Artificial leather and skin material for vehicle interior comprising same

Abstract

The present invention provides an artificial leather which contains plant fibers and improves interlacing between the fibers so as to achieve both flexibility and wear resistance, and a skin material for a vehicle interior comprising the artificial leather. The artificial leather comprises a base material formed by fiber cloth and a surface fiber layer laminated on the base material, and the artificial leather satisfies the following characteristics (1)-(3): (1) both the base material and the surface fiber layer contain plant fibers; (2) the content of plant fibers in the artificial leather is 50 mass% or more with respect to the total mass of the artificial leather; and (3) the peel strength between the base material and the surface fiber layer is 2 N / cm or more, and a skin material for a vehicle interior, which contains the artificial leather.

Description

Technical Field

[0001] The present invention relates to an artificial leather and a surface material for vehicle interior comprising the artificial leather. Background Art

[0002] Conventionally, artificial leather made of synthetic fibers has been widely used in furniture, clothing, automobile interiors, shoes, bags, and the like. However, in recent years, the demand for artificial leather made of plant fibers has been gradually increasing.

[0003] Patent Document 1 below discloses that leaf fibers and curable polymer fibers are mixed at a predetermined ratio and the curable polymer fibers are thermally fused to obtain artificial leather having a predetermined tensile strength while using plant raw materials.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent document 1: Japanese Patent Application Publication No. 2017-106158. Summary of the invention

[0007] Problems to be solved by the invention

[0008] However, the invention described in Patent Document 1 does not consider the interlaced state of fibers for suppressing surface wear at all, and if there is no resin coating on the surface, the wear resistance is insufficient. In addition, for the invention described in Patent Document 1, when the resin coating is applied to the surface, although the wear resistance is improved, the softness is greatly reduced, and it is difficult to obtain a good feel.

[0009] In view of the above level of the prior art, the problem to be solved by the present invention is to provide an artificial leather and a surface material for vehicle interior containing the artificial leather that solves the problems of the prior art and improves the interweaving between fibers while containing plant fibers, thereby achieving both softness and wear resistance.

[0010] Means for solving problems

[0011] The present inventors have conducted intensive studies and repeated experiments to solve the above problems. As a result, they unexpectedly found that among artificial leathers containing plant fibers, artificial leathers having the following structure can solve the above problems, thereby completing the present invention.

[0012] That is, the present invention is as follows.

[0013] [1] An artificial leather comprising a base material composed of a fiber cloth and a surface fiber layer laminated on the base material, wherein the artificial leather satisfies the following characteristics (1) to (3): (1) both the base material and the surface fiber layer contain plant fibers; (2) the content of the plant fibers in the artificial leather is 50% by mass or more relative to the total mass of the artificial leather; and (3) the peel strength between the base material and the surface fiber layer is 2 N / cm or more.

[0014] [2] The artificial leather according to [1] above, wherein the content of the plant fiber in the substrate is 50% by mass or more relative to the total mass of the substrate.

[0015] [3] The artificial leather according to [1] or [2] above, wherein the artificial leather contains a binder resin.

[0016] [4] The artificial leather according to [3] above, wherein the content of the binder resin is greater than 0% by mass and is not less than 20% by mass relative to the total mass of the artificial leather.

[0017] [5] The artificial leather according to [3] or [4] above, wherein the binder resin is a polyurethane resin.

[0018] [6] The artificial leather according to [5] above, wherein the polyurethane resin is a water-dispersible polyurethane resin.

[0019] [7] The artificial leather according to any one of [1] to [6] above, wherein the ratio of the fiber length L of the plant fibers contained in the surface fiber layer to the single yarn diameter D, i.e., the L / D value, is greater than or equal to 50 and less than or equal to 4000.

[0020] [8] The artificial leather according to any one of [1] to [7] above, wherein the surface fiber layer contains cellulose fibrils.

[0021] [9] The artificial leather according to any one of [1] to [8], wherein the specific surface area of ​​the fibers constituting the surface fiber layer is 0.10 m 2 / g or above.

[0022]

[10] The artificial leather according to any one of [1] to [9], wherein the artificial leather further satisfies the following feature (4): (4) the surface fiber layer has a specific surface area of ​​0.5 m 2 / g or more and 1.5m 2 / g or less of cellulose fibrils.

[0023]

[11] The artificial leather according to any one of [1] to

[10] above, wherein the surface fiber layer contains synthetic fibers.

[0024]

[12] The artificial leather according to

[11] above, wherein the content of the synthetic fibers in the surface fiber layer is 25% by mass or more and 50% by mass or less relative to the total mass of the fibers contained in the surface fiber layer.

