KR102002262B1 - Artificial leather and manufacturing method thereof - Google Patents

Abstract

More particularly, the present invention relates to an artificial leather for automobile interior materials used in an automobile interior material covering process, and it is an object of the present invention to provide an artificial leather for automobile interior materials, To an artificial leather for an automobile interior material and a manufacturing method thereof.

Description

Technical Field [0001] The present invention relates to an artificial leather for automobile interior materials,

More particularly, the present invention relates to an artificial leather for automobile interior materials used in an automobile interior material covering process, and it is an object of the present invention to provide an artificial leather for automobile interior materials, To an artificial leather for an automobile interior material and a manufacturing method thereof.

Automobile interior materials such as crash pad, door trim, console box, arm rest, head rest, head liner, Foam layer; And a core layer which is a hard synthetic resin injection product.

The automobile interior material may be manufactured by various methods, for example, a skin layer; And a foam layer formed on the bottom of the skin layer to form a skin layer by vacuum forming the skin layer, then injecting the synthetic resin into the skin layer by attaching the skin layer to the core layer to form an integrated automobile interior material Can be manufactured.

In recent years, in order to maximize the high-quality feeling of automobile interior materials, a method of applying automotive interior materials through a covering process (also called a wrapping process) in which an adhesive is applied to the upper part of the foam layer and the foam layer and the core layer are wrapped with natural leather However, natural leather is expensive, has an animal protection issue, and is trying to apply artificial leather.

For example, Korean Patent Laid-Open Publication No. 10-2018-0078057 (Laid-open date: 2018.07.09) discloses a method for manufacturing an automobile interior material using the skin layer as the artificial leather. A nonwoven fabric is used.

However, the above-mentioned nonwoven fabric is expensive and can not be applied only to high-end vehicles. The sewing line is not clean due to poor stretchability, and the workability in the covering process is lowered. After completion of the covering process, There was a problem that wrinkles occurred. Further, when the artificial leather is applied to an automobile interior material such as a crash pad, unevenness of the automobile interior material is expressed directly on the artificial leather, and it is difficult to prevent uneven transfer of the automobile interior material.

Therefore, it is inevitable to develop artificial leather for automobile interior materials which can prevent the uneven transfer of automobile interior materials, and is cheap and can prevent wrinkles.

KR 10-2018-0078057 A (Released: 2018.07.09)

It is an object of the present invention to provide an artificial leather for automobile interior material and a method for manufacturing the same, which can prevent ruggedness transfer of automobile interior materials and prevent wrinkles at a low cost.

In order to achieve the above object,

The present invention relates to a backing layer which is a woven fabric impregnated from bottom to top; Pore layer; And the skin layer is 80-150% in the longitudinal direction and 150-225% in the width direction.

Further, the artificial leather for an automobile interior material of the present invention is characterized in that it is used in a covering process of an automobile interior material.

The present invention also relates to a method for fabricating a woven fabric, comprising the steps of forming a backside layer (S1) impregnated with a woven fabric;

A skin layer forming step S1 'for forming a skin layer on the release paper;

Forming a pore layer on the backside layer (S3);

A skin layer-spreading step (S5) of spreading a skin layer on the pore layer; And

A release paper removing step (S7) of removing the release paper; Wherein the elongation percentage is 80 to 150% in the longitudinal direction and 150 to 225% in the transverse direction.

The artificial leather for an automobile interior material of the present invention has an effect of preventing convex and concave transfer of an automobile interior material.

Further, the artificial leather for automobile interior material of the present invention has an effect of preventing wrinkles while being inexpensive.

1 is a side sectional view schematically showing a laminated structure of an artificial leather for an automobile interior material according to the present invention.
2 is a side sectional view schematically showing a laminated structure of another embodiment of an artificial leather for an automobile interior material according to the present invention.
3 is a side cross-sectional view schematically showing a laminated structure of another embodiment of an artificial leather for an automobile interior material according to the present invention.
4 is a flowchart illustrating a method of manufacturing an artificial leather for an automobile interior material according to an embodiment of the present invention.
5 is a plan view showing a specimen for measuring the elongation of artificial leather.
Fig. 6 is a photograph showing the appearance of the automobile interior material covering process after using the artificial leather for automobile interior material of the comparative example.
FIG. 7 is a photograph showing the appearance of the automobile interior material covering process after using the artificial leather for automobile interior material according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

In the drawings, the same reference numerals as in the drawings denote the same elements in the drawings, unless they are indicated on other drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIG. 1, the present invention comprises a backside layer 11, which is a woven fabric impregnated from bottom to top; A pore layer 13; And a skin layer (15), wherein the elongation is 80-150% in the longitudinal direction and 150-225% in the width direction.

In the present invention, the longitudinal direction means the machine direction, i.e., the machine direction (MD), and the transverse direction means the transverse direction (TD) perpendicular to the machine direction.

Specifically, the artificial leather for an automobile interior material of the present invention has an elongation of 80-150%, 85-140%, or 90-120% in the longitudinal direction, and 150-225%, 160-220%, or 160- 200%, which is an artificial leather for use in a covering process of an automobile interior material.

In the present invention, the covering step is, for example, an upper layer to a lower layer; Cushion layer; And a core layer. The term " automobile interior material " refers to a process for manufacturing an automobile interior material by applying an adhesive to the top of the cushion layer and then wrapping the cushion layer and the core layer with artificial leather which is a skin layer.

The cushion layer may be, for example, at least one foam selected from the group consisting of polypropylene foam, polyurethane foam, and ethylene-vinyl acetate foam.

Alternatively, as another example of the cushion layer, a cushion layer made of at least one synthetic fiber selected from the group consisting of nylon fibers, polyester fibers, polyolefin fibers, polyethylene terephthalate fibers, and polypropylene fibers Lt; / RTI >

The core layer may be a hard synthetic resin injection molding. Examples of the core layer include polyamide, polycarbonate, acrylonitrile-butadiene-styrene, styrene-acrylonitrile, polyvinyl chloride, polystyrene, polyphenylene sulfide, polypropylene and polyethylene But not limited to, at least one synthetic resin injection product selected from the group consisting of

If the elongation percentage of the artificial leather for automobile interior material is less than the above range, it is difficult to pull the artificial leather during the covering process on the automobile interior material, thereby lowering the workability and wrinkles. If the elongation exceeds the above range, It is not preferable because wrinkles may be generated and the airbag can not be deployed, so that it is possible to have an elongation in the above range.

