CA1044083A - Imitation sheet material with surface grain appearance and method of preparing the material - Google Patents
Imitation sheet material with surface grain appearance and method of preparing the materialInfo
- Publication number
- CA1044083A CA1044083A CA224,589A CA224589A CA1044083A CA 1044083 A CA1044083 A CA 1044083A CA 224589 A CA224589 A CA 224589A CA 1044083 A CA1044083 A CA 1044083A
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Abstract
ABSTRACT
An embossed plastic sheet material having a surface design effect thereon and the process of preparing such material which comprises: applying to compressed areas of an embossed re-lease sheet having a design effect thereon a first polymer charac-terized by a high modulus of elongation: applying a continuous layer of a second polymer characterized by a low modulus of elon-gation over the first polymer in the depressed areas: removing the release sheet to provide a polymeric sheet material composed of a continuous layer of a low modulus polymer, with raised areas com-posed of a high modulus polymer secured thereto, the raised areas of the high modulus polymer forming a substantial part of the sheet surface: and flexing the low modulus polymer in the intervening low areas between the raised high polymer areas to the polymeric sheet to form a weak-hinge effect, thereby providing an imitation leather-type material with an accentuated design effect thereon.
An embossed plastic sheet material having a surface design effect thereon and the process of preparing such material which comprises: applying to compressed areas of an embossed re-lease sheet having a design effect thereon a first polymer charac-terized by a high modulus of elongation: applying a continuous layer of a second polymer characterized by a low modulus of elon-gation over the first polymer in the depressed areas: removing the release sheet to provide a polymeric sheet material composed of a continuous layer of a low modulus polymer, with raised areas com-posed of a high modulus polymer secured thereto, the raised areas of the high modulus polymer forming a substantial part of the sheet surface: and flexing the low modulus polymer in the intervening low areas between the raised high polymer areas to the polymeric sheet to form a weak-hinge effect, thereby providing an imitation leather-type material with an accentuated design effect thereon.
Description
BACKGROU~D OF THE I NVENTION
Sheet materials made with polymers and having an embos-sed grain-liké or other surface design have been prepared in the i~
past by a number of methods. Polymeric imitation leather sheet -materials have been prepared, for example, by casting directly onto a pre-embossed release paper a polymeric material and then stripping the paper from the polymer surface. Surface designs ~ -produced by this method generally exhibit extremely shallow and nondistinctive grain designs. Another technique has been to em-ploy a more deeply pre-embossed release sheet to obtain a more ~ ~
distinctive grain effect; however, air is often entrapped in the ~ -valley areas and the valley areas become distorted in appearance.
A further method has been to emboss a grain-like surface design under heat and pressure onto a polymeric sheet material. This method usually compresses the polymeric layer into the nap or open spaces of the supporting fabric sheet, resulting in a product `
which often exhibits unsatisfactory hard, drape and break proper-ties. Accordingly, there exists a need for a sheet material with ' -an enhanced grain appearance which exhibits satisfactory leather- ;~ --like properties, and to a method for preparing such material.
SUMMARY OF THE INVENTION .`., .
Our invention concerns a new and unique sheet material ~, characterized by a raised design on the surface thereon and the ~-method of preparing such material. In particular, our invention relates to an imitation leather-type sheet material in which the grain of the material has been accentuated and to the method of preparing such material, which includes a combination of polymers having a different modulus of elongation so as to form a material ".. . ..
,
Sheet materials made with polymers and having an embos-sed grain-liké or other surface design have been prepared in the i~
past by a number of methods. Polymeric imitation leather sheet -materials have been prepared, for example, by casting directly onto a pre-embossed release paper a polymeric material and then stripping the paper from the polymer surface. Surface designs ~ -produced by this method generally exhibit extremely shallow and nondistinctive grain designs. Another technique has been to em-ploy a more deeply pre-embossed release sheet to obtain a more ~ ~
distinctive grain effect; however, air is often entrapped in the ~ -valley areas and the valley areas become distorted in appearance.
A further method has been to emboss a grain-like surface design under heat and pressure onto a polymeric sheet material. This method usually compresses the polymeric layer into the nap or open spaces of the supporting fabric sheet, resulting in a product `
which often exhibits unsatisfactory hard, drape and break proper-ties. Accordingly, there exists a need for a sheet material with ' -an enhanced grain appearance which exhibits satisfactory leather- ;~ --like properties, and to a method for preparing such material.
SUMMARY OF THE INVENTION .`., .
Our invention concerns a new and unique sheet material ~, characterized by a raised design on the surface thereon and the ~-method of preparing such material. In particular, our invention relates to an imitation leather-type sheet material in which the grain of the material has been accentuated and to the method of preparing such material, which includes a combination of polymers having a different modulus of elongation so as to form a material ".. . ..
,
-2- ~ ~
. . , ~'P$ii~
having a weak hinge therein.
We have discovered that a sheet material, such as an imitation leather-type material, or other material, which has a raised surface design effect thereon may be prepared, which mater-ial is characteri2ed by an accentuated surface design. ~n our material, the intervening low areas form a "weak hinge" relative to the raised areas of the design, thereby accentuating the sur- ;
face design, and providing a material with a leather-like surface appearance and properties without many of the disadvantages of 10 the prior techniques.
In our discovery, a combination of steps and polymeric -materials is used, each of which materials is characterized by a ~ -difference in the modulus of elongation. We have found that a difference between such polymers of at least about 800 psi~ and often more, for example, 500 to 2500 psi., is required. The modu-lus of elongation as referred to herein is the force in pounds per square inch (psi.) required to provide a 100% elongation of the polymer at 25C, as more fully set forth in specification ASTM D-412-D.
A wide variety of natural and synthetic polymers, such as those presently used in preparing sheet materials, may be em-ployed as the polymeric material in preparing our sheet material, subject only to the essential requirements of the differences in the modulus of elongation as set forth herein. The preferred and typical polymers employed in the practice of our invention include, -~
but are not limited to, liquid compositions containing vinyl-halide resins, such as polyvinyl chloride and copolymers of vinyl chloride, such as vinyl chloride/vinyl acetate resins and similar type resins, and flexible urethane coating-type resins. These polymers and resins, as well as others used to prepare supported flexible polymeric coated sheet materials, may be used alone or in combination, either as the high or low modulus polymers.
