Patent Application
20210108365
Not applicable.
Not applicable.
Embodiments of the present invention relate to artificial or synthetic leather materials, and other upholstery covers.
In a typical seating construction, upholstery materials such as leather, calendered and cast vinyls, knits, and woven fabrics are used as covers in seats, chairs, sofas, benches, transportation seating applications, etc. In order to obtain comfort, materials such as polyurethane urethane foam, polyester batting, metal springs, and elastic webbings are attached to the article frame and subsequently the cover material is installed. For example, artificial or synthetic leather products used in the textile industry are traditionally manufactured by impregnating elastomeric fabrics with urethane. The artificial leather products themselves commonly have a low modulus of elasticity (e.g., high stretch under load). While suitable for use in garments or shoes, these traditional artificial leather products are not suitable for high traffic, high-use furniture environments.
The use of elastomeric fabrics have, in some instances, replaced the abovementioned components in the furniture industry. While the use of these elastomeric fabrics are resilient, they do present some limitations. Traditionally, the elastomeric products are a see-through mesh with limited functional and aesthetic design potential and have a limited ability to incorporate desirable additives such as anti-microbials, flame retardants, and electrostatic discharge protectants.
Accordingly, methods and products are described that provide artificial leather, knit, or woven materials with a high modulus of elasticity. Advantageously, the artificial leather, knit, or woven materials can be used as a load bearing member of furniture without requiring a supporting fill. For example, the materials can be attached to one or more furniture pieces and support the weight of a person or people in excess of 100,000 times without deflection greater than 2 inches.
Generally, the artificial leather material is comprised of multiple layers of plastisol and a layer of an elastomeric fabric. The artificial leather material can also include a backing layer positioned between the plastisol and the elastomeric fabric. Similarly, methods and products are described that provide a woven or knit material with a high modulus of elasticity.
The present invention is described in detail below with reference to the attached drawing figures, wherein:
Traditional artificial leather materials have several drawbacks. As a non-exclusive example, traditional manufacturing techniques can rely on organic solvent baths to facilitate impregnating an elastomeric fabric with vinyl or polyurethane. These solvents can be difficult to properly dispose, increase waste, and increase the complexity and cost of manufacturing the artificial leather material. Additionally, traditional techniques may require post-manufacture processing including embossing and printing to impart color and texture. Again, these post-manufacture processing steps can increase the complexity and cost of producing the artificial leather.
Aspects described herein generally relate to artificial leather products having a high modulus of elasticity usable in high traffic, high use, load bearing applications, such as office or automotive seating. Additionally, the artificial leather products can be incorporated into seats or chair backs in tension framed seating. Methods for producing artificial leather materials having high modulus of elastomeric properties are also described herein.
Additionally, artificial leather materials, such as those described herein can provide a number of beneficial advantages over the natural equivalent. For example, the artificial leather materials can be tailored for the intended end-use by including antimicrobial agents, fire retardants, electrical grounding agents (i.e., materials that dissipate static electricity), and so forth.
As used herein a colorant is any pigment, dye, stain, ink, or any similar organic or inorganic compound included to intentionally alter the hue, tint, shade, tone, saturation, lightness, chroma, intensity, or other visual property of an object.
Additive refers to one, more than one, or any combination of: fire retardant compounds (such as aluminum trihydrate, magnesium hydroxide, and so forth), inorganic anti-microbial compounds (such as elemental copper, copper alloys, or cuprous/cupric compounds; elemental silver, silver alloys, or silver compounds; zinc alloys or zinc compounds), organic antimicrobial compounds (such as halogen-based organic biocides, nitrogen-based organic biocides, quaternary ammonium compounds, phenol/phenolic biocides, and so forth), scratch/mar resistant polymers (such as polypropylene) or compounds, UV protectant materials (such as oxanilides, benzophenones, benzotriazoles, hydroxyphenyltriazines, hydroxybenzophenone, hydroxyphenylbenzotriazole, TiO2, carbon black, 2,2,6,6-tetramethylpiperidine ring containing amines, and so forth), electrostatic dispersants (such as graphite, carbon black, and so forth), or any combination thereof.
