KR19990070075A - Synthetic Leather Products Using Waste Leather - Google Patents

Abstract

The present invention relates to a synthetic leather product produced by incorporating an appropriate amount of waste leather pulverized in a synthetic resin sheet, such as PU, epoxy, PVC by calendering, casting, PU synthetic, extrusion or compression method. Synthetic leather products of the present invention not only exhibits similar functions and effects as conventional synthetic resin leather products, but also recycles waste leather, thereby significantly reducing leather manufacturing costs and solving environmental pollution problems caused by waste treatment.

Description

Synthetic Leather Products Using Waste Leather

The present invention relates to a synthetic leather product in which waste leather pulverized in a synthetic resin sheet such as PU, epoxy, or PVC by calendering, casting, PU synthetic, extrusion, or compression method.

Generally, dermis extracted from animals such as cows or sheep is generally used in applications classified into grain, split and bottom split stages. The dermis supplied to the leather finished product processing plant cannot be supplied as it is extracted directly from the animal, so the finished product can be processed through various processing processes, for example, decontamination, removal of cows, thickness classification, flexibility, patterning, and painting. It is sent to the producing factory. Defects of the dermis generated during such processing and the remaining amount during production, cut the dermis or synthetic leather (product laminated with a synthetic resin sheet such as PU, PVC in the dermis) and various finished products, such as For example, the defects generated during processing in factories that produce clothing, bags, wallets, shoes, gloves, furniture, etc., and the remaining amount during genuine production are used in small amounts in building interior wall materials, but more than 90% is used as waste. It has been treated and incinerated and landfilled. Currently, domestic dermis and synthetic leather production is about 10 trillion S / Feet. The waste leather produced here is 2 trillion S / F, which is 20% of the output, some are used for building interior wall materials, and more than 90 percent is waste. Is being processed. However, waste leather has a terrible smell during incineration and generates harmful gases, which may cause air pollution. Also, even when these wastes are buried underground, they do not decompose for a long time, causing soil pollution.

Accordingly, the inventors have conducted numerous studies and experiments on the method of recycling the waste leather produced in the manufacturing process of synthetic leather products made of synthetic resins such as PP, ABS, PVC, and the like. If synthetic leather products are manufactured by incorporating porridge in the appropriate amount, it can show a similar function and effect as leather products manufactured by conventional casting, calender, and PU synthetic leather methods, and can greatly improve the shrinkage problem occurring in conventional extrusion and compression leather products. In addition, by recycling the waste leather, it can significantly reduce the leather manufacturing cost and solve the environmental pollution problem caused by the treatment of leather waste has come to complete the present invention.

Figure 1 a and b is an exploded perspective view showing a synthetic leather product produced by incorporating the pulverized waste leather into a synthetic resin sheet in a calender, casting or PU synthetic method according to the present invention (symbol (●): pulverized waste leather, (○): Foaming agent, (-): lower surface / woven fabric).

Figure 2 is an exploded perspective view of a replacement product produced by incorporating pulverized waste leather into a synthetic resin sheet by plywood method by physical force or adhesive according to the present invention (symbol (●): pulverized waste leather).

Figure 3 is an exploded perspective view of the synthetic leather product produced by incorporating the pulverized waste leather into the synthetic resin sheet by extrusion or compression method according to the present invention (symbol (●): pulverized waste leather).

Figure 4 is an exploded perspective view showing a synthetic leather product produced by a calender or casting method using a synthetic resin as a raw material according to the prior art.

Figure 5 is an exploded perspective view showing a synthetic leather product produced by the PU synthetic method using a synthetic resin as a raw material according to the prior art.

(Explanation of main parts of drawing)

1a, 2a, 2b, 2c, 2d, 2e, 3a, 4a, 5a: cover layer

1b, 4b: foam layer

1c, 4c, 5b: woven surface layer

The present invention is a synthetic resin made of polyurethane (PU), epoxy, polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polymethyl methacrylate (PMMA), styrene butadiene rubber (SBR) and the like It relates to a synthetic resin product characterized in that the waste leather pulverized in the sheet is incorporated at a ratio of 5 to 200 PHR relative to the synthetic resin.

The present invention also incorporates crushed waste leather in the label layer (1a) and the foam layer (1b) as shown in Figure 1a in the synthetic resin product of the label layer, the foam layer and the woven fabric layer structure by the calendar or casting method Provides synthetic leather products characterized by

The present invention also provides a synthetic leather product characterized by incorporating pulverized waste leather into the label layer (1a) in the synthetic leather product of the label layer and woven surface layer structure by the PU synthetic method, as shown in Figure 1b to provide.

