WO2017188722A1 - Artificial leather for vehicle interior material, and manufacturing method therefor - Google Patents

Artificial leather for vehicle interior material, and manufacturing method therefor Download PDF

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Publication number
WO2017188722A1
WO2017188722A1 PCT/KR2017/004428 KR2017004428W WO2017188722A1 WO 2017188722 A1 WO2017188722 A1 WO 2017188722A1 KR 2017004428 W KR2017004428 W KR 2017004428W WO 2017188722 A1 WO2017188722 A1 WO 2017188722A1
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WIPO (PCT)
Prior art keywords
layer
artificial leather
surface treatment
foam layer
manufacturing
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PCT/KR2017/004428
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French (fr)
Korean (ko)
Inventor
민철희
정용배
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(주)엘지하우시스
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Publication of WO2017188722A1 publication Critical patent/WO2017188722A1/en

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    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N3/00Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N3/00Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/18Artificial 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
    • D06N3/183Artificial 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
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N3/00Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/007Artificial 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
    • D06N3/0077Embossing; Pressing of the surface; Tumbling and crumbling; Cracking; Cooling; Heating, e.g. mirror finish
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N3/00Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04Artificial 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
    • D06N3/06Artificial 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 polyvinylchloride or its copolymerisation products
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N3/00Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04Artificial 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
    • D06N3/06Artificial 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 polyvinylchloride or its copolymerisation products
    • D06N3/065PVC together with other resins except polyurethanes
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N3/00Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12Artificial 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
    • D06N3/14Artificial 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
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N3/00Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/18Artificial 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
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N2209/00Properties of the materials
    • D06N2209/10Properties of the materials having mechanical properties
    • D06N2209/103Resistant to mechanical forces, e.g. shock, impact, puncture, flexion, shear, compression, tear
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N2209/00Properties of the materials
    • D06N2209/16Properties of the materials having other properties
    • D06N2209/1685Wear resistance
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N2211/00Specially adapted uses
    • D06N2211/12Decorative or sun protection articles
    • D06N2211/26Vehicles, transportation
    • D06N2211/263Cars
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N2211/00Specially adapted uses
    • D06N2211/12Decorative or sun protection articles
    • D06N2211/28Artificial leather

Definitions

  • the present invention relates to an artificial leather for automobile interior materials having excellent physical properties and a method of manufacturing the same.
  • artificial leather is manufactured using polyvinyl chloride (PVC) or polyurethane (PU) as a material.
  • PVC polyvinyl chloride
  • PU polyurethane
  • the artificial leather made of PU is manufactured by laminating an adhesive layer and a PU label layer on a fabric layer by casting, and the PU material is difficult to foam, and thus, artificial leather having a cushioning feeling. There is a problem that is difficult to provide.
  • An object of the present invention is to provide an artificial leather for automotive interior having excellent surface properties and cushioning (feel).
  • Another object of the present invention is to provide a method of manufacturing artificial leather.
  • Artificial leather for car interior material layer in accordance with the present invention for achieving the above object; A foam layer formed on the fabric layer; A label layer formed on the foam layer; And an aqueous surface treatment layer formed on the label layer, wherein the embossed pattern is formed on the surface of the aqueous surface treatment layer.
  • the label layer may be formed from a label layer composition comprising a polyurethane (PU) -based resin.
  • PU polyurethane
  • the cover layer may be formed by a rotary screen process.
  • the foam layer may be formed from a foam layer composition comprising a polyvinyl chloride (PVC) resin and a foaming agent.
  • PVC polyvinyl chloride
  • the foam layer composition may include 5 to 10 parts by weight of a blowing agent based on 100 parts by weight of polyvinyl chloride resin.
  • the thickness of the foam layer may be 0.2 ⁇ 0.4mm.
  • the label layer may have a thickness of 50 ⁇ m to 100 ⁇ m.
  • the aqueous surface treatment layer is polyurethane (PU) -based resin; Curing agent containing 1 or more types of isocyanate group and carbodiimide group; And an aqueous solvent comprising at least one of water and alcohol.
  • PU polyurethane
  • the fabric layer may be a woven or nonwoven fabric including one or more of cotton, nylon, polyester, and rayon.
  • Method of manufacturing artificial leather for automobile interior for achieving the above another object (a) on the fabric layer by a calender process using a foam layer composition comprising a polyvinyl chloride (PVC) resin and a blowing agent Forming a foam layer to prepare a sheet; (b) forming a label layer on the sheet by a rotary screen process using a label layer composition comprising a polyurethane (PU) resin; (c) forming an aqueous surface treatment layer on the label layer; And (d) forming an embossed pattern on the surface of the aqueous surface treatment layer.
  • PVC polyvinyl chloride
  • PU polyurethane
  • Foam layer of step (a) may be formed by foaming at a temperature of 220 ⁇ 230 °C.
  • the calendar process of step (a) may be performed using a roller having a temperature of 100 ⁇ 200 °C.
  • the aqueous surface treatment layer of step (c) may be formed by performing a gravure coating process.
  • the embossed pattern of step (d) may be formed by performing a vacuum embossing process.
  • the vacuum embossing process may be performed under a vacuum gauge pressure of 0.04 to 0.07 MPa.
  • the vacuum embossing process may be performed at a temperature of 160 ⁇ 180 °C.
  • the artificial leather for automobile interior according to the present invention has an excellent cushioning effect compared to the artificial leather manufactured only with conventional PVC or PU material by the laminated structure of the PVC foam layer and the PU cover layer.
  • an aqueous surface treatment layer on the PU label layer, it is possible to improve surface properties such as wear resistance and feel.
  • the cover layer including the PU material may be formed on the foam layer including the PVC material without the need for an adhesive layer using a rotary screen process. Accordingly, the embossed pattern can be directly formed by a vacuum embossing process without using a release paper.
  • the production method of artificial leather for automobile interior of the present invention is improved productivity and workability by a calender process, a rotary screen process and a gravure coating process.
  • Figure 1 shows a cross-sectional view of the artificial leather for automobile interior according to the present invention.
  • Figure 2 is a flow chart illustrating a manufacturing method of artificial leather for automobile interior according to the present invention.
  • Figure 3 shows a rotary screen process diagram according to the present invention.
  • Figure 4 shows a photograph taken a cross section of the artificial leather foam layer for automobile interior according to the first embodiment of the present invention.
  • Figure 5 shows a picture of the product (a) containing the normal far-end layer of the present invention and the product (b) including a far-end layer having a wrinkled wrinkles.
  • leather used for automobile interior is divided into natural leather and artificial leather. Since natural leather is expensive and supplies are not smooth, the use of artificial leather is increasing. As mentioned above, artificial leather is generally made of PVC or PU material. Artificial leather made of PVC material has the disadvantage that the wear resistance is weak, the artificial leather made of PU material has a problem that the cushioning feeling is lowered due to the foaming deterioration.
  • the present invention provides an artificial leather for automobile interior materials having excellent cushioning and durability through a configuration including a foam layer including a PVC material and a cover layer including a PU material.
  • the artificial leather of the present invention has an effect of excellent surface properties by forming an aqueous surface treatment layer and an embossed pattern on the top of the artificial leather.
  • the PVC foam layer means a foam layer containing a PVC material
  • the PU label layer means a cover layer containing a PU material
  • Figure 1 shows a cross-sectional view of the artificial leather for automobile interior according to the present invention.
  • Artificial leather for automobile interior material layer 10 according to the present invention;
  • a foam layer 20 formed on the fabric layer;
  • a label layer 30 formed on the foam layer;
  • an aqueous surface treatment layer 40 formed on the label layer, wherein an embossed pattern is formed on the surface of the aqueous surface treatment layer.
  • the far end layer 10 is a part which is in contact with the vehicle seat frame side, in order to secure rigidity, the thickness is uniform, the dimensional stability is high, it is preferable not to be deformed by heat and pressure.
  • the fabric layer 10 may be a woven or nonwoven fabric including one or more of cotton, nylon, polyester, and rayon.
  • the foam layer 20 may be formed from a foam layer composition including a polyvinyl chloride (PVC) resin and a foaming agent.
  • the foamed layer 20 may be formed by mixing a polyvinyl chloride resin and a foaming agent to prepare a foamed layer composition, and applying the composition to a predetermined thickness and then foaming the composition at about 220 to 230 ° C.
  • the foam layer composition may include polyvinylidene chloride (PVDC) resin, chlorinated polyvinyl chloride (CPVC) resin, etc. in addition to the polyvinyl chloride resin.
  • artificial leather made of a PU material it is manufactured by laminating an adhesive layer and a PU label layer on a fabric layer and then performing foaming and drying.
  • the thickness of the PU label layer is thin as 30 ⁇ 70 ⁇ m, accordingly, there is a high probability of pores on the surface of the product when foaming. Therefore, the artificial leather made of PU material is difficult to foam, it is difficult to provide an artificial leather with a cushion (cushion) feeling.
  • the blowing agent is azodicarbonamide (ADCA, Azodicarbonamide), p, p'-oxybisbenzenesulfonyl hydrazide (p, p'-Oxybis (benzenesulfonyl hydrazide)), p-toluenesulfonyl hydrazide (p- toluenesulfonyl hydrazide) and sodium bicarbonate, and the like, but are not limited thereto.
  • the blowing agent After the blowing agent is foamed at approximately 220 ⁇ 230 °C, it may have a volume increase rate of 100 ⁇ 500% by volume.
  • the gas generated from the foaming agent may form bubbles to form a foaming cell in the foaming layer 20.
  • the foaming cell may be a spherical foaming cell, and all of the walls of the pores are formed in a closed structure, and are also called independent pores or closed cells as pores not connected to other pores. Since the foamed cell is not deformed by physical external force, it is possible to improve the soft characteristics and cushioning of the foamed layer 20.
  • the foam layer composition may include 5 to 10 parts by weight of a blowing agent based on 100 parts by weight of polyvinyl chloride resin.
  • a blowing agent based on 100 parts by weight of polyvinyl chloride resin.
