KR102130552B1 - Method for manufacturing artificial leather using a bonding substrate with a reuseable backing cloths - Google Patents

Abstract

The present invention is a reusable support fabric (Backing cloths) in the artificial leather manufacturing process through the improvement of high-density weaving and adhesive bonding process; Method of manufacturing a bonding base material having a reusable support fabric; And a method of manufacturing artificial leather using a bonding material having a reusable support fabric. It is thin and has excellent elasticity, breathability, and touch, so it can effectively mass-produce ultra-thin synthetic leather that can surpass natural leather, as well as the cost of production by reusing backing cloths in the manufacturing process of artificial leather. Can be dramatically lowered.

Description

Method for manufacturing artificial leather using a bonding material having a reusable supporting fabric {Method for manufacturing artificial leather using a bonding substrate with a reuseable backing cloths}

The present invention is a reusable support fabric (Backing cloths) in the artificial leather manufacturing process through the improvement of high-density weaving and adhesive bonding process; Method of manufacturing a bonding base material having a reusable support fabric; And a method of manufacturing artificial leather using a bonding material having a reusable support fabric.

Natural leather is a cloth material that has been used by mankind since ancient times, and has been used noblely as a household goods symbolizing power and wealth. With the development of various textile manufacturing technologies in recent years, the newly emerged artificial leather material has established itself as one of the valuable high-tech products that humans have learned from nature, and recently, in the textile industry, various methods for high value-added products have been sought. In particular, interest in artificial leather is growing.

Natural leather has been used in a variety of ways for clothing and footwear due to its advantages such as excellent durability, gorgeous appearance, soft touch, and excellent heat retention. However, the supply is limited and there are disadvantages such as difficulty in washing, breathability, color fastness, and antiseptic properties. In recent years, problems have been continuously raised in terms of animal protection. While the demand for environmental protection is spreading due to the problems of air and water pollution caused by the tanning process of natural leather, and the problem of harsh handling of animals to obtain natural leather, the demand for natural leather is gradually decreasing. The demand for high quality artificial leather is increasing.

Artificial leather is a product that has resins such as PVC, polyamide, and polyurethane on fabrics, knitted fabrics, or non-woven fabrics by knife coating, laminate, foaming, impregnation, etc., to give the appearance and feel similar to natural leather. , Lighter than natural leather, large surface strength, excellent abrasion resistance, good moisture permeability, antiseptic, various colors, easy to cut, sew, etc., products are uniform, mass production is possible Have.

In recent years, artificial leather has been used for a wide range of applications, ranging from apparel, daily use, and sports and leisure use. As it is supplied with high quality at a price that is comparable or superior to that of natural leather, it has a weight comparable to its functional performance. And sensational aspects such as tactile feel are also important.

However, the consumer's choice is somewhat passive due to consumers' negative perception of artificial leather such as low quality and low cost materials, but when high quality artificial leather is applied to various products, the domestic textile industry is a high value-added industry. It will play an important role in upgrading, and it is expected to improve the favorable attitude of consumers and further lead to the proliferation of purchase and use.

Coating methods currently commercially used in the manufacture of artificial leather may differ depending on the classification method, but generally used methods can be classified into a dry method and a wet method by classification by a film forming method. In other words, the dry and wet method depends on whether the process of forming the coated film into a solidified film after coating with a liquid polyurethane resin is a film formed by solvent volatilization by heating or a film formed by solvent substitution by osmotic pressure in contact with water. It is classified.

The dry product is treated as a low-grade product because it has a stiff feel and breathability compared to the wet product, and the synthetic leather by the wet coating method is a manufacturing process in the case of using a fabric or thick knitted fabric as a base and a nonwoven fabric. Although this is somewhat different, the basic mechanism is to form a micro-porous structure in the process of solidifying the coated polyurethane resin layer in a DMF aqueous solution.

As a result of analyzing the problems of the existing artificial leather products, it was found that the thickness is thin and similar in appearance in a low-cost product family mainly by the dry method, but it does not exhibit the texture peculiar to natural leather, and the unique characteristics of the wet coating product in the expensive product family by the wet method The touch and elasticity of the natural leather due to the formation of phosphorus pores are expressed as it is, but since it must withstand high tension during wet coating, it is inevitable to use a thick fabric for the base fabric, which inevitably increases the thickness of the product.

As a method to improve this, there is a method of maintaining shape stability in the wet coating process by bonding with a cloth-like backing cloth and fineness knitted fabric to which adhesion is given, and peeling after wet coating (Korea Patent Registration Publication) 10-1682165). At the same time, this technology for manufacturing high-quality artificial leather such as natural leather is able to withstand high tension during wet coating by bonding with supporting fabric to support thin stretched fabrics, and for securing shape stability of base fabric. It is divided into the adhesive bonding process, the wet coating process to which it is applied, and the process of peeling the supporting fabric.

However, although a synthetic leather of a thin film can be produced by this method, the support fabric used as a support is about 1,200 won per m, and is used only once and then subjected to a wet coating process and then peeled and discarded.

