Wear-resistant artificial leather and preparation method thereof

Abstract

The invention provides wear-resistant artificial leather which comprises a base cloth layer, a middle buffer layer is arranged on the base cloth layer, the middle buffer layer is composed of 70-80 parts of foaming polyurethane and 20-30 parts of thermoplastic elastomer, a surface wear-resistant layer is arranged on the middle buffer layer, and a wear-resistant layer is arranged on the surface wear-resistant layer. The surface wear-resistant layer is prepared from 80-90 parts of modified polyurethane, 3-5 parts of nano silicon dioxide modified by a silane coupling agent and 2-4 parts of two-dimensional boron nitride, a recycled material layer is further arranged between the base cloth layer and the middle buffer layer, and the recycled material layer is prepared from recycled old leather broken particles and a polyurethane adhesive. A plurality of uniformly distributed micro pits are formed in the surface of one side, deviating from the middle buffer layer, of the surface wear-resistant layer, and a curing layer is arranged on the surface of the surface wear-resistant layer and on the upper surfaces of the plurality of micro pits. The artificial leather has the advantages of excellent wear resistance and air permeability.

Description

Technical Field

[0001] The present invention relates to the technical field of artificial leather design, in particular to wear-resistant artificial leather and a preparation method thereof. Background Art

[0002] Artificial leather is made of foamed or laminated PVC and PU with various formulations on a textile or non-woven base. It can be processed according to different strength, color, gloss, pattern and other requirements. It has a wide variety of patterns, good waterproof performance, neat edges, high utilization rate and is relatively cheaper than genuine leather.

[0003] As described in the invention patent with publication number CN111979787A and named as a PVC artificial leather, it includes a surface layer, a base fabric layer, an adhesive layer adjacent to the base fabric layer and located on the upper layer of the base fabric layer, a foaming layer located between the surface layer and the adhesive layer, and a functional enhancement layer located on the upper layer of the surface layer.

[0004] The above artificial leather was found to have poor wear resistance during actual use. Other existing artificial leathers usually improve wear resistance by adding a single filler (such as calcium carbonate) or surface coating. However, such artificial leathers have problems such as uneven filler dispersion and high-temperature softening, and are less practical. Summary of the Invention

[0005] In view of the deficiencies in the prior art, the present invention provides a wear-resistant artificial leather and a preparation method thereof, which are used to solve the technical problem raised in the background art regarding the poor wear resistance of the existing artificial leather.

[0006] The above technical objectives of the present invention are achieved through the following technical solutions:

[0007] A wear-resistant artificial leather comprises a base fabric layer, an intermediate buffer layer is provided above the base fabric layer, the intermediate buffer layer is composed of 70-80 parts of foamed polyurethane, 20-30 parts of thermoplastic elastomer and 0.6-1 part of foaming agent, a surface wear-resistant layer is provided above the intermediate buffer layer, the surface wear-resistant layer is composed of 80-90 parts of modified polyurethane, 3-5 parts of nano-silicon dioxide modified with a silane coupling agent, and 2-4 parts of two-dimensional boron nitride, a recycled material layer is further provided between the base fabric layer and the intermediate buffer layer, the recycled material layer is composed of recycled old leather crushed particles and polyurethane adhesive, a plurality of evenly distributed micro-pits are provided on the surface of the surface wear-resistant layer on the side facing away from the intermediate buffer layer, and a solidified layer is provided on the upper surface of the plurality of micro-pits.

[0008] The present invention is further configured as follows: the modified polyurethane is composed of a combination of petroleum-based and castor oil-based biomaterials.

[0009] The present invention is further configured as follows: the base fabric layer is a nylon non-woven fabric, and a tear-resistant reinforcement layer is provided on the side of the base fabric layer facing away from the buffer intermediate layer.

[0010] The present invention is further configured such that 0.5-1 part of a disulfide bond dynamic cross-linking agent is added to the intermediate buffer layer.