Hereinafter, the laminated structure of the artificial leather 1 for an automobile interior material according to the present invention will be described in detail.

The backside layer (11)

The fabric is divided into a non-woven fabric and a woven fabric depending on the presence or absence of a woven process such as spinning, weaving, and knitting.

The non-woven fabric means a foamed structure in which fibers are bonded to each other by a chemical action, a mechanical action, or a suitable moisture and heat treatment, without a weaving process.

The woven fabric refers to a fabric formed through a woven process using the yarn after the fiber aggregate is formed into a yarn.

The woven fabric may be divided into a fabric and a fabric according to a weaving method.

The woven fabric means a fabric in which two yarns are entangled in the transverse direction and the longitudinal direction, and refers to a fabric in which the yarns in the longitudinal direction, that is, the warp yarns and the yarns in the transverse direction, that is, the weft yarns are intertwined with each other. The fabric may be divided into a plain weave, a twill weave, and a satin weave according to a manufacturing method.

In addition, the knitted fabric refers to a fabric in which one or more yarns are looped and looped, and can be divided into a circular knitted fabric and a warp knitted fabric according to a manufacturing method , It has a good elasticity compared to the fabric. The circular knitted fabric means a fabric in which yarns are wound in a warp direction, and a warp knitted fabric means a fabric in which threads are wound in a warp direction.

The present invention has the effect of providing artificial leather having a low elongation at a low cost by using the woven fabric impregnated with the back layer (11).

As the woven fabric, it is preferable to use a knitted fabric having better stretchability than a fabric. Among knitted fabrics, it is more preferable to use a circular knitted fabric excellent in elongation as compared with warp knitted fabrics.

The woven fabric may be formed using a yarn having a thickness of 120-170 denier or 130-160 denier, and has an excellent strength within the above range.

The yarn means a yarn obtained by twisting at least one selected from among natural fibers, regenerated fibers and synthetic fibers.

The natural fibers may be cotton fibers, hemp fibers, parent fibers, wool fibers or wool fibers, and the regenerated fibers may be rayon fibers or cupra fibers, and the synthetic fibers may be polyester fibers, nylon fibers, polyolefin fibers, Polyvinyl alcohol fibers, polyamide fibers, polyurethane fibers or polyvinylidene chloride fibers.

In the present invention, polyester fibers having excellent elongation can be used as a specific example of the yarn for forming the backing layer 11.

 Further, the woven fabric is impregnated with a shape-retaining property capable of withstanding repeated elongation and shrinkage at a low cost, and is given a stretch ratio suitable for the covering method.

The impregnation may be carried out by impregnating the impregnation solution containing conventionally known polymeric compounds of a solvent or a water system, for example, a polyurethane resin or a copolymer thereof, followed by coagulation in an aqueous solution of dimethylformamide and a water washing process in water .

The impregnating solution may be a polyurethane solution containing 200-400 parts by weight or 220-300 parts by weight of a solvent for 100 parts by weight of the polyurethane resin.

The solvent may be at least one member selected from the group consisting of dimethylformamide, methyl ethyl ketone, dimethylacetamide, N-methylpyrrolidone, dimethylsulfoxide, and ethyl acetate.

Further, the impregnating solution may further include other additives such as a flame retardant, a dispersant, and a pigment, and the kind and content thereof are not limited.

The aqueous solution of dimethylformamide may contain, for example, 2-10 wt% or 3-8 wt% of dimethylformamide and 90-98 wt% or 92-97 wt% of water.

The content of the polyurethane resin contained in the backside layer 11 of the present invention, which is a woven fabric impregnated in the polyurethane solution, may be 130-600 g / m ² , 150-500 g / m ² , or 260-400 g / m ² . Within the above range, the artificial leather can maintain the elongation suitable for the sensibility such as soft feeling and filling feeling and the covering method, while preventing the deterioration of the quality of repeatedly stretching and shrinking, so that the polyurethane resin content within the above content range can be obtained.

The impregnated amount of the polyurethane resin contained in the backside layer is such that the backside layer is impregnated with dimethylformamide to dissolve the polyurethane resin in the backside layer, and then the dimethylformamide is evaporated to obtain the weight (g / m ² ) can be measured to obtain the impregnation amount of the polyurethane resin in the backside layer.

The backing layer 11 of the present invention can be selectively woven woven fabric formed on one side or both sides of the backing layer 11. In this case, the backing layer 11 is excellent in adhesiveness and sensitivity.

More specifically, the backside layer 11 may be a fabric impregnated with a woven fabric formed with a brushed surface on at least one surface selected from the following: a surface that is in contact with the pore layer 13 and a back surface that comes into contact with the cushion layer by a covering process have.

The backside layer 11 may have a thickness of 0.4-1.08 mm or 0.5-1.0 mm. Within this range, it is possible to prevent increase in cost and maintain moldability while preventing deterioration of mechanical properties such as tensile strength and the like, so that the thickness can be within the above range.

The pore layer (13)

Since the pore layer 13 of the present invention has uniform pores formed in the layer, it is possible to prevent irregularity transfer of components for automobile interior materials, and to provide a feeling of silky feeling and volume feeling on artificial leather, And may be formed by using a porous layer composition comprising 20 to 50 parts by weight of a solvent and 0.5 to 2 parts by weight of a pore-controlling agent per 100 parts by weight of a polyurethane resin as a specific example.

More specifically, the porous layer composition may be coated on the backside layer, followed by coagulation in an aqueous dimethylformamide solution and washing with water.

The aqueous solution of dimethylformamide may contain, for example, 2-10 wt% or 3-8 wt% of dimethylformamide and 90-98 wt% or 92-97 wt% of water.

Hereinafter, each configuration of the porous layer composition will be described in detail.

The polyurethane resin (A)

The polyurethane resin can be prepared by reacting a polyol with a diisocyanate and a chain extender.

