KR102635538B1 - Artificial leather for vehicle interior material and method for manufacturing the same - Google Patents

Abstract

The present invention relates to artificial leather for automobile interior materials and a method of manufacturing the same, wherein the artificial leather for automobile interior materials includes a 3D spacer fabric, a cover layer located on the 3D spacer fabric, and a cover layer located on the cover layer. It includes a surface layer including a surface treatment layer.
The artificial leather for automobile interior materials can simplify the process, remove odors from car seats by blocking odors caused by ammonia (NH ₄ ) gas, and improve durability to improve the problem of fading or deforming even during long-term use. And by improving flexibility, the problem of wrinkles can be improved.

Description

Artificial leather for automobile interior and manufacturing method thereof {ARTIFICIAL LEATHER FOR VEHICLE INTERIOR MATERIAL AND METHOD FOR MANUFACTURING THE SAME}

The present invention relates to artificial leather for automobile interior materials and a method of manufacturing the same. More specifically, the process can be simplified, odors caused by ammonia (NH ₄ ) gas can be blocked to remove odors from car seats, and durability. It relates to artificial leather for automobile interior materials and a method of manufacturing the same, which can improve the problem of sagging or deformation even during long-term use, and improve the problem of wrinkles by improving flexibility.

In general, the interior of a car is recognized as a second living space, and recently, functional seats have been in the spotlight for comfortable and pleasant driving in this interior space of the car.

Natural leather, polyvinyl chloride, and artificial leather such as polyurethane are widely used as materials for such automobile interiors.

Specifically, conventional artificial leather for automobile interior materials includes a foam layer, a cover layer, and a surface treatment layer on polyurethane foam, as disclosed in Korean Patent Registration No. 1450604 (registration date: October 23, 2014). It consists of a layered structure.

The foam layer and the label layer are mainly made of polyvinyl chloride or polyurethane, and are laminated to a predetermined thickness through a calendaring or casting process. Then, through the foaming process, the foam layer is foamed and molded at a certain magnification.

However, when it is desired to form a foam layer and a cover layer made of polyvinyl chloride or polyurethane on the polyurethane foam through a calendaring or casting process, an additional process of laminating the polyurethane foam is required, especially When using flame laminating, an odor occurs due to ammonia (NH ₄ ) gas generated.

In addition, the polyurethane foam has an open cell structure, which causes the car seat to deform when used for a long period of time, or wrinkles due to poor flexibility.

Korean Patent Registration No. 1450604 (registration date: October 23, 2014)

The purpose of the present invention is to provide artificial leather for automobile interior materials that has improved durability so that it does not break or deform even during long-term use, has excellent flexibility to prevent wrinkles, and has improved surface smoothness, adhesion, and ductility.

Another object of the present invention is to simplify the process by eliminating the additional process of laminating polyurethane foam, and to block the odor caused by ammonia (NH ₄ ) gas generated when using flame laminating A car interior material that can remove odors from sheets and improve surface defects caused by penetration of the surface reinforcing structure of the three-dimensional spacer fabric even when the foam layer and cover layer are formed by applying a casting method. A method for manufacturing artificial leather is provided.

According to one embodiment of the present invention, the first fabric layer and the second fabric layer are spaced apart, and a spacer layer that connects the first fabric layer and the second fabric layer with a spacing thread to form a three-dimensional structure. Artificial leather for automobile interior materials comprising a surface layer including a 3D spacer fabric, a cover layer located on a first fabric layer of the 3D spacer fabric, and a surface treatment layer located on the cover layer. to provide.

The first fabric layer includes meshes between stitch places of threads, and the mesh size of the first fabric layer may be between 0.01 mm and 1.5 mm.

The artificial leather for automobile interior materials may have a surface smoothness (S) expressed by Equation 1 below of -0.1 mm to +0.1 mm.

[Equation 1]

Surface smoothness (S) = H ₁ -H ₂

H ₁ (unit: mm) = total height of the artificial leather passing through any one of the intersections of the threads of the first fabric layer

H ₂ (unit: mm) = total height of artificial leather passing through any one of the meshes of the first fabric layer

The label layer may be formed by a casting method.

The thickness of the surface layer may be 0.01 mm to 1.5 mm.

The second fabric layer includes meshes between stitch places of threads, and the mesh size of the second fabric layer may be between 0.01 mm and 3.5 mm.

The ratio of the elongation of the first fabric layer and the elongation of the second fabric layer may be greater than 1:1 and less than or equal to 1:10.

According to another embodiment of the present invention, it includes a first fabric layer and a second fabric layer that are spaced apart, and a spacer layer that connects the first fabric layer and the second fabric layer with a spacing thread to form a three-dimensional structure. Preparing a 3D spacer fabric, preparing a surface layer including a label layer and a surface treatment layer located on the label layer, and laminating the surface layer and the 3D spacer fabric. Provided is a method for manufacturing artificial leather for automobile interior materials including the step of:

The first fabric layer includes meshes between stitch places of threads, and the mesh size of the first fabric layer may be 0.01 mm to 1.5 mm.

