TWI585251B - Composite long fiber textile and its use of the environmental protection of synthetic long fiber artificial leather - Google Patents

Composite long fiber textile and its use of the environmental protection of synthetic long fiber artificial leather Download PDF

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Publication number
TWI585251B
TWI585251B TW103128895A TW103128895A TWI585251B TW I585251 B TWI585251 B TW I585251B TW 103128895 A TW103128895 A TW 103128895A TW 103128895 A TW103128895 A TW 103128895A TW I585251 B TWI585251 B TW I585251B
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TW
Taiwan
Prior art keywords
fiber
composite long
artificial leather
composite
textile
Prior art date
Application number
TW103128895A
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English (en)
Other versions
TW201608068A (zh
Inventor
Chung Chih Feng
Kuo Kuang Cheng
Chih Yi Lin
Kao Lung Yang
Chien Min Wu
Original Assignee
San Fang Chemical Industry Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by San Fang Chemical Industry Co filed Critical San Fang Chemical Industry Co
Priority to TW103128895A priority Critical patent/TWI585251B/zh
Priority to CN201410638085.6A priority patent/CN105350339A/zh
Priority to CN202110538598.XA priority patent/CN113389056A/zh
Priority to US14/693,328 priority patent/US20160053434A1/en
Publication of TW201608068A publication Critical patent/TW201608068A/zh
Application granted granted Critical
Publication of TWI585251B publication Critical patent/TWI585251B/zh
Priority to US17/669,912 priority patent/US20220186427A1/en

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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
