JP4569023B2 - Method for producing napped artificial leather - Google Patents
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- JP4569023B2 JP4569023B2 JP2001089511A JP2001089511A JP4569023B2 JP 4569023 B2 JP4569023 B2 JP 4569023B2 JP 2001089511 A JP2001089511 A JP 2001089511A JP 2001089511 A JP2001089511 A JP 2001089511A JP 4569023 B2 JP4569023 B2 JP 4569023B2
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Description
【０００１】
【発明の属する技術分野】
本発明は、立毛人工皮革の製造方法に関する。
【０００２】
【従来の技術】
従来から立毛人工皮革の高強力化の手段として、極細繊維あるいは極細化可能な繊維からなる繊維ウエブと、織物を重ねてニードルパンチ処理し、絡合一体化した後、高分子弾性体付与処理および起毛処理、さらに極細化可能繊維ウエブを用いた場合には極細化処理を組み合わせて行い、立毛人工皮革の裏面に織物を絡合一体化させる方法が一般に知られている。
【０００３】
かかる従来の立毛人工皮革の製造方法において、用いられる織物の原糸の撚数は、ニードルパンチ処理による損傷を軽減すべく、７００Ｔ／ｍ以上とし、該織物を重ねてニードルパンチ処理を行う場合、極細繊維あるいは極細化可能繊維からなる繊維ウエブの繊維絡合に伴う幅方向の収縮により、絡合一体化する織物に収縮応力が作用し、しわが入った状態で織物が貼り合わされ、局部的に織物の厚みが大きくなる部分が発生し、起毛処理時のシート破れにより生産性が著しく低下するとともに、染色後の製品表面にスジ状の欠点、すなわち織物しわ欠点が発生するという重大な問題があった。
【０００４】
更に従来では、織物を重ねてニードルパンチ処理する際、織物糸が極細繊維ウエブ内部に押し込まれ、これが起毛処理により極細繊維と同時に研削され、裏面に有るべき織物糸が製品表面に露出し、これを染色すると、織物糸と極細繊維の染着性の違いにより、織物糸が濃色に染まるため、製品表面にゴマ粒状の斑点が散在する欠点、すなわち織物糸が露出する欠点が多発するという問題を潜在的に有していた。この欠点は、軽量化のため製品厚みを薄くする程、また織物の目を粗くする程、多発するため、薄地立毛人工皮革では、特に重大な問題であった。
この問題を解決するために、経糸が緯糸を把持する構造を有し、形態保持性が良い紗織、絽織等のからみ組織をとる織物を繊維ウエブに重ねてニードルパンチする方法がある。しかし、この方法ではニードルパンチ処理の際、織物の緯糸を把持しながら交差する２本の経糸が厚み方向に重なる状態で繊維ウエブと絡合一体化するため、経糸部分のみ織物の厚みが厚くなり、染色後の製品表面上にスジ状の欠点が出現するという問題があった。
【０００５】
【発明が解決しようとする課題】
本発明は、かかる従来の立毛人工皮革の製造方法が有する問題点に鑑みてなされたものであり、その目的とするところは織物しわ欠点及び織物糸露出欠点が発生しにくい立毛人工皮革を安定的に得る製造方法を提供せんとするものである。
【０００６】
【課題を解決するための手段】
