KR20190129519A - manufacturing method of Artificial leather and artificial leather by using the same - Google Patents

Abstract

The present invention is artificial leather comprising a reverse layer, a skin layer, and a surface treatment layer from the bottom to the top. More specifically, in artificial leather for automobile interior materials, the present invention relates to: a method for manufacturing artificial leather in which the skin layer and the surface treatment layer can be manufactured in-line; and artificial leather manufactured from the same.

Description

Manufacturing method of artificial leather and artificial leather by using the same

The present invention is a rear layer from the bottom to the top; Skin layer; And an artificial leather comprising a surface treatment layer, in particular in artificial leather for automobile interiors, wherein the skin layer and the surface treatment layer can be manufactured in-line, and a method of manufacturing artificial leather It's about artificial leather.

As disclosed in Korean Patent Application Laid-Open No. 10-2017-0123431 (published: November 8, 2017) and the like, artificial leather has a laminated structure including a fabric layer, a foam layer, a label layer, and a surface treatment layer from below.

In this case, the foam layer and the label layer are formed in a sheet shape by performing a calendering process (hereinafter, 'first process'), and the surface treatment layer is subjected to a gravure coating process (hereinafter, 'secondary process'). Can be formed.

Specifically, the primary process speed is 30-50m / min, the secondary process speed is 10-15m / min and the primary process speed is about 2 to 5 times faster than the secondary process speed inline There was a difficulty in manufacturing.

Therefore, the inventors tried to adjust the secondary process speed to the primary process speed, but in this case, the elongation in the length (MD) direction of the artificial leather, which is the final product, was lowered or the contraction in the width (TD) direction was excessive. Alternatively, when the first process speed is matched with the second process speed, there is a disadvantage in that productivity is lowered.

KR 10-2017-0123431 A (published: November 8, 2017)

In order to solve the problems of the prior art as described above, the present invention satisfies the glossiness required as an artificial leather for automobile interior materials while maintaining mechanical properties, and can also be manufactured in-line artificial leather manufacturing method and artificial leather manufactured therefrom It aims to provide.

In order to achieve the above object,

The present invention provides a back layer and a transfer film preparing step (S1) for preparing a back layer and a transfer film, respectively;

A calendar molding step (S3) of passing the skin layer composition through a calender roll to form a skin layer;

A skin layer stacking step (S5) of stacking a skin layer on the back layer;

A preliminary heating step (S7) of heating the semi-finished product in which the back layer and the skin layer are laminated;

A surface treatment layer forming step of transferring the transfer film on the semi-finished product to form a surface treatment layer (S9); And

An embossing step (S11) of forming an embossed pattern on the surface treatment layer; It provides an in-line artificial leather manufacturing method comprising a.

In addition, the present invention provides an artificial leather produced from the artificial leather manufacturing method.

Artificial leather manufacturing method of the present invention can provide an artificial leather in-line has an excellent productivity effect.

Artificial leather manufactured according to the artificial leather manufacturing method of the present invention has the effect of satisfying the glossiness required as artificial leather for automobile interior materials, while maintaining mechanical properties.

1 is a flow chart showing an embodiment of the artificial leather manufacturing method according to the present invention.
Figure 2 is a side cross-sectional view showing a laminated structure of the transfer film of the present invention.
3 is a view showing a specimen for measuring tensile strength and elongation.

Hereinafter, the configuration and operation of the preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

Here, it should be noted that in adding reference numerals to the elements of each drawing, the same elements are denoted by the same reference numerals as much as possible even if they are shown on different drawings.

1 is a flow chart showing an embodiment of the artificial leather manufacturing method according to the present invention.

1, the present invention provides a back layer and a transfer film preparing step (S1) for preparing a back layer and a transfer film, respectively;

A calendar molding step (S3) of passing the skin layer composition through a calender roll to form a skin layer;

A skin layer stacking step (S5) of stacking a skin layer on the back layer;

A preliminary heating step (S7) of heating the semi-finished product in which the back layer and the skin layer are laminated;

A surface treatment layer forming step of transferring the transfer film on the semi-finished product to form a surface treatment layer (S9); And

An embossing step (S11) of forming an embossed pattern on the surface treatment layer; It relates to an artificial leather manufacturing method comprising a.

Hereinafter, each step will be described in detail.

Back layer and transfer film preparation step (S1)

The back layer and the transfer film preparing step S1 may be a step of preparing the back layer and the transfer film, respectively.