The peeled support fabric has adhesive traces on its surface due to the adhesive bonding process, and traces of the adhesive remain on the back side. In addition, in the wet coating process, foreign substances including PU are buried in the entire supporting fabric, so it has to be disposed of.

In the present invention, the adhesive applied to one surface in the adhesive bonding process of manufacturing the base material by adhesively bonding the knitted fabric base material and the backing cloths during the manufacture of artificial leather is extruded through the back side of the supporting fabric and peeled through the peeling process. Not only does the trace of adhesive remain on the back side of the supporting fabric, but also solves the problem of having to dispose due to the presence of foreign matter including polyurethane (PU) in the entire supporting fabric in the wet coating process. Backing cloths).

The first aspect of the present invention is a method of manufacturing a bonding base material (i) a reusable support fabric and (ii) an elastic base fabric for artificial leather are adhered so as to be peelable from each other,

(a) treating one surface of the support fabric in the form of a fabric with a release agent;

(b) applying a binder on the release agent treatment surface of the support fabric; And

(c) supplying an elastic base fabric for artificial leather, for example, a knitted fabric substrate, onto a binder coating surface of the supporting fabric, followed by pressing to form a bonding substrate,

Depending on the throughput of the release agent in the steps (a)(b)(c) and the application amount of the binder and the process conditions to form the bonding substrate through compression, the warp density and weft density are so that the binder does not spill out on the back side of the supporting fabric. It provides a method of manufacturing a bonding base for manufacturing artificial leather, characterized by using a controlled high-density woven support fabric.

The second aspect of the present invention is a base material for manufacturing artificial leather manufactured by the manufacturing method of the first aspect, (i) a support fabric that is reused by removing and removing it after being used as a support fabric of a bonding base for manufacturing artificial leather one or more times, and ( ii) It provides a bonding base for manufacturing artificial leather having a stretchable base fabric for artificial leather.

The third aspect of the present invention is a support fabric that is reused as a support fabric of an elastic base fabric for artificial leather, which has been peeled off after being used as a support fabric of a bonding base for manufacturing artificial leather manufactured by the manufacturing method of the first aspect. Gives

A fourth aspect of the present invention is a method of manufacturing artificial leather using (i) a reusable support fabric and (ii) a bonding base adhered so that the elastic base fabric for artificial leather is peelable from each other,

(d) forming a microporous polyurethane porous layer having micropores on the side of the elastic base fabric of the bonding base for manufacturing artificial leather, which is prepared by the manufacturing method of the first aspect and the binder is not exposed on the back side of the supporting fabric. ;

(e) optionally forming a skin layer on the surface of the polyurethane pore layer;

(f) peeling and removing the supporting fabric from the stretchable base fabric after (d) forming a microporous polyurethane pore layer or after (e) forming a skin layer; And

(g) (f) provides a method for manufacturing an artificial leather characterized in that it comprises the step of reusing the supporting fabric removed in step (d) as a supporting fabric for a synthetic base for manufacturing artificial leather.

Hereinafter, the present invention will be described in detail.

Figure 1 illustrates a flow chart of a method for manufacturing a synthetic base material for a synthetic leather by adhesively bonding a knitted fabric base material and a supporting fabric for reuse of backing cloths during the manufacturing process of an artificial leather and a method for manufacturing an artificial leather using the combined base material It is done.

As illustrated in Figure 1, one embodiment of the invention,

As (i) a reusable support fabric and (ii) a method for manufacturing artificial leather using a bonding base adhered so that the elastic base fabric for artificial leather can be peeled from each other,

(a) treating one surface of the support fabric in the form of a fabric with a release agent;

(b) applying a binder on the release agent treatment surface of the support fabric;

(c) supplying an elastic base fabric for artificial leather on a binder-coated surface of the supporting fabric and then compressing to form a bonding substrate;

(d) forming a microporous polyurethane porous layer having micropores on the side of the stretchable base fabric of the binder base for artificial leather production in which the binder is not exposed on the back side of the support fabric;

(e) optionally forming a skin layer on the surface of the polyurethane pore layer;

(f) peeling and removing the supporting fabric from the stretchable base fabric after (d) forming a microporous polyurethane pore layer or after (e) forming a skin layer; And

(g) reusing the support fabric removed in step (f) as a support fabric of a bonding base for the production of artificial leather in step (a).

Artificial leather produced using a bonding substrate for producing artificial leather according to the present invention,

(ii) a stretchable base fabric for artificial leather, such as a knitted fabric substrate;

(iii) a microporous polyurethane porous layer having micropores formed on an elastic base fabric for artificial leather; And

(iv) Optionally, a skin layer formed on the microporous polyurethane pore layer 54 may be included.

Optionally, an adhesive layer may be interposed between the microporous polyurethane pore layer and the skin layer.

The microporous polyurethane pore layer (iii) is a polyurethane pore layer in which a myriad of uniform micropores are formed. The polyurethane used to form this layer can be formed by reacting a polyol mixture composed of a polyol and a chain extender with isocyanate.

