US20230002964A1

US20230002964A1 - Innovative leather and manufacturing method thereof

Info

Publication number: US20230002964A1
Application number: US17/845,926
Authority: US
Inventors: Chih-Yi Lin; Kuo-Kuang Cheng; Li-Yuan Chen; Yung-Yu Fu; En-Chih Chang
Original assignee: San Fang Chemical Industry Co Ltd
Current assignee: San Fang Chemical Industry Co Ltd
Priority date: 2021-06-30
Filing date: 2022-06-21
Publication date: 2023-01-05
Also published as: TW202302959A; CN115538177A

Abstract

The present disclosure relates to an innovative leather and a manufacturing method thereof. The innovative leather includes a Polyester substrate, a Polyester adhering layer, and a Polyester surface layer. The Polyester adhering layer is disposed on the Polyester substrate. The Polyester surface layer is disposed on the Polyester adhering layer. All materials of the innovative leather of the present disclosure are the same Polyester materials, thus the innovative leather of the present disclosure can be recycled after the innovative leather of the present disclosure is used. The innovative leather of the present disclosure has recycling benefit.

Description

FIELD

The disclosure relates to an innovative artificial leather and a manufacturing method thereof.

BACKGROUND

Conventional methods for manufacturing an artificial leather generally use various complicated processes, and some of the processes require the use of a solvent, which is harmful to the environment and does not meet requirements for environmental friendliness. Moreover, the artificial leather manufactured by the conventional methods is made of different raw materials, so that the conventional artificial leather cannot be recycled after being used.

SUMMARY OF THE INVENTION

In accordance with one aspect of the present disclosure, an innovative leather includes a Polyester substrate, a Polyester adhering layer and a Polyester surface layer: The Polyester adhering layer is disposed on the Polyester substrate. The Polyester surface layer is disposed on the Polyester adhering layer.
In accordance with another aspect of the present disclosure, a manufacturing method of an innovative leather includes: providing a Polyester substrate; melt-blowing a Polyester adhering layer onto the Polyester substrate; melt-blowing a Polyester surface layer onto the Polyester adhering layer; and thermally compressing and bonding the Polyester substrate, the Polyester adhering layer and the Polyester surface layer.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

FIG. 1 is a schematic structural diagram showing an innovative leather according to an embodiment of the present disclosure.

FIG. 2 shows a flowchart of a manufacturing method of an innovative leather according to an embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

