EP2540909A2 - Artificial leather - Google Patents
Artificial leather Download PDFInfo
- Publication number
- EP2540909A2 EP2540909A2 EP11747741A EP11747741A EP2540909A2 EP 2540909 A2 EP2540909 A2 EP 2540909A2 EP 11747741 A EP11747741 A EP 11747741A EP 11747741 A EP11747741 A EP 11747741A EP 2540909 A2 EP2540909 A2 EP 2540909A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- artificial leather
- flame retardant
- retardant composition
- preliminary
- composition layer
- 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.)
- Granted
Links
- 239000002649 leather substitute Substances 0.000 title claims abstract description 138
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims abstract description 93
- 239000003063 flame retardant Substances 0.000 claims abstract description 93
- 239000000203 mixture Substances 0.000 claims abstract description 85
- 239000004745 nonwoven fabric Substances 0.000 claims abstract description 24
- 239000002952 polymeric resin Substances 0.000 claims abstract description 13
- 229920003002 synthetic resin Polymers 0.000 claims abstract description 13
- 239000011248 coating agent Substances 0.000 claims abstract description 12
- 238000000576 coating method Methods 0.000 claims abstract description 12
- 229920001410 Microfiber Polymers 0.000 claims abstract description 11
- 239000000463 material Substances 0.000 claims description 9
- 239000011230 binding agent Substances 0.000 claims description 8
- 238000002485 combustion reaction Methods 0.000 claims description 5
- 238000012360 testing method Methods 0.000 claims description 5
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims description 4
- 229910052710 silicon Inorganic materials 0.000 claims description 4
- 239000010703 silicon Substances 0.000 claims description 4
- 230000033228 biological regulation Effects 0.000 claims description 3
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 claims description 3
- 230000006866 deterioration Effects 0.000 abstract description 4
- 238000000034 method Methods 0.000 description 18
- 239000000835 fiber Substances 0.000 description 16
- 230000008569 process Effects 0.000 description 15
- 239000004615 ingredient Substances 0.000 description 13
- ZMXDDKWLCZADIW-UHFFFAOYSA-N N,N-Dimethylformamide Chemical compound CN(C)C=O ZMXDDKWLCZADIW-UHFFFAOYSA-N 0.000 description 12
- 239000000243 solution Substances 0.000 description 12
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 6
- 238000005259 measurement Methods 0.000 description 5
- 229920000728 polyester Polymers 0.000 description 5
- -1 polyethylene terephthalate Polymers 0.000 description 5
- 229920000139 polyethylene terephthalate Polymers 0.000 description 5
- 239000005020 polyethylene terephthalate Substances 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- 239000004814 polyurethane Substances 0.000 description 4
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 3
- 230000015271 coagulation Effects 0.000 description 3
- 238000005345 coagulation Methods 0.000 description 3
- 150000002009 diols Chemical class 0.000 description 3
- 238000007598 dipping method Methods 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 229920002635 polyurethane Polymers 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 238000007792 addition Methods 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000009960 carding Methods 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 229920001707 polybutylene terephthalate Polymers 0.000 description 2
- 229920002215 polytrimethylene terephthalate Polymers 0.000 description 2
- 229920005749 polyurethane resin Polymers 0.000 description 2
- 230000002829 reductive effect Effects 0.000 description 2
- 238000007777 rotary screen coating Methods 0.000 description 2
- 238000001878 scanning electron micrograph Methods 0.000 description 2
- 238000009751 slip forming Methods 0.000 description 2
- 238000006467 substitution reaction Methods 0.000 description 2
- 238000005406 washing Methods 0.000 description 2
- TVEXGJYMHHTVKP-UHFFFAOYSA-N 6-oxabicyclo[3.2.1]oct-3-en-7-one Chemical compound C1C2C(=O)OC1C=CC2 TVEXGJYMHHTVKP-UHFFFAOYSA-N 0.000 description 1
- 239000004114 Ammonium polyphosphate Substances 0.000 description 1
- 206010028980 Neoplasm Diseases 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 239000004902 Softening Agent Substances 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 235000019826 ammonium polyphosphate Nutrition 0.000 description 1
- 229920001276 ammonium polyphosphate Polymers 0.000 description 1
- 230000000655 anti-hydrolysis Effects 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- 235000006708 antioxidants Nutrition 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- 201000011510 cancer Diseases 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 238000010828 elution Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 229910052736 halogen Inorganic materials 0.000 description 1
- 150000002367 halogens Chemical class 0.000 description 1
- 238000003384 imaging method Methods 0.000 description 1
- 230000001939 inductive effect Effects 0.000 description 1
- 230000002401 inhibitory effect Effects 0.000 description 1
- 230000000670 limiting effect Effects 0.000 description 1
- 239000002075 main ingredient Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000011259 mixed solution Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 230000036961 partial effect Effects 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000010022 rotary screen printing Methods 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
- 230000007480 spreading Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 0.000 description 1
- 239000012801 ultraviolet ray absorbent Substances 0.000 description 1
Images
Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/564—Polyureas, polyurethanes or other polymers having ureide or urethane links; Precondensation products forming them
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
- D06M23/16—Processes for the non-uniform application of treating agents, e.g. one-sided treatment; Differential treatment
-
- 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
- D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
- D06N3/0063—Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds
-
- 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
- D06N7/0092—Non-continuous polymer coating on the fibrous substrate, e.g. plastic dots on fabrics
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M2200/00—Functionality of the treatment composition and/or properties imparted to the textile material
- D06M2200/30—Flame or heat resistance, fire retardancy properties
-
- 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
- D06N2209/00—Properties of the materials
- D06N2209/06—Properties of the materials having thermal properties
- D06N2209/067—Flame resistant, fire resistant
-
- 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
- D06N2209/00—Properties of the materials
- D06N2209/12—Permeability or impermeability properties
- D06N2209/121—Permeability to gases, adsorption
-
- 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
- D06N2211/00—Specially adapted uses
- D06N2211/12—Decorative or sun protection articles
- D06N2211/28—Artificial leather
Definitions
- the present invention relates to an artificial leather. More specifically, the present invention relates to an artificial leather comprising a flame retardant composition layer
- An artificial leather is produced by impregnating a polymer elastomer in a non-woven fabric comprising three-dimensionally entangled ultrafine fibers, which is widely utilized in a variety of applications such as shoes, clothing, gloves, miscellaneous goods, furniture and automobile interior materials due to natural leather-like soft texture and unique appearance.
