Patent US4448831A successfully refreshed from Google Patents.
US4448831A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Leatherlike fabrics
Assignee: Milliken Research Corp
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Filing: 1977-10-18
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Granted: 1984-05-15
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Expires: 1997-10-18
Abstract
Abstract A napped fabric is treated to bond the nap fibers together while leaving the nap structure largely open and porous. The surface of the bonded nap is then subjected to a series of spaced short cuts to form spaced clumps of bonded fibers which clumps have free ends projecting from the bonded nap so that they can be brushed from stable upright positions to bent-over positions, giving an attractive rough appearance resembling a split suede leather.
Inventors
- 👤 Frank P. Civardi
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 12:52
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/22; B32B5/24; D; D06; D06C; D06C23/00; D06N; D06N3/00; D06N3/007; D06N3/0075; Y; Y10; Y10S; Y10S428/00; Y10S428/904; Y10T; Y10T428/00; Y10T428/23907; Y10T428/2395; Y10T428/23979; Y10T428/23986; Y10T428/23993; Y10T428/24; Y10T428/24355; Y10T428/24471
Claims Analysis
Total Claims: 50
Claim 1
Independent Claim
196 words
An imitation leather material which comprises in combination: a. a woven fabric base sheet material, one surface of which is a napped surface and the other surface of which is not napped; b. the napped surface of the base sheet impregnated with a cross-linked polymeric material; c. the napped impregnated surface of the base sheet characterized by a buffed, flesh-like surface; d. an open-cell flexible polymeric cellular-layer bonded to the other unnapped surface of the base sheet material; e. a thin polymeric skin layer bonded to the surface of the cellular layer; and f. the thin polymeric skin layer characterized by an imitation leather-like surface, the fibers of said nap being bonded together by said impregnation, said bonded nap being severed, after bonding impregnation, along a multitude of short spaced lines to form spaced clumps of bonded fibers, said clumps having free ends and being brushable to and from stable upright positions, in which said free ends of the upright clumps project outwardly from the surrounding bonded nap and said fabric has a rough appearance, to bent-over positions in which said clumps merge with said surrounding bonded nap so that the fabric has a smoother appearance.
Claim 2
Dependent Claim
196 words
An imitation leather material which comprises in combination: a. a woven fabric base sheet material, one surface of which is a napped surface and the other surface of which is not napped; b. the napped surface of the base sheet impregnated with a cross-linked polymeric material; c. the napped impregnated surface of the base sheet characterized by a buffed, flesh-like surface; d. an open-cell flexible polymeric cellular-layer bonded to the other unnapped surface of the base sheet material; e. a thin polymeric skin layer bonded to the surface of the cellular layer; and f. the thin polymeric skin layer characterized by an imitation leather-like surface, the fibers of said nap being bonded together by said impregnation, said bonded nap being severed, after bonding impregnation, along a multitude of short spaced lines to form spaced clumps of bonded fibers, said clumps having free ends and being brushable to and from stable upright positions, in which said free ends of the upright clumps project outwardly from the surrounding bonded nap and said fabric has a rough appearance, to bent-over positions in which said clumps merge with said surrounding bonded nap so that the fabric has a smoother appearance.
Claim 3
Dependent Claim
53 words
Product as in claim 1 in which said cross-linked polymeric material is a cross-linked elastomeric polyurethane, said open-cell layer is a microporous breathable elastomeric polyurethane comprising cavities of generally rounded compact shape connected by smaller passageways which layer permits the passage of water vapor, and said skin is of film-forming flexible polymeric material.
Claim 4
Dependent Claim
34 words
Product as in claim 1 in which said cross-linked polymeric material is a cross-linked elastomeric polyurethane, said cellular layer is a layer of plasticized polyvinylchloride foam, and said skin is of plasticized polyvinyl chloride.
Claim 5
Dependent Claim
105 words
An imitation leather material which comprises in combination: a. a woven fabric base sheet material, one surface of which is a napped surface and the other surface of which is not napped; b. the napped surface of the base sheet impregnated with a cross-linked polymeric material; c. the napped impregnated surface of the base sheet characterized by a buffed, flesh-like surface; d. an open-cell flexible polymeric cellular-layer bonded to the other unnapped surface of the base sheet material; e. A thin polymeric skin layer bonded to the surface of the cellular layer; and f. the thin polymeric skin layer characterized by an imitation leather-like surface.
