JPH07125066A - Air permeable leather and production thereof - Google Patents

Abstract

PURPOSE:To obtain flexible air permeable leather having excellent abrasion resistance while keeping a soft feeling and air permeability by impregnating a nonwoven fabric using fibers specified in fineness with a specific amt. of a thermoplastic resin and compressing the resin impregnated nonwoven fabric to form leather specified in air permeability. CONSTITUTION:A nonwoven fabric formed by three-dimensionally entangling fibers with fineness of 0.01-10d is impregnated with 5-50% by wt. of the nonwoven fabric of a thermoplastic resin from the single surface thereof up to depth of 10-70% to mutually bond fibers. The resin impregnated fabric is compressed to obtain leather wherein the surface layer part l of the single surface thereof has leather like fine continuous patterns and air permeability is 1.0-30cc/cm<2>/sec. As fibers, filaments or staple fibers may be used and, in the case of staple fibers, the length thereof is 10mm or more, pref., 30-50mm.

Description

Detailed Description of the Invention [0001] The present invention relates to the bulkiness of nonwoven fabrics.
Breathable and abrasion resistant while maintaining a soft and warm feel
Breathable leather with excellent wear resistance and its manufacturing method
Such as interior walls, interior materials such as ceiling materials, automobiles, electric
Covering materials, bags, covers for interior parts of vehicles such as cars and ships
Good breathability that can be used as a skin material for
A preferred breathable leather and its manufacturing method. [0002] 2. Description of the Related Art At present, in automobiles, especially automobile interior materials,
PVC leather is often used. The reason is salt
Leather-like appearance of bilazer, low price, abrasion resistance, good moldability
There are some good things to do, such as the ceiling skin material for passenger cars,
It is often used in atrims and instrument panels. On the other hand, textile products have a warm texture,
It is used for ceiling skin materials because of its natural appearance. Well
In addition, although nonwoven fabric has good breathability, it has a problem in durability.
Yes Almost not used in the above applications. [0004] By the way, the aforementioned vinyl chloride
ZA has a design that is difficult to handle,
Because it is cheap to get what you see, it smells like bags and bags.
However, chlorine gas is not generated during combustion.
There are serious obstacles to environmental problems. Also ventilation
It was also unsuitable for leather applications due to its low properties. Fiber products are used for applications other than ceiling skin materials.
In the price performance of PVC leather,
Are used for some door trim ornaments.
Only In addition, the non-woven fabric has little change in pattern.
Fluffing occurs due to long-term use, and the appearance is significantly impaired.
Since it had drawbacks, it is mostly used in applications other than the above-mentioned ceiling skin material.
not being used. For that purpose, a thermoplastic resin is applied to the surface or inside.
After impregnating all parts, general engraving as shown in Fig. 4
A heat engine consisting of a rolled roll 5 and a flat roll 6.
A non-woven fabric that is crimped with a boss is also considered, but a leather-like appearance
Is not only obtained, but also has poor wear resistance.
It was The present invention solves the above-mentioned conventional problems and is flexible.
Excellent wear resistance while maintaining soft and warm feel and breathability
An object is to provide a breathable leather and a manufacturing method thereof.
It is something. [0008] The present invention solves the above problems.
In order to decide, the following measures are taken. That is,
In the present invention, fibers having a fineness of 0.01 to 10d are three-dimensionally
One side of the non-woven fabric, which is made of non-woven fabric
5 to 5% by weight of the non-woven fabric to a depth of 10 to 70%
-50% by weight of thermoplastic resin is impregnated to bind the fibers together
And the non-woven fabric is compressed, and the surface layer of the one side is
It has a fine leather-like continuous pattern and has an air permeability of 1.0.
cc / cm² / Sec to 30 cc / cm² / Sec
It is a passable leather that is characterized by being in the enclosure. The present invention also relates to a fiber of 0.01 to 10d.