Specifically, the polyol may be at least one selected from the group consisting of a polyether polyol, a polyester polyol and a polycarbonate polyol.

The polyether polyol is a diol or a polyol having 2-15 carbon atoms, specifically, an alkyldiol or a glycol and an alkylene oxide having 2-6 carbon atoms, specifically, ethylene oxide or propylene oxide Lt; / RTI >

The polyester polyol may be formed by esterifying one or more glycols with one or more dicarboxylic acids or anhydrides thereof. As a specific example, the glycol may be at least one selected from ethylene glycol, propylene glycol and glycerin, and the dicarboxylic acid may be at least one selected from adipic acid, phthalic acid and maleic acid.

Alternatively, the polyester polyol may be formed by subjecting a lactone or a derivative thereof to ring-opening polymerization using a small amount of a diol, a triol or an amine as an initiator. As a specific example, it may be polycaprolactone (PCL) synthesized by ring-opening polymerization using ε-caprolactone (CL) with diethylene glycol as an initiator.

The polycarbonate polyol may be derived from the reaction of a glycol and a carbonate.

In the present invention, as a specific example of the polyol, 100-150 parts by weight of a polyether polyol and 110-200 parts by weight of a polycarbonate polyol may be mixed with 100 parts by weight of the polyester polyol, It has excellent hydrolysis resistance and chemical resistance while realizing excellent mechanical properties.

The diisocyanate may be a conventional one as used in the art and includes, but is not limited to, 4,4'-diphenylmethane diisocyanate (MDI), xylene diisocyanate (XDI), 1,5-naphthalene diisocyanate Aromatic diisocyanates having benzene rings; Aliphatic diisocyanates such as hexamethylene diisocyanate (HDI) and propylene diisocyanate; And substituted diisocyanates such as 1,4-cyclohexane diisocyanate, isophorone diisocyanate (IPDI), and 4,4'-dicyclohexylmethane diisocyanate (H12MDI); And the like.

More specifically, one kind selected from the group consisting of 4,4-diphenylmethane diisocyanate (MDI), hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI) and dicyclohexylmethane diisocyanate (H12MDI) Or more.

The chain extender may be a conventional one used in the art and is not particularly limited. Preferably, the chain extender is an even number of

A low molecular weight diol compound having a repeating unit or a diamine compound may be used.

Specifically, the chain extender is selected from the group consisting of ethylene glycol (EG), diethylene glycol (DEG), propylene glycol (PG), 1,4-butanediol (1,4-BD), 1,6- HD), methylpentanediol, and isophoronediamine (IPDA).

The chain extender may, for example, be used in an amount of 1-15 parts by weight or 2-10 parts by weight based on 100 parts by weight of the polyol.

Solvent (B)

The solvent (B) may be at least one member selected from the group consisting of dimethylformamide, dimethylacetamide, N-methylpyrrolidone, dimethylsulfoxide, and ethyl acetate.

The solvent (B) may be used in an amount of 20-50 parts by weight or 30-45 parts by weight based on 100 parts by weight of the polyurethane resin (A). When the amount is less than the above range, the viscosity of the pore layer composition is high, And if it exceeds the above range, the viscosity of the porous layer composition is too low to lower the coating property, so that it can be used within the above range.

The porosity regulator (C)

The pore-controlling agent (C) is used to form uniform pores in the pore layer (13), and one or more surfactants selected from the group consisting of anion-based and nonion-based surfactants can be used.

The surfactant is composed of a hydrophilic head and a hydrophobic tail so that micelles or liquid crystals of various structures can be formed through self-assembly in an aqueous solution.

Examples of the anionic surfactant include fatty acids (salts) such as oleic acid, palmitic acid, sodium oleate, potassium palmitate, and triethanolamine salt of oleic acid; Hydroxy group-containing carboxylic acids (salts) such as hydroxyacetic acid, potassium hydroxyacetate, lactic acid, and potassium lactate; Polyoxyalkylene alkyl ether acetic acid (salt) such as polyoxyethylene tridecyl ether acetic acid (sodium salt); Salts of carboxyl-group-substituted aromatic compounds such as potassium trimellitate and potassium pyromellitate; Alkylbenzene sulfonic acids (salts) such as dodecylbenzene sulfonic acid (sodium salt); Polyoxyalkylene alkyl ether sulfonic acid (salt) such as polyoxyethylene 2-ethylhexyl ether sulfonic acid (potassium salt); Higher fatty acid amide sulfonic acids (salts) such as stearoylmethyltaurine (sodium), lauroylmethyltaurine (sodium), myristoylmethyltaurine N (sodium) and palmitoylmethyltaurine (sodium); N-acyl sarcosinate (salt) such as lauroyl sarcosinate (sodium); Alkylphosphonic acid (salt) such as octylphosphonate (potassium salt); Aromatic phosphonic acid (salt) such as phenylphosphonate (potassium salt); Alkylphosphonic acid alkylphosphoric acid esters (salts) such as 2-ethylhexylphosphonate mono 2-ethylhexyl ester (potassium salt); Nitrogen-containing alkylphosphonic acid (salt) such as aminoethylphosphonic acid (diethanolamine salt); Alkylsulfuric acid esters (salts) such as 2-ethylhexyl sulfate (sodium salt); Polyoxyalkylene sulfuric acid esters (salts) such as polyoxyethylene 2-ethylhexyl ether sulfate (sodium salt); Alkylphosphoric acid esters (salts) such as lauryl phosphate (potassium salt), cetyl phosphate (potassium salt) and stearyl phosphate (diethanolamine salt); Polyoxyalkylene alkyl (alkenyl) ether phosphate esters (salts) such as polyoxyethylene lauryl ether phosphate (potassium salt) and polyoxyethylene oleyl ether phosphate (triethanolamine salt); Polyoxyalkylene alkylphenyl ether phosphate esters (salts) such as polyoxyethylene nonylphenyl ether phosphate (potassium salt) and polyoxyethylene dodecylphenyl ether phosphate (potassium salt); Chain long-chain sulfoaccharides such as sodium di-2-ethylhexylsulfosuccinate and sodium dioctylsulfo succinate, long-chain N-acylglutamates such as disodium N-lauroyl glutamate and disodium N-stearoyl-L- A salt thereof; and a salt thereof.

