US20150159320A1 - Imitation leather fabric and method of producing same - Google Patents

Imitation leather fabric and method of producing same Download PDF

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Publication number
US20150159320A1
US20150159320A1 US14/399,846 US201214399846A US2015159320A1 US 20150159320 A1 US20150159320 A1 US 20150159320A1 US 201214399846 A US201214399846 A US 201214399846A US 2015159320 A1 US2015159320 A1 US 2015159320A1
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Prior art keywords
fabric
fibre elements
basis
imitation leather
fabric layer
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Abandoned
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US14/399,846
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English (en)
Inventor
Albert Pui Sang Lau
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Epro Development Ltd
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Epro Development Ltd
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Publication of US20150159320A1 publication Critical patent/US20150159320A1/en
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0006—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using woven fabrics
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
    • D03D13/004—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft with weave pattern being non-standard or providing special effects
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/56—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads elastic
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D25/00—Woven fabrics not otherwise provided for
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
    • D06N3/0025—Rubber threads; Elastomeric fibres; Stretchable, bulked or crimped fibres; Retractable, crimpable fibres; Shrinking or stretching of fibres during manufacture; Obliquely threaded fabrics
    • D06N3/0029—Stretchable fibres; Stretching of fibres during manufacture
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
    • D06N3/0088—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
    • D06N3/009—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin by spraying components on the web
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
    • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/12—Decorative or sun protection articles
    • D06N2211/28—Artificial leather
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
    • D10B2201/01—Natural vegetable fibres
    • D10B2201/02—Cotton
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3179—Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified

Definitions

  • the present invention relates to the field of fabrics and in particular imitation leather fabrics and methods for making same.
  • imitation leather fabric is formed by dip-coating a woven or knitted basis fabric in a chemical resin and then curing it to achieve an imitation leather effect. Dip-coating results in the resin being absorbed on both sides of the basis fabric such that human skin will come into direct contact with the resin when a garment made from the imitation leather fabric is being worn and this may result in skin allergies and other pathological effects. Although a lining could be added to the garment to avoid direct skin contact, this increases manufacturing time and costs and reduces the air permeability of the imitation leather fabric. The dip-coating also tends to waste a relatively large amount of polyurethane resin.
  • the resulting imitation leather will exhibit relatively good stability due to the weft and warp yarns being woven relatively closely and tightly together. However, this also increases stiffness and consequently, poor hand feel and comfort in the imitation leather fabric.
  • the basis fabric is a knitted fabric
  • the stiffness is relatively low due to the relative flexibility of the knitted loop structure. Consequently, this provides a better hand feel and comfort in the imitation leather fabric.
  • knitted basis fabrics tend to exhibit relatively low stability when external forces are applied due to the tendency of the knitted yarn loops to deform randomly and non-uniformly. As such, imitation leather formed from knitted fabrics tend to be less stable and more susceptible to problems such as surface cracking.
  • the present invention seeks to alleviate at least one of the above-described problems.
  • the present invention may involve several broad forms. Embodiments of the present invention may include one or any combination of the different broad forms herein described.
  • the present invention provides an imitation leather fabric formed from a basis fabric, wherein the basis fabric includes:
  • the first set of fibre elements may include at least one warp yarn of the first fabric layer.
  • the second set of fibre elements may include at least one weft yarn of the first fabric layer.
  • the third set of fibre elements may include at least one weft yarn of the second fabric layer.
  • the third set of fibre elements may be in substantial alignment with the second set of fibre elements.
  • the long loop blister weave may include a satin weave.
  • the first set of fibre elements may be relatively non-stretchable.
  • the second set of fibre elements may be relatively stretchable.
  • the third set of fibre elements may be relatively stretchable.
  • the third set of fibre elements may be configured to limit an amount of stretch of the second fibre elements.
  • At least one of the following finishing processes may be applied to the basis fabric:
  • a coating layer may be disposed on the first fabric layer.
  • the coating layer may includes a polyurethane resin.
  • the coating layer may be sprayed on to the basis fabric.
  • the present invention provides a method for producing an imitation leather fabric from a basis fabric, the method including the steps of:
  • the first set of fibre elements may include at least one warp yarn of the first fabric layer.
  • the second set of fibre elements may include at least one weft yarn of the first fabric layer.
  • the third set of fibre elements may include at least one weft yarn of the second fabric layer.
  • the third set of fibre elements may be in substantial alignment with the second set of fibre elements.
  • the long loop blister weave may include a satin weave.
  • the first set of fibre elements may be relatively non-stretchable.
  • the second set of fibre elements may be relatively stretchable.
  • the third set of fibre elements may be relatively stretchable.
  • the third set of fibre elements may be configured to limit an amount of stretch of the second fibre elements.
  • At least one of the following finishing processes are applied to the basis fabric:
  • the present invention includes applying a coating layer to the basis fabric.
  • the coating layer may include a polyurethane resin.
  • the coating layer may be sprayed on to the basis fabric.
  • the step (i) of applying the coating layer may include:
  • step (ii) may include:
  • the present invention includes a basis fabric suitable for use in producing an imitation leather, the basis fabric including:
  • the first set of fibre elements may include at least one warp yarn of the first fabric layer.
  • the second set of fibre elements may include at least one weft yarn of the first fabric layer.
  • the third set of fibre elements may include at least one weft yarn of the second fabric layer.
  • the third set of fibre elements may be in substantial alignment with the second set of fibre elements.
  • the long loop blister weave may include a satin weave.
  • the first set of fibre elements may be relatively non-stretchable.
  • the second set of fibre elements may be relatively stretchable.
  • the third set of fibre elements may be relatively stretchable.
  • the third set of fibre elements may be configured to limit an amount of stretch of the second fibre elements.
  • At least one of the following finishing processes may be applied to the basis fabric:
  • a coating layer may be disposed on the first fabric layer.
  • the coating layer may include a polyurethane resin.
  • the coating layer may be sprayed on to the basis fabric.
  • the combination of the first and second facing fabric layers in the basis fabric provides stability as well as relatively good hand feel and comfort in the imitation leather fabric.
  • the first fabric layer includes first and second sets of fibre elements woven relatively closely and tightly together this configuration assists in providing stability in the basis fabric and alleviates problems such as surface cracking in the imitation leather fabric due to external forces.
  • the second set of fibre elements e.g. weft yarns
