TW202227694A - 人造皮革及其製造方法 - Google Patents

人造皮革及其製造方法 Download PDF

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TW202227694A
TW202227694A TW109147183A TW109147183A TW202227694A TW 202227694 A TW202227694 A TW 202227694A TW 109147183 A TW109147183 A TW 109147183A TW 109147183 A TW109147183 A TW 109147183A TW 202227694 A TW202227694 A TW 202227694A
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layer
thermoplastic polyurethane
artificial leather
temperature
substrate
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TWI765507B (zh
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林至逸
鄭國光
蔣昆霖
戴世明
李德育
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三芳化學工業股份有限公司
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Priority to TW109147183A priority Critical patent/TWI765507B/zh
Priority to CN202110659830.5A priority patent/CN114687217A/zh
Priority to US17/561,982 priority patent/US20220205172A1/en
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Abstract

本發明係關於一種人造皮革及其製造方法。該人造皮革包括：一基材、一接著糊劑層、一成型性表面層、一熱塑性聚氨酯(TPU)接著層、一熱塑性聚氨酯層及一底層。該基材具有一第一表面及一第二表面，該第二表面相對於該第一表面。該接著糊劑層設置於該基材之該第一表面上。該成型性表面層設置於該接著糊劑層上。該熱塑性聚氨酯接著層設置於該基材之該第二表面。該熱塑性聚氨酯層設置於該熱塑性聚氨酯接著層之一表面。該底層設置於該熱塑性聚氨酯層之一表面。本發明之人造皮革之該成型性表面層具有皮革紋路或色水效果，且該底層具有絨毛感且以可提升耐磨性。

Description

人造皮革及其製造方法
本發明關於一種人造皮革及其製造方法。
習知製造人造皮革之方法普遍會採用多種繁複製程，且部分製程中需使用溶劑，例如：液鹼(NaOH)，該溶劑會危害環境，不符合環保需求。並且，習知人造皮革只有單面有經處理，且耐磨效果不佳，造成不適合皮革產品應用之情況。
因此，有必要提供一創新且具進步性之人造皮革及其製造方法，以解決上述習知缺失。
本發明係關於一種人造皮革。在一實施例中，該人造皮革包括：一基材、一接著糊劑層、一成型性表面層、一熱塑性聚氨酯(TPU)接著層、一熱塑性聚氨酯層及一底層。該基材具有一第一表面及一第二表面，該第二表面相對於該第一表面。該接著糊劑層設置於該基材之該第一表面上。該成型性表面層設置於該接著糊劑層上。該熱塑性聚氨酯接著層設置於該基材之該第二表面。該熱塑性聚氨酯層設置於該熱塑性聚氨酯接著層之一表面。該底層設置於該熱塑性聚氨酯層之一表面。