Examples of the nonionic surfactant include polyoxyalkylene straight chain alkyl ethers such as polyoxyethylene hexyl ether, polyoxyethylene octyl ether, polyoxyethylene decyl ether, polyoxyethylene lauryl ether and polyoxyethylene cetyl ether; Polyoxyalkylene branched primary alkyl ethers such as polyoxyethylene 2-ethylhexyl ether, polyoxyethylene isosertyl ether and polyoxyethylene isostearyl ether; Polyoxyalkyl ethers such as polyoxyethylene 1-hexylhexyl ether, polyoxyethylene 1-octylhexyl ether, polyoxyethylene 1-hexyloctyl ether, polyoxyethylene 1-pentylheptyl ether and polyoxyethylene 1-heptylpentyl ether; Renbranched secondary alkyl ethers; Polyoxyalkylene alkyl ethers such as polyoxyethylene oleyl ether; Polyoxyalkylene alkyl phenyl ethers such as polyoxyethylene octyl phenyl ether, polyoxyethylene nonyl phenyl ether, and polyoxyethylene dodecyl phenyl ether; Polyoxyethylene styrylphenyl ether, polyoxyethylene distyryl phenyl ether, polyoxyethylene styrylphenyl ether, polyoxyethylene tribenzylphenyl, polyoxyethylene dibenzylphenyl ether, and polyoxyethylene benzylphenyl ether. Alkylene alkyl aryl phenyl ether; Polyoxyethylene monolaurate, polyoxyethylene monolaurate, polyoxyethylene monooleate, polyoxyethylene monostearate, polyoxyethylene monomyristillate, polyoxyethylene dilaurate, polyoxyethylene diolate, polyoxyethylene dimyristylate, Polyoxyalkylene fatty acid esters such as polyoxyethylene distearate; Sorbitan esters such as sorbitan monopalmitate and sorbitan monooleate; Polyoxyalkylene sorbitan fatty acid esters such as polyoxyethylene sorbitan monostearate and polyoxyethylene sorbitan monooleate; Glycerin fatty acid esters such as glycerin monostearate, glycerin monolaurate and glycerin monopalmitate; Polyoxyalkylene sorbitol fatty acid esters; Sucrose fatty acid esters; Polyoxyalkylene castor oil ethers such as polyoxyethylene castor oil ether; Polyoxyalkylene cured castor oil ethers such as polyoxyethylene hydrogenated castor oil ether; Polyoxyalkylene alkylamino ethers such as polyoxyethylene lauryl amino ether and polyoxyethylene stearyl amino ether; Oxyethylene-oxypropylene block or random copolymer; Oxyethylene-oxypropylene block or terminal alkyl etherate of a random copolymer; Oxyethylene-oxypropylene block or a terminal sucrose ether of a random copolymer; ≪ / RTI >

In the present invention, a specific example of the pore regulator (C) may be a nonionic surfactant having excellent stability over time, and more specifically, polyether modified polysiloxane may be used.

The pore regulator (C) may be used in an amount of 0.5-2 parts by weight or 0.5-1.5 parts by weight based on 100 parts by weight of the polyurethane resin (A). If the pore diameter is less than the above range, sufficient pores are formed in the pore layer And the feeling of volume is lowered. After completion of the covering process of the automobile interior material, wrinkles are slightly generated in the synthetic leather and the prevention of uneven transfer of the automobile interior material may be insignificant. If the range is exceeded, the pores become uneven, And wrinkles are somewhat generated in the artificial leather, and surface physical properties such as abrasion resistance and stain resistance may be lowered. Therefore, it can be used within the above range.

The porous layer composition may further include other additives such as a flame retardant, a dispersant or a pigment, and the kind and content thereof are not limited.

The pore layer 13 of the present invention may be pore-distributed within the layer (FIG. 1), only at the top (FIG. 2), or only at the bottom (FIG. 3).

More specifically, referring to FIG. 2, the pore layer 13 may be divided into a pore-free layer 13a and a pore-free layer 13b.

3, the pore layer 13 may be divided into a pore-free layer 13a and a pore-free layer 13b.

The pore-free layer 13b means a polyurethane layer in which pores in the pore layer 13 are not distributed.

The pore layer 13 of the present invention has a density of 400-800 g / L or 500-700 g / L. When the pore diameter is less than the above range, the pores become uneven and the elongation is decreased to cause wrinkles to some extent in the artificial leather, The surface properties such as stain resistance may be deteriorated. If it exceeds the above range, wrinkles are somewhat generated in the synthetic leather after completion of the covering process of the automobile interior material, and prevention of uneven transfer of the automobile interior material is insufficient. Lt; / RTI >

The pore layer 13 has a thickness of 0.1-0.6 mm or 0.2-0.5 mm and is designed to prevent irregular transfer of the automobile interior material within the above range and to provide a sensation such as soft touch, There is an effect that a stretch ratio suitable for the covering method can be given.

The skin layer (15)

The skin layer 15 of the present invention realizes a texture similar to that of natural leather. In one embodiment, the skin layer 15 comprises 10-60 parts by weight of a solvent and 10-40 parts by weight of a pigment, based on 100 parts by weight of the polyurethane resin. As shown in FIG.

More specifically, the skin layer composition may be applied onto the release paper and dried to form the skin layer composition.

Wherein the polyurethane resin is selected from the group consisting of polyester polyurethane, polyether polyurethane, polycarbonate polyurethane, polyacetal polyurethane, polyacrylate polyurethane, polyester amide polyurethane, polythioether polyurethane and polyolefin polyurethane May be selected from at least one polyurethane resin.

In the present invention, a polycarbonate polyurethane resin having excellent hydrolysis resistance and heat resistance can be used as a specific example of the polyurethane resin.

The solvent may be at least one member selected from the group consisting of dimethylformamide, methyl ethyl ketone, dimethylacetamide, N-methylpyrrolidone, dimethylsulfoxide, and ethyl acetate.

