KR101835769B1 - Synthetic leather having 3-dimensional pattern and Method of manufacturing the same - Google Patents

Abstract

Provided is a method for producing a three-dimensionally patterned artificial leather, comprising the following steps: (a) providing an artificial leather consisting of a base layer, an adhesive layer formed on the base layer, and a simulation layer planted on the adhesive layer; (b) printing, on the simulation layer, specific patterns with ink composed of a resin, a first cross-linking agent, and a second cross-linking agent which carries out a cross-linking reaction at a temperature 40°C higher than the first cross-linking agent; and (c) ironing out the printed simulation layer so as to attach only ink-printed simulation to the adhesive layer. Moreover, provided is an artificial leather produced thereby.

Description

TECHNICAL FIELD [0001] The present invention relates to a synthetic leather having a three-dimensional pattern and a method of manufacturing the same.

The present disclosure relates to a synthetic leather having a three-dimensional pattern and a method of manufacturing the same.

In general, natural leather is widely used in products such as shoes, bags, wallets, pouches, sofas, and clothing, but its resources are limited and not enough to meet demand, The supply and demand is gradually decreasing.

Artificial leather having various patterns on its surface is widely used as a substitute product thereof. Artificial leather is produced by preparing a nonwoven fabric using mixed fibers composed of nylon-polystyrene, polyethylene terephthalate-polystyrene or the like and coating the nonwoven fabric with a synthetic resin. Polyurethane resin is mainly used as a synthetic resin, and a wet process or a dry process is applied to the coating process.

In the dry method, the polyurethane for dry coating is applied on the release paper, and the resultant is heated and dried at an appropriate temperature to be cured. The cured release paper is coated with polyurethane for adhesion, There is an advantage in that the manufacturing process is relatively simple. However, there are problems such as surface characteristics peculiar to the dry method, lack of moisture permeability, and loss of volume feeling.

The wet method is a method in which a polyurethane resin solution is impregnated with various fabric substrates such as a nonwoven fabric, the polyurethane resin is impregnated into the fabric substrate, and then the polyurethane resin is coagulated in a coagulation bath, and a polyurethane Is coated with an appropriate amount and then coagulated in a coagulation bath. The residual solvent remaining on the base material is washed with water and then dried to produce artificial leather, which is advantageous in that the problem of the dry process can be overcome. Flexibility is difficult to implement.

Such artificial leather products are disadvantageous in that the patterns are not varied because the colors are applied by a method of dyeing leather fabrics.

Korean Patent Registration No. 10-221666 provides a method of printing on leather by a method of dye penetration into leather so as to have a saturation of 2 to 5 degrees. This is accomplished by preparing a first semi-finished product having an aqueous dye layer, then using a urethane adhesive, drying the second semi-finished product using a water-based brightener, and then ironing using a hot- And then the dye is printed on the surface of the leather with a roller press to print an arbitrary speckle pattern.

However, this has the disadvantage that the manufacturing process is too complicated. Particularly, a roller printing machine is used in the process of applying a dye. Since only a desired pattern is to be engraved on the surface of the roller, there is a drawback that a product can not produce various patterns. For example, in order to produce a pattern other than a pattern engraved on a roller A separate pattern must be used on the surface of the roller again so that it is not only costly to manufacture but also difficult to cope with the desire of the purchaser.

Korean Patent Laid-Open Publication No. 10-2000-0024411 discloses a method of printing a leather using a method of coating a paint on a leather surface, covering the transfer paper, and heating and pressing the paper with a heating press. However, in such a case, when the pattern of the transfer paper is thermally transferred by heating and pressing with the heating press, the transfer paper is pressed against the leather surface due to heat and the transfer paper does not fall off well. Even if the pattern is transferred away, .

In general, the printed matter is a planar image, and attempts have been made to realize such a planar image as a stereoscopic image. Korean Unexamined Patent Publication No. 10-1999-0017561 discloses a method using a foamed ink as such a stereoscopic printing method. This is based on the principle that a printed portion due to the expanding ink is expanded to form a convex portion. However, the method using the foamed ink has disadvantages such that the degree of foaming of the ink is not constant and thus a uniform solid pattern can not be formed, the thickness of the pattern can not be controlled, and durability and abrasion resistance are poor.