    • D06N3/0036—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • D01D5/34—Core-skin structure; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0006—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using woven fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0011—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using non-woven fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N3/045—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with polyolefin or polystyrene (co-)polymers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/121—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyesters, polycarbonates, alkyds
    • D06N3/123—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyesters, polycarbonates, alkyds with polyesters
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0207—Elastomeric fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/12—Conjugate fibres, e.g. core/sheath or side-by-side
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2274/00—Thermoplastic elastomer material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B2307/734—Dimensional stability
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B27/00—Layered products comprising a layer of synthetic resin
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    • B32B27/00—Layered products comprising a layer of synthetic resin
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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    • B32—LAYERED PRODUCTS
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/10—Conjugate fibres, e.g. core-sheath, side-by-side

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

Description

複合長纖維紡織品及用其製得之環保複合長纖維人工皮革
本發明係關於一種紡織品及人工皮革，特別係關於一種環保複合長纖維人工皮革及複合長纖維紡織品。
習知人工皮革若使用短纖維及其製成的短纖維紡織品基材，會發生基材尺寸安定性不佳，同時為了保持皮革之良好手感，而無法達到輕量化的目標，同時若製造過程含浸或貼合PU樹酯，則會因為含有溶劑而不環保，若人工皮革使用長纖維及其製成的長纖維紡織品基材，雖尺寸安定性佳，但由於長纖維紡織品為薄型結構，無法給予皮革良好的手感，且製造過程含浸或貼合PU樹酯，同樣因為含有溶劑而不環保。
習知人工皮革及其製造方法如下列先前技術專利文獻分析。
1. TW201128019
作法：複合熱可塑性基材與異形斷面纖維並熔噴於基網上，表面再進行熱可塑性基材熱貼合併及進行加熱加壓紋路處理。
缺點：加工較繁瑣，尺寸安定性不佳，無法輕量化，且有附量分布不均勻的問題發生。
2. TW438927
作法：利用非彈性體的纖維與表面配置具彈性體的纖維堆疊構成基材，再經短纖製程獲得人工皮革。
缺點：製程時間長，附量不均勻，抗張強度較低，剝離強度較差，棉網分佈容易不均勻。
3. TW201040352
作法：基材是由利用極細長纖維及高分子彈性體組成。
缺點：尺寸安定性不佳。
基於上述分析，有必要提供一創新且具進步性之環保複合長纖維人工皮革及其製造方法與複合長纖維紡織品及其製造方法，以解決上述習知缺失。
本發明提供一種環保複合長纖維人工皮革，包括一複合長纖維紡織品及一彈性體薄膜。該複合長纖維紡織品係由複合長纖維或複合長纖維與其他長纖維共同製成，該複合長纖維包括至少一蕊部及一鞘部。該至少一蕊部係為聚酯類聚合物、聚醯胺聚合物或聚丙烯聚合物。該鞘部係包覆該至少一蕊部，且該鞘部係為熱可塑性彈性體。該彈性體薄膜係結合於該複合長纖維紡織品。
本發明另提供一種複合長纖維紡織品，係由複合長纖維或該複合長纖維與其他長纖維共同製成，該複合長纖維包括至少一蕊部及一鞘部。該至少一蕊部係為聚酯類聚合物、聚醯胺聚合物或聚丙烯聚合物。該鞘部係包覆該至少一蕊部，且該鞘部係為熱可塑性彈性體。
本發明以複合長纖維或其與其他長纖維共同製成複合長纖維紡織品，並利用複合長纖維紡織品與彈性體薄膜之結合，可製得輕量化、耐磨耗、手感良好及尺寸安定性佳之環保人工皮革。且本發明無需使用溶劑即可製得人工皮革，符合環保之要求。
為了能夠更清楚瞭解本發明的技術手段，而可依照說明書的內容予以實施，並且為了讓本發明所述目的、特徵和優點能夠更明顯易懂，以下特舉較佳實施例，並配合附圖，詳細說明如下。
10‧‧‧環保複合長纖維人工皮革
12‧‧‧複合長纖維紡織品
120‧‧‧複合長纖維
122‧‧‧蕊部
124‧‧‧鞘部
14‧‧‧彈性體薄膜
S41~S43‧‧‧步驟
圖1顯示本發明環保複合長纖維人工皮革之結構示意圖；圖2顯示本發明複合長纖維之結構剖視圖；圖3顯示本發明複合長纖維之另一結構剖視圖；圖4顯示本發明環保複合長纖維人工皮革之製造方法流程圖；圖5A至5C顯示本發明環保複合長纖維人工皮革之製造方法示意圖；圖6顯示發明例1以長纖維複合紡絲機製備複合長纖維之製程示意圖；圖7顯示發明例2以紡黏複合纖維紡絲機製備複合長纖維之製程示意圖；圖8顯示發明例3以熔噴複合纖維紡絲機製備複合長纖維之製程示意圖；及圖9顯示發明例4以手持式熔噴複合纖維紡絲機製備複合長纖維之製程示意圖。
圖1顯示本發明環保複合長纖維人工皮革之結構示意圖。圖2顯示本發明複合長纖維之結構剖視圖。配合參閱圖1及圖2，本發明之環保複合長纖維人工皮革10包括一複合長纖維紡織品12及一彈性體薄膜14。
該複合長纖維紡織品12係可由複合長纖維120製成或由複合長纖維120與聚酯長纖維或聚醯胺長纖維混紡製成，且該複合長纖維紡織品12之型態係可為織布型態(woven)或非織布型態(nonwoven)，其中織布可為平織或針織，且該織布可為一般纖維或高強力纖維與複合長纖維120混織的布。較佳地，該複合長纖維紡織品12之厚度為0.025至10mm，而該複合長纖維紡織品12之抗張強度為1至25 kg/25.4mm。
在本實施例中，該複合長纖維120包括至少一蕊部122及一鞘部124。該至少一蕊部122佔整體纖維重量比例為10至90%，而該鞘部124佔整體纖維重量比例亦可為90至10%。
