Patent Description:
A variety of synthetic alternatives to natural leather have been developed with polyurethane (PU) or polyvinylchloride (PVC) based materials having been mainly used. They are used in a wide variety of applications including for furniture, decoration, handbags, luggage, garments, footwear, car interiors, car seats and the like. However, to meet increasingly strict safety regulations, to be utilised as synthetic leather, they need to meet stringent physical property requirements, regarding e.g., flame retardancy, smoke density and retain a suitable adhesion strength in order to allow a coating layer not to be peeled off at the time of usage, heat resistance, contamination resistance, solvent resistance, hydrolysis resistance, and the like, are required. Often the PU and/or PVC based materials cannot satisfy the above-mentioned physical property requirements.

Other alternatives to natural leather include silicone-based synthetic leather composite materials. Such silicone-based synthetic leather composite materials can have several advantages over the PU and/or PVC based material alternatives. For example, they can generally be prepared using more eco-friendly production methods, using no plasticizer or toxic heavy metal and given the manufacture of organic synthetic leather relies on the use of environmentally problematic solvents such as dimethylformamide (DMF) which often remains, at least partially, in the synthetic leather product post manufacture.

Silicone-based synthetic leather composite materials may be made via several routes but are generally manufactured using a textile support layer and two or more layers of hydrosilylation curable liquid silicone rubber compositions and a release liner. For example, a first liquid silicone rubber (LSR) composition may be coated onto a release liner and is then cured to form a first or skin layer. A second LSR composition, usually having different physical properties to that of the first, is applied over the cured first layer to form an adhesion layer and then a textile support layer is placed onto the second LSR layer prior to cure, after which the second LSR composition is cured to form an adhesive layer situated between the skin layer and the textile support layer. The release liner is subsequently removed as and when required. A layer of hydrosilylation curable silicone elastomer composition may also be applied between the release liner and the textile layer as deemed appropriate to form a silicone-based leather composite material. For example, a third layer may be provided as a protective topcoat on top of the skin layer.

Such silicone-based synthetic leather composite materials are able to outperform conventional PU and PVC synthetic leather, from a physical property perspective because of the ability to provide, for example, better flexibility over a broad temperature range as well as excellent UV & thermal resistance. Topcoats are particularly important as they help to provide advantageous properties such as abrasion resistance, and soil resistance. They also are considered to be kind to the human skin and to provide an excellent hand-feeling for users. However, unfortunately topcoats made from such silicone-based materials, are not able to maintain the same desired appearance of gloss subsequent to abrasion. Post abrasion the gloss may either decrease or increase. Decreased gloss is caused by the appearance of abrasive patterns, due to the adhesive contact between the solid asperity of the abrasive and the surface of the silicone-based synthetic leather composite materials. It is a typical abrasive phenomenon of polymer elastomers. Alternatively, an increase in gloss may be observed for which the root cause is that the rough surface with small grain will be made smooth by repeated frictional interactions with harder materials, i.e., increased gloss which is caused by decreased surface roughness. <CIT> discloses a leather coating composition, a silicone-based synthetic leather utilizing the same as a top coat (<NUM>), a method of making the synthetic leather, and uses of the synthetic leather and the leather coating composition. The leather coating composition comprises a hydrosilylation curable silicone elastomer composition containing: Component (i), one or more polydiorganosiloxane polymer (s) having a viscosity of from <NUM> to <NUM>,<NUM> mPa. s at <NUM> and an alkenyl group and/or alkynyl group content of at least <NUM>% by weight of the polymer (s) per molecule; Component (ii), a reinforcing filler such as finely divided silica optionally treated with one or more known filler treating agents; Component (iii), a silicone resin cross-linker having terminal groups comprising silicone bonded hydrogen; Component (iv), a hydrosilylation catalyst; Component (v), a cured silicone powder; and Component (vi), an eco-diluent.

There remains a need for an improved silicone coating composition which is suitable, upon cure, to form a topcoat for a silicone-based synthetic leather composite material topcoat which is able to visually minimise a change in the level of gloss changes subsequent to abrasion.

There is provided a leather coating composition comprising a hydrosilylation curable silicone elastomer composition containing.

The topcoat is designed to provide a highly crosslinked silicone matrix containing silicon-free micro-particles to decrease change in gloss after abrasion.

There is also provided a synthetic leather having a topcoat in the form of a cured layer of the leather coating composition as described herein, in particular a topcoat for a silicone-based synthetic leather composite material.

There is also provided a silicone coating formed as a reaction product of the cure of the leather coating composition described herein, methods of making the topcoat and the silicone-based synthetic leather composite material utilizing same and uses of products made out of the silicone-based synthetic leather composite material.

Component (i) of the hydrosilylation curable silicone elastomer composition of the leather coating composition is one or more organopolysiloxane polymer(s) having a viscosity of from <NUM> to <NUM>,000mPa. s at <NUM> with at least <NUM> wt. % of the polymer(s) per molecule being unsaturated groups selected from alkenyl groups, alkynyl groups or a mixture thereof as determined using quantitative infra-red analysis in accordance with ASTM E168; e.g. Organopolysiloxane polymer (i) has multiple groups of the formula (I):.

in which each R is independently selected from an aliphatic hydrocarbyl, aromatic hydrocarbyl, or organyl group (that is any organic substituent group, regardless of functional type, having one free valence at a carbon atom). Saturated aliphatic hydrocarbyls are exemplified by, but not limited to alkyl groups such as methyl, ethyl, propyl, pentyl, octyl, undecyl, and octadecyl and cycloalkyl groups such as cyclohexyl. Unsaturated aliphatic hydrocarbyls are exemplified by, but not limited to, alkenyl groups such as vinyl, allyl, butenyl, pentenyl, cyclohexenyl and hexenyl; and by alkynyl groups. Aromatic hydrocarbon groups are exemplified by, but not limited to, phenyl, tolyl, xylyl, benzyl, styryl, and <NUM>-phenylethyl. Organyl groups are exemplified by, but not limited to, halogenated alkyl groups such as chloromethyl and <NUM>-chloropropyl; nitrogen containing groups such as amino groups, amido groups, imino groups, imido groups; oxygen containing groups such as polyoxyalkylene groups, carbonyl groups, alkoxy groups and hydroxyl groups. Further organyl groups may include sulfur containing groups, phosphorus containing groups and/or boron containing groups. The subscript "a" may be <NUM>, <NUM>, <NUM> or <NUM>, but is typically mainly <NUM> or <NUM>.

Siloxy groups may be described by a shorthand (abbreviated) nomenclature, namely - "M," "D," "T," and "Q", when R is an organic group, typically methyl group (further teaching on silicone nomenclature may be found in<NPL>). The M group corresponds to a siloxy group where a = <NUM>, that is R<NUM>SiO<NUM>/<NUM>; the D group corresponds to a siloxy group where a = <NUM>, namely R<NUM>SiO<NUM>/<NUM>; the T group corresponds to a siloxy group where a = <NUM>, namely R<NUM>SiO<NUM>/<NUM>; the Q group corresponds to a siloxy group where a = <NUM>, namely SiO<NUM>/<NUM>.

