Artificial leather with three-dimensional pattern and manufacturing method thereof

Patent metadata

Field	Value
Publication number	US-2018105976-A1
Application number	US-201715787468-A
Country	US
Kind code	A1
Filing date	Oct 18, 2017
Priority date	Oct 19, 2016
Publication date	Apr 19, 2018
Grant date	—

Abstract

Provided are an artificial leather and a method of manufacturing the same. The artificial leather includes: a base fabric; a polyvinyl chloride film bonded to a surface of the base fabric; bonding layer formed on a surface of the film; a first foam layer formed on the bonding layer in a patterned shape; a first color layer formed on a surface of the foam layer and having the same pattern as the first foam layer; and a surface treatment layer formed on a surface of the first color layer with the same pattern as the first color layer or formed on a surface of the bonding layer without the first foam layer and the surface of the first color layer. to the artificial leather of the present invention may have a light weight and implement various three-dimensional patterns and colors as compared with a conventional PVC foam artificial leather.

First claim

What is claimed is:

1 . An artificial leather, comprising:
a base fabric; a polyvinyl chloride film bonded to a surface of the base fabric; a bonding layer formed on a surface of the film; a first foam layer formed on the bonding layer in a patterned shape; a first color layer formed on a surface of the first foam layer and having the same pattern as the first foam layer; and a surface treatment layer formed on a surface of the first color layer with the same pattern as the first color layer or formed on a surface of the bonding layer without the first foam layer and the surface of the first color layer.

2 . The artificial leather of claim 1 , further comprising:
at least two three-dimensional pattern layers having different patterns and colors and sequentially formed between the bonding layer and the surface treatment layer.

3 . The artificial leather of claim 2 , wherein a first three-dimensional pattern layer comprises the first foam layer and the first color layer having the same pattern as the first foam layer and a second three-dimensional pattern layer comprises a second foam layer formed in a second patterned shape and a second color layer having the same pattern as the second foam layer.

4 . The artificial leather of claim 1 , wherein the polyvinyl chloride film comprises a polyvinyl chloride resin, a plasticizer, and a pigment.

5 . Artificial leather, comprising:
a base fabric; a polyvinyl chloride film bonded to a surface of the base fabric; a bonding layer formed on a surface of the film; a base color layer formed on a surface of the bonding layer in a patterned shape; a first foam layer formed on the base color layer in a patterned shape; a first color layer formed on a surface of the first foam layer and having the same pattern as the first foam layer; and a surface treatment layer formed on a surface of the first color layer with the same pattern as the first color layer or formed on the surface of the bonding layer without the base color layer, the surface of the base color layer without the first foam layer, and the surface of the first color layer.

6 . The artificial leather of claim 5 , further comprising:
at least two three-dimensional pattern layers having different patterns and colors and sequentially formed between the base color layer and the surface treatment layer.

7 . The artificial leather of claim 6 , wherein a first three-dimensional pattern layer comprises the first foam layer and the first color layer having the same pattern as the first foam layer and a second three-dimensional pattern layer comprises a second foam layer formed in a second patterned shape and a second color layer having the same pattern as the second foam layer.

8 . The artificial leather of claim 5 , wherein the polyvinyl chloride film comprises a polyvinyl chloride resin, a plasticizer, and a pigment.

9 . A method of manufacturing an artificial leather, comprising:
bonding a polyvinyl chloride film onto a surface of a base fabric; forming a bonding layer by coating and drying a composition for the bonding layer on a surface of the film; forming a foaming layer by coating and drying a composition for the foam layer on the bonding layer in a patterned shape; forming a first color layer by coating and drying a composition for the first color layer on a surface of the foaming layer to have the same pattern as the foam layer; forming a surface treatment layer by coating and drying a composition for the surface treatment layer on a surface of the first color layer to have the same pattern as the first color layer or coating or drying the composition for the surface treatment layer on a surface of the bonding layer without the foam layer and the surface of the first color layer; and hot-pressing to perform foaming of the foam layer.

10 . The method of claim 9 , further comprising alternately forming one or more foam layers and forming one or more color layers.

11 . The method of claim 10 , wherein the one or more foam layers have different patterns and the one or more color layers have different patterns and different colors.

12 . A method of manufacturing an artificial leather, comprising:
bonding a polyvinyl chloride film onto a surface of a base fabric; forming a bonding layer by coating and drying a composition for the bonding layer on a surface of the film; forming a base color layer by coating and drying a composition for the base color layer on a surface of the bonding layer in a patterned shape; forming a first foam layer by coating and drying a composition for the first foam layer on a surface of the base color layer in a patterned shape; forming a first color layer by coating and drying a composition for the first color layer on a surface of the first foam layer to have the same pattern as the first foam layer; forming a surface treatment layer by coating and drying a composition for the surface treatment layer on a surface of the first color layer to have the same pattern as the first color layer, or coating and drying the composition for the surface treatment layer on the surface of the bonding layer without the base color layer, the surface of the base color layer without the first foam layer, and the surface of the first color layer; and hot-pressing to perform foaming of the foam layer.

13 . The method of claim 12 , further comprising alternately forming one or more foam layers and forming one or more color layers.

14 . The method of claim 13 , wherein the one or more foam layers have different patterns and the one or more color layers have different patterns and different colors.

15 . A vehicle comprising an artificial leather of claim 1 .

Assignees

• Hyundai Motor Co Ltd
• Kia Motors Corp
• Kolon Glotech Inc

Inventors

• Jeon Hong-Chan
• Park Bong-Hyun
• Kim Ju-Ahn
• Kim Tae-Gi
• Ha Yong-Tae

Classifications

• B32B5/024

  Woven fabric · CPC title

• B32B5/18

  characterised by features of a layer {of} foamed material · CPC title

• D06N3/0095

  by inversion technique; by transfer processes · CPC title

• B32B9/045

  of synthetic resin · CPC title

• D06N3/146

  characterised by the macromolecular diols used · CPC title