Description:FIELD
The present disclosure relates to a leatherette and a process for its preparation.
DEFINITIONS
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.
Leatherette: The term “leatherette” refers to a synthetic material constructed of paper or cloth or a polymer and finished to simulate the grain, color, and texture of the leather.
Release paper: The term “release paper” refers to a paper or a plastic-based film sheet which is used to prevent a sticky surface from premature adhering.
Sludge: The term “sludge” refers to the thick, soft, wet mud or the similar viscous mixture of the liquid and the solid components, especially the by-product of an industrial or refining process.
Paint Sludge: The term “paint sludge” refers to the byproduct comprising complex materials composed of the different elements such as the uncured polymeric resins, pigments, curing agents, flotation agents and other minor ingredients included in the formulation of paint.
Knife Coating: The term “knife coating” refers to a process of applying a coating to the substrate. The process comprises the step of coating an excess of material to the substrate and removing it by a metering blade to achieve the desired coating thickness.
Bally flex resistance: The term ‘Bally flex resistance’ refers to a measure of how well a particular leather resists cracking or breaking when flexed using a specific motion called Bally flex. This term is typically used in the leather industry to describe the quality of leather products or any other leather item that needs to be flexible and durable. Bally flex resistance is an important quality factor for leather products, particularly those that are designed for high-wear applications. Products with good Bally flex resistance are generally considered to be of higher quality and more durable than those with poor Bally flex resistance.
Stretch: The term ‘stretch’ refers to an increase in length of a seat cushion or backrest cover, expressed as a percentage of the original length, resulting from the application of a specified force for a specified period of time.
Set: The term ‘set’ refers to the residual deformation of a seat cushion or backrest cover, expressed as a percentage of the original thickness, resulting from the application of a specified force for a specified period of time.
Coating adhesion: The term “coating adhesion” refers to the ability of a coating or paint film to adhere to a substrate or surface. Adhesion is a critical property of coatings, as it directly affects their durability, resistance to abrasion, and ability to withstand environmental factors such as humidity and temperature changes.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Paint sludge is a by-product/waste produced in various industrial processes including automotive industry where paints are used in various coating zones such as in primer coat booth, base coat booth and the clear coat booth. Post painting or the unused paint removal in the paint booth are collected and stored as paint sludge coagulant. The paint sludge includes both organic and inorganic constituents and also substances which are intended to coalesce into a film. These coalescing substances make the paint sludge very sticky and difficult to handle.
Conventionally, the paint sludge is disposed off in landfill. However, it is an undesirable solution because of the cost and potential environmental pollution. The treatment of the paint sludge produced from the industries causes a variety of environmental and economic problems. The increasingly strict governmental pollution regulations as well as the increased cost of waste disposal have led to escalating concern in the treatment and disposal of such by-products/waste. Therefore, there is felt a need to dispose the paint sludge in a fruitful manner without disturbing the environment.

Further, leather is used in variety of application such as in sports, jackets, hand bags, suitcase, belts and the like. Leather is a material obtained from the animal skins followed by chemical treatment. However, these leathers are expensive and more sensitive to fluctuations in temperature. Therefore, recently synthetic leather is in demand that comprises paper or cloth or a polymer. However, the conventional synthetic leather is associated with the drawbacks such as low durability, crack formation, peeling, inferior mechanical properties and the like.

Therefore, the present disclosure provides a leatherette by comprising a paint sludge and a process for its preparation that mitigates the drawbacks mentioned hereinabove or at least provide a useful alternative.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
It is an object of the present disclosure to ameliorate one or more problems of the background or to at least provide a useful alternative.
An object of the present disclosure is to provide a leatherette.
Yet another object of the present disclosure is to provide a leatherette comprising a paint sludge.
Still another object of the present disclosure is to provide a simple, economical and environment friendly process for the preparation of a leatherette.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure relates to a leatherette and a process for its preparation.
In an aspect, the present disclosure relates to a leatherette. The leatherette comprises a polyvinyl chloride (PVC) skin layer (B) having a predetermined thickness, a polyvinyl chloride (PVC) foam layer (C) having a predetermined thickness coated on an operative top surface of the PVC skin layer (B), a polyvinyl chloride (PVC) adhesive layer (D) having a predetermined thickness coated on the foam layer (C), a fabric layer (E) having a predetermined thickness laminated on the adhesive layer (D), and a pre-skin layer (A) having a predetermined thickness coated on the operative bottom surface of the PVC skin layer (B). The thickness of the leatherette is in the range of 0.5 mm to 1.5 mm.
In another aspect, the present disclosure relates to a process for preparing the leatherette. The process for preparing the leatherette comprises the steps of obtaining a release paper. A predetermined amount of a polyvinyl chloride (PVC) composition is coated on the release paper, followed by heating at a first predetermined temperature for a first predetermined time period and cooling at a second predetermined temperature for a second predetermined time period to obtain a PVC skin layer (B) comprising an operative top surface and an operative bottom surface. A predetermined amount of a foam composition is coated on the PVC skin layer (B), followed by heating at a third predetermined temperature for a third predetermined time period and cooling at a fourth predetermined temperature for a fourth predetermined time period to obtain a foam layer (C) coated on the operative top surface of the PVC skin layer (B). A predetermined amount of an adhesive composition is coated on the foam layer (C), to obtain an adhesive layer (D) coated on the foam layer (C). A fabric layer (E) of predetermined thickness is laminated on the adhesive layer (D) followed by heating at a fifth predetermined temperature for a fifth predetermined time period and cooling at a sixth predetermined temperature for a sixth predetermined time period to obtain an adhesive bonded fabric layer (E) on the adhesive layer (C). A release paper is removed from the PVC skin layer (B) obtained in the step (b) to obtain the operative bottom surface of the PVC skin layer (B). A predetermined amount of an aqueous pre-skin composition is coated on the operative bottom surface of the PVC skin layer (B), followed by heating at a seventh predetermined temperature for a seventh predetermined time period and cooling at an eight predetermined temperature for an eight predetermined time period to form a pre-skin layer (A) on the operative bottom surface of the PVC skin layer (B) to obtain the leatherette. The coating is done by using a knife coating process.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates the schematic representation of the process of preparation of the leatherette in accordance with the present disclosure; and
Figure 2 illustrates the construction of leatherette in accordance with the present disclosure.
List of Reference Numerals
Release paper 1
PVC skin layer coating 2
Foam layer (C)coating 3
Adhesive layer (D) coating 4
Fabric roll 5
Fabric lamination 6
Leatherette 7
Release paper winding back 8
Pre skin layer (PU/acrylic coating) A
PVC Skin layer B
Paint sludge +PVC Foam layer C
Paint sludge + PVC adhesive layer D
Fabric Layer (Polyester/Nylon) E

DETAILED DESCRIPTION
The present disclosure relates to a leatherette and a process for its preparation.
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details, are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Conventionally, the paint sludge is disposed off in landfill. However, it is an undesirable solution because of the cost and potential environmental pollution. The treatment of the paint sludge produced from the industries causes a variety of environmental and economic problems. The increasingly strict governmental pollution regulations as well as the increased cost of waste disposal have led to escalating concern in the treatment and disposal of such by-products/waste. Therefore, there is felt a need of disposal of the paint sludge in a fruitful manner without disturbing the environment.
Further, leather is used in variety of application such as in sports, jackets, hand bags, suitcase, belts and the like. Leather is a material obtained from the animal skins followed by chemical treatment. However, these leathers are expensive and more sensitive to fluctuations in temperature. Therefore, recently synthetic leather is in demand that comprises paper or cloth or a polymer. However, the conventional synthetic leather is associated with the drawbacks such as low durability, crack formation, peeling, inferior mechanical properties and the like.

The present application provides a leatherette and a process for its preparation.
In an aspect of the present disclosure, there is provided a leatherette.
The leatherette comprises a polyvinyl chloride (PVC) skin layer (B) having a predetermined thickness, a polyvinyl chloride (PVC) foam layer (C) having a predetermined thickness coated on an operative top surface of the PVC skin layer (B), a polyvinyl chloride (PVC) adhesive layer (D) having a predetermined thickness coated on the foam layer (C), a fabric layer (E) having a predetermined thickness laminated on the adhesive layer (D) and a pre-skin layer (A) having a predetermined thickness coated on an operative bottom surface of the PVC skin layer (B). The thickness of the leatherette is in the range of 0.5 mm to 1.5 mm.
In an exemplary embodiment of the present disclosure, the thickness of the leatherette is 0.9 mm. In another exemplary embodiment of the present disclosure, the thickness of the leatherette is 1.25 mm.
In an embodiment of the present disclosure, the predetermined thickness of the polyvinyl chloride (PVC) skin layer (B) is in the range of 0.05 to 0.6 mm. In an exemplary embodiment of the present disclosure, the predetermined thickness of the polyvinyl chloride (PVC) skin layer (B) is 0.15 mm.
In an embodiment of the present disclosure, the predetermined thickness of the foam layer (C) is in the range of 0.1 mm to 0.6 mm. In an exemplary embodiment of the present disclosure, the predetermined thickness of the foam layer (C) is 0.3 mm.
In an embodiment of the present disclosure, the predetermined thickness of the adhesive layer (D) is in the range of 0.05 mm to 0.5 mm. In an exemplary embodiment of the present disclosure, the predetermined thickness of the adhesive layer (D) is in the range of 0.1 mm.
In an embodiment of the present disclosure, the predetermined thickness of the pre-skin layer (A) is in the range of 0.001 mm to 0.1 mm. In an exemplary embodiment of the present disclosure, the predetermined thickness of the pre-skin layer (A) is 0.01 mm.
In an embodiment of the present disclosure, the polyvinyl chloride (PVC) skin layer (B) comprises PVC in an amount in the range of 40 mass% to 60 mass% with respect to the total amount of the polyvinyl chloride (PVC) skin layer (B), at least one plasticizer in an amount in the range of 20 mass% to 50 mass% with respect to the total amount of the polyvinyl chloride (PVC) skin layer (B), at least one heat stabilizer in an amount in the range of 0.1 mass% to 5 mass % with respect to the total amount of the polyvinyl chloride (PVC) skin layer (B), at least one pigment in an amount in the range of 1 to 15 mass % with respect to the total amount of the polyvinyl chloride (PVC) skin layer (B), at least one UV stabilizer in an amount in the range of 0.1 mass% to 5 mass % with respect to the total amount of the polyvinyl chloride (PVC) skin layer (B), at least one antioxidant in an amount in the range of 0.01 mass% to 5 mass % with respect to the total amount of the polyvinyl chloride (PVC) skin layer (B), and at least one defoaming agent in an amount in the range of 0.1 mass% to 2 mass % with respect to the total amount of the polyvinyl chloride (PVC) skin layer (B).
