TWI405886B - 含彈性體之複合纖維及其製造方法，及包含該複合纖維之基材及其製造方法 - Google Patents

含彈性體之複合纖維及其製造方法，及包含該複合纖維之基材及其製造方法 Download PDF

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Publication number
TWI405886B
TWI405886B TW98146104A TW98146104A TWI405886B TW I405886 B TWI405886 B TW I405886B TW 98146104 A TW98146104 A TW 98146104A TW 98146104 A TW98146104 A TW 98146104A TW I405886 B TWI405886 B TW I405886B
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Taiwan
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component
thermoplastic
elastomer
composite
fiber
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TW98146104A
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English (en)
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TW201122178A (en
Inventor
Lung Chuan Wang
Chung Chih Feng
Chih Yi Lin
Szu Wei Huang
Kao Lung Yang
Jui Peng Tung
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San Fang Chemical Industry Co
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Priority to TW98146104A priority Critical patent/TWI405886B/zh
Priority to US12/948,038 priority patent/US20110159235A1/en
Publication of TW201122178A publication Critical patent/TW201122178A/zh
Priority to US13/921,560 priority patent/US9303342B2/en
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Publication of TWI405886B publication Critical patent/TWI405886B/zh

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)

Description

含彈性體之複合纖維及其製造方法，及包含該複合纖維之基材及其製造方法
本發明係關於一種複合纖維之製造方法，及包含該複合纖維之基材及其製造方法，特別是一種含彈性體之複合纖維及其製造方法，及包含該複合纖維之基材及其製造方法。
人工皮革通常係經由下列方法所製成：使用一種彈性聚合物溶液或乳膠液(主要是聚胺基甲酸酯(Polyurethane,PU))攙雜/含浸不織布織物(其中包括由非彈性聚合物例如尼龍或聚酯所組成之纖維)，之後經由溼法或乾法來固化該彈性聚合物。根據此方法，將經該彈性聚合物所攙雜之不織布織物固化成為海綿或塊狀形式而造成一種結構，其中經固化之該彈性聚合物係覆蓋並環繞著纖維束。
天然皮革具有基體上層細緻而下層粗糙的構造，惟在人工皮革之PU含浸階段，需要高度控制技術，且含浸PU的基材，雖質感和耐久性方面均佳，但纖維間充填樹脂而成密實構造，故通氣性不佳，且難以兼具輕量化所要求之性能。又因PU含浸時使用溶劑，製造歩驟複雜，又產生環境問題。
超細纖維人工皮革大部分須藉由溶劑或鹼液進行分纖加工，因該分纖加工製程必須藉由溶劑或鹼液達成，因此將對環境會造成嚴重的污染，而不符合當前重視環保的潮流。
日本專利特開平4-185777號公報，揭示於高密度不織布基材在PU含浸前先含浸較一般少量的黏合劑樹脂而製得人工皮革。惟因含浸黏合劑於不織布表裡濃度並無法均勻分佈，因此所製得的人工皮革係缺乏表面的柔軟感，層間強度亦弱，不足以作為使用於嚴格條件下之鞋材料。