The present invention also provides a label layer (2a, 2b, 2c, 2d ...) incorporating pulverized waste leather as shown in FIG. Provides a split leather alternative, characterized in that heat fusion.

The present invention also provides a synthetic leather product characterized by incorporating the waste leather pulverized in the synthetic resin cover layer (3a) by extrusion or compression method as shown in FIG.

Hereinafter, the synthetic leather product according to the present invention will be described in more detail.

Synthetic resins used in the manufacture of synthetic leather products according to the invention are polyurethane (PU), epoxy and thermoplastic resins, for example polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polymethyl meta Methacrylate (PMMA), styrene butadier rubber (SBR) and the like. In the present invention, by mixing an appropriate amount of the waste leather ground in such a synthetic resin sheet to produce a synthetic leather product.

According to the present invention, the waste leather generated in the manufacturing process of the existing synthetic leather products are properly crushed and mixed in various forms according to the use in the synthetic leather. Waste leather material incorporated in synthetic leather is manufactured as follows. First, the collected waste leather is sorted by color and cut into 5 to 10 cm in the first place, and secondly, it is put into a grinder with a blade and a sieve is installed so that only waste leather of 1 mm or less can be selected and used. The waste leather of 1mm or more is re-input and crushed. The waste leather pulverized in this way is mixed with various synthetic water support materials by mixing in hot water or steam under a blender.

Synthetic leather products according to the present invention is determined by the economical and processing conditions by the amount of crushed waste leather. Use of raw materials in calendars, castings, PU synthetics or extrusions is indicated by the PHR of the amount of each raw material, based on 100 synthetic resins. In addition, the blending ratio of the raw materials may vary depending on the customer's requirements, but due to the nature of the machine, the amount of other raw materials used in the resin 100 is not well worked when the input. Therefore, in the present invention, the waste leather is mixed in a ratio of 5 to 200 PHR relative to resins in synthetic resin sheets such as PVC, PP, and ABS, but is not limited thereto.

According to the present invention, in order to remove the trouble-producing elements that may occur during the production of leather products, stabilizers, plasticizers, fillers, additives, foaming agents, etc., as well as synthetic resins and pulverized waste leather are suitably blended.

The stabilizer is intended to prevent the decomposition of resin due to high temperature during processing, to prevent the generation of dust by light at room temperature, and to prevent discoloration due to various factors during processing, and to maintain the characteristics of the resin itself for a long time. . Stabilizers used herein include metal stabilizers, non-metal stabilizers, composite stabilizers, etc., but various stabilizers may be used in consideration of heat resistance, weather resistance, processability, antioxidant properties, non-toxicity, foaming stability, and the like. For example TLS, DLP, DBL, CD-ST, BA-ST, CA-ST, ZN-ST, butyl tin mercaptide, octyl tin mercaptide, butyl tin malate ( Butyl tin maleate, octyl tin maleate, butyl tin laurate, octyl tin laurate, epoxy compounds and the like can be used in combination. In addition, the amount of stabilizer may also be used in various ways depending on the characteristics of the synthetic resin, it is good to use a ratio of 1 to 10PHR relative to the synthetic resin.

Since plasticizers are intended to increase the fluidity, elasticity, and adhesiveness of leather products, the plasticizer may not be added to the PP, PU resin and the consumer having the same properties as the resin itself, but may be used for synthetic leather. It is used a lot in general, its amount is about 5 to 150% of the synthetic resin is good. There are many types of plasticizers depending on their characteristics, but they use trioctyl trimeuitate (TOTM), dioctyl phthalate (DOP), diisodecyl phthalate (DIDP), diundecyl phthalate (DUP), tricresyl phosphate (TCP), and dioctyl adipate (DOA). It is good.

Fillers are used to increase the strength, durability, heat resistance of the product and to reduce the cost by weight, and there are calcium carbonate, talc, carbon black, diatomaceous earth, and the like, preferably calcium carbonate. The amount of filler used should be less than 30PHR for synthetic resin.

The additive is used to facilitate processability, and stearic acid, lauric acid, wax-like polymer plasticizers (polyester-based plasticizers) and the like are used. The amount of the additive is preferably about 30 PHR or less with respect to the synthetic resin.

The foaming agent is used to form a cell in the product to form a sponge, and various kinds of foams such as ammonium carbonate, azobisformamide, azobisisabutyio nitrile, benzenesulfonyl hydrazide, etc. However, preferably ammonium carbonate and azobisformamide are used, and the amount thereof is preferably about 1 to 10 PHR based on the synthetic resin.

Hereinafter, a synthetic leather product according to the present invention will be described in detail with reference to the drawings.