The back layer assists mechanical properties and serves to maintain the shape of the artificial leather and prevent wrinkles, and may include cotton, rayon, silk, polyolefin (for example, polyethylene, polypropylene, etc.), nylon, polyester, polyurethane, and the like. It may be a flexible polymer such as woven, nonwoven, knitted, plain weave, spunbond, etc. of the various composites based thereon, and may optionally further comprise natural fibers and / or synthetic fibers.

Preferably, the back layer may use a woven or nonwoven fabric containing cotton or rayon and polyester in a weight ratio of 30-40: 60-70 to easily secure mechanical properties such as strength and flame retardant properties.

When the polyester content exceeds the above range, combustibility, covering properties and workability may be reduced, and when the polyester content is below the above range, mechanical properties may be lowered and thus included in the above range.

In addition, the back layer may optionally be a coating layer formed on one surface in order to increase the peel strength with the skin layer to be described later.

Specifically, the artificial leather of the present invention can be used for the adsorption molding of the emboss using a vacuum during the embossing to be described later, in this case, unlike the case of molding the emboss using a press-type embossing roll does not press the semi-finished product at a large pressure Since the resin of the skin layer is not impregnated into the back layer, there may be a disadvantage in that the peel strength of the back layer and the skin layer is lowered. Therefore, the back layer of the present invention may be a coating layer formed on one surface thereof to selectively increase the peel strength with the upper skin layer.

The coating layer may be formed using, for example, one coating solution selected from an acrylic adhesive, a polyurethane adhesive, and polyvinyl chloride plastisol (Plastisol). However, the acrylic adhesive has a disadvantage in that the softness of the artificial leather is increased due to hardness after drying, and the touch is not soft. The polyurethane adhesive has a relatively high material cost, and thus, polyvinyl chloride plastisol can be used. have.

The microhardness is a local hardness for the micro specimens, such as about 0.5-1.0 mm thickness, immediately after the needle contacts the specimen using the Asker Micro Durometer, MD-1 capa under the indentation speed of 1 mm / s, that is, the load of the needle. It means the maximum value (peak hold) when the holding time is 1s.

The polyvinyl chloride plastisol may include 70-130 parts by weight of a plasticizer and 0.5-10 parts by weight of a curing agent based on 100 parts by weight of a polyvinyl chloride resin.

 Specifically, the polyvinyl chloride resin may be a mixed resin consisting of 60-90% by weight homopolymer of vinyl chloride and 10-40% by weight copolymer of vinyl chloride and vinyl acetate.

The vinyl chloride homopolymer is a paste polyvinyl chloride resin prepared by emulsion polymerization, and may be included in the mixed resin at 60-90% by weight or 65-85% by weight. If it is less than the above range may be less than the peel strength of the backing layer and the skin layer, if it exceeds the above range may be undesirable, such as smell may be included in the above range.

The copolymer of vinyl chloride and vinyl acetate is a resin that provides excellent adhesion to a backing layer that is a woven or nonwoven fabric, and the content of vinyl acetate in the copolymer may be included in an amount of 1-15 wt% or 3-10 wt%. If the adhesive strength is less than the above range may be slightly reduced peel strength of the back layer and the skin layer, and if it exceeds the above range may be included in the above range hydrolyzability may be lowered.

In addition, the copolymer of vinyl chloride and vinyl acetate may be included in 10-40% by weight or 15-35% by weight in the mixed resin. When the thickness is less than the above range, the peeling strength of the backing layer and the skin layer may be somewhat lowered, and when it exceeds the above range, mechanical properties such as heat resistance may be slightly lowered, and thus may be included within the above range.

The plasticizer may be at least one selected from a phthalate plasticizer, a terephthalate plasticizer, a benzoate plasticizer, a citrate plasticizer, a phosphate plasticizer and an adipate plasticizer.

In the present invention, it is preferable to use a terephthalate plasticizer which is environmentally friendly and excellent in heat resistance. For example, dioctyl terephthalate may be used as the terephthalate plasticizer, but is not limited thereto.

The plasticizer may be included in an amount of 70-130 parts by weight or 80-120 parts by weight based on 100 parts by weight of the polyvinyl chloride resin. If it is less than the above range, the viscosity of the coating solution may be increased, and workability may be lowered. If it exceeds the above range, the adhesive force may be lowered due to the transition phenomenon of the plasticizer, and thus may be included within the above range.

The curing agent may use a low temperature curing type curing agent to increase energy efficiency and productivity, and may use a block isocyanate curing agent in which part or all of the isocyanate groups are blocked with a blocking agent.

