CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/178,199, filed April 22, 2021, which is incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to leather-like materials that are made from biodegradable and/or industrially compostable materials or from recyclable materials. The present disclosure also relates to processes for forming various leather-like compositions from recyclable, biodegradable and/or industrially compostable bio-derived thermoplastic resins. The leather-like materials of the present disclosure may be used in, for example but not limited to, footwear components, clothing, upholstery, and handbags, and other accessories.

BACKGROUND

[0003] Artificial leathers are generally composed of the combination of a non-woven fabric core and an outer polymer layer with the goal of achieving an appearance, flexibility and/or texture comparable to those of natural animal leathers. Presently, almost all known artificial leathers are derived from non-renewable feedstocks, and most, if not all, do not biodegrade or industrially compost. Furthermore, most existing artificial leathers also cannot be readily recycled.

[0004] The most widely used material for the non-woven fiber core for artificial leathers is polyester fiber. The polyester fiber core is typically combined with one or more coatings of polyurethane or thermoplastic polyurethane as the outer material. As a result, these conventional artificial leathers are not biodegradable nor industrially compostable due in part to their non- biodegradable and non-industrially compostable components, but also because of the dissimilar chemistries of the non-woven fabric and outer layer that are combined into the same final leather-like material. Furthermore, even if the conventional artificial leathers contain certain materials that are biodegradable and/or recyclable, these materials cannot be easily separated from the non-biodegradable, non-recyclable components.

SUMMARY

[0005] In some embodiments, the present disclosure provides a process for producing leather-like material compositions from biodegradable and/or industrially compostable thermoplastic resins and biodegradable and/or industrially compostable non-woven fibers. In various embodiments, a biodegradable and/or industrially compostable leather-like material can be made to have properties and characteristics that are similar to natural animal leathers but are composed of plant-derived materials. The leather-like material according to embodiments of the present disclosure (which may also be referred to as “artificial leather” or “synthetic leather”) may be in the form of a thin, flexible sheet that can be used in place of animal leathers or other artificial leathers, for example, in footwear (e.g., shoes, sandals, slippers, etc.), clothing (e.g., jackets, pants, belts, gloves, etc.), handbags, wallets, and upholstery (e.g., furniture, vehicle seats, etc.). The leather-like materials according to certain embodiments of the present disclosure may have properties such as hand, softness, drape, and/or sewability, that are similar to those of natural leather (e.g., natural bovine leather) or other artificial leathers (e.g., vinyl artificial leather). It is an object of certain embodiments to produce leather-like materials that cause the least amount of environmental harm, but that also boast significant technical performance properties equal or better than that of conventional non-biodegradable petrochemical artificial leathers or natural leathers. By selecting plant-derived feedstocks for producing biopolymers and non-woven fibers, certain embodiments of the present disclosure may contribute to sequestering greenhouse gases from the atmosphere, greatly reduce dependence on non-renewable petroleum oil, and significantly reduce non-biodegradable waste that ends up in landfills every year.

[0006] In some embodiments, the present disclosure provides an artificial leather that is recyclable or biodegradable and/or industrially compostable, and methods for making the same. In some embodiments, an artificial leather of the present disclosure includes a core material and an outer polymer layer disposed on at least one surface of the core material, wherein at least the outer polymer layer includes or consists of one or more bio-derived polymers. In further embodiments, an artificial leather of the present disclosure includes a core material and an outer polymer layer disposed on at least one surface of the core material, wherein at least the outer polymer layer includes or consists of one or more recyclable polymers. In some embodiments, the core material also includes or consists of a recyclable or biodegradable and/or industrially compostable material. The core material may be a non-woven fiber sheet according to some embodiments. In some embodiments, an artificial leather produced in accordance with the present disclosure may be entirely biodegradable and/or industrially compostable. In some embodiments, an artificial leather produced in accordance with the present disclosure may be entirely recyclable.

