Artificial leather and method for manufacturing same

Abstract

The present invention relates to an artificial leather and a method for manufacturing same. According to the present invention, provided are an artificial leather having improved abrasion strength and durability as well as a superior appearance and feel, and a method for manufacturing same.

Description

Artificial leather and method of manufacturing the same

[0001] The present invention relates to artificial leather and a method for manufacturing the same.

[0002]

[0003] Suede-like artificial leather is made by impregnating a polymer elastomer onto a nonwoven fabric in which microfibers are entangled three-dimensionally.

[0004] Abrasion resistance and durability are important factors determining the quality of suede-style artificial leather. For example, when artificial leather is applied to automotive interiors, high abrasion resistance and durability are required for seat areas due to repeated entry and exit. Additionally, suede-style artificial leather must simultaneously satisfy sensory characteristics such as appearance and tactile feel. The rich nap, comparable to that of natural leather, is one of the reasons why artificial leather is used not only in the fashion and clothing sectors but also in various industries such as furniture and automotive seats.

[0005] Generally, to increase the abrasion resistance of suede-like artificial leather, measures are taken such as imparting a rigid structure to the polymer elastomer impregnated on the nonwoven fabric, increasing the impregnation amount of the polymer elastomer, or using a high-density nonwoven fabric to increase shape stability.

[0006] However, while it is expected that high abrasion resistance can be imparted to artificial leather through the above measures, there is a limitation in that the unique tactile characteristics of suede are degraded, such as the length of the fibers formed on the surface of the artificial leather becoming shorter and the texture of the artificial leather becoming hard.

[0007] Conversely, artificial leather designed with long fibers and a flexible texture has problems such as shedding a large amount of fibers during use, generating dust, and pilling caused by friction between fibers, resulting in inferior wear resistance and durability.

[0008]

[0009] The present invention is intended to provide artificial leather having excellent appearance and tactile feel, as well as improved wear resistance and durability.

[0010] And, the present invention is intended to provide a method for manufacturing the artificial leather.

[0011]

[0012] According to one embodiment of the invention,

[0013] An entanglement layer comprising a nonwoven fabric in which ultrafine fibers are entangled three-dimensionally and a first polymer elastomer impregnated on the nonwoven fabric, and

[0014] It comprises a hair layer including a plurality of hairs formed by napping at least a portion of the microfibers located on one surface of the above-mentioned interlocking layer;

[0015] A second polymer elastomer is provided at the boundary portion between the above entanglement layer and the above mower layer and on the pores of the above entanglement layer, and

[0016] A softening agent is applied to the surface of the above-mentioned fibers,

[0017] Artificial leather is provided.

[0018]

[0019] According to one embodiment, the boundary portion between the interlocking layer and the mowing layer is an area from the boundary surface between the interlocking layer and the mowing layer to a height of 5% or less of the total thickness of the mowing layer.

[0020]

[0021] According to one embodiment, the entanglement layer and the fuzz layer have a thickness ratio of 1:0.1 to 1:0.5 (entanglement layer:fuzz layer).

[0022]

[0023] According to one embodiment, the fur layer has a thickness of 0.1 to 0.5 mm.

[0024]

[0025] According to one embodiment, the ultrafine fibers have a fineness of 0.01 to 0.3 denier.

[0026]

[0027] According to one embodiment, the nonwoven fabric has a g / cm³ of 0.175 to 0.250 g / cm³ 3 It has an apparent density.

[0028]

[0029] According to one embodiment, the first polymer elastomer is impregnated at 15 to 35 weight percent based on the total weight of the artificial leather, and the second polymer elastomer is provided at 0.3 to 3 weight percent based on the total weight of the artificial leather.

[0030]

[0031] According to one embodiment, the first polymer elastomer and the second polymer elastomer are each independently one or more resins selected from the group consisting of polyurethane resin, polyurea resin, and polyacrylic acid resin.

[0032]

[0033] According to one embodiment, the softener is one or more silicone-based compounds selected from the group consisting of polydimethylsiloxane, polymethylhydrosiloxane, epoxy-modified silicone, amino-modified silicone, and polyester-modified silicone.

[0034]

[0035] According to another embodiment of the invention.

[0036] A step of preparing an artificial leather substrate comprising an entanglement layer and a fiber layer (wherein the entanglement layer comprises a nonwoven fabric in which ultrafine fibers are entangled three-dimensionally and a first polymer elastomer impregnated on the nonwoven fabric, and the fiber layer comprises a plurality of fibers formed by napping at least a portion of the ultrafine fibers located on one surface of the entanglement layer);

[0037] A step of impregnating a second polymer elastomer onto the artificial leather substrate;

[0038] A step of removing at least a portion of the second polymer elastomer impregnated on the fur layer of the artificial leather substrate; and

[0039] Step of applying a softening agent to the surface of the hairs of the hair layer from which at least a portion of the second polymer elastomer has been removed

[0040] A method for manufacturing the artificial leather, comprising...

[0041]

[0042] According to one embodiment, the step of impregnating the second polymer elastomer onto the artificial leather substrate is performed by impregnating the solution containing the second polymer elastomer at a wet pickup rate of 50 to 100%. Here, the wet pickup rate is a value calculated by the formula [(W1-W0) ÷ W0] 100, where W0 is the weight (g) of the artificial leather substrate before impregnation and W1 is the weight (g) of the artificial leather substrate after impregnation.

[0043]

[0044] According to one embodiment, the step of removing at least a portion of the second polymer elastomer impregnated on the above-mentioned matrix layer is performed under a vacuum of 100 to 200 torr using a slot-type suction device equipped with a suction slot.

[0045]

[0046] According to one embodiment, the step of removing at least a portion of the second polymer elastomer impregnated on the brush layer is performed by adjusting the position of the suction slot so that the distance between the surface of the brush layer and the suction slot is 0.1 to 10 mm.

[0047]

[0048] According to one embodiment, the step of removing at least a portion of the second polymer elastomer impregnated on the fur layer is performed by removing the second polymer elastomer present in a region from the surface of the fur layer to a depth of at least 95% of the total thickness of the fur layer.

