Stain-resistant synthetic leather and method for manufacturing same

• US 9,957,662 B2
• Filed: 06/10/2016
• Issued: 05/01/2018
• Est. Priority Date: 05/04/2016
• Status: Active Grant

• Current Assignee: Soon Kie Jung
• Original Assignee: Soon Kie Jung
• Inventors: Seong, Nak Hyun
• Primary Examiner(s): Tran, Thao T
• Application Number:
  US15/179,242
• Publication Number:
  US 20170321374A1
• Time in Patent Office: 690 Days
• Field of Search: 428 96, 428904, 156 60, 156123
• CPC Class Codes: B32B 5/00 Layered products characterised by the non- homogeneity or physical structure , i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
• CPC Class Codes: D06N 3/0063 Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds
• CPC Class Codes: D06N 3/0065 Organic pigments, e.g. dyes, brighteners
• CPC Class Codes: D06N 3/0077 Embossing; Pressing of the surface; Tumbling and crumbling; Cracking; Cooling; Heating, e.g. mirror finish
• CPC Class Codes: D06N 3/128 with silicon polymers
• CPC Class Codes: D06N 3/14 with polyurethanes
• CPC Class Codes: D06N 3/183 the layers are one next to the other
• CPC Class Codes: D06P 5/003 Transfer printing

Abstract

Provided a stain-resistant synthetic leather, including: (a) a polyurethane synthetic leather; (b) a silane-based coating layer formed on the polyurethane synthetic leather; and (c) a silicone coating layer formed on the silane-based coating layer, wherein the silane-based layer strengthens the binding between the polyurethane synthetic leather and the silicone coating layer, so that the stain-resistant synthetic leather can exhibit texture and flexibility of natural leather per se, and can exhibit excellent water resistance, stain resistance, weather resistance, and wear resistance through the silane-based coating layer and silicone coating layer formed on the polyurethane synthetic leather.

Claims

1. A stain-resistant synthetic leather, comprising:

(a) a polyurethane synthetic leather;

(b) a silane-based coating layer formed on the polyurethane synthetic leather; and

(c) a silicone coating layer formed on the silane-based coating layer, wherein the silane-based layer strengthens the binding between the polyurethane synthetic leather and the silicone coating layer,

which further comprises, between (a) the polyurethane synthetic leather and (b) the silane-based coating layer,

(f) a second adhesive layer; and

(g) a surface reinforcement layer for reinforcing mechanical strength of the synthetic leather, formed on the second adhesive layer.

2. The stain-resistant synthetic leather of claim 1, wherein (a) the polyurethane synthetic leather comprises:

(a-1) a fabric layer forming a leather substrate; and

(a-2) a polyurethane coating layer formed on one surface or both surfaces of the fabric layer.

3. The stain-resistant synthetic leather of claim 1, further comprising:

(d) a print layer formed between (a) the polyurethane synthetic leather and (b) the silane-based coating layer, the print layer having a predetermined color or pattern.

4. The stain-resistant synthetic leather of claim 3, further comprising:

(e) a first adhesive layer for enhancing adhesive strength, formed between (a) the polyurethane synthetic leather and (d) the print layer.

5. The stain-resistant synthetic leather of claim 1, wherein (b) the silane-based coating layer is formed by cross-linkage of a C₁-C₁₀ modified alkylalkoxysilane.

6. The stain-resistant synthetic leather of claim 1, wherein the coating amount of (b) the silane-based coating layer is in the range of 20-30 g/m².

7. The stain-resistant synthetic leather of claim 1, wherein (c) the silicone coating layer comprises:

a linear siloxane;

at least one cyclic siloxane;

a siloxane-based copolymer;

an emulsion of dimethylpolysiloxane and water; and

inorganic particles.

8. The stain-resistant synthetic leather of claim 1, wherein the coating amount of (c) the silicone coating layer is in the range of 20-50 g/m².

9. The stain-resistant synthetic leather of claim 1, wherein an embossing pattern having a plurality of concave portions and convex portions is formed on a surface of the stain-resistant synthetic leather.

10. A method for manufacturing the stain-resistant synthetic leather of claim 1, the method comprising:

(i) preparing a polyurethane synthetic leather;

(ii) forming a silane-based coating layer by coating a silane-based coating composition on one surface or both surfaces of the polyurethane synthetic leather, followed by drying; and

(iii) forming a silicone coating layer by coating a silicone coating composition on the silane-based coating layer, followed by drying,

which comprises between steps (i) and (ii),

(i-4) forming a second adhesive layer on one surface of the polyurethane synthetic leather by coating and drying a second adhesive coating composition; and

(i-5) arranging a surface reinforcement film on the semi-dried second adhesive layer.

11. The method of claim 10, wherein the silane-based coating composition in step (ii) contains:

on the basis of 100 parts by weight of the corresponding composition, 6-16 parts by weight of a C₁-C₁₀ modified alkylalkoxysilane; and

the balance organic solvent to satisfy a total of 100 parts by weight of the composition.

12. The method of claim 10, wherein the silicone coating composition in step (iii) is a two-component composition containing:

a main agent obtained by blending a linear siloxane, at least one cyclic siloxane, a siloxane-based copolymer, a silicone oil, and inorganic particles, in an organic solvent; and

a curing agent containing a metallic catalyst and an organic solvent.

13. The method of claim 10, wherein the drying in step (iii) comprises:

a first step of conducting drying at 60-75°

C. for 1-10 min; and

a second step of conducting aging at 70-90°

C. for 24-30 hours.

14. The method of claim 10, further comprising:

between steps (i) and (ii),

(i-1) forming a print layer having a predetermined color or pattern on the polyurethane synthetic leather by coating and drying a composition for forming a print layer.

15. The method of claim 10, further comprising:

between steps (i) and (ii),

(i-2) forming a first adhesive layer on one surface of the polyurethane synthetic leather by coating and drying a first adhesive coating composition; and

(i-3), while the first adhesive layer is semi-dried, arranging a print release paper having a transfer pattern on the semi-dried first adhesive layer, followed by compressing under a predetermined pressure and temperature, thereby transferring the print layer, and then removing the release paper.

16. The method of claim 10, further comprising:

after step (iii),

(iv) emboss-processing a surface of the dried silicone coating layer.