  • the foaming agent is included in less than 5 parts by weight, the softness and cushioning of the artificial leather may be lowered.
  • it exceeds 10 parts by weight the foam cells of the foam layer are excessively generated, resulting in a decrease in surface properties or durability.
  • the foam layer composition may further include a plasticizer and a heat stabilizer to control the melt strength during foaming.
  • the thickness of the foam layer formed through the foaming process may be 0.2 ⁇ 0.4mm.
  • the thickness of the foam layer is less than 0.2mm, since the thickness is thin, the cushioning of the artificial leather can be reduced, there is a problem that the pattern of the fabric layer woven fabric is exposed to the product surface. On the contrary, when the thickness exceeds 0.4 mm, there is a problem in that the wrinkle wrinkles occur on the surface of the product.
  • folding wrinkles when the artificial leather is bent for a long time, the shape of the foamed cell is deformed and fixed, so that deep wrinkles are generated as shown in FIG. Such bending wrinkles have a problem that is not restored even through heat or steam treatment.
  • the label layer 30 serves to secure surface smoothness, provide color, and may be formed from a label layer composition including a polyurethane (PU) -based resin.
  • the polyurethane resin may be prepared by polymerizing a polycarbonate diol, a polyether diol or a diol containing a carboxyl group, and a diisocyanate compound at about 80 to 100 ° C. Since the produced polyurethane-based resin does not contain volatile organic compounds such as toluene, it is easy to disperse water, does not adversely affect the human body, and is environmentally friendly. For this reason, the label layer 30 is excellent in compatibility with the aqueous surface treatment layer 40 described later, there is an advantage that can improve the surface properties such as touch.
  • the cover layer 30 may have a thickness of 50 ⁇ m to 100 ⁇ m. If the thickness of the cover layer 30 is less than 50 ⁇ m, it may be difficult to secure the surface smoothness, if it exceeds 100 ⁇ m, the cushioning of the artificial leather may be lowered or the adhesive strength with the foam layer.
  • the aqueous surface treatment layer 40 improves scratch resistance, stain resistance and surface properties, and provides an environmentally friendly effect.
  • the aqueous surface treatment layer 40 is a polyurethane resin; Curing agent containing 1 or more types of isocyanate group and carbodiimide group; And an aqueous solvent comprising at least one of water and alcohol.
  • the polyurethane-based resin included in the aqueous coating composition may be the same as the polyurethane-based resin of the label layer 30.
  • Curing agents containing the isocyanate group include toluene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, naphthalene diisocyanate and the like.
  • the curing agent containing the carbodiimide group is 1-ethyl-3- (3-dimethylamino) propyl) carbodiimide (1-ethyl-3- (3- (dimethylamino) propyl) carbodiimide Etc.
  • the aqueous solvent is a solvent in contrast to the organic solvent, it may mean a solvent having an OH group.
  • the water-based coating composition may improve pollution resistance by including an aqueous solvent such as water and alcohol.
  • An embossed pattern (not shown) is formed on the surface of the aqueous surface treatment layer, and the embossed pattern imparts an excellent surface texture to the artificial leather for automobile interior materials and improves surface durability.
  • Figure 2 is a flow chart illustrating a manufacturing method of artificial leather for automobile interior according to the present invention.
  • Manufacturing method of artificial leather for automobile interior is the foam layer forming step (S110), the cover layer forming step (S120), the aqueous surface treatment layer forming step (S130) and the embossing pattern forming step (S140) on the fabric layer It includes.
  • the foam layer 20 is formed from a foam layer composition containing a polyvinyl chloride (PVC) resin and a blowing agent.
  • PVC polyvinyl chloride
  • the calendering process is a roller compaction is performed at the same time as passing the raw material between the rollers rotating in the opposite direction, and then includes a cooling process.
  • the raw material may be kneaded at a temperature of 100 to 200 ° C. before passing the raw material between the rollers, but is not limited thereto.
  • the foam layer composition may be passed through a calender roller to form a pre-foam layer on the fabric layer 10.
  • the calender roller is maintained at a temperature of approximately 100 ⁇ 200 °C, the average rotational speed of the calender roller may be 30m / min ⁇ 100m / min.
  • the temperature of the calender roller is less than 100 ° C, melting of the foam layer composition is not sufficiently performed.
  • shear strength between calender rollers may occur, and adhesion or premature foaming of the foam layer composition may occur on the roller surface.
  • the preliminary foam layer is foamed at a temperature of 220 ⁇ 230 °C to form a foam layer (20).
  • the foaming temperature is less than 220 ° C, the heat transfer of the foam layer is insufficient to reduce the foamability.
  • the foaming temperature exceeds 230 °C the over-foaming phenomenon may occur, bubbles may occur on the surface of the product, there is a problem that the wrinkles occur on the surface of the product.
  • the fabric layer 10 and the foam layer 20 is then cooled to room temperature, thereby producing a semi-finished sheet.
  • the cover layer 30 is formed on the sheet by performing a rotary screen process.
  • the label layer is formed from a label layer composition containing a polyurethane (PU) resin.
  • the rotary screen process is a process in which the raw material is coated on the sheet by rotating the screen net after inputting the raw material into the screen net. More specifically, referring to FIG. 3, different colors and patterns may be formed on fabric layers such as fibers, fabrics, etc. using color reservoirs and screen rollers.
  • a polyurethane resin is applied onto the sheet by a rotating screen roller to form a label layer.
  • the liquid polyurethane (PU) resin stored in the raw material reservoir is supplied to the screen roller.
  • the raw material reservoir may be one or more, injecting a polyurethane resin into the first raw material reservoir, injecting a separate raw material that can give color to the second raw material reservoir, and then rotating the screen roller connected to each reservoir By doing so, a label layer having a color can also be formed.
  • a printing method such as comma coating may be applied, but it is preferable to apply a rotary screen process to secure the surface smoothness of the cover layer 30.
  • the cover layer including the PU material may be formed on the foam layer including the PVC material without the need for the adhesive layer.
  • the embossed pattern was previously formed using a release paper, in the present invention, the embossed pattern may be directly formed by a vacuum embossing process without using a release paper by forming a cover layer including a PU material by performing a rotary screen process. .
  • a gravure coating process is performed to form an aqueous surface treatment layer 40 on the label layer 30.
  • the gravure coating process may include a direct gravure coating, a reverse gravure coating, an offset gravure coating, and the like.
  • a direct gravure coating is one in which coating is performed on a substrate between a roller formed of an elastic rubber and a roller containing a coating liquid, and the rotational speed of these rollers may be the same.
  • the rotation direction of the substrate and the rollers may be reversed.
  • Reverse gravure coating has the opposite direction of rotation of the substrate and the rollers, it is possible to control the application amount by adjusting the speed of the roller.
  • the respective rollers are driven independently of each other, and the coating layer can be uniformly formed in a small amount by high speed.
  • the aqueous coating composition is as described above, and by forming the aqueous surface treatment layer 40, the artificial leather of the present invention can improve scratch resistance, stain resistance, and provide an environmentally friendly effect.
  • An embossed pattern (not shown) is formed on the surface of the aqueous surface treatment layer 40.
  • the embossed pattern may be formed by performing a vacuum embossing process.
  • Vacuum embossing process is a method of transferring the embossed pattern by sucking the artificial leather under a vacuum gauge pressure of 0.04 ⁇ 0.07MPa.
  • the vacuum embossing process is performed at less than 0.04 MPa, it is difficult to form an embossed pattern and the cushioning feeling may be lowered.
  • the aqueous surface treatment layer 40 may be damaged or surface properties may be degraded.
  • the vacuum embossing process may be performed at a temperature of 160 ⁇ 180 °C.
  • the temperature is less than 160 ° C., it is difficult to sufficiently form the embossed pattern.
  • the temperature is more than 180 ° C., the surface properties of the artificial leather become rough or torn due to high temperature.
  • the artificial leather for automobile interior material of the present invention is excellent in surface smoothness and can form a uniform layer through a manufacturing method such as a calender process and a rotary screen process.
  • a manufacturing method such as a calender process and a rotary screen process.
  • a laminated structure including a PVC foam layer, a PU label layer, and an aqueous surface treatment layer, there is an effect of excellent surface properties and thickness of the artificial leather.
  • the foam layer was formed from a foam layer composition containing 5 parts by weight of azodicarbonamide as a foaming agent with respect to 100 parts by weight of polyvinyl chloride resin.
  • a polyurethane resin was applied onto the foam layer by a rotating screen roller to perform a rotary screen process to form a label layer.
  • an aqueous coating composition comprising a polyurethane resin, toluene diisocyanate as a curing agent, and water as an aqueous solvent.
  • a gravure coating process was performed using this, and an aqueous surface treatment layer having a thickness of 20 ⁇ m was formed on the label layer.
  • a vacuum embossing process is performed on the resultant formed with the aqueous surface treatment layer under a vacuum gage pressure of 0.06 MPa and a temperature of 170 to form an embossed pattern on the surface of the aqueous surface treatment layer for automobile interior materials. Artificial leather was produced.
  • a laminate in which a label layer and an aqueous surface treatment layer were laminated from a pre-foam layer formed of a foam layer composition containing a polyvinyl chloride resin and a polyvinyl chloride resin on a fabric layer were laminated. Subsequently, after the laminate was foamed at a temperature of 220, an artificial leather for automobile interior was manufactured in the same manner as in Example 1, except that the vacuum embossing process was performed.
  • a laminate in which an adhesive layer, a pre-foamed layer formed from a foamed layer composition containing a polyurethane resin, and an aqueous surface treatment layer were laminated on a fabric layer was prepared. Subsequently, after the laminate was foamed at a temperature of 220, a foam layer having a thickness of 50 ⁇ m was formed, except that a roll pressing process was performed under a pressure of 4 MPa using an embossing roll having an embossed pattern. Artificial leather for automobile interior was manufactured in the same manner as in Example 1.
  • An artificial leather for automobile interior was manufactured in the same manner as in Example 1, except that the cover layer was formed by performing a comma coating.