[0049]

[0050] According to one embodiment, the step of applying a softening agent to the surface of the bristles is performed using a spray device equipped with a fine spray nozzle, at a rate of 0.05 to 0.5 kg / m² per unit area of ​​the bristles layer. 2 It is performed by spraying softener particles with a particle size of 10 to 500 μm with a spray amount.

[0051]

[0052] According to the present invention, an artificial leather having excellent appearance and tactile feel, as well as improved wear strength and durability, and a method for manufacturing the same are provided.

[0053]

[0054] Hereinafter, artificial leather according to embodiments of the invention and a method for manufacturing the same will be described in more detail.

[0055]

[0056] Unless explicitly stated otherwise in this specification, technical terms are used merely to refer to specific embodiments and are not intended to limit the invention.

[0057] The singular forms used in this specification include plural forms unless the phrases clearly indicate otherwise.

[0058] As used in this specification, the meaning of “includes” specifies certain characteristics, regions, integers, steps, actions, elements, and / or components, and does not exclude the existence or addition of other specific characteristics, regions, integers, steps, actions, elements, components, and / or groups.

[0059] In this specification, terms including ordinal numbers, such as "first" and "second," are used for the purpose of distinguishing one component from another and are not limited by said ordinal numbers. For example, within the scope of the present invention, the first component may also be named the second component, and similarly, the second component may be named the first component.

[0060] As used herein, "denier" is a unit of fineness based on the mass (gram) per 9,000 meters of length of a single fiber strand. For example, 1 denier can be expressed as 1 g / 9,000 m, or 0.11 mg / m, or 0.11 tex.

[0061]

[0062] According to one embodiment of the invention,

[0063] An entanglement layer comprising a nonwoven fabric in which ultrafine fibers are entangled three-dimensionally and a first polymer elastomer impregnated on the nonwoven fabric, and

[0064] It comprises a hair layer including a plurality of hairs formed by napping at least a portion of the microfibers located on one surface of the above-mentioned interlocking layer;

[0065] A second polymer elastomer is provided at the boundary portion between the above entanglement layer and the above mower layer and on the pores of the above entanglement layer, and

[0066] A softening agent is applied to the surface of the above-mentioned fibers,

[0067] Artificial leather is provided.

[0068]

[0069] As a result of the inventors' research, it was confirmed that artificial leather satisfying the above compositions can have excellent appearance and tactile feel, as well as improved wear resistance and durability.

[0070] In particular, the artificial leather can more firmly support the entanglement layer by providing a second polymer elastomer at the boundary between the entanglement layer and the fiber layer and in the pores of the entanglement layer, and can more firmly maintain the physical bond between the nonwoven fabric and the first polymer elastomer in the entanglement layer. Accordingly, the artificial leather can exhibit excellent wear resistance and durability even under repetitive friction environments.

[0071] In addition, as a softening agent is applied to the surface of the fibers, the artificial leather can minimize the occurrence of pilling caused by friction between the fibers during use. Furthermore, by minimizing the second polymer elastomer present on the fiber layer, the artificial leather can exhibit excellent appearance and tactile properties as the fibers are not compressed or clumped by the second polymer elastomer.

[0072]

[0073] The artificial leather above includes the interlocking layer and the fiber layer.

[0074] The above entanglement layer comprises a nonwoven fabric in which ultrafine fibers are entangled three-dimensionally and a first polymer elastomer impregnated on the nonwoven fabric.

[0075] The above-mentioned fiber layer comprises a plurality of fibers formed by napping at least a portion of the ultrafine fibers located on one surface of the above-mentioned interlocking layer.

[0076]

[0077] According to one embodiment, the ultrafine fibers constituting the nonwoven fabric may have a fineness of 0.01 to 0.3 denier. To ensure colorfastness and mechanical properties, it is preferable for the ultrafine fibers to have a fineness of 0.01 denier or higher. However, if the fineness of the ultrafine fibers is too high, the tactile feel of the artificial leather may deteriorate and the nonwoven fabric may become stiff. Therefore, it is preferable for the ultrafine fibers to have a fineness of 0.3 denier or lower.

[0078]

[0079] According to one embodiment, the ultrafine fibers may be fibers of a polyester material such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), and polybutylene terephthalate (PBT).

[0080] As a non-limiting example, the above-mentioned ultrafine fibers may be obtained from sea-island type fibers. The sea-island type fibers are composed of a first polymer and a second polymer with different solubility characteristics in a solvent. By dissolving the first polymer, which is the sea component, into a solvent, only the second polymer, which is the island component, remains to form the ultrafine fibers.

[0081] The first polymer above may be a copolymerized polyester or polystyrene as a solvent-soluble component that is dissolved and eluted in a solvent. As an example, the first polymer is a copolymerized polyester with excellent solubility in an alkaline solvent. The copolymerized polyester may be a copolymerized polyethylene glycol, polypropylene glycol, 1,4-cyclohexanedicarboxylic acid, 1,4-cyclohexanedimethanol, 1,4-cyclohexanedicarboxylate, 2,2-dimethyl-1,3-propanediol, 2,2-dimethyl-1,4-butanediol, 2,2,4-trimethyl-1,3-propanediol, adipic acid, and a metal sulfonate-containing ester unit or a mixture thereof, copolymerized with polyethylene terephthalate, which is the main component.

[0082] The second polymer above may be polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), or polybutylene terephthalate (PBT) as a residual component with relatively low solubility in solvents.

[0083]

[0084] According to one embodiment, the nonwoven fabric has a g / cm³ of 0.175 to 0.250 g / cm³ 3 , or 0.200 to 0.250 g / cm³ 3 , or 0.200 to 0.240 g / cm³ 3 , or 0.210 to 0.240 g / cm³ 3 It can have an apparent density.

[0085] To secure the mechanical properties of the above nonwoven fabric, the nonwoven fabric is 0.175 g / cm² 3 Above, or 0.200 g / cm³ 3 Above, or 0.210 g / cm³ 3 It is desirable to have an apparent density of the above. However, if the apparent density of the nonwoven fabric is too high, the nonwoven fabric becomes stiff and the impregnation amount of the first polymer elastomer may decrease. Therefore, the nonwoven fabric has an apparent density of 0.250 g / cm³ 3 Less than or equal to 0.240 g / cm³ 3 It is desirable to have an apparent density of less than or equal to this.

