WO2017115312A1 - Procédé de traitement de matière de matrice micro-fibreuse non tissée avec une résine - Google Patents

Procédé de traitement de matière de matrice micro-fibreuse non tissée avec une résine Download PDF

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Publication number
WO2017115312A1
WO2017115312A1 PCT/IB2016/058066 IB2016058066W WO2017115312A1 WO 2017115312 A1 WO2017115312 A1 WO 2017115312A1 IB 2016058066 W IB2016058066 W IB 2016058066W WO 2017115312 A1 WO2017115312 A1 WO 2017115312A1
Authority
WO
WIPO (PCT)
Prior art keywords
matrix
treating
microfibrous non
woven
microfibrous
Prior art date
Application number
PCT/IB2016/058066
Other languages
English (en)
Inventor
Carlo BORSANI
Marco SECCO D'ARAGONA
Original Assignee
Naum S.R.L.
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 Naum S.R.L. filed Critical Naum S.R.L.
Priority to EP16838033.5A priority Critical patent/EP3397804A1/fr
Publication of WO2017115312A1 publication Critical patent/WO2017115312A1/fr

Links

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
    • 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
    • D06N3/007—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
    • D06N3/0077—Embossing; Pressing of the surface; Tumbling and crumbling; Cracking; Cooling; Heating, e.g. mirror finish
    • 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
    • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
    • D06N3/0088—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
    • D06N3/009—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin by spraying components on the web
    • 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
    • D06N3/18—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials
    • D06N3/183—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials the layers are one next to the other
    • 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
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0263—Polyamide 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
    • D06N2213/00—Others characteristics
    • D06N2213/03—Fibrous web coated on one side with at least two layers of the same polymer type, e.g. two coatings of polyolefin

