US2071626A - Leather substitute and method of making the same - Google Patents

Leather substitute and method of making the same Download PDF

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Publication number
US2071626A
US2071626A US72798134A US2071626A US 2071626 A US2071626 A US 2071626A US 72798134 A US72798134 A US 72798134A US 2071626 A US2071626 A US 2071626A
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US
United States
Prior art keywords
adhesive
applying
making
fabric
flock
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
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Inventor
Harris Frank
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PLYMOUTH RUBBER CO Inc
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PLYMOUTH RUBBER CO Inc
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Application filed by PLYMOUTH RUBBER CO Inc filed Critical PLYMOUTH RUBBER CO Inc
Priority to US72798134 priority Critical patent/US2071626A/en
Application granted granted Critical
Publication of US2071626A publication Critical patent/US2071626A/en
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Expired - Lifetime legal-status Critical Current

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Classifications

    • 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
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y10T428/24438—Artificial wood or leather grain surface
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31826—Of natural rubber
    • Y10T428/31841—Next to cellulosic

Definitions

  • This invention relates to. materials closely simulating leather in appearance and capable of being used in place of leather for some purposes.
  • Material of this general nature has heretofore been made by napping a fabric and then treating the napped face with an adhesive in the nature of a rubber containing liquid so applied thereto as to saturate the nap, and to so treat the material, as by rolling while under tension, to. produce a leather-simulating surface.
  • the napping operation which picks the fibers from the individual strands of fabric acts to materially weaken the fabric and for some uses, as for linings for shoes, which are subjected to severe stresses in the pulling over and lasting operation, such weakening is a serious matter.
  • the present invention has for an object, therefore, to providematerial possessing all of the desirable characteristics of the product made from the napped fabric, but without the weakness produced by the napping operation, and which will also have certain other advantages over prior constructions, such as greater flexibility and registance "to abrasion and being less pipey when
  • a woven cloth is taken as the foundation material and to this cloth, with its fibers intact, is applied a coating of suitable adhesive cement such as, preferably, a rubber cement, although other types of cement, such as a nitrocellulose cement or combinations of suitable materials, may be employed.
  • suitable adhesive cement such as, preferably, a rubber cement, although other types of cement, such as a nitrocellulose cement or combinations of suitable materials, may be employed.
  • One or both surfaces of the cloth may be so coated.
  • flock is applied to the adhesively coated surface of the cloth.
  • This may be shaken on and beaten in in accordance with the usual method :of putting on flock, or it may be blown on with an air gun under sufficient air pressure to embed the fibers of the flock well into the adhesive.
  • flock fibers are usually shorter than the loosened fibers of a napped fabric. Preferably they are cotton.
  • the cement or adhesive is preferably then allowed to harden. Next the material is placed under tension to loosen the fibers and the flocked surface or surfaces are impregnated when under tension with a suitaLle surfacing binding material, such, for example, as a rubber-containing solution.
  • a rubber cement with a volatile solvent, or latex is quite suitable and preferably also, Where rubber is used, it may contain a suitable vulcanizing agent, together with accelerators, plasticizers, or other usual rubber-modifying or treating constituents, depending on the characteristics desired in the completed product.
  • the saturating adhesive is preferably pressed into the flocked surface as by passing the material between pressure rollers.
  • the saturating material is then set, as by passing'it through a drying chamber, and the sheet material is then subje'cted to further tension, and passed between pressure rollers to apply facial pressure, and allowed or caused to vulcanize or completely set, or the setting or vulcanization may be effected before the final treatment between the pressure rolls.
  • the material so formed may be further treated with surfacing agents such as pyroxylin, boiled oils, or the like, which .will give the desired surface finish tothe final product or will facilitate finishing operations such as embossing or the like, or the material may be otherwise surfaced as may be desired.
  • Material so formed is much stronger than that formed with a napped foundation fabric, so that lighter cloth may be used for equal strength. It also has a more closely bonded surfacing which is not so easily removed by abrasion as is the sheet material made from the napped fabric, as heretofore described. Likewise it has more body, due to the greater mass of fibers in the flocked surface than in the napped surface. When bent it has a finer surface wrinkling or piping, more closely simulating in this respect the piping or wrinkling of high grade leather than is the case of the material having a napped fabric foundation. It likewise is more flexible than this prior material and is capable of more stretching without damage.
  • the method of making a leather substitute which comprises adhesively applying flock to the surface of a woven cloth fabric, applying a binding saturant to said flocked surface, and subjecting said material to facial pressure while under tension.
  • the method of making a leather substitute which comprises applying an adhesive to the surface of a woven cloth fabric, applying flock to said adhesive and permitting the adhesive to harden, and then applying a binding saturant to said flocked surface while the material is under tension, and applying pressure thereto also while the material is under tension.
  • the method of making a leather substitute which comprises applying an adhesive to the surface of a woven cloth fabric, applying flock to said adhesive and permitting the adhesive to harden, and then applying a rubber-containing binding agent to said flocked surface while the material is under tension, and applying pressure thereto while the material is under tension.
  • the method of making a leather substitute which comprises applying an adhesive to the surface of a'woven fabric, applying flock to said adhesive and permitting the adhesive to harden and then applying a rubber-containing binding saturant to said flocked surface while the material is under tension, subjecting the material to pressure, drying and setting the saturant, again pressing under tension, and surface-coating the material.
  • the method of making a leather substitute which comprises applying an adhesive to the surface of a woven .cloth fabric, applying flock to said adhesive and permitting the adhesive to harden, and then applying a binding saturant to said flocked surface while the material is under tension, subjecting thematerial to pressure, drytension.
  • the method of making a leather substitute which comprises applying an adhesive to the surface of a woven cloth fabric, applying flock to said adhesive and permitting the adhesive to harden, and then applying a binding saturant to said flocked surface while the material is under tension, subjecting the material to pressure, drying the saturant, again pressing under tension and surface-coating the material.
  • a leather substitute which comprises a layer of woven cloth coated with rubber into which is embedded flock, and surfaced with rubber saturating said flock and in compressed condition produced by the process of claim 8.
  • the method which comprises applying an adhesive to the surface of a woven textile fabric, applying flock thereto and allowing the adhesive to harden to bond the flock to the fabric, then while the material is under tension saturating the flocked surface with a rubber-containing solution, setting and finishing the surface to simulate leather.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Description

Patented Feb. 23, 1937 UNITED STATES LEATHER SUBSTITUTE AND METHOD OF MAKING THE SAME Frank Harris, Sharon, Mass., assignor to Plymouth Rubber Company, Inc., Canton, Mass.,- a corporation of Massachusetts No Drawing. Application May 28, 1934, Serial No. 727,981
I 8 Claims. This invention relates to. materials closely simulating leather in appearance and capable of being used in place of leather for some purposes. Material of this general nature has heretofore been made by napping a fabric and then treating the napped face with an adhesive in the nature of a rubber containing liquid so applied thereto as to saturate the nap, and to so treat the material, as by rolling while under tension, to. produce a leather-simulating surface. The napping operation, however, which picks the fibers from the individual strands of fabric acts to materially weaken the fabric and for some uses, as for linings for shoes, which are subjected to severe stresses in the pulling over and lasting operation, such weakening is a serious matter.
The present invention has for an object, therefore, to providematerial possessing all of the desirable characteristics of the product made from the napped fabric, but without the weakness produced by the napping operation, and which will also have certain other advantages over prior constructions, such as greater flexibility and registance "to abrasion and being less pipey when In accordance with the present invention, therefore, a woven cloth is taken as the foundation material and to this cloth, with its fibers intact, is applied a coating of suitable adhesive cement such as, preferably, a rubber cement, although other types of cement, such as a nitrocellulose cement or combinations of suitable materials, may be employed. One or both surfaces of the cloth may be so coated. Next flock is applied to the adhesively coated surface of the cloth. This may be shaken on and beaten in in accordance with the usual method :of putting on flock, or it may be blown on with an air gun under sufficient air pressure to embed the fibers of the flock well into the adhesive. Such flock fibers are usually shorter than the loosened fibers of a napped fabric. Preferably they are cotton. The cement or adhesive is preferably then allowed to harden. Next the material is placed under tension to loosen the fibers and the flocked surface or surfaces are impregnated when under tension with a suitaLle surfacing binding material, such, for example, as a rubber-containing solution. For both the initial coating and this saturant, a rubber cement with a volatile solvent, or latex, either natural or artificial, is quite suitable and preferably also, Where rubber is used, it may contain a suitable vulcanizing agent, together with accelerators, plasticizers, or other usual rubber-modifying or treating constituents, depending on the characteristics desired in the completed product. The saturating adhesive is preferably pressed into the flocked surface as by passing the material between pressure rollers. The saturating material is then set, as by passing'it through a drying chamber, and the sheet material is then subje'cted to further tension, and passed between pressure rollers to apply facial pressure, and allowed or caused to vulcanize or completely set, or the setting or vulcanization may be effected before the final treatment between the pressure rolls. If desired, the material so formed may be further treated with surfacing agents such as pyroxylin, boiled oils, or the like, which .will give the desired surface finish tothe final product or will facilitate finishing operations such as embossing or the like, or the material may be otherwise surfaced as may be desired.
Material so formed is much stronger than that formed with a napped foundation fabric, so that lighter cloth may be used for equal strength. It also has a more closely bonded surfacing which is not so easily removed by abrasion as is the sheet material made from the napped fabric, as heretofore described. Likewise it has more body, due to the greater mass of fibers in the flocked surface than in the napped surface. When bent it has a finer surface wrinkling or piping, more closely simulating in this respect the piping or wrinkling of high grade leather than is the case of the material having a napped fabric foundation. It likewise is more flexible than this prior material and is capable of more stretching without damage.
From the foregoing description of the product and a method by which it may be made, it should be evident to those skilled in the art that various changes and modifications may be made without departing from the spirit orscope of this invention as defined by the appended claims.
I claim:
1. The method of making a leather substitute, which comprises adhesively applying flock to the surface of a woven cloth fabric, applying a binding saturant to said flocked surface, and subjecting said material to facial pressure while under tension.
2. The method of making a leather substitute, which comprises applying an adhesive to the surface of a woven cloth fabric, applying flock to said adhesive and permitting the adhesive to harden, and then applying a binding saturant to said flocked surface while the material is under tension, and applying pressure thereto also while the material is under tension.
3. The method of making a leather substitute, which comprises applying an adhesive to the surface of a woven cloth fabric, applying flock to said adhesive and permitting the adhesive to harden, and then applying a rubber-containing binding agent to said flocked surface while the material is under tension, and applying pressure thereto while the material is under tension.
4. The method of making a leather substitute, which comprises applying an adhesive to the surface of a'woven fabric, applying flock to said adhesive and permitting the adhesive to harden and then applying a rubber-containing binding saturant to said flocked surface while the material is under tension, subjecting the material to pressure, drying and setting the saturant, again pressing under tension, and surface-coating the material.
5. The method of making a leather substitute, which comprises applying an adhesive to the surface of a woven .cloth fabric, applying flock to said adhesive and permitting the adhesive to harden, and then applying a binding saturant to said flocked surface while the material is under tension, subjecting thematerial to pressure, drytension. I
6. The method of making a leather substitute, which comprises applying an adhesive to the surface of a woven cloth fabric, applying flock to said adhesive and permitting the adhesive to harden, and then applying a binding saturant to said flocked surface while the material is under tension, subjecting the material to pressure, drying the saturant, again pressing under tension and surface-coating the material.
'7. A leather substitute, which comprises a layer of woven cloth coated with rubber into which is embedded flock, and surfaced with rubber saturating said flock and in compressed condition produced by the process of claim 8.
8. The method which comprises applying an adhesive to the surface of a woven textile fabric, applying flock thereto and allowing the adhesive to harden to bond the flock to the fabric, then while the material is under tension saturating the flocked surface with a rubber-containing solution, setting and finishing the surface to simulate leather.
FRANK HARRIS.
US72798134 1934-05-28 1934-05-28 Leather substitute and method of making the same Expired - Lifetime US2071626A (en)

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