US20160053434A1 - Composite filament textile and environment-friendly composite filament artificial leather manufactured using the same - Google Patents
Composite filament textile and environment-friendly composite filament artificial leather manufactured using the same Download PDFInfo
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- US20160053434A1 US20160053434A1 US14/693,328 US201514693328A US2016053434A1 US 20160053434 A1 US20160053434 A1 US 20160053434A1 US 201514693328 A US201514693328 A US 201514693328A US 2016053434 A1 US2016053434 A1 US 2016053434A1
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- Prior art keywords
- composite filament
- textile
- artificial leather
- filament
- friendly
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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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
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- 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
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- 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
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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
- D06N3/0006—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
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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
- D06N3/0011—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
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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
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- 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
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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
- D06N3/04—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
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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
- D06N3/12—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
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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
- D06N3/12—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
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- D—TEXTILES; PAPER
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Definitions
- the disclosure relates to an artificial leather and a textile, more particular to an environmental-friendly composite filament artificial leather and a composite filament textile.
- a conventional artificial leather is made by staple fiber and a staple fiber textile base manufactured with same, dimensional stability of the base is unstable; meanwhile, in order to maintain good touch feeling of the leather, an objective of lightweight cannot be achieved. Simultaneously, if a PU resin is dipped or laminated in the manufacturing process, it is not environment-friendly because of containing a solvent. If the artificial leather is made by filament and a filament textile base manufactured with same, the dimensional stability is great, but the leather cannot get good touch feeling due to the thin structure of the filament textile; also, a PU resin is dipped or laminated in the manufacturing process, and likewise it is not environment-friendly because of containing a solvent.
- non-elastomer fiber and fiber with the surface configured with an elastomer are stacked to form a base material, and then the artificial leather is obtained through a staple fiber manufacturing process.
- the base material is formed by extremely slender filament and a elastomer.
- an environmental-friendly composite filament artificial leather includes a composite filament textile and an elastomer film.
- the composite filament textile is made of the composite filament or the composite filament and other filament jointly.
- the composite filament includes at least one core portion and a sheath portion.
- the at least one core portion is a polyester-type polymer, a polyamide polymer or a polypropylene polymer.
- the sheath portion sheathes the at least one core portion, and the sheath portion is a thermoplastic elastomer.
- the elastomer film is bonded with the composite filament textile.
- a composite filament textile is provided.
- the composite filament textile is made of the composite filament or the composite filament and other filament jointly.
- the composite filament includes at least one core portion and a sheath portion.
- the at least one core portion is a polyester-type polymer, a polyamide polymer or a polypropylene polymer.
- the sheath portion sheathes the at least one core portion, and the sheath portion is a thermoplastic elastomer.
- the composite filament textile is made of the composite filament or the composite filament and other filament jointly, and by bonding the composite filament textile with the elastomer film, an environment-friendly artificial leather of lightweight, good abrasion, good touch feeling and well dimentional stability can be manufactured.
- the artificial leather can be manufactured without use of any solvent, so as to conform to the environment protection requirement.
- FIG. 1 shows a schematic structural view of an environment-friendly composite filament artificial leather according to the present disclosure.
- FIG. 2 shows a structural cross-sectional view of a composite filament according to the present disclosure.
- FIG. 3 shows a structural cross-sectional view of another composite filament according to the present disclosure.
- FIG. 4 shows a flow diagram of a manufacturing method for an environment-friendly composite filament artificial leather according to the present disclosure.
- FIGS. 5A to 5C show schematic diagrams of a manufacturing method for an environment-friendly composite filament artificial leather according to the present disclosure.
- FIG. 6 shows a schematic diagram of a manufacturing process in which a filament composite spinning machine is used to prepare composite filament according to Embodiment 1.
- FIG. 7 shows a schematic diagram of a manufacturing process in which a spunbond spinning machine is used to prepare composite filament according to Embodiment 2.
- FIG. 8 shows a schematic diagram of a manufacturing process in which a melt-blown spinning machine is used to prepare composite filament according to Embodiment 3.
- FIG. 9 shows a schematic diagram of a manufacturing process in which a handheld melt-blown spinning machine is used to prepare composite filament according to Embodiment 4.
- FIG. 1 shows a schematic structural view of an environment-friendly composite filament artificial leather according to the present disclosure.
- FIG. 2 shows a structural cross-sectional view of a composite filament according to the present disclosure.
- the environment-friendly composite filament artificial leather 10 of the present disclosure includes a composite filament textile 12 and an elastomer film 14 .
- the composite filament textile 12 is made of composite filament 120 or made by blending composite filament 120 and polyester filament or polyamide filament.
- the composite filament textile 12 can be in a woven or nonwoven form, wherein the woven can be loom or knit, and the woven can be made by blending regular filament or high-tenacity filament and the composite filament 120 .
- the thickness of the composite filament textile 12 is 0.025 to 10 mm inclusive, and the tensile strength of the composite filament textile 12 is 1 to 25 kg/25.4 mm inclusive.
- the composite filament 120 includes at least one core portion 122 and a sheath portion 124 .
- the at least one core portion 122 accounts for a proportion of 10 to 90% inclusive of the entire filament weight
- the sheath portion 124 can account for a proportion of 90 to 10% inclusive of the entire filament weight.