本發明係關於一種人造皮革之製造方法。在一實施例中，該人造皮革之製造方法包括以下步驟：提供一基材，該基材具有一第一表面及一第二表面，該第二表面相對於該第一表面；熔噴一熱塑性聚氨酯接著層至該基材之該第二表面；熔噴一熱塑性聚氨酯層至該熱塑性聚氨酯接著層之一表面；熱貼合處理該基材、該熱塑性聚氨酯接著層及該熱塑性聚氨酯層；貼合一底層於該熱塑性聚氨酯層之一表面；製備一成型性表面層；塗佈一接著糊劑層於該成型性表面層之一表面；及貼合該成型性表面層及該接著糊劑層至該基材之該第一表面上。
參閱圖1，其係顯示本發明一實施例人造皮革之結構示意圖。在一實施例中，本發明之人造皮革10包括：一基材11、一接著糊劑層12、一成型性表面層13、一熱塑性聚氨酯(TPU)接著層14、一熱塑性聚氨酯層15及一底層16。
在一實施例中，該基材11具有一第一表面111及一第二表面112，該第二表面112相對於該第一表面111。該基材11可為織布、不織布或網布，或視實際所需變換不同之材質，以符合實際應用。在一實施例中，該基材為至少部分環保材質，亦即部分或全部為環保材質，例如：使用100%回收PET棉花或使用60%回收PET混40%一般PET，利用針軋的方式糾絡成不織布。或者，使用100%回收PET纖維或使用一般PET纖維編織成織布。在一實施例中，該基材11之纖維細度可為0.05~6
在一實施例中，該接著糊劑層12設置於該基材11之該第一表面111上。在一實施例中，該接著糊劑層之固形份為20%~99%，黏度為5000~50000 cps。在一實施例中，該接著糊劑層為樹脂。
在一實施例中，該成型性表面層13設置於該接著糊劑層12上。在一實施例中，該成型性表面層13之固形份為10%%~99%，黏度為500~15000 cps。在一實施例中，該成型性表面層13為成型性樹脂。在一實施例中，該成型性表面層13可搭配珠光或色膏混合，以提供表面色水變化及紋路。
在一實施例中，該熱塑性聚氨酯接著層14設置於該基材11之該第二表面112。在一實施例中，該熱塑性聚氨酯接著層14的厚度為0.05-0.15 mm。在一實施例中，該熱塑性聚氨酯接著層14的厚度可為0.15 mm。
在一實施例中，該熱塑性聚氨酯層15設置於該熱塑性聚氨酯接著層14之一表面141。在一實施例中，該熱塑性聚氨酯層15的厚度為0.15-0.35 mm。在一實施例中，該熱塑性聚氨酯層15的厚度可為0.3 mm。
在一實施例中，該底層16設置於該熱塑性聚氨酯層15之一表面151。在一實施例中，該底層之固形份為5%~50%，黏度為20~2000 cps。
在一實施例中，經耐磨測試機台(STOLL測試機)之耐磨測試，首先確認轉盤上的氣台，氣台加壓後皮膜高度為15mm，壓力值在6±0.5PSI。再將直徑112mm的試片放在轉盤上，並固定。使用砂紙(型號為K225-320J)並加內裡專用砝碼0.5磅附重，來進行磨耗測試。每次測試前25轉，確認是否材料固定；且每300轉需評估砂紙及試片是否良好。測試結果，本發明之該人造皮革10的耐磨強度大於3000轉，如下表1所示。 表1 測試結果
Test Item Unit Result
耐磨 Taber Abrasion ASTM D3884 (H22*500g) Cycles 200+
耐磨  Abrasion GE-63 (12 Kpa) Cycles 25000+
常溫耐屈 Bally Flex(RT) SATRA PM55 Cycles 100000+
耐光 QUV NIKE G37 40℃*40W*24hrs 4.0↑
耐水解 Hydrolysis NIKE G57 24hrs PASS
剝離 Ply Adhesion EN ISO 2411 kg/3cm 4.5↑
因此，本發明之人造皮革10之該成型性表面層13具有皮革紋路或色水效果，且該底層16具有絨毛感且以可提升耐磨性。
