Polyurethane impregnated imitation leather fabric and production method thereof

Abstract

The invention discloses a polyurethane impregnated simulated leather fabric and a production method thereof. The fabric is woven by combing bar GB1, combing bar GB2 and combing bar GB3; combing bar GB1 is a closed variable warp plain weave with at least four needles; combing bar GB2 is an open chain weave with one needle; combing bar GB3 is a reverse closed warp plain weave with two needles; and combing bar GB1 adopts sea island microfiber, combing bar GB2 adopts high shrinkage polyester filament, and combing bar GB3 adopts spandex filament; the front and back sides of the fabric are sea island microfiber surfaces; the fabric is treated with polyurethane impregnation and sanding; the back side of the fabric has long fluff formed by the extension line cut off by the sanding treatment, and the front side of the fabric has short fluff formed by the sanding treatment of the coil. The simulated leather fabric of the invention has a soft and comfortable feel, has the suede effect and leather feel of simulated leather, and the fabric shading cannot be seen, and can replace non-woven microfiber leather and be applied to the fields of automotive interiors, consumer electronic products, etc.

Description

Technical Field

[0001] The invention belongs to the technical field of textile fabrics, and particularly relates to a polyurethane impregnated simulated leather fabric and a production method thereof. Background Art

[0002] At present, there are two main categories of imitation leather microfiber leather products. One category uses non-woven fabric as the base fabric, and achieves imitation leather effect through polyurethane impregnation and other processes, such as Ultrasuede of Toray in Japan and Alcantara in Italy. Because of the use of non-woven technology, the base fabric has no regular texture, and the quality is comparable to that of genuine leather, becoming the world's top imitation leather microfiber leather brand; the other category uses textile fabrics as the base fabric, including woven and knitted fabrics as the base fabric, and achieves imitation leather effect through polyurethane impregnation and other processes. Non-woven microfiber leather technology is monopolized by foreign technology and is expensive; because the base fabric of textile fabric microfiber leather is woven by corresponding weaving equipment according to certain weaving rules, knitted fabrics are coil structures, and woven fabrics are composed of warp and weft interlacing points, which makes it easy for the suede surface of the impregnated product to reveal the background, that is, the woven texture can be seen, but the natural leather effect cannot be achieved, and the quality cannot be guaranteed, which limits its application range; currently, almost all high-end products such as automotive interiors and consumer electronics use foreign non-woven microfiber leather.

[0003] On the basis of textile base fabrics, it has become a top priority to develop imitation leather fabrics with good suede effect, strong imitation leather feel, natural feel without revealing the background pattern and low price. Summary of the invention

[0004] In order to solve the above technical problems, the purpose of the present invention is to provide a polyurethane impregnated simulated leather fabric and a production method thereof; the fabric obtained by the production method of the present invention has the advantages of no background pattern, good fluffy touch and strong leather feel, which broadens the application field of microfiber leather textile fabrics.

[0005] In order to achieve the above technical objectives and the above technical effects, the present invention is implemented through the following technical solutions:

[0006] A polyurethane impregnated simulated leather fabric, the fabric is woven by a comb GB1, a comb GB2, and a comb GB3; the comb GB1 is a closed variable warp plain structure with at least four needles; the comb GB2 is an open chain structure with one needle; the comb GB3 is a reverse closed warp plain structure with two needles; the comb GB1 adopts sea island microfiber, the comb GB2 adopts high shrinkage polyester filament, and the comb GB3 adopts spandex filament; the front and back sides of the fabric are both sea island microfiber surfaces; the fabric is treated with polyurethane impregnation and sanding; the back side of the fabric has long fluff formed by extension lines cut off after sanding, and the front side of the fabric has short fluff formed by sanding the coils.

[0007] Furthermore, the fabric has a transverse density of more than 50 longitudinal rows / inch and a longitudinal density of more than 76 longitudinal rows / inch.

[0008] Furthermore, the fabric has a thickness of 0.75-0.90 mm.

[0009] Furthermore, the combing bar GB1 is a five-needle closed variable warp plain structure, and the inlay yarn numbers are 1-0 / 4-5 / / ; the inlay yarn numbers of the combing bar GB2 are 1-0 / 0-1 / / ; and the inlay yarn numbers of the combing bar GB3 are 1-2 / 1-0 / / .