The label layer may be formed by a casting method.

The artificial leather for automobile interior materials of the present invention and its manufacturing method replace polyurethane foam with a three-dimensional spacer fabric, thereby simplifying the process by eliminating the additional process of laminating polyurethane foam, and eliminating the flame. It can remove odors from car seats by blocking the odor caused by ammonia (NH ₄ ) gas generated when using laminating. It also improves durability to improve the problem of fading or deforming even during long-term use, and improves flexibility to prevent wrinkles. Problems that arise can be improved.

In addition, by improving the surface structure of the three-dimensional spacer fabric while applying the three-dimensional spacer fabric, when forming the foam layer and the label layer by applying a casting method, the surface structure of the three-dimensional spacer fabric is transmitted through There is an additional effect of improving surface defects that occur and improving adhesion and ductility.

Figure 1 is an exploded perspective view showing artificial leather for automobile interior materials.
Figure 2 is a plan view showing an example of a first fabric layer or a second fabric layer.
Figure 3 is a process diagram showing a method of manufacturing artificial leather for automobile interior materials.

Hereinafter, the present invention will be described in more detail.

Artificial leather for automobile interior materials according to an embodiment of the present invention includes a surface layer including a 3D spacer fabric, a cover layer located on the 3D spacer fabric, and a surface treatment layer located on the cover layer. Includes.

Figure 1 is an exploded perspective view showing the artificial leather for automobile interior materials. Hereinafter, the artificial leather 100 for automobile interior materials will be described in detail with reference to FIG. 1.

The artificial leather 100 for automotive interior materials includes a three-dimensional spacer fabric 10 and a surface layer 30 located on the three-dimensional spacer fabric 10. The surface layer 30 includes a label back layer 34, a label layer 32 positioned on the label back layer 34, and a surface treatment layer 33 positioned on the label layer 32.

The three-dimensional spacer fabric 10 is a part in contact with the automobile frame, and serves to secure the mechanical properties of the artificial leather 100 for automobile interior materials, maintain the shape of the artificial leather 100 for automobile interior materials, and prevent wrinkles. This is the layer that performs.

The three-dimensional spacer fabric 10 replaces the polyurethane foam used as the fabric layer of existing artificial leather. This further improves the durability of the fabric layer, eliminating the problem of it breaking or deforming even during long-term use. It can improve wrinkles by improving flexibility. In addition, the three-dimensional spacer fabric 10 has the advantage of having a constant thickness, excellent mechanical properties such as strength, high dimensional stability, and not being deformed by heat and pressure.

Specifically, the three-dimensional spacer fabric 10 is disposed spaced apart from the first fabric layer 11 and the second fabric layer 12, and between the first fabric layer 11 and the second fabric layer 12. It includes a spacer layer 13 located at.

The spacer layer 13 is made of knitted spacing threads, which connect the first fabric layer 11 and the second fabric layer 12 and are spaced at regular intervals. Forms and maintains a three-dimensional structure by supporting it to maintain the structure.

The knitted spacing yarns have sufficient compressive strength and cushioning properties and very good recovery behavior, have high permeability to air, and are knitted in a three-dimensional network structure to generate very high flexibility.

The three-dimensional spacer fabric 10 having this structure can be woven through a double Raschel knitting machine, a Moqqette knitting machine, or a circular knitting machine, and thus the three-dimensional spacer fabric (10) is also called 3D mesh fabric, double cell 3D mesh fabric, DNB 3D mesh fabric, and DNB spacer fabric.

For example, the spacer layer 13 is made of at least one thread, and an empty space is formed in the portion where the thread is not formed. In this case, the thread may have a zigzag shape, and the zigzag shape is a 'V' shape, Any shape, such as a 'U' shape or an arch shape, can be applied in the present invention as long as it prevents the three-dimensional spacer fabric 10 from falling over and provides a cushioning feeling.

For example, the spacer thread may be formed of monoyarn made of polyester, and the fineness of the spacer thread may be 20 dtex to 110 dtex. In this case, since the mono yarn has greater strength than multiyarn of the same fineness, it may be particularly advantageous in improving the restoration effect of the three-dimensional spacer fabric 10.

Meanwhile, the first fabric layer 11 and the second fabric layer 12 are not significantly limited in the present invention as long as they are a knit fabric or woven fabric and are made of yarn. As the first fabric layer 11 and the second fabric layer 12 are made of threads, they may include meshes, which are holes of a certain size, between stitch places of the threads.

Figure 2 is a plan view showing an example of the first fabric layer 11 or the second fabric layer 12. Referring to FIG. 2, the first fabric layer 11 or the second fabric layer 12 includes meshes 113, which are holes of a certain size, between the intersections 112 of the threads 111.

However, when the size of the mesh 113 of the first fabric layer 11 is too large, the surface texture structure of the three-dimensional spacer fabric 10 penetrates the surface of the artificial leather for automobile interior material 100, thereby causing the surface Defect problems may occur.

