WO2022149112A1

WO2022149112A1 - Flexible laminate product having the appearance of leather or hide

Info

Publication number: WO2022149112A1
Application number: PCT/IB2022/050169
Authority: WO
Inventors: Carlos VENDRELL RUS
Original assignee: Pyton, S.L.U.
Priority date: 2021-01-11
Filing date: 2022-01-11
Publication date: 2022-07-14
Also published as: ES2917923B2; ES2917923A1

Abstract

The invention relates to a flexible laminate product having the appearance of leather or hide, comprising a first layer of plastic material and a second layer of cork adhered to said first layer, characterised in that: the first layer consists of a fabric of polyester yarn obtained from recycled plastic materials, the second cork layer has a thickness of less than 0.2 millimetres, preferably between 0.14 and 0.16 millimetres, and comprises a dyeing and smoothing surface coating comprising: several thin, stacked layers consisting of a resin and pigments; at least one layer of dye-fixing lacquer; and an aniline buffer layer.

Description

DESCRIPTION

Flexible laminar product with the appearance of skin or leather.

Technical sector.

The flexible laminar product object of this invention is applicable in the manufacture of leather goods, footwear, decoration and decorative coatings of various objects.

State of the prior art.

Different laminar products or fabrics are currently known on the market that comprise a series of superimposed layers joined together, one of said layers incorporating a cork sheet or particles, and having a decorative printed surface.

In the state of the art it is worth mentioning the existence of some documents related to the present invention.

Specifically, document PT 11058 T refers to printed fabrics comprising at least two interconnected layers, a cork sheet or corrugated cork sheet and a layer of polymeric cover film. Application WO 2011/149370 A1 describes a malleable and moldable cork fabric, based on a natural or agglomerated cork matrix; the cork fabric comprising a first layer made of the natural or agglomerated cork matrix, impregnated with a polymeric material, and at least one second layer made of said polymeric material.

It is obvious that, although there are methods for the preparation of laminar products comprising cork, there are no previously known methods that are particularly adapted according to the specific properties of cork. The surface of a cork sheet that is not optimally prepared can undesirably become flawed and uneven. Likewise, a method that is not optimized according to the properties of the cork and/or the ability of the cork to be processed, or not, under some high physical conditions, can end up damaging the cork and producing a final product that is defective. Additionally, given the possible defects in a cork sheet not prepared in an optimized way, it is questionable that a non-optimized method can be easily applied to customize the decoration of the cork sheet adequately, easily and efficiently.

Explanation of the invention

The inventors of the present invention consider that the problem posed by the transfer or fixation of sheets on the cork layer by applying heat is the risk of causing burns in the cork.

The manufacture of flexible laminar products provided with a first layer of plastic material and a second layer of cork joined together, presents a series of drawbacks inherent to the use of cork when it is desired to obtain a product with an engraving that imitates leather or skin and that presents any desired coloration, since cork is practically impermeable to liquids and gases due to certain substances, such as suberin and waxes, present in its cell wall; and to the presence in said wall of hexagonal-shaped pores filled with air, which makes it inaccessible for other compounds.

On the other hand, it is worth mentioning that the engraving or stamping of the cork to form grooves or reliefs that imitate different types of skins or leathers is also a major problem since, unlike natural leather, which allows the engraving of reliefs to be made at about 100 °C, cork cannot withstand these temperatures without burning.

Therefore, the technical problem that arises is the development of a flexible laminar product, with the appearance of leather or leather, that is ecological and vegan and that allows obtaining an imitation of leather with reliefs and in different colors, for its application in the manufacture of leather goods, footwear and, in general, coatings for various objects; as well as the development of a method for the manufacture of said laminar product.

The flexible laminar product with the appearance of leather or leather, object of this invention, comprising a first layer of plastic material and a second layer of cork adhered to said first layer, has technical characteristics that allow a satisfactory resolution of the aforementioned problems. According to the invention, the first layer of the product consists of a polyester thread fabric obtained from recycled plastic materials, while the second layer of cork comprises a surface coating for staining and smoothing the cork, an embossing and a finish. superficial.

Said surface coating for tinting and smoothing the cork comprises: - several thin, superimposed layers of resin and pigments, and - at least one layer of dye-fixing lacquer; further comprising an aniline buffer layer.