Claim 6
Dependent Claim
105 words
An imitation leather material which comprises in combination: a. a woven fabric base sheet material, one surface of which is a napped surface and the other surface of which is not napped; b. the napped surface of the base sheet impregnated with a cross-linked polymeric material; c. the napped impregnated surface of the base sheet characterized by a buffed, flesh-like surface; d. an open-cell flexible polymeric cellular-layer bonded to the other unnapped surface of the base sheet material; e. A thin polymeric skin layer bonded to the surface of the cellular layer; and f. the thin polymeric skin layer characterized by an imitation leather-like surface.
Claim 7
Dependent Claim
15 words
The material of claim 4 wherein the cross-linked polymeric material comprises a cross-linked nitrile elastomer.
Claim 8
Dependent Claim
27 words
The material of claim 4 wherein the cellular layer is characterized by a density gradient with the higher density cellular material adjacent to the thin polymeric layer.
Claim 9
Dependent Claim
18 words
The material of claim 4 wherein the foam layer comprises two or more cellular layers of different density.
Claim 10
Dependent Claim
34 words
The material of claim 4 wherein the cellular layer comprises two or more cellular layers composed of different cellular materials and different densities, the higher density cellular material adjacent the thin polymeric skin layer.
Claim 11
Dependent Claim
15 words
The material of claim 4 wherein the polymeric skin layer is an elastomeric urethane resin.
Claim 12
Dependent Claim
27 words
The material of claim 4 wherein the laminate comprises an adhesive layer to bond the cellular layer to the unnapped surface of the fabric base sheet material.
Claim 13
Dependent Claim
21 words
The material of claim 4 wherein the leather-like surface is characterized by a grain-like surface composed of raised and low areas.
Claim 14
Dependent Claim
28 words
The material of claim 4 wherein the foam layer comprises a nitrile elastomeric cellular layer, a urethane cellular layer, an acrylic cellular layer, or vinyl chloride cellular layer.
Claim 15
Dependent Claim
32 words
The material of claim 4 wherein the skin polymeric layer is from about 0.1 to 3 mils in thickness, and the cellular layer is from about 3 to 30 mils in thickness.
Claim 16
Dependent Claim
27 words
The material of claim 4 wherein the cellular layer comprises two cellular layers of different densities and ranging from about 20 to 60 pounds per cubic foot.
Claim 17
Dependent Claim
20 words
The material of claim 4 wherein the impregnated polymeric material impregnates the base sheet for a portion of its thickness.
Claim 18
Dependent Claim
18 words
The material of claim 4 wherein the buffed ends of the napped fibers are exposed on the surface.
Claim 19
Dependent Claim
19 words
The material of claim 4 wherein the cellular layer comprises a flexible cellular layer having a breathable open-cell structure.
Claim 20
Dependent Claim
31 words
The material of claim 4 wherein the base sheet material is impregnated for a portion of its thickness with from 1 to 3 dry ounces/square yard of the cross-linked polymeric material.
Claim 21
Dependent Claim
30 words
The material of claim 4 wherein the polymeric thin-skin layer with the surface is an embossed surface and comprises a urethane elastomeric resin with raised areas on the skin layer.
Claim 22
Dependent Claim
180 words
An imitation leather sheet material which comprises in combination: a. a woven fabric base sheet material, one surface of which is napped and sheared, and the other surface of which is not napped b. the fabric of the napped surface of the base sheet material impregnated with at least a partially cross-linked nitrile elastomeric polymer material; c. the impregnated napped surface characterized by a buffed, flesh-like leather appearance; d. a substantially open-cell flexible polymeric cellular layer of from about 3 to 30 mils composed of at least two layers of different densities, the cellular layer composed of a nitrile elastomer, a urethane resin, an acrylic resin or a vinyl chloride resin, the layers bonded together; e. an adhesive layer which bonds the lower density cellular layer to the unnapped surface of the base sheet material; p1 f. a thin urethane elastomeric resin skin layer of from about 0.1 to 3 mils bonded to the surface of the higher density cellular layer; and g. the skin layer characterized by an embossed grain-like leather-like surface therein composed of raised and low areas.