該至少一蕊部122係為聚酯類聚合物、聚醯胺聚合物或聚丙烯聚合物，在本實施例中，該聚酯類聚合物之特性黏度範圍為0.4至1.1，而該聚醯胺聚合物之相對黏度範圍為2.0至3.0，而聚丙烯聚合物之熔融指數範圍為30至150(依據ASTM D1238標準，條件為2.16kg，230℃)。較佳地，該至少一蕊部122係可選自如下的其中一種聚合物：聚對苯二甲酸乙二醇酯(PET)、聚對苯二甲酸丁二醇酯(PBT)、聚對苯二甲酸丙二酯(PTT)、熱塑性脂肪族聚酯(PLA)、聚己內醯胺(Nylon6)、聚己二醯己二胺(Nylon6,6)、聚丙烯單聚合物(Polypropylene Homopolymer)及聚丙烯無規共合物(Polypropylene Random Copolymer)。
該鞘部124係包覆該至少一蕊部122，且該鞘部124係為熱可塑性彈性體。在本實施例中，該鞘部124之原料熔融指數範圍為1至100g/10min，依據ASTM D1238標準，條件為2.16kg，190℃。較佳地，該鞘部124係可選自如下的其中一種聚合物：熱可塑性聚氨酯(TPU)、熱可塑性聚酯彈性體(TPEE)及熱可塑性聚烯烴(TPO)。
參閱圖3，其係顯示本發明複合長纖維之另一結構剖視圖。如圖3所示，在另一實施例中，該複合長纖維120可包括複數個蕊部122及一鞘部124，各該蕊部122係呈間隔設置，且該鞘部124係包覆該等蕊部122。
另外，為達到輕量化及提高尺寸安定性，較佳地，該複合長纖維120之單根纖維丹尼數、密度及強度應分別滿足以下條件：丹尼數為0.001至20dpf；密度為0.8至1.4g/cm3；及強度為0.5至8.0g/den。
再參閱圖1，該彈性體薄膜14係結合於該複合長纖維紡織品12。在本實施例中，該彈性體薄膜14與該複合長纖維紡織品12之結合方式係可選自如下的其中一種：使用固形份為5~55%的水性糊劑黏著或直接以溫度90~180℃進行熱壓黏著。
此外，該彈性體薄膜14係可為發泡薄膜或未發泡薄膜，其中發泡薄膜之密度為0.3至0.9g/cm3及厚度為0.2至2.0mm，而未發泡薄膜之厚度為0.1至2.0mm。且較佳地，該彈性體薄膜14係可由如下的其中一種材料製成：熱可塑性聚氨酯(TPU)、熱可塑性聚酯彈性體(TPEE)及熱可塑性聚烯烴(TPO)。
圖4顯示本發明環保複合長纖維人工皮革之製造方法流程圖。圖5A至5C顯示本發明環保複合長纖維人工皮革之製造方法示意圖。配合參閱圖4之步驟S41及圖5A，製備複合長纖維120。在此步驟中，該複合長纖維120包括至少一蕊部122及一鞘部124。該至少一蕊部122佔整體纖維重量比例為10至90%，而該鞘部124佔整體纖維重量比例為90至10%。
該至少一蕊部122係為聚酯類聚合物、聚醯胺聚合物或聚丙烯聚合物。較佳地，該至少一蕊部122係可選自如下的其中一種聚合物：聚對苯二甲酸乙二醇酯(PET)、聚對苯二甲酸丁二醇酯(PBT)、聚對苯二甲酸丙二酯(PTT)、熱塑性脂肪族聚酯(PLA)、聚己內醯胺(Nylon6)、聚己二醯己二胺(Nylon6,6)、聚丙烯單聚合物(Polypropylene Homopolymer)及聚丙烯無規共合物(Polypropylene Random Copolymer)。
該鞘部124係包覆該至少一蕊部122，且該鞘部124係為熱可塑性彈性體。較佳地，該鞘部124係可選自如下的其中一種聚合物：熱可塑性聚氨酯(TPU)、熱可塑性聚酯彈性體(TPEE)及熱可塑性聚烯烴(TPO)。
另外，在此步驟中，製備該複合長纖維120之方法係可選自如下的其中一種：融熔紡絲法、紡黏法及熔噴法。且較佳地，該至少一蕊部122的押出溫度為180至250℃，而該鞘部124的押出溫度為150至250℃。
配合參閱圖4之步驟S42及圖5B，以該複合長纖維120或該複合長纖維120與聚酯長纖維或聚醯胺長纖維混紡製成一複合長纖維紡織品12。在此步驟中，製成該複合長纖維紡織品12之方法係可選自如下的其中一種：融熔紡絲法、紡黏法、熔噴法及纖維織布法。在本實施例中，纖維織布法包括以平織噴水織機、平織噴氣織機、圓編織機、經編織機、提花織機、橫編織機等其中一種設備織造所構成之織物。此外，該複合長纖維紡織品12之型態係可為織布型態(woven)或非織布型態(nonwoven)。再者，該複合長纖維紡織品12係可與一般纖維或高強力纖維交織或混紡，且該複合長纖維紡織品12係可經熱塑形成鞋面材。
