Sheet material

Abstract

A method for forming a sheet material. The method includes advancing an arrangement comprising a fibrous assembly and a reinforcing structure, the reinforcing structure comprising splittable fibers. The method further includes exposing the arrangement to successive hydroentangling steps, wherein in each such hydroentangling step, the arrangement is exposed to a high-pressure jet of liquid across a surface of the arrangement. Exposing the arrangement to the successive hydroentangling steps entangles the fibers of the fibrous assembly with one another, forming mechanical bonds between the fibers of the fibrous assembly and the reinforcing structure. The mechanical bonds are created by at least some of the fibers of the fibrous assembly being forced into gaps in the reinforcing structure by the high-pressure jet of liquid, at least some of the splittable fibers of the reinforcing structure splitting to form split fibers that reduce the space in the gaps so that the reinforcing structure clamps around the fibers of the fibrous assembly forced into the gaps, and at least some of the fibers of the fibrous assembly being entangled with at least some of the split fibers and at least some of the splittable fibers of the reinforcing structure.

Description

Detailed Description of the Invention

[0001] [Technical field] Examples of the present disclosure relate to methods of forming sheet materials, subsequently formed sheet materials, and arrangements from which sheet materials are formed. [Background technology]

[0002] It is known to form sheet materials using hydroentangling by subjecting an arrangement comprising a fibrous assembly to a high-pressure jet of liquid to interlock the fibers together through entanglement. In some cases, the fibrous assembly may be mechanically bonded to a reinforcing structure during hydroentangling to provide a sheet material with improved mechanical properties, e.g., greater tensile strength.

[0003] There is a need to provide a more durable sheet material by increasing the strength of the mechanical bond between the fiber assembly and the reinforcing structure. [Summary of the Invention] [Means for solving the problem]

[0004] According to various, but not necessarily all, examples of the present disclosure, there is provided a method of forming a sheet material, the method comprising: advancing an arrangement comprising a fiber assembly and a reinforcing structure, the reinforcing structure comprising splittable fibers; exposing the arrangement to successive hydroentangling steps, in each such hydroentangling step the arrangement is exposed to a high pressure jet of liquid over a surface of the arrangement, wherein exposing the arrangement to successive hydroentangling steps entangles the fibers of the fibrous assembly with one another to form mechanical bonds between the fibers of the fibrous assembly and the reinforcing structure, the mechanical bonds being at least some of the fibers of the fiber assembly are forced into gaps in the reinforcing structure by a high-pressure jet of liquid; splitting at least some of the splittable fibers of the reinforcing structure to form split fibers that reduce the space within the gap such that the reinforcing structure clamps around the fibers of the fiber mass forced into the gap; and At least some of the fibers of the fiber assembly are entangled with at least some of the split fibers and at least some of the splittable fibers of the reinforcing structure. Exposure brought about by Includes:

[0005] In some cases, the method includes subjecting the arrangement to successive hydroentangling steps, in which in each such hydroentangling step the arrangement is exposed to a high-pressure jet of liquid over one of the faces of the arrangement, or over each of the faces of the arrangement.

[0006] In some cases, the method includes applying a coating to a surface of the arrangement after the subsequent hydroentangling step. The method may include applying a coating to both surfaces and / or either surface of the arrangement. The coating may be a polymer coating.

[0007] The fiber assembly may comprise synthetic, natural, or naturally derived fibers, or may comprise a blend of synthetic, natural, and / or naturally derived fibers. The fiber assembly may comprise leather fibers, or may comprise primarily leather fibers. The fiber assembly may comprise leather and non-leather fibers. The non-leather fibers may be natural or synthetic.

[0008] The fiber assembly may comprise splittable fibers. The fiber assembly may comprise leather fibers and splittable fibers. The splittable fibers may be non-leather fibers.

[0009] In some cases, the arrangement comprises a fibrous mass on only one face of the reinforcing structure, alternatively, the arrangement may comprise a fibrous mass on each face of the reinforcing structure.

