Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1999-10-01
2001-10-23
Crispino, Richard (Department: 1734)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S209000, C156S219000, C156S230000, C156S240000, C156S247000, C156S277000, C156S289000, C427S147000, C427S274000, C428S151000, C428S195100, C428S904000, C428S915000
Reexamination Certificate
active
06306236
ABSTRACT:
TECHNICAL FIELD
The present invention relates to a release sheet and a process for the preparation of synthetic leather using this release sheet.
BACKGROUND ART
Various methods have been used for the preparation of synthetic leather which include, for example, dyeing, the treatment with a gravure coater or knife coater, or using a release sheet and the like. Among these, a method of using a release sheet is carried out in the following manner. A release sheet is provided in advance in which the desired uneven pattern is formed on the surface having releasability. A raw resin for synthetic leather is then applied on a release resin layer of the release sheet. After dried and solidified, the resin layer is released from the sheet. In a process for the preparation of synthetic leather using such a release sheet, there is a need for providing the same number of release sheets as that of the uneven designs to be applied on the synthetic leather.
Recently, with a wide variety of uses of synthetic leather, various kinds and small lots have been required in the preparation process. Although the requirement for various kinds may be satisfied by preparing various release sheets with various uneven designs, it is difficult to satisfy the requirement for small lots because a release sheet to be used should be changed every uneven designs and, therefore, the preparatory time for the preparation increases and using efficiency of raw materials is lowered. Alternatively, it may also be considered that a release sheet on which at least two uneven patterns are formed in advance is prepared to satisfy the requirement for small lots. In such a case, there is, however, a problem that it is difficult to satisfy the requirement for various kinds. Furthermore, it is also required to lower the costs for release sheets in order to satisfy the requirement for various kinds and small lots in the preparation of synthetic leather. However, there is a limit in lowering the costs for the preparation process using the prior art release sheets where a release resin layer with an uneven pattern is provided on the base material.
The present invention has been done in such circumstances. The present invention provides a release sheet in which various uneven designs can be formed in the desired amount and a process for the preparation of synthetic leather using this release sheet in which synthetic leather can easily be prepared in various kinds and small lots and it is possible to lower the costs.
DISCLOSURE OF THE INVENTION
In order to attain these purposes, the present release sheet comprises a base release sheet, which is a laminate of a base material and a release resin layer, and a design printed sheet which can be stacked releasably on the base material of said base release sheet, said design printed sheet having a base sheet and a convex image layer with the desired pattern positioned on the one side of said base sheet.
In the present invention as described above, a design printed sheet with the desired convex image layer is stacked on the base material of said base release sheet to obtain a release sheet. As a result, the base release sheet may be used repeatedly in the use of any design printed sheet. A wide variety of uneven designs can be formed by stacking two or more design printed sheets sequentially side by side on the base release sheet.
The present process for the preparation of synthetic leather is carried out in the following manner. A resin for synthetic leather is applied on the release resin layer of the release sheet according to the invention, in which the desired design printed sheet is stacked releasably on the base material of the base release sheet, to form a resin layer. As a result, an uneven design corresponding to a convex image layer of the design printed sheet is formed on the resin layer. After a base fabric is adhered to the aforesaid resin layer, the resin layer is released from the release sheet to prepare synthetic leather having the desired uneven design. In the case of preparing synthetic leather having another uneven design, another release sheet according to the invention is used in which the aforesaid base release sheet is still used repeatedly and only the design printed sheet is replaced with another design printed sheet having the desired convex image layer. Another synthetic leather may be prepared in the aforesaid manner using the release sheet thus obtained.
In another embodiment of the process for the preparation of synthetic leather according to the invention, use is made of the release sheet according to the invention wherein plural kinds of design printed sheets having different convex image layers to each other are sequentially stacked side by side releasably on the base material of the base release sheet.
According to the invention, the release sheet comprises a base release sheet, which is a laminate of a base material and a release resin layer, and a design printed sheet to be stacked releasably on the base material of said base release sheet. In the design printed sheet, a convex image layer with the desired pattern is positioned on the one side of a base sheet. It is, therefore, possible to obtain a release sheet corresponding to the desired uneven design at any time by stacking the desired design printed sheet on the base material of the base release sheet. It is also possible to form various kinds of uneven designs from one release sheet by stacking two or more design printed sheets sequentially side by side on the base release sheet. In addition, as the base release sheet can be used repeatedly in the case of using any design printed sheet, when plural kinds of uneven designs are required in the preparation of synthetic leather, its preparation costs are remarkably lowered compared to that in the use of the prior art release sheet and, therefore, for example, the requirement for various kinds and small lots in the preparation of synthetic leather may be satisfied.
REFERENCES:
patent: 3607522 (1971-09-01), Phillips, Jr.
patent: 4092198 (1978-05-01), Scher et al.
patent: 4539056 (1985-09-01), Takeshita et al.
patent: 4959264 (1990-09-01), Dunk et al.
patent: 62-41794-B2 (1987-04-01), None
Arita Keisuke
Takeshita Kazuhisa
Ajinomoto Co. Inc.
Crispino Richard
Lorengo J. A.
Oblon & Spivak, McClelland, Maier & Neustadt P.C.
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