- the at least one core portion 122 is a polyester-type polymer, a polyamide polymer or a polypropylene polymer.
- the intrinsic viscosity of the polyester-type polymer is 0.4 to 1.1 inclusive
- the relative viscosity of the polyamide polymer is 2.0 to 3.0 inclusive
- the melt index of the polypropylene polymer is 30 to 150 inclusive (according to the ASTM D1238 standard, conditions include the weight of 2.16 kg, and the temperature of 230° C.).
- the at least one core portion 122 can be one selected from the following polymers: polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), thermoplastic aliphatic polyester (PLA), polycaprolactam (Nylon6), polyhexamethylene adipamide (Nylon6,6), polypropylene homopolymer and polypropylene random copolymer.
- PET polyethylene terephthalate
- PBT polybutylene terephthalate
- PTT polytrimethylene terephthalate
- PLA thermoplastic aliphatic polyester
- polycaprolactam Nylon6
- polyhexamethylene adipamide Nylon6,6
- polypropylene homopolymer polypropylene random copolymer
- the sheath portion 124 sheathes the at least one core portion 122 , and the sheath portion 124 is a thermoplastic elastomer.
- the raw material melt index of the sheath portion 124 is 1 to 100 g/10 min inclusive, which is according to the ASTM D1238 standard, conditions include the weight of 2.16 kg, and the temperature of 190° C.
- the sheath portion 124 cab be one selected from the following polymers: thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE) and thermoplastic polyolefin (TPO).
- the composite filament 120 can include a plurality of core portions 122 and a sheath portion 124 , the core portions 122 are disposed at intervals, and the sheath portion 124 sheathes the core portions 122 .
- the denier, density and strength of the composite filament 120 should respectively meet the following conditions: the denier is 0.001 to 20 dpf(denier per filament) inclusive; the density is 0.8 to 1.4 g/cm 3 inclusive; and the strength is 0.5 to 8.0 g/den inclusive.
- the elastomer film 14 is bonded with the composite filament textile 12 .
- the elastomer film 14 and the composite filament textile 12 are bonded in one manner selected from the following: bonding by using a water-based adhesive with a solid content of 5-55% inclusive, and bonding by directly performing hot-pressing at a temperature ranging from 90 to 180° C. inclusive.
- the elastomer film 14 can be a foamed film or a non-foamed film, wherein the density of the foamed film is 0.3 to 0.9 g/cm 3 inclusive and the thickness thereof is 0.2 to 2.0 mm inclusive.
- the thickness of the non-foamed film is 0.1 to 2.0 mm inclusive.
- the elastomer film 14 can be made of one selected from the following materials: thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE) and thermoplastic polyolefin (TPO).
- FIG. 4 shows a flow diagram of a manufacturing method for an environment-friendly composite filament artificial leather according to the present disclosure.
- FIGS. 5A to 5C show schematic diagrams of a manufacturing method for an environment-friendly composite filament artificial leather according to the present disclosure.
- composite filament 120 is prepared.
- the composite filament 120 includes at least one core portion 122 and a sheath portion 124 .
- the at least one core portion 122 accounts for a proportion of 10 to 90% inclusive of the entire filament weight
- the sheath portion 124 accounts for a proportion of 90 to 10% inclusive of the entire filament weight.
- the at least one core portion 122 is a polyester-type polymer, a polyamide polymer or a polypropylene polymer.
- the at least one core portion 122 can be one selected from the following polymers: polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), thermoplastic aliphatic polyester (PLA), polycaprolactam (Nylon6), polyhexamethylene adipamide (Nylon6,6), polypropylene homopolymer and polypropylene random copolymer.
- the sheath portion 124 sheathes the at least one core portion 122 , and the sheath portion 124 is a thermoplastic elastomer.
- the sheath portion 124 can be one selected from the following polymers: thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE) and thermoplastic polyolefin (TPO).
- a method for preparing the composite filament 120 can be one selected from the following: a melt spinning by extrusion method, spunbond method and a melt-blown method.
- the extrusion temperature of the at least one core portion 122 is 180 to 250° C. inclusive
- the extrusion temperature of the sheath portion 124 is 150 to 250° C. inclusive.
- a composite filament textile 12 is made of the composite filament 120 or made by blending the composite filament 120 and polyester filament or polyamide filament.
- a method for manufacturing the composite filament textile 12 can be one selected from the following: a melt spinning by extrusion method, a spunbond method, a melt-blown method and a weaving method.
- the weaving method includes: water-jet loom, air-jet loom, a circular loom, a braiding machine, a jacquard loom, and a flat knitting machine.
- the composite filament textile 12 can be in a woven or nonwoven form.
- the composite filament textile 12 can be interwoven or blended with ordinary fiber or high-tenacity fiber, and the composite filament textile 12 can be used be the upper of the shoe material through a thermoplastic process.
- an elastomer film 14 is bonded with the composite filament textile 12 .
- the elastomer film 14 can be made of one selected from the following materials: thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE) and thermoplastic polyolefin (TPO).
- the elastomer film 14 is hot-pressed and laminated to the composite filament textile 12 .
