CN107002350A - 人造革聚氨酯复合材料的维度增强 - Google Patents

人造革聚氨酯复合材料的维度增强 Download PDF

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Publication number
CN107002350A
CN107002350A CN201580067914.2A CN201580067914A CN107002350A CN 107002350 A CN107002350 A CN 107002350A CN 201580067914 A CN201580067914 A CN 201580067914A CN 107002350 A CN107002350 A CN 107002350A
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China
Prior art keywords
embossed
composite material
embossing
layer
material according
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Granted
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CN201580067914.2A
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English (en)
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CN107002350B (zh
Inventor
保罗·麦克卢尔
叶尔曼·瑞斯
马克·埃弗里特·基弗
威廉·G·柯林斯
特蕾西·G·希尔
大卫·迈克尔·布朗
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Watson Automotive Interiors Ltd
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Watson Automotive Interiors Ltd
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    • D—TEXTILES; PAPER
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Abstract

通过经由辊成形技术和平坦成形技术将聚氨酯材料与不可复原的泡沫层和稀松布层组合来形成复合材料。复合材料被压花，以形成由这些层之间的结合所形成的压花图案线的网络勾画的枕状腔室或枕状单元。

Description

人造革聚氨酯复合材料的维度增强
相关申请的交叉引用
本申请要求2014年10月17日提交的美国临时专利申请No.62065470的优先权，该申请的全部内容以引用的方式并入本文。
技术领域
本发明总体上涉及人造革装置和方法，更具体而言，涉及人造革的复合材料/层压材料的三维增强。
背景技术
合成皮革材料用于各种产业。例如，在汽车工业中，合成皮革广泛用于覆盖座椅、方向盘、内饰面板等。由于许多原因，这种材料在环境影响、成本、耐久性和可定制性等方面优于动物皮革。合成皮革通常重量较轻，生产效率更高，并且价格明显低于真皮/动物皮革。
在不同类型的合成皮革中，基于聚氨酯(“PU”)的皮革具有优于基于聚氯乙烯(“PVC”)的皮革的优点。PU合成皮革重量较轻，通常无臭，并且与PVC皮革相比具有增强的透气性。此外，PU皮革不含环境有害物质，例如在PVC中发现的增塑剂。另外，PU皮革不受PVC产品当前表现出的刚度限制的影响。
鉴于PU皮革的诸多优点，人们一直致力于扩展PU皮革的造型可能性，包括多样化皮革外观和提高皮革触觉品质。术语“触觉”指的是材料的触感和感觉。PU皮革的外观和纹理都可以根据用于制作PU皮革的方法而改变。