In an exemplary embodiment of the present disclosure, the polyvinyl chloride (PVC) skin layer (B) comprises PVC in an amount of 52.19 mass% with respect to the total amount of the polyvinyl chloride (PVC) skin layer (B), at least one plasticizer in an amount of 39.144 mass% with respect to the total amount of the polyvinyl chloride (PVC) skin layer (B), at least one heat stabilizer in an amount of 1.04 mass% with respect to the total amount of the polyvinyl chloride (PVC) skin layer (B), at least one pigment in an amount of 6.26 mass% with respect to the total amount of the polyvinyl chloride (PVC) skin layer (B); at least one UV stabilizer in an amount of 0.78 mass% with respect to the total amount of the polyvinyl chloride (PVC) skin layer (B); at least one antioxidant in an amount of 0.3 mass% with respect to the total amount of the polyvinyl chloride (PVC) skin layer (B); and at least one defoaming agent in an amount of 0.26 mass% with respect to the total amount of the polyvinyl chloride (PVC) skin layer (B).
In an embodiment of the present disclosure, the polyvinyl chloride (PVC) skin layer (B) comprises the plasticizer selected from a synthetic plasticizer and a bio plasticizer.
In an embodiment of the present disclosure, the synthetic plasticizer is selected from the group consisting of phthalates, poladipates, sebacates, trimellitates and polymeric adipate, wherein the phthalates are selected from diisononyl phthalate (DINP) and diisodecyl phthalate (DIDP), wherein the sebacates is dioctyl sebacate (DOS), and wherein the trimellitate is tri-2-ethylhexyl trimellitate (TOTM). In an exemplary embodiment of the preset disclosure, the plasticizer used is polymeric adipate.
In an embodiment of the present disclosure, the bio plasticizer is selected from the group consisting of soya bean oil, lactic acid derived, and diacetyl epoxidized vegetable-oleic acid glyceride.
In an embodiment of the present disclosure, the polyvinyl chloride (PVC) skin layer (B) comprises a heat stabilizer selected from the group consisting of barium/zinc (Ba/Zn) stearate, zinc/calcium (Zn/Ca) stearate and organic based stabilizer. In an exemplary embodiment of the present disclosure, the heat stabilizer is liquid Ba/Zn stearate.
In an embodiment of the present disclosure, the organic based stabilizer is selected from the group consisting of OBS 200 and OBS 300.
In an embodiment of the present disclosure, the polyvinyl chloride (PVC) skin layer (B) comprises at least one pigment selected from the group consisting of titanium dioxide, silica and aluminium oxides, and ferro pigment.
In an embodiment of the present disclosure, the polyvinyl chloride (PVC) skin layer (B) comprises a UV stabilizer selected from the group consisting of benzophenone, benzotriazole, bis-benzoxazole, cyanoacrylate, oxanilide, carbon black, titanium dioxide, monomeric sterically hindered amine, oligomeric sterically hindered amine and sterically hindered amine ester. In an exemplary embodiment of the present disclosure, the UV stabilizer is benzotriazole.
In an embodiment of the present disclosure, the polyvinyl chloride (PVC) skin layer (B) comprises an antioxidant selected from the group consisting of octadecyl-3-(3,5-di-tert.butyl-4-hydroxyphenyl)-propionate and bisphenol A. In an exemplary embodiment of the present disclosure, the antioxidant is phenolic antioxidant.
In an embodiment of the present disclosure, the polyvinyl chloride (PVC) skin layer (B) comprises a defoaming agent selected from the group consisting of polydimethylsiloxanes, silicones, alcohols, stearates and glycols. In an exemplary embodiment of the present disclosure, the defoaming agent is silicone defoamer.
In an embodiment of the present disclosure, the polyvinyl chloride (PVC) foam layer (C) comprises at least one plasticizer in an amount in the range of 15 mass% to 50 mass % with respect to the total amount of the PVC foam layer (C), PVC in an amount in the range of 30 mass% to 80 mass% with respect to the total amount of the PVC foam layer (C), a paint sludge in an amount in the range of 10 mass% to 40 mass% with respect to the total amount of the PVC foam layer (C), at least one heat stabilizer in an amount in the range of 0.1 mass% to 5 mass% with respect to the total amount of the PVC foam layer (C), at least one pigment in an amount in the range of 1 mass% to 10 mass% with respect to the total amount of the PVC foam layer (C), at least one UV stabilizer in an amount in the range of 0.1 mass% to 5 mass% with respect to the total amount of the PVC foam layer (C), at least one antioxidant in an amount in the range of 0.1 mass% to 2 mass% with respect to the total amount of the PVC foam layer (C), and at least one foaming agent in an amount in the range of 0.1 mass% to 2 mass% with respect to the total amount of the PVC foam layer (C).
In an exemplary embodiment of the present disclosure, the PVC foam layer (C) comprises at least one plasticizer in an amount of 24.49 mass% with respect to the total amount of the PVC foam layer (C), PVC in an amount of 48.99 mass%, with respect to the total amount of the PVC foam layer (C), the paint sludge in an amount of 19.5 mass% with respect to the total amount of the PVC foam layer (C), at least one heat stabilizer in an amount of 0.97 mass% with respect to the total amount of the PVC foam layer (C), at least one pigment in an amount of 3.9 mass% with respect to the total amount of the PVC foam layer (C), at least one UV stabilizer in an amount of 0.7 mass % with respect to the total amount of the PVC foam layer (C), at least one antioxidant in an amount of 0.29 mass% with respect to the total amount of the PVC foam layer (C), and at least one foaming agent in an amount of 0.97 mass% with respect to the total amount of the PVC foam layer (C).
In an embodiment of the present disclosure, the automotive paint sludge is used in the leatherette.
Automotive paint application involves primer, basecoat and topcoat which are widely used in solvent-based paints. During paint application over automotive components, 70% of paint is deposited on the substrate and 30 % of paint is lost due to over spray. The overspray paint needs to be removed from the paint system to avoid undesired paint particulate deposition over the components and to keep the paint booth clean. This paint is removed through a down draft air circulation system where all the floated particles are directed to the water flow below the paint booth grid skids.
The removed particles are then mixed with the water and coagulant chemical like aluminum sulfates or aluminum chloride ion salts. These chemicals help to form coagulation of paint and separates it from water for ease of removal. The removed coagulates are filtered through to separate water and forms a powder with 25% - 30% moisture content. This powder goes for landfill with industrial hazardous regulations handling protocol.
This filtered powder contains uncured paint material which is removed before crosslinking/oven process. Typical automotive system required, minimum 140 °C /20 min of baking to form cured paint film which give the required performance. The paint sludge will be in the powder form produced by this process.
The automotive paint sludge typically contains uncured polymer resins such as thermosetting acrylic, polyester polyol, polyether polyol, poly hydroxy polyol, blocked isocyante, alkyds, amino resins, pigments, curing agents, surfactants, catalysts and crosslinked agents. In addition, paint sludge typically contains water and/or a variety of organic solvents.
In an embodiment of the present disclosure, the PVC foam layer (C) comprises the plasticizer selected from a synthetic plasticizer and a bio plasticizer.
In an embodiment of the present disclosure, the synthetic plasticizer is selected from the group consisting of phthalates, poladipates, sebacates, trimellitates and polymeric adipate, wherein the phthalates are selected from diisononyl phthalate (DINP) and diisodecyl phthalate (DIDP). The sebacates is dioctyl sebacate (DOS). The trimellitate is tri-2-ethylhexyl trimellitate (TOTM). In an exemplary embodiment of the preseNt disclosure, the plasticizer used is polymeric adipate.
In an embodiment of the present disclosure, the bio plasticizer is selected from the group consisting of soya bean oil, lactic acid derived, and diacetyl epoxidized vegetable-oleic acid glyceride.
In an embodiment of the present disclosure, the PVC foam layer (C) comprises the heat stabilizer selected from the group consisting of zinc/calcium (Zn/Ca) stearate, barium/zinc (Ba/Zn) stearate and organic based stabilizer. In an exemplary embodiment of the present disclosure, the heat stabilizer is barium/zinc (Ba/Zn) stearate.
In an embodiment of the present disclosure, the organic based stabilizer is selected from the group consisting of OBS 200 and OBS 300.
In an embodiment of the present disclosure, the PVC foam layer (C) comprises at least one pigment selected from the group consisting of titanium dioxide, silica and aluminium oxides, and ferro pigment.
In an embodiment of the present disclosure, the PVC foam layer (C) comprises a UV stabilizer selected from the group consisting of benzophenone, benzotriazole, bis-benzoxazole, cyanoacrylate, oxanilide, carbon black, titanium dioxide; monomeric sterically hindered amine, oligomeric sterically hindered amine and sterically hindered amine ester. In an exemplary embodiment of the present disclosure, the UV stabilizer is benzotriazole.
In an embodiment of the present disclosure, the PVC foam layer (C) comprises the antioxidant selected from the group consisting of octadecyl-3-(3,5-di-tert. butyl-4-hydroxyphenyl)-propionate and bisphenol A. In an exemplary embodiment of the present disclosure, the antioxidant is phenolic antioxidant.
In an embodiment of the present disclosure, the PVC foam layer (C) comprises a foaming agent selected from the group consisting of azodicarbonamide, sodium bicarbonate, benzenesulfonyl hydroxide and toluenesulfonyl hydrazine. In an exemplary embodiment of the present disclosure, the foaming agent is azodicarbonamide.
In an embodiment of the present disclosure, the polyvinyl chloride (PVC) adhesive layer (D) comprises at least one plasticizer in an amount in the range of 30 mass% to 40 mass% with respect to the total amount of the PVC adhesive layer (D), PVC in an amount in the range of 40 mass% to 70 mass% with respect to the total amount of the PVC adhesive layer (D), paint sludge in an amount in the range of 2 mass% to 15 mass% with respect to the total amount of the PVC adhesive layer (D), at least one heat stabilizer in an amount in the range of 0.1 mass% to 2 mass % with respect to the total amount of the PVC adhesive layer (D), and at least one pigment in an amount in the range of 0.1 mass% to 2 mass% with respect to the total amount of the PVC adhesive layer (D).