日本專利特開昭54-59499號公報，揭示使黏合劑樹脂的水系乳液含浸於由極細纖維束形成的纏繞不織布基材。其次，只於一面吹送熱風以乾燥，黏合劑樹脂主要在吹送熱風之面側發生遷移，可抑制往另一面的遷移。惟，其只預防遷移時，因上述另一面亦存在些微的黏合劑樹脂之水系乳液，使得二面固化程度不同，故無法製得由表層部位無黏合劑樹脂附著的極細纖維形成之人造皮革用基材。
台灣專利公開第200745408號，係揭示以纖維狀之黏合劑使黏合劑分佈較為均勻。其係利用水溶性熱塑性聚乙烯醇系樹脂(PVA系樹脂)為海島型切面纖維的海成分聚合物，而其於製成不織布後利用水溶性和熱塑性使聚乙烯醇系樹脂圴分佈於不織布內部，但由於PVA系樹脂不具彈性且易水解，所以整體柔軟感仍欠佳，且於潮溼環境中使用時，該物性容易衰減而無法使用。
台灣專利證書號第134197號，揭示了基材由基質纖維和表面配置彈性聚合物的黏合纖維所構成，其特微為使用黏合纖維係分散於該基質纖維中，並軟化於基質纖維之纖維集合體。該發明所使用的黏合纖維的形態主要為芯鞘型，在纖維的基布成形過程中，其為防止纖維間過早互相黏著而影響基布品質，利用離型劑附著於部份基質纖維表面，然而，雖然少了含浸彈性聚合物溶液，但多了此工序在生產時間和成本卻無法有效改善。
因此，有必要提供一創新且富進步性的含彈性體之複合纖維及其製造方法，及包含該複合纖維之基材及其製造方法，以解決上述問題。
本發明提供一種含彈性體之複合纖維之製造方法，包括：(a)提供一第一成份及一第二成份，該第一成份係為熱可塑性非彈性體，該第二成份係為熱可塑性彈性體，且該第二成份之重量比例為5%至70%；及(b)利用一複合噴絲板將該第一成份及一第二成份共同抽絲，以進行分割複合紡絲，而製得複數個複合纖維，其中於每一該等複合纖維之橫切面之圓周中該第一成份及該第二成份係交替分佈，且該第二成份佔該圓周全部長度50%以下。
本發明另提供一種人工皮革之基材，其包括複數個上述之複合纖維，其中，該等複合纖維間之交叉點係為該第二成份軟化而形成彈性結合點。
本發明另提供一種人工皮革之基材之製造方法，包括以下步驟：(a)提供複數個上述之複合纖維；(b)形成複數個纖維網，該等纖維網包含該等複合纖維；(c)堆疊該等纖維網；(d)針軋或水軋該等纖維網；(e)軟化該第二成份，以結合該等複合纖維；及(f)固化該第二成份，使得該等複合纖維間之交叉點係為該第二成份所形成之彈性結合點。
在本發明中，該複合纖維內之熱可塑性彈性體能均勻分散並增加纖維間黏著，且其分割型纖維斷面更可防止該熱可塑性彈性體於纖維及不織布基材生產時過度黏著影響加工，因此在不織布熱壓後能使布表面更加細緻平坦，且物性增強及較高的尺寸安定性。此外，該不織布基材的纖維微細化過程中，不需額外使用溶劑，因此其係無廢棄物產生的環保開纖，而且該不織布基材具有超細纖維的手感和接近天然皮革之回彈觸感，再經加工成為人工皮革後則具有優越的手感和物性表現。
本發明係利用一第一成份(熱可塑性非彈性體)與一第二成份(熱可塑性彈性體(Thermoplastic Elastomer,TPE))進行分割型超細纖維複合紡絲，以製得複合纖維，再將該複合纖維進一歩加工成人工皮革基材與人工皮革。該複合纖維的特點為該第一成份(熱可塑性非彈性體)佔該複合纖維總重量比例為30%至95%，較佳為40%至60%；該第二成份(熱可塑性彈性體)佔該複合纖維總重量比例為5%至70%，該第二成份(熱可塑性彈性體)於該複合纖維橫切面之圓周之分佈為非連續性，並與該第一成份(熱可塑性非彈性體)呈交替分佈，且該第二成分(熱可塑性彈性體)佔該複合纖維橫切面之圓周全部長度50%以下。
該複合纖維之優點為，由於該複合纖維外周顯露的該第二成份(熱可塑性彈性體)減少，因此其不須再經離型劑處理。此外，該複合纖維在經熱軟化或溶液浸潤軟化後，因該第二成份(熱可塑性彈性體)透過該第一成份(熱可塑性非彈性體)的隔開，該第二成份(熱可塑性彈性體)並不會過度黏合而產生橡膠感，而且，軟化流動後，該第一成份(熱可塑性非彈性體)可達到微細化纖維作用。
參考圖1，顯示本發明中含彈性體之複合纖維之第一實施例之橫切面示意圖。該複合纖維1包括一第一成份11及一第二成份12。該第一成份11係為熱可塑性非彈性體，該第二成份12係為熱可塑性彈性體。該第一成份11係顯露於該複合纖維1之外周面，而於該複合纖維1之橫切面之圓周中形成複數個第一線段111。該第二成份12係顯露於該複合纖維1之外周面，而於該複合纖維1之橫切面之圓周中形成複數個第二線段121。該等第一線段111及該等第二線段121係形成該複合纖維1之橫切面之圓周，且該等第一線段111及該等第二線段121係交替分佈。該等第二線段121總長度係佔該複合纖維之橫切面之圓周全部長度50%以下。