The modulus of elongation of the polymers and polymeric liquid compositions employed, whether as organosols, plastisols, solutions, hot melts, emulsions or the like, may be altered by the selection of the particular polymers, as well as by the use of various additives, plasticizers, solvents, diluents, fillers, mo-difiers, oils, monomers, polymers and other materials.
In our process, a first polymer characterized by a high modulus of elongation of not less than 800 psi., and often greater than 2000 psi., from the polymer of low modulus of elongation, and typically having a 100% elongation of from about 2000 to 8000~
e.g., of 4000 to 6000 psi., is applied into the depressed areas -` -of a release sheet, such as a preembossed paper release sheet, having a design effect therein which is desired in the ultimate `-sheet. This first polymer thus forms a discontinuous layer with-in the depressed areas of the release sheet, and is typically quite thin from about 0.01 to 0.50 mils, for example, 0.05 to , 0.1 mils. This discontinuous layer of a first polymer may be applied by the technique known as "spanishing".
A continuous layer of a second polymer characterized by a low modulus of elongation, such as, for example, from about 300 ~-to 3000 psi., e.g., S00 to 1000 psi., is then applied, for example, by casting, coating, laminating, etc., over the first polymer, `
The first polymer is formed of a solid polymer, but the second L
polymer in the continuous layer may be a flexible cellular, cellu-lar-forming on expansion, or noncellular; that is, a solid flexi-ble, layer. The first and second polymers may be hardened, cured, :
,;, '' ~ ;,' ' . ' : \ :
fused, gelled or otherwise formed separately or together, such as by the application of heat, the evaporation of solvents, curing or other techniques. Of course, if desired, a series of first polymers the same or different in composition, elongation and type and color may be used one over the other, or in different areas of the embossed release sheet to provide multiple and different coating layers and design effects. The first polymer should be ~-secured and bonded to the second polymer.
The release sheet is then stripped from the surface of the first and second polymers to provide a polymeric sheet com-posed of a continuous layer of the low modulus second polymer, and -with slightly raised areas composed of the high modulus polymer bonded or secured thereto. The raised areas usually form a major part of the sheet surface area' for example, over 50%, such as from about 80 to 95% of the sheet surface area, as would be repre-sented by the raised portions for grain of natural leather. If desired and as will be illustrated, the second polymer layer may be a foam layer. Optionally, the second polymer layer may be placed on a flexible substrate, such as a supporting sheet mater-ial like a fibrous sheet such as a woven or nonwoven sheet or mesh-like grid or screen material. The substrate sheet may be secured to the second polymer, such as by laminating to the surface of the second polymer layer to provide for a supported sheet material.
In the sheet p~oduct, the intervening low areas between ;
the raised areas of the first polymer are composed of the second polymer having the low modulus. The slightly raised surface of the high modulus polymer is then accentuated by multiple flexing of the sheet material in the low intervening areas, so as to form a "weak hinge" effect which accentuates the raised areas. The , .. . . .
: . . , , :' I '. ,, :
flexing of the hinge area to form a weak hinge also makes the poly-meric sheet loose and crinkled, such as a leather-type material or more natural-looking material, and may be effected by various actions, either alone or in combination.
Flexing may be carried out by subjecting the polymeric sheet, for example, either before, but preferably after, the re-moval of the release paper, to a mechanical flexing action or by a series of shrinkage and expansion steps. For example, with a natural woven fabric supported material, like a jute or cotton woven fabric, a shrinking action may be effected by using water sprays and/or wet steam combined with heat to cause a shrinking and expansion of the substrate material, thereby flexing and weakening the hinge in the hinge area during such actions. Where `
the supporting sheet is composed of a heat-shrinkable polymeric material, heat alone may be employed to flex the sheet. In ano-ther technique, a mechanical action may be used to flex the low modulus polymer in the hingeareas, such as by tumbling folds of the polymeric sheet material, for example, in an oscillating-type tumbler varying from about 90 to 220. Tumbling of the sheet material occurs with the material in overlapping folds inside a cylindrical-type tumbler while subject to heat and moisture, with often the only pressure applied being that of the material falling on itself. If desired, such mechanical action may include the use ;
of additional dunnage or ballast material, such as bundles, bales or balls within the tumbler. Other mechanical techniques would include passing the material in reverse directions over a series of bars or small diameter rolls, etc. Other types of actions effect a weak hinge and fracture in the low areas and may be used, such as chemical techniques like the use of solvents to soften pre~
ferentially the weak hinge area or varying formulations, :. . .
After formation of the weak hinge, the differences in the surface design effects may be further enhanced by applying a clear or pigmented printing ink or other top coating on the raised areas. The purpose of the flexing action is to subject the low modulus polymer to a flex:ing or fractioning action in the low areas. As described, a number of polymers may be used in the practice of our invention, but typically the continuous layer of the low modulus polymer is a flexible polymer, while ~ , the raised areas of the high modulus polymer are composed of harder-type resins, alone or in combination, such as semirigid PVC, vinyl chloride resins, hard PVC resins, acrylic resins, cellulosic such as cellulose acetate butyrate, nitrocellulose and other polymers.
The high and low modulus polymers should be selected so that they are compatible and bonded to each other, or when they are uncompatible, an adhesive tie coat may be employed. In one preferred embodiment, the hard and soft polymers are ali-phatic, flexible, coating-type urethane resins. The urethane resins are typically applied in liquid-solvent compositions~ In another embodiment, the resins may be vinyl chloride resins of different molecular weight or homo or copolymer compositions to obtain the difference in modulus of elongation. The vinyl ~
chloride resins are usually employed as liquid plastisol or `
organosol compositions, and are cast and heated to gel and then fuse the resins. Where desired, the vinyl chloride resins used for the continuous layer of low modulus resin may contain a blowing agent to obtain on heating a cellular foam layer.
According to a broad aspect of the present invention, there is provided a process of preparing a polymeric sheet material with a three-dimensional surface design thereon. The process comprises applying to depressed areas of an embossed release sheet having a design effect thereon, a first polymer ~ - 7 -A
.
