CN101945758B - 平面型高挠性复合材料 - Google Patents

平面型高挠性复合材料 Download PDF

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CN101945758B
CN101945758B CN200980105148.9A CN200980105148A CN101945758B CN 101945758 B CN101945758 B CN 101945758B CN 200980105148 A CN200980105148 A CN 200980105148A CN 101945758 B CN101945758 B CN 101945758B
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foam
frothing
composite
layer
frothing foam
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CN101945758A (zh
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S·迈耶-阿伦斯
A·迈尔-里希特
M·瑙约克斯
T·米夏埃利斯
S·穆拉托维克
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Covestro Deutschland AG
Bayer Intellectual Property GmbH
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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Abstract

本发明涉及一种平面型高挠性复合材料，其包括块状泡沫和与其相结合的基于聚氨酯分散体的平面型发泡泡沫层，本发明还涉及一种用于制备该复合材料的方法以及其用途。

Description

平面型高挠性复合材料
本发明涉及一种平面型高挠性复合材料，其包括块状柔性泡沫(Blockweichschaum)和与其相结合的基于聚氨酯的分散体的平面型发泡泡沫(Schlagschaum)层，本发明还涉及一种用于制备该复合材料的方法以及其用途。
具有基于发泡泡沫的涂层的复合材料是现有技术所熟知的。为制备这种复合材料使用含水聚氨酯分散体或丙烯酸酯分散体，该分散体首先经强烈搅拌或搅动而得到膏状的稠度。该过程非常类似于生产掼奶油(Schlagsahne)。由此也常称为机械发泡泡沫。该泡沫的空气含量通常为20-80体积％。该泡沫的密度以每升泡沫重量表示。
虽然含水分散体本身已形成轻的泡沫，但还需添加剂如硬脂酸铵或SLES以稳定该泡沫。该泡沫按需还可含其它在涂料中常用的添加料如有色颜料、添加剂、活性物质和填料。该所用的分散体应具有适宜高的固含量，以可达足够的每升泡沫重量。对聚氨酯分散体，其固含量通常为40-60％。
为产生泡沫可使用连续运行的工业用发泡装置如在食品工业中所用的发泡装置。该发泡泡沫通常用刮刀施加，其所调节的缝隙宽度基本上决定其湿膜厚度。
该泡沫必须在较高温度干燥以制得可使用的涂层。为去除泡沫中所含的水，该湿泡沫要以多步在升高温度于循环空气流中干燥，并且使得水不沸腾和不破坏该泡沫结构。该干燥过程的最终温度约为160℃。经干燥的泡沫依所设定的每升泡沫重量具有闭孔结构或开孔结构。该干膜厚度通常稍小于湿膜厚度。
该涂层的层厚为0.05-1.0mm，但也可为若干毫米。该泡沫比通常已知的泡沫如海绵和泡沫垫细得多。
涂以泡沫的目的是在材料耗量和重量同时为低的情况下提供体积(Volumengebung)。此外，该涂层通过泡沫结构是非常柔性的且在触觉上也是令人愉悦的。因此发泡泡沫用于医疗制品和工业制品的覆层，也可用于制备皮革状材料。在一些情况下，为抗损坏和由于设计原因，还必须为泡沫配置额外的致密层。使用发泡泡沫的优点还在于，可在无排放物或至少极少排放物的情况下进行加工。
用这类发泡泡沫涂覆材料以形成复合材料目前主要按两种方法实现：
a)在直接涂覆时，该发泡泡沫通过合适的施加方法直接与载体材料相结合。接着在140-170℃的较高温度干燥数分钟以相应固化该发泡泡沫层和产生可供使用性。
为防止在施加期间该所施加的发泡泡沫材料不合意地渗入基材和可使用合适的量，如此调节粘度和每升泡沫重量，以使其以膏状稠度存在。除基材外，决定施加高度的刮刀种类和直到进入干通道的停留时间也对渗入深度有影响。
b)在逆向涂覆(也称为转移涂覆或离型(纸-)涂覆)时，将该发泡泡沫涂层先涂于离型纸上并硬化，在第二步中才与待涂材料相结合。接着经干燥和该涂层牢固结合到待涂材料上后，该离型纸被撕去，任选地经多次重复使用。该方法的优点在于，一方面可经该涂层的离型纸的预压印给出所规定的表面结构如粒面(Narbung)。另一方面还可比直接涂覆能更可控地结合到载体材料上。因此，如此制备的制品通常是非常柔性的。
但这种如现有技术已知的包含基于聚氨酯发泡泡沫层的复合材料的缺点在于，对许多应用而言没有足够的挠性。特别是当例如用于覆盖可移动(机械-)部件时，许多这类复合材料有明显的干扰效果，以致随时间流逝而起皱，由此助长该复合材料的更快磨损。
因此，本发明的目的是提供一种具有基于聚氨酯的发泡泡沫层的复合材料，以克服上述的现有技术的缺点。本发明的目的特别是提供一种不起皱的和可长期不起皱的复合材料，以致保持了基于聚氨酯-分散体的发泡泡沫层的有利特性，即特别是令人愉悦的触感和高的挠性。
本发明的目的是通过由至少两个相互结合的泡沫材料部件组成的平面型复合材料实现的，其特征在于，其包括块状柔性泡沫基层材料和与其相结合的基于聚氨酯的平面型发泡泡沫层。
本发明范围内，块状柔性泡沫意指基于聚氨酯的柔性泡沫材料，其通常(但不是必需的)由使用含主要是仲OH-基的聚醚多元醇作为多元醇成分而得。非常特别优选是可使用EP 0810256A1中所述的方法获得的那种产物作为块状柔性泡沫，例如由Bayer MaterialScience AG所研制的Hypernova柔性泡沫。该申请被全部引入作为参考。所述块状柔性泡沫优选是弹性的。