[0086] In this specification, the apparent density is a value calculated by the following formula by measuring the average thickness and average unit weight of the nonwoven fabric. For example, the smaller the apparent density, the larger the volume of the nonwoven fabric.

[0087] *Apparent density (g / cm³) 3 ) = [Average unit weight (g / m²) 2 ) / Average thickness (mm)] / 1000

[0088]

[0089] According to one embodiment, the interlocking layer comprises a first polymer elastomer impregnated on the nonwoven fabric.

[0090] The first polymer elastomer is intended to provide durability and flexibility to the nonwoven fabric and may be one or more resins selected from the group consisting of polyurethane resin, polyurea resin, and polyacrylic acid resin.

[0091] The first polymer elastomer may be impregnated at 15 to 35 weight%, 20 to 35 weight%, or 20 to 30 weight% based on the total weight of the artificial leather. To ensure the mechanical properties of the artificial leather, it is preferable that the first polymer elastomer be impregnated at 15 weight% or more or 20 weight% or more based on the total weight of the artificial leather. However, if the amount of the first polymer elastomer applied is excessive, the texture of the artificial leather may become stiff, the nap may be reduced, or an excessive amount of polymer elastomer may be exposed between the fibers of the fiber layer, resulting in a deterioration in appearance. Therefore, it is preferable that the first polymer elastomer be impregnated at 35 weight% or less or 30 weight% or less based on the total weight of the artificial leather.

[0092]

[0093] Meanwhile, the artificial leather comprises a fiber layer including a plurality of fibers formed by napping at least some of the microfibers located on one side of the interlocking layer. The fiber layer is not impregnated by the first polymer elastomer.

[0094] For example, the above-mentioned fuzz layer can be obtained by grinding the surface of an impregnated fabric, which is formed by impregnating the first polymer elastomer onto the nonwoven fabric during the manufacturing process of artificial leather, with a suitable grinding means to create fuzz of an appropriate length on the surface.

[0095] According to one embodiment, the fiber layer may have a thickness of 0.1 to 0.5 mm, or 0.2 to 0.5 mm, or 0.2 to 0.4 mm. In order to ensure an appropriate level of tactile feel and dyeability, it is preferable that the thickness of the fiber layer be 0.1 mm or more or 0.2 mm or more. However, if the fiber layer becomes too thick, the surface tactile feel of the artificial leather may deteriorate, and the appearance may be inferior due to an excessive lighting effect. Therefore, it is preferable that the thickness of the fiber layer be 0.5 mm or less or 0.4 mm or less.

[0096]

[0097] According to one embodiment, the interlocking layer and the fluff layer may have a thickness ratio of 1:0.1 to 1:0.5, or 1:0.2 to 1:0.5, or 1:0.2 to 1:0.4 (interlocking layer: fluff layer). In order to ensure an appropriate level of appearance and tactile sensation, it is preferable that the thickness ratio be 1:0.1 or higher or 1:0.2 or higher (interlocking layer: fluff layer). However, if the ratio of the fluff layer becomes relatively too high, the surface tactile sensation of the artificial leather may deteriorate, and the appearance may be inferior due to an excessive lighting effect. Therefore, it is preferable that the thickness ratio be 1:0.5 or lower or 1:0.4 or lower (interlocking layer: fluff layer).

[0098]

[0099] According to one embodiment, a second polymer elastomer is provided at the boundary portion between the interlocking layer and the mower layer and on the voids of the interlocking layer.

[0100] As a second polymer elastomer is provided at the boundary portion between the interlocking layer and the fiber layer and on the pores of the interlocking layer, the fibers of the fiber layer can be more firmly supported in the interlocking layer, and the physical bond between the nonwoven fabric and the first polymer elastomer in the interlocking layer can be maintained more firmly.

[0101] Preferably, the boundary portion between the entanglement layer and the mower layer refers to an area from the boundary surface between the entanglement layer and the mower layer to a height of 5% or less, 3% or less, or 1% or less of the total thickness of the mower layer.

[0102] For example, the artificial leather is obtained by a manufacturing method described below, wherein a second polymer elastomer is impregnated onto an artificial leather substrate comprising the entanglement layer and the fur layer, and then at least a portion of the second polymer elastomer present in the fur layer is removed. Preferably, the second polymer elastomer present in the region extending from the surface of the fur layer facing the interface between the entanglement layer and the fur layer to a depth of 95% or more, 97% or more, or 99% or more of the total thickness of the fur layer is removed. Accordingly, the second polymer elastomer may be provided in the region extending from the interface between the entanglement layer and the fur layer to a height of 5% or less, 3% or less, or 1% or less of the total thickness of the fur layer.

[0103]

[0104] The second polymer elastomer may be one or more resins selected from the group consisting of polyurethane resin, polyurea resin, and polyacrylic acid resin.

[0105] The second polymer elastomer may be the same as or different from the first polymer elastomer. For example, the first polymer elastomer may be a polyurethane resin, and the second polymer elastomer may be a polyacrylic acid resin.

[0106] The second polymer elastomer may be impregnated at 0.3 to 3 weight%, 0.5 to 3 weight%, or 1 to 3 weight% based on the total weight of the artificial leather. In order to ensure that the fibers are firmly supported by the interlocking layer and that the physical bond between the nonwoven fabric of the interlocking layer and the first polymer elastomer is firmly maintained, it is preferable that the second polymer elastomer be applied at 0.3 weight% or more, 0.5 weight% or more, or 1 weight% or more based on the total weight of the artificial leather. However, if the amount of the second polymer elastomer applied is excessive, the fibers may be compressed or clumped together by the second polymer elastomer, which may result in a deterioration in appearance and tactile feel. Therefore, it is preferable that the second polymer elastomer be impregnated at 3 weight% or less based on the total weight of the artificial leather.

