Process for retanning leather

Abstract

The present invention is directed to a process for retanning leather comprising the steps of: a) providing tanned or pre-tanned leather b) treating the tanned leather of step a) with a composition comprising hollow microspheres, preferably as an aqueous composition, the hollow microspheres have a true density of from 0.01 to 0.10 g/cm.sup.3 (25? C.) and/or a bulk density of the dry powder of 0.005 to 0.06 g/cm.sup.3 (25? C.), c) drying, whereby the temperature of the leather during drying does not exceed 75? C. as well as to leather obtained by said process.

Claims

1. A process for retanning leather comprising the steps of: a) providing tanned or pre-tanned leather, b) treating the tanned or pre-tanned leather of step a) with a composition comprising expanded hollow microspheres having a true density of from 0.01 to 0.10 g/cm.sup.3 (25? C.) and/or a bulk density of a dry powder of the expanded hollow microspheres of from 0.005 to 0.06 g/cm.sup.3 (25? C.), and c) drying, whereby a temperature of the leather during drying does not exceed 75? C.

2. The process according to claim 1, wherein in step b) an amount of expanded hollow microspheres used is 0.05 to 1.0% by weight, based on a dry weight of the leather.

3. The process according to claim 1, wherein the composition of step b) is an aqueous composition having a solid content of expanded hollow microspheres from 0.5 to 15% by weight.

4. The process according to claim 1, wherein the expanded hollow microspheres of step b) have a diameter of from 1to 200 ?m.

5. The process according to claim 1, wherein at 23? C., less than 10% of the volume of a cavity present in the expanded hollow microspheres of step b) comprises a liquid (propellant) having a boiling point of less than 80? C. at atmospheric pressure.

6. The process according to claim 1, wherein during drying in step c) the expanded hollow microspheres do not further expand.

7. The process according to claim 1, wherein after drying in step c) the expanded hollow microspheres have a same particle size distribution and/or same spherical shape as in the composition used in step b).

8. The process according to claim 1, wherein after drying in step c) the expanded hollow microspheres are embedded in the leather.

9. The process according to claim 1, wherein drying in step c) is carried out from 1s to 48 h.

10. The process according to claim 1, wherein during drying in step c) the temperature of a surface of the leather does not exceed 80 ? C.

11. The process according to claim 1, wherein the composition of step b) further comprises one or more additives selected from the group consisting of dyes, synthetic tanning agents, resin tanning agents, vegetable tanning agents, polymer tanning agents based on acrylate copolymers, natural polymers, softening retanning agents, fatliquoring agents, dyeing auxiliearies, chromium compounds, aluminium compounds, and zirconium compounds.

12. The process according to claim 11, wherein prior, simultaneously or subsequent to step b) the leather is treated with retanning agents and/or dyeing agents and/or fatliquoring agents.

13. The process according to claim 1, wherein the composition of step b) further comprises a retannage agent and/or dyeing agent.

14. The process according to claim 13, wherein subsequent to step b) the leather is washed and treated with a fat liquoring agent.

15. The process according to claim 1, wherein the composition of step b) further comprises a fat liquoring agent.

16. The process according to claim 15, wherein prior to step b) the leather is treated with a retanning agent and/or dyeing agent.

17. A leather obtained by the process according to claim 1.

18. The leather according to claim 17, wherein the expanded hollow microspheres are embedded in the leather.

19. A buffed or full-grain leather, or a split leather for automotive, furniture, garment, glove, bag, aircraft, lining and/or upper leather articles comprising the leather of claim 17.

20. The process according to claim 1, wherein in step b) the composition comprising the expanded hollow microspheres is an aqueous composition.

21. The process according to claim 4, wherein the expanded hollow microspheres of step b) have a diameter of from 2 to 100 ?m.

22. The process according to claim 4, wherein the expanded hollow microspheres of step b) have a diameter of from 5 to 50 ?m.

Description

EXAMPLES

Example 1

(1) Hollow Microspheres Description

(2) The expanded hollow microsphere sample used in the following examples is based on a thermoplastic copolymer of acrylonitrile and vinylidenchloride containing between 6 and 11 wt % isobutane based on solid weight as propellant or blowing agent. Supplied as a wet cake with a density of 0.22 g/cm.sup.3 it contains 15% of dry expanded hollow microspheres having a true density of 0.04 g/cm.sup.3 and a bulk density of 0.025 g/cm.sup.3. The bulk density is determined by measuring the mass of a defined volume of dried powder of the microspheres according to ISO 8460, section 1 (determination of free-flow bulk-density).

(3) The particle size of the powder version of hollow microspheres has been measured with laser light scattering using a Mastersizer 2000 apparatus from Malvern company. The average particle size D(0.5) is 20 micrometers and particle size distribution is 2.6.

(4) An example of commercial sample of expanded hollow microspheres can be Expancel 461 WE20 from AKZO.

(5) Expanded Hollow Microspheres Slurry

(6) Into 750 ml deionized water containing 1.0 g of a silicone fluid defoamer like SILFORM SE 2 from Wacker Chemie AG, 200 g of expanded hollow microspheres 461 WE20 having a dry content of 15% is added under good agitation until the dispersion is homogeneous. 25.0 g of ACRYSOL ASE-60 with 28% solids acrylic swellable emulsion thickener is added into the mixing vessel continuously over a period of 20-30 minutes.

(7) The pH of the solution is then adjusted with a 95% solution of 2-amino-2-methyl-1-propanol neutralization agent (AMP-95 from Angus Chemie GmbH) in the range 7 to 9. This causes the viscosity of the dispersion to raise to 2000 to 5000 cps (23? C.). The dispersion thus obtained is stable for several months at room temperature. Measured density of the dispersion is 0.55-0.60 g/cm.sup.3 (using a picnometer).