- the elastomer film 14 can bond with the composite filament textile 12 in a coating or spraying manner
- a water-based polyurethane (PU) is coated or sprayed to the composite filament textile 12 , and the water-based polyurethane (PU) can be formed into the elastomer film 14 after drying.
- the composite filament textile is made of the composite filament or the composite filament and another filament jointly, and by bonding the composite filament textile with the elastomer film, an environment-friendly artificial leather of lightweight, good abrasion, good touch feeling and dimensional stability can be manufactured.
- the artificial leather can be manufactured without use of any solvent, so as to conform to the environment protection requirement.
- the artificial leather can be manufactured by only use of hot bonding machining, and compared with the conventional artificial leather which needs a long oven drying process, the process time can be shortened, the energy source discharge can be reduced, the manufacturing cost can be effectively reduced and the production efficiency can be effectively increased.
- the environment-friendly composite filament artificial leather of the present disclosure was breathable, and can be directly formed to the upper of the shoe material.
- the composite filament textile 12 can be in a shoe shape, and the elastomer film 14 can be formed into a shoe surface through hot-pressing.
- the composite filament textile of the present disclosure can also be directly formed into a concave-convex shoe surface through hot-pressing.
- the composite filament textile 12 can be in a shoe shape.
- FIG. 6 shows a schematic diagram of a manufacturing process in which a filament composite spinning machine is used to prepare composite filament according to Embodiment 1. As shown in FIG.
- the filament composite spinning machine is used to manufacture composite filament with a core-sheath section, the temperature in a PBT spinning box is 250° C., the temperature in a TPU spinning box is 220° C., the winding speed is 2500 m/min, and the composite filament with the specification of 100 den/24 f and the single-fiber strength of 4 g/den can be obtained.
- the composite filament is woven by a loom into a fabric which the ends per inch (Warp rate) is 17 and the Picks per inch is 17 and with a thickness of 0.15 mm.
- a TPU film with a thickness of 0.1 mm and the fabric are hot-pressed and laminated with a hot-pressing machine at a temperature of 120° C. and a pressure of 20 kg/cm 2 , and the TPU film and the TPU of the sheath portion of the composite filament are simultaneously softened and melted due to heat and are hot-laminated, so a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.25 mm.
- a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the environment-friendly composite filament artificial leather with various surface textures can be manufactured.
- PU polyurethane
- a ratio of the weight of PET to that of TPU is 6:4.
- FIG. 7 shows a schematic diagram of a manufacturing process in which a spunbond composite fiber spinning machine is used to prepare composite filament according to Embodiment 2. As shown in FIG.
- the spunbond composite fiber spinning machine is used to manufacture composite filament with a core-sheath section, the temperature in a PET spinning box is 260° C., the temperature in a TPU spinning box is 220° C., and spinning is performed through a spunbond process, wherein the air pressure is 9 kg/cm 2 , the wind induced yarn drawing speed is 4000 m/min, and the conveying belt speed is 4 m/min, so the composite filament with a diameter of 20 ⁇ m and a spunbond nonwoven textile with a thickness of 0.22 mm can be manufactured. Then a hot-pressing machine (at a temperature of 110° C. and a pressure of 5 kg/cm 2 ) is used to hot-press the spunbond nonwoven textile, and the spunbond nonwoven textile after the hot-pressing is 0.2 mm in thickness, and has well dimensional stability.
- a hot-pressing machine at a temperature of 110° C. and a pressure of 5 kg/cm 2
- a TPU foamed film with a thickness of 0.1 mm and the spunbond nonwoven textile are hot-pressed and laminated with a hot-pressing machine at a temperature of 110° C. and a pressure of 10 kg/cm 2 , and the TPU film and the TPU of the sheath portion of the composite filament are simultaneously softened and melted due to heat and are hot-laminated, so a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.3 mm.
- a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the environment-friendly composite filament artificial leather with various surface textures can be manufactured.
- PU polyurethane
- FIG. 8 shows a schematic diagram of a manufacturing process in which a melt-blown spinning machine is used to prepare composite filament according to Embodiment 3. As shown in FIG.
- the melt-blown composite fiber spinning machine is used to manufacture composite filament with a core-sheath section, the temperature in a PTT spinning box is 250° C., the temperature in a TPU spinning box is 200° C., and spinning is performed through a melt-blowing process, wherein the high-pressure air pressure is 3000 psi, the high-pressure air temperature is 180° C., and the conveying belt speed is 2 m/min, so the composite filament with a diameter of 20 ⁇ m and a melt-blown nonwoven textile with a thickness of 0.27 mm can be manufactured. Then a hot-pressing machine (at a temperature of 100° C. and a pressure of 5 kg/cm 2 ) is used to hot-press the melt-blown nonwoven textile, and the melt-blown nonwoven textile after the hot-pressing is 0.25 mm in thickness, and has well dimensional stability.
- a hot-pressing machine at a temperature of 100° C. and a pressure of 5 kg/cm 2
- a TPU foamed film with a thickness of 0.1 mm and the melt-blown nonwoven textile are hot-pressed and laminated with a hot-pressing machine at a temperature of 110° C. and a pressure of 10 kg/cm 2 , and the TPU film and the TPU of the sheath portion of the composite filament are simultaneously softened and melted due to heat and are hot-laminated, so a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.35 mm.