Claim 23
Dependent Claim
180 words
An imitation leather sheet material which comprises in combination: a. a woven fabric base sheet material, one surface of which is napped and sheared, and the other surface of which is not napped b. the fabric of the napped surface of the base sheet material impregnated with at least a partially cross-linked nitrile elastomeric polymer material; c. the impregnated napped surface characterized by a buffed, flesh-like leather appearance; d. a substantially open-cell flexible polymeric cellular layer of from about 3 to 30 mils composed of at least two layers of different densities, the cellular layer composed of a nitrile elastomer, a urethane resin, an acrylic resin or a vinyl chloride resin, the layers bonded together; e. an adhesive layer which bonds the lower density cellular layer to the unnapped surface of the base sheet material; p1 f. a thin urethane elastomeric resin skin layer of from about 0.1 to 3 mils bonded to the surface of the higher density cellular layer; and g. the skin layer characterized by an embossed grain-like leather-like surface therein composed of raised and low areas.
Claim 24
Dependent Claim
195 words
An imitation leather material which comprises in combination: a. a woven fabric base sheet material, one surface of which is a napped surface and the other surface of which is not napped; b. the napped surface of the base sheet impregnated with a cross-linked polymeric material; c. the napped impregnated surface of the base sheet characterized by a buffed, flesh-like surface; d. a flexible polymeric cellular-layer bonded to the other unnapped surface of the base sheet material; e. a thin polymeric skin layer bonded to the surface of the cellular layer; and f. the thin polymeric skin layer characterized by an imitation leather-like surface, the fibers of said nap being bonded together by said impregnation, said bonded nap being severed, after bonding impregnation, along a multitude of short spaced lines to form spaced clumps of bonded fibers, said clumps having free ends and being brushable to and from stable upright positions, in which said free ends of the upright clumps project outwardly from the surrounding bonded nap and said fabric has a rough appearance, to bent-over positions in which said clumps merge with said surrounding bonded nap so that the fabric has a smoother appearance.
Claim 25
Dependent Claim
195 words
An imitation leather material which comprises in combination: a. a woven fabric base sheet material, one surface of which is a napped surface and the other surface of which is not napped; b. the napped surface of the base sheet impregnated with a cross-linked polymeric material; c. the napped impregnated surface of the base sheet characterized by a buffed, flesh-like surface; d. a flexible polymeric cellular-layer bonded to the other unnapped surface of the base sheet material; e. a thin polymeric skin layer bonded to the surface of the cellular layer; and f. the thin polymeric skin layer characterized by an imitation leather-like surface, the fibers of said nap being bonded together by said impregnation, said bonded nap being severed, after bonding impregnation, along a multitude of short spaced lines to form spaced clumps of bonded fibers, said clumps having free ends and being brushable to and from stable upright positions, in which said free ends of the upright clumps project outwardly from the surrounding bonded nap and said fabric has a rough appearance, to bent-over positions in which said clumps merge with said surrounding bonded nap so that the fabric has a smoother appearance.
Claim 26
Dependent Claim
53 words
Product as in claim 21 in which said cross-linked polymeric material is a cross-linked elastomeric polyurethane, said cellular layer is a microporous breathable elastomeric polyurethane comprising cavities of generally rounded compact shape connected by smaller passages which layer permits the passage of water vapor, and said skin is of film-forming flexible polymeric material.
Claim 27
Dependent Claim
25 words
Product as in claim 21 in which said cellular layer is a layer of plasticized polyvinylchloride foam, and said skin is of plasticized polyvinyl chloride.
Claim 28
Dependent Claim
16 words
Product as in claim 23 in which said cross-linked polymeric material is a cross-linked elastomeric polyurethane.
Claim 29
Independent Claim
98 words
A method of preparing an imitation leather-like material which comprises: a. impregnating the napped surface of a woven fabric base sheet material having a napped or an unnapped surface with a cross-linkable flexible polymer; b. cross-linking the cross-linkable polymer to form at least a partially cross-linked polymer surface; c. buffing the cross-linked impregnated surface to provide a flesh-like leather surface; d. bonding a flexible open-cell cellular layer to the unnapped surface of the base sheet material; and e. bonding a thin polymeric flexible skin layer to the cellular layer, the skin layer characterized by a leather-like surface appearance.