Turning now to the figures, which are not represented in scale, but rather to clearly show the various embodiments and constructions,
Continuing with reference to
The outward facing layers 102 and 112 include two or more sublayers (collectively referred to as the outward facing layer). These sublayers generally comprise a polyurethane outermost layer 102a and one or more plastisol layers 102b, 102c. Polyurethane layer 102a generally comprises one or more thermosetting or thermoplastic polymers having at least one carbamate moiety. For example, polyurethane layer 102a can be comprised of polymers of di- or tri-isocyanates and polyols.
Additionally, in some aspects, polyurethane layer 102a includes one or more additives. The additives can be included based on the intended use case. For example, fire retardant additives can be included in some aspects of polyurethane layer 102a where artificial leather material 100, 110 or a furniture item including artificial leather material 100, 110 is potentially exposed to open flame or intense heat. Similarly, an organic antimicrobial additive, an inorganic antimicrobial additive, or a combination of both antimicrobial additives can be included in some aspects of polyurethane layer 102a where artificial leather material 100, 110 or a furniture item including artificial leather material 100, 110 is potentially exposed to infectious agents. A grounding additive can be included in some aspects of polyurethane layer 102a where artificial leather material 100, 110 or a furniture item including artificial leather material 100, 110 where the build-up or discharge of static electricity is problematic (such as a clean room).
As will be understood by those skilled in the art, many intended end use cases have multiple potential additive needs. For example, a furniture item that includes artificial leather material 100, 110 intended to be used in a hospital can include antimicrobial additives, fire retardant additives, and scratch/mar additives. Similarly, in some aspects, polyurethane layer 102a can include any combination of two or more additives.
Plastisol layers 102b and 102c are generally formed from a plasticized suspension of polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), any combination thereof, or any other thermoplastic. In some aspects, plastisol layers 102b and 102c can include one or more additives, similar to polyurethane layer 102a.
Although described herein in relation to an artificial leather material, one skilled in the art will understand that outward facing layer 102, the second outward facing layer 112, or any combination thereof may be a woven or knit material. For example, in some aspects material 100 is comprised of an outward facing woven or knit layer 102 and an elastomeric fabric layer 106.
In some aspects, artificial leather material 100, 110 includes a backing layer 104. Backing layer 104 can be comprised of a non-woven polymeric resin. For example, backing layer 104 can be a non-woven polyester, nylon trictot scrim, or any other non-woven polymeric resin.
Elastomeric fabric layer 106 generally provides a high modulus of elasticity to artificial leather material 100, 110. Elastomeric fabric layer 106 can be a woven or knit elastomeric fabric. For example, in some aspects, elastomeric fabric layer 106 is a warp knit elastomeric fabric layer. As discussed in more detail with respect to
Alternatively, in some aspects, elastomeric fabric layer 106 is a woven elastomeric fabric. For example, in some aspects, elastomeric fabric layer 106 is a plane weave or leno weave made by weaving polyester yarns with about 20-22 ends per inch. In some aspects, the polyester yarns are in the range of about 1800-2400 denier. Additionally in some aspects, the polyester yarns are in the range of about 50-75 durometers. The polyester yarns can be mono-component or bi-component yarns made with polyester monofilament strands. For example, in a particular aspect, the elastomeric fabric layer 106 is a 22 ends per inch leno weave with 2400 denier, 55 durometer, bicomponent yarns with monofilament polyester, and elastomer strands.
Turning to
In an aspect, a filling yarn 206 (also referred to as fill yarn 206) may be included as well. For example, in an embodiment, fill yarn 206 can be used in border segments of the artificial leather material 100, 110 to provide a stronger structure for supporting attachment to furniture products, as discussed above. Fill yarn 206 can be a 2 ply about 150 denier yarn in an aspect. The filling yarn 206 can be continuously incorporated into the knit 200. Said another way, fill yarn 206 can run weftwise in successive, uninterrupted courses back and forth across the fabric, as shown.
