Patent Application
20170225438
The present invention relates generally to artificial leather devices and methods and, more specifically, three-dimensional enhancements of composite/laminated materials of same.
Synthetic leather materials are used in a variety of industries. For example, in the automotive industry, synthetic leather is widely used to cover seating, steering wheels, interior panels, and the like. This material is advantageous over animal leather for a number of reasons, including environmental impact, cost, durability, and customizability. Synthetic leather is typically a lighter weight, its production is more efficient, and its price is significantly lower than genuine/animal leather.
As between the different types of synthetic leather, a polyurethane (“PU”) based leather has advantages over polyvinyl chloride (“PVC”) based leather. Synthetic PU leather is lighter weight, is typically odorless, and has enhanced air permeability as compared to PVC leather. Furthermore, PU leather does not contain environmentally harmful substances such as the plasticizers that are found in PVC. Additionally, PU leather does not suffer from the rigidity constraints currently exhibited by PVC products.
In view of the many advantages of PU leather, efforts have focused on expanding its styling possibilities, including diversifying its appearance and improving its haptic quality. The term “haptic” refers to the touch and feel of the material. Both the appearance and the texture of the PU leather can be altered depending on the processes used to make it.
For example, embossment is used to dimensionally enhance PU-containing materials. As used herein “embossment” refers to an impression produced by pressure and/or heat, in respective varying amounts. In previous embossing attempts, cuts or damage to the face of PU material surface were produced due to a number of reasons, including problems with heating or pressing steps, which resulted in melted and cut materials, as well as stresses induced at corners of such embossing. Also, the embossing pattern transfer means used previously have been problematic, including rolls or plates having overly sharp edges contributing to the cutting or damage to the PU surface layer or even more severe cutting through lower composite layers. Use of unsuitable materials, including improper foams and textile scrims, have caused further problems such as distortions in the shape and depth of the embossing design just following the embossing and up to the manufacturing of the final product that incorporates the synthetic leather material, such as an automobile seat as an example.
While some attempts have proved more successful in maintaining the integrity of the embossed design in a synthetic leather, including flat embossing of synthetic leather material without lamination and scrim, the three-dimensional effect of such attempts has been minimal, compromised, and aesthetically unimpressive. These embossments are generally two-dimensional in nature and lack sufficient depth to achieve a more noticeable, realistic, and/or aesthetically pleasing result.
To enhance the three-dimensional appearance of synthetic leather products, a process known as “pillow embossing” has been utilized, which comprises a three-layer PU configuration. While the three-dimensional nature of the face material formed with the composite layers of material, foam, and scrim is better than with flat embossing, these prior attempts have still been less than optimal for embossment goals. Specifically, they have failed to properly protect the composite, such as from melting or cutting, during the embossing process. Also, the materials employed to provide the “pillow” effect have failed to adequately maintain a desired embossed shape.
Accordingly, these and other concerns show there remains a need for a more effective embossing process and more durable resulting product in the field of synthetic leather.
Fortunately, the present invention discovers an elegant, optimized, and versatile dimensional enhancement of artificial leather polyurethane composite material.
The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the present invention. This summary is not an extensive overview of the invention. It is not intended to identify key or critical elements of the invention or to delineate the scope of the invention; its sole purpose is to present concepts of the invention in a simplified form as a prelude to the more detailed description that is subsequently presented.
The present invention includes an embossed composite material and method for forming such an embossed composite material that has the appearance of and similar attributes to leather.
In one embodiment, the embossed composite material includes a plurality of layers of PU material, a foam layer and a base scrim layer, wherein each layer of the composite material is embossed to form pillow-like chambers or cells along the composite material. In another embodiment, the embossed composite material has at least three layers of PU, a textile layer serving as a backing to the three layers of PU, a layer of unclickable PU foam beneath the textile backing layer, and a layer of textile or nonwoven scrim serving as the backing for the PU foam layer. The composite material is embossed to form pillow-like chambers or cells delineated by a network of emboss patter lines formed by the bonding between these layers.
