Artificial Leather Patents (Class 428/904)
  • Patent number: 8951933
    Abstract: Disclosed are a polysiloxane-modified polyhydroxy polyurethane resin characterized by being derived from a reaction between a 5-membered cyclic carbonate polysiloxane compound represented by the below-described formula (1) and an amine compound, and its production process; and a resin composition, thermal recording medium, imitation leather, thermoplastic polyolefin resin skin material, weather strip material, and weather strip, all of which make use of the resin.
    Type: Grant
    Filed: November 25, 2010
    Date of Patent: February 10, 2015
    Assignees: Dainichiseika Color & Chemicals Mfg. Co., Ltd., Ukima Chemicals & Color Mfg. Co., Ltd.
    Inventors: Kazuyuki Hanada, Kazuya Kimura, Kenichi Takahashi, Osamu Kawakami, Manabu Uruno
  • Patent number: 8916257
    Abstract: An embossing and texturizing system capable of imparting a natural cloth-like surface to a flexible thermoplastic material or film simultaneously to either or both of its two exterior surfaces, through the use of a unique device and technique combining metal rolls, metal and rubber rolls, and embossing and texturizing fabric rolls into an embossing system creating the desired visual and tactile feel of natural fabrics as well as additional performance characteristics. The embossing and texturizing system embosses and texturizes the exterior surface of the flexible thermoplastic material or film by selectively altering the exterior surface, and therefore, the film can be embossed simultaneously on either or both of its two exterior surfaces (face and reverse) without necessitating major interruption or adjustment of the system.
    Type: Grant
    Filed: December 31, 2007
    Date of Patent: December 23, 2014
    Assignee: Aberdeen Road Company
    Inventors: Peter McKernan, Don Kauffman, Larry Rinehart, Lititia Carter, Ralph Todd
  • Patent number: 8894908
    Abstract: A die for the production of a surface-structured coating (finish) which can be bonded to a sheet-like substrate, in particular a leather, an imitation leather material, a textile material or a wood surface, and which is formed by application of a liquid plastic material to the surface of the die and subsequent solidification of the plastic material, the die having a surface structure corresponding to the surface structure of the coating, the surface comprising, on a substrate, surface structure elements which are arranged in a screen and may be in the form of elevations or depressions, wherein the surface structure of the die has an identification with the surface structure differing from the environment.
    Type: Grant
    Filed: August 8, 2007
    Date of Patent: November 25, 2014
    Assignee: BASF SE
    Inventors: Tilman Lüdecke Taeger, Klaus Schultze, Jens Schadebrodt
  • Patent number: 8883662
    Abstract: A (semi)grain-finished leather-like sheet composed of an entangled nonwoven fabric of three-dimensionally entangled fiber bundles containing microfine long fibers and an elastic polymer contained in the entangled nonwoven fabric. When dividing the (semi)grain-finished leather-like sheet to five layers with equal thickness, i.e., surface layer, substrate layer 1, substrate layer 2, substrate layer 3 and back layer in this order along the thickness direction, part of the microfine long fibers forming the surface layer and/or the back layer are fuse-bonded to each other and the microfine long fibers forming the intermediate layer are not fuse-bonded. With such a fuse-bonding state of the microfine long fibers, the (semi)grain-finished leather-like sheet combines a low compression resistance and a dense feel each comparable to natural leathers, has a sufficient practical strength, and are excellent in properties which are required according to its use.
    Type: Grant
    Filed: March 28, 2008
    Date of Patent: November 11, 2014
    Assignee: Kuraray Co., Ltd.
    Inventors: Jiro Tanaka, Tsuyoshi Yamasaki, Yoshiyuki Ando, Norio Makiyama, Kimio Nakayama
  • Patent number: 8703648
    Abstract: Disclosed are a polysiloxane-modified polyhydroxy polyurethane resin derived from a reaction between a 5-membered cyclic carbonate compound and an amine-modified polysiloxane compound, and its production process; and a resin composition, thermal recording medium, imitation leather, thermoplastic polyolefin resin skin material, weather strip material, and weather strip, all of which make use of the resin.
    Type: Grant
    Filed: November 25, 2010
    Date of Patent: April 22, 2014
    Assignees: Dainichiseika Color & Chemicals Mfg. Co., Ltd., Ukima Chemicals & Color Mfg. Co., Ltd.
    Inventors: Kazuyuki Hanada, Kazuya Kimura, Kenichi Takahashi, Osamu Kawakami, Manabu Uruno
  • Patent number: 8518840
    Abstract: A synthetic resin leather has a substrate and a synthetic resin layer attached to the substrate. The substrate is a both sides cross-knitted fabric and is prepared by cross-knitting a first yarn with 10 to 40 in count including single spun or mixed spun fibers made of rayon, cotton, polyester, nylon, acryl, or urethane and a second yarn with 50 to 300 in denier including crimpy long fiber filaments, thermoplastic elastomer long fiber filaments or polyurethane long fiber filaments; and knitting the both-sided cross-knitted fabric so loops made of the first yarn and loops made of the second yarn are formed on the front and rear sides of the substrate and are in alternating positions on the front side as compared to the rear side; and, on each side of the substrate, loops of the first and second yarns are formed in alternating positions in longitudinal and transverse directions.
    Type: Grant
    Filed: December 24, 2004
    Date of Patent: August 27, 2013
    Assignee: Okamoto Industries, Inc.
