Composite leather material

Abstract

Engineered leather substrates, methods of making the substrates, engineered leather composites including the substrates, and articles of manufacture which include the engineered leather substrates or composites are disclosed. The substrate includes leather, non-leather fibers, a binding agent and one or more additional components such as cushioning agents, softeners, processing aids, and colorants. A composite material can be formed including the substrate and one or more additional layers, such as top coat layers, reinforcing layers, and cushioning layers. The substrate and or the composite can be chemically or mechanically embossed. The leather used to form the engineered leather substrate can be derived from post- industrial and / or post-consumer materials. The non-leather fibers can be organic or inorganic, and the composition can also include inorganic fillers, such as calcium carbonate, and clays. The cushioning agents can include polymeric microbubbles, foam, rubber particles, and other low density cushioning agents. The binding agents can be synthetic or natural, such as synthetic latex, natural latex, PVA, and starch.

Description

technical field [0001] The present invention is in the field of composite materials generally, and more specifically relates to composite materials comprising leather and an adhesive, referred to for the purposes of this application as engineered leather substrates. Background technique [0002] A variety of consumer goods are manufactured from leather, including leather seats, leather clothing and leather sports items. During the manufacturing process, when leather is cut into shapes, a certain amount of post-industrial waste is generated. A certain amount of post-consumer waste is also generated when leather items are disposed of. [0003] One attempt to provide a composite material comprising leather and a polymeric binder is disclosed in US Patent No. 4,162,996. However, materials formed according to the teachings of this patent appear to be hard and brittle and thus have relatively little utility. [0004] It would be advantageous to provide compositions and methods ...

AI Technical Summary

Problems solved by technology

However, materials formed according to the teachings of this patent appear to be hard and brittle and thus have relatively little use