本発明者らは、織物しわ欠点および織物糸が露出する原因が、パンチング処理の際の織物の形態保持性が低いことであることを見出し、かかる問題を解決するために以下の構成を有する。すなわち、単繊維繊度が０．９ｄｔｅｘ以下の極細繊維と撚数７００Ｔ／ｍ以上の強撚糸よりなる織物に高分子結束剤を付与し結束させたものを重ねてパンチング処理して絡合一体化した後、高分子結束剤の除去処理、高分子弾性体付与処理および起毛処理を行うこともしくは単繊維繊度０．９ｄｔｅｘ以下に極細化可能な繊維よりなる繊維ウエブと撚数７００Ｔ／ｍ以上の強撚糸よりなる織物に高分子結束剤を付与し結束させたものを重ねてパンチング処理して絡合一体化した後、極細化処理、高分子結束剤の除去処理、高分子弾性体付与処理および起毛処理を行う立毛人工皮革の製造方法である。
【０００７】
【発明の実施の形態】
本発明は、上記課題、すなわち、織物しわ欠点および織物糸露出欠点が発生しにくい立毛人工皮革を安定的に得る製造方法について鋭意検討したところ、極細繊維と強撚糸よりなる織物に高分子結束剤を付与し結束させたものを重ねてパンチング処理して、絡合一体化した後、高分子結束剤の除去処理、高分子弾性体付与処理および起毛処理を、さらに極細化可能繊維ウエブを用いた場合には極細化処理を組み合わせて製造することにより、上記特徴を有する立毛人工皮革の製造方法を提供できることを究明したものである。
【０００８】
本発明において、繊維ウエブと絡合一体化させる織物に高分子結束剤を付与させることが必要である。本発明において高分子結束剤とは織物組織を結束させ形態を維持させるものをいうものである。高分子結束剤を付与しない場合、織物を繊維ウエブに重ねてパンチング処理する際、織物の形態がルーズとなり、しわが発生しやすくなるとともに、織物原糸が針のバーブにより繊維ウエブ内部に持ちもまれやすく、製品表面に原糸が露出し触感、外観を著しく損なうため好ましくない。
【０００９】
本発明において織物に付与する高分子結束剤としては、ナイロン、ポリプロピレン、ポリエチレン、アクリル酸エステルなどの非水溶性物質、またはポリビニルアルコール、アクリル系、ビニル系共重合物、スチロール系共重合物、澱粉などの水溶性糊剤を用いることができるが、作業安定性、接着性、粘度安定性、溶出性などから糊剤が好ましく、その中でもポリビニルアルコール、アクリル系、澱粉などが、浸透性、吸湿性、糊抜性の面から好ましい。
【００１０】
糊剤の付着状態としては、織物全体に均一に付着して織物原糸の移動を抑制することが望ましい。糊剤の織物に対する付着量としては１〜１５重量％が好ましく、より好ましくは３〜１０重量％である。付着量が１重量％未満では、織物組織の結束が不十分であり、ニードルパンチの際、針のバーブに原糸が繊維ウエブ内部に持ち込まれやすくなり、織物原糸が製品表面に露出し、触感、外観を著しく損なうため好ましくない。付着量が１５重量％より多いと織物組織の結束が過度となり、ニードルパンチの際、織物と繊維ウエブとの絡合が不十分であるため好ましくない。
【００１１】
これら高分子結束剤の溶出時の溶剤としては、非水溶性物質については、ジメチルホルムアミド（ＤＭＦ）、トルエン、酢酸エチルなどの有機溶剤、水溶性物質については温水または熱水を用いることができる。
【００１２】
本発明に用いられる織物の種類としては平織、綾織、朱子織あるいはそれらの織り方を基本とした各種の織物を使用することができるが、パンチング処理後の織物の厚みが均一である点から好ましくは平織が使用される。織物を構成する織糸は、ポリエステル、ポリアミドなどの合成繊維糸条であれば、使用することができる。かかる糸条としては、フィラメントヤーン、紡績糸など特に限定されないが、好ましくは撚糸が使用される。撚糸の撚数は、７００Ｔ／ｍ以上であることが必要で、７００Ｔ／ｍ以上４０００Ｔ／ｍ以下であることが好ましく、１０００Ｔ／ｍ以上４０００Ｔ／ｍ以下であればより好ましく、２０００Ｔ／ｍ以上３０００Ｔ／ｍ以下であればさらに好ましい。撚数が７００Ｔ／ｍより小さいと、パンチングによる単糸切れが多くなり、製品強力が低下するので好ましくない。撚数が４０００Ｔ／ｍより大きいと、繊維が硬くなりすぎるため、風合の点から好ましくない。
【００１３】