圖2顯示本發明一實施例人造皮革之製造方法流程示意圖。配合參考圖1及圖2，首先參考步驟S21，提供一基材11，該基材11具有一第一表面111及一第二表面112，該第二表面112相對於該第一表面111。該基材11可為織布、不織布或網布，或視實際所需變換不同之材質，以符合實際應用。在一實施例中，該基材為至少部分環保材質，亦即部分或全部為環保材質，例如：使用100%回收PET棉花或使用60%回收PET混40%一般PET，利用針軋的方式糾絡成不織布。或者，使用100%回收PET纖維或使用一般PET纖維編織成織布。
參考步驟S22，熔噴一熱塑性聚氨酯接著層14至該基材11之該第二表面112上。在一實施例中，在熔噴該熱塑性聚氨酯接著層14之步驟中，另包括利用低熔點熱塑性聚氨酯粒子，其熔點為100~150℃，其蕭式硬度為70~90A，並於一設定乾燥溫度乾燥4小時，使得其含水率為100ppm以下。該設定乾燥溫度為60~80℃。
在一實施例中，另包括利用一第一押出機（圖未示出）熔融該熱塑性聚氨酯粒子之步驟，該第一押出機之熔融溫度為80℃-250℃，機頭溫度為210℃-250℃，DIE溫度為210℃-250℃，紡口熱風溫度為220℃-250℃，紡壓控制於4.5MPa-10MPa。該熱塑性聚氨酯接著層14的熔點為90~130℃。
參考步驟S23，熔噴一熱塑性聚氨酯層15至該熱塑性聚氨酯接著層13上。在一實施例中，在熔噴該熱塑性聚氨酯層15之步驟中，另包括利用熱塑性聚氨酯粒子，其熔點為150~180℃，其蕭式硬度為70~90A，並於一設定乾燥溫度乾燥4小時，使得其含水率為100ppm以下。該設定乾燥溫度為80℃。
在一實施例中，另包括利用一第二押出機（圖未示出）熔融該熱塑性聚氨酯粒子之步驟，該第二押出機之熔融溫度為90℃-270℃，機頭溫度為210℃-270℃，DIE溫度為240℃-270℃，紡口熱風溫度為250℃-270℃，紡壓控制於4.5MPa-10MPa。該熱塑性聚氨酯層15的熔點為150~220℃。
參考步驟S24，熱貼合處理該基材11、該熱塑性聚氨酯接著層14及該熱塑性聚氨酯層15。在一實施例中，利用數個平面燙光輪（圖未示出）進行熱貼合處理，其包括預熱輪及壓制輪，該預熱輪之溫度為110℃-160℃，該壓制輪之溫度為50℃，擠壓間隙為0.3-0.8 mm。
參考步驟S25，貼合一底層16於該熱塑性聚氨酯層15之一表面151上。在一實施例中，在貼合該底層16之步驟中，係於70~140℃之烘箱溫度及300~1800rpm風量下，與車速5~8m/min下完成。在一實施例中，係利用水性糊劑或高固糊劑貼合該底層16至該熱塑性聚氨酯層15。該底層16可為聚氨酯樹脂或水溶性聚氨酯樹脂。在一實施例中，係利用PU類塗料進行塗佈造面，以貼合該底層16至該熱塑性聚氨酯層15。
參考步驟S26，製備一成型性表面層13。在一實施例中，係將成型性樹脂塗佈於一離形紙（圖未示出）上。該成型性樹脂可搭配珠光或色膏混合，塗佈於離型紙上烘乾，以提供表面色水變化及紋路。
參考步驟S27，塗佈一接著糊劑層12於該成型性表面層13之一表面131。在一實施例中，於已乾燥之該成型性表面層13，以具接著性糊劑，塗佈於該成型性表面層13之該表面131上，且做預烘以形成該接著糊劑層12。
參考步驟S28，貼合該成型性表面層13及該接著糊劑層12至該基材11之該第一表面111上。在一實施例中，係在70~140℃之烘箱溫度及300~1800rpm風量下，車速5~8m/min，在3~6kg/m 2之壓力下複合完成。
在一實施例中，本發明之人造皮革10與離型紙剝離後，可再依需求做高周波、公母模、真空吸塑等後續加工製程塑形。關於高周波製程:伏特數40~90V、電流值2~4A、模溫0~100℃、熔接秒數2~15s。公母模塑形製程:上模溫:80~110℃、下模溫: 80~110℃、熱壓時間:1~5min、壓力:25~120kg/cm 2。關於真空吸塑:加熱溫度:80~130℃、加熱時間:1~5min、吸塑時間:1~5min、吸塑壓力:-760mmHg。
