KR20090062478A - Artificial leather and method of manufacturing the same - Google Patents

Abstract

Artificial leather and a manufacturing method thereof are provided to offer superior shape stability and abrasion strength of fur formed on the surface by forming narrow gaps between an elastomer and ultrafine fiber located on the surface of the artificial leather. Artificial leather includes an elastoemr in which ultrafine fibers having fineness of 0.001~0.3denier are interwoven. The ultrafine fibers are piloerected on the surface to form fur. The abrasion intensity of the leather is 2,000 time or greater measured with a taber duration method. The surface mean roughness of the artificial leather is 50mum or less. The elastomer is one selected from polyurethane resin and polyurea resin.

Description

Artificial leather and method of manufacturing the same

The present invention relates to artificial leather and a method of manufacturing the same, and more specifically, the gap between the polymer elastic body and the ultrafine fibers located on the surface portion is narrow, the artificial artificial leather for car excellent in shape stability and wear strength without deterioration of appearance and touch and It relates to a manufacturing method thereof.

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. BACKGROUND ART It is widely used as a sheet skin material or interior material of a vehicle (hereinafter, referred to as "vehicle") for transportation such as trains and ships.

Artificial leather (abbreviated as "vehicle artificial leather") used as a vehicle material is required for durability and form stability against friction and external force, and is suitable for bending and mounting. This is required.

In the prior art of manufacturing artificial leather, Korean Patent No. 0323637, etc., the artificial leather manufacturing sheet consisting of a nonwoven fabric having a polyamide microfiber bundle having a single yarn fineness of 0.1 decitex or less and an elastomer contained in the nonwoven fabric, and the The artificial leather produced by dying the sheet after forming the wool on the surface by buffing the sheet.

The conventional artificial leather as described above has a problem in that the cows formed on the surface are not firmly supported by the polymer elastic body, and thus the shape stability and wear strength are weak.

Particularly, in the case of artificial leather for vehicles, since the excellent wear strength and form stability are required, the conventional artificial leather has an unsuitable problem as a vehicle material.

In order to solve such a problem, in other words, in order to provide excellent morphological stability and wear strength to artificial leather, Korean Patent Laid-Open Publication No. 2006-0125162 described above by coating (coating) a silicone rubber composition on the surface of the conventional artificial leather It describes how to improve the wear strength of leather.

In addition, the Republic of Korea Patent Publication No. 1998-054320 discloses a method for improving the durability of artificial leather by heat-sealing a transparent film on the surface of the conventional silver artificial leather.

In addition, Korean Patent No. 10-0558683 discloses a method for improving the wear strength of artificial leather by impregnating (pretreatment) the water-soluble polymer and the water-based polyurethane in the nonwoven fabric before impregnating the polymer elastic material in the nonwoven fabric.

The conventional methods can improve the wear strength and form stability of the artificial leather, but there is a problem that significantly reduces the appearance and feel of the artificial leather has a problem that can not be commercialized as a vehicle material.

An object of the present invention is to provide an artificial leather excellent in the wear strength and form stability of the cows formed on the surface while maintaining the appearance and feel of the artificial leather intact.

The present invention aims to provide an artificial leather and a method of manufacturing the same having excellent morphological stability and wear strength, and excellent touch and appearance of the wool formed on the surface due to the narrow gap between the polymer elastic body and the ultrafine fibers positioned on the surface of the artificial leather.

EMBODIMENT OF THE INVENTION Hereinafter, this invention is demonstrated in detail.

First, the artificial leather according to the present invention has a structure in which a polymer elastic body is impregnated in a nonwoven fabric in which microfibers having a single yarn fineness of 0.001 to 0.3 denier are intertwined with each other, and the microfibers are formed on the surface to form wool. , The wear strength measured by Taber wear method is characterized in that more than 2,000 times.

Recently, the automobile is greatly improved in durability, and as the service life becomes longer, the high durability is required for artificial leather for vehicles used as skin materials.