Examples of typical groups on the organopolysiloxane polymer (i) include mainly alkenyl, alkyl, and/or aryl groups. The groups may be in pendent position (on a D or T siloxy group) or may be terminal (on an M siloxy group). Hence, suitable alkenyl groups in organopolysiloxane polymer (i) typically contain from <NUM> to <NUM> carbon atoms, e.g. vinyl, isopropenyl, allyl, and <NUM>-hexenyl, typically vinyl groups and as previously indicated are present on the polymer in an amount of at least <NUM> wt. % of the polymer(s) per molecule, alternatively from <NUM> to <NUM> wt. % of the polymer(s) per molecule, alternatively from <NUM> to <NUM> wt. % of the polymer(s) per molecule, alternatively from <NUM> to <NUM> wt. % of the polymer(s) per molecule which may be determined using quantitative infra-red analysis in accordance with ASTM E168.

The silicon-bonded organic groups attached to organopolysiloxane polymer (i) other than the unsaturated groups selected from alkenyl groups and/or alkynyl groups are typically selected from monovalent saturated hydrocarbon groups, which typically contain from <NUM> to <NUM> carbon atoms, and monovalent aromatic hydrocarbon groups, which typically contain from <NUM> to <NUM> carbon atoms, which are unsubstituted or substituted with groups that do not interfere with curing of this composition, such as halogen atoms. Preferred species of the silicon-bonded organic groups are, for example, alkyl groups such as methyl, ethyl, and propyl; and aryl groups such as phenyl.

The molecular structure of organopolysiloxane polymer (i) is typically linear, however, there can be some branching due to the presence of T groups (as previously described) within the molecule.

To achieve a useful level of physical properties in the elastomer prepared by curing the hydrosilylation curable silicone elastomer composition as hereinbefore described, the viscosity of organopolysiloxane polymer (i) should be at least 1000mPa. s at <NUM>. The upper limit for the viscosity of organopolysiloxane polymer (i) is limited to a viscosity of up to <NUM>,000mPa. s at <NUM>.

Generally, the or each organopolysiloxane containing at least <NUM> wt. % of the polymer(s) per molecule of unsaturated groups selected from alkenyl groups, alkynyl groups or a mixture thereof. The amount (wt. %) of unsaturated groups present is determined using quantitative infra-red analysis in accordance with ASTM E168. Component (i) has a viscosity of from <NUM> mPa. s to <NUM>,000mPa. s at <NUM>, alternatively <NUM> mPa. s to <NUM>,000mPa. s at <NUM>, alternatively from 2000mPa. s to <NUM>,000mPa. s at <NUM>, alternatively from 2000mPa. s to <NUM>,000mPa. s at <NUM> alternatively from 5000mPa. s to <NUM>,000mPa. s measured at <NUM> relying on the cup/spindle method of ASTM D <NUM>-<NUM> Method B, using an appropriate spindle for the viscosity range unless otherwise indicated.

The organopolysiloxane polymer (i) may be selected from polydimethylsiloxanes, alkylmethylpolysiloxanes, alkylarylpolysiloxanes or copolymers thereof containing e.g. alkenyl and/or alkynyl groups and may have any suitable terminal groups, for example, they may be trialkyl terminated, alkenyldialkyl terminated or may be terminated with any other suitable terminal group combination providing each organopolysiloxane polymer (i) contains at least <NUM> wt. % of the polymer(s) per molecule as previously discussed.

Hence the Organopolysiloxane polymer (i) may be, for the sake of example, dimethylvinyl terminated polydimethylsiloxane, dimethylvinyl terminated dimethylmethylphenylsiloxane, trialkyl terminated dimethylmethylvinyl polysiloxane or dialkylvinyl terminated dimethylmethylvinyl polysiloxane copolymers, although given the high level of alkenyl and/or alkynyl groups present alternatively trialkyl terminated dimethylmethylvinyl polysiloxane or dialkylvinyl terminated dimethylmethylvinyl polysiloxane copolymers.

For example, an organopolysiloxane polymer (i) containing unsaturated groups selected from alkenyl groups and/or alkynyl groups at the two terminals may be represented by the general formula (II):.

In formula (II), each R' may be an alkenyl group or an alkynyl group, which typically contains from <NUM> to <NUM> carbon atoms. Alkenyl groups include but are not limited to vinyl, propenyl, butenyl, pentenyl, hexenyl an alkenylated cyclohexyl group, heptenyl, octenyl, nonenyl, decenyl or similar linear and branched alkenyl groups and alkenylated aromatic ringed structures. Alkynyl groups may be selected from but are not limited to ethynyl, propynyl, butynyl, pentynyl, hexynyl, an alkynylated cyclohexyl group, heptynyl, octynyl, nonynyl, decynyl or similar linear and branched alkenyl groups and alkenylated aromatic ringed structures.

R" does not contain ethylenic unsaturation, each R" may be the same or different and is individually selected from monovalent saturated hydrocarbon group, which typically contain from <NUM> to <NUM> carbon atoms, and monovalent aromatic hydrocarbon group, which typically contain from <NUM> to <NUM> carbon atoms. R" may be unsubstituted or substituted with one or more groups that do not interfere with curing of the hydrosilylation curable silicone elastomer compositiondescribed herein, such as halogen atoms. R‴ is R' or R".

Organopolysiloxane polymer (i), is typically present in an amount of from <NUM>, alternatively from <NUM> wt. % of the composition, to <NUM> wt. %, alternatively <NUM> wt. % of the composition, for example organopolysiloxane polymer (i) may be present in a range of from <NUM> to <NUM> wt. %, alternatively from <NUM> to <NUM> wt. % of the composition.

Component (ii) of the leather coating composition comprising a hydrosilylation curable silicone elastomer composition is a reinforcing silica filler. Preferably Component (ii) of the leather coating composition comprising a hydrosilylation curable silicone elastomer composition is a reinforcing silica filler which is preferably provided in a finely divided form. Reinforcing silica fillers (ii) are often treated with one or more known filler treating agents to prevent a phenomenon referred to as "creping" or "crepe hardening" during processing of the hydrosilylation curable silicone elastomer composition.

Precipitated and/or fumed silicas, alternatively fumed silica is/are particularly preferred because of their relatively high surface area, which is typically at least <NUM><NUM>/g (BET method in accordance with ISO <NUM>: <NUM>). Fillers having surface areas of from <NUM> to <NUM><NUM>/g (BET method in accordance with ISO <NUM>: <NUM>), alternatively of from <NUM> to <NUM><NUM>/g (BET method in accordance with ISO <NUM>: <NUM>), are typically used. Both types of silica are commercially available. Preferably they are provided in a finely divided form.

The amount of reinforcing silica filler (ii) e.g., finely divided silica in the hydrosilylation curable silicone elastomer composition herein is from <NUM> to 40wt. %, alternatively from <NUM> to 30wt. In some instances, the amount of reinforcing silica filler may be from <NUM> to 30wt. , alternatively from <NUM> to 30wt. based on the weight of the composition, alternatively from <NUM> to 30wt. based on the weight of the composition.

When reinforcing silica filler (ii) is naturally hydrophilic (e.g., untreated silica fillers), it is typically treated with a treating agent to render it hydrophobic. These surface modified reinforcing silica fillers (ii) do not clump and can be homogeneously incorporated into organopolysiloxane polymer (i) as the surface treatment makes the fillers easily wetted by organopolysiloxane polymer (i). This results in improved room temperature mechanical properties of the hydrosilylation curable silicone elastomer compositions and resulting cured materials cured therefrom.

