KR20200141844A - Artificial leather for vehicle interior material and method for manufacturing the same - Google Patents

Abstract

The present invention relates to artificial leather for a vehicle interior material and a manufacturing method thereof. According to the present invention, the artificial leather for a vehicle interior material comprises: a 3D spacer fabric including first and second fabric layers and a spacer layer connecting the first and second fabric layers to form a 3D structure; and a surface layer including an effect layer disposed on the first fabric layer and a surface treatment layer disposed on the effect layer. According to the present invention, the artificial leather can simplify processes, can block odors caused by ammonia (NH_4) gas to remove the smell of vehicle seats, can increase durability to solve a problem that a vehicle interior material is sunk or deformed even when used for a long period of time, and can increase flexibility to solve a problem of occurrence of wrinkles.

Description

Artificial leather for interior materials in automobiles and its manufacturing method {ARTIFICIAL LEATHER FOR VEHICLE INTERIOR MATERIAL AND METHOD FOR MANUFACTURING THE SAME}

The present invention relates to artificial leather for automobile interior materials and a method for manufacturing the same, and in more detail, the process can be simplified, and odors from ammonia (NH ₄ ) gas can be blocked to remove the odor of the vehicle seat, and durability By improving the problem of turning off or deforming even when used for a long period of time, it relates to an artificial leather for automobile interior that can improve the problem of wrinkles by improving flexibility and a manufacturing method thereof.

In general, the interior of a vehicle is recognized as a second residential space, and in recent years, functional seats are in the spotlight for comfortable and comfortable driving in such an interior space of a vehicle.

As such materials for automobile interior materials, artificial leather such as natural leather, polyvinyl chloride, and polyurethane is widely used.

Specifically, the conventional artificial leather for automobile interior materials includes a foam layer, a cover layer, and a surface treatment layer on a polyurethane foam as disclosed in Korean Patent Registration No. 1450604 (Registration Date: October 23, 2014). It is made of a laminated structure.

The foam layer and the cover layer are mainly made of polyvinyl chloride or polyurethane, and are laminated to a predetermined thickness through a calendering or casting process. Then, while going through the foaming process, the foamed layer is foamed and molded at a certain magnification.

However, when the foam layer and the cover layer made of polyvinyl chloride or polyurethane are to be formed on the polyurethane foam through a calendering or casting process, an additional process of laminating the polyurethane foam is required. When flame laminating is used, ammonia (NH ₄ ) gas generates odor.

In addition, the polyurethane foam has an open pore (open cell) structure and is deformed when used for a long period of time so that the car seat is turned off or has a problem of wrinkles due to poor flexibility.

Korean Patent Registration No. 1450604 (Registration Date: October 23, 2014)

It is an object of the present invention to provide an artificial leather for automobile interior materials with improved durability, no problem of being turned off or deformed even when used for a long period of time, excellent flexibility and no wrinkles, and improved surface smoothness, adhesion and ductility.

Another object of the present invention is to simplify the process by eliminating the additional process of laminating polyurethane foam, and to block odors caused by ammonia (NH ₄ ) gas generated when using flame laminating It is possible to remove the smell of the sheet, and even when the foam layer and the cover layer are formed by applying the casting method, the surface defect problem caused by the permeation of the surface structure of the three-dimensional spacer fabric can be improved. It is to provide a method of manufacturing artificial leather.

According to an embodiment of the present invention, comprising a spacer layer for forming a three-dimensional structure by connecting the first fabric layer and the second fabric layer spaced apart, and the first fabric layer and the second fabric layer with a spacing thread. An artificial leather for automobile interior material comprising a 3D spacer fabric and a surface layer including a surface layer including a surface layer disposed on the first fabric layer of the 3D spacer fabric, and a surface treatment layer disposed on the cover layer. to provide.

The first fabric layer may include meshes between stitch places of threads, and the size of the meshes of the first fabric layer may be 0.01 mm to 1.5 mm.

The artificial leather for automobile interior material may have a surface smoothness (S) represented by Equation 1 below of -0.1 mm to +0.1 mm.

[Equation 1]

Surface smoothness (S) = H ₁ -H ₂

H ₁ (unit: mm) = total height of artificial leather passing through any one of the intersections of the threads of the first fabric layer

H ₂ (unit: mm) = total height of artificial leather passing through any one of the meshes of the first fabric layer

The cover layer may be formed by a casting method.

The thickness of the surface layer may be 0.01 mm to 1.5 mm.

The second fabric layer may include meshes between stitch places of threads, and the size of the meshes of the second fabric layer may be 0.01 mm to 3.5 mm.

The ratio of the elongation of the first fabric layer and the elongation of the second fabric layer may be greater than 1:1 to 1:10 or less.

