JPS62259B2 - - Google Patents
Info
- Publication number
- JPS62259B2 JPS62259B2 JP57153827A JP15382782A JPS62259B2 JP S62259 B2 JPS62259 B2 JP S62259B2 JP 57153827 A JP57153827 A JP 57153827A JP 15382782 A JP15382782 A JP 15382782A JP S62259 B2 JPS62259 B2 JP S62259B2
- Authority
- JP
- Japan
- Prior art keywords
- sheet
- sea
- fiber bundle
- fibers
- island
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
- 239000000835 fiber Substances 0.000 claims description 114
- 229920001410 Microfiber Polymers 0.000 claims description 37
- 238000000034 method Methods 0.000 claims description 32
- 239000012530 fluid Substances 0.000 claims description 29
- 239000000463 material Substances 0.000 claims description 27
- 229920005989 resin Polymers 0.000 claims description 16
- 239000011347 resin Substances 0.000 claims description 16
- 238000004049 embossing Methods 0.000 claims description 13
- 230000008569 process Effects 0.000 claims description 11
- 238000004519 manufacturing process Methods 0.000 claims description 8
- 238000003825 pressing Methods 0.000 claims description 7
- 238000005507 spraying Methods 0.000 claims description 6
- 239000000126 substance Substances 0.000 claims description 2
- 239000004793 Polystyrene Substances 0.000 description 16
- 239000004745 nonwoven fabric Substances 0.000 description 16
- 229920002223 polystyrene Polymers 0.000 description 16
- -1 polyethylene terephthalate Polymers 0.000 description 14
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 13
- 229920002635 polyurethane Polymers 0.000 description 13
- 239000004814 polyurethane Substances 0.000 description 13
- 229910052709 silver Inorganic materials 0.000 description 13
- 239000004332 silver Substances 0.000 description 13
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 12
- 229920001577 copolymer Polymers 0.000 description 10
- 229920000642 polymer Polymers 0.000 description 8
- 239000002649 leather substitute Substances 0.000 description 7
- 229920002292 Nylon 6 Polymers 0.000 description 6
- 239000010985 leather Substances 0.000 description 6
- 239000002904 solvent Substances 0.000 description 6
- 239000004372 Polyvinyl alcohol Substances 0.000 description 5
- 238000013461 design Methods 0.000 description 5
- 238000004043 dyeing Methods 0.000 description 5
- 239000010410 layer Substances 0.000 description 5
- 229920000139 polyethylene terephthalate Polymers 0.000 description 5
- 239000005020 polyethylene terephthalate Substances 0.000 description 5
- 229920002451 polyvinyl alcohol Polymers 0.000 description 5
- 230000002441 reversible effect Effects 0.000 description 5
- 238000009987 spinning Methods 0.000 description 5
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 4
- 206010061592 cardiac fibrillation Diseases 0.000 description 4
- 230000015271 coagulation Effects 0.000 description 4
- 238000005345 coagulation Methods 0.000 description 4
- 230000002600 fibrillogenic effect Effects 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 238000002156 mixing Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 238000004080 punching Methods 0.000 description 4
- 230000003068 static effect Effects 0.000 description 4
- ZMXDDKWLCZADIW-UHFFFAOYSA-N N,N-Dimethylformamide Chemical compound CN(C)C=O ZMXDDKWLCZADIW-UHFFFAOYSA-N 0.000 description 3
- 229920005749 polyurethane resin Polymers 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 239000007921 spray Substances 0.000 description 3
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- XSTXAVWGXDQKEL-UHFFFAOYSA-N Trichloroethylene Chemical group ClC=C(Cl)Cl XSTXAVWGXDQKEL-UHFFFAOYSA-N 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 150000001298 alcohols Chemical class 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- 238000009960 carding Methods 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 238000009981 jet dyeing Methods 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 229920002285 poly(styrene-co-acrylonitrile) Polymers 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 229920001707 polybutylene terephthalate Polymers 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 229920003225 polyurethane elastomer Polymers 0.000 description 2
- 229920006264 polyurethane film Polymers 0.000 description 2