:characterized by a high modulus of elongation in psi at 100%
elongation. A continuous layer of a second polymer is applied `
over the first polymer in the depressed areas. The second ;;
polymer is characterized by a low modulus of elongation in psi at 100% elongation. The difference in the modulus of elongation between the first and second polymers is no less than 800 psi. me release sheet is removed to provide a polymeric sheet material composed of a continuous layer of a ,: .
low modulus polymer, with raised areas composed of a high `
modulus polymer secured thereto. The low modulus polymer is flexted in the intervening low areas between the raised high polymer areas to the polymeric sheet to form a weak-hinge effect, thereby providing a sheet material with an accentuated design effect thereon.
According to a further broad aspect of the present `
invention, there is provided an imitation leather-type material which comprises in combination a continuous layer of a second polymer, and a discontinuous raised cast area of a first polymer ~
secured to one surface of the layer of the second polymer to ~ ;
provide a surface design effect thereon. me raised area represents a major portion of the surface area of the layer of the second polymer, and substantially less in thickness than the thickness of the layer of the second polymer. The first polymer is characterized by higher modulus of elongation of t, j ,.
greater than 800 psi than the lower modulus of elongation of the second polymer. The raised area forms valley areas of the second polymer between the raised areas. The second polymer in the valley areas is characterized by flexible weak-hinge properties relative to the surrounding raised areas, such pro- ^
perties derived from prior multiple flexing of the valley areas thereby providing a leather-like material.
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Our invention, for the purposes of illustration only, will be described in connection with the preparation of an imita-tion plastic-supported leather sheet material having a grain style ~ ' surface design effect thereon, and employing a combination of .
- 7b - :-~ .
; . :
',' urethane resins.
BRIEF DESCRIPTION OF THE DRAWINGS .
Figs. 1-3 are fragmentary enlarged cross-sectional views of sheet materials during various stages of the process of pre-paration~
Fig. 4 lS a fragmentary cross-sectional partially iso- ~
meric view of a sheet material of our invention as prepared by ~-the process set forth in Figs. 6 and 7. ~
Fig. 5 is a fragmentary cross-sectional partially iso- -meric view of a modification of the sheet material of our invention.
Figs. 6 and 7 represent a schematic diagrammatic illus- '~
tration of a process for preparing the imitation-like leather material of Fig. 4. ;i^`
DESCRIPTIO~ OF THE EMBODIMENTS ..
With reference to Fig. 6, there is shown an embossed paper release sheet 12 and the coating into the depressed areas of the embossed sheet of a first polymer composed of a urethane resin 14 having a high modulus of elongation through the use of a knife ~ -coater 40, with a thickness of the first polymer of about 0.2 to 0.5 mils (dry). The hardening of the solvent urethane resin composition ~n "
in a two-zone hot air oven 42 at temperatures of about 80 to 350F
provides a product as illustrated in Fig. 1. The shee-t is then -passed through a pair of cooling rolls 44, and subsequently a se~
cond polymer composed of a urethane resin coating solution 16 is applied over theareas 14 in a continuous layer through the use of a knife coater 46. The sheet is then directed to a two-zone oven 48 at temperatures generally as before, and then passed through ,;, ',?;' `,'' ' ' ~Jt,~ 3 a pair of cooling rolls 50 to obtain the product as illustrated in Fig. 2, with the second polymer layer of about 1 to 3 mils (dry) in thickness.
A thin layer (e.g., 5 to 12 mils wet) of an adhesive 18 is knife-coated with knife coater 52 onto the surface of the ~;
second polymer layer 16, and a woven fabric sheet 20, such as a woven cotton sheet, is then pressed through opposing rolls 54 into contact with the surface of the wet coated layer of adhesive, and the sheet passed through oven 56 at a temperature of from about 100 to 350 to laminate the woven sheet 20 to the surface of the polymer layer 16. The laminate product emerging from the oven 50 moves through cooling and takeup rolls 58 and is illustrated in Fig.
. . , ~'P$ii~
having a weak hinge therein.
We have discovered that a sheet material, such as an imitation leather-type material, or other material, which has a raised surface design effect thereon may be prepared, which mater-ial is characteri2ed by an accentuated surface design. ~n our material, the intervening low areas form a "weak hinge" relative to the raised areas of the design, thereby accentuating the sur- ;
face design, and providing a material with a leather-like surface appearance and properties without many of the disadvantages of 10 the prior techniques.
In our discovery, a combination of steps and polymeric -materials is used, each of which materials is characterized by a ~ -difference in the modulus of elongation. We have found that a difference between such polymers of at least about 800 psi~ and often more, for example, 500 to 2500 psi., is required. The modu-lus of elongation as referred to herein is the force in pounds per square inch (psi.) required to provide a 100% elongation of the polymer at 25C, as more fully set forth in specification ASTM D-412-D.
A wide variety of natural and synthetic polymers, such as those presently used in preparing sheet materials, may be em-ployed as the polymeric material in preparing our sheet material, subject only to the essential requirements of the differences in the modulus of elongation as set forth herein. The preferred and typical polymers employed in the practice of our invention include, -~
but are not limited to, liquid compositions containing vinyl-halide resins, such as polyvinyl chloride and copolymers of vinyl chloride, such as vinyl chloride/vinyl acetate resins and similar type resins, and flexible urethane coating-type resins. These polymers and resins, as well as others used to prepare supported flexible polymeric coated sheet materials, may be used alone or in combination, either as the high or low modulus polymers.
The modulus of elongation of the polymers and polymeric liquid compositions employed, whether as organosols, plastisols, solutions, hot melts, emulsions or the like, may be altered by the selection of the particular polymers, as well as by the use of various additives, plasticizers, solvents, diluents, fillers, mo-difiers, oils, monomers, polymers and other materials.
In our process, a first polymer characterized by a high modulus of elongation of not less than 800 psi., and often greater than 2000 psi., from the polymer of low modulus of elongation, and typically having a 100% elongation of from about 2000 to 8000~
e.g., of 4000 to 6000 psi., is applied into the depressed areas -` -of a release sheet, such as a preembossed paper release sheet, having a design effect therein which is desired in the ultimate `-sheet. This first polymer thus forms a discontinuous layer with-in the depressed areas of the release sheet, and is typically quite thin from about 0.01 to 0.50 mils, for example, 0.05 to , 0.1 mils. This discontinuous layer of a first polymer may be applied by the technique known as "spanishing".