According to another embodiment of the present invention, the first fabric layer and the second fabric layer are spaced apart, and a spacer layer for forming a three-dimensional structure by connecting the first fabric layer and the second fabric layer with a spacing thread. Preparing a 3D spacer fabric to perform, preparing a surface layer including a label layer and a surface treatment layer positioned on the label layer, and laminating the surface layer and the 3D spacer fabric It provides a method of manufacturing an artificial leather for automobile interior material comprising the step of.

The first fabric layer may include meshes between stitch places of threads, and the mesh size of the first fabric layer may be 0.01 mm to 1.5 mm.

The cover layer may be formed by a casting method.

The artificial leather for automobile interior material of the present invention and its manufacturing method can simplify the process by eliminating the additional process of laminating the polyurethane foam by replacing the polyurethane foam with a three-dimensional spacer fabric, and the flame When laminating is used, the odor of the car seat can be removed by blocking the odor caused by the ammonia (NH ₄ ) gas, and the durability is improved to improve the problem of turning off or deformed even when used for a long period of time, and the flexibility is improved to prevent wrinkles. Problems that arise can be improved.

In addition, by improving the surface weave structure of the 3D spacer fabric while applying the 3D spacer fabric, when the foam layer and the label layer are formed by applying a casting method, the surface weave structure of the 3D spacer fabric is transmitted. There is also an additional effect of improving the surface defect problem that occurs and improving adhesion and ductility.

1 is an exploded perspective view showing artificial leather for automobile interior materials.
2 is a plan view showing an example of a first fabric layer or a second fabric layer.
3 is a process chart showing a manufacturing method of artificial leather for automobile interior materials.

Hereinafter, the present invention will be described in more detail.

The artificial leather for automobile interior according to an embodiment of the present invention comprises a 3D spacer fabric, and a surface layer including a label layer positioned on the three-dimensional spacer fabric and a surface treatment layer positioned on the label layer. Include.

1 is an exploded perspective view showing the artificial leather for automobile interior material. Hereinafter, the artificial leather 100 for automobile interior materials will be described in detail with reference to FIG. 1.

The artificial leather for automobile interior material 100 includes a three-dimensional spacer fabric 10 and a surface layer 30 positioned on the three-dimensional spacer fabric 10. The surface layer 30 includes a back cover layer 34, a cover layer 32 positioned on the back cover layer 34, and a surface treatment layer 33 positioned on the cover layer 32.

The three-dimensional spacer fabric 10 is a part in contact with the automobile frame side, secures mechanical properties of the artificial leather 100 for automobile interior materials, and serves to maintain the shape of the artificial leather 100 for automobile interior materials and prevent wrinkles. It is the layer that performs.

The three-dimensional spacer fabric 10 replaces the polyurethane foam used as the fabric layer of the existing artificial leather, and through this, the durability of the fabric layer is further improved to eliminate the problem of being turned off or deformed even when used for a long time. It can improve and improve the flexibility to improve the problem of wrinkles. In addition, the three-dimensional spacer fabric 10 has an advantage of having a constant thickness, excellent mechanical properties such as strength, high dimensional stability, and not being deformed by heat and pressure.

Specifically, the 3D spacer fabric 10 is spaced apart from the first fabric layer 11 and the second fabric layer 12, and between the first fabric layer 11 and the second fabric layer 12 And a spacer layer 13 located at.

The spacer layer 13 is made of knitted spacing threads, the knitted spacing threads connecting the first fabric layer 11 and the second fabric layer 12, and they Supports to maintain the three-dimensional structure and maintains.

The knitted spacing yarns are knitted in a three-dimensional network structure so that they have sufficient compressive strength, cushioning properties, and very good recovery behavior, have high air permeability, and can generate very high flexibility.

The 3D spacer fabric 10 having such a structure may be woven through a Double Raschel knitting machine, a Moqqette knitting machine, or a Circular Knit machine, and accordingly, the 3D spacer fabric (10) is also referred to as 3D mesh fabric, Double Racelle 3D mesh fabric, DNB 3D mesh fabric, and DNB spacer fabric.

For example, the spacer layer 13 is made of at least one thread, and an empty space portion is formed in a portion where the thread is not formed. In this case, the thread may have a zigzag shape, and the zigzag shape is a'V' shape, In the present invention, any type that can prevent the three-dimensional spacer fabric 10 from being collapsed and provide a cushioning feeling, such as a'U' shape or an arc shape, can be applied in the present invention.

As an example, the spacer thread may be formed of monoyarn made of polyester, and the fineness of the spacer thread may be 20 dtex to 110 dtex. In this case, since the mono yarn has a greater strength than the multiyarn of the same fineness, it may be particularly advantageous to improve the restoration effect of the 3D spacer fabric 10.

Meanwhile, the first fabric layer 11 and the second fabric layer 12 are knitted fabrics or woven fabrics, and are not limited in the present invention as long as they are fabrics made of yarns. As the first fabric layer 11 and the second fabric layer 12 are made of threads, they may include meshes of a predetermined size between stitch places of the threads.