The surface treatment may be undertaken prior to introduction in the composition or in situ (i.e., in the presence of at least a portion of the other components of the composition herein by blending these components together at room temperature or above until the filler is completely treated. Typically, untreated reinforcing silica filler (ii) is treated in situ with a treating agent in the presence of organopolysiloxane polymer (i), whereafter mixing a silicone rubber base material is obtained, to which other components may be added.

Typically reinforcing silica filler (ii) may be surface treated with any low molecular weight organosilicon compounds disclosed in the art applicable to prevent creping of the hydrosilylation curable silicone elastomer composition during processing. For example, organosilanes, organopolysiloxanes, or organosilazanes e.g., hexalkyl disilazane, short chain siloxane diols or fatty acids or fatty acid esters such as stearates to render the filler(s) hydrophobic and therefore easier to handle and obtain a homogeneous mixture with the other components. Specific examples include but are not restricted to silanol terminated trifluoropropylmethyl siloxane, silanol terminated ViMe siloxane, tetramethyldi(trifluoropropyl)disilazane, tetramethyldivinyl disilazane, silanol terminated MePh siloxane, liquid hydroxyl-terminated polydiorganosiloxane containing an average from <NUM> to <NUM> repeating groups of diorganosiloxane in each molecule, hexaorganodisiloxane, hexaorganodisilazane. A small amount of water can be added together with the silica treating agent(s) as a processing aid.

The filler may be introduced into the hydrosilylation curable silicone elastomer composition in the form of a masterbatch or base comprising said filler and an organopolysiloxane polymer. The organopolysiloxane polymer used for the masterbatch or base may be of a similar structure to component (i) but alternatively may be an organopolysiloxane polymer having a viscosity in the same range as component (i) but having an alkenyl and/or alkynyl content of < <NUM> wt. % (ASTM E168 ) of the polymer. If required, the fumed silica may be hydrophobically treated in situ during the preparation of the masterbatch by the introduction of suitable hydrophobing agents into the mixture.

The hydrosilylation curable silicone elastomer composition as described herein is cured using a hydrosilylation cure package comprising an organohydrogenpolysiloxane having <NUM> or more silicon-bonded hydrogen atoms per molecule (Component iii) and a hydrosilylation catalyst (component iv).

Component (iii) of the leather coating composition comprising the hydrosilylation curable silicone elastomer composition is a silicone resin cross-linker having terminal groups comprising silicone bonded hydrogen, which operates as a cross-linker for polymer (i), by the addition reaction of the silicon-bonded hydrogen atoms in component (iii) with the alkenyl groups and/or alkynyl groups in component (i) under the catalytic activity of component (iv) to be mentioned below. Component (iii) contains at least <NUM>,<NUM> parts per million (ppm) of silicon bonded hydrogen (Si-H), alternatively at least <NUM> ppm, alternatively from <NUM> to <NUM>,000ppm of silicon bonded hydrogen, alternatively <NUM> ppm to <NUM>,<NUM> ppm of silicon bonded hydrogen so that the silicon bonded hydrogen atoms of this component can sufficiently react with the alkenyl groups and/or alkynyl groups, typically alkenyl groups, especially vinyl groups of component (i) to form a network structure therewith and thereby cure the composition. The quantity of silicon bonded hydrogen present is also determined using quantitative infra-red analysis in accordance with ASTM E168.

The molecular configuration of component (iii) is resinous, comprising a mixture of Q, T, D and M groups and has a viscosity of from <NUM> to 5000mPa. s at <NUM>, alternatively <NUM> to <NUM> mPa. s at <NUM>, alternatively <NUM> to <NUM> mPa. s at <NUM> using a Brookfield DV 3T Rheometer to obtain a good miscibility with component (i).

Examples of component (iii) of the leather coating composition comprising the hydrosilylation curable silicone elastomer composition include but are not limited to:.

Optionally, other cross-linkers may additionally be utilised. These may include <NUM>,<NUM>,<NUM>,<NUM> -tetramethyldisiloxane, <NUM>,<NUM>,<NUM>,<NUM>-tetramethylcyclotetrasiloxane, tris(hydrogendimethylsiloxy)methylsilane, tris(hydrogendimethylsiloxy)phenylsilane, methylhydrogencyclopolysiloxane, trimethylsiloxy-end-blocked methylhydrogenpolysiloxane, trimethylsiloxy-end-blocked dimethylsiloxane/methylhydrogensiloxane copolymers, dimethylhydrogensiloxy-end-blocked dimethylpolysiloxane, dimethylhydrogensiloxy-end-blocked dimethylsiloxane/methylhydrogensiloxane copolymers, trimethylsiloxy-end-blocked methylhydrogensiloxane/diphenylsiloxane copolymers, trimethylsiloxy-end-blocked methylhydrogensiloxane/diphenylsiloxane/-dimethylsiloxane copolymers, trimethylsiloxy-end-blocked methylhydrogensiloxane/methylphenylsiloxane/-dimethylsiloxane copolymers, dimethylhydrogensiloxy-end-blocked /dimethylsiloxane/-diphenylsiloxane copolymers and/or dimethylhydrogensiloxy-end-blocked methylhydrogensiloxane/dimethylsiloxane/- methylphenylsiloxane copolymers. However, it is preferred that component (iii) is one or more silicone resin as described above.

Component (iii) is typically present in the total composition in an amount of from <NUM> to <NUM> wt. %, <NUM> to <NUM> wt. %, alternatively from <NUM> to <NUM> wt. % of the composition but the amount present is typically determined by the molar ratio of the silicon-bonded hydrogen atoms in component (iii) to the total number of all unsaturated groups, e.g. alkenyl and alkynyl groups, often vinyl groups. In the present composition the molar ratio of the silicon-bonded hydrogen atoms in component (iii) to the total number of all unsaturated groups is from <NUM> : <NUM> to <NUM> : <NUM>, alternatively from <NUM> : <NUM> to <NUM> : <NUM>, alternatively from <NUM> : <NUM> to <NUM> : <NUM>, alternatively from <NUM> : <NUM> to <NUM> : <NUM> preferably with Si-H being in excess.

As hereinbefore described the leather coating composition is cured via a hydrosilylation (addition) reaction catalysed by a hydrosilylation (addition cure) catalyst (iv) that is a metal selected from the platinum metals, i.e., platinum, ruthenium, osmium, rhodium, iridium and palladium, or a compound of such metals. Platinum and rhodium compounds are preferred due to the high activity level of these catalysts for hydrosilylation reactions.

The catalyst (iv) can be a platinum group metal, a platinum group metal deposited on a carrier, such as activated carbon, metal oxides, such as aluminum oxide or silicon dioxide, silica gel or powdered charcoal, or a compound or complex of a platinum group metal.

