KR20070063366A - Method of fabricating synthetic suede - Google Patents

Abstract

A method for manufacturing artificial suede is provided to increase the dimensional stability of the artificial suede, by inserting a reinforcing sheet into a non-woven fiber and binding a suede sheet and the non-woven fiber. A suede sheet is formed(S10). A non-woven fiber is formed, wherein the non-woven fiber has a napping layer formed on a surface thereof(S20). The non-woven fiber and the suede sheet are bound to each other to form a laminated sheet(S30). The laminated sheet is heated to form grains in the laminated sheet(S40). When the non-woven fiber having a napping layer is formed, the non-woven fiber is produced from two kinds of staple fiber having different fineness values.

Description

Method of manufacturing artificial suede {Method Of Fabricating Synthetic Suede}

1 is a flow chart showing the artificial suede manufacturing method according to the present invention,

Figure 2 is a method of manufacturing an artificial suede according to the present invention, the purity of the non-woven fabric forming method,

3 is a cross-sectional view showing a laminated sheet in which a nonwoven fabric and a suede sheet are combined in an artificial suede manufacturing method according to the present invention;

Figure 4 is a cross-sectional view showing the final product grain formed in the artificial suede manufacturing method according to the present invention.

*** Explanation of the Major Symbols in the Drawings ***

10 nonwoven fabric 11: brushed layer

12: suede seat

The present invention relates to an artificial suede manufacturing method, and more particularly to an artificial suede manufacturing method that can form a uniform grain while increasing the dimensional stability of artificial suede.

Looking at the manufacturing process and quality characteristics of the artificial suede artificial suede is usually formed of ultrafine fibers of about 0.5 denier to 0.001 denier, may be impregnated with a polyurethane resin, etc. to give a suitable resilience elasticity as needed. After a series of dyeing processes, and if necessary, forming a brush before and after the polyurethane impregnation process, and as a final step, the buffing work is carried out to make the shape and length of the brush constant, thereby deciding the quality of the artificial suede It has the effect of improving the uniformity of appearance, the density of brushing, and the surface reflection effect.

Artificial suede manufactured by the general manufacturing method as described above is widely used for clothing, shoes, gloves, etc. because of its excellent appearance and feel. However, there is a problem in that deformation is easily caused by low strength to be applied to furniture, vehicles, and men's clothing for which high form stability is required.

In order to solve the above problems, a method of increasing the impregnation amount of the polyurethane resin or increasing the molecular weight of the polyurethane resin during the manufacture of the artificial suede has been proposed, but in this case, the shape stability of the artificial suede is excellent, but the touch is soft. There is a problem that does not show the unique appearance of artificial suede.

In addition, as a method for improving the morphological stability of the artificial suede, in the production of artificial suede, a nonwoven fabric layer of single yarn fineness of at least 1 denier is inserted into a nonwoven fabric layer of microfiber fibers as a reinforcing agent, and then needle punched to the nonwoven fabric. A method of physically bonding microfiber fibers in layers and yarns in a fabric layer is proposed.

However, the method can improve the morphological stability of the artificial suede, but the needle punching causes the fibers of the reinforcing fabric layer having a finer thickness than the microfiber fibers to rise and protrude to the surface of the composite sheet, making the artificial suede feel coarse and hard. There is a problem. In addition, there is a problem in that the appearance is damaged due to the difference in dyeing concentration due to the fineness difference between the microfiber fibers protruding to the surface during the dyeing and the coarse fibers of the reinforcing fabric layer.

In addition, the formation of the brushed layer in the artificial suede is made by buffing, there is a problem that the grain is difficult to be uniformly formed by the difference in the length of the brushed.

The present invention is to solve the above problems, to provide a method of manufacturing artificial suede that can form a uniform grain while increasing the dimensional stability of artificial suede.

The present invention comprises the steps of forming a suede sheet; Forming a nonwoven fabric having a brushed layer on the surface from staple fibers; Bonding the nonwoven fabric and the suede sheet to form a laminated sheet; And forming a grain by heating the laminated sheet.

In addition, the step of forming a nonwoven fabric having a brushed layer on the surface is a method for manufacturing artificial suede, characterized in that the nonwoven fabric is formed from two or more kinds of staple fibers having different fineness.

In addition, the step of forming a nonwoven fabric having a brushed layer on the surface, forming a web from staple fibers; Performing pre-punching to increase the focusing force between the staple fibers; Inserting a reinforcing sheet between the webs; Performing needle punching in an up-down manner to form a nonwoven fabric in which the staple fibers and the reinforcing sheet are combined; And forming a brushed layer on the surface of the nonwoven fabric by performing needle punching in an up manner.