撚糸のトータル繊度は、３０ｄｔｅｘ以上１２０ｄｔｅｘ以下であることが好ましい。トータル繊度が１２０ｄｔｅｘより大きいと、織物の厚みが厚くなるため、製品の薄地化により織物糸が製品表面に露出しやすくなるので好ましくない。３０ｄｔｅｘより小さいと、織物のパンチング処理による損傷が大きくなり、製品強力が低下するので好ましくない。
【００１４】
本発明において撚糸の単糸繊度は、０．３ｄｔｅｘ以上２ｄｔｅｘ以下であることが好ましい。単糸繊度が２ｄｔｅｘより大きいと、極細繊維との染着性の違いにより織物糸露出が目立ちやすくなるので好ましくない。０．３ｄｔｅｘより小さいと、パンチング処理による単糸切れにより製品強力が低下するので好ましくない。
【００１５】
また織物の織密度は、経糸、緯糸ともに１０本／ｃｍ以上が好ましい。織密度が１０本／ｃｍ未満である場合、織物の目が粗くなり、経糸、緯糸相互の把持力が低下し、目ずれしやすいため、パンチングにより織物原糸が繊維ウエブ内部に押し込まれやすく、織物糸が露出する欠点が発生しやすいので好ましくない。
【００１６】
本発明の立毛人工皮革を構成する極細繊維を形成する重合体としては特に限定されることはないが、ポリエチレンテレフタレート、共重合ポリエチレンテレフタレート、ポリブチレンテレフタレート、共重合ポリブチレンテレフタレート、ポリプロピレンテレフタレート、共重合ポリプロピレンテレフタレート、ポリエステルエラストマ等のポリエステル系重合体、ナイロン６、ナイロン６６、ナイロン１２、共重合ナイロン、ポリアミドエラストマ等のポリアミド系重合体、ポリウレタン系重合体、ポリオレフィン系重合体、アクリルニトリル系重合体など、繊維形性能を有する重合体が好適であるが、実用性能の点から、上記のポリエステル系重合体もしくはポリアミド系重合体を好ましく使用することができる。
【００１７】
また、海島型繊維のように複合繊維を構成する一部の重合体を除去することによって極細繊維化されるものまたは相互に剥離あるいは分割することによって極細繊維化されるものについては、被除去成分として、例えばポリスチレン、共重合ポリスチレン、ポリエチレン、ポリプロピレンなどのポリオレフィン系、ポリエステル系、ポリアミド系などの１種または２種の成分を用いることができる。
【００１８】
本発明に用いられる極細繊維の繊度は、立毛人工皮革としての性能、すなわち柔軟性、触感、外観品位、強力特性などを高めるために、０．０００１ｄｔｅｘ以上０．９ｄｔｅｘ以下であれば好ましい。極細繊維の繊度が０．９ｄｔｅｘより大きいと、人工皮革特有の表面のソフトなタッチが得られないので好ましくない。繊度が０．０００１ｄｔｅｘより小さいと、繊維強度が低くなるため好ましくない。本発明において極細化可能繊維を用いる場合、次のような複合繊維が用いられる。例えば２種以上の重合体からなる高分子配列体繊維、互いに相溶性の小さい２種の重合体が隣接して成る易分割型複合繊維などがある。しかし本発明はこれにとらわれるものではなく、その思想を基に発展的形態の繊維が適用可能である。
【００１９】
本発明において極細化可能繊維の繊維ウエブを形成させる場合、その形成手段としては、スパンボンド、メルトブロー、抄紙法、その他カードとクロスラッパーを組み合わせた方法など種々用いることができるが、とりわけ本発明の立毛人工皮革を製造するには、カード、クロスラッパー、ランダムウエブ等を用いてシート化する方法が望ましい。
【００２０】
本発明において、かかる繊維からなるウエブをニードルパンチあるいはウォータージェットパンチして仮絡合させたシートに、織物に高分子結束剤を付与させたものを積層した後、同じくパンチング処理して貼り合わせて製造する。この場合、繊維ウエブに織物を、より強固に絡合一体化させるために、ニードルパンチ処理することが好ましい。
【００２１】