Examples of preferred hydrosilylation catalysts (iv) are platinum-based catalysts, for example, platinum black, platinum oxide (Adams catalyst), platinum on various solid supports, chloroplatinic acids, alcohol solutions of chloroplatinic acid, and complexes of chloroplatinic acid with ethylenically unsaturated compounds such as olefins and organosiloxanes containing ethylenically unsaturated silicon-bonded hydrocarbon groups. Soluble platinum compounds that can be used include, for example, the platinum-olefin complexes of the formulae (PtCl<NUM>. (olefin)<NUM> and H(PtCl<NUM>. olefin), preference being given in this context to the use of alkenes having <NUM> to <NUM> carbon atoms, such as ethylene, propylene, isomers of butene and of octene, or cycloalkanes having five to seven carbon atoms, such as cyclopentene, cyclohexene, and cycloheptene. Other soluble platinum catalysts are, for the sake of example a platinum-cyclopropane complex of the formula (PtCl<NUM>C<NUM>H<NUM>)<NUM>, the reaction products of hexachloroplatinic acid with alcohols, ethers, and aldehydes or mixtures thereof, or the reaction product of hexachloroplatinic acid with methylvinylcyclotetrasiloxane in the presence of sodium bicarbonate in ethanolic solution. Platinum catalysts with phosphorus, sulfur, and amine ligands can be used as well, e.g., (Ph<NUM>P)<NUM>PtCl<NUM>; and complexes of platinum with vinylsiloxanes, such as sym-divinyltetramethyldisiloxane.

Hence, specific examples of suitable platinum-based catalysts include.

The hydrosilylation catalyst (iv) of the hydrosilylation curable silicone elastomer composition is present in the total composition in a catalytic amount, i.e., an amount or quantity sufficient to catalyse the addition/hydrosilylation reaction and cure the composition to an elastomeric material under the desired conditions. Varying levels of the hydrosilylation catalyst (iv) can be used to tailor reaction rate and cure kinetics. The catalytic amount of the hydrosilylation catalyst (iv) is generally between <NUM> ppm, and <NUM>,<NUM> parts by weight of platinum-group metal, per million parts (ppm), based on the weight of the composition; alternatively, between <NUM> and 5000ppm; alternatively, between <NUM> and <NUM>,<NUM> ppm, and alternatively between <NUM> and <NUM>,<NUM> ppm. In specific embodiments, the catalytic amount of the catalyst may range from <NUM> to <NUM>,<NUM> ppm, alternatively <NUM> to <NUM> ppm, alternatively <NUM> to <NUM> ppm and alternatively <NUM> to <NUM> ppm of metal based on the weight of the composition. The ranges may relate solely to the metal content within the catalyst or to the catalyst altogether (including its ligands) as specified, but typically these ranges relate solely to the metal content within the catalyst. The catalyst may be added as a single species or as a mixture of two or more different species. Typically, dependent on the form/concentration in which the catalyst package is provided the amount of catalyst present will be within the range of from <NUM> to <NUM>. % of the composition, alternatively, from <NUM> to <NUM> wt. % of the composition, alternatively, from <NUM> to <NUM> wt. % of the composition, alternatively from <NUM> to <NUM> wt. % % of the composition, alternatively from <NUM> to <NUM> wt. % of the composition.

Component (v) of the hydrosilylation curable silicone elastomer composition herein, are silicon-free organic microparticles having a number average particle size of from <NUM> to <NUM>, alternatively <NUM> to <NUM>, alternatively <NUM> to <NUM>, alternatively <NUM> to <NUM>, alternatively <NUM> to <NUM>. The number average particle sizes may be measured using a field emission scanning electron microscope such as a FEI Nova NanoSEM™ <NUM> scanning electron microscope from Thermo Fisher Scientific. For example, this may be achieved by taking a field emission scanning electron microscope photograph of the particles and then selecting <NUM> particles randomly from the photograph and measuring the diameter of each of particle in the images Then the average diameter is calculated for the particles selected. The silicon-free organic microparticles of component (v) are thermally stable up to a temperature of at least <NUM> and are present in the composition in an amount of from <NUM> to <NUM> wt. %, alternatively in an amount of from of from <NUM> to <NUM> wt. %, alternatively in an amount of from <NUM> to <NUM> wt. % of the composition. They are required to be thermally stable throughout the cure process which is typically held at a temperature between <NUM> and <NUM>. By "thermally stable" we mean that the silicon-free organic microparticles do not thermally degrade at temperatures at or below <NUM>. This is determined by placing a sample of silicon-free organic microparticles in a suitable container and then placing the container into a preheated oven at a temperature of <NUM> and atmospheric pressure, for a period of <NUM> minutes. After the <NUM> minutes in the oven the sample is visually assessed to determine whether the microparticles appear to be in their original form in which case they are deemed thermally stable up to a temperature of <NUM> (pass) or whether they have visually degraded in some way which is visually evident e.g., by agglomeration, liquefaction, carbonization and /or decomposition. The component (v) silicon-free organic microparticles are generally or preferably spherical and/or quasi-spherical in shape. The component (v) silicon-free organic microparticles may be thermoset materials. Furthermore, for the avoidance of doubt the component (v) silicon-free organic microparticles are silicon-free, allowing only for trace contamination, i.e., the silicon-free organic microparticles contain substantially no silicon atoms or silicon containing compounds. The term substantially used above is intended to mean that only trace amounts of silicon are present, typically in the form of impurities.

Component (v) the silicon-free organic microparticles may be made of any suitable organic materials, providing they meet the predefined requirements they may selected from polyurethane microparticles, acrylic microparticles, methacrylic microparticles, polytetrafluoroethylene microparticles, polyester microparticles, polyamide microparticles and/or polyolefin microparticles, and derivatives and or mixtures thereof. For example, they may comprise, but are not limited to one or more of polyethylene, polystyrene, polyvinyl acetate, polyvinyl chloride, polyvinylidene chloride, polyacrylonitrile, polymethyl methacrylate, polybutadiene, polychloroprene, and other vinyl polymers and copolymers thereof; Nylon <NUM>, Nylon <NUM>, and other polyamides; and polyethylene terephthalate, polyacetal, and blends thereof. It was found that the silicon-free organic microparticles of component (v) were successful as a means of minimising visual changes in gloss after abrasion because whilst the small grains on the leather surface will be worn away during abrasion, the appearance of the micro-particles at the topcoat surface will help to compensate for the loss of surface roughness, so as to avoid, in this case, increased gloss. In addition, the presence of the robust silicon-free organic microparticles at the topcoat surface will help to avoid further abrasion of the matrix.

The leather coating composition_may comprise one or more additives. Examples of these optional additives include cure inhibitors, cured silicone elastomer powder, inorganic non-reinforcing fillers, electrically conductive additives, pot life extenders, lubricants, flame retardants, pigments, colouring agents, chain extenders, heat stabilizers, diluents (designed to evaporate during cure), compression set improvement additives, antisqueak agents, antioxidants, antistatic agents, anti-soiling agents and light stabilizers, anti-freeze agents and/or biocides and mixtures thereof.

Optionally, to obtain a longer working time or pot life of the hydrosilylation curable silicone elastomer composition used in or as the leather coating composition because a hydrosilylation cure system is being utilised, a suitable inhibitor may be incorporated into the composition in order to retard or suppress the activity of the catalyst.