Example 2

(8) Unexpanded Microspheres Slurry

(9) Into 750 ml deionized water containing 1.0 g of a silicone fluid defoamer like SILFORM SE 2 with 25% solids from Wacker Chemie AG, 45 g of unexpanded microspheres based on a copolymer of acrylonitrile and vinylidenchloride (like EXPANCEL 460 WU 400) having a dry content of 68% and a density of 1.1 g/cm.sup.3 is added under good agitation until the dispersion is homogeneous. 25.0 g of ACRYSOL ASE-60 with 28% solids acrylic swellable emulsion thickener is added into the mixing vessel continuously over a period of 20-30 minutes.

(10) The pH of the solution is then adjusted with a 95% solution of 2-amino-2-methyl-1-propanol neutralization agent (AMP-95 from Angus Chemie GmbH) in the range 7 to 9. This causes the viscosity of the dispersion to raise to 2000 to 5000 cps (23? C.). The dispersion thus obtained is stable several months at room temperature.

(11) The measured particle size using the Mastersizer 2000 gave a particle size D(0.5) of 15 micrometers.

Example 3

(12) Microsphere Slurry

(13) Into 750 ml deionized water containing 1.0 g of a silicone fluid defoamer like SILFORM SE 2 with 25% solids from Wacker Chemie AG, 200 g of expanded hollow microspheres with a solid content of 15% used in example 1 is added under good agitation until the dispersion is homogeneous.

(14) No acrylic thickener is added. The obtained dispersion has to be used immediately and can be added directly into the drum containing the leather skin.

Example 4

(15) Formulation with Acrylic Binder Dispersion

(16) Into 710 g of a copolymer of acrylic acid and acrylamide having 30% solids containing 1.0 g of a silicone fluid defoamer like SILFORM SE 2 with 25% solids from Wacker Chemie AG, 163 g of expanded hollow microspheres based on a copolymer of acrylonitrile and vinylidenchloride (like the one used in example 1) having a dry content of 15% is added under good agitation until the dispersion is homogeneous.

(17) 71.0 g of ACRYSOL ASE-60 with 28% solids acrylic swellable emulsion thickener is added into the mixing vessel continuously over a period of 20-30 minutes.

(18) The pH of the solution is than adjusted with a neutralization agent (like a 20% solution of 2-amino-2-methyl-1-propanol) in the range 7 to 9. This causes the viscosity of the dispersion to raise to 2000 to 5000 cps (23? C.). The dispersion thus obtained has a solid content of 23-25%, a dry content of microspheres of 2.4%, and is stable several days at room temperature.

Example 5

(19) Formulation with Acrylic Binder Dispersion

(20) Into 250 g deionized water, 100 g of expanded microspheres based on a copolymer of acrylonitrile and vinylidenchloride (like the one used in example 1) having a dry content of 15% is added under good agitation until the dispersion is homogeneous. An methylmethacrylate styrene copolymer obtained with emulsion polymerization (30% solids) is than added over a period of 15-20 minutes to the mixing vessel. When homogeneous, 150 g of an emulsion based on modified lecithin (70% solids) is continuously added under agitation.

(21) The thus obtained formulation has a total solid content of 25-26%, a dry content of microspheres of 1.5% and is stable several weeks at room temperature.

Example 6

(22) Formulation with a Fatliquor Emulsion

(23) Into 180 g glycerine, 120 g of an emulsion of lecithin is added continuously in 15-20 minutes under good agitation. When the mixture is homogenoeous, 380 g of a fatliquor emulsion with 50% solids based on fatty acid sulfonamide sulfosuccinate is added under good agitation followed by the addition of 100 g of expanded hollow microspheres based on a copolymer of acrylonitrile and vinylidenchloride (like that of example 1) having a dry content of 15%.

(24) The formulation is homogeneous, has a solids content of 33-34%, 1.5% dry microspheres and is stable several weeks at room temperature.

(25) Application on Wet Blue Hides

Example 7 (Invention)

(26) Material

(27) 2 corresponding wet blue half hides have been used with a thickness of 1.4-1.6 mm.

(28) Hides have been weighed. All raw material concentrations are expressed in % based on hide weight.

(29) Retannage Process Using Formulation from Example 1 (Expanded Microspheres Slurry)

(30) Washing and Chrome Retannage

(31) The half hide is put into a rotating steel drum filled up with 300% water and heat up to 35? C. 0.3% formic acid (85%) is then added and the drum is allowed to rotate for 30 min. The pH of the liquor is 3.9.

(32) The aqueous solution is then removed from the drum. 100% water is added to the drum and heated to 35? C. 4.0% Chrome 33% is added and the drum rotates for 60 min.

(33) The float is then neutralized with 3.0% of a mixture of organic acid salts (like SELLASOL NG gran from TFL Ledertechnik) for 20 min. To obtain a pH of 4.6, 1.0% sodium bicarbonate is added within 60 min (final PH 5.0). The aqueous solution is then removed from the drum.

(34) Retannage/Dyeing

(35) 50% water is added to the drum and heated to 35? C. 5.0% of a syntan mix of aromatic sulfone (like SELLATAN GSB liq. from TFL Ledertechnik) is added to the water and rotated for 10 min.

(36) Dyeing is than obtained by adding 3.0% of dye (like SELLA STAR Havanna from TFL) to the drum. The drum is let to rotate for 20 min.

(37) Then an acrylic copolymer of acrylic acid and acrylamide (MAGNOPAL PGN, from TFL Ledertechnik) is added to the mixture. The rotation time of the drum is 20 min. A pH of 5.1 has been measured.