It is to be understood that the following disclosure provides many different embodiments or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. The present disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that this description will be thorough and complete, and will fully convey the present disclosure to those of ordinary skill in the art. It will be apparent, however, that one or more embodiments may be practiced without these specific details.
In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present.
It will be understood that singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms; such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
FIG. 1 is a schematic structural diagram showing an innovative leather according to an embodiment of the present disclosure. In an embodiment, the leather 10 of the present disclosure includes a Polyester substrate 11, a Polyester adhering layer 12 and a Polyester surface layer 13.
In an embodiment, the Polyester substrate 11 has a first surface 111 and a second surface 112. The second surface 112 is opposite to the first surface 111. The Polyester substrate 11 is made of a PET (Polyethylene Terephthalate) material, which is an engineering plastic. The Polyester substrate 11 may be a non-woven fabric formed by bonding 100% PET recycled cotton or a mixture of 60% PET recycled cotton and 40% PET cotton by needle punching; or a woven fabric formed by weaving 100% recycled PET fibers or common PET fibers. Therefore, the Polyester substrate 11 is completely made of the Polyester material. In an embodiment, the Polyester substrate 11 may be made of a TPEE (Thermoplastic Polyether Elastomer) material or a PBT (Polybutylene Terephthalate) material.
In an embodiment, the Polyester adhering layer 12 is disposed on the first surface 111 of the Polyester substrate 11. The Polyester adhering layer 12 may be made of a TPEE (Thermoplastic Polyether Elastomer) material, which is an engineering plastic having properties of an elastomer; or a PBT (Polybutylene Terephthalate) material, which is a thermoplastic engineering polymer. The Polyester adhering layer 12 has a weight of 50-400 g/m²and a density of 0.2-0.8 g/cm³. The Polyester adhering layer 12 is thermoplastic, in an embodiment, the Polyester adhering layer 12 may be made of a PET material.
In an embodiment, the Polyester surface layer 13 is disposed on the Polyester adhering layer 12. The Polyester surface layer 13 may be made of a PET, TPEE or PBT material. The Polyester surface layer 13 has a weight of 50-400 g/m²and a density of 0.5-0.9 g/cm³. The Polyester surface layer 13 is thermoplastic.
In an embodiment, the leather 10 of the present disclosure includes the Polyester substrate 11, the Polyester adhering layer 12 and the Polyester surface layer 13. The Polyester substrate 11, the Polyester adhering layer 12 and the Polyester surface layer 13 are made of a single Polyester material without other materials. Therefore, all materials of the leather 10 of the present disclosure are the same Polyester materials, thus the leather 10 of the present disclosure can be recycled and granulated after the leather of the present disclosure is used. The leather of the present disclosure has environmental benefit. Moreover, thermoplastic Polyester recycled particles obtained after recycling and granulation may be added to the manufacturing process of the leather 10 of the present disclosure to further enhance the recycling benefit, thereby saving the manufacturing cost.
In an embodiment, Since the leather 10 of the present disclosure is made of the single Polyester material which has higher glass transition temperature and melting point, when the leather 10 of the present disclosure is applied to a product, the product may have higher temperature resistance and thermal stability. Moreover, since the Polyester material has more excellent mechanical strength, when the leather 10 of the present disclosure is applied to a product, the mechanical strength of the product may be increased. For example, when the leather of the present disclosure is applied to a shoe material, the tensile strength and the tear strength may be increased, so the usability of the product may be enhanced. Furthermore, since the Polyester material has lower density, when the leather 10 of the present disclosure is applied to a product, the overall weight of the product may be decreased, which makes the product lighter and more suitable to wear for a long time.
In an embodiment, as described above, the thermoplastic Polyester recycled particles obtained after recycling and granulation may be added to the manufacturing process of the leather 10 of the present disclosure. The Polyester surface layer 13 includes a thermoplastic Polyester material and a thermoplastic Polyester recycled material. The thermoplastic Polyester material and the thermoplastic Polyester recycled material are mixed in a weight ratio of 75%:25% to 100%:0%.
FIG. 2 shows a flowchart of a manufacturing method of an innovative leather according to an embodiment of the present disclosure. With reference to FIG. 1 and FIG. 2 , referring to step S21 first, a Polyester substrate 11 is provided. The Polyester substrate 11 has a first surface 111 and a second surface 112. The second surface 112 is opposite to the first surface 111. In an embodiment, the Polyester substrate 11 is made of a PET (Polyethylene Terephthalates) material. The Polyester substrate 11 may be a non-woven fabric formed by bonding 100% PET recycled cotton or a mixture of 60% PET recycled cotton and 40% PET cotton by needle punching; or a woven fabric formed by weaving 100% recycled PET fibers or common PET fibers. Therefore, the Polyester substrate 11 is completely made of the Polyester material.
Referring to step S22, a Polyester adhering layer 12 is melt-blown onto the first surface 111 of the Polyester substrate 11. In an embodiment, the step of melt-blowing the Polyester adhering layer 12 further includes using first thermoplastic Polyester particles (not shown) having a melting point of 120-150° C. The first thermoplastic Polyester particles may be PBT particles or TPEE particles. In an embodiment, in the step of melt-blowing the Polyester adhering layer 12, a melt-blowing distance is 250-350 mm.
Referring to step S23, a Polyester surface layer 13 is melt-blown onto the Polyester adhering layer 12. In an embodiment, the step of melt-blowing the Polyester surface layer 13 further includes using second thermoplastic Polyester particles (not shown) having a melting point of 130-170° C. The second thermoplastic Polyester particles may be TPEE particles. In an embodiment, in the step of melt-blowing the Polyester surface layer 13, a melt-blowing distance is 150-250 mm.
In an embodiment, the step of melt-blowing the Polyester surface layer further includes using thermoplastic Polyester recycled particles. The second thermoplastic Polyester particles and the thermoplastic Polyester recycled particles are mixed in a weight ratio of 75%:25% to 100%:0%. The thermoplastic Polyester recycled particles may be thermoplastic Polyester recycled particles obtained by recycling and granulating the leather of the present disclosure after use.
Referring to step S24, the Polyester substrate 11, the Polyester adhering layer 12 and the Polyester surface layer 13 are thermally compressing and bonding. In an embodiment, in the thermally compressing and bonding step, a temperature is 140° C.-160° C. In the thermally compressing and bonding step, since the temperature is higher than the melting point of the first thermoplastic Polyester particles, the Polyester adhering layer 12 may be melted and then bonded with the Polyester substrate 11 and the Polyester surface layer 13.
In an embodiment, after the thermally compressing and bonding step, the leather of the present disclosure may be subjected to surface thermoplastic processing, such as a thermoplastic embossing process, such that the leather of the present disclosure has different surface textures.
Therefore, according to the manufacturing method of the leather of the present disclosure, the Polyester substrate 11, the Polyester adhering layer 12 and the Polyester surface layer 13 are made of the single Polyester material, and thus prepared from the single raw material, so the process and material preparation of the manufacturing method of the leather of the present disclosure are simplified, which can enhance the manufacturing efficiency and lower the manufacturing cost. In addition, the leather 10 of the present disclosure can be recycled and granulated after being used. The leather of the present disclosure has environmental benefit. Moreover, thermoplastic Polyester recycled particles obtained after recycling and granulation may be added to the manufacturing process of the leather 10 of the present disclosure to further enhance the recycling benefit, thereby saving the manufacturing cost.