[0011] The present invention is further configured as follows: the diameter of the micro-pits is 80-90 μm, the depth is 15-20 μm, and the spacing is 150-200 μm.

[0012] The present invention is further configured such that: the curing layer is a UV curing agent.

[0013] A method for preparing wear-resistant artificial leather comprises the following steps:

[0014] S1. Raw material processing and preparation:

[0015] Surface wear-resistant layer: Nano-silicon dioxide and two-dimensional boron nitride are mixed in proportion, placed in a plasma treatment machine for activation, and nano-fillers are obtained, which are then blended with modified polyurethane to form granules;

[0016] Middle buffer layer: Mix and foam polyurethane, thermoplastic elastomer and foaming agent;

[0017] Recycled material layer: crush the recycled old leather and mix it with polyurethane adhesive to form granules to obtain granules for forming the recycled material layer;

[0018] S2, raw material molding:

[0019] The raw materials of the surface wear-resistant layer, the intermediate buffer layer and the recycled material layer are melted and extruded simultaneously through an extruder die, and the base fabric layer is transported by a conveyor belt arranged below the extruder die, so that the raw materials extruded by the extruder and the base fabric layer are compounded by a hot pressing roller and then cooled by a cooling roller for shaping;

[0020] S3. Surface processing:

[0021] Micro-pits are imprinted using laser etching and locked in place using UV curing agent;

[0022] The bonding strength between the surface wear-resistant layer, the middle buffer layer, the recycled material layer and the base fabric layer is enhanced by local infrared heating.

[0023] The present invention is further configured to include:

[0024] S4: Cutting and quality inspection:

[0025] Slitting: Cut the whole artificial leather into rolls or sheets according to demand;

[0026] Quality inspection: The artificial leather is tested for heat insulation and moisture insulation as well as wear resistance through temperature and humidity test chamber and friction tester.

[0027] The present invention is further configured as follows: the tear-resistant reinforcement layer on the base fabric layer is formed by impregnating the base fabric layer with a graphene / epoxy resin solution and then drying it.

[0028] Compared with the existing technology, the beneficial effects are:

[0029] The present application is a wear-resistant artificial leather and a preparation method thereof, which mainly produces an artificial leather with wear-resistant function. The present application uses the synergistic reinforcement of nano-silicon dioxide and two-dimensional boron nitride and the laser-etched micro-pit chip storage design to reduce the wear rate to 45 mg / 1000 times, which is 62.5% lower than that of traditional PU leather, greatly improving the wear resistance. By adding a recycled material layer to the overall artificial leather, the raw material consumption is effectively reduced by 30% and the carbon emissions are reduced by 40%. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 Schematic diagram of the overall structure cross-section of an embodiment of the present invention;

[0031] Figure 2 for Figure 1 A magnified schematic diagram of the structure at A;

[0032] Figure 3 It is a production process flow chart of the present invention.

[0033] In the above figures: 1. base fabric layer; 2. middle buffer layer; 3. surface wear-resistant layer; 4. recycled material layer; 5. micro-pits; 6. solidified layer. DETAILED DESCRIPTION

[0034] The technical solution of the present invention is further described below with reference to the accompanying drawings and embodiments.

[0035] Example:

[0036] Reference Figure 1 The present application is a wear-resistant artificial leather comprising a base fabric layer 1, which is a nylon non-woven fabric. An intermediate buffer layer 2 is disposed above the base fabric layer 1. The intermediate buffer layer 2 is composed of 70-80 parts of foamed polyurethane, 20-30 parts of thermoplastic elastomer, and 0.6-1 parts of foaming agent. The intermediate buffer layer 2 also contains 0.5-1 parts of a disulfide dynamic crosslinker. The added disulfide dynamic crosslinker can trigger bond breaking and recombination through heat or light, achieving self-repair of scratches. Specifically, the recovery rate is >90% after treatment at 60°C for 10 minutes.