In addition, the forming of the laminated sheet may include inserting a heated polyurethane foam between the nonwoven fabric and the suede sheet; And forming the laminated sheet by pressing the nonwoven fabric and the suede sheet.

In addition, the length of the brushed hair constituting the brushed layer is 1 to 3mm, the thickness of the brushed layer is 1.5 to 2.5mm artificial suede manufacturing method characterized in that.

In addition, the step of forming the grains, artificial suede manufacturing method characterized in that to form the grains by heating the laminated sheet in a temperature range of 100 to 150 ℃.

In addition, the step of forming the grains, artificial suede manufacturing method characterized in that to form the grains by heating the laminated sheet in a tumble drier (Tumble Drier).

Hereinafter, with reference to the accompanying drawings will be described in detail the technical features of the present invention. The invention can be better understood by the examples, the following examples are for the purpose of illustrating the invention and are not intended to limit the scope of protection defined by the appended claims.

1 is a flow chart showing a method of manufacturing artificial suede according to the present invention, forming a suede sheet (Suede) (S 10); Forming a nonwoven fabric having a brushed layer on the surface from the staple fibers (S 20); Bonding the nonwoven fabric and the suede sheet to form a laminated sheet (S 30); And forming a grain by heating the laminated sheet (S 40).

The suede sheet is made of microfiber to have a soft touch. The method of forming the microfiber suede sheet includes a method of manufacturing a nonwoven fabric from staple fibers spun in a sea island shape to enable microfiberization, and then a suede sheet from the nonwoven fabric, and a knitted fabric or fabric from the composite spun fiber to enable microfiberization. It is known to make suede sheets from knitted or woven fabrics.

In this embodiment, a method of manufacturing a knitted fabric and then producing a suede sheet is used. When manufacturing suede sheets from nonwoven fabrics, the structural characteristics of the nonwoven fabrics may result in uneven fiber density, and considering the density of brushing formed on the surface of the suede sheets, suede sheets from knitted fabrics can be fabricated. It is advantageous to manufacture.

More specifically, first, a knitted fabric is formed of a composite spun-eluted polyester fiber to allow micronization of fineness of 0.05 denier or less. When forming the knitted fabric, it may be formed by mixing the multifilament for reinforcement according to the use of the final product.

At this time, the composite spun-eluted polyester fiber to be used can be selected from commercially available ultrafine fibers of various forms such as side by side type and island-in-sea type, and preferably, polyester is an island component and an aqueous alkali solution. It is good to composite-spun into the islands-in-sea type using the modified polyester which is soluble in an elution component.

The knitted form of the knitted fabric is not particularly limited, but it is advantageous to form the warp knit to improve the feel and flexibility of the final product.

After the knitted fabric is prepared, dyeing, stabilization and the like are carried out as necessary, and the knitted fabric is impregnated with the polyurethane solution. The impregnation process is intended to give the artificial suede a texture similar to that of natural leather by the unique flexible elasticity and denseness of the polyurethane elastic body.

The impregnation step is a step of impregnating a knitted fabric in a polyurethane solution, then immersed in a coagulating solution, washed with water, and dried. The polyurethane solution used in the impregnation process is made of polyurethane, pigments, organic solvents, etc., in addition, may further include a flame retardant, surfactant, antioxidant and the like. The polyurethane is a general polyurethane polymerized using polyols, diisocyanates, chain extenders.

When the polyurethane solution penetrates into the knitted fabric through the impregnation process, the polyurethane is solidified in the non-based system of the polyurethane or in the non-based system. And after washing with water in hot water of 50 to 70 ℃ and dried.

Next, the sea component of the knitted fabric is eluted. When the elution component is an alkali-soluble copolyester, it is treated with an aqueous alkali solution such as an aqueous solution of caustic soda at 2 to 5% for 30 to 40 minutes at a temperature of 95 to 105 캜, and then the caustic soda component is removed by washing with water. do. When the elution component is polyethylene, it is eluted using a solvent such as toluene or perchloroethylene.

The impregnation and elution steps may be omitted as necessary.

After the elution is completed, a processing agent such as a softening agent or an antistatic agent is treated according to the use of the final product, and brushed by buffing. The raising treatment may optionally be carried out before the impregnation process.

The nonwoven fabric serves to reinforce the suede sheet and is involved in the formation of grain. The nonwoven fabric is manufactured by punching, more specifically as shown in Figure 2, forming a web from staple fibers (S 21); Performing pre-punching to increase the focusing force between the staple fibers (S 23); Inserting a reinforcing sheet between the webs (S 25); Performing needle punching in an up-down manner to form a nonwoven fabric in which the staple fibers and the reinforcing sheet are combined (S 27); And forming a brushed layer on the surface of the nonwoven fabric by performing needle punching in an up manner (S 29).