(38) After this step, 5.0% of the invention formulation from example 1 (microsphere slurry) is added to the drum and rotated for 90 min. The final pH is adjusted to 3.7 by adding 100% water (50? C.) and 3.0% formic acid (85%).

(39) Washing

(40) After these different steps, the drum is drained off and the hide is washed out with 300% hot water (50? C.) for 10 min.

(41) Fatliquoring

(42) A drum containing the hide prepared as described above is filled up with 100% water at 50? C. 5.0% of the formulation of example 1 (microsphere slurry) is added to the drum and let to rotate for 20 min.

(43) Two fatliquor emulsions, for example 4.0% of a combination of a sulfated fatty acid sodium salt and lanolin fatty acid (like CORIPOL BZE from TFL), and 8.0% of a combination of sulphated and sulphonated natural and synthetic substances (like CORIPOL UFB/W from TFL) are added and the drum rotates for 40 min. The pH is set to 3.5 by adding 2.0% formic acid (85%) (The drum is running for 30 min). The aqueous solution is then removed from the drum.

(44) Final Washing

(45) The hide is then washed with 300% warm water (40? C.) for 10 min, followed by 300% water at 25? C. for 10 min.

(46) The final leather is let for the night, then vacuum dried 2 min at 65? C.

Example 8

(47) Retannage Process without Formulation According to Example 1 (Expanded Microspheres Slurry)

(48) The leather preparation is the same as for example 7 but no microsphere slurry is added to the drum.

(49) Results obtained with examples 7 and 8 are given in table 1.

(50) TABLE-US-00001 TABLE 1 Left Side Right side Hide Example 7 (invention) Example 8 (reference) Thickness in 1.7-1.8 mm 1.6 mm backbone Thickness in Belly: 1.8-1.9 mm Belly: 1.6-1.7 mm belly and flanks Flanks: 1.9-2.1 mm Flanks: 1.7-1.8 mm Colour More levelled Flanks pronounced slightly less levelled Hardness 0 ?1/0 slightly softer Tightness +1 especially 0 in flanks more tight Fullness +1 selective filling 0 Backbone similar, overall in belly and flanks flanks empty General Small flanks, more Large flanks tight, noticeable more fullness in loose and empty parts +2 - very good/significant difference +1 - good/noticeable difference 0 - moderate/standard

(51) Leather evaluation showed a noticeable increase in fullness in the loose structured areas of the hide with measurable increase in substance. The leather quality with the formulation from example 1 (microspheres slurry) is more firm, more leveled and tighter in the flanks than the leather made without microspheres slurry.

(52) The leather prepared in Example 7 was subjected to a SEM analysis (FIG. 1) to check the uniformity of particle distribution in the leather and the integrity of the hollow microspheres after the application process. The picture shows that the voids in the leather structure are uniformly filled with hollow particles and that essentially all particles retained their spherical shape and their original size.

(53) Application on Chrome Free Automotive Hides (FOC Leather)

(54) The aim of these trials is to evaluate the ability of the microsphere slurry of the invention, used in combination with an acrylic copolymer, to reduce or replace partly traditional syntan and fatliquor agents while maintaining the leather character and the physical properties.

(55) Material

(56) One automotive wet white shaved hide has been used with a thickness of 1.1 mm. Four pieces have been cut out and named example 9, example 10, example 11 and example 12.

(57) Hides have been weighted. All raw material concentrations are expressed in % based on hide weight.

Example 9 (Reference)

(58) Standard Leather Preparation

(59) Washing and Neutralization

(60) The hide is put into a rotating steel drum filled up with 200% water and heated up to 35? C. The drum is allowed to rotate for 10 min. The pH is 4.9. The aqueous solution is then removed from the drum. 100% water is added to the drum and heated to 35? C. The float is than neutralized with 6.0% of a anionic syntan based on a condensation product of phenol sulfonic acid (like SELLATAN MBS from TFL Ledertechnik) for 60 min. The pH is adjusted to 5.2 by adding 2.0% sodium formate and 0.5% sodium bicarbonate for 60 min. The aqueous solution is then removed from the drum.

(61) Retannage/Dyeing

(62) 100% water is added to the drum and heated to 35? C. A syntan mix like 6.0% of a anionic syntan based on a condensation product of phenol sulfonic acid (like SELLATAN MBS from TFL Ledertechnik)

(63) and 4.0% of a synthetic retanning agent based on condensed sufonated phenol (like SELLATAN RP) is added to the water and rotate for 60 min. The same syntan mix is added again and rotated for another 60 min. The leather is dyed with 2.0% SELLA FAST Grey VW-L and 0.5% SELLA FAST Beige GL for 30 min.

(64) The pH is set to 4.0 by adding 100% water and 1.5% formic acid 85% after 60 min mixing to the mixture. The rotation time of the drum is 20 min. A pH of 5.1 has been measured.

(65) Washing

(66) After these different steps, the drum is drained off and the hide is washed out with 300% hot water (50? C.) for 10 min.

(67) Fatliquoring

(68) A drum containing the hide prepared as described above is filled up with 100% water heated to 50? C. Two fatliquors, 6.0% of a modified Leicithin emulsion (like CORIPOL ALF from TFL) and 10.0% of a fatliquor emulsion based on a long chain alcohol sulfosuccinate (50% solids like CORIPOL ESA), are added and the drum rotates for 90 min. The pH is set to 3.5 by adding 3.0% formic acid 85%, the drum running for 40 min. The aqueous solution is then removed from the drum.

(69) Washing

(70) The hide is washed with 300% water 25? C. for 10 min and then the water is drained off.

(71) Fixation

(72) 300% water is added to the drum and heated up to 35? C. 0.2% formic acid (85%) is added for 10 min followed by 0.5% of a solution of a copolymer of dimethylamine epichlorhydrin (like SELLA FIX E from TFL) for 15 min. The water is subsequently drained off.