[0010] In some cases, the reinforcing structure comprises a structure defined by a woven fabric, the woven fabric comprising splittable fibers. Alternatively, the reinforcing structure may comprise a structure defined by a nonwoven fabric, the nonwoven fabric comprising splittable fibers. In some cases, the reinforcing structure comprises a structure defined by a combination of a woven fabric and a nonwoven fabric, the woven fabric and / or the nonwoven fabric comprising splittable fibers. A nonwoven fabric is defined as any textile structure other than a woven fabric, for example, a knitted fabric or a needlepunched structure.

[0011] In some cases, each splittable fiber of the reinforcing structure comprises at least two different fibers arranged in separate segments across the cross section of the splittable fiber. The at least two different fibers may comprise polyester fibers and polyamide fibers. In some cases, the at least two different fibers comprise microfibers.

[0012] In some cases, each splittable fiber of the reinforcing structure comprises a plurality of fibers disposed in a resin. The plurality of fibers may comprise a plurality of different fibers. The plurality of fibers may comprise polyamide fibers and the resin may comprise a polyester resin. In some cases, the plurality of fibers comprises microfibers.

[0013] The arrangement may comprise a plurality of different respective fibre assemblies and / or a plurality of different respective reinforcing structures, provided that at least one of the reinforcing structures comprises splittable fibres.

[0014] According to various, but not necessarily all, examples of the present disclosure, there is provided a sheet material made by the method described in any of the preceding paragraphs.

[0015] In some cases, the sheet material is substantially free of adhesive bonding of the fibers.In some cases, the sheet material does not comprise adhesive bonding of the fibers.

[0016] According to various, but not necessarily all, examples of the present disclosure, there is provided a sheet material made by the method of any of the preceding paragraphs from an arrangement, the arrangement comprising: a fiber assembly, and Reinforcement structure comprising splittable fibers Equipped with.

[0017] According to various, but not necessarily all, examples of the present disclosure, an arrangement is provided, the arrangement comprising: a fiber assembly, and Reinforcement structure comprising splittable fibers Equipped with.

[0018] The fiber assembly may comprise synthetic, natural, or naturally derived fibers, or may comprise a blend of synthetic, natural, and / or naturally derived fibers. The fiber assembly may comprise leather fibers, or may comprise primarily leather fibers. The fiber assembly may comprise leather and non-leather fibers. The non-leather fibers may be natural, naturally derived, or synthetic.

[0019] The fiber assembly may comprise splittable fibers. The fiber assembly may comprise leather fibers and splittable fibers. The splittable fibers may be non-leather fibers.

[0020] In some cases, the arrangement comprises a fibrous mass on only one face of the reinforcing structure, alternatively, the arrangement may comprise a fibrous mass on each face of the reinforcing structure.

[0021] In some cases, the reinforcing structure comprises a structure defined by a woven fabric, the woven fabric comprising splittable fibers. Alternatively, the reinforcing structure may comprise a structure defined by a nonwoven fabric, the nonwoven fabric comprising splittable fibers. In some cases, the reinforcing structure comprises a structure defined by a combination of a woven fabric and a nonwoven fabric, the woven fabric and / or the nonwoven fabric comprising splittable fibers. A nonwoven fabric is defined as any textile structure other than a woven fabric, for example, a knitted fabric or a needlepunched structure.

[0022] In some cases, each splittable fiber of the reinforcing structure comprises at least two different fibers arranged in separate segments across the cross section of the splittable fiber. The at least two different fibers may comprise polyester fibers and polyamide fibers. In some cases, the at least two different fibers comprise microfibers.

[0023] In some cases, each splittable fiber of the reinforcing structure comprises a plurality of fibers disposed in a resin. The plurality of fibers may comprise a plurality of different fibers. The plurality of fibers may comprise polyamide fibers and the resin may comprise a polyester resin. In some cases, the plurality of fibers comprises microfibers.