因此，利用本發明人造皮革之製造方法，無須使用任何有害環境的溶劑，以符合環保之要求，且本發明利用熔噴製程即可製作本發明之人造皮革10，以節省繁複的製程及時間，可提高製造效率。並且，本發明人造皮革10之該成型性表面層13具有皮革紋路或色水效果，且該底層16具有絨毛感且以可提升耐磨性。 [ 發明例 1]
使用100%回收PET棉花或使用60%回收PET混40%一般PET，利用針軋的方式糾絡成不織布作為基材11。
使用蕭式硬度70~90A、熔點100~150℃的熱塑性聚氨酯粒子，於設定乾燥溫度為80℃下乾燥4小時，測得含水率100ppm以下。再利用第一押出機熔融該熱塑性聚氨酯粒子，其溫度自餵料口至出口依序為80℃、180℃、200℃、210℃、220℃、230℃，機頭溫度230℃，DIE溫度230℃，紡口熱風溫度240℃，紡壓控制在4.5MPa以上、10MPa以下，熔噴該熱塑性聚氨酯接著層14以纖維狀方式舖疊在不織布的基材11之該第二表面112，熔噴該熱塑性聚氨酯接著層14之平均纖維細度約10µm，該熱塑性聚氨酯接著層14之堆疊厚度約0.15mm。
使用硬度70~90A、熔點150~180℃的熱塑性聚氨酯粒子，於設定乾燥溫度為80℃下乾燥4小時，測得含水率100ppm以下。再利用第二押出機熔融該熱塑性聚氨酯粒子，其溫度自餵料口至出口依序為90℃、200℃、220℃、230℃、240℃、250℃，機頭溫度250℃，DIE溫度250℃，紡口熱風溫度250℃，紡壓控制在4.5MPa以上、10MPa以下，熔噴該熱塑性聚氨酯層15以纖維狀方式舖疊在該熱塑性聚氨酯接著層14上，熔噴該熱塑性聚氨酯層15之平均纖維細度約10µm，該熱塑性聚氨酯層15之堆疊厚度約0.30 mm。
將舖疊完成的三層結構（該基材11、該熱塑性聚氨酯接著層14及該熱塑性聚氨酯層15）經經平面燙光輪複合，預熱輪溫度分別為110℃、140℃，壓制輪溫度50℃，擠壓間隙0.75mm，產速9m/min。
研磨該熱塑性聚氨酯層15，以增加毛羽感，條件：砂紙之目數為120~400目，且研磨之轉速600~1000rpm。第一版砂紙之目數為120目，且研磨之轉速800~1000rpm，將該熱塑性聚氨酯層15磨掉0.05mm的厚度；接著，利用一第二版砂紙進行研磨，該第二版砂紙之目數150目，且研磨之轉速800~1000rpm，將該熱塑性聚氨酯層15再磨掉0.05mm的厚度；接著，利用一第三版砂紙進行研磨，該第三版砂紙之目數240目，且研磨之轉速600~800rpm，將該熱塑性聚氨酯層15之該顯露表面粉屑清除乾淨；接著，利用一第四版砂紙進行研磨，該第四版砂紙之目數400目，且研磨之轉速600~800rpm。
貼合該底層16於該熱塑性聚氨酯層15之研磨後之表面151。係於70~140℃之烘箱溫度及300~1800rpm風量下，與車速5~8m/min下完成。
將成型性樹脂塗佈於一離形紙上。該成型性樹脂可搭配珠光或色膏混合，塗佈於離型紙上烘乾，以提供該成型性表面層13之表面色水變化及紋路。
於已乾燥之該成型性表面層13，以具接著性糊劑，塗佈於該成型性表面層13之該表面131上，且做預烘以形成該接著糊劑層12。
在70~140℃之烘箱溫度及300~1800rpm風量下，車速5~8m/min，在3~6kg/m 2之壓力下，貼合該成型性表面層13及該接著糊劑層12至該基材11之該第一表面111上，以製得人造皮革。
經剝離強度測試，本發明例人造皮革之剝離強度均在3 Kg/cm以上 (測試方法：NIKE G44)。且於常溫耐屈10萬次以上(SATRA PM55)，軟硬度可達2.3~3.0(軟硬度計ST300)。並且，本發明例人造皮革具有無翹邊之特性，相較於習知人造皮革其翹邊高度達1cm以上，本發明例人造皮革更適合用於自動化生產之需求。 [ 發明例 2]
使用100%回收PET纖維或使用一般PET纖維編織成織布作為基材11。