In particular, this problem is more problematic when the cover layer 32 and the cover back layer 34 are formed by applying a casting method and the thickness of the surface layer 30 is thin, such as when the foam layer is not included. It can be.

Accordingly, in the present invention, by improving the surface structure of the three-dimensional spacer fabric 10, when forming the label layer 32 and the label back layer 34 by applying a casting method, the three-dimensional spacer fabric ( This is to improve the surface defect problem caused by the penetration of the surface reinforcing structure in 10).

That is, the size of the mesh 113 of the first fabric layer 11 may be 0.01 mm to 1.5 mm, specifically 0.05 mm to 1.0 mm. If the size of the mesh 113 of the first fabric layer 11 exceeds 1.5 mm, a surface defect problem may occur due to the surface reinforcing structure of the three-dimensional spacer fabric 10 being transmitted, and if the size is less than 0.01 mm. The air permeability of the three-dimensional spacer fabric 10 may decrease.

According to the present invention, the surface coating structure of the three-dimensional spacer fabric 10 is improved as described above, the artificial leather for automobile interior material 100 has a surface smoothness (S) expressed by the following equation (1) of -0.1 mm to -0.1 mm. It may be + 0.1 mm, specifically - 0.05 mm to + 0.05 mm.

[Equation 1]

Surface smoothness (S) = H ₁ -H ₂

H ₁ (unit: mm) = total height of the artificial leather passing through any one of the intersections of the threads of the first fabric layer

H ₂ (unit: mm) = total height of artificial leather passing through any one of the meshes of the first fabric layer

In Equation 1, the total height of the artificial leather 100 is calculated by placing the artificial leather 100 on a flat surface and starting from the surface to the top of the artificial leather 100 (for example, the surface of the surface treatment layer 33). means the height up to, and the total height of the artificial leather passing through the intersection or mesh of the first fabric layer 11 is the total height of the artificial leather passing vertically from the flat surface to the intersection or the mesh of the first fabric layer 11 It means the total height of 100.

At this time, the effect of improving the surface smoothness (S) of the artificial leather 100 for automobile interior materials by improving the surface reinforcing structure of the three-dimensional spacer fabric 10 is achieved by the sign layer 32 and the sign back layer ( In the case of forming 34) by a casting method, it can be maximized when the thickness of the surface layer 30 is 0.01 mm to 1.5 mm, specifically 0.02 mm to 1.0 mm.

Meanwhile, the mesh size of the second fabric layer 12 may be 0.01 mm to 3.5 mm, specifically 0.05 mm to 3.0 mm. When the size of the mesh of the second fabric layer 12 is within the above range, the second fabric layer 12 has a greater elongation and greater elastic recovery force than the first fabric layer 11. , the problem of wrinkles occurring when using the artificial leather 100 for automobile interior materials for a long period of time can be improved.

Accordingly, the ratio of the elongation of the first fabric layer 11 and the elongation of the second fabric layer 12 may be greater than 1:1 and less than or equal to 1:10, and specifically greater than 1:1 and less than or equal to 1:5. You can. At this time, the elongation was measured with a load of 100 N according to ISO 13934-1.

Meanwhile, the total thickness of the three-dimensional spacer fabric 10 may be 1 mm to 20 mm, specifically 2 mm to 15 mm, when the total thickness of the three-dimensional spacer fabric 10 is less than 1 mm. Mechanical strength may be reduced, and if it exceeds 20 mm, material costs may be unnecessarily increased as it is formed thicker than necessary.

The marking layer 32 serves to secure the surface smoothness of the artificial leather 100 for automobile interior materials and provide color, and may be manufactured using a casting method, thereby using polyvinyl chloride (PVC). ) It may be made of resin or polyurethane (PU) resin.

The polyvinyl chloride resin may be a straight polyvinyl chloride resin formed through suspension polymerization. The polyvinyl chloride resin may have a degree of polymerization of 1250 to 3000, specifically 1250 to 2000. If the degree of polymerization of the polyvinyl chloride resin is less than 1250, it may be difficult to form the label layer 32 using a casting method, and if it exceeds 3000, ductility may be reduced.

The polyurethane resin may be manufactured by polymerizing polycarbonate diol, polyether diol or diol containing a caroboxyl group, and a diisocyanate-based compound at approximately 80°C to 100°C.

Since the polyurethane resin does not contain volatile organic compounds such as toluene, it is easily dispersed in water, has no adverse effects on the human body, and is environmentally friendly. When the label layer 32 is made of the polyurethane resin, it has excellent compatibility with the surface treatment layer 33 and has the advantage of improving surface properties such as touch.

Since the cover layer 32 is manufactured using the casting method, the feel of artificial leather can be maintained without the foam layer, so it may not necessarily include an additional foam layer.

In addition, as the cover layer 32 is manufactured using the casting method, the thickness of the cover layer 32 may be 5 ㎛ to 400 ㎛, specifically 10 ㎛ to 300 ㎛. If the thickness of the marking layer 32 is less than 5 ㎛, surface smoothness and processability may be reduced, and material costs may increase due to an increase in the amount of pigment added to implement color, and if it exceeds 400 ㎛, it may be used as an automobile interior material. The cushioning feeling of the artificial leather 100 is reduced, and as it is formed thicker than necessary, material costs may be incurred unnecessarily.