Similarly, a filling yarn 208 may be included as well. For example, in an embodiment, fill yarn 208 can be used in border segments of the artificial leather material 100, 110 to provide a stronger structure for supporting attachment to furniture products, as discussed above. Fill yarn 208 can be a 2 ply about 150 denier polyester yarn in an aspect. In an aspect, the fill yarn 208 is an about 840 denier polypropylene yarn. The filling yarn 208 can be continuously incorporated into the knit 200. Said another way, fill yarn 208 can run weftwise in successive, uninterrupted courses back and forth across the fabric, as shown. In an aspect, warp knit elastomeric fabric 200 includes a plurality of elastomeric inlayed yarns 210 that extends coursewise (e.g., through multiple courses of a single wale). The elastomeric inlayed yarn 210 can facilitate a stronger structure by limiting the coursewise elongation. Elastomeric inlayed yarns 210 can be an elastomeric monofilament in the range of about 50-75 durometers and about 1800-2400 denier. For example, in a particular aspect, the plurality of elastomeric inlayed yarns 210 are 72 durometers. Additionally, the plurality of elastomeric inlayed yarns 210 is 1800 denier.
As will be understood by those skilled in the art, warp knit elastomeric fabric 200 is not intended to limit the scope of a warp knit elastomeric fabric suitable for the elastomeric fabric layer 106. Rather, warp knit elastomeric fabric 200 is included as an illustrative example of a warp knit suitable for use as elastomeric fabric layer 106.
Turning to
As shown, the walewise elastomeric yarn 402 passes over a coarse of weftwise elastomeric yarn 406 and under a coarse of weftwise elastomeric yarn 408. Walewise elastomeric yarn 404 passes under a coarse of weftwise elastomeric yarn 406 and over a coarse of weftwise elastomeric yarn 408. This alternating over-under-over pattern continues for the both the weftwise and walewise elastomeric yarns throughout the plain weave elastomeric fabric 400. This plain weave pattern can create an overall walewise and weftwise lock-down thereby providing a high modulus of elasticity, while simultaneously providing a relative stretch 45° off-axis (e.g., 45° off each of the walewise and weftwise axis). This combination may provide a supportive, durable, and comfortable base layer for some aspects of artificial leather material 100, 110.
Turning to
As shown, warp elastomeric yarn 504 alternatively passes under a coarse of a weftwise elastomeric yarn 508a and over the subsequent weftwise elastomeric yarn 508b. Warp elastomeric yarn 506 alternatively passes over a coarse of a weftwise elastomeric yarn 508a and under the subsequent weftwise elastomeric yarn 508b. Concurrently, warp elastomeric yarn 504 alternates positions with warp elastomeric yarn 506 each coarse. Said another way, warp elastomeric yarns 504 and 506 are twisted around each course of the weft elastomeric yarn 508. The weft elastomeric yarn 508 can be continuously incorporated into the elastomeric fabric 500. Said another way, weft elastomeric yarn 508 can run weftwise in successive, uninterrupted courses back and forth across the fabric.
The leno weave elastomeric fabric 500 can create an overall walewise and weftwise lock-down thereby providing a high modulus of elasticity, while simultaneously providing a relative stretch 45° off-axis (e.g., 45° off each of the walewise and weftwise axis). This combination may provide a supportive, durable, and comfortable base layer for some aspects of artificial leather material 100, 110.
Turning to
With reference to
At block 702, an outer layer, such as outer layer 106 as discussed in reference to
Continuing, the primary sub-layer can be formed by dispensing a PVC plastisol, PE plastisol, or PP plastisol in a range of about 80° C.-160° C. on the textured or non-textured paper. Alternatively, the primary sub-layer of the outer layer can be formed by dispensing a polyurethane resin in a range of about 80° C.-140° C. on the textured or non-textured paper. The use of polyurethane can increase the abrasion resistance of the artificial leather material.
One or more secondary sub-layers of the outer layer can be formed by dispensing a plastisol PVC plastisol, PE plastisol, or PP plastisol in a range of about 80° C.-180° C. on the primary sub-layer. In some aspects, a tertiary sub-layer of the outer layer can be formed by dispensing an acrylic vinyl resin in a range of about 140° C.-160° C. on the secondary sub-layers. The primary, secondary, tertiary, or any combination thereof can also include one or more colorants, one or more additives, or both colorants and additives. In a particular aspect, the PVC plastisol, PE plastisol, or PP plastisol does not include a dioctyl phthalate (DOP) plasticizer. Alternatively, in some aspects the outer layer can be formed of traditional calendered vinyl films.