2 is a plan view showing an example of the first fabric layer 11 or the second fabric layer 12. Referring to FIG. 2, the first fabric layer 11 or the second fabric layer 12 includes meshes 113 that are holes having a predetermined size between intersections 112 of the threads 111.

However, when the size of the mesh 113 of the first fabric layer 11 is too large, the surface structure of the three-dimensional spacer fabric 10 penetrates the surface of the artificial leather 100 for automobile interior material Bad problems may occur.

In particular, this problem is more problematic when the thickness of the surface layer 30 is thin, such as when the cover layer 32 and the cover back layer 34 are formed by applying a casting method, and the foam layer is not included. Can be.

Accordingly, in the present invention, when the cover layer 32 and the cover back layer 34 are formed by applying a casting method by improving the surface weaving structure of the 3D spacer fabric 10, the 3D spacer fabric ( This is to improve the problem of surface defects caused by the penetration of the surface structure of 10).

That is, the size of the mesh 113 of the first fabric layer 11 may be 0.01 mm to 1.5 mm, and specifically 0.05 mm to 1.0 mm. When the size of the mesh 113 of the first fabric layer 11 exceeds 1.5 mm, a surface defect problem may occur due to the penetration of the surface weaving structure of the three-dimensional spacer fabric 10, and if it is less than 0.01 mm Air permeability of the 3D spacer fabric 10 may be reduced.

As the present invention improves the surface weaving structure of the three-dimensional spacer fabric 10 as described above, the artificial leather for automobile interior material 100 has a surface smoothness (S) represented by Equation 1 below -0.1 mm to It may be + 0.1 mm, specifically-0.05 mm to + 0.05 mm.

[Equation 1]

Surface smoothness (S) = H ₁ -H ₂

H ₁ (unit: mm) = total height of artificial leather passing through any one of the intersections of the threads of the first fabric layer

H ₂ (unit: mm) = total height of artificial leather passing through any one of the meshes of the first fabric layer

In Equation 1, the total height of the artificial leather 100 is the uppermost end of the artificial leather 100 from the surface with the artificial leather 100 on a flat surface (for example, the surface of the surface treatment layer 33) It means the height of up to, and the total height of the artificial leather passing through the intersection or the mesh of the first fabric layer 11 is the artificial leather passing vertically through the intersection of the first fabric layer 11 or the mesh from the flat surface. It means the total height of 100.

At this time, the effect of improving the surface smoothness (S) of the artificial leather 100 for automobile interior material by improving the surface weaving structure of the three-dimensional spacer fabric 10 is the cover layer 32 and the cover back layer ( 34) is formed by a casting method, and can be maximized when the thickness of the surface layer 30 is 0.01 mm to 1.5 mm, and specifically 0.02 mm to 1.0 mm.

Meanwhile, the size of the mesh of the second fabric layer 12 may be 0.01 mm to 3.5 mm, and specifically 0.05 mm to 3.0 mm. When the size of the mesh of the second fabric layer 12 is within the above range, the second fabric layer 12 has a greater elongation than the first fabric layer 11 and has a greater elastic recovery force. , When using the artificial leather 100 for automobile interior material for a long period of time, it is possible to improve the problem of occurrence of folding wrinkles.

Accordingly, the ratio of the elongation of the first fabric layer 11 and the elongation of the second fabric layer 12 may be greater than 1:1 to 1:10 or less, and specifically, greater than 1:1 to 1:5 or less. I can. At this time, the elongation is measured with a load of 100 N according to ISO 13934-1.

Meanwhile, the total thickness of the 3D spacer fabric 10 may be 1 mm to 20 mm, specifically 2 mm to 15 mm, and the total thickness of the 3D spacer fabric 10 is less than 1 mm Mechanical strength may be deteriorated, and if it exceeds 20 mm, material costs may be unnecessarily required as it is formed thicker than necessary.

The cover layer 32 serves to secure the surface smoothness of the artificial leather 100 for automobile interior materials and provide color, and may be manufactured using a casting method, and accordingly, polyvinyl chloride (PVC ) It may be made of resin or polyurethane (PU) resin.

The polyvinyl chloride resin may be a straight polyvinyl chloride resin formed by suspension polymerization. The polyvinyl chloride resin may have a degree of polymerization of 1250 to 3000, and specifically 1250 to 2000. When the degree of polymerization of the polyvinyl chloride resin is less than 1250, it may be difficult to form the cover layer 32 using a casting method, and when it exceeds 3000, ductility may decrease.

The polyurethane resin may be prepared by polymerizing a polycarbonate diol, a polyether diol or a diol containing a carboxyl group, and a diisocyanate-based compound at approximately 80°C to 100°C.

Since the polyurethane resin does not contain volatile organic compounds such as toluene, it is easy to disperse, does not adversely affect the human body, and is environmentally friendly. When the cover layer 32 is made of the polyurethane resin, it has excellent compatibility with the surface treatment layer 33 and has an advantage of improving surface properties such as a touch.