[0037] like Figure 1 and Figure 2As shown, a surface wear-resistant layer 3 is provided above the middle buffer layer 2. The surface wear-resistant layer 3 is composed of 80-90 parts of modified polyurethane, 3-5 parts of nano-silicon dioxide modified with a silane coupling agent, and 2-4 parts of two-dimensional boron nitride. The modified polyurethane is composed of a combination of petroleum-based and castor oil-based biomaterials. By adding bio-based materials in this way, carbon emissions can be effectively reduced. The surface of the surface wear-resistant layer 3 facing away from the middle buffer layer 2 is provided with a number of evenly distributed micro-pits 5. The diameter of the micro-pits 5 is 80-90μm, the depth is 15-20μm, and the spacing is 150-200μm. The design of a number of micro-pits 5 can store wear debris, thereby reducing the friction loss of the entire artificial leather. As shown Figure 1 and Figure 2 As shown, the surface wear-resistant layer 3 is provided with a curing layer 6 on the surface of the plurality of micro-pits 5, and the curing layer 6 is a UV curing agent. This arrangement realizes a high-precision surface structure by combining laser etching with UV curing, avoiding secondary processing damage.

[0038] like Figure 1 As shown, a recycled material layer 4 is provided between the base fabric layer 1 and the intermediate buffer layer 2. This recycled material layer 4 is composed of 70 parts recycled old leather particles and 30 parts polyurethane adhesive. This arrangement improves waste recycling and reduces raw material production costs. A tear-resistant reinforcement layer is provided on the side of the base fabric layer 1 facing away from the intermediate buffer layer. This tear-resistant reinforcement layer is formed by impregnating the base fabric layer 1 (i.e., a non-woven fabric) with a graphene / epoxy resin solution and then drying it, effectively improving the overall strength of the base fabric layer 1.

[0039] like Figure 3 As shown, a method for preparing wear-resistant artificial leather comprises the following steps:

[0040] 1. Raw material processing and preparation:

[0041] Surface wear-resistant layer 3: Nano-silicon dioxide and two-dimensional boron nitride are mixed in a ratio of 4:3, placed in a plasma treatment machine for activation for 10 minutes, and nano-fillers are obtained, which are then blended with modified polyurethane to form granules.

[0042] Intermediate buffer layer 2: The foamed polyurethane, thermoplastic elastomer and foaming agent are mixed in an internal mixer and then injected with supercritical CO2 for foaming.

[0043] Recycled material layer 4: The recycled old leather is crushed and mixed with a polyurethane adhesive in an internal mixer, and then granulated by an extruder to obtain granules for constituting the recycled material layer 4.

[0044] Base fabric layer 1: The non-woven fabric is impregnated with a graphene / epoxy resin solution and then dried to obtain a base fabric layer 1 with a tear-resistant reinforcement layer.

[0045] 2. Raw material molding:

[0046] The raw materials of the surface wear-resistant layer 3, the middle buffer layer 2 and the recycled material layer 4 are melted and extruded simultaneously through an extruder die. The extruder die is a die with a three-layer flow channel. The processed base fabric layer 1 is transported by a conveyor belt arranged below the extruder die. The raw materials extruded by the extruder are compounded with the base fabric layer 1 through a hot pressing roller and are shaped and cooled by a cooling roller.

[0047] 3. Surface processing:

[0048] First, laser etching is used to emboss the micro-pits 5, and then they are cured and locked by UV curing agent. Finally, infrared local heating is performed by an infrared heater to enhance the bonding strength between the surface wear-resistant layer 3, the middle buffer layer 2, the recycled material layer 4 and the base fabric layer 1.

[0049] Slitting and quality inspection:

[0050] Slitting: Cut the whole artificial leather into rolls or sheets according to demand;

[0051] Quality inspection: The artificial leather is tested for heat insulation and moisture insulation as well as wear resistance through temperature and humidity test chamber and friction tester.

[0052] The following is a test comparison experiment table:

[0053]

[0054]

[0055] This comparison table is based on standardized testing methods and objectively quantifies the comprehensive leadership of the present invention in terms of performance, environmental protection, and cost, providing strong support for industrial promotion.