[0024] The arrangement may comprise a plurality of different respective fibre assemblies and / or a plurality of different respective reinforcing structures, provided that at least one of the reinforcing structures comprises splittable fibres.

[0025] According to various, but not necessarily all, examples of the present disclosure, there is provided clothing, footwear, accessories, or upholstery comprising a sheet material according to the preceding paragraph.

[0026] According to various, but not necessarily all, examples of the present disclosure, there is provided a composite material formed from a web by hydroentangling, the web comprising: a fiber assembly, and Reinforcement structure comprising splittable fibers The composite material is a sheet material. The web is also called a layout.

[0027] According to various, but not necessarily all, examples of the present disclosure, a web is provided, the web comprising: a fiber assembly, and Reinforcement structure comprising splittable fibers The web is also called the arrangement.

[0028] According to various, but not necessarily all, examples of the present disclosure: A fiber assembly interlocked with one another by entanglement, and A reinforced structure comprising split fibers formed from splittable fibers, wherein at least some of the fibers of the assembly are mechanically bonded to the reinforced structure. A composite material is provided, comprising: The composite material is a sheet material.

[0029] According to various, but not necessarily all, examples of the present disclosure, there is provided a method of forming a composite material, the method comprising: forming a web comprising a fiber assembly and a reinforcing structure, the reinforcing structure comprising splittable fibers; exposing the web to a hydroentangling step to form a composite material, wherein the web is exposed to high pressure jets of liquid across a surface of the web; The composite material is a sheet material. The web is also called a layout.

[0030] In accordance with various, but not necessarily all, examples of the present disclosure, examples may be provided as claimed in the accompanying claims.

[0031] For a better understanding of various examples that are helpful in understanding the detailed description, reference will now be made, by way of example only, to the accompanying drawings, in which: [Brief explanation of the drawings]

[0032] [Figure 1] 1 shows a microscope image (25x) of a sheet material not according to an example of the present disclosure. [Figure 2] 1 shows a microscope image (25x) of a sheet material according to an example of the present disclosure. [Figure 3] 1 shows a cross-sectional microscope image (32x) of a sheet material not according to an example of the present disclosure with a coating. [Figure 4] 1 shows a cross-sectional microscope image (32x) of a sheet material according to an example of the present disclosure with a coating. DETAILED DESCRIPTION OF THE INVENTION

[0033] Examples of the present disclosure provide methods of forming sheet materials. Additionally, examples of the present disclosure provide subsequently formed sheet materials and arrangements from which the sheet materials are formed.

[0034] The method includes advancing an arrangement comprising a fiber assembly and a reinforcing structure, the reinforcing structure comprising splittable fibers.

[0035] The method further comprises subjecting the arrangement to successive hydroentangling steps.

[0036] In each such hydroentanglement step, the arrangement is exposed to a high-pressure jet of liquid across the surface of the arrangement. In some instances, the liquid is water.

[0037] Exposing the arrangement to successive hydroentangling steps entangles the fibers of the fibrous assembly with one another, and accordingly, the fibers of the fibrous assembly interlock with one another through entanglement.

[0038] Subjecting the arrangement to successive hydroentangling steps further results in the formation of mechanical bonds between the fibers of the fiber assembly and the reinforcing structure.

[0039] The mechanical connection is at least a) some of the fibers of the fiber aggregate are forced into gaps in the reinforcing structure by a high-pressure jet of liquid; b) splitting at least some of the splittable fibers of the reinforcing structure to form split fibers that reduce the space within the gap such that the reinforcing structure clamps around the fibers of the fiber mass forced into the gap; and c) at least some of the fibers of the fiber assembly are entangled with at least some of the split fibers and at least some of the splittable fibers of the reinforcing structure; is brought about by.

[0040] The split fibers may be microfibers. The clamping occurs because the reinforcing structure presses, squeezes, or tightens around the fibers of the fiber mass that are forced into the gap.

