[Technical Field]
[0001] The present invention relates to an artificial leather and a method for manufacturing
the same. More specifically, the present invention relates to an artificial leather
useful as an alternative to natural leather and a method for manufacturing the same.
[Background Art]
[0002] An artificial leather is manufactured by impregnating a polymeric elastomer in a
non-woven fabric comprising three-dimensionally entangled ultrafine fibers, which
is widely utilized in a variety of applications such as shoes, clothes, gloves, miscellaneous
goods, furniture and automobile interior materials due to natural leather-like soft
texture and unique appearance.
[0003] EP 1 302 587 A2, discloses a process for the preparation of microfibrous non-woven fabric with good
mechanical and dyeing properties comprising the following stages of a) preparation
of a microfiber constituted in general from polyesters used singularly or in mixtures
between them or with nylons 6, nylons 6.6 or other materials normally used in the
textile field, b) preparation, by means of needle-punching, of a felt comprising the
microfiber indicated above, c) impregnation of the felt with polymer binder, d) mechanical
treatment in order to generate the suede effect, e) dyeing of the non-woven fabric,
in which a polyester constituted partially or totally from repeating monomer units
of trimethylene terephthalate (PTT).
[0004] JP 2001-032140A relates to a multicomponent fiber and a leathery sheet using the fiber, wherein the
multicomponent fiber satisfies that a fiber cross section has an island-in-sea structure,
the island component is composed of (A) a crystalline polyester and the sea component
is composed of a mixture material comprising (C) a dispersion component composed of
a crystalline resin and (D) a dispersion component composed of a block copolymer and
present in (B) a dispersion medium component composed of an extractable resin, the
resin C is a crystalline polyester or a crystalline polyamide, the copolymer D comprises
a hard block composed of an aromatic polyester and a soft block composed of an aliphatic
polyether, etc., the ratio of the polyester A/[the sum total of the resin C and the
copolymer D] is (90/10)-(40/60) (weight ratio), etc.
[0005] Such an artificial leather is manufactured using a variety of fibers such as polyethylene
terephthalate fibers and polyamide fibers.
[0006] However, a common artificial leather is made of short fibers containing a single
component. Accordingly, the short fibers constituting the artificial leather exhibit
similar mechanical physical properties and similar entanglement behaviors. As a result,
distance and pores between short fibers are similar. Also, there is a problem of difficulty
of realization of an artificial leather having satisfactory texture, fullness and
flexibility due to differentiation in terms of interaction between short fibers.
[0007] Meanwhile, in order to impart fullness comparable to natural leather to an artificial
leather, a method for increasing a density of a non-woven fabric through a shrinkage
process is suggested. In addition, a method for improving flexibility of the artificial
leather such as softener or tumbling treatment is suggested.
[0008] However, these methods may deteriorate other properties of an artificial leather
such as texture or appearance.
[Disclosure]
[Technical Problem]
[0009] Therefore, the present invention is directed to a method for manufacturing an artificial
leather and the artificial leather manufactured by said method capable of preventing
problems caused by these limitations and drawbacks of the related art.
[0010] The present invention is conceived in response to demand for a more fundamental method
for improving physical properties of artificial leather, such as control of an internal
structure of non-woven fabric.
[0011] It is one aspect to provide a method for manufacturing an artificial leather that
comprises two or more types of short fibers made of different components, thus exhibiting
superior texture, flexibility, breathability and fullness, and enabling great weight
reduction.
[0012] It is another aspect to providean artificial leather manufactured by said method
and that comprises two or more types of short fibers made of different components,
thus exhibiting superior texture, flexibility, breathability and fullness, and enabling
considerable weight reduction.
[Technical Solution]
[0013] In accordance with one aspect of the present invention, provided is an artificial
leather manufactured by a method as described herein and including: a non-woven fabric
containing short fibers having a fineness of 0.00111 to 0.555 dtex (0.001 to 0.5 denier);
and a polymeric elastomer impregnated in the non-woven fabric, wherein the short fibers
are two or more types of polyester short fibers having different numbers of repeat
units of -CH
2-.
[0014] In accordance with another aspect of the present invention, provided is a method
for manufacturing an artificial leather including: preparing two or more types of
island-in-sea conjugate fibers, each comprising a sea component and an island component,
wherein island components of the two or more types of island-in-sea conjugate fibers
are two or more types of polyester polymers having different numbers of repeat units
of -CH
2-; forming a non-woven fabric using the two or more types of island-in-sea conjugate
fibers; and eluting the sea components from the two or more types of island-in-sea
conjugate fibers to form an ultrafine non-woven fabric, wherein a temperature of the
hot roller is maintained within a range of 80 to 200°C, and,
the artificial leather has a recovery rate of 80% or more.
[0015] The general description described above and the following detailed description are
provided only for exemplification and illustration of the present invention and should
be construed as providing more detailed description of claims.
[Advantageous Effects]
[0016] The present invention has the following effects.
[0017] The artificial leather according to the present invention comprises two or more types
of polyester short fibers having different elastic recovery. Short fibers having relatively
high elastic recovery form a spring-like structure during an entanglement process
for forming a non-woven fabric.
[0018] The artificial leather of the present invention has pores exhibiting superior compressive
elasticity (in a thickness direction) and being uniformly formed to have a predetermined
size, as compared to an artificial leather only comprising polyethylene terephthalate
(two repeat units of -CH
2-) short fibers, since it partially comprises the spring-like structure. Accordingly,
the present invention provides an artificial leather that has superior texture, flexibility,
breathability and fullness and enables considerable reduction in weight.
[0019] Furthermore, this spring structure makes surface naps upright, enabling production
of an artificial leather in which the difference in friction coefficient according
to nap direction is minimized, as compared to a common artificial leather in which
naps lie in one direction. Accordingly, the artificial leather of the present invention
can reduce displeasure caused by the difference in friction property according to
the nap direction.
[0020] Meanwhile, when a non-woven fabric was formed using only polyester short fibers having
three or more repeat units (-CH
2-), an interior spring-like structure is readily formed, but entanglement between
short fibers is difficult, a density and mechanical strength of the non-woven fabric
are deteriorated, and an artificial leather satisfying appearance, texture and physical
properties required for artificial leather manufacture companies cannot be produced.
[0021] In addition, the non-woven fabric according to the present invention comprises polyester
short fibers, thus exhibiting superior adhesiveness to the polymeric elastomer, for
example, polyurethane. Accordingly, the artificial leather of the present invention
has superior durability.
[0022] The artificial leather having superior physical properties may be widely utilized
in a variety of fields such as shoes, clothes, gloves, miscellaneous goods, furniture
and vehicle internal materials.
[Best Mode]
[0023] Hereinafter, embodiments of the artificial leather and the method for manufacturing
the same according to the present invention will be described in detail.
[0024] The artificial leather of the present invention comprises a non-woven fabric and
a polymeric elastomer impregnated in the non-woven fabric.
