TUKEK, Rafet (Ataturk Sanayi Bolgesi Urguplu Cad. No:1, Hadimkoy, Istanbul, 34555, TR)
| CLAIMS 1. Process for the formation of porous (spongy) layer and artificial leather produced according to this process characterized in that this invention is to obtain artificial leather (5.12) with similar characteristics to natural leather thanks to its porous (spongy) pattern and corrugated surface through using water or solvent based polyurethane and other auxiliary chemicals in the artificial leather coating processes to coat the intermediate product (4.10) obtained through churning the water based polyurethane and/or acrylic, latex, dye and other auxiliary chemicals with the help of air in order to make them have a porous structure. 2. Process for the formation of porous (spongy) layer and artificial leather produced according to this process as defined in Claim 1 and characterized in that the mixture of porous (spongy) structure used to obtain the intermediate product (4.10) is obtained through churning the mixture prepared using water based polyurethane and/or acrylic, latex, dye and other auxiliary chemicals with the help of air in the foam machine (11). 3. Process for the formation of porous (spongy) layer and artificial leather produced according to this process as defined in Claim 1 and characterized in that what causes churning the mixture prepared using water based polyurethane and/or acrylic, latex, dye and other auxiliary chemicals with the help of air is the existence of a foam machine (11) comprised of a mixing chamber (6), an internal suction pump (7), an internal air pump (8), a mixer (9) and a drain pump (10). 4. Process for the formation of porous (spongy) layer and artificial leather produced according to this process as defined in any of the abovementioned claims and characterized in that the intermediate product (4.10) is obtained through drying the mixture after being dipped into the dipping tank (4.3) at specified viscosities or coating onto the textile texture (4.1) (woven, knitted, nonwoven, etc.) using one or more blades (4.5, 4.7). 5. Process for the formation of porous (spongy) layer and artificial leather produced according to this process as defined in any of the abovementioned claims and characterized in that artificial leather (5.12) is obtained via adhering the patterned carrier paper (5.1) obtained by coating polyurethane and other auxiliary chemicals with a coating blade in preferred thickness and weight, as in traditional coating production method, to the semi finished product (intermediate product) (4.10) with water based porous layer acquired using water based chemicals through the texture unit (5.8) and then drying it in the 3rd furnace (5.9), and finally separating the texture from the carrier paper at the exit point of the machine. 6. Process for the formation of porous (spongy) layer and artificial leather produced according to this process as defined in any of the abovementioned claims and characterized in that the artificial leather (5.12) is produced using this process. 7. Process for the formation of porous (spongy) layer and artificial leather produced according to this process as defined in any of the abovementioned claims and characterized in that the number of coating blades (4.5, 5.5, 4.7, 5.7, 5.3) and of drying furnaces (4.6, 4.8, 5.4, 5.6, 5.9) can be one or more. |
PROCESS FOR PRODUCING ARTIFICIAL LEATHER
Related Field of the Invention
This invention is related to a kind of artificial leather that is particularly produced to be used in furniture, shoes, bag, clothing and accessories sector and the production method developed for the said kind of artificial leather; with the usage of this production method developed through this invention, the artificial leather obtained through using the intermediate product (layer) acquired by churning water based polyurethane and/or acrylic, latex, dye and other auxiliary chemicals in a newly developed foam machinery with the help of air in order to give them a porous structure exhibits very similar characteristics to natural leather thanks to its porous (spongy) pattern and corrugated surface view.
Background of the Invention (Prior Art)
In the conventional technique, the production of the artificial leather having porous (spongy) layer is performed through two principal production techniques:
1. Coating the intermediate product that is obtained by applying solvent based polyurethane process (coagulation process) by polyurethane in order for that the textile texture forms porous (spongy) layer.
2. Production of the product with porous (spongy) layer by coating the textile texture by PU (polyurethane) and PVC (polyvinyl chloride).
1. COATING THE INTERMEDIATE PRODUCT THAT IS OBTAINED BY APPLYING SOLVENT BASED POLYURETHANE PROCESS (COAGULATION PROCESS) BY POLYURETHANE IN ORDER FOR THAT THE TEXTILE TEXTURE FORMS POROUS (SPONGY) LAYER.