The skin layer (iv) may be made of the same polyurethane as the polyurethane constituting the polyurethane pore layer (iii), but the porosity is reduced than the polyurethane pore layer (iii) to protect the polyurethane pore layer (iii). It can be.

The adhesive layer serves as an optional layer to strengthen the adhesion of the polyurethane pore layer and the skin layer, and may be made of a general adhesive used in the art, and it is preferable to use a polyurethane-based adhesive, preferably phosphorus, nitrogen-based It is preferable to use a two-component polyurethane adhesive to which a flame retardant is added, in view of being able to impart flame retardancy of artificial leather.

For example, the artificial leather of the present invention is a three-layered or artificial layer in which an elastic base fabric for artificial leather (ii), a microporous polyurethane porous layer (iii), and a skin layer (iv) are laminated, such as a knitted fabric base material. The elastic base fabric for leather (ii), microporous polyurethane pore layer (iii), adhesive layer, and skin layer (iv) may be in the form of four layers.

In the artificial leather of the present invention, the elastic base fabric for artificial leather (ii) has an average thickness of 0.15 to 0.25 mm, the polyurethane pore layer (iii) has an average thickness of 0.15 to 0.25 mm, and the skin layer (iv) Silver may have an average thickness of 0.05 to 0.10 mm.

According to the present invention, (i) a reusable support fabric and (ii) a method for manufacturing an artificial leather using a bonding base adhered so that the elastic base fabric for artificial leather is peelable from each other, first (d) After explaining steps ~ (g), steps (a) ~ (c) will be described later.

As shown in FIG. 1, in the step (d), the microporous polyurethane porous layer having micropores on the side of the elastic base fabric (ii) of the bonding substrate obtained through steps (a) to (c) (iii) is formed.

To this end, a first polyurethane resin coating solution including a polyurethane resin and an organic solvent capable of dissolving the polyurethane resin is coated on the side of the elastic base fabric of the bonding substrate.

The first polyurethane resin coating solution may include a polyurethane resin, a solvent, a pore control agent, and a toner in a weight ratio of 100: 30 to 60: 0.5 to 2: 0.1 to 1: 5 to 15. The solvent may include one or more selected from dimethylformamide (DMF), ethyl acetate, tetrahydrofuran, ethylene glycol monoethyl ether, and ethylene glycol monoethyl ether acetate, 100 for polyurethane resin : 30 to 60 by weight, preferably 100: 35 to 45 by weight. At this time, if it is less than 30 weight ratio, it is difficult to form uniform pores because the viscosity of the solution is high, and if it exceeds 60 weight ratio, the viscosity of the solution is too low to control the thickness precisely, so it is preferable to use within the above range. The solvent is preferably DMF.

The pore control agent is for forming uniform pores in the polyurethane pore layer, and one or more selected from anionic polyurethane pore control agents and nonionic polyurethane pore control agents may be used. And, the amount of the use is 100: 0.5 to 2 weight ratio with respect to the polyurethane resin, preferably 100: 0.5 to 1.5 weight ratio. If it is less than 0.5 weight ratio, it may not be possible to form sufficient pores in the polyurethane pore layer, more than 2 weight ratio and pores may be uneven, so it is preferable to use within the above range.

The toner is a pigment that imparts the color of the polyurethane pore layer, and the amount of the toner is 100:5-15 weight ratio, preferably 100:7-12 weight ratio, with respect to the polyurethane resin. If it is less than 5 weight ratio, it is difficult to implement color, and it may have a problem of exceeding 15 weight ratio and deteriorating the overall physical properties of the product.

In addition, the first polyurethane resin coating solution may further include at least one selected from anti-yellowing agents, antioxidants, surfactants, and blocking agents (specifically, methanol and ethanol) commonly used in the art.

In addition, the polyurethane resin can be prepared by reacting a polyol, a chain extender, and a diisocyanate in a solvent. The polyol may include three types of polyols: polyester-based polyol (weight average molecular weight 1,000 to 6,000), polyether-based polyol (weight average molecular weight 1,000 to 6,000), and polycarbonate-based polyol (weight average molecular weight 1,000 to 6,000). And the polyol is a polyester-based polyol, polyether-based polyol and polycarbonate-based polyol in a weight ratio of 10 to 60: 20 to 80: 5 to 60, preferably 20 to 40: 30 to 65: 20 to 50 in weight ratio It is good in terms of improving hydrolysis resistance and chemical resistance. The polyol may further include one or two or more flame retardant polyols such as reactive phosphoric acid ester-based polyols and polyether-ester-based polyols, which do not generate harmful gases during polyurethane production and have excellent flame retardant effects.

Through this, by adjusting to a stable polyurethane structure, an additional process of adding a flame retardant is not required, and a polyurethane pore layer can be formed to have good flame retardant performance.

In addition, the chain extender may be a general one used in the art, and is not particularly limited, it may be preferable to use a low molecular weight diol having an even number of repeat units, which is advantageous for increasing crystallinity. Specifically, one or more selected from ethylene glycol, propylene glycol, 1,4-butanediol, 1,6-hexanediol and methylpentanediol may be included. And it is preferable to use 1 to 15 parts by weight of chain extender, preferably 2 to 10 parts by weight, based on 100 parts by weight of polyol. If used in less than 1 part by weight, there may be a problem that the heat resistance and adhesive strength is poor. When used in excess of 15 parts by weight, too much unreacted chain extender is generated, which is uneconomical.