[0025]

[13] The artificial leather according to any one of [1] to

[12] above, wherein the substrate is a textile.

[0026]

[14] The artificial leather according to

[13] above, wherein the cover factor CF of the fabric is greater than or equal to 15 and less than or equal to 40.

[0027]

[15] The artificial leather according to any one of [1] to

[13] above, wherein a height Sz of surface irregularities of the artificial leather is greater than or equal to 200 μm and less than or equal to 600 μm.

[0028]

[16] The artificial leather according to any one of [1] to

[15] , wherein the surface of the artificial leather has raised hair.

[0029]

[17] The artificial leather according to any one of [1] to

[16] above, wherein the artificial leather is dyed.

[0030]

[18] A vehicle interior skin material, comprising the artificial leather according to any one of [1] to

[17] .

[0031] Effects of the Invention

[0032] The artificial leather of the present invention and the vehicle interior skin material comprising the artificial leather have both softness and abrasion resistance while containing plant fibers. DETAILED DESCRIPTION

[0033] Hereinafter, embodiments of the present invention will be described in detail.

[0034] One embodiment of the present invention is an artificial leather comprising a base material composed of a fiber cloth and a surface fiber layer laminated on the base material, wherein the artificial leather satisfies the following characteristics (1) to (3): (1) both the base material and the surface fiber layer contain plant fibers; (2) the content of the plant fibers in the artificial leather is 50% by mass or more relative to the total mass of the artificial leather; and (3) the peel strength between the base material and the surface fiber layer is 2 N / cm or more.

[0035] (Artificial leather)

[0036] The artificial leather of this embodiment includes a base material composed of a fiber cloth and a surface fiber layer laminated on the base material, that is, the surface fiber layer can be laminated only on one side of the base material, or on both sides of the base material. The artificial leather of this embodiment is manufactured by laminating short fibers on one side or both sides of the base material by a papermaking method, and then interweaving the short fibers with each other and with the base material. In this specification, "artificial leather" refers to an artificially manufactured leather sample material.

[0037] The substrate and the surface fiber layer both contain plant fibers. As plant fibers, for example, natural cellulose fibers such as cotton, flax, ramie, hemp, pulp, bamboo, pineapple, banana, coconut, kapok, kenaf, and moon peach can be cited.

[0038] The content of the plant fiber in the artificial leather of this embodiment is 50% by mass or more relative to the total mass of the artificial leather. The higher the content of the plant fiber, the less environmental load can be caused during manufacture or disposal, and the high thermal conductivity of the plant fiber improves the touch.

[0039] The artificial leather of this embodiment has a peel strength between the substrate and the surface fiber layer of 2N / cm or more, preferably 3N / cm or more. When the peel strength is 2N / cm or more, since the interweaving strength between the fibers becomes high, even without resin coating, sufficient wear resistance for suppressing surface damage in actual use can be obtained, thereby improving the softness.

[0040] In order to make the peel strength between the surface fiber layer and the substrate more than 2N / cm, it is preferred to adjust the type of short fibers and textile yarns used in the surface fiber layer and the substrate, the length of single fibers, the thickness, the number of twists, the weight per unit area of ​​the surface fiber layer and the substrate, the thickness, the density, the processing conditions in the interweaving process, etc. As interweaving methods, water flow interweaving method, acupuncture method, etc. are known, but from the viewpoint of preventing the substrate from being damaged, water flow interweaving method is preferably used. In the case of water flow interweaving method, the peel strength can be adjusted by adjusting the nozzle diameter of the spray water flow, the water pressure of the spray water flow, the direction, etc. In addition, in order to improve the peel strength between the surface fiber layer and the substrate, an adhesive resin can also be added.

[0041] In order to make the peel strength 2 N / cm or more, it is particularly important to perform water flow interweaving.

[0042] (Surface fiber layer)

[0043] The ratio of the fiber length L of the plant fiber contained in the surface fiber layer to the single yarn diameter D, i.e., the L / D value, is preferably 50 or more, more preferably 100 or more, and preferably 4000 or less, more preferably 3000 or less, and further preferably 2000 or less. If the L / D value is 50 or more and 4000 or less, the dispersibility and fiber opening of the short fibers in the slurry prepared by dispersing the short fibers in water are good, and the strength of the surface fiber layer is good, and pilling due to friction is less likely to occur.

[0044] In addition, setting the above range is effective in setting the peel strength between the surface fiber layer and the base material to 2 N / cm or more.