- a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the environment-friendly composite filament artificial leather with various surface textures can be manufactured.
- PU polyurethane
- FIG. 9 shows a schematic diagram of a manufacturing process in which a handheld melt-blown spinning machine is used to prepare composite filament according to Embodiment 4. As shown in FIG. 9 , the handheld melt-blown composite fiber spinning machine is used to manufacture composite filament with a core-sheath section, the temperature in a PBT spinning box is 250° C.
- the temperature in a TPU spinning box is 200° C., and spinning is performed through a melt-blowing process, and a spray gun is used to spray yarn onto a shoe last, so as to form a shoe surface, wherein the high-pressure air pressure is 2800 psi, and the high-pressure air temperature is 170° C., so the composite filament with a diameter of 20 ⁇ m and a thickness of 0.2 mm can be manufactured, and the TPU also can be colorized by adding the Color Masterbatch.
- a ratio of the weight of PET to that of TPU is 6:4.
- the temperature in a PET spinning box is 260° C.
- the temperature in a TPU spinning box is 220° C.
- spinning is performed through a spunbond process, wherein the air pressure is 9 kg/cm 2 , the wind induced yarn drawing speed is 4000 m/min, and the conveying belt speed is 4 m/min, so the composite filament with a diameter of 20 ⁇ m and a spunbond nonwoven textile with a thickness of 0.22 mm can be manufactured.
- a hot-pressing machine at a temperature of 110° C. and a pressure of 5 kg/cm 2 ) is used to hot-press the spunbond nonwoven textile, and the spunbond nonwoven textile after the hot-pressing is 0.2 mm in thickness, and has well dimensional stability.
- a water-based polyurethane (PU) is coated onto the spunbond nonwoven textile, and the water-based polyurethane (PU) can be formed into an elastomer film after drying, so as to manufacture an environment-friendly composite filament artificial leather.
- the composite filament with the specification of 100d/24 f manufactured through melt-spinning in Embodiment 1 is taken as wrap
- the high-tenacity polyester filament with the tenacity greater than 6 g/den and the specification of 75 d/24 f is taken as weft
- the two types of filament are manufactured into a plain woven textile with a thickness of 0.12 mm through a loom by means of the wrap density is 120 pieces/2.54 cm
- the weft density is 90 pieces/2.54 cm.
- a CO 2 foamed TPU film with a thickness of 0.12 mm, a foaming expansion ratio of 1.59 and a density of 0.755 g/cm 3 and the plain woven textile are hot-pressed and laminated with a hot-pressing machine at a temperature of 125° C. and a pressure of 25 kg/cm 2 , and the foamed TPU film and the TPU of the sheath portion of the composite filament are simultaneously softened and melted due to heat and are hot-laminated, so a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.24 mm.
- a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the high-physical-property which the tensile strength is 55 kg/cm 2 and environment-friendly composite filament artificial leather with various surface textures can be manufactured.
- the composite filament with the specification of 100 d/24 f manufactured through melt-spinning in Embodiment 1 and the high-tenacity polyester filament with the tenacity greater than 6 g/den and the specification of 50 d/24 f are used to perform a S-twist to manufacture false-twist yarn of 150/48/2, and the false-twist yarn is manufactured into a knitted textile with a thickness of 0.08 mm by using a knitting machine.
- a CO 2 foamed TPU film with a thickness of 0.1 mm, a foaming expansion ratio of 1.57 and a density of 0.763 g/cm 3 and the knitted textile are hot-pressed and laminated with a hot-pressing machine at a temperature of 120° C.
- a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.18 mm
- a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the environment-friendly composite filament artificial leather with various surface textures can be manufactured.
Abstract
Description
- The disclosure relates to an artificial leather and a textile, more particular to an environmental-friendly composite filament artificial leather and a composite filament textile.
- If a conventional artificial leather is made by staple fiber and a staple fiber textile base manufactured with same, dimensional stability of the base is unstable; meanwhile, in order to maintain good touch feeling of the leather, an objective of lightweight cannot be achieved. Simultaneously, if a PU resin is dipped or laminated in the manufacturing process, it is not environment-friendly because of containing a solvent. If the artificial leather is made by filament and a filament textile base manufactured with same, the dimensional stability is great, but the leather cannot get good touch feeling due to the thin structure of the filament textile; also, a PU resin is dipped or laminated in the manufacturing process, and likewise it is not environment-friendly because of containing a solvent.
- The conventional artificial leather and manufacturing method thereof are analyzed in the following patent documents in the prior art.
- 1. TW201128019
- Approach: Spraying the heterogeneous section fiber and a composite thermoplastic material onto the surface of the web, then bonding the thermoplastic base material and the fiber and the web by heating, and then transfer the pattern from the release paper to the surface of composite material.
- Disadvantage: process is complicated, dimensional stability is poor, lightweight cannot be achieved, and a problem of uneven attachment distribution occurs.
- 2. TW438927
- Approach: non-elastomer fiber and fiber with the surface configured with an elastomer are stacked to form a base material, and then the artificial leather is obtained through a staple fiber manufacturing process.
- Disadvantage: manufacturing process time is long, attachment is uneven, tensile strength is low, peeling strength is bad, and web distribution is prone to be uneven.
- 3. TW201040352
- Approach: the base material is formed by extremely slender filament and a elastomer.