Claim 30
Independent Claim
98 words
A method of preparing an imitation leather-like material which comprises: a. impregnating the napped surface of a woven fabric base sheet material having a napped or an unnapped surface with a cross-linkable flexible polymer; b. cross-linking the cross-linkable polymer to form at least a partially cross-linked polymer surface; c. buffing the cross-linked impregnated surface to provide a flesh-like leather surface; d. bonding a flexible open-cell cellular layer to the unnapped surface of the base sheet material; and e. bonding a thin polymeric flexible skin layer to the cellular layer, the skin layer characterized by a leather-like surface appearance.
Claim 31
Dependent Claim
55 words
The method of claim 25 which includes coating the thin polymer skin layer onto a transfer sheet having an embossed design thereon and bonding the cellular layer to the thin skin layer on the transfer sheet, and after bonding the opposite surface of the cellular layer to the base sheet material removing the transfer sheet.
Claim 32
Dependent Claim
21 words
The method of claim 25 which includes applying an adhesive layer to bond the cellular layer to the base sheet material.
Claim 33
Dependent Claim
49 words
The method of claim 25 which includes applying a series of at least two cellular layers of different densities, with the surface of the cellular layer of greater density bonded to the skin layer and the surface of the lower density cellular layer bonded to the base sheet material.
Claim 34
Dependent Claim
15 words
The method of claim 25 wherein the polymeric skin layer is an elastomeric urethane resin.
Claim 35
Dependent Claim
28 words
The method of claim 25 wherein the cellular layer comprises a nitrile elastomeric cellular layer, a urethane cellular layer, an acrylic cellular layer or vinyl chloride cellular layer.
Claim 36
Dependent Claim
32 words
The method of claim 25 wherein the skin polymeric layer is from about 0.1 to 3 mils in thickness and the cellular layer is from about 3 to 30 mils in thickness.
Claim 37
Dependent Claim
15 words
The method of claim 25 wherein the cross-linked polymeric material comprises a cross-linked nitrile elastomer.
Claim 38
Dependent Claim
24 words
The method of claim 25 wherein the impregnation of the polymer does not extend into the main fabric structure of the base sheet material.
Claim 39
Dependent Claim
22 words
The method of claim 25 wherein the density of the cellular layer ranges from about 30 to 60 pounds per cubic foot.
Claim 40
Dependent Claim
24 words
The method of claim 25 which includes buffing the impregnated surface to expose the ends of the napped fibers on the flesh-like leather surface.
Claim 41
Dependent Claim
39 words
The method of claim 25 which includes: coating an embossed transfer sheet with a urethane elastomeric resin coating to form a continuous layer which fills in the embossed design on the transfer sheet to provide an embossed skin layer.
Claim 42
Dependent Claim
19 words
The method of claim 25 which includes flexing the leather-like material to accentuate the grain of the embossed surface.
Claim 43
Dependent Claim
57 words
Method as in claim 25 in which said cross-linkable polymer is a polyurethane which is an elastomer on cross-linking, and said open-cell layer is a microporous breathable elastomeric polyurethane comprising cavities of generally rounded compact shape connected by smaller passages which layer permits the passage of water vapor, and said skin is of film-forming flexible polymeric material.
Claim 44
Dependent Claim
38 words
Method as in claim 25 in which said cross-linkable polymer is a polyurethane which is an elastomer on cross-linking, and said cellular layer is a layer of plasticized polyvinylchloride foam, and said skin is of plasticized polyvinyl chloride.
Claim 45
Independent Claim
179 words
A method of preparing an imitation leather-like material which comprises: a. impregnating the napped surface of a woven fabric base sheet material having a napped or an unnapped surface with a cross-linkable flexible polymer; b. cross-linking the cross-linkable polymer to form at least a partially cross-linked polymer c. buffing the cross-linked impregnated surface to provide a flesh-like leather surface, d. bonding a flexible cellular layer to the unnapped surface of the base sheet material; and e. bonding a thin polymeric flexible skin layer to the cellular layer, the skin layer characterized by a leather-like surface appearance, said buffing comprising severing said impregnated napped surface, after said cross-linking, along a multitude of short spaced lines to form spaced clumps of bonded fibers, said clumps having free ends and being brushable to and from stable upright positions, in which said free ends of the upright clumps project outwardly from the surrounding bonded nap and said fabric has a rough appearance, to bent-over positions in which said clumps merge with said surrounding bonded nap so that the fabric has a smoother appearance.
