Classifications

• • 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
• • 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
  • D06N3/0004—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 ultra-fine two-component fibres, e.g. island/sea, or ultra-fine one component fibres (< 1 denier)
• • 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
• • 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
  • D06N3/007—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by mechanical or physical treatments
  • D06N3/0075—Napping, teasing, raising or abrading of the resin coating
• • 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
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
  • D06P1/16—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using dispersed, e.g. acetate, dyestuffs
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
  • D06P3/02—Material containing basic nitrogen
  • D06P3/04—Material containing basic nitrogen containing amide groups
  • D06P3/32—Material containing basic nitrogen containing amide groups leather skins
• • 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
  • D06N2209/00—Properties of the materials
  • D06N2209/08—Properties of the materials having optical properties
  • D06N2209/0807—Coloured
• • 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
  • D06N2211/00—Specially adapted uses
  • D06N2211/12—Decorative or sun protection articles
  • D06N2211/28—Artificial leather

Definitions

• the present disclosure relates to a method for manufacturing artificial leather having excellent fastness and dyeing properties by using a dope-dyed polyester sea-island type composite yarn, and artificial leather manufactured by the same method.
• Artificial leather includes a non-woven fabric with a three-dimensional structure as a primary backing, and has a microporous structure as a whole due to a three-dimensional structure of ultrafine yarn and polyurethane resin.
• the artificial leather has a touch feeling of a leather skin layer which is similar to natural leather, and thus is widely used in various fields such as shoes, clothes, gloves, miscellaneous goods, furniture, automobile interior materials, etc.
• Korean Patent No. 10-0148515 discloses a method of manufacturing artificial leather having excellent fastness properties and touch feeling.
• the artificial leather is produced by impregnating a nonwoven fabric made of dope-dyed polyamide ultrafine yarn with a polyurethane resin and dyeing the fabric with a vat dye.
• the above method can obtain the effect of improving the dyeing fastness by combination dyeing of the dope-dyed yarn and the piece dyeing method, but since this method uses a vat dye, light resistance is lowered as compared with a disperse dye and the weather resistance of the polyamide fibers is lowered, and thus there is a problem that it is difficult to apply to automotive interior materials.
• Korean Patent No. 10-1218195 discloses a method for manufacturing artificial leather having a circular knitted structure by combining a high-shrinkage polyester with a black dope-dyed polyester-based ultrafine yarn.
• Korean Patent No. 10-0375245 discloses a method of manufacturing a warp knitted fabric used for the production of artificial leather, wherein a surface structure is composed of a sea-island type composite fiber, a medium structure is composed of a spandex elastic yarn, and a backing structure is composed of a highly shrinkable yarn, and then these are subjected to warp knitting, napping, preliminary heat treatment, weight reduction, buffing, and final heat treatment to produce a warp knitted fabric.
• the warp knitted fabric is composed of a surface structure of a dope-dyed ultrafine yarn, a median structure of elastic yarn, and a highly shrinkable backing surface structure, and thus has advantages in terms of excellent fastness, touch feeling, air permeability, and moisture permeability.
• the mechanical strength required for leather is insufficient, and it can be applied only to gray or black achromatic series, so that it is impossible to develop a product with various colors.
• the artificial leather using the dope-dyed ultrafine yarn in this way uses either a metal complex dye or a vat dye in the case of polyamide fibers. Consequently, there is a problem that the light resistance of the artificial leather is lowered compared to disperse dyes, and in the case of using the dope-dyed polyester yarn, the structure is warp-knitted fabric or circular-knitted fabric, which causes a problem that the product quality is inferior to that of nonwoven artificial leather.
• an object of the present disclosure is to provide artificial leather capable of exhibiting a high-quality appearance and high fastness properties by improving the coloring and production process using a dope-dyed polyester sea-island type composite yarn, and a method for manufacturing the same.
