KR20170025341A - Method for manufacturing bonded sheet using recycling leather for automobile interior material - Google Patents

Abstract

Disclosed are synthetic leather having an ink transfer pattern and a manufacturing method thereof. The synthetic leather having an ink transfer pattern comprises a backing closure layer for synthetic leather, a polyolefin foam layer formed on the backing closure layer, a polyolefin sheet layer formed on the foam layer, an ink transfer film layer formed on the polyolefin sheet layer, and a thermoplastic polyurethane transparent protection layer formed on the ink transfer film layer. The synthetic leather is based on a polyolefin resin, includes various ink transfer patterns, and can show low ink breakage, high adhesive force, and high scratch resistance.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a method for manufacturing a cushioning sheet for automobile interior material using recycled leather,

The present invention relates to a method for manufacturing a laminating sheet material for automobiles having excellent lubrication and flexibility using recycled leather technology.

Shaving scrap, which is a raw material of recycled leather, refers to leather processing waste or by-products generated by shaving process to control thickness after the tanning process, which is one of the leather processing processes. The production process is common in the world, I am angry.

The international patent technology of recycled leather is owned by Salamanda (Germany) and Japan, and each recipe is different, and the quality of product is also different.

The type of recycled leather sheet is divided into L / B and Composition Leather. In the case of the former, the first product is a sheet made of leather waste mixed with a binder. Depending on the application, Urethane and paper powder fiber waste are combined together and tensile strength is weak It is mainly used as a shoe-reinforcing agent, a handbag reinforcing agent, an album, a Bible, etc.

Compoisition Leather is also called Bonded leather, and it has a leather-like surface feel on L / B. It has a leather-like surface feel and high tensile strength. Since there is a stiffness disadvantage due to bond hardening during compaction process, There are small items such as stationary, cell phone case.

The recycled leather is priced at $ 23 / M L / B. The value added is Composition Leather, which is being sold by Salamanda. It is sold as a commodity with various items and prices such as Mercedes car seat, bus seat, airplane seat, It is expected that the fermentation will be further diversified.

As a car maker, the automobile seat fabric should be promptly dealt with in accordance with the basic production and development direction of the car maker. The automobile seat sewing is a business for sewing leather and fabric fabrics to seat companies or automobile companies. It is a large-scale employment promotion effect and a joint development business of material industry such as fabric and leather companies.

Artificial leather, on the other hand, is sensitive to consumer sentiments due to the general economy because it is the most advanced material and high-grade material. Clothing, gloves, and shoes are connected with the sewing season, The interior sector is relatively less influential. There are about two Japanese companies that produce high quality artificial leather all over the world.

Although much research has been conducted on the recycling of leather wastes in Korea and elsewhere, the actual utilization rate is very low, less than 10% in Korea, and the London Waste Regulation Treaty (LDG) . As a result, it is anticipated that electric power generation will be expected to minimize the generation of harmful substances in the manufacturing process due to strengthening regulations on harmful substances of human and environment, and it will increase the cases of replacing harmful chemical substances with low toxic materials or recycling existing automobile parts and materials. do.

In terms of commercialization, both domestic and foreign related industries have been striving for diverse fields with differentiation and high added value in order to escape from producing only functional products. Especially, In the automobile sector, it has a lot of influence on the related industries that provide the interior materials, and is concentrating on new countermeasures such as materials, construction method, procurement method, and price.

Particularly, a large amount of fiber used in automobile interior materials is concentrated in a design part where the superiority of the feel of the material, the three-dimensional feeling, and the high-quality feeling of the seat part is required.

In addition to the basic performance of interior materials, automobile interior materials are required to have quality features such as durability (color and pattern), durability such as light resistance and abrasion resistance, selection of materials with low environmental load, and prevention of dirt and contamination.

The waste generated in the leather process is more than 60 thousand tons per year. The chromium generated in the process of leather is absorbed in the waste and is discharged as it is. PVC material is also classified as industrial waste in the material composition and does not rot, There is a problem that various toxic components are released.

The development of recycling and recycling materials using leather waste has progressed actively since the late 1990s in Korea, but the quality development to be used as a reinforcing material in a handbag has not been achieved.