  • Pore / break wrinkles on the surface of the product When the porosity and break wrinkles occurred in the product surface of less than 10%, "none", if more than 10% occurred "marked”.
  • Example 1 the artificial leather for automobile interior materials prepared in Example 1 exhibits excellent cushioning feeling due to high ductility because foam cells are formed in the foam layer.
  • Example 1 by performing the vacuum embossing process in Example 1, it can be seen that the embossed pattern (not shown) on the surface of the aqueous surface treatment layer is formed to have excellent surface texture and surface durability on the artificial leather.
  • Comparative Example 3 formed by performing a comma coating instead of the cover layer was performed with a rotary screen, the surface of the cover layer was not smooth, and the tearing occurred.

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

Abstract

Disclosed is artificial leather for a vehicle interior material, having an excellent surface property and cushiony feeling. According to the present invention, the artificial leather for a vehicle interior material comprises: a fabric layer; a foam layer formed on the fabric layer; a cover layer formed on the foam layer; and an aqueous surface treatment layer formed on the cover layer, wherein an embossed pattern is formed on the surface of the aqueous surface treatment layer.

Description

자동차 내장재용 인조가죽 및 그의 제조방법Artificial leather for automobile interior and its manufacturing method
본 발명은 물성이 우수한 자동차 내장재용 인조가죽 및 그의 제조방법에 관한 것이다. The present invention relates to an artificial leather for automobile interior materials having excellent physical properties and a method of manufacturing the same.
인조가죽은 자동차 내부의 많은 부분을 차지하고 있다. 최근, 깨끗한 환경 및 인체에 유해하지 않은 물성을 확보하기 위해, 자동차 내장재용 인조가죽에 대한 연구가 활발히 진행되고 있다. Artificial leather makes up a large part of the interior of a car. Recently, in order to secure a clean environment and physical properties that are not harmful to the human body, research on artificial leather for automobile interior materials is actively being conducted.
일반적으로 폴리염화비닐(PVC) 또는 폴리우레탄(PU)을 소재로 하여 인조가죽이 제조된다. Generally, artificial leather is manufactured using polyvinyl chloride (PVC) or polyurethane (PU) as a material.
PVC를 소재로 한 인조가죽은 캘린더(Calendar) 방식으로 원단층 상에 PVC 발포층과 PVC 표지층을 적층한 후, 대략 200℃의 온도에서 발포함으로써 제조된다. 그러나, PVC 재질 만으로는 내마모성 및 표면 물성이 우수한 인조가죽을 제공하기 어려운 문제점이 있다. Artificial leather made of PVC is manufactured by laminating a PVC foam layer and a PVC label layer on a fabric layer in a calendar method, and then foaming at a temperature of approximately 200 ° C. However, it is difficult to provide artificial leather having excellent abrasion resistance and surface properties only with PVC material.
또한, PU를 소재로 한 인조가죽은 캐스팅(Casting) 방식으로 원단층 상에 접착층과 PU 표지층을 적층한 후 건조하여 제조되는데, PU 재질은 발포가 어려워, 쿠션(cushion)감이 있는 인조가죽을 제공하기 어려운 문제점이 있다.In addition, the artificial leather made of PU is manufactured by laminating an adhesive layer and a PU label layer on a fabric layer by casting, and the PU material is difficult to foam, and thus, artificial leather having a cushioning feeling. There is a problem that is difficult to provide.
따라서, 내마모성 및 쿠션감이 우수한 인조가죽이 요구되고 있다.Therefore, there is a demand for artificial leather having excellent abrasion resistance and cushioning.
본 발명에 관련된 배경기술로는 대한민국 등록특허공보 제10-0873655호(2008.12.05.등록)가 있으며, 상기 문헌에는 방염 피이브이시 발포 인조가죽 및 그 제조방법이 개시되어 있다.Background art related to the present invention is Republic of Korea Patent Publication No. 10-0873655 (2008.12.05. Registered), the document discloses flame retardant fibish artificial leather and a manufacturing method thereof.
본 발명의 목적은 표면 물성 및 쿠션(cushion)감이 우수한 자동차 내장재용 인조가죽을 제공하는 것이다.An object of the present invention is to provide an artificial leather for automotive interior having excellent surface properties and cushioning (feel).
본 발명의 다른 목적은 상기 인조가죽의 제조방법을 제공하는 것이다. Another object of the present invention is to provide a method of manufacturing artificial leather.
상기 하나의 목적을 달성하기 위한 본 발명에 따른 자동차 내장재용 인조가죽은 원단층; 상기 원단층 상에 형성되는 발포층; 상기 발포층 상에 형성되는 표지층; 및 상기 표지층 상에 형성되는 수성 표면처리층;을 포함하고, 상기 수성 표면처리층 표면에 엠보 무늬가 형성되는 것을 특징으로 한다.Artificial leather for car interior material layer in accordance with the present invention for achieving the above object; A foam layer formed on the fabric layer; A label layer formed on the foam layer; And an aqueous surface treatment layer formed on the label layer, wherein the embossed pattern is formed on the surface of the aqueous surface treatment layer.
상기 표지층은 폴리우레탄(PU)계 수지를 포함하는 표지층 조성물로부터 형성될 수 있다.The label layer may be formed from a label layer composition comprising a polyurethane (PU) -based resin.
상기 표지층은 로터리 스크린(Rotary Screen) 공정으로 형성될 수 있다.The cover layer may be formed by a rotary screen process.
상기 발포층은 폴리염화비닐(PVC) 수지 및 발포제를 포함하는 발포층 조성물로부터 형성될 수 있다.The foam layer may be formed from a foam layer composition comprising a polyvinyl chloride (PVC) resin and a foaming agent.
상기 발포층 조성물은 폴리염화비닐 수지 100중량부에 대하여, 발포제 5~10중량부를 포함할 수 있다.The foam layer composition may include 5 to 10 parts by weight of a blowing agent based on 100 parts by weight of polyvinyl chloride resin.
상기 발포층의 두께는 0.2~0.4mm일 수 있다.The thickness of the foam layer may be 0.2 ~ 0.4mm.
상기 표지층의 두께는 50~100㎛일 수 있다.The label layer may have a thickness of 50 μm to 100 μm.
상기 수성 표면처리층은 폴리우레탄(PU)계 수지; 이소시아네이트기 및 카보디이미드기 중 1종 이상을 포함하는 경화제; 및 물 및 알코올 중 1종 이상을 포함하는 수성 용매;를 포함하는 수계 코팅 조성물로부터 형성될 수 있다.The aqueous surface treatment layer is polyurethane (PU) -based resin; Curing agent containing 1 or more types of isocyanate group and carbodiimide group; And an aqueous solvent comprising at least one of water and alcohol.
상기 원단층은 면, 나일론, 폴리에스터 및 레이온 중 1종 이상을 포함하는 직포 또는 부직포일 수 있다.The fabric layer may be a woven or nonwoven fabric including one or more of cotton, nylon, polyester, and rayon.
상기 다른 목적을 달성하기 위한 본 발명에 따른 자동차 내장재용 인조가죽의 제조방법 (a) 폴리염화비닐(PVC) 수지 및 발포제를 포함하는 발포층 조성물을 이용하여 캘린더(Calendar) 공정으로 원단층 상에 발포층을 형성하여 시트를 제조하는 단계; (b) 폴리우레탄(PU)계 수지를 포함하는 표지층 조성물을 이용하여 로터리 스크린(Rotary Screen) 공정으로 상기 시트 상에 표지층을 형성하는 단계; (c) 상기 표지층 상에 수성 표면처리층을 형성하는 단계; 및 (d) 상기 수성 표면처리층 표면에 엠보 무늬를 형성하는 단계;를 포함하는 것을 특징으로 한다.Method of manufacturing artificial leather for automobile interior according to the present invention for achieving the above another object (a) on the fabric layer by a calender process using a foam layer composition comprising a polyvinyl chloride (PVC) resin and a blowing agent Forming a foam layer to prepare a sheet; (b) forming a label layer on the sheet by a rotary screen process using a label layer composition comprising a polyurethane (PU) resin; (c) forming an aqueous surface treatment layer on the label layer; And (d) forming an embossed pattern on the surface of the aqueous surface treatment layer.
상기 (a) 단계의 발포층은 220~230℃의 온도에서 발포되어 형성될 수 있다.Foam layer of step (a) may be formed by foaming at a temperature of 220 ~ 230 ℃.
상기 (a) 단계의 캘린더 공정은 100~200℃의 온도를 갖는 롤러를 이용하여 수행될 수 있다.The calendar process of step (a) may be performed using a roller having a temperature of 100 ~ 200 ℃.
상기 (c) 단계의 수성 표면처리층은 그라비아(gravure) 코팅 공정을 수행하여 형성될 수 있다.The aqueous surface treatment layer of step (c) may be formed by performing a gravure coating process.
상기 (d) 단계의 엠보 무늬는 진공 엠보싱(Vacuum embossing) 공정을 수행하여 형성될 수 있다.The embossed pattern of step (d) may be formed by performing a vacuum embossing process.
상기 진공 엠보싱 공정은 0.04~0.07MPa의 진공계(Vacuum gauge) 압력 하에서 수행될 수 있다.The vacuum embossing process may be performed under a vacuum gauge pressure of 0.04 to 0.07 MPa.
상기 진공 엠보싱 공정은 160~180℃의 온도에서 수행될 수 있다.The vacuum embossing process may be performed at a temperature of 160 ~ 180 ℃.
본 발명에 따른 자동차 내장재용 인조가죽은 PVC 발포층과 PU 표지층의 적층 구조에 의해, 종래의 PVC 또는 PU 재질로만 제조된 인조가죽에 비하여 쿠션감이 우수한 효과가 있다.The artificial leather for automobile interior according to the present invention has an excellent cushioning effect compared to the artificial leather manufactured only with conventional PVC or PU material by the laminated structure of the PVC foam layer and the PU cover layer.