其中，用于施加发泡泡沫层的发泡泡沫如上一般所述制备。特别优选由聚氨酯-分散体出发来制备发泡泡沫。通常在该(大多可市售得到)聚氨酯分散体中于实际发泡前还加入一种或多种泡沫稳定剂、增稠剂、交联剂和/或颜料。在调节所需的每升泡沫重量的发泡过程中需要时还可加入额外的增稠剂。
本发明范围内，特别优选使用和任选地相互组合使用下列分散体作为聚氨酯分散体：
a)阴离子型脂族聚酯聚氨酯分散体
其中下列由Bayer MaterialScience AG市售的产品是特别适用的：ImpranilLP RSC 1380、1537、1554。
b)离子型/非离子型聚碳酸酯聚氨酯-分散体
其中下列由Bayer MaterialScience AG市售的产品是特别优选的：ImpranilLP RSC 1997。
c)脂族聚碳酸酯聚氨酯-分散体
其中下列由Bayer MaterialScience AG市售的聚氨酯分散体是特别优选的：ImpranilDLU分散体。
本文中将EP1669382A2全部引入作为参考。其中所述的分散体也可有利地用于制备发泡泡沫。
ImpranilDLU是一种基于聚碳酸酯-聚四亚甲基二醇(PC-PTMG)的聚氨酯，其特征是高的稳定性。该产品与纺织涂层中通常用的添加剂是相容的，并经开发用于制备高品质涂层，例如用于衬垫材料的高品质涂层。其可呈机械发泡或作为密实层加工。
另外的四种产品是现存的市售产品的继续研制品，其具有60％的提高的固含量。
ImpranilLP RSC 1380可用于制备时兴的涂层和用于非织造物整理。由于更高的固含量，该产品特性类似于ImpranilDLN。特性相应于ImpranilDLP-R的ImpranilLP RSC 1537特别可作为柔性混合成分用于制备衬垫材料、汽车座椅、运动制品和其它工业制品。ImpranilLPRSC 1537特别适合用作粘附条，并作为含溶剂产品的替代物。产品性能基本与ImpranilDLS一致的ImpranilLP RSC 1554特别适用于机械发泡和用于制备时兴制品和服装制品。所有提及的分散体均是非反应性的，但可与合适的蜜胺树脂或可水分散的多异氰酸酯共交联以改进牢固性。
这里涉及富含固体的60％的聚氨酯分散体。所有产品均不含有机共溶剂、增稠剂和外加的乳化剂。与通常所用的固含量为35-50％的聚氨酯分散体相比，该“高-固体”-分散体为最终用户提供了一系列优点，例如在施加中达到高的固体物质覆盖，并由此通过提高机器利用率而明显节省成本以及降低能源耗费。
可使用现有技术中所熟知的产物作为泡沫稳定剂、增稠剂、交联剂和颜料。优选使用：
增稠剂：            BorchigelALA
                    MiroxAM
                    BYK420
泡沫稳定剂：        StokalSTA
                    StokalSR
                    DicrylanFLN
                    皂
交联剂：            Bayhydrur3100
                    DesmodurDN
                    AcrafixML
颜料：              所有水溶性的Euderm-颜料
该块状柔性泡沫和发泡泡沫层可以以不同方式结合。该两泡沫材料除通过例如缝合、铆合或订合的点固定外，还特别可考虑点或面的胶粘层。
令人意外地表明，这种复合材料保留构成其的成分的特别有利特性。特别是这种复合材料呈高挠性结构，其在长期使用中不易起皱。
此外，如果本发明的复合材料是透水蒸气的，则其对一些应用是有利的。其一方面通过将(通常)施加于发泡泡沫层上的最后的覆盖层去除来实现，因为该发泡泡沫层本身已被认为具有一定的透水蒸气性。为进一步提高透水蒸气性，优选是使发泡泡沫层具有穿孔，特别是微穿孔(例如参见www.wista.com)。微穿孔意指其直径为0.1-2mm的孔且孔密度为10pin/cm2。
由于微穿孔的特征是非常大的透水蒸气性且不透液态水(这特别是指水滴)，所以微穿孔是优选的，并由此有助于防止湿气进入块状泡沫层。
此外，该发泡泡沫的层厚优选为0.2-1.0mm，尤其为0.5-0.8mm。
块状柔性泡沫或发泡泡沫的上述的层厚上限是特别有利的，因为这时材料消耗可限制为最小，超过该限值该复合材料的机械特性不再有明显改进。该所述的下限是特别优选的，因为低于该下限时对该复合材料的机械特性会相应受损，特别是涉及该两层的耐磨性。
块状柔性泡沫与发泡泡沫的结合优选通过不连续的或连续的胶粘层实现，特别是通过基于含水聚氨酯分散体如Impranil LP RSC 4002或Impranil DLP-R的胶粘层实现。
胶粘层为该两泡沫材料提供持久的和可靠的结合。基于含水聚氨酯分散体的胶粘层具有特别的优点，即结合后形成的胶粘层也有非常高的挠性，由此对该复合材料的机械特性无不利影响。
在第二实施方案中，本发明的目的是通过用于制备复合材料的方法实现的，该方法的特征在于，将块状柔性泡沫与发泡泡沫层相结合。
特别是该方法如此实施，其包括下列步骤：
a)在离型纸的整个或部分表面上施加发泡泡沫，特别是密度为200-800g/l的发泡泡沫；
b)硬化步骤a)所施加的发泡泡沫层，特别是在70-170℃的升高温度硬化，以形成该发泡泡沫的层；
c)在发泡泡沫和/或块状柔性泡沫的层上施加胶粘层，特别是基于含水聚氨酯分散体的胶粘层；
d)将所述块状柔性泡沫施加到所述发泡泡沫上；
e)硬化该胶粘层；
f)去除离型纸。
用于制备在步骤a)中的发泡泡沫所用的聚氨酯分散体的固含量优选≥50质量％，因为其优点为可以以任何比例与水混合、更快干燥和此外可调节成非常高的每升泡沫重量。
上述方法导致该两泡沫材料的可靠且持久结合，此外其优点为，通过使用离型纸可将结构引入该发泡泡沫层的无块状柔性泡沫的侧面中。
上述方法特别优选如此进行，即步骤a)-f)在一个操作程序中进行。通过弃去多个分开的操作步骤可相应降低工艺成本。
在第三个实施方案中，本发明的目的通过上述复合材料用于覆盖和/或包封可移动的或不可移动的物体和/或设备的用途来实现。例如其也可用作家具、家具覆层或在汽车领域中用作座椅套。