[0007] In some embodiments, a biodegradable and/or industrially compostable leather-like material of the present disclosure includes a non-woven fabric core layer, and a polymer layer disposed on a surface of the non-woven fabric core layer. In some embodiments, the polymer layer includes or consists of a biodegradable and/or industrially compostable polymer. In some embodiments, the polymer layer has a surface pattern or texture that resembles a pattern or texture of a natural animal leather. In some embodiments, the polymer layer is made from one or more of polylactic acid (PLA), poly(butylene adipate-co-terephthalate) (PBAT), polycaprolactone (PCL), polyhydroxy alkanoate (PHA), polybutylene succinate (PBS), polybutylene succinate adipate (PBS A), polybutylene adipate (PBA), or combinations thereof.

In some embodiments, the non-woven fabric core layer includes a biodegradable and/or industrially compostable material. In some embodiments, the non-woven fabric core layer includes a cellulose-derived fiber (e.g., Lyocell), natural plant fiber (e.g., cotton fiber, flax fiber, hemp fiber, etc.), and/or one or more biodegradable and/or industrially compostable polymers.

In some embodiments, the non-woven fabric core layer is or includes a blend of one or more natural fibers (e.g., natural plant fiber) and one or more biodegradable and/or industrially compostable polymers (e.g., PBAT and/or PLA).

[0008] In some embodiments, a method of manufacturing a biodegradable and/or industrially compostable leather-like material includes providing a thermoplastic biopolymer and a bioderived non-woven fiber sheet, wherein the thermoplastic biopolymer and the bio-derived non- woven fiber sheet are biodegradable and/or industrially compostable, feeding the thermoplastic biopolymer into a mixer to produce a molten biopolymer material, coating one or more surfaces of the bio-derived non-woven fiber sheet with the molten biopolymer material, wherein the molten biopolymer material forms an outer polymer layer attached to the one or more surfaces of the bio-derived non-woven fiber sheet, and patterning (e.g., embossing) the outer polymer layer to produce a surface pattern or texture on the outer polymer layer. In some embodiments, the surface pattern or texture on the outer polymer layer resembles a pattern or texture of a natural animal leather. In some embodiments, the thermoplastic biopolymer includes or consists of one or more of polylactic acid (PLA), poly(butylene adipate-co-terephthalate) (PBAT), polycaprolactone (PCL), polyhydroxy alkanoate (PHA), polybutylene succinate (PBS), polybutylene succinate adipate (PBS A), polybutylene adipate (PBA), or combinations thereof.

[0009] In some embodiments, the method further includes feeding the molten biopolymer material into a first mixing roller, and feeding the molten biopolymer material from the first mixing roller into a strainer. In some embodiments, the method includes feeding the molten biopolymer material from the strainer into a calendaring machine where the molten biopolymer material is coated onto the surface of the bio-derived non-woven fiber sheet. In some embodiments, the method includes cooling the outer polymer layer attached to the bio-derived non-woven fiber sheet. In some embodiments, cooling the outer polymer layer attached to the bio-derived non-woven fiber sheet includes passing the outer polymer layer and the bio-derived non-woven fiber sheet between a plurality of cooling rollers.

[0010] In some embodiments, a recyclable leather-like material includes a non-woven fabric core layer, and a polymer layer disposed on a surface of the non-woven fabric core layer, wherein the polymer layer includes or consists of a recyclable polymer. In some embodiments, the polymer layer has a surface pattern or texture that resembles a pattern or texture of a natural animal leather. In some embodiments, the non-woven fabric core layer also includes or consists of a recyclable polymer. In some embodiments, the polymer layer and/or the non-woven fabric core layer may include, for example, polyether block amide (PEBA), polyamide 6, polyamide 6/6-6, polyamide 12, or a blend containing one or more thereof.

[0011] In some embodiments, a method of manufacturing a recyclable leather-like material includes providing a thermoplastic polymer and a non-woven fiber sheet, wherein the thermoplastic polymer and the non-woven fiber sheet consist of one or more recyclable polymer materials, feeding the thermoplastic polymer into a mixer to produce a molten polymer material, coating one or more surfaces of the non-woven fiber sheet with the molten polymer material, wherein the molten polymer material forms an outer polymer layer attached to the one or more surfaces of the non-woven fiber sheet, and patterning (e.g., embossing) the outer polymer layer to produce a surface pattern or texture on the outer polymer layer. In some embodiments, the surface pattern or texture on the outer polymer layer resembles a pattern or texture of a natural animal leather. In some embodiments, the thermoplastic polymer includes or consists of one or more of polyether block amide (PEBA), polyamide 6, polyamide 6/6-6, polyamide 12, or a blend containing one or more thereof.

