MANUFACTURING DEVICE FOR ARTIFICIAL LEATHER Technical Field The present invention relates to manufacturing device for artificial leather that is widely used in footwear, bags, all kinds of miscellaneous goods, articles for the use of sports and so on, and more particularly, to manufacturing device for artificial leather that impregnates a non-woven fabric with a water dispersed polyurethane resin, dries the non-woven fabric to make the impregnated fabric, coats the impregnated fabric with a water dispersed polyurethane resin having a high viscosity to make a coated fabric, and applies steam to the coated fabric to make the coated fabric solid, whereby the artificial leather can be manufactured at a low expense, without any damage to environment.

Background Art Typically, artificial leather is manufactured in such a manner that a non- woven fabric is impregnated with an oil resin that is made at a ratio of 70 % by weight of DMF and 30 % by weight of high polymers.

However, the DMF exhibits a high poisonous characteristic and gives a bad influence on environment, which has been strictly controlled in practical use.

On the other hand, conventionally developed artificial leather manufacturing apparatuses are highly expensive, occupy a very large area for installment, and need relatively lots of operating persons, thereby making it impossible to reduce the manufacturing cost of the artificial leather.

Disclosure of Invention To solve the above-described problems, it is an object of the present invention to provide manufacturing device for artificial leather that impregnates a non-woven fabric with a water dispersed polyurethane resin, dries the non-woven fabric to make the impregnated fabric, coats the impregnated fabric with a water dispersed polyurethane resin having a high viscosity to make a coated fabric, and applies steam to the coated fabric to make the coated fabric solid, whereby the artificial leather can be manufactured at a low expense, without any damage to environment.

To accomplish this and other objects of the present invention, there is provided manufacturing device for artificial leather that includes: an impregnation tank where a non-woven fabric is impregnated with a water dispersed polyurethane resin at the rate of impregnation of about 50%; a pressing roller connected to the impregnation tank, for pressing the impregnated fabric with the water dispersed polyurethane resin that has been passed through the impregnation tank; a dryer connected to the pressing roller, for drying the impregnated fabric; a water dispersed polyurethane resin supply hopper connected to the dryer, for supplying a water dispersed polyurethane resin to which a thickener is mixed to the impregnated fabric; a knife cutter connected to the water dispersed polyurethane resin hopper, for coating the top surface of the impregnated fabric with the water dispersed polyurethane resin; a steam chamber connected to the knife cutter, for applying steam to the coated fabric with the water dispersed polyurethane resin; a reverse-turning roller for returning the coated fabric through

the steam chamber; a few steam supply pipes disposed on the lower portion of the steam chamber, for applying the steam to the coated fabric; a steam cut-off plate disposed on the upper portion of the steam supply pipes, for preventing the steam emitted from the steam supply pipes from being direct contact with the coated fabric, the steam cut-off plate having a steam raising opening on the sides thereof, respectively, through which the steam is applied to the coated fabric; a condensed water removing belt disposed on the upper portion of the steam chamber, for removing the condensed water on the coated fabric, the condensed water removing belt engaged with a driving and pressing roller disposed on the outside of the steam chamber; a pattern roller through which the coated fabric passed through the steam chamber is selectively passed; and a winding roll for winding the coated fabric.

Brief Description of the Drawings Further objects and advantages of the invention can be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which: FIG. 1 is a schematic block diagram illustrating manufacturing device for artificial leather according to one embodiment of the present invention; FIG. 2 is a schematic block diagram illustrating manufacturing device for artificial leather according to another embodiment of the present invention; FIG. 3 is a sectional view taken along the line A-A in FIG. 1, showing an embodiment of the parts for supplying steam in the steam chamber of the apparatus according to the present invention; and

FIG. 4 is a sectional view taken along the line A-A in FIG. 1, showing another embodiment of the parts for supplying steam in the steam chamber of the apparatus according to the present invention.

Best mode for Carrying Out the Invention Now, an explanation of the preferred embodiments of the present invention will be described with reference to accompanying drawings.

According to one embodiment of the present invention, there is provided an apparatus 1 for manufacturing artificial leather 18 is provided with an impregnation tank 4 in which a non-woven fabric 2 is primarily impregnated with a water dispersed polyurethane resin 3 that is made at a ratio of 70 % by weight of water and a 30 % by weight of a polyurethane resin and with a pressing roller 5 that is adapted to adjust the impregnation rate of the water dispersed polyurethane resin 3 on the non-woven fabric 2.

Desirably, the impregnation rate of the water dispersed polyurethane resin 3 is adjusted to about 50% by weight of the non-woven fabric 1.

And, the apparatus 1 is provided with a dryer 6 that is disposed next to the pressing roller 5 for drying the non-woven fabric 2 impregnated with the water dispersed polyurethane resin 3, i. e. , the impregnated fabric 2a, wherein the dryer 6 has a temperature in a range of 120 °C to 140 °C, thereby producing the impregnated fabric 2a dried.

