US4017656A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Imitation leather material and method of preparing such material
Assignee: BRADFORD INDUSTRIES Inc A DE CORP
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Filing: 1975-09-18
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Granted: 1977-04-12
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Expires: 1995-09-18
Abstract
Abstract An imitation leather material which comprises in combination: a woven fabric base sheet material, one surface of which is a napped surface and the other surface of which is not napped; the napped surface of the base sheet impregnated with a crosslinked polymeric material; the napped impregnated surface of the base sheet characterized by a smooth, buffed, flesh-like surface; an open-cell flexible polymeric foam layer bonded to the other unnapped surface of the base sheet material; a thin polymeric skin layer bonded to the surface of the foam layer; and the thin polymeric skin layer characterized by an imitation leather-like surface.
Inventors
- 👤 Henry R. Lasman
- 👤 Robert J. Lebenson
- 👤 Reuben Wisotzky
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 19:25
CPC Classifications
B; B32; B32B; B32B27/00; B32B27/40; B32B27/06; B32B27/065; B32B3/00; B32B3/26; B32B3/30; B32B5/00; B32B5/22; B32B5/24; B32B5/245; B32B5/26; D; D06; D06N; D06N3/00; D06N3/0002; D06N3/004; D06N3/0086; D06N3/0095; D06N3/04; D06N3/06; D06N3/12; D06N3/14; B32B2260/00; B32B2260/02; B32B2260/021; B32B2260/04; B32B2260/046; B32B2266/00; B32B2266/06; B32B2437/00; B32B2437/02; Y; Y10; Y10S; Y10S428/00; Y10S428/904; Y10T; Y10T428/00; Y10T428/23907; Y10T428/23914; Y10T428/2395; Y10T428/23979; Y10T428/24; Y10T428/24355; Y10T428/24438; Y10T428/24942; Y10T428/24992; Y10T428/249921; Y10T428/249953; Y10T428/249981; Y10T428/249987; Y10T428/249991; Y10T428/249992; Y10T428/26; Y10T428/263; Y10T428/264; Y10T428/265; Y10T428/266; Y10T428/31; Y10T428/31504; Y10T428/31551; Y10T428/31554; Y10T428/31573; Y10T428/3158; Y10T428/31583; Y10T428/31591
Claims Analysis
Total Claims: 37
Claim 1
Independent Claim
106 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 foam layer bonded to the other unnapped surface of the base sheet material; e. a thin polymeric skin layer bonded to the surface of the foam layer; and f. the thin polymeric skin layer characterized by an imitation leather-like surface.
Claim 2
Dependent Claim
106 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 foam layer bonded to the other unnapped surface of the base sheet material; e. a thin polymeric skin layer bonded to the surface of the foam layer; and f. the thin polymeric skin layer characterized by an imitation leather-like surface.
Claim 3
Dependent Claim
15 words
The material of claim 1 wherein the cross-linked polymeric material comprises a cross-linked nitrile elastomer.
Claim 4
Dependent Claim
27 words
The material of claim 1 wherein the foam layer is characterized by a foam density gradient with the higher density foam adjacent to the thin polymeric layer.
Claim 5
Dependent Claim
19 words
The material of claim 1 wherein the foam layer comprises two or more foam layers of different foam density.
Claim 6
Dependent Claim
34 words
The material of claim 1 wherein the foam layer comprises two or more foam layers composed of different foam materials and different foam densities, the higher density foam adjacent the thin polymeric skin layer.
Claim 7
Dependent Claim
15 words
The material of claim 1 wherein the polymeric skin layer is an elastomeric urethane resin.
Claim 8
Dependent Claim
27 words
The material of claim 1 wherein the laminate comprises an adhesive layer to bond the foam layer to the unnapped surface of the fabric base sheet material.
Claim 9
Dependent Claim
21 words
The material of claim 1 wherein the leather-like surface is characterized by a grain-like surface composed of raised and low areas.
Claim 10
Dependent Claim
28 words
The material of claim 1 wherein the foam layer comprises a nitrile elastomeric foam layer, a urethane foam layer, an acrylic foam layer, or vinyl chloride foam layer.
Claim 11
Dependent Claim
32 words
The material of claim 1 wherein the skin polymeric layer is from about 0.1 to 3 mils in thickness, and the foam layer is from about 3 to 30 mils in thickness.
Claim 12
Dependent Claim
28 words
The material of claim 1 wherein the foam layer comprises two foam layers of different foam densities and ranging from about 20 to 60 pounds per cubic foot.
Claim 13
Dependent Claim
22 words
The material of claim 1 wherein the impregnated polymeric material impregnates the base sheet from about 30 to 60% of its thickness.
Claim 14
Dependent Claim
18 words
The material of claim 1 wherein the buffed ends of the napped fibers are exposed on the surface.
Claim 15
Dependent Claim
20 words
The material of claim 1 wherein the foam layer comprises a flexible foam layer having over about 90% open-cell structure.
Claim 16
Dependent Claim
34 words
The material of claim 1 wherein the base sheet material is impregnated up to a thickness of about 60% in depth with from 1 to 3 dry ounces/square yard of the cross-linked polymeric material.