本発明における極細化可能繊維において、特に海島型繊維での海成分を除去する場合、海成分を除去する方法は、溶剤で抽出する方法、熱分解させる方法など種々あるが、一般には高分子弾性体を付与する前または後に、溶剤で抽出する方法が望ましい。また分割型繊維で極細繊維を発現させる方法としては、アルカリ処理や擦過、叩解などの機械的刺激を用いるのが望ましい。
【００２２】
本発明で使用する高分子弾性体としては、ポリウレタン、スチレン−ブタジエン共重合体（以下、ＳＢＲという）、ポリアミノ酸、アクリル系の接着剤などを使用することができるが、実用性能の面でポリウレタンが好ましい。高分子弾性体の付与方法としては、該高分子弾性体を塗布あるいは含浸後凝固する方法、あるいはエマルジョン、ラテックス状で塗布あるいは含浸して乾燥、固着させる方法などを用いることができる。
【００２３】
本発明の起毛処理は、針布やサンドペーパーを使用して行う。とりわけ人工皮革には、高分子弾性体付与後のシート表面をサンドペーパーを使用して起毛処理すなわち研削することにより、良好な立毛と成し得る。かかる起毛処理での研削量は、より良好な立毛を得るため、また仕上げの厚みは、薄いほど織物が製品表面に露出しやすくなるため、０．１５ｍｍ以上０．６０ｍｍ以下が好ましく、０．２０ｍｍ以上０．５０ｍｍ以下であれば更に好ましい。
【００２４】
【実施例】
次に実施例を用いて、本発明をさらに詳細に説明する。
実施例１
島成分としてポリエチレンテレフタレート、海成分としてポリスチレンからなる成分比５５／４５、島数３６、複合繊度２．８ｄｔｅｘ、島繊度０．０４ｄｔｅｘ、繊維長５１ｍｍの海島型複合繊維の原綿を用いて、カード、クロスラッパー工程を経て形成した繊維ウエブを作成し、ついでプレパンチで１００本／ｃｍ2 のニードルパンチを行って不織布にした。該不織布両面に繊度８４ｄｔｅｘ−７２ｆ、撚数２５００Ｔ／ｍの強撚糸を織密度タテ×ヨコ＝２８×２７本／ｃｍに織り上げた平織の織物にポリビニルアルコールを付着量９％で付与させたものを重ね、２５００本／ｃｍ2 のニードルパンチにより織物が絡合一体化した目付６５０ｇ／ｍ2の短繊維よりなる不織布シートを形成した。かかる工程において、繊維ウエブに織物を重ねパンチング処理する際、織物しわが発生することもなく、安定的に該不織布シートを得ることができた。かくして得られたシートを９８℃の熱水でポリビニルアルコールを溶出乾燥後、極細繊維化し、水中でポリウレタンを凝固した後、該樹脂含浸不織布を半裁（スライス）して、２枚のシートとした。得られたシートをバフ機で起毛処理した後、分散染料で染色し、厚さ０．６０ｍｍ、目付２５０ｇ／ｍ2のスエード調人工皮革を得た。得られたスエード調人工皮革の表面には、織物糸露出欠点及び織物しわに起因するスジ状欠点の発生もなく、表面品位、触感共に極めて良好であった。
比較例１
実施例１において、ポリビニルアルコールが付着していない平織織物を用いた。該平織織物は、８４ｄｔｅｘ−７２ｆ、２５００Ｔ／ｍの強撚糸を、織密度タテ×ヨコ＝２８×２７本／ｃｍに織り上げた平織織物であった。
【００２５】
実施例１のプレパンチ上がり不織布の両面に該平織織物を積層し、以下の加工は全て実施例１と同様に行った。かかる工程において、該平織織物を不織布に積層しニードルパンチする際、織物しわが混入し、起毛処理時にシート破れが多発した。かくして得られた立毛人工皮革は、織物しわ起因のスジ状欠点が多発するとともに、ニードルパンチの際に織物原糸が不織布内部に持ち込まれており、製品表面に織物原糸が混在する織物糸露出が多発し、表面品位は不良であり、触感についても不良であった。
【００２６】
【発明の効果】
本発明によれば、風合、ファッション性に優れ、軽量かつ高強力で、特に表面品位の良好な立毛人工皮革を安定的に製造する方法を提供することができる。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing napped artificial leather.
