CA2386390A1 - Synthetic leather - Google Patents
Synthetic leather Download PDFInfo
- Publication number
- CA2386390A1 CA2386390A1 CA002386390A CA2386390A CA2386390A1 CA 2386390 A1 CA2386390 A1 CA 2386390A1 CA 002386390 A CA002386390 A CA 002386390A CA 2386390 A CA2386390 A CA 2386390A CA 2386390 A1 CA2386390 A1 CA 2386390A1
- Authority
- CA
- Canada
- Prior art keywords
- synthetic leather
- polymer
- filaments
- nonwoven material
- carried out
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/016—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the fineness
-
- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
- A43B23/02—Uppers; Boot legs
- A43B23/0205—Uppers; Boot legs characterised by the material
- A43B23/0215—Plastics or artificial leather
-
- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
- A43B23/07—Linings therefor
-
- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
- A43B23/08—Heel stiffeners; Toe stiffeners
- A43B23/16—Heel stiffeners; Toe stiffeners made of impregnated fabrics, plastics or the like
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
- D04H3/11—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by fluid jet
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/12—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
- D06N3/0004—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using ultra-fine two-component fibres, e.g. island/sea, or ultra-fine one component fibres (< 1 denier)
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
- D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
Abstract
The invention relates to a synthetic leather comprising a polymer-impregnate d and/or coated non-woven with a surface area weight of 150 to 500 g/m2 and a tensile strength of > 300 N/5 cm in the longitudinal and perpendicular direction. The non-woven is made of melt-spun, aerodynamically stretched mul ti- component endless filaments indirectly arranged to form a non-woven. Said no n- woven has a titer of < 2 dtex. The multi-component endless filaments are split and hardened when said filaments have attained a strength of 90 % of the supermicro-endless filaments, i.e. a titer of < 0.2 dtex.
Description
Synthetic Leather Description The invention relates to a synthetic leather, consisting of a nonwoven material impregnated and/or coated with a polymer and having a surface weight of 100 to 500 g/m'-and tension strengths in longitudinal and transverse direction of >300 N/5cm Nonwoven materials made of ultra fine entangled filaments are known from document EP-A 0 090 397, which include a layered structure and can be processed into synthetic leather by impregnation and~'or coating with polymers. The starting fibers used are preferably those of the island-in-sea type, wherein the ultra fine fibers are released by dissolution of the matrix polymers. Furthermore, the use of splittable starting fibers is mentioned.
Document EP-A 0 624 676 discloses nonwoven materials made of ultra, fine fibers and processes for their manufacture from bi-component fibers. The starting polymers of the bi-component fibers should thereby have a melting point difference of 30 to 180°C
and are spun as multi-component fibers. The bi-component fibers deposited into a nonwoven nap are subjected to a point calendaring wherein only the fiber component with the lower melting point is melted and resolidified. In a subsequent step, the nonwoven material formed from the segmented fibers is split by mechanical action on the fibers at least to 70% into the ultra fine partial segment fibers.
The nonwoven materials obtained reach tension strength values in longitudinal and transverse direction up to a maximum of 260 N/S cm and can be used as bed linen, absorbents for sanitary products, as well as handkerchiefs, diapers, padding for sleeping bags, synthetic leather, thermo insulating materials and others.
It is an object of the invention to provide low cost and high tension resistant synthetic leathers as well as a process for their manufacture.
In accordance with the invention, this object is achieved with a synthetic leather, which is made of a nonwoven impregnated and/or coated with a polymer, having a surface weight of 100 to 500 g/m'- and tension resistance both in longitudinal and transverse direction of >304N/5 cm, whereby the nonwoven is made of melt spun aerodynamically stretched mufti-component endless filaments immediately laid down into a nonwoven and having a titer of <2 dTex, and the multi-component endless filaments after a pre-consolidation are split at least to 9()% into super-micro endless filaments with a titer of <0.2 dTex and consolidated. Such a synthetic leather has a higher tension strength at a relatively low surface weight and is therefore cost efficient. Furthermore, with respect to its hand it resembles natural materials.
