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
  • D06N3/12—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
• • C—CHEMISTRY; METALLURGY
  • C14—SKINS; HIDES; PELTS; LEATHER
  • C14C—CHEMICAL TREATMENT OF HIDES, SKINS OR LEATHER, e.g. TANNING, IMPREGNATING, FINISHING; APPARATUS THEREFOR; COMPOSITIONS FOR TANNING
  • C14C11/00—Surface finishing of leather
  • C14C11/003—Surface finishing of leather using macromolecular compounds
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• • 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
  • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
  • D06N3/0061—Organic fillers or organic fibrous fillers, e.g. ground leather waste, wood bark, cork powder, vegetable flour; Other organic compounding ingredients; Post-treatment with organic compounds
• • 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
  • D06N3/04—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 by reactions only involving carbon-to-carbon unsaturated bonds
• • 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
  • D06N3/04—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 by reactions only involving carbon-to-carbon unsaturated bonds
  • D06N3/10—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 by reactions only involving carbon-to-carbon unsaturated bonds with styrene-butadiene copolymerisation products or other synthetic rubbers or elastomers except polyurethanes
• • 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
  • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10S428/00—Stock material or miscellaneous articles
  • Y10S428/904—Artificial leather

Definitions

• the present invention relates to a process for making and finishing artificial hides or leathers.
• the main object of this invention is to produce a material having characteristics similar to natural leather.
• Porosity is a distinctive feature of natural leather and is the feature of natural leather which makes same preferred over plastic materials for many uses. I have found that by bonding and coating natural or synthetic fibers with a natural or synthetic latex, in the hereinafter described manner, useful materials can be attained, the characteristics or" feel and porosity of which are practically the same as those of natural leather.
• textile fibers such as cotton, rayon, nylon, acetated fibers, etc., and their waste or combinations of same, are formed into Webs, e.g., in a carding engine, and by laying the Webs one over the other a lap is made of the desired thickness.
• This lap may also be prepared in a machine commonly called a Curlator.
• the lap of the desired thickness is dipped into a latex bath which is characterized by the ability to coagulate at atemperature in the range of from about 60 to about 80 C. and is of approximately the following composition:
• the latex-impregnated lap obtained from the immersion in the latex bath then is heated to a temperature in the range of from about 60 to about 80 C. for a time period requisite to effect the coagulation of the latex and to bond the fibers of the lap together.
• Any suitable means can be employed to effect the coagulation-efiecting heating of the lap.
• the lateximpregnated lap is passed continuously through an oven, the inside temperature of whichis maintained at about 200 to 300 C., at a rate which allows the latex-impregnated lap to be heated to the aforementioned latexcoagulation conditions.
• Coagulation can also be obtained by means of dielectric heating, hot contact, or infrared rays, etc. The object of the invention is not affected by the means for heating the impregnated lap.
• a latex bath having substantially the above-characteristics is employed in order to achieve a final leather-like product of uniform properties.
• Latices which coagulate much below 60 C., e.g., at about 40 C., are difficult to utilize in that premature coagulation in the latex bath preliminary to 3,185,582 Patented May 25, 1965 the impregnation of the lap is a problem.
• latices which coagulate at much above 80 C. e.g., at about 95 C.
• the increased tendency of water in the latex-impregnated lap to evaporate sets up convection currents in the latex solids dispersion which causes rubber particles therein to tend to migrate to the surface of the impregnated lap and coagulate there.
• This migration deprives the fibers located within the interior of the lap of intended bonding material, whereby an inferior product which is likely to delaminate is obtained.
• the impregnated lap loses part of its water by evaporation, but it still contains an appreciable proportion of that initially present, e.g., about 100 to about 300% by weight, based on the dry weight of the bonded lap, and the resultant water-containing bonded lap is squeezed through rolls or by press, neither the rolls nor the press being heated, to reduce the water content of the bonded lap, after which operation the material of reduced water content is dried at a temperature not above 120 C.
• the material after squeezing and before drying, shall contain an amount of water of from to 50% of the total weight of such material so that, upon the evaporation of the water in the drying step, the spaces occupied by the water in said bonded material of reduced water content are superseded by air cells which, in the resultant dry artificial leather product, impart to it the characteristic of porosity.
• the porous, bonded material when it is dry it is coated by means of aerographing, brushing, calender spreading or analogous methods, the coating, or paint, being prepared with casein containing plasticizers such as sulphoricina-ted oil, glycerine, dibutyl phthalate, etc., pigments to impart the desired color such as synthetic iron oxides, loading or filling materials to provide appropriate feel, such as titanium dioxide, lithopone, barium chloride, barium sulphate,
• Coating materials prepared with the foregoing elements lack bonding power and resistance in order to avoid premature aging; and their abrasive resistance also usually has to be increased. All of these necessary properties are obtained by adding to the said coating materials aqueous dispersions of resins such as acrylonitrilebutadiene copolymers, butadiene-styrene copolymers, polyvinyl chloride, polymethyl-methacrylate, other poly- 1 meric derivatives of the acrylates, mixtures of said resins,
• resins such as acrylonitrilebutadiene copolymers, butadiene-styrene copolymers, polyvinyl chloride, polymethyl-methacrylate, other poly- 1 meric derivatives of the acrylates, mixtures of said resins,
• composition An example of a coating mixture, or paint, employed in the present invention may be prepared according to the following composition:
• Pigments for example, synthetic iron oxides,
• Dibutyl phthalate 20 to 35 After applying one coat of the paint on the porous artificial leather, another coat is applied, or two or three as circumstances require, in the latter instances with a paint similar to that described above but free of Wetting agent and characterized by a substantial or total reduction in glycerine or dibutyl phthalate content. As the coats are applied they are dried. When these coats are dry a lustre coat is applied which may be as follows:
• Casein Parts by weight (dry) Casein (dissolved in water, 15 100 Resin (any one or a combination of those given above) 50 Plasticizer (sulphoricinated oil, for example) 25 to 60 Approximately 2% of formaldehyde or other antiferment is added to all these compositions to avoid posterior decomposition of the casein.
• the lustre coating is dry, the resulting coated material is treated again with a 15% to 20% formaldehyde solution and thereafter dried at room temperature or in a drying chamber with hot air at 50 to 80 C. After such drying, the material is ironed at 70 to 80 C. for 5 to 30 seconds at a pressure of approximately from about 25 to about 50 kgs./cm
• a coating e.g., based primarily on plasticized polyvinyl chloride free of casein, is applied to the porous, dry bonded lap prepared by the aforementioned impregnating, coagulating, squeezing and drying steps to provide an excellent leatherlike product.
• polyvinyl chloride coating layer is the following:
• the latex contained in the agglomerating mixture present in the impregnated fiber lap is coagulated by means of heat, and then the material is squeezed, eliminating water contained in the coagulated mass in a proportion which may represent from one to three times the weight of the artificial leather in dry condition.
• the material After squeezing, the material must still contain from 20 to 50% of its weight in water.
• the pressure exerted by the press or squeezing cylinders for squeezing the material after coagulation has to be adjusted so as to leave in the material a water content varying from 20 to 50% of the Weight of the material, according to the end uses for which the artificial leather is intended.
• the material is dried, and once the drying is totally completed the material is suitable for receiving a coating of a weight ranging from 70 to 300 grams per square meter, approximately, and
• the ultimate use of the artifical leather of the present invention does not necessarily require that it be porous, over the first PVC coating which is perfectly anchored on the agglomerated fibers to provide a material possessing the precisely desired degree of porosity, other coating layers may be applied, thus increasing the thickness thereof as desired.
• a method for producing a substitute leather from a lap of fibers comprising impregnating said lap with a latex selected from the group consisting of natural latex, synthetic latex, and mixtures thereof, heating the resultant latex-impregnated lap at a temperature in the range of from about 60 to about C.
• a method for producing a substitute leather from a lap of fibers consisting of impregnating said lap with a latex, heating the impregnated lap at a temperature in the range of from about 60 to about 80 C. for a time period sutiicient to coagulate the latex and bind the fibers of the lap together and to produce a bonded lap containing water in an amount appreciably above 50% by weight of said latex-impregnated lap, squeezing said water-containing bonded lap to reduce the water content thereof to a level in the range of from about 20 to about 50% by weight based on the dry weight of the lap, drying the resulting bonded lap of reduced water content at a temperature of about C.
• said latex is selected from the group consisting of natural latex, synthetic latex, and mixtures thereof.
• a method for producing a substitute leather from a lap of fibers consisting of impregnating said lap with a latex selected from the group consisting of natural latex, synthetic latex, and mixtures thereof,
• resultingporous, dry lap with a plurality of coats including a first coat, intermediate coats, and a final coat,,of a resinous dispersion mixture comprising casein, a polymer selected from the group consisting of butadiene-styrene, butadiene-acrylonitrile, polyvinyl chloride, methylmethacrylate, and mixtures thereof, and pigments, fillers, and at least one plasticizer heating the coated lap after each coating to a temperature sufiicient to dry thecoating material and thereby provide a producthaving substantially the porosity of a similarly coated natural leather.
• a resinous dispersion mixture comprising casein, a polymer selected from the group consisting of butadiene-styrene, butadiene-acrylonitrile, polyvinyl chloride, methylmethacrylate, and mixtures thereof, and pigments, fillers, and at least one plasticizer heating the coated lap after each coating to a temperature sufiicient to dry theco
• a method for producinga substitute leather from a lap of fibers consisting of impregnating said lap with latex, heating the impregnated lap at a temperature in the range of about 60 to about 80 C. for a time period suflicient to coagulate the latex and bind the fibersof the lap together and, to produce a bonded lap containing Water in an amount appreciably above 50% by weight of said latex-impregnated lap, squeezing said water-containing bonded lap to reduce the water content" thereof toa level in the range of about 20 to about 50% by Weight based on the dry lap, drying the resulting bonded lap-of reduced water content at a temperature of about 120 coating material is deposited on said lap in a total amount C.
• said latex is selected from the group consisting of natural latex, synthetic latex and mixtures thereof.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Textile Engineering (AREA)
• Dispersion Chemistry (AREA)
• General Chemical & Material Sciences (AREA)
• Wood Science & Technology (AREA)
• Life Sciences & Earth Sciences (AREA)
• Organic Chemistry (AREA)
• Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Laminated Bodies (AREA)
• Compositions Of Macromolecular Compounds (AREA)

Priority Applications (9)

Applications Claiming Priority (2)

Publications (1)

Family

ID=22231978

Family Applications (1)

Country Status (6)

Cited By (21)

Families Citing this family (4)

Citations (10)

Family Cites Families (1)

• 0
  • DE DENDAT1288061D patent/DE1288061B/de active Pending
• 1954
  • 1954-12-16 DE DEA21751A patent/DE1204618B/de active Pending
  • 1954-12-16 FR FR1115864D patent/FR1115864A/fr not_active Expired
  • 1954-12-16 FR FR1115866D patent/FR1115866A/fr not_active Expired
• 1961
  • 1961-02-28 US US92170A patent/US3185582A/en not_active Expired - Lifetime
• 1962
  • 1962-02-23 FR FR888990A patent/FR81199E/fr not_active Expired
  • 1962-02-28 ES ES0275317A patent/ES275317A1/es not_active Expired
  • 1962-02-28 GB GB7777/62A patent/GB992261A/en not_active Expired
  • 1962-02-28 NL NL275386A patent/NL126058C/xx active

Patent Citations (10)

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