US3841897A
Expired / Lapsed
US
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Artificial leather
Assignee: Toray Industries Inc
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Filing: 1972-10-17
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Granted: 1974-10-15
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Expires: 1992-10-17
Abstract
Abstract Artificial leather is composed of four layers: a fibrous substrate, a urethane polymer layer (III) containing finely divided inorganic particles, a thinner urethane polymer layer (II) consisting of at least about 80 percent by weight of polyurethane, and a coating layer (I) consisting of at least about 80 percent by weight of polyurethane.
Inventors
- 👤 K Okazaki
- 👤 A Higuchi
- 👤 N Imaeda
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 14:01
CPC Classifications
D; D06; D06N; D06N3/00; D06N3/12; D06N3/14; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24355; Y10T428/24438; Y10T428/24446; Y10T428/24942; Y10T428/2495; Y10T428/24967; Y10T428/24975; Y10T428/24992; Y10T428/25; Y10T428/254; Y10T428/26; Y10T428/263; Y10T428/27; Y10T428/273; Y10T428/31504; Y10T428/31551; Y10T428/31554; Y10T428/31609
Claims Analysis
Total Claims: 26
Claim 1
Independent Claim
242 words
ARTIFICIAL LEATHER COMPRISING A FIBROUS SUBSTRATE HAVING A THICKNESS OF ABOUT 0.3 TO 3.0 MM, SAID SUBSTRATE COMPRISING A FABRIC IMPREGNATED WITH A POLYMER, AND COATING LAYERS (III) (II) AND (I) ADHERED IN THAT ORDER TO THE SURFACE OF SAID SUBSTRATE. A. THE COATING LAYER (III) HAVING A THICKNESS OF ABOUT 0.1 TO 3.0 MM, AND COMPRISING A WET COAGULATED POLYMER COMPOSITIONS WHICH CONTAINS ABOUT 50 TO 300 PARTS BY WEIGHT OF INORGANIC PARTICLES PER 100 PARTS BY WEIGHT OF POLYMER SAID INORGANIC PARTICLES HAVING A MEAN PARTICLE DIAMETER OF ABOUT 0.93 TO 5.0 MICRON AND BEING ESSENTIALLY INSOLUBLE IN WATER, AND THE POLYMER IN THIS POLYMER COMPOSITION CONSISTING OF AT LEAST ABOUT 60 PERCENT BY WEIGHT OF POLYURETHANE, B. THE COATING LAYER (II) HAVING A THICKNESS OF ABOUT 0.01 TO 0.3 MM, AND COMPRISING A WET COAGULATED POLYMER COMPOSITION WHICH CONTAINS ABOUT 0 TO 50 PARTS BY WEIGHT OF INORGANIC PARTICLES PER 100 PARTS BY WEIGHT OF POLYMER, SAID INORGANIC PARTICLES HAVING A MEAN PARTICLE DIAMETER OF ABOUT 0.03 TO 5.0 MICRON AND BEING ESSENTIALLY INSOLUBLE IN WATER, AND THE POLYMER IN THIS POLYMER COMPOSITION CONSISTING OF AT LEAST ABOUT 80 PERCENT BY WEIGHT OF POLYURETHANE, AND C. THE COATING LAYER (I) HAVING A THICKNESS OF ABOUT 0.001 TO 0.1 MM AND HAVING A 20 PERCENT MODULUS OF ABOUT 5 TO 100 KG/CM2, AND COMPRISING A DRY-COAGULATED POLYMER COMPOSITION, CONSISTING ESSENTIALLY OF AT LEAST ABOUT 80 PERCENT BY WEIGHT OF POLYURETHANE.