[0025] The non-woven fabric comprises short fibers having a fineness of 0.00111 to 0.555
dtex (0.001 to 0.5 denier). The non-woven fabric having a fineness satisfying a range
defined above has superior texture. When the fineness of the short fibers is lower
than 0.00111 dtex (0.001 denier), the texture of the non-woven fabric is good, but
it is not easy to manufacture the non-woven fabric and color fastness to washing,
indicating a loss level of a dye after washing, may be deteriorated. Meanwhile, when
the fineness of the short fibers exceeds 0.555 dtex (0.5 denier), the texture of the
non-woven fabric may not be good.
[0026] The fineness of short fibers may be calculated by collecting a sample using gold
coating, photographing a cross-section of the sample at a predetermined magnification
with a scanning electron microscope (SEM), measuring a diameter of the short fibers
and applying the diameter of the short fibers to the following Equation:
wherein π is a circular constant, D is a cross-sectional diameter of short fibers
(
µm) and ρ is a fiber density (g/cm
3).
[0027] The non-woven fabric of the present invention comprises two or more types of polyester
short fibers. The two or more types of polyester short fibers have at least one repeat
unit of -CH
2-. Different types of polyester short fibers have different numbers of repeat units
of -CH
2-.
[0028] Selectively, the two or more types of polyester short fibers may have two or four
repeat units. For example, the non-woven fabric may comprise two or more types of
short fibers including polyethylene terephthalate (PET) short fibers, polytrimethylene
terephthalate (PTT) short fibers, and polybutylene terephthalate (PBT) short fibers.
[0029] The polyethylene terephthalate short fibers are relatively cheap and exhibit superior
tensile strength. In addition, the polyethylene terephthalate short fibers have a
high melting point and thus exhibit superior heat resistance. Accordingly, the non-woven
fabric of the present invention may requisitely comprise polyethylene terephthalate
short fibers which are one of the two or more types of polyester short fibers.
[0030] A content of the polyethylene terephthalate short fibers in the non-woven fabric
is 5 to 95% by weight, preferably 10 to 50% by weight. When the content of the polyethylene
terephthalate short fibers is lower than 5% by weight, mechanical strength of the
non-woven fabric may be deteriorated, and when the content of the polyethylene terephthalate
short fibers is higher than 95% by weight, short fibers constituting the non-woven
fabric cannot form a dense structure and, as a result, an artificial leather made
of the non-woven fabric may exhibit deterioration in texture, flexibility and fullness.
[0031] One of parameters, affecting texture, flexibility and fullness of an artificial leather,
is mixing uniformity of short fibers of the non-woven fabric used for manufacture
of the artificial leather. According to the present invention, the two or more types
of polyester short fibers are uniformly mixed to an extent that the non-woven fabric
has an weight variation coefficient (CV%) of 20% or less. When the weight variation
coefficient of the non-woven fabric exceeds 20%, texture, flexibility and fullness
of the artificial leather made of the non-woven fabric may be deteriorated.
[0032] The weight variation coefficient (CV%) is calculated by collecting samples at various
positions of the non-woven fabric, measuring a weight per unit area of the samples,
calculating a standard deviation and an arithmetic mean using the measured weight
per unit area and obtaining the weight variation coefficient in accordance with the
following Equation:
[0033] The different types of polyester short fibers constituting the non-woven fabric of
the present invention may have different "elastic recovery at an elongation of 20%".
[0034] In one embodiment of the present invention, maximum and minimum values of "elastic
recovery at an elongation of 20%" of different types of short fibers constituting
the non-woven fabric of the present invention are present and a ratio of the maximum
value to the minimum value is 10 to 80%.
[0035] When the ratio of the maximum value to the minimum value regarding the elastic recovery
at an elongation of 20% is within the range defined above, two or more types of short
fibers constituting the non-woven fabric may be densely entangled and short fibers
having a relatively high elastic recovery may form a spring-like structure. Accordingly,
the artificial leather made of a non-woven fabric exhibits superior texture, flexibility
and fullness.
[0036] When the ratio of the maximum value to the minimum value regarding the elastic recovery
at an elongation of 20% is lower than 10%, two or more types of short fibers constituting
the non-woven fabric may be densely entangled, and short fibers having a relatively
high elastic recovery may not form a spring-like structure. As a result, texture,
flexibility and fullness of the artificial leather may be deteriorated. On the other
hand, when the ratio of the maximum value to the minimum value regarding the elastic
recovery at an elongation of 20% is higher than 80%, it may not be easy to manufacture
a non-woven fabric.
[0037] Owing to the short fibers having a relatively high elastic recovery that form a spring
structure, compressive elasticity in a thickness direction of the artificial leather
is improved. The compressive elasticity may be represented by compressibility and
recovery rate. That is, the artificial leather made of the non-woven fabric according
to the present invention has a compressibility (thickness direction) of 8 to 50%.
When the compressibility of the artificial leather is lower than 8%, the artificial
leather is hard and rigid, and when the compressibility thereof is higher than 50%,
texture such as fullness is deteriorated.
[0038] Meanwhile, the recovery rate indicates a level of recovery, when a load is removed
after compression. The artificial leather made of the non-woven fabric according to
the present invention has a recovery rate of 80% or more. When the recovery rate of
the artificial leather is lower than 80%, the artificial leather is deteriorated in
shape stability and fullness and cannot exhibit luxury and exclusivity.
[0039] In addition, fibers having a high elastic recovery exhibit superior recovery to an
applied exterior power. When the artificial leather comprises fibers having a high
elastic recovery, surface nap formed through a grinding process such as a buffing
process becomes more upright due to the internal spring structure. Accordingly, a
difference in friction coefficient between forward direction (nap direction) and reverse
direction on the surface of the artificial leather is considerably reduced, a difference
in texture between directions on the surface of the artificial leather is reduced,
the difference according to direction is minimized and surface texture can thus be
improved. When the difference in friction coefficient between forward and reverse
directions is decreased, texture of the artificial leather is superior. In one embodiment
of the present invention, the difference in the friction coefficient is 0.30 or less.
[0040] The two or more types of polyester short fibers constituting the non-woven fabric
have a length of 5 to 100 mm. When the short fibers satisfying the length range are
entangled, manufacture processibility of the non-woven fabric can be improved and
the artificial leather made of the non-woven fabric exhibit superior physical properties.
When the length of the short fibers is lower than 5 mm, it may be difficult to manufacture
the non-woven fabric, and strength and texture of the artificial leather may be deteriorated.
Meanwhile, when the length of the short fibers exceeds 10 mm, it may be difficult
to manufacture the non-woven fabric.
[0041] The polymeric elastomer impregnated in the non-woven fabric may be polyurethane.
Specifically, the polymeric elastomer may be polycarbonatediol, polyesterdiol, polyetherdiol
or a mixture thereof. Selectively, the polymeric elastomer is polysiloxane. The polymeric
elastomer is not limited to polyurethane or polysiloxane.
[0042] A content of the polymeric elastomer in the artificial leather may be 20 to 30% by
weight. When the content of the polymeric elastomer is lower than 20% by weight, the
desired elongation cannot be obtained, and when the content of the polymeric elastomer
exceeds 30% by weight, the texture of the artificial leather is deteriorated, the
artificial leather is readily discolored and an elongation of the artificial leather
is also deteriorated.