“Clickable” foam retains its shape after being cut by a blade, impressed by pressure, impinched with heat, or punched by a die, so it is not suitable for embossing.
As used herein “un-clickable” foam is a foamed material that is adapted for embossing and that does not recover from an embossing operation, thus maintaining its embossed shape.
In one embodiment, the method for forming the embossed composite material includes the following steps: 1) forming a PU leather material having a surface layer and a skin layer adhered to a backing layer; 2) attaching a layer foam to the bottom surface of the PU leather material; 3) attaching a layer of scrim or textile to the bottom surface of the foam layer to form a composite material; and 4) embossing the composite material through the use of an embossing roll to provide an emboss design and pillow-like cells to the composite material.
In another embodiment the method for forming the embossed composite material includes the following steps: 1) forming a PU leather material having a surface layer and a skin layer adhered to a backing layer; 2) attaching a layer foam to the bottom surface of the PU leather material; 3) attaching a layer of scrim or textile the bottom surface of the foam layer to form a composite material; and 4) embossing the composite material through the use of an embossing plate so that the composite material bears an emboss pattern and pillow-like cells are formed within the emboss pattern lines.
A feature discovered by the present invention is to provide dimensional enhancement to polyurethane artificial leather (supported polyurethane or PU coated material) through the use of flat and roller emboss technology. The present process results in a superior three-dimensional effect that has not been achievable prior to the present invention. The devices and processes contemplated by the present invention address the prior concerns of heating, pressure, emboss design, material selection, and other features that contributed to cuts and damage to the synthetic leather material.
Other features of the present invention are the aesthetic enhancement materials having the appearance of leather through the present embossment technique. The three-dimensionally enhanced PU materials formed by the present process are more comparable to the appearance of genuine leather and OVC/vinyl trim components.
Other features and their advantages will be apparent to those skilled in these arts, techniques, and equipment relevant to the present invention from a careful reading of the Detailed Description of Preferred Embodiments.
The purpose of the Abstract hereinabove is to enable the United States Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The Abstract is not provided for interpreting the scope of the claims herein, nor to define the invention or the application, nor to be limiting in any way as to the scope of the invention.
Additional objects and advantages of the present subject matter are set forth in, or will be apparent to, those of ordinary skill in the art from the detailed description herein. Also, it should be further appreciated that modifications and variations to the specifically illustrated, referred and discussed features and elements hereof may be practiced in various embodiments and uses of the invention without departing from the spirit and scope of the subject matter. Variations may include, but are not limited to, substitution of equivalent means, features, or steps for those illustrated, referenced, or discussed, and the functional, operational, or positional reversal of various parts, features, steps, or the like. Still further, it is to be understood that different embodiments, as well as different presently preferred embodiments, of the present subject matter may include various combinations or configurations of presently disclosed features, steps, or elements, or their equivalents (including combinations of features, parts, or steps or configurations thereof not expressly illustrated in the figures or stated in the detailed description of such figures). Additional embodiments of the present subject matter, not necessarily expressed in the summarized section, may include and incorporate various combinations of aspects of features, components, or steps referenced in the summarized objects above, and/or other features, components, or steps as otherwise discussed in this application. Those of ordinary skill in the art will better appreciate the features and aspects of such embodiments, and others, upon review of the remainder of the specification
In the Drawings:
Certain preferred embodiments and examples are disclosed herein. However, the inventive subject matter extends beyond the examples in the specifically disclosed embodiments to other alternative embodiments and/or uses, and to modifications and equivalents thereof. Thus, the scope of the claims below is not limited by any of the particular embodiments described herein. For example, in any method or process disclosed herein, the acts or operations of the method or process may be performed in any suitable sequence and are not necessarily limited to any particular disclosed sequence. Various operations may be described as multiple discrete operations in a manner or order that may be helpful in understanding certain embodiments; however, the order of description should not be understood to imply that these operations are order-dependent. Additionally, the structures, systems, and/or devices described herein may be embodied as integrated components or as separate components. For purposes of comparing various embodiments, certain aspects and advantages of these embodiments are described. Not necessarily all such aspects or advantages are achieved by any particular embodiment. Thus, for example, various embodiments may be carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other aspects or advantages as may also be taught or suggested herein.