• a method for manufacturing a nonwoven artificial leather using a dope-dyed polyester sea-island type composite yarn including the steps of: preparing a sea-island type composite yarn composed of an alkali-soluble resin as a sea component and an alkali-insoluble polyester resin containing a pigment as an island component; making the sea-island type composite yarn into staple fibers to prepare a nonwoven fabric; impregnating the nonwoven fabric with a polyurethane resin to which a pigment is added; removing the sea component by alkaline weight reduction processing of the nonwoven fabric impregnated with the polyurethane resin, thereby preparing an ultrafine nonwoven fabric of the island component; buffing the surface of the ultrafine fiber nonwoven fabric to form napping; and dyeing the napped nonwoven fabric with a disperse dye.
• nonwoven artificial leather using a dope-dyed polyester sea-island type composite yarn which is composed of a dope-dyed polyester ultrafine yarn produced by weight reduction processing of the sea-island type composite yarn, and in which a disperse dye is dyed in a nonwoven fabric impregnated with a pigment-containing polyurethane resin, is provided.
• a non-woven fabric which is made of a dope-dyed polyester sea-island type composite yarn to which an organic or inorganic pigment, or both an organic pigment and an inorganic pigment are added, is produced by: impregnating the same with a polyurethane resin to which an organic or inorganic pigment, or both an organic pigment and an inorganic pigment are added; performing weight reduction processing; and then dying the same with a disperse dye, whereby various colors can be expressed, the artificial leather is uniformly dyed with a dye, and the amount of dye used can be reduced by excellent dyeability and deep color expression.
• an artificial leather having improved fastness properties is produced by preparing a dope-dyed polyester sea-island type composite yarn to which an organic or inorganic pigment, or both an organic pigment and an inorganic pigment are added, making the prepared sea-island type composite yarn into staple fibers to produce a non-woven fabric; impregnating the nonwoven fabric with a polyurethane resin to which a pigment is added; performing alkaline weight reduction processing to make ultrafine fibers, and then buffing the surface of the ultrafine fiber nonwoven fabric to form napping; and dyeing the napped nonwoven fabric with a disperse dye.
• the step of preparing a sea-island type composite yarn includes a step composite-spinning a first polymer of a sea component dissolved and eluted in a solvent, and a second polymer of an island component remaining without being dissolved in solvent.
• the first polymer of the sea component may be composed of a copolyester, polystyrene, polyethylene, or the like. Preferably, it may be composed of a copolyester having excellent alkaline solubility.
• the second polymer of the island component may be composed of a polyester material which can be dyed with a disperse dye without being dissolved in an alkaline solvent, and specific examples thereof include polyethylene terephthalate, polyoxyethylene benzoate, polybutylene terephthalate, polytrimethylene terephthalate, polytriethylene terephthalate, and the like.
• the first polymer of the sea component and the second polymer of the island component are respectively introduced into an extruder, melt-extruded, discharged, and spun through a composite spinning nozzle, wherein a masterbatch chip in which an organic pigment or an inorganic pigment, or both an organic pigment and an inorganic pigment are used is added to the second polymer of the island component through a side feeder, thereby manufacturing a sea-island type composite yarn containing the dope-dyed polyester island component.
• the content of a pigment in the island component is preferably 0.1 to 5.0% by weight. If the content is less than 0.1% by weight, the color after exposure becomes very pale when performing light color dyeing and evaluating light fastness, it is difficult to improve the light resistance, and no reduction in the amount of dye used can be expected. If the content exceeds 5.0% by weight, the color becomes too dark, it is not easy to dye with a specific color, and the color that can be dyed can be limited.
• the step of producing the nonwoven fabric of the present disclosure includes making the sea-island type composite yarn into staple fibers, carding the staple fibers, forming a web via crosslapping, and needle punching the formed web.
• the step of impregnating the nonwoven fabric with a polyurethane resin can be carried out by a process in which the polyurethane resin is dissolved in an organic solvent such as dimethylformamide (DMF), an organic pigment or an inorganic pigment is added thereto, stirred, and homogenized, and after homogenization, the viscosity is adjusted with an organic solvent to obtain an impregnation solution, and the nonwoven fabric is immersed in the impregnation solution.