[0002]
[Prior art]
Conventionally, as a means of increasing the strength of napped artificial leather, a fiber web made of ultrafine fibers or fibers that can be made ultrafine and a fabric are needle punched, entangled and integrated, and then a polymer elastic body imparting treatment and In general, there is known a method in which a woven fabric is entangled and integrated with the back surface of the artificial napped leather by performing a combination of a raising process and a further ultra-thinning fiber web.
[0003]
In such a conventional napped artificial leather manufacturing method, the number of twists of the woven yarn used is 700 T / m or more in order to reduce damage caused by the needle punching process, and when the needle punching process is performed by overlapping the woven fabric, Due to the shrinkage in the width direction associated with the fiber entanglement of the fiber web made of ultrafine fibers or ultrafine fibers, the shrinkage stress acts on the entangled and woven fabric, and the woven fabric is bonded in a state of wrinkles, and locally There is a serious problem that a part where the thickness of the woven fabric increases is generated, and the productivity is significantly reduced due to the tearing of the sheet at the time of the raising process, and a streaky defect, that is, a woven wrinkle defect occurs on the surface of the product after dyeing. It was.
[0004]
Further, conventionally, when needle punching is performed by overlapping fabrics, the fabric yarn is pushed into the ultrafine fiber web, and this is ground simultaneously with the ultrafine fibers by the raising treatment, and the fabric yarn that should be on the back surface is exposed to the product surface. When dyeing the fabric, the fabric yarn is dyed in a dark color due to the difference in the dyeing property between the fabric yarn and the ultrafine fiber, so that the defect that the sesame granular spots are scattered on the product surface, that is, the fabric yarn is exposed frequently occurs. Potentially had. This drawback has been a serious problem particularly in thin raised artificial leather because the product becomes thinner as the thickness of the product is reduced to reduce the weight and the texture of the fabric is increased.
In order to solve this problem, there is a method in which a warp has a structure for gripping a weft and a needle punch is formed by superposing a woven fabric having a entangled structure such as a woven fabric or a woven fabric having good shape retention on a fiber web. However, in this method, during the needle punching process, two warps intersecting with each other while gripping the weft of the woven fabric are entangled and integrated with the fiber web, so that the thickness of the woven fabric is increased only in the warp portion. There was a problem that streaky defects appeared on the surface of the product after dyeing.
[0005]
[Problems to be solved by the invention]
The present invention has been made in view of the problems of the conventional method for producing napped artificial leather, and the object of the present invention is to stabilize napped artificial leather that is less prone to fabric wrinkle defects and fabric yarn exposure defects. It is intended to provide a manufacturing method to be obtained.
[0006]
[Means for Solving the Problems]
The present inventors have found that the cause of the woven wrinkle defect and the woven yarn being exposed is that the shape retaining property of the woven fabric during the punching process is low, and has the following configuration in order to solve such a problem. In other words, a woven fabric made of ultrafine fibers having a single fiber fineness of 0.9 dtex or less and a strong twisted yarn having a twist number of 700 T / m or more was added with a polymer binding agent and bundled together, punched, and entangled and integrated. Thereafter, a fiber web made of fibers that can be subjected to a polymer binding agent removal treatment, a polymer elastic body imparting treatment, and a raising treatment, or a single fiber fineness of 0.9 dtex or less and a twisted yarn of 700 T / m or more. After applying a polymer binding agent to a woven fabric made of a bundle and bundling them together, punching treatment and entanglement and integration, ultrathinning treatment, polymer binder removal treatment, polymer elastic body application treatment and raising treatment This is a method for producing napped artificial leather.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
The present invention has been intensively studied on a production method for stably obtaining the above-mentioned problems, i.e., a napped artificial leather in which the fabric wrinkle defect and the fabric yarn exposure defect are less likely to occur. After being bundled and bundled, punching treatment and entanglement and integration were performed, and then the polymer binding agent removal treatment, polymer elastic body application treatment and raising treatment were further performed using a fiber web that can be made finer. In some cases, it has been clarified that a method for producing napped artificial leather having the above characteristics can be provided by producing a combination of ultrafine processing.