配合參閱圖4之步驟S43及圖5C，結合一彈性體薄膜14於該複合長纖維紡織品12。在此步驟中，該彈性體薄膜14係可由如下的其中一種材料製成：熱可塑性聚氨酯(TPU)、熱可塑性聚酯彈性體(TPEE)及熱可塑性聚烯烴(TPO)。
在本實施例中，該彈性體薄膜14係熱壓貼合於該複合長纖維紡織品12。或者，在另一實施例中，該彈性體薄膜14係可以塗佈或噴塗方式結合於該複合長纖維紡織品12，例如以水溶性聚氨酯(PU)塗佈或噴塗於該複合長纖維紡織品12，而該水溶性聚氨酯(PU)乾燥後可形成該彈性體薄膜14。
本發明以複合長纖維120製成複合長纖維紡織品12，並利用複合長纖維紡織品12與彈性體薄膜14之結合，可製得輕量化、手感良好及尺寸安定性佳之人工皮革。且本發明無需使用溶劑即可製得人工皮 革，符合環保之要求。此外，本發明使用熱黏加工即可製得人工皮革，與傳統人工皮革中需要隴長的烘箱乾燥製程相比亦可縮短加工製程時間，減少能源排放，並可有效降低製造成本及提高生產效能。
此外，本發明環保複合長纖維人工皮革具透溼性，可直接成型鞋面。例如，該複合長纖維紡織品12係可呈鞋型，而該彈性體薄膜14經熱壓可形成鞋面。
另外，本發明複合長纖維紡織品亦可直接熱壓成型具凹凸鞋面。例如，該複合長纖維紡織品12係可呈鞋型。
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。
[發明例1]
以PBT(聚對苯二甲酸丁二酯，IV=0.74)當蕊部成份，搭配TPU(熱可塑性聚氨酯，MI=4,190℃,2.16kg)當鞘部成份，PBT與TPU之重量比為6：4。參閱圖6，其係顯示發明例1以長纖維複合紡絲機製備複合長纖維之製程示意圖。如圖6所示，利用長纖維複合紡絲機製成蕊鞘斷面複合長纖維，PBT紡絲箱溫度為250℃，TPU紡絲箱溫度為220℃，捲取速度為2500m/min，可得複合長纖維規格為100den/24f，單根纖維強度為4g/den。
將複合長纖維整齊排列後，經織布機織成經紗密度每英吋17條及緯紗密度每英吋17條之0.15mm厚的織造網布。
使用厚度為0.1mm之TPU膜與該織造網布，以熱壓機在溫度為120℃、壓力為20kg/cm2進行熱壓貼合，TPU薄膜與纖維鞘部的TPU同時因熱而軟化熔融並完成熱貼合，即可製得厚度為0.25mm，且柔軟又賦有彈性的環保複合長纖維人工皮革半成品。
以離型紙之PU乾式塗佈製程，在離型紙上依序塗佈水溶性聚氨 酯面層及糊劑，再與上述半品成表面進行貼合，即可製得具各種表面紋路的環保複合長纖維人工皮革。
[發明例2]
以PET(聚對苯二甲酸乙二酯，IV=0.5)當蕊部成份，搭配TPU(熱可塑性聚氨酯，MI=50,190℃,2.16kg)當鞘部成份，PBT與TPU之重量比為6：4。參閱圖7，其係顯示發明例2以紡黏複合纖維紡絲機製備複合長纖維之製程示意圖。如圖7所示，利用紡黏複合纖維紡絲機製成蕊鞘斷面複合長纖維，PET紡絲箱溫度為260℃，TPU紡絲箱溫度為220℃，經紡黏製程進行紡絲，其中風壓為9kg/cm2，風引拉伸絲速度為4000m/min，輸送帶速度為4m/min，因此，可製得直徑20μm之複合長纖維及厚度0.22mm之紡黏不織布紡織品，再以熱壓機(溫度110℃、壓力5kg/cm2)熱壓該紡黏不織布紡織品，熱壓後之該紡黏不織布紡織品的厚度為0.2mm，並具有良好的尺寸安定性。
使用厚度為0.1mm之TPU發泡膜與該紡黏不織布紡織品，以熱壓機在溫度為110℃、壓力為10kg/cm2進行熱壓貼合，TPU薄膜與纖維鞘部的TPU同時因熱而軟化熔融並完成熱貼合，故可製得柔軟、彈性及厚度為0.3mm的環保複合長纖維人工皮革半成品。
以離型紙之PU乾式塗佈製程，在離型紙上依序塗佈水溶性聚氨酯面層及糊劑，再與上述半品成表面進行貼合，即可製得具各種表面紋路的環保複合長纖維人工皮革。
