Napped artificial leather and production method thereof

Patent metadata

Field	Value
Publication number	US-10689802-B2
Application number	US-201716306697-A
Country	US
Kind code	B2
Filing date	Jun 21, 2017
Priority date	Jun 22, 2016
Publication date	Jun 23, 2020
Grant date	Jun 23, 2020

Abstract

Disclosed is a napped artificial leather including: a fabric that has been impregnated with a first elastic polymer and that has a napped surface including napped ultrafine fibers with an average fineness of 0.01 to 0.5 dtex, wherein the napped surface has, as measured by a surface roughness measurement in accordance with ISO 25178, an arithmetic mean height (Sa) of 30 μm or less in both a grain direction and a reverse grain direction, and a density of peaks (Spd) having a height of 100 μm or more from a mean height, of 30/432 mm 2 or less in both of the grain direction and the reverse grain direction, and a difference (absolute value) in the density of peaks (Spd) between the grain direction and the reverse grain direction is 20/432 mm 2 or less.

First claim

The invention claimed is:

1. A napped artificial leather, comprising:
a fabric impregnated with a first elastic polymer and having a napped surface comprising napped ultrafine fibers with an average fineness of 0.01 to 0.5 dtex, wherein
the napped surface has, as measured by a surface roughness measurement in accordance with ISO 25178,
an arithmetic mean height (Sa) of 30 μm or less in both a grain direction and a reverse grain direction, and
a density of peaks (Spd) having a height of 100 μm or more from a mean height, of 30/432 mm 2 or less in both the grain direction and the reverse grain direction, and an absolute value of a difference in the density of peaks (Spd) between the grain direction and the reverse grain direction of 20/432 mm 2 or less.

2. The napped artificial leather of claim 1 , wherein the fabric comprises at least one selected from the group consisting of a non-woven fabric, a woven fabric, and a knitted fabric.

3. The napped artificial leather of claim 1 , wherein the napped ultrafine fibers on the napped surface have a second elastic polymer attached thereto.

4. The napped artificial leather of claim 3 , wherein the napped ultrafine fibers on the napped surface have the second elastic polymer attached to at least the vicinity of a base thereof.

5. The napped artificial leather of claim 1 , wherein an average fiber toughness is 8 to 40 cN·%.

6. The napped artificial leather of claim 1 , wherein the fabric comprises a non-woven fabric, and the napped ultrafine fibers are long fibers.

7. The napped artificial leather of claim 1 , wherein an apparent density is 0.4 to 0.7 g/cm 3 .

8. A method of producing the napped artificial leather of claim 1 , the method comprising:
preparing an artificial leather base material comprising a fabric impregnated with a first elastic polymer, wherein the fabric comprises a surface to be napped and the surface comprises ultrafine fibers with an average fineness of 0.01 to 0.5 dtex;
napping the surface, to form a napped surface;
attaching a second elastic polymer to the ultrafine fibers on the napped surface; and
thermally setting the artificial leather base material in a state in which the artificial leather base material is shrunk along a longitudinal direction that is an orientation direction of the fibers.

Assignees

• Kuraray Co

Inventors

• Meguro Masashi

Classifications

• D06N3/0004 Primary

  using ultra-fine two-component fibres, e.g. island/sea, or ultra-fine one component fibres (< 1 denier) · CPC title

• D06N3/00

  Artificial leather, oilcloth or {other} material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof · CPC title

• D06N3/0011

  using non-woven fabrics · CPC title

• D06N3/0075 Primary

  Napping, teasing, raising or abrading of the resin coating (raising, napping of the web before coating D06N3/004) · CPC title

• D06N2213/03

  Fibrous web coated on one side with at least two layers of the same polymer type, e.g. two coatings of polyolefin · CPC title