Meanwhile, an embossed pattern (not shown) may be formed on the surface of the cover layer 32, and the embossed pattern can provide an excellent surface texture to the artificial leather 100 for automobile interior materials and improve surface durability. .

Optionally, the surface layer 30 may further include the label back layer 34 between the three-dimensional spacer fabric 10 and the label layer 32.

The cover back layer 34 can increase the cushioning feel of the artificial leather 100 for automobile interior materials and complement the thickness of the finished product.

The label back layer 34 may also be manufactured using a casting method, and may therefore be made of polyvinyl chloride (PVC) resin or polyurethane (PU) resin.

Since the contents of the polyvinyl chloride resin and the polyurethane resin are the same as those described in the cover layer 32, repeated descriptions will be omitted.

The thickness of the label back layer 34 may be 5 ㎛ to 500 ㎛, specifically 10 ㎛ to 400 ㎛. If the thickness of the cover layer 34 is less than 5 ㎛, the cushioning feeling may be reduced, and if it exceeds 500 ㎛, it may be formed thicker than necessary, resulting in unnecessary material costs.

The surface treatment layer 33 is intended to improve the scratch resistance, stain resistance, and surface properties of the artificial leather 100 for automobile interior materials, and to provide an environmentally friendly effect, and is made of polyurethane (PU) resin, for example. You can.

The surface treatment layer 33 may have a thickness of 4 ㎛ to 30 ㎛, specifically 10 ㎛ to 20 ㎛. By maintaining the thickness of the surface treatment layer 33 within the above range, contamination resistance can be secured while maintaining the flexibility of the artificial leather 100 for automobile interior materials.

If the thickness of the surface treatment layer 33 is less than 4 ㎛, durability may be reduced because the thickness is too thin, and if it exceeds 30 ㎛, consumption of surface treatment agent may increase, resulting in unnecessary material costs.

A method of manufacturing artificial leather for automobile interior materials according to another embodiment of the present invention includes preparing a three-dimensional spacer fabric, preparing a surface layer including a cover layer and a surface treatment layer located on the cover layer, and It includes laminating the surface layer and the three-dimensional spacer fabric.

Figure 3 is a process diagram showing a method of manufacturing artificial leather for automobile interior materials. Hereinafter, a method of manufacturing the artificial leather 100 for automobile interior materials will be described in detail with reference to FIG. 3.

The method of manufacturing the artificial leather 100 for automobile interior materials includes the steps of applying a sol for forming a label layer on a release paper 60 by a casting method to form a label layer 32, and applying a sol for forming a label back layer to the label layer ( 32) forming a sign back layer 34 by applying it by casting, applying a binder 70 by casting on the sign back layer 34 and laminating the three-dimensional spacer fabric 10, and It includes peeling off the release paper 60 and forming a surface treatment layer 33 on the cover layer 32.

First, the sol for forming a label layer is applied on the release paper 60 using a casting method to form the label layer 32 (S3-1).

The casting method typically refers to the application of a liquid substance by a mixing head, and in the present invention, commonly used mixing heads operated at high or low pressure can be used. Specifically, the casting method can be accomplished by using Puromats (manufactured by Krauss Maffei) as a metering unit and applying the sol for forming the label layer in a laminar stream of material.

The sol for forming the label layer includes polyvinyl chloride (PVC) resin or polyurethane (PU) resin.

In addition, the sol for forming the label layer contains 10 to 20 parts by weight of an inorganic additive based on 100 parts by weight of the polyvinyl chloride (PVC) resin in order to secure the surface smoothness of the label layer 32 and realize the color. Alternatively, it may include 3 to 30 parts by weight of a silicone-based additive and 10 to 20 parts by weight of an organic additive based on 100 parts by weight of the polyurethane resin, and may further include a pigment if necessary.

In addition, the sol for forming the label layer may further include any one additive selected from the group consisting of heat stabilizers, flame retardants, fillers, and mixtures thereof to control melt strength and physical properties.

After applying the sol for forming the label layer on the release paper 60, a step of selectively drying may be further included (S3-2).

The drying may be performed at 110°C to 150°C, specifically 130°C to 150°C for 80 seconds to 120 seconds. When dried below the above temperature and time range, the solvent does not evaporate sufficiently and remains, causing whitening to occur on the surface of the artificial leather 100 for automobile interior materials due to non-curing, and surface properties may be deteriorated within the above temperature and time range. If it exceeds this, heat resistance may decrease and discoloration may occur.

Meanwhile, a fine pattern such as an embossed pattern may be formed on the surface of the release paper 60, and through this, the embossed pattern can be transferred to the cover layer 32. The embossed pattern may refer to irregularities formed on the top of the artificial leather 100 for automobile interior materials.

Next, the sol for forming the label back layer is applied on the label layer 32 using a casting method to form the label back layer 34 (S3-3).