[0012] In some embodiments, the method for manufacturing a recyclable leather-like material further includes feeding the molten polymer material into a first mixing roller, and feeding the molten polymer material from the first mixing roller into a strainer. In some embodiments, the method includes feeding the molten polymer material from the strainer into a calendaring machine where the molten polymer material is coated onto the surface of the non- woven fiber sheet. In some embodiments, the method further includes cooling the outer polymer layer attached to the non-woven fiber sheet. In some embodiments, cooling the outer polymer layer attached to the non-woven fiber sheet comprises passing the outer polymer layer and the non-woven fiber sheet between a plurality of cooling rollers.

[0013] The present disclosure further provides products made from or including a recyclable or biodegradable/industrially compostable leather-like material that is made in accordance with any of the embodiments described herein. These products can include, but are not necessarily limited to, footwear (e.g., shoe) components or other apparel, fashion accessories, belts, bags, wallets, vehicle interiors, seating or other furniture, etc. For example, in some embodiments, a shoe component (e.g., a shoe upper, insole, midsole, or outsole) may be made from one or more of the recyclable or biodegradable/industrially compostable leather-like materials described herein. The recyclable or biodegradable/industrially compostable leather-like material according to embodiments of the present disclosure may be used as a substitute for any other artificial or natural leather materials known in the art. [0014] The details of one or more embodiments are set forth in the accompanying description below. Other features and advantages will be apparent from the description and from the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention can be embodied in different forms and thus should not be construed as being limited to the embodiments set forth herein. The appended drawings may not be drawn to scale.

[0016] FIG. 1A is a cross-sectional diagram depicting an artificial leather material according to some embodiments of the present disclosure;

[0017] FIG. IB is a cross-sectional diagram depicting an artificial leather material according to further embodiments of the present disclosure;

[0018] FIG. 2 is a diagram illustrating a system for forming an artificial leather material according to some embodiments of the present disclosure; and

[0019] FIGS. 3A-3C are photographs showing example artificial leather materials made in accordance with embodiments of the present disclosure. FIG. 3A shows a sample material prior to embossing. FIG. 3B shows a sample material after embossing. FIG. 3C is a side view of the sample shown in FIG. 3 A.

DETAILED DESCRIPTION

[0020] FIG. 1A shows a generalized, cross-sectional view of an artificial leather 100 according to certain embodiments. Artificial leather 100 may be formed as a flexible, sheet material that can be cut, shaped, and sized for used in products in place of natural and/or other artificial leathers. For example, artificial leather 100 may be particularly used for footwear (e.g., shoe) components or other apparel, fashion accessories, belts, bags, wallets, vehicle interiors, seating or other furniture, etc. [0021] In some embodiments, artificial leather 100 of the present disclosure includes a core layer 102 and an outer polymer layer 104 disposed on at least one side or surface of core layer 102. As shown in FIG. IB, in some embodiments, both sides or surfaces of core layer 102 may be covered by an outer polymer layer 104 such that, for example, core layer 102 is sandwiched between to outer polymer layers 104. The relative thicknesses of core layer 102 and outer polymer layer(s) 104 are not necessarily drawn to scale. In some embodiments, core layer 102 is a flexible sheet material, and outer polymer layer 104 is provided as a coating onto one or more surfaces of core layer 102. In some embodiments, core layer 102 is in the form of a film. In some embodiments, core layer 102 is in the form of a solid open- or closed-cell foam layer. In some embodiments, core layer 102 is a fabric. In some embodiments, core layer 102 is or includes a non-woven fabric, and outer polymer layer 104 is a coating provided on one or more surfaces of the non-woven fabric. In some embodiments, a non-woven fabric (which may also be referred to herein as “a non-woven fiber core”) includes randomly oriented (e.g., entangled) fibers or filaments that may be consolidated, for example, by friction and/or cohesion and/or adhesion. In some embodiments, core layer 102, by itself, may have an uneven, fibrous appearance. In some embodiments, core layer 102 is manufactured by putting fibers together in the form of a sheet or web, and then binding them either mechanically, with an adhesive, or thermally. In some embodiments, core layer 102 may be produced, for example, by a melt- blown process, a spun-bond process, or a combination of the two. Non-woven fabrics, as used herein according to some embodiments, do not include materials which are formed from weaving or knitting, for example.