[0043] The artificial leather of the present invention has an "elastic recovery at an elongation
of 10%" of 80% or more. The artificial leather having an elastic recovery of 80% or
more can be easily recovered to the original shape although a pressure is applied
thereto for a long period of time. Owing to the superior elastic recovery, when the
artificial leather of the present invention is applied to products such as shoes,
clothes, gloves, miscellaneous goods, furniture and vehicle internal materials, the
products are not wrinkled and a natural and luxurious appearance can be realized.
[0044] Next, a method for manufacturing an artificial leather in accordance with one embodiment
of the present invention will be described in detail.
[0045] First, two or more types of island-in-sea conjugate fibers comprising a sea component
and an island component are prepared. Specifically, a molten solution of a sea component
polymer and a molten solution of an island component polymer solution are prepared
and a conjugate spinning process is performed using a conjugate spinneret to prepare
filaments. Subsequently, the filaments are extended. Crimps are formed on the extended
filaments and the crimped filaments are cut to a predetermined length to obtain island-in-sea
conjugate fibers having a monofiber shape.
[0046] According to the present invention, island components of the two or more types of
island-in-sea conjugate fibers have repeat units of -CH
2- and are polyester polymers which have different numbers of the repeat units.
[0047] That is, the first island-in-sea conjugate fibers may comprise the first and second
polymers as sea and island components and the second island-in-sea conjugate fibers
may comprise first and third polymers as sea and island components. The third island-in-sea
conjugate fibers comprising the first and fourth polymers may be further provided
as the sea and island components. That is, the first to third island-in-sea conjugate
fibers comprise the same polymers as sea components and different polymers as island
components. For the subsequent sea component elution process, the first polymer is
different from the second to fourth polymers in terms of solubility in solvent.
[0048] For example, the second polymer may be polyethylene terephthalate (PET), the third
polymer may be polybutylene terephthalate (PBT), and the fourth polymer may be polytrimethylene
terephthalate (PTT).
[0049] Subsequently, a non-woven fabric is formed of the two or more types of island-in-sea
conjugate fibers.
[0050] Specifically, the two or more types of island-in-sea conjugate fibers are subjected
to opening, blending and carding processes and island-in-sea conjugate fibers having
a monofiber shape are homogeneously blended to form webs. Subsequently, the obtained
webs are laminated through a cross-lapping process and the laminated webs are combined
while the island-in-sea conjugate fibers are entangled by needle punching to prepare
a non-woven fabric.
[0051] Optionally, the process of forming webs by blending two or more types of island-in-sea
conjugate fibers may be carried out by an air-laid method using an air jet, a wet-laid
method in which mixing is performed in water or the like.
[0052] The process of entangling the two or more types of island-in-sea conjugate fibers
may also be carried out by rapid fluid treatment, chemical bonding or hot air through.
[0053] The produced non-woven fabric may have a unit weight of 100 to 700 g/m
2. A final product manufactured using the non-woven fabric using the unit weight has
an optimum density.
[0054] Subsequently, a polymeric elastomer is impregnated in the non-woven fabric.
[0055] For example, a polymeric elastomer solution is prepared and the non-woven fabric
is dipped in the polymeric elastomer solution. The polymeric elastomer solution may
be prepared by dissolving or dispersing polyurethane in a predetermined solvent. For
example, the polymeric elastomer solution may be prepared by dissolving polyurethane
in a dimethylformamide (DMF) solvent or dispersing polyurethane in a water solvent.
The polymeric elastomer solution may also be prepared by directly using a silicone
polymeric elastomer without dissolving or dispersing a polymeric elastomer in a solvent.
[0056] Optionally, a pigment, a light stabilizer, an antioxidant, a flame retardant, a fabric
softener, a coloring agent or the like may be added to the polymeric elastomer solution.
[0057] Before the non-woven fabric is dipped in the polymeric elastomer solution, the non-woven
fabric is padded with an aqueous polyvinyl alcohol solution to stabilize the shape
thereof.
[0058] An amount of the polymeric elastomer impregnated in the non-woven fabric can be controlled
by controlling concentration of the polymeric elastomer solution or the like. Taking
into consideration the fact that the content of polymeric elastomer finally present
in the artificial leather is 20 to 30%, a concentration of the polymeric elastomer
solution is preferably within 5 to 20% by weight. Also, the non-woven fabric is preferably
dipped in the polymeric elastomer solution for 0.5 to 15 minutes while the temperature
of polymeric elastomer solution having a concentration of 5 to 20% by weight is maintained
at 10 to 30°C.
[0059] After dipping the non-woven fabric in the polymeric elastomer solution, the polymeric
elastomer impregnated in the non-woven fabric is coagulated in a coagulation bath
and washed in a washing bath. In the case in which the polymeric elastomer solution
is obtained by dissolving polyurethane in a dimethylformamide solvent, the polymeric
elastomer is coagulated in the coagulation bath containing a mixture of water and
a small amount of dimethylformamide to induce elution of dimethylformamide contained
in the non-woven fabric into the coagulation bath. Polyvinyl alcohol padded in the
non-woven fabric and remaining dimethylformamide are removed from the non-woven fabric
in the washing bath.
[0060] Subsequently, the polymeric elastomer-impregnated non-woven fabric is hot-calendered.
The hot-calendaring is carried out by passing the polymeric elastomer-impregnated
non-woven fabric through a hot roller to compress the fabric. A temperature of the
hot roller is maintained within a range of 80 to 200°C. When the temperature of the
hot roller is lower than 80°C, hot calendering effect cannot be sufficiently obtained
and when the temperature of the hot roller is higher than 200°C, short fibers of the
non-woven fabric surface may be damaged.
[0061] Through the hot calendering process, the polymeric elastomers are rearranged and
short fibers of the non-woven fabric surface are homogeneously arranged. As a result,
during the subsequent process described below, uniform naps are formed on the surface
of the non-woven fabric.
[0062] Subsequently, the sea component is removed from the hot-calendered non-woven fabric.
When the sea component is eluted from the two or more types of island-in-sea conjugate
fibers constituting the non-woven fabric, only the island component remains and the
ultrafine non-woven fabric comprising ultrafine short fibers is formed. The elution
process of the sea component may be carried out using an alkali solvent such as aqueous
sodium hydroxide solution.
[0063] In the case of the non-woven fabric made of the first to third island-in-sea conjugate
fibers, the first polymer which is the sea component is eluted and only the second
to fourth polymers remain as island components. As a result, an ultrafine non-woven
fabric comprising ultrafine short fibers is formed.
[0064] Optionally, the impregnation of the polymeric elastomer described above may be carried
out after the ultrafine process, rather than before the ultrafine process. That is,
instead of impregnating the polymeric elastomer in the non-woven fabric before the
ultrafine process, the polymeric elastomer may be impregnated in the ultrafine non-woven
fabric formed through the ultrafine process.
[0065] Subsequently, the ultrafine non-woven fabric is subjected to a raising process. The
raising process forms a great amount of naps on the surface of the non-woven fabric
by rubbing the surface of the ultrafine non-woven fabric with a polishing means such
as sandpaper.
[0066] Subsequently, the raised non-woven fabric is dyed and then subjected to post-treatment
to complete production of the artificial leather.