使用蕭式硬度70~90A、熔點100~150℃的熱塑性聚氨酯粒子，於設定乾燥溫度為80℃下乾燥4小時，測得含水率100ppm以下。再利用第一押出機熔融該熱塑性聚氨酯粒子，其溫度自餵料口至出口依序為80℃、180℃、 200℃、210℃、220℃、230℃，機頭溫度230℃，DIE溫度230℃，紡口熱風溫度240℃，紡壓控制在4.5MPa以上、10MPa以下，熔噴該熱塑性聚氨酯接著層14以纖維狀方式舖疊在不織布的基材11之該第二表面112上，熔噴該熱塑性聚氨酯接著層14之平均纖維細度約10µm，該熱塑性聚氨酯接著層14之堆疊厚度約0.15mm。
使用蕭式硬度70~90A、熔點150~180℃的熱塑性聚氨酯粒子，於設定乾燥溫度為80℃下乾燥4小時，測得含水率100ppm以下。再利用第二押出機熔融該熱塑性聚氨酯粒子，其溫度自餵料口至出口依序為90℃、200℃、 220℃、230℃、240℃、250℃，機頭溫度250℃，DIE溫度250℃，紡口熱風溫度260℃，紡壓控制在4.5MPa以上、10MPa以下，熔噴該熱塑性聚氨酯層15以纖維狀方式舖疊在該熱塑性聚氨酯接著層14上，熔噴該熱塑性聚氨酯層15之平均纖維細度約10µm，該熱塑性聚氨酯層13之堆疊厚度約0.30 mm。
將舖疊完成的三層結構（該基材11、該熱塑性聚氨酯接著層14及該熱塑性聚氨酯層15）經平面燙光輪複合，該預熱輪之溫度分別為110℃、140℃，該壓制輪之溫度為50℃，擠壓間隙為0.75mm，產速9m/min。
研磨該熱塑性聚氨酯層15，以增加毛羽感，條件：砂紙之目數為120~400目，且研磨之轉速600~1000rpm。第一版砂紙之目數為120目，且研磨之轉速800~1000rpm，將該熱塑性聚氨酯層15磨掉0.05mm的厚度；接著，利用一第二版砂紙進行研磨，該第二版砂紙之目數150目，且研磨之轉速800~1000rpm，將該熱塑性聚氨酯層15再磨掉0.05mm的厚度；接著，利用一第三版砂紙進行研磨，該第三版砂紙之目數240目，且研磨之轉速600~800rpm，將該熱塑性聚氨酯層15之該顯露表面粉屑清除乾淨；接著，利用一第四版砂紙進行研磨，該第四版砂紙之目數400目，且研磨之轉速600~800rpm。
貼合該底層16於該熱塑性聚氨酯層15之研磨後之表面151。係於70~140℃之烘箱溫度及300~1800rpm風量下，與車速5~8m/min下完成。
將成型性樹脂塗佈於一離形紙上。該成型性樹脂可搭配珠光或色膏混合，塗佈於離型紙上烘乾，以提供該成型性表面層13之表面色水變化及紋路。
於已乾燥之該成型性表面層13，以具接著性糊劑，塗佈於該成型性表面層13之該表面131上，且做預烘以形成該接著糊劑層12。
在70~140℃之烘箱溫度及300~1800rpm風量下，車速5~8m/min，在3~6kg/m 2之壓力下，貼合該成型性表面層13及該接著糊劑層12至該基材11之該第一表面111上，以製得人造皮革。
經剝離強度測試，本發明例人造皮革之剝離強度均在1 Kg/cm以上 (測試方法：NIKE G44)。且於常溫耐屈10萬次以上(SATRA PM55)，軟硬度可達4.0~4.5(軟硬度計ST300)。並且，本發明例人造皮革具有無翹邊之特性，相較於習知人造皮革其翹邊高度達1cm以上，本發明例人造皮革更適合用於自動化生產之需求。
上述實施例僅為說明本發明之原理及其功效，而非限制本發明。習於此技術之人士對上述實施例所做之修改及變化仍不違背本發明之精神。本發明之權利範圍應如後述之申請專利範圍所列。
10:人造皮革 11:基材 12:接著糊劑層 13:成型性表面層 14:熱塑性聚氨酯接著層 15:熱塑性聚氨酯層 16:底層 111:第一表面 112:第二表面 131:成型性表面層之表面 141:熱塑性聚氨酯接著層之表面 151:熱塑性聚氨酯層之表面 S21~S28:步驟
圖1顯示本發明一實施例人造皮革之結構示意圖。
圖2顯示本發明一實施例人造皮革之製造方法流程示意圖。
10:人造皮革
11:基材
12:接著糊劑層
13:成型性表面層
14:熱塑性聚氨酯接著層
15:熱塑性聚氨酯層
16:底層
