KR20180076839A - Method of making man-made leather for automobile use, and man-made leather for automobile use - Google Patents

Abstract

Disclosed is a method to manufacture a binding substrate for manufacturing artificial leather for a vehicle. The method includes: a step of supplying a support after processing at least one side of the support with a release agent; a step of coating a binding agent on the release agent-processed surface of the support; and a step of supplying the knitted fabric substrate formed with a coarse denier yarn equal to or less than 40 denier monofilament on the binding agent-coated surface of the support, compressing the knitted fabric substrate, and then bonding and binding the knitted fabric substrate and the support, thereby obtaining a binding substrate of the knitted fabric substrate and the support. The present invention also discloses a binding substrate obtained by the above; a manufacturing method of artificial leather for a vehicle using the binding substrate; and the artificial leather for vehicle obtained by the same. According to the present invention, the manufacturing method of artificial leather for a vehicle using a thin binding substrate obtained by the manufacturing method of the binding substrate can effectively manufacture thin artificial leather for a vehicle capable of being better than natural leather by having excellent stretching ability, breathability, and touch feeling while having a thin thickness.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a method of manufacturing artificial leather for automobiles,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing artificial leather for automobiles, and artificial leather for automobiles. More particularly, the present invention relates to a method for manufacturing artificial leather for automobiles, which is superior in both stretchability, air permeability and touch feeling while being thinner than natural leather, and artificial leather for automobiles.

Artificial leather can be produced by coating a bonding resin such as polyvinyl chloride (PVC), polyamide or polyurethane on a substrate of woven fabric, knitted fabric or nonwoven fabric by a method such as knife coating, lamination, foaming or impregnation, It is a product made to feel. Such synthetic leather is lighter than natural leather, has a high surface strength, is excellent in abrasion resistance, has good moisture permeability and waterproofness, has various colors, is easy to work such as cutting and sewing, Production is possible.

In recent years, artificial leather has been widely used for a wide variety of applications ranging from clothing to life and industrial use. Since it is supplied with a large amount of water at a low cost and high quality comparable to or superior to natural leather, And the like are also becoming important. In particular, in recent years, high-priced products have been increasingly used in applications such as automobile interior materials as well as case accessories such as smart phones and tablet PCs.

However, conventional artificial leather products have a lot of room for improvement when they are applied to automobile interior materials because of the drawbacks of thick, low elasticity, low air permeability and bad touch feeling.

Accordingly, it is an object of the present invention to provide a method for manufacturing an artificial leather for a vehicle, which can effectively produce artificial leather for automobiles, which is thin but excellent in stretchability, air permeability and touch feeling, and can exceed natural leather.

Another object of the present invention is to provide a bonding substrate capable of effectively producing artificial leather for automobiles, which is thin in thickness, superior in stretchability, breathability and touch feeling, and superior to natural leather.

It is still another object of the present invention to provide a method of manufacturing artificial leather for automobiles, which is thin, has excellent stretchability, air permeability and touch feeling, and is superior to natural leather.

Another object of the present invention is to provide an artificial leather for a vehicle which is thin and has excellent stretchability, air permeability and touch feeling, and which can overcome natural leather.

According to an aspect of the present invention,

Treating the at least one surface of the support with a releasing agent and then supplying the support;

Applying a binder onto the release agent treated surface of the support; And

A knitted fabric base made of three denier yarns having a single yarn fineness of not more than 40 deniers is supplied onto the binder-coated surface of the support, and the knitted fabric base is compressed and then the support and the knitted fabric base are combined and bonded, The method comprising the steps of: (1) preparing a base material for a synthetic leather for automobiles;

In one embodiment of the present invention, the step of supplying the support after the release agent treatment may further include drying the support body prior to the step of applying the binder.

In one embodiment of the present invention, the method may further include drying the support substrate and the bonded substrate of the knitted fabric substrate after the step of laminating and bonding the support and the knitted fabric substrate.

In one embodiment of the present invention, the step of drying the bonding substrate of the support and the knitted fabric substrate may further include a step of cylinder-drying the bonding substrate.

In one embodiment of the present invention, the step of applying the binder onto the releasing agent-treated surface of the support may be carried out by a gravure coating method.

In one embodiment of the present invention, at least one side of the knitted fabric substrate is preferably brushed so that the polyurethane resin can be effectively impregnated in a subsequent step.

In an embodiment of the present invention, the knitted fabric substrate is a knitted fabric substrate made of three denier yarns having a single yarn fineness of 20 denier (d) to 30 denier (d), and the stretching ratio in the range of 60 to 120% And the like.

In one embodiment of the present invention, the support is a high-fineness and low-density woven fabric composed of a high-fineness yarn having a yarn monofilament fineness ranging from 200 d to 300 d and a low density structure having a tissue density ranging from 40 x 50 to 60 x 70 Lt; / RTI >

In one embodiment of the present invention, the ratio of the amount of the binder to the amount of the release agent to the amount of the release agent is in the range of 1: 1 to 1: 2, based on the dry weight of the support, It may be preferable in view of balance of releasability.

In one embodiment of the present invention, the releasing agent may be at least one type of releasing agent selected from a fluorine-based compound, a silicon-based compound and an acrylic compound.

In one embodiment of the present invention, the binder may be a polyurethane-based adhesive.

