Abstract:
The present invention is a multi-layered simulated leather composition with a realistic surface appearance. The first layer is a deformable fiber surface layer having a unique uniform random pattern. The second and third membrane and fixative layers conform to the unique uniform random pattern, allowing the unique uniform random pattern to be visible through the membrane. The membrane may be printed on both sides to provide a realistic simulation of leather and allow a user to print a graphic on the simulated leather.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This patent application is a continuation-in-part of U.S. patent application Ser. No. 14/960,142, titled “Nanometallic Transportable Graphic System,” filed on Dec. 4, 2015, which is a continuation-in-part of U.S. patent application Ser. No. 13/326,080, titled “Nanometallic Transportable Graphic System,” filed on Dec. 14, 2011, which claims the benefit of priority to U.S. Provisional Application No. 61/528,502, titled “Transportable Graphic and System,” filed on Aug. 29, 2011. All of the above applications are hereby incorporated by reference in their entirety. 
     
    
     FIELD OF INVENTION 
       [0002]    This invention relates to the field of manufacture using adhesive bonding and more specifically to a simulated leather composition manufactured by adhesive bonding. 
       BACKGROUND OF THE INVENTION 
       [0003]    “Faux” leather is one of several names given to artificial or synthetic leather. These names are often used to describe specific end uses of synthetic leather products such as faux leather (sofa, chair and headboard upholstery), leatherette (auto upholstery, clothing), and koskin (consumer goods). 
         [0004]    Synthetic leather has been popular since the 1940&#39;s, initially for products such as shoes, automobile interiors and upholstery. In the late 1950&#39;s DuPont and other chemical companies began developing polyurethane products. There are two primary types of faux leather construction: polyurethane (“PU”), and polyvinyl chloride (PVC—“Vinyl”). Both polyurethane and vinyl synthetic leathers are used in making clothing, upholstery, and product covers, but both have different characteristics. 
         [0005]    Vinyl upholstery is made from two separate synthetic materials. The fibers of the upholstery are constructed from strong polyester fibers. The fibers are then coated with vinyl, made from polyvinyl chloride (PVC) and plasticizers (phthalic acid). This vinyl is melted onto the surface of the fibers, sealing them closed and making a virtually waterproof surface that is still flexible and tough. 
         [0006]    PU is made by coating a backing fabric such as cotton, polyester or shredded leather with a flexible polymer and then treating it to look more like animal hide. Polyurethane upholstery is the most realistic imitation of genuine leather, with respect to hand, surface feel, and overall appearance. When stitched, gathered, or tufted it actually “breaks” or wrinkles like real leather. Because there are no plasticizers used in PU upholstery there is no cracking or peeling, and it remains supple. Polyurethane is considered preferable to vinyl because it does not create dioxins and does not need additional plasticizers. Polyurethane costs less than real leather but it is more expensive to produce than vinyl. 
         [0007]    A problem known in the art is that synthetic leather can be visually distinguished from real leather. Real leather has inconsistently spaced surface lines forming the characteristic leather pattern while fake leather will have a perfectly even or repeating pattern. 
         [0008]    Another problem is that the surface appearance of synthetic leather is not easily customized for small projects or lots, or with artistic renditions and images. 
         [0009]    There is an unmet need in the art for easily customizable synthetic leather having a realistic appearance. 
       BRIEF SUMMARY OF THE INVENTION 
       [0010]    The present invention is a multi-layered simulated leather composition with a realistic surface appearance. The first layer is a deformable fiber surface layer having a unique uniform random pattern. The second and third membrane and fixative layers conform to the unique uniform random pattern, allowing the unique uniform random pattern to be visible through the membrane. The membrane may be printed on both sides to provide a realistic simulation of leather and allow a user to print a graphic on the simulated leather. 
     
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING(S) 
         [0011]      FIG. 1  illustrates a cross-sectional view of an exemplary embodiment of a simulated leather composition. 
           [0012]      FIG. 2  illustrates a flowchart of an exemplary embodiment of a method of making a simulated leather composition 
       
    
    
     TERMS OF ART 
       [0013]    As used herein, the term “affixed” refers to one or more elements placed in position by placement of a structure, component or compound 
         [0014]    As used herein, the term “electromagnetic target surface” refers to any surface, regardless of materials, contours and porosity, which is sufficiently free from solid particulate matter (e.g., impurities and dust) and liquids to allow the formation of a nano-ionic bond. 
