Napped artificial leather and method for producing the same

Patent metadata

Field	Value
Publication number	US-12325952-B2
Application number	US-202017757785-A
Country	US
Kind code	B2
Filing date	Dec 3, 2020
Priority date	Dec 25, 2019
Publication date	Jun 10, 2025
Grant date	Jun 10, 2025

Abstract

A napped artificial leather includes: a fiber-entangled body obtained by entangling ultrafine fibers; and an elastic polymer impregnated into the fiber-entangled body. The napped artificial leather has, on at least one side thereof, a napped surface formed by napping the ultrafine fibers. The ultrafine fibers contain 0.2 to 8 mass % of carbon black and 0.1 to 5 mass % of a chromatic pigment, and a total ratio of the carbon black and the chromatic pigment is 0.3 to 10 mass %. A content ratio of the elastic polymer is 0.1 to 15 mass % in the napped artificial leather. The elastic polymer is uncolored and the ultrafine fibers are undyed.

First claim

The invention claimed is:

1. A napped artificial leather, comprising:
a fiber-entangled body obtained by entangling ultrafine fibers; and
an elastic polymer impregnated into the fiber-entangled body,
the napped artificial leather having, on at least one side thereof, a napped surface formed by napping the ultrafine fibers,
wherein the ultrafine fibers are fibers of at least one thermoelastic resin selected from the group consisting of an aromatic polyester, an aliphatic polyester, a nylon and a polyolefin,
the ultrafine fibers comprise 0.2 to 8 mass % of carbon black and 0.1 to 5 mass % of a chromatic pigment, and a total ratio of the carbon black and the chromatic pigment is 0.3 to 10 mass %,
a content ratio of the elastic polymer is 0.1 to 15 mass % in the napped artificial leather, and
the elastic polymer is uncolored, and the ultrafine fibers are undyed.

2. The napped artificial leather according to claim 1 , wherein a mass ratio of the chromatic pigment/the carbon black is 0.1 to 2.0.

3. The napped artificial leather according to claim 1 , wherein the napped surface has a lightness L* value of 25 or less, an a* value in the range of −2.5 to 2.5, and a b* value in the range of −2.5 to 2.5 in a color coordinate space (L*a*b*color space).

4. The napped artificial leather according to claim 1 ,
wherein the ultrafine fibers have an average fineness of 1.5 dtex or less.

5. The napped artificial leather according to claim 1 ,
wherein the chromatic pigment comprises a phthalocyanine-based pigment.

6. The napped artificial leather according to claim 1 ,
wherein the chromatic pigment comprises a dioxazine-based pigment.

7. A method for producing the napped artificial leather according to claim 1 , comprising at least:
preparing a fiber-entangled body of island-in-the-sea conjugated fibers comprising, as an island component, at least one thermoplastic resin selected from the group consisting of an aromatic polyester, an aliphatic polyester, a nylon and a polyolefin comprising 0.2 to 8 mass % of carbon black and 0.1 to 5 mass % of a chromatic pigment, and a water-soluble thermoplastic resin as a sea component;
impregnating, into voids of the fiber-entangled body of the island-in-the-sea conjugated fibers, an aqueous liquid for forming an uncolored aqueous elastic polymer, and subsequently removing a part of the aqueous liquid by squeezing off,
dry-coagulating the aqueous elastic polymer in the aqueous liquid impregnated into the voids of the fiber-entangled body of the island-in-the-sea conjugated fibers;
removing by dissolution the water-soluble thermoplastic resin from the island-in-the-sea conjugated fibers using an aqueous solvent, thereby obtaining an artificial leather gray fabric comprising the fiber-entangled body of the ultrafine fibers of the water-insoluble thermoplastic resin; and
napping at least one side of the artificial leather gray fabric by buffing,
wherein the method does not comprise dyeing the artificial leather gray fabric.

8. The method for producing the napped artificial leather according to claim 7 , wherein a mass ratio of the chromatic pigment/the carbon black is 0.1 to 2.0.

9. The method for producing the napped artificial leather according to claim 7 , wherein the ultrafine fibers have an average fineness of 1.5 dtex or less.

10. The method for producing the napped artificial leather according to claim 7 , wherein the chromatic pigment comprises a phthalocyanine-based pigment.

11. The method for producing the napped artificial leather according to claim 7 , wherein the chromatic pigment comprises a dioxazine-based pigment.

12. The napped artificial leather according to claim 1 , wherein the elastic polymer comprises an aqueous elastic polymer.

13. The napped artificial leather according to claim 2 , wherein the elastic polymer comprises an aqueous elastic polymer.

14. The napped artificial leather according to claim 3 ,
wherein the elastic polymer comprises an aqueous elastic polymer.

15. The napped artificial leather according to claim 4 , wherein the napped surface has a lightness L value of 25 or less, an a* value in the range of −2.5 to 2.5, and a b value in the range of −2.5 to 2.5 in a color coordinate space (L*a*b*color space), and
the elastic polymer comprises an aqueous elastic polymer.

16. The napped artificial leather according to claim 5 , wherein the napped surface has a lightness L* value of 25 or less, an a* value in the range of −2.5 to 2.5, and a b* value in the range of −2.5 to 2.5 in a color coordinate space (L*a*b* color space), and
the elastic polymer comprises an aqueous elastic polymer.

17. The napped artificial leather according to claim 6 , wherein the napped surface has a lightness L value of 25 or less, an a value in the range of −2.5 to 2.5, and a b* value in the range of −2.5 to 2.5 in a color coordinate space (L*a*b* color space), and
the elastic polymer comprises an aqueous elastic polymer.

18. The napped artificial leather according to claim 1 , wherein said chromatic pigment comprises a phthalocyanine-based pigment and a dioxazine-based pigment.

Assignees

• Kuraray Co

Inventors

• Hishida Hiroyuki
• Nakayama Kimio
• Meguro Masashi

Classifications

• D06N2209/0823

  within the layer by addition of a colorant, e.g. pigments, dyes · CPC title

• D06N3/0077

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

• D06N3/0065

  Organic pigments, e.g. dyes, brighteners · CPC title

• D06N3/0027

  Rubber or elastomeric fibres · CPC title