[0045] From the viewpoint of increasing the interweaving force between fibers by increasing the static friction, it is preferred that the surface fiber layer contains cellulose fibrils. Here, cellulose fibrils refer to fibers or their bundles with a fiber diameter of several hundred nm to several mm, which are called fibrils and are composed of natural cellulose. Examples of cellulose fibrils include fibrillated cellulose. Examples of fibrillated cellulose include independent fibrils peeled off from the fiber surface or microfibers formed by polymerization of plant sources such as pulp by a high-pressure homogenizer, an ultra-high-pressure homogenizer, or a grinder that applies a high shear force.

[0046] From the viewpoint of mechanical strength, the specific surface area of ​​the fibers constituting the surface fiber layer is preferably 0.10 m 2 / g or more, more preferably 0.20m 2 / g or more, more preferably 0.50m 2 / g or more, and most preferably 0.80m 2 / g or more. In addition, it is preferably 2.0m 2 / g or less, more preferably 1.6m 2 / g or less, more preferably 1.2m 2 / g or less.

[0047] Here, the specific surface area of ​​the fibers constituting the surface fiber layer refers to a value measured using the BET method.

[0048] The surface fiber layer preferably has a specific surface area of ​​0.5 m 2 / g or more and 1.5m 2 The specific surface area of ​​the cellulose fibrils contained in the surface fiber layer is more preferably 0.6 m 2 / g or more and 1.0m 2 / g or less, more preferably 0.6m 2 / g or more and 0.8m 2 / g or less.

[0049] The specific surface area of ​​the surface fiber layer is 0.5 m2 relative to the total mass of the fibers contained in the surface fiber layer. 2 / g or more and 1.5m 2 The content of cellulose fibrils of 100 Å / g or less is preferably 20% by mass or more, more preferably 50% by mass or more.

[0050] For the purpose of improving mechanical properties such as tensile strength or flame retardancy, the surface fiber layer can contain synthetic fibers. When the fiber layer contains synthetic fibers, relative to the total mass of the fibers contained in the surface fiber layer, the content of the synthetic fibers is preferably more than 25% by mass and less than 50% by mass. If the content of the synthetic fibers is more than 25% by mass, the effect obtained by compounding the synthetic fibers can be fully exerted. If it is less than 50% by mass, the environmental load during manufacture or during disposal can be suppressed because the proportion of the plant fibers is fully improved. In addition, due to the high thermal conductivity of the plant fibers, the touch is made good. In addition, since the surface fiber layer contains synthetic fibers different from the plant fiber dyeability, the excellent design of the Maillard hue (Mélange) produced by the different dyeability can be realized. As the synthetic fibers that the surface fiber layer can contain, for example, fibers such as polyester, nylon 6, nylon 66, acrylic, polyurethane, and polylactic acid can be cited.

[0051] (Base material)

[0052] The content of the plant fiber in the substrate contained in the artificial leather of this embodiment is preferably 50% by mass or more relative to the total mass of the substrate. It is more preferably 60% by mass or more, and further preferably 80% by mass or more. When the content is 50% by mass or more, the environmental load during manufacturing or disposal is reduced. In addition, due to the high thermal conductivity of the plant fiber, the touch becomes good.

[0053] For example, for the purpose of improving mechanical properties such as tensile strength or flame retardancy, it is preferred that the substrate can contain fibers other than plant fibers in a range of 50% by mass or less relative to the total mass of the substrate. In the case where the substrate contains fibers other than plant fibers, for example, synthetic fibers such as polyester, nylon 6, nylon 66, acrylic, polyurethane, polylactic acid, semi-synthetic fibers such as acetate, triacetate, Promix, regenerated fibers such as rayon, cupra, Lyocell, inorganic fibers such as glass fiber and carbon fiber, etc. can be used. In particular, from the viewpoint of mechanical properties, synthetic fibers are preferably used.

[0054] The substrate is not particularly limited as long as it is a fiber cloth, and may be, for example, a fabric, a knitted fabric, or a nonwoven fabric. In addition, the fibers constituting the substrate may be one or more. For example, as the substrate, a knitted fabric using composite textile yarns of different materials spun from multiple short fibers, or a knitted fabric using textile yarns or filament yarns of multiple different materials may also be used. From the viewpoint of setting the peel strength between the surface fiber layer and the substrate to 2N / cm or more, the substrate is preferably a fabric.

[0055] When the substrate is a woven fabric, the cover factor CF of the woven fabric defined by the following formula is preferably 15 or more, more preferably 20 or more, further preferably 25 or more, and on the other hand, preferably 40 or less. The above range is effective in setting the peel strength between the surface fiber layer and the substrate to 2 N / cm or more.

