Napped artificial leather and method for producing napped artificial leather

Patent metadata

Field	Value
Publication number	US-2025027269-A1
Application number	US-202218715807-A
Country	US
Kind code	A1
Filing date	Dec 6, 2022
Priority date	Dec 8, 2021
Publication date	Jan 23, 2025
Grant date	—

Abstract

Provided are a napped artificial leather which can restrain spontaneous elongation during the production process, enables the constant load elongation transverse/machine ratio to be set to an appropriate value even without a scrim or a liner, and is excellent in pilling resistance and appearance, and a method of producing the napped artificial leather. The napped artificial leather includes a nonwoven fabric which is an entangled body of microfine fibers, and a high-molecular elastic body attached to the nonwoven fabric, has a napped surface formed by napping the microfine fiber on at least one surface, and satisfies the following conditions (1) and (2):(1) the nonwoven fabric is composed of microfine polyester filaments and (2) the fiber density D 1 in the transverse direction is from 150 to 450 fibers/mm 2 , the fiber density D 2 in the machine direction is from 150 to 450 fibers/mm 2 , and D 1 /D 2 is from 0.7 to 1.1.

First claim

1 .
A napped artificial leather, comprising: a nonwoven fabric, which is an entangled body of microfine fibers; and a high-molecular elastic body attached to the nonwoven fabric, the napped artificial leather having a napped surface formed by napping the microfine fiber on at least one surface, and satisfying the following conditions (1) and (2): (1) the nonwoven fabric comprises microfine polyester filaments, and (2) the fiber density D 1 in the transverse direction is from 150 to 450 fibers/mm 2 , the fiber density D 2 in the machine direction is from 150 to 450 fibers/mm 2 , and D 1 /D 2 is from 0.7 to 1.1.

2 . The napped artificial leather according to claim 1 , further satisfying the following condition (3):
(3) 0.3≤L 1 /L 2 ≤3.5 where L 1 is an elongation in the transverse direction at a constant load of 110.8N and L 2 is an elongation in the machine direction at a constant load of 110.8N.

3 . The napped artificial leather according to claim 1 , wherein the high-molecular elastic body is included in an amount of from 15 to 40% by mass based on the total mass of the high-molecular elastic body and the nonwoven fabric.

4 . The napped artificial leather according to claim 1 , wherein the breaking elongation in the machine direction, which is measured according to Method A in 8.14.1 of JIS L 1096 (1999), is 60% or more.

5 . The napped artificial leather according to claim 1 , wherein the breaking elongation in the transverse direction, which is measured according to Method A in 8.14.1 of JIS L 1096 (1999), is 60% or more.

6 . A method of producing a napped artificial leather according to claim 1 , comprising the following steps (i) to (iii):
(i) a step of preparing a nonwoven fabric, which comprises shrinking, in a hot water, a web-entangled sheet composed of a stacked body of fiber webs each obtained by melt spinning a polyester resin which is an island component and a second resin which is a sea component, and moving and drying the resultant, while tentering the resultant to widen the resultant in the direction perpendicular to the conveying direction, (ii) a step of preparing a composite, which comprises impregnating the nonwoven fabric with a solution containing a high-molecular elastic body, solidifying the high-molecular elastic body, and then dissolving the second resin in a solution to remove the second resin, thereby preparing a composite where the high-molecular elastic body is attached to the nonwoven fabric, (iii) a step of preparing a napped artificial leather, which comprises half-cutting the composite, and subjecting at least one surface of the obtained half-cut material to a grinding treatment, thereby preparing a napped artificial leather.

7 . The method of producing a napped artificial leather according to claim 6 , wherein the step (i) comprises shrinking the web-entangled sheet in a hot water, moving and drying the resultant, while tentering the resultant to widen the resultant in the direction perpendicular to the conveying direction such that the tentering rate W 1 is from 6 to 17%, thereby preparing a beat-shrunk web-entangled sheet.

8 . The method of producing a napped artificial leather according to claim 6 -er 7 , wherein the step (ii) comprises moving and drying the nonwoven fabric, while tentering the nonwoven fabric to widen the nonwoven fabric in the direction perpendicular to the conveying direction, thereby preparing the composite.

9 . The method of producing a napped artificial leather according to claim 8 , wherein the step (iii) comprises subjecting at least one surface of the half-cut material of the composite to a grinding treatment to prepare a napped raw material, and moving and heating the napped raw material, while tentering the napped raw material to widen the napped raw material in the direction perpendicular to the conveying direction, thereby obtaining the napped artificial leather.

10 . The method of producing a napped artificial leather according to claim 9 , wherein, the tentering rate W 1 in the direction perpendicular to the conveying direction in the step (i), the tentering rate W 2 in the direction perpendicular to the conveying direction in the step (ii), and the tentering rate W 3 in the direction perpendicular to the conveying direction in the step (iii) satisfy 0.3≤W 1 /(W 1 +W 2 +W 3 )≤0.8.

Assignees

• Kuraray Co

Inventors

• Iwamoto Akihisa
• Meguro Masashi
• Hishida Hiroyuki

Classifications

• D06N2209/1635

  Elasticity · CPC title

• D06N2207/06

  using liquids, e.g. water · CPC title

• D06N3/123

  with polyesters · CPC title

• D06N3/0072

  Slicing; Manufacturing two webs at one time · CPC title

• D06N3/0036

  Polyester fibres (for elastomeric fibres D06N3/0025) · CPC title