[0041] The arrangement may comprise a plurality of different respective fibre assemblies and / or a plurality of different respective reinforcing structures, provided that at least one of the reinforcing structures comprises splittable fibres.

[0042] In such an arrangement, each fiber assembly may have a different configuration, e.g., comprise different fibers. In such an arrangement, each reinforcing structure may have a different structure and / or configuration, e.g., comprise a structure defined by a woven and / or nonwoven fabric, and / or comprise different fibers. In such an arrangement, not all reinforcing structures need comprise splittable fibers.

[0043] The sheet material is a composite material, i.e., a composite sheet material. The fibrous aggregate included in the arrangement is a web. It should be understood that the in-process strength for the fibrous aggregate is much lower than the strength of the sheet material resulting from the method according to the examples of the present disclosure.

[0044] The arrangement may be formed by conventional means, for example by laying fibers on a support to provide a fiber assembly, and then laying a reinforcing structure on the fiber assembly.

[0045] The fibrous assembly may be a nonwoven web, an air-laid web, a wet-laid web, a needle-punched web, or a carded web.

[0046] The arrangement is subjected to successive hydroentanglement steps in the apparatus. In some examples, the arrangement is supported on a porous conveyor, which may be a support on which the arrangement is formed, and advanced through one or more treatment stations in the apparatus. In other examples, the arrangement is supported on a porous drum, which may be a support on which the arrangement is formed, and advanced through one or more treatment stations. One or more treatment stations include a liquid outlet for exposing the arrangement to a high-pressure jet of such liquid.

[0047] In some examples, the method includes subjecting the arrangement to successive hydroentangling steps, where in each such hydroentangling step, the arrangement is exposed to high-pressure jets of liquid across one of the faces of the arrangement. In other examples, the method includes subjecting the arrangement to successive hydroentangling steps, where in each such hydroentangling step, the arrangement is exposed to high-pressure jets of liquid across each of the respective faces. Each of the successive hydroentangling steps on one or each face of the arrangement may be performed at a different processing station in the apparatus. In such examples, a conveyor or drum is arranged to support and advance the arrangement through each of the respective processing stations.

[0048] The fiber assembly may comprise synthetic, natural, or naturally derived fibers. A non-exhaustive list of examples of natural fibers includes wool, cotton, and flax. A non-exhaustive list of examples of naturally derived fibers includes leather, soy, viscose, and bamboo fibers. A non-exhaustive list of examples of synthetic fibers includes nylon, polyester, and acrylic. Synthetic fibers may be bicomposite fibers. In some examples, the fiber assembly may comprise a combination of synthetic and natural fibers.

[0049] The fibrous assembly may also comprise splittable fibers, which may be naturally occurring or synthetic, and in such instances, subjecting the arrangement to successive hydroentangling steps will also split at least some of those splittable fibers and entangle them.

[0050] In examples where the fiber aggregate comprises leather fibers, such as the illustrated examples described below, the leather fibers may be derived from waste leather. A sheet material formed from an arrangement comprising a fiber aggregate, the fiber aggregate comprising leather fibers, may be an engineered leather product or may be used to form an engineered leather product.

[0051] In conventional sheet materials formed from arrangements comprising aggregates of relatively short and thin fibers, such as leather fibers from waste leather, the strength of the mechanical bond between the aggregate fibers and the reinforcing structure may be insufficient for certain uses of the sheet material, for example, in clothing, footwear, accessories, or upholstery applications.

[0052] By way of example only, the lengths of fibers resulting from the disintegration of waste leather in a textile regeneration unit range from less than 1 mm to up to 20 mm for occasional fibers. The fiber structure of natural leather before disintegration consists of tightly interwoven collagen fiber bundles, which in turn consist of even thinner fibrils, many of which become separated during mechanical action. This results in a range of fiber diameters from approximately 100 microns for bundles to very fine fibers, less than 1 micron for individual fibrils.

[0053] Without being bound by theory, such relatively short and thin fibers may not be sufficiently anchored to the reinforcing structure and therefore may easily separate therefrom.