[0022] Outer polymer layer 104, in some embodiments, may be applied in a fluid state to a surface of core layer 102 via a coating process (e.g., spray-coating, knife-coating, roll-coating, etc.) In other embodiments, outer polymer layer 104 may be formed separately from core layer 102, and the two layers are subsequently adhered or bonded together to form artificial leather 100. In some embodiments, a layer of adhesive material may be disposed between core layer 102 and outer polymer layer 104. In some embodiments, no adhesive material or other layer is disposed between core layer and outer polymer layer(s) 104. In some embodiments, outer polymer layer(s) 104 are applied directly onto one or more surfaces of core layer 102. In some embodiments, artificial leather 100 consists only of core layer 102 and outer polymer layer(s)

104 [0023] Outer polymer layer 104 includes an outer surface 106 facing away from core layer 102 that, in some embodiments, may have a pattern or texture that simulates natural animal leather or skin. For example, outer polymer layer 104 may be molded, embossed, or otherwise patterned such that outer surface 106 includes a pattern or texture that mimics the pattern or texture (“grain”) of mammal leathers (e.g., bovine leather, goat leather, sheep leather, kangaroo leather), bird leathers (e.g., ostrich leather), reptile leathers (e.g., alligator leather, crocodile leather, snake leather), fish leathers (e.g., stingray leather), or other known animal leathers. However, it should be appreciated that the materials selected to form artificial leather 100 according to preferred embodiments are not actually derived from animals. In some embodiments, where artificial leather 100 includes two outer polymer layers 104 (e.g., as shown in FIG. IB), only one or both outer polymer layers 104 may have an outer surface 106 that is patterned or textured to simulate natural animal leather or skin.

[0024] Artificial leather 100 may have a thickness T of less than 10 mm, for example, less than 9 mm, less than 8 mm, less than 7 mm, less than 6 mm, less than 5 mm, less than 4 mm, less than 3 mm, less than 2 mm, or less than 1 mm. T may refer to the total thickness of core layer 102 and outer polymer layer(s) 104. In some embodiments, thickness T may range from 1 mm to 8 mm, for example, from 2 mm to 6 mm or from 3 mm to 5 mm. Since the surface of artificial leather 100 may be uneven, in some embodiments, thickness T may refer to a maximum thickness of artificial leather 100. In other embodiments, thickness T may refer to an average thickness of artificial leather 100. In some embodiments, outer polymer layer 104 may be thinner than core layer 102. In other embodiments, outer polymer later 104 may have a thickness that is substantially equal to a thickness of core layer 102. In further embodiments, artificial leather 100 fabric weight from about 100 grams per square meter (g/m ² or “GSM”) to about 600 g/m ² , preferably from about 300 g/m ² to about 500 g/m ² .

[0025] As will be discussed further herein, the materials for core layer 102 and outer polymer layer(s) 104 in some embodiments includes or consists of biodegradable and/or industrially compostable materials. In some embodiments, the materials for core layer 102 and outer polymer layer(s) 104 includes or consists of recyclable materials. In certain preferred embodiments, core layer 102 and/or outer polymer layer 104 do not include or consist of polyurethanes. In some embodiments, core layer 102 and/or outer polymer layer 104 do not include or consist of chemical cross-linking agents. Chemical cross-linking may prevent or hinder the ability of the materials to be biodegraded, composted, and/or recycled, and therefore such cross-linking should be avoided in certain embodiments. For example, crosslinking can be described as the formation of covalent bonds that hold portions of several polymer chains together. The result is a random three-dimensional network of interconnected chains within the material. This crosslinked material cannot readily be un-crosslinked, and thus, the various precursor ingredients cannot easily be separated back to their individual types and biodegraded or composted.