First, a web is formed from staple fibers. The web is formed by a general web forming process through carding and cross wrappers. As the staple fibers, two or more kinds of staple fibers having different degrees of fineness may be used.

Next, preliminary punching is performed so that the focusing force between the staple fibers may be increased. The preliminary punching is carried out two or more times using a needle. The sedimentation density is suitably about 50 to 150 bones / cm ² . At this time, the needle used is a needle for felt having 6 barb, so that there is no protrusion of barb in order to reduce fiber damage, it is preferable to use a regular needle having a wide spacing between barbs.

Next, a reinforcing sheet is inserted between the webs. The reinforcing sheet is an important means for increasing the strength and density of the artificial suede, and considering the bonding force with the web, it is preferable that the mesh form.

As a material of the reinforcing sheet, a polymer having a fiber forming ability may be used without particular limitation, but in order to manufacture a high-density artificial suede, a polymer having a high heat shrinkage rate is preferable. Specific examples thereof include PET, PBT, nylon, and the like. Moreover, it is preferable that the weight ratio of the said web and a reinforcement sheet is 3: 1-4: 1.

Next, up-down needle punching is performed to form a nonwoven fabric in which the staple fibers and the reinforcing sheet are bonded. The punching density varies depending on the thickness of the sheet, but usually about 500 to 1000 bones / cm ² is appropriate, and a close needle between the barbs is used. The punching forms a nonwoven fabric in which staple fibers and reinforcing sheets are bonded.

Next, needle punching of an up system is performed to form a raising layer on the surface of the nonwoven fabric. In the case of up-down needle punching, a dense nonwoven fabric is formed.However, in the case of needle punching only in one direction, the punched side of the nonwoven fabric is pulled out of the nonwoven fabric to the surface of the nonwoven fabric. A raising layer is formed. It is preferable that the length of the raising of the said raising layer is 1-3 mm. When the length of brushing is less than 1 mm, grain formation by heat shrink mentioned later is difficult, and when it exceeds 3 mm, joining with a suede sheet is difficult. The thickness of the raising layer is suitably 1.5 to 2.5mm.

Next, the nonwoven fabric and the suede sheet are joined to form a laminated sheet. Forming the laminated sheet includes inserting a heated polyurethane foam between the nonwoven fabric and the suede sheet; And forming a laminated sheet by compressing the nonwoven fabric and the suede sheet.

When the polyurethane foam is heated above the glass transition temperature, the polyurethane foam has fluidity, the mobility of the molecular chain is increased, and has an adhesive force. Polyurethane is suitable as an adhesive because it has properties similar to those of the nonwoven fabric or suede sheet and does not lower the feel of artificial suede. The polyurethane foam is preferably 2 to 3mm in thickness.

As shown in FIG. 3, the bonding of the nonwoven fabric and the suede sheet is performed such that the raising layer 11 of the nonwoven fabric is positioned between the nonwoven fabric 10 and the suede sheet 12. This is for formation of grains by heating, which will be described later.

Next, the laminated sheet is heated to form grains. The heating of the laminated sheet is preferably made in a tumble dryer. The tumble dryer is a kind of drum type dryer, which can evenly heat the laminated sheet and apply the appropriate compressive and tensile force to the laminated sheet, thereby helping to form grains.

When the laminated sheet is heated, the fibers constituting the laminated sheet are shrunk, and in particular, as shown in FIG. 4, due to the difference between the thermal contraction rate of the brushed layer of the brushed layer and the thermal contraction rate of the suede surface fiber, the surface of the laminated sheet. That is, grain is formed on the surface where the suede is exposed.

As for the heating temperature of the said laminated sheet, about 100-150 degreeC is good, and about 30-40 minutes are suitable for a heat time.

The following shows specific examples and comparative examples of the present invention.

Example 1

First, polyester is used as an island component, and a warp knitted fabric is formed using microfiber composite fibers spun in a sea island form using modified polyester soluble in an aqueous alkali solution as an elution component, and then eluting the eluting component. The suede sheet was formed through the process.

Moreover, a web is formed by making staple fibers with single yarn fineness of 3 denier and 6 denier at a ratio of 1: 1, and preliminary punching is performed. Next, a mesh-shaped reinforcing sheet is inserted between the webs, needle punching of an up-down method is performed to form a nonwoven fabric, and needle punching of an up method is performed again to form a brushed layer on the surface of the nonwoven fabric. It was. The length of the brushed material constituting the brushed layer was about 2 mm, and the thickness of the brushed layer was 1.5 mm.