    Inventors: Yoshinari Hatori, Shin Nakaya, Akira Nagata, Yasuhiro Tanaka, Kazuomi Ishimaru, Yoshiaki Hirai, Yasuki Kamo
  • Patent number: 8445391
    Abstract: A leather-like sheet composed of a microfine-fiber entangled body made of bundles of microfine fibers and an elastic polymer impregnated therein. The bundles of microfine fibers are composed of microfine monofibers having an average cross-sectional area of 0.1 to 30 ?m2 and have an average cross-sectional area of 40 to 400 ?m2. The bundles of microfine fibers exist in a density of 600 to 4000/mm2 on a cross section taken along the thickness direction of the microfine-fiber entangled body. The elastic polymer contains 30 to 100% by mass of a polymer of ethylenically unsaturated monomer. The polymer of ethylenically unsaturated monomer is composed of a soft component having a glass transition temperature (Tg) of less than ?5° C., a crosslinkable component, and optionally a hard component having a glass transition temperature (Tg) of higher than 50° C. and another component. The polymer of ethylenically unsaturated monomer is bonded to the microfine fibers in the bundles of microfine fibers.
    Type: Grant
    Filed: September 28, 2006
    Date of Patent: May 21, 2013
    Assignee: Kuraray Co., Ltd.
    Inventors: Kimio Nakayama, Tsuyoshi Yamasaki, Nobuo Takaoka, Jiro Tanaka
  • Patent number: 8431648
    Abstract: A coated substrate comprises a substrate and a coating on at least one surface of the substrate. The coating comprises a prepolymer, polymer, or resin produced, for example, by the reaction of (i) an isocyanate (e.g., a polyisocyanate), (ii) an active hydrogen-terminated colorant, and optionally (iii) at least one reactant selected from the group consisting of chain extenders, polyols, internal surfactants, and combinations thereof. Polymer dispersions suitable for use in making such coated substrates comprise such a prepolymer, polymer, or resin.
    Type: Grant
    Filed: January 17, 2011
    Date of Patent: April 30, 2013
    Assignee: Milliken & Company
    Inventors: Jusong Xia, Zhaolin Zhou, Kirkland W. Vogt, Philip G. Harris
  • Patent number: 8334225
    Abstract: Stretchable artificial leather comprising a fibrous substrate comprising tricot knitted fabric, and a polyurethane resin layer laminated on the surface of the fibrous substrate, the stretchable artificial leather having fixed load elongation of from 30 to 60% in each of a longitudinal direction, a lateral direction and a bias direction.
    Type: Grant
    Filed: October 7, 2009
    Date of Patent: December 18, 2012
    Assignees: Honda Motor Co., Ltd., Seiren Co., Ltd.
    Inventors: Tomoyuki Uemura, Atsushi Kakosaka, Yukito Kaneko
  • Patent number: 8283021
    Abstract: An object of the invention is to provide a leather-like sheet having excellent water absorbability (sweat absorbability, defined the same hereinafter), providing a natural leather-like touch, and suitably used as a ball covering or a non-slip covering, without lowering surface wear resistance. An aspect of the invention is directed to a leather-like sheet including a base material having an entangled fiber sheet; and a porous elastic resin layer laminated on a surface of the base material. The porous elastic resin layer has a concave-convex surface. The concave-convex surface of the porous elastic resin layer includes a projection having a top surface and a side surface, and a recess having a bottom surface contiguous to the side surface. The top surface of the projection has openings with a diameter from 10 to 500 nm at a density of 1,000 openings/mm2 or more.
    Type: Grant
    Filed: June 25, 2007
    Date of Patent: October 9, 2012
    Assignee: Kuraray Co., Ltd.
    Inventors: Tetsuya Ashida, Daisuke Tanaka
  • Patent number: 8211529
    Abstract: To endow a velourlike carrier (7), which has a finely fibrous surface, in particular a grain leather having a buffed topside or a synthetic velour material, and has been provided with a dressing (1) which has a grain texture on its face side the dressing (1) consisting of a consolidated polymeric dispersion and being produced separately on a substrate having a textured surface corresponding to the grain texture, with the requisite properties in terms of softness and abrasion resistance, but particularly in terms of air and water vapor permeability, the dressing (1) has capillaries (11) which extend throughout its entire thickness, which everywhere is substantially the same, and is bonded to the carrier (7) via a thin bonding layer (12) formed of a consolidated polymeric dispersion.
    Type: Grant
    Filed: November 15, 2004
    Date of Patent: July 3, 2012
    Assignee: BASF Aktiengesellschaft
    Inventor: Philipp Schaefer
  • Patent number: 8202600
    Abstract: A sheet of an artificial leather substrate contains an upper-layer nonwoven fabric A (1) and a base nonwoven fabric B (2). The upper-layer nonwoven fabric A (1) is a wet-laid nonwoven fabric having a density of 0.30 to 0.50 g/cm3 and being produced with synthetic fibers in which the component fibers have a fineness of 0.005 to 1.1 dtex, a fiber length of 3 to 10 mm and a weight per unit area of 20 to 150 g/m2, and the base nonwoven fabric B (2) is a layer of a nonwoven fabric having a density of 0.15 g/cm3 or more and less than 0.28 g/cm3 and being produced with synthetic fibers in which the component fibers have a fineness greater than that of the component fibers of the upper-layer nonwoven fabric A and 4.5 dtex or less, a fiber length of 2 to 15 mm and a weight per unit area of 50 to 400 g/m2. The upper-layer nonwoven fabric A (1) and the base nonwoven fabric B (2) are layered, made into a single body by entanglement of the component fibers of both layers and impregnated with an elastic polymer.
    Type: Grant
    Filed: July 25, 2007
    Date of Patent: June 19, 2012
    Assignee: Tradik Co., Ltd.