The blocking agent is phenol, ε-caprolactam, methyl ethyl ketone oxime, 1,2-pyrazole, diethyl malonate, diethyl malonate), diisopropylamine, triazole, imidazole and 3,5-dimethylpyrazole may be used. .

The block isocyanate curing agent blocks the isocyanate group to prevent the isocyanate group (-NCO) from reacting with the hydroxyl group (-OH) or the amino group (-NH) at room temperature. This increases and the curing reaction proceeds.

The dissociation temperature of the curing agent may be 100 ° C. or higher or 110-130 ° C.

The curing agent may be included in 0.5-10 parts by weight or 1-5 parts by weight based on 100 parts by weight of the polyvinyl chloride resin. If it is less than the above range, the peel strength of the back layer and the skin layer may be somewhat lowered due to the lowering of the crosslinking degree, and if it exceeds the above range, the unreacted curing agent may remain as an impurity and thus the usability may be lowered, so that it may be used within the above range. .

The coating solution may optionally further comprise one or more other additives selected from the group consisting of stabilizers, fillers, pigments, viscosity reducing agents and dispersants, if the content thereof does not affect the properties of the coating solution. There is no limit.

The thickness of the coating layer may be, for example, 1-10 μm or 2-5 μm. Here, the thickness of the coating layer means the thickness including the coating solution impregnated into the back layer. When the thickness of the coating layer is less than the range, the peeling strength of the back layer and the skin layer may be somewhat lowered. If the thickness exceeds the range, the microhardness of the artificial leather is increased so that the touch feeling is lowered, so that the thickness is within the range. Can be coated.

When the back layer is coated with the prepared coating solution, the peel strength of the back layer and the skin layer may have an excellent peel strength of 2.5-6kgf / 30mm, or 2.5-5.5kgf / 30mm.

In addition, the back layer may have a thickness of 0.4-0.7mm or 0.45-0.65mm, the mechanical strength is lowered if the thickness is less than the above range, and if the thickness exceeds the above range, a material cost may be increased. .

The transfer film 1 is a carrier film layer 10 from the bottom to the top; Release layer 20; And a coating layer 30 (see FIG. 2).

The carrier film layer 10 may include polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (polyethylene) Naphthalate, PEN), polybutylene naphthalate (PBN) and polyethylene terephthalate glycol (Polyethylene Terephthalate Glycol, PETG) film may be one film selected from the group consisting of, as a specific embodiment of the present invention price This inexpensive, it is possible to use a polyethylene terephthalate (PET) film excellent workability in the transfer process.

In addition, the carrier film layer 10 may be, for example, 20-80 μm or 30-60 μm thick. If it is less than the above range, when forming the release layer 20 and the coating layer 30 on the carrier film layer 10, a plurality of wrinkles and flow marks may occur, and if the above range exceeds the raw material value increases As a result, the winding volume may increase and workability may deteriorate, and a carrier film within the thickness range may be used.

The release layer 20 is formed on the carrier film layer 10 to facilitate peeling of the carrier film layer 10 after the transfer process, and to allow the manufactured artificial leather to have a matte property.

Specifically, the release layer 20 may be formed by applying and curing an acrylic composition having a matte property having releasability on top of the carrier film layer 10.

The acrylic composition may be an acrylic composition including 20 to 60 parts by weight of a matting agent based on 100 parts by weight of acrylic resin.

The quencher may be used in any known in the art, without limitation, may comprise 20-60 parts by weight or 30-50 parts by weight based on 100 parts by weight of the acrylic resin. If it is outside the content range, the glossiness of the manufactured artificial leather may be too high or low so that it may not be suitable for automobile interior materials and may be used within the content range.

The acrylic composition may include a gravure coating, a knife coating, a roll coating, a spray coating, a bar coating, a slot die coating on the carrier film layer 10, and It may be applied by one or more methods selected from the reverse coating method, but is not limited thereto.

Subsequently, the applied acrylic composition may be cured at a temperature of 100-150 ° C. to form a release layer.

The coating layer 30 may be formed by applying and drying a surface treating agent composition on the release layer 20. The coating layer 30 forms a surface treatment layer of artificial leather through a transfer process to be described later.

The surface treating agent composition may be an oily surface treating agent or an aqueous surface treating agent, but as an embodiment of the present invention, it is environmentally friendly and improves stain resistance, and simultaneously satisfies the Squeak Index and the dynamic friction coefficient, thereby providing a soft touch feeling and a seating feeling. An aqueous surface treatment agent which can be improved can be used.