- 229920000742 Cotton Polymers 0.000 description 1
- JHWNWJKBPDFINM-UHFFFAOYSA-N Laurolactam Chemical compound O=C1CCCCCCCCCCCN1 JHWNWJKBPDFINM-UHFFFAOYSA-N 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 229920000299 Nylon 12 Polymers 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- CYTYCFOTNPOANT-UHFFFAOYSA-N Perchloroethylene Chemical group ClC(Cl)=C(Cl)Cl CYTYCFOTNPOANT-UHFFFAOYSA-N 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000002202 Polyethylene glycol Substances 0.000 description 1
- 229920002125 Sokalan® Polymers 0.000 description 1
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 244000309466 calf Species 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 230000001112 coagulating effect Effects 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 239000002932 luster Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920002037 poly(vinyl butyral) polymer Polymers 0.000 description 1
- 239000004584 polyacrylic acid Substances 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920001748 polybutylene Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 229920002959 polymer blend Polymers 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000002940 repellent Effects 0.000 description 1
- 239000005871 repellent Substances 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 229950011008 tetrachloroethylene Drugs 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Landscapes
- Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
- Nonwoven Fabrics (AREA)
Description
【発明の詳細な説明】
本発明は、一面が超極細繊維立毛により覆われ
たスエード調表面を示し、他の一面が超極細繊維
によりフイブリル化絡合して形成された緻密な銀
面調表面を示す表裏両面が使用可能なシート状物
およびその製法に関するものである。
従来、天然皮革代替物を目指して、ポリウレタ
ンなどの重合体物質を表面層とした銀面付人工皮
革や、極細繊維束の不織布をベースとし表面を起
毛してスエード調とした立毛人工皮革が生まれた
ことは周知である。しかし従来の人工皮革は銀面
調あるいはスエード調など、用途、目的に応じて
開発されてきたため、それぞれの用途には適した
ものであつても、両者を組み合せたり、リバーシ
ブルとして新しいデザインやフアツシヨンを開発
する素材として使用しようとすると風合や品質が
異質であること、色調が合わないこと、染色堅牢
性に差があることなどが基本的な問題となつて、
かかる目的には対応できなかつた。
近年特に衣料分野を主体に新しいフアツシヨン
素材がとりあげられてきているが、上記のような
銀付調とスエード調を自在に組み合せられる素材
に対する要望が増加してきている。かかる要望に
スエード調素材としては応じられるものが出現し
ているのに対し、銀付人工皮革についてはこれま
でポリウレタン膜が表面に存在するため、光沢や
色調がいかにもビニルライクであり、コンビネー
シヨン用素材としては不適当なものしかなかつ
た。ましてリバーシブル素材などは望むべくもな
かつた。
本発明者らはかかる欠点を改良するとともに、
スエード調と銀付調のコンビネーシヨン使いがで
きるような高品位、風合、良好な染色特性を有す
るシート状物を得るための検討を鋭意すすめ、リ
バーシブル素材としても使用できる表裏両面が使
用可能なシート状物を得るに至つた。
すなわち本発明の目的は、一面はスエード調の
立毛表面であり、他の一面は銀面様の緻密な表面
であるような、表裏両面が使用可能であるシート
状物およびその製造法を得るにある。
本発明は一方の表面が銀面調表面となつてお
り、他方の表面が立毛調表面となつているシート
状物質において、0.2デニール以下の超極細繊
維、該超極細繊維が多数本集まつた超極細繊維束
(1次繊維束と称する)、および該1次繊維束がさ
らに多数本集まつた繊維束(2次繊維束と称す
る)から主としてなる繊維質シートであつて、シ
ートの厚み方向に対し、該銀面様表面近傍は1次
繊維束から枝分れした超極細繊維がフイブリル化
絡合した構造が主体を占め、次いで1次繊維束が
主として絡合した構造を経て、さらに2次繊維束
が主として絡合した構造に至り、遂には2次繊維
束から開繊された立毛によつて主として覆われた
立毛調表面となつているような表面および断面構
造を有することを特徴とする表裏両面使用可能な
シート状物質およびその製造方法に関するもので
ある。
本発明のシート状物質は、超極細繊維がフイブ
リル化して絡み合つて形成された銀面を有し、か
つ該超極細繊維は厚み方向に対して表面から遠ざ
かるにつれ、多数本が集束して1次繊維束を形成
し、さらに1次繊維束が複数本集束して2次繊維
束を形成し、遂には2次繊維束から開繊した超極
細繊維の立毛表面に至るという特別な繊維構造の
ため、構造のバランスが極めて良くなり、良好な
屈曲じわを発生させ、後処理加工で容易に、良好
な揉みシボを付与できるなど高級天然皮革に備わ
つている優れた特長で、これまでの銀面付人工皮
革では達し得なかつた銀面調表面を一面にもち、
他の一面は優美なスエード調の立毛表面であるシ
ート状物となる。
このため本発明のシート状物はスエード調とし
ても、銀付調としても使用でき、コンビネーシヨ
ン使いやリバーシブル使いが可能となるのであ
る。しかも超極細フイブリルが絡合してできた銀
面は従来のポリウレタン膜の銀面と異なり、繊維
質主体であるので、染色や仕上は立毛面と全く共
通で良く、光沢や色調が極めて自然となり、ビニ
ールライクな欠点は解消される。
本発明のシート状物を構成する繊維としては、
少なくとも2種の高分子物質から成る海島型繊維
であつて、多数の島成分と海成分とから成る海島
構造の複数がさらに1コの海に囲まれており、全
海成分を除去後は0.2デニール以下の超極細繊維
が多数本集まつて成る超極細繊維束(1次繊維
束)がさらに複数本集まつて2次繊維束を形成す
るような構造の多成分系繊維が好ましく用いられ
る。
このような多成分系繊維の好ましい概念は第1
図、第2図、および第3図に示した。すなわち、
多数の島成分1と海成分2とから成る海島構造が
さらに大きな1コの海成分3に囲まれているよう
なものである。かかる多成分系繊維は全海成分を
除去すると、多数の超極細繊維から成る1次繊維
束とさらに1次繊維束が複数本集まつて成る2次
繊維束が得られる。
かかる多成分系繊維の製造手段については、例
えば特開昭54―125718に開示された海島型多成分
系繊維用紡糸口金を用いる方法が好ましい。この
方法においては島成分1と海成分2および海成分
3の配置が完全に規制でき、、島成分の本数と太
さを口金設計により任意に変更できる。またこの
方法の変形として島成分流を複数以上に分割して
他の島成分流と合流する機構としてスタテイツク
ミキサーを使用する方法も好ましい。すなわち本
発明の島成分1と海成分2の流れをスタテイツク
ミキサーに導入して海島構造とし、次いで海成分
3で被覆する方法である。
スタテイツクミキサーとしては、例えば特公昭
―53―36182記載のような流体混合器を使用すれ
ば、島本数および太さは混合素子の数で変更で
き、得られる島成分は前述の特殊口金法と同様繊
磯軸方向に実質的に連続となる。フイブリル状態
から1次繊維束を経て2次繊維束に至るまで各超
極細繊維が連続する点で、上記の各手段による多
成分系繊維は本発明の目的に最も適つた繊維であ
る。
しかし本発明の目的からは必ずしも島成分は連
続している必要はなく、フイブリル状態、1次繊
維束、2次繊維束、立毛の構造を生ぜしめる繊維
であれば使用可能である。この意味から例えば特
公昭47―37648記載のような高分子相互配列体の
島成分がポリマブレンドされたものであつて、該
島成分が海島構造をなしているような多成分系繊
維は使用できる。しかし単なるチツプ混合あるい
はエクストルーダ混合もしくは流れを分断するタ
イプのスタテイツクミキサー混合によるポリマブ