[0067] The produced artificial leather has a compressibility of 8 to 50% and a recovery
rate of 80% or more, and the difference between a friction coefficient in a forward
direction (nap direction) and a friction coefficient in a reverse direction on the
surface of the artificial leather is 0.30 or less.
[0068] Hereinafter, the present invention will be described in detail with reference to
examples and comparative examples. These examples are provided only for better understanding
and should not be construed as limiting the scope of the present invention.
Example 1
[0069] Polyethylene terephthalate as an island component and copolymer polyester as a sea
component were conjugate-spun to form filaments and the formed filaments were extended,
crimped and cut to form first conjugate fibers in the form of short fibers having
a fineness of 3.885 dtex (3.5 denier) and a length of 50 mm. A content of polyethylene
terephthalate which was the island component of the first conjugate fibers was 70%
by weight and a content of the copolymer polyester which was the sea component thereof
was 30% by weight.
[0070] In addition, second conjugate fibers in the form of short fibers having a fineness
of 4.44 dtex (4.0 denier) and a length of 51 mm were prepared in the same manner as
in the first conjugate fibers, except that polytrimethylene terephthalate was used
as the island component. The content of polytrimethylene terephthalate which was the
island component of the second conjugate fibers was 70% by weight, and the content
of the copolymer polyester which was the sea component was 30% by weight.
[0071] Subsequently, after the first conjugate fibers and the second conjugate fibers are
supplied at amounts of 90% by weight and 10% by weight, respectively, they are subjected
to opening, blending and then carding/cross-lapping processes to form a web laminate
and the webs of the laminate were combined through needle punching to produce a non-woven
fabric.
[0072] Subsequently, the non-woven fabric was thermally-contracted at a high temperature
to increase a density of the non-woven fabric. Subsequently, polyurethane was dissolved
in dimethylformamide (DMF) as a solvent to prepare a polyurethane solution having
a concentration of 15% by weight, the high-density non-woven fabric was dipped for
8 minutes and the polyurethane was coagulated in an aqueous dimethylformamide solution
having a concentration of 25% by weight. The non-woven fabric was washed with 70°C
water several times to produce a polyurethane-impregnated non-woven fabric.
[0073] Subsequently, the polyurethane-impregnated non-woven fabric was treated with 10%
by weight of a 100°C sodium hydroxide aqueous solution, and only the island component
was left by eluting the copolymer polyester as the sea component from the non-woven
fabric to produce an ultrafine non-woven fabric.
[0074] Subsequently, the surface of the ultrafine non-woven fabric was buffed using a Roughness
No. 240 sandpaper, and dyed in a high-pressure rapid dying machine using a dispersion
dye, fixed, washed, dried and treated with a softener and an anti-static agent to
obtain an artificial leather.
Example 2
[0075] An artificial leather was manufactured in the same manner as in Example 1, except
that the second conjugate fibers were prepared using polybutylene terephthalate as
the island component, instead of polytrimethylene terephthalate.
Example 3
[0076] An artificial leather was manufactured in the same manner as in Example 1, except
that a non-woven fabric was produced such that the contents of the first conjugate
fibers and the second conjugate fibers were 70% by weight and 30% by weight, respectively.
Example 4
[0077] An artificial leather was manufactured in the same manner as in Example 1, except
that a non-woven fabric was produced such that the contents of the first conjugate
fibers and the second conjugate fibers were 50% by weight and 50% by weight, respectively.
Example 5
[0078] An artificial leather was manufactured in the same manner as in Example 1, except
that a non-woven fabric was produced such that the contents of the first conjugate
fibers and the second conjugate fibers were 30% by weight and 70% by weight, respectively.
Example 6
[0079] An artificial leather was manufactured in the same manner as in Example 1, except
that a non-woven fabric was produced such that the contents of the first conjugate
fibers and the second conjugate fibers were 10% by weight and 90% by weight, respectively.
Example 7
[0080] An artificial leather was manufactured in the same manner as in Example 1, except
that, in addition to the first and second conjugate fibers, third conjugate fibers
comprising 70% by weight of polybutylene terephthalate (island component) and 30%
by weight of copolymer polyester (sea component) were further used and a non-woven
fabric was produced such that contents of the first to third conjugate fibers were
90%, 5% and 5%.
Example 8
[0081] An artificial leather was manufactured in the same manner as in Example 7, except
that a non-woven fabric was produced such that contents of the first to third conjugate
fibers were 50%, 25% and 25%.
Example 9
[0082] An artificial leather was manufactured in the same manner as in Example 7, except
that a non-woven fabric was produced such that contents of the first to third conjugate
fibers were 10%, 60% and 30%.
Example 10
[0083] An artificial leather was manufactured in the same manner as in Example 7, except
that a non-woven fabric was produced such that contents of the first to third conjugate
fibers were 10%, 30% and 60%.
Comparative Example 1
[0084] An artificial leather was manufactured in the same manner as in Example 1, except
that a non-woven fabric was produced using only the first conjugate fibers without
the second conjugate fibers.
Comparative Example 2
[0085] An artificial leather was manufactured in the same manner as in Example 1, except
that a non-woven fabric was produced using only the second conjugate fibers without
the first conjugate fibers.
[0086] Elastic recovery, texture, surface texture, friction property, and compressive elasticity
(compressibility and recovery rate) of the artificial leathers manufactured in Examples
and Comparative Examples were measured in accordance with the following methods and
the results are shown in Table 3 below.
Elastic recovery (%)
[0087] A sample in which a distance of 200 mm was marked was mounted on a tensile tester
in which a distance between clamps was 250 mm, elongated to an elongation of 10% at
a speed of 50 mm/min and was stood for one minute. Subsequently, the load was removed
at the same speed as the tensile strength, the sample was stood for three minutes,
an actual distance (x) of the distance marked above was measured and elastic recovery
was measured in accordance with the following equation.
Texture
[0088] In order to measure a texture of the artificial leather, an evaluation group including
five specialists was formed. Functional tests regarding three items including flexibility,
fullness and bending property were performed and evaluation was carried out by grading
on a scale of 0 to 5, with 5 being the best. The scores of the respective items were
summed, the scores assigned by five specialists were further added and evaluation
was carried out in accordance with the following Table 1.
[TABLE 1]
Total |
Texture |
0∼15 |
× |
16∼30 |
Δ |
31∼45 |
○ |
46∼60 |
⊚ |
61∼75 |
☆ |
Surface texture
[0089] In order to measure surface texture of the artificial leather, an evaluation group
including five specialists was formed. Functional tests regarding three items including
flexibility, fullness and bending property were performed and evaluation was carried
out by grading on a scale of 0 to 5, with 5 being the best. The scores of the respective
items were summed, the scores assigned by five specialists were further added and
evaluation was carried out in accordance with the following Table 2:
[TABLE 2]
Total |
Surface texture |
0∼5 |
× |
6∼10 |
Δ |
11∼15 |
○ |
16∼20 |
⊚ |
21∼25 |
☆ |
Friction property
[0090] Friction property was evaluated from the difference between a friction coefficient
in a forward direction (nap direction) and a friction coefficient in a reverse direction
on the surface of the artificial leather and the measurement method is as follows.
[0091] The friction coefficient in the forward direction which is a direction such as nap
direction and the friction coefficient in the reverse direction opposite to the nap
direction were measured using a friction tester (produced by Toyoseiko Co., Ltd.).