[0054] As noted above, in examples of the present disclosure, the reinforcing structure comprises splittable fibers.

[0055] In some examples, the splittable fiber of the reinforcing structure comprises at least two different fibers arranged in separate segments across the cross section of the splittable fiber, for example, the at least two different fibers may comprise polyester fibers and polyamide fibers, which may be microfibers.

[0056] Alternatively, in other examples, each splittable fiber of the reinforcing structure may comprise a plurality of fibers disposed in the resin, i.e., islands in the sea. The plurality of fibers may comprise a plurality of different fibers, which may be microfibers. In some cases, the plurality of fibers comprises polyamide fibers and the resin comprises a polyester resin.

[0057] The reinforcing structure may comprise a structure defined by a woven fabric comprising splittable fibers or a nonwoven fabric comprising splittable fibers. Alternatively, the reinforcing structure may comprise a structure defined by a combination of a woven fabric and a nonwoven fabric, with the woven fabric and / or the nonwoven fabric comprising splittable fibers. Whether the structure is defined by a woven fabric, a nonwoven fabric, or a combination thereof, the structure comprises gaps between the splittable fibers. Accordingly, there are gaps in the reinforcing structure. As described in more detail below, in a woven fabric, the gaps are defined at least by openings in the regular mesh of the woven fabric. In a nonwoven fabric, the gaps are defined at least by voids between individual splittable fibers or individual bundles of splittable fibers that are randomly or irregularly arranged in the nonwoven fabric.

[0058] Woven and nonwoven fabrics are formed from splittable fibers. Accordingly, the method may include forming a woven and / or nonwoven fabric from splittable fibers.

[0059] During the successive hydroentangling steps, as described above, at least some of the fibers of the fiber aggregate are forced into gaps in the reinforcing structure by the high-pressure jet of liquid. Additionally, at least some of the splittable fibers split to form split fibers. Accordingly, without being bound by theory, as the splittable fibers split into split fibers, the size of the gaps in the reinforcing structure decreases, and thus the reinforcing structure tightens around and more tightly holds the fibers of the aggregate that extend into and / or through the gaps in the reinforcing structure. The fibers in the aggregate also entangle with at least some of the split fibers and at least some of the splittable fibers in the reinforcing structure. As a result, in the resulting sheet material, the fibers of the aggregate are mechanically held to the reinforcing structure more tightly than in conventional sheet materials, as shown by the peel strength test data in Table 1 below.

[0060] [Table 1]

[0061] In Table 1 above, the comparative example is a sheet material formed from an arrangement comprising a 240 GSM fiber aggregate comprising leather fibers and a reinforcing structure comprising an 85 GSM non-splittable fiber woven fabric, illustratively comprising non-splittable polyester fibers.

[0062] Example 1 is a sheet material formed from an arrangement comprising a 240 GSM fiber aggregate comprising leather fibers and a reinforcing structure comprising an 85 GSM splittable fiber woven fabric.

[0063] Example 2 is a sheet material formed from an arrangement comprising a 140 GSM fiber aggregate comprising leather fibers and a reinforcing structure comprising a 200 GSM splittable fiber nonwoven.

[0064] In Examples 1 and 2 above, the splittable fibers of the reinforcing structure comprise polyester fibers and polyamide fibers arranged in distinct segments throughout the cross section of the splittable fiber.

[0065] In each case, the hydroentangling method employed is the same, with the layout being subjected to successive hydroentangling steps on each side of the layout, the pressure of the liquid jets, and also the time of exposure to the liquid jets, being selected so that the liquid penetrates deep enough to drive the fibers of the aggregate into the reinforcing structure and further split at least some of the splittable fibers of the reinforcing structure.