Since the casting method is the same as described in the step of forming the label layer 32, repeated descriptions will be omitted.

The solution for forming the label back layer includes polyvinyl chloride (PVC) resin or polyurethane (PU) resin.

The sol for forming the label back layer includes 10 to 20 parts by weight of an inorganic additive based on 100 parts by weight of the polyvinyl chloride (PVC) resin, or 3 to 30 parts by weight of a silicone additive based on 100 parts by weight of the polyurethane resin. It may contain 10 parts by weight to 20 parts by weight of organic additives.

After applying the sol for forming the label back layer on the label layer 32, a step of selectively drying may be further included (S3-4). Since the drying method and conditions are the same as those described in the step of forming the label layer 32, repeated descriptions will be omitted.

Next, the binder 70 is applied on the cover back layer 34 using a casting method (S3-5) and the three-dimensional spacer fabric 10 is laminated (S3-7).

The binder 70 may be an acrylic adhesive, polyurethane adhesive, or polyvinyl chloride plastisol. However, the acrylic adhesive has the disadvantage of being hard after drying, which increases the microhardness of the artificial leather, and the polyurethane adhesive is relatively expensive and increases the material cost, so polyvinyl chloride plastisol can be preferably used.

The polyvinyl chloride plastisol may be formed by stirring 70 to 130 parts by weight of a plasticizer and 0.5 to 10 parts by weight of a curing agent at room temperature (20° C.) based on 100 parts by weight of the polyvinyl chloride resin.

Specifically, the polyvinyl chloride resin may be a mixed resin composed of 60% to 90% by weight of a homopolymer of vinyl chloride and 10% to 40% by weight of a copolymer of vinyl chloride and vinyl acetate.

The vinyl chloride homopolymer is a paste polyvinyl chloride resin prepared by emulsion polymerization and may be included in the mixed resin in an amount of 60% to 90% by weight, specifically 65% to 85% by weight. If the content of the vinyl chloride homopolymer is less than 60% by weight, the peeling strength of the three-dimensional spacer fabric 10 and the surface layer 30 may decrease, and if it exceeds 90% by weight, there may be a problem of generating an odor. You can.

The copolymer of vinyl chloride and vinyl acetate may include a vinyl acetate content of 1% by weight to 15% by weight, specifically 3% by weight to 10% by weight. If the content of vinyl acetate is less than 1% by weight, the adhesive strength may decrease and the peeling strength of the three-dimensional spacer fabric 10 and the surface layer 30 may decrease, and if the content of vinyl acetate exceeds 15% by weight, hydrolyzability may decrease. You can.

In addition, the copolymer of vinyl chloride and vinyl acetate may be included in the mixed resin in an amount of 10% to 40% by weight, specifically 15% to 35% by weight. If the content of the copolymer of vinyl chloride and vinyl acetate is less than 10% by weight, the peel strength of the three-dimensional spacer fabric 10 and the surface layer 30 may decrease, and if it exceeds 40% by weight, heat resistance, etc. Mechanical properties may deteriorate.

The plasticizer may be any one selected from the group consisting of phthalate-based plasticizer, terephthalate-based plasticizer, benzoate-based plasticizer, citrate-based plasticizer, phosphate-based plasticizer, adipate-based plasticizer, and mixtures thereof. However, a terephthalate-based plasticizer that is environmentally friendly and has excellent heat resistance can be used, and specifically, dioctyl terephthalate can be used, but the present invention is not limited thereto.

The plasticizer may be included in an amount of 70 to 130 parts by weight, specifically 80 to 120 parts by weight, based on 100 parts by weight of the mixed resin. If the content of the plasticizer is less than 70 parts by weight, the viscosity of the binder 70 may increase and processability may be reduced, and if it exceeds 130 parts by weight, adhesive strength may be reduced due to migration of the plasticizer.

The curing agent may be a low-temperature curing type to increase energy efficiency and productivity, and a block isocyanate curing agent in which some or all of the isocyanate groups are blocked with a blocking agent may be used.

The blocking agent is phenol, ε-caprolactam, methyl ethyl ketone oxime, 1,2-pyrazole, and diethyl malonate. malonate, diisopropylamine, triazole, imidazole, 3,5-dimethylpyrazole, and mixtures thereof. You can use it.

The block isocyanate curing agent blocks the isocyanate group (-NCO) to prevent it from reacting with the hydroxyl group (-OH) or amino group (-NH) at room temperature, and when it reaches a certain temperature range, the blocking agent dissociates, causing the reactivity of (-NCO). This increases and the hardening reaction progresses.

The dissociation temperature of the curing agent may be 100°C or higher, specifically 110°C to 130°C.

The curing agent may be included in an amount of 0.5 parts by weight to 10 parts by weight, specifically 1 part by weight to 5 parts by weight, based on 100 parts by weight of the mixed resin. If the content of the curing agent is less than 0.5 parts by weight, the peeling strength of the three-dimensional spacer fabric 10 and the surface layer 30 may decrease due to a decrease in the crosslinking degree, and if the content of the curing agent exceeds 10 parts by weight, the unreacted curing agent may be an impurity. The remaining usability may be reduced.