Embodiment 1

100% recycled PET cotton or a mixture of 60% recycled PET cotton and 40% common PET cotton was bonded into a non-woven fabric by needle punching as a Polyester substrate 11.
TPEE particles, having a Shore hardness of 80 A and a melting point of 145° C., were dried at a set drying temperature of 70° C. for 4 hours until the measured water content was 200 ppm or below. Then, the TPEE particles were molten by a first extruder. The first extruder had a temperature of 170° C., 190° C., 210° C., 230° C. and 250° C. sequentially from a feed port to a discharge port, a die-head temperature of 250° C., a die temperature of 255° C. and a spinning nozzle hot air temperature of 275° C. A spinneret pressure was controlled at 1.0-3.0 MPa. A melt-blowing distance from the die to a mesh curtain was 300 mm. The melt-blown Polyester adhering layer 12 was stacked on the Polyester substrate 11 of the non-woven fabric in a fibrous manner. A stacking density was 0.6-0.8 g/cm³, a fiber fineness was 3-50 micrometers, and a stacking weight was 200 g/m².
TPEE particles, having a Shore hardness of 80 A and a melting point of 160° C., were dried at a set drying temperature of 80° C. for 4 hours until the measured water content was 200 ppm or below. Then, the TPEE particles were molten by a second extruder. The second extruder had a temperature of 220° C., 240° C., 260° C., 280° C. and 290° C. sequentially from a feed port to a discharge port, a die-head temperature of 290° C., a die temperature of 300° C. and a spinning nozzle hot air temperature of 320° C. A spinneret pressure was controlled at 1.0-3.0 MPa. A melt-blowing distance from the die to a mesh curtain was 250 mm. The melt-blown Polyester surface layer 13 was stacked on the Polyester adhering layer 12 in a fibrous manner. A stacking density was 0.6-0.8 g/cm³, a fiber fineness was 3-50 micrometers, and a stacking weight was 250 g/m².
The melt-blown and stacked three-layer structure (the Polyester substrate 11, the Polyester adhering layer 12 and the Polyester surface layer 13) was thermally compressed and bonded on a crawler belt. A heating temperature of the crawler belt was set to 150° C., a pressure was 2-5 Kg, an operating speed was 3 m/min. The composite structure was obtained.
Then, surface textures were made by a thermoplastic embossing process, such that a complete-Polyester recyclable environmentally-friendly synthetic leather could be obtained.

