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KR-20260067871-A - ARTIFICIAL LEATHER AND METHOD FOR MANUFACTURING THE SAME

KR20260067871AKR 20260067871 AKR20260067871 AKR 20260067871AKR-20260067871-A

Abstract

The present invention relates to artificial leather and a method for manufacturing the same. According to the present invention, artificial leather having excellent appearance and tactile feel, as well as improved wear resistance and durability, and a method for manufacturing the same are provided.

Inventors

  • 정대영
  • 유혁재
  • 이영일

Assignees

  • 코오롱인더스트리 주식회사

Dates

Publication Date
20260513
Application Date
20241106

Claims (15)

  1. An entanglement layer comprising a nonwoven fabric in which ultrafine fibers are entangled three-dimensionally and a first polymer elastomer impregnated on the nonwoven fabric, and It comprises a hair layer including a plurality of hairs formed by napping at least a portion of the microfibers located on one surface of the above-mentioned interlocking layer; A second polymer elastomer is provided at the boundary portion between the above entanglement layer and the above mower layer and on the pores of the above entanglement layer, and A softening agent is applied to the surface of the above-mentioned fibers, Artificial leather.
  2. In Article 1, Artificial leather, wherein the boundary portion between the above-mentioned interlocking layer and the above-mentioned fiber layer is an area from the boundary surface between the above-mentioned interlocking layer and the above-mentioned fiber layer to a height of 5% or less of the total thickness of the above-mentioned fiber layer.
  3. In Article 1, Artificial leather having a thickness ratio of 1:0.1 to 1:0.5 (interlocking layer:fuzzing layer) between the interlocking layer and the fuzz layer.
  4. In Article 1, The above-mentioned fur layer has a thickness of 0.1 to 0.5 mm, artificial leather.
  5. In Article 1, The above ultrafine fibers are artificial leather having a fineness of 0.01 to 0.3 denier.
  6. In Article 1, The above nonwoven fabric is an artificial leather having an apparent density of 0.175 to 0.250 g/ cm³ .
  7. In Article 1, The first polymer elastomer is impregnated at 15 to 35 weight percent based on the total weight of the artificial leather, and The second polymer elastomer is provided in an amount of 0.3 to 3 weight percent based on the total weight of the artificial leather, Artificial leather.
  8. In Article 1, Artificial leather, wherein the first polymer elastomer and the second polymer elastomer are each independently one or more resins selected from the group consisting of polyurethane resin, polyurea resin, and polyacrylic acid resin.
  9. In Article 1, The above softener is an artificial leather comprising one or more silicone compounds selected from the group consisting of polydimethylsiloxane, polymethylhydrosiloxane, epoxy-modified silicone, amino-modified silicone, and polyester-modified silicone.
  10. A step of preparing an artificial leather substrate comprising an entanglement layer and a fiber layer (wherein the entanglement layer comprises a nonwoven fabric in which ultrafine fibers are entangled three-dimensionally and a first polymer elastomer impregnated on the nonwoven fabric, and the fiber layer comprises a plurality of fibers formed by napping at least a portion of the ultrafine fibers located on one surface of the entanglement layer); A step of impregnating a second polymer elastomer onto the artificial leather substrate; A step of removing at least a portion of the second polymer elastomer impregnated on the fur layer of the artificial leather substrate; and Step of applying a softening agent to the surface of the hairs of the hair layer from which at least a portion of the second polymer elastomer has been removed A method for manufacturing artificial leather according to claim 1, comprising
  11. In Article 10, A method for manufacturing artificial leather, wherein the step of impregnating the artificial leather substrate with a second polymer elastomer is performed by impregnating the substrate with a solution containing the second polymer elastomer at a wet pickup rate of 50 to 100% (wherein the wet pickup rate is a value calculated by the formula [( W1 - W0 ) ÷ W0 ] × 100, where W0 is the weight (g) of the artificial leather substrate before impregnation and W1 is the weight (g) of the artificial leather substrate after impregnation).
  12. In Article 10, A method for manufacturing artificial leather, wherein the step of removing at least a portion of the second polymer elastomer impregnated on the above-mentioned fur layer is performed under a vacuum of 100 to 200 torr using a slot-type suction device equipped with a suction slot.
  13. In Article 12, A method for manufacturing artificial leather, wherein the above step involves adjusting the position of the suction slot so that the distance between the surface of the fur layer and the suction slot is 0.1 to 10 mm to remove at least a portion of the second polymer elastomer impregnated on the fur layer.
  14. In Article 10, A method for manufacturing artificial leather, wherein the step of removing at least a portion of the second polymer elastomer impregnated on the above-mentioned fur layer is performed by removing the second polymer elastomer present in a region from the surface of the above-mentioned fur layer to a depth of at least 95% of the total thickness of the above-mentioned fur layer.
  15. In Article 10, A method for manufacturing artificial leather, wherein the step of applying a softener to the surface of the above fibers is performed by spraying softener particles having a particle size of 10 to 500 μm at a spray amount of 0.05 to 0.5 kg/ m² per unit area of the fiber layer using a spray device equipped with a fine spray nozzle.

Description

Artificial Leather and Method for Manufacturing the Same The present invention relates to artificial leather and a method for manufacturing the same. Suede-like artificial leather is made by impregnating a polymer elastomer onto a nonwoven fabric in which microfibers are entangled three-dimensionally. Abrasion resistance and durability are important factors determining the quality of suede-style artificial leather. For example, when artificial leather is applied to automotive interiors, high abrasion resistance and durability are required for seat areas due to repeated entry and exit from vehicles. Additionally, suede-style artificial leather must simultaneously satisfy sensory characteristics such as appearance and tactile feel. The rich nap, comparable to that of natural leather, is one of the reasons why artificial leather is used not only in the fashion and clothing sectors but also in various industries such as furniture and automotive seats. Generally, to increase the abrasion resistance of suede-like artificial leather, measures are taken such as imparting a rigid structure to the polymer elastomer impregnated on the nonwoven fabric, increasing the impregnation amount of the polymer elastomer, or using a high-density nonwoven fabric to increase shape stability. However, while it is expected that high abrasion resistance can be imparted to artificial leather through the above measures, there is a limitation in that the unique sensory characteristics of suede are degraded, such as the length of the fibers formed on the surface of the artificial leather becoming shorter and the texture of the artificial leather becoming hard. Conversely, artificial leather designed with long fibers and a flexible texture has problems such as shedding a large amount of fibers during use, generating dust, and pilling caused by friction between fibers, resulting in inferior wear resistance and durability. Hereinafter, artificial leather according to embodiments of the invention and a method for manufacturing the same will be described in more detail. Unless explicitly stated otherwise in this specification, technical terms are used merely to refer to specific embodiments and are not intended to limit the invention. The singular forms used in this specification include plural forms unless the phrases clearly indicate otherwise. As used in this specification, the meaning of “includes” specifies certain characteristics, regions, integers, steps, actions, elements, and/or components, and does not exclude the existence or addition of other specific characteristics, regions, integers, steps, actions, elements, components, and/or groups. In this specification, terms including ordinal numbers, such as "first" and "second," are used for the purpose of distinguishing one component from another and are not limited by said ordinal numbers. For example, within the scope of the present invention, the first component may also be named the second component, and similarly, the second component may be named the first component. As used herein, "denier" is a unit of fineness based on the mass (gram) per 9,000 meters of length of a single fiber strand. For example, 1 denier can be expressed as 1 g / 9,000 m, or 0.11 mg/m, or 0.11 tex. According to one embodiment of the invention, An entanglement layer comprising a nonwoven fabric in which ultrafine fibers are entangled three-dimensionally and a first polymer elastomer impregnated on the nonwoven fabric, and It comprises a hair layer including a plurality of hairs formed by napping at least a portion of the microfibers located on one surface of the above-mentioned interlocking layer; A second polymer elastomer is provided at the boundary portion between the above entanglement layer and the above mower layer and on the pores of the above entanglement layer, and A softening agent is applied to the surface of the above-mentioned fibers, Artificial leather is provided. As a result of the inventors' research, it was confirmed that artificial leather satisfying the above compositions can have excellent appearance and tactile feel, as well as improved wear resistance and durability. In particular, the artificial leather can more firmly support the entanglement layer by providing a second polymer elastomer at the boundary between the entanglement layer and the fiber layer and in the pores of the entanglement layer, and can more firmly maintain the physical bond between the nonwoven fabric and the first polymer elastomer in the entanglement layer. Accordingly, the artificial leather can exhibit excellent wear resistance and durability even under repetitive friction environments. In addition, as a softening agent is applied to the surface of the fibers, the artificial leather can minimize the occurrence of pilling caused by friction between the fibers during use. Furthermore, by minimizing the second polymer elastomer present on the fiber layer, the artificial leather can exhibit excellent appearance an