    Inventors: Hozuma Okada, Kunio Ichihashi
  • Patent number: 8178184
    Abstract: A method of producing an entangled sheet of microfine long fibers using long fibers for forming microfine fibers. The method includes a step of forming a long-fiber web made of long fibers for forming microfine fibers, at least one component of the long fibers being a water-soluble, thermoplastic polyvinyl alcohol resin; a step of entangling the long-fiber web to form a long-fiber entangled sheet; a step of shrinking the long-fiber entangled sheet to form a long-fiber shrunk sheet; and a step of converting the long fibers for forming microfine fibers in the long-fiber shrunk sheet to microfine long fibers, thereby producing the entangled sheet of microfine long fibers. The step of entangling is conducted so as to allow the long-fiber entangled sheet to have an interlaminar peel strength of 2 kg/2.5 cm or more. The step of shrinking is conducted so as to shrink in an areal shrinkage of 35% or more.
    Type: Grant
    Filed: June 15, 2005
    Date of Patent: May 15, 2012
    Assignee: Kuraray Co., Ltd.
    Inventors: Yoshiaki Yasuda, Jiro Tanaka, Yoshiyuki Ando, Yoshiki Nobuto, Kimio Nakayama, Yoshihiro Tanba, Tsuyoshi Yamasaki
  • Patent number: 8137789
    Abstract: There are provided a composition for matte layer formation suitable for the production of a matte synthetic leather having a matte surface with a high level of jet-blackness even without the practice of embossing, raising, etc., and a release sheet for the production of a matte synthetic leather by using the composition. The composition for matte layer formation suitable for the production of a matte synthetic leather comprises a thermosetting resin and a matting agent as indispensable components. The matting agent comprises one or at least two types of organic or/and inorganic porous fine particles. The porous fine particles have a mean particle diameter in the range of 0.5 to 20 ?m and a specific surface area in the range of 1 to 1000 m2/g. The release sheet is produced by using the composition.
    Type: Grant
    Filed: September 13, 2006
    Date of Patent: March 20, 2012
    Assignee: Dai Nippon Printing Co., Ltd.
    Inventors: Kenichiro Suto, Yoshiki Kawagoe, Hiroshi Watanabe, Takeshi Kubota, Koichiro Matsudaira
  • Patent number: 8030230
    Abstract: The present invention relates to a flame-retardant leather-like sheet having a soft hand, excellent surface touch and excellent appearance, which includes an entangled nonwoven fabric of microfine polyester fibers having an average single-fiber fineness of 0.5 dtex or less, and an elastic polymer contained inside the nonwoven fabric, wherein a flame-retardant is exhausted into the elastic polymer and wherein a flame retarder solution containing bubbles forcibly formed is applied to a back surface of the leather-like sheet so that the flame retarder is present in a region extending from the back surface to an inside of the leather-like sheet but is not present on side of a front surface of the leather-like sheet.
    Type: Grant
    Filed: August 29, 2007
    Date of Patent: October 4, 2011
    Assignee: Kuraray Co., Ltd.
    Inventors: Yasuhiro Yoshida, Masasi Meguro, Hisao Yoneda, Norio Makiyama, Tatsuya Nakashima, Yasumasa Tatekawa
  • Patent number: 7951452
    Abstract: The suede artificial leather of the present invention comprises a three-dimensional entangled body comprising a superfine fiber having a fineness of 0.2 dtex or less and an elastomeric polymer A, and satisfies the requirements (1) to (4) as specified in the specification. By meeting the requirements, the suede artificial leather acquires excellent color fastness to light and color development in a wide range of colors and a high quality with good suede feeling, surface touch, hand, mechanical properties and color fastness.
    Type: Grant
    Filed: September 26, 2003
    Date of Patent: May 31, 2011
    Assignee: KURARAY Co., Ltd.
    Inventors: Kimio Nakayama, Tsuyoshi Yamasaki, Nobuo Takaoka, Mitsuru Kato, Shuhei Yorimitsu
  • Patent number: 7932192
    Abstract: A substrate for artificial leathers, comprising a nonwoven fabric body made of microfine fiber bundles and an elastic polymer impregnated therein. The substrate for artificial leathers simultaneously satisfies the following requirements 1 to 4: (1) each of the microfine fiber bundles contains 6 to 150 bundled microfine long fibers in average; (2) a cross-sectional area of the microfine long fibers constituting the microfine fiber bundles is 27 ?m2 or less, and 80% or more of the microfine long fibers has a cross-sectional area of from 0.9 to 25 ?m2; (3) an average cross-sectional area of the microfine fiber bundles is from 15 to 150 ?m2; and (4) on a cross section parallel to a thickness direction of the nonwoven fabric body, cross sections of the microfine fiber bundles exist in a density of from 1000 to 3000/mm2 in average.
    Type: Grant
    Filed: December 13, 2006
    Date of Patent: April 26, 2011
    Assignee: Kuraray Co., Ltd.
    Inventors: Michinori Fujisawa, Jiro Tanaka, Tsuyoshi Yamasaki, Norio Makiyama, Yoshiyuki Ando
  • Patent number: 7829486
    Abstract: The leather-like sheet substrate of the present invention comprises a fiber-entangled nonwoven fabric that comprises a microfine fiber bundle (A) and a microfine fiber bundle (B) in a blending ratio (A)/(B) of 30/70 to 70/30 by mass and a polymeric elastomer contained in the fiber-entangled nonwoven fabric. The microfine fiber bundle (A) comprises 10 to 100 microfine fibers each of which has a single fiber fineness of 0.5 dtex or less and which are made of an elastic polymer having a JIS A hardness of 90 to 97. The microfine fiber bundle (B) comprises a microfine fiber which has a single fiber fineness of 0.5 dtex or less and which is made of a non-elastic polymer. Because of its excellent stretchability in both the machine and transverse directions and drapeability, the leather-like sheet substrate is particularly suitable as the material for clothing.