Made of non-woven fabric, then three-dimensionally entangled and heat
Dissolve plastic resin with a solution viscosity of 5000-10000 cps
As a liquid, it is applied and impregnated on one side of the non-woven fabric as a fixed component.
5 to 50% by weight is applied to the non-woven fabric, and then thermocompression bonding is applied to the leather.
Made of breathable leather characterized by giving a leather-like pattern
It is a construction method. The present invention will be described in detail below. In the present invention
In addition, the thickness of the fibers that make up the non-woven fabric is
It greatly affects the air permeability of the
It is not preferable because the temper becomes too high. On the other hand, 0.01
If it is less than d, on the contrary, the air permeability becomes too small, which is preferable.
Absent. The air permeability is based on the JIS L1096A method
It is the value measured by the method. Get proper air permeability
In addition, preferably 0.01 to 5d, more preferably
0.01-3d is preferable. The length of the fiber is not limited to filament.
A table may be used, or 10 mm or less for staples
The upper limit is preferably 30 to 50 mm. [0012] The material is rayon, acetate
Cellulosic fibers like, polyester, polyamide
Such as synthetic fibers. The non-woven fabric is a so-called spunbond non-woven fabric.
Whether it is cloth or meltblown non-woven fabric, it is made of short fibers.
The needle pad can be used for three-dimensional entanglement.
Inch method, fluid such as liquid confounding method may be used. Next, the thermoplastic resin is one side of the non-woven fabric.
Impregnation to a depth of 10 to 70%, preferably 25 to 60%
The fibers are then bound together. Impregnation layer is less than 10%
And the decrease in wear resistance due to less binding between constituent fibers.
On the other hand, if it exceeds 70%, the soft feeling of non-woven fabric
Deterioration and a plastic feeling, which is undesirable
In some cases, the desired air permeability cannot be obtained. Further, as a thermoplastic resin impregnated into the non-woven fabric,
Preferably polyvinyl acetate, polyethylene, poly
Acrylic ester, rubber resin such as polyurethane, etc.
can give. In addition, plasticizers, softeners, etc. for these resins,
Alternatively, you can mix flame retardants, water repellents, pigments, etc.
Yes. It should be noted that blending with a thermoplastic resin is also acceptable.
Does not support. The thermoplastic resin is 5 to 5% by weight of the total weight of the nonwoven fabric.
It is 50% by weight, preferably 10-40% by weight. here
When the amount of the thermoplastic resin is less than 5% by weight,
Since it is not possible to bond the grown fibers together, fluff is generated on the surface of the surface layer.
Is present, which is unfavorable because it causes deterioration of wear resistance. other
On the other hand, if it exceeds 50% by weight, the softness of the nonwoven fabric is low.
It causes a lowering and gives a plastic feeling and the air permeability is remarkable.
It is not preferable because it decreases significantly. The breathable leather of the present invention has a thickness of
It is not preferable that it is 0.5 mm to 5.0 mm. 0.
If it is less than 5 mm, it becomes difficult to form the resin layer, and
Since the amount of resin is extremely small, it should have surface fluff.
Therefore, it is not preferable. On the other hand, if it exceeds 5.0 mm
Not only does it stall up, but also workability during embossing
Is inferior, which is not preferable. Note that the thickness is
Measure with a Kness gauge at 20 cm intervals for the entire width
It However, the size of the presser foot is 9 mm or less.
Above, the load is 100g / cm² And until the thickness subsides
Leave for an appropriate time (normally about 10 seconds). The basis weight is 50 g / m.² ~ 400g /
m² Is preferred. Weight is 50g / m ² Aeration when less than
Which leads to a decrease in the tensile strength of the synthetic leather and the interior of automobiles, etc.
It is preferable because it cannot be used for daily life materials such as materials, bags, bags, etc.
Not good. On the other hand, 400 g / m² Cost is exceeded
Is preferable because it leads to deterioration in the workability during embossing.
