The disclosure relates to an artificial leather and a textile, more particular to an environmental-friendly composite filament artificial leather and a composite filament textile.
If a conventional artificial leather is made by staple fiber and a staple fiber textile base manufactured with same, dimensional stability of the base is unstable; meanwhile, in order to maintain good touch feeling of the leather, an objective of lightweight cannot be achieved. Simultaneously, if a PU resin is dipped or laminated in the manufacturing process, it is not environment-friendly because of containing a solvent. If the artificial leather is made by filament and a filament textile base manufactured with same, the dimensional stability is great, but the leather cannot get good touch feeling due to the thin structure of the filament textile; also, a PU resin is dipped or laminated in the manufacturing process, and likewise it is not environment-friendly because of containing a solvent.
The conventional artificial leather and manufacturing method thereof are analyzed in the following patent documents in the prior art.
1. TW201128019
Approach: Spraying the heterogeneous section fiber and a composite thermoplastic material onto the surface of the web, then bonding the thermoplastic base material and the fiber and the web by heating, and then transfer the pattern from the release paper to the surface of composite material.
Disadvantage: process is complicated, dimensional stability is poor, lightweight cannot be achieved, and a problem of uneven attachment distribution occurs.
2. TW438927
Approach: non-elastomer fiber and fiber with the surface configured with an elastomer are stacked to form a base material, and then the artificial leather is obtained through a staple fiber manufacturing process.
Disadvantage: manufacturing process time is long, attachment is uneven, tensile strength is low, peeling strength is bad, and web distribution is prone to be uneven.
3. TW201040352
Approach: the base material is formed by extremely slender filament and a elastomer.
Disadvantage: dimensional stability is undesirable.
Based on the foregoing analysis, it is necessary to provide an environment-friendly composite filament artificial leather and manufacturing method thereof as well as composite filament textile and manufacturing method thereof, so as to solve the foregoing deficiencies in the prior art.
In accordance with one aspect of the present disclosure, an environmental-friendly composite filament artificial leather includes a composite filament textile and an elastomer film. The composite filament textile is made of the composite filament or the composite filament and other filament jointly. The composite filament includes at least one core portion and a sheath portion. The at least one core portion is a polyester-type polymer, a polyamide polymer or a polypropylene polymer. The sheath portion sheathes the at least one core portion, and the sheath portion is a thermoplastic elastomer. The elastomer film is bonded with the composite filament textile.
In accordance with another aspect of the present disclosure, a composite filament textile is provided. The composite filament textile is made of the composite filament or the composite filament and other filament jointly. The composite filament includes at least one core portion and a sheath portion. The at least one core portion is a polyester-type polymer, a polyamide polymer or a polypropylene polymer. The sheath portion sheathes the at least one core portion, and the sheath portion is a thermoplastic elastomer.
In the present disclosure, the composite filament textile is made of the composite filament or the composite filament and other filament jointly, and by bonding the composite filament textile with the elastomer film, an environment-friendly artificial leather of lightweight, good abrasion, good touch feeling and well dimentional stability can be manufactured. Moreover, in the present disclosure, the artificial leather can be manufactured without use of any solvent, so as to conform to the environment protection requirement.
Aspects of the present disclosure are understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
It is to be understood that the following disclosure provides many different embodiments or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. The present disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that this description will be thorough and complete, and will fully convey the present disclosure to those of ordinary skill in the art. It will be apparent, however, that one or more embodiments may be practiced without these specific details.
In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
It will be understood that singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms; such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
With reference to
The composite filament textile 12 is made of composite filament 120 or made by blending composite filament 120 and polyester filament or polyamide filament. The composite filament textile 12 can be in a woven or nonwoven form, wherein the woven can be loom or knit, and the woven can be made by blending regular filament or high-tenacity filament and the composite filament 120. Preferably, the thickness of the composite filament textile 12 is 0.025 to 10 mm inclusive, and the tensile strength of the composite filament textile 12 is 1 to 25 kg/25.4 mm inclusive.
In some embodiments, the composite filament 120 includes at least one core portion 122 and a sheath portion 124. The at least one core portion 122 accounts for a proportion of 10 to 90% inclusive of the entire filament weight, and the sheath portion 124 can account for a proportion of 90 to 10% inclusive of the entire filament weight.
The at least one core portion 122 is a polyester-type polymer, a polyamide polymer or a polypropylene polymer. In some embodiments, the intrinsic viscosity of the polyester-type polymer is 0.4 to 1.1 inclusive, the relative viscosity of the polyamide polymer is 2.0 to 3.0 inclusive, and the melt index of the polypropylene polymer is 30 to 150 inclusive (according to the ASTM D1238 standard, conditions include the weight of 2.16 kg, and the temperature of 230° C.). Preferably, the at least one core portion 122 can be one selected from the following polymers: polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), thermoplastic aliphatic polyester (PLA), polycaprolactam (Nylon6), polyhexamethylene adipamide (Nylon6,6), polypropylene homopolymer and polypropylene random copolymer.