또한, PU 표지층 상에 수성 표면처리층을 형성함으로써, 내마모성 및 촉감 등의 표면 물성을 향상시킬 수 있다.In addition, by forming an aqueous surface treatment layer on the PU label layer, it is possible to improve surface properties such as wear resistance and feel.
본 발명에서는 로터리 스크린 공정을 이용하여 접착층 필요 없이 PVC 재질을 포함하는 발포층 상에 PU 재질을 포함하는 표지층을 형성할 수 있다. 이에 따라, 이형지의 사용 없이 진공 엠보싱 공정으로 엠보 무늬를 직접 형성할 수 있다.In the present invention, the cover layer including the PU material may be formed on the foam layer including the PVC material without the need for an adhesive layer using a rotary screen process. Accordingly, the embossed pattern can be directly formed by a vacuum embossing process without using a release paper.
아울러, 본 발명의 자동차 내장재용 인조가죽의 제조방법은 캘린더 공정, 로터리 스크린 공정 및 그라비아 코팅 공정에 의해 생산성 및 작업성이 향상된다.In addition, the production method of artificial leather for automobile interior of the present invention is improved productivity and workability by a calender process, a rotary screen process and a gravure coating process.
도 1은 본 발명에 따른 자동차 내장재용 인조가죽의 단면도를 나타낸 것이다.Figure 1 shows a cross-sectional view of the artificial leather for automobile interior according to the present invention.
도 2는 본 발명에 따른 자동차 내장재용 인조가죽의 제조방법을 나타낸 순서도이다.Figure 2 is a flow chart illustrating a manufacturing method of artificial leather for automobile interior according to the present invention.
도 3은 본 발명에 따른 로터리 스크린 공정도를 나타낸 것이다.Figure 3 shows a rotary screen process diagram according to the present invention.
도 4는 본 발명의 실시예 1에 따른 자동차 내장재용 인조가죽 발포층의 단면을 촬영한 사진을 나타낸 것이다.Figure 4 shows a photograph taken a cross section of the artificial leather foam layer for automobile interior according to the first embodiment of the present invention.
도 5는 본 발명의 정상 원단층을 포함하는 제품(a)과 꺾임 주름이 발생한 원단층을 포함하는 제품(b)의 사진을 나타낸 것이다. Figure 5 shows a picture of the product (a) containing the normal far-end layer of the present invention and the product (b) including a far-end layer having a wrinkled wrinkles.
[부호의 설명][Description of the code]
10 : 원단층10: fabric layer
20 : 발포층20: foam layer
30 : 표지층30: cover layer
40 : 수성 표면처리층40: aqueous surface treatment layer
S110 : 원단층 상에 발포층 형성S110: foam layer formed on the fabric layer
S120 : 표지층 형성S120: cover layer formation
S130 : 수성 표면처리층 형성S130: forming an aqueous surface treatment layer
S140 : 엠보 무늬 형성S140: Embossed Formation
본 발명의 이점 및 특징, 그리고 그것들을 달성하는 방법은 첨부되는 도면과 함께 상세하게 후술되어 있는 실시예들을 참조하면 명확해질 것이다. 그러나 본 발명은 이하에서 개시되는 실시예들에 한정되는 것이 아니라 서로 다른 다양한 형태로 구현될 것이며, 단지 본 실시예들은 본 발명의 개시가 완전하도록 하며, 본 발명이 속하는 기술분야에서 통상의 지식을 가진 자에게 발명의 범주를 완전하게 알려주기 위해 제공되는 것이며, 본 발명은 청구항의 범주에 의해 정의될 뿐이다. 명세서 전체에 걸쳐 동일 참조 부호는 동일 구성요소를 지칭한다.Advantages and features of the present invention and methods for achieving them will be apparent with reference to the embodiments described below in detail with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but may be implemented in various forms. It is provided to fully convey the scope of the invention to those skilled in the art, and the present invention is defined only by the scope of the claims. Like reference numerals refer to like elements throughout.
이하 첨부된 도면을 참조하여 본 발명의 바람직한 실시예에 따른 자동차 내장재용 인조가죽 및 그 제조방법에 관하여 상세히 설명하면 다음과 같다.Hereinafter, with reference to the accompanying drawings will be described in detail with respect to artificial leather for automobile interior materials and a method of manufacturing the same according to a preferred embodiment of the present invention.
자동차 내장재용으로 사용되는 가죽은 천연가죽과 인조가죽으로 구분된다. 천연가죽은 가격이 비싸고 공급이 원활하지 못하기 때문에, 인조가죽의 사용량이 증가하고 있다. 전술한 바와 같이, 인조가죽은 일반적으로 PVC 또는 PU 재질로 제조된다. PVC 재질로 이루어진 인조가죽은 내마모성이 취약하다는 단점을 가지고 있으며, PU 재질로 이루어진 인조가죽은 발포성 저하로 인해 쿠션감이 저하되는 문제점이 있다.Leather used for automobile interior is divided into natural leather and artificial leather. Since natural leather is expensive and supplies are not smooth, the use of artificial leather is increasing. As mentioned above, artificial leather is generally made of PVC or PU material. Artificial leather made of PVC material has the disadvantage that the wear resistance is weak, the artificial leather made of PU material has a problem that the cushioning feeling is lowered due to the foaming deterioration.
본 발명에서는 PVC 재질을 포함하는 발포층과 PU 재질을 포함하는 표지층을 포함하는 구성을 통해 쿠션감 및 내구성이 우수한 자동차 내장재용 인조가죽을 제공한다. 또한, 본 발명의 인조가죽은 인조가죽의 최상부에 수성 표면처리층과 엠보 무늬를 형성하여 표면 물성이 우수한 효과가 있다.The present invention provides an artificial leather for automobile interior materials having excellent cushioning and durability through a configuration including a foam layer including a PVC material and a cover layer including a PU material. In addition, the artificial leather of the present invention has an effect of excellent surface properties by forming an aqueous surface treatment layer and an embossed pattern on the top of the artificial leather.
본 발명에서 PVC 발포층은 PVC 재질을 포함하는 발포층을 의미하고, PU 표지층은 PU 재질을 포함하는 표지층을 의미한다.In the present invention, the PVC foam layer means a foam layer containing a PVC material, the PU label layer means a cover layer containing a PU material.
도 1은 본 발명에 따른 자동차 내장재용 인조가죽의 단면도를 나타낸 것이다. 본 발명에 따른 자동차 내장재용 인조가죽은 원단층(10); 상기 원단층 상에 형성되는 발포층(20); 상기 발포층 상에 형성되는 표지층(30); 및 상기 표지층 상에 형성되는 수성 표면처리층(40);을 포함하고, 상기 수성 표면처리층 표면에 엠보 무늬가 형성된다.Figure 1 shows a cross-sectional view of the artificial leather for automobile interior according to the present invention. Artificial leather for automobile interior material layer 10 according to the present invention; A foam layer 20 formed on the fabric layer; A label layer 30 formed on the foam layer; And an aqueous surface treatment layer 40 formed on the label layer, wherein an embossed pattern is formed on the surface of the aqueous surface treatment layer.
상기 원단층(10)은 자동차 시트 프레임 쪽과 접촉되는 부위로서, 강성 확보를 위해, 두께가 일정하고 치수안정성이 높으며, 열과 압력에 변형되지 않는 것이 바람직하다. 상기 원단층(10)은 면, 나일론, 폴리에스터 및 레이온 중 1종 이상을 포함하는 직포 또는 부직포일 수 있다.The far end layer 10 is a part which is in contact with the vehicle seat frame side, in order to secure rigidity, the thickness is uniform, the dimensional stability is high, it is preferable not to be deformed by heat and pressure. The fabric layer 10 may be a woven or nonwoven fabric including one or more of cotton, nylon, polyester, and rayon.
상기 발포층(20)은 폴리염화비닐(PVC) 수지 및 발포제를 포함하는 발포층 조성물로부터 형성될 수 있다. 폴리염화비닐 수지와 발포제를 혼합하여 발포층 조성물을 제조하고, 상기 조성물을 일정 두께로 도포한 후에 이를 대략 220~230℃에서 발포시킴으로써 발포층(20)을 형성할 수 있다. 상기 발포층 조성물에는 폴리염화비닐 수지 외에 폴리비닐리덴클로라이드(PVDC) 수지, 염소화 폴리염화비닐(CPVC) 수지 등이 포함될 수 있다. 반면, PU 재질로 이루어진 인조가죽의 경우, 원단층 상에 접착층과 PU 표지층을 적층한 후 발포 및 건조를 수행하여 제조된다. 상기 PU 표지층의 두께는 30~70㎛로 얇으며, 이에 따라 발포시 제품 표면에 기공이 발생할 확률이 높다. 따라서, PU 재질로 이루어진 인조가죽은 발포가 어려워, 쿠션(cushion)감이 있는 인조가죽을 제공하기 어려운 문제점이 있다.The foam layer 20 may be formed from a foam layer composition including a polyvinyl chloride (PVC) resin and a foaming agent. The foamed layer 20 may be formed by mixing a polyvinyl chloride resin and a foaming agent to prepare a foamed layer composition, and applying the composition to a predetermined thickness and then foaming the composition at about 220 to 230 ° C. The foam layer composition may include polyvinylidene chloride (PVDC) resin, chlorinated polyvinyl chloride (CPVC) resin, etc. in addition to the polyvinyl chloride resin. On the other hand, in the case of artificial leather made of a PU material, it is manufactured by laminating an adhesive layer and a PU label layer on a fabric layer and then performing foaming and drying. The thickness of the PU label layer is thin as 30 ~ 70㎛, accordingly, there is a high probability of pores on the surface of the product when foaming. Therefore, the artificial leather made of PU material is difficult to foam, it is difficult to provide an artificial leather with a cushion (cushion) feeling.