A continuous layer of a second polymer characterized by a low modulus of elongation, such as, for example, from about 300 ~-to 3000 psi., e.g., S00 to 1000 psi., is then applied, for example, by casting, coating, laminating, etc., over the first polymer, `
The first polymer is formed of a solid polymer, but the second L
polymer in the continuous layer may be a flexible cellular, cellu-lar-forming on expansion, or noncellular; that is, a solid flexi-ble, layer. The first and second polymers may be hardened, cured, :
,;, '' ~ ;,' ' . ' : \ :
fused, gelled or otherwise formed separately or together, such as by the application of heat, the evaporation of solvents, curing or other techniques. Of course, if desired, a series of first polymers the same or different in composition, elongation and type and color may be used one over the other, or in different areas of the embossed release sheet to provide multiple and different coating layers and design effects. The first polymer should be ~-secured and bonded to the second polymer.
The release sheet is then stripped from the surface of the first and second polymers to provide a polymeric sheet com-posed of a continuous layer of the low modulus second polymer, and -with slightly raised areas composed of the high modulus polymer bonded or secured thereto. The raised areas usually form a major part of the sheet surface area' for example, over 50%, such as from about 80 to 95% of the sheet surface area, as would be repre-sented by the raised portions for grain of natural leather. If desired and as will be illustrated, the second polymer layer may be a foam layer. Optionally, the second polymer layer may be placed on a flexible substrate, such as a supporting sheet mater-ial like a fibrous sheet such as a woven or nonwoven sheet or mesh-like grid or screen material. The substrate sheet may be secured to the second polymer, such as by laminating to the surface of the second polymer layer to provide for a supported sheet material.
In the sheet p~oduct, the intervening low areas between ;
the raised areas of the first polymer are composed of the second polymer having the low modulus. The slightly raised surface of the high modulus polymer is then accentuated by multiple flexing of the sheet material in the low intervening areas, so as to form a "weak hinge" effect which accentuates the raised areas. The , .. . . .
: . . , , :' I '. ,, :
flexing of the hinge area to form a weak hinge also makes the poly-meric sheet loose and crinkled, such as a leather-type material or more natural-looking material, and may be effected by various actions, either alone or in combination.
Flexing may be carried out by subjecting the polymeric sheet, for example, either before, but preferably after, the re-moval of the release paper, to a mechanical flexing action or by a series of shrinkage and expansion steps. For example, with a natural woven fabric supported material, like a jute or cotton woven fabric, a shrinking action may be effected by using water sprays and/or wet steam combined with heat to cause a shrinking and expansion of the substrate material, thereby flexing and weakening the hinge in the hinge area during such actions. Where `
the supporting sheet is composed of a heat-shrinkable polymeric material, heat alone may be employed to flex the sheet. In ano-ther technique, a mechanical action may be used to flex the low modulus polymer in the hingeareas, such as by tumbling folds of the polymeric sheet material, for example, in an oscillating-type tumbler varying from about 90 to 220. Tumbling of the sheet material occurs with the material in overlapping folds inside a cylindrical-type tumbler while subject to heat and moisture, with often the only pressure applied being that of the material falling on itself. If desired, such mechanical action may include the use ;
of additional dunnage or ballast material, such as bundles, bales or balls within the tumbler. Other mechanical techniques would include passing the material in reverse directions over a series of bars or small diameter rolls, etc. Other types of actions effect a weak hinge and fracture in the low areas and may be used, such as chemical techniques like the use of solvents to soften pre~
ferentially the weak hinge area or varying formulations, :. . .
After formation of the weak hinge, the differences in the surface design effects may be further enhanced by applying a clear or pigmented printing ink or other top coating on the raised areas. The purpose of the flexing action is to subject the low modulus polymer to a flex:ing or fractioning action in the low areas. As described, a number of polymers may be used in the practice of our invention, but typically the continuous layer of the low modulus polymer is a flexible polymer, while ~ , the raised areas of the high modulus polymer are composed of harder-type resins, alone or in combination, such as semirigid PVC, vinyl chloride resins, hard PVC resins, acrylic resins, cellulosic such as cellulose acetate butyrate, nitrocellulose and other polymers.
The high and low modulus polymers should be selected so that they are compatible and bonded to each other, or when they are uncompatible, an adhesive tie coat may be employed. In one preferred embodiment, the hard and soft polymers are ali-phatic, flexible, coating-type urethane resins. The urethane resins are typically applied in liquid-solvent compositions~ In another embodiment, the resins may be vinyl chloride resins of different molecular weight or homo or copolymer compositions to obtain the difference in modulus of elongation. The vinyl ~
chloride resins are usually employed as liquid plastisol or `
organosol compositions, and are cast and heated to gel and then fuse the resins. Where desired, the vinyl chloride resins used for the continuous layer of low modulus resin may contain a blowing agent to obtain on heating a cellular foam layer.
According to a broad aspect of the present invention, there is provided a process of preparing a polymeric sheet material with a three-dimensional surface design thereon. The process comprises applying to depressed areas of an embossed release sheet having a design effect thereon, a first polymer ~ - 7 -A
.
:characterized by a high modulus of elongation in psi at 100%
elongation. A continuous layer of a second polymer is applied `
over the first polymer in the depressed areas. The second ;;
polymer is characterized by a low modulus of elongation in psi at 100% elongation. The difference in the modulus of elongation between the first and second polymers is no less than 800 psi. me release sheet is removed to provide a polymeric sheet material composed of a continuous layer of a ,: .
low modulus polymer, with raised areas composed of a high `
modulus polymer secured thereto. The low modulus polymer is flexted in the intervening low areas between the raised high polymer areas to the polymeric sheet to form a weak-hinge effect, thereby providing a sheet material with an accentuated design effect thereon.
According to a further broad aspect of the present `
invention, there is provided an imitation leather-type material which comprises in combination a continuous layer of a second polymer, and a discontinuous raised cast area of a first polymer ~
secured to one surface of the layer of the second polymer to ~ ;
provide a surface design effect thereon. me raised area represents a major portion of the surface area of the layer of the second polymer, and substantially less in thickness than the thickness of the layer of the second polymer. The first polymer is characterized by higher modulus of elongation of t, j ,.
greater than 800 psi than the lower modulus of elongation of the second polymer. The raised area forms valley areas of the second polymer between the raised areas. The second polymer in the valley areas is characterized by flexible weak-hinge properties relative to the surrounding raised areas, such pro- ^
perties derived from prior multiple flexing of the valley areas thereby providing a leather-like material.