In an exemplary embodiment of the present disclosure, the PVC adhesive layer (D) comprises the plasticizer in an amount of 38.65 mass% with respect to the total amount of the PVC adhesive layer (D), PVC in an amount of 51.54 mass% with respect to the total amount of the PVC adhesive layer (D), the paint sludge in an amount of 7.73 mass% with respect to the total amount of the PVC adhesive layer (D), the at least one heat stabilizer in an amount of 1.03 mass% with respect to the total amount of the PVC adhesive layer (D), and the at least one pigment in an amount of 1.03 mass% with respect to the total amount of the PVC adhesive layer (D).
In an embodiment of the present disclosure, the PVC adhesive layer (D) comprises the plasticizer selected from a synthetic plasticizer and a bio plasticizer.
In an embodiment of the present disclosure, the synthetic plasticizer is selected from the group consisting of phthalates, poladipates, sebacates, trimellitates and polymeric adipate, wherein the phthalates are selected from diisononyl phthalate (DINP) and diisodecyl phthalate (DIDP). The sebacates is dioctyl sebacate (DOS). The trimellitate is tri-2-ethylhexyl trimellitate (TOTM). In an exemplary embodiment of the present disclosure, the plasticizer used is polymeric adipate.
In an embodiment of the present disclosure, the bio plasticizer is selected from the group consisting of soya bean oil, lactic acid derived, and diacetyl epoxidized vegetable-oleic acid glyceride.
In an embodiment of the present disclosure, the PVC adhesive layer (D) comprises a heat stabilizer selected from the group consisting of zinc/calcium (Zn/Ca) stearate, barium/zinc (Ba/Zn) stearate and organic based stabilizer. In an exemplary embodiment of the present disclosure, the heat stabilizer is barium/zinc (Ba/Zn) stearate.
In an embodiment of the present disclosure, the organic based stabilizer is selected from the group consisting of OBS 200 and OBS 300.
In an embodiment of the present disclosure, the PVC adhesive layer (D) comprises at least one pigment selected from the group consisting of titanium dioxide, silica oxide and aluminium oxide, and ferro pigment.
In an embodiment of the present disclosure, the pre-skin layer (A) comprises the pre-skin resin in an amount in the range of 20 mass% to 50 mass% with respect to the total amount of said pre-skin layer (A), water in an amount in the range of 15 mass% to 35 mass% with respect to the total amount of said pre-skin layer (A), at least one leveling agent in an amount in the range of 4 mass% to 12 mass% with respect to the total amount of said pre-skin layer (A), at least one defoaming agent in an amount in the range of 2 mass% to 8 mass% with respect to the total amount of the pre-skin layer (A), at least one matting agent in an amount in the range of 5 mass% to 15 mass% with respect to the total amount of the pre-skin layer (A), and at least one feel agent in an amount in the range of 2 mass% to 10 mass% with respect to the total amount of the pre-skin layer (A).
In an exemplary embodiment of the present disclosure, the pre-skin layer (A) comprises pre-skin resin in an amount of 38.38 mass% with respect to the total amount of said pre-skin layer (A), water in an amount in the range of 15 mass% to 35 mass% with respect to the total amount of said pre-skin layer (A), the at least one leveling agent in an amount of 8.63 mass% with respect to the total amount of said pre-skin layer (A), the at least one defoaming agent in an amount 5.75 mass% with respect to the total amount of the pre-skin layer (A), the at least one matting agent in an amount 11.51 mass% with respect to the total amount of said pre-skin layer (A), and the at least one feel agent in an amount of 6.90 mass% with respect to the total amount of the pre-skin layer (A).
In an embodiment of the present disclosure, the pre-skin layer (A) comprises a pre-skin resin selected from polyurethane resin and acrylic resin. In an exemplary embodiment of the present disclosure, the pre-skin resin is polyurethane resin.
In an embodiment of the present disclosure, the pre-skin layer (A) comprises a leveling agent selected from the group consisting of silicone-based, polyacrylate based and fluorocarbon based leveling agents. In an exemplary embodiment of the present disclosure, the leveling agent is fluorocarbon. In another exemplary embodiment of the present disclosure, the leveling agent is silicone-based.
In an embodiment of the present disclosure, the pre-skin layer (A) comprises a defoaming agent selected from the group consisting of polyether-modified polysiloxanes, silicones, alcohols, stearates and glycols. In an exemplary embodiment of the present disclosure, the defoaming agent is polyether-modified polysiloxanes.
In an embodiment of the present disclosure, the pre-skin layer (A) comprises a matting agent selected from the group consisting of raw rubber, wax, inorganic matting agents, silicate-based, silicic acid gel based, polyester based salts, talc, mica, calcium carbonate, aluminum silicate, non-crystalline synthetic silica and amorphous silicon dioxide. In an exemplary embodiment of the present disclosure, the matting agent is amorphous silicon dioxide.
In an embodiment of the present disclosure, the pre-skin layer (A) comprises a feel agent selected from the group consisting of silicone, wax, polymer based and surfactant. In an exemplary embodiment of the present disclosure, the feel agent is silicone based feel agent.
The so obtained leatherette of the present disclosure has superior physical/mechanical/chemical properties when compared with the commercial/conventional leatherettes. These superior properties are attributed due to the use of paint sludge in the PVC foam layer and in the PVC adhesive layer of the leatherette of the present disclousure. Bally flex resistance test determines the durability of the leatherette which is an important property of the leatherette. The bally flex resistance of the leatherette of the present disclosure is found to be surprisingly higher as compared to the commercial/conventional leatherette thereby making the leatherette durable and flexible.
In another aspect of the present disclosure there is provided a process for the preparation of a leatherette. The process comprises the steps of:
a) obtaining a release paper;
b) coating a predetermined amount of a polyvinyl chloride (PVC) composition on the release paper, followed by heating at a first predetermined temperature for a first predetermined time period and cooling at a second predetermined temperature for a second predetermined time period to obtain a PVC skin layer (B) comprising an operative top surface and an operative bottom surface;
c) coating a predetermined amount of a foam composition on the PVC skin layer (B), followed by heating at a third predetermined temperature for a third predetermined time period and cooling at a fourth predetermined temperature for a fourth predetermined time period to obtain a foam layer (C) coated on the operative top surface of the PVC skin layer (B);
d) coating a predetermined amount of an adhesive composition on the foam layer (C) to obtain an adhesive layer (D) coated on the foam layer (C);
e) laminating a fabric layer (E) of a predetermined thickness on the adhesive layer (D), followed by heating at a fifth predetermined temperature for a fifth predetermined time period and cooling at a sixth predetermined temperature for a sixth predetermined time period to obtain an adhesive bonded fabric layer (E) on the foam layer (C);
f) removing the release paper from the PVC skin layer (B) obtained in the step (b) to obtain the operative bottom surface of the PVC skin layer (B);
g) optionally, coating a predetermined amount of an aqueous pre-skin composition on the operative bottom surface of the PVC skin layer (B), followed by heating at a seventh predetermined temperature for a seventh predetermined time period and cooling to an eight predetermined temperature for an eight predetermined time period period to form a pre-skin layer (A) on the operative bottom surface of the PVC skin layer (B) to obtain the leatherette; and
wherein the coating is done by using a knife coating process.
The process is described in detail.
In a first step of preparing the leatherette, a release paper (1) is obtained.
In an embodiment of the present disclosure, release paper is selected from the group consisting of silicone coated paper, polymethylpentene coated paper, clay coated papers and polyolefin coated paper. In an exemplary embodiment of the present disclosure, release paper is silicone coated paper.
In a second step of preparing the leatherette, a predetermined amount of a polyvinyl chloride (PVC) composition is coated on the release paper, followed by heating at a first predetermined temperature for a first predetermined time period and cooling at a second predetermined temperature for a second predetermined time period to obtain a PVC skin layer (B) comprising an operative top surface and an operative bottom surface.
In an embodiment of the present disclosure, the predetermined amount of the polyvinyl chloride (PVC) composition coated on the release layer is in the range of 100 to 250 gsm. In an exemplary embodiment of the present disclosure, the predetermined amount of the polyvinyl chloride (PVC) composition coated on the release layer is 150 gsm.
In an embodiment of the present disclosure, the first predetermined temperature is in the range of 140 ºC to 180 ºC. In an exemplary embodiment of the present disclosure, the first predetermined temperature is 160 ºC.
In an embodiment of the present disclosure, the second predetermined temperature is in the range of 5 ºC to 30 ºC. In an exemplary embodiment of the present disclosure, the second predetermined temperature is 10 ºC.
In an embodiment of the present disclosure, the first predetermined time period is in the range of 10 to 60 seconds. In an exemplary embodiment of the present disclosure, the first predetermined time period is 45 seconds.
In an embodiment of the present disclosure, the second predetermined time period is in the range of 10 to 60 seconds. In an exemplary embodiment of the present disclosure, the second predetermined time period is 45 seconds.
In an embodiment of the present disclosure, the polyvinyl chloride (PVC) composition is obtained by charging a predetermined amount of at least one plasticizer into a high speed mixer followed by adding a predetermined amount of PVC powder under stirring to obtain a first mixture. Predetermined amounts of at least one heat stabilizer, at least one pigment, at least one UV stabilizer, at least one antioxidant, and at least one defoaming agent is added into the first mixture to obtain the polyvinyl chloride (PVC) composition.
In an embodiment of the present disclosure, the stirring is performed in the range of 800 rpm to 1200 rpm. In an exemplary embodiment of the present disclosure, the stirring is performed at 1000 rpm.
In an embodiment of the present disclosure, the plasticizer used in the polyvinyl chloride (PVC) composition is selected from a synthetic plasticizer and a bio plasticizer.
In an embodiment of the present disclosure, the synthetic plasticizer is selected from the group consisting of phthalates, poladipates, sebacates, trimellitates and polymeric adipate, wherein the phthalates are selected from diisononyl phthalate (DINP) and diisodecyl phthalate (DIDP). The sebacates is dioctyl sebacate (DOS). The trimellitate is tri-2-ethylhexyl trimellitate (TOTM). In an exemplary embodiment of the preset disclosure, the plasticizer used is polymeric adipate.