Embodiment 2

100% recycled PET cotton or a mixture of 60% recycled PET cotton and 40% common PET cotton was bonded into a non-woven fabric by needle punching as a Polyester substrate 11.
PBT particles, having a melting point of 145° C., were dried at a set drying temperature of 75° C. for 4 hours until the measured water content was 200 ppm or below. Then, the TPEE particles were molten by a first extruder. The first extruder had a temperature of 170° C., 185° C., 205° C., 225° C. and 245° C. sequentially from a feed port to a discharge port, a die-head temperature of 255° C., a die temperature of 255° C. and a spinning nozzle hot air temperature of 280° C. A spinneret pressure was controlled at 1.0-3.0 MPa. A melt-blowing distance from the die to a mesh curtain was 300 mm. The melt-blown Polyester adhering layer 12 was stacked on the Polyester substrate 11 of the non-woven fabric in a fibrous manner. A stacking density was 0.2-0.4 g/cm³, a fiber fineness was 3-50 micrometers, and a stacking weight was 150 g/m².
TPEE particles, having a Shore hardness of 80 A and a melting point of 165° C., were dried at a set drying temperature of 80° C. for 4 hours until the measured water content was 200 ppm or below. Then, the TPEE particles were molten by a second extruder. The second extruder had a temperature of 220° C., 240° C., 260° C., 280° C. and 290° C. sequentially from a feed port to a discharge port, a die-head temperature of 290° C., a die temperature of 300° C. and a spinning nozzle hot air temperature of 320° C. A spinneret pressure was controlled at 1.0-3.0 MPa. A melt-blowing distance from the die to a mesh curtain was 200 mm. The melt-blown Polyester surface layer 13 was stacked on the Polyester adhering layer 12 in a fibrous manner. A stacking density was 0.6-0.8 g/cm³, a fiber fineness was 3-50 micrometers, and a stacking weight was 200 g/m².
The melt-blown and stacked three-layer structure (the Polyester substrate 11, the Polyester adhering layer 12 and the Polyester surface layer 13) was thermally compressed and bonded on a crawler belt. A heating temperature of the crawler belt was set to 155° C., a pressure was 2-5 Kg, an operating speed was 3 m/min. The composite structure was obtained.
Then, surface textures were made by a thermoplastic embossing process, such that a complete-Polyester recyclable environmentally-friendly synthetic leather could be obtained.

Embodiment 3

100% recycled PET fibers or common PET fibers were woven into a woven fabric as the Polyester substrate 11.
TPEE particles, having a Shore hardness of 80 A and a melting point of 130° C., were dried at a set drying temperature of 70° C. for 4 hours until the measured water content was 200 ppm or below. Then, the TPEE particles were molten by a first extruder. The first extruder had a temperature of 170° C., 190° C., 210° C., 230° C. and 250° C. sequentially from a feed port to a discharge port, a die-head temperature of 250° C., a die temperature of 255° C. and a spinning nozzle hot air temperature of 275° C. A spinneret pressure was controlled at 1.0-3.0 MPa. A melt-blowing distance from the die to a mesh curtain was 300 mm. The melt-blown Polyester adhering layer 12 was stacked on the Polyester substrate 11 of the non-woven fabric in a fibrous manner. A stacking density was 0.6-0.8 g/cm³, a fiber fineness was 3-50 micrometers, and a stacking weight was 150 g/m².
TPEE particles, having a Shore hardness of 80 A and a melting point of 150° C., were dried at a set drying temperature of 75° C. for 4 hours until the measured water content was 200 ppm or below. Then, the TPEE particles were molten by a second extruder. The second extruder had a temperature of 220° C., 210° C., 260° C., 280° C. and 290° C. sequentially from a feed port to a discharge port, a die-head temperature of 290° C., a die temperature of 300° C. and a spinning nozzle hot air temperature of 320° C. A spinneret pressure was controlled at 1.0-3.0 MPa. A melt-blowing distance from the die to a mesh curtain was 250 mm. The melt-blown Polyester surface layer 13 was stacked on the Polyester adhering layer 12 in a fibrous manner. A stacking density was 0.6-0.8 g/cm³, a fiber fineness was 3-50 micrometers, and a stacking weight was 200 g/m².
The melt-blown and stacked three-layer structure (the Polyester substrate 11, the Polyester adhering layer 12 and the Polyester surface layer 13) was thermally compressed and bonded on a crawler belt. A heating temperature of the crawler belt was set to 140° C. a pressure was 2-5 Kg, an operating speed was 3 m/min. The composite structure was obtained.
Then, surface textures were made by a thermoplastic embossing process, such that a complete-Polyester recyclable environmentally-friendly synthetic leather could be obtained.