- Such artificial leather requires improved high functionality in terms of flexibility, surface quality properties, abrasion resistance, light resistance, elongation and the like according to applications and often requires a variety of properties.
- the artificial leather when used for a surface material adhered to an automobile sheet among the automobile interior materials, there is difficulty in that it satisfies surface quality properties, specifically, superior appearance, air-permeability and texture properties, as well as flame retardancy regulated by the Law among physical properties of automobile in accordance with increased expectation of consumers.
- the present invention is directed to an artificial leather capable of preventing problems caused by these limitations and drawbacks of the related art.
- an artificial leather that can exhibit a level of flame retardancy required in the art, is free of deterioration in soft texture of ultrafine fibers and has greatly improved air-permeability by partially coating a flame retardant composition on a preliminary artificial leather.
- an artificial leather comprising: a preliminary artificial leather comprising a non-woven fabric made of ultrafine fibers and an elastic polymer resin impregnated in the non-woven fabric; and a flame retardant composition layer formed on the preliminary artificial leather by partially coating a flame retardant composition thereon at an area ratio of 60 to 90%, with respect to the total area of the preliminary artificial leather.
- the present invention has the following effects.
- the artificial leather according to the present invention comprises a flame retardant composition layer that is partially coated at an optimal shape and content, thus advantageously exhibiting a level of flame retardancy required in the art and improving economical efficiency.
- the artificial leather according to the present invention can exhibit superior texture and air-permeability due to partial coating of the flame retardant composition layer.
- Such an artificial leather may be used for automobile sheets or the like, requiring superior flame retardancy, appearance and texture.
- preliminary artificial leather means an artificial leather, to which a flame retardant composition is not added, that comprises a non-woven fabric and an elastic polymer resin impregnated in the non-woven fabric.
- FIG. 1 is a plan view illustrating an artificial leather according to one embodiment of the present invention.
- FIG. 2 is a cross-sectional view of the artificial leather taken along the line A-A' of FIG. 1 .
- the artificial leather of the present invention comprises a preliminary artificial leather 30 and a flame retardant composition layer 10 disposed on the preliminary artificial leather 30 by partially coating a flame retardant composition thereon.
- the flame retardant composition is only partially coated on the preliminary artificial leather 30
- grooves are formed in non-coated regions of preliminary artificial leather where the flame retardant composition is not coated and, as a result, the artificial leather of the present invention exhibit superior air-permeability without causing deterioration in texture of preliminary artificial leather made of fine fibers.
- the amount of flame retardant composition used can be greatly reduced since the flame retardant composition is only partially coated on the preliminary artificial leather 30. As a result, production cost of the artificial leather can be reduced and economic efficiency can be thus improved.
- the artificial leather of the present invention comprises a flame retardant composition layer 10 that is formed by partially coating the flame retardant composition at an area ratio of 60 to 90% with respect to the total area of the preliminary artificial leather 30.
- a flame retardant composition layer 10 that is formed by partially coating the flame retardant composition at an area ratio of 60 to 90% with respect to the total area of the preliminary artificial leather 30.
- the area ratio of the flame retardant composition layer 10 is lower than 60%, an artificial leather satisfying flame retardancy required in the art cannot be obtained, and when the area ratio of the flame retardant composition layer 10 is higher than 90%, air-permeability of the artificial leather may be greatly deteriorated.
- the flame retardant composition layer 10 may have a variety of shapes, as shown in FIGs. 1 and 3 to 5 .
- the flame retardant composition layer 10 may include a plurality of discontinuous unit layers having a predetermined shape. That is, the plurality of unit layers constituting the flame retardant composition layer 10 are discontinuously distributed on the preliminary artificial leather 30 and one groove 20 corresponding to the non-coated region of the preliminary artificial leather 20 surrounds the plurality of unit layers.
- the region where the preliminary artificial leather 20 is not coated may be readily burned along the continuously formed groove 20 and flame retardancy of artificial leather may be thus slightly deteriorated.
- a relatively great amount of flame retardant is inevitably used and, as a result, air-permeability and texture of artificial leather may be slightly deteriorated.
- the artificial leather of the present invention may include a plurality of grooves 20 that are discontinuously distributed in non-coated regions of preliminary artificial leather 30 to which the flame retardant composition is not coated.
- the flame retardant composition layer 10 of the present invention may be a body surrounding the plurality of grooves 20.
- the flame retardant composition layer 10 of the present invention may include a plurality of discontinuously distributed unit layers.
- the artificial leather of the present invention including a plurality of grooves 20 that are discontinuously distributed in non-coated regions of preliminary artificial leather 30 to which the flame retardant composition is not coated is subjected to flame retardancy testing, the plurality of grooves 20 are discontinuously distributed, thus preventing blazes from spreading to the entire non-coated regions of the preliminary artificial leather 20.
- the amount of the flame retardant composition coated is low, flame retardancy of artificial leather can be greatly improved.
- the artificial leather including a plurality of discontinuously distributed grooves 20 exhibits superior flame retardancy, as compared to the artificial leather including only continuously formed one groove 20.
- the plurality of grooves 20 of the artificial leather of the present invention may be irregularly and discontinuously distributed, and the flame retardant composition layer 10 may be a body surrounding the plurality of grooves 20.
- Each of the grooves 20 of the artificial leather of the present invention may have a variety of shapes such as circular, polygonal or linear shape.
- FIG. 2 is a cross-sectional view of the artificial leather taken along the line A-A' of FIG. 1 according to one embodiment of the present invention.
- the artificial leather has an upper part thickness that means a level of the flame retardant composition layer 10 that protrudes on the surface of the preliminary artificial leather 30 and a permeation depth that means a level of the flame retardant composition layer 10 permeated into the preliminary artificial leather 30.
- the upper part thickness (a) is preferably within a ratio range of 0.1 to 4% with respect to the thickness (c) of the preliminary artificial leather 30.