[0008]
In the present invention, it is necessary to add a polymer binder to the fabric to be entangled and integrated with the fiber web. In the present invention, the polymer binding agent refers to an agent that binds the fabric structure and maintains the form. When the polymer binder is not applied, when the fabric is piled on the fiber web and punched, the shape of the fabric becomes loose and wrinkles tend to occur, and the fabric yarn is held inside the fiber web by the needle barb. It is not preferred because it is rare and the yarn is exposed on the surface of the product and the touch and appearance are significantly impaired.
[0009]
In the present invention, as the polymer binding agent to be applied to the woven fabric, water-insoluble substances such as nylon, polypropylene, polyethylene, acrylate ester, polyvinyl alcohol, acrylic, vinyl copolymer, styrene copolymer, starch Water-soluble sizing agents can be used, but sizing agents are preferred from the viewpoint of work stability, adhesiveness, viscosity stability, elution, etc. Among them, polyvinyl alcohol, acrylic, starch, etc. are permeable and hygroscopic. From the standpoint of paste removal, it is preferable.
[0010]
As an adhesive state of the paste, it is desirable to uniformly adhere to the entire woven fabric and suppress the movement of the woven fabric yarn. The adhesion amount of the paste to the fabric is preferably 1 to 15% by weight, more preferably 3 to 10% by weight. When the amount of adhesion is less than 1% by weight, the fabric structure is not sufficiently bound, and during needle punching, the yarn is easily brought into the fiber web by the needle barb, and the fabric yarn is exposed on the product surface. This is not preferable because the touch and appearance are significantly impaired. When the adhesion amount is more than 15% by weight, the woven fabric is excessively bound, and the entanglement between the woven fabric and the fiber web is insufficient during needle punching.
[0011]
As a solvent at the time of elution of these polymer binders, organic solvents such as dimethylformamide (DMF), toluene, and ethyl acetate can be used for water-insoluble substances, and hot water or hot water can be used for water-soluble substances.
[0012]
As the types of woven fabric used in the present invention, plain woven fabric, twill woven fabric, satin weaving fabric or various woven fabrics based on these weaving methods can be used, but it is preferable from the viewpoint that the thickness of the woven fabric after punching treatment is uniform. Plain weave is used. The woven yarn constituting the woven fabric can be used as long as it is a synthetic fiber yarn such as polyester or polyamide. Such yarn is not particularly limited, such as filament yarn or spun yarn, but preferably twisted yarn is used. The twist number of the twisted yarn needs to be 700 T / m or more, preferably 700 T / m or more and 4000 T / m or less, more preferably 1000 T / m or more and 4000 T / m or less, and more preferably 2000 T / m or more and 3000 T. / M or less is more preferable. If the number of twists is less than 700 T / m, single yarn breakage due to punching increases, and the product strength decreases, which is not preferable. When the number of twists is greater than 4000 T / m, the fiber becomes too hard, which is not preferable from the viewpoint of texture.
[0013]
The total fineness of the twisted yarn is preferably 30 dtex or more and 120 dtex or less. If the total fineness is greater than 120 dtex, the thickness of the woven fabric is increased, which is not preferable because the woven yarn is likely to be exposed on the product surface due to thinning of the product. If it is less than 30 dtex, damage caused by the punching treatment of the woven fabric increases and the strength of the product decreases, which is not preferable.
[0014]
In the present invention, the single yarn fineness of the twisted yarn is preferably 0.3 dtex or more and 2 dtex or less. If the single yarn fineness is larger than 2 dtex, it is not preferable because the exposure of the fabric yarn becomes conspicuous due to the difference in dyeability with the ultrafine fiber. If it is less than 0.3 dtex, the strength of the product is lowered due to single yarn breakage caused by the punching process, which is not preferable.
