US20220186427A1

US20220186427A1 - Composite filament textile and composite filament artificial leather manufactured using the same

Info

Publication number: US20220186427A1
Application number: US17/669,912
Authority: US
Inventors: Chung-Chih Feng; Kuo-Kuang Cheng; Chih-Yi Lin; Kao-Lung Yang; Chien-Min Wu
Original assignee: San Fang Chemical Industry Co Ltd
Current assignee: San Fang Chemical Industry Co Ltd
Priority date: 2014-08-22
Filing date: 2022-02-11
Publication date: 2022-06-16

Abstract

A composite filament artificial leather includes a composite filament textile and an elastomer film. The composite filament textile includes a plurality of composite filaments. One of the composite filaments includes at least one core portion, a sheath portion and at least one gap structure. The sheath portion is disposed around the core portion. The gap structure is between the core portion and the sheath portion. The elastomer film is bonded with the composite filament textile.

Description

FIELD

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.

BACKGROUND

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 io 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.

SUMMARY OF THE INVENTION

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.

BRIEF DESCRIPTION OF THE DRAWINGS

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.

FIG. 1 shows a schematic structural view of an environment-friendly composite filament artificial leather according to the present disclosure.

FIG. 2 shows a structural cross-sectional view of a composite filament according to the present disclosure.

FIG. 3 shows a structural cross-sectional view of another composite filament according to the present disclosure.

FIG. 4 shows a flow diagram of a manufacturing method for an environment-friendly composite filament artificial leather according to the present disclosure.

FIGS. 5A to 5C show schematic diagrams of a manufacturing method for an environment-friendly composite filament artificial leather according to the present disclosure.

FIG. 6 shows a schematic diagram of a manufacturing process in which a filament composite spinning machine is used to prepare composite filament according to Embodiment 1.

FIG. 7 shows a schematic diagram of a manufacturing process in which a spunbond spinning machine is used to prepare composite filament according to Embodiment 2.

FIG. 8 shows a schematic diagram of a manufacturing process in which a melt-blown spinning machine is used to prepare composite filament according to Embodiment 3.

FIG. 9 shows a schematic diagram of a manufacturing process in which a handheld melt-blown spinning machine is used to prepare composite filament is according to Embodiment 4.

FIG. 10 illustrates a partial cross-sectional view of a composite filament textile according to some embodiments of the present disclosure.

FIG. 11 illustrates a cross-sectional view of a composite filament according to some embodiments of the present disclosure.

FIG. 12 illustrates a side view of a composite filament according to some embodiments of the present disclosure.

FIG. 13 illustrates a cross-sectional view of a composite filament according to some embodiments of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

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.
FIG. 1 shows a schematic structural view of an environment-friendly composite filament artificial leather according to the present disclosure. FIG. 2 shows a structural cross-sectional view of a composite filament according to the present disclosure.
With reference to FIG. 1 and FIG. 2, the environment-friendly composite filament artificial leather 10 of the present disclosure includes a composite filament textile 12 and an elastomer film 14.
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 FIG. 3, which shows a structural cross-sectional view of another composite filament according to the present disclosure. As shown in FIG. 3, in another embodiment, the composite filament 120 can include a plurality of core portions 122 and a sheath portion 124, the core portions 122 are disposed at intervals, and the sheath portion 124 sheathes the core portions 122.
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/cm³inclusive; and the strength is 0.5 to 8.0 g/den inclusive.
Referring to FIG. 1 again, the elastomer film 14 is bonded with the composite filament textile 12. In some embodiments, the elastomer film 14 and the io composite filament textile 12 are bonded in one manner selected from the following:
bonding by using a water-based adhesive with a solid content of 5-55% inclusive, and bonding by directly performing hot-pressing at a temperature ranging from 90 to 180° C. inclusive.
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/cm³inclusive 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).
FIG. 4 shows a flow diagram of a manufacturing method for an environment-friendly composite filament artificial leather according to the present disclosure. FIGS. 5A to 5C show schematic diagrams of a manufacturing method for an environment-friendly composite filament artificial leather according to the present disclosure. With reference to step S41 in FIG. 4 and FIG. 5A, composite filament 120 is prepared. In this step, 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 accounts 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. 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 FIG. 4 and FIG. 5B, a composite filament textile 12 is made of the composite filament 120 or made by blending the composite filament 120 and polyester filament or polyamide filament. In this step, a method for manufacturing the composite filament textile 12 can be one selected from the following: a melt spinning by extrusion method, a spunbond method, a melt-blown method and a weaving method. In some embodiments, the weaving method includes: water-jet loom, air-jet loom, a circular loom, a braiding machine, a jacquard loom, and a flat knitting machine. Furthermore, the composite filament textile 12 can be in a woven or nonwoven form. Furthermore, the composite filament textile 12 can be interwoven or blended with ordinary fiber or high-tenacity fiber, and the composite filament textile 12 can be used be the upper of the shoe material through a thermoplastic process.
With reference to step S43 in FIG. 4 and FIG. 5C, an elastomer film 14 is bonded with the composite filament textile 12. In this step, 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).
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.

