Synthetic Leather and a Manufacturing Process thereof

• US 20090162610A1
• Filed: 12/20/2007
• Published: 06/25/2009
• Est. Priority Date: 12/20/2007
• Status: Abandoned Application

• Current Assignee: Jui-Hung Hwang
• Original Assignee: Jui-Hung Hwang
• Inventors: Hwang, Jui-Hung
• Application Number:
  US11/960,700
• Publication Number:
  US 20090162610A1
• Time in Patent Office: Days
• US Class Current: 428/151
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/0284 Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
• CPC Class Codes: B32B 2262/0292 Polyurethane fibres
• CPC Class Codes: B32B 2262/04 Cellulosic plastic fibres, e.g. rayon
• CPC Class Codes: B32B 2262/065 Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
• CPC Class Codes: B32B 2262/08 Animal fibres, e.g. hair, wool, silk
• CPC Class Codes: B32B 2262/103 Metal fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2305/08 Reinforcements
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2310/0454 Hot air
• CPC Class Codes: B32B 2317/08 Natural leather
• CPC Class Codes: B32B 2367/00 Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 37/203 One or more of the layers being plastic
• CPC Class Codes: B32B 38/06 Embossing
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/06 : characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: D06N 3/0013 : using multilayer webs
• CPC Class Codes: Y10T 428/24438 : Artificial wood or leather grain surface

Abstract

A synthetic leather and a manufacturing process thereof involves having a substrate to be combined with a thermoplastic basic material (TPU MB) in one-time or multiple times of compound procedure for both to become an integrated party of the synthetic leather that prevents easy stripping off, excellent compound results, and excellent air permeability, particularly ideal in lateral and longitudinal ductility and malleability. Furthermore, the synthetic leather of the present invention gives advantages of having smooth surface, free of pilling, multiple choices for the applicable substrate, and perfect for massive production by batch.

Claims

1. A manufacturing method of a synthetic leather comprising the following steps:

selecting a substrate;

combing the substrate and a thermoplastic basic material in a one-time compound procedure for both to get entangled with each other into an integrated part; and

obtaining a finished product of the synthetic leather.

2. The manufacturing method as claimed in claim 1, wherein the substrate is related to a synthetic fiber of Polyethylene Terephthalate (PET), polyester, nylon, cellulose, rayon, ES fiber, activated carbon fiber, stainless steel fiber, wool, cotton, flax, or a mixture of cotton and flax.

3. The manufacturing process as claimed in claim 1, wherein the combination of the substrate and the thermoplastic material are done at least once and are repeated as many times as required.

4. The manufacturing process as claimed in claim 3, wherein the step of combining the substrate and the thermoplastic material includes using a water entangle method, a needle punch method, a melt brown method, a hot air lamination method, or an adhesive binding method.

5. A synthetic leather containing in construction thereof a substrate layer and a thermoplastic basic material layer integrated in one part by using a compound method.

6. The synthetic leather as claimed in claim 5, wherein the substrate is related to a synthetic fiber of Polyethylene Terephthalate (PET), polyester, nylon, cellulose, rayon, ES fiber, activated carbon fiber, stainless steel fiber, wool, cotton, flax, or a mixture of cotton and flax.

7. The synthetic leather as claimed in claim 5, wherein the thermoplastic basic material layer is related to a single layer and additional layer is provided as required.

8. The synthetic leather as claimed in claim 5, wherein the method of combining the substrate and the thermoplastic material includes using a water entangle method, a needle punch method, a melt brown method, a hot air lamination method, or an adhesive binding method.