Not good. The basis weight (g / m² ) Is the size of the sample 1
mx 1m, take one per 1m width, and reach water balance
And the mass was measured. The surface layer on one side of the breathable leather of the present invention
As shown in the sectional view of FIG. 1 and the perspective view of FIG.
A thermoplastic resin with a fine leather-like continuous pattern on the surface of
Is impregnated. Further, the air permeability is 1.0 cc / cm.² /
sec to 30 cc / cm² / Sec range. Ventilation
Degree is 1.0 cc / cm² Permeability is less than / sec
Low and not suitable as breathable leather, 30cc / c
m² If it exceeds / sec, there is too much breathability and a warm feel.
It is lost, which is not preferable. Also, because of the reduced wear resistance
Is not desirable. Here, a method for manufacturing breathable leather is explained.
Reveal First of all, a fiber made of fibers having a fineness of 0.01 to 10 d
Manufacture woven fabric and make it into needle punch or water punch
The non-woven fabric is three-dimensionally entangled. Then, the thermoplastic tree
Dissolve fat and solution viscosity 5000 to 10000 cpa, preferred
Or 6000-9000 cps solution
Apply on one side of the cloth. Application is preferably twice or more
It When the solution viscosity is less than 5000 cps, the impregnation property is improved.
Since it goes up, the back side is also impregnated with thermoplastic resin, and the texture is hard.
It becomes unfavorable. On the other hand, the solution viscosity is 10,000 cp
If it exceeds s, uneven coating is likely to occur and impregnation
Without doing so, it becomes a surface coat and the air permeability decreases significantly, which is preferable.
Absent. The number of times of coating is preferably one or more.
3 times or more. When the number of applications is small, the surface of the application surface
The surface is likely to be uneven, leading to poor appearance.
Not good. [0023] The non-woven fabric is applied and impregnated to the non-woven fabric as a fixed amount
5 to 50% by weight, preferably 10 to 40% by weight
Let If it is less than 5% by weight, the bonding between the constituent fibers will be reduced.
Since it cannot be done, fluff is present on the surface of the surface layer and wear resistance is low.
If it exceeds 50% by weight, it causes non-woven fabric.
When the soft feel of the
At the same time, the air permeability is significantly lowered, which is not preferable. Further, for embossing as shown in FIG.
Heat the non-woven fabric impregnated with the thermoplastic resin with a roll pair.
Crimp. Fig. 3 is a steel carved with a leather pattern
The roll 3 and the leather-like pattern and the unevenness are reversed to form a pair.
And the paper roll 4 that is completely fitted together.
The partial expanded sectional view of a roll pair for boss processing is shown. The page
The par roll 4 takes the pattern of the steel roll 3 over time.
It is made by imprinting on paper and both are completely fitted.
With such an embossing roll, the pressure is
Not only does it tend to spread evenly over the entire surface, the entire surface of the non-woven fabric
The surface is bound by the thermoplastic resin and must not have fluff.
It will be. However, if the unevenness is too deep as mentioned above,
Too much pressure is applied to the convex portion (Fig. 3) of the steel roll 3,
On the contrary, the pressure applied to the concave part of the paper roll (the convex part of the nonwoven fabric)
Insufficient binding between fibers due to thermoplastic resin
And the uniformity of the appearance is inferior, which is not preferable. Such perspective
The linear pressure is preferably 50 Kg / cm to 150 Kg / cm
Good It is better that the temperature of the embossing roll is higher.
However, it is preferably higher than the softening point of the thermoplastic resin.
Yes. In addition, low melting point fiber to further improve wear resistance
It is also possible to mix up to 10% by weight. 10
If the content exceeds 10% by weight, color matching becomes difficult and moldability decreases.
And low melting point fibers are fused to make it paper-like and gloss
It is not desirable because it comes out and the leather-like appearance becomes inferior in uniformity.