[0026] As used herein, “biodegradable” generally refers to a capability of being decomposed by biological activity, in particular, by microorganisms. In some embodiments, materials and foams described in the present disclosure as being biodegradable and/or industrially compostable meet or exceed the requirements set forth in at least one of the following standards: European Standard EN 13432, ASTM D6400, or Australian Standard AS 4736. In some embodiments, materials described in the present disclosure as being biodegradable and/or industrially compostable meet or exceed the requirements set forth in at least European Standard EN 13432. In some embodiments, materials described in the present disclosure as being industrially compostable are configured to demonstrate at least 60% biodegradation (at least 60% of the materials have to be broken down by biological activity) within 180 days of composting in a commercial composting unit. In some embodiments, materials and foams described in the present disclosure as being industrially compostable are configured to demonstrate at least 90% biodegradation within 180 days of composting in a commercial composting unit.

[0027] In some embodiments, the term “recyclable” may generally refer to the ability of a material or product to be collected, separated, or otherwise recovered from the waste stream for reuse or use in manufacturing or assembling another item. In some embodiments, polymers and foams described in the present disclosure as being recyclable refers to the ability of the constituent materials to be recovered, for example, by mechanical recycling, chemical recycling, and/or biological or organic recycling. In some embodiments, polymers and materials described in the present disclosure as being recyclable refers to the ability of the constituent materials to be recovered using standard plastic recycling methods, for example, as set forth in ISO 15270:2008. In some embodiments, recycled materials, foams, and/or products described herein may be produced in accordance with the requirements set forth in the Textile Exchange Recycled Claim Standard 2.0 (RCS, July 1, 2017) and/or the Textile Exchange Global Recycle Standard 4.0 (GRS, July 1, 2017).

[0028] Biodegradable and/or Industrially Compostable Materials

[0029] In some embodiments, the present disclosure provides an artificial leather (which may also be referred to as a “leather-like” material) that is biodegradable and/or industrially compostable, preferably both. The leather-like materials according to some embodiments of the present disclosure may be configured to industrially compost rather than home compost. Industrial composting is conducted in large-scale facilities at temperatures between, for example, 55 °C to 60 °C. Conversely, home composting refers to composting at lower temperatures, like those found in a backyard compost heap at home, hence the title "home". In some embodiments, being industrial compostable, instead of being home compostable, helps ensure that the leatherlike materials will last the usable life of the resulting product it is functionalized into and not breakdown or fall apart mid-use within the finished goods. For example, it would be detrimental for a person to purchase a pair of shoes that were made from the leather-like material of this invention only to have the leather-like material degrade during regular use before the end of the shoe’s usable life.

[0030] In some embodiments, creating a biodegradable and/or industrially compostable leather-like outer layer (e.g., outer polymer layer 104 of FIGS. 1A and IB) begins with providing a suitable polymer or blend of suitable polymers. The suitable polymer, in certain preferred embodiments, is a bio-derived polymer (also referred to as “biopolymer”). As used herein, the terms “bio-derived polymer” or “biopolymer” may be used to refer to polymers that are derived from biological sources (e.g., plants, algae, fungi, microorganisms, etc.) or are made from precursor materials (e.g., monomers) that are derived from biological sources. One non-limiting example of a suitable biopolymer for use in a biodegradable and/or industrially compostable artificial leather of the present disclosure is or includes a bio-derived poly(butylene adipate-co terephthalate) (PBAT), e.g., a bio-derived PBAT manufactured by Novamont SpA, Novara,

Italy. This bio-derived PBAT is both biodegradable and industrially compostable, wherein the polymer’s precursors, namely azelaic acid and bio-derived biobutanediol (bio-BDO) make up the primary bio-derived nature of the polymer. The aforementioned thermoplastic biopolymer resin has shown advantageous technical properties in forming the optimal leather-like structure according to embodiments of the present disclosure. Some of these technical properties include, for example, exceptional aging properties, excellent elongation, and tensile strength, among other benefits.

[0031] In some embodiments, the thermoplastic biopolymer or thermoplastic biopolymer blend used to manufacture the biodegradable and/or industrially compostable leather-like material can be created from any number of aliphatic and aliphatic-aromatic co-polyesters, or the like. Further non-limiting examples of suitable biopolymers finding use in producing the biopolymer blend include polylactic acid (PLA), poly(butylene adipate-c -terephthalate) (PBAT), polycaprolactone (PCL), polyhydroxy alkanoate (PHA), polybutylene succinate (PBS), polybutylene succinate adipate (PBSA), and polybutylene adipate (PBA).