In addition, the solvent used for synthesizing the polyurethane resin may be a general one used in the art, and is not particularly limited, preferably DMF, ethyl acetate, tetrahydrofuran, ethylene glycol monoethyl ether and Ethylene glycol monoethyl ether acetate may include one or more selected from. In addition, it is preferable to use 150 to 350 parts by weight of a solvent, preferably 200 to 300 parts by weight, and more preferably 250 to 300 parts by weight based on 100 parts by weight of the polyol. When used in less than 150 parts by weight, the viscosity may be too high to increase the molecular weight, and when used in excess of 350 parts by weight, viscosity may be low, and thus it may be difficult to synthesize a polyurethane resin having an appropriate viscosity and molecular weight.

In addition, the diisocyanate may be a general one used in the art, and is not particularly limited, 4,4-diphenylmethane diisocyanate (MDI), modified MDI, hexamethylene diisocyanate (HDI), isophorone diisocyanate ( IPDI), dicyclohexyl methane diisocyanate (H12 MDI) and xylene diisocyanate (XDI). In addition, the amount of diisocyanate used is preferably from the viewpoint of increasing the molecular weight, so that the NCO/OH ratio of the polyol and diisocyanate is 0.95 to 1.05, preferably 1.0.

The resultant obtained by applying the first polyurethane resin coating solution on the side of the elastic base fabric of the bonding substrate is immersed in a coagulation bath to solidify the polyurethane resin coating layer. At this time, the polyurethane solution impregnated in the elastic base fabric is solidified by solvent exchange of the coagulating solution, thereby converting the polyurethane of the polyurethane solution into a leather structure. Specifically, when the polyurethane-impregnated elastic base fabric is immersed in the coagulation solution, the solvent of the polyurethane solution impregnated in the elastic base fabric, for example, DMF is eluted with the coagulation solution, solvent-exchanged and solid poly Urethane solidifies into a leather structure. By adjusting the composition of the coagulating solution for solvent-exchanging the polyurethane impregnated elastic base fabric, the physical properties of the artificial leather structure formed by solidification of the polyurethane of the polyurethane solution of the elastic base fabric can be adjusted. For example, as a coagulant for solvent-exchanging a polyurethane-impregnated elastic base fabric, when water alone or a mixed coagulant formed by mixing water and DMF at a constant mixing ratio is used, the mixed coagulant water and By adjusting the mixing ratio between DMF, the physical properties of the artificial leather structure can be controlled.

When the polyurethane-impregnated elastic base fabric is impregnated into the coagulation solution, the solvent of the polyurethane solution impregnated in the polyurethane-impregnated elastic base fabric, for example, DMF is eluted, the polyurethane solution The polyurethane dissolved in the solvent is exchanged and solidified into a leather structure, and the polyurethane solidified into the leather structure is in close contact with the polyurethane-impregnated elastic base fabric, thereby obtaining a form of artificial leather.

Microporous poly by removing the residual moisture or DMF on the surface of the polyurethane-filled elastic base fabric by washing with water and drying by natural drying or hot air, etc. by washing the polyurethane-filled elastic base fabric forming the shape of artificial leather A urethane pore layer can be formed.

The stretchable base fabric may be, for example, a knitted fabric substrate, and a conventional non-woven fabric using a knitted fabric substrate knitted with a very inexpensive polyester monofilament long fiber or a highly shrinkable polyester filament fiber. , Compared to artificial leather manufactured using microfiber material and island-in-the-sea material as a base material, manufacturing cost can be significantly reduced.

In step (e), a skin layer 58 is formed on the surface of the microporous polyurethane pore layer (iii). To this end, a second polyurethane resin coating solution comprising a polyurethane resin and an organic solvent capable of dissolving the polyurethane resin, for example, a mixed solvent of DMF and methyl ethyl ketone (MEK), is applied on a separate release paper and Dry to form a skin layer. The second polyurethane resin coating solution is applied again on the skin layer, and the adhesive layer formed on the release paper and the microporous polyurethane pore layer are pressed against each other and compressed. After the resultant is cured and aged in the combined state, the release paper can be separated to form a skin layer (iv) on the surface of the microporous polyurethane pore layer (iii). The second polyurethane resin coating solution includes a polyurethane resin, a solvent, and a dispersant, and may further include an additive containing at least one selected from anti-yellowing agents, antioxidants, and leveling agents.

In the artificial leather of the present invention, the adhesive layer may be a general adhesive used in the art, but is not particularly limited, but a polyurethane-based adhesive is used, preferably a two-component urethane to which a phosphorus or nitrogen-based flame retardant is added. The use of an adhesive is good in that it can impart flame retardancy of artificial leather.

In step (f), after the step (d) of forming the microporous polyurethane pore layer or after the step of (e) of forming the skin layer, the support fabric is peeled off from the elastic base fabric to obtain artificial leather. Can (Fig. 1).