Specifically, even when the 75kg people repeatedly get on and off about 20,000 times, the appearance and touch are not damaged and the shape stability is maintained as it is.

If the wear strength is less than 2,000 times, it does not have the durability of the above-described level, the appearance and the touch is damaged and stretch or deform during use.

In addition, the artificial leather for vehicles according to the present invention preferably has a surface average roughness of 50 μm or less measured by the method described below.

When the surface average roughness exceeds 50 µm, the surface is too rough and the touch is deteriorated.

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

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

Single yarn fineness of the ultrafine fibers is 0.001 ~ 0.3 denier.

If the single yarn fineness is less than 0.001 denier, the strength of the artificial leather is lowered. If the single yarn fineness is more than 0.3 denier, the touch and lighting effect of the artificial leather is lowered.

Next, look at in detail the method for manufacturing the vehicle artificial leather according to the present invention.

In manufacturing a composite sheet in which microfibers having a single yarn fineness of 0.001 to 0.3 denier are impregnated with a polymer elastic body in a nonwoven fabric interwoven with each other, and then buffing the composite sheet to produce artificial leather having wool on the surface thereof. It is characterized by performing one or more processes selected from the processes of (iii).

(Iii) a process of dry heat treating the artificial leather on which the composite sheet or wool is formed;

(Ii) pressing the artificial leather on which the composite sheet or the wool is formed with a heat roller;

(Iii) imparting a polymer elastic body to artificial leather with wool formed;

(Iii) swelling the polymer elastic body impregnated in the artificial leather with a solvent capable of dissolving the polymer elastic body impregnated in the artificial leather in which the wool is formed;

(Iii) coating a sol (Sol) for coating containing inorganic matter in the form of nanoparticles in artificial leather formed with the wool.

First, in the present invention, the island-in-the-sea composite fiber composed of sea component which is an alkali-soluble copolyester and island components having a single yarn fineness of 0.001 to 0.3 denier is dispersed in the sea component, and then opened, carded, cross-wrapped and Needle punching produces a nonwoven fabric.

Next, the composite sheet impregnated with the polymer elastic body in the nonwoven fabric and then treated with an aqueous alkali solution to elute the sea component to the composite sheet impregnated with the polymer elastic body in the nonwoven fabric intertwined microfibers having a single yarn fineness of 0.001 ~ 0.3 denier Manufacture.

Meanwhile, in the present invention, the nonwoven fabric prepared as described above may be first treated with an aqueous alkali solution to elute the sea component, and then impregnated with the polymer elastomer.

Alkali-soluble copolyester as the sea component has polyethylene terephthalate as a main component, and is an additional component with 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.

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.

It is preferable that the weight ratio of the fiber base material which consists of a polymer elastic body / microfine fiber is 30/70-90/10.

When the weight ratio of the polymer elastomer is less than 30% by weight, the cushioning property is too low, and when it exceeds 90% 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 the organic solvent of the polymer elastomer, toluene, acetone, methyl ethyl ketone and the like can be used in addition to polar solvents such as dimethylformamide, dimethylacetamide, and dimethyl sulfoxide.

Next, the manufactured composite sheet is selectively dry heat treated or compressed with a heat roller.

It is preferable to perform dry heat processing at 120-170 degreeC, and to perform crimping | compression-processing with a heat roller at 140-200 degreeC.

When the temperature is outside the above range, the improvement effect of wear strength and shape stability may be low, or the touch may be degraded.

Next, by buffing the composite sheet to prepare an artificial leather with a wool formed on the surface.

Next, the artificial leather is subjected to dry heat treatment, the artificial leather is pressed with a heat roller, the artificial leather is imparted to the artificial leather, or the artificial elastomer is dissolved in a polymer elastic material impregnated in the artificial leather. Swelling a polymer elastomer impregnated in leather, coating a coating sol (Sol) comprising an inorganic material in the form of nanoparticles in the artificial leather, or by combining one or more of the above processes to manufacture a vehicle artificial leather.