[0032] Depending on the application, additives may be utilized in the biopolymer formulations as well. For example, oligomeric poly(aspartic acid-co-lactide) (PAL) may be optionally compounded into masterbatch for accelerating degradation. Additionally, fillers such as precipitated calcium carbonate from aragonite, starches, or the like may be utilized to reduce cost while maintaining the renewable and biodegradable integrity of the finished artificial leather. In some embodiments, one or more pigments or dyes may also be included to provide a desired color to the outer polymer layer.

[0033] The optimal biopolymer outer structure alone cannot produce a leather-like material without a suitable core layer (e.g., core layer 102). As discussed, the core layer, in some embodiments, is a non-woven fabric. In some embodiments, to achieve the most optimal biodegradable and industrially compostable leather-like material, a bio-derived non-woven fiber core is selected that closely matches the biodegradable and industrially compostable criteria of the outer structure.

[0034] In some embodiments, the non-woven fiber core (e.g., core layer 102) is made from the same material selected for the outer polymer layer (e.g., outer polymer layer 104). In other embodiments, the non-woven fiber core is made from a material that is different than the material selected for the outer polymer layer. In some embodiments, the non-woven fiber core includes or consists of bio-derived fibers, e.g., plant fibers. In some embodiments, the non- woven fiber core for biodegradable and/or industrially compostable artificial leather is or includes Lyocell, a form of Rayon that is a cellulose-derived fiber. In other embodiments, the non-woven core is or includes biodegradable cotton. Still further, blends of natural fibers (e.g., cotton) and PBAT and/or PLA may be used for the non-woven fiber core. For example, a non- woven core in some embodiments may be made by utilizing two or more different kinds of plant fibers (e.g., sorghum, rice, corn, and soybean) as filling fibers, and polylactic acid (PLA) and/or poly (adipic acid)/polybutylene terephthalate (PBAT) as carrier polymers for making the non- woven core. Other plant fibers (e.g., flax, hemp, etc.) may also be used alone or in combination in the non-woven core. Still further, pure blends of extruded fibers from poly (lactic acid) (PLA) and PBAT can be made into a core non-woven material such that, in some embodiments, the outer polymer layer and the core material polymer are the same or similar in their makeup and therefore have the same or similar suitable end of life solution (e.g.,. similar biodegradation profile).

[0035] Recyclable Materials

[0036] In further embodiments, the present disclosure describes a recyclable leather-like material and a method of creating the same. The leather-like material may be non-breathable or breathable (e.g., perforated such that air can pass through the material). Creating a recyclable leather-like structure begins with a suitable high-performance polymer such as those of polyether block amide (PEBA) origin, or the like. A non-limiting example of a suitable polymer is of Poly ether block amide (PEBA) marketed under the trade name of NYFLEX by Nylon Corporation of America, Manchester, NH. Other non-limiting examples of suitable polymers include any number of polyamide block copolymers such as PAE, TP A, TPE-A, COP A, or the like. The aforementioned thermoplastic polymers have shown advantageous technical properties in forming the optimal leather-like structure of the invention. Some of the enhanced technical properties include exceptional aging properties, excellent elongation, and tensile strength, among other benefits.

[0037] In further embodiments, recycled feedstocks may be employed in the manufacturing of the suitable recyclable polymer or polymer blends of the present invention. For example, in one aspect the recyclable flexible foam thermoplastic polymer comprises at least one monomer or polymer derived from a post-consumer or post-industrial recycled feedstock such as caprolactam, recycled polyether block amide polymer, or the like. By way of illustration, caprolactam may be derived from such recycled feedstocks by depolymerizing post-industrial or post-consumer material containing polyamide such as fishing nets, carpet fibers, or industrial waste. Some examples of depolymerized post-consumer or post-industrial recycled caprolactam include ECONYL® caprolactam, whether in flake, liquid or molten, provided by Aquafil USA Inc., Cartersville, Georgia. The thermoplastic polymer may additionally or alternatively comprise a polyamide polymer derived from post-industrial or post-consumer polyamide carpet fiber that is collected, sorted, melted down, and reprocessed. An example of this would be to use post-industrial polyamide carpet fiber, or the like that is collected, sorted, melted down, and reprocessed into upcycled usable polyamide material. An exemplary polyamide polymer derived from post-industrial carpet fiber is Econyl manufactured by the Aquafil USA Inc., Cartersville, Georgia. Additionally, polyamide waste, may be collected from in or around the world’s oceans in the form of fishing nets, or that like, that can then be sorted, melted down, and reprocessed into upcycled usable polyamide material. An exemplary polyamide polymer derived from collected post-industrial fishing nets is Akulon Repurposed manufactured by Koninklijke DSM N.V., Heerlen, the Netherlands. It is an object of certain embodiments to use recycled polymer feedstocks whenever possible.

