Construction of a Novel Substrate of Unfigured Islands-in-Sea Microfiber Synthetic Leather Based on Waste Collagen

This study is to introduce waste collagen into an unfigured islands-in-sea microfiber nonwoven material, replacing the polyurethane impregnation section of the traditional manufacturing process with the collagen impregnation process. The modified collagen was first impregnated in polyamide/low-density polyethylene (PA/LDPE) fiber nonwoven to form a film. Then the low-density polyethylene component was extracted and dissolved in toluene, resulting in a collagen-based microfiber nonwoven substrate. Waste collagen was first modified to introduce C=C into the molecular chain to obtain vinyl collagen (CMA), and then the following film formation conditions for CMA were studied: 73% degree of substitution (DS), 3 h cross-linking time, and 0.005-0.01 wt % initiator concentration. Then, the preparation of CMA-PA/LDPE and toluene extraction processes were investigated. The optimum toluene extraction conditions were obtained as an extraction temperature of 85 °C and an extraction time of 110 min. The properties of the nonwoven materials were compared before (CMA-PA/LDPE) and after (PA-CMA) extraction. It was found that the homogeneity, tensile strength, and static moisture permeability of the PA-CMA materials prepared by CMA with 50 and 73% DS were all superior to those of PA/LDPE. In particular, the static moisture permeability of PA-CMA (691.6 mg/10 cm²·24 h) increased by 36.2% compared to the microfiber synthetic leather substrate currently in the market. Using scanning electron microscopy (SEM), the continuity of a film of PA-CMA with 73% DS was observed to be better and the fibers were differentiated and relatively tighter fiber-to-fiber gap. The studied novel green process can eliminate the large amount of dimethylformamide (DMF) pollution caused by the current solvent-based polyurethane impregnation process.