More specifically, the surface treating agent composition may be a two-component aqueous surface treating agent including 100 parts by weight of the main ingredient, 1-25 parts by weight of the curing agent, 1-25 parts by weight of the aqueous solvent, and 1-15 parts by weight of the silicone compound.

The subject matter may be, but is not limited to, a polycarbonate based polyurethane resin dispersed in water.

The curing agent may include one or more functional groups selected from the group consisting of aziridine groups, isocyanate groups, and carbodiimide groups per molecule.

The silicone compound may be a liquid form in which the polysiloxane is dispersed in water or be a polysiloxane in the form of beads, but preferably, may be in a liquid form in which the polysiloxane is dispersed in water having a better surface feel.

When the content of the silicon compound is less than the above range, the antifouling property is lowered, and when the above range is exceeded, the surface texture is excessively slipped to minimize the Squeak Index, but it is not good enough to meet the dynamic friction coefficient of the appropriate level, so the seating is not good. Can be used within the content range.

In addition, the surface treating agent composition of the present invention may further comprise 0.1-0.5 parts by weight of antifoaming agent, 1-5 parts by weight of leveling agent and 2-7 parts by weight of matting agent for workability, physical properties, and suitable glossiness for automotive interior materials. And, may optionally further include one or more selected from the group consisting of urethane beads, acrylic beads and fluorinated wax.

By further comprising at least one selected from the group consisting of urethane beads, acrylic beads and fluorinated waxes, antifouling properties can be realized by hydrophobicity, and slippage can be further imparted by reducing the surface tension of the aqueous surface treatment agent. .

In addition, depending on the role of the surface treatment agent composition may further include at least one selected from surfactants, co-solvents, modifiers, matting agents, glossifiers and thickening agents, the type and content thereof are not particularly limited. Do not.

Since the method of applying the surface treating agent composition on the release layer 20 is the same as the method of applying the acrylic composition described above, overlapping descriptions will be omitted.

Subsequently, the coating agent 30 may be formed by drying the surface treatment composition applied on the release layer 20 at 110-150 ° C. or 130-150 ° C. for 80-120 seconds to evaporate an aqueous solvent.

The coating layer 30 may have a thickness of 4-30 μm or 4-20 μm. By maintaining the thickness of the coating layer within the above range it can be at the same time to ensure the stain resistance while maintaining the flexibility of the artificial leather. If the thickness is less than the range is too thin, durability can be lowered, if it exceeds the above range, the surface treatment agent composition may require a lot of material costs to increase the material cost can have a thickness within the above range.

Calendar molding step (S3)

The calender forming step (S3) may be a step of forming a skin layer by kneading the skin layer composition through a calender roll at 160-170 ° C.

The skin layer composition may include 60 to 120 parts by weight of a plasticizer and a pigment with respect to 100 parts by weight of polyvinyl chloride resin.

Specifically, the polyvinyl chloride resin included in the skin layer may use a straight polyvinyl chloride resin formed by suspension polymerization.

The polyvinyl chloride resin has an polymerization degree of 1000-3000 or 1200-2000, and has an polymerization degree within the above range, thereby having an excellent surface feel and ductility.

The plasticizer may be used at least one selected from the above phthalate plasticizer, terephthalate plasticizer, trimellitate plasticizer and epoxy plasticizer.

The phthalate-based plasticizer is a plasticizer having very high compatibility with the polyvinyl chloride resin, and for example, dibutyl phthalate, diethylhexyl phthalate, diisononyl phthalate, dipropylheptyl phthalate, diisodecyl phthalate, and butylbenzyl phthalate. It may be one kind, but preferably, isodecyl phthalate, which is a low volatility plasticizer, may be used.

The terephthalate plasticizer is an environmentally friendly plasticizer, for example dioctyl terephthalate may be used, but is not limited thereto.

The trimellitic plasticizer is a plasticizer having excellent volatility, oil resistance, and heat resistance, and may be, for example, one selected from triethylhexyl trimellitate, triisononyl trimellitate, and triisodecyl trimellitate, but is not limited thereto. It is not.

The epoxy plasticizer may be epoxidized soybean oil or epoxidized linseed oil, for example, by epoxidation of a double bond of an unsaturated fatty acid glycerol ester with hydrogen peroxide or peracetic acid, but is not limited thereto.

The plasticizer may be used 60-120 parts by weight, or 70-100 parts by weight based on 100 parts by weight of the polyvinyl chloride resin. If it is less than the above range, the workability and ductility may be lowered, and if it exceeds the above range, the bleeding phenomenon of the plasticizer may occur, and thus it may be used within the above content range to implement excellent ductility.

The pigment may be carbon black, but is not limited thereto.