• an organic solvent such as dimethylformamide (DMF)
• an organic pigment or an inorganic pigment is added thereto, stirred, and homogenized, and after homogenization, the viscosity is adjusted with an organic solvent to obtain an impregnation solution, and the nonwoven fabric is immersed in the impregnation solution.
• the pigment added to the impregnation solution is preferably contained in an amount of 0.1 to 6.0% by weight in the polyurethane resin. If the pigment content is less than 0.1% by weight, color unevenness occurs between the ultrafine yarns of the artificial leather and the polyurethane resin after dyeing. If the pigment content exceeds 6.0% by weight, the color becomes very thick and it is difficult to express various colors in the artificial leather produced.
• the amount of the impregnation solution impregnated into the nonwoven fabric is preferably set such that the polyurethane resin containing a pigment is contained in an amount of 15 to 40% by weight based on the artificial leather as the final product.
• the amount of the impregnation solution is less than 15% by weight, the elasticity specific to the polyurethane resin is hardly exhibited, the ability of the polyurethane resin to grip the fibers constituting the nonwoven fabric is reduced, and fiber dropping occurs in artificial leather, resulting in poor appearance on the surface. If the amount of the impregnation solution exceeds 40% by weight, the soft touch feeling in artificial leather is reduced, which is not preferable.
• the artificial leather of the present disclosure has a uniform color between the ultrafine yarn and the polyurethane resin after dyeing, and exhibits excellent fastness properties as compared to a method for manufacturing a general artificial leather.
• the polyurethane resin impregnated into the nonwoven fabric is coagulated, and then washed in a washing tank. Subsequently, the sea component is removed from the sea-island type composite yarn of the nonwoven fabric, and the staple fibers are ultra-finely fibrillated to produce an ultrafine fiber nonwoven fabric.
• the ultrafine fiber nonwoven fabric step is a step of ultra-finely fibrilating staple fibers by eluting the first polymer as a sea component using an alkaline solvent such as an aqueous sodium hydroxide solution so that only the second polymer as a sea component remains, wherein the bicomponent polymers having different solubility are divided into the sea-island type composite yarns by alkaline weight reduction processing to have a ultrafine fiber shape, and as one strand of fiber is divided into a plurality of ultrafine fibers, it can express a high-grade appearance and a soft touch feeling.
• an alkaline solvent such as an aqueous sodium hydroxide solution
• the single yarn fineness of the island component ultrafine yarn is 0.04 to 0.30 denier after eluting the sea component, and the number of island component fibers per filament is 7 to 36.
• the single yarn fineness is less than 0.04 denier, the amount of dye used may increase, and the fastness properties may deteriorate.
• the single yarn fineness exceeds 0.30 denier, the soft touch feeling specific to ultrafine yarn is hardly exhibited.
• the dyes used in the dyeing step include disperse dyes, such as azo-based disperse dyes, heterocyclic azo-based dyes, anthraquinone-based disperse dyes, condensed disperse dyes, quinoline-based disperse dyes, Coumarin-based disperse dyes, amino ketone-based disperse dyes, and diester-type of disperse dyes.
• disperse dyes such as azo-based disperse dyes, heterocyclic azo-based dyes, anthraquinone-based disperse dyes, condensed disperse dyes, quinoline-based disperse dyes, Coumarin-based disperse dyes, amino ketone-based disperse dyes, and diester-type of disperse dyes.
• the dyeing step may be performed for 30 to 60 minutes at a temperature of the dyeing liquid ranging from 115 to 130° C. for 30 to 60 minutes, and it is also possible to add an ultraviolet absorber, a dispersing agent, and an acid component to the dyeing liquid.
• a reduction cleaning step for removing unfixed dyes and impurities on the surface of the dyed ultrafine fiber nonwoven fabric may be further performed.
• the reduction cleaning step may be performed at 40 to 100° C. for 10 to 30 minutes.