Highly elastic but low-strength knitted fabric base materials such as stretch base fabrics and support fabrics that can effectively support them are used, and adhesive bases and stretch fabrics are adhesively bonded to subsequent wet or dry polys In contrast to the prior art, which is inputted to a urethane impregnation process, etc., in the polyurethane impregnation process, the support fabric is discarded by peeling the elastic base fabric from the support fabric after the polyurethane impregnation process while maintaining the combination of both. In order to implement the step (g) of reusing the support fabric removed in step (f) as the support fabric of the bonding material for manufacturing artificial leather of step (a) or (d), that is, to reuse the support fabric, It is characterized by using a high-density woven support fabric that is designed so that the warp and weft yarns are woven at right angles and use a woven fabric type support fabric, but the binder is not drawn out on the back side of the support fabric during a series of processes.

Table 1 shows the expected cost reduction effect by reusing backing cloths.

Additional production Backing cloths cost Pretreatment cost Bonding substrate production cost existing
fair 1 time 1,200 won/m 300 won/m 1,500 won/m Episode 2 1,200 won/m 300 won/m 1,500 won/m 3rd time 1,200 won/m 300 won/m 1,500 won/m The total amount 4,500 won/3m recycle
fair existing 1,200 won/m 300 won/m 1,500 won/m 1 reuse - 300 won/m 300 won/m Reuse 2 times - 300 won/m 300 won/m The total amount 2,100 won/3m

In order to reuse the supporting fabric according to the present invention, (i) a reusable supporting fabric and (ii) a method of manufacturing a bonding base in which the elastic base fabric for artificial leather is adhered so as to be peelable from each other,

(a) treating one surface of the support fabric in the form of a fabric with a release agent;

(b) applying a binder on the release agent treatment surface of the supporting fabric; And

(c) supplying an elastic base fabric for artificial leather on a binder coating surface of the supporting fabric and then pressing to form a bonding substrate,

Depending on the throughput of the release agent in the steps (a)(b)(c) and the application amount of the binder and the process conditions to form the bonding substrate through compression, the warp density and weft density are so that the binder does not spill out on the back side of the supporting fabric. It is characterized by the use of a controlled high-density woven support fabric.

The peeling process proceeds at the end of the artificial leather manufacturing process, and in order to minimize foreign matters during peeling, it is preferable to apply a minimum amount of adhesive in step (b) and apply thinly.

Meanwhile, in order to reuse the supporting fabric, a washing process may be performed after peeling, and may be a method of drying after passing through a bath containing a washing solution.

For this reason, in the present invention, the support fabric of the bonding base for manufacturing artificial leather may already be used as a support fabric of the bonding base for manufacturing artificial leather one or more times, and may be a support fabric that is reused by peeling off.

In the present invention, when manufacturing a bonding substrate for artificial leather in which a fabric-type backing cloth and an elastic base fabric (eg, a high-strength fineness knitted fabric) are bonded, the fabrication of the backing cloths By improving the high-density weaving and adhesive bonding process, the supporting fabric can be reused in the manufacturing process of artificial leather that forms a microporous coating by a wet method.

For example, through the high-density weaving of the supporting fabric, the adhesiveness is enhanced by preventing the adhesive from leaking to the back side, and the artificial pre-treatment/washing process of the supporting fabric and the gravure coating process that can evenly apply a small amount of adhesive are applied to manufacture artificial leather. The unit cost can be reduced. Therefore, through the manufacturing process for reuse of backing cloths used in manufacturing a bonding substrate for artificial leather, it is possible to significantly reduce the manufacturing cost of the synthetic leather than the existing process.

The texture of the fabric refers to the state where the warp and weft cross each other, and it is necessary to select the appropriate tissue according to the purpose of use of the fabric. The plain fabric is suitable for the supporting fabric of the present invention.

Density is used to indicate the texture of the fabric. It is indicated by the number of warp and weft yarns in 1 inch or 5 cm.

Since the density of the fabric depends on the fineness (thickness) of the yarn, when weaving with plain weave, when the yarn is polyester 150d (denier), the warp density is 180-250, and the weft density is 160-230, In the case of the polyester 250d yarn, when weaving in plain weave, the inclination density is 100 to 170, and when the weft density is 80 to 150, the tissue becomes dense, so that the adhesive can be prevented from leaking on the back side.

The release agent/adhesive agent pre-treatment process conditions and usage can control the warp density and/or weft density together with the fineness (thickness) of the yarn to prevent the adhesive from coming out on the back side of the fabric.

The denser the fabric, the greater the density, the harder, less shrinkage during the polyurethane (PU) wet coating process and/or the water washing process, and the better shape retention.

Since the physical properties are different for each fineness of the yarn, for example 150d, it is preferable that the supporting fabric has a mass of 100 to 150 g/m ² , a tensile strength of 600 to 1000 N, and a tear strength of 15 to 30 N. Below the minimum value, the supportability of the fabric decreases, and if it exceeds the maximum value, a cost increase is a problem.