According to another aspect of the present invention,

A support having at least one side treated with release agent;

A binder layer formed on the release agent treated surface of the support; And

And a knitted fabric base made of a three denier yarn having a single yarn fineness of 40 denier or less as a knit fabric base releasably bonded to the support by the binder layer.

In one embodiment of the present invention, the support is composed of a high-fineness yarn having a yarn monofilament fineness ranging from 200 d to 300 d, a tissue density of 40 x 50 to 60 x 70 and a low- have.

According to another aspect of the present invention,

Treating the at least one surface of the support with a releasing agent and then supplying the support;

Applying a binder onto the release agent treated surface of the support;

A knitted fabric base made of three denier yarns having a single yarn fineness of not more than 40 deniers is supplied onto the binder-coated surface of the support, and the knitted fabric base is compressed and then the support and the knitted fabric base are combined and bonded, ;

Forming a microporous polyurethane porous layer having micropores on the knitted fabric substrate side of the binding substrate; And

And forming a skin layer on the surface of the polyurethane porous layer,

Further comprising peeling and removing the support from the knitted fabric substrate between the step of forming the microporous polyurethane porous layer and the step of forming the skin layer or after the step of forming the skin layer, A method of manufacturing a leather is provided.

In one embodiment of the present invention, the step of forming the microporous polyurethane porous layer comprises:

A first polyurethane resin coating liquid containing a polyurethane resin and an organic solvent capable of dissolving the polyurethane resin is applied on the side of the knitted fabric base material of the binding substrate and the resultant is immersed in a coagulating solution to form a polyurethane resin coating layer Solidifying; And

And washing and coagulating the coagulated polyurethane resin coating layer to form the microporous polyurethane porous layer.

In one embodiment of the present invention, the step of forming the skin layer comprises:

Applying a second polyurethane resin coating solution containing a polyurethane resin and an organic solvent capable of dissolving the polyurethane resin on the release paper and drying to form a skin layer;

Applying the second polyurethane resin coating liquid again on the skin layer to bond the microporous polyurethane porous layer to the adhesive layer formed on the release paper, And

And curing and aging the resultant in the combined state, and then separating the release paper.

According to another aspect of the present invention,

A knitted fabric substrate made of three denier yarns having a single yarn fineness of 40 denier or less as a knitted fabric base material;

A microporous polyurethane porous layer having micropores formed on the knitted fabric substrate; And

And a skin layer formed on the microporous polyurethane porous layer.

In one embodiment of the present invention, an adhesive layer may be further included between the microporous polyurethane porous layer and the skin layer.

According to the method for producing a bonded substrate according to the present invention and the method for producing artificial leather for a vehicle and the like, a highly stretchable but low-strength knitted fabric substrate made of three denier yarns having a yarn monofilament fineness of 40 denier or less and a support In the polyurethane impregnation process or the like, both of them are maintained in the bond, while the polyurethane impregnation process is carried out, a high stretchable knitted fabric is obtained from the support after the polyurethane impregnation process. A new and different process is designed to control the balance of adhesion and releasability between the two so that they can be effectively stripped.

Therefore, according to the process for producing artificial leather for automobiles using the superabsorbent bonded substrate obtained by the process for producing a bonding substrate according to the present invention, it is possible to provide a synthetic leather composition which is superior in both stretchability, air permeability and touch feeling, Artificial leather for a super-stripped vehicle can be effectively manufactured.

Therefore, according to the method for manufacturing a bonded substrate according to the present invention, and the method for manufacturing a synthetic leather for a vehicle, it is possible to effectively mass-produce an artificial leather material for a vehicle, which can be applied to automobile interior materials having a high degree of lightness and thinness.

1 is a schematic process sectional view for explaining a continuous manufacturing process of a bonded substrate for manufacturing artificial leather for a vehicle according to an aspect of the present invention.
2 is a schematic cross-sectional view of a synthetic leather for a vehicle manufactured using a bonding substrate for manufacturing artificial leather for a vehicle according to an aspect of the present invention.

Hereinafter, with reference to the accompanying drawings, a method of manufacturing a bonded substrate for a synthetic leather for a vehicle according to the present invention, a bonded substrate obtained thereby, a method of manufacturing an artificial leather for a vehicle using the bonded substrate, The obtained artificial leather for a vehicle will be described in more detail.

The following embodiments may be modified in various other forms, and the scope of the present invention is not limited to the embodiments described below. Embodiments of the invention are provided to more fully describe the present invention to those skilled in the art. In the accompanying drawings, the size or thickness of each layer is exaggerated for clarity of description. Further, when a layer is described as being "above" another layer, it is meant that the layer may be directly on top of the other layer, and a third other layer may be interposed therebetween.

According to an aspect of the present invention, there is provided a method of manufacturing a bonded substrate for manufacturing artificial leather for a vehicle, comprising: treating the at least one surface of the support with a release agent; Applying a binder onto the release agent treated surface of the support; And a knitted fabric base made of three denier yarns having a single yarn fineness of 40 denier or less on the application surface of the support of the support and then pressing the knitted fabric base so that the support and the knitted fabric base are combined and bonded, .

1 is a schematic process cross-sectional view for explaining a continuous manufacturing system 50 and a process of a bonding substrate for manufacturing artificial leather for a vehicle according to an aspect of the present invention.