(73) Final Washing

(74) The hide is then washed with 300% water 25? C. for 10 min. The water is subsequently drained off.

(75) The final leather is dried for 12 hours and subsequently vacuum dried for 2 min at 45? C.

Example 10 (Invention)

(76) Reduced Syntan Content During Retanning Step

(77) This is the same leather preparation as for example 9, but half of the syntan mix used during retannage step has been replaced by 6.0% of microspheres slurry from example 1 and 4.0% of an acrylic acid acrylamide copolymer (like MAGNOPAL PGN from TFL).

(78) Retannage/Dyeing

(79) 100% water is added to the drum and heated to 35? C. 6.0% of the microspheres slurry from example 1, 4.0% of acrylic acid acrylamide copolymer, 3.0% of an anionic syntan based on a condensation product of phenol sulfonic acid (like SELLATAN MBS from TFL Ledertechnik) and 2.0% of a synthetic retanning agent based on condensed sufonated phenol (like SELLATAN RP) are added to the water and rotate for 60 min. The same syntan composition is added again and let to rotate for another 60 min. The leather is dyed with 2.0% SELLA FAST Grey VW-L and 0.5% SELLA FAST Beige GL for 30 min. The pH is adjusted to be 4.0 by adding 100% water and 1.5% formic acid 85% after 60 min mixing is added to the mixture. The rotation time of the drum is 20 min. A pH of 5.1 has been measured.

Example 11 (Invention)

(80) Reduced Syntan Content During Retanning Step

(81) The same leather preparation as for example 10 but the second syntan based on a synthetic retanning agent based on condensed sufonated phenol (like SELLATAN RP) has been removed and replaced by 3.0% of the first syntan based on a condensation product of phenol sulfonic acid (like SELLATAN MBS from TFL Ledertechnik).

(82) Retannage/Dyeing

(83) 100% water is added to the drum and heated to 35? C. 6.0% of the microspheres slurry from example 1, 4.0% of an acrylic acid acrylamide copolymer (like MAGNOPAL PGN), and 6.0% of an anionic syntan based on a condensation product of phenol sulfonic acid (like SELLATAN MBS from TFL Ledertechnik) are added to the water and allowed to rotate for 60 min. 6.0% of the anionic syntan based on a condensation product of phenol sulfonic acid (like SELLATAN MBS from TFL Ledertechnik) is added again and let to rotate for another 60 min.

(84) The leather is dyed with 2.0% SELLA FAST Grey VW-L and 0.5% SELLA FAST Beige GL for 30 min. The pH is set to 4.0 by adding 100% water and 1.5% formic acid 85% after 60 min mixing. The rotation time of the drum is 20 min. A pH of 5.1 has been measured.

Example 12 (Invention)

(85) Reduced Fatliquor Content During Fatliquoring Step

(86) This is the same leather preparation as for example 9 but half of the fatliquor mix used during the fatliquoring step has been replaced by 6.0% of the microspheres slurry according to example 1 and 4.0% of an acrylic acid acrylamide copolymer (like MAGNOPAL PGN from TFL).

(87) Fatliquoring

(88) A drum containing the hide prepared as described above is filled up with 100% water heated at 50? C. 6.0% microsphere slurry according to example 1, 4.0% of acrylic acid acrylamide copolymer (like MAGNOPAL PGN from TFL). and two fatliquors, 3.0% of a modified leicithin emulsion (CORIPOL ALF) and 5.0% of a fatliquor emulsion based on a long chain alcohol sulfosuccinate (50% solids like CORIPOL ESA), are added and the drum rotates for 90 min.

(89) The pH is set to 3.5 by adding 3.0% formic acid 85%, the drum running for 40 min. The aqueous solution is then removed from the drum.

(90) Leather evaluation and physical properties are given in table 2.

(91) TABLE-US-00002 TABLE 2 Example 9 Example 10 Example 12 Example 11 (reference) (invention) (invention) (invention) Colour 0 0+ 0 0 Softness 0 Very 0 0? 0 soft Tightness 0 0? 0+ Second 0+ best Milling best pattern Fullness 0 0? Slightly 0 + 1 +1 Best overall more empty Full and round Second best General Very soft, Very soft Surprisingly Full, round, nice slightly less soft, round an soft tight round tight very nice Very nice Sample 1.5 mm 1.5 mm 1.6 mm 1.5 mm thickness for density Tear 37 N 42 N 39 N 41 N Strenght Tensile 213 N 198 N 220 N 233 N strength 91% Elong. 106% Elong. 83% Elong. 96% Elong. Stitch 106 N 105 N 94 N 90 N Tear Specific 0.592 g/m.sup.3 0.584 g/m.sup.3 0.571 g/m.sup.3 0.561 g/m.sup.3 weight Weight of 885 g/m.sup.2 873 g/m.sup.2 911 g/m.sup.2 839 g/m.sup.2 sqf after milling +2 - very good/significant difference +1 - good/noticeable difference 0 - moderate/standard

(92) Due to the presence of the microsphere slurry a reduction and replacement of syntan and fatliquor agents was achieved, thereby maintaining the leather character and the physical properties. Said result is surprising to the skilled artisan.

(93) Application on Wet Blue Hides

(94) Material

(95) One wet blue shaved hide has been used with a thickness of 1.1 mm. Four pieces have been cut and named example 13, example 14, example 15 and example 16. Hides have been weighted. All raw material concentrations are expressed in % based on hide weight.