In an embodiment of the present disclosure, the bio plasticizer is selected from the group consisting of soya bean oil, lactic acid derived, and diacetyl epoxidized vegetable-oleic acid glyceride.
In an embodiment of the present disclosure, the predetermined amount of the plasticizer used in the polyvinyl chloride (PVC) composition is in the range of 20 to 50 mass% with respect to the total mass of the polyvinyl chloride (PVC) composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the plasticizer used in the polyvinyl chloride (PVC) composition is 37.5 mass % with respect to the total mass of the polyvinyl chloride (PVC) composition.
In an embodiment of the present disclosure, the heat stabilizer used in the polyvinyl chloride (PVC) composition is selected from the group consisting of zinc/calcium (Zn/Ca) stearate, barium/zinc (Ba/Zn) stearate and organic based stabilizer. In an exemplary embodiment of the present disclosure, the heat stabilizer used in the polyvinyl chloride (PVC) composition is barium/zinc (Ba/Zn) stearate.
In an embodiment of the present disclosure, the organic based stabilizer is selected from the group consisting of OBS 200, and OBS 300.
In an embodiment of the present disclosure, the predetermined amount of the heat stabilizer used in the polyvinyl chloride (PVC) composition is in the range of 0.1 to 5 mass % with respect to the total mass of the polyvinyl chloride (PVC) composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the heat stabilizer used in the polyvinyl chloride (PVC) composition is 1 mass % with respect to the total mass of the polyvinyl chloride (PVC) composition.
In an embodiment of the present disclosure, the pigment used in the polyvinyl chloride (PVC) composition is at least one pigment selected from the group consisting of titanium dioxide, silica oxide and aluminium oxide, and ferro pigment.
In an embodiment of the present disclosure, the predetermined amount of the pigment used in the polyvinyl chloride (PVC) composition is in the range of 1 to 15 mass% with respect to the total mass of the polyvinyl chloride (PVC) composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the pigment used in the polyvinyl chloride (PVC) composition is 6 mass% with respect to the total mass of the polyvinyl chloride (PVC) composition.
In an embodiment of the present disclosure, the UV stabilizer used in the polyvinyl chloride (PVC) composition is selected from the group consisting of benzophenone, benzotriazole, bis-benzoxazole, cyanoacrylate, oxanilide, carbon black, titanium dioxide; monomeric sterically hindered amine, oligomeric sterically hindered amine and sterically hindered amine ester. In an exemplary embodiment of the present disclosure, the UV stabilizer used in the polyvinyl chloride (PVC) composition is benzotriazole.
In an embodiment of the present disclosure, the predetermined amount of the UV stabilizer used in the polyvinyl chloride (PVC) composition is in the range of 0.1 mass% to 5 mass% with respect to the total mass of the polyvinyl chloride (PVC) composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the UV stabilizer used in the polyvinyl chloride (PVC) composition is 0.75 mass% with respect to the total mass of the polyvinyl chloride (PVC) composition.
In an embodiment of the present disclosure, the antioxidant used in the polyvinyl chloride (PVC) composition is selected from the group consisting of octadecyl-3-(3,5-di-tert.butyl-4-hydroxyphenyl)-propionate and bisphenol A. In an exemplary embodiment of the present disclosure, the antioxidant used in the polyvinyl chloride (PVC) composition is phenolic antioxidant.
In an embodiment of the present disclosure, the predetermined amount of the antioxidant used in the polyvinyl chloride (PVC) composition is in the range of 0.01 to 5 mass % with respect to the total mass of the polyvinyl chloride (PVC) composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the antioxidant used in the polyvinyl chloride (PVC) composition is 0.3 mass % with respect to the total mass of the polyvinyl chloride (PVC) composition.
In an embodiment of the present disclosure, the defoaming agent used in the polyvinyl chloride (PVC) composition is selected from the group consisting of polydimethylsiloxanes, silicones, alcohols, stearates and glycols. In an exemplary embodiment of the present disclosure, the defoaming agent used in the polyvinyl chloride (PVC) composition is silicone based defoamers.
In an embodiment of the present disclosure, the predetermined amount of the defoaming agent used in the polyvinyl chloride (PVC) composition is in the range of 0.1 mass% to 2 mass% with respect to the total mass of the polyvinyl chloride (PVC) composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the defoaming agent used in the polyvinyl chloride (PVC) composition is 0.25 mass% with respect to the total mass of the polyvinyl chloride (PVC) composition.
In the third step of preparing the leatherette, a predetermined amount of a foam composition is coated on the operative top surface of the PVC skin layer (B), followed by heating at a third predetermined temperature for a third predetermined time period and cooling at a fourth predetermined temperature for a fourth predetermined time period to obtain a foam layer (C) coated on the operative top surface of the PVC skin layer (B).
In an embodiment of the present disclosure, the predetermined amount of the foam composition coated on the operative top surface of the PVC skin layer (B) is in the range of 250 gsm to 450 gsm. In an exemplary embodiment of the present disclosure, the predetermined amount of the foam composition coated on the operative top surface of the PVC skin layer (B) is 300 gsm.
In an embodiment of the present disclosure, the third predetermined temperature is in the range of 140 ºC to 200 ºC. In an exemplary embodiment of the present disclosure, the third predetermined temperature is 185 ºC.
In an embodiment of the present disclosure, the fourth predetermined temperature is in the range of 5 ºC to 30 ºC. In an exemplary embodiment of the present disclosure, the fourth predetermined temperature is 10 ºC.
In an embodiment of the present disclosure, the third predetermined time period is in the range of 10 seconds to 90 seconds. In an exemplary embodiment of the present disclosure, the third predetermined time period is 45 seconds.
In an embodiment of the present disclosure, the fourth predetermined time period is in the range of 10 seconds to 90 seconds. In an exemplary embodiment of the present disclosure, the fourth predetermined time period is 45 seconds.
In an embodiment of the present disclosure, the foam composition is obtained by charging a predetermined amount of at least one plasticizer in a high speed mixer followed by adding a predetermined amount of PVC powder under stirring to obtain a second mixture. A predetermined amount of a paint sludge is added to the second mixture under stirring to obtain a third mixture. Predetermined amounts of at least one heat stabilizer, at least one pigment, at least one UV stabilizer, at least one antioxidant, and at least one foaming agent is added in the third mixture to obtain the foam composition.
In an embodiment of the present disclosure, the stirring speed is in the range of 800 rpm to 1200 rpm. In an exemplary embodiment, the stirring speed is 1000 rpm.
In an embodiment of the present disclosure, the plasticizer used in the foam composition is selected from a synthetic plasticizer and a bio plasticizer.
In an embodiment of the present disclosure, the synthetic plasticizer is selected from the group consisting of phthalates, poladipates, sebacates, trimellitates and polymeric adipate, wherein the phthalates are selected from diisononyl phthalate (DINP) and diisodecyl phthalate (DIDP). The sebacates is dioctyl sebacate (DOS). The trimellitate is tri-2-ethylhexyl trimellitate (TOTM). In an exemplary embodiment of the preset disclosure, the plasticizer used is polymeric adipate.
In an embodiment of the present disclosure, the bio plasticizer is selected from the group consisting of soya bean oil, lactic acid derived, and diacetyl epoxidized vegetable-oleic acid glyceride.
In an embodiment of the present disclosure, the predetermined amount of the plasticizer used in the foam composition is in the range of 15 mass% to 50 mass% with respect to the total mass of the foam composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the plasticizer used in the foam composition is 24.49 mass% with respect to the total mass of the foam composition.
In an embodiment of the present disclosure, the heat stabilizer used in the foam composition is selected from the group consisting of zinc/calcium (Zn/Ca) stearate, barium/zinc (Ba/Zn) stearate and organic based stabilizer. In an exemplary embodiment of the present disclosure, the heat stabilizer used in the foam composition is barium/zinc (Ba/Zn) stearate.
In an embodiment of the present disclosure, the organic based stabilizer is selected from the group consisting of OBS 200 and OBS 300.
In an embodiment of the present disclosure, the predetermined amount of the heat stabilizer used in the foam composition is in the range of 0.1 mass% to 5 mass% with respect to the total mass of the foam composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the heat stabilizer used in the foam composition is 0.97 mass% with respect to the total mass of the foam composition.
In an embodiment of the present disclosure, the pigment used in the foam composition is at least one pigment selected from the group consisting of titanium dioxide, silica oxide and aluminium oxide, and ferro pigment.
In an embodiment of the present disclosure, the predetermined amount of the pigment used in the foam composition is in the range of 1 mass% to 10 mass% with respect to the total mass of the foam composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the pigment used in the foam composition is 3.9 mass% with respect to the total mass of the foam composition.
In an embodiment of the present disclosure, the UV stabilizer used in the foam composition is selected from the group consisting of benzophenone, benzotriazole, bis-benzoxazole, cyanoacrylate, oxanilide, carbon black, titanium dioxide; monomeric sterically hindered amine, oligomeric sterically hindered amine and sterically hindered amine ester. In an exemplary embodiment of the present disclosure, the UV stabilizer used in the foam composition is benzotriazole.
In an embodiment of the present disclosure, the predetermined amount of the UV stabilizer used in the foam composition is in the range of 0.5 mass% to 5 mass% with respect to the total mass of the foam composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the UV stabilizer used in the foam composition is 0.73 mass% with respect to the total mass of the foam composition.
In an embodiment of the present disclosure, the antioxidant used in the foam composition is selected from the group consisting of octadecyl-3-(3,5-di-tert.butyl-4-hydroxyphenyl)-propionate and bisphenol A. In an exemplary embodiment of the present disclosure, the antioxidant used in the foam composition is phenolic antioxidant.
In an embodiment of the present disclosure, the predetermined amount of the antioxidant used in the foam composition is in the range of 0.1 mass% to 2 mass% with respect to the total mass of the foam composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the antioxidant used in the foam composition is 0.29 mass% with respect to the total mass of the foam composition.
In an embodiment of the present disclosure, the foaming agent used in the foam composition is selected from the group consisting of azodicarbonamide, sodium bicarbonate, benzenesulfonyl hydroxide and toluenesulfonyl hydrazine. In an exemplary embodiment of the present disclosure the foaming agent used in the foam composition is azodicarbonamide.
