WO2007047848A2 - Composite leather material - Google Patents
Composite leather material Download PDFInfo
- Publication number
- WO2007047848A2 WO2007047848A2 PCT/US2006/040902 US2006040902W WO2007047848A2 WO 2007047848 A2 WO2007047848 A2 WO 2007047848A2 US 2006040902 W US2006040902 W US 2006040902W WO 2007047848 A2 WO2007047848 A2 WO 2007047848A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- composite material
- leather
- fibers
- latex
- post
- Prior art date
Links
- 239000010985 leather Substances 0.000 title claims abstract description 139
- 239000002131 composite material Substances 0.000 title claims abstract description 117
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Classifications
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- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
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- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
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Definitions
- the following invention is generally in the field of composite materials, and is more specifically directed to composite materials including leather and a binding agent, which for the purpose of this application will be referred to as an ' engineered leather substrate.
- a variety of consumer goods are prepared from leather, including leather seats, leather apparel, and leather sporting goods. During manufacture, a certain amount of post-industrial waste is produced, as the leather is cut to shape. There is also a certain amount of post-consumer waste generated as leather goods are discarded.
- compositions and methods for using the post-industrial and/or post-consumer leather waste and usable to replace leather in a variety of articles of manufacture It would be advantageous to provide compositions and methods for using the post-industrial and/or post-consumer leather waste and usable to replace leather in a variety of articles of manufacture.
- the present invention provides such compositions and methods.
- the present invention is directed to an engineered leather substrate, methods of making the substrate, engineered leather composites including the substrate, and articles of manufacture which include the engineered leather substrate and/or composite.
- the engineered leather substrate includes non-leather fibers, a binding agent and one or more additional components.
- Representative additional components include cushioning agents, softeners, processing aids, and colorants.
- a composite material can be formed that includes the substrate and one or more additional layers.
- Representative additional layers include top coat layers, reinforcing layers, and cushioning layers. The substrate and/or the composite can be chemically or mechanically embossed.
- the leather used to form the engineered leather substrate can be in the form of fibers, dust, particles, strips, and the like, and generally falls in the size range of between about 0.1 microns and 50 mm, ideally between about 2 mm and 6 mm. hi some embodiments, the leather is derived from post-industrial and/or post-consumer materials.
- the non-leather fibers can be organic or inorganic.
- organic fibers include, but are not limited to, cellulosic fibers, for example, cotton or wood pulp, polyamides, polyester, polyolefms, and polyurethanes and the like.
- inorganic fibers include but are not limited to glass fibers.
- the composition can also include inorganic fillers, such as calcium carbonate, and clays.
- the cushioning agents which generally comprise between 0 and about 50% by weight of the substrate, are elastomeric materials or provide elastomeric type properties. Such agents include, for example, foam, rubber particles, and other low density cushioning agents.
- binding agents can be synthetic or natural.
- binding agents include but are not limited to synthetic latex, natural latex, polyvinyl alcohol (PVA), and starch.
- a softener such as an oil or a humectant can also be present.
- Processing aids examples of which include retention aids, flocculants, and the like, can also be present.
- the engineered leather substrate can be coated and/or embossed for numerous reasons, depending on the end use application.
- Suitable coating layers include, but are not limited to, acrylic and/or polyurethane layers.
- Color coats can be used, and a primer coat can be present between the substrate and the topcoat layer.
- the engineered leather substrate can contain a reinforcing material bound to the substrate, or embodied within the substrate, to provide added strength and/or other properties such as additional softness. This can be done during the wet-lay process or post-processing through the use of adhesives that are water based, 100% solids, UV and moisture cure, hot melt, and the like.
- Representative reinforcing materials include scrims, woven and non-woven materials, films, metal meshes or sheets, and the like.
- the layers can be dyed and/or embossed, chemically and/or mechanically, to provide the composite material with a variety of designs including, but not limited to, geometries, animal prints, floral designs, and the like, for reasons of aesthetics, functionality, or other end use requirements.
- the engineered leather substrate exhibits less shrinking when formed than is observed when other known processes for producing leather materials are used.
- the leather substrate also advantageously provides desirable acoustical properties, for example, sound insulation, absorption, reflection, and deflection.
- the engineered leather substrate can be thermally and/or vacuum molded into desired end-products.
- the engineered leather substrate and/or the composite material formed from this substrate can be used in virtually all applications for which leather itself is used. Examples include, but are not limited to, leather seats, car interiors, briefcases, apparel, furniture, and the like.