Yes. [0026] 【Example】 Example 1 Regular polyester stay with 3d x 51mm cut
160g / m using pull² Create a web of
150g / m by three-dimensionally interlacing with a needle punch² of
Made into a non-woven fabric. Then, the solution of polyvinyl acetate resin is viscous.
Adjusted to 8500 cps, and the amount of solids deposited on the non-woven fabric
Is 50 g / m² 3 by gravure coater
Double coated, impregnated, dried and paired with a paper roll
With a hot embossing roller (180 ° C) that has a leather-like handle
Manufacture breathable leather with pressure of 90 Kg / cm
It was The physical properties of this product are shown in Table 1. [0027] [Table 1] The physical properties of this product are breathable, and the appearance and wind
It was excellent in fitting and wear resistance. Example 2 Thickness from 1d to 4d, cut length from 20mm to 8
Polyester fiber consisting of short fibers with a length of up to 0 mm
Use, basis weight 115g / m² Create a short fiber web of
Eyes made of polyester filament with a fineness of 2d
With 65g / m²A spunbond web was created. One
The short fiber web and the spunbond web
Needle punching on top of each other
Entangled and basis weight 150g / m² A composite non-woven fabric was prepared.
Then, using the same resin solution as in Example 1, the span
The same thermal embossing as in Example 1 was applied to the bond side three times and after drying.
Breathable leather was manufactured by stamping with a roller.
The physical properties of the product are shown in Table 1. Tensile compared to Example 1
Although it had high strength, it had a slightly low elongation and a high breathability. Communication
High temper is due to the breathability of spunbond base fabric
There is. That is, short fiber webs are
Because the fiber entanglement is sparse, the resin impregnation is large.
It The appearance and texture were slightly lower than in Example 1.
It was Example 3 Create a web in the same manner as in Example 1, then design
In order to improve the in-printing property and for the purpose of coloring
Then, a dyed nonwoven fabric was obtained. Then the same conditions as in Example 1
Breathable leather by applying resin with embossed embossing
Was manufactured. The physical properties of this product are shown in Table 1. Example
Compared to 1, there is almost no difference in breathability, texture, appearance and physical properties
A subtle color of breathable leather was obtained. Example 4 A similar web was made in the same manner as in Example 1, and the same
Resin is applied to the surface, and then the thermal transfer printing is applied to improve the design.
I made a donation. Then, in this thermal transfer printing, as in Example 1.
Made of breathable leather with embossed embossing under the same conditions
I made it. The physical properties of this product are shown in Table 1. Compared to Example 1
Has become a product with no difference in breathability, texture, appearance, and physical properties.
However, breathable leather with rich design was obtained. Example 5 2d regular polyester filament
Pan-bonded non-woven fabric (Basis weight 140g / m² ) Create one
Needle punching, then entangle three-dimensionally for 130
g / m² Of a spunbonded non-woven fabric. Then the real
After applying the same resin in the same manner as in Example 4,
Perform thermal transfer printing and emboss embossing to provide breathability
Manufactured. The physical properties are shown in Table 1.
The air permeability was particularly large in comparison with. This is the same as above
Resin impregnation is large due to sparse spunbond fiber entanglement
This is because of the reason. Comparative Example 1 A web was made in the same manner as in Example 1 and then
Viscosity of vinyl acetate resin is lower than that of the example 30
Adjusted to 00 cps and then applied under the same conditions as in Example 1.
Made of breathable leather by embossing after drying and impregnation
I made it. The physical properties are shown in Table 1. Wind compared to Example 1
It is hard to fit and has a strong plastic feel, and it also has a shallow wrinkle.
It did not have a leather-like appearance and had low wear resistance. Comparative Example 2 A web was prepared in the same manner as in Example 1, and then
Viscosity of vinyl acetate resin solution is higher than that of Example 1
Adjust the viscosity to 11000 cps and under the same conditions as in Example 1.
Breathable leather with coating impregnation, drying and embossing
Was manufactured. The physical properties are shown in Table 1. Compared to Example 1.