The incorporation of the pigments in the aforementioned resin allows the desired tinting of the second layer of cork to be carried out, the color being integrated into said superimposed thin layers.

Said thin layers are preferably applied by spraying and may include around ten superimposed thin layers, which are pressed with a roller and dried before applying the next layer, so that the resin with pigment is introduced into the pores or irregularities of the cork, defining in it a smooth surface.

Advantageously, the flexible laminar product, object of the invention, may additionally comprise, above the aniline buffer layer, a final color definition finishing layer, with a glossy or matte texture, based on polyester.

To achieve the appearance of fur or leather, the second layer of cork may comprise an embossed, optionally patterned pattern imitating animal skins; having foreseen, as will be mentioned later, that said engraving is preferably carried out once the surface coating of tinting and smoothing has been applied and prior to the application of the aniline buffer layer and the final color and texture definition layer. polyester base.

With the characteristics mentioned above, the second layer of cork has a thickness of less than 0.20 millimeters and preferably between 0.14 and 0.16 millimeters. This thickness allows the laminar product obtained to have a suitable thickness for the manufacture of leather goods, footwear, or the coating of various objects. On the other hand, if the thickness is larger, it may cause problems during the covering of the pores on the cork surface. That is, a greater thickness would lead to defects during cork coating. In addition, a greater thickness would have too high a flexural strength to reproduce or imitate the properties of this type of product. On the other hand, the pores and/or holes that are obtained in a second layer of cork with a thickness of less than 0.20 millimeters and preferably between 0.14 and 0.16 millimeters, can be adequately covered and result in a Optimum flexible laminar product for the manufacture of leather goods, footwear, or the coating of various objects. In other words, the depth of said pores or holes and the coating effected prevents defects in the tinting, since these are more easily covered by the resin with pigment. Likewise, a thickness of less than 0.20 millimeters, preferably between 0.14 and 0.16 millimeters, of the second layer of cork allows the product to have adequate flexural strength for its application in the manufacture of the aforementioned products. .

The pigmented resin of the thin smoothing and tinting layers of the second layer of cork preferably comprises a polyurethane resin, which provides the cork with adequate resistance against scratches and wear, while maintaining the flexibility of the laminar product obtained. That is, a flexible sheet product according to the invention comprising polyurethane resin in the composition of the surface coating shows better abrasion resistance than a coating that does not comprise polyurethane resin, and is therefore preferable for use in the manufacture of leather goods, footwear and, in general, coatings for various objects. Furthermore, the polyurethane resin contributes better flexural strength than a product that does not comprise polyurethane resin in the surface coating.

In this sense, it should be mentioned that the thickness of the second layer of cork can be between 70% and 80% of the thickness of the first layer of fabric, said first layer of polyester thread fabric providing adequate resistance to the laminar product.

In order to maintain the properties related to the flexibility and resistance of the flexible laminar product, the first layer of fabric and the second layer of cork are preferably joined together by means of an aqueous dispersion adhesive of a self-crosslinking copolymer, free of plasticizer. The second layer of the flexible sheet product can be made of laminated cork. That is, the second layer can be made of laminated cork. Unlike granulated cork, laminated cork improves the visual appearance of the flexible laminar product, more faithfully reproducing the appearance of leather and obtaining a smoother surface and/or with fewer imperfections. In other words, the use of laminated cork avoids defects during tinting and provides a product with a more uniform surface. Despite the fact that laminated cork may initially present holes with a larger diameter than granulated cork, after the surface coating of tinting and smoothing, the final result of a flexible laminar product made with laminated cork results in a smoother surface and/or with fewer imperfections than with granulated cork.

This invention also includes a method of manufacturing the flexible laminar product described above, which has a series of advantages in regard to the application of the surface coating of tinting and smoothing, as well as the printing or engraving of reliefs on the surface. second layer of cork by applying heat, without burning the cork.

According to the invention, this manufacturing method initially comprises: the provision of a high-quality polyester thread made from recycled plastic materials, - the manufacture with the polyester thread of a first layer of fabric, and - the adhesion on said first layer of fabric of a second layer of cork with a thickness of less than 0.20 millimeters and preferably between 0.14 and 0.16 millimeters.