상기 발포제는 아조디카본아미드(ADCA, Azodicarbonamide), p,p'-옥시비스벤젠술포닐 하이드라지드 (p,p'-Oxybis(benzenesulfonyl hydrazide)), p-톨루엔술포닐 하이드라지드 (p-toluenesulfonyl hydrazide) 및 소듐바이카보네이트(Sodiumbicarbonate) 등을 포함할 수 있으나, 이에 제한되는 것은 아니다. 상기 발포제는 대략 220~230℃에서 발포된 후, 100~500 부피%의 부피 증가 비율을 갖을 수 있다. 발포되는 과정에서 발포제로부터 발생한 기체가 기포를 형성하여 발포층(20)에 발포 셀(cell)이 형성될 수 있다. 상기 발포 셀은 구형의 발포 셀일 수 있으며, 기공의 벽면이 모두 닫힌 구조로 형성되어 다른 기공과 연결되지 않은 기공으로서 독립 기공 또는 닫힌 기공(closed cell)이라고도 한다. 상기 발포 셀은 물리적인 외력에 의해 모양이 변형되지 않기 때문에, 발포층(20)의 부드러운(soft) 특성 및 쿠션감을 향상시킬 수 있다.The blowing agent is azodicarbonamide (ADCA, Azodicarbonamide), p, p'-oxybisbenzenesulfonyl hydrazide (p, p'-Oxybis (benzenesulfonyl hydrazide)), p-toluenesulfonyl hydrazide (p- toluenesulfonyl hydrazide) and sodium bicarbonate, and the like, but are not limited thereto. After the blowing agent is foamed at approximately 220 ~ 230 ℃, it may have a volume increase rate of 100 ~ 500% by volume. In the process of foaming, the gas generated from the foaming agent may form bubbles to form a foaming cell in the foaming layer 20. The foaming cell may be a spherical foaming cell, and all of the walls of the pores are formed in a closed structure, and are also called independent pores or closed cells as pores not connected to other pores. Since the foamed cell is not deformed by physical external force, it is possible to improve the soft characteristics and cushioning of the foamed layer 20.
상기 발포층 조성물은 폴리염화비닐 수지 100중량부에 대하여, 발포제 5~10중량부를 포함할 수 있다. 상기 발포제가 5중량부 미만으로 포함되는 경우, 인조가죽의 연성 및 쿠션감이 저하될 수 있다. 반대로, 10중량부를 초과하는 경우, 발포층의 발포 셀(cell)이 과다 생성되어 표면 물성이 저하되거나 내구성이 저하되는 문제점이 있다.The foam layer composition may include 5 to 10 parts by weight of a blowing agent based on 100 parts by weight of polyvinyl chloride resin. When the foaming agent is included in less than 5 parts by weight, the softness and cushioning of the artificial leather may be lowered. On the contrary, when it exceeds 10 parts by weight, the foam cells of the foam layer are excessively generated, resulting in a decrease in surface properties or durability.
상기 발포층 조성물은 발포시 용융강도 조절을 위해, 가소제와 내열안정제를 더 포함할 수 있다.The foam layer composition may further include a plasticizer and a heat stabilizer to control the melt strength during foaming.
발포되는 과정을 통해 형성된 발포층의 두께는 0.2~0.4mm일 수 있다.The thickness of the foam layer formed through the foaming process may be 0.2 ~ 0.4mm.
발포층의 두께가 0.2mm 미만인 경우, 두께가 얇기 때문에 인조가죽의 쿠션감이 저하될 수 있고, 원단층 직포의 무늬가 제품 표면으로 드러나는 문제점이 있다. 반대로, 두께가 0.4mm를 초과하는 경우, 제품 표면에 꺾임 주름이 발생하는 문제점이 있다. 꺾임 주름은 인조가죽이 장시간 꺾여 있을 경우 발포 셀의 형상이 변형 및 고정되어 도 5의 (b)와 같이 깊은 주름이 생성되는 것을 의미한다. 이러한 꺾임 주름은 열이나 스팀 처리를 통해서도 복원되지 않는 문제점이 있다.When the thickness of the foam layer is less than 0.2mm, since the thickness is thin, the cushioning of the artificial leather can be reduced, there is a problem that the pattern of the fabric layer woven fabric is exposed to the product surface. On the contrary, when the thickness exceeds 0.4 mm, there is a problem in that the wrinkle wrinkles occur on the surface of the product. By folding wrinkles, when the artificial leather is bent for a long time, the shape of the foamed cell is deformed and fixed, so that deep wrinkles are generated as shown in FIG. Such bending wrinkles have a problem that is not restored even through heat or steam treatment.
상기 표지층(30)은 표면 평활도를 확보하고, 색상을 제공하기 위한 역할을 하며, 폴리우레탄(PU)계 수지를 포함하는 표지층 조성물로부터 형성될 수 있다. 상기 폴리우레탄계 수지는 폴리카보네이트 디올(polycarbonate diol), 폴리에테르 디올(polyether diol) 또는 카로복실기를 함유하는 디올, 및 디이소시아네이트계 화합물을 대략 80~100℃에서 중합하여 제조될 수 있다. 제조된 폴리우레탄계 수지는 톨루엔 등과 같은 휘발성 유기 화합물을 포함하지 않기 때문에, 수분산이 용이하고, 인체에 악영향이 없으며 친환경적이다. 이로 인해, 상기 표지층(30)은 후술한 수성 표면처리층(40)과의 상용성이 우수하며, 촉감 등의 표면 물성을 향상시킬 수 있는 이점이 있다. The label layer 30 serves to secure surface smoothness, provide color, and may be formed from a label layer composition including a polyurethane (PU) -based resin. The polyurethane resin may be prepared by polymerizing a polycarbonate diol, a polyether diol or a diol containing a carboxyl group, and a diisocyanate compound at about 80 to 100 ° C. Since the produced polyurethane-based resin does not contain volatile organic compounds such as toluene, it is easy to disperse water, does not adversely affect the human body, and is environmentally friendly. For this reason, the label layer 30 is excellent in compatibility with the aqueous surface treatment layer 40 described later, there is an advantage that can improve the surface properties such as touch.
상기 표지층(30)의 두께는 50~100㎛일 수 있다. 상기 표지층(30)의 두께가 50㎛ 미만인 경우, 표면 평활도를 확보하기 어려울 수 있으며, 100㎛를 초과하는 경우, 인조가죽의 쿠션감이 저하되거나 발포층과의 접착력이 저하될 수 있다.The cover layer 30 may have a thickness of 50 μm to 100 μm. If the thickness of the cover layer 30 is less than 50㎛, it may be difficult to secure the surface smoothness, if it exceeds 100㎛, the cushioning of the artificial leather may be lowered or the adhesive strength with the foam layer.
상기 수성 표면처리층(40)은 내스크래치성, 내오염성 및 표면 물성을 향상시키고, 친환경적인 효과를 제공한다. 상기 수성 표면처리층(40)은 폴리우레탄계 수지; 이소시아네이트기 및 카보디이미드기 중 1종 이상을 포함하는 경화제; 및 물 및 알코올 중 1종 이상을 포함하는 수성 용매;를 포함하는 수계 코팅 조성물로부터 형성될 수 있다.The aqueous surface treatment layer 40 improves scratch resistance, stain resistance and surface properties, and provides an environmentally friendly effect. The aqueous surface treatment layer 40 is a polyurethane resin; Curing agent containing 1 or more types of isocyanate group and carbodiimide group; And an aqueous solvent comprising at least one of water and alcohol.
상기 수계 코팅 조성물에 포함되는 폴리우레탄계 수지는 전술한 바와 같이, 표지층(30)의 폴리우레탄계 수지와 같을 수 있다. 상기 이소시아네이트기를 포함하는 경화제는 톨루엔 디이소시아네이트, 헥사메틸렌 디이소시아네이트, 이소포론 디이소시아네이트, 나프탈렌 디이소시아네이트 등이 있다. 상기 카보디이미드기를 포함하는 경화제는 1-에틸-3-(3-디메틸아미노)프로필)카보디이미드(1-ethyl-3-(3-(dimethylamino)propyl)carbodiimide 등이 있다. 상기 수성 용매는 유기 용매와 대비되는 용매이며, OH기를 갖는 용매를 의미할 수 있다. 상기 수계 코팅 조성물은 물, 알코올과 같이 수성 용매를 포함함으로써, 내오염성을 향상시킬 수 있다.As described above, the polyurethane-based resin included in the aqueous coating composition may be the same as the polyurethane-based resin of the label layer 30. Curing agents containing the isocyanate group include toluene diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, naphthalene diisocyanate and the like. The curing agent containing the carbodiimide group is 1-ethyl-3- (3-dimethylamino) propyl) carbodiimide (1-ethyl-3- (3- (dimethylamino) propyl) carbodiimide Etc. The aqueous solvent is a solvent in contrast to the organic solvent, it may mean a solvent having an OH group. The water-based coating composition may improve pollution resistance by including an aqueous solvent such as water and alcohol.
상기 수성 표면처리층 표면에 엠보 무늬(미도시)가 형성되는데, 상기 엠보 무늬는 자동차 내장재용 인조가죽에 우수한 표면 질감을 부여하고, 표면 내구성을 향상시키는 것이다. An embossed pattern (not shown) is formed on the surface of the aqueous surface treatment layer, and the embossed pattern imparts an excellent surface texture to the artificial leather for automobile interior materials and improves surface durability.
도 2는 본 발명에 따른 자동차 내장재용 인조가죽의 제조방법을 나타낸 순서도이다.Figure 2 is a flow chart illustrating a manufacturing method of artificial leather for automobile interior according to the present invention.
본 발명에 따른 자동차 내장재용 인조가죽의 제조방법은 원단층 상에 발포층 형성단계(S110), 표지층 형성단계(S120), 수성 표면처리층 형성단계(S130) 및 엠보 무늬 형성단계(S140)를 포함한다.Manufacturing method of artificial leather for automobile interior according to the present invention is the foam layer forming step (S110), the cover layer forming step (S120), the aqueous surface treatment layer forming step (S130) and the embossing pattern forming step (S140) on the fabric layer It includes.