It is preferable to perform dry heat processing at 120-170 degreeC, and to perform crimping | compression-processing with a heat roller at 140-200 degreeC.

When the temperature is outside the above range, the improvement effect of wear strength and shape stability may be low, or the touch may be degraded.

Solvents capable of dissolving the polymeric elastomer impregnated in artificial leather are dimethylformamide, dimethylacetamide, dimethyl sulfoxide and the like.

Specific examples of the coating sol (Sol) comprising the inorganic particles in the form of nano-particles are (i) inorganic materials in the form of nano-particles (ii) organic acids having an alcohol group and a ketone group as described in Korean Patent Laid-Open Publication No. 2005-0119532, etc. It consists of a stabilizer which is a salt of (i) a basic solution and a solvent which is (i) water or an alcohol.

The inorganic particles in the form of nanoparticles are silicon dioxide, titanium dioxide, aluminum trioxide, and the like.

Artificial leather manufactured by the manufacturing method according to the present invention has a narrow gap between the polymer elastic body and the microfine fibers located on the surface of the artificial leather is excellent in the wear strength of the cow formed on the surface, the transparent film or silicone coating liquid is added to the surface As it is not thermally fused or coated, it retains the feel and appearance of artificial leather.

In the present invention, various physical properties of vehicle artificial leather were evaluated by the following method.

· Wear strength (time)

It is measured by the Rotary Platform Double Head method (also called Taber wear method) according to ASTM 3884 method.

H-18 is used as the wear ring, and the load is 500gf, and the number of wears to the starting point of rupture is obtained and this is called wear strength.

Of artificial leather for vehicle Surface Average Roughness

Carl Zeiss, a type of confocal laser scanning microscope (LSS) facility, LSM 5 PASCAL, a topography software package for LSM, or similar Measure by using LSM equipment.

Specifically, the center area average roughness (Ra) value of 10 unevennesses formed on the surface is measured by scanning the surface area range (width 1,000 μm x length 1,000 μm) of the artificial leather for a vehicle with a laser. From the arithmetic mean value, the ten-point average roughness (Rz) of the surface of the artificial leather for a vehicle is obtained.

Hereinafter, the ten point average roughness Rz is called surface average roughness.

· Touch and appearance

It is excellent if 8 or more out of 10 people feel good and feel after the sensory test of 10 experts, and 5 to 7 people feel good if they feel and feel good, and less than 4 people feel good and feel good. Separated by each.

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) consisting of the sea component of the alkali-soluble copolyester and 300 polyester components dispersed and dispersed in the sea component is also cut to a length of 50 mm to form a short fiber. 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 island-in-the-sea composite fiber.

Next, the prepared nonwoven fabric was impregnated with 40% by weight of polyurethane resin to the nonwoven fabric, and then wet-coagulated, and then dissolved in seawater components in the island-in-the-sea composite fiber by treating with an aqueous alkali solution (caustic soda solution). Prepared.

Next, the composite sheet was buffed twice using a brush to form wool on the surface, and then dried at 150 ° C. to fix the wool, and then dyed to manufacture a vehicle artificial leather.

The results of evaluating various physical properties of the manufactured vehicle artificial leather are shown in Table 1.

Example  2

Artificial leather for a vehicle was manufactured in the same manner as in Example 1 except that the artificial leather in which the cows were formed was pressed with a heat roller at 160 ° C. to fix the cows.

The results of evaluating various physical properties of the manufactured vehicle artificial leather are shown in Table 1.

Example  3

Vehicle artificial leather was manufactured in the same manner as in Example 1, except that a polyurethane resin was applied to the surface of the artificial leather in which the cows were formed for fixing the cows.

The results of evaluating various physical properties of the manufactured vehicle artificial leather are shown in Table 1.

Example  4

The artificial leather for a vehicle was manufactured in the same manner as in Example 1 except that the surface of the artificial leather on which the cows were formed was treated with dimethylformamide to swell the polyurethane resin positioned on the surface of the artificial leather.