Referring to Fig. 1, first, the support is fed along the direction of the arrow while releasing the support 10 from the feeder. The support 10 may be a woven fabric having a high fineness and a low density in terms of adhesion / peeling. When the support 10 is a woven fabric, the support 10 is made of a high-fineness yarn having a yarn monofilament fineness ranging from 200 d to 300 d, a high fineness having a low-density structure ranging from 40 x 50 to 60 x 70 (bins / inch) The woven fabric of low density is preferable in terms of being able to effectively bond and support the knitted fabric substrate 18 made of three denier yarns having a single yarn fineness of 40 denier or less during the entire process of manufacturing artificial leather for automobiles such as a polyurethane impregnation process. The yarns constituting the support 10 include polyester yarns such as polyethylene terephthalate and polybutylene terephthalate; Nylon 6, nylon 66 and the like, and polyvinyl alcohol or the like may be used. When the support 10 is a woven fabric, the woven fabric may be a basic fabric such as plain weave, twill weave, or main weave; Transformation organization derived from the basic organization such as change plain weave, change weaving, Or a woven fabric of double woven, woven, woven, pile, or other special fabric.

The pretreatment apparatus 12 treats at least one surface of the support 10 with a release agent. As the preprocessing apparatus 12, for example, mangles and mesh rolls may be used. Drying the support in the first drying furnace 14 prior to the step 16, 17 of applying the releasing agent to the support 10 followed by the subsequent application of the binder results in a smooth application of the binder in the subsequent binder application step Which is preferable in view of the above. The temperature of the first drying furnace 14 may be adjusted to 130 to 180 ° C, for example, 130 to 160 ° C, specifically 130 to 150 ° C in terms of adhesion. Subsequently, the binder is applied onto the release agent-treated surface of the support 10 while supplying the support 10. The step of applying the binder onto the release agent-treated surface of the support 10 may be carried out in a gravure coating manner in terms of temporary adhesion. For this purpose, the binder is applied onto the releasing agent-treated side of the support by a conventional gravure coating method or a gravure printing method while supplying the binder coating liquid from the binder liquid supply tank 17 to the gravure coating apparatus 16. In the subsequent polyurethane impregnation process for forming a microporous polyurethane porous layer in a synthetic leather manufacturing process for a vehicle, the binder is preferably a polyurethane adhesive in order to prevent contamination by other kinds of resin.

The ratio of the amount of binder to the amount of release agent treated in the support 10 based on the dry weight is in the range of 1: 1 to 1: 2, preferably 1: 1 to 1: 1.5, more preferably 1: To 1: 1.3, more preferably in the range of 1: 1 to 1: 1.2, may be preferable in terms of balance between the adhesive bondability and releasability of the knitted fabric substrate and the support. If the ratio is less than 1: 1, a problem of coating surface defects may occur. If the ratio is larger than 1: 2, a problem of peeling during processing may occur. The releasing agent may be at least one type of releasing agent selected from a fluorine-based compound, a silicon-based compound, and an acrylic compound.

Subsequently, the knitted fabric base material 18 is fed onto the binder-coated surface of the support 10, and the knitted fabric base material 18 is compressed by the compression roller 20 to form the support body 10 by laminating and joining the support body 10 and the knitted- And the knitted base material 26 of the knitted fabric substrate 18 are obtained. In the present invention, the knitted fabric substrate 18 is a knitted fabric made of three denier yarns having a single yarn fineness of 40 denier or less. The knitted fabric substrate 18 is a knitted fabric substrate made of three denier yarns having a single yarn fineness of 20 denier to 30 denier, which is a highly stretch knitted fabric having a stretch ratio within a range of 60 to 120% at room temperature, desirable. At least one side of the knitted fabric substrate 18 is preferably brushed so that the polyurethane resin can be effectively impregnated in a subsequent process for producing artificial leather. The yarn constituting the knitted fabric substrate 18 may be a polyester yarn such as polyethylene terephthalate or polybutylene terephthalate; Nylon 6, nylon 66 and the like, and polyvinyl alcohol or the like may be used. Particularly, polyester yarns are preferable from the viewpoints of minimizing water absorption and high self-durability. Knitted grains prepared by blending polyester yarns with polyamide yarns and / or high-elastic fibers such as spandex can be used. The knitted fabric substrate 18 may be a warp knitted fabric such as a tricot knitted fabric, a rachel knitted fabric, a milanised knitted fabric or the like; Knitted fabrics such as flat knitted fabrics, rubber knitted fabrics, pearl knitted fabrics, double-sided knitted fabrics and double low-fold fabrics; Jacquard knitting; A circular knife or the like. The weight of the knitted fabric base 18 is generally from about 100 g / yd to about 200 g / yd, and from 100 g / yd to 180 g / yd, more preferably from 130 g / yd to 180 g / yd.

The method may further include drying the bonding substrate 26 of the support 10 and the knitted fabric substrate 18 after the step of laminating and bonding the support 10 and the knitted fabric substrate 18. To this end, the supporting body 10 having passed the pressing roller 20 and the joining base material 26 of the knitted fabric substrate 18 are continuously conveyed and passed through the second drying furnace 22. The temperature of the second drying furnace 22 can be adjusted to 130 to 160 DEG C in terms of setting.