The sheath portion 124 sheathes the at least one core portion 122, and the sheath portion 124 is a thermoplastic elastomer. In some embodiments, the raw material melt index of the sheath portion 124 is 1 to 100 g/10 min inclusive, which is according to the ASTM D1238 standard, conditions include the weight of 2.16 kg, and the temperature of 190° C. Preferably, the sheath portion 124 cab be one selected from the following polymers: thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE) and thermoplastic polyolefin (TPO).
Referring to
Moreover, in order to achieve lightweight and increase dimensional stability, preferably, the denier, density and strength of the composite filament 120 should respectively meet the following conditions: the denier is 0.001 to 20 dpf(denier per filament) inclusive; the density is 0.8 to 1.4 g/cm3 inclusive; and the strength is 0.5 to 8.0 g/den inclusive.
Referring to
Furthermore, the elastomer film 14 can be a foamed film or a non-foamed film, wherein the density of the foamed film is 0.3 to 0.9 g/cm3 inclusive and the thickness thereof is 0.2 to 2.0 mm inclusive. The thickness of the non-foamed film is 0.1 to 2.0 mm inclusive. Preferably, the elastomer film 14 can be made of one selected from the following materials: thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE) and thermoplastic polyolefin (TPO).
The at least one core portion 122 is a polyester-type polymer, a polyamide polymer or a polypropylene polymer. Preferably, the at least one core portion 122 can be one selected from the following polymers: polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), thermoplastic aliphatic polyester (PLA), polycaprolactam (Nylon6), polyhexamethylene adipamide (Nylon6,6), polypropylene homopolymer and polypropylene random copolymer.
The sheath portion 124 sheathes the at least one core portion 122, and the sheath portion 124 is a thermoplastic elastomer. Preferably, the sheath portion 124 can be one selected from the following polymers: thermoplastic polyurethane (TPU), thermoplastic polyester elastomer (TPEE) and thermoplastic polyolefin (TPO).
Moreover, in this step, a method for preparing the composite filament 120 can be one selected from the following: a melt spinning by extrusion method, spunbond method and a melt-blown method. Preferably, the extrusion temperature of the at least one core portion 122 is 180 to 250° C. inclusive, and the extrusion temperature of the sheath portion 124 is 150 to 250° C. inclusive.
With reference to step S42 in
With reference to step S43 in
In some embodiments, the elastomer film 14 is hot-pressed and laminated to the composite filament textile 12. Alternatively, in another embodiment, the elastomer film 14 can bond with the composite filament textile 12 in a coating or spraying manner For example, a water-based polyurethane (PU) is coated or sprayed to the composite filament textile 12, and the water-based polyurethane (PU) can be formed into the elastomer film 14 after drying.
In the present disclosure, the composite filament textile is made of the composite filament or the composite filament and another filament jointly, and by bonding the composite filament textile with the elastomer film, an environment-friendly artificial leather of lightweight, good abrasion, good touch feeling and dimensional stability can be manufactured. Furthermore, in the present disclosure, the artificial leather can be manufactured without use of any solvent, so as to conform to the environment protection requirement. Moreover, in the present disclosure, the artificial leather can be manufactured by only use of hot bonding machining, and compared with the conventional artificial leather which needs a long oven drying process, the process time can be shortened, the energy source discharge can be reduced, the manufacturing cost can be effectively reduced and the production efficiency can be effectively increased.
Furthermore, the environment-friendly composite filament artificial leather of the present disclosure was breathable, and can be directly formed to the upper of the shoe material. For example, the composite filament textile 12 can be in a shoe shape, and the elastomer film 14 can be formed into a shoe surface through hot-pressing.
Moreover, the composite filament textile of the present disclosure can also be directly formed into a concave-convex shoe surface through hot-pressing. For example, the composite filament textile 12 can be in a shoe shape.
The present disclosure is illustrated in detail with the following embodiments, but it does not mean that the present disclosure is only limited to the content disclosed by these embodiments.
PBT (polybutylene terephthalate, IV=0.74) is taken as an ingredient of a core portion, TPU (thermoplastic polyurethane, MI=4, 190° C., 2.16 kg) is taken as an ingredient of a sheath portion, and a ratio of the weight of PBT to that of TPU is 6:4. Referring to
After the composite filament is arranged in order, the composite filament is woven by a loom into a fabric which the ends per inch (Warp rate) is 17 and the Picks per inch is 17 and with a thickness of 0.15 mm.
A TPU film with a thickness of 0.1 mm and the fabric are hot-pressed and laminated with a hot-pressing machine at a temperature of 120° C. and a pressure of 20 kg/cm2, and the TPU film and the TPU of the sheath portion of the composite filament are simultaneously softened and melted due to heat and are hot-laminated, so a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.25 mm.
By use of a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the environment-friendly composite filament artificial leather with various surface textures can be manufactured.
