Imitation-leather material and method of preparing such material

Claim 2

In a method of preparing an imitation-leather sheet material, which method comprises: (a) coating a thin wet foam layer of a foam latex composition onto a sheet material, the latex composition comprising a foamable, film-forming, elastomeric, cross-linkable polymer and a cross-linking agent for the polymer; (b) placing a fibrous base sheet material onto the top surface of the wet foam latex layer to provide a wet laminate product; and (c) heating the wet laminate product to dry and cure the foam layer and to provide a dry laminate product, the improvement which comprises (i) providing a heat-coagulable, polymeric, acidic, latex foam composition as the wet foam layer, wherein the latex composition includes an acid or an acid salt to reduce the pH to less than 5.0, and (ii) shock-heating the wet foam layer of the wet laminate product by heating rapidly the wet foam layer in a single heating operation to a temperature of not greater than 450° F. and greater than about 250° F., to heat-coagulate the polymer to a fine, dense, open-cell, foam structure to remove water from the coagulated foam layer and to cross-link the polymer.

Claim 3

The method of claim 1 wherein the polymer has a coagulation temperature of from about 140° F. or less.

Claim 4

The method of claim 1 wherein the latex composition has a pH of from about 2.0 to 5.0.

Claim 5

The method of claim 1 wherein the latex composition includes a paratoluene sulfonic acid or acid salt to reduce the pH to a pH of from about 2.0 to 4.0.

Claim 6

The method of claim 1 wherein the latex composition includes a heat-sensitizing coagulant which comprises a silicone compound.

Claim 7

The method of claim 1 wherein the cross-linking agent is a melamine-formaldehyde resin.

Claim 8

The method of claim 1 wherein the latex composition comprises a minor amount of a thermoplastic polymer to modify the hand properties of the cross-linked coagulated polymer.

Claim 9

The method of claim 1 wherein the latex polymer comprises an elastomeric polyurethane polymer.

Claim 10

The method of claim 1 wherein the latex composition comprises a combination of an elastomeric, cross-linkable, polyurethane polymer and a cross-linkable, carboxylated, acrylonitrile-butadiene polymer, and wherein the cross-linking agent is a melamine-formaldehyde resin.

Claim 11

The method of claim 1 wherein the latex composition includes from about 5% to 30% by weight of the composition of a vinyl-halide polymer.

Claim 12

The method of claim 1 wherein the heat-coagulated, dry foam layer has a dry foam density of greater than about 50 pounds per cubic foot.

Claim 13

The method of claim 1 wherein the fibrous base sheet comprises a nap fabric sheet, wherein the nap fabric side of the sheet is placed in contact with the wet foam layer, and wherein the sheet material comprises a thin, elastomeric urethane resin or a vinyl-halide resin on a release paper, and which method includes the step of stripping the release paper from the resin layer, to provide an imitation-leather sheet laminate material.

Claim 14

The method of claim 1 wherein the dry heat-coagulated foam layer has a thickness of from about 5 to 50 mils.

Claim 15

The method of claim 1 wherein the sheet material comprises a release paper, and which includes the step of stripping the release paper from the dry foam layer of the dry laminate product, to provide an imitation-leather sheet material which comprises the dry heat-coagulated polymer as a dry layer bonded to the fibrous base sheet material.

Claim 16

The method of claim 1 wherein the latex composition has a pH of less than 4.0 and includes a small amount of a paratoluene sulfonic acid, and wherein shock-heating of the wet laminate product is carried out at a temperature of from 250° F. to 300° F.

Claim 17

The product produced by the method of claim 1.

Claim 18

The product produced by the method of claim 9.

Claim 19

The product produced by the method of claim 11.

Claim 20

The product produced by the method of claim 1 wherein the sheet material is stripped from the dry laminate product, to provide an imitation-leather sheet material.

Claim 21

In a method of preparing an imitation-leather laminate sheet material, which method comprises: coating a thin, wet, foam layer of from about 5 to 100 mils of a foamed latex composition, comprising a cross-linkable, elastomeric polyurethane polymer onto a thin, top, flexible, skin layer of a urethane resin or vinyl-chloride resin on a release material, the latex composition containing a melamine-formaldehyde resin, cross-linking agent for the polymer; placing a napped fabric sheet material onto the top surface of the wet foam layer, the napped surface down and in contact with the wet foam layer, to provide a wet laminate product; and heating the wet laminate product to dry and cure the foam layer; and, thereafter, removing the release material from the urethane resin or vinyl-chloride resin layer to provide an imitation-leather substitute material, the improvement which comprises: (a) providing the heat-coagulable, polyurethane polymer composition which has a pH of from about 2.0 to 5.0 and which contains paratoluene sulfonic acid, to provide a heat-coagulated polymer having a coagulation temperature of from about 125° F. or less; and (b) shock-heating the wet foam layer of the wet laminate product by heating rapidly the wet foam layer in a single heating operation in an oven to a temperature of from about 250° F. to 350° F. to heat-coagulate the polymer into a fine, dense, open-cell, foam structure, the foam having a dry density of greater than about 50 pounds per cubic foot, to remove water from the coagulated foam layer and to cross-link the polymer.

Claim 22

In a method of preparing an imitation-leather laminate sheet material, which method comprises: coating a thin, wet, foam layer of from about 5 to 100 mils of a foamed latex composition, comprising a cross-linkable, elastomeric polyurethane polymer onto a thin, top, flexible, skin layer of a urethane resin or vinyl-chloride resin on a release material, the latex composition containing a melamine-formaldehyde resin, cross-linking agent for the polymer; placing a napped fabric sheet material onto the top surface of the wet foam layer, the napped surface down and in contact with the wet foam layer, to provide a wet laminate product; and heating the wet laminate product to dry and cure the foam layer; and, thereafter, removing the release material from the urethane resin or vinyl-chloride resin layer to provide an imitation-leather substitute material, the improvement which comprises: (a) providing the heat-coagulable, polyurethane polymer composition which has a pH of from about 2.0 to 5.0 and which contains paratoluene sulfonic acid, to provide a heat-coagulated polymer having a coagulation temperature of from about 125° F. or less; and (b) shock-heating the wet foam layer of the wet laminate product by heating rapidly the wet foam layer in a single heating operation in an oven to a temperature of from about 250° F. to 350° F. to heat-coagulate the polymer into a fine, dense, open-cell, foam structure, the foam having a dry density of greater than about 50 pounds per cubic foot, to remove water from the coagulated foam layer and to cross-link the polymer.

Claim 23

The laminate product produced by the method of claim 20.