Solvent-free process and product obtained

Abstract

The invention relates to a process for the preparation of a water-based nonwoven microfibre fabric, comprising the steps of: 1) impregnating a fibrous material comprising ultra-fine fibre-generating fibres with an aqueous dispersion containing polyurethane, an inorganic salt containing monovalent or bivalent positive ions and a cross-linking agent (first impregnation), wherein the polyurethane content is between 15% and 40% by mass relative to the mass of the ultra-fine fibres; 2) fixing the polyurethane onto the impregnated fibrous material (first coagulation step); 3) generating ultrafine fibres from the ultra-fine fibre-generating fibres to form a microfibrous material consisting of ultra-fine fibres, by treating the fibrous material with an alkaline, acid or neutral aqueous solution; and 4) impregnating the microfibrous material with an aqueous dispersion containing polyurethane, an inorganic salt containing monovalent or bivalent positive ions and a cross-linking agent, in which the polyurethane is between 15% and 40% by mass relative to the mass of the ultra-fine fibres (second impregnation); 5) fixing the polyurethane onto the impregnated fibrous material (second coagulation step), wherein, the ratio of the polyurethane content of the second impregnation to the polyurethane content of the first impregnation is between 100 and 250%, preferably between 105 and 240%. The invention also relates to new nonwoven suede-like fabric obtained with the solvent-free process of the invention which has a good feel (good hand), high elasticity, excellent resistance to yellowing and high durability. The nonwoven suede-like fabric can be used to make products for the fashion industry (for example for clothing and accessories) and automotive industry (for example products for vehicle interiors, in particular for car seats, panels and ceilings).

Dependencies are inferred from the claim text.