The skin layer composition may further include a heat stabilizer, a flame retardant, or a filler for controlling melt strength and physical properties, and the content thereof is not limited unless it affects physical properties.

The thickness of the skin layer may be 250-600 μm, or 300-550 μm. If it is less than the above range, the surface smoothness and processability are lowered, and the material cost increases due to the increase in the amount of the pigment added to realize the color, and if it exceeds the above range, the cushioning feeling of the artificial leather is lowered and the material cost is thicker than necessary. Can take a lot.

In addition, the speed of the calender forming step (S3) may be 30-50m / min or 35-50m / min.

Skin layer lamination step (S5)

The skin layer stacking step S5 may be a step of thermally plywooding the skin layer on the back layer.

The thermoplywood may be performed at 150-180 ° C.

Preheating Step (S7)

The preliminary heating step (S7) may be a step of heating the semi-finished product laminated the back layer and the skin layer at 110-170 ℃ or 115-150 ℃. If it is less than the temperature range it may not be easy to laminate the semi-finished product and the transfer film, if it exceeds the temperature range may be changed in appearance such as melting of the skin layer can be carried out in the temperature range.

Surface treatment layer forming step (S9)

In the forming of the surface treatment layer (S9), the transfer film is placed on the preheated semifinished product and transferred by applying heat of 120-150 ° C., followed by removing the release layer and the carrier film layer to form a surface treatment layer on the semifinished product. It may be a step of forming.

That is, the coating layer 30 in the transfer film results in a surface treatment layer of artificial leather.

The speed of the surface treatment layer forming step (S7) may be 30-50m / min or 35-50m / min. The artificial leather manufacturing method of the present invention is similar to the calender forming step (S3) described above by forming a surface treatment layer by using a transfer process as described above bar can provide artificial leather in-line, so that the productivity is excellent effect have.

On the other hand, the surface treatment layer of the present invention is formed of a surface treatment agent composition containing a specific range of the silicone compound described above can satisfy the Squeak index and the dynamic coefficient of friction of artificial leather at the same time.

More specifically, the Squeak Index is a value of noise generated in friction between the artificial leather and the human body, that is, the occupant, the Squeeze Index of the artificial leather of the present invention may be less than 0.15, or less than 0.14.

As the Squeak Index satisfies the above range, the noise may be less and the touch of artificial leather may be soft, and if it exceeds the above range, the noise is severe and the stick slip characteristic, which is a friction phenomenon accompanied by vibration, is strong. The quick index may be in the range.

The Squeak Index is a universal testing machine (UTM) using a universal testing machine (UTM) to pile up the artificial leather specimens up and down, pressing down with a weight of 4.5Kg, the force deviation (△ F) and the average force required to pull at a speed of 100mm / min By measuring (Fa), the Squeak index can be calculated by ΔF / Fa.

The coefficient of dynamic friction (μ) is to hold the slip when the object is in sliding contact with other objects, the dynamic friction coefficient of the artificial leather of the present invention may be 0.2-0.5 or 0.25-0.5.

If the coefficient of dynamic friction is less than the range it is not possible to hold the slip, the seating is not good and if the range exceeds the range, because the Squeak index is increased by friction between the artificial leather and the occupant may be within the range .

The coefficient of kinetic friction is measured by the average force (Fa) required to squeeze the artificial leather specimens up and down by using a universal testing machine, and to pull at a weight of 300 kg / min by pressing the weight of 4.5 kg (W). Can be measured.

In addition, the surface crosslinking density of the surface treatment layer is 70-98%, or 75-95% by ensuring the surface crosslinking density in the above range, contaminants do not penetrate the surface treatment agent may have excellent antifouling properties.

The surface crosslinking density was measured by weighing artificial leather specimens up to 1 mg in chemical balance (m1) and then placing them on a container made of mesh or perforated metal plate, and then leaving the container in boiling xylene or decahydro naphthalene for 6-8 hours. . Thereafter, the container with the residue is taken out of a boiling solvent, cooled to room temperature and dried, and the residual amount (m2) is weighed to 1 mg and calculated as m2 / m1 x100.

In addition, the surface tension of the surface treatment layer is 90-130 ° or 95-120 ° by maintaining the surface tension in the above range, it may have excellent antifouling properties compared to the surface treatment layer formed of an oil-based surface treatment agent.

When the surface tension is applied to the artificial leather using a pen (dyne pen) containing a liquid having a specific tension of 20˚ to 60˚, if the tension of the liquid is greater than the surface tension of the artificial leather, the liquid does not spread. When the tension is less than the surface tension of the artificial leather, the liquid spreads flat and spreads well. At this time, the internal tension of the solution was measured to show the surface tension (dyne test). .