[0107]

[0108] According to one embodiment, a softening agent is applied to the surface of the fibers. By applying a second polymeric elastomer to the boundary portion between the entanglement layer and the fiber layer and applying a softening agent to the surface of the fibers, the fibers of the fiber layer can be more firmly supported by the entanglement layer, while friction between the fibers can be minimized. Accordingly, the fiber layer can exhibit improved durability, such as providing an excellent appearance and tactile feel for a long time, as the occurrence of pilling caused by friction between the fibers is reduced.

[0109] According to one embodiment, the softener may be one or more silicone-based compounds selected from the group consisting of polydimethylsiloxane, polymethylhydrosiloxane, epoxy-modified silicone, amino-modified silicone, and polyester-modified silicone.

[0110] It is preferable that the above softening agent be evenly applied to the surface of the bristles in the form of fine particles using a spray device equipped with a fine spray nozzle.

[0111] The above softener is 0.05 to 0.5 kg / m² per unit area of ​​the above fiber layer. 2 , or 0.1 to 0.5 kg / m² 2 , or 0.1 to 0.3 kg / m² 2 It can be applied with a spray amount. In order to enable the effect resulting from the application of the softener to be manifested, the amount of softener applied is 0.05 kg / m² per unit area of ​​the fiber layer. 2 0.1 kg / m³ or more 2 It is desirable that the above be the case. However, if the above softener is applied excessively, the uniformity of the fiber layer may decrease, resulting in a deterioration in appearance. Therefore, the amount of the above softener applied is 0.5 kg / m² per unit area of ​​the fiber layer. 2 Less than or equal to 0.3 kg / m³ 2 It is desirable that it be less than or equal to this.

[0112]

[0113]

[0114] Meanwhile, according to another embodiment of the invention.

[0115] A step of preparing an artificial leather substrate comprising an entanglement layer and a fiber layer (wherein the entanglement layer comprises a nonwoven fabric in which ultrafine fibers are entangled three-dimensionally and a first polymer elastomer impregnated on the nonwoven fabric, and the fiber layer comprises a plurality of fibers formed by napping at least a portion of the ultrafine fibers located on one surface of the entanglement layer);

[0116] A step of impregnating a second polymer elastomer onto the artificial leather substrate;

[0117] A step of removing at least a portion of the second polymer elastomer impregnated on the fur layer of the artificial leather substrate; and

[0118] Step of applying a softening agent to the surface of the hairs of the hair layer from which at least a portion of the second polymer elastomer has been removed

[0119] A method for manufacturing the artificial leather, comprising...

[0120]

[0121] According to one embodiment, a step of preparing an artificial leather substrate comprising the interlocking layer and the fur layer is performed.

[0122] As previously explained, the entanglement layer comprises a nonwoven fabric in which ultrafine fibers are entangled three-dimensionally and a first polymer elastomer impregnated on the nonwoven fabric. The fuzz layer comprises a plurality of fuzzes formed by napping at least some of the ultrafine fibers located on one surface of the entanglement layer.

[0123] The above artificial leather material can be prepared by manufacturing one that satisfies the above composition or by obtaining a commercial product.

[0124]

[0125] A step of impregnating the artificial leather substrate with a second polymer elastomer is performed. The impregnation step may be performed by immersing the artificial leather substrate in a solution containing the second polymer elastomer (hereinafter, the second polymer elastomer solution) to obtain an impregnated cloth, and squeezing the impregnated cloth to impart an appropriate pickup rate.

[0126] The second polymer elastomer solution may be prepared by dissolving or dispersing the second polymer elastomer in a predetermined solvent. Pigments, light stabilizers, antioxidants, flame retardants, softeners, colorants, etc. may be added to the second polymer elastomer solution.

[0127] According to one embodiment, the second polymer elastomer solution may have a concentration with a solid content of 0.5 to 10 weight%, or 0.5 to 8 weight%, or 1 to 8 weight%, or 1 to 5 weight%. In order to enable the effect of imparting the second polymer elastomer to be manifested, it is preferable that the second polymer elastomer solution have a concentration with a solid content of 0.5 weight% or more or 1 weight% or more. However, if the concentration of the second polymer elastomer solution is excessively high, the tactile feel and appearance of the artificial leather may be degraded. Therefore, it is preferable that the second polymer elastomer solution have a concentration with a solid content of 10 weight% or less, or 8 weight% or less, or 5 weight% or less.

[0128] According to one embodiment, the step of impregnating the second polymer elastomer onto the artificial leather substrate may be performed by impregnating the second polymer elastomer solution at a wet pickup rate of 50 to 100% or 60 to 100%. Here, the wet pickup rate is a value calculated by the formula [(W1-W0) ÷ W0] 100, where W0 is the weight (g) of the artificial leather substrate before impregnation and W1 is the weight (g) of the artificial leather substrate after impregnation.

[0129] In order to enable the effect resulting from the application of the second polymer elastomer, it is preferable that the wet pickup rate be 50% or more or 60% or more. However, if the wet pickup rate is excessively high, the work efficiency of subsequent steps may decrease and the tactile feel of the artificial leather may be insufficient. Therefore, it is preferable that the wet pickup rate be 100% or less.

[0130] According to one embodiment, the impregnated fabric can be compressed using a squeezing roller or a mangle roller in order to impart the wet pickup rate.

[0131]

[0132] A step of removing at least a portion of the second polymer elastomer impregnated on the fiber layer of the artificial leather substrate is performed. This step is performed by a method of selectively removing the second polymer elastomer present on the fiber layer after impregnating the second polymer elastomer onto the artificial leather substrate.

[0133] Preferably, a second polymeric elastomer is removed from a region extending to a depth of 95% or more, 97% or more, or 99% or more of the total thickness of the fur layer, from the surface of the fur layer facing the interface between the entanglement layer and the fur layer. Accordingly, a second polymeric elastomer may be provided in a region extending to a height of 5% or less, 3% or less, or 1% or less of the total thickness of the fur layer, from the interface between the entanglement layer and the fur layer.