[0038] The thermoplastic polymer used to manufacture the recyclable artificial leather, according to certain embodiments, can be optionally created from any number of flexible polyamides or polyamide copolymers, or the like. A non-limiting example of a suitable polymer includes polyether block amide (PEBA), polyamide 6, polyamide 6/6-6, and polyamide 12. Any suitable polymer type may be utilized in this invention provided that it meets the highly demanding requirements of low hardness, moderate melt-flow, high elongation, and above all 100% recyclability.

[0039] A suitable recyclable material for outer polymer layer 104 alone cannot produce a recyclable leather-like material without a suitable non-woven fiber core (e.g., core layer 102). To achieve the most optimal recycled and recyclable leather-like material for the aforementioned invention, a recyclable non-woven fiber core is selected that closely matches the recycled and/or recyclable criteria of the outer structure for being formed in a leather-like material making process. In some embodiments, both the outer polymer layer and the non-woven fiber core a recyclable non-woven fiber core can be made from any of the recyclable materials described above and herein. In some embodiments, the outer polymer layer and the non-woven fiber core are made from the same recyclable material (e.g., ECONYL® caprolactam). In other embodiments, the outer polymer layer is made from a first recyclable material, and the non- woven fiber core is made from a second recyclable material that is different than the first recyclable material. In some embodiments, an artificial leather according to certain embodiments is configured such that the outer polymer layer may be separated from the non- woven fiber core by methods known in the art. In some embodiments, separation of the outer polymer layer from the non-woven fiber core may allow for each of these components to be recycled separately.

[0040] Additionally, in some embodiments, blending two or more recyclable thermoplastic polymers, rather than a single polymer, may provide a desirable combination of properties at a lower price. There are a number of ways to blend polymers together successfully. One method, for example, may use twin-screw extrusion to melt two or more polymer resins together. The polymer resin blend is then extruded into a strand, cooled, and fed into a pelletizer for producing an array of pelletized pieces called a masterbatch. Another method of polymer resin blending is to use compatibilizing agents to join unlike chemistries together in a polymer blend. This may use twin-screw extrusion or the like to melt the compatibilizer and two or more polymers together in the non-limiting thermoplastic polymer types that are described above.

[0041] Processes for Manufacturing an Artificial Leather

[0042] In accordance with some embodiments of the present disclosure, a suitable thermoplastic biopolymer is provided for producing outer polymer layer 104; followed by selection of a suitable non-woven fiber core (e.g., core layer 102) of biodegradable and/or industrially compostable origin; controlling the extrusion, mixing, and calendaring such that a desirable leather-like material is formed.

[0043] In some embodiments, a process of manufacturing biodegradable and industrially compostable leather-like material includes the steps of: producing a suitable thermoplastic biopolymer; producing a suitable bio-derived non-woven fiber core; forming a leather-like material through the actions of mixing, straining, calendaring, embossing, cooling, and windings.

[0044] In some embodiments, a forming process for making a biodegradable and/or industrial compostable artificial leather is employed in which a suitable biopolymer or biopolymer blend (e.g., one or more of the thermoplastic biopolymers as described above) is selected and then fed into a mixer, for example, a Banbury mixer. Following initial mixing, the now semi-molten thermoplastic biopolymer mass is fed into a first mixing roller before it is fed into a strainer. Following proper straining, the semi-molten thermoplastic biopolymer mass is fed into a second mixing roller before being fed into a calendering machine where it is coated as an outer surface layer on a non-woven fiber core. The non-woven fiber core should also include or consist of biodegradable and/or industrially compostable material according to certain embodiments. In some embodiments, the thermoplastic biopolymer is coated directly onto the non-woven fiber core without the need for any additional adhesive or binding material. The now joined thermoplastic biopolymer and non-woven fiber core is fed through various cooling rollers and an embossing machine before being fed to a winder for completion of the now fully formed leather-like material. In further embodiments, forming processes may include one or more of the following: casting, film blowing, coating and the like.