Embossing step (S11)

The embossing step (S11) may be a step of forming an embossed pattern by using a compression embossing roll or a vacuum adsorption embossing roll on the skin layer and the surface treatment layer.

When the embossed pattern is formed by using the compressed embossing roll, the skin may be irradiated to the top of the skin layer and the surface treatment layer, and may be performed under a pressure of 1-5Mpa or 2-4Mpa.

In addition, in the case of forming the embossed pattern using the vacuum adsorption embossing roll, it may be performed under a vacuum pressure of 0.02-0.08Mpa, or 0.04-0.07Mpa after irradiating infrared rays on the skin layer and the surface treatment layer.

The infrared irradiation step is a step of irradiating infrared rays for 5-15 seconds or 10-15 seconds at 150-180 ℃ to the surface of the semi-finished product on which the surface treatment layer is formed, the skin layer and the surface when irradiating infrared rays under the temperature and time Embossing is not well formed in the embossing step to be described later because the treatment layer is not softened, and when irradiated with infrared rays exceeding the temperature and time, the skin layer and the surface treatment layer may melt, and thus infrared rays may be irradiated within the time. .

Artificial leather manufacturing method of the present invention can provide an artificial leather in-line has an excellent productivity effect.

The present invention also relates to an artificial leather produced from the artificial leather manufacturing method.

Artificial leather of the present invention is the back layer sequentially from below; Skin layer; Surface treatment layer; And embossed pattern; may include.

In addition, the glossiness of the artificial leather of the present invention is 0.5-1.3 or 0.8-1.1, it may have a glossiness suitable for artificial leather for automotive interior materials.

The glossiness is made of artificial leather 100mm x 100mm specimens, L (brightness): 20-25, a (+ a * is a red value, -a * is a green value): ± 0.1 ~ 1.0 , b (+ b * value is yellow value, -b * value is blue value): The light was shot at an incidence angle of 60 ° under the condition of ± 0.1 to 1.0 and measured with a glossmeter.

The artificial leather of the present invention may be artificial leather for automotive interior materials, more specifically, instrument panel, door trim, dashboard, console box, arm rest, head rest, filler trim, head liner, glove box trunk cover trim or steering It may be an artificial leather for automobile interior material used for the wheel cover.

Artificial leather manufactured according to the artificial leather manufacturing method of the present invention has the effect of satisfying the glossiness required as artificial leather for automobile interior materials, while maintaining mechanical properties.

Hereinafter, preferred examples are provided to aid the understanding of the present invention, but the following examples are merely for exemplifying the present invention, and it will be apparent to those skilled in the art that various changes and modifications can be made within the scope and spirit of the present invention. It is natural that such variations and modifications fall within the scope of the appended claims.

EXAMPLE

1. Manufacture of artificial leather

Example

(1) back layer and transfer film preparation step

A backing layer having a thickness of 0.6 mm, which is a woven fabric containing cotton or rayon and polyester in a weight ratio of 30-40: 60-70, is prepared.

In addition, after the gravure coating of the acrylic composition on the carrier film layer is a polyethylene terephthalate film having a thickness of 38-50㎛ and cured at 140 ℃ to form a release layer, the gravure coating on top of the release layer again an aqueous surface treatment agent After drying at 140 ℃ to form a coating layer of 15㎛ thickness carrier film layer from the bottom to the top; Release layer; And prepare a transfer film laminated the coating layer.

At this time, the aqueous surface treatment agent 5 parts by weight of the curing agent (XR-78-017, Stahl) based on 100 parts by weight of the water-dispersed polycarbonate polyurethane resin (WF-13-549, Stahl), aqueous solvent ( 15 parts by weight of water and 20 parts by weight of isopropyl alcohol) and 5 parts by weight of a silicone compound (HM-13-118, Stahl).

(2) calendar forming step

Phthalate plasticizer ^① (DIDP, LG Chemical) 90 parts by weight, epoxy plasticizer ^② (Woochang Industry) 5 parts by weight and pigment based on 100 parts by weight of a straight polyvinyl chloride resin (LS130S, LG Chemical) having a degree of polymerization After kneading the skin layer composition comprising a, pass through a calender roll of 160-170 ℃ to form a skin layer 350-500㎛ thickness.

(3) skin layer stacking step

Subsequently, the skin layer is placed on top of the back layer, and heat is applied at 170-180 ° C. to thermally laminate.