    Type: Grant
    Filed: January 29, 2004
    Date of Patent: November 9, 2010
    Assignee: Kuraray Co., Ltd.
    Inventors: Yoshiki Nobuto, Yoshihiro Tanba
  • Patent number: 7824737
    Abstract: Novel synthetic leather articles comprise a substrate and a coating applied to a surface of the substrate. The coating comprises a resin and a polymeric colorant. The polymeric colorant comprises a chromophore and an oligomeric constituent bound to the chromophore. Novel methods for producing synthetic leather articles using polymeric colorants are also provided.
    Type: Grant
    Filed: June 17, 2009
    Date of Patent: November 2, 2010
    Assignee: Milliken & Company
    Inventors: Jusong Xia, Zhaolin Zhou, Chenghua Chen
  • Patent number: 7820568
    Abstract: A leather-like sheet excellent in repulsive feeling is provided by a leather-like sheet substantially including a fibrous material which is a leather-like sheet in which a staple fiber nonwoven fabric (A) in which ultra-fine fibers of an average single fiber fineness of 0.0001 to 0.5 dtex and an average fiber length of 1 to 10 cm are entangled with each other and a woven or knitted fabric (B) including a conjugate fiber in which two or more polyesters are disposed in side-by-side or eccentric sheath-core relationship are laminated.
    Type: Grant
    Filed: August 1, 2005
    Date of Patent: October 26, 2010
    Assignee: Toray Industries, Inc.
    Inventors: Tomoyuki Horiguchi, Kentaro Kajiwara, Satoru Shimoyama
  • Patent number: 7820574
    Abstract: A grain-finished leather-like sheet having a fibrous substrate layer, a polyurethane non-porous layer and a polyurethane surface layer which are successively laminated in this order. The polyurethane surface layer contains a binder polyurethane and polyurethane fine particles having a particle size of 1 to 50 ?m. The total thickness of the polyurethane non-porous layer and the polyurethane surface layer is 150 ?m or more. The polyurethane surface layer contains the polyurethane fine particles in an amount of 10 to 40 parts by mass per 100 parts by mass of the binder polyurethane. The polyurethane fine particles are not exposed to the surface. The grain-finished leather-like sheet characterized by the above features has a smooth and luster surface, a good hand, and excellent scratch resistance, abrasion resistance and buckling wrinkle resistance. The sheet hardly damages or soils an object which is in contact with its surface by friction.
    Type: Grant
    Filed: June 20, 2006
    Date of Patent: October 26, 2010
    Assignee: Kuraray Co., Ltd.
    Inventors: Tetsuya Ashida, Norio Makiyama
  • Patent number: 7727607
    Abstract: A decorative dry paint wall film includes a layer of dry paint, a pressure-sensitive adhesive layer on one side of the dry paint layer, and a release liner in releasable contact with the dry paint layer on a side opposite from the pressure-sensitive adhesive (PSA). The release liner has a matte release coat layer that contacts the dry paint layer. The release liner is released from the dry paint layer after the PSA side is attached to a wall. The matte release coat transfers a matte finish to the dry paint layer when the release liner is removed. The wall film includes a barrier layer to protect against significant discoloration of the color in the dry paint layer caused by migration of azo-type pigments from a painted wall surface. The barrier layer in one embodiment comprises a dry emulsion containing ethylene-vinyl alcohol and a dispersed polymeric material which in one embodiment comprises a urethane material.
    Type: Grant
    Filed: February 16, 2007
    Date of Patent: June 1, 2010
    Assignee: The Procter & Gamble Company
    Inventors: Frank Yen-Jer Shih, Roger A. Fahlsing, Anneke Margaret Kaminski, John Vincent Fontana, Douglas Bruce Zeik, Martin Ian James
  • Patent number: 7704900
    Abstract: Provided is an artificial leather sheet that comprises microfine fibers of an inelastic polymer having a mean fiber diameter of at most 5 ?m and an elastic polymer, in which the major portion of the elastic polymer forms a fibrous structure of the entangled nonwoven fabric with the microfine fibers of inelastic polymer throughout the entire layer of the artificial leather sheet in the thickness direction thereof, and a part of the elastic polymer forms a porous layer integrated with the entangled nonwoven fabric structure on at least one face of the artificial leather sheet. The artificial leather sheet does not substantially undergo structure deformation even when repeatedly elongated and deformed. It has good elastic stretchability, and has a soft and dense feel, and its appearance is good not detracting from the drapability of the sheet.
    Type: Grant
    Filed: August 30, 2004
    Date of Patent: April 27, 2010
    Assignee: Kuraray Co., Ltd.
    Inventors: Shinichi Yoshimoto, Tetsuya Ashida, Hisao Yoneda
  • Patent number: 7662461
    Abstract: Novel synthetic leather articles comprise a substrate and a coating applied to a surface of the substrate. The coating comprises a resin and a polymeric colorant. The polymeric colorant comprises a chromophore and an oligomeric constituent bound to the chromophore. Novel methods for producing synthetic leather articles using polymeric colorants are also provided.
