Automobile seat leather-based fabric and preparation method thereof

Abstract

The invention discloses a leather-based fabric for automobile seats, which is woven by a warp-knitted Carmel loom and is formed by weaving polyester 75D low-elasticity DTY (draw textured yarn) and polyester 75D FDY (fully drawn yarn) filaments through three guide bars. The problem that an existing leather-based fabric has odor can be solved, and the fabric has dimensional stability, strong wear resistance and environment-friendly air permeability while high strength, high ultraviolet resistance and high wrinkle resistance are guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of textile fabrics, and particularly relates to a high-strength and low-odor automotive seat leather base fabric and a preparation method thereof. Background Art

[0002] At present, in recent years, China's macro economy has continued to grow, and the living standards of residents have increased rapidly. With the substantial improvement of the consumption level, it has also brought about a rapid improvement in the automotive field, especially the demand in the new energy market is becoming increasingly strong. With the booming development of the automotive market, the market for automotive interior fabrics has gradually expanded. The textile fibers used in automotive interiors are mainly synthetic fibers, such as polyester fibers, which are widely used because of their good abrasion resistance, tear resistance, and mildew resistance. The reason is that the use of its high strength, elongation ability, and fire, water, and ultraviolet resistance has been increasing in various applications. However, when producing automotive seat leather base fabrics through low-elastic DTY yarns and polyester filaments, it is difficult to eliminate the odor of the automotive seat leather base fabrics after production by existing processes, and the produced automotive seat leather base fabrics are generally lower than the standard in terms of tear strength and breaking strength, and the effects of dimensional stability, ultraviolet resistance, and wrinkle resistance are also not satisfactory. Therefore, it is necessary to develop a high-strength and low-odor automotive seat leather base fabric, which has the characteristics of high strength, dimensional stability, ultraviolet resistance, and good wrinkle resistance, and at the same time, through dyeing and finishing processing, the odor level of the fabric surface is lower, reducing the odor of automotive interior fabrics, and the fabric is strong, wear-resistant, environmentally friendly, and breathable. Summary of the Invention

[0003] In order to solve certain or some technical problems existing in the prior art, one of the purposes of the present application is to provide an automotive seat leather base fabric, which can solve the problem of odor of the existing leather base fabric, and enable the fabric to have dimensional stability, strong wear resistance, and environmental protection breathability while ensuring high strength, high ultraviolet resistance, and high wrinkle resistance.

[0004] Another purpose of the present application is to provide a method for preparing an automotive seat leather base fabric, through dyeing and finishing processing, so that the odor level of the fabric surface is lower, reducing the odor of automotive interior fabrics, and the fabric is strong, wear-resistant, environmentally friendly, and breathable.

[0005] To solve the above existing technical problems, one of the purposes of the present application is achieved by adopting the following technical solution:

[0006] An automotive seat leather base fabric, characterized in that: the leather base fabric is woven by a warp knitting Carmal loom, and the leather base fabric is woven by three guide bars with 75D low-elastic DTY yarns of polyester and 75D FDY filaments of polyester.

[0007] High-strength yarns are selected, which are made of 75D polyester low-elastic DTY yarns and 75D polyester FDY filaments, and woven by three combs. Through various dyeing and finishing processes, the fabric has a flat surface, high strength, and low odor. After being compounded with automotive leather, it has good color migration, good heat shrinkage, and good resilience.

[0008] Preferably, the number of head lines of the leather base fabric is 590 - 610.

[0009] The second object of this application is achieved by the following technical solutions:

[0010] A method for preparing an automotive seat leather base fabric, the steps of the preparation method include:

[0011] S1. Blanket forming: Use a warp knitting Karl Mayer loom to weave 75D polyester low-elastic DTY yarns and 75D polyester FDY filaments into a blanketing through three combs;

[0012] S2. Edge rolling: Immerse and roll the cloth edges flat to avoid curling problems during degreasing and dyeing;

[0013] S3. Pretreatment degreasing: Use a high-temperature and high-pressure overflow dyeing machine for degreasing and water washing in the cylinder;

[0014] Using a high-temperature and high-pressure overflow dyeing machine for degreasing and water washing in the cylinder can greatly remove the oil agents, sizing agents, and dirt on the cloth surface, ensure the cloth surface is clean, and facilitate the uniformity of dyeing. For dark colors, it can be considered to complete degreasing and dyeing in the same bath in one step. Generally, the degreasing temperature is 80 - 90 °C, and the desizing auxiliaries are: degreasing agent, dispersing leveling agent, and liquid caustic soda.