  • the second set of fibre elements may be stretchable such that some degree of softness (and hence good hand feel and comfort) in the basis fabric may be afforded in comparison with existing imitations leather fabrics formed from non-stretch woven basis fabrics.
  • the long loop third set of fibre elements of the second fabric layer may be configured to limit the amount of stretch of the second fibre elements in the first fabric layer, this may also assist in alleviating risk that the stretchiness afforded by the second set of fibre elements will compromise the stability provided by the first fabric layer.
  • the second fabric layer includes the first and third sets of fibre elements woven together in a long loop blister weave, this may also alleviate overall stiffness in the basis fabric and enhances the hand feel and comfort of the imitation leather fabric, in a similar manner to knitted yarn loops.
  • the combination of the first fabric layer and the second fabric layer may produce a regular and discontinuous “pothole” effect in the basis fabric which assists in improving the overall textured look and feel of the imitation leather.
  • the present invention may provide waterproofing, air permeability and heat insulative characteristics.
  • the present invention may not involve dip-coating the basis fabric in a polyurethane resin.
  • the polyurethane resin coating layer may be sprayed on to a selected surface of the basis fabric thereby alleviating risk of direct contact with a wearer's skin.
  • FIG. 1 depicts a construction chart of a basis fabric in accordance with an embodiment of the present invention
  • FIG. 2 depicts a side view of a basis fabric showing a twill or plain woven first fabric layer and a second fabric layer consisting of a satin weave with long blister stiches;
  • FIG. 3 depicts a side view of the basis fabric in FIG. 2 after undergoing shrinkage whereby the long loop blisters are more pronounced on the second fabric layer, and with a polyurethane resin coating layer having been applied to the first fabric layer;
  • FIG. 4 shows a chart comparing the physical performance test results in respect of an embodiment of the present invention against test results for imitation leather fabrics produced from traditional woven non-stretch fabric, traditional woven stretch fabric, and, knitted fabric;
  • FIG. 5 shows a chart comparing the colourfastness performance test results in respect of embodiments of the present invention against test results for imitation leather fabrics produced from traditional woven non-stretch fabric, traditional woven stretch fabric, and, knitted fabric;
  • FIG. 6 shows a chart indicating further colourfastness performance test results in respect of embodiments of the present invention.
  • FIG. 7 shows a chart indicating yet further colourfastness performance test results in respect of embodiments of the present invention.
  • FIG. 8 depicts magnified and corresponding regular images of the long loop blister weaves of the second fabric layer in embodiments of the present invention when the third set of fibre elements is made from cotton, compared to when the third set of fibre elements is made from a combination of cotton, polyester and Spandex materials;
  • FIG. 9 shows magnified images of the first fabric layer (without a polyurethane resin coating) and corresponding second fabric layer of the basis fabric of an embodiment of the present invention before and after stretching;
  • FIG. 10 shows magnified images of the imitation leather fabric embodiment (with the polyurethane resin coating layer) and a traditional imitation leather fabric made from knitted basis fabric when they are both in a stretched state and in relaxed states so as to demonstrate the visible difference in cracking;
  • FIG. 11 shows magnified images of “potholes” formed in the basis fabric of embodiments of the present invention, wherein the potholes assist in enhancing a look and feel of imitation leather.
  • FIGS. 1 to 11 including an imitation leather fabric and a method of making same which involves coating a double-layer basis fabric with a polyurethane resin.
  • the basis fabric includes a first fabric layer which is formed by weaving together a first set of relatively non-elastic fibre elements with a second set of relatively elastic fibre elements to form a traditional twill or plain weave (e.g. 1/1 plain, 2/1 twill, 3/1 twill and so on).
  • the first set of fibre elements include warp yarns and the second set of fibre elements include weft yarns of the first fabric layer.
  • the weft and warp fibre elements are relatively closely and tightly woven together such that the weave is configured to provide stability to the imitation leather fabric when external forces act upon the imitation leather fabric.
  • the first set of fibre elements are made from a cotton material having a yarn count in the range of approximately 10-60 Ne.
  • the second set of fibre elements are made from any cotton, polyester core-spun stretchable yarn or cotton, cotton core-spun stretchable yarn or a combination thereof. If the weft threads are made from a polyester material, the linear mass density should be in the range of 75-150 D. Alternatively, if the weft threads are made from a Spandex material, the linear mass density of the weft threads should typically be in the range of 40-70 D.
  • the degree of stretch of the second set of fibre elements is approximately in the range of 20-40%.
  • the basis fabric also includes a second fabric layer which faces the first fabric layer.
  • the second fabric layer is formed by weaving together a third set of fibre elements (the weft yarns of the second fabric layer) with the first set of fibre elements (which serve as both the warp yarns of the first and second fabric layers) to form long blister stiches in a satin imperial weave.
  • the long blister stitches of the second fabric layer float over multiple fibre elements in the first set of fibre elements (e.g. over 7-15 fibre elements at a time) and are in alignment with the second fibre elements in the first fabric layer.
  • the third set of fibre elements are made from either pure cotton, or, a combination of cotton and elastic yarns (e.g. polyester or Spandex).