The synthetic leather is preferably one wherein the mufti-component endless filament is a bi-component endless filament of two incompatible polymers, especially a polyester and a polyamide. Such a mufti-component endless filament has a good splitablility into super-micro endless filaments and provides for a favorable ratio of strength to surface weight.
The synthetic leather is preferably one wherein the mufti-component endless filaments have a cross-section with orange type mufti-segment stmcture, whereby the segments alternatingly respectively include one of the two incompatible polymers. Apart from this orange type multi-segment structure of the mufti-component endless filaments, other arrangements of the incompatible polymers in the mufti-component endless filament are possible, such as side-by-side or chrysanthemum leaf type arrangements. Such arrangements of the incompatible polymers in the mufti-component endless filament have proven to be very well splittable.
A synthetic leather is preferred, wherein at least one of the two incompatible polymers forming the mufti-component endless filaments includes an additive such as color pigments, permanently active anti-statics and/or additives influencing the hydrophilic or hydrophobic properties, in amounts of up to 10% by weight. The synthetic leather made of spun colored fibers has a very high, high temperature light resistance. Furthermore, static charging can be reduced or prevented with the additives, and the humidity transport properties improved.
Especially preferred is a synthetic leather wherein the nonwoven material is impregnated with 10 to 45% by weight of a polymer, relative to the starting weight of the nonwoven material. In accordance with the invention, a lower impregnation of the starting nonwoven is required than in conventional products for the same or even superior strength properties of the synthetic leather In the process in accordance with the invention for the manufacture of a synthetic leather the mufti-component endless filaments are spun from the melt, aerodynamically stretched and immediately deposited into a nonwoven, a pre-consolidation is carried out, .and the nonwoven material is consolidated by high pressure fluid jets and simultaneously split into super-micro endless filaments with a titer of <0.2 dTex and subsequently impregnated and/or coated with a polymer. The synthetic leathers obtained are very even with respect to their thickness, have a widely isotropic thread distribution have no tendency to delamination and are distinguished by high module values.
Preferably, the process for the manufacture of the synthetic leather is carried out in such a way that the consolidation and splitting of the mufti-component endless filaments is earned out in that the pre-consolidated nonwoven material is repeatedly subjected alternatingly from both sides to high pressure water jets. The starting nonwoven material for the synthetic leather thereby has a good surface and a degree of splitting of the mufti-component endless filaments of > 90%.
The process for consolidation and splitting of the mufti-component endless filaments is preferably carried out on a machine with rotating sieve drums. This type of machines allows the construction of very compact installations.
Preferably, the nonwoven material split into super-micro endless filaments and consolidated with high pressure fluid jets is impregnated with a polyurethane dissolved in dimethyl formamide and the polymer coagulated in a known manner.
It is especially preferred during the manufacture of the synthetic leather in accordance with the invention that the impregnation with a polymer is carried out with the help of an aqueous polyurethane-latex dispersion and is subsequently coagulated. This type of impregnation of the starting nonwoven material does not lead to solvent residues and is therefore environmentally friendly.
Especially preferred is a process wherein the mufti-component endless filaments are spun colored. The binding of the pigment into the polymer fibers leads to excellent hot light resrstances.
Further preferred for the different applications is an after treatment by grinding or buffing. The surface consistency and hand of the material obtained can thereby be improved, while furthermore a so-called 'write effect' can be achieved. 'Write effect' refers to the exposure of micro fiber ends at the surface of the synthetic leather which can be visibly oriented.
The synthetic leathers manufactured in accordance with the invention are especially suited for use in shoe industry as upper, inner lining, trimming or heel lining. They are further suitable as materials for clothing. Because of the good mechanical strength and, for spun colored products, because of their high hot light resistance, the synthetic leathers in accordance with the invention are suited for use in automobile interiors, for the manufacture of dash boards, side panels, hat rests, roof linings or trunk linings and for the manufacture of upholstery furniture, especially as cover materials for arm chairs, sofas or chairs.