[0015] S4. Dyeing: Endow the fabric with color, the dyeing temperature is 128 - 135 °C, the time is 30 - 60 min, the bath ratio is 1:10 - 1:15, and the dyeing time is 3 - 5 hours;

[0016] For textile fabrics used in automotive interiors, generally, high requirements are placed on the color fastness and color migration. When selecting dyes, high-quality dye suppliers such as Huntsman and DyStar are preferred to promote the stability of dyeing quality. Generally, the dyeing temperature is 128 - 135 °C, the time is 30 - 60 min, the bath ratio is 1:10 - 1:15, the dyeing time is 3 - 5 hours, and the nozzle is 100 - 110#.

[0017] S5. Water washing and deodorization: Remove the residual odor on the cloth surface;

[0018] S6. Dehydration and opening: Remove excessive moisture on the cloth surface and open the cloth surface from the rope shape to facilitate subsequent drying and shaping;

[0019] S7. Shaping and drying: The shaping conditions are 130 - 160 °C, the speed is 20 - 50 m / min, and with a positive overfeed of about 3 - 10%, so that the basic size of the cloth surface is stable;

[0020] After dyeing, the fabric is still wet after dehydration and opening, with residual moisture. Through setting and drying, the basic size of the fabric is stabilized, facilitating the subsequent application of auxiliaries. The preferred setting conditions are a temperature of 130 - 160 °C, a speed of 20 - 50 m / min, with a positive overfeed of about 3 - 10%. By controlling the tension, the basic size stability of the fabric surface can be better achieved, facilitating the subsequent application of auxiliaries.

[0021] S8. Finished product setting: The setting temperature is 130 - 180 °C, the speed is 20 - 50 m / min, with a positive overfeed of about 3 - 10%.

[0022] Preferably, the padding temperature in step S2 is 90 - 100 °C, the speed is 15 - 60 m / min, and the roll pressure is 0.3 - 0.4 mpa.

[0023] By coordinating the padding temperature with the speed and the roll pressure, the fabric edge can be better padded flat, avoiding the problem of curling during degreasing and dyeing.

[0024] Preferably, the degreasing temperature in step S3 is 80 - 90 °C, the time is 20 - 40 min, and the desizing auxiliaries during degreasing are: degreasing agent, dispersing leveling agent, liquid caustic soda.

[0025] Preferably, the steps of water washing and deodorizing in S5 include:

[0026] A1. Overflow water washing, temperature 60 - 80 °C, time 10 - 30 min;

[0027] A2. After draining and then refilling with water, wash twice, temperature 40 - 70 °C, time 10 - 30 min.

[0028] For automotive interior fabrics, there are generally requirements for odor level testing. For example, BYD, Volkswagen, Geely, etc. have strict control over odors. Therefore, in the fabric production process, removing the residual odor on the fabric surface is crucial. After dyeing, it is necessary to conduct sufficient water washing. Generally, first, overflow water washing is carried out at a temperature of 60 - 80 °C for 10 - 30 min, and then after draining and refilling with water, wash twice at a temperature of 40 - 70 °C for 10 - 30 min, which can make the fabric free of abnormal odors.

[0029] Preferably, in the dark-colored grey fabric, steps S3 and S4 adopt a degreasing treatment that combines degreasing and dyeing in one bath.

[0030] Preferably, the setting temperature in step S8 is 140 - 170 °C, the speed is 20 - 50 m / min, with a positive overfeed of about 3 - 10%, and the dosage of functional auxiliaries is 5 - 20 g / L.