KR 10-0221666 B1 KR 10-2000-0024411 A KR 10-1999-0017561 A

As a result of intensive studies of the above problems, the present disclosure has found that when a specific pattern is printed on a synthetic leather with an ink containing an adhesive, the printed portion is bonded to the base layer of the synthetic leather and the length of the non- Is retained so that a three-dimensional pattern is formed on the surface of the artificial leather, and this disclosure has been completed on the basis of this finding.

Accordingly, one aspect of the present disclosure is to provide a method of manufacturing an artificial leather on which a three-dimensional pattern is formed.

Another aspect of the present disclosure is to provide a synthetic leather on which a three-dimensional pattern is formed.

A method of manufacturing a synthetic leather having a three-dimensional pattern according to the present disclosure for achieving the above-described one aspect comprises:

(a) providing a synthetic leather comprising a base layer and a matt layer on the base layer;

(b) printing a specific pattern on the patterned layer with an ink comprising a resin, a first crosslinking agent, and a second crosslinking agent which undergoes a crosslinking reaction at a temperature higher than 40 ° C higher than the first crosslinking agent; And

(c) ironing the printed pattern layer to bond only the printed copy to the base layer.

According to an exemplary embodiment, in step (a) of providing the artificial leather, the replica may be formed by a flocking method and have a thickness of 1 to 20 denier and a length of 0.3 to 2 mm.

According to an exemplary embodiment, the resin may comprise a polyurethane, a polycarbonate, an acrylic resin or a mixture thereof.

According to an exemplary embodiment, the first crosslinking agent may undergo a crosslinking reaction with the resin at 18 to 40 占 폚, and the second crosslinking agent may undergo a crosslinking reaction with the resin at 80 to 150 占 폚.

According to an exemplary embodiment, the second crosslinking agent is in the form of a capsule, and the capsule is dissolved in the ironing step (c), so that the second crosslinking agent inside the capsule can undergo a crosslinking reaction with the resin.

According to an exemplary embodiment, the printing step (b) is carried out at 18 to 40 캜, followed by a crosslinking reaction of the resin and the first crosslinking agent for 30 seconds to 24 hours, whereby 50 to 70% by weight of the resin is crosslinked, The ironing step (c) may be carried out at 80 to 150 ° C.

According to an exemplary embodiment, the mixing weight ratio of the resin: first crosslinking agent: second crosslinking agent may be 100: 3 to 6: 3 to 6.

The artificial leather having the three-dimensional pattern according to the present invention for achieving the above-mentioned different aspects includes a base layer, an adhesive layer formed on the base layer, and a simulated layer formed on the adhesive layer, And a second crosslinking agent which undergoes a crosslinking reaction at a temperature higher than 40 DEG C higher than the resin, the first crosslinking agent and the first crosslinking agent do.

According to an exemplary embodiment, the first crosslinking agent may comprise polyurethane and ethyl acetate.

According to an exemplary embodiment, the second crosslinking agent may be in the form of a capsule.

The method for producing a synthetic leather having a three-dimensional pattern according to the present disclosure can produce artificial leather having two or more three-dimensional patterns using monochromatic inks.

1 is a schematic cross-sectional view of a synthetic leather having a three-dimensional pattern formed according to one embodiment of the present disclosure;
2 is a photograph of artificial leather of (a) and (b) before a three-dimensional pattern is formed according to one embodiment of the present disclosure.

Before describing the present disclosure in more detail, it is to be understood that the words or words used in the present specification and claims should not be construed in a conventional or dictionary sense, And should be construed in accordance with the meaning and concept consistent with the technical idea of this disclosure. Therefore, the constitution of the embodiment described in the present specification is merely a preferred example of the present disclosure, and not all of the technical ideas of the present disclosure are described. Therefore, various equivalents and variations And the like.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of the present disclosure will be described in detail so that those skilled in the art can easily carry out the present disclosure. Moreover, in the description of the present disclosure, a detailed description of related art which may unnecessarily obscure the gist of the present disclosure is omitted.