Subsequently, the application on the second layer of cork of a surface coating for tinting and smoothing, which initially comprises. This application first comprises the preparation of an aqueous solution of polyurethane resin and pigment for tinting cork in a predetermined shade, then applying a first thin layer of said aqueous solution of polyurethane resin and pigment on the cork. second layer of cork.

The application of this first thin layer of aqueous solution of polyurethane resin and pigments on the second layer of cork is carried out by spraying or spraying it; then performing roller pressing of said thin layer against the second layer of cork and drying of said first thin layer. With the pressure of the roller, the thin layer of the aqueous solution of polyurethane resin and pigment covers the possible irregularities of the cork surface to form a smooth and uniform surface.

Once said first thin layer is dry, the application is repeated between 5 and 10 times, pressing with a roller and drying successive layers of said aqueous solution of polyurethane resin and pigment, reaching the product once this superimposition of layers is finished. fine, up to 80% of the color of the tint to be obtained.

The repetitive application of successive thin layers of the aforementioned aqueous solution of polyurethane resin and pigment makes it possible to achieve homogeneity in thickness and texture and avoid tinting defects, thus overcoming the tendency of the cork to repel the pigment.

This manufacturing method subsequently contemplates the application of at least one layer of dye-fixing lacquer, said layer being made up of an aqueous solution of polyurethane, spray or aerosol type.

Subsequently, the engraving or stamping is carried out on the tinted surface of the second layer of cork with an embossed pattern of imitation leather or leather, and the buffering of the engraved surface with an alcohol and aniline solution. This buffering can be done manually by applying the alcohol and aniline solution with a sponge.

In one embodiment of the invention, this method additionally comprises the application of a final color-defining layer with a glossy or matte texture, based on polyester, on the aforementioned buffer.

It is worth mentioning that the engraving or embossing of this second layer of cork is done hot, at a temperature below 85° and preferably below 80° to prevent burns to the cork during the engraving or embossing of the cork. same.

Once the nature of the invention has been sufficiently described, it is stated for the appropriate purposes that the materials, shape, size and arrangement of the elements described may be modified, as long as this does not imply an alteration of the essential characteristics of the invention that are claimed below.

Brief description of the figures

To complement the description that is being made and in order to help a better understanding of the characteristics of the invention, a set of figures is attached as an integral part of said description where, for illustrative and non-limiting purposes, the following has been represented :

FIG. 1a shows a second layer of granulated cork according to the present invention.

FIG. 1b shows a second cork layer made of laminated cork according to the present invention.

FIG. 2a shows a flexible sheet product comprising a second layer of granulated cork according to one embodiment of the present invention.

FIG. 2b shows a flexible sheet product comprising a second layer of laminated cork according to one embodiment of the present invention.

Detailed description of the embodiments

In FIGS. 2a and 2b show different embodiments of a flexible laminar product with the appearance of skin or leather; understanding; a first layer of plastic material and a second layer of cork adhered to said first layer: characterized in that: the first layer consists of a polyester thread fabric obtained from recycled plastic materials, the second layer of cork has a thickness of less than 0 0.2 millimeters, preferably between 0.14 and 0.16 millimeters, and comprises a surface coating for tinting and smoothing comprising: several thin layers, superimposed, made up of a resin and pigments, at least one layer of fixing lacquer of the dye and; a layer of aniline buffer.

In FIG. 1 a shows a second layer of granulated cork that could be included in an embodiment of the flexible laminar product according to the present invention, and FIG 1b shows a second layer of laminated cork that could be included in another embodiment of the laminar product. flexible in accordance with the present invention. A second layer of granulated cork has a greater number of pores on the surface, which can present more difficulties during coating and present more defects and irregularities on the product surface than a product made with a second layer of laminated cork. Despite the fact that laminated cork may initially present holes with a larger diameter than granulated cork, after the surface coating of tinting and smoothing, the final result of a flexible laminar product made with laminated cork results in a smoother surface and/or with fewer imperfections than with granulated cork. A second layer of laminated cork presents better results to reproduce leather products and properties suitable for the manufacture of leather goods, footwear and, in general, coatings for various objects.