Example 1 A nonwoven nap with a surface weight of about 160 glm'- is produced from a polyester-polyamide (PES-PA) bi-component endless filament and subjected to a water jet needling at pressures of up to 250 bar. After the water jet needling, which at the same time leads to a splitting of the starting filaments, the bi-component endless filaments have a titer of <0.2 dTex.
The consolidated nonwoven material is subjected to an impregnation with a polyurethane (PUR) dissolved in dimethyl formamide, whereby about 12% by weight PUR are applied relative to the starting weight of the nonwoven material. The polymer impregnated nonwoven material obtained is superficially ground and finished, for example, with special silicones for improvement of its hand. A synthetic leather with a nubuk type surface is achieved.
Document EP-A 0 624 676 discloses nonwoven materials made of ultra, fine fibers and processes for their manufacture from bi-component fibers. The starting polymers of the bi-component fibers should thereby have a melting point difference of 30 to 180°C
and are spun as multi-component fibers. The bi-component fibers deposited into a nonwoven nap are subjected to a point calendaring wherein only the fiber component with the lower melting point is melted and resolidified. In a subsequent step, the nonwoven material formed from the segmented fibers is split by mechanical action on the fibers at least to 70% into the ultra fine partial segment fibers.
The nonwoven materials obtained reach tension strength values in longitudinal and transverse direction up to a maximum of 260 N/S cm and can be used as bed linen, absorbents for sanitary products, as well as handkerchiefs, diapers, padding for sleeping bags, synthetic leather, thermo insulating materials and others.
It is an object of the invention to provide low cost and high tension resistant synthetic leathers as well as a process for their manufacture.
In accordance with the invention, this object is achieved with a synthetic leather, which is made of a nonwoven impregnated and/or coated with a polymer, having a surface weight of 100 to 500 g/m'- and tension resistance both in longitudinal and transverse direction of >304N/5 cm, whereby the nonwoven is made of melt spun aerodynamically stretched mufti-component endless filaments immediately laid down into a nonwoven and having a titer of <2 dTex, and the multi-component endless filaments after a pre-consolidation are split at least to 9()% into super-micro endless filaments with a titer of <0.2 dTex and consolidated. Such a synthetic leather has a higher tension strength at a relatively low surface weight and is therefore cost efficient. Furthermore, with respect to its hand it resembles natural materials.
The synthetic leather is preferably one wherein the mufti-component endless filament is a bi-component endless filament of two incompatible polymers, especially a polyester and a polyamide. Such a mufti-component endless filament has a good splitablility into super-micro endless filaments and provides for a favorable ratio of strength to surface weight.
The synthetic leather is preferably one wherein the mufti-component endless filaments have a cross-section with orange type mufti-segment stmcture, whereby the segments alternatingly respectively include one of the two incompatible polymers. Apart from this orange type multi-segment structure of the mufti-component endless filaments, other arrangements of the incompatible polymers in the mufti-component endless filament are possible, such as side-by-side or chrysanthemum leaf type arrangements. Such arrangements of the incompatible polymers in the mufti-component endless filament have proven to be very well splittable.
A synthetic leather is preferred, wherein at least one of the two incompatible polymers forming the mufti-component endless filaments includes an additive such as color pigments, permanently active anti-statics and/or additives influencing the hydrophilic or hydrophobic properties, in amounts of up to 10% by weight. The synthetic leather made of spun colored fibers has a very high, high temperature light resistance. Furthermore, static charging can be reduced or prevented with the additives, and the humidity transport properties improved.
Especially preferred is a synthetic leather wherein the nonwoven material is impregnated with 10 to 45% by weight of a polymer, relative to the starting weight of the nonwoven material. In accordance with the invention, a lower impregnation of the starting nonwoven is required than in conventional products for the same or even superior strength properties of the synthetic leather In the process in accordance with the invention for the manufacture of a synthetic leather the mufti-component endless filaments are spun from the melt, aerodynamically stretched and immediately deposited into a nonwoven, a pre-consolidation is carried out, .and the nonwoven material is consolidated by high pressure fluid jets and simultaneously split into super-micro endless filaments with a titer of <0.2 dTex and subsequently impregnated and/or coated with a polymer. The synthetic leathers obtained are very even with respect to their thickness, have a widely isotropic thread distribution have no tendency to delamination and are distinguished by high module values.