~ _ 7a -A '!', ~ ". .
4-~
Our invention, for the purposes of illustration only, will be described in connection with the preparation of an imita-tion plastic-supported leather sheet material having a grain style ~ ' surface design effect thereon, and employing a combination of .
- 7b - :-~ .
; . :
',' urethane resins.
BRIEF DESCRIPTION OF THE DRAWINGS .
Figs. 1-3 are fragmentary enlarged cross-sectional views of sheet materials during various stages of the process of pre-paration~
Fig. 4 lS a fragmentary cross-sectional partially iso- ~
meric view of a sheet material of our invention as prepared by ~-the process set forth in Figs. 6 and 7. ~
Fig. 5 is a fragmentary cross-sectional partially iso- -meric view of a modification of the sheet material of our invention.
Figs. 6 and 7 represent a schematic diagrammatic illus- '~
tration of a process for preparing the imitation-like leather material of Fig. 4. ;i^`
DESCRIPTIO~ OF THE EMBODIMENTS ..
With reference to Fig. 6, there is shown an embossed paper release sheet 12 and the coating into the depressed areas of the embossed sheet of a first polymer composed of a urethane resin 14 having a high modulus of elongation through the use of a knife ~ -coater 40, with a thickness of the first polymer of about 0.2 to 0.5 mils (dry). The hardening of the solvent urethane resin composition ~n "
in a two-zone hot air oven 42 at temperatures of about 80 to 350F
provides a product as illustrated in Fig. 1. The shee-t is then -passed through a pair of cooling rolls 44, and subsequently a se~
cond polymer composed of a urethane resin coating solution 16 is applied over theareas 14 in a continuous layer through the use of a knife coater 46. The sheet is then directed to a two-zone oven 48 at temperatures generally as before, and then passed through ,;, ',?;' `,'' ' ' ~Jt,~ 3 a pair of cooling rolls 50 to obtain the product as illustrated in Fig. 2, with the second polymer layer of about 1 to 3 mils (dry) in thickness.
A thin layer (e.g., 5 to 12 mils wet) of an adhesive 18 is knife-coated with knife coater 52 onto the surface of the ~;
second polymer layer 16, and a woven fabric sheet 20, such as a woven cotton sheet, is then pressed through opposing rolls 54 into contact with the surface of the wet coated layer of adhesive, and the sheet passed through oven 56 at a temperature of from about 100 to 350 to laminate the woven sheet 20 to the surface of the polymer layer 16. The laminate product emerging from the oven 50 moves through cooling and takeup rolls 58 and is illustrated in Fig.
3. The laminate is then moved to a stripping station 60 wherein the release paper 12 is stripped and directed to windup roll 64 while the woven laminate sheet is directed to windup roll 62.
With reference to Fig. 7, the woven laminate sheet 62 is then processed to flex the intervening low areas between the raised areas of polymer 14 and the low modulus polymer layer 16, that is, the intervening areas presenting the grain of the imitation lea-ther design. Fig. 7 illustrates a process whereby a combinationof techniques is employed to accentuate the raised areas and to fraction and flex the low areas to form a weak-hinge effect. Fig.
7 illustrates forming a weak hinge by heat-shrinking of the sheet material 62, followed by an oscillating tumbling motion. In Fig.
7, the coated fabric roll 62 has the underlying fabric portion thereof wet by water spray 66 and, thereafter, the coated sheet 62 is passed through an infrared oven 68 to effect a partial drying with shrinkage of the fabric 20, and resulting in flexing of the intervening low areas. On emerging from the oven, the underside of . : ~
-the fabric is then sprayed with wet steam 70, and, thereafter, is directed to a cylindrical oscillatory-type tumbler device 72. The tumbler device 72 provides for approximately 180 oscillation about its cylindrical axis so that the fabric material 62 within the tumbler folds over on itself, Typically, 30 to 60 yards of the multiple-folded coated sheet 62 may be in the tumbler at one time, with a throughput speed of 10 to 20 yards per minute. The tumbler 72 is heated so that the coated fabric material 62, as it folds back and forth on itself in the tumbler in the presence of moisture -.: . .
and'heat, provides for continued fracture of the low interveningareas of the second pol~mer 16, and yields a "weak hinge" effect, such that the raised areas are accentuated. Typically, the rela-tive humidity in the tumbler 72 ranges from about 40 to 100%, for example, about 60-80%, at a temperature of from about 85 to 200F, e.g., 100 to 160F. If desired, bales of fabric material, medicine balls, etc., may be added to the tumbler. The coated fabric material 62 is then removed from the tumbler 72 and passed through a gravure roller coating station 74 wherein a printing layer or top coat, such as a clear urethane resin top coat 34, is placed on the raised areas to accentuate further the grain, and then passed :, through an oven 76, with the final product 10 recovered in a windup roll.
The final product of the process described in Figs. 6 ;-~and 7 is illustrated in Fig. 4 which includes the woven fabric supporting sheet 20, the thin adhesive tie layer 18 laminating the sheet to the continuous layer of the low modulus polyer 16, with the raised grain areas represented by the high modulus polymer 14 and intervening low areas with a weak hinge that has been flexed 22 with the clear top coat 34 to accentuate further the raised areas.
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A modification of the plastic embossed product shown in Fig. 4 is illustrated in Fig. 5 wherein the sheet 32 contains a woven fabric 20 and a continuous polymeric layer of low modulus polymer comprising, for example, a flexible cellular vinyl chloride resin foam 24, with raised embossed areas 26 composed of a high modulu~ vinyl chloride resin, with the intervening low areas, the weak-hinge effect 28 and a clear top coat 30 over the raised areas.
In this modification, a foam cellular layer is substituted for the solid flexible urethane layer as more particularly described. If desired, the foam layer 24 may be formed from a vinyl chloride plastisol containing a blowing agent, such as azodicarbonamide, and `
the sheet substrate laminated or bonded onto the`top of the layer in the gel state prior to fusing, so that the intermediate adhesive layer 18 as shown in Fig. 4 may be eliminated.
