A method for preparing a breathable bio-based synthetic leather

Abstract

The present application relates to a kind of preparation method of breathable bio-based synthetic leather, select the base cloth containing pineapple fiber, wet water-based bio-based slurry is scraped on the base cloth, is formed by oven drying, and water-based bio-based base is selected plate release paper, the prepared dry water-based surface layer slurry is scraped on the release paper, the prepared dry water-based middle layer slurry is scraped on the surface layer film that has been dried, the prepared dry water-based bottom layer slurry is scraped on the middle layer film that has been dried, water-based bio-based base is adhered on dry water-based bottom layer by sticking wheel, and is solidified after third oven drying;Release paper is separated from synthetic leather, and water-based bio-based synthetic leather semi-finished product is prepared;Synthetic leather semi-finished product is preheated by oven first;Again, the surface is baked by heating tube heating cover, so that water-based bio-based synthetic leather surface softens immediately and is adsorbed with vacuum wheel, and is demoulded cooling;By wheel suction flower becomes pattern, product pattern depth is adjustable, and the hand feeling is full, and the strong leather feeling is strong.

Description

Technical Field

[0001] This invention relates to the field of synthetic leather, and more particularly to a method for preparing bio-based synthetic leather with absorbent texture. Background Technology

[0002] In the synthetic leather industry, existing common bio-based synthetic leather is generally made by using release paper as a mold, coating bio-based materials onto the release paper, drying it into a film, and then bonding the bio-based base fabric to the bio-based surface film with an adhesive. This process has several drawbacks: 1. Due to the limitations of the release paper production process and the dry lamination process, it cannot produce deep, coarse patterns, resulting in relatively simple patterns; 2. Due to the dry process, the bio-based coating cannot be too thick, making the product feel less full and lacking the feel of genuine leather. Summary of the Invention

[0003] The present invention aims to solve the problems existing in the prior art by providing a method for preparing bio-based synthetic leather with absorbent texture. The leather can be patterned by using a wheel to absorb texture, and the depth of the texture can be adjusted, resulting in a full hand feel and a strong genuine leather feel.

[0004] The technical solution adopted by this invention to solve its technical problem is as follows: A method for preparing this absorbent bio-based synthetic leather includes the following steps:

[0005] Step 1: Selection of bio-based substrate:

[0006] The bio-based base fabric is made of pineapple fiber. The base fabric containing pineapple fiber is more resilient than traditional cotton fiber, the fabric is crisp and wrinkle-free, and has a soft and smooth feel. The surface of pineapple fiber is very rough, with longitudinal gaps and pores, which makes the base fabric better for bio-based coating, and the overall adhesion is strong, which can better facilitate printing.

[0007] Step 2: Preparation of wet-process water-based bio-based slurry: by weight

[0008] Mix 100 parts of water-based bio-based resin and 5-10 parts of bio-based filler in a disperser at low speed. While stirring, add 0.3-0.5 parts of dispersant, 0.5-1 parts of crack inhibitor, 1-3 parts of thickener, 2-5 parts of foam stabilizer, and 0.2-0.5 parts of curing agent in sequence to ensure that each additive has sufficient mixing time, resulting in a more uniform mixture and better mixing effect.

[0009] Step 3: Production of wet-process aqueous bio-based base liquor: by weight

[0010] The slurry prepared in step two is applied to the selected bio-based fabric using a direct coating production line, and then dried in an oven to form a water-based bio-based base. The water-based bio-based base has good folding resistance, high peel strength, and excellent environmental performance.

[0011] Step 4: Preparation of dry-process water-based surface layer slurry: by weight

[0012] Stir 100 parts of water-based dry resin in a disperser, and while stirring, add the following in sequence: 0.8-1.5 parts of leveling agent, 1-2 parts of hand feel agent, 0.8-1.5 parts of thickener, 0.5-0.8 parts of curing agent, and 3-10 parts of water-based color paste;

[0013] Step 5: Preparation of dry-process water-based intermediate layer slurry: by weight

[0014] Stir 100 parts of water-based dry resin in a disperser, and while stirring, add 0.5-1 parts of leveling agent, 1-2 parts of thickener, 0.2-0.5 parts of curing agent, and 3-8 parts of water-based color paste in sequence;