    Type: Grant
    Filed: March 31, 2006
    Date of Patent: February 16, 2010
    Assignee: Milliken & Company
    Inventors: Jusong Xia, Zhaolin Zhou, Chenghua Chen
  • Patent number: 7601656
    Abstract: A leather-like sheet excellent in stretchability which is obtained by integrating by entanglement of a woven or knitted fabric and an ultrafine fiber of 0.0001 to 0.5 dtex, wherein at least one face of the leather-like sheet is substantially composed of said ultrafine fibers, and said woven or knitted fabric consists of a conjugate fiber in which two or more kinds of polyester-based polymers, at least one of which consists essentially of polytrimethylene terephthalate, are stuck along the fiber length direction side-by-side, or a conjugate fiber in which two or more kinds of polyester-based polymers, at least one of which consists essentially of polytrimethylene terephthalate, forms an eccentric sheath-core type conjugate structure, and the fiber constituting the woven or knitted fabric has a twist coefficient of 20000 or below.
    Type: Grant
    Filed: February 10, 2005
    Date of Patent: October 13, 2009
    Assignee: Toray Industries, Inc.
    Inventors: Tomoyuki Horiguchi, Katsuhiko Mochizuki, Akira Karasawa
  • Patent number: 7566488
    Abstract: A skin material for balls which is a sheet-form material comprising a base layer and formed on one side there of a coating layer made of a polymeric elastomer, characterized in that (1) the coating layer is composed of three layers (C-1), (C-2), and (C-3) disposed in this order from the surface side, (2) the layer (C-3) on the base layer side is made of a porous polymeric elastomer, (3) the layer (C-1) on the surface side is made of a polymeric elastomer containing a pressure-sensitive adhesive, and (4) the coating layer comprises one or more polymeric elastomers which have or do not have fine through-holes extending from the surface side to the base layer; and a ball having the skin material bonded to the surface. The skin material for ball-game balls brings about excellent wet gripping and is excellent also in wearing resistance and impact absorption.
    Type: Grant
    Filed: March 17, 2004
    Date of Patent: July 28, 2009
    Assignee: Teijin Cordley Limited
    Inventors: Masahisa Mimura, Shogo Takahashi
  • Publication number: 20090047476
    Abstract: An artificial leather including an entangled body made of bundles of microfine fibers and an elastic polymer impregnated into the entangled body. A part of the elastic polymer penetrates into the bundles of microfine fibers. The degree of penetration of the elastic polymer is from 1 to 30% by area when measured on a cross section which is taken along a direction perpendicular to a lengthwise direction of the bundles of microfine fibers. The fiber-holding property is improved by the elastic polymer which partly penetrates into the bundles of microfine fibers, and therefore, the artificial leather has a good hand without deteriorating the surface quality.
    Type: Application
    Filed: February 27, 2007
    Publication date: February 19, 2009
    Applicant: KURARAY CO., LTD.
    Inventors: Masasi Meguro, Yasuhiro Yoshida, Hisao Yoneda
  • Patent number: 7462386
    Abstract: The leather-like sheet of the invention comprises a napped part of ultrafine fibers and a grainy part of nonporous elastic polymer randomly existing in the surface of a substrate prepared by infiltrating a porous polymer elastomer into a three-dimensionally intermingled nonwoven fabric of ultrafine fibers of not more than 0.5 dtex, and this is characterized in that the nonporous elastic polymer is infiltrated into the substrate to a depth thereof of from 5 to 20 ?m from the surface of the substrate. The production method of the invention is for producing a nubuck-type leather-like sheet of good surface abrasion resistance. A grainy part of resin and ultrafine fibers and a part of the ultrafine fibers are mingled on the surface of the substrate, and the sheet has an elegant and three-dimensional appearance like natural leather.
    Type: Grant
    Filed: July 23, 2002
    Date of Patent: December 9, 2008
    Assignee: Kuraray Co., Ltd.
    Inventors: Tsuyoshi Yamasaki, Hidekazu Andoh, Yoshihiro Tamba
  • Patent number: 7378032
    Abstract: A paint composition for leather comprising a fluorine-containing resin and a silicone oil, and a paint composition for leather comprising a curable fluorine-containing resin, a curing agent and a silicone oil can have both soft feeling of a leather itself and film properties such as soil resistance and abrasion resistance.
    Type: Grant
    Filed: December 18, 2003
    Date of Patent: May 27, 2008
    Assignee: Daikin Industries, Ltd.
    Inventors: Akihiko Ueda, Masahiko Maeda
  • Patent number: 7282253
    Abstract: A non-woven fabric with melange-type visual appearance and endowed with high-durability comprising a fiber part and a matrix binder characterized by the binder matrix being a polyurethane characterized by the presence of soft segments and rigid segments, the former constituted from mixtures of polycarbonate-polyols and polyester-polyols, and the latter, from urethane groups deriving from the reaction of isocyanates with ureic polyols, and groups deriving from the reaction between the free isocyanate groups and water, and the fiber part comprises a fiber of melange appearance that is a mixture of two or more fibers with different dyeability characteristics.
    Type: Grant
    Filed: December 19, 2003
    Date of Patent: October 16, 2007
    Inventors: Silvia Marini, Omar Teofrasti
  • Patent number: 7264864
    Abstract: A tile, made for example of leather, having a first face, a second face, side edges and a plurality of holes that bring into communication first face with second face. In a lining made with such tiles like this, the holes lead the air from below to above the tiles. To improve further the air flow through the tile, on the second face a plurality of grooves are made that extend from a central zone up to the side edges of the tile. This way, an air path is formed between the lining and the floor leading the air to holes and then into the room at the side of first face. A favorable exchange rate through a floor lining made with them is obtained, combined with a heat exchanger embedded in the floor.