- the ratio of the upper part thickness (a) is lower than 0.1%, an artificial leather satisfying a level of flame retardancy required in the art cannot be produced, and when the ratio of the upper part thickness (a) is higher than 4%, the texture of artificial leather may be greatly deteriorated.
- the permeation depth (b) is preferably within a ratio range of 5 to 50% with respect to the thickness (c) of the preliminary artificial leather 30.
- the ratio of the permeation depth (b) is lower than 5%, adhesion force is deteriorated and durability is thus degraded and, on the other hand, when the ratio of the permeation depth (b) is higher than 50%, the texture of artificial leather may be hardened.
- the upper part thickness (a) and permeation depth (b) of the flame retardant composition layer 10 may be measured by imaging the cross-section of a sample with a scanning electron microscope (SEM).
- the flame retardant composition may comprise a flame retardant and a binder.
- a flame retardant a phosphorous-based flame retardant is preferred than a halogen-based flame retardant which is a cancer-inducing substance.
- the binder enhances adhesion force and may be selected from a variety of types of binders.
- a urethane-based binder containing silicon exhibits superior heat resistance due to presence of silicon, thus inhibiting decomposition of silicon during combustion, and can form a cross-linkage with urethane, thus improving flame retardancy of the artificial leather.
- the urethane-based binder advantageously has strong adhesion force with the preliminary artificial leather 30 as well as superior adhesion force with other material such as sponge.
- the flame retardant composition may comprise, in addition to the flame retardant and binder, a variety of additives.
- useful additives include an anti-oxidant, an anti-static agent, an ultraviolet ray absorbent, an anti-hydrolysis agent and a softening agent.
- the preliminary artificial leather 30, as defined above, is an artificial leather, to which the flame retardant composition is not added, that comprises a non-woven fabric (not shown) and an elastic polymer resin (not shown) impregnated in the non-woven fabric and may be produced in accordance with the following method.
- island-in-sea fibers are prepared through a conjugate spinning process.
- the island ingredient of the island-in-sea fibers may be nylon or polyester, and the polyester may be polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT) or polybutylene terephthalate (PBT).
- PET polyethylene terephthalate
- PTT polytrimethylene terephthalate
- PBT polybutylene terephthalate
- the island-in-sea fibers are formed into short fibers such as staple fibers through a cutting process.
- the short fiber-type island-in-sea fibers are subjected to carding and cross-lapping processes to form webs.
- the webs may be directly formed through a spun bonding without any cutting process using long fiber-type island-in-sea fibers.
- a plurality of webs thus formed are joined together using a needle punch or water jet punch to complete a non-woven fabric.
- a process for impregnating an elastic polymer resin in the non-woven fabric and an ultra-fining process for removing the island ingredient of the island-in-sea fibers are sequentially performed to complete a preliminary artificial leather 30.
- the ultra-fining process is first performed and impregnation of the elastic polymer resin is then performed.
- the process of impregnating the elastic polymer resin in the non-woven fabric may be carried out by a coating, dipping process or the like. Of them, the dipping process that is simple and easy will be described in more detail.
- a polyurethane or silicone resin may be used as the elastic polymer resin.
- the polyurethane resin may be a polycarbonate diol resin, a polyester diol resin or a polyether diol resin, or a mixture thereof.
- a process for dipping a non-woven fabric in a composition comprising the elastic polymer resin, a process for solidifying the elastic polymer resin in a coagulation bath and a process for washing the non-woven fabric with water in a washing bath are sequentially performed to complete impregnation of the elastic polymer resin.
- the coagulation solution contained in the coagulation bath may be a mixed solution containing water, dimethylformamide and the like.
- the ultra-fining process will be described in more detail.
- the sea ingredient is removed by elution using an alkali solution such as aqueous sodium hydroxide solution.
- an alkali solution such as aqueous sodium hydroxide solution.
- the remaining island ingredient constitutes ultrafine fibers.
- the ultrafine fibers formed by the ultra-fining process preferably have a fineness of 0.3 denier or less in terms of texture.
- the present invention is not limited thereto. That is, the preliminary artificial leather 30 may be produced by producing ultrafine fibers, producing a non-woven fabric using the ultrafine fibers, and impregnating an elastic polymer resin in the non-woven fabric.
- the artificial leather described above exhibits excellent flame retardancy as well as superior air-permeability. That is, the artificial leather has a horizontal burning speed (that is measured in accordance with automobile interior material combustion test regulation of FMVSS. No. 302) of 100 mm/min or less, and an air-permeability of 20 to 50 L/min/100cm 2 .
- the horizontal burning speed is a parameter indicating flame retardancy, which is mainly used when the artificial leather is used as an interior material such as automobile sheet.
- the horizontal burning speed of the artificial leather exceeds 100 mm/min, it cannot have a level of flame retardancy required in the art and may be unsuitable for use in interior materials for automobiles.
- the air-permeability of the artificial leather means a level at which air is permeated into or is discharged from an automobile sheet, when the artificial leather is used for the automobile sheet. As air-permeability increases, a driver feels comfortable and fresh, and on the other hand, as air-permeability decreases, the driver feels unfresh and uncomfortable.
- the artificial leather preferably has an air-permeability of 20 to 50 L/min/100cm 2 .
- a copolymer polyester in which 5 mol% of polyester units containing metal sulfonate are copolymerized with polyethylene terephthalate as a main ingredient is molten to prepare a molten solution of a sea ingredient, and polyethylene terephthalate (PET) is molten to prepare a molten solution of an island ingredient.
- PET polyethylene terephthalate
- 50% by weight of the sea ingredient molten solution and 50% by weight of the island ingredient molten solution were conjugate-spun to obtain filaments having a single yarn fineness of 3 denier and comprising 16 island ingredients on the cross-section thereof, and the filaments were extended at an extension ratio of 3.5 to produce filament-type island-in-sea fibers.
- the island-in-sea fibers were crimped such that the number of crimps became 15/inch, thermally set at 130°C, and cut to 51 mm to prepare staple-type island-in-sea fibers.
- the staple-type island-in-sea fibers were subjected to carding and cross-lapping processes to form webs and the webs were subjected to a needle-punch process to produce a non-woven fabric.