Claims (12)

1.由至少两个相互结合的泡沫材料部件构成的平面型复合材料，其特征在于，其包括基于聚氨酯的块状柔性泡沫基层材料和与其结合的由基于聚氨酯的分散体制得的整个或部分打有孔的平面型发泡泡沫层。
2.权利要求1的复合材料，其特征在于，该发泡泡沫层在其整个或部分表面上打有微孔。
3.权利要求1的复合材料，其特征在于，该发泡泡沫的层厚为0.2-1.0mm。
4.权利要求3的复合材料，其特征在于，该发泡泡沫的层厚为0.5-0.8mm。
5.权利要求1的复合材料，其特征在于，该块状柔性泡沫与发泡泡沫通过不连续的或连续的胶粘层相互结合。
6.权利要求5的复合材料，其特征在于，该块状柔性泡沫与发泡泡沫通过基于含水聚氨酯分散体的胶粘层相互结合。
7.权利要求1的复合材料，其特征在于，该块状柔性泡沫是弹性的。
8.用于制备权利要求1的复合材料的方法，其特征在于，使所述块状柔性泡沫与所述发泡泡沫层相结合。
9.权利要求8的方法，其特征在于，按下列步骤实施：
a)准备离型纸，并在该离型纸的整个或部分表面上施加发泡泡沫；
b)硬化通过步骤a)所施加的发泡泡沫层，以形成该发泡泡沫层；
c)在发泡泡沫层与离型纸相对置的侧上和/或块状柔性泡沫层上施加胶粘层；
d)将所述块状柔性泡沫施加到所述发泡泡沫上，它们之间含粘合层；
e)硬化该胶粘层；
f)去除离型纸。
10.权利要求9的方法，其中在步骤a)中的所述发泡泡沫的密度为200-800g/l。
11.权利要求9的方法，其中步骤c)的所述胶粘层是基于含水聚氨酯分散体的胶粘层。
12.权利要求9的方法，其特征在于，该步骤a)-f)在一个操作程序中进行。
CN200980105148.9A 2008-02-15 2009-02-04 平面型高挠性复合材料 Expired - Fee Related CN101945758B (zh)

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