  • FIG. 8 shows a magnified view ( 8 a ) of a long loop blister weave of the second fabric layer and a regular view ( 8 b ) of the corresponding first fabric layer of the basis fabric in embodiments of the present invention in which the third set of fibre elements are made from pure cotton.
  • a magnified view ( 8 c ) of a long loop blister weave of the second fabric layer and a regular view ( 8 d ) of a corresponding first fabric layer are shown where the third set of fibre elements are made from a combination of cotton, polyester and Spandex.
  • the first fabric layer and the second fabric layer are woven simultaneously using a Picanol rapier weaving machine which is configured to alternately shoot the second set of fibre elements (i.e. the weft yarns of the first fabric layer) and the third set of fibre elements (i.e. the weft yarns of the second fabric layer) across the first set of fibre elements (i.e. warp yarns of the first and second fabric layers) in single or double quantities.
  • the long loop blister stiches formed in the satin weaved second fabric layer are configured to limit the amount of stretch that is allowed in the second fibre elements of the first fabric layer so as to ensure that the stability of the basis fabric is maintained.
  • the length of the long loop blister stiches chosen will have a bearing upon the extent to which the first fabric layer will be allowed to stretch in the direction of the second set of fibre elements (i.e. in the weft direction of the first fabric layer) and will therefore assist in maintaining a suitable balance of relatively flexibility and stability in the imitation leather fabric.
  • FIG. 2 represents a side-view of the basis fabric in an embodiment of the present invention.
  • the series of dots ( 1 ) represent the first set of fibre elements (i.e. the warp yarns of the first and second fabric layers) extending orthogonally relative to the page.
  • the second set of fibre elements ( 2 ) i.e. the weft yarns of the first fabric layer
  • the third set of fibre elements ( 3 ) i.e.
  • the weft yarns of the second fabric layer is shown floating over multiple warp yarns (in this case over 7 warp yarns) at a time before being secured by a single warp yarn so as to form long blister stiches of a satin weave.
  • the basis fabric shown in FIG. 2 is in greige fabric form, the first fabric layer has not yet undergone shrinkage and accordingly the long blister stiches of the second fabric layer have not yet formed more pronounced loop configurations.
  • a finishing is applied to the basis fabric when in greige form. This involves fabric-face side-singeing the basis fabric at 30-45 m/min, water rinsing at 10-20 m/min at normal water temperature, heat-setting the basis fabric at a speed of 20-30 m/min with a heat set temperature of between 160-175° C., and shrinking the basis fabric at a speed of 40-50 m/min.
  • the basis fabric When the basis fabric is in greige form, it will have a relatively high shrinkage percentage rate. When it is shrunk, the long blister stitches in the second fabric layer are adapted to form more pronounced long loop configurations similar to knitted loops and thereby provide better hand feel and comfort in the imitation leather fabric.
  • the specific characteristics of the first set of fibre elements should be selected taking into account the stretchability of the basis fabric, the quantity of long blister stitches on the second fabric layer and so on. If the yarn densities of the first and second sets of fibre elements in the first fabric layer are too high, there will not be sufficient shrinkage to give rise to the long loop effect on the second fabric layer as depicted in FIG. 3 .
  • the warp yarn density of the basis fabric can be controlled to between 80 and 180 yarns per inch, and the weft yarn density of basis fabric can be controlled to between 100 and 200 yarns per inch.
  • dimensional stability in the weft direction is able to be controlled to within approximately 40-60%.
  • the basis fabric Before coating the basis fabric, the basis fabric is desized in a composition consisting of detergent (0.5 g/Litre) in 60 litres of water at a temperature of 60° C. for 10 minutes. The basis fabric is then rinsed in water at 25° C. for 2 minutes before being tumble dried at 70° C. for 30 minutes. Thereafter, the basis fabric is sprayed with a composition consisting of 60% resin, 1% catalyst and 39% water. After the composition is sprayed on, the basis fabric is hand brushed until it is smooth and without hair, then is cured at 100° C. for 30 minutes.
  • detergent 0.5 g/Litre
  • the basis fabric is then sprayed with a further composition consisting of 80% polyurethane (aqueous emulsion of copolymer), 5% resin, 1% catalyst and 14% water.
  • a pigment could be applied to change the colour of the imitation leather.
  • a black leather colour can be obtained by adding 20 g/0.1 L of black pigment. It is estimated that approximately 400 g of this composition may generally be required to be sprayed on to an amount of basis fabric required to form an average-sized jacket.
  • the basis fabric is brushed again and this process of spraying and brushing is repeated until the basis fabric surface becomes shiny. Thereafter, the basis fabric is cured at approximately 140° C. for 20 minutes.
  • the basis fabric is again rinsed and softened in a composition consisting of silicone oil (1 g/litre) in 60 litres of water at 30° C. for 10 minutes.
  • the basis fabric is tumble dried at 70° C. for 30 minutes and then further tumbled dried at 30° C. for 30 minutes with plastic balls added to the tumble dryer so as to further enhance the imitation leather effect.
  • FIG. 3 show the same side-view of the basis fabric in an embodiment of the present invention except that the basis fabric has had the finishing applied to it and the first fabric layer has shrunk so as to give rise to enhanced looped configurations ( 3 ) in the satin weave of the second fabric layer. Also, the polyurethane resin coating ( 4 ) has been sprayed on to the surface of the first fabric layer.