Embodiment 4

100% recycled PET fibers or common PET fibers were woven into a woven fabric as the Polyester substrate 11.
PBT particles, having a melting point of 145° C., were dried at a set drying temperature of 75° C. for 4 hours until the measured water content was 200 ppm or below. Then, the TPEE particles were molten by a first extruder. The first extruder had a temperature of 170° C. 185° C., 205° C., 225° C. and 245° C. sequentially from a feed port to a discharge port, a die-head temperature of 255° C., a die temperature of 255° C. and a spinning nozzle hot air temperature of 280° C. A spinneret pressure was controlled at 1.0-3.0 MPa. A melt-blowing distance from the die to a mesh curtain was 300 mm. The melt-blown Polyester adhering layer 12 was stacked on the Polyester substrate 11 of the non-woven fabric in a fibrous manner. A stacking density was 0.2-0.4 g/cm³, a fiber fineness was 3-50 micrometers, and a stacking weight was 150 g/m².
TPEE particles, having a Shore hardness of 80 A and a melting point of 155° C., were dried at a set drying temperature of 80° C. for 4 hours until the measured water content was 200 ppm or below. Then, the TPEE particles were molten by a second extruder. The second extruder had a temperature of 220° C., 240° C., 260° C., 280° C. and 290° C. sequentially from a feed port to a discharge port, a die-head temperature of 290° C., a die temperature of 300° C. and a spinning nozzle hot air temperature of 320° C. A spinneret pressure was controlled at 1.0-3.0 MPa. A melt-blowing distance from the die to a mesh curtain was 250 mm. The melt-blown Polyester surface layer 13 was stacked on the Polyester adhering layer 12 in a fibrous manner. A stacking density was 0.6-0.8 g/cm³, a fiber fineness was 3-50 micrometers, and a stacking weight was 200 g/m².
The melt-blown and stacked three-layer structure (the Polyester substrate 11, the Polyester adhering layer 12 and the Polyester surface layer 13) was thermally compressed and bonded on a crawler belt. A heating temperature of the crawler belt was set to 150° C., a pressure was 2-5 Kg, an operating speed was 3 m/min. The composite structure was obtained.
Then, surface textures were made by a thermoplastic embossing process, such that a complete-Polyester recyclable environmentally-friendly synthetic leather could be obtained.

