JP7118351B2 - 発泡樹脂層及び合成皮革 - Google Patents
発泡樹脂層及び合成皮革 Download PDFInfo
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- JP7118351B2 JP7118351B2 JP2019083039A JP2019083039A JP7118351B2 JP 7118351 B2 JP7118351 B2 JP 7118351B2 JP 2019083039 A JP2019083039 A JP 2019083039A JP 2019083039 A JP2019083039 A JP 2019083039A JP 7118351 B2 JP7118351 B2 JP 7118351B2
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- foamed resin
- synthetic leather
- resin layer
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Description
本発明の発泡樹脂層は、ポリ塩化ビニル系樹脂及び熱可塑性ポリウレタンエラストマーを少なくとも含む。上記ポリ塩化ビニル系樹脂及び上記熱可塑性ポリウレタンエラストマーは、それぞれ、一種のみを使用してもよいし、二種以上を使用してもよい。
発泡度=(発泡部の面積+非発泡部の面積)/非発泡部の面積
本発明の発泡樹脂層を有する合成皮革を、「本発明の第一の合成皮革」と称する場合がある。本発明の発泡樹脂層を用いた本発明の第一の合成皮革は、軽量であり且つ耐摩耗性に優れる。また、耐屈曲性(特に、耐低温屈曲性)及び風合いにも優れる。
基布(商品名「CU19302」、savings-textile社製、目付:185g/m2、厚さ:600μm)の一方の面に、ポリ塩化ビニル系接着剤を、塗布量15g/m2となるように塗布し、乾燥して接着層を形成し、基布と接着層が積層された積層体を作製した。一方、ポリ塩化ビニル(平均重合度:2000)100質量部、及び熱可塑性ポリウレタンエラストマー(ショアA硬度:75、融点:170℃)10質量部、フタル酸ジアルキル系可塑剤90質量部、発泡剤(アゾジカルボンアミド)2.5質量部、及び添加剤(充填剤、安定剤、耐光向上剤、顔料、及び難燃剤を含む)15質量部を添加して160℃で5分間混練し、その後冷却して樹脂組成物を作製した。得られた樹脂組成物をカレンダー法によりシート化して未発泡樹脂シートを得、次いで加熱状態で上記積層体の接着層表面に貼り合わせ、210℃で2分間加熱して発泡剤を発泡させ、厚さ500μmの樹脂発泡体を作製した。次に、樹脂発泡体表面に、リバースコーターを用いて、水性ポリカーボネート系ポリウレタン樹脂(商品名「ハイドラン WLS-210」、DIC株式会社製)100質量部に、顔料10質量部、濡れ性向上剤0.3質量部、消泡剤0.3質量部、及び架橋剤3質量部を混合して得た組成物を、塗布して塗膜を形成し、当該塗膜を130℃で5分間加熱して塗膜を乾燥・架橋させ、厚さ30μmの表皮層を形成した。次に、表皮層表面に、リバースコーターを用いて、水性ポリカーボネート系ポリウレタン樹脂(商品名「WF-78-143」、Stahl社製)、シリコーン系化合物(商品名「HM-54-002」、Stahl社製)、及びカルボジイミド系架橋剤混合して得た組成物を、塗布して塗膜を形成し、当該塗膜を130℃で5分間加熱して塗膜を乾燥・架橋させ、厚さ20μmの表面処理層を形成した。そして、形成された表面処理層にエンボス加工でシボ柄を付して、合成皮革を作製した。
ポリ塩化ビニル系樹脂の種類、熱可塑性ポリウレタンエラストマーの種類、及び各成分の配合量などを表に示すように変更したこと以外は実施例1と同様にして合成皮革を作製した。
発泡剤として、熱膨張性マイクロカプセル5.0質量部を使用した以外は、実施例1と同様にして合成皮革を作製した。
実施例及び比較例で得られた合成皮革に関し、以下の評価を行った。結果を表1に示す。なお、実施例及び比較例で得られた発泡樹脂層の見掛け密度は表に示すとおりである。
実施例及び比較例で得られた合成皮革から、 幅10mm、長さ150mmの大きさの試験片を、縦方向(長手方向)から1枚採取し、裏面(基布層面)に幅10mm、長さ15mm、厚さ3mmの大きさのウレタンフォームを貼り付けた。JIS L0849に規定する「学振形染色摩擦堅老度試験機」(株式会社大栄科学精機製作所製)を用い、JIS L3102の6号綿布による摩擦試験を実施した。荷重1kgで3万回往復摩耗した。そして、摩耗後の試験片(表面保護層表面)を目視で観察し、学振摩耗性について以下の判定基準に従って判定した。
[判定基準]
○(良好):表面保護層が摩耗で削り取られることなく残っており、表皮層の露出がないもの
△(使用可能):表面保護層が摩耗で削り取られているが基布層の露出のないもの