- the present invention will be better understood with reference to the following detailed description.
- the various components of the engineered leather substrate, and composite materials, including the substrate and topcoat layers, reinforcing layers, and/or adhesives, are discussed in detail below.
- the resulting engineered leather substrate and resulting composite are unique materials. Examples of the uniqueness of the materials include, but are not limited to, lighter weight material than traditional leather, manufacturing efficiencies (utilizing existing equipment with reduced waste), and flexibility of design for multiple end-use applications.
- the engineered leather substrate and resulting composite can provide strategic acoustic properties, improved softness, breathability, and conformability.
- the original manufacturer of the leather used to form the composite material can obtain a cost benefit, because landfill and/or incineration costs are reduced.
- the manufacturer of the engineered leather substrate and resulting composites also obtains a cost benefit because the material cost is reduced, and the engineered leather substrate can be used in a finished three-dimensional part or application.
- the engineered leather substrate includes leather, non-leather fibers, and a binding agent, hi addition, the substrate includes one or more additional components. Examples of these components are described in more detail below.
- the leather can be from virtually any source of leather, including virgin materials, post-industrial materials, and post-consumer materials.
- post- consumer and post-industrial materials include, but are not limited to, shoes, fabrics, furniture, office products, clothing, automotive applications, sporting goods, recreational vehicles, construction materials, aircraft, tack, and the like.
- the sources of leather can also include blue shavings, tanning shavings, split hide waste, reject/off specification hides (irregulars and seconds), buffing powder, pattern trim, binder waste, die cut waste, and sewing waste.
- the leather sources include virgin material and animal hides, including cow, ostrich, elephant, alligator, kangaroo, snake, lizard, and the like.
- Kangaroo leather is unique in that it actually tends to get stronger when it gets thinner, although it also tends to be a relatively expensive leather.
- engineered leather materials and regenerated leather material can also be used.
- the particle size of the leather is generally in the range of about 0.1 microns to 50 millimeters overall, ideally between about 2 and about 6 mm, and less than about 25 millimeters.
- the size of the leather particles is from about 0.1 micron to about 50 mm.
- the particles typically have a length of from 1-7 mm, but fine particles can also be used.
- the particles need not be of a constant diameter. They can be flattened/layered to achieve substantially constant thickness (i.e., no more than about 25% variance in thickness).
- the source of the leather fibers is known, it is possible to track these fibers through the process to the composite material and products formed from the composite material. As a result, it is possible to trace the fibers in the end product back to their source.
- the composition also includes additional fibers ("non-leather fibers").
- non-leather fibers When the composite leather material does not include such other fibers, the resulting material may not be optimal.
- One purpose of these other fibers is to provide breathability, porosity, strength, binding, processability, fire retardancy, and/or improved insulation properties to the composite material. Like the binding agents, these fibers are an integral part of a wet process for making sheet goods.
- the non-leather fibers can be organic and/or inorganic, and can be derived from post-industrial, virgin, and/or post-consumer fibrous materials. Representative examples include cellulosic materials, polymeric materials, and glass-like materials.
- the other fibers are typically in the range of between about 1 and about 50% by weight of the fibers (leather fibers and other fibers), between about 5 and about 30% by weight of the fibers, or between about 5 and about 20 % by weight of the fibers.
- the other fibers are post-industrial regenerated natural fibers which include, but are not limited to, cotton, wood, hemp and jute.
- the fibers can include synthetics, such as polyester, nylon, acrylics, polyamides, polyolefins such as polyethylene and polypropylene, polyethers, and aramids.
- the fibers range in size from nano to coarse deniers and lengths from 0.1 micron to 3 inch. These fibers most typically come from post-industrial sources as well. Representative natural fibers which can be added include hemp, jute, and kenaf.
- Certain of these fibers can provide fire retardancy, moisture management, strength, flexibility, drape and the like. Higher amounts of specific "non-leather fibers” tend to increase the stiffness of the composite materials, whereas higher amounts of other "non- leather fibers” tend to increase the softness of the composite materials.
- the stiffness and/or softness can be ascertained using standard ASTM, FLTM, SAE, or other assays for stiffness and softness.
- Representative assays include, for example, FLTM BN 157-01 (leather softness), ASTM D 2208 and D 571 (breaking strength), ASTM D 5733 (tear strength), FLTM BN 105-03 (shrinkage), SAE J948 (abrasion resistance), ISO 188, ATMS E 145, ISO 105-A02, ASTM D 683, AATCC- Process 1, and ISO R 527-Type 2 (resistance to heat aging), ASTM D 747 (stiffness), ISO 3795 and SAE J 369 (flammability).