[0010] Furthermore, the specifications of the sea-island microfiber are 105D / 36F or 130D / 36F, the specifications of the high-shrinkage polyester filament are 30D / 12F, and the spandex filament is 40D spandex filament.

[0011] The present invention further provides a method for producing a polyurethane-impregnated simulated leather fabric, comprising the following steps:

[0012] (1) A base fabric is knitted on a warp knitting machine using three comb bars GB1, GB2 and GB3, wherein the comb bar GB1 uses sea-island microfibers to knit at least four stitches of closed variable warp plain weave, the comb bar GB2 uses high shrinkage polyester filaments to knit one stitch of open chain weave, and the comb bar GB3 uses spandex yarns to knit two stitches of reverse closed warp plain weave; both sides of the base fabric are sea-island microfiber sides, and the front side of the base fabric is composed of coils, and the back side of the base fabric is composed of extension lines;

[0013] (2) The base fabric which has not been subjected to the sanding treatment is impregnated with the polyurethane resin slurry. After the impregnation, a polyurethane film is formed on the surface of the base fabric. The base fabric is then sanded, and the extension lines on the back side of the base fabric are cut to form long pile. The loops on the front side of the base fabric are sanded to form short pile, thereby obtaining a polyurethane impregnated simulated leather fabric.

[0014] Furthermore, the polyurethane slurry comprises the following components in parts by weight: 8 to 30 parts of polyurethane, 60 to 80 parts of DMF and 1 to 3 parts of color paste.

[0015] Furthermore, before the impregnation treatment, the base fabric is subjected to the following processes in sequence: unwinding, flat-width refining, fiber opening, pre-setting, dyeing, and setting; after the sanding treatment, the base fabric is subjected to water washing and post-setting treatment.

[0016] Furthermore, the content of polyurethane in the fabric is 8% to 20%.

[0017] Furthermore, during the sanding process, the sanding process parameters used on the front side of the fabric are: 220 mesh * 1 sandpaper, speed 18m / min, sanding tension 6%; the sanding process parameters used on the back side of the fabric are: 180 mesh * 1 sandpaper, speed 18m / min, sanding tension 6%.

[0018] The beneficial effects of the present invention are:

[0019] The fabric of the present invention is woven by three warp knitting combs, comb GB1 adopts sea island ultrafine fiber filaments to weave a closed variable warp plain structure with a transverse needle number of at least 4 needles, comb GB2 adopts polyester high shrinkage filaments to weave an open chain structure with 1 needle, and comb GB3 adopts spandex yarns to weave a reverse closed warp plain structure with 2 needles; the organizational structure design is matched with the specifically selected yarns, so that the surface (front and back) of the woven fabric base cloth is covered by the sea island fibers, and the back has a longer extension line, and the polyester high shrinkage yarns and the spandex yarns are hidden in the inner layer of the fabric; the sea island fibers cover the surface of the fabric, which can give the fabric a softer and smoother feel; and the back of the fabric The longer extension lines form a better long-pile effect after impregnation and sanding treatment, and can cover the background texture; the front side of the fabric has a fine short-pile effect formed by the coils after impregnation and sanding treatment; the comb bar GB2 uses polyester high-shrinkage filaments to weave an open chain structure with 1 needle, so that the fabric will shrink very tightly in the longitudinal direction, the longitudinal elasticity is reduced, the longitudinal density is increased, the coils are arranged closely, and the fabric background texture will not be exposed after sanding; the comb bar GB3 uses spandex yarn to weave a closed warp plain structure with a transverse needle number of 2 needles, and the comb bar GB3 is opposite to the comb bar GB1. During the processing, the spandex shrinks, so that the fabric surface can be further tightened and maintain a slight elasticity.

[0020] The polyurethane content of the fabric of the present invention is 8% to 20%; this content is relatively reasonable, and can make the fabric feel and leather feel close to real leather, with good simulated leather effect, and will not cause the defect of hardening of the fabric.