At block 704, the artificial leather material is assembled. For example, while the final sub-layer (i.e., the last secondary sub-layer, or the tertiary sub-layer) is still in a liquid or gel state, a woven elastomeric fabric, such as plain weave elastomeric fabric 400 of
For another example, after an outer layer is solidified an elastomeric fabric with lock-down created by bi-axial (e.g., walewise and weftwise) elastomeric yarns, such as elastomeric fabrics 200 of
The adhesive can include a water-based adhesive (such as those available from Stahl™, 3M™, Worthen™, Henkel™, and others), a hot melt polyurethane (PUR) adhesive (such as those available from 3M™, Henkel™, and others), a latex-based adhesive (such as those available from 3M™, Henkel™, Master Bond™, and others), or any other adhesive. Alternatively, a backing, such as backing 104 of
Additionally, in some aspects the elastomeric fabric can be affixed to, or imbedded in, the outer layer while under tension. Pre-tensioning the elastomeric fabric may provide a more durable artificial leather material by stretch matching the outer layer and the elastomeric fabric. This can reduce the shear force between the outer layer, backing layer, elastomeric fabric layer, or any combination thereof during repeated load and non-load cycles. Additionally, pre-tensioning the elastomeric fabric can facilitate ensuring the outer layer or backing layer has a functional elongation (e.g., capacity for elongation under load without rupture) greater than or equal to the elastomeric fabric. In other words, pre-tensioning the elastomeric fabric can, in some embodiments, ensure that the outer layer or backing layer can elongate at least as much as the elastomeric fabric layer while under load thereby avoiding splitting, tearing, or rupturing the outer layer or backing layer.
For example, the elastomeric fabric can be tensioned with enough force to elongate the elastomeric fabric in the range of 3%-20%. In some aspects, the elastomeric fabric is tensioned to 12%-15% elongation. In some aspects, the elastomeric fabric is tensioned to 3%-5% elongation. In some aspects, the elastomeric fabric is tensioned to 5%-12% elongation.
The term “about” is used herein in relation to dimensional properties and accounts for variations in manufacturing tolerances. As such, about is used synonymously with ±10% of the relevant quantity in the relevant unit.
The subject matter of the technology described herein is described with specificity to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Moreover, although the terms “step” and/or “block” may be used herein to connote different elements of the methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly described.
Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the scope of the claims below. Embodiments of our technology have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to readers of this disclosure after and because of reading it. Alternative means of implementing the aforementioned can be completed without departing from the scope of the claims below. Certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims.
As used herein and in connection with the clauses listed hereinafter, the terminology “any of clauses” or similar variations of said terminology is intended to be interpreted such that features of claims/clauses may be combined in any combination. For example, an exemplary clause 4 may indicate the method/apparatus of any of clauses 1 through 3, which is intended to be interpreted such that features of clause 1 and clause 4 may be combined, elements of clause 2 and clause 4 may be combined, elements of clause 3 and 4 may be combined, elements of clauses 1, 2, and 4 may be combined, elements of clauses 2, 3, and 4 may be combined, elements of clauses 1, 2, 3, and 4 may be combined, and/or other variations. Further, the terminology “any of clauses” or similar variations of said terminology is intended to include “any one of clauses” or other variations of such terminology, as indicated by some of the examples provided above.
Clause 1. A multilayer elastomeric material comprising: an outer polyurethane layer; a plastisol layer adjacent the outer polyurethane layer; a first adhesive layer; and an elastomeric fabric.
Clause 2. The multilayer elastomeric material of clause 1, wherein the multilayer elastomeric material further comprises a non-woven reinforcing layer adjacent the plastisol layer and the adhesive layer.
Clause 3. The multilayer elastomeric material of clauses 1 or 2, wherein the multilayer elastomeric material further comprises: a second adhesive layer adjacent the elastomeric fabric and opposite the first adhesive layer; and another outer polyurethane layer.
Clause 4. The multilayer elastomeric material of any of clauses 1 through 3, wherein the adhesive layer comprises a thermoplastic adhesive, a water based latex adhesive, or a low melt polyurethane adhesive.
Clause 5. The multilayer elastomeric material of any of clauses 1 through 4, wherein the elastomeric fabric is comprised of a co-polyester monofilament.