Embodiment 5

The whole leather product of this disclosure in the above embodiments 1-4 is crushed and then melted and granulated to form thermoplastic polyester recycled particles.
100% recycled PET cotton or a mixture of 60% recycled PET cotton and 40% common PET cotton was bonded into a non-woven fabric by needle punching as a Polyester substrate 11.
TPEE particles, having a Shore hardness of 80 A and a melting point of 125° C., were dried at a set drying temperature of 70° C. for 4 hours until the measured water content was 200 ppm or below. Then, the TPEE particles were molten by a first extruder. The first extruder had a temperature of 170° C., 190° C., 210° C., 230° C. and 250° C. sequentially from a feed port to a discharge port, a die-head temperature of 250° C., a die temperature of 255° C. and a spinning nozzle hot air temperature of 275° C. A spinneret pressure was controlled at 1.0-3.0 MPa. A melt-blowing distance from the die to a mesh curtain was 300 mm. The melt-blown Polyester adhering layer 12 was stacked on the Polyester substrate 11 of the non-woven fabric in a fibrous manner. A stacking density was 0.6-0.8 g/cm³, a fiber fineness was 3-50 micrometers, and a stacking weight was 200 g/m².
TPEE particles, having a Shore hardness of 80 A and a melting point of 140° C., and the above thermoplastic polyester recycled. particles were mixed and were dried at a set drying temperature of 70° C. for 4 hours until the measured water content was 200 ppm or below. The thermoplastic polyester recycled particles are mixed into the TPEE particles, and the TPEE particles and the thermoplastic polyester recycled particles were mixed in a weight ratio of 85%:15%. Then, the mixed TPEE particles and the thermoplastic polyester recycled particles were molten by a second extruder. The second extruder had a temperature of 220° C., 240° C., 260° C., 280° C. and 290° C. sequentially from a feed port to a discharge port, a die-head temperature of 290° C., a die temperature of 300° C. and a spinning nozzle hot air temperature of 320° C. A spinneret pressure was controlled at 1.0-3.0 MPa. A melt-blowing distance from the die to a mesh curtain was 250 mm. The melt-blown Polyester surface layer 13 was stacked on the Polyester adhering layer 12 in a fibrous manner. A stacking density was 0.6-0.8 g/cm³, a fiber fineness was 3-50 micrometers, and a stacking weight was 200 g/m².
The melt-blown and stacked three-layer structure (the Polyester substrate 11, the Polyester adhering layer 12 and the Polyester surface layer 13) was thermally compressed and bonded on a crawler belt. A heating temperature of the crawler belt was set to 130° C., a pressure was 2-5 Kg, an operating speed was 3 m/min. The composite structure was obtained.
Then, surface textures were made by a thermoplastic embossing process, such that a complete-Polyester recyclable environmentally-friendly synthetic leather could be obtained.

Embodiment 6

The whole leather product of this disclosure in the above embodiments 1-4 is crushed and then melted and granulated to form thermoplastic polyester recycled particles.
100% recycled PET fibers or common PET fibers were woven into a woven fabric as the Polyester substrate 11.
TPEE particles, having a Shore hardness of 80 A and a melting point of 130° C., were dried at a set drying temperature of 70° C. for 4 hours until the measured water content was 200 ppm or below. Then, the TPEE particles were molten by a first extruder. The first extruder had a temperature of 170° C., 190° C., 210° C., 230° C. and 250° C. sequentially from a feed port to a discharge port, a die-head temperature of 250° C., a die temperature of 255° C. and a spinning nozzle hot air temperature of 275° C. A spinneret pressure was controlled at 1.0-3.0 MPa. A melt-blowing distance from the die to a mesh curtain was 300 mm. The melt-blown Polyester adhering layer 12 was stacked on the Polyester substrate 11 of the non-woven fabric in a fibrous manner. A stacking density was 0.6-0.8 g/cm³, a fiber fineness was 3-50 micrometers, and a stacking weight was 150 g/m².
TPEE particles, having a Shore hardness of 80 A and a melting point of 150° C., and the above thermoplastic polyester recycled particles were mixed and were dried at a set drying temperature of 75° C. for 4 hours until the measured water content was 200 ppm or below. The thermoplastic polyester recycled particles were mixed into the TPEE particles, and the TPEE particles and the thermoplastic polyester recycled particles were mixed in a weight ratio of 75%:25%. Then, the mixed TPEE particles and the thermoplastic polyester recycled particles were molten by a second extruder. The second extruder had a temperature of 220° C., 240° C., 260° C., 280° C. and 290° C. sequentially from a feed port to a discharge port, a die-head temperature of 290° C., a die temperature of 300° C. and a spinning nozzle hot air temperature of 320° C. A spinneret pressure was controlled at 1.0-3.0 MPa. A melt-blowing distance from the die to a mesh curtain was 150 mm. The melt-blown Polyester surface layer 13 was stacked on the Polyester adhering layer 12 in a fibrous manner. A stacking density was 0.6-0.8 g/cm³, a fiber fineness was 3-50 micrometers, and a stacking weight was 200 g/m².
The melt-blown and stacked three-layer structure (the Polyester substrate 11, the Polyester adhering layer 12 and the Polyester surface layer 13) was thermally compressed and bonded on a crawler belt. A heating temperature of the crawler belt was set to 140° C., a pressure was 2-5 Kg, an operating speed was 3 m/min. The composite structure was obtained.
Then, surface textures were made by a thermoplastic embossing process, such that a complete-Polyester recyclable environmentally-friendly synthetic leather could be obtained.
Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, and composition of matter, means, methods and steps described in the specification. As those skilled in the art will readily appreciate form the present disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized in accordance with some embodiments of the present disclosure.
Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, and compositions of matter, means, methods or steps. In addition, each claim constitutes a separate embodiment, and the combination of various claims and embodiments are within the scope of the disclosure.

