KR20090058197A - Artificial leather and method of manufacturing the same - Google Patents

Abstract

A manufacturing method of artificial leather is provided to offer excellent deluxe sensibility due to superior lighting effect by offering high linear density of ultrafine fibers existing in the surface of the leather. Artificial leather includes elastomers which is dipped in a composite seat(A) comprised of non-woven(1) having ultrafine fiber of which fineness is 0.01~0.3 denier and reinforced textile(2). The ultrafine fiber comprising the non-woven, is piloerected on the surface. Linear density of the ultrafine fiber existing in the surface is 35/100mum or greater. The reinforced textile is one selected of fabric and knitting. Apparent density of the composite sheet is 0.25g/cm^3 or greater.

Description

Artificial leather and method of manufacturing the same

1 to 2 are schematic cross-sectional views of the composite sheet (A) constituting the present invention.

The present invention relates to artificial leather and a method of manufacturing the same, more specifically, because the linear density of the ultrafine fibers present on the surface is high, high sensitivity is expressed by the excellent lighting effect effect, and even when used for a long time, the shape stability is excellent, and the physical properties are lowered. The present invention relates to an artificial leather and a method of manufacturing the same, which can lower the content of the polymer elastomer without improving daylight and friction fastness.

Artificial leather is composed of a nonwoven fabric in which microfibers are intertwined three-dimensionally and a polymer elastomer impregnated in the nonwoven fabric. The artificial leather has excellent feel, light effect, and drape, and has a soft texture and unique appearance similar to that of natural leather. It is widely used as an interior material, and is widely used as a seat skin material or interior material of transportation means (hereinafter, referred to as "vehicle") of automobiles, airplanes, trains, and ships.

Artificial leather (hereinafter referred to as "furniture and automobile artificial leather"), which is used for furniture materials or automobile materials, is required to have high density of nonwoven fabric constituting artificial leather as durability and form stability against friction and external force are required. .

Typically, artificial leather is composed of a nonwoven fabric made of synthetic short fibers and a polyurethane resin impregnated in the nonwoven fabric, and the surface has a structure in which synthetic short fibers are embedded.

As a conventional method of manufacturing a nonwoven fabric for manufacturing artificial leather having a high density, Korean Patent Laid-Open Publication No. 1997-0043453 discloses shrinkage of a three-dimensional entangled nonwoven fabric first by heat-treating the highly shrinkable staple composite fiber by opening, guiding, cross-lapping and needle punching. Then, a method of manufacturing a nonwoven fabric for artificial leather having a high density is disclosed by heating with steam to shrink secondly, treating with a heated calender and shrinking thirdly.

However, the conventional method as described above requires high-shrink staple composite fibers, which requires an additional process such as polymer modification, resulting in increased cost, difficulty in controlling the shrinkage ratio of the nonwoven fabric, and deterioration in strength and alkali resistance of the nonwoven fabric. Several problems have arisen.

Another conventional method has been proposed to increase the density of the nonwoven fabric by increasing the needle punching when manufacturing the nonwoven fabric for artificial leather manufacturing, but in this case, the fibers forming the nonwoven fabric are damaged due to excessive needle punching. This worsening problem has occurred.

An object of the present invention is to provide an artificial leather that can solve all of the above conventional problems.

In the present invention, since the fine density of the fine fibers present on the surface is high, the high sensitivity is expressed by the excellent lighting effect effect, and the shape stability is excellent even when used for a long time, and the content of the polymer elastomer can be lowered without deteriorating the physical properties. To provide improved artificial leather.

In addition, the present invention is to provide a method for manufacturing the artificial leather.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

First, the artificial leather according to the present invention is impregnated with a polymer elastomer in the composite sheet (A) in which the nonwoven fabric 1 and the reinforcing fabric 2 made of ultrafine fibers having a fineness of 0.01 to 0.3 denier are entangled with each other. The microfibers constituting the nonwoven fabric 1 have a structure in which hair is formed, and the linear density of the microfibers present on the surface is 35 or more / 100 µm or more.