The binder 70 may further include, if necessary, any other additive selected from the group consisting of stabilizers, fillers, pigments, viscosity lowering agents, dispersants, and mixtures thereof, the content of which is that of the coating solution. There are no particular restrictions as long as it does not affect physical properties.

After applying the binder 70 on the label back layer 34, a step of selectively drying may be further included (S3-6). Since the drying method and conditions are the same as those described in the step of forming the label layer 32, repeated descriptions will be omitted.

Next, the release paper 60 is peeled off (S3-8) and a surface treatment layer 33 is formed on the cover layer 32 to prepare the surface layer 30 (S3-9).

The surface treatment layer 33 may be formed by applying and drying an aqueous surface treatment agent on the cover layer 32.

The aqueous surface treatment agent may be a two-component aqueous surface treatment agent containing 1 to 25 parts by weight of a curing agent, 1 to 25 parts by weight of an aqueous solvent, and 1 to 15 parts by weight of a silicone compound, based on 100 parts by weight of the main agent. there is.

The main agent may be a water-dispersed polycarbonate-based polyurethane resin, and the curing agent may contain any one functional group selected from the group consisting of an aziridine group, an isocyanate group, a carbodiimide group, and mixtures thereof per molecule. However, the present invention is not limited to this.

The silicone compound may be in the form of a liquid polysiloxane dispersed in water or bead-shaped polysiloxane, but is preferably in a liquid form dispersed in water, which has a better surface texture.

The aqueous solvent may be water, alcohol, or a mixture of water and alcohol.

The aqueous surface treatment agent can be applied using gravure coating. The gravure coating process includes direct gravure coating, reverse gravure coating, and offset gravure coating. The direct gravure coating is performed on a substrate between a roller made of elastic rubber and a roller containing a coating liquid, and the rotation speeds of these rollers may be the same. Additionally, the rotation directions of the substrate and rollers may be opposite. In the reverse gravure coating, the rotation directions of the substrate and rollers are opposite, and the application amount can be adjusted by adjusting the speed of the rollers. In the offset gravure coating, each roller is driven independently of each other, and a coating layer can be uniformly formed even with a small amount due to high speed.

The drying may be performed at 110°C to 150°C, specifically 130°C to 150°C for 80 seconds to 120 seconds. When dried below the above temperature and time range, the aqueous solvent fails to evaporate and remains, causing whitening to occur on the surface of the artificial leather 100 for automobile interior materials due to non-curing, and surface properties may deteriorate. If the range is exceeded, heat resistance may decrease and discoloration may occur.

Hereinafter, embodiments of the present invention will be described in detail so that those skilled in the art can easily practice it. However, the present invention may be implemented in many different forms and is not limited to the embodiments described herein.

[Manufacturing example: Manufacturing of artificial leather]

(Example 1)

A three-dimensional spacer fabric with a thickness of 4 mm and including a first fabric layer, a second fabric layer, and a spacer layer made of polyester was prepared. The mesh size of the first fabric layer was 0.05 mm, the mesh size of the second fabric layer was 0.1 mm, and the ratio of the elongation of the first fabric layer to the elongation of the second fabric layer was 1:2.

A sol for forming a label layer was prepared by mixing 100 parts by weight of a polyvinyl chloride resin with a degree of polymerization of 1000, 10 parts by weight of an inorganic additive, and 4 parts by weight of a black pigment.

The sol for forming a cover layer prepared above was cast to a thickness of 0.2 mm on release paper on which a fine pattern was formed, and dried at 110° C. for about 2 minutes to prepare a cover layer.

A sol for forming a label back layer was prepared by mixing 100 parts by weight of a polyvinyl chloride resin with a degree of polymerization of 1300 and 10 parts by weight of an inorganic additive.

The prepared sol for forming the label back layer was cast on the cover layer to a thickness of 0.6 mm and dried at 110° C. for about 2 minutes to prepare the label back layer.

Acrylic adhesive was cast to a thickness of 0.3 mm on the cover back layer, dried at 110° C. for about 30 seconds, and then the three-dimensional spacer fabric was adhered.

An aqueous surface treatment agent containing 5 parts by weight of a curing agent, 20 parts by weight of an aqueous solvent, and 5 parts by weight of a silicone compound based on 100 parts by weight of a polycarbonate-based polyurethane resin was gravure coated on the cover layer and then dried at 140° C. to remove the aqueous solvent. By evaporating, a surface treatment layer with a thickness of 15 μm was formed, thereby producing artificial leather with a thickness of 5 mm.

(Example 2)

A three-dimensional spacer fabric with a thickness of 4 mm and including a first fabric layer, a second fabric layer, and a spacer layer made of polyester was prepared. The mesh size of the first fabric layer was 0.05 mm, the mesh size of the second fabric layer was 0.1 mm, and the ratio of the elongation of the first fabric layer to the elongation of the second fabric layer was 1:2.