원단층Fabric layer 상에  On 발포층Foam layer 형성단계(S110) Formation step (S110)
원단층(10)을 마련한 후, 캘린더(Calendar) 공정을 수행하여 상기 원단층(10) 상에 발포층(20)을 형성하여 시트를 제조한다. 이때, 발포층(20)은 폴리염화비닐(PVC) 수지 및 발포제를 포함하는 발포층 조성물로부터 형성된다.After preparing the fabric layer 10, by performing a calendar (Calendar) process to form a foam layer 20 on the fabric layer 10 to prepare a sheet. At this time, the foam layer 20 is formed from a foam layer composition containing a polyvinyl chloride (PVC) resin and a blowing agent.
상기 캘린더 공정은 반대방향으로 회전하는 롤러 사이에 원료를 통과시킴과 동시에 롤러압착이 수행되고, 이후에 냉각 과정을 포함한다. 상기 캘린더 공정은 롤러 사이에 원료를 통과시키기 전에, 원료를 100~200℃의 온도에서 혼련할 수 있으나, 이에 제한되는 것은 아니다.The calendering process is a roller compaction is performed at the same time as passing the raw material between the rollers rotating in the opposite direction, and then includes a cooling process. In the calendering process, the raw material may be kneaded at a temperature of 100 to 200 ° C. before passing the raw material between the rollers, but is not limited thereto.
예를 들어, 발포층 조성물을 캘린더 롤러에 통과시켜 원단층(10) 상에 예비 발포층을 형성할 수 있다. 상기 캘린더 롤러는 대략 100~200℃의 온도로 유지되며, 상기 캘린더 롤러의 평균 회전속도는 30m/min~100m/min일 수 있다. 상기 캘린더 롤러의 온도가 100℃ 미만인 경우, 발포층 조성물의 용융이 충분히 이루어지지 않는다. 반대로, 200℃를 초과하는 경우, 캘린더 롤러끼리 shear strength가 발생하여 롤러 표면에 발포층 조성물의 점착 또는 조기 발포가 발생할 수 있다. For example, the foam layer composition may be passed through a calender roller to form a pre-foam layer on the fabric layer 10. The calender roller is maintained at a temperature of approximately 100 ~ 200 ℃, the average rotational speed of the calender roller may be 30m / min ~ 100m / min. When the temperature of the calender roller is less than 100 ° C, melting of the foam layer composition is not sufficiently performed. On the contrary, when it exceeds 200 ° C., shear strength between calender rollers may occur, and adhesion or premature foaming of the foam layer composition may occur on the roller surface.
상기 예비 발포층은 220~230℃의 온도에서 발포되어 발포층(20)을 형성한다. 상기 발포 온도가 220℃ 미만인 경우, 발포층의 열전달이 미흡하여 발포성이 저하될 수 있다. 발포 온도가 230℃를 초과하는 경우, 과발포 현상이 발생하여 제품 표면에 기포가 생길 수 있으며, 제품 표면에 꺾임 주름이 발생하는 문제점이 있다. 상기 원단층(10)과 발포층(20)은 이후에 상온까지 냉각됨으로써, 반제품의 시트로 제조된다. The preliminary foam layer is foamed at a temperature of 220 ~ 230 ℃ to form a foam layer (20). When the foaming temperature is less than 220 ° C, the heat transfer of the foam layer is insufficient to reduce the foamability. When the foaming temperature exceeds 230 ℃, the over-foaming phenomenon may occur, bubbles may occur on the surface of the product, there is a problem that the wrinkles occur on the surface of the product. The fabric layer 10 and the foam layer 20 is then cooled to room temperature, thereby producing a semi-finished sheet.
표지층Cover layer 형성단계(S120) Formation step (S120)
로터리 스크린(Rotary Screen) 공정을 수행하여 상기 시트 상에 표지층(30)을 형성한다. 이때, 표지층은 폴리우레탄(PU)계 수지를 포함하는 표지층 조성물로부터 형성된다.The cover layer 30 is formed on the sheet by performing a rotary screen process. At this time, the label layer is formed from a label layer composition containing a polyurethane (PU) resin.
상기 로터리 스크린 공정은 스크린망 내부에 원료를 투입한 후, 상기 스크린망을 회전시켜 원료가 시트 상에 코팅되는 공정이다. 보다 구체적으로, 도 3을 참조하면, 원료 저장소(colour reservoir)와 스크린 롤러(screen roller)를 이용하여 섬유, 직물 등과 같은 원단층 상에 서로 다른 색상 및 무늬를 형성할 수 있다. The rotary screen process is a process in which the raw material is coated on the sheet by rotating the screen net after inputting the raw material into the screen net. More specifically, referring to FIG. 3, different colors and patterns may be formed on fabric layers such as fibers, fabrics, etc. using color reservoirs and screen rollers.
예를 들어, 상기 반제품의 시트를 로터리 스크린 장치에 주입한 후, 회전하는 스크린 롤러에 의해 시트 상에 폴리우레탄 수지가 도포되어 표지층이 형성된다. 이때, 원료 저장소에 저장된 액상의 폴리우레탄(PU) 수지가 스크린 롤러에 공급된다. 상기 원료 저장소는 1개 이상일 수 있으며, 제1원료 저장소에 폴리우레탄 수지를 주입하고, 제2원료 저장소에 색상을 부여할 수 있는 별도의 원료를 주입한 후, 각각의 저장소에 연결된 스크린 롤러를 회전시킴으로써, 색상을 갖는 표지층을 형성할 수도 있다.For example, after injecting the sheet of semi-finished product into the rotary screen device, a polyurethane resin is applied onto the sheet by a rotating screen roller to form a label layer. At this time, the liquid polyurethane (PU) resin stored in the raw material reservoir is supplied to the screen roller. The raw material reservoir may be one or more, injecting a polyurethane resin into the first raw material reservoir, injecting a separate raw material that can give color to the second raw material reservoir, and then rotating the screen roller connected to each reservoir By doing so, a label layer having a color can also be formed.
상기 로터리 스크린 공정 외에 콤마코팅 등의 인쇄방식을 적용할 수 있으나, 표지층(30)의 표면 평활도 확보를 위해 로터리 스크린 공정을 적용하는 것이 바람직하다. 이처럼, 로터리 스크린 공정을 수행하는 경우, 접착층이 필요 없이 PVC 재질을 포함하는 발포층 상에 PU 재질을 포함하는 표지층을 형성할 수 있다. 또한, 기존에는 이형지를 사용하여 엠보 무늬를 형성하였으나, 본 발명에서는 로터리 스크린 공정을 수행하여 PU 재질을 포함하는 표지층을 형성함으로써, 이형지의 사용 없이 진공 엠보싱 공정으로 엠보 무늬를 직접 형성할 수 있다.In addition to the rotary screen process, a printing method such as comma coating may be applied, but it is preferable to apply a rotary screen process to secure the surface smoothness of the cover layer 30. As such, when performing the rotary screen process, the cover layer including the PU material may be formed on the foam layer including the PVC material without the need for the adhesive layer. In addition, although the embossed pattern was previously formed using a release paper, in the present invention, the embossed pattern may be directly formed by a vacuum embossing process without using a release paper by forming a cover layer including a PU material by performing a rotary screen process. .
수성 Mercury 표면처리층Surface treatment layer 형성단계(S130) Formation step (S130)
그라비아(gravure) 코팅 공정을 수행하여 상기 표지층(30) 상에 수성 표면처리층(40)을 형성한다.A gravure coating process is performed to form an aqueous surface treatment layer 40 on the label layer 30.
상기 그라비아 코팅 공정에는 다이렉트(direct) 그라비아 코팅, 리버스(reverse) 그라비아 코팅, 옵셋(offset) 그라비아 코팅 등이 있다. 다이렉트 그라비아 코팅은 탄성 고무로 형성된 롤러와 코팅액을 함유하는 롤러 사이에서 기재 상에 코팅이 수행되는 것이며, 이들 롤러들의 회전 속도는 동일할 수 있다. 또한, 기재와 롤러들의 회전 방향이 반대일 수 있다. 리버스 그라비아 코팅은 기재와 롤러들의 회전 방향이 반대이고, 롤러의 속도를 조절하여 도포량을 조절할 수 있다. 옵셋 그라비아 코팅은 각각의 롤러들이 서로 독립적으로 구동되며, 고속에 의해 적은 양으로도 균일하게 코팅층을 형성할 수 있다. The gravure coating process may include a direct gravure coating, a reverse gravure coating, an offset gravure coating, and the like. A direct gravure coating is one in which coating is performed on a substrate between a roller formed of an elastic rubber and a roller containing a coating liquid, and the rotational speed of these rollers may be the same. In addition, the rotation direction of the substrate and the rollers may be reversed. Reverse gravure coating has the opposite direction of rotation of the substrate and the rollers, it is possible to control the application amount by adjusting the speed of the roller. In the offset gravure coating, the respective rollers are driven independently of each other, and the coating layer can be uniformly formed in a small amount by high speed.
수계 코팅 조성물은 전술한 바와 같으며, 상기 수성 표면처리층(40)을 형성함으로써, 본 발명의 인조가죽은 내스크래치성, 내오염성을 향상시키고, 친환경적인 효과를 제공할 수 있다.The aqueous coating composition is as described above, and by forming the aqueous surface treatment layer 40, the artificial leather of the present invention can improve scratch resistance, stain resistance, and provide an environmentally friendly effect.