The polymer elastomer is a polyurethane resin, a polyurea resin, or the like, and a polyurethane resin is most preferable in view of processability.

The ultrafine fibers are polyester fibers and the like, but the present invention does not specifically limit the kind of ultrafine fibers.

Single fineness of the ultrafine fibers is 0.01 ~ 0.3 denier.

If the single yarn fineness is less than 0.01 denier, the strength of artificial leather is lowered, and if it exceeds 0.3 denier, the touch and lighting effect of artificial leather is lowered.

The reinforcing fabric 2 is a fabric or knitted fabric, the apparent density of the composite sheet (A) is 0.25g / cm 3 or more, when the apparent density is less than 0.25g / cm 3, the shape stability of the artificial leather, lighting effects, daylight And wear fastness is lowered.

The linear density of the ultrafine fibers present on the surface of the artificial leather is 35 or more / 100㎛, If the linear density is less than 35 / 100㎛, the morphological stability, lighting effect, daylight and wear fastness of the artificial leather is reduced.

The composite sheet (A) may be a form in which the reinforcing fabric 2 is positioned below the nonwoven fabric 1 as shown in FIG. 1 and entangled with the nonwoven fabric, and the reinforcing fabric 2 is made of the nonwoven fabric 1 as shown in FIG. May be interwoven with the nonwoven.

1 to 2 are schematic cross-sectional views of the composite sheet (A).

In the present invention, the linear density of the artificial leather was evaluated by the following method.

· Reinforcement fabric of surface microfiber (2) length direction Linear density and  Reinforcing Fabrics (2) Width direction Linear density

After measuring 10 times the fraction of microfiber per 100㎛ (unit length) at 1mm interval along the transverse or longitudinal direction of the photograph taken on the surface of artificial leather, which is a sample, by scanning electron microscope It was set as the length direction linear density of the original fabric (2) or the width direction linear density of the original fabric (2) for reinforcement.

The method of manufacturing artificial leather according to the present invention needle punching together the web (Web) and reinforcing fabric (2) made of island-in-the-sea composite fibers having a single yarn fineness of 0.01-0.3 denier after sea component elution. The nonwoven fabric 1 composed of island-in-the-sea composite fiber and the reinforcing fabric 2 are integrally interwoven to produce a composite sheet A having an apparent density of 0.25 g / cm 3, and then the composite sheet A is opened. After shrinking, impregnating the polymer elastomer in the heat-shrinkable composite sheet (A), and then treated the composite sheet (A) impregnated with the polymer elastomer with an aqueous alkali solution to remove the sea component of the island-in-the-sea composite fiber in the composite sheet (A). After eluting, it is characterized in that the buffing and thermocompression.

Next, look at one example of a method for producing the artificial leather according to the present invention in detail.

First, in the present invention, the island-in-the-sea composite fiber composed of sea component that is an alkali-soluble copolyester and island components having a single yarn fineness of 0.01 to 0.3 denier is dispersed in the sea component, and then opened, carded, and cross-wrapped. After manufacturing the web (Web) made of the islands-in-the-sea composite fibers, needle punching together the web (Web) and the reinforcing fabric (2) by the non-woven fabric (1) and the reinforcement fabric made of the island-in-the-sea composite fiber (2) is integrally entangled to produce a composite sheet A having an apparent density of 0.25 g / cm 3.

Next, the heat shrinkage of the composite sheet (A), and then impregnated the polymer elastic body into the heat-shrinkable composite sheet (A), and then treated the composite sheet (A) impregnated with the polymer elastomer with an aqueous solution of a composite sheet ( After dissolving the sea component of the island-in-the-sea composite fiber in A), it is buffed and thermo-compressed to produce artificial leather for furniture and vehicles.

On the other hand, in the present invention, the composite sheet (A) prepared as described above is first treated with an aqueous alkali solution to elute the sea component, and then may be impregnated with a polymer elastic body.