111:第一表面
112:第二表面
131:成型性表面層之表面
141:熱塑性聚氨酯接著層之表面
151:熱塑性聚氨酯層之表面

Claims (17)

  1. 一種人造皮革，包括： 一基材，具有一第一表面及一第二表面，該第二表面相對於該第一表面； 一接著糊劑層，設置於該基材之該第一表面上； 一成型性表面層，設置於該接著糊劑層上； 一熱塑性聚氨酯(TPU)接著層，設置於該基材之該第二表面； 一熱塑性聚氨酯層，設置於該熱塑性聚氨酯接著層之一表面；及 一底層，設置於該熱塑性聚氨酯層之一表面。
  2. 如請求項1之人造皮革，其中該接著糊劑層之固形份為20%~99%，黏度為5000~50000 cps。
  3. 如請求項1之人造皮革，其中該成型性表面層之固形份為10%~99%，黏度為500~15000 cps。
  4. 如請求項3之人造皮革，其中該成型性表面層為成型性樹脂。
  5. 如請求項1之人造皮革，其中該基材為織布或不織布。
  6. 如請求項5之人造皮革，其中該基材之纖維細度為0.05~6
  7. 如請求項1之人造皮革，其中該底層之固形份為5%~50%，黏度為20~2000 cps。
  8. 如請求項7之人造皮革，其中該底層為樹脂。
  9. 一種人造皮革之製造方法，包括以下步驟： 提供一基材，該基材具有一第一表面及一第二表面，該第二表面相對於該第一表面； 熔噴一熱塑性聚氨酯接著層至該基材之該第二表面； 熔噴一熱塑性聚氨酯層至該熱塑性聚氨酯接著層之一表面； 熱貼合處理該基材、該熱塑性聚氨酯接著層及該熱塑性聚氨酯層； 貼合一底層於該熱塑性聚氨酯層之一表面； 製備一成型性表面層； 塗佈一接著糊劑層於該成型性表面層之一表面；及 貼合該成型性表面層及該接著糊劑層至該基材之該第一表面上。
  10. 如請求項9之人造皮革之製造方法，其中在熔噴該熱塑性聚氨酯接著層之步驟中，另包括利用低熔點熱塑性聚氨酯粒子，其熔點為100~150℃，其蕭式硬度為70~90A，並於一設定乾燥溫度乾燥4小時，使得其含水率為100ppm以下。。
  11. 如請求項10之人造皮革之製造方法，其中另包括利用一第一押出機熔融該熱塑性聚氨酯粒子之步驟，該第一押出機之熔融溫度為80℃-250℃，機頭溫度為210℃-250℃，DIE溫度為210℃-250℃，紡口熱風溫度為220℃-250℃，紡壓控制於4.5MPa-10MPa。
  12. 如請求項9之人造皮革之製造方法，其中在熔噴該熱塑性聚氨酯層之步驟中，另包括利用熱塑性聚氨酯粒子，其熔點為150~180℃，其蕭式硬度為70~90A，並於一設定乾燥溫度乾燥4小時，使得其含水率為100ppm以下。。
  13. 如請求項12之人造皮革之製造方法，其中另包括利用一第二押出機熔融該熱塑性聚氨酯粒子之步驟，該第二押出機之熔融溫度為90℃-270℃，機頭溫度為210℃-270℃，DIE溫度為240℃-270℃，紡口熱風溫度為250℃-270℃，紡壓控制於4.5MPa-10MPa。。
  14. 如請求項10之人造皮革之製造方法，其中在熱貼合處理步驟中，係利用數個平面燙光輪，其包括預熱輪及壓制輪，該預熱輪之溫度為110℃-160℃，該壓制輪之溫度為50℃，擠壓間隙為0.75 mm。
  15. 如請求項10之人造皮革之製造方法，其中在貼合該底層之步驟中，係於70~140℃之烘箱溫度及300~1800rpm風量下，與車速5~8m/min下完成。
  16. 如請求項10之人造皮革之製造方法，其中在製備該成型性表面層步驟中，係將成型性樹脂塗佈於一離形紙上。
  17. 如請求項10之人造皮革之製造方法，其中在貼合該成型性表面層及該接著糊劑層至該基材之該第一表面之步驟中，係在70~140℃之烘箱溫度及300~1800rpm風量下，車速5~8m/min，在3~6kg/m 2之壓力下複合完成。
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