Typical urethane formulations which have been employed in preparing the product illustrated in Fig. 4 by the process of ^
Figs. 6 and 7 are shown in Table I.
TABLE I
The physical properties of the polymers employed above are set forth in Table II.
TABLE I I .`
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'....... ................. ............................................ ... ,: .' A. First Polymer .
Clear aliphatic polyester urethane elastomer 100 parts ~ -Pigment dispersion 7 parts :.
Methyl cellosolve added as required .
Viscosity cps 12,000 at 72F
..
B. Second Polymer .
Clear allphatic polyester urethane elastomer 100 parts Pigment dispersion 7 parts .
Silicone surfactant 2 parts ,.
Methyl cellosolve : xylol (l:l)as required Viscosity cps 5000 at 72F
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C. Adhesive Coat Clear aromatic polyester urethane elastomer 100 parts ~ ~-Pigment dispersion 7 parts Dimethyl formamide : toluol : methylethyl , . :
ketone (1~1:1) as required Viscosity cps 16,000 to 18,000 at 72F ~ ;
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TABLE II
PHYSICAL PROPERTIES
~olymer A B C
Tensile strength PSI (ASTM_D_412) 6-7,000 5550 7500 % Elongation ::
(ASTM D-412) 120 390 620 Tensile modulus (PSI)(ASTM-D-412) ~
10~% 5-6,000 725 685 200% --- 1700 1000 300% --- 3800 1940 ', AQ illustrated, the hard first and the soft second poly-mers differ in modulus of elongation in psi. at 100% by about 43-5300 p~i. .
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Our invention has been described in certain embodiments, however, modifications, changes and alterations of these embodi-ments may be made and will be apparent to persons skilled in the art.
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With reference to Fig. 7, the woven laminate sheet 62 is then processed to flex the intervening low areas between the raised areas of polymer 14 and the low modulus polymer layer 16, that is, the intervening areas presenting the grain of the imitation lea-ther design. Fig. 7 illustrates a process whereby a combinationof techniques is employed to accentuate the raised areas and to fraction and flex the low areas to form a weak-hinge effect. Fig.
7 illustrates forming a weak hinge by heat-shrinking of the sheet material 62, followed by an oscillating tumbling motion. In Fig.
7, the coated fabric roll 62 has the underlying fabric portion thereof wet by water spray 66 and, thereafter, the coated sheet 62 is passed through an infrared oven 68 to effect a partial drying with shrinkage of the fabric 20, and resulting in flexing of the intervening low areas. On emerging from the oven, the underside of . : ~
-the fabric is then sprayed with wet steam 70, and, thereafter, is directed to a cylindrical oscillatory-type tumbler device 72. The tumbler device 72 provides for approximately 180 oscillation about its cylindrical axis so that the fabric material 62 within the tumbler folds over on itself, Typically, 30 to 60 yards of the multiple-folded coated sheet 62 may be in the tumbler at one time, with a throughput speed of 10 to 20 yards per minute. The tumbler 72 is heated so that the coated fabric material 62, as it folds back and forth on itself in the tumbler in the presence of moisture -.: . .
and'heat, provides for continued fracture of the low interveningareas of the second pol~mer 16, and yields a "weak hinge" effect, such that the raised areas are accentuated. Typically, the rela-tive humidity in the tumbler 72 ranges from about 40 to 100%, for example, about 60-80%, at a temperature of from about 85 to 200F, e.g., 100 to 160F. If desired, bales of fabric material, medicine balls, etc., may be added to the tumbler. The coated fabric material 62 is then removed from the tumbler 72 and passed through a gravure roller coating station 74 wherein a printing layer or top coat, such as a clear urethane resin top coat 34, is placed on the raised areas to accentuate further the grain, and then passed :, through an oven 76, with the final product 10 recovered in a windup roll.
The final product of the process described in Figs. 6 ;-~and 7 is illustrated in Fig. 4 which includes the woven fabric supporting sheet 20, the thin adhesive tie layer 18 laminating the sheet to the continuous layer of the low modulus polyer 16, with the raised grain areas represented by the high modulus polymer 14 and intervening low areas with a weak hinge that has been flexed 22 with the clear top coat 34 to accentuate further the raised areas.
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A modification of the plastic embossed product shown in Fig. 4 is illustrated in Fig. 5 wherein the sheet 32 contains a woven fabric 20 and a continuous polymeric layer of low modulus polymer comprising, for example, a flexible cellular vinyl chloride resin foam 24, with raised embossed areas 26 composed of a high modulu~ vinyl chloride resin, with the intervening low areas, the weak-hinge effect 28 and a clear top coat 30 over the raised areas.
In this modification, a foam cellular layer is substituted for the solid flexible urethane layer as more particularly described. If desired, the foam layer 24 may be formed from a vinyl chloride plastisol containing a blowing agent, such as azodicarbonamide, and `
the sheet substrate laminated or bonded onto the`top of the layer in the gel state prior to fusing, so that the intermediate adhesive layer 18 as shown in Fig. 4 may be eliminated.
Typical urethane formulations which have been employed in preparing the product illustrated in Fig. 4 by the process of ^
Figs. 6 and 7 are shown in Table I.
TABLE I
The physical properties of the polymers employed above are set forth in Table II.
TABLE I I .`
, `
;, .
ts ~
.;;'' TABLE I :
'....... ................. ............................................ ... ,: .' A. First Polymer .
Clear aliphatic polyester urethane elastomer 100 parts ~ -Pigment dispersion 7 parts :.
Methyl cellosolve added as required .
Viscosity cps 12,000 at 72F
..
B. Second Polymer .
Clear allphatic polyester urethane elastomer 100 parts Pigment dispersion 7 parts .
Silicone surfactant 2 parts ,.