[0066] Accordingly, a sheet material formed from an arrangement comprising a reinforcing structure having a structure defined by a woven fabric, the woven fabric comprising splittable fibers, has a peel strength that is approximately 10% greater than a corresponding comparative example in which the woven fabric does not comprise splittable fibers. If the reinforcing structure comprises a nonwoven fabric comprising splittable fibers rather than a woven fabric comprising splittable fibers, an even greater increase in peel strength (approximately 102%) is found. Moreover, in such an example, the nonwoven fabric imparts greater elasticity to the formed sheet material compared to a sheet material in which the reinforcing structure comprises a woven fabric.

[0067] In Table 1 above, peel strength is a measure of the force required to pull the entangled fiber assembly away from the reinforcing structure.

[0068] The sheet materials of Examples 1 and 2, as well as the comparative example, are formed from arrangements comprising a fibrous aggregate on only one side of a reinforcing structure. As noted above, such arrangements may be formed by conventional means, for example, by laying fibers on a support to provide the fibrous aggregate, and then laying the reinforcing structure on the fibrous aggregate. In the subsequently formed sheet material after the successive hydroentangling steps, the reinforcing structure therefore serves as a reinforcing backing. In such examples, the reinforcing backing may define the top or bottom surface of the sheet material.

[0069] In other examples, the arrangement may comprise a fibrous assembly on each side of the reinforcing structure, i.e., a sandwich-type structure. In such examples, the arrangement may be formed by conventional means, for example, by laying fibers on a support to provide a fibrous assembly, followed by laying a reinforcing structure on the fibrous assembly, and then subsequently laying additional fibers on a protective structure to provide a second fibrous assembly. In the subsequently formed sheet material, the reinforcing structure thus serves as a reinforcing core.

[0070] In other examples, the deposited and subsequently formed sheet material may include a different number of reinforcing structures and fiber aggregates as described above.

[0071] 1 and 2 show microscope (×25) images of the face of the sheet material of Comparative Example and Example 1, respectively. In the microscope images, a reinforcing structure 10 is shown overlying a fiber mass. In each figure, the woven mesh structure 12 of the reinforcing structure 10 (formed from interlaced yarns 14, i.e., perpendicular yarns) is visible. A plurality of gaps, or openings 16, are defined in the mesh 12 through which leather fibers 18 are visible, some of which extend into and / or through the openings 16.

[0072] From a comparison of Figures 1 and 2, it is clear that, on average, the gaps 16 (i.e., openings in the mesh) in the reinforcing structure 10 of Figure 2 are smaller and less clearly defined than the gaps 16 (i.e., openings in the mesh) in the reinforcing structure 10 of Figure 1. As previously discussed, during successive hydroentangling steps, at least some of the splittable fibers break apart, becoming split fibers that reduce the size of the gaps, i.e., openings. Without being bound by theory, it is believed that as the splittable fibers break apart, the interlaced yarns spread out and occupy more space, thereby partially filling the gaps, i.e., openings 16, and thus reducing their size, on average. Accordingly, the space within the gaps is reduced, and thus the reinforcing structure tightens around the fibers of the fibrous mass that are forced into the gaps.

[0073] Similarly, in the nonwoven fabric of Example 2, the gaps, i.e., voids, defined (not shown) between individual splittable fibers or individual bundles of splittable fibers decrease in size as a result of the splittable fibers separating during hydroentanglement, for the same reasoning discussed above.

[0074] Accordingly, the fibers of the aggregate are forced into gaps in the reinforcing structure by the pressurized water jets during hydroentangling and are held in the reinforcing structure more tightly than in the comparative example due to the reduced gap size. The fibers of the aggregate are also entangled with at least some of the splitting and splittable fibers of the reinforcing structure. Moreover, splitting of the splittable fibers in the reinforcing structure may also form additional smaller gaps in the reinforcing structure. Accordingly, the fibers of the aggregate are also forced into these smaller gaps in the reinforcing structure by the pressurized water jets during hydroentangling and may be fixed therein by entanglement and / or clamping of the reinforcing structure.

[0075] As a result, in the resulting sheet material, the fibers of the assembly are mechanically held to the reinforcing structure more tightly than in conventional materials, which is reflected in the peel strength data above.