As the cover layer 32 is manufactured by using the casting method, it may not include a foam layer because it can retain the feeling of artificial leather without a foam layer.

In addition, as the label layer 32 is manufactured using the casting method, the thickness of the label layer 32 may be 5 μm to 400 μm, and specifically 10 μm to 300 μm. When the thickness of the cover layer 32 is less than 5 µm, surface smoothness and workability may be deteriorated, and the material cost may increase due to an increase in the amount of pigment to implement color, and when it exceeds 400 µm, for the automobile interior material As the cushioning feeling of the artificial leather 100 is deteriorated and it is formed thicker than necessary, material cost may be unnecessary.

Meanwhile, an embossed pattern (not shown) may be formed on the surface of the cover layer 32, and the embossed pattern may impart an excellent surface texture to the artificial leather 100 for automobile interior materials and improve surface durability. .

Optionally, the surface layer 30 may further include the back cover layer 34 between the three-dimensional spacer fabric 10 and the cover layer 32.

The cover back layer 34 may increase the cushioning feeling of the artificial leather 100 for automobile interior materials and supplement the thickness of the finished product.

The cover back layer 34 may also be manufactured using a casting method, and thus may be made of polyvinyl chloride (PVC) resin or polyurethane (PU) resin.

Since the contents of the polyvinyl chloride resin and the polyurethane resin are the same as those described for the cover layer 32, a repetitive description will be omitted.

The thickness of the cover back layer 34 may be 5 µm to 500 µm, and specifically 10 µm to 400 µm. When the thickness of the cover back layer 34 is less than 5 μm, the cushioning feeling may be deteriorated, and when it exceeds 500 μm, the material cost may be unnecessary as it is formed thicker than necessary.

The surface treatment layer 33 is to improve scratch resistance, stain resistance and surface properties of the artificial leather 100 for automobile interior materials, and to provide an eco-friendly effect, for example, made of polyurethane (PU) resin. I can.

The surface treatment layer 33 may have a thickness of 4 µm to 30 µm, and specifically 10 µm to 20 µm. By maintaining the thickness of the surface treatment layer 33 within the above range, it is possible to simultaneously secure contamination resistance while maintaining the flexibility of the artificial leather 100 for automobile interior materials.

If the thickness of the surface treatment layer 33 is less than 4 μm, the thickness may be too thin and durability may be deteriorated. If it exceeds 30 μm, the consumption of the surface treatment agent may increase and material cost may be unnecessary.

The manufacturing method of artificial leather for automobile interior according to another embodiment of the present invention includes preparing a three-dimensional spacer fabric, preparing a surface layer including a label layer and a surface treatment layer positioned on the label layer, and the And laminating the surface layer and the three-dimensional spacer fabric.

3 is a process chart showing a method of manufacturing the artificial leather for automobile interior materials. Hereinafter, a method of manufacturing the artificial leather 100 for automobile interior materials will be described in detail with reference to FIG. 3.

The manufacturing method of the artificial leather for automobile interior material 100 includes forming a cover layer 32 by applying a cover layer forming sol on a release paper 60 by a casting method, and applying the cover layer forming sol to the cover layer ( 32) forming the back cover layer 34 by coating it on the back cover layer 34, applying a binder 70 on the back cover layer 34 by a casting method and laminating the three-dimensional spacer fabric 10, and And peeling off the release paper 60 and forming a surface treatment layer 33 on the cover layer 32.

First, a cover layer-forming sol is applied on a release paper 60 by a casting method to form a cover layer 32 (S3-1).

The casting method typically refers to the application of a liquid material by a mixing head, and in the present invention, a generally used mixing head operated at high or low pressure may be used. Specifically, the casting method may be performed by using Puromats (manufactured by Krauss Maffei) as a measuring unit, and applying the sol for forming the label layer in a laminar stream of material.

The sol for forming the label layer includes polyvinyl chloride (PVC) resin or polyurethane (PU) resin.

In addition, the sol for forming the label layer contains 10 parts by weight to 20 parts by weight of an inorganic additive based on 100 parts by weight of the polyvinyl chloride (PVC) resin in order to secure the surface smoothness of the label layer 32 and implement color. Alternatively, 3 to 30 parts by weight of a silicone additive and 10 to 20 parts by weight of an organic additive may be included with respect to 100 parts by weight of the polyurethane resin, and a pigment may be further included if necessary.

In addition, the sol for forming the label layer may further include any one additive selected from the group consisting of a heat stabilizer, a flame retardant, a filler, and a mixture thereof to control melt strength and physical properties.

After applying the label layer forming sol on the release paper 60, it may further include a step of selectively drying (S3-2).

The drying may be performed at 110°C to 150°C, specifically 130°C to 150°C for 80 seconds to 120 seconds. When drying below the temperature and time range, the solvent does not sufficiently evaporate and remains, so that whitening may occur on the surface of the artificial leather 100 for automobile interior materials due to uncuring and the surface properties may be deteriorated, and the temperature and time range If exceeded, the heat resistance may be lowered and discoloration may occur.