- Disadvantage: dimensional stability is undesirable.
- Based on the foregoing analysis, it is necessary to provide an environment-friendly composite filament artificial leather and manufacturing method thereof as well as composite filament textile and manufacturing method thereof, so as to solve the foregoing deficiencies in the prior art.
- In accordance with one aspect of the present disclosure, an environmental-friendly composite filament artificial leather includes a composite filament textile and an elastomer film. The composite filament textile is made of the composite filament or the composite filament and other filament jointly. The composite filament includes at least one core portion and a sheath portion. The at least one core portion is a polyester-type polymer, a polyamide polymer or a polypropylene polymer. The sheath portion sheathes the at least one core portion, and the sheath portion is a thermoplastic elastomer. The elastomer film is bonded with the composite filament textile.
- In accordance with another aspect of the present disclosure, a composite filament textile is provided. The composite filament textile is made of the composite filament or the composite filament and other filament jointly. The composite filament includes at least one core portion and a sheath portion. The at least one core portion is a polyester-type polymer, a polyamide polymer or a polypropylene polymer. The sheath portion sheathes the at least one core portion, and the sheath portion is a thermoplastic elastomer.
- In the present disclosure, the composite filament textile is made of the composite filament or the composite filament and other filament jointly, and by bonding the composite filament textile with the elastomer film, an environment-friendly artificial leather of lightweight, good abrasion, good touch feeling and well dimentional stability can be manufactured. Moreover, in the present disclosure, the artificial leather can be manufactured without use of any solvent, so as to conform to the environment protection requirement.
- Aspects of the present disclosure are understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
-
FIG. 1 shows a schematic structural view of an environment-friendly composite filament artificial leather according to the present disclosure. -
FIG. 2 shows a structural cross-sectional view of a composite filament according to the present disclosure. -
FIG. 3 shows a structural cross-sectional view of another composite filament according to the present disclosure. -
FIG. 4 shows a flow diagram of a manufacturing method for an environment-friendly composite filament artificial leather according to the present disclosure. -
FIGS. 5A to 5C show schematic diagrams of a manufacturing method for an environment-friendly composite filament artificial leather according to the present disclosure. -
FIG. 6 shows a schematic diagram of a manufacturing process in which a filament composite spinning machine is used to prepare composite filament according to Embodiment 1. -
FIG. 7 shows a schematic diagram of a manufacturing process in which a spunbond spinning machine is used to prepare composite filament according to Embodiment 2. -
FIG. 8 shows a schematic diagram of a manufacturing process in which a melt-blown spinning machine is used to prepare composite filament according to Embodiment 3. -
FIG. 9 shows a schematic diagram of a manufacturing process in which a handheld melt-blown spinning machine is used to prepare composite filament according to Embodiment 4. - It is to be understood that the following disclosure provides many different embodiments or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. The present disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that this description will be thorough and complete, and will fully convey the present disclosure to those of ordinary skill in the art. It will be apparent, however, that one or more embodiments may be practiced without these specific details.
- In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
- It will be understood that singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
- Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms; such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
-
FIG. 1 shows a schematic structural view of an environment-friendly composite filament artificial leather according to the present disclosure.FIG. 2 shows a structural cross-sectional view of a composite filament according to the present disclosure. - With reference to
FIG. 1 andFIG. 2 , the environment-friendly composite filamentartificial leather 10 of the present disclosure includes acomposite filament textile 12 and anelastomer film 14. - The
composite filament textile 12 is made ofcomposite filament 120 or made by blendingcomposite filament 120 and polyester filament or polyamide filament. Thecomposite filament textile 12 can be in a woven or nonwoven form, wherein the woven can be loom or knit, and the woven can be made by blending regular filament or high-tenacity filament and thecomposite filament 120. Preferably, the thickness of thecomposite filament textile 12 is 0.025 to 10 mm inclusive, and the tensile strength of thecomposite filament textile 12 is 1 to 25 kg/25.4 mm inclusive. - In some embodiments, the
composite filament 120 includes at least onecore portion 122 and asheath portion 124. The at least onecore portion 122 accounts for a proportion of 10 to 90% inclusive of the entire filament weight, and thesheath portion 124 can account for a proportion of 90 to 10% inclusive of the entire filament weight. - The at least one
core portion 122 is a polyester-type polymer, a polyamide polymer or a polypropylene polymer. In some embodiments, the intrinsic viscosity of the polyester-type polymer is 0.4 to 1.1 inclusive, the relative viscosity of the polyamide polymer is 2.0 to 3.0 inclusive, and the melt index of the polypropylene polymer is 30 to 150 inclusive (according to the ASTM D1238 standard, conditions include the weight of 2.16 kg, and the temperature of 230° C.). Preferably, the at least onecore portion 122 can be one selected from the following polymers: polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), thermoplastic aliphatic polyester (PLA), polycaprolactam (Nylon6), polyhexamethylene adipamide (Nylon6,6), polypropylene homopolymer and polypropylene random copolymer. - The