The sea component is an alkali-soluble copolyester, mainly composed of polyethylene terephthalate, and as an additional component, a molecular weight of 400 to 20000, most preferably 1000 to 4000 polyethylene glycol, polypropylene glycol, 1,4-cyclohexanedicar Acids, 1,4-cyclohexanedimethanol, 1,4-cyclohexanedicarboxylate, 2,2-dimethyl-1,3-propanediol, 2,2-dimethyl-1,4-butanediol, 2, 2,4-trimethyl 1,3-propanediol and copolyester obtained by copolymerizing 25% by weight or less of one or two or more selected from adipic acid.

Polyester is used as the island component.

Polyurethane resins, polyurea resins, polyacrylic acid resins, and the like may be used as the polymer elastomer, but polyurethane resins are preferable in terms of processed tablets, abrasion resistance, and hydrolysis resistance.

The weight ratio of the fibrous base composed of polymer elastomer / microfiber is preferably 10/90 to 9/10.

When the weight ratio of the polymer elastomer is less than 10% by weight, the cushioning property is too low, and when it exceeds 70% by weight, the feel and light effect are too low.

The method of filling the polymer elastomer may be applied by wet coagulation or dry coagulation after impregnating and / or applying the organic solvent solution or the aqueous dispersion of the polymer elastomer to the nonwoven fabric.

As an organic solvent of a high molecular elastic body, toluene, acetone, methyl ethyl ketone, etc. other than polar solvents, such as dimethylformamide, dimethylacetamide, and dimethyl sulfoxide, can be used.

Before impregnating the polymer elastomer, polyvinyl alcohol may be impregnated into the composite sheet (A), for example, by padding the composite sheet (A) in an aqueous polyvinyl alcohol solution. It is dissolved and removed in the hot water treatment performed before the impregnated polyvinyl alcohol aqueous alkali solution treatment.

The reinforcing fabric 2 is a woven or knitted fabric.

As a specific method of thermally shrinking the composite sheet A, a method of dry heat treating the composite sheet or a method of treating the composite sheet with steam may be used.

As a specific method of thermally compressing the buffed artificial leather, a method of passing the buffed artificial leather between heated calender rolls may be used.

The artificial leather of the present invention described above has high linear density of microfibers present on the surface, resulting in high quality sensitivity with excellent lighting effect effect, excellent shape stability even for long time use, and low content of polymer elastomer without deterioration of physical properties. Can improve daylight and friction fastness.

Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples.

However, the present invention is not limited by the following examples.

Example  One

The island-in-the-sea composite fiber (single-fiber fineness: 0.05 denier of the island component) composed of the sea component of the alkali-soluble copolyester and 70 island components of the polyester resin dispersed and dispersed in the sea component is cut to a length of 50 mm to form short fibers. After the lamination web of the island-in-the-sea composite short fiber through carding and cross wrapper process, 75 denier polyester filament was used as the warp and weft under the laminated web, and the inclined density and 80 pieces of 100 / inch were used. After arranging the reinforcing plain weave fabric woven at a weft density of / inch, they were needle punched to produce a composite sheet (A) having a side density of 0.30 g / cm 3.

Next, the prepared composite sheet (A) was heat-shrinked by dry heat treatment at 180 ° C. for 2 minutes, and impregnated with 40 wt% of the polyurethane resin by weight of the composite sheet, followed by wet coagulation, and an aqueous alkali solution (caustic soda). Aqueous solution) to elute the sea component in the island-in-the-sea composite fiber, and then buffed using a brush and passed through the calender roll at 170 ℃ through thermo-compression and then dyed to prepare artificial leather.

The longitudinal linear density of the reinforcing fabric (2) of the ultrafine fibers present on the surface of the manufactured furniture and artificial leather was 38/100/100 μm, and the linear density of the reinforcing fabric (2) was 39/100/100 μm.