The solvent may be used in an amount of 10-60 parts by weight or 20-55 parts by weight based on 100 parts by weight of the polyurethane resin.

The pigment may be one commonly used in the art, and its content is not limited. For example, the pigment may be used in an amount of 5-30 parts by weight or 10-25 parts by weight based on 100 parts by weight of the polyurethane resin.

The skin layer composition may further include at least one additive selected from the group consisting of a UV inhibitor, a light stabilizer, an antioxidant, a flame retardant, a slip agent, an antistatic agent, a dispersant, and a surfactant, The type is not limited unless it affects the present invention.

In addition, the skin layer 15 may have a thickness of 0.01-0.3 mm or 0.02-0.1 mm, and the skin layer 15 may have an excellent elongation while realizing a texture similar to that of natural leather within the above range.

The artificial leather 1 for an automobile interior material of the present invention is provided with an adhesive layer (not shown) between the pore layer 13 and the skin layer 15 to improve peel strength between the pore layer 13 and the skin layer 15, As shown in FIG.

The adhesive layer may be formed using at least one adhesive selected from the group consisting of polyurethane, polyamide, ethylene vinyl acetate, ethylene ethyl acetate, styrene-based thermoplastic elastomer, polyester, ethylene-acrylic copolymer and polyolefin adhesive .

In one embodiment of the present invention, a polyurethane adhesive may be used as the adhesive. In this case, for example, the polyurethane adhesive may contain 1-25 parts by weight of dimethylformamide or 5-20 parts by weight 15 to 45 parts by weight or 20 to 40 parts by weight of methyl ethyl ketone, and 5 to 20 parts by weight or 10 to 15 parts by weight of a crosslinking agent.

The thickness of the adhesive layer may be 0.01-0.3 mm or 0.02-0.1 mm, and the peeling strength between the pore layer 13 and the skin layer 15 may be improved within the above range.

The synthetic leather (1) for an automobile interior material of the present invention may further comprise a surface treatment layer (not shown) for selectively adjusting the degree of gloss on the surface of the skin layer (15) and improving the functions of light resistance, hydrolysis resistance, Time).

The surface treatment layer may be formed by applying a surface treatment agent to the surface of the skin layer 15.

The surface treating agent may be formed using an aqueous surface treating agent or an oily surface treating agent. In one specific embodiment of the present invention, the amount of the curing agent is 1-30 parts by weight or 1-25 parts by weight, -30 parts by weight or 1-25 parts by weight, and the silicone compound 1-10 parts by weight or 1-5 parts by weight.

The subject may be, but is not limited to, a water-dispersed polycarbonate-based polyurethane resin.

The curing agent may contain, per molecule, at least one functional group selected from the group consisting of an aziridine group, an isocyanate group, and a carbodiimide group.

The silicone compound may be in the form of a liquid in which the polysiloxane is dispersed in water or may be a polysiloxane in the form of beads, but may be in the form of a liquid, preferably dispersed in water with better surface feel.

The aqueous solvent may be water or an alcohol or a mixture of water and an alcohol.

The silicone compound may be in the form of a liquid in which the polysiloxane is dispersed in water or may be a polysiloxane in the form of beads, but may be in the form of a liquid, preferably dispersed in water with better surface feel.

The surface treatment layer may have a thickness of 1-20 mu m or 5-10 mu m, but is not limited thereto.

The artificial leather for automobile interior material of the present invention may have a thickness of 0.8-1.5 mm or 0.85-1.3 mm, and the covering effect can be easily effected within the above range.

The artificial leather for an automobile interior material of the present invention may have a softness of 3.5-6 or 4-5, and within the above range, there is an effect of excellent sensitivity such as soft touch and filling feeling.

The softness is measured by pressing a 100 mm pi artificial leather specimen with a ST300D instrument using a soft measuring instrument (SDL Atlas, ST300D) at a temperature of 23 ± 2 ° C and a relative humidity of 50 ± 5% The readings were read by reading the moving scale.

In addition, synthetic leather for automobile interior material of the present invention and the amount of generation of volatile organic compounds (VOCs) can be 1-300㎍ / m ³ or 1-150㎍ / m ^3, it is environmentally sound effect within this range.

The amount of the volatile organic compounds (VOCs) generated in the artificial leather specimen (4 cm x 9 cm in width and 4 cm in length) was sealed in a 3 L bag and heated in an oven at 65 ° C for 2 hours. The specimens were taken out from the bag and left in a laboratory at 25 ° C for 30 minutes. Volatile organic compounds (VOCs) emitted from the specimen were collected and their amount was measured by gas chromatography (GC).

The artificial leather for an automobile interior material of the present invention can be applied to at least one automobile interior material selected from the group consisting of a crash pad, a door trim, a console box, an armrest, a headrest, and a headliner.

The artificial leather 1 for an automobile interior material of the present invention as described above has an effect of preventing uneven transfer of an automobile interior material.

Further, the artificial leather (1) for automobile interior material of the present invention has an effect of preventing wrinkles while being inexpensive.

Referring to FIG. 4, the present invention includes a backside layer forming step (S1) for impregnating a woven fabric;

A skin layer forming step S1 'for forming a skin layer on the release paper;

Forming a pore layer on the backside layer (S3);

A skin layer-spreading step (S5) of spreading a skin layer on the pore layer; And

A release paper removing step (S7) of removing the release paper; Wherein the elongation is 80-150% in the longitudinal direction and 150-225% in the width direction.

Hereinafter, each step will be described in detail.

The backside layer forming step (S1)

The backside layer forming step (S1) may be a step of impregnating the woven fabric with the impregnation solution.

Specifically, the woven fabric is impregnated with an impregnation solution (for example, a polyurethane solution), followed by coagulation in an aqueous dimethylformamide solution and a water washing process in water. The polyurethane resin is impregnated with a specific amount in the woven fabric, It has an emotional property such as a soft touch and filling feeling and a shape retaining ability to withstand repeated elongation and shrinking, and has an effect of maintaining a stretch ratio suitable for a covering method.

Since the woven fabric, the impregnating solution and the aqueous solution of dimethylformamide have been described in detail above, repetitive description thereof will be omitted.