The results of evaluating various physical properties of the manufactured vehicle artificial leather are shown in Table 1.

Example  5

Except for coating the sol (Sool) consisting of nanoparticles of silicon dioxide, organic acid having an alcohol group and a ketone group, a stabilizer, a basic solution and water (solvent) on the surface of the artificial leather on which the cows are formed for fixing the cows An artificial leather for a vehicle was manufactured in the same manner as in Example 1.

The results of evaluating various physical properties of the manufactured vehicle artificial leather are shown in Table 1.

Example  6

Car artificial leather was manufactured in the same manner as in Example 1, except that the heat treatment was performed at 150 ° C. before the composite sheet was buffed.

The results of evaluating various physical properties of the manufactured vehicle artificial leather are shown in Table 1.

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 300 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 island-in-the-sea composite fiber.

Next, the prepared nonwoven fabric was impregnated with 40% by weight of polyurethane resin to the nonwoven fabric, and then wet-coagulated, and then dissolved in seawater components in the island-in-the-sea composite fiber by treating with an aqueous alkali solution (caustic soda solution). Prepared.

Next, the composite sheet was buffed twice using a brush to form a wool on the surface, and then dyed to prepare a vehicle artificial leather.

The results of evaluating various physical properties of the manufactured vehicle artificial leather are shown in Table 1.

Property evaluation result division Wear strength (times) Surface Average Roughness (㎛) touch Exterior Example 1 2,320 30 Great Great Example 2 2,370 36 Great Great Example 3 2,410 41 Great Great Example 4 2,350 37 Great Great Example 5 2,420 36 Great Great Example 6 2,480 40 Great Great Comparative Example 1 1,860 70 Great Great

The present invention has a narrow gap between the polymer elastic body and the microfine fibers located on the surface of the artificial leather is excellent in morphological stability and wear strength of the wool formed on the surface, excellent in touch and appearance.

Claims (9)

A microelastic fiber is impregnated in a nonwoven fabric in which microfibers having a single yarn fineness of 0.001 to 0.3 denier are entangled with each other, and the microfibers are formed on the surface of the microfibers to form a wool, measured by Taber wear method. Artificial leather, characterized in that the wear strength is more than 2,000 times. The artificial leather according to claim 1, wherein the surface average roughness of the artificial leather is 50 µm or less. The artificial leather according to 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 stiffness measured by the cantilever method is 100 mm or less. In manufacturing a composite sheet in which microfibers having a single yarn fineness of 0.001 to 0.3 denier are impregnated with a polymer elastic body in a nonwoven fabric interwoven with each other, and then buffing the composite sheet to produce artificial leather having wool on the surface thereof. A method of manufacturing artificial leather, characterized in that for carrying out one or more steps selected from the steps of (iii). (Iii) a process of dry heat treating the artificial leather on which the composite sheet or wool is formed; (Ii) pressing the artificial leather on which the composite sheet or the wool is formed with a heat roller; (Iii) imparting a polymer elastic body to artificial leather with wool formed; (Iii) swelling the polymer elastic body impregnated in the artificial leather with a solvent capable of dissolving the polymer elastic body impregnated in the artificial leather in which the wool is formed; (Iii) coating a sol (Sol) for coating containing inorganic matter in the form of nanoparticles in artificial leather formed with the wool. The method of manufacturing artificial leather according to claim 5, wherein the dry heat treatment is performed at 120 to 170 ° C. The method of manufacturing artificial leather according to claim 5, wherein the heat roller is pressed at 140 to 200 ° C. The method for producing artificial leather according to claim 5, wherein the solvent capable of dissolving the polymer elastomer impregnated in artificial leather is one selected from dimethylformamide, dimethylacetamide, and dimethyl sulfoxide. The method of manufacturing artificial leather according to claim 5, wherein the inorganic material in the form of nanoparticles is one selected from silicon dioxide, titanium dioxide and aluminum trioxide.