[0021] The production method of the present invention adopts a high-density base fabric design and a post-processing process of first impregnation and then sanding, which can obtain a simulated leather fabric with no visible shading, good tactile feel of the velvet and strong leather feel. The high-density design can ensure that the velvet surface of the fabric does not reveal the shading and has a good quality appearance. The process of not sanding the base fabric before impregnation and sanding it after impregnation can avoid the problem that the velvet is covered by polyurethane after impregnation, resulting in the inability to form a good suede effect;

[0022] The simulated leather fabric of the present invention has a soft and comfortable feel, has the suede effect and leather feel of simulated leather, and no fabric background pattern can be seen. It can replace non-woven microfiber leather and be applied to the fields of automobile interiors, consumer electronic products, etc., thereby broadening the application field of microfiber leather textile fabrics and increasing the international competitiveness of products. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 The present invention is a structural diagram of a polyurethane-impregnated simulated leather fabric. DETAILED DESCRIPTION

[0024] The technical solutions in the present invention will be described clearly and completely below in conjunction with the accompanying drawings and specific embodiments. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0025] like Figure 1 As shown, the present invention provides a polyurethane impregnated simulated leather fabric, which is woven by a comb GB1, a comb GB2, and a comb GB3; the comb GB1 is a closed variable warp plain structure with at least four needles; the comb GB2 is an open chain structure with one needle; the comb GB3 is a reverse closed warp plain structure with two needles; and the comb GB1 adopts sea island microfiber, the comb GB2 adopts high shrinkage polyester filament, and the comb GB3 adopts spandex filament; the front and back sides of the fabric are both sea island microfiber surfaces; the fabric is treated with polyurethane impregnation and sanding; the back side of the fabric has long fluff formed by the extension line cut off after the sanding treatment, and the front side of the fabric has short fluff formed by the coil being sanded.

[0026] The fabric has a horizontal density of more than 50 longitudinal rows / inch and a vertical density of more than 76 horizontal rows / inch; the fabric thickness is 0.75-0.90mm. This high-density base fabric design can ensure that the suede surface of the fabric does not show the background pattern, and has a good quality appearance. This thickness design can ensure that the suede surface is plump, and the fabric has a strong leather feel and a soft feel.

[0027] Furthermore, the combing bar GB1 can preferably be a five-needle closed variable warp plain structure with the inlay yarn number being 1-0 / 4-5 / / ; the inlay yarn number of the combing bar GB2 is 1-0 / 0-1 / / ; and the inlay yarn number of the combing bar GB3 is 1-2 / 1-0 / / .

[0028] Preferably, the specifications of the sea-island microfiber are 105D / 36F or 130D / 36F, the specifications of the high shrinkage polyester filament are 30D / 12F, and the spandex yarn is 40D spandex filament.

[0029] The present invention further provides a method for producing a polyurethane-impregnated simulated leather fabric, comprising the following steps:

[0030] (1) A base fabric is knitted on a warp knitting machine using three comb bars GB1, GB2 and GB3, wherein the comb bar GB1 uses sea-island microfibers to knit at least four stitches of closed variable warp plain weave, the comb bar GB2 uses high shrinkage polyester filaments to knit one stitch of open chain weave, and the comb bar GB3 uses spandex yarns to knit two stitches of reverse closed warp plain weave; both sides of the base fabric are sea-island microfiber sides, and the front side of the base fabric is composed of coils, and the back side of the base fabric is composed of extension lines;

[0031] (2) After the base fabric is unrolled, flat-width refined, opened, pre-shaped, dyed, and fixed, the base fabric that has not been sanded is impregnated in a polyurethane resin slurry, and excess liquid is squeezed out, and then enters a coagulation tank, and is treated with a DMF aqueous solution in the coagulation tank to form a polyurethane film on both sides of the fabric base fabric; the polyurethane slurry comprises the following components in parts by weight: 8 to 30 parts of polyurethane, 60 to 80 parts of DMF, and 1 to 3 parts of color paste; after the impregnation treatment, both sides of the base fabric are sanded, the extension line on the back side of the base fabric is cut to form long fluff, and the coil on the front side of the base fabric is sanded to form short fluff; after the sanding treatment, the base fabric is washed and post-shaped to obtain a polyurethane impregnated simulated leather fabric; the content of polyurethane in the fabric is 8% to 20%.

[0032] In the open width refining process, the temperature is 90°C, the speed is 20-30m / min, and the bath ratio is 1:40.

[0033] In the fiber opening process, the fiber opening temperature is 110°C, the time is 60 min, the heating rate is 1°C / min, the bath ratio is 1:40, and the number of cleaning passes is 2.