Embodiment 1

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 FIG. 6, which shows a schematic diagram of a manufacturing process in which a filament composite spinning machine is used to prepare composite filament according to Embodiment 1. As shown in FIG. 6, the filament composite spinning machine is used to manufacture composite filament with a core-sheath section, the temperature in a PBT spinning box is 250° C., the temperature in a TPU spinning box is 220° C., the winding speed is 2500 m/min, and the composite filament with the specification of 100 den/24f and the single-fiber strength of 4 g/den can be obtained.
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 is 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.

Embodiment 2

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 FIG. 7, which shows a schematic diagram of a manufacturing process in which a spunbond composite fiber spinning machine is used to prepare composite filament according to Embodiment 2. As shown in FIG. 7, the spunbond composite fiber spinning machine is used to manufacture composite filament with a core-sheath section, the temperature in a PET spinning box is 260° C., the temperature in a TPU spinning box is 220° C., and spinning is performed through a spunbond process, wherein the air pressure is 9 kg/cm², the wind induced yarn drawing speed is 4000 m/min, and the conveying belt speed is 4 m/min, so the composite filament with a diameter of 20 μm and a spunbond nonwoven textile with a thickness of 0.22 mm can be manufactured. Then a hot-pressing machine (at a temperature of 110° C. and a io pressure of 5 kg/cm²) is used to hot-press the spunbond nonwoven textile, and the spunbond nonwoven textile after the hot-pressing is 0.2 mm in thickness, and has well dimensional stability.
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.

Embodiment 3

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 FIG. 8, which shows a schematic diagram of a manufacturing process in which a melt-blown spinning machine is used to prepare composite filament according to Embodiment 3. As shown in FIG. 8, the melt-blown composite fiber spinning machine is used to manufacture composite filament with a core-sheath section, the temperature in a PTT spinning box is 250° C. , the temperature in a TPU spinning box is 200° C., and spinning is performed through a melt-blowing process, wherein the high-pressure air pressure is 3000 psi, the high-pressure air temperature is 180° C., and the conveying belt speed is 2 m/min, so the composite filament with a diameter of 20 μm and a melt-blown nonwoven textile with a thickness of 0.27 mm can be manufactured. Then a hot-pressing machine (at a temperature of 100° C. and a pressure of 5 kg/cm²) is used to hot-press the melt-blown nonwoven textile, and the melt-blown nonwoven textile after the hot-pressing is 0.25 mm in thickness, and has well dimensional stability.
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 is 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.