- FLTM BN 157-01 leather softness
- ASTM D 2208 and D 571 breaking strength
- ASTM D 5733 to head strength
- FLTM BN 105-03 shrinkage
- SAE J948 abrasion resistance
- ISO 188 ATMS E 145, ISO 105-A02, ASTM D 683, AATCC- Process 1, and ISO R 527-Type 2 (resistance to heat aging), AS
- Representative natural materials include cotton, wood, wool, silk, hemp, and jute, Due to the large amount of cotton used in industrial textile processing, a significant amount of post-industrial cotton is available as a waste stream, and, accordingly, is a relatively inexpensive material. Opened, cut, and refined cellulose and cotton fiber can act to strengthen or soften the substrate. Certain natural fibers may require refining before blending with the leather.
- Representative synthetic materials include polyester, nylon, acrylics, polyamides, polyolefins such as polyethylene and polypropylene, polyethers, and the like. Due to the large amount of synthetics used in industrial processing of textiles, a significant amount of post-industrial synthetic material is available as a waste stream, and, accordingly, is a relatively inexpensive material. The addition of these fibers can contribute to other unique characteristics of the composite material. These characteristics are ideally measured by ASTM or other assay standards described herein, which vary depending on the end-use of the product. The amount of the other fibers vary depending on the unique characteristics of the product required to achieve the desired properties of the end-product including the composite leather material.
- the cushioning agents allow the material to have properties, such as softness and resiliency, that mirror those of some natural leathers. If the composite leather material is to be used for wall coverings, footwear or other similar applications, a cushioning agent may not be required. In addition to providing resiliency, the cushioning agents can provide additional functions such as enhanced acoustics, conformability and/or slip resistance.
- the amount of the cushioning agents ranges from 0 to about 50%, in another embodiment, between about 1 and about 25 %, and in a third embodiment, between about 5 and about 15 %.
- elastomeric and “cushioning agent” encompass particles formed of an elastomer, including, but not limited to, other particles that act elastomeric by virtue of their compression/expansion behavior under stress even if the polymers themselves are not truly classified as elastomers.
- the cushioning agent is in the form of microspheres, which can be hollow, pre-expanded, or expandable microspheres.
- finely ground particles of rubber, foam, plastics, latex, and the like, ideally in the size range of 15 -150 microns, can be used
- the elastomeric agents provide the composite material with some degree of flexibility, and can also provide other benefits such as resiliency, acoustic properties, opacity, and the like. They are, however, specifically used in the leather substrates to provide some degree of beneficial rebound or memory effects.
- inorganic fillers are an integral part of the formulation. The fillers help to minimize the overall cost of the formulations, and provide other functions as well. The other functions include reinforcement, abrasion resistance, fire retardancy, noise reduction, heat resistance, barrier properties, porosity, efficiency in processing, and the like.
- the fillers can also provide smoothness to the sheet, therefore making it easier to emboss and, therefore, more aesthetically pleasing. They can also alter the porosity.
- the fillers are typically present in a weight range of from about 0 to about 50 percent, for example, about 0.5 to about 10 percent, and typically about 2 to about 6 percent.
- low density materials include ceramics and other non-elastomerics such as glass microbubbles, can be used as low density fillers, even if they don't necessarily provide cushioning.
- low density engineered materials includes materials engineered to fall within a size range of from 1 micron to one inch.
- the particles can have any shape, including spherical, plate-like, non-uniform, and the like. These particles are particularly useful in embodiments where light weight and/or cushioning is desired.
- suitable fillers include talc, mica, clay, titanium dioxide, carbon black, calcium carbonate and other metal carbonates, pigments, ceramic and zirconia microspheres, particulate forms of the 2 nd regeneration leather composite described herein, and the like.
- a 2 nd regeneration leather composite is formed from the composite material described herein, for example from waste material left over from end-use applications, which is converted to a filler for re-use.
- the filler formed from the 2 nd generation leather composite includes leather, non-leather fibers, binder, and other various components as described herein.
- the particles used can have a variety of shapes. They can range, for example, from non-spherical and/or non-uniform, to predominantly spherical, with a uniform shape. They can have a variable aspect ratio, and can be present in a relatively broad size distribution, so long as the particles provide the desirable properties, as fillers or as cushioning agents.