[0076] In some instances after hydroentangling (i.e., downstream of hydroentangling), the arrangement may undergo conventional treatment, such as impregnation, before applying a coating (as described below) to soften, harden, or improve the handling of the sheet material. In some cases, this process may also lightly bond the fibers. However, such bonding contributes little to the overall strength, and the integrity of the product relies primarily on entanglement.

[0077] Except for the possible impregnation finish treatment mentioned above, no adhesives are required to structurally bind the fibers together, and thus the sheet material may be substantially free of adhesive bonding of the fibers, with mechanical interlocking of the fibers being the sole or primary means of achieving and maintaining structural integrity.

[0078] In other instances, after hydroentangling, the arrangement is not subjected to conventional treatment, such as impregnation, before applying a coating, and accordingly, in such instances, the sheet material does not comprise adhesive bonding of the fibers.

[0079] In some instances, the sheet material comprises a coating, for example a polymeric coating, and accordingly the method may include applying such a coating to the arrangement after the successive hydroentangling steps.

[0080] 3 and 4 show cross-sectional enlarged views (×32) of sheet material with polymer coating 22 formed from Comparative Example and Example 1, respectively.

[0081] In each figure, a regular mesh 12 formed from the interlaced yarns 14 of the woven fabric of the reinforcing structure 10 is visible. Intertwined leather fibers 18 are visible extending into and / or through the gaps, i.e., openings 16. Notably, there are fewer and smaller gaps 20 beneath the polymer coating 22 in the sheet material shown in FIG. 4 than in the comparative example of FIG. 3. Without being bound by theory, this is believed to be because the intertwined leather fibers 18, held together by the split and splittable fibers, fill the openings, thereby creating a flat surface, and the splittable fibers in the yarns 14 of the reinforcing structure split to some extent during hydroentanglement, providing a larger surface area available for bonding to the polymer coating 22, i.e., more contact or anchoring points. Accordingly, a better bond is formed to the polymer coating 22, as reflected in the peel strength data provided in Table 2 below.

[0082] Table 2 provides peel strength test data for pulling the polymer coating from the remaining portion of each sheet material.

[0083] [Table 2]

[0084] In the comparative example, as well as examples 1 and 2, the coating was applied as a layer on top of the reinforcing structure.

[0085] Sheet materials (coated or uncoated) according to examples of the present disclosure may be processed by conventional procedures to produce materials, e.g., leather-like materials, suitable for, e.g., clothing, footwear, accessories, and upholstery applications. Typical procedures include coloring, treating with softening oils, drying, buffing, and surface finishing.

[0086] In sheet materials according to examples of the present disclosure, the increased strength of the mechanical bond between the fiber assembly and the reinforcing structure, and further better constrain to the coating, if present, results in more durable such materials, e.g., leather-like materials for clothing, footwear, accessories, and upholstery applications.

[0087] Thus, a method of forming a sheet material, the subsequently formed sheet material, and the arrangement from which the sheet material is formed are described, which have many of the advantages detailed above. Moreover, in the examples of the present disclosure, the sheet material does not comprise, or is substantially free of, adhesive bonding of fibers, e.g., fibers of a fiber assembly to a reinforcing structure, or any of the fibers of a fiber assembly. Mechanical interlocking is the sole or primary means of achieving and maintaining the integrity of the sheet material. This is not only environmentally friendly, but also results in a sheet material that is more flexible and malleable than materials formed using adhesives to achieve and maintain the integrity of the material.

[0088] While embodiments of the present invention have been described in the preceding paragraphs with reference to various examples, it will be appreciated that modifications can be made to the examples given without departing from the scope of the invention as claimed. For example, yarn sizes in woven fabrics could be selected to provide different properties, e.g., to increase or decrease thickness and density. Furthermore, to tailor the properties of the sheet material, a reinforcing structure formed from a combination of both woven and nonwoven fabrics could also be provided, with each respective fabric comprising different types of splittable fibers, and possibly also comprising non-splittable fibers as part of the reinforcing structure.