    Type: Grant
    Filed: November 10, 2003
    Date of Patent: September 4, 2007
    Inventor: Ivano Vagnoli
  • Patent number: 7258909
    Abstract: The leather-like sheet for balls of the present invention comprises a fiber-entangled fabric and a porous surface layer disposed on the surface of the fiber-entangled fabric. The porous surface layer has a pattern formed by a plurality of outwardly projecting pebbles and valleys between the pebbles. A plurality of microholes having an average diameter of 5 to 100 ?m are formed on surfaces of the pebbles, but the microhole is substantially not formed on surfaces of the valleys. The leather-like sheet exhibits a sufficient surface abrasion resistance and an excellent non-slip properties because of its high sweat-absorbing ability under wet conditions.
    Type: Grant
    Filed: March 4, 2004
    Date of Patent: August 21, 2007
    Assignee: Kuraray Co., Ltd.
    Inventors: Kazundo Akamata, Yoshio Ishihara
  • Patent number: 7186451
    Abstract: The invention is directed to a composite sheet suitable for use as artificial leather or a precursor to artificial leather, where both surfaces have a napped or brushed appearance. The composite sheet comprises a low-density, lightly bonded non-woven web that is stitch-bonded and bulked such that the stitch-bonding yarns are not visible to the naked eyes without the need of post-processing steps to hide the yarns. The composite sheet may have binder resin(s) dispersed therein and activated.
    Type: Grant
    Filed: March 31, 2003
    Date of Patent: March 6, 2007
    Assignee: XYMID, LLC
    Inventors: Dimitri Peter Zafiroglu, Stephen H. Tsiarkezos
  • Patent number: 7169457
    Abstract: There are provided a composition for matte layer formation suitable for the production of a matte synthetic leather having a matte surface with a high level of jet-blackness even without the practice of embossing, raising, etc., and a release sheet for the production of a matte synthetic leather by using the composition. The composition for matte layer formation suitable for the production of a matte synthetic leather comprises a thermosetting resin and a matting agent as indispensable components. The matting agent comprises one or at least two types of organic or/and inorganic porous fine particles. The porous fine particles have a mean particle diameter in the range of 0.5 to 20 ?m and a specific surface area in the range of 1 to 1000 m2/g. The release sheet is produced by using the composition.
    Type: Grant
    Filed: December 26, 2002
    Date of Patent: January 30, 2007
    Assignee: Dai Nippon Printing Co., Ltd.
    Inventors: Kenichiro Suto, Yoshiki Kawagoe, Hiroshi Watanabe, Takeshi Kubota, Koichiro Matsudaira
  • Patent number: 7105227
    Abstract: The leather-like sheet substrate of the invention comprises a nonwoven fabric of three-dimensionally entangled superfine fibers (A) of at most 0.5 dtex in fineness and a polymer elastomer (B) filled in the entangled interspaces of the nonwoven fabric, in which the superfine fibers (A) comprise an organophosphorus component-copolymerized polyester and the polymer elastomer (B) contains a metal hydroxide or is copolymerized with an organophosphorus component. The leather-like sheet substrate of the invention and artificial leather obtained from it contain no halogen and are resistant to flames. These have a soft feel and are suitable to applications in the interior field that requires flame retardancy, especially to seats for vehicles, etc.
    Type: Grant
    Filed: February 18, 2002
    Date of Patent: September 12, 2006
    Assignee: Kuraray Co., Ltd.
    Inventors: Yoshiaki Yasuda, Yasuhiro Takeda, Shuhei Ishino, Yoshihiro Tanba
  • Patent number: 7091139
    Abstract: The flame-retardant leather-like sheet substrate of the present invention comprises a layer (A) that is made of an entangled nonwoven fabric comprising a polyester superfine fiber (a) of a single fiber fineness of 0.5 dtex or less containing no flame-retardant component and a flame-retardant polyester superfine fiber (b) of a single fiber fineness of 0.5 dtex or less containing a flame-retardant component in a ratio, (a)/(b), of 100/0 to 40/60 by mass, and a layer (B) that is made of an entangled nonwoven fabric comprising the polyester superfine fiber (a) and the flame-retardant polyester superfine fiber (b) in a ratio, (a)/(b), of 70/30 to 0/100 by mass. The entangled nonwoven fabrics of the layers (A) and (B) are impregnated with an elastomeric polymer (c) containing a flame-retardant component. The ratio of the polyester superfine fiber (a) and the flame-retardant polyester superfine fiber (b) in the flame-retardant leather-like sheet substrate is 10:90 to 90:10 by mass.
    Type: Grant
    Filed: June 5, 2003
    Date of Patent: August 15, 2006
    Assignee: KURARAY Co., Ltd.
    Inventors: Yoshiki Nobuto, Yoshiaki Yasuda, Yoshihiro Tanba
  • Patent number: 7037590
    Abstract: The present invention relates to a water vapor-permeable coating composite containing one or more flexible substrates, which are coated on one or both sides with one or more identical or different coating compositions, provided that at least one coating composition contains, as binder, a silica sol-modified aqueous polymer dispersion prepared from unsaturated monomers.