レンドでは紡糸性が悪く、また繊維は本質的に不
連続であるので、本発明の効果を得るための適正
な製糸条件の工夫が必要となり、また海島構造に
なる限界島比率が前述の好適な製造手段に比べ、
低くなるのは止むを得ない。
上記の多成分系繊維を構成する島成分として
は、例えばナイロン6,ナイロン66,ナイロン
12,その他の共重合ナイロンなどのポリアミド
類,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などの
ポリエステル類,ポリエチレン,ポリプロピレン
などのポリオレフイン類,ポリアクリロニトリ
ル,ポリウレタン,およびビニル重合体などが用
いられる。また海成分としては、例えばポリスチ
レン,ポリプロピレン,アルカリ可溶の共重合ポ
リエチレンテレフタレート,ポリアミド,ポリウ
レタン,スチレン―アクリロニトリル共重合体,
スチレンとアクリル酸の高級アルコールエステル
および/またはメタクリル酸の高級アルコールエ
ステルとの共重合体,ポリビニルアルコール,共
重合ポリビニルアルコールなどが用いられる。海
成分としては紡糸の容易さ、溶解除去の容易さの
点でポリスチレン,スチレン―アクリロニトリル
共重合体,スチレンとアクリル酸の高級アルコー
ルエステルおよび/またはメタクリル酸の高級ア
ルコールエステルとの共重合体が好ましい。また
高速流体流により海成分を割裂しやすくする点
で、海成分にポリエチレングリコールなどの異種
ポリマを若干量混合することは好ましい。島成分
と海成分の選択は溶剤に対する溶解性が異なる組
み合せが必要であり、海成分2と海成分3の選択
は同種のポリマであつても異種のポリマであつて
も良いが、溶剤に対する溶解性は同じである組み
合せが好ましい。島成分1―海成分2―海成分3
の好ましい組み合せとしては、ナイロン6―ポリ
スチレン(共重合体を含む)−ポリスチレン(共
重合体を含む)、ポリエチレンテレフタレート
(共重合体を含む)―ポリスチレン(共重合体を
含む)―ポリスチレン(共重合体を含む)、ポリ
ブチレンテレフタレート―ポリスチレン(共重合
体を含む)―ポリスチレン(共重合体を含む)な
どが挙げられるが、もちろんこれらに限定される
ものではない。
1次繊維束を形成する島成分の本数は、どの多
成分系繊維の製造手段を選択するかということ
と、口金の設計、流体混合器の素子数、ブレンド
における島比率などの可変条件の設定により、コ
ントロールが可能である。少なくとも5本以上の
多数本が必要であるが、多数本になればなる程太
さは細化し、フイブリル化して形成される銀面構
造が緻密化し、また立毛も緻密化するので好適で
ある。この点からは前述の特殊流体混合器を使用
する方法は、島本数を極めて多くとることが簡単
であり特に好ましい。
2次繊維束を形成する1次繊維束の本数は、島
成分と海成分2の合流の流路をいくつ設けるかに
よつてコントロールが可能であり、好ましくは5
本以上の複数本が用いられる。上限については特
に制限はないが、口金の製作精度で限界がある。
島成分の太さは、本発明の目的を達成するため
には0.2デニール以下、好ましくは0.15デニール
以下の超極細を必要とする。これにより太い繊維
を用いると、例えフイブリル化絡合させて銀面が
形成できても、平滑性や緻密性が劣り、またスエ
ード調表面の立毛品位が劣るので、本発明の目的
とする高級感を有するシートは得られない。
上述したような超極細繊維のフイブリル、1次
繊維束、2次繊維束が相互に絡合して成る本発明
のシート状物の好ましい概念を第4図に示した。
すなわち超極細繊維が多数本集束して成る1次繊
維束5は表面近傍で超極細繊維にフイブリル化し
て、かつ密に絡合して緻密な銀面層4を形成し、
裏面に向つては1次繊維束5がさらに複数本集束
して2次繊維束6を形成し、全体としても絡合構
造となつている。さらに、2次繊維束は開繊して
立毛7を形成し立毛表面となる。このような基本
構造に樹脂が付着した構造、特に少なくとも表面
および表面近傍に近い部分やシート内部の空隙に
樹脂が存在する構造も好ましい。特に超極細繊維
や繊維束をとりまく形で存在するのが良い。もち
ろん第4図はあくまで1つの概念図であつて、フ
イブリル化絡合構造4、1次繊維束5、2次繊維
束6の相対関係はこの通りであつても、厚み方向
における比率関係は変つても全く差し支えない。
かかる構造の関係は高速流体流の噴き当て処理に
より生じるので、局部的には4,5,6の各構造
が入り乱れて絡合する場合もあるが、本発明の効
果が得られる範囲内であれば差し支えないことで
ある。
このような構造の本発明の銀付皮革様シート状
物を得る手段としては大別して2方法ある。その
1は、前述の多成分系繊維を適当な長さにカツト
してステープルフアイバーとして開綿、カード、
ウエブ形成の工程を経てシート状ウエブとし、次
いでニードルパンチにより絡合を行なつて不織布
シートを得、該不織布の片面から高速流体流を噴
き当てて海成分の割裂と、露出した超極細繊維束
のフイブリル化絡合を行ない、然る後に多成分系
繊維の海成分に対しては溶剤で、島成分に対して
は非溶剤である液体により海成分を溶解除去し、
次いで高速流体流で処理した面を一型押しあるい
はプレスし、高速流体流で処理していない面をバ
フして本発明のシート状物とする方法である。
また海成分溶解工程と型押しあるいはプレス工
程を逆にしても良い。これら主工程の間に通常の
人工皮革製造の技術を組み合せることは、目的の
皮革シートの品質設計に応じ自由に行なえば良
い。
すなわち、不織布の収縮を高速流体流処理の前
もしくは後に行なうこと、ポリウレタンエラスト
マーなどの樹脂液を高速流体流処理の後に付与
し、湿式凝固あるいは乾式凝固により樹脂を繊維
あるいは繊維束のまわりに付与すること、厚目の
不織布の両面に、高速流体流処理を行ないその後
の適当な工程でスライスすること、型押しもしく
はプレス前に適当な樹脂を塗布することなどの技
術が組合せ可能である。
その2はその1と同様ニードルパンチした絡合
不織布とした後、多成分系繊維の海成分に対する
溶剤で、島成分に対しては非溶剤である液体によ
り海成分を溶解除去したシートに、片面から高速
流体流を噴き当てて主として表面の超極細繊維束
をフイブリル化絡合させて緻密な表面をもつシー
トとし、次いで高速流体流で処理した面を型押し
もしくはプレスし、高速流体流で処理していない
面をバフして本発明のシート状物とする方法であ
る。この方法においてもその1と同様人工皮革の
既存の技術との組合せを自由に行なうことができ
る。すなわち不織布を収縮させること、海成分の
除去前にポリビニルアルコールなどの仮固定性高
分子を付与し、その後の適当な工程で抽出除去す
ること、高速流体流処理後に仮固定性高分子およ
び/またはポリウレタンエラストマーなどの樹脂
を付与し、湿式凝固もしくは乾式凝固させ、次い
で仮固定性高分子を抽出除去すること、型押しま
たはプレス前に適当な樹脂を付与しておくこと、
両面に高速流体流処理を行ないその後の適当な工
程でスライスすることなどの技術が使用可能であ
る。またこの方法において海成分除去時の寸法安
定性を良くするために海成分除去の前後とも高速
流体流処理を行なうことも可能である。
すなわち本発明の表裏両面使用可能なシート状
物を得るには、超極細繊維フイブリル化絡合構
造、1次繊維束、2次繊維束の構造を形成するた
めに高速流体流の噴き当て処理と海成分の溶解除
去処理が重要であり、特に高速流体流の噴き当て
方が重要である。
高速流体流に用いられる流体としては、水が最
も好ましいが、目的に応じて有機溶剤やアルカ
リ、酸の水溶液なども用い得る。かかる流体は高
圧ポンプにより圧力をかけ、孔径の小さいノズル
もしくは間隔の狭いスリツトから噴射させて、高
速の柱状流あるいはカーテン流として、不織布シ
ートの面に噴き当てる。圧力条件は海成分が存在
するその1の方法では、海成分の割裂および超極
細繊維のフイブリル化の両作用を必要とするの
で、比較的高い圧力条件を要し、70〜300Kgcm2程
度の範囲が好ましい。一方、海成分が存在しない
その2の方法では、海成分の割裂は必要でないた
め、比較的低い圧力条件で良く5〜100Kg/cm2程
度が良好な範囲である。噴き当てによる打撃軌跡
を避けるため、噴出ノズルとシートを相対的に動
かす方法や通し回数を重ねる方法またはパルス流
による方法は有効である。
かかる高速流体流を噴き当てることにより最初
2次繊維束構造のみであつた繊維構造が、噴き当
ての影響をうけやすい表面に近い部分は1次繊維
束に分割され、かつ液圧を直接うける表面および
表面近傍は1次繊維束がさらに分割されて超極細
繊維がフイブリル化し、該フイブリルは絡合して
極めて緻密な表面を形成し、その後の型押しもし
くはプレスにより銀面化できる。一方、2次繊維
束の面はバフ操作により開繊、立毛化し、スエー
ド調表面となる。
型押しもしくはプレスの条件は繊維素材と樹脂
素材の特性から決めれば良く、特に制限はない。
通常100〜250℃の温度で、圧力のかかる条件で行
なわれる。型押しもしくはプレス前に適当な樹脂
を付与する場合は、ポリウレタン樹脂、塩ビ系樹
脂、ポリビニルブチラール樹脂、ポリアクリル酸
樹脂、ポリアミノ酸樹脂、シリコン樹脂やこれら
の混合物もしくは共重合体などが用いられる。
上記により得られる本発明の表裏両面使用可能
なシート状物は、仕上樹脂の塗布処理、染色処
理、撥水処理、揉み処理などの高次加工処理を行
なつて高品位化して商品価値を高め、天然皮革が
用いられている衣料用途、靴用途、資材用途など
の各種用途に適用できる。この場合、銀面調表面
と立毛調表面を自在に使用して従来にないデザイ
ンが創造できるのは言うまでもない。
以下本発明を実施例にて詳しく説明する。部お
よび%は全て重量に関するものである。
実施例 1