[0031] Final shaping of the finished product, which is the last process in fabric processing. It has three purposes. First, to fix the basic requirements such as the style, width, gram weight, and thickness of the finished product; second, to add functional auxiliaries to endow the fabric with high strength, dimensional stability, and wrinkle resistance; third, to remove the residual temperature on the fabric surface to a great extent. When carrying out final shaping production, it should be noted that the empty machine should be started for 20 minutes before starting on the final shaping machine, the air volume should be turned to the maximum, and the oven door should be opened to disperse the odor. Generally, the final shaping conditions are 140 - 170 °C, the speed is 20 - 50 m / min, with a positive overfeed of about 3 - 10%, controlling the tension, and the general dosage of functional auxiliaries is 5 - 20 g / L. After final shaping of the finished product, the leather base fabric can have characteristics such as high strength, dimensional stability, ultraviolet resistance, and good wrinkle resistance, and through dyeing and finishing processing, the odor level of the fabric surface is low, reducing the odor of automotive interior fabrics, and the fabric has strong wear resistance, environmental protection, and breathability.

[0032] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0033] It can solve the problem of odor in the existing leather base fabric, enabling the fabric to have dimensional stability, strong wear resistance, environmental protection, and breathability while ensuring high strength, high ultraviolet resistance, and high wrinkle resistance. Through dyeing and finishing processing, the odor level of the fabric surface is even lower, reducing the odor of automotive interior fabrics, and the fabric has strong wear resistance, environmental protection, and breathability. Description of the Drawings

[0034] Figure 1 Front view of the finished product of the present invention;

[0035] Figure 2 Back view of the finished product of the present invention;

[0036] Figure 3 Dyeing curve graph of the present invention;

[0037] Figure 4 Process diagram of water washing and odor removal of the present invention. Detailed Embodiments

[0038] Next, in combination with the drawings and specific embodiments, the present application will be further described. It should be noted that on the premise of no conflict, the following described embodiments or technical features can be arbitrarily combined to form new embodiments.

[0039] In the description of the present application, it should be understood that the orientation or positional relationship indicated by terms such as "upper", "lower", "left", "right", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation to the present application.

[0040] The terms "first", "second", etc. in this application are used to distinguish similar objects, rather than to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged under appropriate circumstances, so that the embodiments of this application can be implemented in an order other than those illustrated or described here, and the objects distinguished by "first", "second", etc. are usually of the same category, and the number of objects is not limited. For example, the first object can be one or multiple. In addition, "and / or" in the specification and claims means at least one of the connected objects, and the character " / ", generally represents an "or" relationship between the associated objects before and after.

[0041] Example 1:

[0042] As Figures 1 to 4 shown, the grey fabric is selected from 75D / 36F polyester drawn textured yarn DTY (AAA) and 75D / 36F polyester filament FDY (AAA), with 610 warp ends, and woven on a Karl Mayer warp knitting machine; edge rolling, temperature 90°C, speed 15 m / min, roll pressure 0.3 mpa; pre-treatment for degreasing, degreasing temperature 85°C, time 30 min; dyeing, temperature 130°C, time 30 min, liquor ratio 1:10, dyeing time 4 hours, nozzle 100#; water washing and deodorizing, first overflow water washing, temperature 70°C, time 30 min, then drain and refill with water, wash twice, temperature 50°C, time 20 min; dehydration and open-width, remove excessive moisture on the fabric surface and open the fabric surface from the rope shape to facilitate subsequent drying and shaping; drying, temperature 140°C, speed 30 m / min, with positive overfeed of about +5%, control the tension; finished product shaping, temperature 160°C, speed 25 m / min, with positive overfeed of about +10%, add functional flame retardant agent 30 g / L. Note that when shaping, the empty machine should be started for 20 minutes before loading, the air volume should be turned to the maximum, and the oven door should be opened to disperse the odor. This process can meet the automotive interior standard odor level 3.5 and the flame retardant GB8410-2006 standard grade A-0. See Tables 1 and 2 below for details:

[0043] Table 1

[0044]

[0045] Table 2

[0046]

[0047] Example 2:

[0048] Grey fabric made of 75D / 72F polyester drawn textured yarn DTY (AAA) and 75D / 36F polyester filament FDY (AA), with 600 warp ends, woven on Karl Mayer warp knitting machine; edge rolling, temperature 100°C, speed 25 m / min, roll pressure 0.3 mpa; pre-treatment for degreasing, degreasing temperature 90°C, time 30 min; dyeing, temperature 130°C, time 40 min, bath ratio 1:12, dyeing time 4.5 hours, nozzle 100#; water washing for deodorization, first overflow water washing, temperature 70°C, time 30 min, then drain and refill with water, temperature 70°C, time 30 min, add 2% clay deodorizing agent to improve the odor, then drain and refill with water, temperature 50°C, time 30 min; dehydration and opening, remove excessive water on the fabric surface, open the fabric surface from rope shape to facilitate subsequent drying and shaping; drying, temperature 150°C, speed 25 m / min, with positive overfeed about +3%, control the tension; finished product shaping, temperature 170°C, speed 30 m / min, with positive overfeed about +10%, add 10 g / L functional tear strength enhancer. Note during shaping production: Run the empty machine for 20 minutes before loading the fabric onto the shaping machine, turn the air volume to the maximum, and open the oven door to disperse the odor. This process can meet the automotive interior standard odor level 3.0 and the tear strength above 38 N. The performance tests of each yarn are shown in Table 3 and Table 4:

[0049] Table 3: Comparison of Yarn Tensile Strength Tests

[0050]

[0051] Table 4: Physical Properties of Finished Products

[0052]

[0053]

[0054] It can be seen from Table 3 and Table 4 that the finished fabrics made of 75D low-elastic DTY polyester yarn and 75D FDY polyester filament can meet the standard requirements in terms of odor, tear resistance and breaking resistance, thus providing a new choice for the current automotive seat leather base fabric.

[0055] The above embodiments are only the preferred embodiments of the present application and cannot be used to limit the scope of protection of the present application. Any non-substantial changes and substitutions made by those skilled in the art based on the present application belong to the scope of protection required by the present application.

Claims

1. A leather-based fabric for automobile seats, characterized in that: The leather-based fabric is woven by a warp-knitting Kamaier loom, and the leather-based fabric is woven from polyester 75D low-elastic DTY yarn and polyester 75D FDY filament through three combs.

2. The automotive seat leather-based fabric according to claim 1, characterized in that: The leather-based fabric has 590-610 head grains.

3. A method for preparing the automotive seat leather-based fabric as claimed in claim 1 or 2, characterized in that: The steps of the preparation method include S1. Grey cloth forming: polyester 75D low-elastic DTY yarn and polyester 75DFDY filament are woven into grey cloth through three combs using a warp knitting Kamel loom; S2. Edge rolling: Dip and roll the edges of the cloth to make them smooth to avoid curling during degreasing and dyeing; S3, pre-treatment degreasing: using high temperature and high pressure overflow dyeing machine, degreasing and washing in the tank; S4, dyeing: give color to the fabric, dyeing temperature is 128-135℃, time is 30-60min, bath ratio is 1:10-1:15, dyeing time is 3-5 hours; S5, Wash and deodorize: remove the residual odor on the fabric; S6, dehydration and opening: remove excess moisture from the cloth and open the cloth from the rope shape to facilitate subsequent drying and shaping; S7, shaping and drying: shaping conditions are 130-160℃, speed 20-50m / min, with positive overfeed of about 3-10%, so that the basic size of the cloth surface is stable; S8. Finished product shaping: The shaping temperature is 130-180°C, the speed is 20-50m / min, and positive overfeed is about 3-10%.

4. The method for preparing a leather-based fabric for automobile seats according to claim 3, characterized in that: The padding temperature in step S2 is 90-100° C., the speed is 15-60 m / min, and the roller pressure is 0.3-0.4 MPa.

5. The method for preparing a leather-based fabric for automobile seats according to claim 3, characterized in that: The degreasing temperature in step S3 is 80-90° C., the time is 20-40 min, and the desizing aids in the degreasing process are: degreasing agent, dispersing and leveling agent, and liquid alkali.

6. The method for preparing a leather-based fabric for automobile seats according to claim 1, characterized in that: The step of washing and deodorizing comprises: A1. Overflow water washing, temperature 60-80℃, time 10-30min; A2. Drain the water and then refill it with water, wash twice at a temperature of 40-70℃ for 10-30 minutes.

7. The method for preparing a leather-based fabric for automobile seats according to claim 1, characterized in that: The step S3 and the step S4 of the dark grey cloth adopt a degreasing treatment in which degreasing and dyeing are completed in one step in the same bath.

8. The method for preparing a leather-based fabric for automobile seats according to claim 1, characterized in that: The setting temperature in step S8 is 140-170° C., the speed is 20-50 m / min, with positive overfeed of about 3-10%, and the dosage of the functional additive is 5-20 g / L.

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