例如，使用压花来在维度上增强含PU材料。如本文所用的，“压花”指的是通过加压和/或加热以各种变化量产生的压印。在以前的压花尝试中，由于许多原因，包括加热或加压步骤的问题(其导致熔化和切割的材料以及在这种压花的拐角处引起的应力)，导致PU材料表面的切割或损坏。另外，以前使用的压花图案转印装置也是有问题的，包括具有过度锋利边缘的辊或板造成的PU表面层的切割或损坏，或者甚至更严重的穿过下部复合层的切割。使用不合适的材料(包括不适当的泡沫和纺织品稀松布)已经引起了进一步的问题：诸如紧随压花加工、并且直到包含合成皮革材料的最终产品(例如作为实例的汽车座椅)的制造的压花设计的形状和深度上的变形等。
虽然在保持合成皮革中的压花设计的完整性方面(包括没有层状体和稀松布的合成皮革材料的平坦压花)一些尝试已经被证明是更成功的，但是这种尝试的三维效果被最小化、受到损害，并且在美学上比较平庸。这些压花本质上通常是二维的，并且缺乏足够的深度以实现更明显、真实和/或美观的结果。
为了改善合成皮革产品的三维外观，已经使用了称为“枕状压花”的方法，其包括三层PU的构造。虽然用材料、泡沫和稀松布的复合层形成的面材的三维性质优于使用平坦压花形成的面材的三维性质，但是这些现有尝试仍然不足以达到压花目标。具体而言，它们在压花过程中不能适当地保护复合材料免受例如熔化或切割。另外，用于提供“枕状”效果的材料不能充分保持所需的压花形状。
因此，这些和其他问题表明：在合成皮革领域中仍然需要更有效的压花方法和更耐用的最终产品。
发明内容
幸运的是，本发明提供了人造革聚氨酯复合材料的简洁、优化和多功能的维度增强。
以下呈现本发明的简化发明内容，以便提供对本发明的一些方面的基本理解。该发明内容不是本发明的广泛概述。其不意在确定本发明的关键或重要要素或描述本发明的范围；其唯一目的是以简化的形式呈现本发明的构思，作为随后呈现的更详细描述的序言。
本发明包括压花复合材料和形成这种具有皮革外观和类似属性的压花复合材料的方法。
在一个实施例中，压花复合材料包括多层PU材料、泡沫层和基底稀松布层，其中，复合材料的各层被压花以形成沿着复合材料的枕状腔室或枕状单元。在另一实施例中，压花复合材料具有至少三层PU、用作三层PU的背衬的纺织品层、纺织品背衬层下面的一层不可复原的PU泡沫以及用作PU泡沫层的背衬的一层纺织品或非织造稀松布。复合材料被压花，以形成由这些层之间的结合所形成的压花图案线的网络勾画的枕状腔室或枕状单元。
“可复原的”泡沫在被刀片切割、压力按压、受热侵蚀或被模具冲压之后保持其原来形状，因此不适于压花。
如本文所用的，“不可复原的”泡沫是适于压花的泡沫材料，其不能从切压花操作中恢复，从而保持其压花形状。
在一个实施例中，用于形成压花复合材料的方法包括以下步骤：1)形成具有表面层和粘附到背衬层的表层的PU皮革材料；2)将一层泡沫附接到PU皮革材料的底面；3)将一层稀松布或纺织品附接到泡沫层的底面以形成复合材料；以及4)通过使用压花辊对复合材料进行压花，以对复合材料提供压花设计和枕状单元。
在另一实施例中，用于形成压花复合材料的方法包括以下步骤：1)形成具有表面层和粘附到背衬层的表层的PU皮革材料；2)将一层泡沫附接到PU皮革材料的底面；3)将一层稀松布或纺织品附接到泡沫层的底面以形成复合材料；以及4)通过使用压花板对复合材料进行压花，使得复合材料承载压花图案，并且在压花图案线内形成枕状单元。
本发明所呈现的特征的目的在于通过使用平坦压花技术和辊压花技术来提供对聚氨酯人造革(被支撑的聚氨酯或PU涂层材料)的维度增强。本方法产生了在本发明之前不可实现的优异三维效果。本发明所设想的装置和方法解决了加热、加压、压花设计、材料选择以及造成合成皮革材料的切割和损坏的其它特征的现有问题。
本发明的其它特征是通过本发明的压花技术实现具有皮革外观的美学增强材料。通过本方法形成的三维增强PU材料与真皮和OVC/乙烯基裁剪部件的外观更相似。
通过仔细阅读优选实施例的详细说明，本领域技术人员将会清楚地了解其他特征及其优点、与本发明相关的技术和设备。
上述摘要的目的是使美国专利商标局和公众一般能够从粗略检查中快速确定技术公开内容的性质和要点。摘要不用于解释本文的权利要求的范围，也不用于限定本发明或本申请，也不以任何方式限制本发明的范围。