[發明例3]
以PTT(聚對苯二甲酸丙二酯，IV=0.55)當蕊部成份，搭配TPU(熱可塑性聚氨酯，MI=80,190℃,2.16kg)當鞘部成份，PTT與TPU之重量比為6：4。參閱圖8，其係顯示發明例3以熔噴複合纖維紡絲機製備複 合長纖維之製程示意圖。如圖8所示，利用熔噴複合纖維紡絲機製成蕊鞘斷面複合長纖維，PTT紡絲箱溫度為250℃，TPU紡絲箱溫度為200℃，經熔噴製程進行紡絲，其中高壓空氣壓力為3000psi，高壓空氣溫度為180℃，輸送帶速度為2m/min，因此，可製得直徑20μm之複合長纖維及厚度0.27mm之熔噴不織布紡織品，再以熱壓機(溫度100℃、壓力5kg/cm2)熱壓該熔噴不織布紡織品，熱壓後之該熔噴不織布紡織品的厚度為0.25mm，並具有良好的尺寸安定性。
使用厚度為0.1mm之TPU發泡膜與該熔噴不織布紡織品，以熱壓機在溫度為110℃、壓力為10kg/cm2進行熱壓貼合，TPU薄膜與纖維鞘部的TPU同時因熱而軟化熔融並完成熱貼合，故可製得柔軟、彈性及厚度為0.35mm的環保複合長纖維人工皮革半成品。
以離型紙之PU乾式塗佈製程，在離型紙上依序塗佈水溶性聚氨酯面層及糊劑，再與上述半品成表面進行貼合，即可製得具各種表面紋路的環保複合長纖維人工皮革。
[發明例4]
以PBT(聚對苯二甲酸丁二酯，IV=0.74)當蕊部成份，搭配TPU(熱可塑性聚氨酯，MI=80,190℃,2.16kg)當鞘部成份，PBT與TPU之重量比為7：3。參閱圖9，其係顯示發明例4以手持式熔噴複合纖維紡絲機製備複合長纖維之製程示意圖。如圖9所示，利用手持式熔噴複合纖維紡絲機製成蕊鞘斷面複合長纖維，PBT紡絲箱溫度為250℃，TPU紡絲箱溫度為200℃，經熔噴製程進行紡絲，並利用噴槍將絲噴在鞋體上，使其形成鞋面，其中高壓空氣壓力為2800psi，高壓空氣溫度為170℃，因此，可製得直徑20μm之複合長纖維及厚度0.2mm的鞋材，並可在TPU加色，賦予鞋子色彩。
[發明例5]
以PET(聚對苯二甲酸乙二酯，IV=0.5)當蕊部成份，搭配TPU(熱可塑性聚氨酯，MI=50,190℃,2.16kg)當鞘部成份，PBT與TPU之重量比為6：4。利用紡黏複合纖維紡絲機(圖7)製成蕊鞘斷面複合長纖維，PET紡絲箱溫度為260℃，TPU紡絲箱溫度為220℃，經紡黏製程進行紡絲，其中風壓為9kg/cm2，風引拉伸絲速度為4000m/min，輸送帶速度為4m/min，因此，可製得直徑20μm之複合長纖維及厚度0.22mm之紡黏不織布紡織品，再以熱壓機(溫度110℃、壓力5kg/cm2)熱壓該紡黏不織布紡織品，熱壓後之該紡黏不織布紡織品的厚度為0.2mm，並具有良好的尺寸安定性。
塗佈水溶性聚氨酯(PU)於該紡黏不織布紡織品，該水溶性聚氨酯(PU)乾燥後可形成彈性體薄膜，以製得環保複合長纖維人工皮革。
[發明例6]
以發明例1中，經熔融紡絲製得，規格為100d/24f之複合纖維為經紗，以單位強度大於6g/den，規格為75d/24f的高強力聚酯長纖維為緯紗，兩種長纖維經織布機，以經密120根/2.54cm，緯密90根/2.54cm，製得一厚度為0.12mm的平織紡織品。使用厚度為0.12mm，發泡倍率1.59倍，密度0.755g/cm3之CO2發泡TPU膜與該織造網布，以熱壓機在溫度為125℃、壓力為25kg/cm2進行熱壓貼合，TPU發泡薄膜與纖維鞘部的TPU同時因熱而軟化熔融並完成熱貼合，故可製得柔軟、彈性及厚度為0.24mm的環保複合長纖維人工皮革半成品。以離型紙之PU乾式塗佈製程，在離型紙上依序塗佈水溶性聚氨酯面層及糊劑，再與上述半品成表面進行貼合，即可製得具各種表面紋路，且抗張強度為55kg/cm的高物性環保複合長纖維人工皮革。
[發明例7]