在本實施例中，該第一成份11係包括複數個第一直條狀外型，其二端皆為該等第一線段111，該第二成份12係包括複數個第二直條狀外型，其二端皆為該等第二線段121。
參考圖2，顯示本發明中含彈性體之複合纖維之第二實施例之橫切面示意圖。該複合纖維2包括一第一成份21及一第二成份22。該第一成份21係為熱可塑性非彈性體，該第二成份22係為熱可塑性彈性體。該第一成份21係顯露於該複合纖維2之外周面，而於該複合纖維2之橫切面之圓周中形成複數個第一線段211。該第二成份22係顯露於該複合纖維2之外周面，而於該複合纖維2之橫切面之圓周中形成複數個第二線段221。在本實施例中，該第一成份21係包括複數個第一扇形，其弧邊係為該等第一線段211；該第二成份22係包括複數個第二扇形，其弧邊係為該等第二線段221。
參考圖3，顯示本發明中含彈性體之複合纖維之第三實施例之橫切面示意圖。該複合纖維3包括一第一成份31及一第二成份32。該第一成份31係為熱可塑性非彈性體，該第二成份32係為熱可塑性彈性體。該第一成份31係顯露於該複合纖維3之外周面，而於該複合纖維3之橫切面之圓周中形成複數個第一線段311。該第二成份32係顯露於該複合纖維3之外周面，而於該複合纖維3之橫切面之圓周中形成複數個第二線段321。在本實施例中，該第一成份31係包括一中央部312及複數個第一外圍部313，該等第一外圍部313係由該中央部312向外延伸，其外端係為該等第一線段311；該第二成份32係包括複數個第二外圍部，每一第二外圍部係位二個第一外圍部313之間，該等第二外圍部之一端係連接該中央部312，另一端係為該等第二線段321。
本發明之含彈性體之複合纖維之製造方法，包括以下步驟：(a)提供一第一成份及一第二成份，該第一成份係為熱可塑性非彈性體，該第二成份係為熱可塑性彈性體，且該第二成份之重量比例為5%至70%；及(b)利用一複合噴絲板將該第一成份及一第二成份共同抽絲，以進行分割複合紡絲，而製得複數個複合纖維，其中於每一該等複合纖維之橫切面之圓周中該第一成份及該第二成份係交替分佈，且該第二成份佔該圓周全部長度50%以下。
以上述第二實施例之複合纖維2為例，在該步驟(b)之紡絲步驟時，該第一成份21(熱可塑性非彈性體)與該第二成份22(熱可塑性彈性體)以間隔的被擠押出成扇形總數目8~128的複合纖維2，較佳數目為16~48。如果該總數目過少，該第二成份22(熱可塑性彈性體)於經熱軟化或溶液浸潤軟化後分散性不佳，使得所製成之人工皮革基材或人工皮革的強度或手感均不佳；如果該總數目過多，該第二成份22(熱可塑性彈性體)於經熱軟化或溶液浸潤軟化後會將該複合纖維2完全包覆住，使得所製成之人工皮革基材或人工皮革的手感不佳。因此，該第二成份22(熱可塑性彈性體)於該複合纖維2橫切面分佈為所佔圓周全部長度50%以下，較佳40%以下，如所佔比例過高，則該第二成份22(熱可塑性彈性體)於經熱軟化或溶液浸潤軟化後，該等複合纖維2間會過度黏合，使得所製成之人工皮革基材或人工皮革的手感過硬。
本發明中該第一成份之材質可以是聚酯類聚合物、聚醯胺類聚合物或聚烯烴類聚合物。該聚酯類聚合物係為聚對苯二甲酸乙二酯(PET)、聚對苯二甲酸丁二酯(PBT)、聚對苯二甲酸丙二酯(PTT)及其改質物或共聚物。該聚醯胺類聚合物係為聚醯胺6(PA6)、聚醯胺66(PA66)、聚醯胺12(PA12)及其改質物或共聚物。該聚烯烴類聚合物係為聚乙烯(PE)、聚丙烯(PP)及其改質物或共聚物。此外，依需求亦可添加染料、碳黑、增塑劑、安定劑等功能性助劑。
本發明中該第二成份之材質可以是熱可塑性苯乙烯嵌段共聚物彈性體(Thermoplastic Styrenic Block Copolymer Elastomer)、熱可塑性聚酯彈性體(Thermoplastic Polyester Elastomer,TPEE)、熱可塑性聚烯烴彈性體(Thermoplastic Olefin,TPO)、硫化熱可塑性聚烯烴彈性體(Thermoplastic Vulcanizate,TPV)或熱可塑性聚醯胺彈性體(Thermoplastic Polyamide,TPA)。該熱可塑性苯乙烯嵌段共聚物彈性體係為苯乙烯-丁二烯-苯乙烯熱可塑性彈性體(Styrene-Butadiene-Styrene,SBS)、苯乙烯-乙烯/丁烯-苯乙烯熱可塑性彈性體(Styrene-Ethylene/Butylene-Styrene,SEBS)、苯乙烯-乙烯/丙烯-苯乙烯熱可塑性彈性體(Styrene-Ethylene/Propylene-Styrene,SEPS)、苯乙烯-異戊二烯-苯乙烯熱可塑性彈性體(Styrene-Isoprene-Styrene,SIS)或其混合物。該熱可塑性聚烯烴彈性體(Thermoplastic Olefin,TPO)係為熱可塑性乙烯-丙烯嵌段共聚物彈性體(Thermoplastic Ethylene-Propylene Copolymer,TEP)。此外，依需求亦可添加染料、碳黑、防黏劑、安定劑等。