Alternatively, optionally, the backside layer forming step (S1) may further comprise a buffing step (S0) of forming a bristle on one side or both sides of the woven fabric before impregnating the woven fabric into the impregnation solution, Adhesion and sensitivity are excellent.

Skin layer formation step S1 '

The skin layer forming step S1 'may be a step of forming a skin layer by applying and drying a skin layer composition on the release paper separately from the backside layer forming step S1.

The release paper may have an emboss pattern.

Since the detailed description of the skin layer composition is the same as described above, the overlapping description will be omitted.

The application may be performed by one method selected from, for example, bar coating, knife coating, roll coating, slit coating, screen printing or spray coating, but is not limited thereto.

The drying may be carried out at 60-125 [deg.] C or at a temperature of 65-120 [deg.] C for 1-10 min or 3-7 min until the polyurethane skin layer composition is completely dried.

The pore layer forming step (S3)

The pore layer forming step (S3) may be a step of forming a pore layer on the back layer.

Specifically, a porous layer composition is coated on the backside layer, and then a wet (cohesive) coating layer having micropores uniformly formed through coagulation and water washing in an aqueous solution of dimethylformamide is formed, Layer can be formed.

In the present invention, the wet coating layer is a layer in which the porous layer composition is coated thinly on top of the back layer, then immersed in an aqueous solution of dimethylformamide to solidify, and then washed with water, ≪ / RTI >

Since the specific description of the porous layer composition is the same as described above, the overlapping description is omitted.

Meanwhile, since the pore layer forming step (S3) is independent of the skin layer forming step (S1 '), the pore layer forming step (S3) can be performed while changing the front side.

Skin layer deposition step (S5)

The step (S5) of aging the skin layer may be aged at a temperature of 60-95 ° C or 70-90 ° C for 40-60 hours or 45-55 hours.

Alternatively, the method may further include an adhesive layer forming step (S4) of forming an adhesive layer by applying an adhesive to the skin layer and drying the skin layer before the skin layer spreading step (S5) so that the skin layer and the pore layer are well joined with each other In this case, the adhesive layer on the skin layer and the pore layer may be bonded.

Since the detailed description of the adhesive is the same as described above, duplicate description is omitted.

The drying of the adhesive can be cured at a temperature of 70-120 [deg.] C or 75-110 [deg.] C for 30 seconds - 5 minutes or 1 minute - 3 minutes.

In the release paper removing step (S7)

The step of removing the release paper (S7) is a step of peeling the release paper located on one side of the skin layer, the lower side being a woven fabric impregnated upward from the lower part through the step. Pore layer; And the skin layer of the present invention is completed.

The method of manufacturing an artificial leather for an automobile interior material of the present invention may further include a step (S9) of selectively forming a surface treatment layer by applying a surface treatment agent on the skin layer after the release paper removing step (S7).

Specifically, the surface treatment layer may be formed by applying and drying a surface treatment agent on the skin layer, which is the uppermost layer from which release paper has been removed.

Since the detailed description of the surface treatment agent is the same as described above, the overlapping description is omitted.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope and spirit of the invention as disclosed in the accompanying claims. Changes and modifications may fall within the scope of the appended claims.

<Examples>

1. Manufacture of artificial leather for automobile interior materials

[Example 1]

(1) the backside layer forming step (S1)

After impregnating the knitted ring formed by weaving the 120-170 denier polyester yarn (絲) to the impregnation solution to this, the water washing step in the coagulation and water from dimethyl formamide an aqueous solution of 5% poly 300g / m ² A back layer having a thickness of 0.7 mm impregnated with a urethane resin was formed.

The impregnating solution is a polyurethane solution containing 250 parts by weight of dimethylformamide, 25 parts by weight of a flame retardant, and 30 parts by weight of a pigment, based on 100 parts by weight of the polyurethane resin.

(2) Pore layer formation step (S3)

Subsequently, 35 parts by weight of dimethylformamide, 1 part by weight of a pore-controlling agent (BYK-L 9525 by Uniamaterials Co., Ltd.), 10 parts by weight of a flame retardant, 10 parts by weight of a dispersant (BYK Korea, DISPERBYK -130), and 10 parts by weight of a pigment was coated on a wet coating layer formed by uniformly forming fine pores through coagulation and washing with water in a 5% aqueous solution of dimethylformamide And dried through a thermal tenter to form a pore layer having a thickness of 0.3 mm on the backside layer.

(3) Skin layer formation step S1 '

A skin layer composition comprising 15 parts by weight of dimethylformamide, 30 parts by weight of methyl ethyl ketone and 15 parts by weight of pigment was applied to 100 parts by weight of the polyurethane resin on the embossed paper and dried at 100 DEG C for 5 minutes Thereby forming a skin layer having a thickness of 0.04 mm.

(4) Adhesive layer formation step (S4)

Subsequently, a polyurethane adhesive containing 5-20 parts by weight of dimethylformamide, 20-40 parts by weight of methyl ethyl ketone and 10-15 parts by weight of a crosslinking agent is applied to 100 parts by weight of the polyurethane resin on the skin layer, For 1 minute to form an adhesive layer having a thickness of 0.04 mm.

(5) Skin layer deposition step (S5) and release paper removing step (S7)

Subsequently, the adhesive layer on the skin layer and the porous layer were bonded to each other, aged at a temperature of 80 ° C for 48 hours, and then the release paper on the skin layer was peeled off.

(6) Surface treatment layer formation step (S9)

Subsequently, on the skin layer on which the release liner had been peeled off, a two-component type aqueous surface treatment agent containing 1 to 25 parts by weight of a curing agent, 1 to 25 parts by weight of an aqueous solvent, and 1 to 5 parts by weight of a silicone compound with respect to 100 parts by weight of a polyurethane resin To form a surface treatment layer having a thickness of 5-10 탆 to prepare artificial leather for automobile interior materials according to the present invention.

[Example 2]

(1), (3) - (6): The procedure of Example 1 was repeated.

(2) Pore layer formation step (S3)

Except that 35 parts by weight of dimethylformamide, 0.5 part by weight of a pore-controlling agent (BYK-L 9525, UniJam Co., Ltd.), 10 parts by weight of a flame retardant, , DISPERBYK-130) and 10 parts by weight of pigment were used to form a pore layer.