[0045] In some embodiments, and without imparting limitations to the disclosure herein, a manufacturing process for producing a biodegradable and/or industrially compostable leather like material may include one or more of the following steps:

1. A suitable thermoplastic is selected and then fed into a mixer, e.g., a Banbury mixer.

2. Following initial mixing, the now semi-molten thermoplastic biopolymer mass is fed into a first mixing roller before it is fed into a strainer.

3. Following proper straining, the semi-molten thermoplastic biopolymer mass is fed into a second mixing roller before being fed into a calendering machine where it is coated as an outer surface to a non-woven fiber core. 4. The now joined thermoplastic biopolymer-non-woven is fed through various cooling rollers and an embossing machine before being fed to a winder for completion of the now fully formed leather-like material.

[0046] In some embodiments, a process for forming a recyclable artificial leather material may include steps similar to the processes described above for making a biodegradable and/or industrially compostable leather-like material, except that a recyclable polymer or blend of recyclable polymers (e.g., as described above) is used in place of the thermoplastic biopolymer. Moreover, in certain embodiments, a non-woven fiber core consisting of recyclable materials is preferably used for forming the recyclable artificial leather.

[0047] In some embodiments, a forming process for making a recyclable artificial leather is employed in which a suitable recyclable polymer or recyclable polymer blend (e.g., one or more of the recyclable polymers as described above) is selected and then fed into a mixer, for example, a Banbury mixer. Following initial mixing, the now semi-molten recyclable thermoplastic polymer mass is fed into a first mixing roller before it is fed into a strainer. Following proper straining, the semi-molten recyclable thermoplastic polymer mass is fed into a second mixing roller before being fed into a calendering machine where it is coated as an outer surface layer on a non-woven fiber core. The non-woven fiber core should also include or consist of a recyclable material according to certain embodiments. In some embodiments, the recyclable thermoplastic biopolymer is coated directly onto the non-woven fiber core without the need for any additional adhesive or binding material. The now joined recyclable thermoplastic polymer and non-woven fiber core is fed through various cooling rollers and an embossing machine before being fed to a winder for completion of the now fully formed leather-like material. In further embodiments, forming processes may include one or more of the following: casting, film blowing, coating and the like.

[0048] FIG. 2 illustrates an example system 200 that may be used to produce an artificial leather material according to embodiments of the present invention. In some embodiments, the raw thermoplastic polymer material (e.g., a biodegradable/industrially compostable biopolymer and/or recyclable polymer discussed above) is fed into a mixer 202, for example, a Banbury mixer. The raw thermoplastic polymer material may be fed into mixer 202, for example, in the form of pellets or the like. Following initial mixing, the now semi-molten thermoplastic polymer mass is fed into a first mixing roller 204 before it is fed into a strainer 206. Following proper straining by strainer 206, the semi-molten thermoplastic polymer mass is fed into a second mixing roller 208 before being fed into a calendering machine 210 where it is coated as an outer surface layer on a non-woven fiber core. The now joined thermoplastic polymer and non-woven fiber core is fed through various cooling rollers 212 before being fed to a winder 214 for completion of the now fully formed artificial leather material.

[0049] FIGS. 3A-3C show example materials made in accordance with embodiments of the present disclosure. FIG. 3A shows a sample material prior to embossing. FIG. 3B shows a sample having an outer polymer layer that has been embossed to have a leather-like pattern.

Both samples have already been saturated and/or coated with the outer polymer onto or into the non-woven core layer. FIG. 3C shows a side view of the sample shown in FIG. 3 A. The samples have a fabric weight of about 400 g/m ² to about 500 g/m ² .

[0050] Although a few embodiments have been described in detail above, other modifications are possible. Other embodiments may be within the scope of the following claims. It should be understood that various changes, substitutions, and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.

It should also be apparent that individual elements identified herein as belonging to a particular embodiment may be included in other embodiments of the invention. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, and composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure herein, processes, machines, manufacture, composition of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention.