Non-woven artificial leather using dope-dyed polyester sea-island type composite yarn and method for manufacturing same

Abstract

Method for manufacturing artificial leather having excellent fastness and dyeing properties by using a dope-dyed polyester sea-island type composite yarn and artificial leather produced by the method are disclosed. A non-woven fabric is made of a dope-dyed polyester sea-island type composite yarn, to which an organic pigment and/or inorganic pigment is added. The yarn is impregnated with a polyurethane resin containing an organic and/or inorganic pigment, followed by weight reduction processing and dying with a disperse dye. The fabric/artificial leather expresses an uniform and deep color.

1 . A method for manufacturing nonwoven artificial leather using a dope-dyed polyester sea-island type composite yarn, the method including the steps of:
 preparing a sea-island type composite yarn composed of an alkali-soluble resin as a sea component and an alkali-insoluble polyester resin containing a pigment as a island component;   making the sea-island type composite yarn into staple fibers to prepare a nonwoven fabric;   impregnating the nonwoven fabric with a polyurethane resin to which a pigment is added;   removing the sea component by alkaline weight reduction processing of the nonwoven fabric impregnated with the polyurethane resin, thereby preparing an ultrafine nonwoven fabric of the island component;   buffing the surface of the ultrafine fiber nonwoven fabric to form napping; and   dyeing the napped nonwoven fabric with a disperse dye.   
     
     
         2 . The method for manufacturing nonwoven artificial leather using a dope-dyed polyester sea-island type composite yarn according to  claim 1 ,
 wherein the dyeing step is performed for 30 to 60 minutes at a temperature of the dyeing liquid ranging from 115 to 130° C.   
     
     
         3 . The method for manufacturing a nonwoven artificial leather using a dope-dyed polyester sea-island type composite yarn according to  claim 1 ,
 wherein after the dyeing step, further including a reduction cleaning step of the dyed nonwoven fabric with a reduction cleaning liquid at 40 to 100° C. for 10 to 30 minutes.   
     
     
         4 . An nonwoven artificial leather using a dope-dyed polyester sea-island type composite yarn, which is composed of a dope-dyed polyester ultrafine yarn produced by weight reduction processing of the sea-island type composite yarn, and in which a disperse dye is dyed in a nonwoven fabric impregnated with a pigment-containing polyurethane resin. 
     
     
         5 . The nonwoven artificial leather using a dope-dyed polyester sea-island type composite yarn according to  claim 4 ,
 wherein a content of a pigment in the dope-dyed polyester ultrafine yarn is 0.1 to 5.0% by weight.   
     
     
         6 . The nonwoven artificial leather using a dope-dyed polyester sea-island type composite yarn according to  claim 4 ,
 wherein a content of a pigment in the polyester resin is 0.1 to 6.0% by weight.   
     
     
         7 . The nonwoven artificial leather using a dope-dyed polyester sea-island type composite yarn according to  claim 4 ,
 wherein the pigment-containing polyurethane resin is contained in an amount of 15 to 40% by weight in the artificial leather.   
     
     
         8 . The nonwoven artificial leather using a dope-dyed polyester sea-island type composite yarn according to  claim 4 ,
 wherein the ultrafine yarn of the ultrafine fiber nonwoven fabric has single yarn fineness of 0.04 to 0.30 denier.