[0056] (Mathematical formula 1)

[0057]

[0058] {In the formula, C w D is the total fineness of the warp yarn (cotton yarn count), w is the warp density (root / 2.54cm), C f is the total fineness of the weft yarn (cotton yarn count), D f is the weft yarn density (root / 2.54cm)}.

[0059] The definition of the above-mentioned cover factor does not limit the fibers used in the fabric to textile yarns such as cotton, but can be calculated after converting to the cotton yarn count equivalent to the fineness when long fibers are used. If the cover factor is 15 or more, the surface of the artificial leather will not form unevenness, so that the touch becomes good. In addition, since the interweaving with the surface fiber layer becomes stronger, the peeling strength with the surface fiber layer is improved. On the other hand, if the cover factor is 40 or less, the softness of the artificial leather is improved, so the feel becomes good, and the tracking property to complex shapes such as automobile interiors and furniture is also good.

[0060] (Binder resin)

[0061] From the viewpoint of further improving the interweaving strength between fibers, the artificial leather of this embodiment may contain a binder resin. On the other hand, when the artificial leather does not contain a binder resin, it has the advantage of being able to achieve very high conformability to the shapes of automobile interiors, furniture, etc. Therefore, it is possible to appropriately select whether to contain a binder resin according to the characteristics required for each application.

[0062] When the artificial leather contains a binder resin, the content of the binder resin is preferably greater than 0% by mass and less than 20% by mass, and more preferably greater than 0% by mass and less than 15% by mass, relative to the total mass of the artificial leather. If the content of the binder resin is less than 20% by mass, the mechanical properties such as wear resistance and tensile strength are improved, and the softness of the artificial leather is sufficiently high, so the hand feel becomes good, and the followability to complex shapes of automobile interiors, furniture, etc. is easily improved. In addition, from the viewpoint of strengthening the bonding strength between the fibers constituting the surface fiber layer, the content of the binder resin is preferably 5% by mass or more, and more preferably 8% by mass or more.

[0063] The type of binder resin is not particularly limited, and for example, acrylic resin, urethane resin, polyester resin, vinyl acetate resin, etc. can be used. From the viewpoint of both flexibility and durability, the binder resin is preferably a urethane resin, and particularly from the viewpoint of reducing environmental load, a water-dispersible urethane resin is preferably used.

[0064] (Other preferred aspects of artificial leather)

[0065] For the artificial leather of this embodiment, from the viewpoint of imparting a smooth touch like suede and nubuck, the height Sz of the surface irregularities is preferably 200 μm or more and 600 μm or less, more preferably 500 μm or less, and further preferably 450 μm or less. When Sz is 200 μm or more, a soft touch can be obtained because the surface has moderate irregularities. On the other hand, Sz z When the thickness is 600 μm or less, the surface is less likely to feel rough.

[0066] In order to make Sz 200 μm or more and 600 μm or less, it is preferable to raise the surface. Sz can be appropriately adjusted by raising conditions, etc. z In addition, the S can also be adjusted based on the type of short fibers and textile yarns used in the surface fiber layer and the base material, the length, thickness, twist number of the single fiber, the unit area weight, thickness, density of the surface fiber layer and the base material, the type and amount of the binder resin, the processing conditions in the interweaving process, etc. z Make adjustments.

[0067] The artificial leather of the present embodiment is preferably dyed. As a dyeing method, dyeing treatment using a jet dyeing machine is preferred from the viewpoint of improving the texture.

[0068] In order to improve the wear resistance and flame retardancy, the artificial leather of the present embodiment can form a resin layer on the surface. In addition, by setting it as a resin layer mixed with a pigment, it can also be colored. The method for forming the resin layer is not particularly limited, and can include a method of forming a resin layer by drying the solvent after applying a resin solution in which a resin is dissolved in a solvent, a method of forming the resin layer by reacting the resin after applying the resin solution (dry method), a method of pasting a resin film composed of a synthetic resin (lamination method), a method of introducing a coagulation bath to coagulate it after applying the resin solution (wet method), etc.

[0069] (Surface materials for vehicle interior)

[0070] Another embodiment of the present invention is a vehicle interior skin material comprising the above-mentioned artificial leather. The vehicle interior skin material of this embodiment can be suitably used as a skin material to be attached to a seat, a door trim, an instrument panel, a roof panel, and the like.

[0071] The vehicle interior skin material of this embodiment may be laminated with urethane foam on the back to impart cushioning properties. In addition, embossing or embroidery may be performed for design and functionality.

[0072] Example

[0073] Hereinafter, the present invention will be specifically described by way of Examples and Comparative Examples, but the present invention is not limited to the Examples.