Example 13 (Invention)

(96) Retannage Process Description

(97) Washing and Chrome Retannage

(98) The hides are put into a rotating steel drum filled up with 300% water and heated up to 35? C. 0.3% formic acid 85% is then added and the drum is allowed to rotate for 30 min. The pH of the float is 3.8-3.9. The aqueous solution is then removed from the drum. 100% water is added to the drum and heated to 35? C. 4.0% Chrome 33% is added and the drum rotates for 60 min. The float is then neutralized with 3.0% of a mixture of organic acid salts (like Sellasol NG gan TFL Ledertechnik) for 20 min. A pH of 4.6 was measured and 1.0% sodium bicarbonate was added for 60 min to obtain a final pH of 5.0. The aqueous solution is then removed from the drum.

(99) Retannage/Dyeing

(100) 50% water is added to the drum and heated to 35? C. 6.0% of an aromatic sulfone syntan (like SELLATAN GSB liq. from TFL Ledertechnik) is added to the water and rotated for 40 min.

(101) Fatliquoring

(102) A drum containing the hide prepared as described above is filled up with 100% water heated at 50? C. 8.0% microspheres slurry from example 1 and 14% of a fatliquor based on a long chain alcohol sulfosuccinate (like CORIPOL MK from TFL Ledertechnik) are added to the drum and rotated for 120 min. The pH is set to 3.5 by adding 2.0% formic acid 85% and the drum is running for 30 min. The aqueous solution is subsequently removed from the drum.

(103) Final Washing

(104) The hide is then washed with 300% warm water (40? C.) for 10 min followed by 300% water at 25? C. for 10 min.

(105) The final leather is let for the night than vacuum dried 2 min at 65? C., hanged dry and milled 48 hours.

(106) The final leather articles prepared above have been finished.

Example 14 (Reference)

(107) Leather preparation is the same as for example 13 except that no microspheres slurry has been added.

Example 15 (Invention)

(108) Leather preparation is the same as for example 13 (containing 8.0% of microspheres slurry) except that the fatliquor has been replaced by 14.0% of a carboxylated polyamide polymer.

Example 16 (Reference)

(109) Leather preparation is the same as for example 15 except that no microspheres slurry has been added.

(110) All leather articles prepared above have been finished.

(111) Finishing of leather articles from examples 13, 14, 15 and 16.

(112) Prebase Application

(113) One coat of Prebase is applied via Roller coater using a RRC Roller 21 SS.

(114) The prebase is formulated as follows: 800 g of a composition made by mixing an acrylic copolymer with a polyurethane dispersion and fillers is diluted with 100 g of water. It is then added in the following order: 100 g of an polyether based polyurethane dispersion, 30 g of pigment and 20 g of an ethylene urea based crosslinker.

(115) Application conditions are set in order to apply 3 g/sqf (square foot) wet. The hide is then rested 12 h before being milled for 2 h.

(116) Basecoat Application

(117) After the precoat has been applied, a basecoat is then prepared for application on the hide. The basecoat is formulated as followed.

(118) 770 parts of a compound containing an acrylic copolymer, a polyurethane dispersion, matting agent and additives is mixed with 30 g of a silica matting agent and diluted into 200 g water. 200 g of pigment compound is then added to the mixture under good agitation.

(119) After viscosity adjustment at 25 with Cup Ford 4 (23? C.), the basecoat is applied airless in one coat of 8-10 g/sqf wet.

(120) After drying 2 min at 80? C., the hide is let to rest for 12 h and then milled for 4 h.

(121) Color Coat Application

(122) Often a color coat is applied before the final topcoat. It allows to adjust the basecoat color and is slightly crosslinked. The color coat has been prepared as follows: 330 g of a matting polyurethane dispersion is mixed with 250 g of a NMP free polyether based polyurethane dispersion and 120 g of water. 50 g of a silicone additive and 110 g of pigment are added.

(123) To this mixture, 100 g of a polyisocyanate crosslinker is added prior application. Color coat viscosity is adjusted at 25-27 Cup Ford 4 (23? C.). The color coat is applied in 1 coat of 3.0-3.4 g/sqf wet. The leather is allowed to dry 2 min at 80? C.

(124) Topcoat Application

(125) The topcoat is formulated as followed.

(126) 330 g of a matting polyurethane dispersion used to make the color coat is mixed with 60 g of a NMP free polyester polyether based polyurethane dispersion and 120 g of water. 90 g of a mixture of silicone additives and 5 g of pigment are added. To this mixture, 20 g of a polycarbodiimide crosslinker and 160 g of a polyisocyanate crosslinker are added prior application. Topcoat viscosity is adjusted at 25-30 Cup Ford 4 (23? C.). The topcoat is applied in 2 successive coats of 2.0-2.4 g/sqf wet. The leather is allowed to dry 2 min at 80? C. after each applications.

(127) Leather evaluations and physical properties are given in table 3 and 4.

(128) TABLE-US-00003 TABLE 3 Example 13 Example 14 Crust Evaluation (invention) (reference) Thickness in backbone 1.2-1.3 mm 1.1 mm Thickness in belly and flanks 1.2-1.3 mm 1.0-1.1 mm Colour 0 0 Softness +1 0 Milling +1 flanks 0 Fullness overall +1 0 General +1 0 Evaluation after finishing General Fuller, more round 0 Filling effect in Flanks +1 0 Softness 0+ 0 Thickness of sample for 1.30 mm 1.25 mm testing after finishing Area Weight 872 g/m.sup.2 872.6 g/m.sup.2 Specific weight 0.673 g/m.sup.3 0.700 g/m.sup.3 Tear Strenght 38 N F max 33 N F max Stitch Tear 90 N max 73 N max 71 N/mm 56 N/mm Tensile strength 202 N max 201 N max 92% Elongation 80% Elongation +2 - very good/significant difference +1 - good/noticeable difference 0 - moderate/standard

(129) Improvement in flank filling and milling break in the flanks with example 13.

