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Sheet-like article and a production method therefor

a production method and technology of a sheet-like article, applied in the field of environmental protection production methods of sheet-like articles, can solve the problems of poor softness of texture, high harmfulness of organic solvents to the human body and the environment, and stiff texture of coagulating polyurethane, etc., to achieve elegant surface quality, fold and crease recovery and flexibility, and dense fiber feel

Inactive Publication Date: 2020-05-14
TORAY IND INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0014]An object of the present invention is to provide a sheet-like article that can be produced from an environment-friendly production process, compares favorably in terms of a uniform feel with artificial leather products produced from organic solvent based polyurethane, and has elegant surface quality and good texture, and also relates to a production method therefor.
[0015]Another object of the present invention is to provide a sheet-like article that contains a porous polyurethane structure produced from water-dispersed polyurethane and has fold and crease recoverability and flexibility equivalent to those of artificial leather products produced from solvent based polyurethane, and also relates to a production method therefor.
[0027]According to the present invention, a porous structure can be developed from water-dispersed polyurethane using an environment-friendly production process to achieve fold and crease recoverability and flexibility closely equivalent to those of products produced from a fibrous base material containing organic solvent based polyurethane, making it possible to provide a sheet-like article containing raised hairs with a uniform length similar to those in artificial leather produced from organic solvent based polyurethane and having elegant surface quality with a dense fiber feel and good texture with high flexibility and crease recoverability.

Problems solved by technology

However, since organic solvents are generally high in harmfulness to the human body and the environment, the production of a sheet-like article strongly requires a technique that does not use an organic solvent.
However, sheet-like articles that are produced by impregnating a fibrous base material with a dispersion liquid of a water-dispersible polyurethane, which is prepared by dispersing a water-dispersible polyurethane in a liquid, and subsequently coagulating the polyurethane tend to have the problem of stiff texture.
However, such texture still tends to be poor in softness compared to products produced from a base material containing a solution of polyurethane in an organic solvent.
However, such texture still tends to be poor in softness compared to products produced from a base material containing a solution of polyurethane in an organic solvent.

Method used

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
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  • Sheet-like article and a production method therefor
  • Sheet-like article and a production method therefor
  • Sheet-like article and a production method therefor

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0193]Polyethylene terephthalate copolymerized with 8 mol % sodium 5-sulfoisophthalate was used as sea component and polyethylene terephthalate was used as island component to produce an island-in-sea type composite fiber in which the composition ratio was 20 mas % sea component and 80 mas % island component, the number of islands was 16 islands / filament, and the average filament diameter was 20 μm. The island-in-sea type composite fiber obtained was cut into pieces with a fiber length of 51 mm to provide staple. It was then passed through a card and a cross lapper to form a fiber web, which was subjected to needle punching to produce a non-woven fabric.

[0194]The non-woven fabric obtained in this manner was shrunk by immersing it in hot water at a temperature of 97° C. for 2 minutes, and then dried at a temperature of 100° C. for 5 minutes. Subsequently, the resulting nonwoven fabric was impregnated with a dispersion liquid prepared by adjusting water-dispersed polyurethane dispersi...

example 2

[0196]Except that the same nonwoven fabric as in Example 1 was impregnated with a dispersion liquid prepared by adjusting water-dispersed polyurethane dispersion liquid A to a solid content of 20%, adding an epoxy based crosslinking agent [CR-5L, manufactured by DIC] to an effective component content of 5 mass % relative to the polyurethane solid content, adding an association type viscosity improver [Thickner 627N, manufactured by San Nopco Limited] to an effective component content of 4 mass % relative to the polyurethane solid content, and adding magnesium sulfate to 1.2 mass % relative to the polyurethane solid content, the same procedure as in Example 1 was carried out to provide artificial leather with a metsuke of 223 g / m2. The falling-off rate of polyurethane during the water-dispersed polyurethane coagulation step in hot water was as small as 0.1%, suggesting scarce occurrence. The resulting artificial leather had good appearance quality and good texture free of a paper-lik...

example 3

[0197]Polyethylene terephthalate copolymerized with 8 mol % sodium 5-sulfoisophthalate was used as sea component and polyethylene terephthalate was used as island component to produce an island-in-sea type composite fiber in which the composition ratio was 20 mas % sea component and 80 mas % island component, the number of islands was 16 islands / filament, and the average filament diameter was 20 μm. The island-in-sea type composite fiber obtained was cut into pieces with a fiber length of 51 mm to provide staple. It was then passed through a card and a cross lapper to form a fiber web, which was subjected to needle punching to produce a non-woven fabric.

[0198]The non-woven fabric obtained in this manner was shrunk by immersing it in hot water at a temperature of 97° C. for 5 minutes, and then dried at a temperature of 100° C. for 10 minutes. Subsequently, an aqueous solution containing 10 mass % (solid content) of PVA with a degree of saponification of 99% and a degree of polymeriza...

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Abstract

The invention relates to an environmentally friendly production method for a sheet-like article that does not use an organic solvent in the production process and provides a sheet-like article that compares favorably in terms of a uniform feel with artificial leather products produced from an organic solvent based polyurethane and in particular has good surface quality and texture and also provides a production method therefor. The present invention aims to provide a sheet-like article comprising a fibrous base material formed of ultrafine fibers and / or ultrafine fiber bundles provided with, as a binder, a polymer elastomer having a hydrophilic group, any thickness-directional cross section of the sheet-like article containing regions occupied by the polymer elastomer, the regions including independent regions each with a cross-sectional area of 50 μm2 or more, the total area of the independent regions accounting for 0.1% or more and 5.0% or less of the cross-sectional area of the artificial leather in an observation view field. The production method for the sheet-like article according to the present invention provides a production process for a sheet-like article including a fibrous base material formed of ultrafine fibers and, as a binder, a polymer elastomer having a hydrophilic group, the process including a step for adding an aqueous resin dispersion liquid containing a water-dispersed polymer elastomer and a viscosity improver to a fibrous base material and a step for coagulating the polymer elastomer in hot water at a temperature of 50° C. to 100° C.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This is a divisional patent application of U.S. National Phase Application 15 / 119,025, filed on Aug. 15, 2016, which is a U.S. National Phase application of PCT / JP2015 / 054941, filed on Feb. 23, 2015, and claims priority to Japanese Patent Application No. 2014-036516, filed on Feb. 27, 2014, the disclosures of each of these applications being incorporated herein by reference in their entireties for all purposes.FIELD OF THE INVENTION[0002]The invention relates to an environmentally friendly production method for a sheet-like article that does not use an organic solvent in the production process and particularly relates to a sheet-like article that has good surface quality and texture and to a production method therefor.BACKGROUND OF THE INVENTION[0003]Sheet-like articles made up mainly of a fibrous base material, such as nonwoven fabric, and polyurethane have excellent features that natural leathers do not have, and are widely utilized in ...

Claims

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D06N3/00D06N3/14
CPCD06N3/0004D06N2205/023D06N3/14
Inventor MURAHARA, HISASHINAKAI, SHUNICHIROTSUCHIMOTO, TAKAHIRO
Owner TORAY IND INC
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