[0134]

[0135] According to one embodiment, the step of removing at least a portion of the second polymer elastomer impregnated on the above-mentioned matrix layer can be performed under a vacuum of 100 to 200 torr using a slot-type suction device equipped with a suction slot.

[0136] Here, the suction slot may be of an appropriate shape considering process efficiency. As a non-limiting example, the step may be performed using a variable suction slot adjustable to a width substantially equal to the width of the artificial leather substrate.

[0137]

[0138] According to one embodiment, the step of removing at least a portion of the second polymer elastomer impregnated on the fur layer can be performed while adjusting the position of the suction slot so that the distance between the surface of the fur layer and the suction slot is 0.1 to 10 mm, or 0.1 to 8 mm, or 0.1 to 5 mm.

[0139] In order to ensure that the second polymer elastomer present on the above-mentioned fiber layer is sufficiently removed and remains only at the boundary between the entanglement layer and the fiber layer, it is preferable that the position of the suction slot be adjusted so that the distance between the surface of the fiber layer and the suction slot is 10 mm or less, 8 mm or less, or 5 mm or less. However, when performing the above step, if the position of the suction slot is too close to the surface of the fiber layer, not only the second polymer elastomer but also a part of the first polymer elastomer impregnated on the nonwoven fabric of the entanglement layer may be removed, and the fibers may be damaged and the appearance deteriorated. Therefore, it is preferable that the position of the suction slot be adjusted so that the distance between the surface of the fiber layer and the suction slot is 0.1 mm or more.

[0140] Through the above steps, the second polymer elastomer may be impregnated in an amount of 0.3 to 3 weight%, or 0.5 to 3 weight%, or 1 to 3 weight% based on the total weight of the artificial leather.

[0141]

[0142] A step of applying a softening agent to the surface of the hairs of the hair layer from which at least a portion of the second polymer elastomer has been removed is performed.

[0143] According to one embodiment, the softener may be one or more silicone-based compounds selected from the group consisting of polydimethylsiloxane, polymethylhydrosiloxane, epoxy-modified silicone, amino-modified silicone, and polyester-modified silicone.

[0144] The step of applying the above softener can be performed by using a spray device equipped with a fine spray nozzle to evenly apply the softener in the form of fine particles onto the surface of the bristles.

[0145] In the above step, the softener may be used by dissolving or dispersing it in a predetermined solvent. Preferably, the softener may be sprayed at a concentration of 0.1 to 5 weight%, or 0.5 to 5 weight%, or 0.5 to 3 weight%. In order to provide an appropriate level of softener, it is preferable that the softener be sprayed at a concentration of 0.1 weight% or more or 0.5 weight% or more. However, if the concentration of the softener is too high, it is difficult to apply the softener in the form of fine particles, and the efficiency of the spraying process may decrease. Therefore, it is preferable that the softener be sprayed at a concentration of 5 weight% or less or 3 weight% or less.

[0146]

[0147] According to one embodiment, the step of applying a softening agent to the surface of the bristles is performed using a spray device equipped with a fine spray nozzle, at a rate of 0.05 to 0.5 kg / m² per unit area of ​​the bristles layer. 2 This can be carried out by spraying softener particles with a particle size of 10 to 500 μm with a spray amount.

[0148] Preferably, the softener is 0.05 to 0.5 kg / m² per unit area of ​​the fiber layer. 2 , or 0.1 to 0.5 kg / m² 2 , or 0.1 to 0.3 kg / m² 2 It can be applied with a spray amount. In order to enable the effect resulting from the application of the softener to be manifested, the amount of softener applied is 0.05 kg / m² per unit area of ​​the fiber layer. 2 0.1 kg / m³ or more 2 It is desirable that the above be the case. However, if the above softener is applied excessively, the uniformity of the fiber layer may decrease, resulting in a deterioration in appearance. Therefore, the amount of the above softener applied is 0.5 kg / m² per unit area of ​​the fiber layer. 2 Less than or equal to 0.3 kg / m³ 2 It is desirable that it be less than or equal to this.

[0149] In addition, using the spray device, the softener may be sprayed in the form of particles with a particle size of 10 to 500 μm, or 10 to 450 μm, or 50 to 450 μm, or 50 to 400 μm, or 100 to 400 μm, or 100 to 350 μm, or 150 to 350 μm, or 150 to 300 μm. In order to provide an appropriate level of softener, it is preferable that the softener be sprayed in the form of particles with a particle size of 10 μm or more, or 50 μm or more, or 100 μm or more, or 150 μm or more. However, if the particle size of the softener is too large, the softener may form drops and be distributed unevenly on the fur layer. Therefore, it is preferable that the above softener be sprayed in the form of particles with a particle size of 500 μm or less, or 450 μm or less, or 400 μm or less, or 350 μm or less, or 300 μm or less.

[0150]

[0151] According to one embodiment, in order to apply the softener more uniformly on the surface of the hairs, a calendering process may be additionally performed after the application of the softener.

[0152] The above calendering process can be performed using a device equipped with a calender roll. Here, it is preferable that the gap of the calender roll be 60 to 80% of the thickness of the artificial leather substrate fed into the device. In order to ensure that the softener is applied more uniformly to the surface of the wool, it is preferable that the gap of the calender roll be 80% or less of the thickness of the artificial leather substrate. However, excessive roll compression may cause fine softener particles to form drops, resulting in uneven application. Therefore, it is preferable that the gap of the calender roll be 60% or more of the thickness of the artificial leather substrate.

[0153]

[0154] According to one embodiment, a process for curing or drying the second polymer elastomer and the softener applied to the artificial leather substrate is performed. This process may be performed using a tenter known in the art to which the present invention belongs to be applicable to curing and drying processes. Preferably, the process may be performed for 1 to 10 minutes, 3 to 10 minutes, or 5 to 10 minutes at a temperature of 130 to 180 ℃, or 140 to 180 ℃, or 140 to 170 ℃.

[0155]

[0156]

[0157] Preferred embodiments are presented below to aid in understanding the invention. However, the following embodiments are merely illustrative of the invention and do not limit the invention to these embodiments.