• the reduction cleaning liquid may be sodium hydroxide or sodium hydrosulfite, and through the reduction cleaning step, undyed dyes on the artificial leather are removed.
• a rinsing step using water may be further performed for removing the cleaning solution.
• the method for manufacturing the artificial leather of the present disclosure solves problems such as dyeing unevenness of the artificial leather for fashion goods such as suede-type of furniture skin material, inner skin and outer skin of bags, deterioration of the fastness, and the like, and improves the drawback of excessively adding a dye for developing a deep color, thereby reducing costs and improving fastness properties.
• Polyethylene terephthalate was prepared as an island component, an alkali-soluble copolymer polyester was prepared as a sea component, and then the island component and the sea component were introduced into an extruder, followed by melt extrusion.
• a master batch containing 4 wt % of carbon black, 8 wt % of yellow organic pigment, and 8 wt % of red organic pigment was side-fed to the island component, and discharged through a spinning nozzle so that the content of a pigment in the island component was 1 wt %.
• a dope-dyed polyester sea-island type composite yarn was prepared.
• the composite yarn was crimped so that the crimp number became 10 to 13/inch, fixed by heating, and then cut into a size of 51 mm to prepare a sea-island type of staple fiber.
• the sea-island staple fibers were laminated into a web through a carding step and a crosslapping step, followed by needle punching to prepare a nonwoven fabric.
• Polyurethane and carbon black were mixed in a dimethylformamide organic solvent to prepare an impregnation solution, and then the nonwoven fabric was immersed in the impregnation solution which was coagulated to prepare a polyurethane resin-impregnated nonwoven fabric in which 30 wt % of polyurethane resin (containing 0.1 wt % of carbon black in the polyurethane resin) was impregnated.
• the polyurethane resin-impregnated nonwoven fabric was treated with a 5 wt % sodium hydroxide aqueous solution to elute a sea component.
• a polyester ultrafine fiber nonwoven fabric having a number of island components divided per filament of 16, single yarn fineness of 0.15 denier, and an L* value of 36.12, a a* value of 9.58, and a b* value of 13.16 when measured with a CIELAB color display system, was prepared.
• the surface of the ultrafine fiber nonwoven fabric was ground with sandpaper having roughness of #240 to form napping (thickness of 1.0 mm), and then dyed under the following dyeing conditions.
• the dyeing residue was discharged from a dyeing machine and water was again added to the dyeing machine, and then 8 g/ of sodium hyposulfite and 4 g/ of sodium hydroxide were added, and the mixture was performed the reduction cleaning step at 80° C. under a bath ratio of 1:30 for 20 minutes. Thereafter, it was dried for 10 minutes at 130° C. to prepare artificial leather.
• examples in which the pigment was contained in the ultrafine yarn of the nonwoven fabric and the polyurethane resin could reduce the amount of dye used for expressing the same chromaticity as compared with comparative examples in which the pigment was not contained.
• the artificial leather according to the present disclosure can express various colors by dyeing a pigment and a dye on ultrafine fiber dope-dyed yarn, and due to excellent dyeability and development of deep color, a luxuriously high-quality appearance and a soft touch feeling are expressed.
• a luxuriously high-quality appearance and a soft touch feeling are expressed.
• products for high-grade applications for example, as artificial leather for a suede-type furniture skin material, artificial leather for fashion goods such as inner skin and outer skin of bags, and automobile interior materials.

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

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• 2017
  • 2017-09-25 KR KR1020170123458A patent/KR102360127B1/ko active IP Right Grant
• 2018
  • 2018-08-30 WO PCT/KR2018/010040 patent/WO2019059553A1/ko unknown
  • 2018-08-30 US US16/645,178 patent/US20210025111A1/en active Pending
  • 2018-08-30 EP EP18859915.3A patent/EP3660207A4/en not_active Withdrawn
  • 2018-08-30 CN CN201880061664.5A patent/CN111164258A/zh active Pending

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