Preferably, the process for the manufacture of the synthetic leather is carried out in such a way that the consolidation and splitting of the mufti-component endless filaments is earned out in that the pre-consolidated nonwoven material is repeatedly subjected alternatingly from both sides to high pressure water jets. The starting nonwoven material for the synthetic leather thereby has a good surface and a degree of splitting of the mufti-component endless filaments of > 90%.
The process for consolidation and splitting of the mufti-component endless filaments is preferably carried out on a machine with rotating sieve drums. This type of machines allows the construction of very compact installations.
Preferably, the nonwoven material split into super-micro endless filaments and consolidated with high pressure fluid jets is impregnated with a polyurethane dissolved in dimethyl formamide and the polymer coagulated in a known manner.
It is especially preferred during the manufacture of the synthetic leather in accordance with the invention that the impregnation with a polymer is carried out with the help of an aqueous polyurethane-latex dispersion and is subsequently coagulated. This type of impregnation of the starting nonwoven material does not lead to solvent residues and is therefore environmentally friendly.
Especially preferred is a process wherein the mufti-component endless filaments are spun colored. The binding of the pigment into the polymer fibers leads to excellent hot light resrstances.
Further preferred for the different applications is an after treatment by grinding or buffing. The surface consistency and hand of the material obtained can thereby be improved, while furthermore a so-called 'write effect' can be achieved. 'Write effect' refers to the exposure of micro fiber ends at the surface of the synthetic leather which can be visibly oriented.
The synthetic leathers manufactured in accordance with the invention are especially suited for use in shoe industry as upper, inner lining, trimming or heel lining. They are further suitable as materials for clothing. Because of the good mechanical strength and, for spun colored products, because of their high hot light resistance, the synthetic leathers in accordance with the invention are suited for use in automobile interiors, for the manufacture of dash boards, side panels, hat rests, roof linings or trunk linings and for the manufacture of upholstery furniture, especially as cover materials for arm chairs, sofas or chairs.
Example 1 A nonwoven nap with a surface weight of about 160 glm'- is produced from a polyester-polyamide (PES-PA) bi-component endless filament and subjected to a water jet needling at pressures of up to 250 bar. After the water jet needling, which at the same time leads to a splitting of the starting filaments, the bi-component endless filaments have a titer of <0.2 dTex.
The consolidated nonwoven material is subjected to an impregnation with a polyurethane (PUR) dissolved in dimethyl formamide, whereby about 12% by weight PUR are applied relative to the starting weight of the nonwoven material. The polymer impregnated nonwoven material obtained is superficially ground and finished, for example, with special silicones for improvement of its hand. A synthetic leather with a nubuk type surface is achieved.
Example 2 A nonwoven nap with a surface weight of about 110 g/m2 is produced from a PES-PA bi-component endless filament and subjected to a water jet needling at pressures of up to 2~0 bar.
After the water jet needling, which at the same time leads to a splitting of the starting filaments, the bi-component endless filaments have a titer of <0.2 dTex. The consolidated nonwoven material is subjected to an impregnation with an aqueous polyurethane-latex dispersion, whereby about 10% by weight PUR are applied relative to the starting weight of the nonwoven material.
The polyurethane is coagulated by treatment with hot water or saturated steam and subsequently dried and cross-linked at about 150 to 160°C. The polymer impregnated nonwoven material obtained is superficially ground and finished, for example, with special silicones for improvement of its hand. A synthetic leather with a nubuk type surface is achieved.
After the water jet needling, which at the same time leads to a splitting of the starting filaments, the bi-component endless filaments have a titer of <0.2 dTex. The consolidated nonwoven material is subjected to an impregnation with an aqueous polyurethane-latex dispersion, whereby about 10% by weight PUR are applied relative to the starting weight of the nonwoven material.