This production technique consists of two basic steps. In the first step, semi finished product (intermediate product) is obtained by applying polyurethane on the textile texture (woven, knitted, nonwowen, etc.) for creating porous structure to be used (as the details will be provided in 1.1) as the texture for in the second step. The semi finished product (intermediate product) that is obtained by applying porous polyurethane onto the textile texture is exposed the coating process (as details will be provided in 1.2)
1.1 Polyurethane semi finished product production process (coagulation production process) required for establishment of a porous (spongy) layer based on the previous technique:
As to the production of polyurethane artificial leather using the known technique, especially for the solvent based production process (coagulated production process) used to produce porous (spongy) layer, textile texture (woven, knitted, nonwoven, etc.) is dipped into the tank (1.3 "preliminary dipping unit") holding the mixture of specified viscosities comprised of solvent based polyurethane, solvent, dye and other additional raw materials called pasta (dipping) or is coated with a knife (coating), and the paste is given to the textile texture (woven, knitted, nonwoven, etc.). After the paste is saturated by or coated the textile texture (woven, knitted, nonwoven, etc.), it is dipped into the main coagulation bath (1.6) and become coagulated. Lastly, washing and pressing processes are applied; and thus the porous (spongy) semi finished product (intermediate product), which is required for the coating process, is obtained.
In this production technique, the solvent, DMF (dimethylformamide) that exists by
80 per cent in the polyurethane paste used to produce the porous (spongy) structure, merges in the air we breath since it does not leave the product totally despite all pressing processes, and it also merges in the soil since it cannot be removed from the system totally despite all recycling activities. Thus, it damages the ecological system.
1.2 Polyurethane coated production process of the semi finished product (coagulated product) produced with porous (spongy) layer based on the previous technique Patterned carrier paper in the coating machinery is coated with polyurethane, solvent and other auxiliary chemicals through the 1 st coating blade (2.3) within the required thickness and weight (by grams). Then, it is dried in the 1 st furnace (2.4). This carrier paper with chemicals, after the drying process, comes to the 2 nd coating blade (2.5) and is once again coated with polyurethane, solvent and other auxiliary chemicals within the required thickness and weight (by grams). As before, after being dried in the 2 nd furnace (2.6), this carrier paper with chemicals comes to the 3 rd coating blade (2.7) and is once again coated with polyurethane, solvent and other auxiliary chemicals within the required thickness and weight (by grams) through the 3 rd coating blade (2.7). Finally, the semi finished texture ' product (intermediate product) obtained through the coagulated production process applied to the paper with chemicals is adhered in the texture unit (2.8) and dried in the 3 rd furnace (2.9). The product is obtained through separation of the texture and the patterned carrier paper at the exit of the cooling cylinders (2.10) of the machinery. Nevertheless, this production method causes contamination of both the air and the soil with 90 % solvent, DMF, in the coating polyurethane, thus damages the ecological system.
2. PRODUCTION OF THE PRODUCT WITH POROUS (SPONGY) LAYER BY COATING THE TEXTILE TEXTURE BY PU (POLYURETHANE) AND PVC (POLYVINYL CHLORIDE)
Patterned carrier paper in the coating machinery is coated with polyurethane and/or polyvinyl chloride, solvent and other auxiliary chemicals through the 1 st coating blade (3.3) within the required thickness and weight (by grams). Then, it is dried in the 1 st furnace (3.4). This carrier paper with chemicals, after the drying process, comes to the 2 nd coating blade (3.5) and is once again coated with polyvinyl chloride and other auxiliary chemicals within the required thickness and weight (by grams). As before, after being dried in the 2 nd furnace (3.6), this carrier paper with chemicals comes to the 3 rd coating blade (3.7) and is once again coated with polyvinyl chloride and other auxiliary chemicals within the required thickness and weight (by grams) through the 3 rd coating blade (2.7). Finally, textile texture (woven, knitted, nonwoven, etc.) is adhered to the paper with chemicals in the texture unit (3.8) and dried in the 3 rd furnace (3.9). The product is obtained through separation of the texture and the patterned carrier paper at the exit of the machinery. The number of coating blades at this stage may be increased or decreased, as requested.