本文阐述了本主题的其它目的和优点，并且根据本文的详细说明，本领域普通技术人员将清楚这些目的和优点。另外，应该进一步理解，在不脱离主题的精神和范围的情况下，可以在本发明的各种实施例和用途中实践本发明的具体示出的、被引用的和讨论的特征和要素的修改和变化。变化可以包括但不限于用等效的装置、特征或步骤替代所示出、参考或讨论的那些装置、特征或步骤，以及对各种部件、特征、步骤等在功能、操作或位置上进行反转。此外，还应当理解，本主题的不同实施例以及不同的当前优选实施例可以包括当前公开的特征、步骤或元件或其等同物的各种组合或构造(包括特征、部件或步骤的组合或未在附图中明确示出或在这些附图的详细说明中陈述的特征、部件或步骤的构造)。不一定在发明内容部分中表示的本主题的附加实施例可以包括并且并入以上概括对象中参考的特征、部件或步骤的各方面的各种组合和/或在本申请中以其它方式讨论的其他特征、部件或步骤。本领域普通技术人员在评阅本说明书的其余部分之后将能更好地理解这些实施例和其它实施例的特征和方面。
附图说明
在附图中：
图1A是根据本发明实施例的压花复合材料的一部分的透视图；
图1B是根据本发明实施例的压花复合材料的一部分的剖视图；
图2是示出根据本发明实施例的压花复合材料的制造方法的视图；
图3是示出根据本发明实施例的用于制造压花复合材料的材料的剖视图；
图4是示出根据本发明实施例的压花复合材料的制造方法的视图；
图5是示出根据本发明实施例的用于制造压花复合材料的材料的剖视图；
图6是根据本发明实施例的压花复合材料的制造方法的视图；
图7是根据本发明实施例的用于制造压花复合材料的压花装置的透视图；
图8是根据本发明实施例的用于制造压花复合材料的压花装置的透视图；
图9是根据本发明实施例的压花复合材料的剖视图。
具体实施方式
本文公开了某些优选实施例和实例。然而，本发明的主题超出了具体公开的实施例中的实例而延伸到其他替代实施例和/或用途以及本发明主题的修改和等同方案。因此，所附权利要求的范围不受本文所述的任何特定实施例的限制。例如，在本文公开的任何方法或过程中，方法或过程的动作或操作可以以任何合适的顺序进行，并且不一定限于任何特定公开的顺序。可能会以有助于理解某些实施例的方式或顺序将各种操作描述为多个离散操作；然而，描述的顺序不应被理解为暗示这些操作是依赖于顺序的。另外，本文描述的结构、系统和/或装置可以被实现为集成部件或单独部件。为了比较各种实施例，描述了这些实施例的某些方面和优点。不一定通过任何特定实施例来实现所有这样的方面或优点。因此，例如，可以以实现或优化本文教导的一个优点或一组优点的方式来执行各种实施例，而不一定实现本文也教导或提出的其它方面或优点。
本发明包括压花复合材料和用于制造具有皮革外观和特性的压花复合材料的方法和装置。
本发明允许用于形成合成皮革的PU材料的维度增强。如本文所用的，术语“PU”指的是含有聚氨酯的材料或涂有聚氨酯的材料。可以通过图案或设计改变PU材料。这里，所使用的材料和方法为最终PU合成皮革产品的设计提供了二维外观和三维外观。
在图1A和图1B中示出了根据本发明实施例的维度增强的PU皮革10的实例。如图所示，PU皮革10在外观上被压花有装饰性的三维图案。该图案由在压花过程中形成的标记或线12和枕状单元14的网络限定，在压花过程中，材料层通过加热和加压在结合线12处或沿着结合线12结合在一起。
本发明可以设想除了图1A和1B所示的图案之外的各种图案。例如，压花图案可以是对称的或不对称的。枕状单元14的形状可以是几何的或随机的。结合线12和枕状单元14的维度也可以是一致的或不一致的。术语“线”用于描述表示复合材料层相对于所使用的压花装置上的相应雕刻结合或熔化在一起的区域的任何标记或可见压印。假如压花图案适合于保持复合材料之间的结合从而保持枕状单元的完整性，则可以使用各种各样的图案设计来形成本发明的PU皮革材料。
用于形成PU皮革10的不同材料有助于压花的有效性，以赋予在诸如汽车座椅的最终产品中在使用之后可保持的三维图案。在图1B中，示出了用于形成复合材料的不同材料的PU皮革10的一个实施例的剖视图包括PU面材20、泡沫材料22和稀松布材料24。这些材料中的每一种包括通过这里描述的装置和方法组合的一个或多个层。