A sol for forming a label layer was prepared by mixing 100 parts by weight of a polyester mixed polyurethane resin, 10 parts by weight of a silicone additive, 20 parts by weight of an organic additive, and 4 parts by weight of a black pigment.

The sol for forming a cover layer prepared above was cast to a thickness of 30 ㎛ on release paper on which a fine pattern was formed, and dried at 110° C. for about 2 minutes to prepare a cover layer.

A sol for forming a label back layer was prepared by mixing 100 parts by weight of polyester mixed polyurethane resin, 10 parts by weight of a silicone-based additive, and 20 parts by weight of an organic additive.

The prepared sol for forming a label back layer was cast on the label layer to a thickness of 30 ㎛ and dried at 110°C for about 2 minutes to prepare a label back layer.

Acrylic adhesive was cast to a thickness of 0.3 mm on the cover back layer, dried at 110° C. for about 30 seconds, and then the three-dimensional spacer fabric was adhered.

An aqueous surface treatment agent containing 5 parts by weight of a curing agent, 20 parts by weight of an aqueous solvent, and 5 parts by weight of a silicone compound based on 100 parts by weight of a polycarbonate-based polyurethane resin was gravure coated on the cover layer and then dried at 140° C. to remove the aqueous solvent. By evaporating, a 15 ㎛ thick surface treatment layer was formed to produce artificial leather with a thickness of 4.5 mm.

(Comparative Example 1)

Artificial leather was manufactured in the same manner as in Example 1, except that a three-dimensional spacer fabric with a mesh size of 2.0 mm in the first fabric layer was used.

(Comparative Example 2)

In Example 1, artificial leather with a thickness of 5 mm was manufactured in the same manner as in Example 1, except that a 25 ppi filter foam with a thickness of 4 mm was used in place of the three-dimensional spacer fabric. did.

[Experimental Example 1: Measurement of surface smoothness of artificial leather]

Surface smoothness was measured for the artificial leather manufactured in the above examples and comparative examples.

Specifically, the artificial leather prepared in the Examples and Comparative Examples was cut in the vertical direction and then measured at any one point among the intersections of the threads of the first fabric layer using a high-magnification optical microscope. 1 The total height of the artificial leather measured at any point among the meshes of the fabric layer was measured and calculated using Equation 1 above, and the results are shown in Table 1 below.

surface smoothness
(Unit: mm) Example 1 0.03 Example 2 0.04 Comparative Example 1 0.19

Referring to Table 1, it can be seen that the artificial leather manufactured in the above example has superior surface smoothness compared to the artificial leather manufactured in Comparative Example 1.

Accordingly, the artificial leather manufactured in the above example has a surface texture structure of the three-dimensional spacer fabric even when the foam layer and the cover layer are formed by applying a casting method by controlling the size of the mesh of the first fabric layer. It can be seen that the surface defect problem caused by penetration has been improved.

[Experimental Example 2: Measurement of physical properties of artificial leather]

Peel strength, softness, sensitivity (touch), stiffness, and wrinkling were measured for the artificial leather manufactured in the examples and comparative examples, and the results are shown in Table 2 below.

The peeling strength was determined by manufacturing artificial leather into specimens with a width of 30 mm and a length of 150 mm, taking five pieces in each of the horizontal and vertical directions, impregnating the foam side with a solvent such as methyl ethyl ketone (MEK), and then applying the sample to the surface layer. The surface layer and the three-dimensional spacer fabric were forcibly separated from the surface layer by a length of 50 mm parallel to the short side, taking care not to apply stress. After peeling, leave the test piece indoors for more than 2 hours to sufficiently volatilize the solvent, then fix the peeled surface layer and the three-dimensional spacer fabric to the clamp of a tensile tester, and then set the load when peeling 50 mm at 200 mm/min to the maximum value. It was obtained as an average value. The test scores were calculated as the average of 5 specimens.

The softness was measured using a softness measuring device (SDL Atlas, ST300D) under the conditions of a temperature of 23 ± 2 ℃ and a relative humidity of 50 ± 5%, after preparing 5 artificial leather specimens with pi (ð) of 100 mm, Measurements were made by pressing the ST300D device and reading the movement of the scale for 15 seconds.

The above sensibility (touch feeling) was evaluated by internal experts on artificial leather by directly touching it with their hands and evaluating the relative softness (ⓞ: very soft, ○: soft level, △: flat touch).

For the above-mentioned stiffness, take 5 artificial leather specimens of 250 mm in width and 200 mm in length in the horizontal and vertical directions, place the short side on a horizontal bar in line with the SCALE baseline (A), and press the specimen with a press plate of the same size as the specimen. It was pressed and slid in the direction of the inclined surface at a speed of about 10 mm/sec, and the position (B) of one end of the test piece when it came into contact with the inclined surface was read as SCALE. The stiffness is expressed in terms of moving distance (scale of point B) (mm), and is expressed as the average value of five surfaces and backs measured both vertically and horizontally.