         [0015]    As used herein, the term “fixative” refers to a material capable of attaching itself to another material. 
         [0016]    As used herein, the term “geometrically conform” refers to modifying an element&#39;s shape or configuration to make it substantially similar to the shape or configuration of another element. 
         [0017]    As used herein, the term “metallically infused” refers to having a composition in which one or more metallic particles are dispersed or suspended. Metallic particles include, but are not limited to, copper, silver, platinum, zinc, zirconium, gold, iridium, metal alloys, and combinations of these metallic particles and other alloys. 
         [0018]    As used herein, the term “metallically infused target surface adhesion layer (TSAL)” refers to a layer constructed from polymer and infused with metallic particles. A metallically infused TSAL bonds inks or toners and a target surface. 
         [0019]    As used herein, the term “metallically infused protection layer” refers to a layer constructed from polymer and infused with metallic particles. A metallically infused protection layer protects a metallically infused target surface adhesion layer and any bound inks from mechanical, chemical and environmental degradation. 
         [0020]    As used herein, the term “nano-ionic bonding force field” refers to ionic bond created by the presence of nanometallic particles in one surface that bond to a target surface without the use of adhesive. A nano-ionic bond force field creates a physical bond between the surfaces. 
         [0021]    As used herein, the term “parts per hundred” refers to the number of parts of an additive added to a base composition per one hundred parts of the base composition. For example, an additive added at 40 parts per hundred would have 20 parts added to a base composition having 50 parts. 
         [0022]    As used herein, the term “printable membrane” refers to a pliable sheet of a substance capable of receiving printed graphics or indicia. 
         [0023]    As used herein, the term “softening point” refers to the temperature at which a specimen of a material is penetrated to a depth of 1 mm by a flat-ended needle with a 1 mm 2  circular or square cross-section. 
         [0024]    As used herein, the term “spunbound fiber” refers to fabrics produced by depositing extruded, spun filaments in a uniform random manner, followed by bonding the fibers. 
         [0025]    As used herein, the term “texture” or “surface texture” refers to any tactile or visual quality. 
         [0026]    As used herein, the term “unique uniform random pattern” refers to a pattern of uniform elements (e.g. fibers) having a random directional orientation within a plane or sample. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0027]      FIG. 1  illustrates a cross-sectional view of an exemplary embodiment of simulated leather composition  100 . Simulated leather composition  100  includes a deformable fiber surface layer  10  having a unique uniform random pattern  11  which creates a unique uniform random pattern  11 . A fixative layer  20  atop deformable fiber surface layer  10  conforms to unique uniform random pattern  11 . A printable membrane layer  30  atop fixative layer  20  also conforms to unique uniform random pattern  11 . 
         [0028]    In the exemplary embodiment, deformable fiber surface layer  10  is a spunbound fiber. In certain embodiments, deformable fiber surface layer  10  is heat-bound spun polymer fibers, such as, but not limited to, Eco-Fi®. Unique uniform random pattern  11  is created by the affixation of randomly placed moveable fibers. 
         [0029]    In the exemplary embodiment, fixative layer  20  is a pressure sensitive adhesive composition. In one embodiment, fixative layer  20  is an adhesive composition such as, but not limited to, a carboxylated styrene butadiene polymer, a stabilized natural rubber latex emulsion, or any combination thereof. In the exemplary embodiment, the carboxylated styrene butadiene polymer has a styrene-to-butadiene ratio of 25:75. In certain embodiments, the adhesive composition making up fixative layer  20  may also include additives such as, but not limited to, a tackifying resin, an antioxidant, an ultraviolet (UV) stabilizer, or any combination thereof. 
         [0030]    The tackifying resin may be added to the composition at approximately  40  parts per hundred to approximately 140 parts per hundred. The antioxidant may be added to the composition at up to approximately 0.5 parts per hundred. The UV stabilizer may be added to the composition at up to approximately 0.5 parts per hundred. The tackifying resin may be a rosin ester tackifying resin with a softening point of approximately 20 degrees C. to approximately 80 degrees C. or an aliphatic tackifying resin with a softening point of approximately 20 degrees C. to approximately 140 degrees C. 
