Grained artificial leather

Patent metadata

Field	Value
Publication number	US-11015288-B2
Application number	US-201716097514-A
Country	US
Kind code	B2
Filing date	Apr 28, 2017
Priority date	May 9, 2016
Publication date	May 25, 2021
Grant date	May 25, 2021

Abstract

Disclosed is a grain-finished artificial leather including: an artificial leather base material; and a resin layer stacked on at least one surface of the artificial leather base material, wherein the artificial leather base material contains: a fiber-entangled body of ultrafine fibers; 3 to 50 mass % of a first elastic polymer; 2.5 to 6 mass %, in terms of phosphorus atoms, of first phosphorous-based flame retardant particles having an average particle size of 1 to 10 μm; and 1 to 6 mass % of a plasticizer, and the resin layer contains: a second elastic polymer; and a total content, in terms of phosphorus atoms or in terms of hydroxyl groups, of 0 to 8 mass % of flame retardant particles having an average particle size of 1 to 10 μm and being at least one selected from the group consisting of second phosphorous-based flame retardant particles and first metal hydroxide particles.

First claim

The invention claimed is:

1. A grain-finished artificial leather, comprising:
an artificial leather base material; and
a resin layer stacked on at least one surface of the artificial leather base material,
wherein
the artificial leather base material comprises a fiber-entangled body of ultrafine fibers, where the ultrafine fibers have an average fineness of 0.9 dex or less; 3 to 50 mass % of a first elastic polymer; 2.5 to 6 mass %, in terms of phosphorus atoms, of first phosphorous-based flame retardant particles having an average particle size of 1 to 10 μm; and 1 to 6 mass % of a plasticizer comprising a fatty acid ester obtained from a fatty acid having 12-18 carbon atoms and a polyhydric alcohol, and
the resin layer comprises a second elastic polymer; and a total content, in terms of phosphorus atoms or in terms of hydroxyl groups, of 0 to 8 mass % of flame retardant particles having an average particle size of 1 to 10 μm and being at least one selected from the group consisting of second phosphorous-based flame retardant particles and first metal hydroxide particles.

2. The grain-finished artificial leather according to claim 1 ,
wherein the artificial leather base material comprises 0.5 to 5 mass % of the fatty acid ester as the plasticizer.

3. The grain-finished artificial leather according to claim 1 , wherein the artificial leather base material further comprises second metal hydroxide particles.

4. The grain-finished artificial leather according to claim 3 ,
wherein a total content, in terms of phosphorus atoms or in terms of hydroxyl groups, of the first phosphorous-based flame retardant particles and the second metal hydroxide particles contained in the artificial leather base material is 2 to 6 mass %.

5. The grain-finished artificial leather according to claim 1 , wherein a total content, in terms of phosphorus atoms or in terms of hydroxyl groups, of the flame retardant particles contained in the resin layer is 2 to 8 mass %.

6. The grain-finished artificial leather according to claim 1 , wherein
the first phosphorous-based flame retardant particles or the second phosphorous-based flame retardant particles comprise at least one selected from the group consisting of a polyphosphate, an organic metal phosphate, an organic metal phosphinate, and an organic metal phosphonate.

7. The grain-finished artificial leather according to claim 1 , wherein the first metal hydroxide particles or the second metal hydroxide particles comprise at least one selected from the group consisting of aluminum hydroxide and magnesium hydroxide.

8. The grain-finished artificial leather according to claim 1 , wherein the first elastic polymer comprises 60 mass % or more of a polycarbonate-based polyurethane, and the polyurethane has a 100% modulus of 0.5 to 5 MPa.

9. The grain-finished artificial leather according to claim 1 , wherein the second elastic polymer comprises 60 mass % or more of a polycarbonate-based polyurethane.

10. The grain-finished artificial leather according to claim 9 , wherein the ultrafine fibers have an average fineness of 0.01 to 0.6 dtex.

11. The grain-finished artificial leather according to claim 1 , wherein the ultrafine fibers comprise polyester-based fibers, and the artificial leather base material has an apparent density of 0.60 to 0.85 g/cm 3 , where the apparent density of the artificial leather base material is determined based on a thickness (mm) and a basis weight (g/cm 2 ) of the artificial leather base material measured in compliance with JIS L 1913.

12. The grain-finished artificial leather according to claim 2 , wherein the artificial leather base material further comprises second metal hydroxide particles.

13. The grain-finished artificial leather according to claim 12 ,
wherein a total content, in terms of phosphorus atoms or in terms of hydroxyl groups, of the first phosphorous-based flame retardant particles and the second metal hydroxide particles contained in the artificial leather base material is 2 to 6 mass %.

14. The grain-finished artificial leather according to claim 2 , wherein a total content, in terms of phosphorus atoms or in terms of hydroxyl groups, of the flame retardant particles contained in the resin layer is 2 to 8 mass %.

15. The grain-finished artificial leather according to claim 2 , wherein
the first phosphorous-based flame retardant particles or the second phosphorous-based flame retardant particles comprise at least one selected from the group consisting of a polyphosphate, an organic metal phosphate, an organic metal phosphinate, and an organic metal phosphonate.

16. The grain-finished artificial leather according to claim 2 , wherein the first metal hydroxide particles or the second metal hydroxide particles comprise at least one selected from the group consisting of aluminum hydroxide and magnesium hydroxide.

17. The grain-finished artificial leather according to claim 2 , wherein the first elastic polymer comprises 60 mass % or more of a polycarbonate-based polyurethane, and the polyurethane has a 100% modulus of 0.5 to 5 MPa.

18. The grain-finished artificial leather according to claim 2 , wherein the second elastic polymer comprises 60 mass % or more of a polycarbonate-based polyurethane.

19. The grain-finished artificial leather according to claim 18 , wherein the ultrafine fibers have an average fineness of 0.01 to 0.6 dtex.

20. The grain-finished artificial leather according to claim 2 , wherein the ultrafine fibers comprise polyester-based fibers, and the artificial leather base material has an apparent density of 0.60 to 0.85 g/cm 3 , where the apparent density of the artificial leather base material is determined based on a thickness (mm) and a basis weight (g/cm 2 ) of the artificial leather base material measured in compliance with JIS L 1913.

Assignees

• Kuraray Co

Inventors

• Nakayama Kimio
• Narumoto Naoto

Classifications

• D06M13/285 Primary

  Phosphines; Phosphine oxides; Phosphine sulfides; Phosphinic or phosphinous acids or derivatives thereof · CPC title

• D06M13/224

  Esters of carboxylic acids; Esters of carbonic acid · 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

• D06M11/45

  Oxides or hydroxides of elements of Groups 3 or 13 of the Periodic Table; Aluminates · CPC title

• D06M13/288

  Phosphonic or phosphonous acids or derivatives thereof · CPC title