In the present disclosure, a three-dimensional pattern means a pattern having two or more tones formed on a pattern having a different length.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a sectional view of a synthetic leather formed with a three-dimensional pattern according to one embodiment of the present disclosure; Fig. The artificial leather according to the present disclosure comprises the steps of: (a) providing a synthetic leather comprising a base layer, an adhesive layer formed on the base layer and a cast layer worn on the adhesive layer; (b) printing a specific pattern on the patterned layer with an ink comprising a resin, a first crosslinking agent, and a second crosslinking agent which undergoes a crosslinking reaction at a temperature higher than 40 ° C higher than the first crosslinking agent; And (c) ironing the printed pattern layer to bond only the printed pattern to the adhesive layer.

<Provision of artificial leather>

Prepare an artificial leather that needs printing on the surface. The artificial leather may be manufactured by a manufacturing method conventionally used in artificial leather manufacturing, or may be provided, according to one embodiment of the present disclosure, artificial leather produced by the following method of hooking. Also commercially available artificial leather may be provided.

In one embodiment, the artificial leather may comprise a base layer 1, an adhesive layer 2 on the base layer, and a simulated layer 4 on the adhesive layer. A base layer is formed on the release paper. The base layer can be produced by using a polyurethane resin, a thermoplastic polyurethane resin (TPU), a polycarbonate resin, a polyvinyl chloride resin, a silicone resin, or the like.

In one embodiment, a liquid resin such as a two-part polyurethane resin or a two-part polycarbonate resin is applied on the release paper at a thickness of 30 to 100 占 퐉, specifically 40 to 80 占 퐉, more specifically 50 to 70 占 퐉 And then dried to form a base layer.

In one embodiment, the base layer is formed by passing the release paper coated with the liquid resin through a thermal conveyor at a temperature range of from 70 to 120 캜, specifically from 80 to 110 캜, more specifically from 90 to 100 캜, Or in a maturing room at a temperature of 20 to 80 ° C, specifically 30 to 70 ° C, more particularly 40 to 60 ° C, for 1 hour to 24 hours, in particular 2 hours to 12 hours, Followed by aging for 3 to 6 hours.

The adhesive layer 2 is formed by applying an adhesive to the base layer in a thickness of 5 to 40 μm, specifically 10 to 30 μm, more specifically 15 to 20 μm. The adhesive may be a polyurethane, a polyamide, an ethylene vinyl acetate, an ethylene ethyl acetate, a styrene thermoplastic elastomer, a polyester It is preferable to use them alone or in combination of two or more among them, but the present invention is not limited thereto, and it is possible to use various well-known adhesives (for example, polyolefin resin, polyolefin resin, Can be applied.

Prepare a replica of the adhesive layer in the container. The simulant may be selected from the group consisting of polyester, nylon, polyethylene, rayon, and mixtures thereof, but is not limited thereto. The thickness of the simulant may be 1 to 10 denier, 2 to 8 denier, or 3 to 5 denier. The length of the simulations may be 0.3 to 2 mm, 0.4 to 1 mm, or 0.5 to 0.8 mm.

If the thickness of the simulacrum is less than 1 denier, vortexes may occur in the container, and the simulations may become entangled. If the denier is larger than 10 denier, the skin of the peach skin can not be obtained. If the length of the copy is smaller than 0.3 mm, it is difficult to form a three-dimensional pattern because the distinction between the copy and the unimaged copy is not clear even if the copy imprinted on the base layer is adhered to the base layer during the printing process. Can not be obtained.

The simulant can be applied to the adhesive layer in a folding manner such as an electrostatic method or a spray method. The electrostatic system means, for example, that a simulant is placed in a box placed under the adhesive layer, a positive terminal is placed in a box, a minus terminal is placed on the upper side of the adhesive layer, It can be linearly and vertically close to the adhesive layer while moving from the plus terminal to the minus terminal. Specific details thereof are disclosed in Korean Patent Publication Nos. 2008-0097063 and 2014-0033798, the entire contents of which are incorporated herein by reference.