The apparatus 1 of the present invention is further provided with a water dispersed polyurethane resin supply hopper 7 for applying a water dispersed polyurethane resin 3 having a high viscosity (about 7,000 cP) on the top surface

of the impregnated fabric 2a and with a knife cutter 8 for adjusting the coated resin in the thickness in a range between about 0.5 mm and 1.5 mm, thereby producing the coated fabric 2b.

The water dispersed polyurethane resin that has been secondarily applied is made at a ratio of 70 % by weight of water and 30 % by weight of solid powder, wherein the solid powder is a composition comprising 100 % by weight of polyurethane resin, 10 % by weight of a desired color toner, 5 % by weight of a desired thickener, and 5 % by weight of ammonium acetate as other additives.

And, the apparatus 1 of the present invention is provided with a steam chamber 9 that applies steam to the coated fabric 2b such that the water dispersed polyurethane resin 3 on the coated fabric 2b becomes solidified. In more detail, the steam having a temperature in a range of 75 °C to 100 °C is emitted from the steam chamber 9, which enables the water dispersed polyurethane resin that has been secondarily coated to be hardened and solidified.

If the temperature of the steam chamber 9 is high, 70 % by weight of water that is used for dispersing the urethane is heated such that the surface film on the coated water dispersed polyurethane resin is damaged. Hence, it is desirable that the temperature of the steam chamber 9 is in a range between 90 °C and 95 °C.

The steam supply from the steam chamber 9 is carried out by means of various kinds of parts. As shown in FIG. 3, for example, there are provided a few steam supply pipes 10 that are disposed on the lower portion of the steam chamber 9 and a steam cut-off plate 11 that is made of stainless and disposed on the upper portion of the steam supply pipes 10, i. e. , on the direct bottom portion through which the coated fabric 2b is just passed. The steam cut-off plate 11

with a steam raising opening 11 a on the both sides thereof functions to cut off the direct contact of the steam with the coated fabric 2b and to apply the steam through the steam raising openings 11 a such that the steam comes in indirect contact with the coated water dispersed polyurethane resin coated on the coated fabric 2b, thereby making the water dispersed polyurethane resin 3 solidified on the coated fabric 2b.

On the other hand, the supply of the steam in the steam chamber 9 is made by using a few electric heaters 12 that are disposed into an appropriate amount of water contained in the steam chamber 9 such that the heating of the water by the operation of the electric heaters 12 is allowed to apply the steam to the coated fabric 2b.

The apparatus 1 of the present invention is provided with a condensed water removing belt 13 that is disposed on the upper portion of the stream chamber 9, for removing the condensed water on the coated fabric 2b.

The condensed water removing belt 13 is formed by an endless belt and driven by a driving and pressing roller 14 connected to a driving motor. The condensed water removing belt 13 is made by laminating sponge 16 and a non- woven fabric 17 and serves to absorb the steam splashed to the upper portion of the steam chamber 9 such that it prevents the condensed water formed by the steam from falling on the coated fabric 2b.

The driving and pressing roller 14 serves to press the condensed water absorbed on the condensed water removing belt 13 such that the condensed water becomes dehydrated. The running speed of the condensed water removing belt 13 is controlled appropriately according to the amount of the condensed water generated.

There is further provided an electric heater 24 as shown in FIG. 1 on the top side of the condensed water removing belt 13, if necessary, which enables the condensed water to be removed in more effective manner.

The apparatus 1 of the present invention is provided with a reverse-turning roller 15 that is disposed on the end portion of the rear side of the steam chamber 9, for returning the coated fabric 2b that has passed through the steam chamber 9 through the lower portion of the steam chamber 9, with a result that the water dispersed polyurethane resin whose surface has been once solidified is completely solidified up to the interior thereof.

Of course, the forward and reverse passing of the coated fabric 2b through the steam chamber 9 is carried out in a single system, which is aimed to achieve a maximum working efficiency even in the minimum area of space occupied by the coated fabric 2b in the steam chamber 9.

The coated fabric 2b, which has been reversely passed through the steam chamber 9, is passed through a water tank 16 in which cool water is contained.

In the above clearing process, the coated fabric 2b becomes cool and at the same time, the cells on the surface film thereof become large such that the glaze on the surface of the water dispersed polyurethane resin 3 can be removed.

The apparatus 1 of the present invention is provided with a dehydrating roller 17 that is disposed on the rear side of the water tank 16, for dehydrating the coated fabric 2b and with a winding roller 19 on which the coated fabric 2b completely dehydrated through the dehydrating roller 17 is wound, thereby completing the production of the artificial leather 18 according to the present invention.

The apparatus 1 of the present invention is provided with a pattern roller

20 that is disposed on the front portion of the winding roller 19, for forming a predetermined pattern on the coated fabric 2b, which enables the artificial leather 18 finally made to have the predetermined pattern thereon.

As shown in FIG. 2, on the other hand, the coated fabric 2b that has been passed through the steam chamber 9 is returned without any via of the water tank 16 and is then passed through a steam roller 21 and a silicon roller 22. At this time, a shape sheet 23 on which a predetermined pattern is formed is met with the coated fabric 2b and thus covered thereon. Next, the coated fabric on which the shape sheet 23 is pressed is wound on the winding roller 19 and is then kept at a dryer having a temperature of about 140 °C, such that the predetermined pattern is thermally pressed on the coated fabric 2b.

