US 12,331,439 B2
Plant protein based imitation leather material and methods of making same
Xiaokun Wang, Troy, NY (US); Kening Lang, Troy, NY (US); and Elizabeth Watson, Troy, NY (US)
Assigned to Uncaged Innovations Inc, Troy, NY (US)
Filed by Uncaged Innovations, Inc., Troy, NY (US)
Filed on Jan. 4, 2024, as Appl. No. 18/404,029.
Application 18/404,029 is a continuation in part of application No. 18/115,401, filed on Feb. 28, 2023.
Application 18/115,401 is a continuation of application No. 17/830,314, filed on Jun. 1, 2022, abandoned.
Claims priority of provisional application 63/292,256, filed on Dec. 21, 2021.
Prior Publication US 2024/0141564 A1, May 2, 2024
This patent is subject to a terminal disclaimer.
Int. Cl. D04H 1/08 (2012.01); D06N 3/00 (2006.01); D06N 3/14 (2006.01)
CPC D04H 1/08 (2013.01) [D06N 3/0056 (2013.01); D06N 3/0061 (2013.01); D06N 3/0077 (2013.01); D06N 3/14 (2013.01); D10B 2211/20 (2013.01); D10B 2331/10 (2013.01); D10B 2401/063 (2013.01); Y10S 428/904 (2013.01)] 15 Claims
OG exemplary drawing
 
1. A method of producing a monolayer imitation leather material, comprising:
combining into a mixture,
a one or more plant protein powder in an amount in a range of about 28% to about 65% (w/w), wherein the one or more plaint protein powder comprises an at least 70% protein content and wherein the one or more plant protein powder is comprised of wheat gluten, brown rice protein, barley protein, maize protein, or any combination thereof,
a one or more non-proteinaceous polymer in an amount in a range of about 25% to about 50% (w/w), wherein the one or more non-proteinaceous polymer comprises technically specified or block natural rubber (TSR), ribbed smoked sheet natural rubber (RSS), high ammonia natural rubber latex concentrate, low ammonia natural rubber latex concentrate, deproteinized natural rubber latex concentrate with a dry rubber content in a range of about 50% to about 62%, waterborne polyurethane-polyester copolymer, polyurethane-polycarbonate copolymer, polyurethane-polyether copolymer, or any combination thereof,
a one or more plasticizer in an amount in a range of about 8% to about 25% (w/w),
a one or more cross-linking agent in an amount in a range of about 1% to about 5% (w/w, based on a weight of the protein content of the one or more plant protein powder), and
a curing agent in an amount in a range of about 1% to about 10% (w/w, based on a weight of the one or more non-proteinaceous polymer),
calendering the mixture into a monolayer sheet,
wherein the calendering is conducted at a controlled roll temperature in a range from about 35° C. to 90° C., and
wherein the calendered monolayer sheet is affixed onto a surface of a carrier fabric, and
wherein the calendered monolayer sheet comprises a thickness in a range from about 0.5 mm to about 5 mm, and
curing the calendered monolayer sheet at a temperature in a range from about 100° C. to about 160° C., at a pressure in a range from about 0.3 Mpa to about 5 Mpa, and for a period of time in a range from about 10 minutes to about 60 minutes.