[0015]
The weaving density of the woven fabric is preferably 10 pieces / cm or more for both the warp and the weft. When the weaving density is less than 10 pieces / cm, the woven fabric becomes coarser, the gripping force between the warp and weft is reduced, and misalignment easily occurs, so that the woven fabric yarn is easily pushed into the fiber web by punching, It is not preferable because the defect that the woven yarn is exposed tends to occur.
[0016]
The polymer forming the ultrafine fibers constituting the napped artificial leather of the present invention is not particularly limited, but polyethylene terephthalate, copolymerized polyethylene terephthalate, polybutylene terephthalate, copolymerized polybutylene terephthalate, polypropylene terephthalate, copolymerized Polyester polymers such as polypropylene terephthalate and polyester elastomer, nylon polymers such as nylon 6, nylon 66, nylon 12, copolymer nylon and polyamide elastomer, polyurethane polymers, polyolefin polymers, acrylonitrile polymers, etc. A polymer having fiber shape performance is suitable, but from the viewpoint of practical performance, the above-mentioned polyester polymer or polyamide polymer can be preferably used.
[0017]
In addition, for components that are made into ultrafine fibers by removing a part of the polymer constituting the composite fiber, such as sea-island type fibers, or those that are made into ultrafine fibers by peeling or dividing each other, components to be removed For example, one or two types of components such as polyolefins such as polystyrene, copolymerized polystyrene, polyethylene, and polypropylene, polyesters, and polyamides can be used.
[0018]
The fineness of the ultrafine fiber used in the present invention is preferably 0.0001 dtex or more and 0.9 dtex or less in order to enhance performance as a napped artificial leather, that is, flexibility, touch feeling, appearance quality, strength properties and the like. When the fineness of the ultrafine fiber is larger than 0.9 dtex, it is not preferable because a soft touch on the surface peculiar to artificial leather cannot be obtained. If the fineness is smaller than 0.0001 dtex, the fiber strength is lowered, which is not preferable. In the present invention, the following composite fiber is used when the ultrathinnable fiber is used. For example, there are a polymer array fiber composed of two or more kinds of polymers and an easily split type composite fiber composed of two kinds of polymers having low compatibility with each other. However, the present invention is not limited to this, and a developed form of fiber can be applied based on the idea.
[0019]
In the present invention, when forming a fiber web of ultra-thinnable fibers, various means such as spun bond, melt blow, paper making, and other methods combining cards and cross wrappers can be used. In order to produce napped artificial leather, a method of forming a sheet using a card, a cross wrapper, a random web or the like is desirable.
[0020]
In the present invention, a web made of such fibers is temporarily entangled by needle punching or water jet punching, and after laminating a fabric with a polymer binder added thereto, the same punching treatment is performed and pasted together. To manufacture. In this case, it is preferable to perform needle punching in order to more strongly entangle the woven fabric with the fiber web.
[0021]
In the ultra-thinnable fiber in the present invention, in particular, when removing sea components from sea-island type fibers, there are various methods for removing sea components such as extraction with a solvent, thermal decomposition, etc. A method of extracting with a solvent before or after applying the body is desirable. Further, as a method for expressing the ultrafine fibers with the split type fibers, it is desirable to use mechanical stimulation such as alkali treatment, rubbing and beating.
[0022]
As the elastic polymer used in the present invention, polyurethane, styrene-butadiene copolymer (hereinafter referred to as SBR), polyamino acid, acrylic adhesive, etc. can be used. Is preferred. As a method for applying the polymer elastic body, a method of solidifying after applying or impregnating the polymer elastic body, a method of applying or impregnating the polymer elastic body in the form of emulsion or latex, and drying and fixing can be used.
[0023]
The raising treatment of the present invention is performed using a needle cloth or sandpaper. In particular, artificial leather can be formed with good napping by raising the surface of the sheet after applying the polymer elastic body using a sandpaper, that is, grinding. The amount of grinding in the raising treatment is preferably 0.15 mm or more and 0.60 mm or less, because the fabric is more easily exposed on the product surface as the finished thickness is thinner, and the finished thickness is preferably 0.20 mm. More preferably, it is 0.50 mm or less.
[0024]
【Example】
Next, the present invention will be described in more detail using examples.