- the fillers include functional groups (i.e., functionalized fillers), and/or functional surfaces. These functional groups can permit subsequent chemical bonds to be formed, and can provide for various physical and chemical properties.
- the surface of a filler can be made hydrophilic, hydrophobic, fire retardant, and the like.
- suitable functional groups include halo, such as fluoro, hydroxyl, amine, thiol, carboxylic acid, sulfonic acid, amide, olefin, and the like.
- Binding agents help to bind the fillers, fibers and other ingredients in the formulation, and to provide strength and durability.
- the binding agents can provide an adhesive bond between the leather component and the other fibers, and can also provide structural and/or other characteristics, such as water resistance, to the composite and resulting products that include the composite.
- the binding agents include anionic, cationic, and non-ionic binders and are typically present in about 3 to about 50%, for example, between about 15 and about 35% by weight, on a dry weight basis.
- binders/binding agents include latex materials, such as butadiene copolymers, acrylates, vinyl-acrylics, styrene-acrylics, styrene-butadiene, nitrile-butadiene, olefin containing polymers, e.g., vinyl acetate-ethylene copolymers, vinyl ester copolymers, halogenated copolymers, e.g., vinylidene chloride polymers.
- Latex binders when used, can contain functionality. Any kind of latex can be used, although acrylics may be preferred because they tend to provide good heat and light . stability.
- Acrylics include those formed from ethyl acrylate, butyl acrylate methyl (meth)acrylate, carboxylated versions thereof, glycidylated versions thereof, self-crosslinking versions thereof (for example, those including N-methyl acrylamide), and copolymers and blends thereof, including copolymers with other monomers such as acrylonitrile.
- Natural polymers such as starch, natural rubber latex, dextrin, cellulosic polymers, and the like can also be used.
- the type of processing aid, and whether a processing is needed, depends on the nature of the binder. If a cationic polymer is used, an anionic processing aid is required. If an anionic polymer is used, a cationic processing aid is required.
- cationic processing aids include cationic polyacrylamides, di/tri valent cations, metal salts, epichlorohydrin-amine adducts such as Kymene®, alum, polyamines, polyethylene imine, polylysine, and other cationic polymers. Processing aids are typically required for wet-laid processes, although the amount can be almost negligible. The amount can typically range from about 0.01 to about 5%.
- non-leather fibers, binding agent, fillers, and the like discussed above can be used to provide specific benefits in the end use product.
- the following optional components can be added separately or as part of the binding agent used in wet processing. Some components can be included into the finished product during post processing, for example, coating, impregnation, saturation, embossing, molding, and the like.
- Crosslinkers can be used to provide additional strength and durability. Examples include phenolics, melamine formaldehyde (MF) and urea formaldehyde (UF) resins, epoxies, isocyanates, ethylene imines, and metal salts.
- MF melamine formaldehyde
- UF urea formaldehyde
- Softeners and/or flexibilizers can be included to provide flexibility and hand to a product.
- the softeners are provided in ranges of between about 0 and about 30%, and the quantity will depend on the intended use. Examples include glycerine, silicones, plasticizers such as carboxylic acid esters, for example, citric and phthalate esters, lecithin and other phospholipids, oil emulsions, fats, oils, fatty acid and fatty acid derivatives such as epoxidized soybean oil, and fat liquor.
- Various humectants can also be used, some of which can have softening properties.
- humectants include, but are not limited to, propylene glycol, dipropylene glycol, glycerin, hexylene glycol, polyethylene glycol, sorbitol, mannitol, xylitol, urea, hyaluronic acid, lactamide monoethanolamine, acetamide monoethanolamine, and combinations thereof.
- Retention and Drainage Aids can be added to control the aggregate size of the fiber/filler flocculant formed in wet end processes. They can assist in the formation of a sheet form of the composite materials, and also reduce the time it takes to form sheets without leaving significant residues in the water. Examples include cationic polyelectrolytes, cationic latex, metal salts and metal ions such as alum, sodium chloride, and the like, other cationic materials such as epicholorohydrin-amine adducts, e.g., Kymene® products from Hercules, and polyethylene imines.
- additives can improve the water repellency and water absorbency characteristics of the substrate.
- Representative examples include wax, silicones, fluorinated materials, hydrocarbon additives, oils and fats.
- additives can improve the water-absorbing capability of the substrate.
- hydrophilic fibers as all or part of the other fibers.
- hydrophilic materials such as polyalcohols, for example polyethylene glycol and polyvinyl alcohol, hydrophilic silicones, polyethers, polycarboxylates, superabsorbent polymers, and the like.