Optionally, the step of drying the bonding substrate 26 may further comprise drying the bonding substrate 26 with the cylinder 24. [ To this end, the joining base material 26 having passed through the second drying furnace 22 is continuously conveyed and guided so as to contact the cylinder dryer 24. The cylinder dryer 24 has a feature of surface smoothing compared with a conventional drying furnace. The temperature of the cylinder dryer 22 can be adjusted to 100 to 150 DEG C in terms of surface smoothness. Then, the binding base material 26 having passed through the cylinder dryer 22 is wound up to obtain a binding base material for a synthetic leather for a vehicle according to the present invention.

According to another aspect of the present invention, a bonding substrate for manufacturing artificial leather for a vehicle, which can be obtained through the above-described process, comprises: a support (10) having at least one surface treated with a releasing agent; A binder layer (not shown) formed on the release agent treated surface of the support; And a knitted fabric base material 18 made of three denier yarns having a single yarn fineness of 40 denier or less as a knitted fabric base material releasably bonded on the support 10 by the binder layer.

The support 10 may be preferably a woven fabric having a high fineness and a low density in terms of adhesion / peeling. When the support 10 is a woven fabric, the support 10 is a high-fineness and low-density woven fabric composed of a high-fineness yarn having a yarn monofilament fineness ranging from 200 d to 300 d, a low density structure having a tissue density ranging from 40 x 50 to 60 x 70, (18 in Fig. 1, 52 in Fig. 2) composed of three denier yarns having a single yarn fineness of 40 denier or less is preferable in terms of being able to effectively bond and support the knitted fabric during the entire process of producing artificial leather such as a polyurethane impregnation process .

The binder layer formed on the releasing agent-treated surface of the support 10 in terms of preventing contamination by other kinds of resins in the polyurethane impregnation process for forming the microporous polyurethane porous layer in the subsequent synthetic leather production process for a vehicle, It is preferable to include a polyurethane-based adhesive.

The ratio of the application amount of the binder to the throughput of the release agent on the basis of the dry weight in the support (10) is in the range of 1: 1 to 1: 2, and the ratio of the binder to the support Lt; / RTI > The releasing agent may be at least one type of releasing agent selected from a fluorine-based compound, a silicon-based compound, and an acrylic compound.

The knitted fabric substrate 18 is a knitted fabric made of three denier yarns having a single yarn fineness of 40 denier or less. The knitted fabric substrate 18 is preferably a highly stretch knitted fabric having a stretch ratio in the range of 60 to 120% at room temperature as a knitted fabric base made of three denier yarns having a single yarn fineness of 20 denier to 30 denier. At least one side of the knitted fabric substrate 18 is preferably brushed so that the polyurethane resin can be effectively impregnated in a subsequent process for producing artificial leather.

2 is a schematic cross-sectional view of a synthetic leather 100 for a vehicle manufactured using a bonding substrate for manufacturing artificial leather for a vehicle according to an aspect of the present invention.

Referring to FIG. 2, the artificial leather 100 according to another aspect of the present invention includes a knitted fabric base material 52 made of three denier yarns having a single yarn fineness of 40 denier or less; A microporous polyurethane porous layer 54 having micropores formed on the knitted fabric substrate 52; And a skin layer (58) formed on the microporous polyurethane porous layer (54). Alternatively, an adhesive layer 56 may be interposed between the microporous polyurethane porous layer 54 and the skin layer 58.

With respect to the details of the knitted fabric substrate 52, the description of the knitted fabric substrate in the above-mentioned binding substrate for artificial leather making can be applied as it is.

The microporous polyurethane porous layer 54 is a polyurethane porous layer in which a large number of uniform micropores are formed. The polyurethane used to form this layer is formed by reacting an isocyanate with a polyol mixture composed of a polyol and a chain extender. This will be described in detail below.

The skin layer 58 may be made of the same polyurethane as the polyurethane constituting the polyurethane porous layer 54 but may have a lower porosity than the polyurethane porous layer 54 to protect the polyurethane porous layer 54 It is possible.

The adhesive layer 56 serves as an optional layer for enhancing the adhesion between the polyurethane porous layer 54 and the skin layer 58 and may be made of a general adhesive used in the related art and may be formed of a polyurethane adhesive It is preferable to use a two-component type polyurethane adhesive to which a phosphorus-based, nitrogen-based flame retardant is added, from the viewpoint that flame retardancy of the artificial leather can be imparted.

The artificial leather 100 for a vehicle according to the present invention has a three-layer structure or a knitted fabric substrate 52 in which a knitted fabric substrate 52, a microporous polyurethane porous layer 54 and a skin layer 58 are laminated, A porous polyurethane porous layer 54, an adhesive layer 56, and a skin layer 58 are laminated.

In the artificial leather of the present invention, the average thickness of the knitted fabric substrate 52 is 0.15 to 0.25 mm, the average thickness of the polyurethane porous layer 54 is 0.15 to 0.25 mm, the skin layer 58 has an average thickness of 0.05 To 0.10 mm.

A method for manufacturing a synthetic leather for a vehicle according to another aspect of the present invention uses the method for manufacturing a synthetic resin base for a vehicle according to one aspect of the present invention or the bonding base material for manufacturing a synthetic leather for a vehicle according to another aspect of the present invention.