A polyurethane foam having a thickness of 2 mm was heated and inserted between the suede sheet and the nonwoven fabric, and pressed to form a laminated sheet.

The laminated sheet is washed with water to make it wet, and then dried in a tumble dryer at a temperature of 130 ° C. for 40 minutes to produce artificial suede with grains.

Example 2

In the method of Example 1, in forming a nonwoven fabric, artificial suede with grains was produced in the same manner as in Example 1 without inserting a reinforcing sheet.

Example 3

In forming the nonwoven fabric of Example 1, artificial suede with grains was produced in the same manner as in Example 1, with the length of the brushed part constituting the brushed layer being 4 mm.

Example 4

In the method of Example 1, the heating temperature of the tumble dryer was 90 degreeC, and the artificial suede in which the grain was formed was produced by the method similar to Example 1.

The above examples were evaluated for the following items and are shown in Table 1 below.

1) Form stability

Based on the results of sensory tests by 10 experts, 8 or more judges that form stability is excellent *** and 5-7 judges that form stability is excellent **, and 8 or more judges The case where it judged that stability was bad was shown by * mark.

2) Appearance

Based on the sensory test results by 10 experts, 8 or more judged that the appearance was excellent *** and 5 to 7 judged that the appearance was excellent ** The case where it judged that it was bad was shown by * mark.

3) Softness

On the basis of the sensory test results by 10 experts, 8 or more judged that the softness was excellent ***, and 5 to 7 judged that the softness was excellent. The case where it judged that softness was bad was shown with *.

Table 1. Each Example  Quality characteristic comparison

Shape stability Exterior Softness Example 1 *** *** *** Example 2 * *** *** Example 3 *** ** ** Example 4 *** ** ***

As you can see from the table above,

Embodiments of the present invention were considered to be relatively excellent in terms of shape stability, appearance, and softness, and in particular, in forming a nonwoven fabric, an embodiment in which a reinforcing sheet was inserted, and the length of brushing and the temperature of the tumble dryer were appropriately set. It can be seen that the quality of 1.

Although the preferred embodiments of the present invention have been described above, the present invention is not limited thereto, and various modifications and changes can be made within the scope of the claims and the detailed description of the invention and the accompanying drawings. Naturally, it belongs to the scope of the invention.

As described above, the artificial suede manufacturing method according to the present invention can increase the dimensional stability of the artificial suede by inserting a reinforcing sheet in combining the suede sheet and the nonwoven fabric, and forming the nonwoven fabric.

In addition, in combining the suede sheet and the nonwoven fabric, by using a polyurethane foam rather than a punching method, it is possible to prevent the touch of the artificial suede is lowered.

Moreover, by using the heat shrink of the raising layer of a nonwoven fabric, uniform grain can be formed through heat processing.

Claims (7)

Forming a suede sheet; Forming a nonwoven fabric having a raised layer on the surface; Bonding the nonwoven fabric and the suede sheet to form a laminated sheet; And Heating the laminated sheet to form a grain (Grain) comprising the artificial suede manufacturing method. The method of claim 1, Forming a nonwoven fabric having a brushed layer on the surface, An artificial suede manufacturing method comprising forming a nonwoven fabric from two or more kinds of staple fibers having different fineness from each other. The method of claim 1, Forming a nonwoven fabric having a brushed layer on the surface, Forming a web from staple fibers; Performing pre-punching to increase the focusing force between the staple fibers; Inserting a reinforcing sheet between the webs; Performing needle punching in an up-down manner to form a nonwoven fabric in which the staple fibers and the reinforcing sheet are combined; And A method of manufacturing artificial suede, comprising the steps of forming a brushed layer on the surface of the nonwoven fabric by performing needle punching. The method of claim 1, Forming the laminated sheet, Inserting a heated polyurethane foam between the nonwoven and suede sheets; And And pressing the nonwoven fabric and the suede sheet to form a laminated sheet. The method of claim 1, The length of the brushed hair constituting the brushed layer is 1 to 3mm, the thickness of the brushed layer is 1.5 to 2.5mm artificial suede manufacturing method. The method of claim 1, Forming the grains, Method for producing artificial suede, characterized in that to form a grain by heating the laminated sheet in a temperature range of 100 to 150 ℃. The method of claim 1, Forming the grains, The laminated sheet is heated in a tumble drier (Tumble Drier) artificial suede manufacturing method characterized in that to form grains.

Images