[0074] The methods for measuring various physical properties of artificial leather used in Examples and the like are as follows.

[0075] (a) Peel strength between fiber layer and substrate (N / cm)

[0076] Two rectangular samples (samples A and B) with a short side of 2.5 cm and a long side of 10 cm were cut from the artificial leather in a manner perpendicular to the long side. The entire surface of the surface layer side (the raised surface side in the case of raised artificial leather) of the two samples was treated with 50 mg / cm 2The synthetic rubber adhesive Threebond 1521 (manufactured by Threebond) was applied with a coating amount of . After coating, the surfaces of the two samples coated with the adhesive were immediately bonded together so that the long and short sides of each other were aligned. The bonded samples were compressed at 0.4 MPa using a mangle and placed under conditions of 20°C and 50% RH for more than 5 hours. The bonded samples were cut off 2.5 mm at both ends of the short side with scissors to form a size of 2.0 cm (width) × 10 cm (length). After cutting a seam at the junction of the substrate and the surface fiber layer of sample A from the short side with the blade of a razor, the substrate and the surface fiber layer were peeled off by about 2 cm with fingers. Then, using the Tensilon universal testing machine (TENSILON) (model RTC-1210A) manufactured by A&D COMPANY, the substrate and the surface fiber layer are held by a fixture with a holding length of 2 cm, and the substrate and the surface fiber layer are peeled off with a crosshead speed of 100 mm / minute and a recording paper speed of 50 mm / minute, and the stress at this time is measured. In the multiple peaks of the obtained stress-displacement diagram, the peaks of the three points of the large peak are read in sequence from the maximum peak and the peaks of the three points of the small peak are read in sequence from the minimum peak, and the average value of a total of 6 points is obtained. Using the sample of the bonding, the boundary of the substrate and the surface fiber layer of sample B is also cut out with a fracture, and the same measurement is implemented again. The value obtained by dividing the average value of the two results obtained by the sample width (2 cm) is used as the peel strength.

[0077] (b) Cover factor CF

[0078] The cover factor CF was calculated using the following formula: When the fiber used was a long fiber, it was calculated by converting it into a cotton yarn count equivalent to the fineness.

[0079] (Mathematical formula 2)

[0080]

[0081] {In the formula, C w D is the total fineness of the warp yarn (cotton yarn count), w is the warp density (root / 2.54cm), C f is the total fineness of the weft yarn (cotton yarn count), and D f is the weft yarn density (root / 2.54cm).

[0082] (c) Specific surface area (m2) of the plant fibers used as the raw material of the surface fiber layer and the fibers contained in the surface fiber layer 2 / g)

[0083] The specific surface area is measured using an automatic specific surface area measuring device (manufactured by Shimadzu Corporation, Gemini2360). The sample mass used for the measurement is 0.20g to 0.60g. The unit into which the sample is put is dried at 60°C for 30 minutes and then cooled for 10 minutes. Then, the unit is installed in the above-mentioned specific surface area measuring device, and the specific surface area is calculated using the following BET formula by adsorbing nitrogen on the sample surface. It should be noted that the sample for measurement was prepared as shown below.

[0084] P / {V(P0-P)}=1 / (V m ×C)+{(C-1) / (V m ×C)}(P / P0)

[0085] {Wherein, P: pressure, P0: saturated water vapor pressure (Pa), V: nitrogen adsorption amount (mg / g), V m : Monomolecular layer adsorption amount (mg / g), and C: Parameters related to adsorption heat, etc. (-) < 0.}

[0086] (Plant fiber used as raw material of the surface fiber layer)

[0087] The steps of centrifugation, removal of supernatant, and dilution with ethanol were repeated three times using the aqueous dispersion of plant fibers. Then, the steps of centrifugation, removal of supernatant, and dilution with tert-butyl alcohol were repeated twice using the ethanol dispersion of plant fibers obtained above. Then, the tert-butyl alcohol dispersion of plant fibers obtained above was centrifuged, the supernatant was removed, a small amount of tert-butyl alcohol was added, and freeze-dried to prepare a sample for measurement.

[0088] (Fibers in the surface fiber layer)

[0089] The surface fiber layer is peeled off from the artificial leather. When the surface fiber layer has an adhesive resin and / or a surface resin layer, a solvent that can dissolve the adhesive resin and / or the surface resin layer but does not dissolve the fibers is used to dissolve and remove the adhesive resin and / or the surface resin layer, thereby preparing a sample for measurement.

