Napped artificial leather and method for producing the same

Patent metadata

Field	Value
Publication number	US-2023340723-A1
Application number	US-202017757785-A
Country	US
Kind code	A1
Filing date	Dec 3, 2020
Priority date	Dec 25, 2019
Publication date	Oct 26, 2023
Grant date	—

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

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 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, a water-insoluble thermoplastic resin 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.

Assignees

• Kuraray Co

Inventors

• Hishida Hiroyuki
• Nakayama Kimio
• 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

• D06N3/0011 Primary

  using non-woven fabrics · CPC title

• D06N3/0027

  Rubber or elastomeric fibres · CPC title

• D06N3/0065

  Organic pigments, e.g. dyes, brighteners · 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