sheath portion 124 sheathes the at least onecore portion 122, and thesheath portion 124 is a thermoplastic elastomer. In some embodiments, the raw material melt index of thesheath portion 124 is 1 to 100 g/10 min inclusive, which is according to the ASTM D1238 standard, conditions include the weight of 2.16 kg, and the temperature of 190° C. Preferably, thesheath portion 124 cab be one selected from the following polymers: thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE) and thermoplastic polyolefin (TPO). - Referring to
FIG. 3 , which shows a structural cross-sectional view of another composite filament according to the present disclosure. As shown inFIG. 3 , in another embodiment, thecomposite filament 120 can include a plurality ofcore portions 122 and asheath portion 124, thecore portions 122 are disposed at intervals, and thesheath portion 124 sheathes thecore portions 122. - Moreover, in order to achieve lightweight and increase dimensional stability, preferably, the denier, density and strength of the
composite filament 120 should respectively meet the following conditions: the denier is 0.001 to 20 dpf(denier per filament) inclusive; the density is 0.8 to 1.4 g/cm3 inclusive; and the strength is 0.5 to 8.0 g/den inclusive. - Referring to
FIG. 1 again, theelastomer film 14 is bonded with thecomposite filament textile 12. In some embodiments, theelastomer film 14 and thecomposite filament textile 12 are bonded in one manner selected from the following: bonding by using a water-based adhesive with a solid content of 5-55% inclusive, and bonding by directly performing hot-pressing at a temperature ranging from 90 to 180° C. inclusive. - Furthermore, the
elastomer film 14 can be a foamed film or a non-foamed film, wherein the density of the foamed film is 0.3 to 0.9 g/cm3 inclusive and the thickness thereof is 0.2 to 2.0 mm inclusive. The thickness of the non-foamed film is 0.1 to 2.0 mm inclusive. Preferably, theelastomer film 14 can be made of one selected from the following materials: thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE) and thermoplastic polyolefin (TPO). -
FIG. 4 shows a flow diagram of a manufacturing method for an environment-friendly composite filament artificial leather according to the present disclosure.FIGS. 5A to 5C show schematic diagrams of a manufacturing method for an environment-friendly composite filament artificial leather according to the present disclosure. With reference to step S41 inFIG. 4 andFIG. 5A ,composite filament 120 is prepared. In this step, thecomposite filament 120 includes at least onecore portion 122 and asheath portion 124. The at least onecore portion 122 accounts for a proportion of 10 to 90% inclusive of the entire filament weight, and thesheath portion 124 accounts for a proportion of 90 to 10% inclusive of the entire filament weight. - The at least one
core portion 122 is a polyester-type polymer, a polyamide polymer or a polypropylene polymer. Preferably, the at least onecore portion 122 can be one selected from the following polymers: polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), thermoplastic aliphatic polyester (PLA), polycaprolactam (Nylon6), polyhexamethylene adipamide (Nylon6,6), polypropylene homopolymer and polypropylene random copolymer. - The
sheath portion 124 sheathes the at least onecore portion 122, and thesheath portion 124 is a thermoplastic elastomer. Preferably, thesheath portion 124 can be one selected from the following polymers: thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE) and thermoplastic polyolefin (TPO). - Moreover, in this step, a method for preparing the
composite filament 120 can be one selected from the following: a melt spinning by extrusion method, spunbond method and a melt-blown method. Preferably, the extrusion temperature of the at least onecore portion 122 is 180 to 250° C. inclusive, and the extrusion temperature of thesheath portion 124 is 150 to 250° C. inclusive. - With reference to step S42 in
FIG. 4 andFIG. 5B , acomposite filament textile 12 is made of thecomposite filament 120 or made by blending thecomposite filament 120 and polyester filament or polyamide filament. In this step, a method for manufacturing thecomposite filament textile 12 can be one selected from the following: a melt spinning by extrusion method, a spunbond method, a melt-blown method and a weaving method. In some embodiments, the weaving method includes: water-jet loom, air-jet loom, a circular loom, a braiding machine, a jacquard loom, and a flat knitting machine. Furthermore, thecomposite filament textile 12 can be in a woven or nonwoven form. Furthermore, thecomposite filament textile 12 can be interwoven or blended with ordinary fiber or high-tenacity fiber, and thecomposite filament textile 12 can be used be the upper of the shoe material through a thermoplastic process. - With reference to step S43 in
FIG. 4 andFIG. 5C , anelastomer film 14 is bonded with thecomposite filament textile 12. In this step, theelastomer film 14 can be made of one selected from the following materials: thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE) and thermoplastic polyolefin (TPO). - In some embodiments, the
elastomer film 14 is hot-pressed and laminated to thecomposite filament textile 12. Alternatively, in another embodiment, theelastomer film 14 can bond with thecomposite filament textile 12 in a coating or spraying manner For example, a water-based polyurethane (PU) is coated or sprayed to thecomposite filament textile 12, and the water-based polyurethane (PU) can be formed into theelastomer film 14 after drying. - In the present disclosure, the composite filament textile is made of the composite filament or the composite filament and another filament jointly, and by bonding the composite filament textile with the elastomer film, an environment-friendly artificial leather of lightweight, good abrasion, good touch feeling and dimensional stability can be manufactured. Furthermore, in the present disclosure, the artificial leather can be manufactured without use of any solvent, so as to conform to the environment protection requirement. Moreover, in the present disclosure, the artificial leather can be manufactured by only use of hot bonding machining, and compared with the conventional artificial leather which needs a long oven drying process, the process time can be shortened, the energy source discharge can be reduced, the manufacturing cost can be effectively reduced and the production efficiency can be effectively increased.