Inhibitors of platinum metal-based catalysts, generally a platinum metal-based catalyst is well known in the art. Hydrosilylation or addition-reaction inhibitors include hydrazines, triazoles, phosphines, mercaptans, organic nitrogen compounds, acetylenic alcohols, silylated acetylenic alcohols such as methyl (tris(<NUM>,<NUM>-dimethyl-<NUM>-propynyloxy))silane, maleates, fumarates, ethylenically or aromatically unsaturated amides, ethylenically unsaturated isocyanates, olefinic siloxanes, unsaturated hydrocarbon monoesters and diesters, conjugated ene-ynes, hydroperoxides, nitriles, and diaziridines. Alkenyl-substituted siloxanes as described in <CIT> may be used, of which cyclic methylvinylsiloxanes are preferred.

Another class of known inhibitors of platinum catalysts includes the acetylenic compounds disclosed in <CIT>. Acetylenic alcohols such as <NUM>-methyl-<NUM>-butyn-<NUM>-ol constitute a preferred class of inhibitors that will suppress the activity of a platinum-containing catalyst at <NUM>. Hydrosilylation curable silicone elastomer compositions containing these inhibitors typically require heating at temperature of <NUM> or above to cure at a practical rate.

Examples of acetylenic alcohols and their derivatives include <NUM>-ethynyl-<NUM>-cyclohexanol (ETCH), <NUM>-methyl-<NUM>-butyn-<NUM>-ol, <NUM>-butyn-<NUM>-ol, <NUM>-butyn-<NUM>-ol, propargyl alcohol, <NUM>,<NUM>-dimethyl-<NUM>-hexyn-<NUM>-ol, <NUM>-ethynylcyclopentanol, <NUM>-phenyl-<NUM>-propynol, <NUM>-methyl-<NUM>-penten-<NUM>-yn-<NUM>-ol, and mixtures thereof.

When present, inhibitor concentrations as low as <NUM> mole of inhibitor per mole of the metal of catalyst (iv) will in some instances impart satisfactory storage stability and cure rate. In other instances, inhibitor concentrations of up to <NUM> moles of inhibitor per mole of the metal of catalyst (iv) are required. The optimum concentration for a given inhibitor in a given composition is readily determined by routine experimentation. Dependent on the concentration and form in which the inhibitor selected is provided/available commercially, when present in the composition, the inhibitor is typically present in an amount of from <NUM> to <NUM> wt. % of the composition. Mixtures of the above may also be used.

Another optional additive which may be included in the hydrosilylation curable silicone elastomer composition is a suitable cured silicone elastomer powder. The cured silicone elastomer powder may have any suitable average particle size, for example, from <NUM> to <NUM>, alternatively <NUM> to <NUM>, alternatively from <NUM> to <NUM>. as measured using the Dow Silicone Corporation Corporate Test Method CTM <NUM> which is available to the public upon request. They may contain chemically functional groups, e.g., epoxy groups (meth)acryloxy groups or may be coated e.g., with a silica treated coating.

The cured silicone elastomer powder is made from a suitable curable silicone composition. These may include, for example, addition (hydrosilylation) reaction-curing silicone compositions, condensation reaction-curing silicone compositions, organoperoxide-curing silicone compositions, and ultraviolet-curing silicone compositions. Addition reaction-curing and condensation reaction-curing silicone compositions are preferred for their ease of handling. Commercial examples which may be utilised as component (v) include, for the sake of example, Dowsil™ 23N Additive, Dowsil™ 603T additive and Dowsil ™ <NUM> Cosmetic Powder from Dow Silicones Corporation.

When present, the cured silicone rubber powder is present in the hydrosilylation curable silicone elastomer composition in an amount of from <NUM> to <NUM> wt. % of the composition, alternatively from <NUM> to 15wt. % of the composition, alternatively from <NUM>. % of the composition.

Inorganic non-reinforcing fillers, when present, in the hydrosilylation curable silicone elastomer composition, may comprise crushed quartz, diatomaceous earths, barium sulphate, iron oxide, titanium dioxide and carbon black, wollastonite and platelet type fillers such as, graphite, graphene, talc, mica, clay, sheet silicates, kaolin, montmorillonite and mixtures thereof. Other inorganic non-reinforcing fillers which might be used alone or in addition to the above include aluminite, calcium sulphate (anhydrite), gypsum, calcium sulphate, magnesium carbonate, aluminium trihydroxide, magnesium hydroxide (brucite), graphite, copper carbonate, e.g., malachite, nickel carbonate, e.g., zarachite, barium carbonate, e.g., witherite and/or strontium carbonate e.g., strontianite.

Inorganic non-reinforcing fillers when present may alternatively or additionally be selected from aluminium oxide, silicates from the group consisting of olivine group; garnet group; aluminosilicates; ring silicates; chain silicates; and sheet silicates. The olivine group comprises silicate minerals, such as but not limited to, forsterite and Mg<NUM>SiO<NUM>. The garnet group comprises ground silicate minerals, such as but not limited to, pyrope; Mg<NUM>Al<NUM>Si<NUM>O<NUM>; grossular; and Ca<NUM>Al<NUM>Si<NUM>O<NUM>. Aluminosilicates comprise ground silicate minerals, such as but not limited to, sillimanite; Al<NUM>SiO<NUM>; mullite; 3Al<NUM>O<NUM>. 2SiO<NUM>; kyanite; and Al<NUM>SiO<NUM>. The ring silicates group comprises silicate minerals, such as but not limited to, cordierite and Al<NUM>(Mg,Fe)<NUM>[Si<NUM>AlO<NUM>]. The chain silicates group comprises ground silicate minerals, such as but not limited to, wollastonite and Ca[SiO<NUM>].

Suitable sheet silicates e.g., silicate minerals which may be utilised include but are not limited to mica; K<NUM>AI<NUM>[Si<NUM>Al<NUM>O<NUM>](OH)<NUM>; pyrophyllite; Al<NUM>[Si<NUM>O<NUM>](OH)<NUM>; talc; Mg<NUM>[Si<NUM>O<NUM>](OH)<NUM>; serpentine for example, asbestos; Kaolinite; Al<NUM>[Si<NUM>O<NUM>](OH)<NUM>; and vermiculite. When present, the non-reinforcing filler(s) is/are present up to a cumulative total of from <NUM> to 50wt. of the composition.

Whenever deemed necessary the non-reinforcing filler may also be treated as described above with respect to the reinforcing silica fillers (ii) to render them hydrophobic and thereby easier to handle and obtain a homogeneous mixture with the other components. As in the case of the reinforcing silica fillers (ii) surface treatment of the non-reinforcing fillers makes them easily wetted by organopolysiloxane polymer (i) and silicon-free organic microparticles (v) when present which may result in improved properties of the hydrosilylation curable silicone elastomer compositions, such as better processability (e.g., lower viscosity, better mold releasing ability and/or less adhesive to processing equipment, such as two roll mill), heat resistance, and mechanical properties.

Any suitable antioxidants, antistatic agents, anti-soiling agents and/or light stabilizers may be utilised in the composition.

Preferably the electrically conductive additives which may be used herein are inorganic. Examples of electrically conductive additives which may be present in the composition include metal particles, metal oxide particles, metal-coated metallic particles (such as silver-plated nickel), metal coated non-metallic core particles (such as silver coated talc, or mica or quartz) and a combination thereof. Metal particles may be in the form of powder, flakes or filaments, and mixtures or derivatives thereof.