PET (polyethylene terephthalate, IV=0.5) is taken as an ingredient of a core portion, TPU (thermoplastic polyurethane, MI=50, 190° C., 2.16 kg) is taken as an ingredient of a sheath portion, and a ratio of the weight of PET to that of TPU is 6:4. Referring to
A TPU foamed film with a thickness of 0.1 mm and the spunbond nonwoven textile are hot-pressed and laminated with a hot-pressing machine at a temperature of 110° C. and a pressure of 10 kg/cm2, and the TPU film and the TPU of the sheath portion of the composite filament are simultaneously softened and melted due to heat and are hot-laminated, so a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.3 mm.
By use of a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the environment-friendly composite filament artificial leather with various surface textures can be manufactured.
PTT (polytrimethylene terephthalate, IV=0.55) is taken as an ingredient of a core portion, TPU (thermoplastic polyurethane, MI=80, 190° C., 2.16 kg) is taken as an ingredient of a sheath portion, and a ratio of the weight of PTT to that of TPU is 6:4. Referring to
A TPU foamed film with a thickness of 0.1 mm and the melt-blown nonwoven textile are hot-pressed and laminated with a hot-pressing machine at a temperature of 110° C. and a pressure of 10 kg/cm2, and the TPU film and the TPU of the sheath portion of the composite filament are simultaneously softened and melted due to heat and are hot-laminated, so a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.35 mm.
By use of a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the environment-friendly composite filament artificial leather with various surface textures can be manufactured.
PBT (polybutylene terephthalate, IV=0.74) is taken as an ingredient of a core portion, TPU (thermoplastic polyurethane, MI=80, 190° C., 2.16 kg) is taken as an ingredient of a sheath portion, and a ratio of the weight of PBT to that of TPU is 7:3. Referring to
PET (polyethylene terephthalate, IV=0.5) is taken as an ingredient of a core portion, TPU (thermoplastic polyurethane, MI=50, 190° C., 2.16 kg) is taken as an ingredient of a sheath portion, and a ratio of the weight of PET to that of TPU is 6:4. A spunbond composite fiber spinning machine (
A water-based polyurethane (PU) is coated onto the spunbond nonwoven textile, and the water-based polyurethane (PU) can be formed into an elastomer film after drying, so as to manufacture an environment-friendly composite filament artificial leather.
The composite filament with the specification of 100d/24 f manufactured through melt-spinning in Embodiment 1 is taken as wrap, the high-tenacity polyester filament with the tenacity greater than 6 g/den and the specification of 75 d/24 f is taken as weft, and the two types of filament are manufactured into a plain woven textile with a thickness of 0.12 mm through a loom by means of the wrap density is 120 pieces/2.54 cm, and the weft density is 90 pieces/2.54 cm. A CO2 foamed TPU film with a thickness of 0.12 mm, a foaming expansion ratio of 1.59 and a density of 0.755 g/cm3 and the plain woven textile are hot-pressed and laminated with a hot-pressing machine at a temperature of 125° C. and a pressure of 25 kg/cm2, and the foamed TPU film and the TPU of the sheath portion of the composite filament are simultaneously softened and melted due to heat and are hot-laminated, so a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.24 mm. By use of a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the high-physical-property which the tensile strength is 55 kg/cm2 and environment-friendly composite filament artificial leather with various surface textures can be manufactured.
The composite filament with the specification of 100 d/24 f manufactured through melt-spinning in Embodiment 1 and the high-tenacity polyester filament with the tenacity greater than 6 g/den and the specification of 50 d/24 f are used to perform a S-twist to manufacture false-twist yarn of 150/48/2, and the false-twist yarn is manufactured into a knitted textile with a thickness of 0.08 mm by using a knitting machine. A CO2 foamed TPU film with a thickness of 0.1 mm, a foaming expansion ratio of 1.57 and a density of 0.763 g/cm3 and the knitted textile are hot-pressed and laminated with a hot-pressing machine at a temperature of 120° C. and a pressure of 15 kg/cm2, and the foamed TPU film and the TPU of the sheath portion of the composite filament are simultaneously softened and melted due to heat and are hot-laminated, so a soft and elastic semi-finished product of the environment-friendly composite filament artificial leather can be manufactured with a thickness of 0.18 mm By use of a polyurethane(PU) dry coating process with a release paper, first to coating a water-based polyurethane be the surface layer and second to coating a water-based adhesive, both of them are sequentially coated on the release paper, then the foregoing semi-finished product are laminate to water-based adhesive, finally release from the release paper, the environment-friendly composite filament artificial leather with various surface textures can be manufactured.
Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, and composition of matter, means, methods and steps described in the specification. As those skilled in the art will readily appreciate form the present disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure.
Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, and compositions of matter, means, methods or steps. In addition, each claim constitutes a separate embodiment, and the combination of various claims and embodiments are within the scope of the invention.
Number | Date | Country | Kind |
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103128895 | Aug 2014 | TW | national |