The twisting process of imparting twist to the yarn can increase the strength of the yarn and improve the focusability. In particular, it improves the working efficiency in the weaving process, and the degree of twisting is both weak (100~300TM) and steel (1,000~3,000TM) to achieve this purpose.

Normally, the warp yarn uses a stronger thread (used with grass) than the weft yarn, and the weft yarn uses a thick thread with less twist than the warp yarn, and the strength is warp> weft, and the elasticity is warp <weft. It is possible to use a support fabric imparted by twisting in the Z direction or twisting in the S direction.

Figure 2 illustrates an adhesive bonding system for manufacturing a bonding base for artificial leather using a reusable support fabric.

Referring to FIG. 2, first, the support fabric is supplied along the direction of the arrow while releasing the support fabric from the supply device.

In the case of disposing of the supporting fabric after the conventional peeling, the reusable support according to the present invention is used, unlike the use of a low density woven fabric having a tissue density in the range of 40x50 to 60x70 (number/inch) considering only the adhesion/peeling side. According to the processing amount of the release agent in the steps (a)(b)(c) and the coating amount of the binder and the process conditions for forming the bonding substrate through compression, the fabric is subjected to warp density and weft so that the binder does not spill out on the back side of the supporting fabric. Use a high-density woven support fabric with controlled density. Since the density of the fabric varies depending on the fineness (thickness) of the yarn, for example, when weaving in plain weave, the polyester 150d (denier) yarn has a warp density of 180-250 and a weft density of 160-230 days At this time, in the case of polyester 250d yarn, when weaving in plain weave, the inclination density is 100-170, and when the weft density is 80-150, the tissue becomes dense, so that the adhesive can be prevented from coming out on the back side.

According to the present invention, the reusable support fabric may also use high-definition yarn having a yarn single yarn fineness in a range of 200d to 300d. As an elastic base fabric for artificial leather, when used as a combined base for artificial leather production with a knitted fabric base made of three denier yarns with a single yarn fineness of 40 denier or less, it is effective during the entire process of artificial leather production, such as polyurethane impregnation process. It is preferable in terms of being able to support in combination.

Yarns constituting the supporting fabric are polyester yarns such as polyethylene terephthalate and polybutylene terephthalate; Polyamide yarns such as nylon 6 and nylon 66 are generally used, and polyvinyl alcohol yarns may be used.

When the supporting fabric is a woven fabric, these woven fabrics include basic structures such as plain weave, twill weave, and runner weave; Transformed tissue derived from the basic organization such as change plain weave, change twill, change runnership; Alternatively, it may be a double woven fabric, a woven fabric, a cotton woven fabric, a pile woven fabric, or another special tissue woven fabric.

In the step (a), at least one surface of the supporting fabric is treated with a release agent in the pretreatment device.

The release agent may be at least one release agent selected from fluorine-based compounds, silicone-based compounds, and acrylic-based compounds.

As the pre-treatment device, for example, a mangle (mesh) and a mesh roll (mesh roll) or the like can be used.

After treating the release agent on the support fabric, drying the support fabric in the first drying furnace prior to step (b) of applying the subsequent binder is preferred in terms of allowing the binder to be smoothly applied in the subsequent binder application step. The temperature of the first drying furnace may be adjusted to 130 to 180°C, for example, 130 to 160°C, and specifically 130 to 150°C in terms of fixation.

Subsequently, the binder is applied on the surface of the release agent treatment of the support fabric while supplying the support fabric.

The step of applying the binder on the surface of the release agent treatment of the supporting fabric may be performed by a gravure coating method in terms of temporary adhesion. In addition, by applying a gravure coating process, a very small amount of adhesive can be applied thinly and evenly so that the binder does not spill out on the back side of the supporting fabric.

While supplying the binder coating liquid from the binder coating liquid supplying tank to the gravure coating device, the binder is applied on the release agent treatment surface of the supporting fabric by a conventional gravure coating method or gravure printing method.

It is preferable that the binder is a polyurethane-based adhesive in terms of preventing contamination by other types of resin in the polyurethane impregnation process for forming the microporous polyurethane pore layer during the subsequent artificial leather manufacturing process.

The ratio of the amount of application of the binder based on the dry weight in the support fabric: the throughput of the release agent not only considers aspects that can balance the adhesive bondability and release properties of the elastic base fabric for the artificial leather and the support fabric. It can be adjusted within the range of 1:1 to 1:2 so as not to come out on the back of the supporting fabric. Preferably it may be in the range of 1:1 to 1:1.5, more preferably in the range of 1:1 to 1:1.3, and more preferably in the range of 1:1 to 1:1.2. If the ratio is less than 1:1, a problem of coating surface defects may occur, and when it is greater than 1:2, a problem of peeling during the process may occur.

Subsequently, after supplying the elastic base material for artificial leather on the bonding surface of the supporting fabric, and then compressing it with a pressing roller, the support base and artificial leather are fabricated and combined by combining and supporting the base fabric. A base material for manufacturing artificial leather of a base fabric is obtained.