[0090] (d) Height S of the surface irregularities of artificial leather z

[0091] A single exposure microscope (VR-3200 manufactured by Keyence Co., Ltd.) was used to observe artificial leather sampled in a 15 cm square size and photographed at 40 times magnification. For the photographed data, in order to exclude the unevenness that is not from the surface fiber layer, the entire measurement range area was specified and the surface shape correction (quadratic surface correction) was performed. Then, the "surface roughness measurement" of the analysis screen was specified as the entire measurement range area as the measurement area, and the filter setting without a low-pass filter and a high-pass filter was performed to obtain the maximum height S z In the sampled artificial leather, the measurement portion was changed and the measurement was performed 10 times, and the average value was used as the result. In this measurement, when the surface of the artificial leather has deformation due to embossing or embroidery, etc., 10 places excluding the deformed portion were measured.

[0092] (e) Wear resistance

[0093] According to JIS-L-1096 (2015 edition) 8.19 "Abrasion strength" (Method E: Martindale method), the wear resistance test of the surface fiber layer of artificial leather was carried out under the condition of pressing load (12kPa). The relationship between the number of abrasions and the exposure state of the substrate was judged according to the following evaluation criteria, and 0 and ◎ were qualified.

[0094] ×: At 30,000 times, the base material was exposed.

[0095] △: At 30,000 times, the base fabric was not exposed, but at 40,000 times, the base fabric was exposed.

[0096] ○: At 40,000 times, the base fabric was not exposed, but at 50,000 times, the base fabric was exposed.

[0097] ◎: After 50,000 times, the base material was not exposed.

[0098] (f) Softness

[0099] The artificial leather sampled in a 25 cm square was placed in a room at 20°C and 65% humidity for more than 10 hours, and the humidity was adjusted. Then, the feeling when treated in the same room was graded according to the following evaluation criteria as the evaluation of softness. The evaluation was performed at intervals of 0.5 grades.

[0100] Level 5: Quite soft.

[0101] Level 4: Soft and flexible.

[0102] Level 3: Slightly soft.

[0103] Level 2: Slightly harder.

[0104] Level 1: Quite hard.

[0105] (g) Touch

[0106] The artificial leather sampled in a 25 cm square is placed in a room at 20°C and 65% humidity for more than 10 hours, and the humidity is adjusted. Then, the touch is evaluated by rating the feeling of tracing the sample surface with bare hands in the same room according to the following evaluation criteria. The evaluation is performed at intervals of 0.5 levels.

[0107] Level 5: Very good touch.

[0108] Level 4: The touch is quite good.

[0109] Level 3: Good touch.

[0110] Level 2: Slightly poor touch.

[0111] Level 1: Poor touch.

[0112] (Example 1)

[0113] The specific surface area of ​​the fibrillated product is 0.67 m 2 / g and L / D value of 250 cotton staple fibers and 3mm fiber length and 4μm fiber diameter polyester staple fibers were mixed in a mass ratio of 70:30 and dispersed in water to prepare a slurry for the surface fiber layer. A fabric composed of 20-count cotton / PET (65 / 35) spun yarns with a warp density of 55 strands / 2.54cm and a weft density of 60 strands / 2.54cm was used as the base material, and a unit area weight of 140g / m was made on one side of the base material (hereinafter referred to as the "surface layer") 2 In addition, the weight per unit area on the opposite side (hereinafter referred to as the "back layer") is 60 g / m 2 The slurry was used to stack short fibers to continuously produce a three-layer laminated nonwoven fabric sheet. Then, a straight-flow jet nozzle with an aperture of 0.1 mm was used to spray water from the surface layer at a pressure of 4.0 MPa and from the back layer at a pressure of 3.0 MPa to perform interlacing treatment, and the sheet was dried using a pin tenter to produce a nonwoven fabric with a unit area weight of 330 g / m 2 The surface layer of the sheet was polished with #400 sandpaper, and then the sheet was impregnated with a water dispersion of a polyether-based water-based polyurethane resin with a concentration of 9 mass % and 3 mass % of sodium sulfate, so that the adhesion rate of the polyurethane resin was 14.3 mass % relative to the mass of the sheet after impregnation, and heated and dried for 3 minutes with a pin-type tenter dryer to produce an artificial leather raw yarn. The raw yarn was dyed black with a liquid jet dyeing machine to produce a suede-like artificial leather.

[0114] (Example 2)

[0115] In addition to using a specific surface area of ​​0.53m 2An artificial leather was produced in the same manner as in Example 1, except that pineapple staple fibers having an L / D value of 250 and a length of 20 were used instead of cotton staple fibers, and a fabric consisting of 20-count pineapple fiber / PET (45 / 55) spun yarns having a warp density of 55 strands / 2.54 cm and a weft density of 60 strands / 2.54 cm was used as the base material, and the sheet was impregnated with the polyurethane resin so that the adhesion rate relative to the mass of the sheet after impregnation was 4.1% by mass.