Generally, synthetic leather products are manufactured by calender, casting or PU synthetic method using synthetic resins such as PU, epoxy, PE, PVC, PP, PMMA, SBR, etc. As shown in FIG. 4, a conventional synthetic leather product composed of a cover layer 4a, a foam layer 4b, and a woven fabric lower layer 4c, which is produced by the dry method of the PU synthetic method, is shown in FIG. As described above, the cover layer 5a and the woven fabric lower layer 5b are formed.

The synthetic leather product according to the present invention is composed of a label layer 1a, foamed layer 1b, and a cloth lower surface layer 1c incorporating pulverized waste leather into a synthetic resin (see Fig. 1). In the drawings, reference symbol (?) Represents pulverized waste leather, (?) Represents a blowing agent, and (?) Represents a lower surface / cloth. In FIG. 1a, the label layer 1a and the foam layer 1b are produced by incorporating pulverized waste leather into synthetic resins, plasticizers, stabilizers, fillers, additives, and foaming agents, such as PVC and PU, in a conventional calendering or casting method (Example 1 See Table 1 in -6). That is, the plywood of the labeling layer 1a and the foaming layer 1b is laminated by heating and melting in an oven at 150 to 250 ° C. The plywood of the labeling layer 1a, the foaming layer 1b and the cladding layer 1c is heated. Plywood by melting or by coating an adhesive on a woven fabric may be heated plywood. In FIG. 1B, only the labeling layer 1a is coated on the woven fabric layer 1c without using a foaming agent, and put into an oven at 150 to 250 ° C. to be laminated by thermal melting (see Table 2 of Example 7). 1a and b, the lower surface 1c of the woven fabric may be the same as the clad used in the conventional leather products. In addition, the cover layer 1a of FIGS. 1A and 1B may freely produce a predetermined pattern, i.e., a leather pattern, a wooden pattern, using a transfer paper and an embossing roll R / P on the surface to provide a beautiful appearance choice to the consumer. Can be. Synthetic leather products shown in Figures 1a and b can be used as a raw material for furniture, such as chairs, sofas, clothing, footwear.

In FIG. 2, the label layer 2a in which the pulverized waste leather is mixed is produced by plywood in two, three, four or more layers. The cover layer 2a may not be used alone in a product, and may be freely produced with leather, wood, or the like to smooth the surface and provide a beautiful appearance choice to the consumer. It can be used as a split alternative leather product. Layers (2a), (2b), (2c), ... in Fig. 2 are physically plywood by applying heat or plywood using an adhesive. That is, plywood is laminated in one, two, three ... according to the thickness specification of the leather product required by the consumer. In the calendering process, the thickness of the cover layer can be produced from 0.01 to 0.8mm, and in the post-treatment process, the cover layer can be produced up to 6mm by plywood in double, triple ... Leather products shown in Figure 2 can be used for the patterned state or gloves, shoes, and also useful for clothing, shoes, gloves, wallets, bags by plywood the synthetic resin sheet of conventional PVC, PU, etc. Can be used.

The product shown in FIG. 3 is produced by incorporating pulverized waste leather into various extrusion and pressed product sheets (cover layer 3a) produced by a conventional extrusion method and a pressing process (see Table 3 of Example 8). Existing extruded products are produced by forcibly withdrawing the processed raw materials while passing through T-Die, so that when the finished product is heated again, it is returned to its original state (shrinkability). In addition, the press force is also forced to return to the original state by pressing. Therefore, in the present invention, a proper amount of filler is added to prevent shrinkage, and lung leather also serves as a kind of filler. Therefore, synthetic leather products using pulverized waste leather can greatly improve the shrinkage problem occurring in conventional extrusion and compression products, and also has an economic advantage by recycling waste leather.

Synthetic leather products according to the present invention is produced in the same manner as the existing synthetic leather processing process, and thus functionally similar to the existing synthetic leather. Existing synthetic leather exhibits a similar effect by the surface processing of the cover layer in showing the effect of natural leather, but there is a limit to the effect of the natural leather (surface embossing state, touch feeling, smell). However, the synthetic leather product of the present invention has the advantage of having a similar effect to the natural leather in the sense of touch and smell by incorporating the pulverized waste leather. In addition, the synthetic leather product of the present invention is a general synthetic leather, various processes (sewing, cutting, etc.) required for the production of finished products of natural leather is the same as the existing products. In addition, by recycling waste leather, manufacturing cost can be greatly reduced, and environmental pollution caused by leather waste treatment can be prevented.

Hereinafter, although this invention is demonstrated based on an Example, the technical scope of this invention is not limited to these.

Example 1-6

Synthetic resins, stabilizers, plasticizers, fillers, additives, milled waste leather and foaming agents in the composition ratios shown in Table 1 below were combined to prepare synthetic leather products of Example 1-6 by a calender or casting method.