FIG 2a shows a flexible laminar product comprising a second layer of granulated cork according to one embodiment of the present invention and FIG 2b shows a flexible laminar product comprising a second layer of laminated cork according to another. embodiment of the present invention. Although both embodiments would fulfill the purpose of the invention, if we compare both figures we can see that the surface of the product in FIG 2b is smoother and more uniform, due to the characteristics of the second layer of laminated cork. In other words, the use of a second layer of laminated cork with a thickness of less than 0.2 millimeters, preferably between 0.14 and 0.16 millimeters, gives rise to a flexible laminar product with fewer defects on its surface, which can be produced during coating or tinting.

The second layer of cork used in the embodiments of FIG. 2a and 2b comprises an engraving forming a pattern in relief imitating skin or leather. However, it is contemplated that the second cork layer does not comprise any engraving. Such embodiments also comprise a polyester-based gloss texture and color-defining topcoat. In other embodiments, the use of a final color definition and matte texture layer is contemplated or that said final layer is not carried out.

The second layer of cork used in the previous embodiments has a thickness comprised between 70% and 80% of the thickness of the first layer of fabric. However, other percentages can be used to make the flexible sheet product.

Claims

1.- Flexible laminar product with the appearance of skin or leather; understanding; a first layer of plastic material and a second layer of cork adhered to said first layer: characterized in that:

- the first layer consists of a polyester yarn fabric obtained from recycled plastic materials,

- the second layer of cork has a thickness of less than 0.2 millimeters, preferably between 0.14 and 0.16 millimeters, and comprises a tinted and smoothed surface coating comprising:

- several thin layers, superimposed, made up of a resin and pigments,

- at least one layer of dye-fixing lacquer and;

- a layer of aniline buffering.

2. Flexible laminar product, according to claim 1, characterized in that it comprises a final layer for definition of color and glossy or matte texture, based on polyester.

3. Flexible laminar product, according to claim 1 or 2, characterized in that the second layer of cork comprises an engraving forming a pattern in relief imitating skin or leather.

4. Flexible laminar product, according to any one of claims 1-3, characterized in that the pigmented resin of the smoothing and tinting layers of the second cork layer comprises polyurethane resin.

5. Flexible laminar product, according to any one of claims 1-4, characterized in that the second layer of cork has a thickness between 70% and 80% of the thickness of the first layer of fabric.

6. Flexible laminar product, according to any one of claims 1-5, characterized in that the first layer of fabric and the second layer of cork are joined by means of an aqueous dispersion adhesive of a self-crosslinking copolymer, free of plasticizer.

7. Flexible laminar product, according to any one of claims 1-6, characterized in that the second layer is made of laminated cork.

8. Method of manufacturing a flexible laminar product with the appearance of skin or leather; characterized by comprising:

- provide a first layer of fabric comprising polyester yarn made from recycled plastic materials,

- adhering to said first layer of fabric a second layer of cork with a thickness of less than 0.2 millimeters and, preferably, between 0.14 and 0.16 millimeters,

- apply on the second layer of cork a surface coating of tinting and smoothing; comprising: preparing an aqueous solution of polyurethane resin and pigment for tinting cork in a predetermined shade, applying by spraying or spraying a first thin layer of the aqueous solution of polyurethane resin and pigment, roller pressing said layer thin against the second layer of cork and drying said first thin layer; repeat, between 5 and 10 times of application, pressing and drying successive thin layers of aqueous solution of polyurethane resin and pigment; and applying at least one layer of dye fixing lacquer;

- apply an engraving or stamping on the tinted surface of the second cork layer of a pattern in relief and,

- buffer the etched surface with a solution of alcohol and aniline.

9. Manufacturing method, according to claim 8, characterized in that it comprises applying a final layer to define the color and glossy or matte texture, based on polyester, on the buffer.

10. Manufacturing method, according to claim 8 or 9, characterized in that applying the engraving or stamping is done hot at a temperature below 85 ^e C. and preferably below 80 ^e .

11. Manufacturing method, according to any one of claims 8-10, characterized in that the first layer of fabric is provided:

- includes providing the polyester thread, and - make the first layer of fabric with the polyester thread.