特開昭54―125718の海島型多成分系繊維用紡糸
口金を用いて、島成分をポリエチレンテレフタレ
ート、海成分をポリスチレン(島/海比率60/4
0)とし、海成分中に16本の島が存在するような
海島構造が、さらに16本集まつて1個のポリスチ
レンの海に囲まれた断面をもつ多成分系繊維
(島/全海比率=48/52)を紡糸し、2.5倍に延
伸、クリンプ、カツトの各工程により3.8デニー
ル×51mmのステープルフアイバーを得た。島成分
1本は0.007デニールの超極細繊維となつてい
た。このステープルフアイバーを開綿、カード、
クロスラツパー、ニードルパンチの各工程を通し
不織布とした。該不織布の片面に、直径0.1mmの
孔が0.6mm間隔で1列に並んだ噴射ノズルから、
圧力100Kg/cm2で柱状水流を噴き当てる処理を3
回繰り返し、その後乾燥した。次いでポリエステ
ル系ポリウレタンの15%ジメチルホルムアミド溶
液を水流を噴き当てていない側から含浸し、水で
湿式凝固後乾燥したシートに、2液ポリウレタン
をグラビアコーターで4g/m2塗布し、160℃で
皮革様シボの彫刻されたエンボスロールで型押し
して銀面とした後、トリクロルエチレンで処理し
て多成分系繊維の海成分を除去した。さらに裏面
を150メツシユのサンドペーパーでバフして立毛
表面とした後、銀面に顔料を含有したポリウレタ
ン系仕上剤をグラビアコーターで2g/m2塗布し
120℃で1時間高温染色機で揉みを加えて染色
し、本発明の一面が銀面調で、他の一面ば立毛調
のシート物を得た。走査型電子顕微鏡で柱状水流
処理後の不織布を観察したところ、明らかに表面
は超極細繊維がフイブリル化して絡合し、次いで
超極細繊維が16本集束した1次繊維束が見え、そ
の下は1次繊維束がさらに16本集束した2次繊維
束主体の絡合層となつていた。さらに仕上つたシ
ート状物の一方の表面はエンボスによりフイブリ
ル化した繊維とそれをとりまく樹脂が一体化した
銀面となつており、その下に1次繊維束とポリウ
レタン多孔質の部分、次いで2次繊維束とポリウ
レタン多孔質の層が裏面まで続いていることが観
察された。他の一方は優美な立毛が密生したスエ
ード調表面となつており、立毛は2次繊維束に連
続していた。
得られた本発明にかかるシート状物の銀面は、
エンボスによる型押しシボと、染色時にうける揉
みによるランダムな揉みシボが適度にミツクスさ
れ、天然皮革銀面様の高品位の表面外観をしてお
り、一方、立毛面は天然鹿皮調のスエードのよう
な気品ある外観を示しており、リバーシブル素材
として好適であつた。
実施例 2
特開昭54―125718の装置において、1つの島成
分流が複数以上に分割されて他の島成分流と合流
する機構の部分として、特公昭53―36182記載の
流体混合器の混合素子(内径10mm)を10段重ねた
ものを用いた紡糸装置を作製し、該紡糸装置を用
いてナイロン6の流れとポリスチレンの流れと
を、ナイロン6/ポリスチレン比率が50/50にな
るよう上記流体混合器に導入し、合流分割された
ポリマ流は16本に分けられ、この16本をさらに1
個のポリスチレンの海でナイロン6/全ポリスチ
レン比率が40/60となるよう被覆する方法によ
り、本発明の多成分系繊維を得た。該多成分系繊
維の断面はナイロン6の微細な約400の島がポリ
スチレンの海に囲まれた海島構造が、さらに16本
集まつて1個のポリスチレンの海に囲まれた構造
となつていた。6デニール×51mmのステープルと
したものの島成分の1本は、平均0.0004デニール
の超極細繊維となつていた。このステープルフア
イバーを、カード,クロスラツパー,ニードルパ
ンチの各工程を通し不織布とした。該不織布に5
%のポリビニルアルコール水溶液を付与し乾燥し
て収縮させた後、パークロルエチレンで処理して
多成分系繊維の海成分を溶解除去した。次いで熱
水をシヤワリングしてポリビニルアルコールを除
去した後、直径0.1mmの孔が0.6mm間隔で1列に並
んだ噴射ノズルから、圧力60Kg/cm2で柱状水流を
両面に3回ずつ噴き当てて乾燥した。続いて10%
のポリウレタンエマルジヨン液を含浸して乾燥
後、スライスにより2枚のシートに分割し、それ
ぞれの水流処理面にポリウレタンを5g/m2グラ
ビアコーターで塗布し、150℃で皮革様シボの彫
刻されたエンボスロールで型押しをし、水流処理
をしていない面をバフ掛けして立毛面とし、次い
で含金染料を用いて100℃で1時間の染色を行な
つたあと、タンブラーで揉み加工を行なつて本発
明のシート状物を得た。走査型電子顕微鏡で柱状
水流処理後の不織布を観察したところ、実施例1
の本発明例と同様表面は超極細繊維がフイブリル
化絡合しており、次いで超極細繊維が集束した1
次繊維束、さらに1次繊維束が16本集束した2次
繊維束の構造になつていた。表面の超極細繊維の
絡合状態は、実施例1で見られたよりさらに緻密
であつた。仕上つたシート状物についてはこのよ
うな繊維構造にポリウレタンが付着しており、一
方の表面はエンボスにより超極細繊維とそれをと
りまくポリウレタン樹脂が一体化して銀面を形成
しているような構造になつていた。他の表面は2
次繊維束が開繊した立毛が密生したスエード調表
面となつていた。
得られた本発明のシートの銀面はエンボスによ
る型押シボと、タンブラー揉み加工によるランダ
ムな揉みシボが適度にミツクスされ、羊皮調の高
品位の表面外観をしており、また他方の立毛面は
高級カーフスエード調の気品ある外観を示してお
り、リバーシブル素材に好適であつた。
実施例 3
実施例1および実施例2の本発明例で用いた紡
糸方法および特公昭47―37648記載の紡糸方法を
用いて、第1表に示す原料および成分比率を用い
て本発明の多成分系繊維を得た。これらの繊維を
用いてカード、クロスラツパー、ニードルパンチ
の各工程を通し不織布とした後、その片面に直径
0.1mmの孔が0.6mm間隔で1例に並んだ噴射ノズル
から、圧力100Kg/cm2で高速柱状水流を噴き当て
て乾燥し、トリクロルエチレンにより海成分を溶
解除去した。さらに同様の噴き当て処理を圧力70
Kg/cm2として、先に噴き当てを行なつたと同じ面
に施し、乾燥した後、ポリウレタン溶液をグラビ
アコーターで塗布し、170℃のエンボスロールに
より型押し加工を行ない表面をサンドペーパーで
バフ掛けして立毛表面とした後、実施例4,5に
ついては120℃、1時間の液流染色、実施例6に
ついては100℃、1時間の液流染色を行なつた。
得られた本発明のシート状物は、実施例1,2の
本発明例と同様の超極細繊維のフイブリル化絡合
とそれをとりまくポリウレタン樹脂が一体化して
成る銀面層、次いで超極細繊維て集束した1次繊
維束、さらに1次繊維束が集束した2次繊維束、
そして2次繊維束から開繊した緻密な立毛の構造
となつていた。
これら本発明のシート状物はそれぞれエンボス
ロールによる型押しシボと、液流染色での揉み作
用によるシボが適度にミツクスされ、天然皮革様
の自然な感じのする表面外観をしている銀面と、
鹿皮調の立毛表面を表裏に有しており、本発明の
目的を達していた。
【表】Detailed Description of the Invention The present invention has a suede-like surface covered with napped ultra-fine fibers on one side, and a dense silver-like surface formed by fibrillation and entanglement of ultra-fine fibers on the other side. The present invention relates to a sheet-like product that can be used on both the front and back sides, and a method for producing the same. Conventionally, with the aim of being a substitute for natural leather, artificial leather with a silver surface made of a polymer material such as polyurethane as a surface layer, and napped artificial leather with a suede-like appearance based on a nonwoven fabric made of microfine fiber bundles have been created. That is well known. However, conventional artificial leather has been developed depending on the use and purpose, such as silver-like or suede-like, so even if it is suitable for each use, it is possible to combine the two or make it reversible to create new designs and fashions. When trying to use it as a material for development, basic problems such as different textures and quality, incompatibility in color tone, and differences in color fastness became problems.