[Comparative Example]

(1) the backside layer forming step (S1)

A web is formed using a short fiber marine sheet having a weight ratio of nylon (component) and polyester (sea component) of 60-80: 40-50, and then the web is bonded by a plurality of needle punching The prepared nonwoven fabric was prepared.

Subsequently, the non-woven fabric was subjected to a weight reduction process in a 5% NaOH aqueous solution to dissolve the solution, and then the resultant was polished to form a backside layer of microfine nonwoven fabric.

(2) Porous layer formation step (S3): not performed.

(3) - (4): The procedure of Example 1 was repeated.

(5) Skin layer deposition step (S5) and release paper removing step (S7)

Subsequently, the adhesive layer and the back layer on the skin layer were bonded to each other, aged at a temperature of 80 ° C for 48 hours, and the release paper on the bottom of the skin layer was peeled off.

(6) Surface treatment layer formation step (S9)

Next, an oil-based surface treatment agent containing 95% by weight of urethane acrylate and 5% by weight of methylene dicyclohexyl diisocyanate as a curing agent was applied onto the skin layer on which the release liner had been peeled off to form a surface treatment layer having a thickness of 10 탆, Artificial leather for automobile interior material was manufactured.

[Reference Example 1]

(1) Backside layer forming step (S1): The same process as in the comparative example was carried out.

(2) - (6): The procedure of Example 1 was repeated.

[Reference Example 2]

(1) the backside layer forming step (S1)

A web is formed using a short fiber marine sheet having a weight ratio of nylon (component) and polyester (sea component) of 60-80: 40-50, and then the web is bonded by a plurality of needle punching The prepared nonwoven fabric was impregnated with the impregnation solution, which was then coagulated and washed with water in a 5% aqueous solution of dimethylformamide.

Here, the impregnation solution is a polyurethane solution containing 150 parts by weight of dimethylformamide, and 30 parts by weight of pigment, based on 100 parts by weight of the polyurethane resin.

Subsequently, a weight reduction process was performed in a 5% aqueous solution of NaOH to dissolve the solution, and the resultant solution was polished to form a back side layer of microfine nonwoven fabric impregnated with polyurethane resin at 390 g / m ² .

(2) - (5): The same procedure as in Comparative Example was carried out.

(6): The procedure of Example 1 was repeated.

[Reference Example 3]

(1) Backside layer forming step (S1): The same procedure as in Reference Example 2 was carried out.

(2) - (6): The procedure of Example 1 was repeated.

[Reference Example 4]

(1) the backside layer forming step (S1)

A backing layer having a thickness of 0.7 mm, which is a circular knitted fabric formed by weaving polyester yarns of 120 to 170 denier, was prepared.

(2) - (5): The same procedure as in Comparative Example was carried out.

(6): The procedure of Example 1 was repeated.

[Reference Example 5]

(1) the backside layer forming step (S1)

A backing layer having a thickness of 0.7 mm, which is a circular knitted fabric formed by weaving polyester yarns of 120 to 170 denier, was prepared.

(2) - (6): The procedure of Example 1 was repeated.

[Referential Example 6]

(1) Backside layer forming step (S1): The same procedure as in Example 1 was carried out.

(2) - (5): The same procedure as in Comparative Example was carried out.

(6): The procedure of Example 1 was repeated.

[Reference Example 7]

(1), (3) - (6): The procedure of Example 1 was repeated.

(2) Pore layer formation step (S3)

Except that 35 parts by weight of dimethylformamide, 7 parts by weight of a pore-controlling agent (BYK-L 9525, UNIKAMI Co., Ltd.), 10 parts by weight of a flame retardant, , DISPERBYK-130) and 10 parts by weight of pigment were used to form a pore layer.

 [Reference Example 8]

(1), (3) - (6): The procedure of Example 1 was repeated.

(2) Pore layer formation step (S3)

Except that 35 parts by weight of dimethylformamide, 0.1 part by weight of a pore-controlling agent (BYK-L 9525 by Uni-Jam Co., Ltd.), 10 parts by weight of a flame retardant, , DISPERBYK-130) and 10 parts by weight of pigment were used to form a pore layer.

2. Measurement of physical properties and sensibility of artificial leather for automobile interior materials

The elongation percentage of artificial leather for automobile interior materials of Examples 1-2, Comparative Examples and Reference Example 1-8, the prevention of uneven transfer and the prevention of wrinkles after completion of the covering process of the automobile interior material, the sensitivity (soft touch and filling ), And the amounts of soft and volatile organic compounds (VOCs) were measured. The results are shown in Table 1 below.

The amount of the polyurethane resin impregnated in the backside layer and the density of the pore layer were measured.

(1) Elongation: A tensile tester (Instron) was used, and after drawing 100 mm of a line (ℓ) on the specimen of FIG. 5, the elongation at break at 200 mm / Respectively.

[Formula 1]

L = (L ₁ -L ₀ ) / L ₀ X 100

(Where L is the elongation (%), L _{0 is} the distance between the gauge points before the test, and L ₁ is the distance between the gauge points when the skin or bubbles break after the test)

 (2) Whether to prevent uneven transfer: After the covering process of the automobile interior material was completed with the artificial leather, the presence / absence of uneven transfer was visually confirmed.

When the uneven transfer is totally present, X, when the uneven transfer is partially present, and when there is no uneven transfer.

(3) Whether to prevent wrinkles: After the covering process of the automobile interior material was completed with the artificial leather, wrinkles were visually confirmed.

When the wrinkles were completely exerted, it was indicated as X, when the wrinkles occurred partially, and when the wrinkles did not occur.

(4) Sensibility: After completing the covering process of the automobile interior material with the above artificial leather, the artificial leather experts directly touched the soft touch and the filling sensation.

When the sensibility is excellent, when the sensibility is flat, when the sensibility is not good, and when the sensibility is not good,

(5) Softness: An artificial leather specimen having a pi (pi) of 100 mm was prepared using a softness measuring instrument (SDL Atlas, ST300D) at a temperature of 23 ± 2 ° C and a relative humidity of 50 ± 5% ST300D Measurement was made by reading the numerical value of the scale moved for 15 seconds by pushing with the instrument.