Identical test specimens, objects in need of testing, were used as upper and lower
friction materials and the upper material was set such that the nap direction thereof
was opposite to a movement direction of the friction tester. Meanwhile, the lower
friction material was adhered during measurement of friction coefficient in the forward
direction such that the friction tester movement direction was equivalent to the nap
direction, and the lower friction material was adhered during measurement of friction
coefficient in the reverse direction such that the friction tester movement direction
was opposite to the nap direction.
[0092] Under conditions including a movement distance of about 20 cm and a balance weight
of 200 g of the lower friction material, an object to which a friction force was applied,
a load cell of 1 kg and a chart scale of X1, various friction coefficients were measured
three times and an average of the obtained measures was calculated to obtain a final
friction coefficient value.
[0093] The value of friction coefficient was determined by reading a maximum static frictional
force.
[0094] Friction property was determined from an absolute value of the difference between
forward friction coefficient and reverse friction coefficient obtained using the friction
coefficient value.
Compressive elasticity
[0095] The compressive elasticity (in the thickness direction) of the artificial leather
was determined from a compressibility and a recovery rate, and the compressibility
and recovery rate of the artificial leather were measured using a VMS PV-Series apparatus
produced by G&P Technology.
[0096] An initial load of 900 gf/cm
2 was applied to a spherical indenter and the load was maintained for 30 seconds. Subsequently,
30 seconds after the initial load was removed, a maximum thickness (T1) of the artificial
leather was measured to a level of 1/1,000 mm. The initial load was applied for 30
seconds again and a minimum thickness (T2) was measured to a level of 1/1,000 mm.
Subsequently, 30 seconds after the initial load was removed, the thickness (T3) of
the artificial leather was measured to a level of 1/1,000 mm. In addition, a compressibility
and a recovery rate were calculated using the following equation.
[TABLE 3]
No. of Ex. |
Elastic recovery |
Texture |
Surface texture |
Friction property |
Compressibility (%) |
Recovery rate (%) |
Ex. 1 |
90 |
☆ |
☆ |
0.10 |
13.5 |
95.0 |
Ex. 2 |
87 |
☆ |
⊚ |
0.21 |
12.0 |
93.0 |
Ex. 3 |
92 |
☆ |
☆ |
0.10 |
15.3 |
95.3 |
Ex. 4 |
93 |
☆ |
☆ |
0.09 |
18.2 |
97.0 |
Ex. 5 |
93 |
☆ |
☆ |
0.15 |
15.5 |
96.5 |
Ex. 6 |
92 |
⊚ |
⊚ |
0.20 |
13.0 |
95.1 |
Ex. 7 |
89 |
☆ |
☆ |
0.15 |
13.0 |
94.7 |
Ex. 8 |
87 |
☆ |
⊚ |
0.18 |
14.3 |
95.2 |
Ex. 9 |
88 |
☆ |
⊚ |
0.22 |
16.1 |
95.0 |
Ex. 10 |
82 |
○ |
⊚ |
0.25 |
10.2 |
92.2 |
Comp. Ex. 1 |
76 |
○ |
○ |
0.35 |
7.3 |
70 |
Comp. Ex. 2 |
78 |
× |
Δ |
0.33 |
8.0 |
78 |
1. A method for manufacturing an artificial leather comprising:
preparing two or more types of island-in-sea conjugate fibers, each comprising a sea
component and an island component, wherein island components of the two or more types
of island-in-sea conjugate fibers are two or more types of polyester polymers having
different numbers of repeat units of -CH2-;
forming a non-woven fabric using the two or more types of island-in-sea conjugate
fibers;
impregnating a polymeric elastomer in the non-woven fabric;
passing the polymeric elastomer-impregnated non-woven fabric through a hot roller
to compress the polymeric elastomer-impregnated non-woven fabric; and
eluting the sea components from the two or more types of island-in-sea conjugate fibers
to form an ultrafine non-woven fabric,
wherein a temperature of the hot roller is maintained within a range of 80 to 200°C,
and, the artificial leather has a recovery rate of 80% or more,
wherein recovery rate is measured using a VMS PV-Series apparatus produced by G&P
Technology as follows:
an initial load of 900 gf/cm2 is applied to a spherical indenter and the load is maintained for 30 seconds;
subsequently, 30 seconds after the initial load is removed, a maximum thickness (T1)
of the artificial leather is measured to a level of 1/1,000 mm;
the initial load is applied for 30 seconds again and a minimum thickness (T2) is measured
to a level of 1/1,000 mm;
subsequently, 30 seconds after the initial load is removed, the thickness (T3) of
the artificial leather is measured to a level of 1/1,000 mm,
and, a recovery rate is calculated using the following equation,
2. An artificial leather comprising:
a non-woven fabric comprising short fibers having a fineness of 0.00111 to 0.555 dtex
(0.001 to 0.5 denier); and
a polymeric elastomer impregnated in the non-woven fabric,
wherein the short fibers are two or more types of polyester short fibers having different
numbers of repeat units of -CH2-, and
the artificial leather is manufactured by a method comprising:
preparing two or more types of island-in-sea conjugate fibers, each comprising a sea
component and an island component, wherein island components of the two or more types
of island-in-sea conjugate fibers are two or more types of polyester polymers having
different numbers of repeat units of -CH2-;
forming a non-woven fabric using the two or more types of island-in-sea conjugate
fibers;
impregnating a polymeric elastomer in the non-woven fabric;
passing the polymeric elastomer-impregnated non-woven fabric through a hot roller
to compress the polymeric elastomer-impregnated non-woven fabric; and
eluting the sea components from the two or more types of island-in-sea conjugate fibers
to form an ultrafine non-woven fabric,
wherein a temperature of the hot roller is maintained within a range of 80 to 200°C,
and
wherein the artificial leather has a recovery rate of 80% or more, wherein recovery
rate is measured using a VMS PV-Series apparatus produced by G&P Technology as follows:
an initial load of 900 gf/cm2 is applied to a spherical indenter and the load is maintained for 30 seconds;
subsequently, 30 seconds after the initial load is removed, a maximum thickness (T1)
of the artificial leather is measured to a level of 1/1,000 mm;
the initial load is applied for 30 seconds again and a minimum thickness (T2) is measured
to a level of 1/1,000 mm;
subsequently, 30 seconds after the initial load is removed, the thickness (T3) of
the artificial leather is measured to a level of 1/1,000 mm,
and, a recovery rate is calculated using the following equation,
3. The artificial leather according to claim 2, wherein number of the repeat units of
each of the two or more types of polyester short fibers is two to four.
4. The artificial leather according to claim 2, wherein the non-woven fabric comprises
5 to 95% by weight of polyethylene terephthalate short fibers.
5. The artificial leather according to claim 2, wherein the non-woven fabric has a weight
variation coefficient of 20% or less,
wherein the weight variation coefficient (CV%) is calculated by collecting samples
at various positions of the non-woven fabric, measuring a weight per unit area of
the samples, calculating a standard deviation and an arithmetic mean using the measured
weight per unit area and obtaining the weight variation coefficient in accordance
with the following Equation:
6. The artificial leather according to claim 2, wherein the two or more types of polyester
short fibers have a length of 5 to 100 mm.