Meanwhile, a fine pattern such as an embossed pattern may be formed on the surface of the release paper 60, and through this, the embossed pattern may be transferred to the cover layer 32. The embossed pattern may mean unevenness formed on the top of the artificial leather 100 for automobile interior material.

Next, a back cover layer forming sol is applied on the cover layer 32 by a casting method to form the back cover layer 34 (S3-3).

Since the casting method is the same as described in the step of forming the cover layer 32, a repetitive description will be omitted.

The sol for forming the back cover layer also includes polyvinyl chloride (PVC) resin or polyurethane (PU) resin.

The cover surface layer forming sol contains 10 parts by weight to 20 parts by weight of an inorganic additive based on 100 parts by weight of the polyvinyl chloride (PVC) resin, or 3 parts by weight to 30 parts by weight of a silicone additive based on 100 parts by weight of the polyurethane resin It may contain 10 parts by weight to 20 parts by weight of parts and organic additives.

After applying the sol for forming the back cover layer on the cover layer 32, a step of selectively drying may be further included (S3-4). Since the drying method and conditions are the same as those described in the step of forming the cover layer 32, a repetitive description will be omitted.

Next, a binder 70 is applied on the cover surface layer 34 by a casting method (S3-5), and the three-dimensional spacer fabric 10 is laminated (S3-7).

The binder 70 may be an acrylic adhesive, a polyurethane adhesive, or a polyvinyl chloride plastisol. However, since the acrylic adhesive is hard after drying, there is a disadvantage in that the microhardness of the artificial leather is increased, and the polyurethane adhesive is relatively expensive and the material cost increases, and polyvinyl chloride plastisol may be preferably used.

The polyvinyl chloride plastisol may be formed by stirring at room temperature (20°C) with respect to 100 parts by weight of the polyvinyl chloride resin, 70 parts by weight to 130 parts by weight of a plasticizer and 0.5 parts by weight to 10 parts by weight of a curing agent.

Specifically, the polyvinyl chloride resin may be a mixed resin comprising 60% to 90% by weight of a vinyl chloride homopolymer and 10% to 40% by weight of a 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 an amount of 60% to 90% by weight, specifically 65% to 85% by weight, in the mixed resin. If the content of the vinyl chloride homopolymer is less than 60% by weight, the peel strength between the three-dimensional spacer fabric 10 and the surface layer 30 may be reduced, and if it exceeds 90% by weight, there is a problem that a smell occurs. I can.

In the copolymer of vinyl chloride and vinyl acetate, the content of vinyl acetate in the copolymer may be 1% to 15% by weight, specifically 3% to 10% by weight. When the content of the vinyl acetate is less than 1% by weight, the adhesive strength may decrease, so that the peel strength between the three-dimensional spacer fabric 10 and the surface layer 30 may decrease, and if it exceeds 15% by weight, the hydrolyzability may decrease. I can.

In addition, the copolymer of vinyl chloride and vinyl acetate may be included in 10% to 40% by weight, specifically 15% to 35% by weight in the mixed resin. When the content of the copolymer of vinyl chloride and vinyl acetate is less than 10% by weight, the peel strength of the three-dimensional spacer fabric 10 and the surface layer 30 may be reduced, and when it exceeds 40% by weight, heat resistance, etc. Mechanical properties may deteriorate.

The plasticizer may be any one selected from the group consisting of a phthalate plasticizer, a terephthalate plasticizer, a benzoate plasticizer, a citrate plasticizer, a phosphate plasticizer, an adipate plasticizer, and a mixture thereof. However, it is possible to use a terephthalate plasticizer that is environmentally friendly and has excellent heat resistance, and specifically, dioctyl terephthalate may be used, but the present invention is not limited thereto.

The plasticizer may be included in an amount of 70 to 130 parts by weight, specifically 80 to 120 parts by weight, based on 100 parts by weight of the mixed resin. When the content of the plasticizer is less than 70 parts by weight, the viscosity of the binder 70 may increase and thus processability may decrease, and when the content of the plasticizer exceeds 130 parts by weight, adhesion may decrease due to migration of the plasticizer.

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

The blocking agent is phenol, ε-caprolactam, methyl ethyl ketone oxime, 1,2-pyrazole, and diethyl malonate. malonate), diisopropylamine, triazole, imidazole, 3,5-dimethylpyrazole, and any one selected from the group consisting of a mixture thereof Can be used.

The block isocyanate curing agent blocks the isocyanate group so that the isocyanate group (-NCO) does not react with the hydroxyl group (-OH) or the amino group (-NH) at room temperature, and when it reaches a certain temperature range, the blocking agent dissociates and the reactivity of (-NCO) This increases and the curing reaction proceeds.