Embodiment 4

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 FIG. 9, which shows a schematic diagram of a manufacturing process in which a handheld melt-blown spinning machine is used to prepare composite filament according to Embodiment 4. As shown in FIG. 9, the handheld melt-blown composite fiber spinning machine is used to manufacture composite filament with a core-sheath section, the temperature in a PBT spinning box is 250° C. , and the temperature in a TPU spinning box is 200° C., and spinning is performed through a melt-blowing process, and a spray gun is used to spray yarn onto a shoe last, so as to form a shoe surface, wherein the high-pressure air pressure is 2800 psi, and the high-pressure air temperature is 170° C., so the composite filament with a diameter of 20 μm and a thickness of 0.2 mm can be manufactured, and the TPU also can be colorized by adding the Color Masterbatch.

Embodiment 5

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 (FIG. 7) is used to manufacture composite filament with a core-sheath section, the temperature in a PET spinning box is 260° C., the temperature in a TPU spinning box is 220° C. , and spinning is performed through a spunbond process, wherein the air pressure is 9 kg/cm², the wind induced yarn drawing speed is 4000 m/min, and the conveying belt speed is 4 m/min, so the composite filament with a diameter of 20 μm and a spunbond nonwoven textile with a thickness of 0.22 mm can be manufactured. Then a hot-pressing machine (at a temperature of 110° C. and a pressure of 5 kg/cm²) is used to hot-press the spunbond nonwoven textile, and the spunbond nonwoven textile after the hot-pressing is 0.2 mm in thickness, and has well dimensional stability.
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.

Embodiment 6

The composite filament with the specification of 100d/24f 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 75d/24f 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 CO₂foamed TPU film with a thickness of 0.12 mm, a foaming expansion ratio of 1.59 and a density of 0.755 g/cm³and 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/cm²and environment-friendly composite filament artificial leather with various surface textures can be manufactured.

Embodiment 7

The composite filament with the specification of 100d/24f 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 50d/24f 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 CO₂foamed TPU film with a thickness of 0.1 mm, a foaming expansion ratio of 1.57 and a density of 0.763 g/cm³and 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.
FIG. 10 illustrates a partial cross-sectional view of a composite filament textile 12′ according to some embodiments of the present disclosure. FIG. 11 illustrates a cross-sectional view of a composite filament 120 a according to some embodiments of the present disclosure. FIG. 12 illustrates a side view of a composite filament 120 a according to some embodiments of the present disclosure. The composite filament textile 12′ of FIG. 10 is similar to the composite filament textile 12 of FIG. 1, except for structures of the composite filaments 120a. As shown in FIG. 11 and FIG. 12, one of the composite filaments 120 a may include at least one core portion 122, a sheath portion 124 and at least one gap structure 126.
The core portion 122 of FIG. 11 may be the same as the core portion 122 of FIG. 2. The sheath portion 124 of FIG. 11 may be the same as the sheath portion 124 of FIG. 2. That is, the sheath portion 124 is disposed around the core portion 122.
The gap structure 126 is between the core portion 122 and the sheath portion 124. Thus, the sheath portion 124 contacts a portion of the core portion 122. In some embodiments, as shown in FIG. 11, a profile of the gap structure 126 may be substantially conformal with a profile of a portion of an outer surface 122 a of the core portion 122 in the cross-sectional view. In addition, a width W of the gap structure 126 may gradually decrease from a center to sides in the cross-sectional view. Further, the gap structure 126 may be in an arc shape from the cross-sectional view.
In some embodiments, as shown in FIG. 11 and FIG. 12, the composite filament 120 a may include a plurality of gap structures 126, and shapes of the gap structures 126 may be different. In addition, the contact portion (e.g., regions between the sheath portion 124 and the core portion 122 without the gap structure 126) of the sheath portion 124 and the core portion 122 surrounds the gap structures 126. In some embodiments, an area of the contact portion of the sheath portion 124 and the core portion 122 may be greater than an area of the gap structure 126 from the side view to avoid weakening the bonding strength of the sheath portion 124 and the core portion 122. In some embodiments, the composite filament 120 a may be formed by, for example, melt-spinning or controlling the viscosity difference between the sheath portion 124 and the core portion 122.
The elastomer film 14 (shown in FIG. 1) may be bonded with the composite filament textile 12′ to form the composite filament artificial leather 10 of FIG. 1.
In the embodiment illustrated in FIG. 10 through FIG. 12, the gap structure 126 may release the stress caused by the mutual extrusion between the composite filaments 120 a during the textile forming process, thereby preventing the composite filament 120 a from cracking due to stress concentration. Thus, the gap structure 126 may also be referred to as “a stress releasing structure.” In addition, a maximum width of the gap structure 126 may be 0.005 μm to 0.1 μm from the cross-sectional view, and a length L of the gap structure 126 may be 0.1 μm to 6 μm is from the cross-sectional view, to effectively release the stress.
FIG. 13 illustrates a cross-sectional view of a composite filament 120 b according to some embodiments of the present disclosure. The composite filament 120 b of FIG. 13 is similar to the composite filament 120 a of FIG. 11, except that the composite filament 120b includes a plurality of core portions 122.
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.