Definitions

  • the present invention is intended to provide protection to a process of treating a non- woven microfibrous matrix with resin.
  • Hides are appropriately treated, prepared and mounted for improving their aesthetic appearance and resistance to various stresses.
  • animal hides has a number of drawbacks: each hide is different from the others, even if they are of the same species, in terms of mechanical resistance, thickness and their various inherent physical and aesthetic properties, which are typically desired by its users.
  • the hide may be exposed to thickness and mechanical resistance alterations. Furthermore, hides may exhibit unevenness due to diseases, accidents, scratches, etc. This causes difficulties to leather working factories, which require a homogeneous product for later use, and will incur higher cost during pre-treatment. Furthermore, raw natural hides are the subject of hard negotiations in special commodities exchange, due to a relatively restricted market; this will expose market operators to the risk of being victims of speculations, resulting in unsteady costs and unavailability of hides.
  • the last pass, with the resin still in a fluid state, is the deposition of a textile support which imparts physical and phenotypic properties to the product. It will be understood that such product may cause problems in the adhesion of the various layers, with a risk of product peeling, especially under stress.
  • this type of product has poor breathability.
  • the release paper shall have any decorative elements preset thereon.
  • a well-known drawback thereof is that the manufacturer will have to handle large volumes of identical decorative elements.
  • release paper is usually available in large rolls, involving large-scale production.
  • imitation leather obviously looks different from natural leather, as identical serially repeated decorative patterns are recognized, and reveal the printing operation. Likewise, the feel is very different from the feel of natural leather.
  • the invention has the object to conceive and provide a process of treating a microfibrous non-woven matrix that can be also carried out continuously and involves relatively low manufacturing and maintenance costs.
  • it has the object of providing a process of treating a microfibrous non- woven matrix that might lead to a product that is aesthetically identical to natural leather, preferably having an even thickness, and with a decorative pattern obtained without using release paper, preferably having breathable properties and meeting the requirements of those that cannot or do not want to use animal hides.
  • Another object of the present invention is to make and provide a product that is very similar to leather, in terms of physical and phenotypic properties.
  • FIG. 1 is a top view of the microfibrous material of the invention.
  • FIG. 2 is a 1 Ox-enlarged view of a detail of Figure 1 and
  • FIGS. 3 and 4 are 1 Ox-enlarged cross-sectional views of the microfibrous material of Figure 1.
  • the treatment process of the invention includes the provision of a microfibrous non- woven matrix composed of one or more impregnated polyamide or polyester fibers, which may have been enriched - during manufacturing - with reinforcement elements, such as water-based polyurethane resins or solvent-based polyurethane resins. In certain cases, such products should be added with or even entirely made of collagen fibers.
  • the matrix is a non-microporous microfibrous non- woven matrix.
  • non-woven matrix shall be intended as "a matrix made of a non- woven fabric”.
  • the matrix so formed undergoes treatment through successive steps, as described hereinafter in detail for the novel and improved aspects thereof to be clearly recognized.
  • the top surface of the matrix is treated by hot calendering and/or buffing, for proper preparation to the subsequent steps of the process. In some cases, for certain treatments, both processing steps may be carried out.
  • a coating resin may be also deposited, for reducing surface porosity.
  • a resin base coat preferably made of a water-based or solvent-based polyurethane, being deposited and distributed over the top surface.
  • the coat is deposited using a reverse-cylinder printing machine, in which the cylinder deposits a layer of desired material on the substrate while rotating in a direction opposite to the matrix being fed.
  • the aforementioned grouting step C) may be carried out using a grouting roller rotating in a direction opposite to the surface to be grouted, to thereby form a smooth and compact layer on said surface of said microfibrous non-woven matrix.
  • the surface to be grouted is fed in a preset direction of feed, whereas the grouting step C) is carried out using a counter-rotating grouting roller that contacts said surface to be grouted with a lateral surface portion whose peripheral tangential velocity is opposite to the direction of speed of the surface to be grouted.
  • the aforementioned grouting step will deposit 20 to 150 g/m 2 of resin, more preferably 30 to 50 g/m 2 of resin on the top surface of said microfibrous non- woven matrix.
  • the product so obtained is entirely comparable to a natural sanded leather, i.e. natural leather that has been tanned and has to undergo the well-known finishing process, as shown in Figure 1.
  • the material so treated may undergo a buffing step, such that its surface will be prepared for further processing and the adhesion properties of the top surface with the following layers will be increased.
  • a continuous layer of resin material preferably made of water- or solvent-based polyurethane, is deposited, using a micro-droplet spray printing technology, to form the various continuous layers required.
  • This step is typically composed of a number of successive substeps, preferably at least three substeps, to provide an adequate thickness, for later processing to be performed by the operator as required.
  • 10g/m 2 to 25 g/m 2 of material should be deposited for each of the continuous layers.
  • micro droplets is used to designate droplets with sizes ranging from 0.3 to 1.1 mm, more preferably from 0.4 to 0.8 mm.
  • the spray deposition of a continuous layer is separated from the spray deposition of the next continuous layer by hot drying of the matrix, preferably at a temperature ranging from 80°C to 150°C, more preferably at a temperature ranging from 90°C to 110°C, Preferably such hot drying step on the aforementioned matrix consist in an oven-drying step.
  • the required processing steps for spray deposition of a continuous layer of resin are alternated with as many oven-drying steps, at a temperature ranging from 80°C to 150°C, for the time required for thorough drying of the deposited layer, for maximized coating of the surface, and preparation thereof to the next steps.
  • An optimal range from 90°C to 1 10°C resulted from experimental tests.
  • the amount of resin that is sprayed during such step of spray deposition of a continuous layer of resin may range from 2 to 50 g/m , more preferably from 10 to 20 g/m for each layer.
  • the same resin may be used for the successive layers, otherwise different types of resins may be used for one or more of the continuous layers to be formed.
  • the multilayer configuration so obtained has well-defined purposes, which will be better explained below with reference, by way of example, to a three-layer deposition.
  • the first layer acts as an "adhesive" between the coat deposited by grouting on the microfibrous matrix and the next layer, generally referred to as "intermediate layer".
  • the intermediate layer is associated with the third layer which, according to the particular embodiment as described herein, acts as a base for the subsequent surface treatments required to obtain the technical resistance, the aesthetic effect and/or the feel required in the final product.
  • the aforementioned "intermediate layer” may comprise multiple successive layers, and the third layer may also comprise multiple successive layers.
  • the aforementioned spray deposition step is carried out in a starting condition in which:
  • the aforementioned step of spray deposition of resin is carried out in a condition in which said surface of said microfibrous non- woven matrix has been grouted and is at a temperature ranging from 5 to 51 °C.
  • the aforementioned step of spray deposition of resin is carried out after said grouting step, and before drying the grouting layer, i.e. with the grouting layer still wet. This will provide optimized adhesion of the spray-deposited resin on the grouted surface.
  • the adhesion between the layers so formed and those that come next may be based on affinity or on the use of additives having an adhesive power.
  • the process will continue with a hot embossing step, which involves partial melting of the fibers of the matrix, for permanent deformation of said fibers of said matrix. This will impress a permanent pattern of an embossed design on the aforementioned surface, by pressure.
  • the composite resin material undergoes hot compression by rollers or plates having appropriate decorations.
  • this hot embossing step is carried out at a temperature ranging from 130 to 170°C, and in any case at a temperature that can melt the fibers of the microfibrous non- woven matrix.
  • the temperature and pressure properties will obviously vary according to the materials that form the composite resin of the matrix or the aesthetic features to be impressed on the surface. Therefore, this processing step will define some of the aesthetic and tactile qualities of the finished product.
  • the material so obtained preferably undergoes a drumming or tumbling step, to soften, smoothen and swell the microfibrous material for further treatment. This step is particularly recommended when specific softness and volume properties are required in the material being manufactured.
  • these protective steps comprise resins, preferably made of water- or solvent- based polyurethane, applied with the micro droplet spray printing technology to form the various continuous layers to be formed, with a deposition amount ranging from 10 g/m to 25 g/m 2 for each of the continuous protective layer to be formed.
  • the first protective layer applied to the surface after the hot embossing step is a layer of said polyurethane resins having adhesive properties, for improved adhesion of the subsequent continuous protective layers to the surface of the matrix. Therefore, the first protective layer so deposited has the purpose of enhancing adhesion of the subsequently deposited continuous protective layers to the surface.
  • the deposition technique that is used for the aforementioned continuous protective layers substantially coincides with the spray deposition technique as described above for the previous processing steps.
  • the process of treatment of the original matrix can provide a product as shown in the figures.
  • Figure 1 shows the non-serial pattern of the decorative element, which makes the product visually comparable to natural leather.
  • Figure 2 is an enlarged view of Figure 1 and more clearly shows the roughness of the top surface.
  • Figures 3 and 4 highlight the multi-layer configuration of the resin deposited on the matrix.
  • the darker surface layer proves that the last layers of protective resin have been deposited.
  • the various successive resin layers, deposited by micro- droplet spray printing to form continuous layers as described above may be obtained from the same material or from different materials, such that a continuous multi-layer arrangement of materials is formed, ensuring various properties.
  • the amounts of materials so deposited to form the finished product will depend on the physical, especially mechanical properties to be obtained, such as particular resistances to wear-causing agents, such as bending, scratching, elongation, to special chemicals, or properties such as waterproofness, breathability, etc.
  • the matrix may be also enriched with reinforcing fibers, using a resin with a binding action, such as a water- or solvent-based polyurethane resin and/or collagen fibers.
  • the intended object was fulfilled, with the provision of a process of treating a microfibrous non- woven matrix that can provide a material whose exterior appearance is wholly comparable to leather; i.e. having all the desired inherent characteristics, a pleasant feel and all leather-like aspects.
  • the coating step may be repeated a number of times other than that described above, according to the desired physical properties.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