(4) preheating step

The semi-finished product in which the back layer and the skin layer are laminated is preheated at 120-150 ° C.

(5) surface treatment layer forming step

The transfer film was placed on top of the preheated skin layer and heat was applied at 120-150 ° C., and then the carrier film layer and the release layer were removed to have a thickness of 15 μm on the skin layer (coating layer). ) Was formed.

(6) embossing step

Subsequently, the back layer; Skin layer; After irradiating infrared light at 150-180 ° C. for 14 seconds on a semi-finished product having a surface treatment layer laminated thereon, an embossed pattern was formed on the skin layer and the surface treatment layer under a pressure of 4 Mpa by using a compression embossing roll to manufacture artificial leather. It was.

Comparative example

(1) back layer preparation stage

A backing layer having a thickness of 0.6 mm, which is a woven fabric containing cotton or rayon and polyester in a weight ratio of 30-40: 60-70, is prepared.

(2) calendar forming step

Pre-foaming layer composition comprising 85 parts by weight of a plasticizer, 6 parts by weight of foaming agent, and 2 parts by weight of heat stabilizer, and polyvinyl chloride resin having a degree of polymerization of 100 parts by weight of polyvinyl chloride resin (LS100, LG Chemical Co., Ltd.) having a degree of polymerization of 1000. After kneading the skin layer composition containing 95 parts by weight of the plasticizer and the pigment with respect to 100 parts by weight, respectively, it was passed through a calender roll at 160-170 ° C. to form a prefoam layer having a thickness of 0.3 mm and a thickness of 150 μm, respectively. .

(3) back layer; Pre-foaming layer; Skin layer stacking step

Subsequently, the backing layer was thermally laminated at the bottom of the pre-foaming layer at 150-180 ° C., and then the skin layer was thermally laminated at the 150-180 ° C. on the top of the pre-foaming layer in which the backing layer was laminated.

(4) foaming step

Subsequently, the back layer; Pre-foaming layer; The back layer by passing the semi-finished product laminated skin layer through an oven at 220 ℃ foaming the pre-foaming layer; Foam layer; The semi-finished product in which the skin layer was laminated was prepared.

(5) surface treatment layer forming step

Gravure coating on the preheated skin layer using a gravure coating to give a two-component oil-based surface treatment agent containing 95% by weight of urethane acrylate and 5% by weight of methylene dicyclohexyl diisocyanate as a curing agent. A layer was formed.

(6) embossing step

Subsequently, the back layer; Foam layer; Skin layer; And irradiating infrared light at 150-180 ° C. for 14 seconds on the semi-finished product having the surface treatment layer laminated thereon, and forming embossed patterns on the skin layer and the surface treatment layer under pressure of 4 Mpa by using a press-type embossing roll. Prepared.

Reference Example

Except for preparing a transfer film containing no release layer in (1) was prepared artificial leather in the same composition and method as in the embodiment.

2. Speed measurement of artificial leather

When manufacturing the artificial leather of the above Examples, Comparative Examples and Reference Examples, the speed of each calendering process (primary process) and surface treatment layer forming process (secondary process) was measured and the results are shown in Table 1 below. It was.

Example Comparative example Reference Example Primary process speed (m / min) 50 50 50 2nd process speed (m / min) 50 15 50

As confirmed in Table 1, the embodiment and the reference example in which the surface treatment layer was formed using the transfer film are similar in speed to the calendering process (primary process) and the surface treatment layer forming process (secondary process). While it is possible to manufacture artificial leather inline, the comparative example confirms that the first process speed is about 3.3 times faster than the second process speed, making it impossible to manufacture artificial leather inline.

In other words, the embodiment according to the artificial leather manufacturing method of the present invention can be produced in-line artificial leather can be confirmed that the productivity is excellent.

3. Measurement of physical properties of artificial leather

Glossiness, tensile strength and elongation of the artificial leather of Examples, Comparative Examples and Reference Examples prepared above were measured and the results are shown in Table 2 below.

-Glossiness is made of artificial leather 100mm x 100mm, L (brightness): 20-25, a (+ a * is red, -a * is green): ± 0.1 ~ 1.0 , b (+ b * value is yellow value, -b * value is blue value): Measured using a glossmeter (BYK, Micro-TRI-gloss) by shooting light at an angle of incidence of 60 ° under conditions of ± 0.1 to 1.0 It was.

The tensile strength and elongation of the specimen of Figure 3 in the transverse, longitudinal direction of each of the five to draw a mark (ℓ) in 100mm length, after being bitten by a tensile testing machine (Universal Testing Machine, UTM) speed of 200mm / min Obtain the maximum weight when the specimen breaks by tension.