It was not possible to meet such a purpose. In recent years, new fashion materials have been introduced, especially in the clothing field, and there is an increasing demand for materials that can freely combine the silver-finish and suede-like styles described above. While suede-like materials have appeared that can meet these demands, silver-covered artificial leather has until now had a polyurethane film on its surface, resulting in a vinyl-like luster and color tone, making it difficult to use for combination wear. There were only inappropriate materials. Moreover, there was no way I could have hoped for a reversible material. The present inventors improved such drawbacks, and
We are actively researching ways to obtain a sheet-like material with high quality, texture, and good dyeing properties that can be used in a combination of suede and silver-tone finishes, and can also be used as a reversible material on both the front and back sides. A sheet-like product was obtained. That is, the object of the present invention is to obtain a sheet-like product that can be used on both the front and back surfaces, with one side having a suede-like raised surface and the other side having a silver-like dense surface, and a method for producing the same. be. The present invention provides a sheet-like material in which one surface has a silver-like surface and the other surface has a raised-like surface. A fibrous sheet consisting mainly of ultra-fine fiber bundles (referred to as primary fiber bundles) and fiber bundles in which a large number of the primary fiber bundles are gathered (referred to as secondary fiber bundles), and in the thickness direction of the sheet. On the other hand, the vicinity of the grain-like surface is mainly composed of a structure in which ultrafine fibers branched from a primary fiber bundle are fibrillated and entangled, and then a structure in which the primary fiber bundles are mainly entangled, and then further It is characterized by having a surface and cross-sectional structure in which the secondary fiber bundles reach a structure in which they are mainly entangled, and finally become a raised-like surface mainly covered with raised fibers opened from the secondary fiber bundles. The present invention relates to a sheet-like material that can be used on both sides, and a method for producing the same. The sheet-like material of the present invention has a silver surface formed by fibrillating and intertwining ultrafine fibers, and as the ultrafine fibers move away from the surface in the thickness direction, a large number of the ultrafine fibers converge into one. It has a special fiber structure in which a secondary fiber bundle is formed, and then multiple primary fiber bundles are brought together to form a secondary fiber bundle, and finally the secondary fiber bundle reaches the napped surface of the opened ultra-fine fiber. As a result, the structural balance is extremely well-balanced, good bending wrinkles are generated, and good kneading texture can be easily imparted through post-processing. It has a silver-like surface all over, which cannot be achieved with silver-surfaced artificial leather.
The other side is a sheet-like material with an elegant suede-like raised surface. Therefore, the sheet-like material of the present invention can be used as a suede-like material or as a silver-like material, and can be used in combination or reversibly. Moreover, unlike the silver surface of conventional polyurethane films, the silver surface created by the entanglement of ultra-fine fibrils is mainly fibrous, so the dyeing and finishing can be exactly the same as the raised surface, resulting in an extremely natural gloss and color tone. , vinyl-like drawbacks are eliminated. The fibers constituting the sheet material of the present invention include:
It is a sea-island type fiber made of at least two kinds of polymeric substances, and a plurality of sea-island structures made of many island components and sea components are further surrounded by one sea, and after removing all the sea components, the sea-island structure is 0.2 A multicomponent fiber having a structure in which a plurality of ultrafine fiber bundles (primary fiber bundles) consisting of a large number of ultrafine fibers of denier or less are further assembled to form a secondary fiber bundle is preferably used. The preferred concept for such multicomponent fibers is the first one.
2 and 3. That is,
It is as if a sea-island structure consisting of a large number of island components 1 and a sea component 2 is surrounded by one larger sea component 3. When the whole sea component is removed from such a multicomponent fiber, a primary fiber bundle consisting of a large number of ultra-fine fibers and a secondary fiber bundle consisting of a plurality of primary fiber bundles are obtained. As for the means for producing such multicomponent fibers, for example, a method using an island-in-the-sea type spinneret for multicomponent fibers disclosed in JP-A No. 125718/1986 is preferred. In this method, the arrangement of the island component 1, sea component 2, and sea component 3 can be completely controlled, and the number and thickness of the island component can be arbitrarily changed by the design of the cap. As a modification of this method, it is also preferable to use a static mixer as a mechanism for dividing the island component flow into a plurality of parts or more and merging them with other island component flows. That is, in this method, the flow of the island component 1 and the sea component 2 of the present invention is introduced into a static mixer to form a sea-island structure, and then the sea component 3 is coated. As a static mixer, if a fluid mixer such as that described in Japanese Patent Publication No. 53-36182 is used, the number and thickness of the islands can be changed by changing the number of mixing elements, and the obtained island component can be obtained using the above-mentioned special mouth method. Similarly, the fibers are substantially continuous in the axial direction. The multicomponent fibers produced by each of the above means are the most suitable fibers for the purpose of the present invention in that each ultrafine fiber is continuous from the fibril state through the primary fiber bundle to the secondary fiber bundle. However, for the purpose of the present invention, the island components do not necessarily have to be continuous, and any fiber that produces a fibrillar state, a primary fiber bundle, a secondary fiber bundle, or a nap structure can be used. In this sense, for example, multicomponent fibers such as those described in Japanese Patent Publication No. 47-37648, in which island components of a polymer mutual array are blended with a polymer and the island components form a sea-island structure, can be used. . However, polymer blends made by simple chip mixing, extruder mixing, or static mixer mixing of the type that breaks the flow have poor spinnability, and the fibers are essentially discontinuous. It is necessary to devise the conditions, and the critical island ratio resulting in a sea-island structure is lower than the above-mentioned preferred manufacturing method.
The decline is unavoidable. Examples of island components constituting the above multicomponent fibers include nylon 6, nylon 66, nylon
12, Other polyamides such as copolymerized nylon, polyesters such as polyethylene terephthalate, copolymerized polyethylene terephthalate, polybutylene terephthalate, copolymerized polybutylene terephthalate, polyolefins such as polyethylene and polypropylene, polyacrylonitrile, polyurethane, and vinyl polymers. Combination etc. are used. Examples of sea components include polystyrene, polypropylene, alkali-soluble copolymerized polyethylene terephthalate, polyamide, polyurethane, styrene-acrylonitrile copolymer,
Copolymers of styrene and higher alcohol esters of acrylic acid and/or higher alcohol esters of methacrylic acid, polyvinyl alcohol, copolymerized polyvinyl alcohol, etc. are used. As the sea component, polystyrene, styrene-acrylonitrile copolymer, copolymer of styrene and higher alcohol ester of acrylic acid and/or higher alcohol ester of methacrylic acid are preferable from the viewpoint of ease of spinning and ease of dissolution and removal. . Further, it is preferable to mix a small amount of a different type of polymer such as polyethylene glycol with the sea component in order to make it easier to split the sea component by a high-speed fluid flow. The selection of the island component and the sea component requires combinations with different solubility in the solvent, and the selection of the sea component 2 and sea component 3 may be the same or different polymers, but the solubility in the solvent is Combinations having the same gender are preferred. Island component 1 - Sea component 2 - Sea component 3
Preferred combinations include nylon 6 - polystyrene (including copolymers) - polystyrene (including copolymers), polyethylene terephthalate (including copolymers) - polystyrene (including copolymers) - polystyrene (copolymers). Examples include, but are not limited to, polybutylene terephthalate-polystyrene (including copolymers)-polystyrene (including copolymers). The number of island components that form the primary fiber bundle depends on which multicomponent fiber manufacturing method is selected, and variable conditions such as the design of the die, the number of elements in the fluid mixer, and the island ratio in the blend. control is possible. A large number of fibers (at least 5 or more) is required, but the larger the number, the thinner the thickness, the more dense the grain structure formed by fibrillation, and the more dense the naps are, so it is preferable. From this point of view, the method using the special fluid mixer described above is particularly preferable because it is easy to use a very large number of Shimamotos. The number of primary fiber bundles forming the secondary fiber bundle can be controlled by how many channels are provided for the confluence of the island component and the sea component 2, and is preferably 5.
