# US 10,307,988 B2 · Method for manufacturing hybrid-nature leather having excellent appearance quality and durability

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- Number: US 10,307,988 B2
- Document ID: US10307988B2
- Status: Granted
- Kind: B2
- Application number: 15/439,744
- Filed: 2017-02-22
- Published: 2018-05-03
- Granted: 2019-06-04
- Earliest claimed: 2016-11-03
- Assignees: Hyundai Motor Company
- Applicants: Hyundai Motor Company
- Inventors: Mi Jung Yun; Hye Min Lee; Gun Kang; Soon Joon Jung; Jang Won Lee; Hak Nam Lee; Doo Yong Lee; Sang Hyun Kim
- Web page: https://patentgrep.com/patent/US10307988B2

## CPC

- B32B 7/04: Interconnection of layers
- B32B 9/025: {comprising leather}
- B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)}
- B32B 9/047: {made of fibres or filaments}
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/30: comprising vinyl {(co)polymers; comprising acrylic (co)polymers}
- C14B 7/02: Composite leathers (with one or more laminae of plastics material B32B)
- D06N 3/0018: {Collagen fibres or collagen on fibres}
- D06N 3/0036: {Polyester fibres (for elastomeric fibres D06N3/0025)}
- D06N 3/0061: {Organic fillers or organic fibrous fillers, e.g. ground leather waste, wood bark, cork powder, vegetable flour; Other organic compounding ingredients; Post-treatment with organic compounds}
- D06N 3/0065: {Organic pigments, e.g. dyes, brighteners}
- D06N 3/0077: {Embossing; Pressing of the surface; Tumbling and crumbling; Cracking; Cooling; Heating, e.g. mirror finish}
- D06N 3/0086: {characterised by the application technique}
- D06N 3/042: {Acrylic polymers (D06N3/045 takes precedence)}
- D06N 3/14: with polyurethanes
- D06N 7/0092: {Non-continuous polymer coating on the fibrous substrate, e.g. plastic dots on fabrics}
- D06P 3/32: leather {skins}
- B32B 37/0076: {characterised in that the layers are not bonded on the totality of their surfaces}
- B32B 37/1292: {selectively, e.g. in stripes, in patterns (B32B37/0076 takes precedence)}
- B32B 38/06: Embossing
- B32B 2250/02: 2 layers
- B32B 2255/00: Coating on the layer surface
- B32B 2255/02: on fibrous or filamentary layer
- B32B 2255/26: Polymeric coating
- B32B 2255/28: Multiple coating on one surface
- B32B 2260/02: Composition of the impregnated, bonded or embedded layer
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/046: Synthetic resin
- B32B 2262/0284: Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
- B32B 2307/4026: within the layer by addition of a colorant, e.g. pigments, dyes
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/554: Wear resistance
- B32B 2307/71: Resistive to light or to UV
- B32B 2307/7265: Non-permeable
- B32B 2307/732: Dimensional properties
- B32B 2317/08: Natural leather
- B32B 2367/00: Polyesters, e.g. PET, i.e. polyethylene terephthalate
- B32B 2605/003: Interior finishings
- D06N 2201/06: Animal fibres, e.g. hair, wool, silk
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C14B: MECHANICAL TREATMENT OR PROCESSING OF SKINS, HIDES OR LEATHER IN GENERAL; PELT-SHEARING MACHINES; INTESTINE-SPLITTING MACHINES (making leather substitutes B29, D06N; making articles from leather B68F; mechanical cleaning of hides or the like D06G; artificial leather D06N)
- D06N: WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06P: DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM

## Abstract

A method for manufacturing hybrid-natural leather having excellent appearance quality and good durability such as light resistance, water resistance, elongation and abrasion resistance is provided. Particularly, the fiber layer having a similar structure to the natural leather is introduced to the natural leather and the natural leather and the fiber layer are bonded and fused with each other under a specific condition to manufacture hybrid-natural leather having excellent durability while preventing wrinkles, stretching, and the like from being generated.

## Claims

### Claim 1

A method of manufacturing hybrid-natural leather, comprising:
a bonding step of forming a laminate of a leather layer and a fiber layer; and
a fusing step of integrating the leather layer and the fiber layer by coating a fusion composition on the fiber layer and then applying heat and pressure to the laminate,
wherein the fusing step includes:
coating the fusion composition including 75 wt % to 95 wt % of a filler, 7 wt % to 13 wt % of an acrylic resin binder, and 3 wt % to 7 wt % of an urethane binder, and
applying a temperature of 100° C. to 120° C. and pressure of 100 kg/cm2 to 120 kg/cm2.

### Claim 2 (depends on 1)

The method of manufacturing hybrid-natural leather of claim 1, wherein the leather layer is natural leather, and the fiber layer is formed by polyethylene terephthalate (PET).

### Claim 3 (depends on 1)

The method of manufacturing hybrid-natural leather of claim 1, wherein a thickness of the fiber layer is 0.01 mm to 0.2 mm.

### Claim 4 (depends on 1)

The method of manufacturing hybrid-natural leather of claim 1, wherein before the bonding step, at least one of a tanning process, a dyeing process, and a branching process is performed with respect to the leather layer.

### Claim 5 (depends on 1)

The method of manufacturing hybrid-natural leather of claim 1, further comprising:
after the fusing step, a surface-treating step of forming sequentially a base painting layer, a color coating layer, and a top coating layer on the laminate.

### Claim 6 (depends on 5)

The method of manufacturing hybrid-natural leather of claim 5, wherein the base painting layer is formed by a method of coating a base paint composition comprising 14 wt % to 20 wt % of a filler, 7 wt % to 13 wt % of an acrylic resin, and 60 wt % to 80 wt % of polyurethane on the laminate.

### Claim 7 (depends on 5)

The method of manufacturing hybrid-natural leather of claim 5, wherein the color coating layer is formed by a method of coating a color coating composition comprising 13 wt % to 19 wt % of a filler, 7 wt % to 13 wt % of an acrylic resin, and 62 wt % to 72 wt % of polyurethane on the base painting layer.

### Claim 8 (depends on 5)

The method of manufacturing hybrid-natural leather of claim 5, wherein the top coating layer is formed by a method of coating a top coating composition comprising 8 wt % to 10 wt % of matt polyurethane, 40 wt % to 60 wt % of polyurethane, 5 wt % to 9 wt % of water-soluble silicon, 8 wt % to 12 wt % of an acrylic resin, 5 wt % to 9 wt % of a cross linker, and 2 wt % to 4 wt % of a sunscreen agent on the color coating layer.

### Claim 9 (depends on 5)

The method of manufacturing hybrid-natural leather of claim 5, wherein in the surface-treating step, embossing for the laminate is performed before forming the color coating layer after forming the base painting layer.

### Claim 10 (depends on 9)

The method of manufacturing hybrid-natural leather of claim 9, wherein the embossing is performed at a temperature of 150° C. to 170° C. and pressure of 150 kg/cm2 to 170 kg/cm2.

### Claim 11 (depends on 1)

The method of manufacturing hybrid-natural leather of claim 1, wherein the bonding step comprises a step of forming the laminate by applying a curable composition between the leather layer and the fiber layer by a dot method.

### Claim 12 (depends on 11)

The method of manufacturing hybrid-natural leather of claim 11, wherein the curable composition is transferred to the leather layer or the fiber layer.