本發明另外關於一種人工皮革之基材，其包括複數個複合纖維(即上述之複合纖維)，每一複合纖維包括一第一成份(即上述之第一成份)及一第二成份(即上述之第二成份)，該第一成份係為熱可塑性非彈性體，該第二成份係為熱可塑性彈性體，該第二成份佔該複合纖維總重量比例為5%至70%，於該複合纖維之橫切面之圓周中該第一成份及該第二成份係交替分佈，且該第二成份佔該圓周全部長度50%以下，其中，該等複合纖維間之交叉點係為該第二成份軟化而形成彈性結合點。
該第一成份之材質係選自由聚酯類聚合物、聚醯胺類聚合物及聚烯烴類聚合物所組成之群，該第二成份之材質係選自由熱可塑性苯乙烯嵌段共聚物彈性體、熱可塑性聚酯彈性體(TPEE)、熱可塑性聚烯烴彈性體(TPO)、硫化熱可塑性聚烯烴彈性體(TPV)及熱可塑性聚醯胺彈性體(TPA)所組成之群。
較佳地，該基材更包括複數個混合纖維，其係為熱可塑性非彈性體，其材質係選自由聚酯類聚合物、聚醯胺類聚合物及聚烯烴類聚合物所組成之群。該等複合纖維佔該基材總重量比例為5%至75%。
該等複合纖維係形成複數個第一纖維網，該等混合纖維係形成複數個第二纖維網，該等第一纖維網及該等第二纖維網係彼此堆疊；或者該等混合纖維係混合後且形成複數個第三纖維網，該等第三纖維網係堆疊而成。該等混合纖維與該等複合纖維間之交叉點係為該第二成份軟化而形成彈性結合點。
將上述之複合纖維製成該基材之方法如下：(a)提供複數個複合纖維(即上述之複合纖維)，每一複合纖維包括一第一成份(即上述之第一成份)及一第二成份(即上述之第二成份)，該第一成份係為熱可塑性非彈性體，該第二成份係為熱可塑性彈性體，該第二成份佔該複合纖維總重量比例為5%至70%，於該複合纖維之橫切面之圓周中該第一成份及該第二成份係交替分佈，且該第二成份佔該圓周全部長度50%以下；(b)形成複數個纖維網，該等纖維網包含該等複合纖維；(c)堆疊該等纖維網；(d)針軋或水軋該等纖維網；(e)利用加熱或溶液浸潤以軟化該第二成份，以結合該等複合纖維；及(f)利用移除熱或溶液以固化該第二成份，使得該等複合纖維間之交叉點係為該第二成份所形成之彈性結合點。
如果僅有該等複合纖維，則該步驟(b)係將該等複合纖維形成複數個第一纖維網，該步驟(c)係堆疊該等第一纖維網，該步驟(d)係針軋或水軋該等第一纖維網。
如果該步驟(a)更包括一提供複數個混合纖維之步驟，該等混合纖維係為熱可塑性非彈性體，且該等複合纖維佔總重量比例為5%至75%。之後步驟會有以下二種可能情況。
第一種可能情況：該步驟(b)係將該等複合纖維形成複數個第一纖維網，且將該等混合纖維係形成複數個第二纖維網，該步驟(c)係堆疊該等第一纖維網及該等第二纖維網，該步驟(d)係針軋或水軋該等第一纖維網及該等第二纖維網，該步驟(e)係軟化該第二成份，以結合該等複合纖維及該等混合纖維，該步驟(f)係固化該第二成份，使得該等混合纖維與該等複合纖維間之交叉點係為該第二成份軟化而形成彈性結合點。
第二種可能情況：該步驟(b)係混合該等複合纖維及該等混合纖維，且形成複數個第三纖維網，該步驟(c)係堆疊該等第三纖維網，該步驟(d)係針軋或水軋該等第三纖維網，該步驟(e)係軟化該第二成份，以結合該等複合纖維及該等混合纖維，該步驟(f)係固化該第二成份，使得該等混合纖維與該等複合纖維間之交叉點係為該第二成份軟化而形成彈性結合點。
以下以一實施例說明該不織布基材之製造方法。首先，可藉由紡黏法成網、熔吹法成網、梳理法成網、濕法成網或氣流成網將該等複合纖維製作成複數個纖維網，其中後三者可以先行製得約3至約30丹尼之未延伸絲，然後將此未延伸絲經延伸、定型、皺折、上油、烘乾及切棉等製程處理，製得細度為1丹尼至10丹尼、長度為2公分至10公分之具皺折的複合短纖棉(staple fiber)。然後，可將該複合短纖棉依5%~100%的重量比率與其他短纖棉混合後製成一纖維網。之後，再將多層纖維網經重疊，其中不同層之纖維網的纖維成分和比例均可不同。最後進行針軋(或水軋)使纖維間產生糾絡以製成基重為100g/m2 至1000g/m2 之不織布，此不織布再經80℃~200℃熱壓整理將該不織布表面燙平，即可作為人工皮革的不織布基材。
與該複合纖維混合製成不織布的短纖棉或長纖維，可以包含一種以上的短纖棉或長纖維，該短纖棉或長纖維可為聚酯類聚合物、聚醯胺類聚合物、聚烯烴類聚合物的單一成分之短纖棉，或二種以上成份之複合短纖棉或複合長纖維。
本發明另外關於一種人工皮革，其包括一基材(即上述之基材)及一彈性皮膜。該基材係為一不織布基材。該彈性皮膜係位於該基材之一表面，該彈性皮膜之材質係為彈性聚合物或乳膠。
該人工皮革之製造方法包括但不限於以下三種。