[0089] For example, at least one surface of the arrangement may have a tissue layer applied to it prior to hydroentangling of that surface.

[0090] The features set out in the preceding description may be used in combinations other than those expressly set out.

[0091] Although functions have been described with reference to certain features, those functions may be performed by other features, whether or not described.

[0092] Although features have been described with reference to certain embodiments, those features may also be present in other embodiments, whether or not they are described.

[0093] The term "comprise" is used in this document in an inclusive, not exclusive sense, i.e., any reference to X comprising Y indicates that X may comprise only one Y, or may comprise more than one Y. If "comprise" is intended to be used in the exclusive sense, then this will be made clear in the context by referring to "comprising only one ---" or by using "consisting".

[0094] In this description, various examples have been referenced. The description of a feature or function with respect to an example indicates that the feature or function is present in that example. Use of the term "example" or "for example" or "may" herein, whether explicitly stated or not, indicates that such feature or function is present in at least the described example, whether or not it is described as an example, and that it may, but not necessarily, be present in some or all other examples. Thus, "example," "for example," or "may" refers to a particular instance in a class of examples. The characteristics of the instance can be characteristics of that instance only, or of the class, or of a subclass of that class that includes some but not all of the instances in the class. Thus, a feature described with reference to one example but not another implicitly discloses that it can, where possible, be used in other examples, but not necessarily in other examples.

[0095] While an effort has been made in the foregoing specification to draw attention to those features of the invention which are believed to be particularly important, it is to be understood that applicant seeks protection for any patentable feature or combination of features previously mentioned and / or shown in the drawings, whether or not particular emphasis has been placed on them.

Claims

1. 1. A method of forming a sheet material, the method comprising: forming a web comprising a fiber assembly and a woven fabric reinforcing structure, the fiber assembly comprising leather fibers and the woven fabric reinforcing structure comprising splittable fibers; exposing the web to successive hydroentangling steps, wherein in each such hydroentangling step, the web is exposed to a high pressure jet of liquid over a surface of the web, and exposing the web to successive hydroentangling steps causes the leather fibers of the fiber assembly to entangle with each other and form a mechanical bond between the leather fibers of the fiber assembly and the woven fabric reinforcing structure, the mechanical bond being at least some of the leather fibers of the fiber assembly are forced into gaps in the woven fabric reinforcing structure by the high-pressure jet of liquid; at least some of the splittable fibers of the woven fabric reinforcement structure split to form split fibers that reduce the space within the gap; and At least some of the leather fibers of the fiber assembly are entangled with at least some of the split fibers and at least some of the dividable fibers of the woven fabric reinforcing structure. the exposing is brought about by A method comprising:

2. The method of claim 1 , wherein the method includes applying a coating to a face of the sheet material after the continuous hydroentangling step.

3. The method of claim 2 , wherein the coating is a polymer coating.

4. The method according to any one of claims 1 to 3, wherein the fibre mass comprises predominantly leather fibres.

5. The method of any one of claims 1 to 4, wherein the fiber aggregate comprises leather fibers and splittable fibers.

6. The method of any one of claims 1 to 5, wherein the web comprises a fibrous mass on only one face of the woven fabric reinforcement structure.

7. The method of any one of claims 1 to 5, wherein the web comprises a fibrous mass on each side of the woven fabric reinforcement structure.

8. 8. The method of any one of claims 1 to 7, wherein each splittable fiber of the woven reinforcement structure comprises at least two different fibers arranged in separate segments across the cross section of the splittable fiber.

9. The method of claim 8 , wherein the at least two different fibers comprise polyester fibers and polyamide fibers.

10. The method of any one of claims 1 to 9, wherein each of the splittable fibers of the woven fabric reinforcement structure comprises a plurality of fibers disposed in a resin.

11. The method of claim 10 , wherein the plurality of fibers comprises polyamide fibers and the resin comprises a polyester resin.

Images