Pot life extenders, such as triazole, may be used, but are not considered necessary in the scope of the present invention. The hydrosilylation curable silicone elastomer composition may thus be free of pot life extender.

In the case of lubricants, the lubricants may be reactive with other ingredients of the composition or unreactive therewith. They may include organopolysiloxanes having an analogous basic structure to that of component (i) but only having one unsaturated group e.g., one alkenyl group per molecule. Alternatively, the lubricant may be an organic wax or the like. When reactive the wax may for example be alkenylated wax having from <NUM> to <NUM> carbons per molecule, alternatively having from <NUM> to <NUM> carbons per molecule with at least one alkenylated group e.g., a vinyl group per molecule.

Unreactive lubricants may be present in the composition if desired these may include but are not limited to boron nitride, graphite, molybdenum sulfide and the like, or mixtures thereof.

Examples of flame retardants include aluminium trihydrate, magnesium hydroxide, calcium carbonate, zinc borate, wollastonite, mica and chlorinated paraffins, hexabromocyclododecane, triphenyl phosphate, dimethyl methylphosphonate, tris(<NUM>,<NUM>-dibromopropyl) phosphate (brominated tris), and mixtures or derivatives thereof.

Examples of pigments include carbon black, iron oxides, titanium dioxide, chromium oxide, bismuth vanadium oxide and mixtures or derivatives thereof.

Examples of colouring agents include vat dyes, reactive dyes, acid dyes, chrome dyes, disperse dyes, cationic dyes and mixtures thereof.

Where the optional additives may be used for more than one reason e.g., as a non-reinforcing filler and flame retardant, when present they may function in both roles. When or if present, the aforementioned additional components are cumulatively present in an amount of from <NUM> to 30wt. %, alternatively of from <NUM> to <NUM> wt. % of the composition.

In order to prevent premature cure in storage, the composition is stored prior to use in two-parts, Part A and part B. Typically, part A contains some of organopolysiloxane polymer (i) and reinforcing silica filler (ii) and hydrosilylation catalyst (iv) and part B will contain the remainder of organopolysiloxane polymer (i) and reinforcing silica filler (ii) together with components organohydrogenpolysiloxane (iii) and, usually if present, the inhibitor, but this can vary dependent on the choice of the inhibitor used. The two-part composition may be designed to be mixed together in any suitable ratio, dependent on the amounts of organopolysiloxane polymer (i) and reinforcing silica filler (ii) in part B and as such can be mixed in a Part A : Part B weight ratio of from <NUM> : <NUM> to <NUM> : <NUM> but are preferably mixed in a Part A : Part B weight ratio of from <NUM> : <NUM> to <NUM> : <NUM>, alternatively from <NUM> : <NUM> to <NUM> : <NUM>, alternatively <NUM>:<NUM>.

Optional additives may be introduced into the silicone elastomeric composition in either Part A or part B as required providing they do not cause a negative effect on any of the other ingredients in that respective part.

The individual parts of the hydrosilylation curable silicone elastomer composition used for the leather coating composition may be prepared in any way suitable. Any mixing techniques and devices described in the prior art can be used for this purpose. The particular device to be used will be determined dependent on the viscosities of components and the final curable coating composition. Suitable mixers include but are not limited to paddle type mixers e.g., planetary mixers and kneader type mixers. Cooling of components during mixing may be desirable to avoid premature curing of the composition.

As previously discussed, component (ii) the reinforcing silica filler may be introduced into the composition in the form of a fumed silica masterbatch used to introduce fumed silica into both part A or Part B of the composition may comprise from <NUM> to 45wt. % of fumed silica and from <NUM> to 75wt. % of organopolysiloxane containing at least <NUM> alkenyl and/or alkynyl groups per molecule. The organopolysiloxane may be component (i) above and/or an organopolysiloxane in the same viscosity range as component (i) but having an alkenyl and/or alkynyl content of <<NUM> wt. % of the polymer. In one embodiment the organopolysiloxane containing at least <NUM> alkenyl and/or alkynyl groups per molecule in the fumed silica masterbatch is a dimethylvinyl terminated polydimethylsiloxane having a viscosity of between <NUM>,<NUM> and <NUM>,000mPa. s at <NUM> and a vinyl content of from <NUM> to <NUM> wt. % of the polymer, alternatively a vinyl content of from <NUM> to <NUM> wt. % of the polymer determined using quantitative infra-red analysis in accordance with ASTM E168. Such a masterbatch may comprise just the fumed silica and polymer but may optionally also contain small amounts of other ingredients such as hexamethyldisilazane (HMDZ), divinyltetramethyldisiloxane, dimethylhydroxy terminated methylvinyl siloxane polymer having a viscosity of <NUM> to 100mPa. s and a vinyl content of <NUM> to <NUM> wt. %, alternatively <NUM> to <NUM> wt. % of said polymer (determined using quantitative infra-red analysis in accordance with ASTM E168); and/or water.

Hence, when Part A and Part B are mixed together the hydrosilylation curable silicone elastomer composition may comprise:.

The total wt. % of the composition including components (i) to (v) and any additives is 100wt. % but may be any suitable combination of the above.

The order for mixing components in the hydrosilylation curable silicone elastomer composition of the leather coating composition is not critical. Suitable parts A and B are prepared and then part A and part B are mixed together in a predetermined ratio between <NUM>: <NUM> and <NUM>:<NUM> e.g., for the sake of example, a <NUM> : <NUM> ratio shortly prior to use.

Curing of the hydrosilylation curable silicone elastomer composition of the leather coating composition may be carried out at a suitable temperature for hydrosilylation cure. For example, a cure temperature of from about <NUM> to <NUM>, alternatively from <NUM> to <NUM>, alternatively of from <NUM> to <NUM>.

The leather coating composition as described is utilised as a topcoat for synthetic leather materials, particularly silicone-based synthetic leather composite materials, because once cured it provides outstanding abrasion and scratch resistance protection. The leather coating composition may also be applied to various other types of leather, for example conventional leather, nubuck or suede. The leather coating composition as hereinbefore described may be applied to finished leather or during the final wet stage in finishing leather but is preferably used as a topcoat for synthetic leather, particularly silicone-based synthetic leather composite materials. Leather having a topcoat in the form of a reaction product from the cure of the leather coating composition described above has a greatly increased abrasion resistance. This increase in abrasion resistance is achieved without detriment to the compatibility and the flexibility of the final coating; other additives often used to increase abrasion resistance may harshen the touch of the coated leather and increase resistance to bending, causing cracks in the structure of the coating.

The application and uses of the leather coating composition as hereinbefore described will be more apparent from the following further description taken in conjunction with the accompanying Figures in which <FIG> are cross-sectional views showing the layers in the structure of a silicone-based synthetic leather composite material during or post manufacture; Detailed Description of the methods of making a silicone-based synthetic leather composite material using the hydrosilylation curable silicone elastomer composition as hereinbefore described in conjunction with the aforementioned Figures.