Therefore, development of leather sheet using leather waste which is suitable for car seat and can replace PVC material is required to further develop materials having characteristics of high soft, thin thickness, high tear strength and tensile strength suitable for car seat product characteristics .

As mentioned above, one of the recent trends in automotive materials that are emerging is the preference for leather as an interior material, the difficulty in supplying and supplying raw materials for automotive car seats, the increasing preference for materials that are differentiated, and the low-carbon LCA Assessment-based materials are growing in popularity, and the development of new materials that combine the advantages of natural leather with the merits of synthetic leather is required.

Korean Patent Laid-Open No. 10-2013-0131397 (published Dec. 03, 2013) Korean Registered Patent No. 10-0828824 (registered on May 2, 2008)

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a method for manufacturing a cushioning sheet material for automobiles which is environmentally friendly, has excellent lubrication and flexibility by using recycled leather technology.

The inventors of the present invention have completed the present invention by enhancing mutual bonding between leather wastes and textile wastes, introducing and experimenting various ideas on processing conditions of a bonded sheet by a dry method, resin processing conditions, and the like.

According to an aspect of the present invention, there is provided a method of manufacturing a laminated sheet for automotive interior materials, comprising: preparing a shaving scrap; Adding the shaving scrap to a kneader (m / c) to obtain a fiber by undifferentation and rubbing; And a step of mixing the fibers, the main adhesive resin and the auxiliary resin, heating them, and performing a roll-milling process to obtain a sheet.

Here, the shaving scrap may have a moisture content of 8 to 15%.

The fibers may be fibers of 0.4 to 1.0 mm in size.

The main adhesive resin and the auxiliary resin may be ethylene vinyl acetate (EVA) resin.

The shaving scrap may be a mixture of waste paper or waste paper in a natural leather shaving scrap.

In addition, the manufacturing method may further include a step of dyeing the sheet obtained subsequently to the step of obtaining the sheet.

The manufacturing method may further include adding at least one auxiliary agent selected from a viscosifying auxiliary agent, a releasing agent and a softening agent.

The bonded sheet produced according to the present invention is environmentally friendly, has excellent lubrication and flexibility, and can be suitably used in automotive interior materials.

The production method according to the present invention is a product by dry method rather than a wet method using water, and it is easy to control the physical properties and thickness of the product, and various product groups can be conveniently manufactured.

According to the present invention, a separate physical process is required for the smoothing of the sheet and the improvement of the bonding force. However, in the manufacturing method according to the present invention, So that productivity can be improved.

In addition, by utilizing leather waste, recycling of waste can be facilitated to achieve resource reduction and waste reduction, and the market of raw materials for automobile seats represented by natural leather and synthetic leather can be diversified.

1 is a photograph of a work of a kneader machine according to an embodiment of the present invention.
2 is a contrast photograph of a kneader machine according to an embodiment of the present invention.
FIG. 3 is a photograph of a test result according to moisture content of a scrap scrap according to an embodiment of the present invention.
FIG. 4 is data of a kneader machine processing time and a temperature experiment result according to an embodiment of the present invention.
5 is data of a roll mill test result according to an embodiment of the present invention.
FIG. 6 is a result of experimental data on the mixing of waste fibers according to an embodiment of the present invention.
FIG. 7 is a result of experimental data of mixed waste paper according to an embodiment of the present invention.

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

The inventors of the present invention have completed the present invention by enhancing mutual bonding between leather wastes and textile wastes, introducing and experimenting various ideas on processing conditions of a bonded sheet by a dry method, resin processing conditions, and the like.

According to an aspect of the present invention, there is provided a method of manufacturing a laminated sheet for automotive interior materials, comprising: preparing a shaving scrap; Adding the shaving scrap to a kneader (m / c) to obtain a fiber by undifferentation and rubbing; And a step of mixing the fibers, the main adhesive resin and the auxiliary resin, heating them, and performing a roll-milling process to obtain a sheet.

Here, the shaving scrap may have a moisture content of 8 to 15%.

The fibers may be fibers of 0.4 to 1.0 mm in size.

The main adhesive resin and the auxiliary resin may be ethylene vinyl acetate (EVA) resin.

The shaving scrap may be a mixture of waste paper or waste paper in a natural leather shaving scrap.

In addition, the manufacturing method may further include a step of dyeing the sheet obtained subsequently to the step of obtaining the sheet.

