Method for manufacturing synthetic leather using different liquid silicone rubber coating solutions

• US 9,925,752 B2
• Filed: 07/30/2012
• Issued: 03/27/2018
• Est. Priority Date: 07/19/2012
• Status: Active Grant

• Current Assignee: TKG ECO Material Company Limited
• Original Assignee: Jeongsan International Co., Ltd.
• Inventors: Kweon, Dowan, Park, Choongryeol, Byun, Heeun
• Primary Examiner(s): Mckinnon, Shawn
• Assistant Examiner(s): McKinnon, Lawshawnda T
• Application Number:
  US14/124,521
• Publication Number:
  US 20150165745A1
• Time in Patent Office: 2,066 Days
• Field of Search: None
• CPC Class Codes: B32B 2037/268 Release layers
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2479/00 Furniture
• CPC Class Codes: B32B 25/042 of natural rubber or synthetic rubber
• CPC Class Codes: B32B 25/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 25/20 comprising silicone rubber
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 37/15 with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
• CPC Class Codes: B32B 37/26 with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: D04H 1/587 characterised by the bonding agents used
• CPC Class Codes: D04H 1/64 the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• CPC Class Codes: D06N 2209/067 Flame resistant, fire resistant
• CPC Class Codes: D06N 2209/143 Inert, i.e. inert to chemical degradation, corrosion resistant
• CPC Class Codes: D06N 2209/146 Soilproof, soil repellent
• CPC Class Codes: D06N 2211/28 Artificial leather
• CPC Class Codes: D06N 3/128 with silicon polymers
• CPC Class Codes: Y10T 442/2041 Two or more non-extruded coatings or impregnations

Abstract

The present invention relates to a method for manufacturing synthetic leather for various interior materials and various miscellaneous goods using liquid silicone rubber coating solutions, and particularly, to a method for manufacturing synthetic leather having physical properties optimized so as to be suitable for a use using a different textile according to the use thereof.

Claims

1. A method for manufacturing synthetic leather using different liquid silicone rubber (LSR) coating solutions, the method comprising:

performing primary coating on release paper using a first coating solution containing a first liquid silicone rubber (LSR) having a shore hardness (shore A) of 50 or more and an elongation of less than 300%;

performing secondary coating on the release paper coated with the first coating solution using a second coating solution containing a second liquid silicone rubber (LSR) having a shore hardness (shore A) of less than 50 and an elongation of 300% or more;

uniting the release paper coated with the second coating solution with a textile and drying the united textile; and

separating the release paper from the textile united with the release paper,

wherein the first liquid silicone rubber (LSR) and the second liquid silicone rubber (LSR) comprise a first part and a second part that are mixed with each other,

wherein the first part includes 30˜

60 wt % of dimethylvinyl-terminated dimethyl siloxane, 30˜

60 wt % of alumina hydrate, less than 10 wt % of trimethylated silica, less than 10 wt % of dimethylvinylated and trimethylated silica, and less than 1% of platinum catalyst,

wherein the second part includes 30˜

60% of dimethylvinyl-terminated dimethyl siloxane, 30˜

60% of methylhydrogen siloxane, less than 10 wt % of alumina hydrate, less than 10 wt % of trimethylated silica, and less than 1% of dimethylvinylated and trimethylated silica, and

wherein the textile is woven using a spun yarn made of aramid fiber and oxidized pan fiber (OPF).

2. The method of claim 1, further comprising, after the separating of the release paper, surface treating a surface from which the release paper is separated using a silicone surface coating agent.

3. The method of claim 1, wherein the synthetic leather is used as an interior material of an aircraft or a ship.

4. A synthetic leather having a structure in which a first coating layer containing a first liquid silicone rubber (LSR) having a shore hardness (shore A) of 50 or more and an elongation of less than 300% is laminated on a textile by a second coating layer containing a second liquid silicone rubber (LSR) having a shore hardness (shore A) of less than 50 and an elongation of 300% or more,

wherein the first liquid silicone rubber (LSR) and the second liquid silicone rubber (LSR) comprise a first part and a second part that are mixed with each other,

wherein the first part includes 30˜

60 wt % of dimethylvinyl-terminated dimethyl siloxane, 30˜

60 wt % of alumina hydrate, less than 10 wt % of trimethylated silica, less than 10 wt % of dimethylvinylated and trimethylated silica, and less than 1% of platinum catalyst,

the second part includes 30˜

60 wt % of dimethylvinyl-terminated dimethyl siloxane, 30˜

60 wt % of methylhydrogen siloxane, less than 10 wt % of alumina hydrate, less than 10 wt % of trimethylated silica, and less than 1% of dimethylvinylated and trimethylated silica, and

wherein the textile is woven using a spun yarn made of aramid fiber and oxidized pan fiber (OPF).

5. The synthetic leather of claim 4, wherein the synthetic leather is used as an interior material of an aircraft or a ship.