在一个实施例中，PU面材20由图2所示的方法形成。离型纸30通过导辊32提供，并前进穿过引入涂层的一系列固化腔室。在第一固化腔室34处，用一定量的水性PU涂覆离型纸30，所述水性PU固化(干燥和凝固)以形成PU表面层。在第二固化腔室40处，涂覆离型纸30被进一步涂覆一定量的由具有脂族异氰酸酯基的聚碳酸酯二元醇制成的PU树脂38，以形成PU表层，其用作相对于离型纸的纹理转印层。在第三固化腔室42处，离型纸30被进一步涂覆一定量的由具有脂族基的聚碳酸酯二元醇制成的PU粘合剂树脂44，以用作PU粘合剂层。通过该方法，在离型纸上形成PU表面层。接下来，通过使用辊50将背衬材料48引入并层压到涂覆离型纸30的表面上。最后，去除离型纸(未示出)以获得PU面材20。
在图3中，示出了本发明的PU面材20的一个实施例的横截面。PU面材20包括PU表面层60、PU表层82、PU粘合剂层64和背衬层66。
本发明可以设想PU面材20的替代实施例。例如，PU表层62可以是两层而不是单层。在另一实施例中，PU表层62可以是顶层，从而代替图3所示的表面层60。另外，PU表层62与背衬层66之间可以包括硅树脂层(未示出)。另外，如果PU面材包括穿孔(未示出)，则可以使用具有不同颜色的多个表层，使得内表层的颜色是不同的并且通过外表层的穿孔可见。
PU面材20的各层的重量和厚度的比例也可以变化。在一个实施例中，表面层60、表层62和粘合剂层64一起占PU面材20的总重量的约30％，剩余的重量归属于背衬层。在另一实施例中，表面层60、表层62和粘合剂层64一起可以占PU面材20的总重量的约27％至约30％，剩余的重量归属于背衬层。在另一实施例中，表面层60、表层62和粘合剂层64一起可以重约120g/m2，背衬层可以重约320g/m2。
皮革外观的模拟可以部分地通过离型纸30的表面上的纹理图案实现，该纹理图案转印到PU面材20的表面。可以获得各种各样的纹理图案，包括平滑的、粗糙的和技术性的(具有重复的设计和形状)纹理图案。PU面材可进一步是穿孔的。另外，PU面材20可以具有通过在加工期间引入的一种或多种染料赋予的各种各样的颜色。
用于背衬层66的材料也可以变化。特定的背衬材料为PU面材提供厚度、拉伸强度和拉伸性能。在一个实施例中，背衬可以是圆形针织纺织品。圆形针织纺织品可以是平坦的或起绒的。这些类型的纺织品为PU面材提供了增强的可修剪性。圆形针织的起绒版本还可以增强PU面材的触觉特征。也可以设想使用经编绒面革纺织品，特别是如果PU面材要被穿孔。背衬也可以是非织造材料，包括非织造绒面革。其它材料也是合适的，只要如下所述背衬适于结合泡沫材料22的表面即可。
为了形成根据本发明要压花的PU复合材料，PU面材20与泡沫材料和稀松布背衬组合。在一个实施例中，PU复合材料通过图4所示的方法形成。该方法包括通过一系列三个相邻辊的明火层压，三个相邻辊沿相反的方向转动，中间辊沿着与外辊相反的方向转动。首先，提供泡沫材料70并将其引导到第一辊72。当泡沫材料70围绕第一辊72通过时，第一明火74熔化泡沫材料70，以产生粘性表面。接下来，提供PU面材20并将其引导到第一辊72旁边的第二辊76。随着PU面材20和泡沫材料70在第一辊72与第二辊76的咬合部之间被挤压，PU面材20的底表面或背衬侧结合到泡沫材料70的粘性表面上。随着泡沫材料70的结合侧与第二辊76接触，泡沫材料70的非结合侧或相反侧被第二明火82熔化，以产生粘性表面。最后，提供稀松布或织物背衬78并将其引导到第二辊76旁边的第三辊80。随着稀松布背衬78和泡沫材料70在第二辊76与第三辊80的咬合部之间被挤压，稀松布背衬78结合到泡沫材料70的非结合粘性表面上，以产生用于压花的复合材料26。
在替代实施例(未示出)中，与图4所示的连续方法相反，泡沫层和稀松布层的层压可以在两个单独的通过过程中完成。
在图5中示出了形成的PU复合材料26的一个实施例的横截面。除了在该实施例中包括表面层60、表层62、粘合剂层64和背衬层66的PU面层之外，复合材料还包括泡沫层70和稀松布或织物层78。该复合材料26用于形成压花复合材料10的一个实施例。
用于这些附加层的材料为复合材料提供了增强的性能，特别是，不可复原的泡沫是泡沫层70的优选材料。“可复原的”泡沫在被刀片切割或被模具冲压或加热之后重新恢复其原来形状，因此不适于压花。如本文所用的，“不可复原的”泡沫是适于压花的泡沫材料，其不能从模切/压花操作中恢复，从而保持其压花形状。这种不可复原的泡沫使得压花能够永久地保持在适当的位置，以产生本发明所需的三维效果。
在一个实施例中，泡沫层70是厚度为约3mm至约5.2mm的聚酯型聚氨酯。为了实现泡沫与外部PU面和稀松布层之间的结合，优选地在根据本发明的一个实施例的熔化方法中，如前所述将泡沫加热成在两侧熔化，泡沫的任一侧的厚度减小约1mm。因此，该方法中的起始泡沫材料70应该在约5mm与约7.2mm之间，以在复合材料中实现约3mm与5.2mm之间的最终泡沫厚度。也可以设想其它厚度，只要如下所述泡沫层能够有效保持压花图案即可。
在另一实施例中，泡沫材料可以是由Foamex innovations,International制造且称为LG 160035的市售聚酯型聚氨酯泡沫。在另一实施例中，聚酯型聚氨酯泡沫可以从Foamex innovations获得并被称为L2185040。在另一实施例中，泡沫可以具有以下性质：表观密度约为1.85lb/ft3，泡沫塑料泡孔数约为75CPI，并且挠度缩进力约为65lb/50"2。在另一实施例中，泡沫可以具有以下特性范围。
纺织品层或非织造稀松布层72提供免受压花板和辊的热量的保护，并且可以通过稀松布选择来改变产品的维度稳定性。
PU复合材料的压花图案可以通过辊压花方法或平坦压花方法来实现。在图6和图7中示出了根据本发明的辊压花方法的一个实施例。首先，PU复合材料通过导辊90提供并被压花辊装置卷绕。随着复合材料被供给到压花站94，复合材料的张力通过一个或多个杆92保持。压花站94包括三个相邻的辊，其中雕刻压花辊100在加热接收辊96与加压辊106之间。将复合材料26引入加热接收辊96和加热压花辊100的咬合部中，使复合材料26的PU面材20侧与压花辊100接触，而复合材料26的背衬24侧与加热接收辊96接触。加压辊106有助于压花辊100与接收辊96之间的咬合部的紧密性。当复合材料在压花辊100与接收辊96之间通过时，在压花站处提供的热量和压力赋予复合材料压花图案。然后将压花复合材料102卷绕在缠绕件104上以用于各种应用。
热量、压力和张力参数有助于辊压花方法的有效性并且有助于所得压花复合材料的维度稳定性。在一个实施例中，雕刻压花辊100的温度不高于约140摄氏度/245华氏度。在另一实施例中，温度为约120摄氏度/245华氏度。
用于辊的材料也可以变化。在一个实施例中，加热接收辊96由金属制成。在另一实施例中，加热辊96由钢制成，在另一实施例中，加热辊96的温度不高于约190摄氏度/375华氏度。在另一实施例中，加压辊106由尼龙材料制成。
在压花辊100、复合材料和加热接收辊96之间的接触点处的停留时间由辊压花机的线速度控制。在一个实施例中，线速度为约3码/分钟至约5码/分钟。在一个实施例中，压力保持在约4MPa(兆帕)与约8MPa之间。
另外，雕刻压花辊可以产生各种压花设计。图案在辊表面中被雕刻到精确的深度和图形布置。特别是，雕刻压花辊100包括适于将图案转印到复合材料26上的突起和凹部阵列。突起和凹部的维度可以变化，只要压花图案能够被有效地转移穿过复合材料26而不损坏材料即可。
在图8中示出了根据本发明的平坦压花方法的一个实施例。首先将PU复合材料提供给平坦压花装置。复合材料206被引导到板式压花机的压花站210。压花站包括顶部雕刻压花板200、接收垫202和加热底板204。顶部压花板200下降到复合材料的表面上。作为选择，将顶板和底板按压在一起。在压花站处施加的热量和压力导致复合材料的位于板之间的一部分上的压花图案。然后将压花复合材料208移出压花站210。作为选择，与通过复合材料206片材的压花节段或压花部分相反，可以通过连续通道进行平坦压花。因此，整个复合材料或仅复合材料的一部分可以被压花。