Claim 2
Dependent Claim
242 words
ARTIFICIAL LEATHER COMPRISING A FIBROUS SUBSTRATE HAVING A THICKNESS OF ABOUT 0.3 TO 3.0 MM, SAID SUBSTRATE COMPRISING A FABRIC IMPREGNATED WITH A POLYMER, AND COATING LAYERS (III) (II) AND (I) ADHERED IN THAT ORDER TO THE SURFACE OF SAID SUBSTRATE. A. THE COATING LAYER (III) HAVING A THICKNESS OF ABOUT 0.1 TO 3.0 MM, AND COMPRISING A WET COAGULATED POLYMER COMPOSITIONS WHICH CONTAINS ABOUT 50 TO 300 PARTS BY WEIGHT OF INORGANIC PARTICLES PER 100 PARTS BY WEIGHT OF POLYMER SAID INORGANIC PARTICLES HAVING A MEAN PARTICLE DIAMETER OF ABOUT 0.93 TO 5.0 MICRON AND BEING ESSENTIALLY INSOLUBLE IN WATER, AND THE POLYMER IN THIS POLYMER COMPOSITION CONSISTING OF AT LEAST ABOUT 60 PERCENT BY WEIGHT OF POLYURETHANE, B. THE COATING LAYER (II) HAVING A THICKNESS OF ABOUT 0.01 TO 0.3 MM, AND COMPRISING A WET COAGULATED POLYMER COMPOSITION WHICH CONTAINS ABOUT 0 TO 50 PARTS BY WEIGHT OF INORGANIC PARTICLES PER 100 PARTS BY WEIGHT OF POLYMER, SAID INORGANIC PARTICLES HAVING A MEAN PARTICLE DIAMETER OF ABOUT 0.03 TO 5.0 MICRON AND BEING ESSENTIALLY INSOLUBLE IN WATER, AND THE POLYMER IN THIS POLYMER COMPOSITION CONSISTING OF AT LEAST ABOUT 80 PERCENT BY WEIGHT OF POLYURETHANE, AND C. THE COATING LAYER (I) HAVING A THICKNESS OF ABOUT 0.001 TO 0.1 MM AND HAVING A 20 PERCENT MODULUS OF ABOUT 5 TO 100 KG/CM2, AND COMPRISING A DRY-COAGULATED POLYMER COMPOSITION, CONSISTING ESSENTIALLY OF AT LEAST ABOUT 80 PERCENT BY WEIGHT OF POLYURETHANE.
Claim 3
Dependent Claim
162 words
Artificial leather as claimed in claim 1, wherein the thickness of said fibrous substrate is about 0.5 to 1.5 mm, the thickness of said coating layer (I) is about 0.003 to 0.05 mm, the 20 percent modulus of said coating layer (I) is about 10 to 70 kg/cm2, the thickness of said coating layer (II) is about 0.03 to 0.25 mm, said coating layer (II) contains about 0 to 20 parts by weight of inorganic compound particles per 100 parts by weight of polymer, these inorganic particles having a mean particle diameter of about 0.1 to 3.0 micron, and being essentially insoluble in water, the thickness of said coating layer (III) is about 0.3 to 2.0 mm, said coating layer (III) contains about 80 to 200 parts by weight of inorganic compound particles per 100 parts by weight of polymer, and these inorganic compound particles having a mean particle diameter of about 0.1 to 3.0 micron and being essentially insoluble in water.
Claim 4
Dependent Claim
117 words
Artificial leather as claimed in claim 1, wherein the thickness of said coating layer (I) is about 0.005 to 0.02 mm, the 20 percent modulus of said coating layer (I) is about 15 to 50 kg/cm2, the thickness of said coating layer (II) is about 0.05 to 2.0 mm, said coating layer (II) is essentially free of inorganic particles, the thickness of said coating layer (III) is about 0.5 to 1.0 mm, said coating layer (III) contains about 120 to 160 parts by weight of inorganic compound particles per 100 parts by weight of polymer, and these inorganic compound particles have a mean particle diameter of about 0.5 to 2.0 micron and are essentially insoluble in water.
Claim 5
Dependent Claim
106 words
Artificial leather as claimed in claim 1, wherein said polymer contained in said coating layers (I) and (II) is composed of more than 80 wt% of polyurethane and less than 20 wt% of another polymer selected from the group consisting of polyvinyl chloride, poly-vinylidene chloride, poly-vinyl acetate, poly-acrylic acid, alkyl-polyacrylate, poly-methacrylic acid, alkyl-poly-methacrylate, a copolymer consisting of at least one of the above mentioned polymer segments, and mixtures of the above mentioned polymer, and said polymer contained in said coating layer (III) is composed of more than about 60 percent by weight of polyurethane and less than about 40 percent by weight of such other polymer.
Claim 6
Dependent Claim
129 words
Artificial leather as claimed in claim 1, wherein the polyurethane contained in said coating layer (I), (II) and (III) is the reaction product of a polymer diol, di-isocyanate and di-amine and/or lower molecular diol, wherein the polymer diol is at least one kind of polymer diol from the group composed of poly-ether-diol, poly-ester-diol and poly-ether-ester-diol, and the polymer contained in impregnating composition is selected from the group consisting of the polyurethane in this claim, and one kind of other polymer from the group composed of polyvinyl chloride, copolymer of vinyl chloride and vinyl acetate, poly-acrylic acid and its ester, and poly-methacrylic acid and its ester, and a mixture of more than about 50 percent by weight of polyurethane and less than about 50% by weight of such other polymer.
Claim 7
Dependent Claim
70 words
Artificial leather as claimed in claim 1, wherein a dimethyl formamide solution with 25 percent by weight of polyurethane is used in said coating layer (I) and said impregnating composition, having a viscosity of about 50 to 3,000 poises at 20* C, and dimethyl formamide solutions with 25 wt% are used in said coating layers (II) and (III), having a viscosity of about 200 to 5,000 poises at 20* C.