[0056] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the purpose and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A wear-resistant artificial leather, characterized by: The invention comprises a base fabric layer (1), an intermediate buffer layer (2) is provided above the base fabric layer (1), the intermediate buffer layer (2) is composed of 70-80 parts of foamed polyurethane, 20-30 parts of thermoplastic elastomer and 0.6-1 parts of foaming agent, a surface wear-resistant layer (3) is provided above the intermediate buffer layer (2), the surface wear-resistant layer (3) is composed of 80-90 parts of modified polyurethane, 3-5 parts of nano-silicon dioxide modified with a silane coupling agent, and 2-4 parts of two-dimensional boron nitride, a recycled material layer (4) is further provided between the base fabric layer (1) and the intermediate buffer layer (2), the recycled material layer (4) is composed of recycled old leather crushed particles and polyurethane adhesive, a surface of the surface wear-resistant layer (3) facing away from the intermediate buffer layer (2) is provided with a plurality of evenly distributed micro-pits (5), and the surface wear-resistant layer (3) is provided with a solidified layer (6) on the upper surface of the plurality of micro-pits (5).

2. The wear-resistant artificial leather according to claim 1, characterized in that: The modified polyurethane is composed of a combination of petroleum-based and castor oil-based biomaterials.

3. The wear-resistant artificial leather according to claim 1, characterized in that: The base fabric layer (1) is a nylon non-woven fabric, and a tear-resistant reinforcement layer is provided on the side of the base fabric layer (1) facing away from the buffering intermediate layer.

4. The wear-resistant artificial leather according to claim 1, characterized in that: 0.5-1 part of a disulfide bond dynamic cross-linking agent is also added to the intermediate buffer layer (2).

5. The wear-resistant artificial leather according to claim 1, characterized in that: The micro-pits (5) have a diameter of 80-90 μm, a depth of 15-20 μm, and a spacing of 150-200 μm.

6. The wear-resistant artificial leather according to claim 1, characterized in that: The curing layer (6) is a UV curing agent.

7. The method for preparing a wear-resistant artificial leather according to any one of claims 1 to 6, characterized in that: The steps include: S1. Raw material processing and preparation: Surface wear-resistant layer (3): nano-silicon dioxide and two-dimensional boron nitride are mixed in proportion, placed in a plasma treatment machine for activation, and nano-fillers are obtained, and then blended with modified polyurethane to form granules; Middle buffer layer (2): foamed polyurethane, thermoplastic elastomer and foaming agent are mixed and foamed; Recycled material layer (4): crushing the recycled old leather and mixing it with a polyurethane adhesive to form granules to obtain granules for forming the recycled material layer (4); S2, raw material molding: The raw materials of the surface wear-resistant layer (3), the raw materials of the intermediate buffer layer (2) and the raw materials of the recycled material layer (4) are melted and extruded simultaneously through an extruder die, and the base fabric layer (1) is transported by a conveyor belt arranged below the extruder die, so that the raw materials extruded by the extruder and the base fabric layer (1) are compounded by a hot pressing roller and then cooled by a cooling roller for shaping; S3. Surface processing: Laser etching is used to imprint micro-pits (5), and the micro-pits are locked by curing with a UV curing agent; The bonding strength between the surface wear-resistant layer (3), the middle buffer layer (2), the recycled material layer (4) and the base fabric layer (1) is enhanced by local infrared heating.

8. The method for preparing a wear-resistant artificial leather according to claim 7, characterized in that: Also includes S4: Cutting and quality inspection: Slitting: Cut the whole artificial leather into rolls or sheets according to demand; Quality inspection: The artificial leather is tested for heat insulation and moisture insulation as well as wear resistance through temperature and humidity test chamber and friction tester.

9. The method for preparing a wear-resistant artificial leather according to claim 7, characterized in that: The tear-resistant reinforcement layer on the base fabric layer (1) is formed by impregnating the base fabric layer (1) with a graphene / epoxy resin solution and then drying it.

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