The elastic base fabric for artificial leather may be a knitted fabric composed of three denier yarns having a single yarn fineness of 40 denier or less. It is preferable from the viewpoint of the touch that the knitted fabric substrate made of a three denier yarn having a single yarn fineness of 20 denier to 30 denier is a highly elastic knitted fabric substrate having a stretch ratio in the range of 60 to 120% at room temperature.

It is preferable that at least one surface of the elastic base fabric for artificial leather is brushed so that the polyurethane resin can be effectively impregnated in a subsequent process for manufacturing artificial leather.

Yarns constituting a stretch base for artificial leather are polyester yarns such as polyethylene terephthalate and polybutylene terephthalate; Polyamide yarns such as nylon 6 and nylon 66 are generally used, and polyvinyl alcohol yarns may be used. In particular, the use of polyester yarns is preferred in terms of minimizing water absorption and high durability. A knitted fabric knitted by blending high elastic fibers such as polyamide yarn and/or spandex with polyester yarn may also be used. The stretch base fabric for artificial leather includes warp knitted fabrics such as tricot knitted fabric, raschel knitted fabric, and Milanese knitted fabric; Knitted fabrics such as flat knitted fabrics, rubber knitted fabrics, pearl knitted fabrics, double-sided knitted fabrics, and double jersey fabrics; Jacquard knitting; Circular knitted fabric;

The weight of the stretch base fabric for artificial leather is generally about 100 g/yd to 200 g/yd, in terms of tensile strength, 100 g/yd to 180 g/yd, more preferably 130 g/yd to 180 It can be g/yd.

After the step (c) of combining and combining the support fabric and the elastic base fabric for artificial leather, the method may further include drying the support fabric and the elastic base fabric for artificial leather. The second base is passed by continuously transporting the bonding base material of the support fabric and the synthetic base fabric for artificial leather that have passed through the pressing roller. The temperature of the second drying furnace can be adjusted to 130 to 160°C in terms of setting.

Optionally, after the step of drying the bonding substrate, the method may further include cylinder drying the bonding substrate.

To this end, the bonding substrate that has passed through the second drying furnace is continuously transported and passed while guiding the cylinder dryer to contact. The cylinder dryer has the characteristics of surface smoothing compared to a conventional drying furnace. The temperature of the cylinder dryer can be adjusted to 100 to 150°C in terms of surface smoothness.

Subsequently, when the bonding substrate that has passed through the cylinder dryer is wound up, a bonding substrate for manufacturing artificial leather according to the present invention can be obtained.

The bonding substrate for producing artificial leather of the present invention that can be obtained through the above process,

At least one side of the support fabric treated with a release agent;

A binder layer formed on the release agent treatment surface of the support fabric; And

It includes a stretchable base fabric for artificial leather that is detachably coupled to the support fabric by the binder layer, but the binder is not exposed to the back side of the support fabric, and is characterized by being reusable after removing and peeling during the artificial leather manufacturing process. .

Therefore, the support fabric may be a support fabric that is reused by being peeled off after being used as a support fabric for a bonding base for manufacturing artificial leather at least once.

The present invention through the step (f) of removing the supporting fabric from the elastic base (base) fabric after the step (d) to form a microporous polyurethane pore layer or after the step (e) to form a skin layer, It is possible to provide a support fabric that is reused as a support fabric of an elastic base fabric for artificial leather, which has been peeled off after being used as a support fabric of a bonding base for manufacturing artificial leather.

Furthermore, if the method of manufacturing the bonding material for manufacturing artificial leather according to the present invention is performed, (i) the support material that is reused by peeling off after being used as a supporting material for the bonding material for manufacturing artificial leather at least once and (ii) elasticity for artificial leather It is possible to provide a bonding substrate for manufacturing artificial leather with a base fabric.

According to the present invention, according to a method of manufacturing an artificial leather using a bonding substrate obtained by adhesively bonding a knitted fabric substrate and a peelable removable and reusable support fabric, the thickness is thin, and the elasticity, breathability, and touch feeling are all excellent to surpass natural leather. In addition to being able to mass-produce ultra-thin synthetic leather that can be effectively produced, it is possible to significantly reduce production costs by reusing backing cloths during the manufacturing of artificial leather.

Therefore, it is possible to effectively mass-produce artificial leather materials that can be applied to information and communication (IT) devices, such as smartphones and tablet PCs, which have a very high demand for light weight and thin film, or for sports goods, furniture, and fashion materials. As well as,

In the adhesive bonding process, when reusing the backing cloths that are peeled off and discarded after the wet coating process, only the pre-treatment cost of 300 won per m is additionally incurred, thereby lowering the manufacturing cost.

Figure 1 illustrates a flow chart of a method for manufacturing a synthetic base material for a synthetic leather adhesively bonding a knitted fabric base material and a supporting fabric for reuse of backing cloths during the manufacturing process of an artificial leather and a synthetic leather manufacturing method using the bonding material It is done.
Figure 2 illustrates an adhesive bonding system for manufacturing a bonding base for artificial leather using a reusable support fabric.

