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

a composite yarn and non-woven technology, applied in the direction of dyeing process, textiles and papermaking, etc., can solve the problems of increased dyeing cost, two-tone or uneven dyeing, and dyeing difference between ultrafine yarns, so as to achieve excellent dyeing and color expression, the effect of reducing the amount of dye used

Pending Publication Date: 2021-01-28
KOLON IND INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention relates to a non-woven fabric that is made from a special type of yarn to which an organic or inorganic pigment, or both, are added. The fabric is then impregnated with a polyurethane resin, and then weight reduction processing is performed to create an ultrafine fiber non-woven fabric. The non-woven fabric is then dried with a disperse dye, resulting in a non-woven fabric with vivid colors, uniform dyeing, and reduced dye usage. This non-woven fabric has high-quality and fastness properties, making it useful for various applications such as interior materials for vehicles. The invention provides an improved method for producing a non-woven fabric with enhanced pigment expression and reduced dye usage.

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.

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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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0038]Polyethylene terephthalate was prepared as an island component, an alkali-soluble copolymer polyester was prepared as a sea component, and then the island component and the sea component were introduced into an extruder, followed by melt extrusion. When the island component was melt-extruded, a master batch containing 4 wt % of carbon black, 8 wt % of yellow organic pigment, and 8 wt % of red organic pigment was side-fed to the island component, and discharged through a spinning nozzle so that the content of a pigment in the island component was 1 wt %. Thereby, a dope-dyed polyester sea-island type composite yarn was prepared.

[0039]Subsequently, the composite yarn was crimped so that the crimp number became 10 to 13 / inch, fixed by heating, and then cut into a size of 51 mm to prepare a sea-island type of staple fiber. The sea-island staple fibers were laminated into a web through a carding step and a crosslapping step, followed by needle punching to prepare a nonwoven fabric....

text example 2

Measurement of Dyeing Fastness

[0055]The light fastness and rubbing fastness of the artificial leathers prepared in the examples and comparative examples were measured by the following method, and the evaluation results are shown in Table 3.[0056]Fastness to light: The artificial leather was irradiated with light at 338.6 KJ / m2 according to the method specified in ISO 105-B06: 1998 Condition Five, and the grade of fastness to light was determined using the grayscale (ISO 105 A02).[0057]Fastness to rubbing: The fastness to rubbing was measured according to the ISO 105×12 method. In the evaluation of the fastness to dry rubbing, two specimens of a 50 mm width and a 130 mm length parallel to the longitudinal direction were fixed to the test stand of the rubbing tester, and rubbers of the test rollers were covered with white cotton cloth of a 50 mm length and a 50 mm length and fixed. After applying a load of 9±0.2 N to the rubber, the surface of the specimen was reciprocated 10 times at...

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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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...

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): D06N3/00D06N3/14D06P1/16
CPCD06N3/0011D06N3/0004D06N3/14D06N2209/0807D06P1/16D06N2211/28D06N3/0075D06N3/00D06N3/0036D06P3/32
Inventor PARK, JONG-HOPIAO, ZHEQUANJUNG, DAE-YOUNG
Owner KOLON IND INC
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