    Type: Grant
    Filed: November 1, 2002
    Date of Patent: May 2, 2006
    Assignee: Bayer Aktiengesellschaft
    Inventors: Thorsten Rische, Tillmann Hassel, Jürgen Meixner, Detlef-Ingo Schütze
  • Patent number: 6900148
    Abstract: A leather-like sheet material comprising a substrate layer composed of an entangled nonwoven fabric consisting of ultrafine fibers and an elastic polymer or elastomer filled therein and having, on one side (side A) of the substrate layer, a grain layer comprising an elastomer mainly consisting of a polyurethane, wherein the ultrafine fibers (a) constituting the side A of the substrate layer have a mean fineness substantially within the range of 0.01 to 0.5 decitex and the ultrafine fibers (b) substantially constituting the other side (side B) opposite to the side A of the substrate layer have a mean fineness of not more than ½ of the mean fineness of the ultrafine fibers (a).
    Type: Grant
    Filed: July 2, 2002
    Date of Patent: May 31, 2005
    Assignee: Kuraray Co., Ltd.
    Inventors: Hisao Yoneda, Yoshiki Nobuto, Kohei Hayashi
  • Patent number: 6863953
    Abstract: The present invention provides a surface material which can be replaced to the conventional surface material made of soft polyvinylchloride resin. This surface material is useful for the various uses such as the material for car interior, surface material furniture or the material for porches. The present invention is the urethane resin surface material comprising, a mixed resin sheet composed of 50-95 wt. % thermoplastic polyurethane and 50-5 wt. % of acrylic soft resin and the Shore A hardness of said urethane resin surface material is 60-80. On one side surface of the mixed resin sheet, a layer of knitted, woven, nonwoven fabric or soft foam sheet can be provided. As the thermoplastic polyurethane resin, the thermoplastic polyurethane resin of Shore A hardness 65-90 is desirable, and as the acrylic soft resin, the acrylic soft resin of Shore A hardness 50-80 is desirable.
    Type: Grant
    Filed: September 10, 2002
    Date of Patent: March 8, 2005
    Assignee: Okamoto Industries, Inc.
    Inventors: Toshimasa Mori, Yoshinari Hatori, Tetsuo Nodera, Haruhide Kawai
  • Patent number: 6852418
    Abstract: A composite structure is disclosed. The structure includes one or several polyurethane layers, a support layer, in particular a textile support layer, as well as an optional adhesive layer placed between these layers. The composite structure is characterized in that at least one of the polyurethane layers contains a polyurethane having the formula (I) wherein O—R1—O— is the radical of a polyole with primary and/or secondary hydroxyl functional end groups, R1 and R2 independently represent an organic radical which includes aliphatic, cyclo-aliphatic, aromatic and/or heterocyclic groups, and n is an integer number between 1 and 50,000. Also disclosed is a method of manufacturing the composite structure and its use as imitation leather.
    Type: Grant
    Filed: July 7, 2000
    Date of Patent: February 8, 2005
    Assignee: Benecke-Kaliko AG
    Inventors: Claus Zürbig, Hans-Hinrich Kruse
  • Patent number: 6846759
    Abstract: A method of making a soft, well cushioned, fabric suitable for use in an automotive interior, furniture and upholstery. The fabric which is formed by depositing a coating of a high temperature adhesive having a viscosity of 6×104 to 75×104 centipoise at its application temperature on one surface of a felt cloth followed by laying down a layer of a second material on top of the adhesive-coated surface of the felt cloth to form a composite. The composite is then passed through a hot pinch point to firmly bond the second layer to the felt cloth.
    Type: Grant
    Filed: September 24, 2001
    Date of Patent: January 25, 2005
    Assignee: Knowlton Nonwovens, Inc.
    Inventor: Stephen D. Copperwheat
  • Publication number: 20040253370
    Abstract: The present invention relates to a process for preparing a synthetic suede leather, a synthetic suede leather obtainable by said process and the use of said synthetic suede leather as a cover in automotive and furniture applications or as outer garments. The process comprises the steps of (a) foaming a composition comprising an aqueous polyurethane dispersion; (b) applying the foamed composition to a textile substrate composed of a yarn; (c) coagulating the polyurethane dispersion; (d) drying; and (e) condensation said foamed composition containing pigments during application. The textile substrate is preferably pre-dyed with disperse dyes.
    Type: Application
    Filed: July 22, 2004
    Publication date: December 16, 2004
    Inventor: Werner Hoersch
  • Publication number: 20040242099
    Abstract: The leather-like sheet of the present invention comprises an entangled nonwoven fabric which is made of a mixture comprising fibers of an elastic polymer and microfine fibers of a inelastic polymer having an average single fiber fineness of 0.1 dtex or less. The fibers of the elastic polymer are partially porous and are partially fuse-bonded to each other. With such fibrous structure, the leather-like sheet substantially sustains repeated extensional deformations without causing permanent change of its original structure and configuration. The leather-like sheet are excellent in elastic stretchability, soft and dense feel and drapeability, and is successfully made into a napped leather-like sheet excellent in appearance, feel, elastic stretchability and drapeability.
    Type: Application
    Filed: May 27, 2004
    Publication date: December 2, 2004
    Applicant: Kuraray Co., Ltd.
    Inventors: Shinichi Yoshimoto, Tetsuya Ashida, Hisao Yoneda
  • Publication number: 20040197590
    Abstract: The present invention relates to a synthetic leather free from halogens and prepared with a method characterized in that it comprises the following stages: a) forming, in a mould by means of slush moulding, a first layer, i.e. the visible layer in the finished leather, from a polyolefin composition grafted with silanes and cross-linkable in the presence of water, b) in immediate succession, forming, in said mould by means of slush moulding, a second layer from a polyolefin composition having a semi-crystalline phase with a high melting point not less than 120° C. and preferably not less than 140° C.