- the non-woven fabric was padded with 5% by weight of an aqueous polyvinyl alcohol solution and then dried, and the dried non-woven fabric was dipped in 10% by weight of a 25°Cpolyurethane solution obtained by dissolving polyurethane in dimethylformamide (DMF) as a solvent, for 2 minutes. Then, the polyurethane solution-dipped non-woven fabric was coagulated in 15% by weight of an aqueous dimethylformamide solution and washed with water to obtain a polyurethane-impregnated non-woven fabric.
- DMF dimethylformamide
- the polyurethane-impregnated non-woven fabric was treated with 5% by weight of an aqueous sodium hydroxide solution, and the sea ingredient of the composite fiber was eluted and subjected to a ultra-fining process to obtain a preliminary artificial leather 30 having a unit weight of 346.3g/m 2 , a thickness of 0.95 mm, and air-permeability of 56.4 L/min/100cm 2 .
- a flame retardant composition having a viscosity of 7,800 comprising 40% by weight of water, 40% by weight of ammonium polyphosphate as a phosphorous-based flame retardant, and 20% by weight of a polyurethane-based binder was coated in the shape as shown in FIG. 1 on the one surface of the preliminary artificial leather 30 using a rotary screen coating method and air-dried at 130°C for 10 minutes to obtain an artificial leather provided with the flame retardant composition layer 10 having an area ratio of 65%, a upper part thickness (a) of 16 ⁇ m and a permeation depth (b) of 100 ⁇ m.
- the rotary screen coating was performed using a rotary screen printing machine (produced by Ichinose Co., Ltd.) and an 80 mesh screen (produced by Stork Co. Ltd.)
- An artificial leather was obtained in the same manner as Example 1, except that the flame retardant composition was coated in the shape shown in FIG. 4 .
- An artificial leather was obtained in the same manner as Example 1, except that the flame retardant composition was coated in the shape shown in FIG. 5 .
- An artificial leather was obtained in the same manner as Example 1, except that the flame retardant composition was coated over the entire surface of the preliminary artificial leather 30.
- An artificial leather was obtained in the same manner as Example 1, except that the area ratio of the flame retardant composition layer 10 was changed into 55%.
- the area ratio (%) of the flame retardant composition layer 10 was expressed as a ratio of area of the flame retardant composition layer 10 formed on the preliminary artificial leather 30, with respect to the total area of the preliminary artificial leather 30.
- samples with a size of 50 ⁇ 50 were prepared at predetermined points of the artificial leather and the prepared samples were imaged using an image analyzer (using Image-Pro Plus as a software and JVC Digital Camera KY-F70B), and an area ratio of the flame retardant composition layer 10 was calculated in accordance with the following equation through an area analysis program.
- the total number of samples herein used was five, an arithmetic mean of the measured values was calculated, and an area ratio of the flame retardant composition layer 10 was finally obtained.
- Area ratio % of flame retardant composition layer 10 area of flame retardant composition layer 10 coated on preliminary artificial leather 30 / area of preliminary artificial leather 30 ⁇ 100
- a ratio (%) of a upper part thickness of the flame retardant composition layer 10, as shown in FIG. 2 is a ratio of the upper part thickness (a), defined as an average height of the flame retardant composition layer 10 that protrudes upward from the surface of the preliminary artificial leather 30, with respect to the average thickness (c) of the preliminary artificial leather 30.
- the average thickness (c) of the preliminary artificial leather 30 and the upper part thickness (a), corresponding to the average height of the flame retardant composition layer 10 were measured using a scanning electron microscope (SEM).
- the thickness (c) of the preliminary artificial leather 30 and the upper part thickness (a) of the flame retardant composition layer 10 were calculated at the two points.
- the measurements were performed for the five samples in total, arithmetic means of the measured values were calculated, and the average thickness (c) of the preliminary artificial leather 30 and the average upper part thickness (a) of flame retardant composition layer 10 were finally obtained.
- the ratio (%) of the upper part thickness of the flame retardant composition layer 10 was obtained using the average thickness (c) of the preliminary artificial leather 30 and the average upper part thickness (a) of flame retardant composition layer 10.
- the ratio (%) of permeation depth (b) of the flame retardant composition layer 10, as shown in FIG. 2 is a ratio of permeation depth (b), defined as an average depth of the flame retardant composition layer 10 permeated inside from the surface of the preliminary artificial leather 30, with respect to the average thickness (c) of preliminary artificial leather 30.
- the average thickness (c) of preliminary artificial leather 30 and the permeation depth (b) corresponding to the average depth of the flame retardant composition layer 10 were measured using a scanning electron microscope (SEM).
- the amount of coated flame retardant composition (g/m 2 ) was obtained from the difference between a weight of the preliminary artificial leather 30 before formation of the flame retardant composition layer 10 and a weight of the preliminary artificial leather 30 after formation of the flame retardant composition layer 10.
- FMVSS Federal Motor Vehicle Safety Standard
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Abstract
Description
- The present invention relates to an artificial leather. More specifically, the present invention relates to an artificial leather comprising a flame retardant composition layer
- An artificial leather is produced by impregnating a polymer elastomer in a non-woven fabric comprising three-dimensionally entangled ultrafine fibers, which is widely utilized in a variety of applications such as shoes, clothing, gloves, miscellaneous goods, furniture and automobile interior materials due to natural leather-like soft texture and unique appearance.
- Such artificial leather requires improved high functionality in terms of flexibility, surface quality properties, abrasion resistance, light resistance, elongation and the like according to applications and often requires a variety of properties.
- For example, when the artificial leather is used for a surface material adhered to an automobile sheet among the automobile interior materials, there is difficulty in that it satisfies surface quality properties, specifically, superior appearance, air-permeability and texture properties, as well as flame retardancy regulated by the Law among physical properties of automobile in accordance with increased expectation of consumers.
- That is, in order to impart flame retardancy required in the art to artificial leathers, a great amount of flame retardant is inevitably used. When an artificial leather is treated with a great amount of flame retardant, the artificial leather disadvantageously becomes hard in texture and exhibits deteriorated air-permeability.
