# US 11,441,260 B2 · Sheet-like material

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- Number: US 11,441,260 B2
- Document ID: US11441260B2
- Status: Granted
- Kind: B2
- Application number: 16/497,206
- Filed: 2018-03-27
- Published: 2020-03-26
- Granted: 2022-09-13
- Earliest claimed: 2017-03-29
- Assignees: Toray Industries, Inc.
- Applicants: Toray Industries, Inc.
- Inventors: Takanori Furui; Makoto Kaneko; Ryuji Shikuri; Gen Koide; Hirohito Yamamoto; Makoto Nishimura; Jun Yoshida
- Web page: https://patentgrep.com/patent/US11441260B2

## CPC

- D06M 15/564: Polyureas, polyurethanes or other polymers having ureide or urethane links; Precondensation products forming them
- D06N 3/14: with polyurethanes
- B32B 5/022: {Non-woven fabric}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 5/28: impregnated with or embedded in a plastic substance {(not used)}
- C08J 5/046: {with synthetic macromolecular fibrous material}
- C08L 67/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds (C08L67/06 takes precedence)
- C08L 75/04: Polyurethanes
- D06N 3/00: Artificial leather, oilcloth or {other} material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N 3/12: with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds {, e.g. gelatine proteins}
- B32B 2262/0276: Polyester fibres
- C08J 2367/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds; (C08J2367/06 takes precedence)
- C08J 2375/04: Polyurethanes
- C08J 2425/04: Homopolymers or copolymers of styrene
- C08J 2467/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds (C08J2467/06 takes precedence)
- C08J 2475/04: Polyurethanes
- C08L 2205/025: containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
- C08L 2205/03: containing three or more polymers in a blend
- C08L 2205/16: Fibres; Fibrils
- C08L 2205/22: Mixtures comprising a continuous polymer matrix in which are dispersed crosslinked particles of another polymer
- D06M 2101/32: Polyesters
- D06M: TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- 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
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)

## Abstract

The present invention provides a sheet-like material in which a plant-derived raw material of low environmental impact is used. The invention also provides a sheet-like material that ideally has a uniform and refined nap and a sheet-like material that is strong, has excellent shape stability, is lightweight and is very pliable. This sheet-like material is characterized in being made of nonwoven fabric that is made of polyester microfiber containing a 1,2-propanediol-derived component in an amount prescribed in the present application and a polyurethane elastomer resin containing structural monomers prescribed in the present application. This sheet-like material is also made of a base sheet, in which a nonwoven fabric that has microfibers as the main component is laminated and unified with a woven or knitted material, and an elastomer resin, and is characterized in that the woven or knitted material is configured from fibers containing polyester as the main component and that 1-500 ppm of a 1,2-propanediol-derived component are contained in the polyester.

## Claims

### Claim 1

An artificial leather comprising:
a nonwoven fabric including a microfiber having an average single fiber diameter of 0.3 to 7 μm; and
an elastomer resin,
wherein
a polymer constituting the microfiber is a polyester obtained from a dicarboxylic acid and/or an ester-forming derivative thereof and a diol,
a 1,2-propanediol-derived component is contained at 1 to 500 ppm in the polyester,
the elastomer resin is a polyurethane resin (D) including a copolymerized polycarbonate diol (A1) that includes a structural unit derived from an alkanediol (a1) having 3 to 5 carbon atoms and a structural unit derived from an alkanediol (a2) having 8 to 20 carbon atoms and that has a molar ratio of the alkanediol (a2) to a total number of moles of the alkanediol (a1) and the alkanediol (a2) of 50 to 95 mol %, an organic diisocyanate (B), and a chain extender (C) as essential constituent monomers,
the polyurethane resin (D) further includes a polycarbonate diol (A2) including a structural unit derived from an alkanediol (a3) having 4 to 6 carbon atoms as an essential constituent monomer, and
the elastomer resin has a porous structure and a proportion of micropores having a pore diameter of 0.1 to 20 μm occupying all pores of the porous structure is 60% or more.

### Claim 2

An artificial leather comprising:
a sheet substrate formed by laminating and integrating a nonwoven fabric having a microfiber as a main body with a woven or knitted fabric; and
an elastomer resin,
wherein
the woven or knitted fabric is composed of fibers including a polyester as a main component, and
a 1,2-propanediol-derived component is contained at 1 to 500 ppm in the polyester,
wherein the elastomer resin is a polyurethane resin (D) including a copolymerized polycarbonate diol (A1) that includes a structural unit derived from an alkanediol (a1) having 3 to 5 carbon atoms and a structural unit derived from an alkanediol (a2) having 8 to 20 carbon atoms and that has a molar ratio of the alkanediol (a2) to a total number of moles of the alkanediol (a1) and the alkanediol (a2) of 50 to 95 mol %, an organic diisocyanate (B), and a chain extender (C) as essential constituent monomers,
wherein the polyurethane resin (D) further includes a polycarbonate diol (A2) including a structural unit derived from an alkanediol (a3) having 4 to 6 carbon atoms as an essential constituent monomer.

### Claim 3 (depends on 2)

The artificial leather according to claim 2, wherein a single fiber diameter of a yarn forming the woven or knitted fabric is 0.3 to 50 μm.