- additives provide coloring to the substrate.
- additives include organic and inorganic pigments and dyes, examples of which include phthalocynanine blue, iron oxide, carbon black, indigo, and the like.
- additives can be added to keep the fillers and pigments wetted and well dispersed in the formulation, as well as providing other functional uses such as water absorbency. In wet end processing, they can also control the formation of the sheet.
- Examples include carboxylate, ethoxylate and sulfonate-based materials, e.g.,
- Tamol® L Tamol® 73 IA
- Morcryl ® All from Rohm and Haas.
- Chelating Agents are used to chelate the metal ions in the wet end process.
- EDTA and EDTA derivatives are additives that help to improve repellency to oil, fats and greases, and inc ;lluuddee fluorinated additives such as Scotch Guard®.
- a coagulant/flocculant can also be added to the fiber furnish to facilitate flocculation of the particles.
- Suitable cationic coagulants include alum and/or other polymer high charge coagulants, for example, polycationic (cationic polymers), and mineral salt divalent and trivalent ions, examples of which include calcium and aluminum salts, respectively.
- the process used to prepare the materials is a wet-laid process.
- the products are prepared using a single-ply fourdrinier machine. The process is described in more detail below.
- the wet laid process involves the formation of a fibrous mat or sheet from an aqueous slurry having a mixture of ingredients that contribute to strength, uniformity, and other sheet related properties important to a specific application.
- the ingredients in the mixture are chosen to improve processing, e.g,. retention aids or some specific property of the finished sheet, such as porosity, softness, water repellency, etc. It is typically a batch process in which all the components are added together at one stage in the process, in a sequential manner, or certain components can be withheld and added at an appropriate point in the process to have the most desirable effect in terms of the formation of the fibrous sheet and its properties.
- Typical processes that have been used for this purpose have traditionally been based on papermaking methods, and involve using a fourdrinier or cylinder machines in which the fibrous mat or sheet is formed on a preformed wire mesh, then dried and rolled into a finished rolled good. The thickness of the sheet is controlled by the amount of fiber and other ingredients in the slurry. These sheets can then be post processed using techniques such as calendaring, coating, laminating, bonding, embossing, extrusion, molding, etc., to add other layers or substrates that impart additional properties to the sheet such as strength, impermeability, styling, shape, dimensional stability, etc.
- the wet end process involves making an aqueous slurry in which a mixture of components is dispersed. This can be done as a batch process in which all of the components are added at the same time in a machine chest fitted with mixing capabilities or certain components may be held and added at the appropriate time and at a specified location (e.g., further downstream from the machine chest) to get the best desired results.
- a batch process one would typically start with water in the machine chest and in a sequential manner the other components can be added while mixing.
- fibers e.g., leather, cellulose, cotton, etc.
- fillers/pigments and dyes e.g., talc, carbon black, etc.
- binders such as latex and/or other resins
- retention and drainage aids e.g., alum, bentonite clays, cationic polymers, etc.
- wet and dry strength additives e.g., Kymene®
- ingredients that add specific functions to the finished product such as softening or cushioning agents (e.g., polymer microspheres, plasticizers, e.g., epoxidized soybean oil), crosslinkers, etc.
- softening or cushioning agents e.g., polymer microspheres, plasticizers, e.g., epoxidized soybean oil
- plasticizers e.g., epoxidized soybean oil
- crosslinkers etc.
- the order of addition is such that the fibers and fillers are added to the water and mixed well before the addition of the binder.
- the binder that is used is either anionic or nonionic in character and can only be deposited onto the fiber/filler surface by adding a cationic coagulant (retention/drainage aid) to the above mixture. This results in the formation of fiber/filler/binder floes or aggregates.
- the flocculant is usually the last component to be added to the process to get the deposition to take place. All other functional ingredients, such as softeners, crosslinkers, etc., are added prior to the addition of the flocculant.
- the amount of fibers, fillers, binders and the like which are added depend on the final basis weight or the thickness of the sheet that is to be made.
- the solids concentration of the slurry is ⁇ 3-4%, and is usually decided by the sheet formation process and the desired uniformity of the sheet. These processes are well known to those in the paper making art and have some similarities with other wet laid methods used in nonwovens.
- the conventional equipment that is typically used for such a wet end process involves the use of a fourdrinier or a cylinder machine. This is very well known in the paper making industry.
- the sheet that is formed on the wire is then typically dried over a drum drier and then rolled into sheet goods ready for shipment or post-processing.