The manufacturing method may further include adding at least one auxiliary agent selected from a viscosifying auxiliary agent, a releasing agent and a softening agent.

On the other hand, when an element is referred to as "including" an element throughout the specification, it is to be understood that the element may include other elements. Also, when a part is located "above" another part, it may include not only being directly in contact with the upper part, have.

Hereinafter, embodiments of the present invention will be described in detail so that those skilled in the art can easily carry out the present invention. The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

Undifferentiation test

In this experiment, disk mill, cutting mill, Kneader m / c and Niagara beater were used for the physical treatment experiments.

As a result of fiber grinding using Cutting mill, Disk mill, Kneader m / c and Niagara beater, it was confirmed that the shortest fiberization was achieved with an average fiber length of 0.4 ~ 1.0mm during the crushing process using Kneader m / c . When the length of the fiber is less than a certain length, the physical properties are deteriorated and the bending property is poor, so the formability is bad. The fiber length is excessively long and the surface touchability is very poor. mm showed the best bond strength and surface roughness.

Treatment method Cutting mill Disk mill Kneader m / c Niagara beater Average fiber length (mm) 2.0 to 3.0 1.0 to 2.0 0.4 to 1.0 3.0 to 4.0

The shaving scrap was not pulverized and cut, and was put into a Kneader m / c. As a result, as shown in FIG. 2, the undifferentiated and rubbed effect occurred, and a separate grinding step was not necessary.

Characteristic test according to processing time and temperature of Kneader m / c

EVA resin is insoluble and affects adhesion when water is present.

Determination of the optimum moisture content suitable for sheet manufacture is required through measurement of moisture content

Shaving scrap collected on site and shaving scrap for 7 days were 30 ~ 55% and 16% moisture content, respectively. As a result, when the sheet was produced using the sheet, the binding force of the sheet was lowered as in the following E-1 (This is a result of moisture interfering with the combination of resin and SC)

The amount of shaving scrap used was reduced from 20 g to 10 g. As a result of the E-1 and E-1-1 tests, when the shaving scrap content was 20 g and the resin was 8 g as in E-1-1, The E-1-1 formulation was inadequate because of the poor adhesion at the time of roll milling. In the case of E-1, the volume ratio was almost similar to that of the conventional non-drying shaving scrap using fully dried shaving scrap. Good adhesion between rollers, good roll mill workability.

Shaving scrap was prepared by changing the mixing time of Kneader m / c to 5 minutes, 10 minutes and 15 minutes while keeping the resin constant at 80%. As a result, the resin and shaving scrap were uniformly mixed The Kneader m / c mixing time of short A-1 and A'-1 showed a large number of thick and uneven thicknesses of the final sheet. On the other hand, when Kneader m / c mixing time was 15 minutes, The thickness of the sheet is uniform.

The problem that the insoluble resin added to the water decreased the adhesion between the fibers was solved by adjusting the moisture content of the shaving scrap to about 10%. The uniformity of the sheet was obtained by mixing the shaving scrap with the resin for 15 minutes The results were solved and overall excellent characteristics were shown.

Sheet uniformity test according to the pressure and the number of revolutions of the roller mill

B-1 and B'-1 were the same under all conditions and experiments were conducted to confirm the uniformity of the sheet according to the pressure of the roll mill used for the production of the sheet of mixed resin through the Kneader m / c work.

As a result, a uniform sheet was not produced under the condition that the pressure of the roll mill was 50 kgf / cm 2 or less and the surface was uneven. On the condition of 100 kgf / cm 2 higher than that, The pressure of the mill is more than 100kgf / cm2.

As a result of producing the sheet by changing the number of revolutions of the roll mill from 10 r.pm to 20 r.pm, when the rpm is high B '' - 1 and B '' '- 1, The separation of the sheet is not easy, and the contact time between the roll and the sheet is short because of the high rotation speed, so that it is difficult to produce a uniform sheet.

Therefore, the roll mill pressure is 100 gf / cm 2, and the roll mill rotation is most suitable for the properties and uniformity of B'-1 sheet produced at 10 r.p.m.

Bonded Sheet Resin Processing Condition Test

Pellet resin is a resin with a melting point of 110 ° C or less. This is because the shrinkage temperature of the shaving scrap is as low as 110 ° C in order to produce a sheet under no shaving scrap deformation.