7. The artificial leather according to claim 2, wherein an elastic recovery of the artificial
leather at an elongation of 10% is 80% or more,
wherein the elastic recovery is measured as follows:
a sample in which a distance of 200 mm is marked is mounted on a tensile tester in
which a distance between clamps are 250 mm, elongated to an elongation of 10% at a
speed of 50 mm/min and is stood for one minute;
subsequently, the load is removed at the same speed as the tensile strength, the sample
is stood for three minutes, an actual distance (x) of the distance marked above is
measured and elastic recovery is measured in accordance with the following equation;
8. The artificial leather according to claim 2, wherein a difference between a friction
coefficient in a forward direction parallel to a nap direction of the artificial leather
and a friction coefficient in a reverse direction of the forward direction is 0.30
or less,
wherein the friction coefficient in the forward direction which is a direction such
as nap direction and the friction coefficient in the reverse direction opposite to
the nap direction are measured using a friction tester produced by Toyoseiko Co.,
Ltd.,
wherein identical test specimens are used as upper and lower friction materials and
the upper material is set such that the nap direction thereof is opposite to a movement
direction of the friction tester,
the lower friction material is adhered during measurement of friction coefficient
in the forward direction such that the friction tester movement direction is equivalent
to the nap direction, and,
the lower friction material is adhered during measurement of friction coefficient
in the reverse direction such that the friction tester movement direction is opposite
to the nap direction,
under conditions including a movement distance of about 20 cm and a balance weight
of 200 g of the lower friction material, an object to which a friction force is applied,
a load cell of 1 kg and a chart scale of X1, friction coefficients are measured three
times and an average of the obtained measures is calculated to obtain a final friction
coefficient value, and
the values of friction coefficients are determined by reading a maximum static frictional
force.
9. The artificial leather according to claim 2, wherein the artificial leather has a
compressibility of 8 to 50%,
wherein compressibility is measured using a VMS PV-Series apparatus produced by G&P
Technology as follows:
an initial load of 900 gf/cm2 is applied to a spherical indenter and the load is maintained for 30 seconds,
subsequently, 30 seconds after the initial load is removed, a maximum thickness (T1)
of the artificial leather is measured to a level of 1/1,000 mm,
the initial load is applied for 30 seconds again and a minimum thickness (T2) is measured
to a level of 1/1,000 mm,
subsequently, 30 seconds after the initial load is removed, the thickness (T3) of
the artificial leather is measured to a level of 1/1,000 mm,
and, a compressibility is calculated using the following equation,
1. Verfahren zum Herstellen eines Kunstleders, das umfasst:
Erstellen von zwei oder mehr Arten von Insel-im-Meer-Konjugatfasern, die jeweils eine
Meerkomponente und eine Inselkomponente umfassen, wobei Inselkomponenten der zwei
oder mehr Arten von Insel-im-Meer-Konjugatfasern zwei oder mehr Arten von Polyesterpolymeren
mit unterschiedlichen Anzahlen von Wiederholungseinheiten von - CH2- sind;
Ausbilden eines Vliesstoffs unter Verwendung der zwei oder mehr Arten von Insel-im-Meer-Konjugatfasern;
Imprägnieren eines polymeren Elastomers in dem Vliesstoff;
Führen des mit polymerem Elastomer imprägnierten Vliesstoffs durch eine heiße Walze,
um den mit polymerem Elastomer imprägnierten Vliesstoff zu komprimieren; und
Eluieren der Meerkomponenten aus den zwei oder mehr Arten von Insel-im-Meer-Konjugatfasern,
um einen ultrafeinen Vliesstoff auszubilden,
wobei eine Temperatur der heißen Walze innerhalb eines Bereichs von 80 bis 200 °C
gehalten wird, und
das Kunstleder eine Rückstellungsrate von wenigstens 80 % aufweist,
wobei die Rückstellungsrate unter Verwendung einer Einrichtung der VMS PV-Serie, die
von G&P Technology angefertigt wird, wie folgt gemessen wird:
eine Anfangslast von 900 gf/cm2 wird auf einen kugelförmigen Indenter angelegt und die Last wird 30 Sekunden lang
gehalten;
anschließend wird 30 Sekunden nachdem die Anfangslast entfernt wurde eine Maximaldicke
(T1) des Kunstleders auf eine Höhe von 1/1000 mm gemessen;
die Anfangslast wird erneut 30 Sekunden lang angelegt und eine Mindestdicke (T2) wird
auf eine Höhe von 1/1.000 mm gemessen;
anschließend wird 30 Sekunden nachdem die Anfangslast entfernt wurde die Dicke (T3)
des Kunstleders auf eine Höhe von 1/1000 mm gemessen und
eine Rückstellungsrate wird unter Verwendung der folgenden Gleichung berechnet:
2. Kunstleder, das umfasst:
einen Vliesstoff, der Kurzfasern mit einer Feinheit von 0,00111 bis 0,555 dtex (0,001
bis 0,5 Denier) umfasst; und
ein polymeres Elastomer, das in dem Vliesstoff imprägniert ist,
wobei die Kurzfasern zwei oder mehr Arten von Polyester-Kurzfasern mit unterschiedlichen
Anzahlen von Wiederholungseinheiten von -CH2,- sind, und
das Kunstleder durch ein Verfahren hergestellt wird, das umfasst:
Erstellen von zwei oder mehr Arten von Insel-im-Meer-Konjugatfasern, die jeweils eine
Meerkomponente und eine Inselkomponente umfassen, wobei Inselkomponenten der zwei
oder mehr Arten von Insel-im-Meer-Konjugatfasern zwei oder mehr Arten von Polyesterpolymeren
mit unterschiedlichen Anzahlen von Wiederholungseinheiten von - CH2- sind;
Ausbilden eines Vliesstoffs unter Verwendung der zwei oder mehr Arten von Insel-im-Meer-Konjugatfasern;
Imprägnieren eines polymeren Elastomers in dem Vliesstoff;
Führen des mit polymerem Elastomer imprägnierten Vliesstoffs durch eine heiße Walze,
um den mit polymerem Elastomer imprägnierten Vliesstoff zu komprimieren; und
Eluieren der Meerkomponenten aus den zwei oder mehr Arten von Insel-im-Meer-Konjugatfasern,
um einen ultrafeinen Vliesstoff auszubilden,
wobei eine Temperatur der heißen Walze innerhalb eines Bereichs von 80 bis 200 °C
gehalten wird und
wobei das Kunstleder eine Rückstellungsrate von wenigstens 80 % aufweist, wobei die
Rückstellungsrate unter Verwendung einer Einrichtung der VMS PV-Serie, die von G&P
Technology angefertigt wird, wie folgt gemessen wird:
eine Anfangslast von 900 gf/cm2 wird auf einen kugelförmigen Indenter angelegt und die Last wird 30 Sekunden lang
gehalten;
anschließend wird 30 Sekunden nachdem die Anfangslast entfernt wurde eine Maximaldicke
(T1) des Kunstleders auf eine Höhe von 1/1000 mm gemessen;
die Anfangslast wird erneut 30 Sekunden lang angelegt und eine Mindestdicke (T2) wird
auf eine Höhe von 1/1.000 mm gemessen;
anschließend wird 30 Sekunden nachdem die Anfangslast entfernt wurde die Dicke (T3)
des Kunstleders auf eine Höhe von 1/1000 mm gemessen und
eine Rückstellungsrate wird unter Verwendung der folgenden Gleichung berechnet:
3. Kunstleder nach Anspruch 2, wobei die Anzahl der Wiederholungseinheiten von jeder
der zwei oder mehr Arten von Polyester-Kurzfasern zwei bis vier beträgt.
