Process for forming a synthetic leather

Patent metadata

Field	Value
Publication number	US-11746465-B2
Application number	US-201817267958-A
Country	US
Kind code	B2
Filing date	Aug 21, 2018
Priority date	Aug 21, 2018
Publication date	Sep 5, 2023
Grant date	Sep 5, 2023

Abstract

A process of making a synthetic leather includes (i) first, contacting a textile with an aqueous solution containing a cationic hydroxyethylcellulose polymer to form a modified textile component; (ii) subsequently, impregnating the modified textile component with an aqueous polyurethane dispersion externally stabilized with an anionic surfactant; and (iii) precipitating the polyurethane in the modified textile component. And a synthetic leather formed by the process.

First claim

We claim:

1. A process comprising:
(i) first, contacting a textile with an aqueous solution consisting of (i) a cationic hydroxyethylcellulose polymer, (ii) water, and (iii) optionally silicone oil to form a modified textile component;
(ii) subsequently, impregnating the modified textile component with an aqueous polyurethane dispersion externally stabilized with an anionic surfactant; and
(iii) precipitating, in the absence of a free inorganic salt, the polyurethane in the modified textile component.

2. The process of claim 1 comprising (iv) forming a synthetic leather.

3. The process of claim 1 comprising selecting a cationic hydroxyethylcellulose polymer that is a hydroxyethylcellulose polymer with a quaternary ammonium cation group.

4. The process of claim 3 comprising selecting a cationic hydroxyethylcellulose polymer having a weight average molecular weight (Mw) from 100,000 Dalton to 3,000,000 Dalton.

5. The process of claim 4 wherein cationic hydroxyethylcellulose polymer has a Structure (A)

wherein
n is an integer from 200 to 10,000,
x is an integer from 0 to 30, and
y is an integer from 1 to 10.

6. The process of claim 5 comprising
(i) first, contacting the textile with an aqueous solution consisting of (i) the cationic hydroxyethylcellulose polymer, (ii) water, and (iii) silicone oil to form a modified textile component.

7. The process of claim 5 comprising
(i) first, contacting the textile with an aqueous solution consisting of (i) the cationic hydroxyethylcellulose polymer, and (ii) water to form a modified textile component.

8. The process of claim 1 comprising selecting an anionic surfactant that is a sulfonate surfactant.

9. The process of claim 1 comprising maintaining, during the impregnating, a Cation:Anion Ratio from 0.1 to 10.

10. The process of claim 1 comprising drying the modified textile component before impregnating the modified textile component with the aqueous polyurethane dispersion.

11. The process of claim 1 comprising forming a synthetic leather comprising from 20 wt % to 70 wt % polyurethane.

12. The process of claim 1 wherein the aqueous solution comprising a cationic hydroxyethylcellulose polymer is void of organic solvent.

13. The process of claim 12 wherein the aqueous polyurethane dispersion is void of organic solvent.

Assignees

• Dow Global Technologies Llc
• Rohm & Haas
• Dow Chemical Co

Inventors

• Tai Xiangyang
• Qu Zhaohui
• Zhao Ruijun
• Guo Yunlong
• Pang Xiaoyi

Classifications

• D06N3/02 Primary

  with cellulose derivatives · CPC title

• D06M15/09

  Cellulose ethers · CPC title

• D06M23/00

  Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process · CPC title

• D06N3/0086

  characterised by the application technique · CPC title

• D06N3/14

  with polyurethanes · CPC title