In an embodiment of the present disclosure, the predetermined amount of the foaming agent used in the foam composition is in the range of 0.1 mass% to 2 mass% with respect to the total mass of the foam composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the foaming agent used in the foam composition is 0.97 mass% with respect to the total mass of the foam composition.
In the fourth step of preparing the leatherette, a predetermined amount of an adhesive composition is coated on the foam layer (C) to obtain an adhesive layer (D) coated on the foam layer.
In an embodiment of the present disclosure, the predetermined amount of the adhesive composition coated on the foam layer (C) is in the range of 50 gsm to 150 gsm. In an exemplary embodiment of the present disclosure, the predetermined amount of the adhesive composition coated on the foam layer (C) is 100 gsm.
In an embodiment of the present disclosure, the adhesive composition is obtained by charging a predetermined amount of at least one plasticizer in a high speed mixer followed by adding a predetermined amount of PVC powder under stirring to obtain a fourth mixture. A predetermined amount of paint sludge is added to the fourth mixture under stirring to obtain a fifth mixture. A predetermined amount of at least one heat stabilizer, and at least one pigment is added into the fifth mixture to obtain the adhesive composition.
In an embodiment of the present disclosure, the stirring speed is in the range of 800 rpm to1200 rpm. In an exemplary embodiment the stirring speed is 1000 rpm.
In an embodiment of the present disclosure, the plasticizer used in the adhesive composition is selected from a synthetic plasticizer and a bio plasticizer.
In an embodiment of the present disclosure, the synthetic plasticizer is selected from the group consisting of phthalates, poladipates, sebacates, trimellitates and polymeric adipate, wherein the phthalates are selected from diisononyl phthalate (DINP) and diisodecyl phthalate (DIDP). The sebacates is dioctyl sebacate (DOS). The trimellitate is tri-2-ethylhexyl trimellitate (TOTM). In an exemplary embodiment of the preset disclosure, the plasticizer used is polymeric adipate.
In an embodiment of the present disclosure, the bio plasticizer is selected from the group consisting of soya bean oil, lactic acid derived, and diacetyl epoxidized vegetable-oleic acid glyceride.
In an embodiment of the present disclosure, the predetermined amount of the plasticizer used in the adhesive composition is in the range of 30 mass% to 40 mass% with respect to the total mass of the adhesive composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the plasticizer used in the adhesive composition is 38.65 mass% with respect to the total mass of the adhesive composition.
In an embodiment of the present disclosure, the heat stabilizer used in the adhesive composition is selected from the group consisting of zinc/calcium (Zn/Ca) stearate, barium/zinc (Ba/Zn) stearate and organic based stabilizer. In an exemplary embodiment of the present disclosure the heat stabilizer used in the adhesive composition is barium/zinc (Ba/Zn) stearate.
In an embodiment of the present disclosure, the organic based stabilizer is selected from the group consisting of OBS 200 and OBS 300.
In an embodiment of the present disclosure, the predetermined amount of the heat stabilizer used in the adhesive composition is in the range of 0.1 mass% to 2 mass% with respect to the total mass of the adhesive composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the heat stabilizer used in the adhesive composition is 1.03 mass% with respect to the total mass of the adhesive composition.
In an embodiment of the present disclosure, the pigment used in the adhesive composition is at least one pigment selected from the group consisting of titanium dioxide, silica oxide and aluminium oxide, and ferro pigment.
In an embodiment of the present disclosure, the predetermined amount of the pigment used in the adhesive composition is in the range of 0.1 mass% to 2 mass% with respect to the total mass of the adhesive composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the pigment used in the adhesive composition is 1.03 mass% with respect to the total mass of the adhesive composition.
In the fifth step of preparing the leatherette, a fabric layer (E) of predetermined thickness is laminated on the adhesive layer (D), followed by heating at a fifth predetermined temperature for a fifth predetermined time period and cooling at a sixth predetermined temperature for a sixth predetermined time period to obtain an adhesive bonded fabric layer (E).
In an embodiment of the present disclosure, the fifth predetermined temperature is in the range of 140 ºC to 200 ºC. In an exemplary embodiment of the present disclosure, the fourth predetermined temperature is 180 ºC.
In an embodiment of the present disclosure, the sixth predetermined temperature is in the range of 5 ºC to 30 ºC. In an exemplary embodiment of the present disclosure, the sixth predetermined temperature is 10 ºC.
In an embodiment of the present disclosure, the fifth predetermined time period is in the range of 10 seconds to 90 seconds. In an exemplary embodiment of the present disclosure, the fifth predetermined time period is 45 seconds.
In an embodiment of the present disclosure, the sixth predetermined time period is in the range of 10 seconds to 90 seconds. In an exemplary embodiment of the present disclosure, the sixth predetermined time period is 45 seconds.
In an embodiment of the present disclosure, the fabric layer is selected from the group consisting of synthetic, biopolyester, nylon, cotton, wool, linen and bamboo and carbon fiber. In an exemplary embodiment of the present disclosure, the fabric layer is polyester layer.
In the sixth step of preparing the leatherette, the release paper is removed from the PVC skin layer (B) to obtain an operative bottom surface of the PVC skin layer (B).
In the last step of preparing the leatherette, a predetermined amount of an aqueous pre-skin composition is coated on the operative bottom surface of the PVC skin layer (B) followed by heating at a seventh predetermined temperature for a seventh predetermined time period and cooling to an eight predetermined temperature for eighth predetermined time period to form a pre-skin layer (A) on the operative bottom surface of the PVC skin layer (B) and to obtain the leatherette.
In an embodiment of the present disclosure, the predetermined amount of an aqueous pre-skin composition coated on the operative bottom surface of the PVC skin layer is in the range of 10 gsm to 20 gsm. In an exemplary embodiment of the present disclosure, the predetermined amount of an aqueous pre-skin composition coated on the operative bottom surface of the PVC skin layer is 15 gsm.
In an embodiment of the present disclosure, the seventh predetermined temperature is in the range of 100 ºC to 180 ºC. In an exemplary embodiment of the present disclosure, the seventh predetermined temperature is 140 ºC.
In an embodiment of the present disclosure, the eight predetermined temperature is in the range of 5 ºC to 30 ºC. In an exemplary embodiment of the present disclosure, the eight predetermined temperature is 10 ºC.
In an embodiment of the present disclosure, the seventh predetermined time period is in the range of 10 seconds to 90 seconds. In an exemplary embodiment of the present disclosure, the seventh predetermined time period is 60 seconds.
In an embodiment of the present disclosure, the eight predetermined time period is in the range of 10 seconds to 50 seconds. In an exemplary embodiment of the present disclosure, the eight predetermined time period is 30 seconds.
In an embodiment of the present disclosure, the aqueous pre-skin composition is obtained by mixing predetermined amounts of pre-skin resin, distilled water, at least one leveling agent, at least one defoaming agent, at least one matting agent, and at least one feel agent under stirring at a speed in the range of 100 rpm to 200 rpm for a time period in the range of 5 minutes to 30 minutes.
In an exemplary embodiment of the present disclosure, the stirring speed is 120 rpm.
In an embodiment of the present disclosure, the pre-skin resin is selected from polyurethane resin and acrylic resin. In an exemplary embodiment of the present disclosure, the pre-skin resin is polyurethane.
In an embodiment of the present disclosure, the leveling agent used in the aqueous polyurethane (PU) composition is selected from the group consisting of silicone-based, polyacrylate based and fluorocarbon based leveling agents. In an exemplary embodiment of the present disclosure the leveling agent used in the aqueous polyurethane (PU) composition is fluorocarbon based leveling agent.
In an embodiment of the present disclosure, the predetermined amount of the pre-skin resin used in the pre-skin composition is in the range of 20 mass% to 50 mass%. In an exemplary embodiment of the present disclosure, the predetermined amount of the pre-skin resin used in the pre-skin composition is 38.38 mass%.
In an embodiment of the present disclosure, the predetermined amount of the leveling agent used in the aqueous pre-skin composition is in the range of 4 mass% to 12 mass% with respect to the total amount of the aqueous pre-skin composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the leveling agent used in the aqueous pre-skin composition is 8.63 mass% with respect to the total amount of the aqueous pre-skin composition.
In an embodiment of the present disclosure, the defoaming agent used in the aqueous pre-skin composition is selected from the group consisting of polyether-modified polysiloxanes, silicones, alcohols, stearates and glycols. In an exemplary embodiment of the present disclosure the defoaming agent used in the aqueous polyurethane (PU) composition is polyether-modified foam-destroying polysiloxanes.
In an embodiment of the present disclosure, the predetermined amount of the defoaming agent used in the aqueous pre-skin composition is in the range of 2 mass% to 8 mass% with respect to the total amount of the aqueous pre-skin composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the defoaming agent used in the aqueous pre-skin composition is 5.7 mass% with respect to the total amount of the aqueous pre-skin composition.
In an embodiment of the present disclosure, the pre-skin layer (A) comprises a matting agent selected from the group consisting of raw rubber, wax, inorganic matting agents, silicate-based, silicic acid gel based, polyester based salts, talc, mica, calcium carbonate, aluminum silicate, non-crystalline synthetic silica and amorphous silicon dioxide. In an exemplary embodiment of the present disclosure, the matting agent is amorphous silicon dioxide.
In an embodiment of the present disclosure, the predetermined amount of the matting agent used in the aqueous pre-skin composition is in the range of 5 mass% to 10 mass% with respect to the total amount of the aqueous pre-skin composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the matting agent used in the aqueous pre-skin composition is 11.51 mass% with respect to the total amount of the aqueous pre-skin composition.
In an embodiment of the present disclosure, the feel agent used in the aqueous pre-skin composition is selected from the group consisting of silicone, wax, polymer based and surfactant. In an exemplary embodiment of the present disclosure the feel agent used in the aqueous pre-skin composition is silicone based.
In an embodiment of the present disclosure, the predetermined amount of the feel agent used in the aqueous pre-skin composition is in the range of 2 mass% to 10 mass% with respect to the total amount of the pre-skin composition. In an exemplary embodiment of the present disclosure, the predetermined amount of the feel agent used in the aqueous pre-skin composition is 6.9 mass% with respect to the total amount of the aqueous pre-skin composition.
The coating in the present disclosure is done by knife coating process.
In an embodiment of the present disclosure, the release paper is selected from the group consisting of silicone coated paper, polymethylpentene coated paper, clay coated papers and poly-olefin coated paper. In an exemplary embodiment of the present disclosure, the release paper is silicone coated paper.
