper of # 150 in the sanding machine, weighing 265g / m² and apparent density 0.455g / cm3, and dyed at 125 ° C for 60 minutes using a blue dispersion dye in a liquid dyeing machine. It was washed with water, dried, and treated with a softening agent and an antistatic agent to obtain a suede-type artificial leather having a thickness of 0.65 mm, a weight of 270 g / m 2, and an apparent density of 0.425 g / cm 3.

The obtained artificial leather sheet had an elegant appearance and feel, and the flexibility and strength characteristics were also excellent as shown in Table 1.

Comparative Example 1

PET with an intrinsic viscosity of 0.71 and polyethylene with a MI 16 of sea component, spun with a component ratio of 60:40 and 37 number of bones, stretched, crimped and cut at 2.8 times, 3 denier, 51 mm, 15 crimped water / The ultrafine fiber (or island-in-the-sea fiber) (A) of the polymer array system of in was obtained.

This ultrafine fiber becomes a single yarn fineness of 0.05 denier after the ultrafine treatment. This ultrafine fiber was made into a uniform web via a card and a cross wrapper.

In order to prepare the fabric reinforcing cloth (D), PET with an intrinsic viscosity of 0.63 was melt-spun in a spin draw method at 185 degrees to obtain long fibers of 50 denier 24 filaments. Using the long fibers as warp and weft yarns, a plain fabric having a weight of 80 g / m 2, and a warp and weft density of 74 bones / in and 48 bones / in was produced, respectively.

Next, the ultrafine fiber (A) web having a weight of 95 g / m 2 is exposed on the front and back surfaces thereof, and the fabric reinforcement cloth (D) having a weight of 50 g / m 2 is inserted therebetween, and laminated to form a three-layer sheet. Thereafter, needle punching was performed at a needle depth of 7 mm and 3,000 sheets / cm 3 to prepare a three-layer composite sheet having a weight of 220 g / m 2 and an apparent density of 0.245 g / cm 3.

When the composite sheet was immersed in hot water at 90 degrees for 3 minutes, the sheet had a surface shrinkage of 20%, yielding a sheet having a weight of 280 g / m 2 and an apparent density of 0.294 g / cm 3. The sheet was impregnated in a 15% polyurethane (hereinafter referred to as PU) -dimethylformamide (hereinafter referred to as DMF) solution and coagulated in a 10% aqueous solution of DMF maintained at 50 degrees, and passed through toluene maintained at 85 degrees to remove polyethylene. After washing with hot water at 95 ° C., DMF was removed from the inside of the sheet to obtain an elastomer-impregnated microfiber composite sheet having a PU adhesion amount of 40% of the total fiber. The sheet thus obtained had a weight of 280 g / m 2 and an apparent density of 0.302 g / cm 3.

The sheet was brushed using sandpaper of # 150 in the sanding machine, which weighed 265g / m2 and had an apparent density of 0.345g / cm3, and was dyed at 125 degrees for 60 minutes using a blue dispersion dye in a liquid dyeing machine. It was washed with water, dried, and treated with a softening agent and an antistatic agent to obtain a suede-type artificial leather having a thickness of 0.7 mm, a weight of 275 g / m 2, and an apparent density of 0.354 g / cm 3.

The obtained artificial leather sheet has a rough appearance and a poor touch, and also evaluates the flexibility and strong properties are shown in Table 1.

TABLE 1

According to the present invention, after the ultrafine treatment of the island-in-the-sea fine fiber and the polymer blend-type ultrafine fiber, a wrap is formed, respectively, and the reinforcement cloth is inserted into the web composed of the fibers of the two ultra-fine fibers. After the three-layer sheet was formed, the surface of the microfibers (A) of the bubble, which was needle punched and heat-treated and shrinked, was brushed with a sanding machine. Thus, the obtained artificial leather had a high density of brushing, high tensile strength, elegant appearance and flexibility. It is possible to obtain artificial leather with excellent touch.

Claims (1)

Polymer array method by inserting a woven fabric reinforcement fabric (C) made of a highly shrinkable fiber sole yarn having a heat shrinkage rate of 15% or more between a web composed of two kinds of ultrafine fibers having different forms of micronized expression. The ultrafine fiber (A) -woven fabric reinforcement fabric (C) -polymer brand of ultrafine fiber (B) was laminated in a three-layer structure, and then needle punched and heat-treated and shrinked by a conventional method. , The method of manufacturing artificial leather with excellent high density, high strength and flexibility, characterized in that to raise the surface layer of the ultrafine fiber (A) of the polymer array method.