Hereinafter, the present invention will be described in more detail through examples. However, these examples are for illustrative purposes only, and the scope of the present invention is not limited to these examples.

Example One

800 Tm was equally applied to the yarn used for warp by twisting in the Z direction. After performing the twisting process to impart twist to the yarn, the support fabric was woven with a Water-Jet loom. At this time, the sexual width: 54".

Density is KS K 0511:2009 C method, mass is KS K 0514:2017, tensile strength is KS K 0520:2015 Grab method (CRE Type), tear strength is KS K 0536:2014 tongue method, drapeability Measured by KS K ISO 9073-9:2016 Method A (diameter of the used model plate: 30 cm) and shown in Table 2 below.

Test Items Test result Normal Weaving ( Comparative Example 1 ) High density Weaving ( Example One) 4100/80 5000/96 density
(All /5.0cm) slope 165.2 185.0 Weft 145.6 165.4 Mass (g/m ² ) 114.4 132.1 The tensile strength
(N) slope 830 950 Weft 750 900 Tear strength
(N) slope 24 20 Weft 23 20 Drape castle
(%) 76.5 81.3 Surface image

Whether adhesive backing O X

As a result of applying the fluorine-based release agent and applying a polyurethane adhesive thereon as a gravure roll to pre-treat the support fabric, in the case of the support fabrics of Examples 1 and 1 with different weaving densities, the adhesive of the adhesive fabric of Comparative Example 1 Although it came out on the back side, in Example 1, the adhesive did not come out on the back side of the support fabric (Table 2).

Claims (11)

(i) a reusable support fabric and (ii) a method of manufacturing a bonding base in which an elastic base fabric for artificial leather is adhered so as to be peelable from each other,
(a) treating one surface of the support fabric in the form of a fabric with a release agent;
(b) applying a binder on the release agent treatment surface of the supporting fabric; And
(c) supplying an elastic base fabric for artificial leather on a bonding surface of the supporting fabric and then compressing to form a bonding substrate,
Depending on the throughput of the release agent in the steps (a)(b)(c) and the application amount of the binder and the process conditions to form the bonding substrate through compression, the warp density and weft density are so that the binder does not spill out on the back side of the supporting fabric. Adjusted support fabric is used,
A method of manufacturing a bonding material for manufacturing artificial leather, wherein the supporting material of a bonding material for manufacturing artificial leather is a support material that is reused by being peeled off after being used as a supporting material for a bonding material for manufacturing artificial leather one or more times. According to claim 1, The inclination density and the weft density of the support fabric is adjusted to 180 to 250 number/inch, and 160 to 230 number/inch, respectively, or 100 to 170 number/inch, and 80 to 150 number/, respectively. Method of manufacturing a bonding material for manufacturing artificial leather, adjusted in inches. The method according to claim 1, wherein the step (b) of applying the binder on the release agent treatment surface of the support fabric is characterized in that the binder is applied thinly and evenly with a small amount of binder application by applying a gravure coating method so that it does not spill out on the back side of the support fabric. Method of manufacturing a bonding base for leather production. The method according to claim 1, further comprising drying the supporting fabric after the release agent treatment step and before the binder application step. The method of claim 1, further comprising the step of drying the bonding substrate after step (c) to form a bonding substrate having (i) a reusable support fabric and (ii) a stretchable base fabric for artificial leather. Characteristic Method of manufacturing a bonding base for artificial leather manufacturing. The method of claim 5, further comprising the step of cylinder drying the bonding substrate after the bonding substrate drying step. The method of claim 1, wherein the synthetic base material for artificial leather is a knitted fabric substrate. The method according to claim 7, wherein at least one surface of the knitted fabric base is brushed. Claim 1 to claim 8, wherein the manufacturing base material for manufacturing artificial leather produced by the method according to any one of claims 1 to 8, (i) once used as a supporting material for the manufacturing base material for manufacturing artificial leather and then removed and reused to support fabric And (ii) a bonding base for manufacturing artificial leather having a stretchable base fabric for artificial leather. After being used as a supporting fabric for a bonding base for manufacturing artificial leather manufactured by the manufacturing method according to any one of claims 1 to 8, peeled and removed, and reused as a supporting fabric for an elastic base fabric for artificial leather. Supporting fabric. As a method of manufacturing artificial leather using (i) a reusable support fabric and (ii) a bonding base adhered so that the elastic base fabric for artificial leather is peelable from each other,
(d) Fine having fine pores on the side of the elastic base fabric of the base material for manufacturing artificial leather, manufactured by the manufacturing method according to any one of claims 1 to 8, wherein the binder is not exposed on the back side of the supporting fabric. Forming a porous polyurethane pore layer;
(e) optionally forming a skin layer on the surface of the polyurethane pore layer;
(f) peeling and removing the supporting fabric from the stretchable base fabric after the step (d) of forming a microporous polyurethane pore layer or after the step of (e) of forming a skin layer; And
(g) A method of manufacturing an artificial leather comprising the step of reusing the supporting fabric removed in step (f) as a supporting fabric of a bonding base for manufacturing artificial leather in step (d).

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