- the binder can also be cationic in nature, unlike conventional anionic materials, and in such cases the material would have a natural affinity for the negatively-charged fibers and fillers and a cationic retention aid would not be needed. However, there may be a need in such a case to add some anionic retention aids to make sure that a substantial part of the solids are captured effectively on the screen.
- the forming wire screen can be made of polyolefms, polyester or other fiber materials that can become part of the sheet and can act as a scrim material that supports the fibrous sheet or mat that has been formed. Such replaceable wire mesh screens that can become part of the formed substrate are known in the art.
- the finished sheet can also go through several post processing steps such as calendering, lamination, extrusion, coating, embossing, foaming, molding, etc., to add further layers, modify the surface or attachments (e.g,. scrims, plastic extrusion, foam, etc.) that provide specific benefits such as strength, flexibility, dimensional stability, water repellency, etc.
- This can be done on-line using equipments such as size press, spray coating, laminating, etc., or off-line such as extrusion, embossing, etc.
- These post- or in- process steps enhance the value and features obtained from the sheet substrate made by the wet end process.
- the engineered leather substrate is coated with one or more topcoat layers.
- Such layers can improve the durability and or wearability of the material, provide UV protection, and/or provide a color to the material.
- the topcoat layer can be formed from any of a variety of suitable materials, including clear or. dyed, transparent, translucent or opaque materials. Examples of materials that can form the topcoat layer include but are not limited to acrylics and polyurethanes available in a variety of forms. Representative forms include solutions, solids, and dispersions.
- the coloring can be applied to the substrate itself, to one or more of the topcoat layers, or both.
- a primer is ideally used to seal the engineered leather substrate. If one dyes the substrate rather than applying the color in additional layers, it needs to be dyed before any other components are applied.
- Suitable primers include but are not limited to acrylics, urethanes, and silane-functionalized polymers.
- the color can be applied using pigments and dyes.
- suitable pigments include carbon black and titanium dioxide.
- Suitable dyes can include but are not limited to products from the family of dyes that are basic, reactive, or acid dyes
- the reinforcing layers can provide stitchability, strength, stretchability, and hand.
- the reinforcing layer can be any material that reinforces the substrate sufficiently for its desired end use. Examples include scrims, wovens, knits, non- wovens, solid sheets, films, foams, and the like. These layers can be formed from synthetic or organic fibers, fiberglass, plastics, metals such as steel, aluminum or tin, and other suitable materials.
- the layers can be applied using a chemical application process, a hot melt process, or a spun lace process, for example, to add drapeability and strength.
- the backing can be cushioning, such as a needle punch or sheet foam.
- the thickness and density of the reinforcing layer(s) varies depending on the nature of the end-product. In order to increase strength, scrim may be supplied to the composite web.
- Suitable scrim is known in the art and available commercially and may be a plastic material such as nylon, or may be metallic, for example, steel, aluminum or tin. Scrim may be either supplied to the process in which the composite web is formed in which case the composite web is formed in/on the scrim. In another embodiment, the scrim may be adhered to the formed composite web either just as it is formed but before drying, or to a dried composite web using an adhesive. In order to improve the hand, a crimp can be supplied to the composite.
- Crimping is known, particularly in the papermaking arts, to improve the hand (feel) of a web and equipment and processes are known in the art for such a purpose.
- suitable reinforcing materials include microdenier fabric construction, polyurethane or polyolefin foam, latex foam, and hot-melt backing. These can be provided with appropriate chemicals such that, when heated, the layer can provide chemical embossing to the composite material.
- the substrates can also be chemically and/or mechanically embossed prior to being attached to the leather substrate.
- the material can be subjected to plating, breathable film application, and/or molding steps.
- an adhesive is used to hold the substrate to the reinforcing layer.
- the reinforcing layer is itself an adhesive, for example, a polyolefin scrim, in which case, no adhesive is necessary.
- the adhesives can be in the form of a sheet, a scrim, a powder, a liquid, a curable composition, and the like. When provided in liquid form, they can be applied using a variety of methods, for example, knife coating, spray coating, employing a doctor blade, and the like.
- the adhesives can be curable, such as urethanes, acrylates, epoxies, thermoset, thermoplastic, such as ethylene vinyl acetate (EVA), polyvinyl chloride (PVC) plastisols, and polyolefms, such as polypropylene and polyethylene, hot-melt, pressure-sensitive adhesives, and rubber cement.
- the adhesive formulations can be 100% solids (i.e., all of the components of the composition are UV-curable, so there are no volatile emissions), water-based, or solvent-based.