[0015] Step Six: Preparation of Dry-Process Water-Based Undercoat Slurry: by weight

[0016] Stir 100 parts of water-based dry-process base resin with a disperser, and while stirring, add 0.3-0.8 parts of leveling agent, 1-3 parts of thickener, and 3-6 parts of curing agent in sequence;

[0017] Step 7: Dry process for producing water-based bio-based veneers:

[0018] Produced using a dry-process line, using flat release paper, the dry-process water-based top layer slurry prepared in step four is coated onto the release paper and dried in a first oven to form a film; the dry-process water-based middle layer slurry prepared in step five is coated onto the dried top layer film and dried in a second oven to form a film; the dry-process water-based bottom layer slurry prepared in step six is ​​coated onto the dried middle layer film; the water-based bio-based base layer prepared in step three is bonded to the dry-process water-based bottom layer using a bonding wheel and dried and cured in a third oven; the release paper is then peeled off from the synthetic leather to obtain a semi-finished water-based bio-based synthetic leather product;

[0019] Step 8: Post-processing with texturing:

[0020] The semi-finished water-based bio-based synthetic leather prepared in step seven above is further processed on a vacuum roller machine with appropriate vacuum rollers. The semi-finished synthetic leather is first preheated in an oven and then baked on the surface by an electric heating tube cover. After the surface of the water-based bio-based synthetic leather is softened, it is immediately adsorbed by the vacuum roller. After demolding and cooling, the surface of the leather will show the texture of the roller used, thus producing water-based bio-based synthetic leather with three-dimensional texture and full hand feel.

[0021] To further improve the process, the rotation speed in step two is controlled at 300-700 rpm, the stirring time at 60-90 minutes, and the viscosity at 8000-10000 cps.

[0022] To further improve the process, in step three, the slurry prepared in step two is applied to the selected bio-based fabric using a direct coating production line, with the feed rate controlled at 500-800g / m.

[0023] To further improve the process, in step three, the oven temperature is controlled between 100-170℃, and the temperature is increased in a gradient manner.

[0024] To further improve the process, in step four, the speed of the disperser during stirring is controlled at 200-500 rpm, the stirring time is 30-60 minutes, and the viscosity is controlled at 3000-5000 cps.

[0025] To further improve the process, in step five, the stirring speed of the disperser is controlled at 300-800 rpm, the stirring time is 50-80 minutes, and the viscosity is controlled at 4000-6000 cps.

[0026] To further refine the process, in step six, the speed of the disperser during stirring is controlled at 500-900 rpm, the stirring time is 30-40 minutes, and the viscosity is controlled at 10000-15000 cps.

[0027] To further refine the process, in step seven, when applying the dry water-based top layer slurry prepared in step four onto the release paper, the feed rate is controlled at 80-100 g / m²; the temperature during film formation in the first oven is controlled at 90-130℃, with a gradual increase in temperature; when applying the dry water-based intermediate layer slurry prepared in step five onto the dried top layer film, the feed rate is controlled at 110-130 g / m²; the temperature during film formation in the second oven is controlled at 90-140℃, with a gradual increase in temperature; when applying the dry water-based bottom layer slurry prepared in step six onto the dried intermediate layer film, the feed rate is controlled at 100-120 g / m²; and the temperature during curing in the third oven is controlled at 110-140℃, with a gradual increase in temperature.

[0028] To further improve the process, the preheating temperature of the oven in step eight is controlled at 150-170℃, and the temperature is increased in a gradient manner; the temperature of the heating tube heating cover when baking the surface is controlled at 180-210℃; after the water-based bio-based synthetic leather surface is softened, it is immediately adsorbed by the vacuum wheel, and the vacuum degree is controlled at -0.05-0.07Mpa.

[0029] The beneficial effects of this invention are: the resulting synthetic leather has a three-dimensional texture and a full feel, making it feel like real leather. The texture depth of existing synthetic leather can only reach 0-0.05mm, but this invention can form patterns by using a roller, and the printing texture depth can reach 0.1-0.3mm. The texture depth of the product is adjustable, and it has good physical properties, which are close to natural leather while being more environmentally friendly. Detailed Implementation

[0030] The present invention will be further described below:

[0031] Example 1

[0032] A method for preparing absorbent bio-based synthetic leather includes the following steps:

[0033] 1. Selection of bio-based substrate:

[0034] The bio-based base fabric is selected from base fabrics containing pineapple fibers;

[0035] 2. Preparation of wet-process water-based bio-based slurry:

[0036] 100 parts of water-based bio-based resin, 5 parts of bio-based filler, 0.3 parts of dispersant, 0.5 parts of crack inhibitor, 1 part of thickener, 2 parts of foam stabilizer, and 0.2 parts of curing agent; stir at low speed using a disperser, with the speed controlled at 300 rpm, and add all the additives in sequence while stirring, stirring for 60 minutes, with a viscosity of 8000 cps;

[0037] 3. Production of wet-process aqueous bio-based base liquor:

[0038] The prepared slurry is coated onto the selected bio-based fabric using a direct coating production line, with the feed rate controlled at 500g / m. The fabric is then dried in an oven to form a water-based bio-based base, with the temperature controlled at a gradual increase of 100℃.

[0039] 4. Preparation of dry-process water-based surface layer slurry:

[0040] 100 parts of water-based dry resin, 0.8 parts of leveling agent, 1 part of hand feel agent, 0.8 parts of thickener, 0.5 parts of curing agent, and 3 parts of water-based color paste; stir with a disperser at 200 rpm, adding all additives sequentially while stirring for 30 minutes, achieving a viscosity of 3000 cps;

[0041] 5. Preparation of dry-process water-based intermediate layer slurry:

[0042] 100 parts of water-based dry resin, 0.5 parts of leveling agent, 1 part of thickener, 0.2 parts of curing agent, and 3 parts of water-based color paste; stir with a disperser at 300 rpm, adding all additives sequentially while stirring for 50 minutes, achieving a viscosity of 4000 cps;

[0043] 6. Preparation of dry-process water-based primer:

[0044] 100 parts of water-based dry-process base resin, 0.3 parts of leveling agent, 1 part of thickener, and 3 parts of curing agent; stir with a disperser at a speed of 500 rpm, adding all additives sequentially while stirring for 30 minutes, to a viscosity of 10000 cps.

[0045] 7. Dry process for producing water-based bio-based laminates:

[0046] Produced using a dry-process line, flat release paper is selected. The dry-process water-based top layer slurry prepared in step four is coated onto the release paper, with the material intake controlled at 80 g / m². It is then dried in a first oven to form a film, with the temperature gradually increasing from 90°C. The dry-process water-based middle layer slurry prepared in step five is coated onto the dried top layer film, with the material intake controlled at 110 g / m². It is then dried in a second oven to form a film, with the temperature gradually increasing from 90°C. The dry-process water-based bottom layer slurry prepared in step six is ​​coated onto the dried middle layer film, with the material intake controlled at 100 g / m². The pre-prepared water-based bio-based base coat is then bonded to the dry-process water-based bottom layer using a bonding wheel. It is then dried and cured in a third oven, with the temperature gradually increasing from 110°C. The release paper is then peeled off from the synthetic leather to obtain a semi-finished water-based bio-based synthetic leather product.

[0047] 8. Post-processing: (This likely refers to a specific process or step, but the context is unclear.)

[0048] The semi-finished water-based bio-based synthetic leather prepared in step seven above is further processed on a vacuum roller with a texture depth of 0.1 mm on a vacuum suction machine. The semi-finished synthetic leather is first preheated in an oven with the temperature controlled at a gradient increase of 150°C. Then, the surface is baked by an electric heating tube heating cover with the temperature controlled at 180°C, so that the surface of the water-based bio-based synthetic leather is softened and immediately adsorbed onto the vacuum roller. The vacuum degree is controlled at -0.05 MPa. After demolding and cooling, the leather surface will show the texture of the roller used, resulting in a water-based bio-based synthetic leather with a three-dimensional texture and a full hand feel.

[0049] Example 2

[0050] A method for preparing absorbent bio-based synthetic leather includes the following steps:

[0051] 1. Selection of bio-based substrate:

[0052] The bio-based base fabric is selected from base fabrics containing pineapple fibers;

[0053] 2. Preparation of wet-process water-based bio-based slurry:

[0054] 100 parts of water-based bio-based resin, 7 parts of bio-based filler, 0.4 parts of dispersant, 0.7 parts of crack inhibitor, 2 parts of thickener, 3 parts of foam stabilizer, and 0.3 parts of curing agent; stir at low speed using a disperser, controlling the speed at 500 rpm, and add all the additives sequentially while stirring, stirring for 75 minutes, with a viscosity of 9000 cps;

[0055] 3. Production of wet-process aqueous bio-based base liquor:

[0056] The prepared slurry is coated onto the selected bio-based fabric using a direct coating production line, with the feed rate controlled at 650g / m. After drying in an oven, the water-based bio-based base is formed, with the temperature controlled at a gradient increase of 135℃.

[0057] 4. Preparation of dry-process water-based surface layer slurry:

[0058] 100 parts of water-based dry resin, 1.1 parts of leveling agent, 1.5 parts of hand feel agent, 1.1 parts of thickener, 0.6 parts of curing agent, and 6 parts of water-based color paste; stir with a disperser at a speed of 350 rpm, add all additives sequentially while stirring, stir for 45 minutes, and achieve a viscosity of 4000 cps;

[0059] 5. Preparation of dry-process water-based intermediate layer slurry:

[0060] 100 parts of water-based dry resin, 0.7 parts of leveling agent, 1.5 parts of thickener, 0.3 parts of curing agent, and 5 parts of water-based color paste; stir with a disperser at a speed of 550 rpm, add all additives sequentially while stirring, stir for 65 minutes, and achieve a viscosity of 5000 cps.

[0061] 6. Preparation of dry-process water-based primer:

[0062] 100 parts of water-based dry-process base resin, 0.5 parts of leveling agent, 2 parts of thickener, and 4 parts of curing agent; stir with a disperser at 700 rpm, adding all additives sequentially while stirring for 35 minutes, resulting in a viscosity of 12000 cps.

[0063] 7. Dry process for producing water-based bio-based laminates:

[0064] Produced using a dry-process line, flat release paper is selected. The dry-process water-based top layer slurry prepared in step four is coated onto the release paper, with the material intake controlled at 90 g / m². It is then dried in a first oven to form a film, with the temperature gradually increasing from 110°C. The dry-process water-based middle layer slurry prepared in step five is coated onto the dried top layer film, with the material intake controlled at 120 g / m². It is then dried in a second oven to form a film, with the temperature gradually increasing from 115°C. The dry-process water-based bottom layer slurry prepared in step six is ​​coated onto the dried middle layer film, with the material intake controlled at 110 g / m². The pre-prepared water-based bio-based base coat is then bonded to the dry-process water-based bottom layer using a bonding wheel. It is then dried and cured in a third oven, with the temperature gradually increasing from 125°C. The release paper is then peeled off from the synthetic leather to obtain a semi-finished water-based bio-based synthetic leather product.

[0065] 8. Post-processing: (This likely refers to a specific process or step, but the context is unclear.)

[0066] The semi-finished water-based bio-based synthetic leather prepared in step seven above is further processed on a vacuum roller with a texture depth of 0.15 mm on a vacuum suction machine. The semi-finished synthetic leather is first preheated in an oven with the temperature controlled at a gradient increase of 160℃. Then, the surface is baked by an electric heating tube heating cover with the temperature controlled at 195℃, so that the surface of the water-based bio-based synthetic leather is softened and immediately adsorbed onto the vacuum roller. The vacuum degree is controlled at 0.06 MPa. After demolding and cooling, the leather surface will show the texture of the roller used, resulting in a water-based bio-based synthetic leather with a three-dimensional texture and a full hand feel.

[0067] Example 3

[0068] A method for preparing absorbent bio-based synthetic leather includes the following steps:

[0069] 1. Selection of bio-based substrate:

[0070] The bio-based base fabric is selected from base fabrics containing pineapple fibers;

[0071] 2. Preparation of wet-process water-based bio-based slurry:

[0072] 100 parts of water-based bio-based resin, 10 parts of bio-based filler, 0.5 parts of dispersant, 1 part of crack inhibitor, 3 parts of thickener, 5 parts of foam stabilizer, and 0.5 parts of curing agent; stir at low speed using a disperser, with the speed controlled at 300-700 rpm, and add all the additives in sequence while stirring, stirring for 90 minutes, with a viscosity of 10000 cps;

[0073] 3. Production of wet-process aqueous bio-based base liquor:

[0074] The prepared slurry is coated onto the selected bio-based fabric using a direct coating production line, with the feed rate controlled at 800 g / m. After drying in an oven, the water-based bio-based base is formed, with the temperature controlled at a gradient increase of 170°C.

[0075] 4. Preparation of dry-process water-based surface layer slurry:

[0076] 100 parts of water-based dry resin, 1.5 parts of leveling agent, 2 parts of hand feel agent, 1.5 parts of thickener, 0.8 parts of curing agent, and 10 parts of water-based color paste; stir with a disperser at 500 rpm, adding all additives sequentially while stirring for 60 minutes, achieving a viscosity of 5000 cps.

[0077] 5. Preparation of dry-process water-based intermediate layer slurry:

[0078] 100 parts of water-based dry resin, 1 part of leveling agent, 2 parts of thickener, 0.5 parts of curing agent, and 8 parts of water-based color paste; stir with a disperser at 800 rpm, adding all additives sequentially while stirring for 80 minutes, resulting in a viscosity of 6000 cps.

[0079] 6. Preparation of dry-process water-based primer:

[0080] 100 parts of water-based dry-process base resin, 0.8 parts of leveling agent, 3 parts of thickener, and 6 parts of curing agent; stir with a disperser at a speed of 900 rpm, adding all additives sequentially while stirring for 40 minutes, resulting in a viscosity of 15000 cps.

[0081] 7. Dry process for producing water-based bio-based laminates:

[0082] Produced using a dry-process line, flat release paper is selected. The dry-process water-based top layer slurry prepared in step four is coated onto the release paper, with the material intake controlled at 100g / m². It is then dried in a first oven to form a film, with the temperature gradually increasing from 130℃. The dry-process water-based middle layer slurry prepared in step five is coated onto the dried top layer film, with the material intake controlled at 130g / m². It is then dried in a second oven to form a film, with the temperature gradually increasing from 140℃. The dry-process water-based bottom layer slurry prepared in step six is ​​coated onto the dried middle layer film, with the material intake controlled at 120g / m². The pre-prepared water-based bio-based base coat is then bonded to the dry-process water-based bottom layer using a bonding wheel. It is then dried and cured in a third oven, with the temperature gradually increasing from 140℃. The release paper is then peeled off from the synthetic leather to obtain a semi-finished water-based bio-based synthetic leather product.

[0083] 8. Post-processing: (This likely refers to a specific process or step, but the context is unclear.)

[0084] The semi-finished water-based bio-based synthetic leather prepared in step seven above is further processed on a vacuum roller with a texture depth of 0.2 mm on a vacuum suction machine. The semi-finished synthetic leather is first preheated in an oven with the temperature controlled at a gradient increase of 170℃. Then, the surface is baked by an electric heating tube heating cover with the temperature controlled at 210℃, so that the surface of the water-based bio-based synthetic leather is softened and immediately adsorbed by the vacuum roller. The vacuum degree is controlled at 0.07 MPa. After demolding and cooling, the leather surface will show the texture of the roller used, resulting in a water-based bio-based synthetic leather with a three-dimensional texture and a full hand feel.

[0085] The physical properties are shown in the table below:

[0086]

[0087]

[0088] The preparation method used in this invention produces synthetic leather with a three-dimensional texture, a full hand feel, adjustable texture depth, and good physical properties, which can meet the requirements for use in synthetic leather.

[0089] Although the invention has been described with reference to preferred embodiments, those skilled in the art will understand that various changes in form and detail are possible within the scope of the claims.

Claims

1. A method for preparing absorbent bio-based synthetic leather, characterized in that: Includes the following steps: Step 1: Selection of bio-based substrate: The bio-based base fabric is selected from a base fabric containing pineapple fiber, wherein the surface of the pineapple fiber has longitudinal gaps and pores; Step 2: Preparation of wet-process water-based bio-based slurry: Mix 100 parts of water-based bio-based resin and 5-10 parts of bio-based filler in a disperser at low speed. While stirring, add 0.3-0.5 parts of dispersant, 0.5-1 parts of crack inhibitor, 1-3 parts of thickener, 2-5 parts of foam stabilizer, and 0.2-0.5 parts of curing agent in sequence. Step 3: Production of wet-process aqueous bio-based base liquor: The slurry prepared in step two is coated onto the selected bio-based fabric using a direct coating production line, and then dried in an oven to form an aqueous bio-based base. Step 4: Preparation of dry-process water-based surface layer slurry: Stir 100 parts of water-based dry resin in a disperser, and while stirring, add the following in sequence: 0.8-1.5 parts of leveling agent, 1-2 parts of hand feel agent, 0.8-1.5 parts of thickener, 0.5-0.8 parts of curing agent, and 3-10 parts of water-based color paste; Step 5: Preparation of dry-process water-based intermediate layer slurry: Stir 100 parts of water-based dry resin in a disperser, and while stirring, add 0.5-1 parts of leveling agent, 1-2 parts of thickener, 0.2-0.5 parts of curing agent, and 3-8 parts of water-based color paste in sequence; Step Six: Preparation of Dry-Process Water-Based Substrate: Stir 100 parts of water-based dry-process base resin with a disperser, and while stirring, add 0.3-0.8 parts of leveling agent, 1-3 parts of thickener, and 3-6 parts of curing agent in sequence; Step 7: Dry process for producing water-based bio-based veneers: The dry production line is used, and flat release paper is selected. The dry water-based surface layer slurry prepared in step four above is coated onto the release paper and dried in the first oven to form a film. The dry water-based intermediate layer slurry prepared in step five above is coated onto the dried surface film and then dried in a second oven to form a film. The dry water-based base coat slurry prepared in step six is ​​applied to the dried intermediate layer film. The water-based bio-based base coat prepared in step three is then bonded to the dry water-based base coat using a bonding wheel. The mixture is then dried and cured in a third oven. The release paper is then peeled off from the synthetic leather to obtain a semi-finished water-based bio-based synthetic leather product. When the dry water-based top coat slurry prepared in step four is applied to the release paper, the feed rate is controlled at 80-100 g / m². The temperature during film formation in the first oven is controlled at 90-130℃, with a gradual temperature increase. The process involves several steps: First, when applying the dry water-based intermediate layer slurry prepared in step five to the dried top layer film, the application rate should be controlled at 110-130 g / m². Second, the drying temperature in the second oven should be controlled at 90-140℃, with a gradual increase in temperature. Third, when applying the dry water-based bottom layer slurry prepared in step six to the dried intermediate layer film, the application rate should be controlled at 100-120 g / m². Fourth, the drying temperature in the third oven should be controlled at 110-140℃, with a gradual increase in temperature. Step 8: Post-processing with texturing: The semi-finished water-based bio-based synthetic leather prepared in step seven above is first preheated in an oven; then the surface is baked by an electric heating tube cover, so that the surface of the water-based bio-based synthetic leather is softened and immediately adsorbed by the vacuum wheel, then demolded and cooled; the preheating temperature of the oven is controlled at 150-170℃, and the temperature is increased in a gradient manner; the temperature of the surface is controlled at 180-210℃ when the electric heating tube cover bakes the surface, so that the surface of the water-based bio-based synthetic leather is softened and immediately adsorbed by the vacuum wheel, and the vacuum degree is controlled at -0.05-0.07Mpa.

2. The method for preparing a bio-based synthetic leather with absorbent texture according to claim 1, characterized in that: In step three, the oven temperature is controlled between 100-170℃, and the temperature is increased in a gradient manner.

3. The method for preparing a bio-based synthetic leather with absorbent texture according to claim 1, characterized in that: In step four, the speed of the disperser during stirring is controlled at 200-500 rpm, the stirring time is 30-60 minutes, and the viscosity is 3000-5000 cps.

4. The method for preparing a bio-based synthetic leather with absorbent texture according to claim 1, characterized in that: In step five, the speed of the disperser during stirring is controlled at 300-800 rpm, the stirring time is 50-80 minutes, and the viscosity is 4000-6000 cps.

5. The method for preparing a bio-based synthetic leather with absorbent texture according to claim 1, characterized in that: In step six, the speed of the disperser during stirring is controlled at 500-900 rpm, the stirring time is 30-40 minutes, and the viscosity is 10000-15000 cps.

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