第一種方法：將一彈性聚合物溶液或乳膠液以直接均勻塗佈於一離型紙上，該彈性聚合物溶液或乳膠液之後經烘乾去除溶劑後形成一彈性皮膜。上述塗佈和烘乾步驟可依不同功能或厚度需求而重覆進行以形成一多層彈性皮膜。最後於該彈性皮膜表面均勻塗佈一彈性聚合物接著劑後，將上述不織布基材貼合並加以烘乾，使該彈性皮膜與該不織布基材能充分接著，待冷卻後將該離型紙予以剝離即得一人工皮革。
第二種方法：將一彈性聚合物溶液或乳膠液直接均勻塗佈於該不織布基材上，之後進行溶劑脫除使該彈性聚合物凝固後，再依序進行水洗去除溶劑和將水份乾燥後，此時凝固後的彈性聚合物形成一彈性皮膜。接著，依不同需求進行研磨(研磨該彈性皮膜)、貼合(將該不織布基材及該彈性皮膜貼合於另一PU上)等表面加工處理即得一人工皮革。
第三種方法：將該不織布基材於一彈性聚合物溶液或乳膠液內進行含浸，使該彈性聚合物溶液或乳膠液滲入於該不織布基材內部。經羅拉擠壓後使該彈性聚合物溶液或乳膠液的吸收量能維持在所需比例，略為烘乾去除溶劑後再於表面塗佈該彈性聚合物溶液或乳膠液，之後進行溶劑脫除使該彈性聚合物凝固後，再依序進行水洗去除溶劑和將水份乾燥後，此時凝固後的彈性聚合物形成一彈性皮膜。接著，依不同需求進行研磨(研磨該彈性皮膜)、貼合(將該不織布基材及該彈性皮膜貼合於另一PU上)等表面加工處理即得一人工皮革。
上述彈性聚合物之材質可以是聚氯乙烯、聚醯胺、聚酯、聚酯-醚共聚物、聚丙烯酸酯共聚物、聚胺基甲酸酯、氯丁橡膠、苯乙烯-丁二烯共聚物、矽樹脂、聚胺基酸、聚胺基酸-聚胺甲酸酯共聚物等合成樹脂或天然高分子樹脂、或其混合物等。此外，依需求亦可添加顏料、染料、交聯劑、填充劑、增塑劑、安定劑等。
本發明之優點如下。該複合纖維內之熱可塑性彈性體能均勻分散並增加纖維間黏著，且其分割型纖維斷面更可防止該熱可塑性彈性體於纖維及不織布基材生產時過度黏著影響加工，因此在不織布熱壓後能使布表面更加細緻平坦，且物性增強及較高的尺寸安定性。此外，該不織布基材的纖維微細化過程中，不需額外使用溶劑，因此其係無廢棄物產生的環保開纖，而且該不織布基材具有超細纖維的手感和接近天然皮革之回彈觸感，再經加工成為人工皮革後則具有優越的手感和物性表現。
該熱可塑性彈性體在經熱軟化或溶液浸潤軟化，因具低流動性，故其可流動並分散於纖維間；之後當移除熱或溶液時，該熱可塑性彈性體之狀態回復為固態，因此可增加纖維之間的黏著力，由於纖維間除了物理性的糾絡外，多了該熱可塑性彈性體所提供的黏著力。除了可增人工皮革基材及人工皮革強度外，在縱向和橫向的伸長率也會因此下降，改善材料的尺寸安定性。而利用此方法製成之人工皮革基材已具有該熱可塑性彈性體分散於內部，除了可使該基材具有些許人工皮革的彈性觸感，其可縮小針軋或水軋所造成的軋痕，使表面更為細緻平坦，再經塗佈加工時，可減少彈性聚合物溶液或乳膠液的塗佈次數和用量，可減少製造時間和成本。
在本發明中，該人工皮革基材或人工皮革於熱處理或溶液過程中，該熱可塑性彈性體則如同海島型纖維的海成份一樣，該熱可塑性彈性體將成可流動狀分散之，並使另一不受熱或溶液影響之纖維微細化，但此時該熱可塑性彈性體並無須移除，而是分散於纖維間，且在冷卻之後作為纖維間黏合劑，所以在整個纖維微細化過程中，並無任何成份被移除，所以無須再進行移除物的後處理，因此為一環保的纖維微細化製程。
茲以下列實例予以詳細說明本發明，唯並不意謂本發明僅侷限於此等實例所揭示之內容。
實例1：
將苯乙烯-乙烯/丁烯-苯乙烯熱可塑性彈性體(SEBS)酯粒(熔融質量流動率為25g/10min，科騰聚合物股份有限公司製造)與聚對苯二甲酸丁二醇酯(PBT)酯粒(極限黏度0.94dl/gr，長春人造樹脂廠製造)為原料投入複合紡絲進行24分割複合紡絲，其中苯乙烯-乙烯/丁烯-苯乙烯熱可塑性彈性體熔融溫度設定為270℃。聚對苯二甲酸丁二醇酯熔融溫度設定為280℃，其中苯乙烯-乙烯/丁烯-苯乙烯熱可塑性彈性體/聚對苯二甲酸丁二醇酯的複合重量比例為40/60，以700m/min速度進行紡絲捲取，製成15丹尼(den)之複合纖維後，再以進行2.8倍延伸，並於加以熱定型處理，之後經皺褶機再切成長度60mm之複合短纖棉。該複合短纖棉之物性為細度6丹尼，纖維強度2.1克/丹尼，伸長率80%。
該複合短纖棉再與細度2丹尼之聚酯短纖棉進行依30/70的重比例混棉，開棉後再經梳棉機製成纖維網，將該纖維網再經5層堆疊後，依序經粗軋、精軋工序使纖維產生物理性的糾絡即製成不織布，此不織布之單位面積重量為220g/m2 。此不織布再經160℃熱壓使表面平整化處理，此時，苯乙烯-乙烯/丁烯-苯乙烯即同時熔融軟化，在熱壓與冷卻過程中，同時使纖維開纖並使纖維間產生局部黏著，以製得人工皮革之基材。由於該熱可塑性彈性體分散黏著於纖維間，使得該人工皮革之基材具有較佳表現，且以手搓揉之，已具有些許人工皮革的手感。
比較例1：