Clause 6. The multilayer elastomeric material of clause 5, wherein the co-polyester monofilament has a diameter in the range of 0.35 mm and 0.55 mm.
Clause 7. The multilayer elastomeric material of clauses 5 or 6, wherein the elastomeric fabric is comprised of a warp knit of the co-polyester monofilament.
Clause 8. The multilayer elastomeric material of clause 7, wherein the warp knit has 10-14 ends per inch.
Clause 9. The multilayer elastomeric material of clauses 5 or 6, wherein the elastomeric fabric is comprised of a plain weave of the co-polyester monofilament.
Clause 10. The multilayer elastomeric material of clause 9, wherein the plain weave has 20-24 ends per inch.
Clause 11. The multilayer elastomeric material of any of clauses 5 through 10, wherein the co-polyester monofilament is between 50 and 80 durometer.
Clause 12. The multilayer elastomeric material of any of clauses 5 through 11, wherein the co-polyester monofilament has a linear density of between 1700 and 1900 denier.
Clause 13. A method for manufacturing a multilayer elastomeric material comprising: applying a liquid polyurethane to a form to form an outer polyurethane layer, wherein the liquid polyurethane is at a temperature between 70° C. and 150° C. when applied to the form; applying a plastisol at a temperature between 140° C. and 160° C. to the outer polyurethane layer; applying an adhesive at a temperature between 90° C. and 110° C. to the plastisol; and applying an elastomeric fabric to the adhesive.
Clause 14. The method of clause 13, wherein the form is comprised of a textured or non-textured paper.
Clause 15. The method of clauses 13 or 14, wherein the functional elongation of the tensioned elastomeric fabric is between 3%-20% elongation.
Clause 16. The method of any of clauses 13 through 15, wherein the elastomeric fabric is comprised of a plurality of elastomeric yarns in a plain weave, leno weave, or warp knit configuration.
Clause 17. The method of clause 16, wherein the warp knit is comprised of walewise parallel stitch-loop chains of a polymeric yarn.
Clause 18. The method of clause 17, wherein the polymeric yarn is formed from about 150 denier, 3 ply, about 68 filament yarn.
Clause 19. The method of clause 17, wherein the warp knit is further comprised of a coursewise inlayed elastomeric monofilament in a range of about 50-75 durometers and about 1800-2400 denier.
Clause 20. The method of clause 16, wherein the plain weave or leno weave is comprised of elastomeric bi-component monofilament warp and weft yarns in a range of about 20-25 ends per inch, about 50-75 durometers, and about 1800-2400 denier.
Clause 21. A multilayer elastomeric material comprising: an upholstery cover material, an adhesive layer, and an elastomeric support.
Clause 22. The multilayer elastomeric material of clause 21, wherein the upholstery cover material is a knit fabric, a woven fabric, a calendered vinyl film, or a cast plastisol vinyl film.
Clause 23. The multilayer elastomeric material of clauses 21 or 22, wherein the adhesive layer is comprised of a water-based natural rubber water dispersion.
Clause 24. The multilayer elastomeric material of clauses 21 or 22, wherein the adhesive layer is comprised of a water-based acrylic latex.
Clause 25. The multilayer elastomeric material of clauses 21 or 22, where the adhesive layer is comprised of a thermoplastic adhesive.
Clause 26. The multilayer elastomeric material of any clauses 21 through 25, wherein the elastomeric support is a biaxially oriented extrusion of a polyester copolymer.
Clause 27. The multilayer elastomeric material of any clauses 21 through 26, wherein the elastomeric support is a warp fabric comprised of 7 to 12 ends per inch of a 55 to 75 co-polyester monofilament.
Clause 28. The multilayer elastomeric material of any clauses 21 through 26, wherein the elastomeric support is a woven fabric comprised of 10 to 25 ends per inch of a 55 to 75 durometer co-polyester monofilament.
Clause 29. The multilayer elastomeric material of any clauses 21 through 26, wherein the elastomeric support is a woven fabric comprised of 10 to 25 ends per inch of a bi-component 55 to 75 durometer co-polyester monofilament.
Clause 30. The multilayer elastomeric material of any clauses 21 through 29, wherein the upholstery cover material has a functional elongation equal to or higher than the elastomeric support.