A silicone-based synthetic leather composite material comprising a coating which is the reaction product from the cure of the leather coating composition (<NUM>) as hereinbefore described, may comprise several layers of cured liquid silicone rubber (<NUM>,<NUM>) each having a different function as well as a textile support layer (<NUM>). Excluding the topcoat which is made from the leather coating composition described herein, a silicone-based synthetic leather composite material comprises at least a textile support layer (<NUM>), an adhesive layer made from a first liquid silicone rubber material (<NUM>) and a second or skin layer (<NUM>) made from a second liquid silicone rubber material. The adhesive layer (<NUM>) is provided as an effective adhesive between the textile support (<NUM>) and the second (skin) layer (<NUM>). In use the adhesive or first layer (<NUM>) is adhered to the textile support layer (<NUM>) and adhered or laminated to the skin layer (<NUM>). The leather coating composition as hereinbefore described functions as a protective topcoat (<NUM>) which is a third layer on top of and bound to the skin layer (<NUM>), i.e., the second layer (<NUM>) is situated between the adhesive layer (<NUM>) and the topcoat layer (<NUM>).

Typically, a release liner (<NUM>) is provided to protect the external surface of the silicone-based synthetic leather composite material until required. Dependent on the process relied upon for making the silicone-based synthetic leather composite material. The release liner (<NUM>) may be included in the initial combination of layers adhered to the skin layer (<NUM>) or to the topcoat (<NUM>), dependent on the process preferred. In the former case the release liner (<NUM>) may be removed prior to application of the topcoat. In the latter case the topcoat is applied onto the skin before application of the release liner onto the topcoat, or the topcoat is first applied onto the release liner, before application of the additional layers.

The textile support layer (<NUM>) may be made from any suitable textile material for example woven, knitted or non-woven textiles made from synthetic resin fibers, natural fibers and/or, microfibers. These may include but are not restricted to polyester fiber, a viscose rayon fiber, a polyamide fiber, nylon, an acrylic fiber, a polyolefin fiber; cellulose fibers such as cotton; and elastic textile materials, such as spandex, may be used as may mixtures of any two or more of the above. The textile support layer is designed to enhance mechanical strength of silicone leather.

The leather coating composition as hereinbefore described (i.e., the topcoat layer (<NUM>)) is typically applied with a wet film thickness of <NUM> to <NUM>, alternatively <NUM> to <NUM> corresponding to a dry coating thickness of about <NUM> to <NUM>, alternatively <NUM> to <NUM> alternatively <NUM> to <NUM>. It can be cured at any suitable temperature, for example at about <NUM> to <NUM>, alternatively from <NUM> to <NUM>, alternatively of from <NUM> to <NUM> for a period of from for a suitable period, e.g., between <NUM> seconds and <NUM> minutes, alternatively <NUM> seconds to <NUM> minutes, alternatively <NUM> seconds to <NUM> minutes, alternatively <NUM> seconds to <NUM> minutes.

Any suitable liquid silicone rubber composition may be utilised as the adhesive or first layer (<NUM>). This must be able to adhere to the textile support layer (<NUM>) and typically once cured has a low durometer Shore A hardness e.g., between <NUM> and <NUM> and a soft hand feeling to the touch. A commercial example of a suitable hydrosilylation curable liquid silicone rubber composition designed to function as the adhesive layer (<NUM>) is Dowsil™ LCF <NUM> Binder, from Dow Silicones Corporation. Dowsil™ LCF <NUM> Binder is provided to the customer in a two-part form as is standard for a hydrosilylation curable composition to avoid premature cure and as such the two-parts of Dowsil™ LCF <NUM> Binder are mixed together immediately prior to use.

The adhesive layer (<NUM>) may be of any desired dry thickness, for example <NUM> to <NUM> thick, alternatively <NUM> to <NUM>, alternatively <NUM> to <NUM>, alternatively <NUM> to <NUM>, alternatively <NUM> to <NUM> thick. It can be cured at any suitable temperature, for example at <NUM> to <NUM>, alternatively <NUM> to <NUM>, alternatively <NUM> to <NUM> for a suitable period of up to <NUM> minutes, alternatively <NUM> to <NUM> minutes, alternatively for a period of from <NUM> minutes to <NUM> minutes, alternatively <NUM> minutes to <NUM> minutes.

As previously indicated the first or adhesive layer (<NUM>) is designed to be sandwiched between and to adhere the textile support (<NUM>) to the second or skin coating layer (<NUM>).

The second or skin coating composition (<NUM>) as hereinbefore described is designed as a protective synthetic leather which is usually bonded to adhesive layer (<NUM>). and may be used alone or with a suitable topcoat (<NUM>) such as the one described herein. Any suitable liquid silicone rubber composition may be utilised to form the second or skin layer (<NUM>) which typically once cured has a larger durometer Shore A hardness than the first or adhesive layer (<NUM>) e.g., greater than or equal to (≥) <NUM>, alternatively, greater than or equal to (≥) <NUM>. Commercial examples of suitable liquid silicone rubber compositions curable to function as the second or skin layer (<NUM>) are Dowsil™ LCF <NUM> Skin and Dowsil™ LCF <NUM> Skin both from Dow Silicones Corporation, which given they are both hydrosilylation curable liquid silicone rubber compositions are again provided to the user in two-parts which are mixed together immediately prior to use to avoid premature cure in storage prior to use. Dowsil™ LCF <NUM> Skin has a high shore A durometer value of about <NUM> and provides abrasion resistance and has compared to Dowsil™ LCF <NUM> Skin a relatively low viscosity. The latter is much higher viscosity as it is a fumed silica reinforced version of the former having high mechanical strength. Often a mixture of Dowsil™ LCF <NUM> Skin and Dowsil™ LCF <NUM> Skin is used as the second or skin layer (<NUM>) to benefit from the advantages of both compositions.

The skin layer (<NUM>) may be of any suitable dry thickness, for example, the adhesive layer may be of any desired thickness, for example <NUM> to <NUM>, thick, <NUM> to <NUM>, alternatively <NUM> to <NUM>, alternatively <NUM> to <NUM>, alternatively <NUM> to <NUM> thick. If the skin layer was applied direct onto the release paper, and the average thickness of the skin layer was determined this was determined by measuring the length and width of a sample of release paper, coating the release paper with the, in this case, skin layer composition, curing same, weighing the resulting release paper coated and calculating the average thickness on the basis of the following formula: <MAT> The average dry coat thickness of each other layer where given, was determined in an analogous fashion by determining the weight of the respective layer and using the above formulation. In each case the density was determined in accordance with ASTM D792. The skin layer can be cured at any suitable temperature, for example at <NUM> to <NUM>, alternatively <NUM> to <NUM>, alternatively <NUM> to <NUM> for a period of from <NUM> seconds to <NUM> minutes, alternatively <NUM> seconds to <NUM> minutes.

If desired the final silicone leather product may be post cured at a temperature between about <NUM> and <NUM>, generally but not necessarily if desired towards the lower end of the range e.g., from <NUM> to <NUM> for from <NUM> to <NUM> hours, alternatively from <NUM> to <NUM> hours, alternatively from <NUM> to <NUM> hours.

The leather coating composition as hereinbefore described may be applied as a topcoat on a preformed silicone-based synthetic leather composite material e.g. (<NUM>, <NUM>, <NUM>) as shown in <FIG> by any suitable coating method e.g. spraying, rolling, brushing, spin coating, dip coating, solvent casting, slot die coating, spray coating, knife coating, or gravure coating. The adhesive layer (<NUM>) and skin layer (<NUM>) may be applied via the same means.