According to another aspect of the present invention, there is provided a method of manufacturing a synthetic leather for a vehicle, comprising the steps of: (a) treating at least one surface of a support with a release agent; (b) applying a binder onto the release agent treated surface of the support; (c) a knitted fabric base made of three denier yarns having a single yarn fineness of not more than 40 deniers is supplied onto the binder-coated surface of the support, and then the knitted fabric is pressed and bonded to the support, Obtaining a bond substrate; (d) forming a microporous polyurethane porous layer having micropores on the knitted fabric substrate side of the binding substrate; And (e) forming a skin layer on the surface of the polyurethane porous layer, wherein (d) the step of forming the microporous polyurethane porous layer and (e) the step of forming the skin layer or (e) peeling off the support from the knitted fabric substrate after the step of forming the skin layer.

In the method of manufacturing artificial leather for automobiles according to another aspect of the present invention, steps (a) to (c) correspond to a method of manufacturing a binding substrate for artificial leather for automobiles according to an aspect of the present invention, The details of these steps are replaced with the above description, and the steps (d) and (e) will be described in detail below.

In step (d), the microporous polyurethane porous layer 54 having micropores is formed on the side of the knitted fabric substrate 52 of the binding substrate obtained through steps (a) to (c). To this end, a first polyurethane resin coating liquid containing a polyurethane resin and an organic solvent capable of dissolving the polyurethane resin is applied on the side of the knitted fabric substrate 52 of the bonded substrate.

Specifically, the first polyurethane resin coating liquid may contain a polyurethane resin, a solvent, a pore-controlling agent, and a toner in a weight ratio of 100: 30 to 60: 0.5 to 2: 0.1 to 1: 5 to 15. The solvent may include at least one selected from the group consisting of dimethylformamide (DMF), ethyl acetate, tetrahydrofuran, ethylene glycol monoethyl ether and ethylene glycol monoethyl ether acetate, 30 to 60 weight ratio, preferably 100: 35 to 45 weight ratio. If the ratio is less than 30 parts by weight, the viscosity of the solution is too high to form uniform pores. If the ratio is more than 60 parts by weight, the viscosity of the solution is too low to precisely control the thickness. The solvent is preferably DMF.

The porosity regulator is for forming uniform pores in the polyurethane porous layer 54, and one or more selected from anionic polyurethane porosity regulator and nonionic polyurethane porosity regulator can be used. The amount of the polyurethane resin to be used may be 100: 0.5 to 2 by weight, preferably 100: 0.5 to 1.5 by weight, based on the polyurethane resin. If the weight ratio is less than 0.5, sufficient pores may not be formed in the polyurethane porous layer 54, and the pore size may be more than 2 by weight and non-uniform pores may be used.

The toner is a pigment that imparts the color of the polyurethane porous layer 54. The amount of the toner to be used may be 100: 5 to 15: 1 by weight, preferably 100: 7 to 12: 1 by weight based on the polyurethane resin. If the ratio is less than 5 parts by weight, it may be difficult to realize the color, and it may exceed 15 parts by weight and cause deterioration of the physical properties of the product.

In addition, the first polyurethane resin coating liquid may further include at least one selected from yellowing inhibitors, antioxidants, surfactants and blocking agents (specifically, methanol and ethanol) commonly used in the art.

The polyurethane resin can be produced by reacting a polyol, a chain extender, and a diisocyanate in a solvent. The polyol may include three kinds of polyols: a polyester-based polyol (weight average molecular weight: 1,000 to 6,000), a polyether-based polyol (weight average molecular weight: 1,000 to 6,000) and a polycarbonate-based polyol (weight average molecular weight: 1,000 to 6,000). The polyol is a polyester polyol, a polyether polyol and a polycarbonate polyol in a weight ratio of 10 to 60:20 to 80: 5 to 60, preferably 20 to 40:30 to 65:20 to 50, Is preferable in terms of hydrolysis resistance and chemical resistance. The polyol may further include one kind or two or more kinds of flame-retardant polyols such as a reaction-type phosphoric acid ester polyol and a polyether ester-type polyol which are free from generation of noxious gas during production of polyurethane and excellent in flame retarding effect. Thereby, it is possible to form the polyurethane porous layer 54 so as to have a good flame retardant performance without any additional step of separately adding a flame retardant by adjusting to a stable polyurethane structure.

The chain extender may be any of those commonly used in the art, and is not particularly limited, but it may be preferable to use a low molecular weight diol having an even number of repeating units, which is advantageous for increasing the degree of crystallization. Specifically, it may include at least one selected from ethylene glycol, propylene glycol, 1,4-butanediol, 1,6-hexanediol, and methylpentanediol. The amount of the chain extender is preferably 1 to 15 parts by weight, preferably 2 to 10 parts by weight, based on 100 parts by weight of the polyol. If it is used in an amount of less than 1 part by weight, heat resistance and adhesion may be deteriorated. If it is used in an amount exceeding 15 parts by weight, unreacted chain extender is excessively generated, which is uneconomical.

The solvent used for synthesizing the polyurethane resin may be a solvent commonly used in the art and is not particularly limited, but DMF, ethyl acetate, tetrahydrofuran, ethylene glycol monoethyl ether, Ethylene glycol monoethyl ether acetate, and ethylene glycol monoethyl ether acetate. The amount of the solvent to be used is preferably 150 to 350 parts by weight, preferably 200 to 300 parts by weight, more preferably 250 to 300 parts by weight based on 100 parts by weight of the polyol. When the amount is less than 150 parts by weight, the viscosity may be too high to increase the molecular weight. When the amount is more than 350 parts by weight, it may be difficult to synthesize a polyurethane resin having a proper viscosity and molecular weight.

