Method for producing synthetic leather and synthetic leather produced by the same

• US 10,456,958 B2
• Filed: 04/11/2016
• Issued: 10/29/2019
• Est. Priority Date: 04/11/2016
• Status: Active Grant

• Current Assignee: Soon Kie Jung
• Original Assignee: Soon Kie Jung
• Inventors: Koo, Ja Yun
• Primary Examiner(s): Sengupta, Sonya M
• Application Number:
  US15/095,652
• Publication Number:
  US 20170291331A1
• Time in Patent Office: 1,296 Days
• Field of Search: 427389, 427412, 428473, 156235, 156239, 156289
• CPC Class Codes: B29C 41/30 incorporating preformed parts or layers, e.g. moulding around inserts or for coating articles
• CPC Class Codes: B29K 2083/005 LSR, i.e. liquid silicone rubbers, or derivatives thereof
• CPC Class Codes: B29L 2009/005 coated
• CPC Class Codes: B32B 2037/268 Release layers
• 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 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 1/64 the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• CPC Class Codes: D06N 2201/0245 Acrylic resin fibres
• CPC Class Codes: D06N 2201/0272 Aromatic polyamide fibres
• CPC Class Codes: D06N 2201/0281 Polyurethane fibres
• 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 3/0006 using woven fabrics
• CPC Class Codes: D06N 3/0034 Polyamide fibres for elastomeric fibres D06N3/0025
• CPC Class Codes: D06N 3/0097 Release surface, e.g. separation sheets; Silicone papers
• CPC Class Codes: D06N 3/128 : with silicon polymers
• CPC Class Codes: D06N 3/183 : the layers are one next to the other
• CPC Class Codes: Y10T 442/2041 : Two or more non-extruded coatings or impregnations

Abstract

The present invention provides a method for producing synthetic leather using a silicone rubber coating liquid; and synthetic leather produced by the method.

Claims

1. A method for producing synthetic leather, the method comprising:

(a) a first coating process of knife-coating a release paper with a first coating liquid including a first silicone rubber having a viscosity of 100 Pa·

s or more, an elongation of 300% or more, and a shore A hardness of 50 or more;

(b) a second coating process of knife-coating the release paper coated with the first coating liquid with a second coating liquid including a second silicone rubber having a viscosity of 100 Pa·

s or more, an elongation of 300% or more, and a shore A hardness of less than 50;

(c) a bonding process of bonding the release paper coated with the second coating liquid with a fabric, followed by drying and curing; and

(d) a separation process of separating the release paper from the coated fabric bonded onto the release paper.

2. The method of claim 1, further comprising:

a surface treatment process of treating the surface of the fabric, from which the release paper is separated, with a silicone surface coating agent, after the separation process of (d).

3. The method of claim 1, wherein the fabric of (c) is woven with one or more fibers selected from the group consisting of an aramid fiber, an oxidized polyacrylonitrile fiber, a shrinkage fiber, a spandex, a polyester fiber, and a nylon.

4. A synthetic leather produced by the method of claim 1.

5. A synthetic leather produced by the method of claim 2.

6. A synthetic leather produced by the method of claim 3.