Non-woven artificial leather using dope-dyed polyester sea-island type composite yarn and method for manufacturing same

Abstract

Method for manufacturing artificial leather having excellent fastness and dyeing properties by using a dope-dyed polyester sea-island type composite yarn and artificial leather produced by the method are disclosed. A non-woven fabric is made of a dope-dyed polyester sea-island type composite yarn, to which an organic pigment and / or inorganic pigment is added. The yarn is impregnated with a polyurethane resin containing an organic and / or inorganic pigment, followed by weight reduction processing and dying with a disperse dye. The fabric / artificial leather expresses an uniform and deep color.

Description

TECHNICAL FIELD[0001]The present disclosure relates to a method for manufacturing artificial leather having excellent fastness and dyeing properties by using a dope-dyed polyester sea-island type composite yarn, and artificial leather manufactured by the same method.BACKGROUND ART[0002]Artificial leather includes a non-woven fabric with a three-dimensional structure as a primary backing, and has a microporous structure as a whole due to a three-dimensional structure of ultrafine yarn and polyurethane resin. Thus, the artificial leather has a touch feeling of a leather skin layer which is similar to natural leather, and thus is widely used in various fields such as shoes, clothes, gloves, miscellaneous goods, furniture, automobile interior materials, etc.[0003]Conventional ultrafine fiber nonwoven artificial leather has difficulty in uniform dying and deep shade development of ultrafine yarns, and due to the non-dyeability of the polyurethane resin, a dyeing difference occurs between...

AI Technical Summary

Benefits of technology

[0014]According to the present disclosure, a non-woven fabric, which is made of a dope-dyed polyester sea-island type composite yarn to which an organic or inorganic pigment, or both an organic pigment and an inorganic pigment are added, is produced by: impregnating the same with a polyurethane resin to which an organic or inorganic pigment, or both an organic pigment and an inorganic pigment are added; performing weight reduction processing; and then dying the same with a disperse dye, whereby various colors can be expressed, the artificial leather is uniformly dyed with a dye, and the amount of dye used can be reduced by excellent dyeability and deep color expression.

[0015]In addition, high-grade quality is expressed while having excellent fastness, thereby making it possible to develop products for advanced applications such as interior materials for a vehicle.DETAILED DESCRIPTION OF THE EMBODIMENTS

[0016]According to one embodiment of the present disclosure, an artificial leather having improved fastness properties is produced by preparing a dope-dyed polyester sea-island type composite yarn to which an organic or inorganic pigment, or both an organic pigment and an inorganic pigment are added, making the prepared sea-island type composite yarn into staple fibers to produce a non-woven fabric; impregnating the nonwoven fabric with a polyurethane resin to which a pigment is added; performing alkaline weight reduction processing to make ultrafine fibers, and then buffing the surface of the ultrafine fiber nonwoven fabric to form napping; and dyeing the napped nonwoven fabric with a disperse dye.

[0017]The step of preparing a sea-island type composite yarn includes a step composite-spinning a first polymer of a sea component dissolved and eluted in a solvent, and a second polymer of an island component remaining without being dissolved in solvent.

[0018]The first polymer of the sea component may be composed of a copolyester, polystyrene, polyethylene, or the like. Preferably, it may be composed of a copolyester having excellent alkaline solubility.

[0019]The second polymer of the island component may be composed of a polyester material which can be dyed with a disperse dye without being dissolved in an alkaline solvent, and specific examples thereof include polyethylene terephthalate, polyoxyethylene benzoate, polybutylene terephthalate, polytrimethylene terephthalate, polytriethylene terephthalate, and the like.

Problems solved by technology

Conventional ultrafine fiber nonwoven artificial leather has difficulty in uniform dying and deep shade development of ultrafine yarns, and due to the non-dyeability of the polyurethane resin, a dyeing difference occurs between the ultrafine yarn and the polyurethane resin, and two-tone or uneven dyeing occur.

As an excessive amount of dye is introduced for the development of deep shade, the dyeing cost increases and the fastness decreases, so that it is difficult to achieve a luxuriously high quality.

The above method can obtain the effect of improving the dyeing fastness by combination dyeing of the dope-dyed yarn and the piece dyeing method, but since this method uses a vat dye, light resistance is lowered as compared with a disperse dye and the weather resistance of the polyamide fibers is lowered, and thus there is a problem that it is difficult to apply to automotive interior materials.

Since the above method uses a black dope-dyed ultrafine yarn, it is possible to have excellent fastness and provide an effect of generating no dye migration, but artificial leather is limited to circular knitted fabric of dope-dyes polyester yarn.

Consequently, since the quality characteristics are limited compared to the suede type of artificial leather made of non-woven fabric, there is a disadvantage that usage is limited to high value-added products for furniture, interior materials, high-quality miscellaneous goods, and the like.

However, there is a disadvantage in that the mechanical strength required for leather is insufficient, and it can be applied only to gray or black achromatic series, so that it is impossible to develop a product with various colors.

Consequently, there is a problem that the light resistance of the artificial leather is lowered compared to disperse dyes, and in the case of using the dope-dyed polyester yarn, the structure is warp-knitted fabric or circular-knitted fabric, which causes a problem that the product quality is inferior to that of nonwoven artificial leather.