[0158]

[0159] Example 1

[0160] An artificial leather substrate was prepared, consisting of an entanglement layer with a thickness of 0.6 mm and a wool layer with a thickness of 0.2 mm. The entanglement layer is a nonwoven fabric (apparent density 0.220 g / m²) in which ultrafine fibers of polyethylene terephthalate with a fineness of 0.2 denier are three-dimensionally entangled. 3 It includes a first polymer elastomer impregnated on the nonwoven fabric. The first polymer elastomer is applied such that it contains 25% by weight of polyurethane resin solids based on the total weight of the artificial leather substrate. The fiber layer comprises a plurality of fibers formed by napping at least some of the ultrafine fibers located on one side of the interlocking layer.

[0161] An impregnated fabric was obtained by immersing the artificial leather substrate in a second polymer elastomer solution for 60 seconds. Polyacrylic acid resin was used as the second polymer elastomer. The second polymer elastomer solution was prepared to have a concentration of 1 weight% of the solid content of the second polymer elastomer. The impregnated fabric was compressed with a mangle roller so that the wet pickup rate of the second polymer elastomer solution became 90%.

[0162] The second polymer elastomer impregnated on the fiber layer was selectively suctioned and removed using a slot-type suction device equipped with a suction slot having a width equal to the width of the artificial leather substrate. The suction was performed under a vacuum of 150 torr while adjusting the distance between the surface of the fiber layer and the suction slot to 0.1 to 5 mm. Through the suction, the second polymer elastomer present in the region from the surface of the fiber layer facing the interface between the interlocking layer and the fiber layer to a depth of 99% of the total thickness of the fiber layer was removed. Additionally, through the suction, the second polymer elastomer was impregnated to a level of 3 weight percent based on the total weight of the artificial leather.

[0163] Next, a softening agent was applied to the surface of the fibers constituting the fiber layer using a spray device equipped with a fine spray nozzle. A polydimethylsiloxane solution with a solid content of 1 wt% was used as the softening agent. The softening agent was in the form of fine particles with a particle size of 200 μm at a rate of 0.2 kg / m² per unit area of ​​the fiber layer. 2 It was sprayed with a spray amount of [amount]. After the application of the softener, a calendering process was performed so that the softener could be applied more uniformly on the surface of the fibers. The calendering process was performed under a gap of 80% relative to the thickness of the artificial leather.

[0164] Next, the artificial leather substrate was heat-treated using a tenter at a temperature of 150°C for 5 minutes to cure the second polymer elastomer applied to the artificial leather substrate and to dry the softener.

[0165]

[0166] Example 2

[0167] Artificial leather was manufactured in the same manner as in Example 1, except that the second polymer elastomer solution used had a concentration of 0.5 wt% solid content of the second polymer elastomer.

[0168]

[0169] Example 3

[0170] Artificial leather was manufactured in the same manner as in Example 1, except that the softener used had a concentration of 0.5 weight% of solid content.

[0171]

[0172] Example 4

[0173] Artificial leather was manufactured in the same manner as in Example 1, except that the second polymer elastomer solution used had a concentration of 0.5 wt% solid content of the second polymer elastomer, and the softener used had a concentration of 0.5 wt% solid content of the softener.

[0174]

[0175] Example 5

[0176] Artificial leather was manufactured in the same manner as in Example 1, except that the second polymer elastomer solution used had a concentration of 3 weight% solid content of the second polymer elastomer.

[0177]

[0178] Example 6

[0179] Artificial leather was manufactured in the same manner as in Example 1, except that the softener used had a concentration of 3 weight% solid content.

[0180]

[0181] Example 7

[0182] Artificial leather was manufactured in the same manner as in Example 1, except that the second polymer elastomer solution used had a solid content of 3 wt% of the second polymer elastomer, and the softener used had a solid content of 0.5 wt% of the softener.

[0183]

[0184] Example 8

[0185] Artificial leather was manufactured in the same manner as in Example 1, except that the second polymer elastomer solution used had a solid content of 0.5 wt% of the second polymer elastomer, and the softener used had a solid content of 3 wt% of the softener.

[0186]

[0187] Example 9

[0188] Artificial leather was manufactured in the same manner as in Example 1, except that the second polymer elastomer solution used had a solid content of 2 wt% of the second polymer elastomer, and the softener used had a solid content of 3 wt% of the softener.

[0189]

[0190] Example 10

[0191] Artificial leather was manufactured in the same manner as in Example 1, except that the wet pickup rate of the second polymer elastomer solution was set to 60%.

[0192]

[0193] Example 11

[0194] Artificial leather was manufactured in the same manner as in Example 1, except that the suction was performed under a vacuum of 100 torr while adjusting the distance between the surface of the fur layer and the suction slot to 0.1 to 7 mm so that the second polymer elastomer present in the region up to a depth of 97% of the total thickness of the fur layer was removed.

[0195]

[0196] Example 12

[0197] 0.3 kg / m² of the above softener per unit area of ​​the above fiber layer 2 Artificial leather was manufactured using the same method as in Example 1 above, except that it was sprayed with a spray amount of [amount].

[0198]

[0199] Example 13

[0200] Artificial leather was manufactured in the same manner as in Example 1, except that the softener was sprayed in the form of fine particles with a particle size of 300 μm.

[0201]

[0202] Example 14

[0203] Artificial leather was manufactured in the same manner as in Example 1, except that the above calendering process was performed under a gap of 60% relative to the thickness of the artificial leather.

[0204]

[0205] Example 15

[0206] As the above artificial leather substrate, a nonwoven fabric in which ultrafine fibers of polyethylene terephthalate material with a fineness of 0.15 denier are three-dimensionally entangled (apparent density 0.205 g / m²) 3Artificial leather was manufactured in the same manner as in Example 1, except that it was composed of an entanglement layer (thickness 0.65 mm) comprising a first polymer elastomer impregnated on the nonwoven fabric and a fiber layer (thickness 0.15 mm).

[0207]

[0208] Comparative Example 1

[0209] The artificial leather substrate applied in Example 1 (i.e., not treated with the second polymer elastomer and softener) was prepared as the artificial leather of Comparative Example 1.