Methyl cellosolve : xylol (l:l)as required Viscosity cps 5000 at 72F
r~
C. Adhesive Coat Clear aromatic polyester urethane elastomer 100 parts ~ ~-Pigment dispersion 7 parts Dimethyl formamide : toluol : methylethyl , . :
ketone (1~1:1) as required Viscosity cps 16,000 to 18,000 at 72F ~ ;
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TABLE II
PHYSICAL PROPERTIES
~olymer A B C
Tensile strength PSI (ASTM_D_412) 6-7,000 5550 7500 % Elongation ::
(ASTM D-412) 120 390 620 Tensile modulus (PSI)(ASTM-D-412) ~
10~% 5-6,000 725 685 200% --- 1700 1000 300% --- 3800 1940 ', AQ illustrated, the hard first and the soft second poly-mers differ in modulus of elongation in psi. at 100% by about 43-5300 p~i. .
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Our invention has been described in certain embodiments, however, modifications, changes and alterations of these embodi-ments may be made and will be apparent to persons skilled in the art.
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Claims (31)
1. A process of preparing a polymeric sheet material with a three-dimensional surface design thereon, which process comprises:
(a) applying to depressed areas of an embossed re-lease sheet having a design effect thereon a first polymer charac-terized by a high modulus of elongation in psi. at 100% elongation;
(b) applying a continuous layer of a second polymer characterized by a low modulus elongation in psi. at 100% elonga-tion over the first polymer in the depressed areas, the difference in the modulus of elongation between the first and second polymers being no less than 800 psi.;
(c) removing the release sheet to provide a polymer-ic sheet material composed of a continuous layer of a low modulus polymer, with raised areas composed of a high modulus polymer secured thereto, and (d) flexing the low modulus polymer in the interven-ing low areas between the raised high polymer areas to the poly-meric sheet to form a weak-hinge effect, thereby providing a sheet material with an accentuated design effect thereon.
(a) applying to depressed areas of an embossed re-lease sheet having a design effect thereon a first polymer charac-terized by a high modulus of elongation in psi. at 100% elongation;
(b) applying a continuous layer of a second polymer characterized by a low modulus elongation in psi. at 100% elonga-tion over the first polymer in the depressed areas, the difference in the modulus of elongation between the first and second polymers being no less than 800 psi.;
(c) removing the release sheet to provide a polymer-ic sheet material composed of a continuous layer of a low modulus polymer, with raised areas composed of a high modulus polymer secured thereto, and (d) flexing the low modulus polymer in the interven-ing low areas between the raised high polymer areas to the poly-meric sheet to form a weak-hinge effect, thereby providing a sheet material with an accentuated design effect thereon.
2. The process of claim 1 wherein the first polymer is characterized by a modulus of elongation at 100% elongation of about 2,000 to 8,000 psi.
3. The process of claim 1 wherein the second polymer has a modulus of elongation at 100% elongation from about 300 to 3,000 psi.
4. The process of claim 1 wherein the polymers are selec-ted from a group consisting of aliphatic urethane elastomers, vinyl chloride resins and combinations thereof.
5. The process of claim 1 wherein the raised areas of the first polymer represent over about 80% of the surface area of the polymeric sheet.
6. The process of claim 1 wherein the continuous layer of the second polymer is a flexible foam layer.
7. The process of claim 1 which includes the step of securing a fibrous sheet material to one surface of the contin-uous layer of the second polymer.
8. The process of claim 6 wherein the step of flexing the low modulus polymer layer includes subjecting the polymeric sheet to moisture and heat to provide for shrinkage of a fabric sheet bonded to the continuous layer.
9. The process of claim 1 wherein flexing the low modulus polymer includes subjecting the polymeric sheet to an oscilla-ting-type tumbling action.
10. The process of claim 1 which includes applying to the continuous layer of the second polymer a woven fabric sheet material, and flexing the low modulus polymer by subjecting the woven fabric surface of the polymeric sheet to moisture and heat and to a mechanical action, so as to flex the low-modulus second polymer in the intervening low areas of the polymeric sheet.
11. The process of claim 1 which includes coating the top surface of the raised area with a polymeric layer to enhance further the surface design effect.
12. The process of claim 1 which includes coating a layer of an adhesive material onto the surface of the continuous layer of the second polymer, and placing onto the adhesive material and bonding to the continuous layer of the second polymer a flex-ible sheet material.
13. The process of claim 1 wherein the difference in the modulus of elongation at 100% elongation between the first and second polymers ranges from about 4300 to 5300 psi.
14. A process of preparing a polymeric imitation leather-type material having an enhanced grain-like surface appearance, which process comprises:
(a) casting into the depressed valley areas of a pre-embossed paper release sheet having a design effect embossed therein a liquid composition of a first polymer of an aliphatic polyester urethane elastomer or a vinyl chloride resin, the polymer characterized by a high modulus of elongation in psi of 100% elongation of from about 2000 psi to 8000 psi;
(b) casting a continuous layer of a liquid composition of a second polymer of an aliphatic polyester urethane elas-tomer or a vinyl chloride resin over the first polymer, the second polymer characterized by a low modulus of elongation in psi, at 100% elongation of from about 300 to 3000 psi, and having a modulus of at least 800 psi lower than the first poly-mer, the difference in the modulus of elongation between the first and second polymers being no less than 800 psi;
(c) heating the polymers to effect the solidification thereof;
(d) laminating a shrinkable fibrous supporting sheet material to one surface of the second polymer;
(e) stripping the paper release sheet to provide a laminated sheet material with slightly raised areas composed of the high modulus polymer, the raised areas representing a sub-stantial part of the surface area; and (f) subjecting the laminated sheet material to a combi-nation of heat and moisture and mechanical means to provide flexing and fractioning of the low modulus polymer in the valley areas to form a weak hinge in such areas, thereby accentuating the design effect.
(a) casting into the depressed valley areas of a pre-embossed paper release sheet having a design effect embossed therein a liquid composition of a first polymer of an aliphatic polyester urethane elastomer or a vinyl chloride resin, the polymer characterized by a high modulus of elongation in psi of 100% elongation of from about 2000 psi to 8000 psi;
(b) casting a continuous layer of a liquid composition of a second polymer of an aliphatic polyester urethane elas-tomer or a vinyl chloride resin over the first polymer, the second polymer characterized by a low modulus of elongation in psi, at 100% elongation of from about 300 to 3000 psi, and having a modulus of at least 800 psi lower than the first poly-mer, the difference in the modulus of elongation between the first and second polymers being no less than 800 psi;
(c) heating the polymers to effect the solidification thereof;
(d) laminating a shrinkable fibrous supporting sheet material to one surface of the second polymer;
(e) stripping the paper release sheet to provide a laminated sheet material with slightly raised areas composed of the high modulus polymer, the raised areas representing a sub-stantial part of the surface area; and (f) subjecting the laminated sheet material to a combi-nation of heat and moisture and mechanical means to provide flexing and fractioning of the low modulus polymer in the valley areas to form a weak hinge in such areas, thereby accentuating the design effect.