(130) The effect remains even after 48 hours milling. The finishing print retention was evaluated similar.

(131) On finished quarters the filling effect was still visible.

(132) The physical properties increased with 8.0% microspheres slurry, especially stitch tear. The specific weight is also reduced for example 13.

(133) TABLE-US-00004 TABLE 4 Example 15 Example 16 (invention) (reference) Thickness in 1.2-1.3 mm 1.1 mm backbone Thickness in 1.2-1.3 mm 1.0-1.1 mm belly and flanks Strong increase in flanks Colour 0 0 Softness +1 0 Milling +1 especially in flanks more 0 full and even milling break Fullness overall +1 0 General +1 0 Finished leather Thickness of 1.25 mm 1.2 mm sample for area weight Area weight 778 g/m.sup.2 789 g/m.sup.2 Specific weight 0.625 g/m.sup.2 0.660 g/m.sup.2 Tensile strenght 201 N 182 N 69% Elongation 83% Elongation Tear strenght 52 N 51 N Softness 0+ 0 Milling 0+ More 0 regular in flanks Fullness overall +1 Especially 0 flanks and belly part General More full in flanks 0 +2 - very good/significant difference +1 - good/noticeable difference 0 - moderate/standard

(134) A noticeable improvement in flank filling and milling break in the flanks was evaluated for example 15.

(135) The selective filling effect remains even after 48 hours milling.

(136) After finishing the effect of the microspheres remains still visible, especially in the flank and belly area.

(137) Moreover, the leather according to the present invention becomes fuller, with a more regular milling in the flank and belly areas after embossing.

(138) Vegetable Application on Light Wet Blue Hides

(139) Reduced Vegetable Tannin Content with Microsphere Slurry

(140) Material

(141) One wet blue shaved hide has been used with a thickness of 1.8 mm. Two pieces have been cut out and named example 17 and example 18.

(142) Hides have been weighted. All raw material concentrations are expressed in % based on the hide weight.

Example 17 ( Invention)

(143) Retannage Process Description

(144) Washing

(145) The hides are put into a rotating steel drum filled up with 300% water and heated up to 35? C. 0.5% of tetrasodium salt of ethylene diamine tetraacetic acid (like BORON ST from TFL) is then added and the drum is allowed to rotate for 30 min. The pH is 3.9-4.0. The aqueous solution is subsequently removed from the drum.

(146) Neutralization/Retannage/Dyeing

(147) The drum is filled up with 100% water and heated up to 35? C.

(148) To the float 2.0% of a mixture of organic acid salts (like Sellasol NG gan TFL Ledertechnik), 2.0% of sodium formate and 4.0% of a syntan based on a neutral aromatic sulfone (like SELLATAN AG liq. From TFL) is added successively and the drum is rotated for 30 min. The pH is 4.8 after sodium formate addition and 4.9 after 30 min rotation.

(149) Two syntans are added successively (6.0% of SELLATAN SU-V and 6.0% of SELLATAN RP) and let to rotate for 40 min. Two fatliquors are then added to the drum (2.0% of a combination of a sulfated fatty acid sodium salt and lanolin fatty acid (like CORIPOL BZE from TFL)), 2.0% of a emulsion of modified lecithin (like CORIPOL ALF from TFL) and let to rotate for 20 min.

(150) Then 8.0% microspheres slurry from example 1 and 10% Mimosa are added to the drum and let to rotate for 60 min. The pH is 4.8.

(151) 0.5% INVADERM LU and a mixture of two brown dyes (1.0% of SELLA FAST BROWN HF-G and 2.0% of SELLA FAST BROWN HF-R) are added and rotation continues for 180 min.

(152) Then 100% of water at 50? C. is added to the drum with 1.0% of formic acid to bring the pH at 4.0.

(153) The drum is allowed to rotate during the night.

(154) Next day the hides are washed with 300% water at 50? C.

(155) Fatliquoring

(156) A drum containing the hide prepared as described above is filled up with 150% water heated at 50? C. 4.0% of an acrylic copolymer is added and rotated for 20 min. 5.0% of a combination of a sulfated fatty acid sodium salt and lanolin fatty acid (like CORIPOL BZE from TFL) and 5.0% of an emulsion of modified lecithin (like CORIPOL ALF from TFL) are added and the drum rotates for 40 min. 2.0% of a retanning agent based on condensed sufonated phenol (like SELLATAN RP from TFL) is added and the drum rotates 20 min. 1.0% of formic acid 85% is then added followed after 20 min by 1.5% formic acid 85%. After 30 min. The final pH is 3.5. The hides are washed with 300% 35? C. hot water.

(157) The aqueous solution is then removed from the drum.

(158) Fixation

(159) 150% of 35? C. water is added to the drum followed by 1.0% of a solution of a copolymer of dimethylamine epichlorhydrin (like SELLA FIX E TFL). After 30 min, the hides are washed with 300% water.

(160) The final leather is let for the night, then vacuum dried for 2 min at 60? C. and hanged dry.

Example 18 (Reference)

(161) Leather preparation is the same as for example 17 except that instead of 6.0% of hollow microspheres slurry, 10% of vegetable extract (Quebracho tannin) has been added.

(162) Leather evaluations and physical properties are given in table 5

(163) TABLE-US-00005 TABLE 5 Example 18 Example 17 Evaluation: (reference) (invention) Colour/levellness 0 0 Fullness overall +1 0 Fullness flanks +1 +1 Softness 0+ 0 Tightness 0 More +1 More compact spongy, less tight General Slightly better leather character in tightness and temper Area weight 1575 g/m.sup.2 1488 g/m.sup.2 Specific weight 630 g/m.sup.3 588 g/m.sup.3 Stitch tear 167 N 202 N ?2 = poor/not acceptable ?1 = unsatisfactory 0 = moderate +1 = good +2 = very good

(164) The aim of the trial was the direct comparison of 10% Quebracho vs. 6.0% of hollow microspheres slurry (from example 1) on corresponding low chrome tanned wet blue made with a vegetable/synthetic retanning system.