4. Kunstleder nach Anspruch 2, wobei der Vliesstoff 5 bis 95 Gew.-% von Polyethylenterephthalat-Kurzfasern
umfasst.
5. Kunstleder nach Anspruch 2, wobei der Vliesstoff einen Gewichtsvariationskoeffizienten
von höchstens 20 % aufweist,
wobei der Gewichtsvariationskoeffizient (CV%) durch Sammeln von Proben an verschiedenen
Positionen des Vliesstoffs, Messen eines Gewichts pro Flächeneinheit der Proben, Berechnen
einer Standardabweichung und eines arithmetischen Mittels unter Verwendung des gemessenen
Gewichts pro Flächeneinheit und Erhalten des Gewichtsvariationskoeffizienten gemäß
der folgenden Gleichung berechnet wird:
Gewichtsvariationskoeffizient (CV%) = Standardabweichung/arithmetisches Mittel.
6. Kunstleder nach Anspruch 2, wobei die zwei oder mehr Arten von Polyester-Kurzfasern
eine Länge von 5 bis 100 mm aufweisen.
7. Kunstleder nach Anspruch 2, wobei eine elastische Rückstellung des Kunstleders bei
einer Dehnung von 10 % wenigstens 80 % ist, wobei die elastische Rückstellung wie
folgt gemessen wird:
eine Probe, in der ein Abstand von 200 mm markiert ist, wird an einem Zugprüfgerät
gelagert, in dem ein Abstand zwischen Klemmen 250 mm beträgt, wird bei einer Geschwindigkeit
von 50 mm/min auf eine Dehnung von 10 % gedehnt und eine Minute lang stehengelassen;
anschließend wird die Last mit der gleichen Geschwindigkeit wie die Zugfestigkeit
entfernt, die Probe drei Minuten lang stehen gelassen, ein tatsächlicher Abstand (x)
des oben markierten Abstands gemessen und die elastische Rückstellung gemäß der folgenden
Gleichung gemessen;
8. Kunstleder nach Anspruch 2, wobei eine Differenz zwischen einem Reibungskoeffizienten
in einer Vorwärtsrichtung parallel zu einer Strichrichtung des Kunstleders und einem
Reibungskoeffizienten in einer Rückwärtsrichtung der Vorwärtsrichtung höchstens 0,30
beträgt,
wobei der Reibungskoeffizient in der Vorwärtsrichtung, die eine Richtung wie etwa
die Strichrichtung ist, und der Reibungskoeffizient in der Rückwärtsrichtung entgegengesetzt
zu der Strichrichtung unter Verwendung eines Reibungsprüfgeräts, das von Toyoseiko
Co., Ltd. angefertigt wird, gemessen werden,
identische Prüfkörper als obere und untere Reibungsmaterialien verwendet werden und
das obere Material derart festgelegt wird, dass die Strichrichtung davon einer Bewegungsrichtung
des Reibungsprüfgeräts entgegengesetzt ist,
das untere Reibungsmaterial während der Messung des Reibungskoeffizienten in der Vorwärtsrichtung
derart angeklebt wird, dass die Reibungsprüfgerätbewegungsrichtung der Strichrichtung
gleicht und
das untere Reibungsmaterial während der Messung des Reibungskoeffizienten in der Rückwärtsrichtung
derart angeklebt wird, dass die Reibungsprüfgerätbewegungsrichtung der Strichrichtung
entgegengesetzt ist,
unter Bedingungen, die einen Bewegungsabstand von etwa 20 cm und ein Gegengewicht
von 200 g des unteren Reibungsmaterials, ein Objekt, an das eine Reibungskraft angelegt
wird, eine Lastdose von 1 kg und einen Diagrammmaßstab von X1 einschließt, wobei Reibungskoeffizienten
dreimal gemessen werden und ein Durchschnitt der erhaltenen Messungen berechnet wird,
um einen endgültigen Reibungskoeffizientenwert zu erhalten, und
wobei die Werte der Reibungskoeffizienten durch Ablesen einer statischen Maximalreibungskraft
bestimmt werden.
9. Kunstleder nach Anspruch 2, wobei das Kunstleder eine Komprimierbarkeit von 8 bis
50 % aufweist,
wobei die Komprimierbarkeit unter Verwendung einer Einrichtung der VMS PV-Serie, die
von G&P Technology angefertigt wird, wie folgt gemessen wird:
eine Anfangslast von 900 gf/cm2 wird auf einen kugelförmigen Indenter angelegt und die Last wird 30 Sekunden lang
gehalten,
anschließend wird 30 Sekunden nachdem die Anfangslast entfernt wurde eine Maximaldicke
(T1) des Kunstleders auf eine Höhe von 1/1.000 mm gemessen,
die Anfangslast wird erneut 30 Sekunden lang angelegt und eine Mindestdicke (T2) auf
eine Höhe von 1/1000 mm gemessen,
anschließend wird 30 Sekunden nachdem die Anfangslast entfernt wurde die Dicke (T3)
des Kunstleders auf eine Höhe von 1/1.000 mm gemessen
und eine Komprimierbarkeit wird unter Verwendung der folgenden Gleichung berechnet:
1. Procédé de fabrication d'un cuir artificiel comprenant :
la préparation de deux types ou plus de fibres conjuguées îlot-mer, comprenant chacune
un composant mer et un composant îlot, les composants îlot des deux types ou plus
de fibres conjuguées îlot-mer étant deux types ou plus de polymères polyester ayant
différents nombres d'unités de répétition de -CH2- ;
la formation d'un textile non tissé à l'aide des deux types ou plus de fibres conjuguées
îlot-mer ;
l'imprégnation d'un élastomère polymère dans le textile non tissé ;
le passage du textile non tissé imprégné d'élastomère polymère à travers un rouleau
chaud pour comprimer le textile non tissé imprégné d'élastomère polymère ; et
l'élution des composants mer à partir des deux types ou plus de fibres conjuguées
îlot-mer pour former un textile non tissé ultrafin, dans lequel la température du
rouleau chaud est maintenue dans une plage de 80 à 200 °C, et, le cuir artificiel
a un taux de récupération de 80 % ou plus, le taux de récupération étant mesuré à
l'aide d'un appareil de la série PV VMS produit par G&P Technology comme suit :
une charge initiale de 900 gf / cm 2 est appliquée sur un pénétrateur sphérique et la charge est maintenue pendant 30
secondes ;
puis, 30 secondes après le retrait de la charge initiale, une épaisseur maximale (T1)
du cuir artificiel est mesurée à un niveau de 1/1 000 mm ;
la charge initiale est à nouveau appliquée pendant 30 secondes et une épaisseur minimale
(T2) est mesurée à un niveau de 1/1 000 mm ;
ensuite, 30 secondes après le retrait de la charge initiale, l'épaisseur (T3) du cuir
artificiel est mesurée à un niveau de 1/1 000 mm et un taux de récupération est calculé
à l'aide de l'équation suivante, Taux de récupération (%) = [(T3 - T2) / (T1 - T2)]
× 100.