The polyurethane is coagulated by treatment with hot water or saturated steam and subsequently dried and cross-linked at about 150 to 160°C. The polymer impregnated nonwoven material obtained is superficially ground and finished, for example, with special silicones for improvement of its hand. A synthetic leather with a nubuk type surface is achieved.
Claims (15)
1. Synthetic leather consisting of a nonwoven material impregnated and/or coated with a polymer and having a surface weight of 100 to 500 g/m2 and a tension strength in longitudinal as well as transverse direction of >300 N/5 cm, whereby the nonwoven material is made of melt spun multi-component endless filaments with a titer of < 2 dTex aerodynamically stretched and immediately deposited into a nonwoven nap, the multi-component endless filaments being split after a pre-consolidation at least to 90% into super-micro endless filaments with a titer of < 0.2 dTex and consolidated.
2. Synthetic leather according to claim 1, characterized in that the multi-component endless filament is a bicomponent endless filament made of two incompatible polymers, especially a polyester and a polyamide.
3. Synthetic leather according to claim 1 or 2, characterized in that the multi-component endless filaments have a cross-section with orange type multi-segment structure, whereby the segments alternatingly include respectively one of the two incompatible polymers.
4. Synthetic leather according to one of claims 1 to 3, characterized in that at least one of the multi-component endless filament forming incompatible polymers includes an additive, such as color pigments, permanently active anti-statics and/or additives influencing the hydrophilic or hydrophobic characteristics in amounts of up to 10% by weight.
5. Synthetic leather according to one of claims 1 to 4, characterized in that the nonwoven material is impregnated with 10 to 45 % by weight of a polymer, relative to the starting weight of the nonwoven material.
6. Process for the manufacture of a synthetic leather according to one of the claims 1 to 5, characterized in that multi-component endless filaments are spun from the melt, aerodynamically stretched and immediately thereafter deposited into a nonwoven nap, a pre-consolidation is carried out and the nonwoven material is consolidated by high pressure fluid jets and simultaneously split into super-micro filaments with a titer of < 0.2 dTex, and subsequently impregnated and/or coated with a polymer.
7. Process according to claim 6, characterized in that the consolidation and splitting of the multi-component endless filaments is carried out in that the pre-consolidated nonwoven material is repeatedly subjected alternately from both sides to high pressure fluid jets.
8. Process according to claim 7, characterized in that consolidation and splitting of the multi-component endless filament is carried out on a unit with rotating sieve drums.
9. Process according to one of claims 6 to 8, characterized in that the impregnation with a polymer is carried out with a polyurethane dissolved in dimethyl formamide and the polymer coagulated.
10. Process according to one of claims 6 to 8, characterized in that the impregnation with a polymer is carried out with an aqueous polyurethane latex dispersion.
11. Process according to one of claims 7 to 10, characterized in that the coloring of the multi-component endless filaments is carried out by spin coloring.
12. Process according to one of claims 7 to 11, characterized in that its after treatment is carried out by grinding or buffing.
13. Use of a synthetic leather manufactured according to one of claims 7 to 12, characterized in that the synthetic leather is used in the shoe industry as upper, inner lining, trimming or heel lining.
14. Use of a synthetic leather manufactured according to one of claims 7 to 12, characterized in that the synthetic leather is used in automobile interiors field for the manufacture of dash boards, side panels, hat rests, roof linings or trunk linings.