The appearance is extremely uneven, and the breathability is extremely low.
It has a very low breathability and is called a breathable leather.
It wasn't good. Conventional Example 1 Table 1 shows the physical properties of general vinyl chloride leather. This is the texture
Is very plastic-like and very bad at the time of burning
The generation of elemental gas was not preferable. The characteristics in the table are judged according to the following procedure.
It was   Abrasion resistance: Taber test according to JIS L-1096
Using a wear wheel (NO.CS-10) with a test machine, a load of 500 g,
It was based on 1000 grades.   Appearance: The degree of leather-like appearance was visually compared and judged. Grade 5: Leather-like pattern with good uniformity and no fluff on the surface
Yes. Grade 4: Good leather-like pattern with slightly good uniformity and hair on the surface
I have no wings. Grade 3: Poor uniformity of leather pattern or fluff on the surface
To be Grade 2: The leather-like pattern is easy to collapse and the texture is shallow or fluffy.
is there. Grade 1: The leather-like pattern is unclear or has a lot of fuzz.   Texture: The softness is compared and judged by touch as follows.
It was Grade 5: Softest Level 4: Soft Grade 3: Hard Grade 2: Hard and stiff Grade 1: It's like a plastic However, judging from the required characteristics of leather-like nonwoven fabric, the appearance,
It is not as important a factor as wear resistance, and even a grade 3 grade will pass.
I can say.   Comprehensive evaluation: Comparative evaluation by slightly weighting the above three items
did. A: Best (pass) B: Good (pass) C: Normal (pass) D: Bad (failed) E: Worst (fail) [0037] The breathable leather of the present invention is made of non-woven fabric.
It has excellent wear resistance, appearance and texture,
Moreover, it was breathable. The method of the present invention
Is the effect that can reliably and stably manufacture the above breathable leather.
Play the fruit.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional view of a breathable leather of the present invention. FIG. 2 is a perspective view of the breathable leather of the present invention. FIG. 3 is a partial cross-sectional view of a pair of embossing rolls used in the present invention. FIG. 4 is a partial cross-sectional view of a pair of conventional embossing rolls. [Explanation of reference numerals] 1 surface layer 2 resin-impregnated fiber layer 2'fiber layer 3 leather-like steel roll 4 leather-like paper roll 5 conventional embossing roll 6 flat roll

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[Procedure amendment] [Date of submission] June 29, 1994 [Procedure amendment 1] [Document name for amendment] Specification [Item name for amendment] 0037 [Correction method] Change [Correction content] [0037] [Invention The breathable leather of the present invention is excellent in abrasion resistance, appearance and texture even though it is made of non-woven fabric,
Moreover, it was breathable. Further, the method of the present invention has the effect of reliably and stably producing the above-mentioned breathable leather. Furthermore, by applying a cut pile to the surface layer portion of the breathable leather of the present invention by an electric flocking method or the like, it has become possible to develop various uses.

Claims (1)

Claims: 1. A non-woven fabric comprising fibers having a fineness of 0.01 to 10d entangled three-dimensionally, and the weight of the non-woven fabric from one side of the non-woven fabric to a depth of 10 to 70%. 5 to 50% by weight of the thermoplastic resin is impregnated to bind the fibers to each other, and the nonwoven fabric is compressed, and the surface layer on one side has a fine continuous pattern of leather tone, The degree is 1.0 cc / cm ² / sec to 30 cc / cm ² / se
Breathable leather characterized by being in the range of c. 2. A non-woven fabric made of fibers having a fineness of 0.01 to 1.0 d is produced, and then three-dimensionally entangled to make a thermoplastic resin solution having a solution viscosity of 5000 to 10000 cps, which is coated and impregnated on one side of the non-woven fabric. Then, 5 to 50% by weight is applied to the non-woven fabric as a fixed amount, and then thermocompression bonding is applied to give a leather-like pattern.