The diisocyanate may be any of those commonly used in the art, and includes, but is not limited to, 4,4-diphenylmethane diisocyanate (MDI), modified MDI, hexamethylene diisocyanate (HDI), isophorone diisocyanate IPDI), dicyclohexylmethane diisocyanate (H ₁₂ MDI), and xylene diisocyanate (XDI). The use amount of the diisocyanate is preferably such that the NCO / OH ratio of the polyol and the diisocyanate is 0.95 to 1.05, preferably 1.0, from the viewpoint of increasing the molecular weight.

Thereafter, the result of coating the first polyurethane resin coating solution on the side of the knitted fabric substrate 52 of the bonded substrate is immersed in the coagulation bath to solidify the polyurethane resin coating layer. At this time, the polyurethane solution impregnated in the knitted fabric substrate 52 is solidified by the solvent exchange of the coagulating liquid, so that the polyurethane of the polyurethane solution is converted into the leather structure. Specifically, when the polyurethane impregnated woven fabric substrate 52 is immersed in the coagulating solution, the solvent of the polyurethane solution impregnated in the knitted fabric substrate 52, for example, DMF, is eluted as a coagulating solution, The urethane is solidified in the leather structure. The physical properties of the artificial leather structure formed by coagulation of the polyurethane of the polyurethane solution of the knitted fabric substrate 52 can be controlled by adjusting the composition of the coagulating liquid for solvent-exchanging the polyurethane-impregnated knitted fabric substrate 52. For example, when a coagulating solution for solvent-exchanging a polyurethane-impregnated woven fabric substrate 52 is used alone or in the form of a mixed coagulating solution formed by mixing water and DMF at a constant mixing ratio, By adjusting the mixing ratio between DMF, the physical properties of the artificial leather structure can be controlled.

When the polyurethane impregnated knitted fabric substrate 52 is impregnated with the coagulating solution as described above, the solvent of the polyurethane solution impregnated in the polyurethane impregnated woven fabric substrate 52, for example, DMF is eluted, and the polyurethane solution And the polyurethane solidified by the leather structure is brought into close contact with the polyurethane impregnated knitted fabric base material 52, whereby the shape of artificial leather can be obtained.

The polyurethane filled knit fabric 52 in the form of artificial leather is washed with water or naturally dried or dry-dried by hot air or the like to remove moisture or DMF remaining on the surface of the polyurethane filled knit fabric substrate 52, The urethane porous layer 54 can be formed.

The artificial leather for a vehicle using the knitted fabric substrate 52 configured as described above uses a knitted fabric knitted using polyester monofilament long fibers and highly-hydraulically-made polyester filament fibers, which are very inexpensive, , Manufacturing costs can be greatly reduced as compared with artificial leather produced using a microfibre material or a sea chart material as a base material.

In step (e), a skin layer 58 is formed on the surface of the microporous polyurethane porous layer 54. For this purpose, a second polyurethane resin coating liquid containing a polyurethane resin and a mixed solvent of an organic solvent capable of dissolving the polyurethane resin, for example, DMF and methyl ethyl ketone (MEK) is applied on a separate release paper And dried to form a skin layer. The second polyurethane resin coating solution is coated again on the skin layer, and the adhesive layer formed on the release paper and the microporous polyurethane porous layer 54 are pressed against each other and bonded. After the resultant is cured and aged in the combined state, the release layer is separated and a skin layer 58 may be formed on the surface of the microporous polyurethane porous layer 54. The second polyurethane resin coating liquid may further include an additive containing at least one selected from the group consisting of a polyurethane resin, a solvent and a dispersing agent, and a yellowing inhibitor, an antioxidant and a leveling agent.

In the artificial leather for automobiles of the present invention, the adhesive layer may be a general adhesive used in the art, and it is not particularly limited, but it is preferable to use a polyurethane adhesive, and preferably a phosphorus-nitrogen flame retardant It is preferable to use a two-component type urethane adhesive which is capable of imparting flame retardancy to an artificial leather.

(D) forming the microporous polyurethane porous layer, (e) forming the skin layer, or (e) forming the skin layer, 2) is peeled off from the knitted fabric substrate 52 and removed to obtain the artificial leather 100 for a vehicle according to another aspect of the present invention.

Hereinafter, the present invention will be described in more detail based on examples. However, the following examples are for illustrative purposes only and are not intended to limit the scope of the present invention.

Example  One

A tricot knitted fabric (elongation: about 75% to about 115%) having a weight of about 130 g / yd was produced (thickness: about 0.18 mm) using a nylon yarn having a single yarn fineness of 20 d (manufactured by Hyosung Corporation) The surface was brushed with a mosquito. Thereafter, the dyeing process was carried out using an ordinary acid dye to prepare a tricot knitted fabric 18. This was supplied to a continuous manufacturing system 50 of a bonded substrate for artificial leather making according to the invention shown in Fig.