以發明例1中，經熔融紡絲製得，規格為100d/24f之複合纖維與單位強度大於6g/den，規格為50d/24f的高強力聚酯長纖維進行S型假捻，製得150/48/2之假捻紗，該假捻紗使用針織機，製得一厚度為0.08mm的針織紡織品。使用厚度為0.1mm，發泡倍率1.57倍，密度0.763g/cm3之CO2發泡TPU膜與該針織布，以熱壓機在溫度為120℃、壓力為15kg/cm2進行熱壓貼合，TPU發泡薄膜與纖維鞘部的TPU同時因熱而軟化熔融並完成熱貼合，故可製得柔軟、彈性及厚度為0.18mm的環保複合長纖維人工皮革半成品。以離型紙之PU乾式塗佈製程，在離型紙上依序塗佈水溶性聚氨酯面層及糊劑，再與上述半品成表面進行貼合，即可製得具各種表面紋路的環保複合長纖維人工皮革。
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。
10‧‧‧環保複合長纖維人工皮革
12‧‧‧複合長纖維紡織品
120‧‧‧複合長纖維
14‧‧‧彈性體薄膜

Claims (13)

  1. 一種環保複合長纖維人工皮革，包括：一複合長纖維紡織品，係由複合長纖維製成，該複合長纖維包括至少一蕊部及一鞘部，該至少一蕊部係為聚酯類聚合物、聚醯胺聚合物或聚丙烯聚合物，該鞘部係包覆該至少一蕊部，且該鞘部係為熱可塑性彈性體；及一彈性體薄膜，係結合於該複合長纖維紡織品，該彈性體薄膜係由如下的其中一種材料製成：熱可塑性聚氨酯(TPU)、熱可塑性聚酯彈性體(TPEE)及熱可塑性聚烯烴(TPO)。
  2. 如請求項1之環保複合長纖維人工皮革，其中該複合長纖維紡織品之型態係為織布型態(woven)或非織布型態(nonwoven)。
  3. 如請求項1之環保複合長纖維人工皮革，其中該彈性體薄膜與該複合長纖維紡織品之結合方式選自如下的其中一種：使用固形份為5~55%的水性糊劑黏著或以溫度90~180℃進行熱壓黏著。
  4. 如請求項1之環保複合長纖維人工皮革，其中該彈性體薄膜係為未發泡薄膜，厚度為0.1至2.0mm。
  5. 如請求項1之環保複合長纖維人工皮革，其中該彈性體薄膜係為發泡薄膜，密度為0.3至0.9g/cm3，厚度為0.2至2.0mm。
  6. 如請求項1之環保複合長纖維人工皮革，其中該複合長纖維紡織品係由複合長纖維與聚酯長纖維或聚醯胺長纖維混紡製成。
  7. 如請求項1之環保複合長纖維人工皮革， 其中該至少一蕊部佔整體纖維重量比例為10至90%，該鞘部佔整體纖維重量比例為90至10%。
  8. 如請求項1之環保複合長纖維人工皮革，其中該至少一蕊部係選自如下的其中一種聚合物：聚對苯二甲酸乙二醇酯(PET)、聚對苯二甲酸丁二醇酯(PBT)、聚對苯二甲酸丙二酯(PTT)、熱塑性脂肪族聚酯(PLA)、聚己內醯胺(Nylon6)、聚己二醯己二胺(Nylon6,6)、聚丙烯單聚合物(Polypropylene Homopolymer)及聚丙烯無規共合物(Polypropylene Random Copolymer)。
  9. 一種複合長纖維紡織品，係由複合長纖維製成，該複合長纖維包括至少一蕊部及一鞘部，該至少一蕊部係為聚酯類聚合物、聚醯胺聚合物或聚丙烯聚合物，該鞘部係包覆該至少一蕊部，且該鞘部係為熱可塑性彈性體。
  10. 如請求項9之複合長纖維紡織品，其係由複合長纖維與聚酯長纖維或聚醯胺長纖維混紡製成。
  11. 如請求項9之複合長纖維紡織品，其中該至少一蕊部佔整體纖維重量比例為10至90%，該鞘部佔整體纖維重量比例為90至10%。
  12. 如請求項9之複合長纖維紡織品，其中該至少一蕊部係選自如下的其中一種聚合物：聚對苯二甲酸乙二醇酯(PET)、聚對苯二甲酸丁二醇酯(PBT)、聚對苯二甲酸丙二酯(PTT)、熱塑性脂肪族聚酯(PLA)、聚己內醯胺(Nylon6)、聚己二醯己二胺(Nylon6,6)、聚丙烯單聚合物(Polypropylene Homopolymer)及聚丙烯無規共合物(Polypropylene Random Copolymer)。
  13. 如請求項9之複合長纖維紡織品， 其中該鞘部係選自如下的其中一種聚合物：熱可塑性聚氨酯(TPU)、熱可塑性聚酯彈性體(TPEE)及熱可塑性聚烯烴(TPO)。
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