Grained artificial leather and method for manufacturing grained artificial leather

Patent metadata

Field	Value
Publication number	US-11499266-B2
Application number	US-201816494820-A
Country	US
Kind code	B2
Filing date	May 21, 2018
Priority date	May 31, 2017
Publication date	Nov 15, 2022
Grant date	Nov 15, 2022

Abstract

Disclosed is a grain-finished artificial leather including an artificial leather base material, and a grain layer stacked on the artificial leather base material. The artificial leather base material includes a fiber-entangled body including ultrafine fibers having an average fineness of 0.4 dtex or less, an elastic polymer, and fine particles having an average particle size of 10 μm or less. The content ratio of the fine particles is 10 to 40 mass %, and the ratio of the elastic polymer to the total amount of the elastic polymer and the fine particles is 20 to 80 mass %. Also, a total of an apparent density of the elastic polymer and an apparent density of the fine particles is 0.23 to 0.55 g/cm 3 .

First claim

The invention claimed is:

1. A grain-finished artificial leather comprising:
an artificial leather base material; and
a grain layer stacked on the artificial leather base material,
wherein the artificial leather base material comprises a fiber-entangled body comprising ultrafine fibers having an average fineness of 0.4 dtex or less, an elastic polymer, and fine particles having an average particle size of 10 μm or less, and
a content ratio of the fine particles is 10 to 40 mass %, and a ratio of the elastic polymer to a total amount of the elastic polymer and the fine particles is 20 to 80 mass %, and
a total of an apparent density of the elastic polymer and an apparent density of the fine particles is 0.23 to 0.55 g/cm 3 .

2. The grain-finished artificial leather according to claim 1 ,
wherein the artificial leather base material has a content ratio of the fiber-entangled body of 30 to 80 mass %, and a content ratio of the elastic polymer of 10 to 40 mass %.

3. The grain-finished artificial leather according to claim 1 ,
wherein the fine particles are attached to the elastic polymer.

4. The grain-finished artificial leather according to claim 1 ,
wherein the elastic polymer comprises a polyurethane and an acrylic elastic polymer.

5. The grain-finished artificial leather according to claim 1 ,
wherein the fine particles have a Mohs hardness of 1 to 4.

6. The grain-finished artificial leather according to claim 1 ,
wherein the fine particles comprises at least one selected from the group consisting of talc, magnesium silicate, calcium sulfate, aluminum silicate, calcium carbonate, magnesium oxide, magnesium carbonate, magnesium hydroxide, aluminum hydroxide, and mica.

7. The grain-finished artificial leather according to claim 1 ,
wherein the artificial leather base material further comprises a plasticizer.

8. The grain-finished artificial leather according to claim 1 ,
wherein the plasticizer is liquid at 23° C.

9. The grain-finished artificial leather according to claim 1 ,
wherein the artificial leather base material has an apparent density of 0.45 to 0.85 g/cm 3 .

10. The grain-finished artificial leather according to claim 1 ,
wherein the ultrafine fibers comprise nylon ultrafine fibers having an average fineness of 0.025 dtex or less.

11. The grain-finished artificial leather according to claim 1 ,
wherein an arithmetic mean height S a of a surface of the grain layer is 30 μm or less when the grain-finished artificial leather is caused to extend in a semicircular shape along an outer surface of a cylindrical mandrel having an outer radius of 8.7 mm, with the grain layer located on an inner side.

12. A method for producing a grain-finished artificial leather, the method comprising:
preparing an artificial leather base material; and
forming a grain layer on a surface of the artificial leather base material by direct coating,
wherein the artificial leather base material comprises a fiber-entangled body comprising ultrafine fibers having an average fineness of 0.4 dtex or less, an elastic polymer, and fine particles having an average particle size of 10 μm or less,
a content ratio of the fine particles is 10 to 40 mass %, and a ratio of the elastic polymer to a total amount of the elastic polymer and the fine particles is 20 to 80 mass %, and
a total of an apparent density of the elastic polymer and an apparent density of the fine particles is 0.23 to 0.55 g/cm 3 .

13. The method according to claim 12 ,
wherein the forming comprises:
forming an undercoat layer by applying a solution of an undercoat layer-forming elastic polymer to a surface of the artificial leather base material, followed by drying; and
forming a skin layer by applying a resin solution including a skin layer-forming elastic polymer to a surface of the undercoat layer.

14. The method according to claim 13 ,
wherein a water absorption time when 3 cc of water droplets are dripped to the surface of the undercoat layer is 3 minutes or more.

Assignees

• Kuraray Co

Inventors

• Nakayama Kimio
• Sato Hayaki
• Narumoto Naoto
• Iwamoto Akihisa

Classifications

• D06N3/08

  with a finishing layer consisting of polyacrylates, polyamides or polyurethanes {or polyester} · CPC title

• D06N3/14 Primary

  with polyurethanes · CPC title

• D06N3/042

  Acrylic polymers (D06N3/045 takes precedence) · CPC title

• D06N3/0063

  Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds · CPC title

• D06N3/0027 Primary

  Rubber or elastomeric fibres · CPC title