Composite leather material
Engineered leather substrates, methods of making the substrates, engineered leather composites including the substrates, and articles of manufacture which include the engineered leather substrates or composites are disclosed. The substrate includes leather, non-leather fibers, a binding agent and one or more additional components such as cushioning agents, softeners, processing aids, and colorants. A composite material can be formed including the substrate and one or more additional layers, such as top coat layers, reinforcing layers, and cushioning layers. The substrate and or the composite can be chemically or mechanically embossed. The leather used to form the engineered leather substrate can be derived from post-industrial and/or post-consumer materials. The non-leather fibers can be organic or inorganic, and the composition can also include inorganic fillers, such as calcium carbonate, and clays. The cushioning agents can include polymeric microbubbles, foam, rubber particles, and other low density cushioning agents. The binding agents can be synthetic or natural, such as synthetic latex, natural latex, PVA, and starch.
1 . A composite material comprising:
leather fibers;
a binding agent;
non-leather fibers; and a
cushioning agent.
2 . The composite material of claim 1 , wherein the leather materials comprise post-industrial or post-consumer waste.
3 . The composite material of claim 1 , wherein the binding agent is a latex.
4 . The composite material of claim 3 , wherein the latex is an acrylic latex.
5 . The composite material of claim 1 , wherein the non-leather fibers comprise cellulose.
6 . The composite material of claim 5 , wherein the cellulose fibers are cotton fibers.
7 . The composite material of claim 1 , wherein the cushioning agent comprises polymeric microbubbles.
8 . The composite material of claim 1 , wherein the cushioning agent comprises foam particles.
9 . A composite material comprising:
leather fibers;
a latex binder;
non-leather fibers; and
a cushioning agent.
10 . The composite material of claim 9 , wherein the leather materials comprise post-industrial or post-consumer waste.
11 . The composite material of claim 9 , wherein the binding agent is a latex.
12 . The composite material of claim 11 , wherein the latex is an acrylic latex.
13 . The composite material of claim 9 , wherein the non-leather fibers comprise cellulose.
14 . The composite material of claim 13 , wherein the cellulose fibers are cotton fibers.
15 . The composite material of claim 9 , wherein the cushioning agent comprises polymeric microbubbles.
16 . The composite material of claim 9 , wherein the cushioning agent comprises foam particles.
17 . A composite material comprising:
leather fibers;
a latex binder;
non-leather fibers; and
a reinforcing substrate.
18 . The composite material of claim 17 , wherein the leather materials comprise post-industrial or post-consumer waste.
19 . The composite material of claim 17 , wherein the binding agent is a latex.
20 . The composite material of claim 19 , wherein the latex is an acrylic latex.
21 . The composite material of claim 17 , wherein the non-leather fibers comprise cellulose.
22 . The composite material of claim 21 , wherein the cellulose fibers are cotton fibers.
23 . The composite material of claim 19 , wherein the reinforcing substrate is a scrim, woven, or non-woven material.
24 . The composite material of claim 19 , wherein the reinforcing agent comprises a foam layer.
25 . A composite material comprising:
leather fibers;
a latex binder;
non-leather fibers; and
a topcoat and/or color coat layer.
26 . The composite material of claim 25 , wherein the leather materials comprise post-industrial or post-consumer waste.
27 . The composite material of claim 25 , wherein the binding agent is a latex.
28 . The composite material of claim 27 , wherein the latex is an acrylic latex.
29 . The composite material of claim 25 , wherein the non-leather fibers comprise cellulose.
30 . The composite material of claim 29 , wherein the cellulose fibers are cotton fibers.
31 . The composite material of claim 29 , wherein the topcoat layer is chemically or mechanically embossed.
32 . A composite material comprising:
leather fibers;
a latex binder;
non-leather fibers; and
inorganic fillers, where the fillers provide the composite material with fire retardance, noise reduction, low density, enhanced smoothness, easier drainability, abrasion resistance, or stiffness.
33 . The composite material of claim 32 , wherein the leather materials comprise post-industrial or post-consumer waste.
34 . The composite material of claim 32 , wherein the binding agent is a latex.
35 . The composite material of claim 34 , wherein the latex is an acrylic latex.
36 . The composite material of claim 32 , wherein the non-leather fibers comprise cellulose.
37 . The composite material of claim 36 , wherein the cellulose fibers are cotton fibers.
38 . The composite material of claim 32 , wherein the inorganic fillers comprise one or more of talc, mica, clay, titanium dioxide, carbon black, carbonate salts, pigments, ceramic microspheres, or zirconia microspheres.
39 . The composite material of claim 32 , wherein the inorganic fillers are functionalized fillers.
40 . The composite material of claim 32 , wherein the inorganic fillers comprise 2 nd generation leather composite material.
41 . A composite material comprising:
leather fibers;
a latex binder; and
non-leather fibers; wherein the material is provided with mechanical and/or chemical embossing.
42 . The composite material of claim 41 , wherein the leather materials comprise post-industrial or post-consumer waste.
43 . The composite material of claim 41 , wherein the binding agent is a latex.
44 . The composite material of claim 43 , wherein the latex is an acrylic latex.
45 . The composite material of claim 41 , wherein the non-leather fibers comprise cellulose.
46 . The composite material of claim 45 , wherein the cellulose fibers are cotton fibers.
47 . The composite material of claim 41 , further comprising a cushioning agent.
48 . The composite material of claim 41 , wherein the cushioning agent comprises polymeric microbubbles or foam particles.
49 . A composite material comprising:
leather fibers;
a latex binder; and
non-leather fibers; wherein the latex binder is selected to provide heat and/or UV protection to the composite material such that the material can survive exposure to sunlight and temperatures of around 100° F. for a period of three years before the material experiences significant cracking.
50 . The composite material of claim 49 , wherein the leather materials comprise post-industrial or post-consumer waste.
51 . The composite material of claim 49 , wherein the binding agent is a latex.
52 . The composite material of claim 51 , wherein the latex is an acrylic latex.
53 . The composite material of claim 49 , wherein the non-leather fibers comprise cellulose.
54 . The composite material of claim 53 , wherein the cellulose fibers are cotton fibers.
55 . The composite material of claim 49 , further comprising a cushioning agent.
56 . The composite material of claim 49 , wherein the cushioning agent comprises polymeric microbubbles or foam particles.
57 . An article of manufacture comprising a composite material, wherein the composite material comprises leather fibers, a latex binder, and non-leather fibers.
58 . The article of claim 57 , wherein the leather materials comprise post-industrial or post-consumer waste.
59 . The article of claim 57 , wherein the binding agent is a latex.
60 . The article of claim 59 , wherein the latex is an acrylic latex.
61 . The article of claim 57 , wherein the non-leather fibers comprise cellulose.
62 . The article of claim 61 , wherein the cellulose fibers are cotton fibers.
63 . The article of claim 57 , further comprising cushioning agent.
64 . The article of claim 63 , wherein the cushioning agent comprises polymeric microbubbles or foam particles.