Claim 46
Independent Claim
179 words
A method of preparing an imitation leather-like material which comprises: a. impregnating the napped surface of a woven fabric base sheet material having a napped or an unnapped surface with a cross-linkable flexible polymer; b. cross-linking the cross-linkable polymer to form at least a partially cross-linked polymer c. buffing the cross-linked impregnated surface to provide a flesh-like leather surface, d. bonding a flexible cellular layer to the unnapped surface of the base sheet material; and e. bonding a thin polymeric flexible skin layer to the cellular layer, the skin layer characterized by a leather-like surface appearance, said buffing comprising severing said impregnated napped surface, after said cross-linking, along a multitude of short spaced lines to form spaced clumps of bonded fibers, said clumps having free ends and being brushable to and from stable upright positions, in which said free ends of the upright clumps project outwardly from the surrounding bonded nap and said fabric has a rough appearance, to bent-over positions in which said clumps merge with said surrounding bonded nap so that the fabric has a smoother appearance.
Claim 47
Dependent Claim
55 words
Method as in claim 40 said cross-linkable polymer is a polyurethane which is an elastomer on cross-linking, and said cellular layer is a microporous breathable elastomeric polyurethane comprising cavities of generally rounded compact shape connected by smaller passages which layer permits the passage of water vapor, and said skin is of film-forming flexible polymeric material.
Claim 48
Dependent Claim
38 words
Method as in claim 40 in which said cross-linkable polymer is a polyurethane which is an elastomer on cross-linking, and said cellular layer is a layer of plasticized polyvinylchloride foam, and said skin is of plasticized polyvinyl chloride.
Claim 49
Independent Claim
223 words
A method of preparing an imitation leather-like material, which method comprises: a. impregnating the napped and sheared surface of a woven fabric sheet material having a napped and an unnapped surface with a cross-linkable nitrile elastomeric polymer; b. cross-linking the impregnated elastomeric polymer c. buffing the cross-linked polymer surface to provide a flesh-like leather surface; d. coating a thin skin layer of from 0.1 to 3 mils of a flexible elastomeric urethane resin onto a transfer sheet having an embossed grain-like surface thereon; e. coating a series of at least substantially open-cell layers onto the skin layer, the foam layers composed of an elastomeric cellular, an acrylic cellular or a urethane cellular material, the cellular layers having a thickness of from about 3 to 30 mils, the cellular layers having a difference in cellular densities; f. coating a thin layer of an adhesive resin onto the exposed surface of the cellular layer; g. placing the unnapped surface of the base sheet material onto the adhesive layer; h. heating the laminate so formed to bond the coating layers together and to the base sheet material to form an integral, flexible, composite sheet material; i. removing the transfer sheet; and j. recovering a flexible, leather-like laminate material with a grain-like embossed surface on the skin layer and a leather flesh-like surface on the opposite surface.
Claim 50
Independent Claim
223 words
A method of preparing an imitation leather-like material, which method comprises: a. impregnating the napped and sheared surface of a woven fabric sheet material having a napped and an unnapped surface with a cross-linkable nitrile elastomeric polymer; b. cross-linking the impregnated elastomeric polymer c. buffing the cross-linked polymer surface to provide a flesh-like leather surface; d. coating a thin skin layer of from 0.1 to 3 mils of a flexible elastomeric urethane resin onto a transfer sheet having an embossed grain-like surface thereon; e. coating a series of at least substantially open-cell layers onto the skin layer, the foam layers composed of an elastomeric cellular, an acrylic cellular or a urethane cellular material, the cellular layers having a thickness of from about 3 to 30 mils, the cellular layers having a difference in cellular densities; f. coating a thin layer of an adhesive resin onto the exposed surface of the cellular layer; g. placing the unnapped surface of the base sheet material onto the adhesive layer; h. heating the laminate so formed to bond the coating layers together and to the base sheet material to form an integral, flexible, composite sheet material; i. removing the transfer sheet; and j. recovering a flexible, leather-like laminate material with a grain-like embossed surface on the skin layer and a leather flesh-like surface on the opposite surface.
References Cited (Backward Citations)
US4017656A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-05-15 | 1987-11-14 | 1988-05-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-05-15 | 1991-11-14 | 1992-05-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-05-15 | 1995-11-14 | 1996-05-15 | $7700.00 | Window Closed / Lapsed |