The present invention includes an embossed composite material and processes and devices for making an embossed composite material having the appearance and attributes of leather.
This invention allows for the dimensional enhancement of PU materials used to form synthetic leather. As used herein, the term “PU” refers to polyurethane containing or polyurethane coated materials. PU materials can be altered by a pattern or design. Here, the materials and processes used provide both two dimensional and a three dimensional aspect to the design of the final PU synthetic leather product.
An example of a dimensionally-enhanced PU leather 10 according to an embodiment of the present invention is illustrated in
A variety of patterns other than the one illustrated in
Different materials used to form the PU leather 10 contribute to the effectiveness of embossing to impart a three-dimensional pattern that is maintainable after use in a final product, such as in an automobile seat. In
In one embodiment, the PU face material 20 is formed by a process illustrated in the
In
Alternative embodiments of the PU face material 20 are contemplated by the present invention. For example, the PU skin layer 62 can be two layers rather than a single layer. In another embodiment, the PU skin layer 62 can be the top layer, substituting the surface layer 60 illustrated in
The proportions by weight and thickness of each layer of the PU face material 20 can also vary. In one embodiment, the surface layer 60, the skin layer 62, and the binder layer 64 together account for about 30% of the total weight of the PU face material 20, leaving the remainder of the weight attributed to the backing layer. In another embodiment, these three layers may be between about 27% and about 30% of the total weight of the PU face material 20, leaving the remainder of the weight attributed to the backing layer. In yet another embodiment, these three layers together may weigh about 120 g/m2 and the backing layer may weigh about 320 g/m2.
The simulation of the appearance of leather is achievable in part by the grain pattern on the surface of the release paper 30, which grain pattern becomes transferred to surface of the PU face material 20. A wide variety of grain patterns are available, including smooth, course, and technical (having repeating designs and shapes). The PU face material can further be perforated. Additionally, the PU face material 20 can be a wide variety of colors that are imparted through one or more dyes introduced during processing.
The material used for the backing layer 66 can also vary. The particular backing material provides thickness, tensile strength, and stretch properties to the PU face material. In one embodiment, the backing can be a circular knit textile. The circular knit textile can be flat or napped. These types of textiles provide enhanced trimability to the PU face material. The napped version of the circular knit can also enhance the haptic features of the PU face material. The use of tricot suede textile is also contemplated, especially if the PU face material is to be perforated. The backing can also be a nonwoven material, including nonwoven suede. Other materials could be suitable provided the backing is adapted to bind the surface of the foam material 22, as later described
To form the PU composite material that is to be embossed according to the present invention, the PU face material 20 is combined with the foam material and a scrim backing. In one embodiment, the PU composite material is formed by a process illustrated in the
In an alternative embodiment (not show), the lamination of the foam layer and the scrim layer can be done in two separate passes, as opposed to a continuous process illustrated in
A cross-section of one embodiment of the PU composite material 26 formed is illustrated in
The materials used for these additional layers provide enhanced properties to the composite material. In particular, the use of an un-clickable foam is a preferred material for the foam layer 70. “Clickable” foam resumes its afore-shape after being cut by a blade or punched by a die, or heated, so it is not suitable for embossing. As used herein “un-clickable” foam is a foamed material that is adapted for embossing that does not recover from a die cutting/embossing operation, thus maintaining its embossed shape. This un-clickable foam enables the embossment to be held in place permanently to give the three-dimensional effect desired in the present invention.