After the simulant has been planted, it is naturalized or aged in a maturing room, and then the release paper is peeled off, thereby producing artificial leather by the hooking method according to one embodiment of the present disclosure. The aging step is carried out in a natural state or in a maturing room at a temperature of 20 to 80 DEG C, specifically 30 to 70 DEG C, more particularly 40 to 60 DEG C, for 1 to 24 hours, specifically 2 to 12 hours , More specifically from 3 hours to 6 hours.

<Printing Step>

Artificial leather can be used in various fields such as shoes, clothes, gloves, miscellaneous goods, furniture and automobile interior materials, and it is required that artificial leather is formed with patterns, patterns and the like according to the field to be used. The present disclosure can provide an artificial leather having a three-dimensional pattern or pattern formed by adjusting the length of the simulated leather.

According to one embodiment, a specific pattern is printed with ink in a simulated artificial leather at room temperature, for example at 18 to 40 占 폚. The printing can be performed by printing, gravure printing, offset printing, screen printing, lithographic printing, inkjet printing, digital printing, and the like, and various known printing methods can be applied.

The ink may be a two-part type including a main resin such as a polyurethane or a polycarbonate and a cross-linking agent. The ink may further contain additives such as an adhesive resin, a pigment, a diluent, a viscosity controlling agent, a dispersing agent, a defoaming agent, a lubricant, and an accelerator. In the simulated inked portion, the resin can be bonded to the base layer while being crosslinked.

The crosslinking agent may be a mixture of a low temperature crosslinking agent (first crosslinking agent) and a high temperature crosslinking agent (second crosslinking agent). In the present disclosure, the low-temperature crosslinking agent (first crosslinking agent) means a crosslinking agent capable of undergoing a crosslinking reaction with the resin at room temperature, for example, at 18 to 40 ° C, or 20 to 30 ° C, Means a crosslinking agent which undergoes a crosslinking reaction with the resin at 80 占 폚 or more, for example, at 80 to 150 占 폚, or 90 to 120 占 폚.

In one embodiment, the low temperature crosslinking agent may be a mixture of 40 to 60 parts by weight of methylol acrylamide and 40 to 60 glycyl methacrylates.

In another embodiment, the low temperature crosslinking agent may comprise from 60 to 80 parts by weight of polyurethane and from 20 to 40 parts by weight of ethyl acetate. In this regard, the trade name D-ACE 575, produced by Dongsung Chemical Co., Ltd., may be used.

In another embodiment, the low temperature crosslinking agent is selected from the group consisting of para-toluene sulfonic acid (TSA), urea-co-formaldehyde, tri-methylpropane trimethacrylate (TMPTMA), divinylbenzene (DVB) (1-Hydroxy-2,2-dimethoxyethyl acrylamide), N, N-methylenebisacrylamide (N, N-dimethoxyethyl) At least one of ethylene glycol diacrylate, di (ethylene glycol) diacrylate, boric acid, and glutaraldehyde may be selected from the group consisting of ethylene glycol diacrylate, ethylene glycol diacrylate, .

In one embodiment, the high temperature crosslinking agent is selected from the group consisting of 1,3-propanediol, 2,3,4-trimethyl-1,3-pentanediol, 2-butene- Butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,2-cyclohexanedimethanol, 1,2-hexanediol, 1,3-hexanediol, 2-methyl- Methylene-2, 4-pentanediol, ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycol, propylene glycol , Dipropylene glycol, polypropylene glycol, tripropylene glycol, glycerol, polyglycerol, ethylene carbonate, and 1,2-propylene carbonate.

In one embodiment, SUPESIN DCL-75, a trade name of Dong-A Chemical Co., Ltd., may be used as a high-temperature crosslinking agent.

In one embodiment, the hot cross-linking agent may be in a capsule-containing form having a membrane that is dissolved at 80 to &lt; RTI ID = 0.0 &gt; 150 C. &lt; / RTI &gt; On the other hand, the low temperature crosslinking agent defined in the present disclosure may be contained in a capsule to become a second crosslinking agent. The high-temperature crosslinking agent can crosslink the resin while the capsules melt at 80 to 150 ° C.