L'invention concerne un procédé de traitement d'une matrice non tissée micro-fibreuse imprégnée de résine, caractérisé en ce qu'il comprend les étapes de traitement suivantes : - fournir une matrice non tissée micro-fibreuse ayant une surface supérieure à traiter ; - préparer ladite surface supérieure de ladite matrice par calandrage à chaud et/ou polissage ; - couler ladite matrice par dépôt et distribution d'un revêtement de résine de base sur cette dernière ; - réaliser un dépôt par pulvérisation de micro-gouttelettes d'une ou plusieurs résines, une étape de séchage à chaud étant réalisée sur ladite matrice entre le dépôt d'une couche et le dépôt de la couche suivante, de préférence une étape de séchage au four à une température comprise entre 80 °C et 150 °C, plus de préférence à une température comprise entre 90 °C et 110 °C ; - gaufrer à chaud la surface de ladite matrice, ladite étape de gaufrage étant réalisée par fusion partielle des fibres de ladite matrice, pour entraîner une déformation permanente dans lesdites fibres de ladite matrice; - réaliser un dépôt par pulvérisation de micro-gouttelettes pour former une ou plusieurs couches de protection continues d'une ou plusieurs résines.
PCT/IB2016/058066 2015-12-30 2016-12-29 Procédé de traitement de matière de matrice micro-fibreuse non tissée avec une résine WO2017115312A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP16838033.5A EP3397804A1 (fr) 2015-12-30 2016-12-29 Procédé de traitement de matière de matrice micro-fibreuse non tissée avec une résine

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT102015000089330 2015-12-30
ITUB2015A009810A ITUB20159810A1 (it) 2015-12-30 2015-12-30 Processo di trattamento di una matrice non tessuta di materiale microfibroso in resina

Publications (1)

Publication Number Publication Date
WO2017115312A1 true WO2017115312A1 (fr) 2017-07-06

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2016/058066 WO2017115312A1 (fr) 2015-12-30 2016-12-29 Procédé de traitement de matière de matrice micro-fibreuse non tissée avec une résine

Country Status (3)

Country Link
EP (1) EP3397804A1 (fr)
IT (2) ITUB20159810A1 (fr)
WO (1) WO2017115312A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3775363B1 (fr) 2018-04-11 2023-03-01 MARIO LEVI S.p.A. Procédé de fabrication de cuir synthétique

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3462326A (en) * 1966-05-31 1969-08-19 Uniroyal Inc Method of making a leather-like microporous sheet material
EP0504701A1 (fr) * 1991-03-19 1992-09-23 Lorica S.p.A. Procédé pour convertir cuir artificiel en feuilles de matières avec une apparition semblable au cuir naturel

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3462326A (en) * 1966-05-31 1969-08-19 Uniroyal Inc Method of making a leather-like microporous sheet material
EP0504701A1 (fr) * 1991-03-19 1992-09-23 Lorica S.p.A. Procédé pour convertir cuir artificiel en feuilles de matières avec une apparition semblable au cuir naturel

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3775363B1 (fr) 2018-04-11 2023-03-01 MARIO LEVI S.p.A. Procédé de fabrication de cuir synthétique

Also Published As

Publication number Publication date
EP3397804A1 (fr) 2018-11-07
IT201600132183A1 (it) 2018-06-29
ITUB20159810A1 (it) 2017-06-30

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