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

The curing agent may be included in an amount of 0.5 to 10 parts by weight, specifically 1 to 5 parts by weight, based on 100 parts by weight of the mixed resin. When the content of the curing agent is less than 0.5 parts by weight, the peel strength between the three-dimensional spacer fabric 10 and the surface layer 30 may decrease due to a decrease in crosslinking degree. When the content of the curing agent exceeds 10 parts by weight, the unreacted curing agent is used as an impurity. The remaining usability may decrease.

The binder 70 may optionally further include any one other additive selected from the group consisting of a stabilizer, a filler, a pigment, a viscosity reducing agent, a dispersant, and a mixture thereof, as needed, and the content of the coating solution It is not particularly limited as long as it does not affect physical properties.

After applying the binder 70 on the back cover layer 34, a step of selectively drying may be further included (S3-6). Since the drying method and conditions are the same as those described in the step of forming the cover layer 32, a repetitive description will be omitted.

Next, the release paper 60 is peeled (S3-8), and a surface treatment layer 33 is formed on the cover layer 32 to prepare the surface layer 30 (S3-9).

The surface treatment layer 33 may be formed by applying and drying an aqueous surface treatment agent on the cover layer 32.

The aqueous surface treatment agent may be a two-component aqueous surface treatment agent comprising 1 part by weight to 25 parts by weight of a curing agent, 1 part by weight to 25 parts by weight of an aqueous solvent, and 1 part by weight to 15 parts by weight of a silicone compound, based on 100 parts by weight of the main body. have.

The subject may be a water-dispersed polycarbonate-based polyurethane resin, and the curing agent may contain any one functional group selected from the group consisting of an aziridine group, an isocyanate group, a carbodiimide group, and a mixture thereof per molecule. However, the present invention is not limited thereto.

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

The aqueous solvent may be water or alcohol or a mixture of water and alcohol.

The aqueous surface treatment agent may be applied using a gravure coating. The gravure coating process includes direct gravure coating, reverse gravure coating, and offset gravure coating. In the direct gravure coating, coating is performed on a substrate between a roller formed of an elastic rubber and a roller containing a coating liquid, and the rotation speed of these rollers may be the same. In addition, the rotation direction of the substrate and the rollers may be opposite. In the reverse gravure coating, the rotation direction of the substrate and the rollers are opposite, and the amount of application may be adjusted by adjusting the speed of the rollers. In the offset gravure coating, rollers are driven independently of each other, and a coating layer can be uniformly formed with a small amount by high speed.

The drying may be performed at 110°C to 150°C, specifically 130°C to 150°C for 80 seconds to 120 seconds. When drying below the above temperature and time range, the aqueous solvent cannot evaporate and remains, and thus whitening occurs on the surface of the artificial leather 100 for automobile interior materials due to uncuring, and the surface properties may be deteriorated, and the temperature and time If it exceeds the range, heat resistance may decrease, resulting in discoloration.

Hereinafter, embodiments of the present invention will be described in detail so that those skilled in the art can easily implement the present invention. However, the present invention may be implemented in various different forms and is not limited to the embodiments described herein.

[Production example: manufacture of artificial leather]

(Example 1)

A three-dimensional spacer fabric having a thickness of 4 mm and including a first fabric layer and a second fabric layer and a spacer layer made of polyester was prepared. The size of the mesh of the first fabric layer was 0.05 mm, the size of the mesh of the second fabric layer was 0.1 mm, and the ratio of the elongation of the first fabric layer and the elongation of the second fabric layer was 1:2.

A sol for forming a label layer was prepared by mixing 100 parts by weight of a polyvinyl chloride resin having a polymerization degree of 1000, 10 parts by weight of an inorganic additive, and 4 parts by weight of a black pigment.

The prepared sol for forming a label layer was cast on a release paper having a fine pattern to a thickness of 0.2 mm, and dried at 110° C. for about 2 minutes to prepare a label layer.

100 parts by weight of a polyvinyl chloride resin having a degree of polymerization of 1300 and 10 parts by weight of an inorganic additive were mixed to prepare a sol for forming a back cover layer.

The prepared sol for forming the back cover layer was cast on the cover layer to a thickness of 0.6 mm, and dried at 110° C. for about 2 minutes to prepare the back cover layer.

An acrylic adhesive was cast on the back cover layer to a thickness of 0.3 mm, dried at 110° C. for about 30 seconds, and then the three-dimensional spacer fabric was adhered.

After gravure coating an aqueous surface treatment agent containing 5 parts by weight of a curing agent, 20 parts by weight of an aqueous solvent, and 5 parts by weight of a silicone compound based on 100 parts by weight of a polycarbonate-based polyurethane resin on the cover layer, the aqueous solvent was dried at 140°C By evaporation, a 15 µm-thick surface treatment layer was formed to prepare an artificial leather having a thickness of 5 mm.