In an embodiment of the present disclosure, the PVC resin is selected from synthetic PVC resin and a PVC resin derived from bio source.
In an embodiment of the present disclosure, the thickness of the polyvinyl chloride (PVC) skin layer (B)is in the range of 0.05 mm to 0.6 mm. In an exemplary embodiment of the present disclosure, the thickness of the polyvinyl chloride (PVC) skin layer (B) is 0.15 mm.
In an embodiment of the present disclosure, the thickness of the foam layer (C) is in the range of 0.1 mm to 0.6 mm. In an exemplary embodiment of the present disclosure, the thickness of the foam layer (C) is 0.3 mm
In an embodiment of the present disclosure, the thickness of the adhesive layer (D)is in the range of 0.05 mm to 0.20 mm. In an exemplary embodiment of the present disclosure, the thickness of the adhesive layer (D) is 0.1 mm.
In an embodiment of the present disclosure, the thickness of the pre-skin layer (A) is in the range of 0.001 mm to 0.1 mm. In an exemplary embodiment of the present disclosure, the thickness of the pre-skin layer (A) is 0.01 mm.
The present disclosure uses paint sludge waste into PVC compounding and makes a flexible leatherette finished material for seat and other automotive application. The present disclosure advantageously provides a sustainable up cycling product made out of the leatherette. By the present disclosure, the waste paint sludge can be used in knife coating process successfully, as well as the process for preparing the leatherette does not allow any other hazardous by products. By this process, the amount of paint sludge which goes for incineration will be reduced so as the impact on the environment is reduced which subsequently helps to reduce the carbon footprint.
The present disclosure uses the paint sludge produced by paint industry majorly by automotive OEM (Original equipment manufacturer) in the leatherette construction as one of the component along with poly vinyl chloride and additives to make a leatherette which could be used for many automotive applications such as seat cover, gear boot cover, door trim, arm rest, instrument panel skin, roof liner, luggage tray cover, spare wheel cover, convertible top and floor carpets.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.
EXPERIMENTAL DETAILS
Example 1: Process for preparing the leatherette in accordance with the present disclosure.
(a) Preparing the PVC composition to form a PVC skin layer (B) in the leatherette in accordance with the present disclosure.
37.5 kilogram of polymeric adipate (plasticizer) is charged in a high-speed mixer followed by slowly adding 50 kilogram of PVC powder under stirring at 1000 rpm for 30 minutes to obtain a first mixture. To the so obtained first mixture 1.0 kilogram gm of Ba/Zn stabilizer (heat stabilizer), 750 gm of benzotriazole (UV stabilizer), 6 .0 kilogram of titanium dioxide (pigment), 300 gram of phenolic antioxidant (antioxidant), and 250 gram of silicone defoamers (defoaming agent) is added under constant stirring for 30 minutes at room temperature to obtain a polyvinyl chloride (PVC) composition.
(b) Preparing the foam composition to form a PVC foam layer (C) in the leatherette in accordance with the present disclosure.
25 kilograms of polymeric adipate (plasticizer) is charged in a high-speed mixer followed by slowly adding 50 kilograms of PVC powder under stirring at 1000 rpm for 30 minutes to obtain a second mixture. To the so obtained second mixture 20 kilogram of paint sludge powder is added under constant stirring for 20 minutes/hours to obtain a third mixture. To the so obtained mixture 1.0 kilogram gm of Ba/Zn stabilizer (heat stabilizer), 750 gm of benzotriazole (UV stabilizer), 4.0 kilogram of titanium dioxide (pigment), 300 gram of phenolic antioxidant antioxidant), and 1.0 kilogram of azodicarbonamide (foaming agent) is added under constant for 30 minutes at room temperature to obtain a foam composition.
(c) Preparing the adhesive composition to form an adhesive layer (D) in the leatherette in accordance with the present disclosure.
37.5 kilogram of polymeric adipate (plasticizer) is charged in a high-speed mixer followed by slowly adding 50 kilogram of PVC powder under stirring at 1000 rpm for 25 minutes to obtain a fourth mixture. To the so obtained fourth mixture 7.5 kilogram of paint sludge powder is added at constant stirring for 20 minutes to obtain a fifth mixture. To the so obtained fifth mixture 1.0 kilogram of Ba/Zn stabilizer (heat stabilizer) and 1.0 kilogram of titanium dioxide (pigment) is added under constant stirring for 25 minutes at room temperature to obtain the adhesive composition.
(d) Preparing the aqueous polyurethane (PU) composition to form an aqueous pre-skin layer (A) in the leatherette in accordance with the present disclosure.
5 liter polyurethane (PU) resin, 3.75 liter of distilled water, 1.125 kilogram of fluorocarbon based leveling agent (leveling agent), 0.75 kilogram of polyether-modified polysiloxanes (defoaming agent), 1.5 kilogram of amorphous silicon dioxide (matting agent), and 0.9 kilogram of silicone based feel agent (feel agent) are mixed in a vessel using a stirrer at a speed 120 rpm for 15 minutes to obtain the aqueous polyurethane (PU) composition.
(e) Preparing the leatherette in accordance with the present disclosure
A silicon coated paper (release paper) is obtained and unwinded. On the unwinded release paper 150 gsm of a polyvinyl chloride (PVC) composition obtained in step (1a) is coated by using the knife coating process followed by heating at 160 °C for 45 seconds and cooling at 10° C for 45 seconds to obtain a PVC skin layer comprising an operative top surface and an operative bottom surface.
To the so obtained PVC skin layer, 350 gsm of a PVC foam composition obtained in step (1b) is coated by using the knife coating process followed by heating at 185 °C in an oven for 45 seconds minutes and cooling at 10 ° C for 45 seconds minutes to obtain a foam layer (C) coated on top operative surface of the PVC skin layer.
To the so obtained foam layer (C), 100 gsm of an adhesive composition obtained in step (1c) is coated by using the knife coating process, subsequently a polyester layer (fabric layer (A)) is laminated on the adhesive layer (D) by lamination process, followed by heating at 180 °C in an oven for 45 seconds and cooling at 10° C for 45 seconds to obtain an adhesive bonded fabric layer on the foam layer.
The release paper was removed from the operative bottom surface of the PVC skin layer (B) to obtain the operative bottom surface of the PVC skin layer (B). To the so obtained operative bottom surface of the PVC skin layer (B) an aqueous polyurethane (PU) composition (pre-skin composition) obtained in step (1D) was applied followed by heating at 140 °C in an oven for 60 seconds and cooling at 10° C for 30 seconds to obtain a polyurethane (PU) layer (pre-skin layer (B)) coated on the operative bottom surface of the PVC skin layer (B) to obtain the leatherette.
Figure 1 illustrates the process of preparing the leatherette by using the knife process. The knife coating process involves coating the PVC skin composition on a moving release paper by knife and passing through oven to fuse and soften and form a skin layer and then cooling the skin layer to make ready for the subsequent coating as required and finally laminating to the fabric to obtain the leatherette. A thickness of so obtained leatherette was 1.25 mm.
Example 2: Comparative example
The commercially available/conventional leatherette comprises:
A. top surface (customer touch) of water-based polyurethane (PU) lacquer (pre-skin layer A),
B. (aesthetic layer) of polyvinyl chloride (PVC) (PVC skin layer B),
C. polyvinyl chloride (PVC) foam layer-devoid of paint sludge (foam layer C),
D. polyvinyl chloride (PVC) adhesive layer-devoid of paint sludge (adhesive layer D),
E. fabric ( fabric layer E).
Example 3: Physical/Mechanical/Chemical properties of the leatherette prepared in accordance with the present disclosure and the commercial/conventional leatherette
The physical mechanical/chemical tests were performed to analyze the properties of the leatherette prepared in accordance with the present disclosure and the commercial/conventional leatherette.
The results are shown below in Table 1
Table 1: Physical/mechanical/chemical properties of the leatherette prepared in accordance with the present disclosure and the commercial/conventional leatherette.
Sr. no. Properties Direction Method of measurement Commercial/
conventional leatherette (Example 2)
Comparative Example Leatherette prepared of the present disclosure (Example 1)
1 Total Weight (GSM)

ASTM D751 1020 ± 50 820 to 840
2 Thickness (mm) 1.2 ± 0.1 1.25 to 1.33
3 Breaking Strength (N) Warp

ASTM D5034 650 minimum 677 to 683
Weft 450 minimum 478 to 480
4 Elongation at Break
(%) Warp 80 minimum 103 to 105
Weft 100 minimum 138 to 149
5 Tear strength
(N) Warp ASTM D5587 110 minimum 111 to 116
Weft 110 minimum 109 to 112
6 Coating Adhesion
(N/5cm) Warp
ISO
2411 30 minimum 28 to 29
Weft 30 minimum 30 to 31
7 Stretch (%) Warp
SAE
J855 10 to 30 30.92
Weft 30 to 60 47.63
8 Set (%) Warp 10 maximum 4.34
Weft 10 maximum 5.79
9 Bally Flex Resistance (Cycles) Warp ISO
5402-1 100000 cycles minimum 220000 cycles crack
Weft

From Table 1, it is evident that the leatherette of the present disclosure (Example 1) has superior physical/mechanical/chemical properties than the commercial/conventional leatherette (Example 2). The superior physical/mechanical/chemical properties are attributed due to the use of paint sludge in the PVC foam layer and in the PVC adhesive layer of the leatherette of the present disclousure. Further, though the leatherette of the present disclosure has lower GSM value as compared to the GSM of the conventional leatherette, the leatherette of the present disclosure resulted into higher Breaking Strength, higher Elongation at Break, and higher Tear strength (Trapezoid). This surprising result proved that the so obtainbed leatherette of the present disclosure is better as compared to the conventional leatherette. Still further, the coating adhesion and the stretch and the set of the leatherette of the present disclosure has also been improved. Moreover, it is surprisingly found that the leatherette of the present disclosure has increased Bally flex resistance (2.2 times) which determines the durability of the leatherette. From Table 1, it is depicted that the Bally flex resistance of the leatherette of the present disclosure (Example 1) is 220000 cycles that is improved durability in view of the commercial/conventional leatherette (Example 2) having the Bally flex resistance of 100000 cycles. Products with good Bally flex resistance are generally considered to be of higher quality and more durable than those with poor Bally flex resistance.