[0116] (Example 3)

[0117] In addition to using a specific surface area of ​​1.42m 2 / g and L / D value of 250 instead of cotton staple fibers with a specific surface area of ​​0.67m 2 Artificial leather was produced in the same manner as in Example 1 except that the cotton staple fibers had an L / D value of 250 and were not impregnated with the aqueous dispersion of the aqueous polyurethane resin.

[0118] (Example 4)

[0119] In the manufacture of non-woven fabrics, in addition to the surface layer weight per unit area of ​​100g / m 2 And the unit area weight of the back layer is 35g / m 2 Artificial leather was produced in the same manner as in Example 1, except that the sheet was paper-made in the manner of , and a solvent-based polyurethane resin was used instead of an aqueous polyurethane resin and the polyurethane resin was impregnated so that the adhesion rate of the polyurethane resin was 23.6% by mass relative to the sheet mass.

[0120] (Example 5)

[0121] In addition to using a specific surface area of ​​0.30m 2 / g and L / D value of 3500 instead of cotton staple fiber with a specific surface area of ​​0.67m 2 Artificial leather was produced in the same manner as in Example 1 except that the cotton staple fibers had an L / D value of 250 and an % yield.

[0122] (Example 6)

[0123] In addition to using a specific surface area of ​​0.58m 2 Artificial leather was produced in the same manner as in Example 1 except that wool staple fibers having an L / D value of 2,500 and 0.1% / g were used instead of the cotton staple fibers.

[0124] (Example 7)

[0125] In addition to being used as a slurry, the specific surface area of ​​​​0.67m 2Artificial leather was produced in the same manner as in Example 1 except that a slurry in which cotton staple fibers having an L / D value of 250 and having a density of 100 / g were dispersed in water and a fabric consisting of 30-count cotton yarns having a warp density of 48 yarns / 2.54 cm and a weft density of 50 yarns / 2.54 cm was used as the substrate.

[0126] (Example 8)

[0127] Artificial leather was produced in the same manner as in Example 1 except that the mixing ratio of cotton staple fibers to polyester staple fibers in the slurry was 35:65 and a fabric composed of 20-count cotton yarns with a warp density of 55 yarns / 2.54 cm and a weft density of 60 yarns / 2.54 cm was used as the base material.

[0128] (Example 9)

[0129] Artificial leather was produced in the same manner as in Example 1 except that a woven fabric composed of 30-count cotton / PET (65 / 35) spun yarns having a warp density of 35 yarns / 2.54 cm and a weft density of 40 yarns / 2.54 cm was used as the substrate.

[0130] (Example 10)

[0131] In addition to impregnating the sheet so that the adhesion rate of the polyurethane resin is 6.6% by mass relative to the sheet mass, and applying a pigment-containing water-dispersed polyurethane resin at a rate of 25 g / m 2 Artificial leather was produced in the same manner as in Example 1 except that a coating amount of 200 % was applied to the surface of the surface layer of the raw yarn instead of dyeing the raw yarn.

[0132] (Example 11)

[0133] In addition to using a specific surface area of ​​0.15m 2 / g of cotton staple fibers to replace the specific surface area of ​​0.67m 2 Artificial leather was produced in the same manner as in Example 1 except that the cotton staple fibers were reduced to / g.

[0134] (Example 12)

[0135] In addition to using a specific surface area of ​​0.3m 2 / g of cotton staple fibers to replace the specific surface area of ​​0.67m 2 Artificial leather was produced in the same manner as in Example 1 except that the cotton staple fibers were reduced to / g.

[0136] (Example 13)

[0137] In addition to using a specific surface area of ​​1.8m 2 / g of cotton staple fibers to replace the specific surface area of ​​0.67m2 Artificial leather was produced in the same manner as in Example 1 except that the cotton staple fibers were reduced to / g.

[0138] (Example 14)

[0139] Artificial leather was produced in the same manner as in Example 1 except that cotton staple fibers having an L / D value of 80 were used instead of cotton staple fibers having an L / D value of 250.