A polyester wool yarn with a single yarn fineness of 250 d was used to produce a woven fabric having a mat density of 65x45 and a width of 60 inches. The woven fabric 10 was supplied to the manufacturing system shown in Fig. 1, (Asahi Guard AG-7135) was treated with a fluorinated water repellent agent and dried in the first drying furnace 14. Next, the woven fabric support 10 treated with the fluorine-based water repellent agent was coated with a water-soluble polyurethane (homogeneous chemical W-ACE 3004A) as a binder with a 250 mesh gravure roll 16.

The amount of the water-soluble polyurethane binder applied to the support on the basis of the dry weight: the ratio of the throughput of the fluorine-based water repellent agent release agent was adjusted to 1: 1.2.

A tricot knitted fabric 18 is supplied onto the binder coated surface of the woven fabric support 10 and then pressed to form a woven fabric support 10 and a tricot knitted fabric 18 which are then subjected to a second drying The kneaded base material 26 of the woven fabric support 10 and the tricot knitted fabric 18 was prepared by passing through a cylinder 22 and a cylinder dryer 24 of about 130 캜 and cutting both corners about 2 cm.

The bonded substrate 26 was immersed in a water bath having a water / DMF ratio of 7: 3 and then coated with a wet polyurethane (PU) coating solution (product name: MP 120K) according to a conventional procedure . The resultant was immersed in a coagulating solution having a water: DMF ratio of 7: 3 to coagulate the PU resin coating layer, and the resultant was washed with water again and dried to give a fine coat (18 in FIG. 1 or 52 in FIG. 2) A porous PU pore layer 54 was formed. Thereafter, the woven fabric support body 10 was peeled off.

Separately, the PU coating solution was coated on the release paper and dried to form a PU skin layer. The PU skin layer was further formed by applying the PU coating liquid on the microporous PU porous layer 54 as an adhesive, and then pressing the PU skin layer 58 on the microporous PU porous layer 54 and bonding the resultant to the dry lamination process. The resultant was cured and aged in the state where the PU skin layer 58 was formed, and then the release paper was separated to produce a synthetic leather 100 for a superframe vehicle having a thickness of about 0.40 mm.

Example  2

The artificial leather for super-coated vehicles was produced in the same manner as in Example 1 by using the tricot knitted fabric 18 and the bonded substrate 26 of the woven fabric support 10 and the tricot knitted fabric 18 was produced , A tricot knitted fabric having a weight of about 150 g / yd was prepared (thickness: about 0. 22 mm) by using a nylon yarn of 30 d of single yarn fineness (manufactured by Hyosung Co., Ltd.). Thus, an artificial leather 100 for a super-coated article having a thickness of 0.45 mm was produced.

Comparative Example  One

The artificial leather for super-coated vehicles was produced in the same manner as in Example 1 using the tricot knitted fabric 18, except that the woven fabric support 10 and the joint base 26 of the tricot knitted fabric 18 were not used Artificial leather for a superframe vehicle was made using only a tricot knitted fabric 18 made of a nylon yarn having a single yarn fineness of 20d manufactured in Example 1 and having a thickness of about 0.18 mm.

Specifically, the microporous PU porous layer was formed on the tricot knitted fabric 18 by the polyurethane impregnation process in the same manner as described in Example 1. However, since the strength of the tricot knitted fabric 18 was not sufficient, the tricot knitted fabric 18 was broken during the impregnation process and the process could not proceed.

Comparative Example  2

The artificial leather for super-coated vehicles was produced in the same manner as in Example 1 by using the tricot knitted fabric 18 and the bonded substrate 26 of the woven fabric support 10 and the tricot knitted fabric 18 was produced , A tricot knitted fabric having a weight of about 180 g / yd was prepared (thickness: about 0.25 mm) by using nylon yarn of 50 d of single yarn fineness (produced by Hyosung Co., Ltd.). Thus, an artificial leather 100 for a superfine article having a thickness of 0.58 mm was produced.

Comparative Example  3

Using the tricot knitted fabric 18, an artificial leather for super-coated vehicles was produced in the same manner as in Example 1, except that the bonding substrate 26 of the woven fabric support 10 and the tricot knitted fabric 18 was produced . However, the amount of the water-soluble polyurethane binder applied to the support on the basis of the dry weight: the ratio of the throughput of the fluorine-based water repellent agent release agent was changed to 1: 0.9. As a result, when the woven fabric support 10 was peeled off after the formation of the microporous PU pore layer 54, there was a problem in that the peeling did not proceed smoothly and the artificial leather partially peeled and was broken, .

Comparative Example  4

Using the tricot knitted fabric 18, an artificial leather for super-coated vehicles was produced in the same manner as in Example 1, except that the bonding substrate 26 of the woven fabric support 10 and the tricot knitted fabric 18 was produced . However, the amount of the water-soluble polyurethane binder applied to the support on the basis of the dry weight: the ratio of the throughput of the fluorine-based water repellent agent release agent was changed to 1: 2.2. As a result, when the microporous PU porous layer was formed on the tricot knitted fabric 18 using the polyurethane impregnation process according to the procedure described in Example 1, the woven fabric of the bonding substrate 26 The bonding between the support 10 and the tricot knitted fabric 18 is partially peeled off, so that the polyurethane impregnation process can not proceed smoothly.