- Therefore, the present invention is directed to an artificial leather capable of preventing problems caused by these limitations and drawbacks of the related art.
- That is, it is one object of the present invention to provide an artificial leather that can exhibit a level of flame retardancy required in the art, is free of deterioration in soft texture of ultrafine fibers and has greatly improved air-permeability by partially coating a flame retardant composition on a preliminary artificial leather.
- In accordance with one aspect of the present invention, provided is an artificial leather comprising: a preliminary artificial leather comprising a non-woven fabric made of ultrafine fibers and an elastic polymer resin impregnated in the non-woven fabric; and a flame retardant composition layer formed on the preliminary artificial leather by partially coating a flame retardant composition thereon at an area ratio of 60 to 90%, with respect to the total area of the preliminary artificial leather.
- The present invention has the following effects.
- First, the artificial leather according to the present invention comprises a flame retardant composition layer that is partially coated at an optimal shape and content, thus advantageously exhibiting a level of flame retardancy required in the art and improving economical efficiency.
- Second, the artificial leather according to the present invention can exhibit superior texture and air-permeability due to partial coating of the flame retardant composition layer.
- Such an artificial leather may be used for automobile sheets or the like, requiring superior flame retardancy, appearance and texture.
- The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
-
FIG. 1 is a plan view illustrating an artificial leather according to one embodiment of the present invention; -
FIG. 2 is a cross-sectional view of the artificial leather taken along the line A-A' ofFIG. 1 ; and -
FIGs. 3 to 6 are plan views illustrating an artificial leather according to another embodiment of the present invention. - Those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. Accordingly, the present invention includes all alternations and modifications that fall within the scope of inventions described in claims and equivalents thereto.
- The term herein used "preliminary artificial leather" means an artificial leather, to which a flame retardant composition is not added, that comprises a non-woven fabric and an elastic polymer resin impregnated in the non-woven fabric.
- Hereinafter, embodiments of artificial leather according to the present invention will be described with reference to the annexed drawings in more detail.
-
FIG. 1 is a plan view illustrating an artificial leather according to one embodiment of the present invention. -
FIG. 2 is a cross-sectional view of the artificial leather taken along the line A-A' ofFIG. 1 . - As shown in
FIGs. 1 and 2 , the artificial leather of the present invention comprises a preliminaryartificial leather 30 and a flameretardant composition layer 10 disposed on the preliminaryartificial leather 30 by partially coating a flame retardant composition thereon. According to one embodiment of the present invention illustrated inFIGs. 1 and 2 , since the flame retardant composition is only partially coated on the preliminaryartificial leather 30, grooves are formed in non-coated regions of preliminary artificial leather where the flame retardant composition is not coated and, as a result, the artificial leather of the present invention exhibit superior air-permeability without causing deterioration in texture of preliminary artificial leather made of fine fibers. - In addition, the amount of flame retardant composition used can be greatly reduced since the flame retardant composition is only partially coated on the preliminary
artificial leather 30. As a result, production cost of the artificial leather can be reduced and economic efficiency can be thus improved. - On the other hand, when, in the related art, the flame retardant composition is coated over the entire surface of the preliminary
artificial leather 30, problems such as reduction in economic efficiency and deteriorations in texture and air-permeability of artificial leather occur due to use of a great amount of flame retardant composition. - The artificial leather of the present invention comprises a flame
retardant composition layer 10 that is formed by partially coating the flame retardant composition at an area ratio of 60 to 90% with respect to the total area of the preliminaryartificial leather 30. When the area ratio of the flameretardant composition layer 10 is lower than 60%, an artificial leather satisfying flame retardancy required in the art cannot be obtained, and when the area ratio of the flameretardant composition layer 10 is higher than 90%, air-permeability of the artificial leather may be greatly deteriorated. - The flame
retardant composition layer 10 may have a variety of shapes, as shown inFIGs. 1 and 3 to 5 . - For example, as shown in
FIG. 5 , the flameretardant composition layer 10 may include a plurality of discontinuous unit layers having a predetermined shape. That is, the plurality of unit layers constituting the flameretardant composition layer 10 are discontinuously distributed on the preliminaryartificial leather 30 and onegroove 20 corresponding to the non-coated region of the preliminaryartificial leather 20 surrounds the plurality of unit layers. - However, when one
groove 20 surrounding discontinuously distributed unit layers is formed, the region where the preliminaryartificial leather 20 is not coated may be readily burned along the continuously formedgroove 20 and flame retardancy of artificial leather may be thus slightly deteriorated. As a result, in order to impart a level of flame retardancy required in the art to an artificial leather, a relatively great amount of flame retardant is inevitably used and, as a result, air-permeability and texture of artificial leather may be slightly deteriorated. - On the other hand, as shown in
FIGs. 1 ,3 and 4 , the artificial leather of the present invention may include a plurality ofgrooves 20 that are discontinuously distributed in non-coated regions of preliminaryartificial leather 30 to which the flame retardant composition is not coated. - The flame
retardant composition layer 10 of the present invention, as shown inFIGs. 1 and3 , may be a body surrounding the plurality ofgrooves 20. Alternatively, as shown inFIG. 4 , the flameretardant composition layer 10 of the present invention may include a plurality of discontinuously distributed unit layers. - When the artificial leather of the present invention including a plurality of
grooves 20 that are discontinuously distributed in non-coated regions of preliminaryartificial leather 30 to which the flame retardant composition is not coated is subjected to flame retardancy testing, the plurality ofgrooves 20 are discontinuously distributed, thus preventing blazes from spreading to the entire non-coated regions of the preliminaryartificial leather 20. As a result, although the amount of the flame retardant composition coated is low, flame retardancy of artificial leather can be greatly improved. - Accordingly, when the flame retardant composition is coated at a constant amount on the preliminary
artificial leather 30, the artificial leather including a plurality of discontinuouslydistributed grooves 20 exhibits superior flame retardancy, as compared to the artificial leather including only continuously formed onegroove 20. - The plurality of