More than one book is used. There is no particular limit on the upper limit, but there is a limit depending on the manufacturing precision of the cap. The thickness of the island component needs to be ultra-fine, 0.2 denier or less, preferably 0.15 denier or less, in order to achieve the object of the present invention. As a result, if thick fibers are used, even if a silver surface can be formed by fibrillation and entanglement, the smoothness and density will be poor, and the raised quality of the suede-like surface will be poor. It is not possible to obtain a sheet with FIG. 4 shows a preferred concept of the sheet-like article of the present invention, which is formed by intertwining fibrils of ultrafine fibers, primary fiber bundles, and secondary fiber bundles as described above.
That is, the primary fiber bundle 5 made up of a large number of ultra-fine fibers is fibrillated into ultra-fine fibers near the surface, and is tightly intertwined to form a dense grain layer 4.
A plurality of primary fiber bundles 5 are further bundled toward the back surface to form a secondary fiber bundle 6, and the entire fiber bundle has an entangled structure. Further, the secondary fiber bundle is opened to form a raised nap 7, which becomes a raised nap surface. It is also preferable to have a structure in which a resin is attached to such a basic structure, particularly a structure in which the resin is present at least on the surface, in a portion near the surface, or in a void inside the sheet. In particular, it is preferable that it exists in a form surrounding ultra-fine fibers or fiber bundles. Of course, FIG. 4 is just one conceptual diagram, and even though the relative relationship between the fibrillated entangled structure 4, the primary fiber bundle 5, and the secondary fiber bundle 6 is as shown, the ratio relationship in the thickness direction may change. There is no problem at all.
Since this structure relationship is caused by the jetting process of high-speed fluid flow, the structures 4, 5, and 6 may be locally mixed and entangled, but within the range where the effects of the present invention can be obtained. There is nothing wrong with that. There are roughly two methods for obtaining the silvered leather-like sheet material of the present invention having such a structure. The first method is to cut the multi-component fibers mentioned above to an appropriate length and use them as staple fibers, such as open cotton, carded fibers, etc.
A sheet-like web is formed through the process of web formation, and then entangled with a needle punch to obtain a nonwoven fabric sheet.A high-speed fluid stream is sprayed from one side of the nonwoven fabric to split the sea component and expose the exposed ultrafine fiber bundles. After that, the sea component of the multicomponent fiber is dissolved and removed using a solvent for the sea component and a non-solvent liquid for the island component.
Next, the surface treated with the high-speed fluid flow is pressed or pressed, and the surface not treated with the high-speed fluid flow is buffed to form the sheet-like product of the present invention. Alternatively, the sea component dissolving step and the embossing or pressing step may be reversed. Conventional artificial leather manufacturing techniques may be freely combined between these main steps depending on the desired quality design of the leather sheet. That is, shrinkage of the nonwoven fabric is performed before or after high-speed fluid flow treatment, and a resin liquid such as a polyurethane elastomer is applied after high-speed fluid flow treatment, and the resin is applied around the fibers or fiber bundles by wet coagulation or dry coagulation. It is possible to combine techniques such as subjecting both sides of a thick non-woven fabric to a high-speed fluid flow treatment followed by slicing in an appropriate step, or applying an appropriate resin before embossing or pressing. Part 2 is the same as in Part 1, after making an entangled nonwoven fabric by needle punching, one side is attached to a sheet in which the sea component has been dissolved and removed using a liquid that is a solvent for the sea component of the multicomponent fiber and a non-solvent for the island component. A high-speed fluid stream is ejected from the surface to fibrillate and entangle the ultrafine fiber bundles on the surface to form a sheet with a dense surface.The surface treated with the high-speed fluid stream is then embossed or pressed, and the surface treated with the high-speed fluid stream is then treated with a high-speed fluid stream. In this method, the untreated surface is buffed to form the sheet-like product of the present invention. Similar to Part 1, this method can also be freely combined with existing artificial leather techniques. In other words, shrinking the nonwoven fabric, applying a temporary fixing polymer such as polyvinyl alcohol before removing the sea component and removing it by extraction in a subsequent appropriate process, and applying the temporary fixing polymer and/or after high-speed fluid flow treatment. Applying a resin such as polyurethane elastomer, wet coagulation or dry coagulation, then extracting and removing the temporary fixing polymer, applying an appropriate resin before embossing or pressing,
Techniques such as high velocity fluid flow treatment on both sides followed by slicing in a suitable step can be used. In addition, in this method, it is also possible to perform high-speed fluid flow treatment both before and after removing the sea component in order to improve the dimensional stability during the removal of the sea component. That is, in order to obtain the sheet-like product of the present invention that can be used on both the front and back sides, a high-speed fluid flow jetting treatment and a high-speed fluid flow jetting treatment are performed to form the structure of the ultrafine fiber fibrillated entangled structure, the primary fiber bundle, and the secondary fiber bundle. Dissolving and removing sea components is important, especially the method of spraying high-speed fluid flow. Although water is most preferable as the fluid used for high-speed fluid flow, organic solvents, aqueous solutions of alkalis, acids, etc. may also be used depending on the purpose. The fluid is pressurized by a high-pressure pump and is injected from a nozzle with a small diameter or narrowly spaced slits, and is applied to the surface of the nonwoven fabric sheet as a high-speed columnar flow or curtain flow. In method 1, where a sea component is present, relatively high pressure conditions are required because both the splitting of the sea component and the fibrillation of the ultra-fine fibers are required, and the pressure is in the range of about 70 to 300 kgcm2 . is preferred. On the other hand, in the second method in which no sea component is present, splitting of the sea component is not necessary, so a relatively low pressure condition is sufficient and a favorable range is about 5 to 100 kg/cm 2 . In order to avoid the impact locus caused by the spray abutment, it is effective to move the jet nozzle and the sheet relatively, to increase the number of passes, or to use a pulsed flow. By spraying such a high-speed fluid flow, the fiber structure, which was initially composed of only secondary fiber bundles, is divided into primary fiber bundles in the areas near the surface that is easily affected by the spray, and the surface that is directly exposed to the liquid pressure is divided into primary fiber bundles. In the vicinity of the surface, the primary fiber bundle is further divided to form ultrafine fibers into fibrils, and the fibrils are intertwined to form an extremely dense surface, which can be made into a grain surface by subsequent embossing or pressing. On the other hand, the surface of the secondary fiber bundle is opened and raised by buffing, resulting in a suede-like surface. The conditions for embossing or pressing may be determined based on the characteristics of the fiber material and resin material, and are not particularly limited.
