Nubuck-leather-like sheet and manufacturing process therefor

Patent metadata

Field	Value
Publication number	US-10689800-B2
Application number	US-201415033432-A
Country	US
Kind code	B2
Filing date	Oct 27, 2014
Priority date	Nov 1, 2013
Publication date	Jun 23, 2020
Grant date	Jun 23, 2020

Abstract

Disclosed is a nubuck-finished leather-like sheet including a non-woven fabric that is an entangled body of ultrafine filaments, wherein the non-woven fabric includes a napped surface having napped fibers formed thereon, and the napped fibers are fixed to an acrylic resin on the napped surface while being laid down. Preferably, the acrylic resin is present so as to retain voids in the napped surface, while being made malleable.

First claim

The invention claimed is:

1. An artificial leather, comprising:
a non-woven fabric that is an entangled body of ultrafine filaments with a fineness of 2 dtex or less;
wherein:
the non-woven fabric is impregnated with a polyurethane so that the polyurethane is present in internal voids of the non-woven fabric;
at least one surface of the non-woven fabric is prepared by napping ultrafine filaments at the at least one surface to obtain napped fibers, applying an acrylic resin to the at least one surface, and subjecting the at least one surface to heated roll processing by calendering so that the napped fibers are fixed to the acrylic resin on the at least one surface while being laid down and not being fused to one another;
the acrylic resin comprises a softener;
the acrylic resin is present in an amount of 1 to 20 parts by mass per 100 parts by mass of the non-woven fabric; and
the acrylic resin is discontinuously present on the at least one surface.

2. The artificial leather according to claim 1 , wherein the napped fibers have an average length of 50 to 200 μm.

3. The artificial leather according to claim 1 , wherein the non-woven fabric is an entangled body of ultrafine filaments with a fineness of 0.2 dtex or less.

4. The artificial leather according to claim 1 , wherein the artificial leather has an air-permeability of 7.5 to 30 cc/cm 2 /sec, as measured with a Gurley type densometer.

5. A method of producing an artificial leather, comprising:
dyeing a base material comprising a non-woven fabric comprising an entangled body of ultrafine filaments with a fineness of 2 dtex or less, the non-woven fabric being impregnated with polyurethane and having napped fibers on at least one surface;
impregnating an acrylic resin composition into the dyed base material at the at least one surface, the acrylic resin composition comprising a resin solution of an acrylic resin and a softener;
drying the resin solution to migrate in the direction of the at least one surface of the base material to solidify the acrylic resin; and
performing heated roll processing by calendering on the at least one surface of the base material so that the napped fibers are fixed to the acrylic resin on the at least one surface while being laid down and not being fused to one another to obtain the artificial leather;
wherein:
the acrylic resin composition is applied such that, in the artificial leather, the acrylic resin is present in an amount of 1 to 20 parts by mass per 100 parts by mass of the non-woven fabric; and
in the artificial leather, the acrylic resin is discontinuously present on the at least one surface.

Assignees

• Kuraray Co

Inventors

• Wakimoto Yoshiaki
• Tanaka Jiro
• Warita Masato
• Nagayama Rei

Classifications

• D06N3/004 Primary

  using flocked webs or pile fabrics upon which a resin is applied; Teasing, raising web before resin application · CPC title

• D10B2403/0111

  One hairy surface, e.g. napped or raised (for pile fabrics D03D27/00, D04B1/02, D04B21/02) · CPC title

• D06N3/0077

  Embossing; Pressing of the surface; Tumbling and crumbling; Cracking; Cooling; Heating, e.g. mirror finish · CPC title

• D06N3/0011

  using non-woven fabrics · CPC title

• D06N2211/14

  Furniture, upholstery · CPC title