將100%的聚酯短纖棉開棉後再經梳棉機製成纖維網，與實例1相同的條件，依序經粗軋、精軋工序使纖維產生物理性的糾絡即製成不織布，此不織布之單位面積重量為220g/m2 ，此不織布再經190℃熱壓使表面平整化處理。
參考表1，顯示比較例1(100%聚酯短纖)之基材與實例1(30% SEBS複合短纖+70%聚酯短纖)之基材之物性比較。如表1所示，有添加苯乙烯-乙烯/丁烯-苯乙烯熱可塑性彈性體/聚對苯二甲酸丁二醇酯複合短纖棉的基材在撕裂強度、抗張強度、剝離強度、破裂強度的表現均有顯著的增加，而伸長率的下降對於基材加工時尺寸穩定會有所助益。
表1：比較例1(100%聚酯短纖)之基材與實例1(30% SEBS複合短纖+70%聚酯短纖)之基材之物性比較，其中MD係為機械方向(Mechanical Direction)，CD係為剖面方向(Cross Direction)
實例2：
將熱可塑性聚酯彈性體(TPEE)酯粒(硬度72D，樂金化學股份有限公司製造)與聚對苯二甲酸乙二醇酯(PET)酯粒(極限黏度0.94dl/gr，長春人造樹脂廠製造)為原料投入複合紡絲進行24分割複合紡絲，其中該熱可塑性聚酯彈性體熔融溫度設定為275℃。該聚對苯二甲酸乙二醇酯熔融溫度設定為280℃，其中該熱可塑性聚酯彈性體/聚對苯二甲酸乙二醇酯的複合重量比例為40/60，以700m/min速度進行紡絲捲取，製成10丹尼之複合纖維後，再以進行2.5倍延伸，並於加以熱定型處理，之後經皺褶機再切成長度60mm複合短纖維，則該複合短纖維之物性為細度4丹尼，纖維強度2.5克/丹尼，伸長率50%。
該複合短纖維再與聚酯短纖棉進行依30/70的重量比例混棉，開棉後再經梳棉機製成纖維網，將纖維網再經5層堆疊後，依序經粗軋、精軋工序使纖維產生物理性的糾絡即製成不織布，此不織布再經180℃熱壓使表面平整化處理後，TPEE即同時熔融軟化，在熱壓與冷卻過程中，同時使纖維開纖並使纖維間產生局部黏著，以製得人工皮革之基材。由於該熱可塑性彈性體分散黏著於纖維間，使得此人工皮革之基材具有較佳表現，且以手搓揉之，已具有些許人工皮革的手感。
實例3：
將苯乙烯-乙烯/丁烯-苯乙烯熱可塑性彈性體(SEBS)酯粒(熔融質量流動率為25g/10min，科騰聚合物股份有限公司製造)與聚對苯二甲酸乙二醇酯(PET)酯粒(極限黏度0.64dl/gr，新光合成纖維股份有限公司製造)為原料投入複合紡絲進行24分割複合紡絲，其中該苯乙烯-乙烯/丁烯-苯乙烯熱可塑性彈性體熔融溫度設定為270℃，該聚對苯二甲酸乙二醇酯熔融溫度為285℃。該苯乙烯-乙烯/丁烯-苯乙烯熱可塑性彈性體/聚對苯二甲酸乙二醇酯的複合重量比例為45/55，以800m/min速度進行紡絲捲取，製成13丹尼之複合纖維後，再以進行3.1倍延伸，並於加以熱定型處理，之後經皺褶機再切成長度60mm複合短纖維，則該複合短纖維之物性為細度4.5丹尼，纖維強度2.0克/丹尼，伸長率60%。
該複合短纖維再與細度2丹尼聚對苯二甲酸乙二醇酯短纖棉進行依35/65的重比例混棉，開棉後再經梳棉機製成纖維網，將纖維網再經5層堆疊後，依序經粗軋、精軋工序使纖維產生物理性的糾絡即製成不織布，此不織布之單位面積重量為220g/m2 ，此不織布再經160℃熱壓使表面平整化處理後，該苯乙烯-乙烯/丁烯-苯乙烯熱可塑性彈性體即同時熔融軟化，在熱壓與冷卻過程中，同時使纖維開纖並使纖維間產生局部黏著，以製得人工皮革之基材。
實例4：
將乙烯-丙烯熱可塑性彈性體(TEP)酯粒(熔融質量流動率為50g/10min，Vistamaxx公司製造)與聚酯(PET)粒(極限黏度0.64dl/gr，新光合成纖維股份有限公司製造)為原料投入複合紡絲進行32分割複合紡絲，其中該乙烯-丙烯熱可塑性彈性體熔融溫度設定為270℃，該聚酯熔融溫度設定為290℃，其中乙烯-丙烯熱可塑性彈性體(TEP)/聚酯的複合重量比例為35/65。製得之複合纖維經牽伸器以5000m/min速度進行延伸，經延伸的複合纖維之物性為細度3丹尼，纖維強度5.0克/丹尼，伸長率45%。該複合纖維經牽伸器延伸後，將其鋪成質量均勻的纖維網，纖維網再經7層堆疊後，依序經粗軋、精軋工序使纖維產生物理性的糾絡即製成不織布，此不織布之單位面積重量為330g/m2 。此不織布再經160℃熱壓使表面平整化處理時，該乙烯-丙烯熱可塑性彈性體即同時熔融軟化，在熱壓與冷卻過程中，同時使纖維開纖並使纖維間產生局部黏著，以製得人工皮革之基材。
實例5：