[0140] (Comparative Example 1)

[0141] The same slurry as in Example 1 was used to continuously produce a single-layer nonwoven fabric sheet by papermaking to a weight per unit area of ​​200 g / m 2 . Then, a straight-flow jet nozzle with an aperture of 0.1 mm was used to spray water at a pressure of 4.0 MPa from the surface layer and 3.0 MPa from the back layer to perform an interlacing treatment, and the sheet was dried using a pin-type tentering machine. The surface layer of the sheet was polished with #400 sandpaper, and then the sheet was impregnated with a solution of a solvent-based polyurethane resin so that the adhesion rate of the polyurethane resin was 40% by mass relative to the mass of the sheet after impregnation. The sheet was heated and dried in a pin-type tentering dryer for 3 minutes to produce an artificial leather yarn. A solvent-based polyurethane resin containing a pigment was coated with a knife coater at a rate of 25 g / m 2 The coating amount of was applied on the surface of the surface layer of the raw yarn to produce artificial leather.

[0142] (Comparative Example 2)

[0143] Artificial leather was produced in the same manner as in Comparative Example 1 except that the adhesion rate of the solvent-based polyurethane was 4.8% by mass based on the mass of the impregnated sheet and the raw yarn was dyed black using a jet dyeing machine instead of coating the surface with a solvent-based polyurethane resin containing a pigment.

[0144] (Comparative Example 3)

[0145] Artificial leather was produced in the same manner as in Example 1 except that the mixing ratio of cotton staple fibers to polyester staple fibers in the slurry was 35:65 and a fabric composed of 20-count polyester spun yarns with a warp density of 55 yarns / 2.54 cm and a weft density of 60 yarns / 2.54 cm was used as the base material.

[0146] Various physical properties and evaluation results of the artificial leathers produced in the above Examples and Comparative Examples are shown in Tables 1 to 3 below.

[0147]

[0148]

[0149] [Table 3]

[0150]

[0151] Industrial Applicability

[0152] Since the present invention is an artificial leather containing a large amount of plant fibers and having both softness and wear resistance, it can be widely used in applications such as furniture, clothing, automobile industry, shoes, bags, etc., and is particularly suitable for use as a surface material for vehicle interior.

Claims

1. An artificial leather comprising a base material composed of a fiber cloth and a surface fiber layer laminated on the base material, wherein: The artificial leather satisfies the following characteristics (1) to (3): (1) Both the substrate and the surface fiber layer contain plant fibers; (2) the content of the plant fiber in the artificial leather is 50% by mass or more relative to the total mass of the artificial leather; and (3) The peel strength between the substrate and the surface fiber layer is 2 N / cm or more.

2. The artificial leather according to claim 1, wherein The content of the plant fiber in the substrate is 50% by mass or more relative to the total mass of the substrate.

3. The artificial leather according to claim 1 or 2, wherein: The artificial leather contains a binder resin.

4. The artificial leather according to claim 3, wherein: The content of the binder resin is greater than 0% by mass and equal to or greater than 20% by mass relative to the total mass of the artificial leather.

5. The artificial leather according to claim 3, wherein: The binder resin is a polyurethane resin.

6. The artificial leather according to claim 5, wherein: The polyurethane resin is a water-dispersible polyurethane resin.

7. The artificial leather according to claim 1 or 2, wherein: The value of L / D, which is a ratio of the fiber length L of the plant fibers contained in the surface fiber layer to the single yarn diameter D, is 50 or more and 4000 or less.

8. The artificial leather according to claim 1 or 2, wherein: The surface fiber layer contains cellulose fibrils.

9. The artificial leather according to claim 1 or 2, wherein: The specific surface area of ​​the fibers constituting the surface fiber layer is 0.10 m 2 / g or above.

10. The artificial leather according to claim 1 or 2, wherein: The artificial leather also satisfies the following feature (4): (4) The surface fiber layer has a specific surface area of ​​0.5 m 2 / g or more and 1.5m 2 / g or less of cellulose fibrils.

11. The artificial leather according to claim 1 or 2, wherein: The surface fiber layer contains synthetic fibers.

12. The artificial leather according to claim 11, wherein The content of the synthetic fibers in the surface fiber layer is 25% by mass or more and 50% by mass or less relative to the total mass of the fibers contained in the surface fiber layer.

13. The artificial leather according to claim 1 or 2, wherein: The substrate is a fabric.

14. The artificial leather according to claim 13, wherein: The cover factor CF of the fabric is greater than or equal to 15 and less than or equal to 40.

15. The artificial leather according to claim 1 or 2, wherein: The height S of the surface irregularities of the artificial leather z It is 200 μm or more and 600 μm or less.

16. The artificial leather according to claim 1 or 2, wherein: The artificial leather has napped surfaces.

17. The artificial leather according to claim 1 or 2, wherein: The artificial leather is dyed.

18. A surface material for vehicle interior, wherein: The vehicle interior skin material comprises the artificial leather according to claim 1 or 2.

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