(Example 2)

A three-dimensional spacer fabric having a thickness of 4 mm and including a first fabric layer and a second fabric layer and a spacer layer made of polyester was prepared. The size of the mesh of the first fabric layer was 0.05 mm, the size of the mesh of the second fabric layer was 0.1 mm, and the ratio of the elongation of the first fabric layer and the elongation of the second fabric layer was 1:2.

A sol for forming a label layer was prepared by mixing 100 parts by weight of a polyester-mixed polyurethane resin, 10 parts by weight of a silicone additive, 20 parts by weight of an organic additive, and 4 parts by weight of a black pigment.

The prepared sol for forming a label layer was cast to a thickness of 30 μm on a release paper having a fine pattern, and dried at 110° C. for about 2 minutes to prepare a label layer.

100 parts by weight of a polyester-mixed polyurethane resin, 10 parts by weight of a silicone additive, and 20 parts by weight of an organic additive were mixed to prepare a sol for forming a back cover layer.

The prepared sol for forming the back cover layer was cast on the cover layer to a thickness of 30 μm, and dried at 110° C. for about 2 minutes to prepare the back cover layer.

An acrylic adhesive was cast on the back cover layer to a thickness of 0.3 mm, dried at 110° C. for about 30 seconds, and then the three-dimensional spacer fabric was adhered.

After gravure coating an aqueous surface treatment agent containing 5 parts by weight of a curing agent, 20 parts by weight of an aqueous solvent, and 5 parts by weight of a silicone compound based on 100 parts by weight of a polycarbonate-based polyurethane resin on the cover layer, the aqueous solvent was dried at 140°C By evaporation, a 15 µm-thick surface treatment layer was formed to prepare artificial leather having a thickness of 4.5 mm.

(Comparative Example 1)

In Example 1, an artificial leather was manufactured in the same manner as in Example 1, except that a three-dimensional spacer fabric having a mesh size of 2.0 mm of the first fabric layer was used.

(Comparative Example 2)

In Example 1, an artificial leather having a thickness of 5 mm was prepared in the same manner as in Example 1, except that a 25 ppi filter foam having a thickness of 4 mm was used to replace the three-dimensional spacer fabric. I did.

[Experimental Example 1: Measurement of surface smoothness of artificial leather]

Surface smoothness was measured for the artificial leather prepared in the above Examples and Comparative Examples.

Specifically, after cutting the artificial leather prepared in Examples and Comparative Examples in a vertical direction, using a high magnification optical microscope, the total height of the artificial leather measured at any one point among the intersections of the yarns of the first fabric layer 1 After measuring the total height of the artificial leather measured at any one point among the meshes of the fabric layer, it was obtained through Equation 1, and the results are shown in Table 1 below.

Surface smoothness
(Unit: mm) Example 1 0.03 Example 2 0.04 Comparative Example 1 0.19

Referring to Table 1, it can be seen that the artificial leather manufactured in Example 1 has superior surface smoothness compared to the artificial leather manufactured in Comparative Example 1.

Therefore, the artificial leather manufactured in the above embodiment controls the size of the mesh of the first fabric layer, so that even when the foam layer and the cover layer are formed by applying a casting method, the surface structure of the three-dimensional spacer fabric is It can be seen that the problem of surface defects caused by transmission has been improved.

[Experimental Example 2: Measurement of physical properties of artificial leather]

Peel strength, softness, sensibility (touch), stiffness, and wrinkles were measured for the artificial leather prepared in Examples and Comparative Examples, and the results are shown in Table 2 below.

For the peel strength, a specimen of 30 mm in width and 150 mm in length was prepared from the produced artificial leather, and 5 pieces were collected in each of the horizontal and vertical directions, and a solvent such as methyl ethyl ketone (MEK) was impregnated on the bubble side, and then the surface layer was Taking care not to apply stress, the surface layer and the three-dimensional spacer fabric were forcibly separated by 50 mm in length parallel to the short side. After peeling, leave the test piece indoors for at least 2 hours to sufficiently volatilize the solvent, and then fix the peeled surface layer and the three-dimensional spacer fabric to the clamps of the tensile tester, respectively, and the load when peeling 50 mm at 200 mm/min is maximized. It was calculated as an average value. The test results were obtained from the average of 5 specimens.

The softness is at a temperature of 23±2° C. and a relative humidity of 50±5%, using a softness measuring device (SDL Atlas, ST300D) to prepare five artificial leather specimens having a pie (ð) of 100 mm, It was measured by pressing the ST300D device and reading the value that the scale moved for 15 seconds.

The sensibility (touch) was directly touched by internal experts for artificial leather and evaluated the relative softness (ⓞ: very soft, ○: soft level, △: flat touch).

For the strength, take 5 artificial leather specimens having a width of 250 mm and a length of 200 mm in each of the horizontal and vertical directions, and set the short side on the horizontal bar to the SCALE baseline (A), Press and slide at a speed of about 10 mm/sec in the direction of the inclined surface, and the position (B) of the other end when one end of the test piece contacts the inclined surface was read as SCALE. The stiffness was expressed as a moving distance (scale of point B) (mm), and five surfaces and back surfaces were measured in both length and width, and the average value was shown.