grooves 20 of the artificial leather of the present invention, as shown inFIG. 6 , may be irregularly and discontinuously distributed, and the flameretardant composition layer 10 may be a body surrounding the plurality ofgrooves 20. - Each of the
grooves 20 of the artificial leather of the present invention may have a variety of shapes such as circular, polygonal or linear shape. - Meanwhile, so as to improve both flame retardancy and air-permeability, the flame
retardant composition layer 10 should have an optimal permeation depth and an upper part thickness.FIG. 2 is a cross-sectional view of the artificial leather taken along the line A-A' ofFIG. 1 according to one embodiment of the present invention. As shown inFIG. 2 , the artificial leather has an upper part thickness that means a level of the flameretardant composition layer 10 that protrudes on the surface of the preliminaryartificial leather 30 and a permeation depth that means a level of the flameretardant composition layer 10 permeated into the preliminaryartificial leather 30. - In order to produce an artificial leather having flame retardancy corresponding to a horizontal burning speed of 100 mm/min or less and an air-permeability of 20 to 50 L/min/100cm2, the upper part thickness (a) is preferably within a ratio range of 0.1 to 4% with respect to the thickness (c) of the preliminary
artificial leather 30. When the ratio of the upper part thickness (a) is lower than 0.1%, an artificial leather satisfying a level of flame retardancy required in the art cannot be produced, and when the ratio of the upper part thickness (a) is higher than 4%, the texture of artificial leather may be greatly deteriorated. - The permeation depth (b) is preferably within a ratio range of 5 to 50% with respect to the thickness (c) of the preliminary
artificial leather 30. When the ratio of the permeation depth (b) is lower than 5%, adhesion force is deteriorated and durability is thus degraded and, on the other hand, when the ratio of the permeation depth (b) is higher than 50%, the texture of artificial leather may be hardened. - The upper part thickness (a) and permeation depth (b) of the flame
retardant composition layer 10 may be measured by imaging the cross-section of a sample with a scanning electron microscope (SEM). - The flame retardant composition may comprise a flame retardant and a binder. As the flame retardant, a phosphorous-based flame retardant is preferred than a halogen-based flame retardant which is a cancer-inducing substance. The binder enhances adhesion force and may be selected from a variety of types of binders. In particular, a urethane-based binder containing silicon exhibits superior heat resistance due to presence of silicon, thus inhibiting decomposition of silicon during combustion, and can form a cross-linkage with urethane, thus improving flame retardancy of the artificial leather. Meanwhile, the urethane-based binder advantageously has strong adhesion force with the preliminary
artificial leather 30 as well as superior adhesion force with other material such as sponge. - The flame retardant composition may comprise, in addition to the flame retardant and binder, a variety of additives. Examples of useful additives include an anti-oxidant, an anti-static agent, an ultraviolet ray absorbent, an anti-hydrolysis agent and a softening agent.
- The preliminary
artificial leather 30, as defined above, is an artificial leather, to which the flame retardant composition is not added, that comprises a non-woven fabric (not shown) and an elastic polymer resin (not shown) impregnated in the non-woven fabric and may be produced in accordance with the following method. - First, island-in-sea fibers are prepared through a conjugate spinning process. The island ingredient of the island-in-sea fibers may be nylon or polyester, and the polyester may be polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT) or polybutylene terephthalate (PBT).
- Subsequently, the island-in-sea fibers are formed into short fibers such as staple fibers through a cutting process. The short fiber-type island-in-sea fibers are subjected to carding and cross-lapping processes to form webs. Alternatively, the webs may be directly formed through a spun bonding without any cutting process using long fiber-type island-in-sea fibers.
- A plurality of webs thus formed are joined together using a needle punch or water jet punch to complete a non-woven fabric.
- Subsequently, a process for impregnating an elastic polymer resin in the non-woven fabric and an ultra-fining process for removing the island ingredient of the island-in-sea fibers are sequentially performed to complete a preliminary
artificial leather 30. Alternatively, the ultra-fining process is first performed and impregnation of the elastic polymer resin is then performed. - The process of impregnating the elastic polymer resin in the non-woven fabric may be carried out by a coating, dipping process or the like. Of them, the dipping process that is simple and easy will be described in more detail.
- First, a polyurethane or silicone resin may be used as the elastic polymer resin. The polyurethane resin may be a polycarbonate diol resin, a polyester diol resin or a polyether diol resin, or a mixture thereof.
- A process for dipping a non-woven fabric in a composition comprising the elastic polymer resin, a process for solidifying the elastic polymer resin in a coagulation bath and a process for washing the non-woven fabric with water in a washing bath are sequentially performed to complete impregnation of the elastic polymer resin. The coagulation solution contained in the coagulation bath may be a mixed solution containing water, dimethylformamide and the like.
- The ultra-fining process will be described in more detail. Of the composite fiber comprising an island ingredient and a sea ingredient, the sea ingredient is removed by elution using an alkali solution such as aqueous sodium hydroxide solution. As a result of removal of sea ingredient, the remaining island ingredient constitutes ultrafine fibers. The ultrafine fibers formed by the ultra-fining process preferably have a fineness of 0.3 denier or less in terms of texture.
- Although the method for producing the preliminary
artificial leather 30 using island-in-sea fibers has been described, the present invention is not limited thereto. That is, the preliminaryartificial leather 30 may be produced by producing ultrafine fibers, producing a non-woven fabric using the ultrafine fibers, and impregnating an elastic polymer resin in the non-woven fabric. - The artificial leather described above exhibits excellent flame retardancy as well as superior air-permeability. That is, the artificial leather has a horizontal burning speed (that is measured in accordance with automobile interior material combustion test regulation of FMVSS. No. 302) of 100 mm/min or less, and an air-permeability of 20 to 50 L/min/100cm2.
- The horizontal burning speed is a parameter indicating flame retardancy, which is mainly used when the artificial leather is used as an interior material such as automobile sheet. When the horizontal burning speed of the artificial leather exceeds 100 mm/min, it cannot have a level of flame retardancy required in the art and may be unsuitable for use in interior materials for automobiles.
- The air-permeability of the artificial leather means a level at which air is permeated into or is discharged from an automobile sheet, when the artificial leather is used for the automobile sheet. As air-permeability increases, a driver feels comfortable and fresh, and on the other hand, as air-permeability decreases, the driver feels unfresh and uncomfortable.