In this production method, the porous (spongy) structure is ensured with the use of a chemical, which is called azodicarbonamide, added into the PVC (polyvinyl chloride). High temperature during the drying stage distorts the structure and makes it have a porous
(spongy) one. The artificial leather, which is produced using this production method, causes contamination of the air through evaporation of the azodicarbonamid during the drying process, as well as contamination of the ecological system by the dangerous components contained in PVC (polyvinyl chloride), plasticizers and other auxiliary chemicals. Aims of the Invention
Different from the production of the conventional productions of artificial leather, the artificial leather developed by this invention is produced by using the intermediate product
(layer) derived from the porous structure which is created through churning water based polyurethane and/or acrylic, latex, die and other auxiliary chemicals with air in the foam machine in different artificial leather processes. Thus, it is not needed any prophor harmful to the human health, DMF, other solvents (IBA, IPA, TOL, MEK etc.) and other chemicals except for air for the porous structure, this method gains the artificial leather produced by the said method with the characteristics having natural leather texture and outlook that is different from the known artificial leathers.
Definition of the Figures
FIGURE 1 - Production Process for the Polyurethane Semi Finished Product Required for Creation of a Porous (Spongy) Layer (Coagulation Production Process) (the Known Technique)
FIGURE 2 - Production Process of the Semi Finished Product Produced with Porous (Spongy) Layer (Coagulated Product) through Polyurethane Coating (the Known Technique)
FIGURE 3 - Production Process for the Products with Porous (Spongy) Layer by Coating Textile Textures with PU (polyurethane) and PVC (polyvinyl chloride) (the
Known Technique)
FIGURE 4 - Production of Semi Finished Product (Intermediate Product) Obtained Using Water Based Chemicals Churned with Air
FIGURE 5 - Polyurethane Coating of the Semi Finished Product (Intermediate Product) with Semi Finished Porous Layer Obtained Using Water Based Chemicals Churned with Air
FIGURE 6 - Cross Section of the Foam Machine Definition of the Elements (Features/ Components/Parts) on the Figures
1.1 Textile Texture (woven, knitted, nonwoven etc.) (prior art)
1.2 Battery (prior art)
1.3 Front Dipping Unit (prior art) 1.4 Calibration Cylinders (prior art)
1.5 Dipping/Coating Unit (prior art)
1.6 Main Coagulation Bath (prior art)
1.7 Pressing Cylinders (prior art)
1.8 Washing Bath (prior art) 1.9 Furnace (prior art)
1.10 Cooling Cylinders (prior art)
1.11 Exit Winding Unit (prior art)
2.1 Patterned Carrier Paper (prior art)
2.2 Battery (prior art) 2.3 1. Coating Blade (prior art)
2.4 1. Furnace (prior art)
2.5 2. Coating Blade (prior art)
2.6 2. Furnace (prior art)
2.7 3. Coating Blade (prior art) 2.8 Texture Unit (prior art)
2.9 3. Furnace (prior art)
2.10 Cooling Cylinders (prior art)
2.11 Patterned Carrier Paper (prior art)
2.12 Artificial Leather (prior art) 3.1 Patterned Carrier Paper (prior art)
3.2 Battery (prior art)
3.3 1. Coating Blade (prior art) 3.4 ' 1. Furnace (prior art)
3.5 2. Coating Blade (prior art)
3.6 2. Furnace (prior art)
3.7 3. Coating Blade (prior art) 3.8 Texture Unit (prior art)
3.9 3. Furnace (prior art)
