US-12617911-B2 - Artificial leather for crash pads and crash pads manufactured using the same

Abstract

Disclosed are an artificial leather for crash pads and a crash pad manufactured using the same. The artificial leather for crash pads may have improved workability when workers directly cover a crash pad with the artificial leather for crash pads and require reduced manufacturing costs by using a textile substrate layer made of a circular knit fabric that satisfies a specific physical property range.

Inventors

• Jin Gi Ahn
• De Eun Park
• Jung Gyun Noh
• Kyeong Hoon Jang
• Dae Sik Kim
• Sung Moo LEE
• Dong Seog Noh
• Yong Bae Jung
• Chang Hoon Lee
• Kyung Hak Kang

Assignees

• HYUNDAI MOTOR COMPANY
• KIA CORPORATION
• LX HAUSYS, LTD.
• TAS FL
• YONG SAN CO., LTD.

Dates

Publication Date

20260505

Application Date

20221010

Priority Date

20211203

Claims (14)

1. 1 . An artificial leather for crash pads consisting essentially of: a textile substrate layer; a wet foaming layer disposed on the textile substrate layer; and an upper layer disposed on the wet foaming layer, wherein the textile substrate layer comprises a circular knit fabric and a polyurethane composite resin, wherein the circular knit fabric has an elongation in a longitudinal direction (L) of about 30 to 80% and an elongation in a width direction (W) of about 50 to 140% at a temperature of about 20 to 30° C., and wherein the circular knit has a tensile strength in the longitudinal direction (L) of about 20 to 70 kgf/cm and a tensile strength in the width direction (W) of about 20 to 50 kgf/cm at a temperature of about 20 to 30° C.
2. 2 . The artificial leather according to claim 1 , wherein the circular knit fabric is impregnated with the polyurethane composite resin.
3. 3 . The artificial leather according to claim 1 , wherein the circular knit comprises yarns having a thickness of about 100 to 150 denier.
4. 4 . The artificial leather according to claim 1 , wherein the circular knit comprises yarns comprising one or more selected from the group consisting of natural fibers, synthetic fibers, and regenerated fibers.
5. 5 . The artificial leather according to claim 1 , wherein the polyurethane composite resin comprises a polyurethane resin, wherein the polyurethane resin comprises one or more selected from the group consisting of polycarbonate-based polyurethane resins, polyester-based polyurethane resins, and polyether-based polyurethane resins.
6. 6 . The artificial leather according to claim 5 , wherein the polyurethane composite resin further comprises an additive, and the polyurethane composite resin comprises the additive in an amount of about 30 to 150 parts by weight, based on 100 parts by weight of the polyurethane resin.
7. 7 . The artificial leather according to claim 6 , wherein the additive comprises one or more selected from the group consisting of calcium carbonate, flame retardants, surfactants, and toners.
8. 8 . An artificial leather for crash pads consisting essentially of: a textile substrate layer; a wet foaming layer disposed on the textile substrate layer; an upper layer disposed on the wet foaming layer; and a napped layer on at least one surface of the textile substrate layer, wherein the textile substrate layer comprises a circular knit fabric and a polyurethane composite resin, wherein the circular knit fabric has an elongation in a longitudinal direction (L) of about 30 to 80% and an elongation in a width direction (W) of about 50 to 140% at a temperature of about 20 to 30° C., and wherein the circular knit has a tensile strength in the longitudinal direction (L) of about 20 to 70 kgf/cm and a tensile strength in the width direction (W) of about 20 to 50 kgf/cm at a temperature of about 20 to 30° C.
9. 9 . The artificial leather according to claim 8 , wherein the napped layer comprises fibers having a thickness of about 0.6 to 0.8 mm.
10. 10 . An artificial leather for crash pads consisting essentially of: a textile substrate layer; a wet foaming layer disposed on the textile substrate layer; an upper layer disposed on the wet foaming layer; and a non-napped layer on at least one surface of the textile substrate layer, wherein the textile substrate layer comprises a circular knit fabric and a polyurethane composite resin, wherein the circular knit fabric has an elongation in a longitudinal direction (L) of about 30 to 80% and an elongation in a width direction (W) of about 50 to 140% at a temperature of about 20 to 30° C., and wherein the circular knit has a tensile strength in the longitudinal direction (L) of about 20 to 70 kgf/cm and a tensile strength in the width direction (W) of about 20 to 50 kgf/cm at a temperature of about 20 to 30° C.
11. 11 . The artificial leather according to claim 10 , wherein the non-napped layer comprises a polyurethane resin impregnated with ester fibers.
12. 12 . The artificial leather according to claim 1 , wherein the upper layer comprises: a binder layer; a skin layer disposed on the binder layer; and a surface treatment layer disposed on the skin layer.
13. 13 . A crash pad comprising the artificial leather for crash pads according to claim 1 .
14. 14 . A vehicle comprising a crash pad of claim 13 .

Description

CROSS-REFERENCE TO RELATED APPLICATION This application claims under 35 U.S.C. § 119(a) the benefit of priority to Korean Patent Application No. 10-2021-0171459, filed on Dec. 3, 2021, the entire contents of which are incorporated herein by reference. TECHNICAL FIELD The present invention relates to an artificial leather for crash pads, a crash pad including the artificial leather, and a vehicle including the crash pad. The artificial leather for crash pads may have improved workability when workers directly cover a crash pad with the artificial leather for crash pads and require reduced manufacturing costs using a textile substrate layer made of a circular knit fabric that satisfies a specific physical property range. BACKGROUND A vehicle interior component called a “crash pad” is installed underneath the windshield, and is manufactured so as to attach thereto an instrument panel that is integrated with various instruments such as a speedometer and a fuel gauge, as well as audio and navigation systems and the like. For example, the crash pad includes a textile substrate layer made of polyurethane that absorbs shocks and exhibits a buffering property for safety, and a skin layer that exhibits various patterns thereon. A typical crash pad includes a product that includes a textile substrate layer, the surface of which is treated by spraying. However, the method has a limitation of difficulty achieving various surface patterns, and also has disadvantages such as difficulty in realizing a luxurious interior vehicle atmosphere, such as a highly classy texture. In recent years, a crash pad covered with natural leather has been developed in order to achieve a highly sophisticated texture and a luxurious interior atmosphere in a vehicle. Natural leather can create a much more luxurious interior atmosphere, but varies greatly depending on the age or area of the cow due to the nature of natural leather materials generally manufactured from cowhide, and are prone to wrinkling, shrinkage, and deformation depending on the management method. In addition, natural leather is entirely dependent on imports and is very expensive, thus being limited to high-end cars and having a limitation on expansion of application thereof to a greater variety of vehicle models. Accordingly, there is increasing need to develop artificial leather that exhibits various functionalities and excellent physical properties while exhibiting a feel, texture, and appearance comparable to natural leather, and a crash pad using the same. A generally used method of manufacturing artificial leather for automobile interior materials includes applying a water-dispersible urethane resin or an organic solvent-type urethane solution containing an organic solvent such as dimethylformamide or methyl ethyl ketone onto release paper, drying the resulting paper to form a film of a surface layer, applying an adhesive agent onto the surface layer, crosslinking and curing the result, and laminating the result with a textile substrate such as a short fiber-type microfiber nonwoven fabric or woven fabric. However, this method has a problem in that a lot of wrinkles are generated when applied as a covering material for crash pads because only the surface coating layer of water-dispersible urethane is formed on the textile substrate, such as a short-fiber nonwoven fabric or woven fabric having a relatively low density. The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention, and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art. SUMMARY In preferred aspect, provided is an artificial leather for crash pads that makes it easy for workers to cover a crash pad with the artificial leather for automobile crash pads and reduces manufacturing costs by forming a textile substrate layer with a circular knit fabric that is impregnated with a polyurethane composite resin and satisfies a specific physical property range. Further, in preferred aspects, provided is an artificial leather for crash pads that is capable of improving the emotional quality without damaging the appearance, and satisfying airbag deployment test criteria by forming a textile substrate layer with a circular knit fabric impregnated and coated with a polyurethane composite resin and satisfying a specific physical property range. In another preferred aspect, provided is a crash pad including the artificial leather for crash pads. The objects of the present invention are not limited to those described above. Other objects of the present invention will be clearly understood from the following description, and are able to be implemented by means defined in the claims and combinations thereof. In one aspect, provided is an artificial leather for crash pads including a textile substrate layer, a wet foaming layer disposed on the textile substra