[0210]

[0211] Comparative Example 2

[0212] An artificial leather substrate with the same composition as that applied in Example 1 above was prepared.

[0213] A softener was applied to the surface of the fibers constituting the fiber layer of the artificial leather substrate using a spray device equipped with a fine spray nozzle. A polydimethylsiloxane solution having a solid content of 1 wt% was used as the softener. The softener was applied in the form of fine particles with a particle size of 200 μm at a rate of 0.2 kg / m² per unit area of ​​the fiber layer. 2 It was sprayed with a spray amount of [amount]. After the application of the softener, a calendering process was performed so that the softener could be applied more uniformly on the surface of the fibers. The calendering process was performed under a gap of 80% relative to the thickness of the artificial leather.

[0214] Next, the artificial leather substrate was heat-treated using a tenter at a temperature of 150°C for 5 minutes to dry the softener applied to the artificial leather substrate.

[0215]

[0216] Comparative Example 3

[0217] An artificial leather substrate with the same composition as that applied in Example 1 above was prepared.

[0218] An impregnated fabric was obtained by immersing the artificial leather substrate in a solution containing a second polymer elastomer and a softener for 60 seconds. As the second polymer elastomer, polyacrylic acid resin was applied at a concentration of 1 weight% solid content. As the softener, polydimethylsiloxane was applied at a concentration of 1 weight% solid content. The impregnated fabric was compressed with a mangle roller so that the wet pickup rate of the solution became 80%.

[0219] Next, the artificial leather substrate was heat-treated using a tenter at a temperature of 150°C for 5 minutes to cure the second polymer elastomer applied to the artificial leather substrate and to dry the softener.

[0220]

[0221] Comparative Example 4

[0222] An artificial leather substrate with the same composition as that applied in Example 1 above was prepared.

[0223] A solution containing a second polymer elastomer and a softener was applied to the surface of the bristles constituting the bristles layer using a spray device equipped with a fine spray nozzle. As the second polymer elastomer, polyacrylic acid resin was applied at a concentration with a solid content of 1 wt%. As the softener, polydimethylsiloxane was applied at a concentration with a solid content of 1 wt%. The solution was applied in the form of fine particles with a particle size of 200 μm at a rate of 0.2 kg / m² per unit area of ​​the bristles layer. 2 It was sprayed with a spray amount of [amount]. After the application of the softener, a calendering process was performed so that the solution could be applied more uniformly on the surface of the bristles. The calendering process was performed under a gap of 80% relative to the thickness of the artificial leather.

[0224] Next, the artificial leather substrate was heat-treated using a tenter at a temperature of 150°C for 5 minutes to cure the second polymer elastomer applied to the artificial leather substrate and to dry the softener.

[0225]

[0226] Test example

[0227] (1) Evaluation of wear characteristics of artificial leather

[0228] The artificial leather according to the above examples and comparative examples was evaluated for wear characteristics according to the test method of the international standard ISO 12947-1 using the Martindale wear and pilling tester (Lissajous pattern C type) of James Heal.

[0229] Specifically, after rubbing an artificial leather specimen using the above tester, the pilling resistance was visually assessed and assigned a grade from 1 to 5. Here, grade 5 indicates the best pilling resistance. The assessment of pilling resistance was performed after 10,000, 30,000, and 50,000 cycles of friction, respectively.

[0230] Then, the weight of the artificial leather specimen was measured before and after the friction, and the weight loss rate (weight%) due to friction was calculated. The weight loss rate (weight%) is the percentage of the weight reduced after the friction compared to the initial weight of the artificial leather specimen before the friction. The calculation of the weight loss rate was performed after 10,000 cycles, 30,000 cycles, and 50,000 cycles of friction, respectively.

[0231] In evaluating the above wear characteristics, the friction refers to one full rotation of the two outer drive units of the Martindale. A cycle signifies the completion of all translational wear motions following a Lissajous figure composed of 16 frictions. A Lissajous is one of an infinite variety of curves drawn by two points performing simple motions in the vertical direction. In the Martindale, the Lissajous is created by 16 frictions, with a total length of 3.02 m. The rotational speed of the Martindale is 47 ± 2.5 rpm, and the exposed specimen area is 6.45 cm². 2 am.

[0232]

[0233] (2) Evaluation of the appearance and tactile sensation of artificial leather

[0234] An evaluation team consisting of 10 artificial leather experts was formed.

[0235] The evaluation panel above sensorially evaluated the appearance (fuzz length, surface uniformity) and tactile sensation of the artificial leather according to the above examples and comparative examples and assigned grades from 1 to 5. Here, grade 5 means that the appearance or tactile sensation is the best.

[0236]

[0237] Friction (cycle) Peeling (Grade) Weight Loss (Weight%) Appearance (Grade) Tactile Feel (Grade) Example 11 51.44 43 52.25 53.1 Example 21 51.54 43 52.55 45.2 Example 31 40.73 33 52.05 52.9 Example 41 40.93 43 52.35 43.8 Example 51 51.34 33 51.75 52.1

[0238]

[0239] Friction (cycle) Peeling (Grade) Weight Loss (Weight%) Appearance (Grade) Tactile Feel (Grade) Example 61 51.9343 52.75 53.5 Example 71 50.7333 51.35 52.1 Example 81 51.7343 53.15 45.6 Example 91 51.8333 52.35 53.1 Example 101 51.6443 52.25 53.2

[0240]

[0241] Friction (cycle) Peeling (Grade) Weight Loss (Weight%) Appearance (Grade) Tactile Feel (Grade) Example 111 51.44 33 52.25 53.0 Example 121 51.34 43 52.55 53.4 Example 131 51.54 43 52.25 53.2 Example 141 51.44 43 52.15 53.0 Example 151 41.64 43 52.75 55.4

[0242]

[0243] Friction (cycle) Peeling (Grade) Weight Loss (Weight%) Appearance (Grade) Tactile Feel (Grade) Comparative Example 11 41.34 43 44.15 36.0 Comparative Example 21 51.84 23 44.85 36.5 Comparative Example 31 51.22 33 53.25 53.9 Comparative Example 41 51.22 33 54.55 56.2

[0244]

[0245] Based on the results of the above test examples, it was confirmed that the artificial leather according to the above examples has excellent abrasion strength and durability, showing a high pilling grade and a low weight loss rate while having an appearance and feel equivalent to that of the artificial leather of the comparative examples.