(6) Amount of volatile organic compounds (VOCs) generated: Artificial leather specimens (4 cm x 9 cm in width and 4 cm in height) were sealed in a 3 L bag and heated in a 65 ° C. oven for 2 hours. The specimens were taken out from the bag and left in a laboratory at 25 ° C for 30 minutes. Volatile organic compounds (VOCs) emitted from the specimen were collected and their amount was measured by gas chromatography (GC).

(7) Measurement of impregnation amount of polyurethane resin in backside layer

The backside layer was impregnated with dimethylformamide to dissolve the polyurethane resin in the backside layer, and the dimethylformamide was evaporated to measure the weight (g / m &lt; ² &gt;) of the reduced backside layer. As the impregnation amount.

As can be seen from Table 1, the artificial leather for automobile interior materials of Examples 1 and 2 according to the present invention prevents uneven transfer of automobile interior materials, and has excellent elongation, excellent wrinkle prevention, excellent sensitivity and ductility (See Fig. 7).

On the other hand, the comparative example using the non-impregnated nonwoven fabric as the backing layer and the reference example 1 were very low in elongation, so that wrinkles could not be prevented and the sensibility and ductility were lowered. In particular, the comparative example did not include the pore layer, And the surface treated layer was formed by the oily surface treating agent, and it was confirmed that the amount of volatile organic compounds (VOCs) generated was large, which was not environmentally friendly.

Also, in Reference Example 2 and Reference Example 3 using the impregnated nonwoven fabric as the backing layer, the elongation was so low that wrinkles could not be prevented, and the sensibility and ductility were lowered than in Examples 1 and 2. In particular, It was confirmed that the prevention of uneven transfer is greatly deteriorated.

In addition, Reference Example 4 and Reference Example 5 using the un-impregnated ring knitted fabric as the backing layer had a disadvantage in that the elongation was so large that wrinkles were generated, the appearance was poor, and the airbag was not developed. Particularly, It was confirmed that the prevention of uneven transfer is greatly deteriorated.

Also, the impregnated circular knitted fabric was used as the backing layer, but Reference Example 6, which did not include the pore layer, had a wrinkle somewhat close to the lower limit of elongation suitable for the covering process, It was confirmed that the sensibility and ductility were lowered.

On the other hand, Reference Example 7 in which the density of the pore layer is too small has a drawback that the elongation in the width direction is somewhat small and the surface properties such as abrasion resistance and stain resistance are lowered and wrinkles are slightly generated. 8 showed more wrinkles in the synthetic leather than in Examples 1 and 2, and it was confirmed that prevention of uneven transfer of the automobile interior material was insignificant.

1: Artificial leather for automobile interior materials
11: backside layer 13: pore layer
15: Skin layer

Claims (19)

A bottom layer 11, which is a ring-knife impregnated from the bottom to the top; A pore layer 13; And the skin layer (15) is 80-150% in the longitudinal direction and 150-225% in the width direction. The artificial leather for automobile interior material,
The pore layer has a density of 400-800 g / L,
The artificial leather for an automobile interior material is for use in a covering process of at least one automobile interior material selected from the group consisting of a crash pad, a door trim, a console box, an armrest, a headrest and a headliner. The method according to claim 1,
Wherein said artificial leather for automobile interior material has a elongation of 85-140% in the longitudinal direction and 160-220% in the transverse direction. delete delete The method according to claim 1,
Wherein the content of the polyurethane resin contained in the back layer (11) is 130-600 g / m ² . The method according to claim 1,
The backing layer (11) has a thickness of 0.4-1.08 mm. delete The method according to claim 1,
The pore layer (13) has a density of 500-700 g / L. The method according to claim 1,
Wherein the circular knitted fabric has a brim formed on a surface contacting with the pore layer (13). The method according to claim 1,
Wherein the circular knitted fabric has a brim formed on the back surface contacting with the cushion layer by the covering process. The method according to claim 1,
Wherein the circular knitted fabric has bridges formed on both sides thereof. The method according to claim 1,
The artificial leather for an automobile interior material further comprises an adhesive layer between the pore layer (13) and the skin layer (15), and further comprises a surface treatment layer on the surface of the skin layer (15). The method according to claim 1,
Wherein the artificial leather for automobile interior material has a softness of 3.5-6. delete A backside layer forming step (S1) of impregnating a circular knife;
A skin layer forming step S1 'for forming a skin layer on the release paper;
Forming a pore layer on the backside layer (S3);
A skin layer-spreading step (S5) of spreading a skin layer on the pore layer; And
A release paper removing step (S7) of removing the release paper; Is 80-150% in the longitudinal direction and 150-225% in the width direction. The method of manufacturing an artificial leather for an automobile interior material,
The pore layer has a density of 400-800 g / L,
The artificial leather for an automobile interior material is for use in a covering process of at least one automobile interior material selected from the group consisting of a crash pad, a door trim, a console box, an armrest, a headrest and a headliner. Gt; 16. The method of claim 15,
The skin layer forming step S1 'is a step of forming a skin layer by applying and drying a skin layer composition on the release paper,
Wherein the skin layer composition comprises 10-60 parts by weight of a solvent and 10-40 parts by weight of a pigment with respect to 100 parts by weight of the polyurethane resin. 16. The method of claim 15,
The porous layer forming step (S3) is a step of forming a porous layer by coating a porous layer composition on the back layer, which is the circular knitted fabric,
Wherein the pore layer composition comprises 20 to 50 parts by weight of a solvent and 0.5 to 2 parts by weight of a pore-controlling agent per 100 parts by weight of the polyurethane resin. 16. The method of claim 15,
Further comprising an adhesive layer forming step (S4) of forming an adhesive layer by applying and drying an adhesive on an upper surface of the skin layer before the step (S5) of binding the skin layer. 16. The method of claim 15,
Further comprising a step (S9) of forming a surface treatment layer by applying a surface treatment agent on the skin layer after the release paper removing step (S7).

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