將熱可塑性聚酯彈性體(TPEE)酯粒(硬度72D，樂金化學股份有限公司製造)與聚酯(PET)粒(極限黏度0.64dl/gr，新光合成纖維股份有限公司製造)為原料投入複合紡絲進行16分割複合紡絲，其中該熱可塑性聚酯彈性體熔融溫度設定為275℃，該聚酯熔融溫度設定為280℃。熱可塑性聚酯彈性體/聚酯(PET)粒的複合重量比例為30/70，製得之複合纖維經牽伸器以5000m/min速度進行延伸，經延伸的複合纖維之物性為細度3.5丹尼，纖維強度4.5克/丹尼，伸長率55%。該複合纖維經牽伸器延伸後，將其鋪成質量均勻的纖維網，纖維網再經6層堆疊後，依序經粗軋、精軋工序使纖維產生物理性的糾絡即製成不織布，此不織布之單位面積重量為330g/m2 ，此不織布再經190℃熱壓使表面平整化處理後，熱可塑性聚酯彈性體即同時熔融軟化，在熱壓與冷卻過程中，同時使纖維開纖並使纖維間產生局部黏著，以製得人工皮革之基材。
實例6：
將實例1所得之人工皮革基材含浸固成份為30%之彈性聚氨酯溶液，經擠壓將多餘的彈性聚氨酯溶液擠出，並使彈性聚氨酯溶液分佈均勻。接著，塗佈彈性聚氨酯溶液以形成中引層，入水將溶劑二甲基甲醯胺移出使聚氨酯凝固形成多微孔的中引層(彈性皮膜)，再經水洗將溶劑清淨後再進行乾燥，即為兼具優越物性及超細纖維手感的人工皮革。
比較例2：
將比較例1所得之人工皮革基材施予和實例6相同加工處理，含浸固成份為30%之彈性聚氨酯溶液，經擠壓將多餘的彈性聚氨酯溶液擠出，並使彈性聚氨酯溶液分佈均勻，接著塗佈彈性聚氨酯溶液以形成中引層，入水將溶劑二甲基甲醯胺移出使聚氨酯凝固形成多微孔的中引層(彈性皮膜)，再經水洗將溶劑清淨後再進行乾燥，即為人工皮革。
參考表2，顯示比較例2(100%聚酯短纖)之人工皮革與實例6(30% SEBS複合短纖+70%聚酯短纖)之人工皮革之物性比較。如表2所示，有添加苯乙烯-乙烯/丁烯-苯乙烯熱可塑性彈性體/聚對苯二甲酸丁二醇酯複合短纖棉的人工皮革在撕裂強度、抗張強度、剝離強度、破裂強度的表現均有顯著的增加，而在手感方面，具有超細纖維的細緻感。表2：比較例2(100%聚酯短纖)之人工皮革與實例6(30% SEBS複合短纖+70%聚酯短纖)之人工皮革之物性比較，其中MD係為機械方向(Mechanical Direction)，CD係為剖面方向(Cross Direction)
實例7：
將實例1所得之人工皮革基材含浸固成份為22%之彈性聚氨酯溶液，經擠壓將多餘的彈性聚氨酯溶液擠出，並使彈性聚氨酯溶液分佈均勻，接著經二甲基甲醯胺水溶液進行預凝，再經擠壓將多餘的二甲基甲醯胺水溶液進擠出，接著塗佈彈性聚氨酯溶液以形成中引層，入水將溶劑二甲基甲醯胺移出使聚氨酯凝固形成多微孔的中引層(彈性皮膜)，再經水洗將溶劑清淨後再進行乾燥，即為兼具優越物性及超細纖維手感的人工皮革。
實例8：
將實例1至實例5所得之人工皮革基材含浸固成份為30%之水性彈性聚氨酯溶液，經擠壓將多餘的水性彈性聚氨酯溶液擠出，並使水性彈性聚氨酯溶液分佈均勻，接著進行預凝後，塗佈水性彈性聚氨酯溶液以形成中引層，再經水洗將溶劑清淨後再進行乾燥，即為兼具優越物性及超細纖維手感的人工皮革半成品。
先將彈性聚氨酯溶液塗佈於離型紙上，經烘乾揮發去除溶劑後使彈性聚氨酯固化成薄膜，此時凝固後的彈性聚合物形成一彈性皮膜，接著於彈性聚氨酯薄膜表面塗佈一層貼合膠並再將上述之人工皮革半成品貼合後，再經烘乾使貼合膠層完成反應，最後再將離型紙剝除，即為兼具優越物性及超細纖維手感的人工皮革。
上述實施例僅為說明本發明之原理及其功效，並非限制本發明，因此習於此技術之人士對上述實施例進行修改及變化仍不脫本發明之精神。本發明之權利範圍應如後述之申請專利範圍所列。
1．．．本發明中含彈性體之複合纖維之第一實施例
2．．．本發明中含彈性體之複合纖維之第二實施例
3．．．本發明中含彈性體之複合纖維之第三實施例
11．．．第一成份
12．．．第二成份
21．．．第一成份
22．．．第二成份
31．．．第一成份
32．．．第二成份
111．．．第一線段
121．．．第二線段
211．．．第一線段
221．．．第二線段
311．．．第一線段
312．．．中央部
313．．．第一外圍部
321．．．第二線段
圖1顯示本發明中含彈性體之複合纖維之第一實施例之橫切面示意圖；
圖2顯示本發明中含彈性體之複合纖維之第二實施例之橫切面示意圖；及
圖3顯示本發明中含彈性體之複合纖維之第三實施例之橫切面示意圖。
1．．．本發明中含彈性體之複合纖維之第一實施例
11．．．第一成份
12．．．第二成份
111．．．第一線段
121．．．第二線段

Claims (15)

  1. 一種含彈性體之複合纖維之製造方法，包括：(a)提供一第一成份及一第二成份，該第一成份係為熱可塑性非彈性體，該第二成份係為熱可塑性彈性體，且該第二成份之重量比例為5%至70%；及(b)利用一複合噴絲板將該第一成份及一第二成份共同抽絲，以進行分割複合紡絲，而製得複數個複合纖維，其中於每一該等複合纖維之橫切面之圓周中該第一成份及該第二成份係交替分佈，且該第二成份佔該圓周全部長度50%以下。
  2. 如請求項1之製造方法，其中於每一該等複合纖維之橫切面中，該第一成份係包括複數個第一直條狀外型，其二端皆為該等第一線段，該第二成份係包括複數個第二直條狀外型，其二端皆為該等第二線段。