The present invention will now be described in detail by way of particular examples.

EXAMPLES (Example 1) The non-woven fabric 2 wound on a roll was supplied to an impregnation tank 4 and thus impregnated with a water dispersed polyurethane resin 3 contained in the impregnation tank 4.

The non-woven fabric 2 impregnated with the water dispersed polyurethane resin 3 was passed through a pressing roller 5 in which it was pressed to have a water content ratio of 50 % on the non-woven fabric 2 and was then passed through a dryer 6 having a temperature of about 130 °C.

The non-woven fabric (i. e. , the impregnated fabric 2a) impregnated with the water dispersed polyurethane resin 3 that had been passed through the dryer 6 was smooth on the surface thereof and was integrated with the non-woven fabric

2.

A water dispersed polyurethane resin 3 that was added with a thickener having a high viscosity like honey was supplied on the top surface of the impregnated fabric 2a from a water dispersed polyurethane resin supply hopper 7, and the supplied water dispersed polyurethane resin was coated in a thickness of about 1 mm by means of a knife cutter 8. Thus, the coated fabric 2b with the water dispersed polyurethane resin was sequentially passed through a steam chamber 9.

The internal temperature of the steam chamber 9 was in a range of about 90 °C to 95 °C, and the coated fabric 2b was reversely passed through the lower portion of the steam chamber 9 by using a reverse-turning roller 15 such that the water dispersed polyurethane resin whose surface had been once solidified was completely solidified up to the interior thereof.

Upon passing the coated fabric 2b through the steam chamber 9, the steam, which was generated by means of a few steam supply pipes 10 on the lower portion of the steam chamber 9 or by virtue of the water heated by a few electric heaters 12 in the lower portion of the steam chamber 9, wasn't directly raised by means of a steam cut-off plate 11 and raised through a steam raising opening 1 la on the sides of the steam cut-off plate 11, respectively, such that the water dispersed polyurethane resin 3 on the coated fabric 2b became solidified.

The coated fabric 2b, which was passed through the steam chamber 9 by means of the reverse-turning roller 15, was then passed through a water tank 16 in which cool water was contained such that the heat thereon obtained by the application of the steam became cool and at the same time, the cells on the surface film thereof became large, thereby removing the glaze on the surface of

the water dispersed polyurethane resin 3. Next, the coated fabric 2b was dehydrated by using a dehydrating roller 17 on. the end portion of the water tank 16 and was wound on a winding roller 19, thereby completing the production of the artificial leather 18.

As a result, it was found that the artificial leather 18 had the feelings that general leather having no glaze had and the surface thereof was very smooth. It could be therefore appreciated that the artificial leather in this example had excellent surface smoothness that could be found in the artificial leather manufactured in existing apparatuses.

(Example 2) The impregnation with a water dispersed polyurethane resin 3, drying, knife coating with a water dispersed polyurethane resin 3 mixed with a thickener, and passing through a steam chamber 9 of the non-woven fabric 2 were carried out in the same manner as in Example 1, and after passing through the steam chamber 9, the coated fabric 2b was passed through a steam roller 21 and a silicon roller 22, along with a shape sheet 23 on which a predetermined pattern was formed, thereby forming the coated fabric integrally with the shape sheet 23.

The coated fabric 2b on which the shape sheet 23 was pressed was wound on a winding roller 19 and then kept at a dryer having a temperature of about 140 °C, such that the predetermined pattern was thermally pressed on the coated fabric 2b.

Then, the shape sheet 23 was separated from the artificial leather 18.

As a result, it was found that the surface of the artificial leather 18 was very smooth and the artificial leather had excellent surface smoothness that could be found in the artificial leather manufactured in existing apparatuses. Also, it was found that the predetermined pattern on the shape sheet 23 was directly

formed on the water dispersed polyurethane resin 3 coated on the surface of the artificial leather, thereby obtaining an excellent pattern thereon.

Industrial applicability As set forth in the foregoing, there is provided manufacturing device for artificial leather that is produced by impregnating a non-woven fabric with a water dispersed polyurethane resin that does not give any damage to environment and drying the non-woven fabric, thus to produce an impregnated fabric, coating the impregnated fabric with a water dispersed polyurethane resin in which a thickener is added, thus to produce a coated fabric, making the coated fabric exposed to steam produced from a steam chamber and passing it through a water tank or thermally pressing it with a shape sheet having a predetermined pattern, thus to form the predetermined pattern on the coated fabric.

The apparatus according to the present invention can provide artificial leather that does not give any damage to environment when compared with the existing organic solvent type apparatus for manufacturing artificial leather, and also provide the artificial leather at a low expense by the reduction of the installation cost of the manufacturing apparatus and the reduction of personnel expenses.

While the present invention has been described with reference to a few specific embodiments, the description is illustrative of the invention and is not to be construed as limiting the invention. Various modifications may occur to those skilled in the art without departing from the true spirit and scope of the invention as defined by the appended claims.