It is usually carried out at a temperature of 100 to 250°C and under pressure. When applying a suitable resin before embossing or pressing, polyurethane resins, vinyl chloride resins, polyvinyl butyral resins, polyacrylic acid resins, polyamino acid resins, silicone resins, and mixtures or copolymers thereof are used. The sheet-like product of the present invention, which can be used on both the front and back sides, obtained as described above is subjected to high-order processing such as coating with finishing resin, dyeing, water repellent treatment, and rubbing to improve its quality and increase its commercial value. It can be applied to various applications where natural leather is used, such as clothing, shoes, and materials. In this case, it goes without saying that an unprecedented design can be created by freely using the silver-like surface and the raised-like surface. The present invention will be explained in detail below with reference to Examples. All parts and percentages are by weight. Example 1 Using a sea-island type multi-component fiber spinneret disclosed in JP-A-54-125718, the island component was polyethylene terephthalate and the sea component was polystyrene (island/sea ratio 60/4).
0), a multicomponent fiber with a cross section in which 16 islands exist in the sea component, and 16 islands are gathered together to form a single polystyrene sea (island/total sea ratio). = 48/52), and a staple fiber of 3.8 denier x 51 mm was obtained through the steps of stretching 2.5 times, crimping, and cutting. One island component was an ultra-fine fiber of 0.007 denier. Open this staple fiber, card,
It was made into a non-woven fabric through the steps of cross wrapping and needle punching. From an injection nozzle in which holes with a diameter of 0.1 mm are lined up in a row at intervals of 0.6 mm on one side of the nonwoven fabric,
3. Spraying a columnar water stream at a pressure of 100Kg/ cm2
It was repeated several times and then dried. Next, a 15% dimethylformamide solution of polyester-based polyurethane was impregnated from the side not sprayed with water, and after wet coagulating with water, the dried sheet was coated with 2-component polyurethane at 4 g/m 2 using a gravure coater, and the leather was coated at 160°C. It was embossed with an emboss roll with a pattern carved into it to give it a silver surface, and then treated with trichlorethylene to remove the sea component of the multicomponent fiber. Furthermore, the back side was buffed with 150 mesh sandpaper to create a raised surface, and then a polyurethane finish containing pigment was applied to the silver surface at 2 g/m 2 using a gravure coater.
The material was rubbed and dyed in a high-temperature dyeing machine at 120° C. for 1 hour to obtain a sheet product of the present invention with a silver-like appearance on one side and a raised-like appearance on the other side. When we observed the nonwoven fabric after the columnar water treatment using a scanning electron microscope, we could clearly see that the ultra-fine fibers were fibrillated and entangled on the surface, and then a primary fiber bundle of 16 ultra-fine fibers was visible, and below that was a The primary fiber bundles were further bundled into an entangled layer consisting mainly of secondary fiber bundles. Furthermore, one surface of the finished sheet is a silver surface where the fibers fibrillated by embossing and the resin surrounding them are integrated, and below that is a primary fiber bundle and a porous polyurethane part, and then a secondary fiber bundle and a porous polyurethane part. It was observed that the fiber bundles and polyurethane porous layer continued to the back side. The other side had a suede-like surface with dense, elegant naps, and the naps were continuous with the secondary fiber bundles. The silver surface of the obtained sheet material according to the present invention is
The embossed texture and the random texture caused by rubbing during dyeing are appropriately mixed to create a high-quality surface appearance similar to the silver surface of natural leather, while the raised surface has a natural deerskin-like suede appearance. It has an elegant appearance, making it suitable as a reversible material. Example 2 In the apparatus of JP-A No. 54-125718, the fluid mixer described in JP-B No. 53-36182 is used as a part of the mechanism in which one island component flow is divided into a plurality of parts or more and merges with other island component flows. A spinning device using 10 stacked elements (inner diameter 10 mm) was fabricated, and the spinning device was used to combine the flow of nylon 6 and the flow of polystyrene so that the nylon 6/polystyrene ratio was 50/50. The polymer flow introduced into the fluid mixer, merged and split, is divided into 16 streams, and these 16 streams are further divided into 1 stream.
The multicomponent fiber of the present invention was obtained by a method of coating with a sea of polystyrene so that the ratio of nylon 6/total polystyrene was 40/60. The cross-section of the multicomponent fiber had a sea-island structure in which about 400 fine islands of nylon 6 were surrounded by a sea of polystyrene, and then 16 islands were gathered together to form a sea-island structure surrounded by a sea of polystyrene. . One of the island components of the 6 denier x 51 mm staple was an ultra-fine fiber with an average size of 0.0004 denier. This staple fiber was made into a nonwoven fabric through carding, cross wrapping, and needle punching processes. 5 on the nonwoven fabric
% polyvinyl alcohol aqueous solution was applied, dried and shrunk, and then treated with perchlorethylene to dissolve and remove the sea component of the multicomponent fiber. Next, after removing polyvinyl alcohol by showering hot water, a columnar water stream was sprayed on both sides three times at a pressure of 60 kg/cm 2 from an injection nozzle with holes 0.1 mm in diameter arranged in a row at 0.6 mm intervals. Dry. followed by 10%
After impregnating the sheet with a polyurethane emulsion solution and drying it, the sheet was divided into two sheets by slicing, and the water-treated surface of each sheet was coated with 5 g/ m2 of polyurethane using a gravure coater, and a leather-like grain was carved at 150℃. Emboss with an embossing roll, buff the side that has not been treated with water jets to create a raised surface, then dye with a metal-containing dye at 100℃ for 1 hour, then rub with a tumbler. A sheet-like product of the present invention was thus obtained. When the nonwoven fabric after columnar water treatment was observed with a scanning electron microscope, it was found that Example 1
Similar to the present invention example, the surface has ultra-fine fibers fibrillated and entangled, and then a single layer of ultra-fine fibers bundled together.
The structure was a secondary fiber bundle in which 16 primary fiber bundles were bundled together. The entangled state of the ultrafine fibers on the surface was even more dense than that observed in Example 1. For finished sheet-like products, polyurethane is attached to such a fiber structure, and one surface has a structure in which the ultra-fine fibers and the surrounding polyurethane resin are integrated by embossing to form a silver surface. I was getting used to it. Other surfaces are 2
It had a suede-like surface with dense raised fibers made of opened fiber bundles. The silver surface of the resulting sheet of the present invention has a moderate mix of embossed grains and random textured grains created by tumbler rolling, giving it a high-quality sheepskin-like surface appearance. It had an elegant appearance similar to high-quality calf suede, and was suitable for reversible materials. Example 3 Using the spinning method used in the invention examples of Example 1 and Example 2 and the spinning method described in Japanese Patent Publication No. 47-37648, the multicomponent of the present invention was prepared using the raw materials and component ratios shown in Table 1. A fiber was obtained. These fibers are used to create a non-woven fabric through the carding, cross-wrapping, and needle-punching processes, and then one side of the non-woven fabric has a diameter
It was dried by spraying a high-speed columnar water stream at a pressure of 100 Kg/cm 2 from a spray nozzle with 0.1 mm holes arranged at 0.6 mm intervals, and the sea components were dissolved and removed using trichlorethylene. Furthermore, the same spraying process is carried out at a pressure of 70
Kg/cm 2 , apply on the same surface as previously sprayed, and after drying, apply polyurethane solution with a gravure coater, embossing with a 170℃ embossing roll, and buff the surface with sandpaper. After that, Examples 4 and 5 were subjected to jet dyeing at 120° C. for 1 hour, and Example 6 was jet dyed at 100° C. for 1 hour.