The occurrence of wrinkles was measured by pulling an artificial leather specimen having a width of 210 mm and a length of 300 mm with a force of 10 N in the horizontal and vertical directions (ⓞ: no wrinkles, ○: fine wrinkles, △: wrinkles Occur).

Example 1 Example 2 Comparative Example 1 Comparative Example 2 Peel strength (N/30mm) 18 18 18 18 ductility 3 4 4 5 Emotion Ⓞ Ⓞ ○ ○ Lecture (mm) 100 110 120 120 Whether wrinkles occur Ⓞ Ⓞ ○ ○

Referring to Table 2, it can be seen that the artificial leather prepared in the above example has particularly excellent wrinkle resistance compared to the artificial leather prepared in the comparative example.

That is, the artificial leather manufactured in the above embodiment improved durability by replacing the polyurethane foam with a three-dimensional spacer fabric, thereby improving the problem of turning off or deforming even when used for a long period of time, while improving the flexibility and improving the problem of wrinkles. Able to know.

In addition, the artificial leather prepared in the above embodiment is formed by applying the casting method to form the foam layer and the cover layer, thereby imparting excellent surface texture and surface durability, while reducing the thickness of the foam layer, the cover layer, and the surface treatment layer. It improves the peel strength with the three-dimensional spacer fabric, and it is possible to manufacture the artificial leather without an additional configuration such as a back layer, etc., thereby improving ductility, thereby exhibiting an excellent cushioning feeling.

In addition, the artificial leather prepared in the above embodiment improves the surface weaving structure of the three-dimensional spacer fabric, so that even when the foam layer and the cover layer are formed by applying the casting method, the surface fabrication structure of the three-dimensional spacer fabric The problem of surface defects caused by permeation was also improved.

Although the preferred embodiments of the present invention have been described in detail above, the scope of the present invention is not limited thereto, and various modifications and improvements by those skilled in the art using the basic concept of the present invention defined in the following claims are also present. It belongs to the scope of rights of

100: artificial leather
10: 3D spacer fabric
11: first fabric layer, 12: second fabric layer, 13: spacer layer
30: surface layer
32: label layer, 33: surface treatment layer, 34: cover back layer
60: Hyungji Lee
70: binder
111: thread, 112: stitch places, 113: mesh
S3-1: Cover layer casting step
S3-2: label layer drying step
S3-3: Casting the back cover layer
S3-4: Step of drying the cover surface layer
S3-5: Binder Casting Step
S3-6: Binder drying step
S3-7: 3D spacer fabric lamination step
S3-8: Release paper peeling step
S3-9: Step of forming a surface treatment layer

Claims (8)

3D spacer fabric including a first fabric layer and a second fabric layer spaced apart, and a spacer layer connecting the first fabric layer and the second fabric layer with a spacing thread to form a three-dimensional structure , And
And a surface layer including a label layer positioned on the first fabric layer of the three-dimensional spacer fabric, and a surface treatment layer positioned on the label layer,
The first fabric layer includes meshes between stitch places of threads, and the size of the meshes of the first fabric layer is 0.01 mm to 1.5 mm. leather. The method of claim 1,
The artificial leather for automobile interior materials is an artificial leather for automotive interior materials having a surface smoothness (S) of -0.1 mm to +0.1 mm represented by Equation 1 below.
[Equation 1]
Surface smoothness (S) = H ₁ -H ₂
H ₁ (unit: mm) = total height of artificial leather passing through any one of the intersections of the threads of the first fabric layer
H ₂ (unit: mm) = total height of artificial leather passing through any one of the meshes of the first fabric layer The method of claim 1,
The cover layer is artificial leather for automobile interior materials formed by a casting method. The method of claim 1,
The thickness of the surface layer is 0.01 mm to 1.5 mm artificial leather for automobile interior. The method of claim 1,
The second fabric layer includes meshes between stitch places of threads, and the size of the meshes of the second fabric layer is 0.01 mm to 3.5 mm. leather. The method of claim 5,
The ratio of the elongation of the first fabric layer and the elongation of the second fabric layer is greater than 1: 1 to 1: 10 or less. A 3D spacer fabric comprising a first fabric layer and a second fabric layer spaced apart from each other, and a spacer layer connecting the first fabric layer and the second fabric layer with a spacing thread to form a three-dimensional structure The steps to prepare,
Preparing a surface layer comprising a label layer and a surface treatment layer positioned on the label layer, and
Laminating the surface layer and the three-dimensional spacer fabric,
The first fabric layer includes meshes between stitch places of threads, and the size of the mesh of the first fabric layer is 0.01 mm to 1.5 mm. Manufacturing method. The method of claim 7,
The method of manufacturing artificial leather for automobile interior materials, wherein the cover layer is formed by a casting method.

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