- Furthermore, the environment-friendly composite filament artificial leather of the present disclosure was breathable, and can be directly formed to the upper of the shoe material. For example, the
composite filament textile 12 can be in a shoe shape, and theelastomer film 14 can be formed into a shoe surface through hot-pressing. - Moreover, the composite filament textile of the present disclosure can also be directly formed into a concave-convex shoe surface through hot-pressing. For example, the
composite filament textile 12 can be in a shoe shape. - The present disclosure is illustrated in detail with the following embodiments, but it does not mean that the present disclosure is only limited to the content disclosed by these embodiments.
- PBT (polybutylene terephthalate, IV=0.74) is taken as an ingredient of a core portion, TPU (thermoplastic polyurethane, MI=4, 190° C., 2.16 kg) is taken as an ingredient of a sheath portion, and a ratio of the weight of PBT to that of TPU is 6:4. Referring to
FIG. 6 , which shows a schematic diagram of a manufacturing process in which a filament composite spinning machine is used to prepare composite filament according to Embodiment 1. As shown inFIG. 6 , the filament composite spinning machine is used to manufacture composite filament with a core-sheath section, the temperature in a PBT spinning box is 250° C., the temperature in a TPU spinning box is 220° C., the winding speed is 2500 m/min, and the composite filament with the specification of 100 den/24 f and the single-fiber strength of 4 g/den can be obtained. - After the composite filament is arranged in order, the composite filament is woven by a loom into a fabric which the ends per inch (Warp rate) is 17 and the Picks per inch is 17 and with a thickness of 0.15 mm.
- A TPU film with a thickness of 0.1 mm and the fabric are hot-pressed and laminated with a hot-pressing machine at a temperature of 120° C. and a pressure of 20 kg/cm2, and the TPU film and the TPU of the sheath portion of the composite filament are simultaneously softened and melted due to heat and are hot-laminated, so a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.25 mm.
- By use of a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the environment-friendly composite filament artificial leather with various surface textures can be manufactured.
- PET (polyethylene terephthalate, IV=0.5) is taken as an ingredient of a core portion, TPU (thermoplastic polyurethane, MI=50, 190° C., 2.16 kg) is taken as an ingredient of a sheath portion, and a ratio of the weight of PET to that of TPU is 6:4. Referring to
FIG. 7 , which shows a schematic diagram of a manufacturing process in which a spunbond composite fiber spinning machine is used to prepare composite filament according to Embodiment 2. As shown inFIG. 7 , the spunbond composite fiber spinning machine is used to manufacture composite filament with a core-sheath section, the temperature in a PET spinning box is 260° C., the temperature in a TPU spinning box is 220° C., and spinning is performed through a spunbond process, wherein the air pressure is 9 kg/cm2, the wind induced yarn drawing speed is 4000 m/min, and the conveying belt speed is 4 m/min, so the composite filament with a diameter of 20 μm and a spunbond nonwoven textile with a thickness of 0.22 mm can be manufactured. Then a hot-pressing machine (at a temperature of 110° C. and a pressure of 5 kg/cm2) is used to hot-press the spunbond nonwoven textile, and the spunbond nonwoven textile after the hot-pressing is 0.2 mm in thickness, and has well dimensional stability. - A TPU foamed film with a thickness of 0.1 mm and the spunbond nonwoven textile are hot-pressed and laminated with a hot-pressing machine at a temperature of 110° C. and a pressure of 10 kg/cm2, and the TPU film and the TPU of the sheath portion of the composite filament are simultaneously softened and melted due to heat and are hot-laminated, so a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.3 mm.
- By use of a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the environment-friendly composite filament artificial leather with various surface textures can be manufactured.
- PTT (polytrimethylene terephthalate, IV=0.55) is taken as an ingredient of a core portion, TPU (thermoplastic polyurethane, MI=80, 190° C., 2.16 kg) is taken as an ingredient of a sheath portion, and a ratio of the weight of PTT to that of TPU is 6:4. Referring to
FIG. 8 , which shows a schematic diagram of a manufacturing process in which a melt-blown spinning machine is used to prepare composite filament according to Embodiment 3. As shown inFIG. 8 , the melt-blown composite fiber spinning machine is used to manufacture composite filament with a core-sheath section, the temperature in a PTT spinning box is 250° C., the temperature in a TPU spinning box is 200° C., and spinning is performed through a melt-blowing process, wherein the high-pressure air pressure is 3000 psi, the high-pressure air temperature is 180° C., and the conveying belt speed is 2 m/min, so the composite filament with a diameter of 20 μm and a melt-blown nonwoven textile with a thickness of 0.27 mm can be manufactured. Then a hot-pressing machine (at a temperature of 100° C. and a pressure of 5 kg/cm2) is used to hot-press the melt-blown nonwoven textile, and the melt-blown nonwoven textile after the hot-pressing is 0.25 mm in thickness, and has well dimensional stability. - A TPU foamed film with a thickness of 0.1 mm and the melt-blown nonwoven textile are hot-pressed and laminated with a hot-pressing machine at a temperature of 110° C. and a pressure of 10 kg/cm2, and the TPU film and the TPU of the sheath portion of the composite filament are simultaneously softened and melted due to heat and are hot-laminated, so a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.35 mm.