3.10 Cooling Cylinders (prior art)
3.11 Patterned Carrier Paper (prior art)
3.12 Artificial Leather (prior art)s 4.1 Textile Texture (woven, knitted, nonwoven etc.)
4.2 Battery
4.3 Dipping Tank
4.4 Pressing Cylinder
4.5 Production of Semi Finished Product l.-Scraping Blade 4.6 Production of Semi Finished Product 1. Furnace
4.7 Production of Semi Finished Product 2. Scraping Blade
4.8 Production of Semi Finished Product 2. Furnace
4.9 Cooling Cylinders
4.10 Semi Finished Product (Intermediate Product) 5.1 Patterned Carrier Paper
5.2 Battery
5.3 Production by Polyurethane Coating 1. Coating Blade
5.4 Production by Polyurethane Coating 1. Furnace
5.5 Production by Polyurethane Coating 2. Coating Blade 5.6 Production by Polyurethane Coating 2. Furnace
5.7 Production by Polyurethane Coating 3. Coating Blade
5.8 Texture Unit 5.9 Production by Polyurethane Coating 3. Furnace
5.10 Cooling Cylinders
5.11 Patterned Carrier Paper
5.12 Artificial Leather Post Produced by Polyurethane Coating 6 Mixing Chamber
7 Internal Suction Pump
8 Internal Air Pump
9 Mixer
10 Drain Pump 11 Foam Machine
Detailed Description of the Invention Foam Machine (H)'
The mixture, which is prepared with water based polyurethane and/or acrylic, latex, dye and other auxiliary chemicals put into the mixing chamber (6) within the unit, is taken into the foam machine (11) through internal suction pump (7). Air is pumped to this mixture within the foam machine (11), in required amounts, from the internal air pump (8), and it is churned through mixing by the mixer (9). This churned mixture is, then, sent to the dipping tank (4.3) or Semi Finished Product Production Scraping Blades (4.5 or 4.7), whichever is preferred, through the drain pump (10). After the churned mixture is used for dipping or coating with at least one blade onto the textile texture (woven, knitted, nonwoven, etc.) and dried, we acquire the water based semi finished product (intermediate product) (4.10) required for coating procedure.
POROUS (SPONGY) LAYER FORMATION PROCESS AND ARTIFICIAL LEATHER
PRODUCED THROUGH THIS PROCESS:
1.1 Production of semi finished product (intermediate product) through using water based chemicals churned with air. After the mixture, which is prepared with water based polyurethane and/or acrylic, latex, dye and other auxiliary chemicals is churned with air in the foam machine (11), dipping procedure is applied to the semi finished product production in specified viscosities in the dipping tank (4.3) or at least one semi finished product production is dried through dressing onto the textile texture (4.1) (woven, knitted, nonwoven, etc.) with 1 st scraping blade (4.5) or the semi finished product production with 2 nd scraping blade (4.7); and thus the water based semi finished product (intermediate product) (4.10) required for the coating process is obtained.
At this stage cooling cylinders (4.9) start working to cool the water based semi finished product (4.10) coming out of the 2 nd furnace (4.8) hot, and prevent potential problems in hot winding.
1.2 Polyurethane Coating of the Semi Finished Product (Intermediate Product) with Semi Finished Porous Layer Obtained Using Water Based Chemicals Churned with Air In the coating machine, the patterned carrier paper (5.1) is coated with water or solvent based polyurethane and other auxiliary chemicals in preferred thickness and weight in grams through the polyurethane coating production 1 st coating blade (5.3), and the polyurethane coating production is dried in the 1 st furnace (5.4). The carrier paper with chemicals, after drying, comes to the 2 nd coating blade (5.5) and it is coated with water or solvent based polyurethane and other auxiliary chemicals in preferred thickness and weight in grams. In the same way, the carrier paper with chemicals leaves the polyurethane coating production 2 nd furnace (5.6) after completion of the drying procedure, comes to the polyurethane coating production 3 rd furnace (5.7), and is coated with water or solvent based polyurethane and other auxiliary chemicals in preferred thickness and weight in grams. This coating procedure is done with at least one blade. Similarly, the drying procedures can also be realized in one or more furnaces according to the number of blades used. Finally, the patterned carrier paper (5.1) is adhered through the texture unit (5.8) to the semi finished product (intermediate product) (4.10) with water based porous layer obtained through production with water based chemicals, and dried in polyurethane coating production 3 rd furnace (5.9). With the separation of the texture and patterns carrier paper (5.1) at the exit of the machine, artificial leather (5.12) is obtained following the polyurethane coating Production. Withfn this basic concept, being the subject of this invention, it is possible to develop various applications for the Process for the Formation of Porous (Spongy) Layer and Artificial Leather Produced According to This Process; thus, this invention cannot be limited with the examples set here in this document, and it is as defined in the claims.
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