Method for manufacturing soft fine crepe type bio-based microfiber base

Abstract

The application discloses a manufacturing method of soft fine-crease type bio-based microfiber base fabric, and the manufacturing method comprises the following steps: bio-based nylon microfiber preparation, needle punching non-woven fabric in the middle of the fiber layer, adding polyurethane slurry containing bio-based nylon micro powder, solidification, extraction, oiling treatment and drying, and the bio-based microfiber base fabric with soft and fine-crease is obtained after the extraction, oiling and drying.

Description

Technical Field

[0001] This invention belongs to the field of artificial leather preparation technology, specifically relating to a method for manufacturing a soft, finely wrinkled bio-based microfiber base. Background Technology

[0002] As environmental protection concepts gain wider acceptance, the synthetic leather industry is also vigorously developing towards eco-friendly practices. Using bio-based materials in synthetic leather products can effectively reduce carbon emissions during production and use, minimizing environmental impact and positively contributing to economic, environmental, and social benefits.

[0003] With the rapid development of microfiber synthetic leather technology, the market has increasingly demanded products that feel like genuine leather, with softness and delicate wrinkles. This drives microfiber synthetic leather to continuously change its structure and improve its quality while effectively reducing carbon emissions, achieving a combination of softness and delicate wrinkles. Summary of the Invention

[0004] To address the above problems, the present invention aims to provide a method for manufacturing a soft, finely wrinkled bio-based microfiber bass.

[0005] To achieve the above objectives, the following technical solution is proposed:

[0006] A method for manufacturing a soft, finely wrinkled bio-based microfiber bass includes the following steps:

[0007] 1) Prepare bio-based nylon microfibers by preparing a three-layer fiber web with filter mesh sandwiched between the microfiber layers and needle-punching and interweaving to obtain a nonwoven fabric.

[0008] 2) Immerse the nonwoven fabric from step 1) into a polyurethane slurry containing ultrafine bio-based nylon micropowder, solidify, extract, oil, and dry to obtain a soft, finely wrinkled bio-based microfiber base.

[0009] Furthermore, bio-based nylon microfibers are prepared by using one or more of the following bio-based nylons: PA56, PA410, PA510, PA610, PA1010, and PA1012 as island phase materials and LDPE or PET as marine phase materials, employing fixed-island or non-fixed-island processes.

[0010] Furthermore, the needle density in step 1) is 20-800 P / cm 2 The needle depth is 2-20mm, distributed across 8 needle plates, meaning there are 8 needle plates arranged sequentially on the needle puncture equipment for needle puncture.

[0011] Furthermore, the filter cloth in step 1) is one of polyester filter cloth, polypropylene filter cloth, nylon filter cloth, or vinylon filter cloth.

[0012] Furthermore, the filter mesh size is 2000~5000 mesh.

[0013] Further, the ultrafine bio-based nylon micro powder mentioned in step 2) is PA56 micro powder, PA410 micro powder, PA510 micro powder, PA610 micro powder, PA1010 micro powder or PA1012 micro powder, and the particle size range of the ultrafine bio-based nylon micro powder is 4~10 micrometers.

[0014] Furthermore, the polyurethane slurry containing added ultrafine bio-based nylon micropowder comprises, by weight, 35-55 parts of oily bio-based polyurethane resin with a solid content of 30%; 10-20 parts of ultrafine bio-based nylon micropowder; 15-55 parts of dimethylformamide; and 0.2-0.5 parts of coagulation regulator. The above components are mixed and dispersed for 20 minutes. The viscosity of the wet slurry is adjusted by adjusting the amount of dimethylformamide, and the viscosity range at 40°C is 3000 cps to 15000 cps.

[0015] Furthermore, the extraction described in step 2) is either a reduced extraction of toluene or a reduced extraction of alkali.

[0016] Furthermore, the drying described in step 2) is a continuous kneading drying process, with a drying temperature of 100-150℃ and a drying time of 25-50 minutes.

[0017] The beneficial effects of this invention are as follows:

[0018] This invention utilizes bio-based nylon chips as the island phase material during the microfiber spinning process. Ultrafine bio-based nylon micropowder is added to the wet impregnation slurry. By using bio-based materials as raw materials, the carbon emissions during the production and subsequent use of microfiber synthetic leather products are significantly reduced. Two layers of filter mesh are sandwiched between the microfiber nonwoven fabric layers. During impregnation, these meshes filter the ultrafine bio-based nylon micropowder in the wet slurry, resulting in a higher content of ultrafine bio-based nylon micropowder in the upper and lower layers, and a lower content in the middle layer. This achieves a final product with a higher density in the upper and lower layers and a lower density in the middle layer, forming a three-layer structure that is tight on the outside and loose on the inside. This structure ensures a smooth surface wrinkle reduction while maintaining a relatively soft overall feel. Detailed Implementation

[0019] The present invention will be further described below with reference to embodiments, but the scope of protection of the present invention is not limited thereto.

[0020] Example 1

[0021] 1) Using PA56 / LDPE at a mass ratio of 50:50 as raw material, bio-based island fiber with a fineness of 6.5 dtex was prepared by island spinning.

[0022] 2) The above-mentioned island fibers are simultaneously processed into three layers of fiber web of equal weight and thickness using three web-laying machines. When the three layers of web are combined, a 2000-mesh nylon filter cloth is laid between the upper and middle layers and the middle and lower layers. The filter cloth and the microfiber layer are interwoven together by needle punching to form a nonwoven fabric with a needle punching density of 20 p / cm. 2 80p / cm 2 150p / cm 2 260p / cm 2 400p / cm 2 580p / cm 2 800p / cm 2 240p / cm 2 The needle-punching depths were 12mm, 20mm, 8mm, 7mm, 7mm, 6mm, 4mm, and 2mm, distributed across eight needle-punching plates. The final high-temperature heat-pressed thickness was 2.5mm, and the density was 0.280kg / m³. 2 .

[0023] 3) Prepare impregnation slurry, wherein the impregnation slurry comprises, by weight:

[0024] Oil-based bio-based polyurethane resin (30% solids content, 100% initial modulus of 6.0 MPa): 55 parts;

[0025] Solvent (DMF): 30 parts;

[0026] Ultrafine bio-based nylon micro powder (PA56): 20 parts, particle size 6 micrometers;

[0027] Solidification regulator (SP-710S): 0.5 parts;

[0028] After high-speed stirring and dispersion for 20 minutes, the viscosity of the wet slurry was measured to be 12500 cps (40℃) using a rotational viscometer.

[0029] 4) The nonwoven fabric prepared in step 2) is immersed in the impregnation slurry prepared in step 3) and rolled multiple times to ensure full penetration. It is then placed in a DMF coagulation bath with a mass concentration of 40% for 15 minutes to coagulate. After rolling, it is washed away in 80°C hot water. Then, it is placed in 80°C hot toluene for 60 minutes to extract the marine components from the microfiber. After extraction, it is oiled and then washed away in 90°C hot water. Finally, it is placed in a continuous tweening machine at 135°C for tweening and drying for 45 minutes to obtain a bio-based microfiber base with inconsistent structure and density between the upper and lower layers and the middle layer.

[0030] 5) The prepared microfiber base was sheeted into three layers along the filter mesh using a sheeting machine, and the mesh was thoroughly removed using a sanding machine. The densities of the upper, middle, and lower layers were measured to be 0.671 kg / m³.2 0.482kg / m 2 0.686 kg / m 2 A single-layer microfiber base layer with a density of 0.608 kg / m³ was prepared using nonwoven fabric without adding a filter mesh, under the same other processes and formulations. 2 For comparison, products prepared by the method of the present invention have finer wrinkles when the difference in softness is not significant.

[0031] Implement column 2

[0032] 1) Using PA510 / LDPE at a mass ratio of 50:50 as raw material, bio-based island fiber with a fineness of 6.5 dtex was prepared by island spinning.

[0033] 2) The above-mentioned island fibers are simultaneously processed into three layers of fiber web of equal weight and thickness using three web-laying machines. When the three layers of web are combined, a 3000-mesh nylon filter cloth is laid between the upper and middle layers and the middle and lower layers. The filter cloth and the microfiber layer are interwoven together by needle punching to form a nonwoven fabric with a needle punching density of 20 p / cm. 2 80p / cm 2 150p / cm 2 260p / cm 2 400p / cm 2 580p / cm 2 800p / cm 2 240p / cm 2 The needle-punching depths were 12mm, 20mm, 8mm, 7mm, 7mm, 6mm, 4mm, and 2mm, distributed across eight needle-punching plates. The final high-temperature heat-pressed thickness was 2.5mm, and the density was 0.280kg / m³. 2 .

[0034] 3) Prepare impregnation slurry, wherein the impregnation slurry comprises, by weight:

[0035] Oil-based bio-based polyurethane resin (30% solids content, 100% initial modulus of 6.0 MPa): 35 parts;

[0036] Solvent (DMF): 30 parts;

[0037] Ultrafine bio-based nylon micro powder (PA510): 10 parts, particle size 6 micrometers;

[0038] Solidification regulator (SP-710S): 0.2 parts;

[0039] After high-speed stirring and dispersion for 20 minutes, the viscosity of the wet slurry was measured to be 5300 cps (40℃) using a rotational viscometer.

[0040] 4) Same as step 4 in Example 1.

[0041] The prepared microfiber base was sheeted into three layers along the filter mesh using a sheeting machine, and the mesh was thoroughly removed using a sanding machine. The densities of the upper, middle, and lower layers were measured to be 0.556 kg / m³. 2 0.347kg / m 2 0.550kg / m 2 A single-layer microfiber base layer with a density of 0.488 kg / m³ was prepared using nonwoven fabric without adding a filter mesh, under the same other processes and formulations. 2 For comparison, products prepared by the method of the present invention have finer wrinkles when the difference in softness is not significant.

[0042] Example 3

[0043] 1) Same as step 1 in Example 1).

[0044] 2) The above-mentioned island fibers are simultaneously processed into three layers of fiber web of equal weight and thickness using three web-laying machines. When the three layers of web are combined, a 2000-mesh polyester filter cloth is laid between the upper and middle layers and the middle and lower layers. The filter cloth and the microfiber layer are interwoven together by needle punching to form a nonwoven fabric with a needle punching density of 20 p / cm. 2 80p / cm 2 150p / cm 2 260p / cm 2 400p / cm 2 580p / cm 2 800p / cm 2 240p / cm 2 The needle-punching depths were 12mm, 20mm, 8mm, 7mm, 7mm, 6mm, 4mm, and 2mm, distributed across eight needle-punching plates. The final high-temperature heat-pressed thickness was 2.5mm, and the density was 0.280kg / m³. 2 .

[0045] 3) Prepare impregnation slurry, wherein the impregnation slurry comprises, by weight:

[0046] Oil-based bio-based polyurethane resin (30% solids content, 100% initial modulus of 6.0 MPa): 40 parts;

[0047] Solvent (DMF): 20 parts;

[0048] Ultrafine bio-based nylon micro powder (PA510): 15 parts, particle size 8 micrometers;

[0049] Solidification regulator (SP-710S): 0.3 parts;

[0050] After high-speed stirring and dispersion for 20 minutes, the viscosity of the wet slurry was measured to be 12800 cps using a rotational viscometer.

[0051] 4) Same as step 4 in Example 1.

[0052] The prepared microfiber base was sheeted into three layers along the filter mesh using a sheeting machine, and the mesh was thoroughly removed using a sanding machine. The densities of the upper, middle, and lower layers were measured to be 0.694 kg / m³. 2 0.501kg / m 2 0.701kg / m 2 A single-layer microfiber base layer with a density of 0.633 kg / m³ was prepared using nonwoven fabric without adding a filter mesh, under the same other processes and formulations. 2 For comparison, products prepared by the method of the present invention have finer wrinkles when the difference in softness is not significant.

[0053] Example 4

[0054] 1) Using PA610 / LDPE at a mass ratio of 50:50 as raw material, bio-based island fiber with a fineness of 6.5 dtex was prepared by island spinning.

[0055] 2) The above-mentioned island fibers are simultaneously processed into three layers of fiber web of equal weight and thickness using three web-laying machines. When the three layers of web are combined, a 3000-mesh nylon filter cloth is laid between the upper and middle layers and the middle and lower layers. The filter cloth and the microfiber layer are interwoven together by needle punching to form a nonwoven fabric with a needle punching density of 20 p / cm. 2 80p / cm 2 150p / cm 2 260p / cm 2 400p / cm 2 580p / cm 2 800p / cm 2 240p / cm 2 The needle-punching depths were 12mm, 20mm, 8mm, 7mm, 7mm, 6mm, 4mm, and 2mm, distributed across eight needle-punching plates. The final high-temperature heat-pressed thickness was 2.5mm, and the density was 0.280kg / m³. 2 .

[0056] 3) Prepare impregnation slurry, wherein the impregnation slurry comprises, by weight:

[0057] Oil-based bio-based polyurethane resin (30% solids content, 100% initial modulus of 6.0 MPa): 40 parts;

[0058] Solvent (DMF): 40 parts;

[0059] Ultrafine bio-based nylon micro powder (PA1010): 15 parts, particle size 10 micrometers;

[0060] Solidification regulator (SP-710S): 0.3 parts;

[0061] After high-speed stirring and dispersion for 20 minutes, the viscosity of the wet slurry was measured to be 4900 cps (40℃) using a rotational viscometer.

[0062] 4) Same as step 4 in Example 1.

[0063] The prepared microfiber base was sheeted into three layers along the filter mesh using a sheeting machine, and the mesh was thoroughly removed using a sanding machine. The densities of the upper, middle, and lower layers were measured to be 0.610 kg / m³. 2 0.438kg / m 2 0.604 kg / m 2 A single-layer microfiber base layer with a density of 0.561 kg / m³ was prepared using nonwoven fabric without adding a filter mesh, under the same other processes and formulations. 2 For comparison, products prepared by the method of the present invention have finer wrinkles when the difference in softness is not significant.

[0064] Example 5

[0065] 1) Using PA610 / LDPE at a mass ratio of 50:50 as raw material, bio-based island fiber with a fineness of 6.5 dtex was prepared by island spinning.

[0066] 2) The above-mentioned island fibers are simultaneously processed into three layers of fiber web of equal weight and thickness using three web-laying machines. When the three layers of web are combined, a 5000-mesh nylon filter cloth is laid between the upper and middle layers and the middle and lower layers. The filter cloth and the microfiber layer are interwoven together by needle punching to form a nonwoven fabric with a needle punching density of 20 p / cm. 2 80p / cm 2 150p / cm 2 260p / cm 2 400p / cm 2 580p / cm 2 800p / cm 2 240p / cm 2 The needle-punching depths were 12mm, 20mm, 8mm, 7mm, 7mm, 6mm, 4mm, and 2mm, distributed across eight needle-punching plates. The final high-temperature heat-pressed thickness was 2.5mm, and the density was 0.280kg / m³. 2 .

[0067] 3) Prepare impregnation slurry, wherein the impregnation slurry comprises, by weight:

[0068] Oil-based bio-based polyurethane resin (30% solids content, 100% initial modulus of 6.0 MPa): 35 parts;

[0069] Solvent (DMF): 20 parts;

[0070] Ultrafine bio-based nylon micro powder (PA56): 20 parts, particle size 4 micrometers;

[0071] Solidification regulator (SP-710S): 0.3 parts;

[0072] After high-speed stirring and dispersion for 20 minutes, the viscosity of the wet slurry was measured to be 14600 cps (40℃) using a rotational viscometer.

[0073] 4) Same as step 4 in Example 1.

[0074] The prepared microfiber base was sheeted into three layers along the filter mesh using a sheeting machine, and the mesh was thoroughly removed using a sanding machine. The densities of the upper, middle, and lower layers were measured to be 0.749 kg / m³. 2 0.436kg / m 2 0.751kg / m 2 A single-layer microfiber base layer with a density of 0.649 kg / m³ was prepared using nonwoven fabric without adding a filter mesh, under the same other processes and formulations. 2 For comparison, products prepared by the method of the present invention have finer wrinkles when the difference in softness is not significant.

[0075] Example 6

[0076] 1) Using PA56 / LDPE at a mass ratio of 50:50 as raw material, bio-based island fiber with a fineness of 6.5 dtex was prepared by island spinning.

[0077] 2) The above-mentioned island fibers are simultaneously processed into three layers of fiber web of equal weight and thickness using three web-laying machines. When the three layers of web are combined, a 3000-mesh nylon filter cloth is laid between the upper and middle layers and the middle and lower layers. The filter cloth and the microfiber layer are interwoven together by needle punching to form a nonwoven fabric with a needle punching density of 20 p / cm. 2 80p / cm 2 150p / cm 2 260p / cm 2 400p / cm 2 580p / cm 2 800p / cm 2 240p / cm 2The needle-punching depths were 12mm, 20mm, 8mm, 7mm, 7mm, 6mm, 4mm, and 2mm, distributed across eight needle-punching plates. The final high-temperature heat-pressed thickness was 2.5mm, and the density was 0.280kg / m³. 2 .

[0078] 3) Prepare impregnation slurry, wherein the impregnation slurry comprises, by weight:

[0079] Oil-based bio-based polyurethane resin (30% solids content, 100% initial modulus of 6.0 MPa): 55 parts;

[0080] Solvent (DMF): 30 parts;

[0081] Ultrafine bio-based nylon micro powder (PA1010): 20 parts, particle size 8 micrometers;

[0082] Solidification regulator (SP-710S): 0.5 parts;

[0083] After high-speed stirring and dispersion for 20 minutes, the viscosity of the wet slurry was measured to be 11400 cps (40℃) using a rotational viscometer.

[0084] 4) Same as step 4 in Example 1.

[0085] The prepared microfiber base was sheeted into three layers along the filter mesh using a sheeting machine, and the mesh was thoroughly removed using a sanding machine. The densities of the upper, middle, and lower layers were measured to be 0.720 kg / m³. 2 0.463 kg / m 2 0.712kg / m 2 A single-layer microfiber base layer with a density of 0.625 kg / m³ was prepared using nonwoven fabric without adding a filter mesh, under the same other processes and formulations. 2 For comparison, products prepared by the method of the present invention have finer wrinkles when the difference in softness is not significant.

Claims

1. A method for manufacturing a soft fine crepe type bio-based microfiber base, characterized by It comprises the following steps: 1) preparing bio-based nylon ultrafine fibers, preparing the bio-based nylon ultrafine fibers into a three-layer fiber web, sandwiching filter cloth between the ultrafine fiber layers, and needling to obtain a non-woven fabric; 2) immersing the non-woven fabric of step 1) in polyurethane slurry added with superfine bio-based nylon powder, coagulating, extracting, oiling, and drying to obtain a soft and fine crepe type bio-based microfiber; The needle density in step 1) is 20-800 P / cm 2 The needle depth is 2-20 mm, distributed on 8 needle plates. The specification of the filter cloth is 2000-5000 mesh; The superfine bio-based nylon powder in step 2) is PA56 powder, PA410 powder, PA510 powder, PA610 powder, PA1010 powder, or PA1012 powder, and the particle size of the superfine bio-based nylon powder ranges from 4 to 10 microns; The added superfine bio-based nylon powder polyurethane slurry comprises 30% oil-based bio-based polyurethane resin with a solid content of 35-55 parts by weight, superfine bio-based nylon powder 10-20 parts, dimethylformamide 15-55 parts, and coagulation regulator 0.2-0.5 parts. The above components are mixed and dispersed for 20 minutes, the wet slurry viscosity is adjusted by adjusting the amount of dimethylformamide, and the viscosity at 40°C ranges from 3000 cps to 15000 cps.

2. The method of manufacturing a soft fine crepe bio-based microfiber base according to claim 1, wherein One or more of bio-based nylon PA56, PA410, PA510, PA610, PA1010, and PA1012 is used as the island phase material, and LDPE or PET is used as the sea phase material to prepare bio-based nylon ultrafine fibers by fixed island or non-fixed island process.

3. The method of manufacturing a soft fine crepe bio-based microfiber base according to claim 1, wherein The filter cloth in step 1) is one of polyester filter cloth, polypropylene filter cloth, polyamide filter cloth, and vinylon filter cloth.

4. The method of manufacturing a soft fine crepe bio-based microfiber base according to claim 1, wherein The extraction in step 2) is toluene or alkali extraction.

5. The method of manufacturing a soft fine crepe bio-based microfiber base according to claim 1, wherein The drying in step 2) is continuous rubbing and drying, the drying temperature is 100-150°C, and the drying time is 25-50 min.