The occurrence of wrinkles was measured by pulling an artificial leather specimen with a width of 210 mm and a length of 300 mm in the horizontal and vertical directions with a force of 10 N (ⓞ: no wrinkles, ○: fine wrinkles, △: wrinkles) generation).

Example 1 Example 2 Comparative Example 1 Comparative Example 2 Peel strength (N/30mm) 18 18 18 18 ductility 3 4 4 5 Emotion ⓞ ⓞ ○ ○ Stiffness (mm) 100 110 120 120 Whether wrinkles occur ⓞ ⓞ ○ ○

Referring to Table 2, it can be seen that the artificial leather manufactured in the Example has particularly excellent wrinkle resistance compared to the artificial leather manufactured in the Comparative Example.

In other words, the artificial leather manufactured in the above example improved durability by replacing polyurethane foam with a three-dimensional spacer fabric, improving the problem of sagging or deforming even during long-term use, and improving flexibility to improve the problem of wrinkles. Able to know.

In addition, the artificial leather manufactured in the above example applies a casting method to form the foam layer and the cover layer, thereby providing excellent surface texture and surface durability, while reducing the thickness of the foam layer, the cover layer, and the surface treatment layer. The peeling strength from the three-dimensional spacer fabric is improved, and the artificial leather can be manufactured without additional components such as a back layer, thereby improving ductility, thereby providing excellent cushioning.

In addition, the artificial leather manufactured in the above example improves the surface structure of the three-dimensional spacer fabric, so that even when the foam layer and the cover layer are formed by applying the casting method, the surface structure of the three-dimensional spacer fabric is improved. The problem of surface defects caused by penetration has also been improved.

Although the preferred embodiments of the present invention have been described in detail above, the scope of the present invention is not limited thereto, and various modifications and improvements made by those skilled in the art using the basic concept of the present invention defined in the following claims are also possible. falls within the scope of rights.

100: artificial leather
10: 3D spacer fabric
11: first fabric layer, 12: second fabric layer, 13: spacer layer
30: surface layer
32: cover layer, 33: surface treatment layer, 34: cover back layer
60: Release paper
70: Binder
111: thread, 112: stitch places, 113: mesh
S3-1: Cover layer casting step
S3-2: Label layer drying step
S3-3: Cover back layer casting step
S3-4: Cover layer drying step
S3-5: Binder casting step
S3-6: Binder drying step
S3-7: 3D spacer fabric laminating step
S3-8: Release paper peeling step
S3-9: Surface treatment layer formation step

Claims (8)

A 3D spacer fabric comprising a first fabric layer and a second fabric layer spaced apart from each other, and a spacer layer connecting the first fabric layer and the second fabric layer with a spacing thread to form a three-dimensional structure. , and
It includes a surface layer including a label layer positioned on the first fabric layer of the three-dimensional spacer fabric, and a surface treatment layer positioned on the label layer,
The first fabric layer includes meshes between stitch places of threads, the mesh size of the first fabric layer being between 0.01 mm and 1.5 mm,
Artificial leather for automobile interior materials has a surface smoothness (S) expressed by Equation 1 below of -0.04 mm to +0.04 mm.
[Equation 1]
Surface smoothness (S) = H ₁ -H ₂
H ₁ (unit: mm) = total height of the artificial leather passing through any one of the intersections of the threads of the first fabric layer
H ₂ (unit: mm) = total height of artificial leather passing through any one of the meshes of the first fabric layer delete According to claim 1,
The cover layer is artificial leather for automobile interior materials formed by a casting method. According to claim 1,
Artificial leather for automobile interior materials, wherein the surface layer has a thickness of 0.01 mm to 1.5 mm. According to claim 1,
The second fabric layer includes meshes between stitch places of threads, and the mesh size of the second fabric layer is 0.01 mm to 3.5 mm. leather. According to claim 5,
Artificial leather for automobile interior materials, wherein the ratio of the elongation of the first fabric layer and the elongation of the second fabric layer is greater than 1:1 and less than or equal to 1:10. A 3D spacer fabric comprising a first fabric layer and a second fabric layer spaced apart from each other, and a spacer layer connecting the first fabric layer and the second fabric layer with a spacing thread to form a three-dimensional structure. Steps to prepare,
Preparing a surface layer including a label layer and a surface treatment layer located on the label layer, and
Comprising the step of laminating the surface layer and the three-dimensional spacer fabric,
The first fabric layer includes meshes between stitch places of threads, and the mesh size of the first fabric layer is 0.01 mm to 1.5 mm, and the artificial leather for automobile interior material A method of manufacturing artificial leather for automobile interior materials, wherein the surface smoothness (S) expressed by Equation 1 below is -0.04 mm to +0.04 mm.
[Equation 1]
Surface smoothness (S) = H ₁ -H ₂
H ₁ (unit: mm) = total height of the artificial leather passing through any one of the intersections of the threads of the first fabric layer.
H ₂ (unit: mm) = total height of artificial leather passing through any one of the meshes of the first fabric layer According to claim 7,
A method of manufacturing artificial leather for automobile interior materials, wherein the cover layer is formed by a casting method.