  3. 如請求項1之製造方法，其中於每一該等複合纖維之橫切面中，該第一成份係包括複數個第一扇形，該第二成份係包括複數個第二扇形。
  4. 如請求項1之製造方法，其中於每一該等複合纖維之橫切面中，該第一成份係包括一中央部及複數個第一外圍部，該等第一外圍部係由該中央部向外延伸，該第二成份係包括複數個第二外圍部，每一第二外圍部係位二個第一外圍部之間。
  5. 如請求項1之製造方法，其中該第一成份之材質係選自由聚酯類聚合物、聚醯胺類聚合物及聚烯烴類聚合物所組成之群。
  6. 如請求項5之製造方法，其中該聚酯類聚合物係為聚對苯二甲酸乙二酯(PET)、聚對苯二甲酸丁二酯(PBT)、聚對苯二甲酸丙二酯(PTT)及其改質物或共聚物，該聚醯胺類聚合物係為聚醯胺6(PA6)、聚醯胺66(PA66)、聚醯胺12(PA12)及其改質物或共聚物，該聚烯烴類聚合物係為聚乙烯(PE)、聚丙烯(PP)及其改質物或共聚物。
  7. 如請求項1之製造方法，其中該第二成份之材質係選自由熱可塑性苯乙烯嵌段共聚物彈性體(Thermoplastic Styrenic Block Copolymer Elastomer)、熱可塑性聚酯彈性體(TPEE)、熱可塑性聚烯烴彈性體(TPO)、硫化熱可塑性聚烯烴彈性體(TPV)及熱可塑性聚醯胺彈性體(TPA)所組成之群。
  8. 如請求項7之製造方法，其中該熱可塑性苯乙烯嵌段共聚物彈性體係為苯乙烯-丁二烯-苯乙烯熱可塑性彈性體(SBS)、苯乙烯-乙烯/丁烯-苯乙烯熱可塑性彈性體(SEBS)、苯乙烯-乙烯/丙烯-苯乙烯熱可塑性彈性體(SEPS)、苯乙烯-異戊二烯-苯乙烯熱可塑性彈性體(SIS)或其混合物，該熱可塑性聚烯烴彈性體(TPO)係為熱可塑性乙烯-丙烯嵌段共聚物彈性體(Thermoplastic Ethylene-Propylene Copolymer,TEP)。
  9. 一種人工皮革之基材，包括複數個複合纖維，每一複合纖維包括一第一成份及一第二成份，該第一成份係為熱可塑性非彈性體，該第二成份係為熱可塑性彈性體，該第二成份佔該複合纖維總重量比例為5%至70%，於該複合纖維之橫切面之圓周中該第一成份及該第二成份係交替分佈，且該第二成份佔該圓周全部長度50%以下，其中，該等複合纖維間之交叉點係為該第二成份軟化而形成彈性結合點，且該等複合纖維佔該基材總重量比例為5%至75%。
  10. 如請求項9之基材，更包括複數個混合纖維，其係為熱可塑性非彈性體，該等混合纖維與該等複合纖維間之交叉點係為該第二成份軟化而形成彈性結合點，該等混合纖維之材質係選自由聚酯類聚合物、聚醯胺類聚合物及聚烯烴類聚合物所組成之群。
  11. 如請求項9之基材，其中該第一成份之材質係選自由聚酯類聚合物、聚醯胺類聚合物及聚烯烴類聚合物所組成之群，該第二成份之材質係選自由熱可塑性苯乙烯嵌段共聚物彈性體(Thermoplastic Styrenic Block Copolymer Elastomer)、熱可塑性聚酯彈性體(TPEE)、熱可塑性聚烯烴彈性體(TPO)、硫化熱可塑性聚烯烴彈性體(TPV)及熱可塑性聚醯胺彈性體(TPA)所組成之群。
  12. 一種人工皮革之基材之製造方法，包括以下步驟：(a)提供複數個複合纖維，每一複合纖維包括一第一成份及一第二成份，該第一成份係為熱可塑性非彈性體，該第二成份係為熱可塑性彈性體，該第二成份佔該複合纖維總重量比例為5%至70%，於該複合纖維之橫切面之圓周中該第一成份及該第二成份係交替分佈，且該第二成份佔該圓周全部長度50%以下；(b)形成複數個纖維網，該等纖維網包含該等複合纖維；(c)堆疊該等纖維網；(d)針軋或水軋該等纖維網；(e)軟化該第二成份，以結合該等複合纖維；及(f)固化該第二成份，使得該等複合纖維間之交叉點係為該第二成份所形成之彈性結合點。
  13. 如請求項12之製造方法，其中該第一成份之材質係選自由聚酯類聚合物、聚醯胺類聚合物及聚烯烴類聚合物所組成之群，該第二成份之材質係選自由熱可塑性苯乙烯嵌段共聚物彈性體(Thermoplastic Styrenic Block Copolymer Elastomer)、熱可塑性聚酯彈性體(TPEE)、熱可塑性聚烯烴彈性體(TPO)、硫化熱可塑性聚烯烴彈性體(TPV)及熱可塑性聚醯胺彈性體(TPA)所組成之群。
  14. 如請求項12之製造方法，其中該步驟(b)係利用紡黏法成網、熔吹法成網、梳理法成網、濕法成網或氣流成網形成該等纖維網。
  15. 如請求項12之製造方法，其中該步驟(e)中係利用加熱或溶液浸潤以軟化該第二成份，該步驟(f)係利用移除熱或溶液以固化該第二成份。
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