×(不良):基布層の露出のあるもの
実施例及び比較例で得られた合成皮革から、幅40mm、長さ70mmの大きさの試験片を縦方向(長手方向)、横方向(幅方向)それぞれ1枚採取した。デマッチャ試験機「FT-1521」(株式会社上島製作所製)を用い、JIS K6260に準拠した一定のストロークで試験片に繰り返し屈曲の負荷を与え、-10℃×30000回の繰り返しで割れの有無を評価した。下記判定基準に従って判定した。割れの長さは縦方向試験片と横方向試験片の平均値とした。
[判定基準]
○(良好):割れが発生していない
△(使用可能):割れは無いが、白化発生
×(不良):割れ発生
実施例及び比較例で得られた合成皮革から、150mm四方の大きさの試験片を1枚採取し、「GT303 Leather Softness Tester」(GOTECH TESTING MACHINRS INC.製)を用いて、500gの荷重で押し込んだときの歪み測定値(BLC値)を測定した。歪み測定値が大きいものほど柔らかい風合いであることを示す。
実施例及び比較例において、カレンダー法により発泡樹脂層を得るための未発泡樹脂シートを作製しようとした際の加工性について、下記判定基準に従って判定した。
[判定基準]
○(良好):カレンダーロールから均一な厚みの未発泡樹脂シートを取り出せる
△(使用可能):未発泡樹脂シートを取り出すまでの混粘時間が倍以上かかる
×(不良):混錬時間を倍以上かけて、未発泡樹脂シートを取り出せるが厚みが不均一
実施例及び比較例で得られた発泡樹脂層について、アスカーゴム硬度計C型(高分子計器株式会社製)を用いて、JIS K7312に基づくアスカーC硬度を測定した。
11 基布層
12 接着層
13 発泡樹脂層
14 表皮層
15 表面保護層
Claims (10)
- ポリ塩化ビニル系樹脂及び熱可塑性ポリウレタンエラストマーを含 み、
前記熱可塑性ポリウレタンエラストマーのショアA硬度は50~80であり、
前記熱可塑性ポリウレタンエラストマーの含有量は、前記ポリ塩化ビニル系樹脂100質量部に対して1~50質量部であり、
前記ポリ塩化ビニル系樹脂の平均重合度(JIS K6721に準拠)は1200~3500であり、
車両内装用合成皮革用途である、 発泡樹脂層。 - 見掛け密度が0.3~0.7g/cm3である請求項1に記載の発泡樹脂層。
- 平均セル径が50~250μmである請求項1または2に記載の発泡樹脂層。
- 独立気泡構造を有する請求項1~3のいずれか1項に記載の発泡樹脂層。
- さらに可塑剤を含む請求項1~4のいずれか1項に記載の発泡樹脂層。
- 前記可塑剤の含有量が、前記ポリ塩化ビニル系樹脂100質量部に対して40~90質量部である、請求項5に記載の発泡樹脂層。
- 自動車内装の合成皮革用途である請求項1~6のいずれか1項に記載の発泡樹脂層。
- 請求項1~7のいずれか1項に記載の発泡樹脂層を有する合成皮革。
- 基布層と、前記発泡樹脂層と、ポリウレタン系樹脂を含む表皮層とを、この順に備え、
前記基布層と前記発泡樹脂層とがポリ塩化ビニル系樹脂を主成分とする接着層により接合している請求項8に記載の合成皮革。 - 基布層と、前記発泡樹脂層と、最表面に位置する表面保護層とをこの順に有し、前記基布層及び前記表面保護層を両端面に有する積層体を含む合成皮革であり、
前記積層体は、単位面積あたりの質量が300~500g/m2、厚さが1.0~1.3mm、JIS L0849に規定される摩擦に対する染色堅ろう度試験において荷重1kgとし3万往復の摩擦試験を前記表面保護層側に行った際前記表面保護層の下層が露出しない状態であり、BLC値が4.0~6.0である、請求項8または9に記載の合成皮革。
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JP2013518191A (ja) | 2010-02-01 | 2013-05-20 | ベネッケ・カリコ・アクチェンゲゼルシャフト | 多層シート材料およびその製造方法 |
US20180099594A1 (en) | 2015-01-22 | 2018-04-12 | Lg Hausys, Ltd. | Seat cover for automobile and manufacturing method therefor |
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JPS6057844B2 (ja) * | 1982-01-07 | 1985-12-17 | 株式会社クラレ | 人工皮革靴の製造方法 |
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JPH0633580B2 (ja) * | 1988-03-30 | 1994-05-02 | バンドー化学株式会社 | 塩化ビニル系樹脂発泡レザーの製造方法 |
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