- By use of a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the environment-friendly composite filament artificial leather with various surface textures can be manufactured.
- PBT (polybutylene terephthalate, IV=0.74) is taken as an ingredient of a core portion, TPU (thermoplastic polyurethane, MI=80, 190° C., 2.16 kg) is taken as an ingredient of a sheath portion, and a ratio of the weight of PBT to that of TPU is 7:3. Referring to
FIG. 9 , which shows a schematic diagram of a manufacturing process in which a handheld melt-blown spinning machine is used to prepare composite filament according to Embodiment 4. As shown inFIG. 9 , the handheld melt-blown composite fiber spinning machine is used to manufacture composite filament with a core-sheath section, the temperature in a PBT spinning box is 250° C. , and the temperature in a TPU spinning box is 200° C., and spinning is performed through a melt-blowing process, and a spray gun is used to spray yarn onto a shoe last, so as to form a shoe surface, wherein the high-pressure air pressure is 2800 psi, and the high-pressure air temperature is 170° C., so the composite filament with a diameter of 20 μm and a thickness of 0.2 mm can be manufactured, and the TPU also can be colorized by adding the Color Masterbatch. - PET (polyethylene terephthalate, IV=0.5) is taken as an ingredient of a core portion, TPU (thermoplastic polyurethane, MI=50, 190° C., 2.16 kg) is taken as an ingredient of a sheath portion, and a ratio of the weight of PET to that of TPU is 6:4. A spunbond composite fiber spinning machine (
FIG. 7 ) is used to manufacture composite filament with a core-sheath section, the temperature in a PET spinning box is 260° C., the temperature in a TPU spinning box is 220° C., and spinning is performed through a spunbond process, wherein the air pressure is 9 kg/cm2, the wind induced yarn drawing speed is 4000 m/min, and the conveying belt speed is 4 m/min, so the composite filament with a diameter of 20 μm and a spunbond nonwoven textile with a thickness of 0.22 mm can be manufactured. Then a hot-pressing machine (at a temperature of 110° C. and a pressure of 5 kg/cm2) is used to hot-press the spunbond nonwoven textile, and the spunbond nonwoven textile after the hot-pressing is 0.2 mm in thickness, and has well dimensional stability. - A water-based polyurethane (PU) is coated onto the spunbond nonwoven textile, and the water-based polyurethane (PU) can be formed into an elastomer film after drying, so as to manufacture an environment-friendly composite filament artificial leather.
- The composite filament with the specification of 100d/24 f manufactured through melt-spinning in Embodiment 1 is taken as wrap, the high-tenacity polyester filament with the tenacity greater than 6 g/den and the specification of 75 d/24 f is taken as weft, and the two types of filament are manufactured into a plain woven textile with a thickness of 0.12 mm through a loom by means of the wrap density is 120 pieces/2.54 cm, and the weft density is 90 pieces/2.54 cm. A CO2 foamed TPU film with a thickness of 0.12 mm, a foaming expansion ratio of 1.59 and a density of 0.755 g/cm3 and the plain woven textile are hot-pressed and laminated with a hot-pressing machine at a temperature of 125° C. and a pressure of 25 kg/cm2, and the foamed TPU film and the TPU of the sheath portion of the composite filament are simultaneously softened and melted due to heat and are hot-laminated, so a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.24 mm. By use of a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the high-physical-property which the tensile strength is 55 kg/cm2 and environment-friendly composite filament artificial leather with various surface textures can be manufactured.
- The composite filament with the specification of 100 d/24 f manufactured through melt-spinning in Embodiment 1 and the high-tenacity polyester filament with the tenacity greater than 6 g/den and the specification of 50 d/24 f are used to perform a S-twist to manufacture false-twist yarn of 150/48/2, and the false-twist yarn is manufactured into a knitted textile with a thickness of 0.08 mm by using a knitting machine. A CO2 foamed TPU film with a thickness of 0.1 mm, a foaming expansion ratio of 1.57 and a density of 0.763 g/cm3 and the knitted textile are hot-pressed and laminated with a hot-pressing machine at a temperature of 120° C. and a pressure of 15 kg/cm2, and the foamed TPU film and the TPU of the sheath portion of the composite filament are simultaneously softened and melted due to heat and are hot-laminated, so a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.18 mm By use of a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the environment-friendly composite filament artificial leather with various surface textures can be manufactured.
- Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, and composition of matter, means, methods and steps described in the specification. As those skilled in the art will readily appreciate form the present disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure.
- Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, and compositions of matter, means, methods or steps. In addition, each claim constitutes a separate embodiment, and the combination of various claims and embodiments are within the scope of the invention.
Claims (13)
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US17/669,912 Continuation-In-Part US20220186427A1 (en) | 2014-08-22 | 2022-02-11 | Composite filament textile and composite filament artificial leather manufactured using the same |
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Also Published As
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TWI585251B (en) | 2017-06-01 |
CN113389056A (en) | 2021-09-14 |
TW201608068A (en) | 2016-03-01 |
CN105350339A (en) | 2016-02-24 |
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