Artificial leather for automotive interior materials and method of manufacturing the same

Abstract

The present invention relates to an artificial leather for automotive interior materials and a method of manufacturing the same. More specifically, the artificial leather of the present invention has a seam line formed thereon, and is used in a covering process of automotive interior materials. According to the present invention, the artificial leather of the present invention is wrinkle-free, allows easy deployment of an airbag, and has excellent durability.

1 . An artificial leather for automotive interior materials, comprising a back layer ( 10 ), a pore layer ( 20 ), an adhesive layer ( 30 ), and a skin layer ( 40 ) laminated in order from bottom to top,
 wherein a thickness ratio of the back layer ( 10 ) to the pore layer ( 20 ) is 1.5 to 3:1,   the pore layer ( 20 ) is composed of a non-porous portion ( 21 ) positioned at a lower portion thereof and a porous portion ( 22 ) positioned at an upper portion thereof, and   an area of 70% or more of the pore layer ( 20 ) has a thickness ratio of the non-porous portion ( 21 ) to the porous portion ( 22 ) of 0.5 to 1.5:1 when a vertical line is drawn from an arbitrary point of an upper end of the pore layer ( 20 ) through the lowest point of a pore located at the lowermost position among pores present in the porous portion ( 22 ).   
     
     
         2 . The artificial leather according to  claim 1 , wherein a thickness ratio of the back layer ( 10 ) to the pore layer ( 20 ) is 1.6 to 2.9:1. 
     
     
         3 . The artificial leather according to  claim 1 , wherein a thickness ratio of the non-porous portion ( 21 ) to the porous portion ( 22 ) is 0.6 to 1.4:1. 
     
     
         4 . The artificial leather according to  claim 1 , wherein the artificial leather has an elongation of 80 to 180% in a length direction and an elongation of 110 to 290% in a width direction. 
     
     
         5 . The artificial leather according to  claim 1 , wherein the artificial leather has an elongation of 90 to 170% in a length direction and an elongation of 120 to 280% in a width direction. 
     
     
         6 . The artificial leather according to  claim 1 , wherein the artificial leather has a tensile strength of 30 to 80 kgf/30 mm in a length direction and a tensile strength of 20 to 70 kgf/30 mm in a width direction. 
     
     
         7 . The artificial leather according to  claim 1 , wherein the artificial leather has a tensile strength of 35 to 70 kgf/30 mm in a length direction and a tensile strength of 25 to 60 kgf/30 mm in a width direction. 
     
     
         8 . The artificial leather according to  claim 1 , wherein the artificial leather has a softness of 3.6 to 4.5. 
     
     
         9 . The artificial leather according to  claim 1 , wherein the artificial leather has a seam line on the back layer corresponding to a back thereof, and is used in a covering process of one or more automotive interior materials selected from the group consisting of a crash pad, a door trim, a console box, an armrest, a headrest, and a headliner. 
     
     
         10 . The artificial leather according to  claim 1 , wherein the back layer ( 10 ) is a circular knitted fabric impregnated with polyurethane. 
     
     
         11 . The artificial leather according to  claim 1 , wherein the artificial leather further comprises a surface treatment layer on a surface of the skin layer ( 40 ). 
     
     
         12 . A method of manufacturing an artificial leather for automotive interior materials, the method comprising:
 back layer formation step S 1  of forming a back layer by impregnating a knitted fabric;   skin layer formation step S 1 ′ of forming a skin layer on an upper portion of a release paper;   pore layer formation step S 3  of forming a pore layer on an upper portion of the back layer;   adhesive layer formation step S 4  of forming an adhesive layer on an upper portion of the skin layer;   skin layer bonding step S 5  of bonding the skin layer on which the adhesive layer has been formed to an upper portion of the pore layer; and   release paper removal step S 7  of removing the release paper,   wherein a thickness ratio of the back layer to the pore layer is 1.5 to 3:1,   the pore layer is composed of a non-porous portion positioned at a lower portion thereof and a porous portion positioned at an upper portion thereof, and   an area of 70% or more of the pore layer has a thickness ratio of the non-porous portion to the porous portion of 0.5 to 1.5:1 when a vertical line is drawn from an arbitrary point of an upper end of the pore layer through the lowest point of a pore located at the lowermost position among pores present in the porous portion.   
     
     
         13 . The method according to  claim 12 , wherein, in back layer formation step S 1 , the knitted fabric is a circular knitted fabric. 
     
     
         14 . The method according to  claim 12 , wherein skin layer formation step S 1 ′ is a step of applying a skin layer composition onto an upper portion of a release paper and drying the release paper to form a skin layer,
 wherein the skin layer composition comprises 10 to 60 parts by weight of a solvent and 10 to 40 parts by weight of a pigment based on 100 parts by weight of a polyurethane resin. 
 
     
     
         15 . The method according to  claim 12 , wherein pore layer formation step S 3  is a step of applying a pore layer composition on an upper portion of a back layer, which is the impregnated knitted fabric, and then performing coagulation in an aqueous dimethylformamide solution and rinsing to form a pore layer,
 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 control agent based on 100 parts by weight of a polyurethane resin.