[0034] In the pre-setting process, the setting temperature is 180°C and the machine speed is 20m / min.

[0035] In the dyeing process, the dyeing temperature is 130° C., the holding time of the dyeing temperature is 30 minutes, and the pH is 4.5.

[0036] In the setting process after dyeing, the setting temperature is 180°C and the machine speed is 20m / min.

[0037] After impregnation and before sanding, the fabric was dried at a temperature of 130°C and a speed of 10 m / min.

[0038] During the sanding process, the sanding process parameters used on the front side of the fabric are: 220 mesh * 1 sandpaper, speed 18m / min, sanding tension 6%; the sanding process parameters used on the back side of the fabric are: 180 mesh * 1 sandpaper, speed 18m / min, sanding tension 6%.

[0039] The washing process is as follows: the impregnated sanded fabric is washed in hot water at 90°C for 30 minutes.

[0040] In the post-setting process, the setting temperature is 180°C and the machine speed is 20m / min.

[0041] Example

[0042] The polyurethane impregnated simulated leather fabric of this embodiment is woven by comb GB1, comb GB2 and comb GB3; the comb GB1 is a five-needle closed variable warp plain structure, and the inlay yarn number is 1-0 / 4-5 / / ; the comb GB2 is a one-needle open chain structure, and the inlay yarn number is 1-0 / 0-1 / / ; the comb GB3 is a two-needle reverse closed warp plain structure, and the inlay yarn number is 1-2 / 1-0 / / ; and the comb GB1 adopts 105D / 36F sea island microfiber, the comb GB2 adopts 30D / 12F high shrinkage polyester filament, and the comb GB3 adopts 40D spandex yarn; the front and back of the fabric are both sea island microfiber surfaces; the fabric is treated with polyurethane impregnation and sanding; the back of the fabric has long fluff formed by the extension line cut off after the sanding treatment, and the front of the fabric has short fluff formed by the sanding treatment of the coil.

[0043] The transverse density of the fabric is 60 longitudinal rows / inch and the longitudinal density is 80 transverse rows / inch; the thickness of the fabric is 0.8mm.

[0044] The method for producing the polyurethane-impregnated imitation leather fabric of this embodiment comprises the following steps:

[0045] (1) A base fabric is knitted on a 28G warp knitting machine using three comb bars GB1, GB2 and GB3; comb bar GB1 uses sea island microfiber to knit a five-needle closed variable warp plain weave, and the inlay yarn number is 1-0 / 4-5 / / ; comb bar GB2 uses high shrinkage polyester filament to knit a one-needle open chain weave, and the inlay yarn number is 1-0 / 0-1 / / ; comb bar GB3 uses spandex to knit a two-needle reverse closed warp plain weave, and the inlay yarn number is 1-2 / 1-0 / / ; both sides of the base fabric are sea island microfiber surfaces, and the front side of the base fabric is composed of coils, and the back side of the base fabric is composed of extension lines;

[0046] (2) After the base fabric is unwound, flat-width refined, opened, pre-shaped, dyed, and shaped, the base fabric that has not been sanded is impregnated in a polyurethane resin slurry, and excess liquid is squeezed out, and then enters a coagulation tank, and is treated with a DMF aqueous solution in the coagulation tank to form a polyurethane film on both sides of the fabric base fabric; the polyurethane slurry comprises the following components in parts by weight: 15 parts of polyurethane, 70 parts of DMF, and 1 part of color paste; after the impregnation treatment, both sides of the base fabric are sanded, the extension line on the back side of the base fabric is cut to form long fluff, and the loop on the front side of the base fabric is sanded to form short fluff; after the sanding treatment, the base fabric is washed and post-shaped to obtain a polyurethane impregnated simulated leather fabric; the content of polyurethane in the fabric of this embodiment is 15%.

[0047] In the open width refining process, the temperature is 90°C, the speed is 20 / min, and the bath ratio is 1:40.

[0048] In the fiber opening process, the fiber opening temperature is 110°C, the time is 60 min, the heating rate is 1°C / min, the bath ratio is 1:40, and the number of cleaning passes is 2.

[0049] In the pre-setting process, the setting temperature is 180°C and the machine speed is 20m / min.

[0050] In the dyeing process, the dyeing temperature is 130° C., the holding time of the dyeing temperature is 30 minutes, and the pH is 4.5.