Elongation is calculated according to the following equation.

[Equation 1]

L = (L ₁ -L ₀ ) / L ₀ X 100

(However, L: elongation (%), L ₀ : distance between the marks before the test, L ₁ : distance between the marks when the skin or bubble (back layer) is broken after the test)

Example Comparative example Reference Example Glossiness 0.8 0.8 70-90 Tensile strength (kgf / 30mm) L 33.25 31.26 30.65 W 20.54 22.35 21.49 % Elongation L 57.56 48.28 53.1 W 168.27 170.2 165.45

As confirmed in Table 2, the artificial leather of the embodiment according to the artificial leather manufacturing method of the present invention, while securing the mechanical properties similar to the artificial leather of the comparative example in which a surface treatment layer was formed using a conventional gravure coating, for automotive interior materials It can be confirmed that the glossiness required as an artificial leather is satisfied.

On the other hand, the reference example was confirmed that the transfer film does not contain a release layer, artificial leather after the transfer process exhibited a high gloss due to the high gloss PET film, it was confirmed that it is not preferable as artificial leather for automotive interior materials.

Through the data of Table 1 and Table 2, the embodiment according to the present invention can satisfy the glossiness required as the artificial leather for automobile interior materials while maintaining mechanical properties, and can be manufactured in-line, thus providing excellent productivity.

1: transfer film 10: carrier film layer
20: release layer 30: coating layer

Claims (16)

A back layer and a transfer film preparing step of preparing a back layer and a transfer film, respectively (S1);
A calendar molding step (S3) of passing the skin layer composition through a calender roll to form a skin layer;
A skin layer stacking step (S5) of stacking a skin layer on the back layer;
A preliminary heating step (S7) of heating the semi-finished product in which the back layer and the skin layer are laminated;
A surface treatment layer forming step of transferring the transfer film on the semi-finished product to form a surface treatment layer (S9); And
An embossing step (S11) of forming an embossed pattern on the surface treatment layer; In-line artificial leather manufacturing method comprising a. The method of claim 1,
The back layer and the back film in the transfer film preparation step (S1) is a synthetic leather manufacturing method that is a woven or non-woven fabric containing cotton or rayon and polyester in a weight ratio of 30-40: 60-70. The method of claim 1,
In the back layer and the transfer film preparing step (S1), the transfer film is a carrier film layer from the bottom to the top; Release layer; Artificial leather manufacturing method comprising a coating layer. The method of claim 3,
The carrier film layer is artificial leather manufacturing method of one kind selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate and polyethylene terephthalate glycol film. The method of claim 3,
The release layer is artificial leather manufacturing method formed by coating and curing the acrylic composition. The method of claim 5,
The acrylic composition is artificial leather manufacturing method comprising 20 to 60 parts by weight of a matting agent with respect to 100 parts by weight of acrylic resin. The method of claim 3,
The coating layer is artificial leather manufacturing method formed by applying and drying the surface treatment agent composition on the release layer. The method of claim 7, wherein
Wherein the surface treatment agent composition is a two-component aqueous surface treatment agent comprising a composition 100 parts by weight, 1-25 parts by weight of a curing agent, 1-25 parts by weight of an aqueous solvent and 1-15 parts by weight of a silicone compound. The method of claim 1,
Speed of the calender forming step (S3) is artificial leather manufacturing method that is 30-50m / min. The method of claim 1,
Speed of the surface treatment layer forming step (S7) is 30-50m / min artificial leather manufacturing method. The method of claim 1,
Artificial leather manufacturing method further comprises an infrared irradiation step before the embossing step (S11). The method of claim 1,
The embossing step (S11) is a synthetic leather manufacturing method to form an embossed pattern using a compression type embossing roll or vacuum embossing roll. Artificial leather manufactured according to the artificial leather manufacturing method of any one of claims 1 to 12. The method of claim 13,
Squeeze index of the artificial leather is less than 0.15, the coefficient of kinetic friction is 0.2-0.5 artificial leather. The method of claim 13,
The artificial leather has L (brightness): 20-25, a (+ a * is red value, -a * is green value): ± 0.1 ~ 1.0, b (+ b * value is yellow value, -b * is blue color Value): Artificial leather, wherein the glossiness measured by a glossmeter by shooting light at an angle of incidence of 60 ° under a condition of ± 0.1 to 1.0 is 0.5-1.3. The method of claim 13,
The artificial leather is artificial leather for car interior materials.

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