- the material exhibits minimal shrinking, for example, around 5% versus the 40 to 50 % observed in traditional leather preparation, such as tanning processes.
- the other fibers appear to inhibit shrinkage of the regenerated leather, which is an improvement over the results with new leather.
- the filled nature of the material in some embodiments, provides sound absorptive properties.
- a substrate was formed including, in approximate ranges, leather (47%), nylon (10%), acrylic latex (15%) and epoxidized soybean oil (28%).
- This composite leather material provided relatively good drapability and tensile strength, and is suitable for use in automotive applications.
- the engineered leather substrate can be used to prepare articles of manufacture, such as apparel, garments and accessories, furnishings, leather seats, dashboards, and the like in automotive applications, footwear, office supplies, sporting goods and equipment, and entertainment industries.
- Representative product applications include, but are not limited to, automotive seating, automotive interiors, home, office, and retail furnishings and accessories, jewelry, belts and suspenders, watch bands, outerwear, footwear, apparel, hats, gloves, crafts and hobbies, saddle and tack, pet accessories, such as leashes, wall and floor coverings, menu covers, book bindings and covers, outdoor gaming equipment and accessories, toiletry kits, wallets, handbags, backpacks, luggage, sports balls, sports headgear, other athletic equipment, duffle bags, sports accessories, hydration bags, binocular and eyeglass cases, game pieces and accessories, camera bags and cases, costumes and novelties, and telecommunication and electronics accessories.
- pet accessories such as leashes, wall and floor coverings, menu covers, book bindings and covers, outdoor gaming equipment and accessories, toiletry kits, wallets, handbags, backpacks, luggage, sports balls, sports headgear, other athletic equipment, duffle bags, sports accessories, hydration bags, binocular and eyeglass cases, game pieces and accessories, camera bags and cases, costumes and novelties
- These articles of manufacture can be prepared using the engineered leather substrate and/or composite leather material described herein. Suitable properties needed for each of these articles of manufacture, and the various components needed in each article of manufacture are well known to those of skill in the art. For example, in non-cushioning applications, no cushioning agent is needed. In moldable applications, certain backing materials are needed. If the material is to be stitched, then the backing is typically more than just a scrim.
- FLTM BN 180-14 resistance to pilling
- FLTM BN 157-01 softness
- ASTM D 1813 thickness
- SAE J323-Method A cold flexibility
- ASTM D 2208 and ASTM D 571 breaking strength
- ASTM D 2208 elongation
- ASTM D 5733 retract strength
- FLTM BN 106-02 stress fatigue resistance
- FLTM BN 105-03 shrinkage
- FLTM BI 109-01 and FLTM BI 110-01 appearance
- ASTM D 523 gloss
- ISO 2411 FLTM BN 151-05, and DVM-0038-IP
- SAE J948 resistance to abrasion
- SAE J365 resistance to scuffing
- FLTM BO 111- 02 indention and recovery
- FLTM BN 103-01 resistance to migration, staining, and blocking
- FLTM BI 106-01 coating adhesion
- FLTM BN 180-14 resistance to pilling
- FLTM BN 157-01 softness
- a series of engineered leather substrates and composites was prepared using the following compositions:
- the acrylic latex can vary in monomer composition and functionality, which can provide different glass transition temperatures and other physical and chemical properties, depending on the desired end use. For example, if a relatively stiffer composite material is desired, the latex may include acrylonitrile and/or methyl methacrylate. If a relatively softer composite material is desired, the latex may include butyl acrylate and/or ethyl acrylate.
- the nitrile latex in this example was a carboxylated acrylonitrile/butadiene copolymer, although other nitrile latexes, such as those including styrene, and self-crosslinking versions, such as those including N-methyl acrylamide, can be used.
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- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Dermatology (AREA)
- Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
- Treatment And Processing Of Natural Fur Or Leather (AREA)
- Laminated Bodies (AREA)
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP06836398A EP1948432A4 (en) | 2005-10-20 | 2006-10-19 | Composite leather material |
MX2008005226A MX2008005226A (en) | 2005-10-20 | 2006-10-19 | Composite leather material. |
BRPI0617689-5A BRPI0617689A2 (en) | 2005-10-20 | 2006-10-19 | composite leather material |
JP2008536801A JP2009512792A (en) | 2005-10-20 | 2006-10-19 | Composite leather material |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US72854405P | 2005-10-20 | 2005-10-20 | |
US60/728,544 | 2005-10-20 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2007047848A2 true WO2007047848A2 (en) | 2007-04-26 |
WO2007047848A3 WO2007047848A3 (en) | 2009-04-30 |
Family
ID=37963283
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2006/040902 WO2007047848A2 (en) | 2005-10-20 | 2006-10-19 | Composite leather material |
Country Status (8)
Country | Link |
---|---|
US (1) | US20070184742A1 (en) |
EP (1) | EP1948432A4 (en) |
JP (1) | JP2009512792A (en) |
KR (1) | KR20080058495A (en) |
CN (1) | CN101563467A (en) |
BR (1) | BRPI0617689A2 (en) |
MX (1) | MX2008005226A (en) |
WO (1) | WO2007047848A2 (en) |
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JP2009207748A (en) * | 2008-03-05 | 2009-09-17 | Toyota Boshoku Corp | Genuine leather facing material, and method for molding the same |
EP2261137A1 (en) | 2009-06-11 | 2010-12-15 | Haynest B.V. | Moulded part as well as use of such a moulded part |
ITVI20100181A1 (en) * | 2010-06-29 | 2011-12-30 | Texim Srl | REGENERATED LEATHER AND A METHOD OF REALIZING SUCH A REGENERATED LEATHER. |
AT507040B1 (en) * | 2008-06-19 | 2013-11-15 | Lackinger Gerald Mag | cOMPOSITE BODY |
EP2808462A1 (en) * | 2013-05-30 | 2014-12-03 | Flooring Technologies Ltd. | Composite wood panel with leather particles or printed layer of leather particles and process for their preparation |
WO2022218977A3 (en) * | 2021-04-12 | 2022-11-24 | Nuvi Releaf Gmbh | New layer composite for use as imitation leather |
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- 2006-10-19 BR BRPI0617689-5A patent/BRPI0617689A2/en not_active IP Right Cessation
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- 2006-10-19 JP JP2008536801A patent/JP2009512792A/en active Pending
- 2006-10-19 MX MX2008005226A patent/MX2008005226A/en unknown
- 2006-10-19 EP EP06836398A patent/EP1948432A4/en not_active Withdrawn
- 2006-10-19 CN CNA2006800442566A patent/CN101563467A/en active Pending
- 2006-10-19 WO PCT/US2006/040902 patent/WO2007047848A2/en active Application Filing
- 2006-10-19 KR KR1020087011819A patent/KR20080058495A/en not_active Application Discontinuation
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Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2009207748A (en) * | 2008-03-05 | 2009-09-17 | Toyota Boshoku Corp | Genuine leather facing material, and method for molding the same |
AT507040B1 (en) * | 2008-06-19 | 2013-11-15 | Lackinger Gerald Mag | cOMPOSITE BODY |
EP2261137A1 (en) | 2009-06-11 | 2010-12-15 | Haynest B.V. | Moulded part as well as use of such a moulded part |
NL1037033C2 (en) * | 2009-06-11 | 2010-12-15 | Ingenia Holding B V | FORM AND APPLICATION OF SUCH FORM. |
ITVI20100181A1 (en) * | 2010-06-29 | 2011-12-30 | Texim Srl | REGENERATED LEATHER AND A METHOD OF REALIZING SUCH A REGENERATED LEATHER. |
WO2012001490A1 (en) * | 2010-06-29 | 2012-01-05 | Texim Srl | Regenerated bonded leather and method for making it |
EP2808462A1 (en) * | 2013-05-30 | 2014-12-03 | Flooring Technologies Ltd. | Composite wood panel with leather particles or printed layer of leather particles and process for their preparation |
EP2808463A1 (en) * | 2013-05-30 | 2014-12-03 | Flooring Technologies Ltd. | Composite wood panel with leather particles or printed layer of leather particles and process for their preparation |
WO2022218977A3 (en) * | 2021-04-12 | 2022-11-24 | Nuvi Releaf Gmbh | New layer composite for use as imitation leather |
Also Published As
Publication number | Publication date |
---|---|
US20070184742A1 (en) | 2007-08-09 |
BRPI0617689A2 (en) | 2011-08-02 |
EP1948432A2 (en) | 2008-07-30 |
CN101563467A (en) | 2009-10-21 |
WO2007047848A3 (en) | 2009-04-30 |
MX2008005226A (en) | 2008-10-17 |
KR20080058495A (en) | 2008-06-25 |
JP2009512792A (en) | 2009-03-26 |
EP1948432A4 (en) | 2012-01-25 |
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