- However, as air-permeability excessively increases, the content of the flame
retardant composition layer 10 is decreased and flame retardancy of artificial leather is thus excessively deteriorated. Accordingly, the artificial leather preferably has an air-permeability of 20 to 50 L/min/100cm2. - Hereinafter, the present invention will be described in detail with reference to examples and comparative examples. These examples are provided only for a better understanding and should not be construed as limiting the scope and spirit of the present invention.
- A copolymer polyester in which 5 mol% of polyester units containing metal sulfonate are copolymerized with polyethylene terephthalate as a main ingredient is molten to prepare a molten solution of a sea ingredient, and polyethylene terephthalate (PET) is molten to prepare a molten solution of an island ingredient. Then, 50% by weight of the sea ingredient molten solution and 50% by weight of the island ingredient molten solution were conjugate-spun to obtain filaments having a single yarn fineness of 3 denier and comprising 16 island ingredients on the cross-section thereof, and the filaments were extended at an extension ratio of 3.5 to produce filament-type island-in-sea fibers. Then, the island-in-sea fibers were crimped such that the number of crimps became 15/inch, thermally set at 130°C, and cut to 51 mm to prepare staple-type island-in-sea fibers.
- Then, the staple-type island-in-sea fibers were subjected to carding and cross-lapping processes to form webs and the webs were subjected to a needle-punch process to produce a non-woven fabric.
- Then, the non-woven fabric was padded with 5% by weight of an aqueous polyvinyl alcohol solution and then dried, and the dried non-woven fabric was dipped in 10% by weight of a 25°Cpolyurethane solution obtained by dissolving polyurethane in dimethylformamide (DMF) as a solvent, for 2 minutes. Then, the polyurethane solution-dipped non-woven fabric was coagulated in 15% by weight of an aqueous dimethylformamide solution and washed with water to obtain a polyurethane-impregnated non-woven fabric.
- Then, the polyurethane-impregnated non-woven fabric was treated with 5% by weight of an aqueous sodium hydroxide solution, and the sea ingredient of the composite fiber was eluted and subjected to a ultra-fining process to obtain a preliminary
artificial leather 30 having a unit weight of 346.3g/m2, a thickness of 0.95 mm, and air-permeability of 56.4 L/min/100cm2. - Subsequently, a flame retardant composition having a viscosity of 7,800 comprising 40% by weight of water, 40% by weight of ammonium polyphosphate as a phosphorous-based flame retardant, and 20% by weight of a polyurethane-based binder was coated in the shape as shown in
FIG. 1 on the one surface of the preliminaryartificial leather 30 using a rotary screen coating method and air-dried at 130°C for 10 minutes to obtain an artificial leather provided with the flameretardant composition layer 10 having an area ratio of 65%, a upper part thickness (a) of 16µm and a permeation depth (b) of 100µm. The rotary screen coating was performed using a rotary screen printing machine (produced by Ichinose Co., Ltd.) and an 80 mesh screen (produced by Stork Co. Ltd.) - Artificial leathers were obtained in the same manner as Example 1, except that area ratios of the flame
retardant composition layer 10 were changed into 75% and 85%, respectively. - An artificial leather was obtained in the same manner as Example 1, except that the flame retardant composition was coated in the shape shown in
FIG. 4 . - Artificial leathers were obtained in the same manner as Example 4, except that area ratios of the flame
retardant composition layer 10 were changed into 75% and 85%, respectively. - An artificial leather was obtained in the same manner as Example 1, except that the flame retardant composition was coated in the shape shown in
FIG. 5 . - An artificial leather was obtained in the same manner as Example 1, except that the flame retardant composition was coated over the entire surface of the preliminary
artificial leather 30. - An artificial leather was obtained in the same manner as Example 1, except that the area ratio of the flame
retardant composition layer 10 was changed into 55%. - Next, physical properties of artificial leathers obtained in Examples and Comparative Examples were measured in accordance with the following method and the results thus obtained are shown in Table 1.
- The area ratio (%) of the flame
retardant composition layer 10 was expressed as a ratio of area of the flameretardant composition layer 10 formed on the preliminaryartificial leather 30, with respect to the total area of the preliminaryartificial leather 30. - Specifically, samples with a size of 50×50 were prepared at predetermined points of the artificial leather and the prepared samples were imaged using an image analyzer (using Image-Pro Plus as a software and JVC Digital Camera KY-F70B), and an area ratio of the flame
retardant composition layer 10 was calculated in accordance with the following equation through an area analysis program. The total number of samples herein used was five, an arithmetic mean of the measured values was calculated, and an area ratio of the flameretardant composition layer 10 was finally obtained. - A ratio (%) of a upper part thickness of the flame
retardant composition layer 10, as shown inFIG. 2 , is a ratio of the upper part thickness (a), defined as an average height of the flameretardant composition layer 10 that protrudes upward from the surface of the preliminaryartificial leather 30, with respect to the average thickness (c) of the preliminaryartificial leather 30. The average thickness (c) of the preliminaryartificial leather 30 and the upper part thickness (a), corresponding to the average height of the flameretardant composition layer 10 were measured using a scanning electron microscope (SEM). - Specifically, two points were selected in the cross-section SEM image of the artificial leather such that the distance therebetween became 1000µm, and the thickness (c) of the preliminary
artificial leather 30 and the upper part thickness (a) of the flameretardant composition layer 10 were calculated at the two points. The measurements were performed for the five samples in total, arithmetic means of the measured values were calculated, and the average thickness (c) of the preliminaryartificial leather 30 and the average upper part thickness (a) of flameretardant composition layer 10 were finally obtained. Subsequently, the ratio (%) of the upper part thickness of the flameretardant composition layer 10 was obtained using the average thickness (c) of the preliminaryartificial leather 30 and the average upper part thickness (a) of flameretardant composition layer 10. - The ratio (%) of permeation depth (b) of the flame
retardant composition layer 10, as shown inFIG. 2 , is a ratio of permeation depth (b), defined as an average depth of the flameretardant composition layer 10 permeated inside from the surface of the preliminaryartificial leather 30, with respect to the average thickness (c) of preliminaryartificial leather 30. The average thickness (c) of preliminaryartificial leather 30 and the permeation depth (b) corresponding to the average depth of the flameretardant composition layer 10 were measured using a scanning electron microscope (SEM). - Specifically, two points were selected in the cross-section SEM image of the artificial leather such that the distance therebetween became 1000µm, and the thickness (c) of preliminary
artificial leather 30 and the permeation depth (b) of flameretardant composition layer 10 were calculated at the two points. The measurements were performed for the five samples in total, arithmetic means of the measured values were calculated, and average thickness (c) of the preliminaryartificial leather 30 and the average permeation depth (b) of flameretardant composition layer 10 were finally obtained. Subsequently, the ratio (%) of permeation depth of the flameretardant composition layer 10 was obtained using the average thickness (c) of the preliminaryartificial leather 30 and the average permeation depth (b) of the flameretardant composition layer 10. - The amount of coated flame retardant composition (g/m2) was obtained from the difference between a weight of the preliminary
artificial leather 30 before formation of the flameretardant composition layer 10 and a weight of the preliminaryartificial leather 30 after formation of the flameretardant composition layer 10. - A horizontal burning speed (mm/min), indirectly indicating a flame retardancy level of artificial leather, was measured in accordance with automobile interior material combustion test regulation of Federal Motor Vehicle Safety Standard (FMVSS) No. 302.