The fabric layer may be adhered to the adhesive layer in any suitable manner e.g., lamination.

In such circumstances the preformed silicone-based synthetic leather composite material has typically been prepared by several alternative processes.

The above is depicted in <FIG> which depict a silicone-based synthetic leather composite material with the release liner present (<FIG>) and without the release liner (<FIG>). In the case of <FIG> the silicone-based synthetic leather composite material has been prepared and is now ready for application of the topcoat as hereinbefore described by any suitable application means (e.g., spraying, rolling, brushing, spin coating, dip coating, solvent casting, slot die coating, spray coating, knife coating, or gravure coating) as described above on top of the skin layer (<NUM>).

The leather coating composition as hereinbefore described is then applied on to the surface of the skin layer (<NUM>) from which the release liner (<NUM>) has been removed and is cured to form a protective topcoat on the silicone-based synthetic leather composite material.

In an alternative embodiment silicone-based synthetic leather composite material may be prepared in a continuous process with a topcoat using the leather coating composition as hereinbefore described in the continuous process. In this case the process followed may be:.

The different layers for such a process are depicted in <FIG>, wherein <FIG> depicts the release liner (<NUM>) present and <FIG> depicts the final silicone-based synthetic leather composite material with the release liner removed.

Any suitable release liner may be used for example super matting release paper ARX175DM from the Japan Asahi company, release paper DE-<NUM>, DE-<NUM>, DE-43C, DE-73J from the Japan Dai Nippon Printing Co. , Ltd or semi-matting release paper DE-<NUM> also from the Japan Dai Nippon Printing Co. Each cure step may take place in a suitable oven, e.g., by curing and drying in a hot-air oven or may be undertaken in a conveyor oven in the case of a continuous process.

The above processes depict the preparation of a silicone-based synthetic leather composite material. The reader may appreciate that should the need arise additional layers may be introduced into the material if desired.

Synthetic leathers, particularly silicone-based synthetic leather composite materials may be designed to have a wide variety of properties given the content of the different layers, e.g. they may have excellent flame retardancy, smoke density, heat resistance, contamination resistance, solvent resistance, hydrolysis resistance, and the like as required for the end use of the leather. End uses envisaged include but are not limited to furniture, decoration, handbags, binders, luggage, garments, phone covers, covers for electronic goods, book covers, footwear, car interiors, car seats, wearable devices and/or medical beds/seats and the like.

In the following examples the hydrosilylation curable silicone elastomer composition which forms the leather coating composition and several comparatives were tested to show the advantage the coating herein described with respect to maintaining gloss after abrasion. All viscosities are measured at <NUM> relying on the cup/spindle method of ASTM D1084-<NUM> Method B, using a Brookfield® rotational viscometer with spindle LV-<NUM> (designed for viscosities in the range between <NUM>,<NUM>-<NUM>,<NUM>,000mPa. s) or a Brookfield® rotational viscometer with spindle LV-<NUM> (designed for viscosities in the range between <NUM> -<NUM>,000mPa. s) for viscosities less than 1000mPa. s and a rotation speed of 10rpm unless otherwise indicated. Alkenyl and/or alkynyl content and Si-H content was determined using quantitative infra-red analysis in accordance with ASTM E168.

The ingredients used in the leather coating composition used together with the names given in the following Tables/examples are defined below:.

Table <NUM> provides details of the starting materials used for the silica masterbatch in the composition described below. The fumed silica was mixed with the Vinyl-terminated siloxane polymer in the presence of the small molecules which acted as hydrophobing treating agents of the silica resulting in the in-situ treatment of the silica whilst the silica and polymer are being mixed. As previously indicated the polymer used may be component (i) or a mixture of component (i) and another polymer if desired but in this case no component (i) is present in the masterbatch.

Several LSR compositions were prepared as examples (Ex. <NUM>-<NUM>) and comparative examples (comp. <NUM> - <NUM>) in two-part compositions. The total composition of each composition after part A and part B were mixed is depicted in Tables 2a (examples) and 3a (comparatives).

Prior to mixing, the part A composition incorporated the following:.

The part B composition incorporated the following:.

Shortly prior to use the Part A compositions and their respective part B compositions were mixed together in a <NUM> : <NUM> weight ratio to make the final hydrosilylation curable silicone elastomer composition under test.

Once prepared the topcoat composition was utilised in the preparation of a silicone-based synthetic leather composite material via the following process. The skin layer (<NUM>) used was a mixture of Dowsil™ LCF <NUM> Skin and Dowsil™ LCF <NUM> Skin and adhesive layer (<NUM>), was in the form of Dowsil™ LCF <NUM> Binder and before curing this underwent a lamination bonding process to a microfiber-based textile layer (<NUM>) which combination was then cured at a temperature of <NUM> for a period of three minutes.

The resulting silicone leather was then analysed using a Taber abrasion test using TABER® Abraser (Abrader) Model <NUM>1was used for the testing. The Taber abrasion test is used to evaluate the abrasion resistant performance of the leather samples. Three samples of each example or comparative underwent <NUM> cycles of abrasion using a CS-<NUM> Wheel and a <NUM> weight. After the abrasion step and prior to evaluation, the abraded surface was cleaned with deionized water and allowed to air dry. Each sample was then visually assessed and any objectionable changes in gloss, color or texture were noted. To pass the test, there should be substantially no wear-through of the coating or any objectionable changes in gloss, color or grain.

The results for the examples having a topcoat in accordance with the disclosure herein are provided in Table 2b.

The high crosslinking density due to the nature of the polymer and cross-linker is thought to restrict the chain mobility and thus minimized adhesive contact. This resulted in an abrasive pattern was avoided, and the gloss would not decrease after abrasion. On the other hand, micro-particles in the topcoat would appear on the surface after abrasion. As a result, although the small grains were worn away, the appeared micro-particles would help to compensate the loss of surface roughness, so as to avoid increased gloss.

Analogous testing was then carried out on silicone leather top coated with the comparative compositions using the same processes and test methods as described above. The compositions for the topcoats are depicted in Table 3a and the results are depicted in Table 3b.

SDG stands for significant decrease in gloss and Δ gray value stands for the change in gray value.

Claim 1:
A leather coating composition comprising a hydrosilylation curable silicone elastomer composition containing
Component (i), one or more organopolysiloxane polymer(s) having a viscosity of from <NUM> to <NUM>,000mPa.s at <NUM> with at least <NUM> weight % of the polymer(s) being unsaturated groups selected from alkenyl groups, alkynyl groups or a mixture thereof as determined using quantitative infra-red analysis in accordance with ASTM E168;
Component (ii) a reinforcing silica filler which may optionally be hydrophobically treated;
Component (iii) a silicone resin cross-linker having terminal (M) groups comprising silicone bonded hydrogen, wherein the molar ratio of Si-H groups in component (iii) to unsaturated groups in the composition is from <NUM> : <NUM> to <NUM> : <NUM>;
Component (iv) a hydrosilylation catalyst; and
Component (v) silicon-free organic microparticles having a number average particle size of from <NUM> to <NUM> determined using a field emission scanning electron microscope which are thermally stable up to a temperature of at least <NUM> using the test method disclosed in the description and which silicon-free organic microparticles are present in the leather coating composition in an amount of from <NUM> to <NUM> wt. %.