Claim 8
Dependent Claim
67 words
Artificial leather as claimed in claim 6, wherein the viscosities of dimethyl formamide solution with 25 wt% of polyurethane used in said coating layer (I) and said impregnating composition are about 100 to 1,500 poises at 20* C, and the viscosities of dimethyl formamide solution with 25 wt% of polyurethane used in said coating layers (II) and (III) are about 500 to 3,000 poises at 20* C.
Claim 9
Dependent Claim
67 words
Artificial leather as claimed in claim 6, wherein the viscosities of dimethyl formamide solution with 25 wt% of polyurethane used in said coating layer (I) and said impregnation composition are about 300 to 800 poises at 20* C, and the viscosities of dimethyl formamide solution with 25 wt% of polyurethane used in said coating layers (II) and (III) are about 800 to 2,000 poises at 20* C.
Claim 10
Dependent Claim
39 words
Artificial leather as claimed in claim 1, wherein the inorganic compound contained in said coating layer (II) and (III) is selected from the group consisting of calcium carbonate, zinc oxide, titanium oxide, zinc carbonate and kaolinite, and mixtures thereof.
Claim 11
Dependent Claim
42 words
Artificial leather as claimed in claim 1, wherein the apparent density difference between coating layers (III) and (II) is about 0.05 to 0.8 g/cm3, and the apparent density of said coating layer (III) is larger than that of said coating layer (II).
Claim 12
Dependent Claim
43 words
Artificial leather as claimed in claim 1, wherein the apparent density difference between said coating layers (III) and (II) is about 0.07 to 0.6 g/cm3, and the apparent density of said coating layer (III) is larger than that of said coating layer (II).
Claim 13
Dependent Claim
43 words
Artificial leather as claimed in claim 1, wherein the apparent density difference between said coating layers (III) and (II) is about 0.08 to 0.4 g/cm3, and the apparent density of said coating layer (III) is larger than that of said coating layer (II).
Claim 14
Dependent Claim
16 words
Artificial leather as claimed in claim 1 having a crease-forming angle of more than about 40*.
Claim 15
Dependent Claim
16 words
Artificial leather as claimed in claim 1 having a crease-forming angle of more than about 60*.
Claim 16
Dependent Claim
16 words
Artificial leather as claimed in claim 1 having a crease-forming angle of more than about 80*.
Claim 17
Dependent Claim
31 words
Artificial leather as claimed in claim 1, wherein the water vapor permeability is more than about 3.0 mg/cm2 hr. and the flexibility resistance is more than about 10 X 104 times.
Claim 18
Dependent Claim
31 words
Artificial leather as claimed in claim 1, wherein the water vapor permeability is more than about 5.0 mg/cm2 hr. and the flexibility resistance is more than about 15 X 104 times.
Claim 19
Dependent Claim
31 words
Artificial leather as claimed in claim 1, wherein the water vapor permeability is more than about 8.0 mg/cm2 hr. and the flexibility resistance is more than about 20 X 104 times.
Claim 20
Dependent Claim
33 words
Artificial leather as claimed in claim 1, wherein the entire thickness of the multi-layer composed of said coating layers (II) and (III), not including said fibrous substrate, is about 0.1 to 3.6 mm.
Claim 21
Dependent Claim
33 words
Artificial leather as claimed in claim 1, wherein the entire thickness of the multi-layer composed of said coating layers (II) and (III), not including said fibrous substrate, is about 0.3 to 2.0 mm.
Claim 22
Dependent Claim
33 words
Artificial leather as claimed in claim 1, wherein the entire thickness of the multi-layer composed of said coating layers (II) and (III), not including said fibrous substrate, is about 0.5 to 1.5 mm.
Claim 23
Dependent Claim
19 words
Artificial leather as claimed in claim 1, wherein the surface of the fibrous substrate is treated to flatten same.
Claim 24
Dependent Claim
15 words
Artificial leather as defined in claim 1, wherein layer (III) is thicker than layer (II).
Claim 25
Dependent Claim
15 words
Artificial leather as defined in claim 1, wherein layer (II) is thicker than layer (I).
Claim 26
Dependent Claim
24 words
Artificial leather as defined in claim 1, wherein layer (III) is thicker than layer (II) and wherein layer (II is thicker than layer (I).
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1977-10-14 | 1978-04-15 | 1978-10-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1981-10-14 | 1982-04-15 | 1982-10-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1985-10-14 | 1986-04-15 | 1986-10-15 | $7700.00 | Window Closed / Lapsed |