엠보Emboss 무늬 형성단계(S140) Pattern forming step (S140)
상기 수성 표면처리층(40) 표면에 엠보 무늬(미도시)를 형성한다. 엠보 무늬는 진공 엠보싱(Vacuum embossing) 공정을 수행하여 형성될 수 있다. 진공 엠보싱 공정은 0.04~0.07MPa의 진공계(Vacuum gauge) 압력 하에서 인조가죽을 빨아들여 엠보 무늬를 전사하는 방법이다. 진공 엠보싱 공정이 0.04MPa 미만에서 수행되는 경우, 엠보 무늬를 형성하기 어려워 쿠션감이 저하될 수 있다. 반대로, 0.07MPa를 초과하여 수행되는 경우, 수성 표면처리층(40)이 손상되거나, 표면 물성이 저하될 수 있다. An embossed pattern (not shown) is formed on the surface of the aqueous surface treatment layer 40. The embossed pattern may be formed by performing a vacuum embossing process. Vacuum embossing process is a method of transferring the embossed pattern by sucking the artificial leather under a vacuum gauge pressure of 0.04 ~ 0.07MPa. When the vacuum embossing process is performed at less than 0.04 MPa, it is difficult to form an embossed pattern and the cushioning feeling may be lowered. On the contrary, when it is performed in excess of 0.07 MPa, the aqueous surface treatment layer 40 may be damaged or surface properties may be degraded.
또한, 상기 진공 엠보싱 공정은 160~180℃의 온도에서 수행될 수 있다.In addition, the vacuum embossing process may be performed at a temperature of 160 ~ 180 ℃.
160℃ 미만에서 수행되는 경우, 엠보 무늬를 충분히 형성하기 어렵고, 180℃를 초과하여 수행되는 경우, 고온에 의해 인조가죽의 표면 물성이 거칠어지거나 찢기는 문제점이 발생한다.When the temperature is less than 160 ° C., it is difficult to sufficiently form the embossed pattern. When the temperature is more than 180 ° C., the surface properties of the artificial leather become rough or torn due to high temperature.
종래에는 엠보 무늬를 형성하기 위해 요철무늬를 롤러로 찍어내는 방식을 수행하였으나, 이는 표면 물성이 우수한 인조가죽을 제공하는데 한계가 있다. 본 발명에서는 상기 진공 엠보싱 공정에 의해, 쿠션감 및 연성(softness)을 상승시킴으로써, 촉감 등의 표면 물성을 향상시킬 수 있다.Conventionally, in order to form the embossed pattern was performed by dipping the uneven pattern with a roller, this has a limitation in providing an artificial leather with excellent surface properties. In the present invention, surface properties such as touch can be improved by increasing the feeling of cushioning and softness by the vacuum embossing step.
전술한 바와 같이, 본 발명의 자동차 내장재용 인조가죽은 캘린더 공정, 로터리 스크린 공정 등의 제조방법을 통해, 표면 평활도가 우수하고, 균일한 층을 형성할 수 있다. 또한, PVC 발포층과 PU 표지층, 수성 표면처리층을 포함하는 적층 구조를 통해, 인조가죽의 두께감과 동시에 표면 물성이 우수한 효과가 있다.As described above, the artificial leather for automobile interior material of the present invention is excellent in surface smoothness and can form a uniform layer through a manufacturing method such as a calender process and a rotary screen process. In addition, through a laminated structure including a PVC foam layer, a PU label layer, and an aqueous surface treatment layer, there is an effect of excellent surface properties and thickness of the artificial leather.
이와 같이 자동차 내장재용 인조가죽 및 그 제조방법에 대하여 그 구체적인 실시예를 살펴보면 다음과 같다.As described above with respect to the artificial leather for automobile interior materials and a method of manufacturing the same as follows.
1. 자동차 내장재용 인조가죽의 제조1. Manufacturing of artificial leather for automobile interior
실시예Example 1 One
면을 포함하는 원단 재질의 부직포를 0.6mm 두께로 제단하여 원단층을 마련하였다. 캘린더 공정을 수행하여 상기 원단층 상에 예비 발포층을 형성한 후, 이를 220℃의 온도에서 발포시켜 0.3mm 두께의 발포층을 형성하였다. 발포층은 폴리염화비닐 수지 100중량부에 대하여, 발포제로서 아조디카본아미드 5중량부를 포함하는 발포층 조성물로부터 형성되었다. A nonwoven fabric made of cotton, including cotton, was cut to a thickness of 0.6 mm to prepare a fabric layer. After performing a calendering process to form a pre-foam layer on the fabric layer, it was foamed at a temperature of 220 ℃ to form a foam layer of 0.3mm thickness. The foam layer was formed from a foam layer composition containing 5 parts by weight of azodicarbonamide as a foaming agent with respect to 100 parts by weight of polyvinyl chloride resin.
이어서, 로터리 스크린 공정을 수행하여 회전하는 스크린 롤러에 의해, 상기 발포층 상에 폴리우레탄 수지가 도포되어 표지층을 형성하였다. Subsequently, a polyurethane resin was applied onto the foam layer by a rotating screen roller to perform a rotary screen process to form a label layer.
이어서, 폴리우레탄 수지, 경화제로서 톨루엔 디이소시아네이트, 수성 용매로서 물을 포함하는 수계 코팅 조성물을 제조하였다. 이를 이용하여 그라비아 코팅 공정을 수행하였으며, 상기 표지층 상에 20㎛ 두께의 수성 표면처리층을 형성하였다.Subsequently, an aqueous coating composition was prepared comprising a polyurethane resin, toluene diisocyanate as a curing agent, and water as an aqueous solvent. A gravure coating process was performed using this, and an aqueous surface treatment layer having a thickness of 20 μm was formed on the label layer.
이어서, 상기 수성 표면처리층이 형성된 결과물에 0.06MPa의 진공계(Vacuum gage) 압력 및 170의 온도 하에서 진공 엠보싱(vacuum embossing) 공정을 수행하여, 수성 표면처리층 표면에 엠보 무늬를 형성하여 자동차 내장재용 인조가죽을 제조하였다.Subsequently, a vacuum embossing process is performed on the resultant formed with the aqueous surface treatment layer under a vacuum gage pressure of 0.06 MPa and a temperature of 170 to form an embossed pattern on the surface of the aqueous surface treatment layer for automobile interior materials. Artificial leather was produced.
비교예Comparative example 1 One
카렌더 공정을 통해, 원단층 상에 폴리염화비닐 수지를 포함하는 발포층 조성물로부터 형성된 예비 발포층, 폴리염화비닐 수지로부터 표지층, 수성 표면처리층이 적층된 적층체를 제조하였다. 이어서, 상기 적층체를 220의 온도에서 발포시킨 후, 진공 엠보싱 공정을 수행한 점을 제외하고, 상기 실시예 1과 동일한 방법으로 자동차 내장재용 인조가죽을 제조하였다. Through a calendering process, a laminate in which a label layer and an aqueous surface treatment layer were laminated from a pre-foam layer formed of a foam layer composition containing a polyvinyl chloride resin and a polyvinyl chloride resin on a fabric layer were laminated. Subsequently, after the laminate was foamed at a temperature of 220, an artificial leather for automobile interior was manufactured in the same manner as in Example 1, except that the vacuum embossing process was performed.
비교예Comparative example 2 2
카렌더 공정을 통해, 원단층 상에 접착층, 폴리우레탄 수지를 포함하는 발포층 조성물로부터 형성된 예비 발포층, 수성 표면처리층이 적층된 적층체를 제조하였다. 이어서, 상기 적층체를 220의 온도에서 발포시킨 후, 50㎛ 두께의 발포층을 형성하였고, 엠보 무늬를 갖는 엠보 롤을 이용하여 4MPa의 압력 하에서 롤 프레싱 공정을 수행한 점을 제외하고, 상기 실시예 1과 동일한 방법으로 자동차 내장재용 인조가죽을 제조하였다. Through a calendering process, a laminate in which an adhesive layer, a pre-foamed layer formed from a foamed layer composition containing a polyurethane resin, and an aqueous surface treatment layer were laminated on a fabric layer was prepared. Subsequently, after the laminate was foamed at a temperature of 220, a foam layer having a thickness of 50 μm was formed, except that a roll pressing process was performed under a pressure of 4 MPa using an embossing roll having an embossed pattern. Artificial leather for automobile interior was manufactured in the same manner as in Example 1.
비교예Comparative example 3 3
콤마 코팅을 수행하여 표지층을 형성한 점을 제외하고는 상기 실시예 1과 동일한 방법으로 자동차 내장재용 인조가죽을 제조하였다.An artificial leather for automobile interior was manufactured in the same manner as in Example 1, except that the cover layer was formed by performing a comma coating.
2. 물성 평가 방법 및 그 결과2. Method of evaluating physical properties
표지층의 표면 평활도 측정 : 표지층의 표면이 매끄럽거나 균열이 발생하지 않은 경우 "우수"라고 기재하였으며, 표지층의 표면이 매끄럽지 않거나 찢김이 발생한 경우 "보통"이라고 기재하였다. Measurement of the surface smoothness of the label layer: When the surface of the label layer is not smooth or cracks are described as "excellent", it is described as "normal" when the surface of the label layer is not smooth or torn.
연성(softness)의 측정 : 온도 23±2℃ 및 상대습도 50±5% 조건에서, 연성 측정 기기(제조사, ST300D)를 이용하여 하기 표 1에 기재하였다. 구체적으로, 상기 자동차 내장재용 인조가죽 대하여 파이(π)가 100㎜인 시험편 5매를 준비한 후, ST300D 기기로 눌러서 15초 동안 눈금이 움직인 수치를 읽음으로써 연성(softness)을 측정할 수 있다.Measurement of softness: at a temperature of 23 ± 2 ° C. and a relative humidity of 50 ± 5%, it is shown in Table 1 below using a ductility measuring instrument (manufacturer, ST300D). Specifically, after preparing five test pieces having pi (π) of 100 mm for the artificial leather for automobile interior materials, the softness can be measured by reading the numerical value of the scale moved for 15 seconds by pressing the ST300D device.
제품 표면의 기공/꺾임 주름 발생 여부 : 제품 표면에 기공 및 꺾임 주름이 10% 이하로 발생된 경우, "없음", 10% 이상 발생된 경우 "있음"으로 표시하였다.Pore / break wrinkles on the surface of the product: When the porosity and break wrinkles occurred in the product surface of less than 10%, "none", if more than 10% occurred "marked".