[0246] Comparative Example 1 above was not provided with a second polymer elastomer and a softener on the artificial leather substrate, and it was confirmed that although the appearance and tactile feel were excellent, the pilling grade was generally lower than that of the examples and weight loss proceeded rapidly as the friction cycle increased.

[0247] Comparative Example 2 above was provided with only a softener on an artificial leather substrate, and although the appearance was excellent, it exhibited poor wear characteristics similar to Comparative Example 1 as the friction cycle increased.

[0248] Comparative Example 3 above is an artificial leather substrate impregnated with a mixture of a second polymer elastomer and a softener, and as the second polymer elastomer is present throughout the fur layer, it showed a high pilling grade but an inferior appearance.

[0249] Comparative Example 4 above was obtained by finely spraying a second polymer elastomer and a softener onto an artificial leather substrate, and it was confirmed that although a high pilling grade was exhibited due to the presence of the second polymer elastomer throughout the fur layer, the appearance was inferior and the wear characteristics were poor.

[0250]

[0251] Although the present invention has been described above by limited embodiments, the present invention is not limited thereto, and it is obvious that various modifications and variations are possible within the scope of the technical spirit of the present invention and the equivalent scope of the claims described below by those skilled in the art to which the present invention belongs.

Claims

1. An entanglement layer comprising a nonwoven fabric in which ultrafine fibers are entangled three-dimensionally and a first polymer elastomer impregnated on the nonwoven fabric, and It comprises a hair layer including a plurality of hairs formed by napping at least a portion of the microfibers located on one surface of the above-mentioned interlocking layer; A second polymer elastomer is provided at the boundary portion between the above entanglement layer and the above mower layer and on the pores of the above entanglement layer, and A softening agent is applied to the surface of the above-mentioned fibers, Artificial leather.

2. In Paragraph 1, Artificial leather, wherein the boundary portion between the above-mentioned interlocking layer and the above-mentioned fiber layer is an area extending from the boundary surface between the above-mentioned interlocking layer and the above-mentioned fiber layer to a height of 5% or less of the total thickness of the above-mentioned fiber layer.

3. In Paragraph 1, Artificial leather having a thickness ratio of 1:0.1 to 1:0.5 (interlocking layer:fuzzing layer) between the interlocking layer and the fuzz layer.

4. In Paragraph 1, The above-mentioned fur layer has a thickness of 0.1 to 0.5 mm, artificial leather.

5. In Paragraph 1, The above ultrafine fibers are artificial leather having a fineness of 0.01 to 0.3 denier.

6. In Paragraph 1, The above nonwoven fabric is 0.175 to 0.250 g / cm² 3 Artificial leather having a visible density.

7. In Paragraph 1, The first polymer elastomer is impregnated at 15 to 35 weight percent based on the total weight of the artificial leather, and The second polymer elastomer is provided in an amount of 0.3 to 3 weight percent based on the total weight of the artificial leather, Artificial leather.

8. In Paragraph 1, Artificial leather, wherein the first polymer elastomer and the second polymer elastomer are each independently one or more resins selected from the group consisting of polyurethane resin, polyurea resin, and polyacrylic acid resin.

9. In Paragraph 1, The above softener is an artificial leather comprising one or more silicone compounds selected from the group consisting of polydimethylsiloxane, polymethylhydrosiloxane, epoxy-modified silicone, amino-modified silicone, and polyester-modified silicone.

10. A step of preparing an artificial leather substrate comprising an entanglement layer and a fiber layer (wherein the entanglement layer comprises a nonwoven fabric in which ultrafine fibers are entangled three-dimensionally and a first polymer elastomer impregnated on the nonwoven fabric, and the fiber layer comprises a plurality of fibers formed by napping at least a portion of the ultrafine fibers located on one surface of the entanglement layer); A step of impregnating a second polymer elastomer onto the artificial leather substrate; A step of removing at least a portion of the second polymer elastomer impregnated on the fur layer of the artificial leather substrate; and Step of applying a softening agent to the surface of the hairs of the hair layer from which at least a portion of the second polymer elastomer has been removed A method for manufacturing artificial leather according to claim 1, comprising 11. In Paragraph 10, A method for manufacturing artificial leather, wherein the step of impregnating the artificial leather substrate with a second polymer elastomer is performed by impregnating the substrate with a solution containing the second polymer elastomer at a wet pickup rate of 50 to 100% (wherein the wet pickup rate is a value calculated by the formula [(W1-W0) ÷ W0] × 100, where W0 is the weight (g) of the artificial leather substrate before impregnation and W1 is the weight (g) of the artificial leather substrate after impregnation).

12. In Paragraph 10, A method for manufacturing artificial leather, wherein the step of removing at least a portion of the second polymer elastomer impregnated on the above-mentioned fur layer is performed under a vacuum of 100 to 200 torr using a slot-type suction device equipped with a suction slot.

13. In Paragraph 12, A method for manufacturing artificial leather, wherein the above step involves adjusting the position of the suction slot so that the distance between the surface of the fur layer and the suction slot is 0.1 to 10 mm to remove at least a portion of the second polymer elastomer impregnated on the fur layer.

14. In Paragraph 10, A method for manufacturing artificial leather, wherein the step of removing at least a portion of the second polymer elastomer impregnated on the above-mentioned fur layer is performed by removing the second polymer elastomer present in a region from the surface of the above-mentioned fur layer to a depth of at least 95% of the total thickness of the above-mentioned fur layer.

15. In Paragraph 10, The step of applying a softening agent to the surface of the above bristles is to use a spray device equipped with a fine spray nozzle at a rate of 0.05 to 0.5 kg / m² per unit area of ​​the bristles layer. 2 A method for manufacturing artificial leather, performed by spraying softener particles with a particle size of 10 to 500 μm with a spray amount.