Table 1.

ingredient (Unit: PHR) Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Cover layer Foam layer Cover layer Foam layer Cover layer Foam layer Cover layer Foam layer Cover layer Foam layer Cover layer Foam layer Synthetic resin PVC 100 100 100 100 100 100 100 100 100 100 100 100 stabilizator Ba-Zn-St 3.0 2 3.4 2 3.3 2 3.3 2 3.5 2 3.5 2 Ba-Cd-St - 1.5 One 1.5 One 2 One 1.5 One 1.5 One 2 Plasticizer DOP 40 44 50 52 60 60 - 38 - 54 - 66 DUP - - - - - - 20 - 25 - 30 - DIDP - - - - - - 20 - 25 - 30 - Filler CaCO ₃ 10 10 10 10 20 5 10 10 10 10 20 5 additive Stearic acid 0.1 0.2 0.1 0.1 0.2 0.1 0.1 0.1 0.1 0.1 0.2 0.1 Epoxy resin 3 4 3 4 5 3 3 3 3 3 5 2 MMA preparation 0.2 - 0.2 - 0.5 - 0.2 - 0.2 - 0.5 - Grinded Leather - 60 140 80 120 100 100 120 80 140 60 160 40 blowing agent Azobisporamide - One - 1.4 - 1.6 - 1.2 - 1.2 - 1.6

* Note: In above 1, the label layer is (1a) of FIG. 1, and a foam layer is (1b).

Example 7

Synthetic resin, stabilizer, plasticizer, filler, additives and milled waste leather of the same as in Example 1-6, except that the blowing agent is not used to prepare a synthetic leather product of Example 7 by the PU synthetic method .

Table 2.

(Unit: PHR) Example 7 Cover layer 2a Cover layer 2b Cover layer 2c Cover layer (2d) Synthetic resin 100 100 100 100 stabilizator 1 to 7 1 to 7 1 to 7 1 to 7 Prosecution To 20 To 20 To 20 To 20 Filler To 30 To 30 To 30 To 30 additive To 30 To 30 -50 To 30 Grinded Leather 5 to 200 5 to 200 5 to 200 5 to 200

* Label layers 2a, 2b, 2c, 2d, and 2e represent the quantity of label layers due to thickness variation at the request of the consumer.

Example 8

Except not using a plasticizer and a blowing agent, the same synthetic resins, stabilizers, fillers, additives, and milled waste leather as in Example 1-6 were combined as shown in Table 3 below, followed by heat-sealing in an oven at 150 to 250 ° C. Synthetic leather products were prepared.

Table 3.

(Unit: PHR) Example 8 Cover layer 3a Resin 100 stabilizator 1 to 15 Filler 50 additive To 30 Grinded Leather 5 to 200

As described above, the synthetic leather product according to the present invention exhibits similar functions and effects to leather products produced by conventional casting, calender and PU synthetic leather methods, and can be used as an alternative to splits extracted from the dermis. Can be. In addition, the present invention is very economically useful to recycle the waste leather, the manufacturing cost of the leather is greatly reduced and can solve the environmental pollution problem caused by the treatment of leather waste is very industrially useful.

Claims (7)

Crushed into a synthetic resin sheet made of polyurethane (PU), epoxy, polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polymethyl methacrylate (PMMA), styrene butadiene rubber (SBR), etc. Synthetic leather product, characterized in that it is incorporated in a ratio of 5 to 200 PHR relative to the synthetic resin. The synthetic leather product according to claim 1, wherein the pulverized waste leather is incorporated into the labeling layer (1a) and the foaming layer (1b) as shown in FIG. 1A by a calendering or casting method. The synthetic leather product according to claim 1, wherein the pulverized waste leather is incorporated into the labeling layer (1a) as shown in FIG. 1B by the PU synthetic method. The method of claim 1, wherein the pulverized waste leather is incorporated into the cover layer (2a, 2b, 2c, 2d ...) as shown in Figure 2, two-, three-ply, four-ply or more 150-250 ℃ A split leather alternative, characterized by heat fusion at a temperature of The synthetic leather product according to claim 1, wherein the pulverized waste leather is incorporated into a synthetic resin sheet (cover layer 3a) by an extrusion or pressing method as shown in FIG. The synthetic leather product according to any one of claims 1 to 5, further comprising one or more selected from stabilizers, plasticizers, fillers, blowing agents, and additives. The synthetic leather product according to claim 6, which contains 1 to 10 PHR of stabilizer, 5 to 150 PHR of plasticizer, 30 PHR or less of filler, 1 to 10 PHR of blowing agent, and 30 PHR or less of additive.