[표 1]TABLE 1
Figure PCTKR2017004428-appb-I000001
Figure PCTKR2017004428-appb-I000001
[표 1] 및 도 4을 참조하면, 실시예 1에 의해 제조된 자동차 내장재용 인조가죽은 발포층에 발포 셀이 형성됨으로써, 높은 연성에 의해 우수한 쿠션감을 나타내는 것을 알 수 있다. 또한, 실시예 1에서 진공 엠보싱 공정을 수행하여, 수성 표면처리층 표면에 엠보 무늬(미도시)를 형성하여 인조가죽에 우수한 표면 질감 및 표면 내구성이 형성됨을 알 수 있다. 또한, 표지층이 로터리 스크린으로 수행되지 않고 콤마 코팅으로 수행되어 형성된 비교예 3의 경우, 표지층의 표면이 매끄럽지 않고, 찢김이 발생한 결과를 보여주었다.Referring to Table 1 and FIG. 4, it can be seen that the artificial leather for automobile interior materials prepared in Example 1 exhibits excellent cushioning feeling due to high ductility because foam cells are formed in the foam layer. In addition, by performing the vacuum embossing process in Example 1, it can be seen that the embossed pattern (not shown) on the surface of the aqueous surface treatment layer is formed to have excellent surface texture and surface durability on the artificial leather. In addition, in the case of Comparative Example 3 formed by performing a comma coating instead of the cover layer was performed with a rotary screen, the surface of the cover layer was not smooth, and the tearing occurred.
이상 첨부된 도면을 참조하여 본 발명의 실시예들을 설명하였으나, 본 발명은 상기 실시예들에 한정되는 것이 아니라 서로 다른 다양한 형태로 제조될 수 있으며, 본 발명이 속하는 기술 분야에서 통상의 지식을 가진 자는 본 발명의 기술적 사상이나 필수적인 특징을 변경하지 않고서 다른 구체적인 형태로 실시될 수 있다는 것을 이해할 수 있을 것이다. 그러므로 이상에서 기술한 실시예들은 모든 면에서 예시적인 것이며 한정적이 아닌 것으로 이해해야만 한다.Although the embodiments of the present invention have been described above with reference to the accompanying drawings, the present invention is not limited to the above embodiments and can be manufactured in various forms, and having ordinary skill in the art to which the present invention pertains. It will be understood by those skilled in the art that the present invention may be embodied in other specific forms without changing the technical spirit or essential features of the present invention. Therefore, it should be understood that the embodiments described above are exemplary in all respects and not restrictive.

Claims (16)

  1. 원단층;Distal layer;
    상기 원단층 상에 형성되는 발포층; A foam layer formed on the fabric layer;
    상기 발포층 상에 형성되는 표지층; 및A label layer formed on the foam layer; And
    상기 표지층 상에 형성되는 수성 표면처리층;을 포함하고,It includes; an aqueous surface treatment layer formed on the label layer,
    상기 수성 표면처리층 표면에 엠보 무늬가 형성되는 것을 특징으로 하는 자동차 내장재용 인조가죽.Artificial leather for automobile interior, characterized in that the embossed pattern is formed on the surface of the aqueous surface treatment layer.
  2. 제1항에 있어서,The method of claim 1,
    상기 표지층은 폴리우레탄(PU)계 수지를 포함하는 표지층 조성물로부터 형성되는 것을 특징으로 하는 자동차 내장재용 인조가죽.The cover layer is artificial leather for automobile interior, characterized in that formed from a cover layer composition comprising a polyurethane (PU) resin.
  3. 제1항에 있어서,The method of claim 1,
    상기 표지층은 로터리 스크린(Rotary Screen) 공정으로 형성되는 것을 특징으로 하는 자동차 내장재용 인조가죽.The cover layer is an artificial leather for automobile interior, characterized in that formed by a rotary screen (Rotary Screen) process.
  4. 제1항에 있어서,The method of claim 1,
    상기 발포층은 폴리염화비닐(PVC) 수지 및 발포제를 포함하는 발포층 조성물로부터 형성되는 것을 특징으로 하는 자동차 내장재용 인조가죽.The foam layer is artificial leather for automobile interior, characterized in that formed from a foam layer composition comprising a polyvinyl chloride (PVC) resin and a blowing agent.
  5. 제4항에 있어서,The method of claim 4, wherein
    상기 발포층 조성물은 폴리염화비닐 수지 100중량부에 대하여, 발포제 5~10중량부를 포함하는 것을 특징으로 하는 자동차 내장재용 인조가죽.The foam layer composition is artificial leather for automobile interior, characterized in that containing 5 to 10 parts by weight of the blowing agent with respect to 100 parts by weight of polyvinyl chloride resin.
  6. 제1항에 있어서,The method of claim 1,
    상기 발포층의 두께는 0.2~0.4mm인 것을 특징으로 하는 자동차 내장재용 인조가죽.The thickness of the foam layer is artificial leather for automobile interiors, characterized in that 0.2 ~ 0.4mm.
  7. 제1항에 있어서,The method of claim 1,
    상기 표지층의 두께는 50~100㎛인 것을 특징으로 하는 자동차 내장재용 인조가죽.The thickness of the cover layer is artificial leather for automobile interiors, characterized in that 50 ~ 100㎛.
  8. 제1항에 있어서,The method of claim 1,
    상기 수성 표면처리층은 폴리우레탄(PU)계 수지; 이소시아네이트기 및 카보디이미드기 중 1종 이상을 포함하는 경화제; 및 물 및 알코올 중 1종 이상을 포함하는 수성 용매;를 포함하는 수계 코팅 조성물로부터 형성되는 것을 특징으로 하는 자동차 내장재용 인조가죽.The aqueous surface treatment layer is polyurethane (PU) -based resin; Curing agent containing 1 or more types of isocyanate group and carbodiimide group; And an aqueous solvent comprising at least one of water and an alcohol.
  9. 제1항에 있어서,The method of claim 1,
    상기 원단층은 면, 나일론, 폴리에스터 및 레이온 중 1종 이상을 포함하는 직포 또는 부직포인 것을 특징으로 하는 자동차 내장재용 인조가죽.The fabric layer is artificial leather for automobile interior, characterized in that the woven or non-woven fabric containing at least one of cotton, nylon, polyester and rayon.
  10. (a) 폴리염화비닐(PVC) 수지 및 발포제를 포함하는 발포층 조성물을 이용하여 캘린더(Calendar) 공정으로 원단층 상에 발포층을 형성하여 시트를 제조하는 단계;(a) preparing a sheet by forming a foam layer on a fabric layer by a calender process using a foam layer composition comprising a polyvinyl chloride (PVC) resin and a blowing agent;
    (b) 폴리우레탄(PU)계 수지를 포함하는 표지층 조성물을 이용하여 로터리 스크린(Rotary Screen) 공정으로 상기 시트 상에 표지층을 형성하는 단계; (b) forming a label layer on the sheet by a rotary screen process using a label layer composition comprising a polyurethane (PU) resin;
    (c) 상기 표지층 상에 수성 표면처리층을 형성하는 단계; 및(c) forming an aqueous surface treatment layer on the label layer; And
    (d) 상기 수성 표면처리층 표면에 엠보 무늬를 형성하는 단계;를 포함하는 것을 특징으로 하는 자동차 내장재용 인조가죽의 제조 방법.(d) forming an embossed pattern on the surface of the aqueous surface treatment layer; manufacturing method of artificial leather for automobile interiors comprising the.
  11. 제10항에 있어서,The method of claim 10,
    상기 (a) 단계의 발포층은 220~230℃의 온도에서 발포되어 형성되는 것을 특징으로 하는 자동차 내장재용 인조가죽의 제조 방법.The foaming layer of step (a) is a method of manufacturing artificial leather for automobile interiors, characterized in that formed by foaming at a temperature of 220 ~ 230 ℃.
  12. 제10항에 있어서,The method of claim 10,
    상기 (a) 단계의 캘린더 공정은 100~200℃의 온도를 갖는 롤러를 이용하여 수행되는 것을 특징으로 하는 자동차 내장재용 인조가죽의 제조 방법.The calendar process of step (a) is a method of manufacturing artificial leather for automobile interiors, characterized in that is carried out using a roller having a temperature of 100 ~ 200 ℃.
  13. 제10항에 있어서,The method of claim 10,
    상기 (c) 단계의 수성 표면처리층은 그라비아(gravure) 코팅 공정을 수행하여 형성되는 것을 특징으로 하는 자동차 내장재용 인조가죽의 제조 방법.The aqueous surface treatment layer of step (c) is a manufacturing method of artificial leather for automobile interior, characterized in that formed by performing a gravure coating process (gravure).
  14. 제10항에 있어서,The method of claim 10,
    상기 (d) 단계의 엠보 무늬는 진공 엠보싱(Vacuum embossing) 공정을 수행하여 형성되는 것을 특징으로 하는 자동차 내장재용 인조가죽의 제조 방법.The embossed pattern of step (d) is formed by performing a vacuum embossing (Vacuum embossing) manufacturing method of artificial leather for automobile interiors.
  15. 제14항에 있어서,The method of claim 14,
    상기 진공 엠보싱 공정은 0.04~0.07MPa의 진공계(Vacuum gauge) 압력 하에서 수행되는 것을 특징으로 하는 자동차 내장재용 인조가죽의 제조 방법.The vacuum embossing process is a manufacturing method of artificial leather for automobile interior, characterized in that carried out under a vacuum gauge (Vacuum gauge) pressure of 0.04 ~ 0.07MPa.
  16. 제14항에 있어서,The method of claim 14,
    상기 진공 엠보싱 공정은 160~180℃의 온도에서 수행되는 것을 특징으로 하는 자동차 내장재용 인조가죽의 제조 방법.The vacuum embossing process is a method of manufacturing artificial leather for automobile interiors, characterized in that carried out at a temperature of 160 ~ 180 ℃.
PCT/KR2017/004428 2016-04-29 2017-04-26 Artificial leather for vehicle interior material, and manufacturing method therefor WO2017188722A1 (en)

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