Example  2

The same process as in Example 1 except that a composite sheet having an apparent density of 0.29 g / cm 3 was produced using a polyester warp knitted fabric instead of a reinforcing plain weave fabric, and the composite sheet was dried by steam at 200 ° C. And artificial leather was manufactured under the conditions.

The longitudinal linear density of the reinforcing fabric (2) of the ultrafine fibers present on the surface of the manufactured furniture and artificial leather was 37/100/100 μm, and the linear density of the reinforcing fabric (2) in the width direction was 37/100/100 μm.

Comparative Example  One

The island-in-the-sea composite fiber (single-fiber fineness: 0.05 denier of the island component) consisting of the sea component of the alkali-soluble co-polyester and 70 polyester components dispersed and arranged in the sea component is also cut to a length of 50 mm to form short fibers. After the lamination web of the islands-in-the-sea composite short fibers was manufactured through a carding and cross wrapper process, needle punching was performed to prepare a nonwoven fabric of the islands-in-sea composite fiber.

Next, the prepared nonwoven fabric was impregnated with 40% by weight of the polyurethane resin relative to the nonwoven fabric, and then wet coagulated, and then treated with an aqueous alkali solution (caustic soda solution) to have an apparent density of 0.21 g / cm 3 in an island-in-the-sea composite fiber. The sea component was eluted, then buffed with a brush and dyed to prepare artificial leather.

The lengthwise linear density of the reinforcing fabric (2) of the ultrafine fibers present on the surface of the manufactured artificial leather was 31 bone / 100 µm, and the width density of the reinforcing fabric (2) was 30 yarn / 100 µm.

In the present invention, since the fine density of the fine fibers present on the surface is high, the high sensitivity is expressed by the excellent lighting effect effect, and the shape stability is excellent even when used for a long time, and the content of the polymer elastomer can be lowered without deteriorating the physical properties. Is improved.

Claims (11)

The polymer elastic body is impregnated in the composite sheet A in which the nonwoven fabric 1 composed of ultrafine fibers having a fineness of 0.01 to 0.3 denier and the reinforcing fabric 2 are intertwined with each other, and the surface of the microfiber constitutes the nonwoven fabric 1. An artificial leather, characterized in that the fibers have a structure in which the hairs are hairlined, and the linear density of the ultrafine fibers present on the surface is 35 or more 100 µm or more. The artificial leather according to claim 1, wherein the reinforcing fabric (2) is one selected from woven fabrics and knitted fabrics. The artificial leather according to claim 1, wherein the composite sheet (A) has an apparent density of 0.25 g / cm 3 or more. The artificial leather of claim 1, wherein the polymer elastomer is one selected from a polyurethane resin and a polyurea resin. The artificial leather according to claim 1, wherein the microfiber is a polyester fiber. Nonwoven fabric consisting of the island-in-the-sea composite fiber by needle punching together a web (Web) made of island-in-the-sea composite fibers having a single yarn fineness of 0.01-0.3 denier after sea-solution eluting And the reinforcing fabric 2 are integrally entangled to produce a composite sheet A having an apparent density of 0.25 g / cm 3, and then thermally shrink the composite sheet A, and then the heat shrinkable composite sheet A ), Impregnating the polymer elastomer with the polymer elastomer and then treating the composite sheet (A) impregnated with an aqueous alkali solution to elute the sea component of the island-in-the-sea composite fiber in the composite sheet (A), and then buffing and thermocompressing Method of manufacturing artificial leather, characterized in that. The method for producing artificial leather according to claim 6, wherein the sea component is an alkali-soluble copolyester and the island component is a polyester. 7. The method of manufacturing artificial leather according to claim 6, wherein the reinforcing fabric (2) is one selected from woven or knitted fabrics. 7. The method of claim 6, wherein the polymer elastic body is one selected from a polyurethane resin and a polyurea resin. The method of manufacturing artificial leather according to claim 6, wherein the heat shrinkage is performed by one method selected from a dry heat treatment method and a steam treatment method. 7. The method of claim 6, wherein the thermocompression is performed by passing the buffed artificial leather between heated calender rolls.

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