(165) The process of the present invention leads to a leather quality, specific and area weight and stitch tear resistance being advantageous.

Examples 19 to 26

(166) Material

(167) Four corresponding wet blue pieces from one hide have been used with a thickness of approximately 1.0-1.1 mm.

(168) The hides have been weighted. All raw material concentrations are expressed in % based on hide shaved weight. For all examples, the leather has been dried at 60? C.

(169) The retannage process uses the formulation from example 1 (expanded microspheres slurry Expancel 461 WE 20 available form AKZO) in comparison with unexpanded microspheres Expancel 820 SL 40 (slurry).

(170) Application formulation and process are the same for the two samples except weight quantities that have been varied.

Example 19

(171) Washing and Chrome Retannage

(172) The half hide is put into a rotating steel drum filled up with 300% water and heated up to 40? C.

(173) 0.3% formic acid 85% is then added and the drum is allowed to rotate for 20 min.

(174) The pH of the liquor is 3.6.

(175) The aqueous solution is then removed from the drum.

(176) 150% water is added to the drum and heated to 40? C. 3.0% of a solution of a chrome syntan (TANNESCO HN gran. from TFL Ledertechnik, with a chrome oxide content of 12%) is added and the drum rotates for 30 min.

(177) The float is neutralized with 2.0% of sodium formate for 20 min followed by addition of 1.5% sodium bicarbonate for 60 min to obtain a final pH of 5.0.

(178) The aqueous solution is then removed from the drum. Subsequently, the hides are washed with 200% water at 35? C. for 10 minutes.

(179) Retannage/Dyeing

(180) 100% water is added to the drum and heated to 35? C. 3.0% of a syntan based on urea-formaldehyde condensated sulfonated phenolic resin (SELLATAN FL liq. from TFL Ledertechnik) is added to the water and rotated for 20 min.

(181) Dyeing is then obtained by adding 2.0% of dye (like SELLA FAST Grey A TFL) to the drum. The drum is rotated for 60 min.

(182) Subsequently fatliquoring is performed by adding 100% water at 50? C. and 14% of a long chain alcohol sulfosuccinate (CORIPOL MK from TFL).

(183) After this step, 10.0% of the formulation according to the invention (example 1, (0.3% solid expanded microsphere) is added to the drum and rotated for 120 min. The final pH is adjusted to be 3.4 by adding 2.5% formic acid 85%.

(184) Washing

(185) After these different steps, the drum is drained off and the hide is washed out with 200% hot water (50? C.) for 10 min followed by a final washing with 200% water at 25? C.

(186) Drying

(187) The leathers were vacuum dried at 60? C. for 2 min, subsequently hang dried and staked.

Example 20

(188) 0.98% of solid expanded microspheres (Expancel 461 WE20 from AKZO) have been employed. Otherwise, the same formulation and application process as described in Example 19 above has been used.

(189) Unexpanded Microspheres (State of the Art)

Example 21

(190) 10% of a 3% aqueous solution of unexpanded microspheres (Expancel 820 SL40 from AKZO) have been used. Otherwise, the same formulation and application process as described in Example 19 has been used.

Example 22

(191) 2.5% of a 40% aqueous solution of unexpanded microspheres (Expancel 820 SL40 from AKZO) (corresponding to 1.0% solid unexpanded microspheres) have been used. Otherwise, the same formulation and application process as described in Example 19 has been used.

(192) TABLE-US-00006 TABLE 6 Example 19 Example 20 Example 21 Example 22 expanded expanded unexpended unexpended Reference microspheres microspheres microspheres microspheres Solid content 15 15 40 40 wt % Diameter 20 20 13 13 d(0.5).sup.a ?m Density 0.22 0.22 1.164 1.164 (g/cm.sup.3) Bulk density.sup.b 0.027 0.027 0.475 0.475 (g/cm.sup.3) Leather characteristics % solids 0 0.3 0.98 0.3 1.0 microspheres Fullness 0 1 1 0 0 Belly fullness 0 1 1.5 0 0 Softness 0 0 0.5 0 0 Average 1.0-1.1 1.2-1.3 1.2-1.3 1.0-1.1 1.0-1.1 thickness backbone area (mm) Average 1.0-1.1 1.2-1.3 1.2-1.3 1.0-1.1 1.0-1.1 thickness central area (mm) Average 1.0 1.3-1.4 1.4-1.5 1.0-1.1 1.0 thickness belly area (mm) +2/?2 significant difference compared with reference +1/?1 difference compared with reference 0 reference .sup.ameasured with Malvern Mastersizer 2000 .sup.bmeasured according to ISO 8460 (product is 100% dried powder)
Leather Evaluation/Results:

(193) A pronounced filling effect, especially in the belly, was found for examples 19 and 20 prepared with expanded microspheres Expancel 461 WE20 when compared to the reference without microspheres and also when compared to examples 21 and 22 treated with unexpanded microspheres Expancel 820 SL.

(194) The leather thickness increases from 1.0-1.1 mm up to 1.4-1.5 mm in belly when 1.0% expanded microspheres Expancel 461 WE20 are used.

(195) There is no filling effect for the piece treated with unexpanded microspheres Expancel 820SL40 when compared to non-treated leather.