TECHNICAL ADVANCES AND ECONOMIC SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a leatherette, which
• is environment friendly;
• is economical;
• reduces environment pollution; and
• has comparatively high Bally flex resistance
and
a process for preparing the leatherette, which
• is simple;
• is eco-friendly;
• is economical and profitable;
• helps to reduce the carbon footprint; and
• does not produce any other hazardous by products.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM:
1. A leatherette comprising:
(a) a polyvinyl chloride (PVC) skin layer (B) having a predetermined thickness;
(b) a polyvinyl chloride (PVC) foam layer (C) having a predetermined thickness coated on an operative top surface of said PVC skin layer (B);
(c) a polyvinyl chloride (PVC) adhesive layer (D) having a predetermined thickness coated on said foam layer (C);
(d) a fabric layer (E) having a predetermined thickness laminated on said adhesive layer (D); and
(e) a pre-skin layer (A) having a predetermined thickness coated on an operative bottom surface of said PVC skin layer (B);
wherein a thickness of said leatherette is in the range of 0.5 mm to 1.5 mm.
2. The leatherette as claimed in claim 1, wherein said predetermined thickness of:
i) said polyvinyl chloride (PVC) skin layer (B) is in the range of 0.05 mm to 0.6 mm;
ii) said polyvinyl chloride (PVC) foam layer (C) is in the range of 0.1 mm to 0.6 mm;
iii) said polyvinyl chloride (PVC) adhesive layer (D) is in the range of 0.05 mm to 0.5 mm; and
iv) said pre-skin layer (A) is in the range of 0.001 mm to 0.1 mm.
3. The leatherette as claimed in claim 1, wherein said polyvinyl chloride (PVC) skin layer (B) comprises:
a) PVC in an amount in the range of 40 mass% to 60 mass% with respect to the total amount of said polyvinyl chloride (PVC) skin layer (B);
b) at least one plasticizer in an amount in the range of 20 mass% to 50 mass% with respect to the total amount of said polyvinyl chloride (PVC) skin layer (B);
c) at least one heat stabilizer in an amount in the range of 0.1 mass% to 5 mass % with respect to the total amount of said polyvinyl chloride (PVC) skin layer (B);
d) at least one pigment in an amount in the range of 1 to 15 mass % with respect to the total amount of said polyvinyl chloride (PVC) skin layer (B);
e) at least one UV stabilizer in an amount in the range of 0.1 mass% to 5 mass % with respect to the total amount of said polyvinyl chloride (PVC) skin layer (B);
f) at least one antioxidant in an amount in the range of 0.01 mass% to 5 mass % with respect to the total amount of said polyvinyl chloride (PVC) skin layer (B); and
g) at least one defoaming agent in an amount in the range of 0.1 mass% to 2 mass % with respect to the total amount of said polyvinyl chloride (PVC) skin layer (B).
4. The leatherette as claimed in claim 3, wherein
a) said plasticizer is selected from the group consisting of phthalates, poladipates, sebacates, trimellitates, polymeric adipate, soya bean oil, lactic acid derived, and diacetyl epoxidized vegetable-oleic acid glyceride;
wherein said phthalates are selected from diisononyl phthalate (DINP), and diisodecyl phthalate (DIDP);
wherein said sebacates is dioctyl sebacate (DOS); and
wherein said trimellitate is tri-2-ethylhexyl trimellitate (TOTM);
b) said heat stabilizer is selected from the group consisting of zinc/calcium (Zn/Ca) stearate, barium/zinc (Ba/Zn) stearate and organic based stabilizer;
wherein said organic based stabilizer is selected from OBS 200 and OBS 300;
c) said pigment is at least one selected from the group consisting of titanium dioxide, silica and aluminium oxides, and ferro pigment;
d) said UV stabilizer is selected from the group consisting of benzophenone, benzotriazole, bis-benzoxazole, cyanoacrylate, oxanilide, carbon black, titanium dioxide, monomeric sterically hindered amine, oligomeric sterically hindered amine and sterically hindered amine ester;
e) said antioxidant is selected from the group consisting of octadecyl-3-(3,5-di-tert.butyl-4-hydroxyphenyl)-propionate and bisphenol A; and
f) said defoaming agent is selected from the group consisting of polydimethylsiloxanes, silicones, alcohols, stearates and glycols.
5. The leatherette as claimed in claim 1, wherein said PVC foam layer (C) comprises:
(i) at least one plasticizer in an amount in the range of 15 mass% to 50 mass % with respect to the total amount of said PVC foam layer (C);
(ii) PVC in an amount in the range of 30 mass% to 80 mass% with respect to the total amount of said PVC foam layer (C);
(iii) a paint sludge in an amount in the range of 10 mass% to 40 mass% with respect to the total amount of said PVC foam layer (C);
(iv) at least one heat stabilizer in an amount in the range of 0.1 mass% to 5 mass% with respect to the total amount of said PVC foam layer (C);
(v) at least one pigment in an amount in the range of 1 mass% to 10 mass% with respect to the total amount of said PVC foam layer (C);
(vi) at least one UV stabilizer in an amount in the range of 0.1 mass% to 5 mass% with respect to the total amount of said PVC foam layer (C);
(vii) at least one antioxidant in an amount in the range of 0.1 mass% to 2 mass% with respect to the total amount of said PVC foam layer (C); and
(viii) at least one foaming agent in an amount in the range of 0.1 mass% to 2 mass% with respect to the total amount of said PVC foam layer (C).
6. The leatherette as claimed in claim 5, wherein
(i) said plasticizer is selected from the group consisting of phthalates, poladipates, sebacates, trimellitates, polymeric adipate, soya bean oil, lactic acid derived, and diacetyl epoxidized vegetable-oleic acid glyceride;
wherein said phthalates are selected from diisononyl phthalate (DINP) and diisodecyl phthalate (DIDP),
wherein said sebacates is dioctyl sebacate (DOS) and
wherein said trimellitate is tri-2-ethylhexyl trimellitate (TOTM);
g) said heat stabilizer is selected from the group consisting of zinc/calcium (Zn/Ca) stearate, barium/zinc (Ba/Zn) stearate and organic based stabilizer,
wherein said organic based stabilizer is selected from OBS 200 and OBS 300;
h) said pigment is at least one selected from the group consisting of titanium dioxide, silica and aluminium oxides, and ferro pigment;
(ii) said UV stabilizer is selected from the group consisting of benzophenone, benzotriazole, bis-benzoxazole, cyanoacrylate, oxanilide, carbon black, titanium dioxide, monomeric sterically hindered amine, oligomeric sterically hindered amine and sterically hindered amine ester;
(iii) said antioxidant is selected from the group consisting of octadecyl-3-(3,5-di-tert.butyl-4-hydroxyphenyl)-propionate and bisphenol A; and
(iv) said foaming agent is selected from the group consisting of azodicarbonamide, sodium bicarbonate, benzenesulfonyl hydroxide and toluenesulfonyl hydrazine.
7. The leatherette as claimed in claim 1, wherein said PVC adhesive layer (D) comprises:
i) at least one plasticizer in an amount in the range of 30 mass% to 40 mass% with respect to the total amount of said PVC adhesive layer (D);
ii) PVC in an amount in the range of 40 mass% to 70 mass% with respect to the total amount of said PVC adhesive layer (D);
iii) paint sludge in an amount in the range of 2 mass% to 15 mass% with respect to the total amount of said PVC adhesive layer (D);
iv) at least one heat stabilizer in an amount in the range of 0.1 mass% to 2 mass% with respect to the total amount of said PVC adhesive layer (D); and
v) at least one pigment in an amount in the range of 0.1 mass% to 2 mass% with respect to the total amount of said PVC adhesive layer (D).
8. The leatherette as claimed in claim 7, wherein
i) said plasticizer is selected from the group consisting of phthalates, poladipates, sebacates, trimellitates, polymeric adipate, soya bean oil, lactic acid derived, and diacetyl epoxidized vegetable-oleic acid glyceride;
wherein said phthalates are selected from diisononyl phthalate (DINP) and diisodecyl phthalate (DIDP),
wherein said sebacates is dioctyl sebacate (DOS), and
wherein said trimellitate is tri-2-ethylhexyl trimellitate (TOTM);
ii) said heat stabilizer is selected from the group consisting of zinc/calcium (Zn/Ca) stearate, barium/zinc (Ba/Zn) stearate and organic based stabilizer;
wherein said organic based stabilizer is selected from OBS 200 and OBS 300;
iii) said pigment is at least one selected from the group consisting of titanium dioxide, silica oxide and aluminium oxide, and ferro pigment.
9. The leatherette as claimed in claim 1, wherein said pre-skin layer (A) comprises:
(i) pre-skin resin in an amount in the range of 20 mass% to 50 mass% with respect to the total amount of said pre-skin layer (A);
(ii) water in an amount in the range of 15 mass% to 35 mass% with respect to the total amount of said pre-skin layer (A);
(iii) at least one leveling agent in an amount in the range of 4 mass% to 12 mass% with respect to the total amount of said pre-skin layer (A);
(iv) at least one defoaming agent in an amount in the range of 2 mass% to 8 mass% with respect to the total amount of said pre-skin layer (A);
(v) at least one matting agent in an amount in the range of 5 mass% to 15 mass% with respect to the total amount of said pre-skin layer (A); and
(vi) at least one feel agent in an amount in the range of 2 mass% to10 mass% with respect to the total amount of said pre-skin layer (A).
10. The leatherette as claimed in claim 9, wherein said
i) said pre-skin resin is selected from polyurethane resin and acrylic resin;
ii) said leveling agent is selected from the group consisting of silicone-based, polyacrylate based and fluorocarbon based leveling agents;
iii) said defoaming agent is selected from the group consisting of polyether-modified polysiloxanes, silicones, alcohols, stearates and glycols;
iv) said matting agent is selected from the group consisting of raw rubber, wax, inorganic matting agents, silicate-based, silicic acid gel based, polyester based salts, talc, mica, calcium carbonate, aluminum silicate, non-crystalline synthetic silica and amorphous silicon dioxide; and
v) said feel agent is selected from the group consisting of silicone, wax, and polymer based and surfactant.