The diameter of the capsule may be a few microns, for example, greater than 0 microns and less than 3 microns. The outer wall of the capsule may be composed of melamine resin, formaldehyde, yeast, starch or dextrin. By increasing the number of coatings, the outer wall can be further strengthened, thereby reducing the probability of breaking the capsules due to temperature and pressure during the printing process.

After printing, the printed artificial leather is allowed to stand for 30 seconds to 24 hours, specifically for 10 minutes to 18 hours, more specifically for 1 hour to 12 hours, and the resin and the low temperature crosslinking agent are subjected to a crosslinking reaction (first crosslinking reaction ). A part of the whole resin, for example, 50 to 70% by weight can be crosslinked by the low-temperature crosslinking agent. The degree of crosslinking can be measured by xylene solvent extraction method using ASTM D2765. The resin may be bonded to the base layer while being crosslinked.

<Ironing Process>

After completion of the crosslinking reaction (first crosslinking reaction) by the low-temperature crosslinking agent, the printed surface of the artificial leather, that is, the replicated layer is ironed at 80 to 150 캜, more specifically at 100 to 150 캜 to crosslink the resin and the high- (Second crosslinking reaction). The crosslinked resin may be bonded to the base layer by imparting an adhesive force to the primer. The ironing can be performed by using hot rolls, hot presses, or general household irons, but is not limited thereto.

The ironing is carried out for 5 minutes or less, more specifically 1 minute or less, most specifically 1 second to 3 seconds to carry out the second crosslinking reaction.

When the high-temperature crosslinking agent is contained in the capsule, the capsule is dissolved by heat at 80 to 150 ° C, and the crosslinking agent inside the crosslinking agent can give an adhesive force to the resin while performing a crosslinking reaction with the resin.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a sectional view of a synthetic leather formed with a three-dimensional pattern according to one embodiment of the present disclosure; Fig. As shown in Fig. 1, the entire simulation is pressed during the ironing step, but since only the simulation of the printed portion is applied to the simulation 3 of the portion on which the ink 5 is printed, only the simulation of the printed portion is attached to the adhesive layer 2, The simulated portion 4 of the non-existent portion is reproduced again, and a three-dimensional pattern showing two tones as shown in the right photograph (b) of FIG. 2 can be formed. Therefore, the method of forming the three-dimensional pattern according to the present disclosure can be more effectively applied to the artificial leather made by the folding method in which the simulation is formed upright on the base layer.

The copy of the printed portion through the first crosslinking reaction can be crosslinked by 50 to 70% by weight, which can be stored as a semi-finished product. Since 50 to 70% by weight is crosslinked, penetration of contaminants into the printed simulated portion can be prevented.

When the second first crosslinking reaction is performed by printing a pattern different from the initial printing pattern without introducing the semi-finished product directly into the ironing process and introduced into the ironing process, a three-dimensional pattern having three tonnes can be formed .

In one embodiment, the mixing weight ratio of resin: first crosslinker: second crosslinker can be from 100: 3 to 6: 3 to 6. When the mixing weight ratio of the first crosslinking agent is less than 3, the crosslinking does not occur at the minimum, and the contaminants may enter during storage in the semi-finished product. If the mixing weight ratio is more than 6, the second crosslinking reaction is lowered.

If the mixing weight ratio of the high-temperature crosslinking agent is less than 3, a three-dimensional pattern may not be formed, and if it is more than 6, excessive crosslinking may occur, resulting in breakage of the copy.

2 is a photograph of an artificial leather before and after a three-dimensional pattern is formed. 2 (a) is a photograph of artificial leather before a three-dimensional pattern is formed, and right (b) is a photograph of artificial leather after a three-dimensional pattern is formed according to one embodiment of the present disclosure. As shown in the right picture (b) of Fig. 2, according to the present disclosure, since printing of the printed portion adheres to the base layer to shorten the length of the simulated layer even when printing is performed with monochrome ink, There is an effect that can be shown.

Hereinafter, the present disclosure will be described in more detail by way of examples, but the following examples do not limit the scope of the present disclosure.

Example

An artificial leather having a thickness of about 2 denier and a length of about 0.5 mm was coated on a thermoplastic polyurethane (TPU) base layer having a thickness of about 0.5 mm by artificial leather by a flocculation method. About 100 g of a polyurethane resin (Songwon Industry, P-2190A), about 3 g of a first crosslinking agent (D-ACE 575), about 2 g of a second crosslinking agent (SUPESIN DCL-75) A predetermined pattern as shown in Fig. 2 (b) was printed with an ink of 3 g. After about 30 minutes, artificial leather printed at a rate of about 3 m / min was passed through a heat roll at a pressure of about 20 kg / cm 2 at a temperature of about 120 ° C. According to the embodiment, a three-dimensional pattern having two tones can be formed as shown in the right photograph (b) of FIG.

Although the present disclosure has been described in detail by way of specific examples, it is to be understood that the present disclosure is not intended to be limited thereto and that various changes and modifications may be made by those skilled in the art It is obvious that the modification or improvement is possible.

All such modifications and variations are intended to fall within the scope of the present disclosure, and the scope of protection of the present disclosure will be apparent from the appended claims.

1: Base layer 2: Adhesive layer
3: Simulation of the printed part 4: Simulation of the unprinted part
5: Ink

Claims (12)

(a) providing a synthetic leather comprising a base layer, an adhesive layer formed on the base layer and a simulated layer formed on the adhesive layer;
(b) printing a specific pattern on the patterned layer with an ink comprising a resin, a first crosslinking agent, and a second crosslinking agent which undergoes a crosslinking reaction at a temperature higher than 40 ° C higher than the first crosslinking agent; And
(c) ironing the printed simulated layer to adhere only the simulated printed ink to the adhesive layer. The method according to claim 1,
Wherein the simulated leather in step (a) is formed by a flocking method to form a three-dimensional pattern having a thickness of 1 to 10 denier and a length of 0.3 to 2 mm. The method according to claim 1,
Wherein the resin is a polyurethane, polycarbonate, acrylic resin or a mixture thereof. The method according to claim 1,
Wherein the first crosslinking agent is crosslinked with the resin at 18 to 40 占 폚 and the second crosslinking agent is crosslinked with the resin at 80 to 150 占 폚. The method according to claim 1,
Wherein the second crosslinking agent is in the form of a capsule and the capsule is dissolved in the ironing step (c), whereby a three-dimensional pattern is formed in which the second crosslinking agent inside the capsule undergoes a crosslinking reaction with the resin. The method according to claim 1,
Wherein the printing step (b) is carried out at 18 to 40 캜, followed by a crosslinking reaction of the resin and the first crosslinking agent for 30 to 24 hours, whereby 50 to 70% by weight of the resin is crosslinked, and the ironing step (c) Wherein a three-dimensional pattern is formed at 80 to 150 ° C. The method according to claim 1,
Wherein a weight ratio of said resin: first crosslinking agent: second crosslinking agent is 100: 3 to 6: 3 to 6. A base layer, an adhesive layer formed on the base layer, and a simulated layer formed on the adhesive layer, wherein a specific pattern is printed on a part of the simulated layer of the simulated layer using ink, Wherein the ink comprises a resin, a first crosslinking agent, and a second crosslinking agent which undergoes a crosslinking reaction at a temperature higher than 40 DEG C higher than that of the first crosslinking agent and the first crosslinking agent. The method of claim 8,
The simulated leather is formed by a flocking method and has a three-dimensional pattern having a thickness of 1 to 10 denier and a length of 0.3 to 2 mm. The method of claim 8,
Wherein the resin is a polyurethane, polycarbonate, acrylic resin or a mixture thereof. The method of claim 8,
Wherein the first crosslinking agent is a three-dimensional pattern formed of polyurethane and ethyl acetate. The method of claim 8,
Wherein the second crosslinking agent is a capsule-like three-dimensional pattern.

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