  • the first fabric layer of the basis fabric is formed by weaving together a first set of fibre elements (the warp of the first fabric layer) made from 100% cotton (16 Ne) with a second set of fibre elements (the weft of the first fabric layer) made from a combination of 100% cotton (16 Ne) and polyester core-spun elastic yarn (P150 D/70 D).
  • the yarn density of the first set of fibre elements is 64 yarns per inch when the basis fabric is in greige fabric form and is adapted to have a yarn density of 93 yarns per inch after the finishing process is applied (that is, after being singed, rinsed, heat set and shrunk but not after the resin and polyurethane coating has been sprayed on).
  • the yarn density of the second set of fibre elements is 110 yarns per inch when the basis fabric is in greige fabric form, and is adapted to have a yarn density of 116 yarns per inch when the basis fabric has undergone finishing.
  • the construction chart for this exemplary basis fabric is represented in FIG. 1 .
  • the second set of fibre elements comprises approximately 91.1% cotton, 7.6% polyester and 1.3% Spandex.
  • the finishing applied to the basis fabric includes face-side singeing at a speed of 40 m/min, water rinsing at a speed of 20 m/min in normal water temperature, heat-setting at a speed of 20 m/min at a heat-set temperature of 160° C., and shrinking the basis fabric at a speed of 40 m/min.
  • the coating is applied in accordance with the steps outlined above.
  • FIG. 4 shows the physical performance test results in respect of the above exemplary embodiment compared against results for imitation leather fabrics produced from traditional woven non-stretch fabric, traditional woven stretch fabric, and, knitted fabric. It is evident that embodiments of the present invention demonstrate relatively good dimensional stability in accordance with the AATCC315 standard test, and, relatively low stiffness (i.e. which provides better hand feel and comfort) in accordance with the ASTMD4032 standard test. Accordingly, imitation leather embodiments of the present invention enjoy not only the construction stability afforded by use of a woven basis fabric, but also, good hand feel and comfort afforded by the long loop blister weave (having a looped configuration similar to that of a knitted yarn loops).
  • FIG. 11 shows magnified images of the “potholes” (A) formed in embodiments of the basis fabric between the intersection points (B) of the long loop blisters of the second fabric layer and the woven structure of the first fabric layer. Furthermore, it is evident from FIG. 4 that embodiments of the present invention also demonstrate relatively comparable waterproofing characteristics as well as air permeability (of about 78.3%).
  • FIG. 5 shows the chemical performance test results in respect of the above exemplary embodiment compared against results for imitation leather fabrics produced from traditional woven non-stretch fabric, traditional woven stretch fabric, and, knitted fabric. It is evident from the results shown in FIG. 5 that the exemplary embodiments demonstrate relatively good colour-fastness in accordance with the AATCC8 standards test and is comparable to imitation leather produced using knitted fabrics.
  • FIGS. 6 and 7 show further charts indicating the results of further colourfastness and crocking tests of samples of embodiments of the present invention in accordance with AATCC8 and AATCC135 standards under varying conditions.
  • Standards test AATCC135 is designed to measure the amount of fabric colour change which occurs when a sample is subjected to automatic laundering procedures commonly used in the home.
  • Standards test AATCC8 is designed to measure the amount of colour that is transferred from a surface of coloured textile materials to other surface by rubbing.
  • the codes starting with “GT11” refer to sample fabric reference numbers that have been tested.
  • FIG. 9 shows magnified images of an embodiment of the basis fabric without a polyurethane resin coating.
  • Magnified image ( 9 a ) shows the first fabric layer before being stretched whilst magnified image ( 9 b ) shows the first fabric layer after being stretched.
  • the second set of fibre elements (Y) i.e. the weft yarns of the first fabric layer
  • Y the weft yarns of the first fabric layer
  • the first fibre elements (X) i.e. the warp yarns
  • the woven configuration of the first fabric layer with the relatively elastic second fibre elements (Y) assists in providing both stability and some comfort to the basis fabric.
  • Magnified image ( 9 c ) shows the corresponding second fabric layer of the basis fabric before being stretched whilst magnified image ( 9 d ) shows the corresponding second fabric layer after being stretched.
  • the long loop blister stiches of the third fibre elements (Z) are arranged in alignment with the direction of the second fibre elements (Y) and are suitably stretchable to accommodate stretching of the second fibre elements (Y) in the first fabric layer.
  • the long loop blisters (Z) of the second fabric layer are fully stretched as shown in FIG. 9 d ), they will also limit any further stretching of the elastic second fibre elements (Y) so as to maintain stability in the basis fabric.
  • FIG. 10 shows magnified images of the imitation leather fabric embodiment of the present invention when in a stretched state ( 10 c ) and after being stretching, in a relaxed state ( 10 d ). It is evident from these images that stretching of the imitation leather fabric embodiment does not result in distinctively visible cracks appearing.
  • magnified image ( 10 a ) is of an imitation leather fabric traditionally made from knitted fabric with a polyurethane resin coating when in a stretched state whilst image ( 10 b ) shows the fabric after being stretched, in a relaxed state.
  • stretching of the traditionally made imitation leather results in distinctive cracking (C) becoming visible.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dispersion Chemistry (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Woven Fabrics (AREA)
  • Laminated Bodies (AREA)
US14/399,846 2012-05-15 2012-05-15 Imitation leather fabric and method of producing same Abandoned US20150159320A1 (en)