Claims

What is claimed is:

1. An innovative leather, comprising:

a Polyester substrate;

a Polyester adhering layer, disposed on the Polyester substrate; and

a Polyester surface layer, disposed on the Polyester adhering layer.

2. The innovative leather of claim 1, wherein the Polyester substrate is a PET (Polyethylene Terephthalate) material, a TPEE (Thermoplastic Polyether Elastomer) material or a PBT (Polybutylene Terephthalate) material.

3. The innovative leather of claim 1, wherein the Polyester adhering layer is a PET (Polyethylene Terephthalate) material, a TPEE (Thermoplastic Polyether Elastomer) material or a PBT (Polybutylene Terephthalate) material.

4. The innovative leather of claim 3, wherein the Polyester adhering layer has a weight of 50-400 g/m²and a density of 0.2-0.8 g/cm³.

5. The innovative leather of claim 1, wherein the Polyester surface layer is a PET (Polyethylene Terephthalate) material, a TPEE (Thermoplastic Polyether Elastomer) material or a PBT (Polybutylene Terephthalate) material.

6. The innovative leather of claim 5, wherein the Polyester surface layer has a weight of 50-400 g/m²and a density of 0.5-0.9 g/cm³.

7. The innovative leather of claim 1, wherein The Polyester surface layer comprises a thermoplastic Polyester material and a thermoplastic Polyester recycled material, the thermoplastic Polyester material and the thermoplastic Polyester recycled material are mixed in a weight ratio of 75%:25% to 100%:0%.

8. A manufacturing method of an innovative leather, comprising:

providing a Polyester substrate;

melt-blowing a Polyester adhering layer onto the Polyester substrate;

melt-blowing a Polyester surface layer onto the Polyester adhering layer; and

thermally compressing and bonding the Polyester substrate, the Polyester adhering layer and the Polyester surface layer.

8. The manufacturing method of claim 8, wherein the step of melt-blowing the Polyester adhering layer further comprises using first thermoplastic Polyester particles having a melting point of 120-150° C.

10. The manufacturing method of claim 9, wherein the first thermoplastic Polyester particles are PBT particles or TPEE particles.

11. The manufacturing method of claim 8, wherein the step of melt-blowing the Polyester surface layer further comprises using second thermoplastic Polyester particles having a melting point of 130-170° C.

12. The manufacturing method of claim 11, wherein the second thermoplastic Polyester particles are TPEE particles.

13. The manufacturing method of claim 11, wherein the step of melt-blowing the Polyester surface layer further comprises using thermoplastic Polyester recycled particles, the second thermoplastic Polyester particles and the thermoplastic Polyester recycled particles are mixed in a weight ratio of 75%:25% to 100%:0%.

14. The manufacturing method of claim 8, wherein in the thermally bonding step, a temperature is 140° C.-160° C.

15. The manufacturing method of claim 8, wherein in the step of melt-blowing the Polyester adhering layer, a melt-blowing distance is 250-350 mm.

16. The manufacturing method of claim 8, wherein in the step of melt-blowing the Polyester surface layer, a melt-blowing distance is 150-250 mm.