15. An imitation leather-type material which comprises in combination:
(a) a continuous layer of a second polymer, (b) a discontinuous raised cast area of a first polymer secured to one surface of the layer of the second polymer to provide a surface design effect thereon;
(c) the raised area representing a major portion of the surface area of the layer of the second polymer, and sub-stantially less in thickness than the thickness of the layer of the second polymer;
(d) the first polymer characterized by a higher modulus of elongation of greater than 800 psi than the lower modu-lus of elongation of the second polymer; and (e) the raised area forming valley areas of the second polymer between the raised areas, the second polymer in the valley areas characterized by flexible weak-hinge properties relative to the surrounding raised areas, such properties derived from prior multiple flexing of the valley areas, thereby providing a leather-like material.
(a) a continuous layer of a second polymer, (b) a discontinuous raised cast area of a first polymer secured to one surface of the layer of the second polymer to provide a surface design effect thereon;
(c) the raised area representing a major portion of the surface area of the layer of the second polymer, and sub-stantially less in thickness than the thickness of the layer of the second polymer;
(d) the first polymer characterized by a higher modulus of elongation of greater than 800 psi than the lower modu-lus of elongation of the second polymer; and (e) the raised area forming valley areas of the second polymer between the raised areas, the second polymer in the valley areas characterized by flexible weak-hinge properties relative to the surrounding raised areas, such properties derived from prior multiple flexing of the valley areas, thereby providing a leather-like material.
16. The material of claim 15 wherein the raised areas have a thickness of from about 0.01 to 0.5 mils.
17. The material of claim 15 wherein the modulus of elonga-tion of the first polymer is about 2000 to 8000 psi.
18. The material of claim 15 wherein the modulus of elonga-tion of the second polymer is about 300 to 3000 psi.
19. The material of claim 15 wherein the first and second polymers are selected from a group of polymers of vinyl halide resins, urethane elastomers and combinations thereof.
20. The material of claim 15 wherein the continuous layer of the second polymer is secured to a fibrous sheet material.
21. The material of claim 15 wherein the continuous layer of the second polymer comprises a flexible foam layer.
22. The material of claim 15 wherein the surface of the raised areas contains a thin polymeric top coating layer to accentuate the surface design effect as an imitation leather-type sheet material.
23. The material of claim 15 wherein the raised areas repre-sent over 80% of the surface area.
24. The material of claim 15 which includes a flexible supporting sheet material bonded to the layer of the second polymer by an adhesive layer.
25. An imitation leather sheet material having a three-dimensional surface design effect thereon, which material com-prises:
(a) a continuous flexible layer of a second polymer;
(b) a flexible fibrous sheet material bonded to the layer of the second polymer;
(c) raised areas of a first polymer secured to one sur-face of the layer of the second polymer, the first polymer being characterized by a modulus of elongation of greater than 800 psi than the lower modulus of elongation of said second polymer;
(d) the first and second polymers composed of vinyl-halide resin, urethane elastomers or combinations thereof;
(e) the raised areas providing a raised surface effect thereon designed to simulate the grain of natural leather, and forming over the majority of the surface area of the surface of the layer of the second polymer;
(f) the raised areas having a thickness of from about 0.01 to 0.5 mils and greater than the thickness of the layer of the second polymer; and (g) the intervening low valley areas between the raised areas of the first polymer characterized by a flexible weak-hinge property so as to accentuate the surface design effect and to impart a crinkled imitation leather-type surface to the sheet material.
(a) a continuous flexible layer of a second polymer;
(b) a flexible fibrous sheet material bonded to the layer of the second polymer;
(c) raised areas of a first polymer secured to one sur-face of the layer of the second polymer, the first polymer being characterized by a modulus of elongation of greater than 800 psi than the lower modulus of elongation of said second polymer;
(d) the first and second polymers composed of vinyl-halide resin, urethane elastomers or combinations thereof;
(e) the raised areas providing a raised surface effect thereon designed to simulate the grain of natural leather, and forming over the majority of the surface area of the surface of the layer of the second polymer;
(f) the raised areas having a thickness of from about 0.01 to 0.5 mils and greater than the thickness of the layer of the second polymer; and (g) the intervening low valley areas between the raised areas of the first polymer characterized by a flexible weak-hinge property so as to accentuate the surface design effect and to impart a crinkled imitation leather-type surface to the sheet material.
26. The material of claim 25 wherein the modulus of elongation of the first polymer is about 2000 to 8000 psi, said second polymer having a low modulus of elongation of from about 300 to 1000 psi.
27. The process of claim 1 which includes applying to the continuous layer of the second polymer a woven fabric sheet material, and flexing the low modulus polymer by subjecting the woven fabric surface of the polymeric sheet to moisture and heat and to a mechanical action, so as to flex the low modulus second polymer in the intervening low areas of the polymeric sheet.
28. The process of claim 1 wherein the difference in the modulus of elongation at 100% elongation between the first and second polymers ranges from about 4300 to 5300 psi.
29. The process of claim 1 wherein the step of flexing the low modulus polymer layer includes subjecting the polymeric sheet to moisture and heat to provide for shrinkage of a fabric sheet bonded to the continuous layer.
30. The material of claim 15 wherein the difference in modulus of elongation between the low and high modulus polymers is from about 1500 to 2500 psi.
31. The process of claim 14 wherein the difference in the modulus of elongation between the first and second polymers is about 1500 to 2500 psi.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US46012774A | 1974-04-11 | 1974-04-11 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1044083A true CA1044083A (en) | 1978-12-12 |
Family
ID=23827486
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA224,589A Expired CA1044083A (en) | 1974-04-11 | 1975-04-11 | Imitation sheet material with surface grain appearance and method of preparing the material |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1044083A (en) |
-
1975
- 1975-04-11 CA CA224,589A patent/CA1044083A/en not_active Expired
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