         [0031]    Fixative layer  20  has a lower fixative surface  21  and an upper fixative surface  22 . A fixative transfer backing may initially cover upper fixative surface  22  to allow transfer of fixative layer  20  to deformable fiber surface layer  10 . Once lower fixative surface  21  is bonded to unique uniform random pattern  11 , the fixative transfer backing may be removed to allow upper fixative surface  22  to bond to printable membrane layer  30 . 
         [0032]    Printable membrane layer  30  has a lower membrane surface  31  and an upper membrane surface  32 . Lower membrane surface  31  may have a lower printed pattern which can mimic leather or imitate any other desired material. Upper membrane surface  32  may have an upper printed pattern which may provide additional definition to the lower printed pattern or present a different image. In certain embodiments, upper membrane surface  32  also has a coating  33  of a protective substance, such as, but not limited to, a polymer. 
         [0033]    In the exemplary embodiment, printable membrane layer  30  is a nanometallic transportable graphic apparatus with at least one printable, metallically infused target surface adhesion layer (TSAL)  34  integrally bound to at least one metallically infused protection layer  35  and a variable, user-selected electromagnetic target surface. In certain embodiments, printable membrane layer  30  may lack protection layer  35 . In the exemplary embodiment, the electromagnetic target surface is fixative layer  20 . TSAL  34  has a non-porous outer surface to which ink may be applied in a printing process. Both TSAL  34  and metallically infused protection layer  35  are infused with nanometallic particles  36  smaller than 100 nm. Nanometallic particles  36  of TSAL  34  create a nano-ionic bonding force field  37  between TSAL  34  and the target surface. 
         [0034]    In the exemplary embodiment, nanometallic particles  36  are selected from the group consisting of copper, silver, platinum, zinc, zirconium, gold, iridium, metal alloys and combinations thereof. In the exemplary embodiment, nanometallic particles  36  have a size in the range of approximately 25 nm to approximately 65 nm. The concentration of nanometallic particles  36  in each of metallically infused TSAL  34  and metallically infused protection layer  35  is between 1 ppm and 100 ppm. 
         [0035]      FIG. 2  illustrates a flowchart of an exemplary embodiment of method  200  of making simulated leather composition. 
         [0036]    In step  202 , method  200  applies lower fixative surface  21  of fixative layer  20  to deformable fiber surface layer  10  such that fixative layer  20  conforms to unique uniform random pattern. During this step, a fixative transfer backing covers upper fixative surface  22  of fixative layer  20 . 
         [0037]    In step  204 , method  200  applies pressure to fixative layer  20  and the fixative transfer backing. 
         [0038]    In step  206 , method  200  removes the fixative transfer backing from upper fixative surface  22 . 
         [0039]    In optional step  208 , method  200  prints a lower printed pattern on lower membrane surface  31  of printable membrane layer  30 . This lower printed pattern can mimic leather or imitate any other desired material. 
         [0040]    In step  210 , method  200  applies lower membrane surface  31  to upper fixative surface  22 . During step  210  (and step  208 , if implemented), a membrane transfer backing covers upper membrane surface  32 . In certain embodiments, this membrane transfer backing may be a carrier infused with nanometallic particles. 
         [0041]    In step  212 , method  200  applies pressure to printable membrane layer  30 , fixative layer  20 , and deformable fiber surface layer  10 . 
         [0042]    In step  214 , method  200  removes the membrane transfer backing. 
         [0043]    In optional step  216 , method  200  prints an upper printed pattern on upper membrane surface  32 . 
         [0044]    In optional step  218 , method  200  applies a coating to upper membrane surface  32 . 
         [0045]    It will be understood that many additional changes in the details, materials, procedures and arrangement of parts, which have been herein described and illustrated to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. Moreover, the terms “about,” “substantially” or “approximately” as used herein may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. 
         [0046]    It should be further understood that the drawings are not necessarily to scale; instead, emphasis has been placed upon illustrating the principles of the invention.