- An air-permeability (L/min/100cm2) was measured in accordance with the Frazier testing method of ASTM D 737.
TABLE 1 Shape of groove formed on artificial leather Area ratio (%) Ratio of Ratio of upper part thickness (%) Ratio of permeation depth (%) Coating amount (g/m2) Horizontal combustion speed (mm/min) Air-permeability (L/min/100cm2) Ex. 1 Discontinuous circles 65 1.7 10.5 35.7 Self-fire extinguishing 44 Ex. 2 Discontinuous circles 75 1.7 10.5 44.5 Self-fire extinguishing 37 Ex. 3 Discontinuous circles 85 1.7 10.5 49.8 Self-fire extinguishing 33 Ex. 4 Discontinuous circles 65 1.7 10.5 38.1 Self-fire extinguishing 46 Ex. 5 Discontinuous circles 75 1.7 10.5 43.1 Self-fire extinguishing 37 Ex. 6 Discontinuous circles 85 1.7 10.5 51.1 Self-fire extinguishing 34 Ex. 7 One groove surrounding discontinuously coated circular regions 65 1.7 10.5 33.7 99 46 Comp. Ex. 1 Absence of groove due to entire-surface coating of flame retardant composition 100 1.7 10.5 60.6 Self-fire extinguishing 15 Comp. Ex. 2 Discontinuous circles 55 1.7 10.5 30.6 141 49 - Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
Claims (9)
- An artificial leather comprising:a preliminary artificial leather comprising a non-woven fabric made of ultrafine fibers and an elastic polymer resin impregnated in the non-woven fabric; anda flame retardant composition layer formed on the preliminary artificial leather by partially coating a flame retardant composition thereon at an area ratio of 60 to 90%, with respect to the total area of the preliminary artificial leather.
- The artificial leather according to claim 1, wherein the artificial leather comprises a plurality of grooves discontinuously distributed in non-coated regions of the preliminary artificial leather where the flame retardant composition is not coated.
- The artificial leather according to claim 2, wherein the flame retardant composition layer is a body surrounding the grooves.
- The artificial leather according to claim 2, wherein each of the grooves has a circular, polygonal or linear shape.
- The artificial leather according to claim 1, wherein the artificial leather has a horizontal burning speed, measured in accordance with automobile interior material combustion test regulation of FMVSS. No. 302, of 100 mm/min or less, and an air-permeability of 20 to 50 L/min/100cm2.
- The artificial leather according to claim 1, wherein the flame retardant composition layer has an upper portion thickness of 0.1 to 4% and a permeation depth of 5 to 50%, with respect to a thickness of the preliminary artificial leather.
- The artificial leather according to claim 1, wherein the flame retardant composition layer comprises a phosphorous-based flame retardant.
- The artificial leather according to claim 1, wherein the flame retardant composition layer comprises a urethane binder containing silicon.
- The artificial leather according to claim 1, wherein the ultrafine fiber has a fineness of 0.3 denier or less.
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PCT/KR2011/001335 WO2011105851A2 (en) | 2010-02-26 | 2011-02-25 | Artificial leather |
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WO2014151786A1 (en) * | 2013-03-15 | 2014-09-25 | Church & Dwight Co., Inc. | Method and composition for depositing textured imprints onto a substrate surface |
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JP6186405B2 (en) * | 2015-04-23 | 2017-08-23 | 株式会社加平 | Patterned sheet, patterned sheet manufacturing method, and manufacturing apparatus |
CN112192912B (en) * | 2020-08-18 | 2023-05-02 | 浙江梅盛新材料有限公司 | Artificial leather with flame retardant property and preparation method and preparation device thereof |
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- 2011-02-25 WO PCT/KR2011/001335 patent/WO2011105851A2/en active Application Filing
- 2011-02-25 JP JP2012554938A patent/JP5956351B2/en active Active
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JP2014523976A (en) * | 2011-06-28 | 2014-09-18 | イー・アイ・デュポン・ドウ・ヌムール・アンド・カンパニー | Pattern-forming flame-retardant flexible substrates and methods for producing them |
WO2014151786A1 (en) * | 2013-03-15 | 2014-09-25 | Church & Dwight Co., Inc. | Method and composition for depositing textured imprints onto a substrate surface |
US9592661B2 (en) | 2013-03-15 | 2017-03-14 | Church & Dwight Co., Inc. | System for depositing an imprint onto a substrate |
Also Published As
Publication number | Publication date |
---|---|
EP2540909A4 (en) | 2013-10-09 |
JP2013520581A (en) | 2013-06-06 |
EP2540909B1 (en) | 2016-09-07 |
WO2011105851A2 (en) | 2011-09-01 |
WO2011105851A3 (en) | 2012-01-19 |
JP5956351B2 (en) | 2016-07-27 |
KR101680533B1 (en) | 2016-11-29 |
KR20110098675A (en) | 2011-09-01 |
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