[0051] In the setting process after dyeing, the setting temperature is 180°C and the machine speed is 20m / min.

[0052] After impregnation and before sanding, the fabric was dried at a temperature of 130°C and a speed of 10 m / min.

[0053] During the sanding process, the sanding process parameters used on the front side of the fabric are: 220 mesh * 1 sandpaper, speed 18m / min, sanding tension 6%; the sanding process parameters used on the back side of the fabric are: 180 mesh * 1 sandpaper, speed 18m / min, sanding tension 6%.

[0054] The washing process is as follows: the impregnated sanded fabric is washed in hot water at 90°C for 30 minutes.

[0055] In the post-setting process, the setting temperature is 180°C and the machine speed is 20m / min.

[0056] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any modifications or equivalent transformations made using the contents of the present invention's specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A polyurethane impregnated imitation leather fabric, characterized in that: The fabric is woven by combing bar GB1, combing bar GB2 and combing bar GB3; the combing bar GB1 is a closed variable warp plain weave with at least four needles; the combing bar GB2 is an open chain weave with one needle; the combing bar GB3 is a reverse closed warp plain weave with two needles; the combing bar GB1 adopts sea island microfiber, the combing bar GB2 adopts high shrinkage polyester filament, and the combing bar GB3 adopts spandex filament; the front and back sides of the fabric are both sea island microfiber surfaces; the fabric is treated with polyurethane impregnation and sanding; the back side of the fabric has long fluff formed by the extension line cut off after the sanding treatment, and the front side of the fabric has short fluff formed by the sanding treatment of the coil; The thickness of the fabric is 0.75-0.90 mm; the specification of the sea-island microfiber is 105D / 36F or 130D / 36F, the specification of the high-shrinkage polyester filament is 30D / 12F, and the spandex yarn is 40D spandex filament.

2. The polyurethane impregnated imitation leather fabric according to claim 1, characterized in that: The fabric has a transverse density of more than 50 longitudinal rows / inch and a longitudinal density of more than 76 longitudinal rows / inch.

3. The method for producing a polyurethane impregnated imitation leather fabric as claimed in claim 1 or 2, characterized in that: The steps include: (1) A base fabric is knitted on a warp knitting machine using three comb bars GB1, GB2 and GB3, wherein the comb bar GB1 uses sea-island microfibers to knit at least four stitches of closed variable warp plain weave, the comb bar GB2 uses high shrinkage polyester filaments to knit one stitch of open chain weave, and the comb bar GB3 uses spandex yarns to knit two stitches of reverse closed warp plain weave; both sides of the base fabric are sea-island microfiber sides, and the front side of the base fabric is composed of coils, and the back side of the base fabric is composed of extension lines; (2) The base fabric which has not been subjected to the sanding treatment is impregnated with the polyurethane resin slurry. After the impregnation, a polyurethane film is formed on the surface of the base fabric. The base fabric is then sanded, and the extension lines on the back side of the base fabric are cut to form long pile. The loops on the front side of the base fabric are sanded to form short pile, thereby obtaining a polyurethane impregnated simulated leather fabric.

4. A method for producing a polyurethane-impregnated imitation leather fabric according to claim 3, characterized in that: The polyurethane resin slurry comprises the following components in parts by weight: 8-30 parts of polyurethane, 60-80 parts of DMF and 1-3 parts of color paste.

5. A method for producing a polyurethane-impregnated imitation leather fabric according to claim 3, characterized in that: Before the impregnation treatment, the base fabric also undergoes the following processes in sequence: unwinding, flat-width refining, fiber opening, pre-setting, dyeing, and setting; after the sanding treatment, the base fabric also undergoes water washing and post-setting treatment.

6. A method for producing a polyurethane-impregnated imitation leather fabric according to claim 3, characterized in that: The content of polyurethane in the fabric is 8% to 20%.

7. A method for producing a polyurethane impregnated imitation leather fabric according to claim 3, characterized in that: During the sanding process, the sanding process parameters used on the front side of the fabric are: 220 mesh * 1 sandpaper, speed 18m / min, sanding tension 6%; the sanding process parameters used on the back side of the fabric are: 180 mesh * 1 sandpaper, speed 18m / min, sanding tension 6%.

Images