Claim 17
Dependent Claim
75 words
The material of claim 1 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 composed of a discontinuous layer of a first urethane resin forming the desired embossed pattern on a continuous layer of a second urethane resin, the first urethane resin having a modulus of elongation at 100% elongation of greater than 800 psi than the second resin.
Claim 18
Dependent Claim
30 words
The material of claim 16 wherein the first resin has a modulus of elongation at 100% elongation of 2000 to 8000 psi, and the second resin 300 to 3000 psi.
Claim 19
Dependent Claim
18 words
The material of claim 1 wherein the foam layer is a flexible, open-cell, cross-linked, carboxylated, acrylonitrile-butadiene foam material.
Claim 20
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 foam layer of from about 3 to 30 mils composed of at least two layers of different foam densities, the foam 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 foam layer to the unnapped surface of the base sheet material; f. a thin urethane elastomeric resin skin layer of from about 0.1 to 3 mils bonded to the surface of the higher density foam layer; and g. the skin layer characterized by an embossed grain-like leather-like surface therein composed of raised and low areas.
Claim 21
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 foam layer of from about 3 to 30 mils composed of at least two layers of different foam densities, the foam 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 foam layer to the unnapped surface of the base sheet material; f. a thin urethane elastomeric resin skin layer of from about 0.1 to 3 mils bonded to the surface of the higher density foam layer; and g. the skin layer characterized by an embossed grain-like leather-like surface therein composed of raised and low areas.
Claim 22
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 foam layer to the unnapped surface of the base sheet material; and e. bonding a thin polymeric flexible skin layer to the foam layer, the skin layer characterized by a leather-like surface appearance.
Claim 23
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 foam layer to the unnapped surface of the base sheet material; and e. bonding a thin polymeric flexible skin layer to the foam layer, the skin layer characterized by a leather-like surface appearance.
Claim 24
Dependent Claim
55 words
The method of claim 20 which includes coating the thin polymeric skin layer onto a transfer sheet having an embossed design thereon and bonding the foam layer to the thin skin layer on the transfer sheet, and after bonding the opposite surface of the foam layer to the base sheet material removing the transfer sheet.
Claim 25
Dependent Claim
21 words
The method of claim 20 which includes applying an adhesive layer to bond the foam layer to the base sheet material.
Claim 26
Dependent Claim
54 words
The method of claim 20 which includes applying a series of at least two foam layers of different foam densities on the foam layer, with the surface of the foam layer of greater density bonded to the skin layer and the surface of the lower density foam layer bonded to the base sheet material.
Claim 27
Dependent Claim
15 words
The method of claim 20 wherein the polymeric skin layer is an elastomeric urethane resin.
Claim 28
Dependent Claim
28 words
The method of claim 20 wherein the foam layer comprises a nitrile elastomeric foam layer, a urethane foam layer, an acrylic foam layer or vinyl chloride foam layer.
Claim 29
Dependent Claim
32 words
The method of claim 20 wherein the skin polymeric layer is from about 0.1 to 3 mils in thickness, and the foam layer is from about 3 to 30 mils in thickness.
Claim 30
Dependent Claim
15 words
The method of claim 20 wherein the cross-linked polymeric material comprises a cross-linked nitrile elastomer.
Claim 31
Dependent Claim
24 words
The method of claim 20 wherein the impregnation of the polymer does not exceed about 60% of the depth of the base sheet material.
Claim 32
Dependent Claim
22 words
The method of claim 20 wherein the foam density of the layer ranges from about 30 to 60 pounds per cubic foot.
Claim 33
Dependent Claim
24 words
The method of claim 20 which includes buffing the impregnated surface to expose the ends of the napped fibers on the flesh-like leather surface.
Claim 34
Dependent Claim
82 words
The method of claim 20 which includes: a. coating an embossed transfer sheet with a first urethane elastomeric resin coating to form a discontinuous layer of the first resin which fills in the embossed design on the transfer sheet; and b. coating the first resin layer with a second urethane elastomeric resin continuous layer, the first urethane resin having a modulus of elongation at 100% elongation of greater than 800 psi than the second urethane resin to provide an embossed skin layer.
Claim 35
Dependent Claim
19 words
The method of claim 20 which includes flexing the leather-like material to accentuate the grain of the embossed surface.
Claim 36
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 foam layers onto the skin layer, the foam layers composed of an elastomeric foam, an acrylic foam or a urethane foam, the foam layers having a thickness of from about 3 to 30 mils, the foam layers having a difference in foam densities; f. coating a thin layer of an adhesive resin onto the exposed surface of the foam 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 37
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 foam layers onto the skin layer, the foam layers composed of an elastomeric foam, an acrylic foam or a urethane foam, the foam layers having a thickness of from about 3 to 30 mils, the foam layers having a difference in foam densities; f. coating a thin layer of an adhesive resin onto the exposed surface of the foam 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)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1980-04-11 | 1980-10-11 | 1981-04-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1984-04-11 | 1984-10-11 | 1985-04-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1988-04-11 | 1988-10-11 | 1989-04-12 | $7700.00 | Window Closed / Lapsed |