Touch  evaluation

For the artificial leather for automobiles obtained in Examples 1-2 and Comparative Example 2, the touch feeling was evaluated according to the following evaluation criteria by hand touch.

◎: Very soft

○: Smooth

△: slightly stiff

X: Very hard

touch thickness Example 1 ◎ 0.40 mm Example 2 ◎ 0.45 mm Comparative Example 2 ○ 0.58 mm

Referring to Table 1, it can be seen that the thickness of the artificial leather of the vehicle manufactured using the bonding substrate according to the present invention is thinner and the touch feeling is smoother.

10: Support
12: Pretreatment device
14: First drying furnace
16: Gravure coating device
17: Binder coating liquid supply tank
18: knitting fabric
20: Compression roller
22: Second drying furnace
26: bonding substrate
50: Continuous manufacturing system of a bonded substrate for producing artificial leather according to the present invention
52:
54: microporous polyurethane porous layer
56: Optional adhesive layer
58: Skin layer
100: artificial leather for automobile

Claims (16)

Treating the at least one surface of the support with a releasing agent and then supplying the support;
Applying a binder onto the release agent treated surface of the support; And
A knitted fabric substrate consisting of three denier yarns having a single yarn fineness of not more than 40 deniers is supplied onto the binder-coated surface of the support, and then the knitted fabric substrate is compressed, and the support and the knitted fabric substrate are combined and joined, To obtain a bonded substrate of a base material for a vehicle. The method according to claim 1,
And drying the support before the step of applying the binder after the step of supplying the support after treating the releasing agent. The method according to claim 1,
And drying the bonded substrate of the support and the knitted fabric substrate after the step of joining and bonding the support and the knitted fabric substrate. The method of claim 3,
Further comprising the step of drying the bonding substrate after the step of drying the bonding substrate of the support and the knitted fabric substrate. The method according to claim 1,
Wherein the step of applying the binder onto the releasing agent-treated surface of the support is carried out by a gravure coating method. The method according to claim 1,
Wherein at least one side of the knitted fabric substrate is brushed. ≪ RTI ID = 0.0 > 11. < / RTI > The method according to claim 1,
Wherein the knitted fabric base is a highly elastic knitted fabric having a stretch ratio within a range of 60 to 120% at room temperature as a knitted fabric base made of three denier yarns having a single yarn fineness of 20 denier to 30 denier (2). The method according to claim 1,
Characterized in that the support is a high-fineness woven fabric having a low-density structure having a yarn monofilament fineness ranging from 200 d to 300 d and a low density structure having a tissue density ranging from 40 x 50 to 60 x 70 (b / inch) (2). The method according to claim 1,
Wherein the ratio of the amount of the binder to the amount of the release agent to the amount of the release agent is in a range of 1: 1 to 1: 2 based on the dry weight of the support. A support having at least one side treated with release agent;
A binder layer formed on the release agent treated surface of the support; And
And a knitted fabric substrate detachably joined to the support by the binder layer, the knitted fabric substrate comprising a three-denier yarn having a single yarn fineness of 40 denier or less. 11. The method of claim 10,
The support is characterized in that the support is a high-fineness and low-density woven fabric having a yarn monofilament fineness ranging from 200 d to 300 d and a low density structure having a tissue density ranging from 40 x 50 to 60 x 70 (b / inch) Binding substrate for manufacturing artificial leather for automobiles. Treating the at least one surface of the support with a releasing agent and then supplying the support;
Applying a binder onto the release agent treated surface of the support;
A knitted fabric substrate consisting of three denier yarns having a single yarn fineness of not more than 40 deniers is supplied onto the binder-coated surface of the support, and then the knitted fabric substrate is compressed, and the support and the knitted fabric substrate are combined and joined, Obtaining a bonded substrate of a substrate;
Forming a microporous polyurethane porous layer having micropores on the knitted fabric substrate side of the binding substrate; And
And forming a skin layer on the surface of the polyurethane porous layer,
Further comprising peeling and removing the support from the knitted fabric substrate between the step of forming the microporous polyurethane porous layer and the step of forming the skin layer or after the step of forming the skin layer, ≪ / RTI > 13. The method of claim 12,
Wherein forming the microporous polyurethane porous layer comprises:
A first polyurethane resin coating liquid containing a polyurethane resin and an organic solvent capable of dissolving the polyurethane resin is applied on the side of the knitted fabric base material of the binding substrate and the resultant is immersed in a coagulating solution to form a polyurethane resin coating layer Solidifying; And
And washing and drying the coagulated polyurethane resin coating layer to form the microporous polyurethane porous layer. 13. The method of claim 12,
The step of forming the skin layer may include:
Applying a second polyurethane resin coating solution containing a polyurethane resin and an organic solvent capable of dissolving the polyurethane resin on the release paper and drying to form a skin layer;
Applying the second polyurethane resin coating liquid again on the skin layer to bond the microporous polyurethane porous layer to the adhesive layer formed on the release paper, And
And curing and aging the resultant in the combined state, and separating the release paper. A knitted fabric substrate made of three denier yarns having a single yarn fineness of 40 denier or less as a knitted fabric base material;
A microporous polyurethane porous layer having micropores formed on the knitted fabric substrate; And
And a skin layer formed on the microporous polyurethane porous layer. 16. The method of claim 15,
Further comprising an adhesive layer between the microporous polyurethane porous layer and the skin layer.

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