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PCT/CN2012/000662 WO2013170395A1 (fr) 2012-05-15 2012-05-15 Tissu de similicuir et son procédé de fabrication

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Cited By (3)

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US20130048140A1 (en) * 2010-02-26 2013-02-28 Sanko Tekstil Isletmeleri San. Ve Tic. A.S. Woven fabric that looks and performs like a knitted fabric and method of making thereof
US20150299944A1 (en) * 2012-12-18 2015-10-22 Kyowa Leather Cloth Co., Ltd. Laminated sheet and method of manufacturing the same
USRE49640E1 (en) * 2012-07-12 2023-09-05 Chen Feng Method of manufacturing velvet plush and article thereof

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WO2017091975A1 (fr) * 2015-12-01 2017-06-08 盈保发展有限公司 Tissu présentant une haute étirabilité, une bonne respirabilité, des capacités d'absorption de l'humidité et d'évacuation de l'humidité
WO2021179187A1 (fr) * 2020-03-10 2021-09-16 加通汽车内饰(常熟)有限公司 Cuir artificiel et procédé de préparation associé, et siège de véhicule et véhicule
IT202100016673A1 (it) * 2021-06-25 2022-12-25 Tecno Gi S P A Materiale di rinforzo per pelletteria e calzature

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Publication number Priority date Publication date Assignee Title
US6323144B1 (en) * 1999-08-20 2001-11-27 Milliken & Company Convertible fabric
US7484277B2 (en) * 2004-10-08 2009-02-03 Kuraray Co., Ltd. Nonwoven fabric for artificial leather and process for producing artificial leather substrate
CN201389997Y (zh) * 2009-03-18 2010-01-27 义乌市鑫挺人造革有限公司 仿真皮绒合成革
CN201416115Y (zh) * 2009-07-03 2010-03-03 海宁市顺达印花装饰品有限责任公司 一种运用分次印刷离型转移技术的仿真皮纺织面料

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130048140A1 (en) * 2010-02-26 2013-02-28 Sanko Tekstil Isletmeleri San. Ve Tic. A.S. Woven fabric that looks and performs like a knitted fabric and method of making thereof
US9885130B2 (en) * 2010-02-26 2018-02-06 Sanko Tekstil Isletmeleri Sanayi Ve Woven fabric that looks and performs like a knitted fabric and method of making thereof
US10221506B2 (en) 2010-02-26 2019-03-05 Sanko Tekstil Isletmeleri San. Ve Tic. A.S. Method of making woven fabric that performs like a knitted fabric
US11519108B2 (en) 2010-02-26 2022-12-06 Sanko Tekstil Isletmeleri San. Ve Tic. A.S. Woven fabric that looks and performs like a knitted fabric and method of making thereof
USRE49640E1 (en) * 2012-07-12 2023-09-05 Chen Feng Method of manufacturing velvet plush and article thereof
US20150299944A1 (en) * 2012-12-18 2015-10-22 Kyowa Leather Cloth Co., Ltd. Laminated sheet and method of manufacturing the same
US9885148B2 (en) * 2012-12-18 2018-02-06 Kyowa Leather Cloth Co., Ltd. Laminated sheet and method of manufacturing the same

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CN104602905B (zh) 2016-06-29
WO2013170395A1 (fr) 2013-11-21

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