2. Cuir artificiel comprenant :
un textile non tissé comprenant des fibres courtes ayant une finesse de 0,00111 à
0,555 dtex (0,001 à 0,5 denier) ; et
un élastomère polymère imprégné dans le textile non tissé, dans lequel les fibres
courtes sont deux types ou plus de fibres courtes en polyester ayant différents nombres
d'unités de répétion de -CH2-, et
le cuir artificiel est fabriqué par un procédé comprenant :
la préparation de deux types ou plus de types de fibres conjuguées îlot-mer, comprenant
chacune un composant mer et un composant îlot, les composants îlot des deux types
ou plus de fibres conjuguées îlot-mer étant deux ou plusieurs types de polymères polyester
ayant différents nombres d'unités de répétition de -CH2- ;
la formation d'un textile non tissé à l'aide des deux types ou plus de fibres conjuguées
d'îlot-mer ;
l'imprégnation d'un élastomère polymère dans le textile non tissé ;
le passage du textile non tissé imprégné d'élastomère polymère à travers un rouleau
chaud pour comprimer le textile non tissé imprégné d'élastomère polymère ; et
l'élution des composants de la mer à partir des deux types ou plus de fibres conjuguées
îlot-mer pour former un textile non tissé ultrafin, dans lequel la température du
rouleau chaud est maintenue dans une plage de 80 à 200 °C, et dans lequel le cuir
artificiel a un taux de récupération de 80 % ou plus, le taux de récupération étant
mesuré à l'aide d'un appareil de la série PV VMS produit par G&P Technology comme
suit :
une charge initiale de 900 gf / cm 2 est appliquée sur un pénétrateur sphérique et la charge est maintenue pendant 30
secondes ;
puis, 30 secondes après le retrait de la charge initiale, une épaisseur maximale (T1)
du cuir artificiel est mesurée à un niveau de 1/1 000 mm ;
la charge initiale est à nouveau appliquée pendant 30 secondes et une épaisseur minimale
(T2) est mesurée à un niveau de 1/1 000 mm ;
ensuite, 30 secondes après le retrait de la charge initiale, l'épaisseur (T3) du cuir
artificiel est mesurée à un niveau de 1/1 000 mm et un taux de récupération est calculé
à l'aide de l'équation suivante, Taux de récupération (%) = [(T3 - T2) / (T1 - T2)]
× 100
3. Cuir artificiel selon la revendication 2, dans lequel le nombre des unités de répétition
de chacun des deux types ou plus de fibres courtes en polyester est de deux à quatre.
4. Cuir artificiel selon la revendication 2, dans lequel le textile non-tissé comprend
5 à 95 % en poids de fibres courtes de polyéthylène téréphtalate.
5. Cuir artificiel selon la revendication 2, dans lequel le textile non tissé a un coefficient
de variation de poids de 20 % ou moins, dans lequel le coefficient de variation de
poids (CV%) est calculé en collectant des échantillons à différentes positions du
textile non-tissé, en mesurant un poids par unité de surface des échantillons, en
calculant un écart-type et une moyenne arithmétique à l'aide du poids mesuré par unité
de surface et en obtenant le coefficient de variation de poids conformément à l'équation
suivante :
coefficient de variation de poids (CV%) = écart type / moyenne arithmétique.
6. Cuir artificiel selon la revendication 2, dans lequel les deux types ou plus de fibres
courtes en polyester ont une longueur de 5 à 100 mm.
7. Cuir artificiel selon la revendication 2, dans lequel une récupération élastique du
cuir artificiel à un allongement de 10 % est de 80 % ou plus, la récupération élastique
étant mesurée comme suit :
un échantillon dans lequel une distance de 200 mm est marquée est monté sur un testeur
de traction dans lequel une distance entre les pinces est de 250 mm, allongée à un
allongement de 10 % à une vitesse de 50 mm / min et est maintenue pendant une minute
;
ensuite, la charge est enlevée à la même vitesse que la résistance à la traction,
l'échantillon est maintenu pendant trois minutes, une distance réelle (x) de la distance
indiquée ci-dessus est mesurée et la récupération élastique est mesurée conformément
à l'équation suivante ;
8. Cuir artificiel selon la revendication 2, dans lequel une différence entre un coefficient
de frottement dans une direction avant parallèle à une direction de la fibre du cuir
artificiel et un coefficient de frottement dans une direction inverse de la direction
avant est de 0,30 ou moins, dans lequel le coefficient de frottement dans la direction
avant qui est une direction telle que la direction de la fibre et le coefficient de
frottement dans la direction inverse opposée à la direction de la fibre sont mesurés
à l'aide d'un testeur de friction produit par Toyoseiko Co., Ltd., dans lequel des
échantillons identiques sont utilisés comme des matériaux de frottement supérieurs
et inférieurs et le matériau supérieur est placé de telle sorte que sa direction de
fibre est opposée à une direction de mouvement du testeur de frottement, le matériau
de frottement inférieur est collé pendant la mesure du coefficient de frottement dans
la direction avant de telle sorte que la direction de mouvement du testeur de friction
soit équivalent à la direction de la fibre, et le matériau frottement inférieur est
collé pendant la mesure du coefficient de frottement dans le sens inverse de telle
sorte que le sens de déplacement du testeur de frottement soit opposé au sens de la
fibre, dans des conditions comprenant une distance de déplacement d'environ 20 cm
et un contrepoids de 200 g du matériau de frottement inférieur, un objet auquel une
force de frottement est appliqué, une cellule de charge de 1 kg et une échelle de
graphique de X1, les coefficients de frottement sont mesurés trois fois et une moyenne
des mesures obtenues est calculée pour obtenir une valeur finale de coefficient de
frottement, et les valeurs des coefficients de frottement sont déterminées en lisant
une force de frottement statique maximale.
9. Cuir artificiel selon la revendication 2, dans lequel le cuir artificiel a une compressibilité
de 8 à 50 %, la compressibilité étant mesurée à l'aide d'un appareil de la série PV
VMS produit par G&P Technology comme suit :
une charge initiale de 900 gf / cm2 est appliquée sur un pénétrateur sphérique et la charge est maintenue pendant 30
secondes, puis 30 secondes après la suppression de la charge initiale, une épaisseur
maximale (T1) du cuir artificiel est mesurée à un niveau de 1/1 000 mm, la charge
initiale est à nouveau appliquée pendant 30 secondes et une épaisseur minimale (T2)
est mesurée à un niveau de 1/1 000 mm, ensuite, 30 secondes après le retrait de la
charge initiale, l'épaisseur (T3) du cuir artificiel est mesurée à un niveau de 1/1
000 mm et une compressibilité est calculée à l'aide de l'équation suivante, Compressibilité
(%) = [(T1 - T2) / T1] × 100