Claims

What is claimed is:

1. A composite filament artificial leather, comprising:

a composite filament textile including a plurality of composite filaments, wherein one of the composite filaments includes at least one core portion, a sheath portion disposed around the core portion and at least one gap structure between the core portion and the sheath portion; and

an elastomer film bonded with the composite filament textile.

2. The composite filament artificial leather of claim 1, wherein a profile of the gap structure is substantially conformal with a profile of a portion of an outer io surface of the core portion in a cross-sectional view.

3. The composite filament artificial leather of claim 1, wherein the sheath portion contacts a portion of the core portion.

4. The composite filament artificial leather of claim 3, wherein the contact portion of the sheath portion and the core portion surrounds the gap structure.

5. The composite filament artificial leather of claim 4, wherein an area of the contact portion of the sheath portion and the core portion is greater than an area of the gap structure from a side view.

6. The composite filament artificial leather of claim 1, wherein a width of the gap structure gradually decreases from a center to sides in a cross-sectional view.

7. The composite filament artificial leather of claim 1, wherein a maximum width of the gap structure is 0.005 μm to 0.1 μm from a cross-sectional view.

8. The composite filament artificial leather of claim 1, wherein a length of the gap structure is 0.1 μm to 6 μm from a cross-sectional view.

9. The composite filament artificial leather of claim 1, wherein the one of the composite filaments includes a plurality of gap structures, and shapes of the gap structures are different.

10. The composite filament artificial leather of claim 1, wherein the gap structure is in an arc shape from a cross-sectional view.

11. A composite filament textile, which includes a plurality of composite filaments, wherein one of the composite filaments includes at least one core portion, a sheath portion disposed around the core portion and at least one gap structure between the core portion and the sheath portion.

12. The composite filament textile of claim 11, wherein a profile of the gap structure is substantially conformal with a profile of a portion of an outer surface of the core portion in a cross-sectional view.

13. The composite filament textile of claim 11, wherein the sheath portion contacts a portion of the core portion.

14. The composite filament textile of claim 13, wherein the contact portion of the sheath portion and the core portion surrounds the gap structure.

15. The composite filament textile of claim 14, wherein an area of the contact portion of the sheath portion and the core portion is greater than an area of the gap structure from a side view.

16. The composite filament textile of claim 11, wherein a width of the gap structure gradually decreases from a center to sides in a cross-sectional view.

17. The composite filament textile of claim 11, wherein a maximum width of the gap structure is 0.005 μm to 0.1 μm from a cross-sectional view.

18. The composite filament textile of claim 11, wherein a length of the gap structure is 0.1 μm to 6 μm from a cross-sectional view.

19. The composite filament textile of claim 11, wherein the one of the composite filaments includes a plurality of gap structures, and shapes of the gap structures are different.

20. The composite filament textile of claim 11, wherein the gap structure is in an arc shape from a cross-sectional view.