- Shaving scrap was fixed with 15g and resin mixing experiment

- Kneader m / c mixing time: 15 minutes

Adhesive resin division characteristic VA 810 VA-1 No auxiliary resin added / Hard / Flexibility / Failing to bend VA-2 Somewhat hard / poor flexibility / VA-3 Good flexibility / bending property VA-4 Strength / Flexibility Normal / Good bending property VA-5 Somewhat Hard / Flexibility Normal / VA-6 Strength Normal / Flexibility Normal / Bendability Normal VA-7 The presence of LDPE 5302 in poorly meltable and foamed form VC 710 VC-1 No auxiliary resin added / Hard / Flexibility Normal / Good bending property VC-2 Somewhat hard / poor flexibility / VC-3 Somewhat hard / poor flexibility / VC-4 Somewhat hard / poor flexibility / VC-5 Somewhat hard / poor flexibility / VC-6 Somewhat hard / poor flexibility / VC-7 The presence of LDPE 5302 in poorly meltable and foamed form EVA 1633 E1633-1 No auxiliary resin added / Hard / Flexibility / Failing to bend E1633-2 Somewhat hard / poor flexibility / poor bending E1633-3 Hard / Flexibility Bad / Bendability Normal (EVA 1834) E1633-4 Somewhat hard / poor flexibility / poor bending E1633-5 Very Hard / Poor Flexibility / Bad Flexibility E1633-6 Very Hard / Poor Flexibility / Bad Flexibility E1633-7 Non-sheet production due to poor meltability of LDPE 5302 EVA 1540 E1540-1 No auxiliary resin added E1540-2 Poor adhesion / poor flexibility / poor bending with auxiliary resin E1540-3 Poor adhesion / poor flexibility / poor bending with auxiliary resin E1540-4 Poor adhesion / poor flexibility / poor bending with auxiliary resin E1540-5 No sheet production due to poor adhesion with auxiliary resin (MB-100) E1540-6 No sheet production due to poor adhesion with auxiliary resin (E-220F) E1540-7 Non-sheet production due to poor meltability of LDPE 5302

VA-810 treated with VA-810 alone had some problems of bending property and flexibility, but VA-3, 4, 5 and 6 with 10% of auxiliary resin had problems of bending property and flexibility Relatively good results (compatibility with VA 810 and auxiliary resin EVA 1834 / VS 430 / MB-100 / E 220F)

When VC 710 is applied, it is rather hard (generally, it is hard due to the effect of VC 710, which is the main starting point)

EVA 1633 Resin Hard It has strong optical strength and low flexibility because it has excellent optical adhesiveness.

EVA 1540 is the most excellent material in terms of flexibility, strength and bending property when the content of resin is 30 ~ 40% in the previous experiment, but it is difficult to manufacture sheet with no complication with auxiliary agent, Flexibility, bending, etc. are exposed.

VA 810 is used as main adhesive resin and EVA 1834 auxiliary resin is suitable.

Application of main adhesive resin and auxiliary resin Shaving scrap Experiment by moisture content

The standard content of the experiment was based on 40 g of shaving scrap (moisture content: 10%), 32 g of VA 810 (80% of S.C) and 8 g of EVA 1834 (20% of S.C).

If the moisture content is more than 10%, the moisture inside the fiber does not come out due to the addition of the resin and the fiber binding force is poor.

Fiber mixing experiment

In the physical property analysis table above, 10% of the waste cotton fiber and 10% of the waste cotton fiber showed the most excellent physical properties in total fiber amount, and the amount of waste cotton fiber and waste paper was continuously increased Since there is no significant effect on the physical properties, it is judged that it is appropriate to fix the usage amount to 10% in terms of physical properties.

When VA 810 + EVA 1834 is used, the VA content is somewhat low at 33%, which greatly reduces the problem of surface tackiness.

Adhesive resin used should have a VA content of 30% or more to maintain the interfiber adhesive strength, and a resin having a melting point of 80 ° C or lower (processing temperature Max 110 ° C) is suitable. However, being.

However, when VA 810 + EVA 1834 is used in the overall physical properties, it has excellent physical properties without much difficulty in manufacturing the product, and has excellent productivity due to reduction of tacky property, so it is confirmed that suitable resin can be used according to the use of the product .