11. A process for the preparation of a leatherette, said process comprising the following steps:
(a) obtaining a release paper;
(b) coating a predetermined amount of a polyvinyl chloride (PVC) composition on said release paper, followed by heating at a first predetermined temperature for a first predetermined time period and cooling at a second predetermined temperature for a second predetermined time period to obtain a PVC skin layer (B) comprising an operative top surface and an operative bottom surface;
(c) coating a predetermined amount of a foam composition on said PVC skin layer (B), followed by heating at a third predetermined temperature for a third predetermined time period and cooling at a fourth predetermined temperature for a fourth predetermined time period to obtain a foam layer (C) coated on said operative top surface of said PVC skin layer (B);
(d) coating a predetermined amount of an adhesive composition on said foam layer (C) to obtain an adhesive layer (D) coated on said foam layer (C);
(e) laminating a fabric layer (E) of a predetermined thickness on said adhesive layer (D), followed by heating at a fifth predetermined temperature for a fifth predetermined time period and cooling at a sixth predetermined temperature for a sixth predetermined time period to obtain an adhesive bonded fabric layer (E);
(f) removing said release paper from said PVC skin layer (B) obtained in said step (b) to obtain said operative bottom surface of said PVC skin layer (B);
(g) coating a predetermined amount of an aqueous pre-skin composition on said operative bottom surface of said PVC skin layer (B), followed by heating at a seventh predetermined temperature for a seventh predetermined time period and cooling to an eight predetermined temperature for an eight predetermined time period to form a pre-skin layer (A) on said operative bottom surface of the PVC skin layer (B) to obtain said leatherette; and
wherein said coating is done by using a knife coating process.
12. The process as claimed in claim 11, wherein said predetermined amount of said:
a. polyvinyl chloride (PVC) composition coated on said release layer is in the range of 100 gsm to 250 gsm;
b. PVC foam composition coated on said operative top surface of said PVC skin layer (B) is in the range of 250 gsm to 450 gsm;
c. PVC adhesive composition coated on said foam layer (C) is in the range of 50 gsm to 150 gsm; and
d. pre-skin composition coated on said operative bottom surface of PVC skin layer (B) is in the range of 10 gsm to 20 gsm.
13. The process as claimed in claim 11, wherein said:
a) first predetermined temperature is in the range of 140 ºC to 180 ºC;
b) second predetermined temperature is in the range of 5 ºC to 30 ºC;
c) third predetermined temperature is in the range of 140 ºC to 200 ºC;
d) fourth predetermined temperature is in the range of 5 ºC to 30 ºC;
e) fifth predetermined temperature is in the range of 140ºC to 200 ºC;
a) sixth predetermined temperature is in the range of 5 ºC to 30 ºC;
b) seventh predetermined temperature is in the range of 100 ºC to 180 ºC; and
c) eighth predetermined temperature is in the range of 5 ºC to 30ºC.
14. The process as claimed in claim 11, wherein said
(i) first predetermined time period is in the range of 10 seconds to 60 seconds;
(ii) second predetermined time period is in the range of 10 seconds to 60 seconds;
(iii) third predetermined time period is in the range of 10 seconds to 90 seconds;
(iv) fourth predetermined time period is in the range of 10 seconds to 90 seconds;
(v) fifth predetermined time period is in the range of 10 seconds to 90 seconds;
(vi) sixth predetermined time period is in the range of 10 seconds to 90 seconds;
(vii) seventh predetermined time period is in the range of 10 seconds to 90 seconds; and
(viii) eighth predetermined time period is in the range of 10 seconds to 50 seconds.
15. The process as claimed in claim 11, wherein said polyvinyl chloride (PVC) composition is obtained by the following process steps:
a. charging a predetermined amount of at least one plasticizer into a high speed mixer followed by adding a predetermined amount of PVC powder under stirring to obtain a first mixture; and
b. adding a predetermined amounts of at least one heat stabilizer, at least one pigment, at least one UV stabilizer, at least one antioxidant, and at least one defoaming agent into said first mixture to obtain said polyvinyl chloride (PVC) composition.
16. The process as claimed in claim 15, wherein said
i) plasticizer is selected from the group consisting of phthalates, poladipates, sebacates, trimellitates, polymeric adipate, soya bean oil, lactic acid derived, and diacetyl epoxidized vegetable-oleic acid glyceride;
wherein said phthalates are selected from diisononyl phthalate (DINP) and diisodecyl phthalate (DIDP),
wherein said sebacates is dioctyl sebacate (DOS) and
wherein said trimellitate is tri-2-ethylhexyl trimellitate (TOTM);
ii) heat stabilizer is selected from the group consisting of zinc/calcium (Zn/Ca) stearate, barium/zinc (Ba/Zn) stearate and organic based stabilizer;
wherein said organic based stabilizer is selected from OBS 200 and OBS 300;
iii) pigment is at least one selected from the group consisting of titanium dioxide, silica and aluminium oxides, and ferro pigment;
iv) UV stabilizer is selected from the group consisting of benzophenone, benzotriazole, bis-benzoxazole, cyanoacrylate, oxanilide, carbon black, titanium dioxide, monomeric sterically hindered amine, oligomeric sterically hindered amine and sterically hindered amine ester;
v) antioxidant is selected from the group consisting of octadecyl-3-(3,5-di-tert.butyl-4-hydroxyphenyl)-propionate and bisphenol A; and
vi) defoaming agent is selected from the group consisting of polydimethylsiloxanes, silicones, alcohols, stearates and glycols.
17. The process as claimed in claim 11, wherein said foam composition is obtained by the following process steps:
a. charging a predetermined amount of at least one plasticizer in a high speed mixer followed by adding a predetermined amount of PVC powder under stirring to obtain a second mixture;
b. adding a predetermined amounts of paint sludge to said second mixture under stirring to obtain a third mixture, and
c. adding a predetermined amounts of at least one heat stabilizer, at least one pigment, at least one UV stabilizer, at least one antioxidant, and at least one foaming agent into said third mixture to obtain said foam composition.
18. The process as claimed in claim 17, wherein said
(i) plasticizer is selected from the group consisting of phthalates, poladipates, sebacates, trimellitates, polymeric adipate, soya bean oil, lactic acid derived, and diacetyl epoxidized vegetable-oleic acid glyceride;
wherein said phthalates are selected from diisononyl phthalate (DINP) and diisodecyl phthalate (DIDP),
wherein said sebacates is dioctyl sebacate (DOS) and
wherein said trimellitate is tri-2-ethylhexyl trimellitate (TOTM);
(ii) heat stabilizer is selected from the group consisting of zinc/calcium (Zn/Ca) stearate, barium/zinc (Ba/Zn) stearate and organic based stabilizer;
wherein said organic based stabilizer is selected from OBS 200 and OBS 300;
(iii) pigment is at least one selected from the group consisting of titanium dioxide, silica and aluminium oxides, and ferro pigment;
(iv) UV stabilizer is selected from the group consisting of benzophenone, benzotriazole, bis-benzoxazole, cyanoacrylate, oxanilide, carbon black, titanium dioxide, monomeric sterically hindered amine, oligomeric sterically hindered amine and sterically hindered amine ester;
(v) antioxidant is selected from the group consisting of octadecyl-3-(3,5-di-tert.butyl-4-hydroxyphenyl)-propionate and bisphenol A; and
(vi) foaming agent is selected from the group consisting of azodicarbonamide, sodium bicarbonate, benzenesulfonyl hydroxide and toluene sulfonyl hydrazine.
19. The process as claimed in claim 11, wherein said adhesive composition is obtained by the following process steps:
a. charging a predetermined amount of at least one plasticizer in a high speed mixer followed by adding a predetermined amount of PVC powder under stirring to obtain a fourth mixture; and
b. adding a predetermined amounts of paint sludge to said fourth mixture under stirring to obtain a fifth mixture, and
c. adding predetermined amounts of at least one heat stabilizer and at least one pigment into said fifth mixture to obtain said adhesive composition.
20. The process as claimed in claim 19, wherein said
a. plasticizer is selected from the group consisting of phthalates, poladipates, sebacates, trimellitates, polymeric adipate soya bean oil, lactic acid derived, and diacetyl epoxidized vegetable-oleic acid glyceride;
wherein said phthalates are selected from diisononyl phthalate (DINP) and diisodecyl phthalate (DIDP),
wherein said sebacates is dioctyl sebacate (DOS) and
wherein said trimellitate is tri-2-ethylhexyl trimellitate (TOTM);
b. heat stabilizer is selected from the group consisting of zinc/calcium (Zn/Ca) stearate, barium/zinc (Ba/Zn) stearate and organic based stabilizer;
wherein said organic based stabilizer is selected from OBS 200 and OBS 300;
c. pigment is selected from the group consisting of organic and inorganic pigments.
21. The process as claimed in claim 11, wherein said aqueous pre-skin composition is obtained by mixing a predetermined amount of pre-skin resin, distilled water, at least one leveling agent, at least one defoaming agent, at least one matting agent, and at least one feel agent under stirring at a speed in the range of 100 rpm to 200 rpm for a time period in the range of 5 minutes to 30 minutes.
22. The process as claimed in claim 21, wherein said;
i) pre-skin resin is selected from polyurethane and acrylic resin;
ii) leveling agent is selected from the group consisting of silicone-based, polyacrylate based and fluorocarbon based leveling agents;
iii) defoaming agent is selected from the group consisting of polyether-modified polysiloxanes, silicones, alcohols, stearates and glycols;
iv) matting agent is slected from the group consisting of raw rubber, wax, inorganic matting agents, silicate-based, silicic acid gel based, polyester based salts, talc, mica, calcium carbonate, aluminum silicate, non-crystalline synthetic silica amorphous silicon dioxide; and
v) feel agent is selected from the group consisting of silicone, wax, polymer based and surfactant.
23. The process as claimed in claim 11, wherein said fabric layer is at least one selected from the group consisting of synthetic polyester, bio polyester, nylon, cotton, wool, linen, bamboo, carbon fiber.
24. The process as claimed in claim 11, wherein a thickness of said:
(i) polyvinyl chloride (PVC) skin layer (B) is in the range of 0.05 mm to 0.6 mm;
(ii) PVC foam layer (C) is in the range of 0.1 mm to 0.6 mm;
(iii) PVC adhesive layer (D) is in the range of 0.05 mm to 0.20 mm; and
(iv) pre-skin layer (E) is in the range of 0.001 mm to 0.1 mm.
Dated this 21st day of March, 2023

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT CHENNAI