In one embodiment the foam layer 70 is polyester polyurethane that is between about 3 mm and about 5.2 mm in thickness. To achieve bonding between the foam and the outer PU face and scrim layers, the foam is preferably heated to melt on both sides, such as previously described. In the melting process according to one embodiment of the present invention, the foam thickness is reduced by about 1 mm on either side. Thus, the starting foam material 70 in this process should be between about 5 mm and about 7.2 mm to achieve a final foam thickness of between about 3 mm and 5.2 mm in the composite material. Other thicknesses are contemplated provided the foam layer effectively maintains the embossing pattern, as later described.
In another embodiment, the foam material may be a polyester polyurethane foam made commercially available by Foamex Innovations, International and designated as LC 160035. In another embodiment, the polyester polyurethane form may be commercially available from Foamex Innovations and designated as LZ185040. In still another embodiment the foam may have the following properties: an apparent density of about 1.85 lb/ft3, a cell count of about 75 CPI, and an indentation force deflection of about 65 lb/50″2. In yet another embodiment, the foam may have the following property ranges.
The textile or nonwoven scrim layer 72 provides protection from the heat of the embossing plates and rollers and dimensional stability to the product can be modified through scrim selection.
The embossing pattern of the PU composite material may be achieved through roll or flat embossing processes. One embodiment of a roll embossing process according the present invention is illustrated in
The heating, pressure and tension parameters contribute to the effectiveness of the roll embossing process and to the dimensional stability of the resulting embossed composite material. In one embodiment, the temperature of the engraved emboss roller 100 is not greater than about 140 degrees C./245 degrees F. In another embodiment, the temperature is about 120 degrees C./245 degrees F.
The materials used for the rolls can also vary. In one embodiment, the heated receiving roll 96 is made of metal. In another embodiment, the heated roll 96 is made of steel. In yet another embodiment, the temperature of the heated roll 96 is not greater than about 190 degrees C./375 degrees F. In another embodiment, the press roll 106 is made of a nylon material.
The dwell time at the contact point between the embossing roll 100, the composite material, and the heated receiving roll 96 is controlled by the line speed of the roll embossing machine. In one embodiment, the line speed is between about 3 and about 5 yards per minute. In one embodiment, the pressure was maintained between about 4 and about 8 MPa (megapascals).
Additionally, the engraved embossing rollers can create a variety of emboss designs. The patterns are engraved into the roller surface to precise depths and motif arrangement. In particular, the engraved embossing roll 100 includes an array of protrusions and recesses that are adapted for transfer a pattern on to the composite material 26. The dimensions of the protrusions and recesses can vary provided that the embossing pattern is transferred effectively through the composite material 26 without damaging the material.
One embodiment of a flat embossing process according the present invention is illustrated in
The heating, pressure and tension parameters contribute to the effectiveness of the flat embossing process and to the dimensional stability of the resulting embossed composite material. In one embodiment, the following parameters may be used for the plate embosser. The temperature of the emboss plate may be not greater than about 190 degrees C./380 degrees F. on the face of the plate touching the PU material. The temperature of the bottom heater plate may be not greater than about 200 degrees C./400 degrees F. on side touching the bottom scrim layer of the PU material. Dwell time varies by the emboss pattern to be used. In one embodiment, the dwell time may be between about 5 and about 15 seconds from the time the pressure control is engaged to when it is released. In another embodiment, the pressure used may be between about 10 and about 30 psi.
Additionally, the embossing plates can create a variety of emboss designs on the PU composite material. The patterns are engraved into metal material to precise depths and motif arrangement.
A cross-section of one embodiment the embossed composite material is illustrated in
Those skilled in the relevant arts will appreciate from the foregoing description of preferred embodiments that substitutions and modification can be made without departing from the spirit and scope of the invention which is defined by the appended claims.
The present application claims the benefit of priority of U.S. Provisional Application No. 62/065,470, filed Oct. 17, 2014, which is incorporated herein by reference in its entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US15/56237 | 10/19/2015 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62065470 | Oct 2014 | US |