Evaluation items Monkey SC-1 SC-2 SC-3 SP-1 SP-2 SP-3 thickness mm 0.8 0.8 0.9 0.8 0.9 0.8 The tensile strength kgf / 1.27m 3.7 3.6 3.3 3.9 3.5 3.2 Phosphorus strength kgf 0.3 0.4 0.5 0.4 0.4 0.6 Elongation rate % 12.4 11.3 11.7 13.7 16.7 11.3 flexibility mm 3.0 3.0 3.0 2.8 3.3 2.6

Optimal manufacturing process

The optimal usage of WS 180 is 15 ~ 20% of the resin content

division Shaving scrap (S.C) VA 810 EVA 1834 WS 180 Tacky flexibility VAS-6-2 40g 32g 8g 6 g (15% of resin) 2-3 Hard VAS-6-3 40g 32g 8g 7g (17.5% of resin) 1-2 Hard VAS-6-4 40g 32g 8g 8 g (20% of resin) 1-2 Hard

For ST / A usage, the optimum amount of ST / A is 2.5 ~ 20% of resin content

division Shaving scrap (S.C) VA 810 EVA 1834 ST / A Tacky flexibility VAW-1-1 40g 32g 8g 1 g (2.5% of resin) 2-3 Medium VAW-1-2 40g 32g 8g 2 g (5% of resin) 2 Medium VAW-1-3 40g 32g 8g 3 g (7.5% of resin) 2-3 Medium VAW-1-4 40g 32g 8g 4 g (10% of resin) 2-3 Medium VAW-1-5 40g 32g 8g 5g (12.5% of resin) 2-3 Medium VAW-1-6 40g 32g 8g 6 g (15% of resin) 2-3 Medium VAW-1-7 40g 32g 8g 7g (17.5% of resin) 2-3 Medium VAW-1-8 40g 32g 8g 8 g (20% of resin) 2 Medium

Optimization result with no addition of lubricant

division content Shaving scrap (S.C) (moisture content: 10%) 40g VA 810 (80% of fibers) 32g EVA 1834 (20% of fibers) 8g

W-1500: Increase of flexibility and viscosity of paste, but adhesion of roll mill and deterioration of physical properties

ST / A and WS 180 improve tacky when using above content

Properties Blank (no lubricant)> ST / A Mix> WS 180 Mix

Manufacturing process

Shaving scrap Moisture content: 10%

Kneader m / c Setting temp. : 95 ° C (high melting temperature of the applied resin)

Kneader m / c Mixing time: Fiber alone: 5 minutes (milling) -> Resin mixing: 10 minutes (Adhesion)

Roll mill Number of revolutions: 10r.p.m

Roll mill pressure: 100kgf / cm2

Primary Roll mill temp. : 90 占 폚 / Second roll mill temp: 50 or 85 占 폚

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. It will be possible. It is therefore to be understood that the above-described embodiments are illustrative in all aspects and not restrictive. For example, each component described as a single entity may be distributed and implemented, and components described as being distributed may also be implemented in a combined form.

The scope of the present invention is defined by the appended claims rather than the detailed description and all changes or modifications derived from the meaning and scope of the claims and their equivalents are to be construed as being included within the scope of the present invention do.

Claims (7)

Preparing a shaving scrap;
Adding the shaving scrap to a kneader (m / c) to obtain a fiber by undifferentation and rubbing; And
Mixing the fiber, the main adhesive resin and the auxiliary resin, and heating and rolling the same to obtain a sheet
Wherein the step of forming the adhesive layer comprises the steps of: The method according to claim 1,
Wherein the shaving scrap has a water content of 8 to 15%. The method according to claim 1,
Wherein the fibers are fibers having a size of 0.4 to 1.0 mm. The method according to claim 1,
Wherein the main adhesive resin and the auxiliary resin are ethylene vinyl acetate (EVA) resins. The method according to claim 1,
Wherein the shaving scrap is a mixture of waste paper fibers or waste paper in a natural leather shaving scrap. The method according to claim 1,
Further comprising the step of dyeing the obtained sheet. The method according to claim 1,
And further adding at least one auxiliary agent selected from the group consisting of an antioxidant, a viscosity improving agent, a releasing agent and a softening agent.

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