The obtained sheet-like product of the present invention consists of a grain layer formed by integrating a fibrillated entanglement of ultra-fine fibers and a polyurethane resin surrounding it, as in Examples 1 and 2, and then a layer of ultra-fine fibers. A primary fiber bundle that is bundled together, a secondary fiber bundle that is further bundled by the primary fiber bundle,
The fibers had a structure of dense naps that were opened from secondary fiber bundles. These sheet-like products of the present invention have a silver surface with a natural surface appearance similar to natural leather, with a moderate mix of embossed grains created by embossing rolls and grains created by the rubbing action of jet dyeing. ,
It had a deerskin-like raised surface on the front and back, and achieved the object of the present invention. 【table】
第1図、第2図および第3図は本発明で用い得
る多成分系繊維1本の断面図である。第4図は本
発明のシート状物の断面概念図である。
FIGS. 1, 2, and 3 are cross-sectional views of one multicomponent fiber that can be used in the present invention. FIG. 4 is a conceptual cross-sectional view of the sheet-like product of the present invention.
Claims (1)
の表面が立毛調表面となつているシート状物質に
おいて、0.2デニール以下の超極細繊維、該超極
細繊維が多数本集まつた超極細繊維束(1次繊維
束と称する)、および該1次繊維束がさらに多数
本集まつた繊維束(2次繊維束と称する)から主
としてなる繊維質シートであつて、シートの厚み
方向に対し、1次繊維束から枝分れした超極細繊
維がフイブリル化絡合した構造を主体とする銀面
調表面から1次繊維束が主として絡合した構造を
経て、さらに2次繊維束が主として絡合した構造
に至り、遂には2次繊維束から開繊された立毛に
よつて主として覆われた立毛調表面となつている
ような表面および断面構造を有することを特徴と
する表裏両面使用可能なシート状物質。 2 少なくとも銀面調表面および/またはシート
内部の空隙部分に樹脂が存在することを特徴とす
る特許請求の範囲第1項に記載の表裏両面使用可
能なシート状物質。 3 少なくとも下記○イ〜○ホの各工程を組み合わせ
ることを特徴とする表裏両面使用可能なシート状
物質の製造方法。 ○イ 少なくとも2種の高分子物質からなる海島型
繊維であつて、多数の島成分と海成分とからな
る海島構造の複数個が更に1個の海に囲まれて
おり、全海成分除去後は、0.2デニール以下の
超極細繊維が多数本集まつてなる超極細繊維束
(1次繊維束)が更に複数本集まつて2次繊維
束を形成するような構造の多成分系繊維が三次
元絡合した構造を有する繊維質シートを得る工
程。 ○ロ 繊維質シートの少なくとも一方の表面に高速
の流体流を噴き当てる工程。 ○ハ 多成分系繊維の海成分を、溶解または分解除
去する工程。 ○ニ 流体流を噴き当てた一の面を型押し、もしく
はプレスする工程。 ○ホ 型押し、もしくはプレスをした面と逆の面を
バフして超極細繊維の立毛表面とする工程。[Claims] 1. A sheet-like material in which one surface has a silver-like surface and the other surface has a raised-like surface, ultrafine fibers of 0.2 denier or less, and a large number of the ultrafine fibers. A fibrous sheet mainly consisting of an assembled ultra-fine fiber bundle (referred to as a primary fiber bundle) and a fiber bundle in which a larger number of the primary fiber bundles are assembled (referred to as a secondary fiber bundle), In the thickness direction of the sheet, from the silvery surface, which is mainly composed of a structure in which ultrafine fibers branched from a primary fiber bundle are fibrillated and entangled, the primary fiber bundle passes through a structure in which the primary fiber bundles are mainly entangled, and then further It is characterized by having a surface and cross-sectional structure in which the secondary fiber bundles reach a structure in which they are mainly entangled, and finally become a raised-like surface mainly covered with raised fibers opened from the secondary fiber bundles. A sheet material that can be used on both sides. 2. A sheet-like material that can be used on both the front and back sides according to claim 1, characterized in that a resin is present at least on the grain-like surface and/or in the voids inside the sheet. 3. A method for producing a sheet-like material that can be used on both sides, characterized by combining at least the following steps ○I to ○E. ○B A sea-island type fiber made of at least two types of polymeric substances, in which a plurality of sea-island structures made of a large number of island components and a sea component are further surrounded by one sea, and after all sea components are removed, is a tertiary multi-component fiber with a structure in which a large number of ultra-fine fibers of 0.2 denier or less are gathered together (primary fiber bundle), which are further gathered together to form a secondary fiber bundle. A process of obtaining a fibrous sheet with a pre-entangled structure. ○B A process of spraying a high-speed fluid stream onto at least one surface of the fibrous sheet. ○C Process of dissolving or decomposing and removing the sea components of multi-component fibers. ○D A process of embossing or pressing one side onto which a fluid stream has been applied. ○E Process of buffing the opposite side of the embossed or pressed side to create a raised surface of ultra-fine fibers.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP57153827A JPS5943158A (en) | 1982-09-06 | 1982-09-06 | Sheet substance capable of using front and back surfaces and production thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP57153827A JPS5943158A (en) | 1982-09-06 | 1982-09-06 | Sheet substance capable of using front and back surfaces and production thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS5943158A JPS5943158A (en) | 1984-03-10 |
| JPS62259B2 true JPS62259B2 (en) | 1987-01-07 |
Family
ID=15570950
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP57153827A Granted JPS5943158A (en) | 1982-09-06 | 1982-09-06 | Sheet substance capable of using front and back surfaces and production thereof |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS5943158A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2005226213A (en) * | 2004-01-14 | 2005-08-25 | Toray Ind Inc | Method for producing leather-like sheet |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0381392U (en) * | 1989-12-11 | 1991-08-20 | ||
| CN105593432B (en) * | 2013-09-30 | 2019-05-31 | 可乐丽股份有限公司 | Fleece-like artificial leather and method for producing the same |
-
1982
- 1982-09-06 JP JP57153827A patent/JPS5943158A/en active Granted
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2005226213A (en) * | 2004-01-14 | 2005-08-25 | Toray Ind Inc | Method for producing leather-like sheet |
Also Published As
| Publication number | Publication date |
|---|---|
| JPS5943158A (en) | 1984-03-10 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US4476186A (en) | Ultrafine fiber entangled sheet and method of producing the same | |
| JPS6152274B2 (en) | ||
| TWI422728B (en) | Substrate for artificial leather and producing method thereof | |
| US4741075A (en) | Composite sheet and method of producing same | |
| JPS62259B2 (en) | ||
| JPS6229548B2 (en) | ||
| JPH0367147B2 (en) | ||
| JP2007262616A (en) | Manufacturing method of nubuck-like artificial leather | |
| JPH0316427B2 (en) | ||
| JP3409554B2 (en) | Leather-like sheet and method for producing the same | |
| JPS622075B2 (en) | ||
| JP3391885B2 (en) | Leather-like sheet and its production method | |
| JPH0424466B2 (en) | ||
| JPS6024227B2 (en) | Sheet material that can be used on both sides and its manufacturing method | |
| JPS6323317B2 (en) | ||
| JPS6157433B2 (en) | ||
| JPS6043464B2 (en) | Manufacturing method for leather-like sheet material | |
| JPH0138914B2 (en) | ||
| JPS6045625A (en) | Nonwoven yarn having interlaced layer | |
| JPH0694629B2 (en) | Method for manufacturing flexible leather-like sheet | |
| JPS6075680A (en) | Manufacture of leathery sheet having silver layer | |
| JPS6139437B2 (en) | ||
| JPS6238470B2 (en) | ||
| JPS6238475B2 (en) | ||
| JPH0138917B2 (en) |