Example 1
Using the raw material of the sea-island type composite fiber of polyethylene terephthalate as the island component, component ratio 55/45 consisting of polystyrene as the sea component, number of islands 36, composite fineness 2.8 dtex, island fineness 0.04 dtex, fiber length 51 mm, A fiber web formed through a cross-wrapper process was prepared, and then a needle punch of 100 / cm 2 was performed with a pre-punch to make a nonwoven fabric. A plain woven fabric obtained by weaving a strong twisted yarn having a fineness of 84 dtex-72f and a twist number of 2500 T / m on both sides of the nonwoven fabric to a woven density of warp density × width = 28 × 27 pieces / cm, and having a polyvinyl alcohol applied with an adhesion amount of 9% A non-woven sheet made of short fibers having a basis weight of 650 g / m 2 in which the woven fabric was entangled and integrated by a 2500 needle / cm 2 needle punch was formed. In this process, when the woven fabric was piled on the fiber web and punched, the nonwoven fabric sheet could be stably obtained without generating woven wrinkles. Polyvinyl alcohol was eluted and dried with hot water at 98 ° C., and the sheet thus obtained was made into ultrafine fibers. After the polyurethane was solidified in water, the resin-impregnated nonwoven fabric was cut into two pieces (slices) to obtain two sheets. The obtained sheet was brushed with a buffing machine and dyed with a disperse dye to obtain a suede-like artificial leather having a thickness of 0.60 mm and a basis weight of 250 g / m 2 . The surface of the obtained suede-like artificial leather was extremely good in both surface quality and tactile sensation without the occurrence of fabric yarn exposure defects and streak-like defects caused by fabric wrinkles.
Comparative Example 1
In Example 1, a plain woven fabric to which polyvinyl alcohol was not attached was used. The plain woven fabric was a plain woven fabric obtained by weaving 84 dtex-72f, 2500 T / m strong twisted yarn to a woven density of warp density × width = 28 × 27 / cm.
[0025]
The plain woven fabric was laminated on both sides of the pre-punched non-woven fabric of Example 1, and the following processes were all performed in the same manner as in Example 1. In this process, when the plain woven fabric was laminated on the nonwoven fabric and needle punched, the fabric wrinkles were mixed and sheet tearing occurred frequently during the raising process. The napped artificial leather thus obtained has a lot of streak-like defects caused by fabric wrinkles, and the fabric yarn is brought into the nonwoven fabric during needle punching, and the fabric yarn is exposed on the product surface. Frequently occurred, the surface quality was poor, and the touch was also poor.
[0026]
【The invention's effect】
According to the present invention, it is possible to provide a method for stably producing a napped artificial leather that is excellent in texture and fashionability, is lightweight and highly strong, and has particularly good surface quality.
Claims (7)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001089511A JP4569023B2 (en) | 2001-03-27 | 2001-03-27 | Method for producing napped artificial leather |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001089511A JP4569023B2 (en) | 2001-03-27 | 2001-03-27 | Method for producing napped artificial leather |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2002285479A JP2002285479A (en) | 2002-10-03 |
| JP4569023B2 true JP4569023B2 (en) | 2010-10-27 |
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|---|---|---|---|
| JP2001089511A Expired - Fee Related JP4569023B2 (en) | 2001-03-27 | 2001-03-27 | Method for producing napped artificial leather |
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| JP5540731B2 (en) * | 2010-01-27 | 2014-07-02 | 東レ株式会社 | Artificial leather and method for producing the same |
| JP5640397B2 (en) * | 2010-02-26 | 2014-12-17 | 東レ株式会社 | Manufacturing method of sheet-like material |
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| JPS62177270A (en) * | 1986-01-31 | 1987-08-04 | 東レ株式会社 | Production of high strength soft leather like article |
| JPH10273885A (en) * | 1997-03-31 | 1998-10-13 | Toray Ind Inc | Fiber napped sheet and method for producing the same |
| JP3484598B2 (en) * | 1997-04-07 | 2004-01-06 | 東レ株式会社 | Method of manufacturing nap sheet |
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