    Type: Application
    Filed: May 7, 2004
    Publication date: October 7, 2004
    Inventors: Paolo Cittadini, Marco De Giorgi
  • Patent number: 6800384
    Abstract: A synthetic resin leather comprising a substrate at least one surface of which is arranged with a synthetic resin layer, wherein said synthetic resin layer contains 1 to 70 weight parts of bridged polyalkylene oxide to 100 weight parts of synthetic resin. As the synthetic resin, polyvinyl chloride resin, acrylic soft resin, mixed resin composed of 50-95 wt. % of thermoplastic polyurethane and 50-5 wt. % of acrylic soft resin, copolymer of polyester resin or polyolefin resin can be used. A surface coating layer containing powder of natural organic substance can be arranged over the surface of synthetic resin layer of said synthetic resin leather. As the powder of natural organic substance, collagen can be desirably used. Further, on the surface of the synthetic resin leather, it is desirable to mark a pattern and to make the height of convex part of the pattern higher than 0.05 mm.
    Type: Grant
    Filed: April 8, 2002
    Date of Patent: October 5, 2004
    Assignee: Okamoto Industries, Inc.
    Inventors: Masao Suzuki, Masao Sasaki
  • Patent number: 6784127
    Abstract: A polyurethane elastomer fiber non-woven fabric contains polyurethane elastomer fiber filaments melt-bonded with one another, and has a tensile elongation of 100% or more, a 50% elongation recovery of 75% or more and a tear strength per METSUKE of 5.5 gf or more. The non-woven fabric can be prepared by a method of providing a thermoplastic polyurethane elastomer having Shore hardness A of 92 or more, drying the elastomer to a water content of 150 ppm or less, and melt-spinning and, at the same time, spraying it together with a high speed gas stream so as to deposit and laminate the elastomer into a sheet form. A synthetic leather using the non-woven fabric is also provided. The non-woven fabric has not only an excellent elasticity but also high tear strength.
    Type: Grant
    Filed: September 24, 2001
    Date of Patent: August 31, 2004
    Assignees: Kanebo, Limited, Kanebo Gohsen, Limited
    Inventors: Yukio Yamakawa, Tadashi Furuya, Eiji Kawabata, Yutaka Tanaka
  • Publication number: 20040157037
    Abstract: The suede-finished leather-like sheet of the present invention comprises a fiber-entangled nonwoven fabric comprising a layer (I) made of a microfine fiber (A) having an average fineness of 0.5 dtex or less and a layer (II) made of a microfine fiber (B) having an average fineness equal to or less than that of the microfine fiber (A), and a polymeric elastomer impregnated in the fiber-entangled nonwoven fabric. The layers (I) and (II) are integrated by entanglement such that a ratio of the microfine fiber (A) to the microfine fiber (B) is 10/90 to 90/10 by mass. The surface of the layer (I) is a napped surface made mainly of a raised microfine fiber (A). The microfine fibers (A) and (B) are respectively formed by converting a microfine fiber-forming fiber (a) and a microfine fiber-forming fiber (b), each having an elongation at break and a tenacity of specific ranges, into microfine fibers.
    Type: Application
    Filed: February 6, 2004
    Publication date: August 12, 2004
    Applicant: KURARAY CO., LTD.
    Inventors: Fumihiro Yamaguchi, Hisao Yoneda
  • Patent number: 6770582
    Abstract: A composite laminate suitable for use in upholstery, automotive interiors and the like, which is made of a polyester felt substrate, an adhesive coating is contained on said felt substrate which obviates the need for a barrier layer for a vinyl laminate, with a vinyl film overlaying and bonding with said adhesive to said substrate. The method of making the laminate is also disclosed.
    Type: Grant
    Filed: September 24, 2001
    Date of Patent: August 3, 2004
    Assignee: Knowlton Nonwovens, Inc.
    Inventor: Stephen D. Copperwheat
  • Patent number: 6767853
    Abstract: A fibrous substrate for artificial leather, containing microfine fiber bundles, each of which is composed of 3-50 microfine fibers (A) containing an elastic polymer and having an average fineness of 0.5 denier or less and 15 or more microfine fibers (B) containing a non-elastic polymer and having an average fineness of 0.2 denier or less. The microfine fiber bundles satisfy the following conditions (1)-(3): (1) the ratio of the number of strands of the A to the number of strands of the B in cross sections of the bundles (A/B) is 1/5 or less, (2) the ratio of the weight of the A to the weight of the B in the bundles (A/B) is 10/90-60/40, and (3) the microfine fibers (B) containing the non-elastic polymer encircle each of the microfine fibers (A) comprising the elastic polymer.
    Type: Grant
    Filed: July 3, 2000
    Date of Patent: July 27, 2004
    Assignee: Kuraray Co., Ltd.
    Inventors: Kimio Nakayama, Tsuyoshi Yamasaki, Yoshihiro Tamba
  • Publication number: 20040121113
    Abstract: A synthetic leather is made by a impregnating a non-woven or woven textile with an aqueous polyurethane dispersion comprised of a nonionizable polyurethane and an external stabilizing surfactant. The impregnated textile is then exposed to water containing a coagulant for a coagulation time sufficient to coagulate the dispersion. The method may be used to form a synthetic leather having excellent wet ply adhesion and may contain an insoluble multivalent cation organic acid.
    Type: Application
    Filed: June 27, 2003
    Publication date: June 24, 2004
    Inventors: Larry Wayne Mobley, Ramki Subramanian, Kenneth W. Skaggs, Weijun Zhou, Debkumar Bhattacharjee, Roger Moore