15. Use of a synthetic leather manufactured according to one of claims 7 to 12, characterized in that the synthetic leather is used in the clothing or upholstery furniture industries, especially as cover materials for arm chairs, sofas or chairs.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE19947869.4 | 1999-10-05 | ||
| DE19947869A DE19947869A1 (en) | 1999-10-05 | 1999-10-05 | Synthetic leather |
| PCT/EP2000/008548 WO2001025530A1 (en) | 1999-10-05 | 2000-09-01 | Synthetic leather |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2386390A1 true CA2386390A1 (en) | 2001-04-12 |
Family
ID=7924512
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002386390A Abandoned CA2386390A1 (en) | 1999-10-05 | 2000-09-01 | Synthetic leather |
Country Status (22)
| Country | Link |
|---|---|
| US (1) | US6838043B1 (en) |
| EP (1) | EP1226304A1 (en) |
| JP (1) | JP2003511568A (en) |
| KR (1) | KR20020043605A (en) |
| CN (1) | CN1174143C (en) |
| AU (1) | AU772800B2 (en) |
| BG (1) | BG106564A (en) |
| BR (1) | BR0014505A (en) |
| CA (1) | CA2386390A1 (en) |
| CZ (1) | CZ20021153A3 (en) |
| DE (1) | DE19947869A1 (en) |
| EE (1) | EE200200167A (en) |
| HU (1) | HUP0203698A2 (en) |
| IL (1) | IL148867A0 (en) |
| MX (1) | MXPA02002829A (en) |
| NO (1) | NO20021519L (en) |
| PL (1) | PL354450A1 (en) |
| RU (1) | RU2233359C2 (en) |
| SK (1) | SK4582002A3 (en) |
| TR (1) | TR200200908T2 (en) |
| WO (1) | WO2001025530A1 (en) |
| ZA (1) | ZA200202652B (en) |
Families Citing this family (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE10132255A1 (en) * | 2001-07-04 | 2003-01-23 | Achter Viktor Gmbh & Co Kg | Artificial suede and a manufacturing process therefor |
| DE10258112B4 (en) * | 2002-12-11 | 2007-03-22 | Carl Freudenberg Kg | Process for producing a sheet from at least partially split yarns, fibers or filaments |
| DE102005014317A1 (en) * | 2005-03-30 | 2006-10-05 | Carl Freudenberg Kg | Synthetic leather, process for its preparation and its use |
| JPWO2007099951A1 (en) * | 2006-02-28 | 2009-07-16 | 株式会社クラレ | Artificial leather and method for producing the same |
| TWI321601B (en) * | 2007-08-20 | 2010-03-11 | San Fang Chemical Industry Co | Manufacturing method for environment friendly ultra-fine filament products having low resistance to deformation and high physical property |
| EP2251473A1 (en) * | 2009-04-29 | 2010-11-17 | Fiscagomma S.p.A. | Label |
| CN102234938B (en) * | 2010-05-07 | 2014-09-24 | 福建兰峰制革有限公司 | Process for manufacturing super-fiber nubuck leather |
| EP2582874B1 (en) * | 2010-06-15 | 2014-09-03 | LANXESS Deutschland GmbH | Cut-to-size format |
| DE102011056933A1 (en) * | 2011-12-22 | 2013-06-27 | Bayerische Motoren Werke Aktiengesellschaft | Interior component for a motor vehicle |
| DE102012018852B4 (en) * | 2012-09-25 | 2016-01-07 | Carl Freudenberg Kg | Use of microfiber nonwovens for the production of decorative laminates |
| US9284663B2 (en) * | 2013-01-22 | 2016-03-15 | Allasso Industries, Inc. | Articles containing woven or non-woven ultra-high surface area macro polymeric fibers |
| TWI510357B (en) * | 2013-02-08 | 2015-12-01 | Shu Chieh Wang | Composite laminated structure for shoe stiffener and preparing method thereof |
Family Cites Families (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE2539725C3 (en) * | 1974-09-13 | 1979-12-06 | Asahi Kasei Kogyo K.K., Osaka (Japan) | Suede-like artificial leather with a layer of pile on one surface and method for its production |