Example 23

(196) Formulation of a fatliquor emulsion containing expanded hollow microspheres Expancel 461 WE20 has been formulated into a fatliquor as follows:

(197) Into a 3000 ml glass reactor equipped with propeller stirrer 500.0 g process oil is added. To 100.0 g of a slurry of expanded hollow microspheres (Expancel 461 WE20 from AKZO) is added under constant stirring at 25? C. successively, 20.0 g of ethoxylated (20 moles) isodecyl alcohol (from Elementis), 200.0 g of leicithin, 700.0 g deionized water and finally 20.0 g of sorbitan monooleate (Span 80 from CRODA).

(198) A viscous brownish dispersion is obtained containing 0.97% solids hollow microspheres.

Example 24

(199) The reference sample has been formulated like example 23 except that no microspheres have been added.

(200) A viscous brownish dispersion is obtained.

(201) Leather Preparation with Fatliquors Formulations of Example 23 and Example 24

(202) Material

(203) Two corresponding wet blue half hides have been used with a thickness of 1.4-1.6 mm.

(204) Hides have been weighted. All raw material concentrations are expressed in based on hide weight.

Example 25 (Invention)

(205) Retannage Process Using Formulation According to Example 23 (Expanded Microspheres Fatliquor)

(206) Washing and Chrome Retannage

(207) The half hide is put into a rotating steel drum filled up with 300% water and heated up to 35? C.

(208) 0.3% ethoxylated sulfated fatty alcohol (Borron SAF from TFL Ledertechnik) and 0.3% formic acid 85% is then added and the drum is allowed to rotate for 20 min. The pH of the liquor is 3.3.

(209) The aqueous solution is then removed from the drum and the hide is neutralized as follows: 100% water is added to the drum and heated up to 35? C.

(210) To the float 2.0% of sodium formate and 2.0% a mixture of organic acid salts (like SELLASOL NG gran from TFL Ledertechnik) is then added for 20 min to obtain a pH of 4.9. Finally, 0.5% sodium bicarbonate is added and the drum is rotated for 60 min (final pH 5.3).

(211) The aqueous solution is then removed from the drum. The hide is washed with 300% water at 35? C. for 10 minutes.

(212) Retannage

(213) 50% water is added to the drum and heated to 35? C. 5.0% of a syntan mix of a retanning agent based on condensed sufonated phenol (like SELLATAN RP from TFL Ledertechnik) is added to the water and rotated for 40 min. 200% water is then added and rotated for 60 min. The pH is adjusted to 4.5 with 1.0% formic acid. The hide is washed with 300% water at 50? C. for 10 minutes.

(214) Fatliquoring

(215) 200% water is added to the drum at 50? C. and subsequently 15% of fatliquor emulsion from example 23 is added. The drum is let to rotate for 120 min. After this treatment step the final pH is 4.0 and adjusted to be 3.6 (adding of 1.0% formic acid for 25 minutes).

(216) Washing

(217) After these different steps, the drum is drained off and the hide is washed out with 200% water (25? C.) for 10 min.

(218) The final leather is stored for 12 hours at room temperature and subsequently vacuum dried for 2 min at 60? C.

Example 26 (Reference)

(219) Retannage Process Using Formulation from Example 24 (Fatliquor without Expanded Microspheres Fatliquors)

(220) Washing and Chrome Retannage

(221) The half hide is put into a rotating steel drum filled up with 300% water and heated up to 35? C.

(222) 0.3% ethoxylated sulfated fatty alcohol (Borron SAF from TFL Ledertechnik) and 0.3% formic acid 85% is then added and the drum is allowed to rotate for 20 min. The pH of the liquor is 3.3.

(223) The aqueous solution is then removed from the drum and the hide is neutralized as follows: 100% water is added to the drum and heated up to 35? C.

(224) To the float 2.0% of sodium formate and 2.0% a mixture of organic acid salts (like SELLASOL NG gran from TFL Ledertechnik) for 20 min is added to obtain a pH of 4.9. Finally, 0.5% sodium bicarbonate is added and the drum is rotated for 60 min (final pH 5.3).

(225) The aqueous solution is then removed from the drum. The hide is washed with 300% water at 35? C. for 10 minutes.

(226) Retannage

(227) 50% water is added to the drum and heated to 35? C. 5.0% of a syntan mix of an retanning agent based on condensed sufonated phenol (like SELLATAN RP from TFL Ledertechnik) is added to the water and rotated for 40 min. 200% water is then added and rotated for 60 min. The pH is set to 4.5 with 1.0% formic acid. The hide is than washed with 300% water at 50? C. for 10 minutes.

(228) Fatliquoring

(229) 200% water is added to the drum at 50? C. Then 15% of fatliquor from example 24 (fatliquor emulsion without hollow microspheres) is added. The drum is rotated for 120 min. The final pH is 4.0 after this treatment and adjusted to be 3.6 by adding 1.0% formic acid for 25 minutes.

(230) Washing

(231) After these different steps, the drum is drained off and the hide is washed out with 200% water (25? C.) for 10 min.

(232) The final leather is stored for 12 hours at room temperature and subsequently vacuum dried for 2 min at 60? C.

(233) Results

(234) Leather that has been treated with the fatliquor containing expanded microspheres (example 23) has a much better fullness compared with the leather treated with the fatliquor not containing microspheres (example 24).

(235) TABLE-US-00007 TABLE 7 Example 23 Example 24 (with (without microspheres) microspheres) Colour 0 0 Touch Slightly Silky Slightly silky Softness +1 +1 Fullness +1 0 Tightness 0 0 Filling/softening/ +1 Softening/ +1 retanning Effect retanning Exhaustion after 0 Milky Almost no 0 Milky acidification microspheres visible ?2 = poor/not acceptable/strong difference ?1 = unsatisfactory/noticeable difference 0 = moderate/standard +1 = good/noticeable difference