| JPS539301A (en) | 1976-07-12 | 1978-01-27 | Mitsubishi Rayon Co | Production of leather like sheet structre |
| US4390566A (en) * | 1981-03-09 | 1983-06-28 | Toray Industries, Inc. | Method of producing soft sheet |
| EP0090397B1 (en) * | 1982-03-31 | 1990-01-24 | Toray Industries, Inc. | Ultrafine fiber entangled sheet and method of producing the same |
| FR2546536B1 (en) | 1983-05-25 | 1985-08-16 | Rhone Poulenc Fibres | PROCESS FOR THE TREATMENT OF NONWOVEN TABLECLOTHS AND PRODUCT OBTAINED |
| TW246699B (en) * | 1992-10-05 | 1995-05-01 | Unitika Ltd | |
| FR2749860B1 (en) * | 1996-06-17 | 1998-08-28 | Freudenberg Spunweb Sa | NON WOVEN TABLECLOTH FORMED OF VERY THIN CONTINUOUS FILAMENTS |
| JP3187357B2 (en) * | 1997-11-10 | 2001-07-11 | 帝人株式会社 | Leather-like sheet and method for producing the same |
-
1999
- 1999-10-05 DE DE19947869A patent/DE19947869A1/en not_active Withdrawn
-
2000
- 2000-09-01 BR BR0014505-0A patent/BR0014505A/en not_active Application Discontinuation
- 2000-09-01 CZ CZ20021153A patent/CZ20021153A3/en unknown
- 2000-09-01 EP EP00960579A patent/EP1226304A1/en not_active Withdrawn
- 2000-09-01 MX MXPA02002829A patent/MXPA02002829A/en unknown
- 2000-09-01 TR TR2002/00908T patent/TR200200908T2/en unknown
- 2000-09-01 US US10/110,053 patent/US6838043B1/en not_active Expired - Fee Related
- 2000-09-01 CA CA002386390A patent/CA2386390A1/en not_active Abandoned
- 2000-09-01 PL PL00354450A patent/PL354450A1/en not_active Application Discontinuation
- 2000-09-01 CN CNB008138117A patent/CN1174143C/en not_active Expired - Fee Related
- 2000-09-01 EE EEP200200167A patent/EE200200167A/en unknown
- 2000-09-01 WO PCT/EP2000/008548 patent/WO2001025530A1/en not_active Application Discontinuation
- 2000-09-01 AU AU72825/00A patent/AU772800B2/en not_active Ceased
- 2000-09-01 RU RU2002112342/04A patent/RU2233359C2/en not_active IP Right Cessation
- 2000-09-01 SK SK458-2002A patent/SK4582002A3/en unknown
- 2000-09-01 JP JP2001528253A patent/JP2003511568A/en active Pending
- 2000-09-01 IL IL14886700A patent/IL148867A0/en unknown
- 2000-09-01 KR KR1020027004256A patent/KR20020043605A/en not_active Application Discontinuation
- 2000-09-01 HU HU0203698A patent/HUP0203698A2/en not_active Application Discontinuation
-
2002
- 2002-03-26 NO NO20021519A patent/NO20021519L/en not_active Application Discontinuation
- 2002-04-02 BG BG106564A patent/BG106564A/en unknown
- 2002-04-04 ZA ZA200202652A patent/ZA200202652B/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| BG106564A (en) | 2002-10-31 |
| AU772800B2 (en) | 2004-05-06 |
| KR20020043605A (en) | 2002-06-10 |
| CZ20021153A3 (en) | 2002-06-12 |
| DE19947869A1 (en) | 2001-05-03 |
| ZA200202652B (en) | 2005-09-28 |
| RU2233359C2 (en) | 2004-07-27 |
| JP2003511568A (en) | 2003-03-25 |
| SK4582002A3 (en) | 2002-08-06 |
| NO20021519D0 (en) | 2002-03-26 |
| CN1377433A (en) | 2002-10-30 |
| EP1226304A1 (en) | 2002-07-31 |
| MXPA02002829A (en) | 2003-10-14 |
| BR0014505A (en) | 2002-08-27 |
| US6838043B1 (en) | 2005-01-04 |
| CN1174143C (en) | 2004-11-03 |
| WO2001025530A1 (en) | 2001-04-12 |
| HUP0203698A2 (en) | 2003-04-28 |
| IL148867A0 (en) | 2002-09-12 |
| TR200200908T2 (en) | 2002-08-21 |
| NO20021519L (en) | 2002-03-26 |
| AU7282500A (en) | 2001-05-10 |
| EE200200167A (en) | 2003-04-15 |
| PL354450A1 (en) | 2004-01-12 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Discontinued |