热量、压力和张力参数有助于平坦压花方法的有效性并且有助于所得压花复合材料的维度稳定性。在一个实施例中，以下参数可用于板式压花机。在接触PU材料的压花板的表面上，压花板的温度可以不高于约190摄氏度/380华氏度。在接触PU材料的底部稀松布层的侧面上，底部加热板的温度可以不高于约200摄氏度/400华氏度。停留时间根据要使用的压花图案而变化，在一个实施例中，从启动压力控制到解除压力控制的停留时间可以在约5秒与约15秒之间。在另一实施例中，所使用的压力可以在约10psi与约30psi之间。
另外，压花板可以在PU复合材料上产生各种压花设计。图案在金属材料中被雕刻到精确的深度和图形布置。
在图9中示出了压花复合材料的一个实施例的横截面。如图所示，压花图案实现为穿过整个复合材料。然而，鉴于复合材料的性质，PU面材层和泡沫层的顶部具有相似的曲率，其似乎是泡沫和稀松布层的底部的曲率的镜像。如所描述的，压花图案形成枕状单元14，枕状单元14由PU面和稀松布突起300限定并包含在结合线12内。
相关领域的技术人员将从上述优选实施例的描述中理解到：在不脱离由所附权利要求限定的本发明的精神和范围的情况下，可以进行替换和修改。

Claims (21)

1.一种压花复合材料，包括：
聚氨酯层；
不可复原的泡沫层，其具有顶面和相反的底面，其中，所述顶面结合到所述聚氨酯层；
背衬，其结合到所述不可复原的泡沫层的所述底面，其中，所述聚氨酯层、所述不可复原的泡沫层和所述背衬均具有形成枕状单元的压花图案，并且所述枕状单元由压花突起和所述压花图案所形成的压花线限定。
2.根据权利要求1所述的压花复合材料，其中，所述聚氨酯层包括：顶面层；表层，其结合到所述顶面层；以及纺织品背衬层，其用粘合剂层结合到所述表层。
3.根据权利要求2所述的压花复合材料，其中，所述顶面层、所述表层和所述粘合剂层的组合重量为所述聚氨酯层的总重量的约27％至约30％。
4.根据权利要求2所述的压花复合材料，其中，所述纺织品背衬层由圆形针织织物制成。
5.根据权利要求4所述的压花复合材料，其中，所述圆形针织织物是起绒的。
6.根据权利要求1所述的压花复合材料，其中，所述不可复原的泡沫层由聚酯型聚氨酯泡沫制成。
7.根据权利要求6所述的压花复合材料，其中，所述不可复原的泡沫层的厚度为约3mm至约5.2mm。
8.根据权利要求1所述的压花复合材料，其中，所述聚氨酯层的所述压花图案基本上平行于所述不可复原的泡沫层的所述顶面的所述压花图案，并且所述背衬的所述压花图案基本上平行于所述不可复原的泡沫层的所述底面的所述压花图案。
9.根据权利要求1所述的压花复合材料，其中，所述背衬是纺织品层或非织造织物层。
10.一种压花复合材料的制造方法，包括以下步骤：
提供聚氨酯层、不可复原的泡沫层和背衬；
组合所述聚氨酯层、所述不可复原的泡沫层和所述背衬，以形成复合材料；
将图案压花在所述复合材料上，以形成具有枕状单元的压花复合材料，所述枕状单元由压花突起和所述图案所形成的压花线限定。
11.根据权利要求10所述的压花复合材料的制造方法，其中，所述压花步骤包括以下步骤：
提供具有压花站的辊压花装置；
将所述复合材料供给到所述压花站，所述压花站具有邻近接收辊的雕刻压花辊；以及
使所述复合材料通过所述接收辊和所述雕刻压花辊的咬合部。
12.根据权利要求11所述的压花复合材料的制造方法，还包括加热所述接收辊和所述雕刻压花辊的步骤，其中，将所述接收辊加热到比所述雕刻压花辊高的温度。
13.根据权利要求11所述的压花复合材料的制造方法，还包括以下步骤：
将所述接收辊加热到约190℃的温度；以及
将所述雕刻压花辊加热到约150℃的温度，其中，所述加热步骤在所述复合材料通过所述咬合部之前。
14.根据权利要求11所述的压花复合材料的制造方法，还包括以下步骤：
将所述接收辊加热到约190℃至约195℃的温度；以及
将所述雕刻压花辊加热到约120℃至约180℃的温度，其中，所述加热步骤在所述复合材料通过所述咬合部之前。
15.根据权利要求11所述的压花复合材料的制造方法，其中，所述通过步骤以约3码/分钟至约5码/分钟的线速度进行。
16.根据权利要求11所述的压花复合材料的制造方法，还包括以下步骤；
提供邻近所述雕刻压花辊的加压辊；以及
将所述雕刻压花辊压向所述接收辊，以保持约4MPa至约8MPa的压力。
17.根据权利要求10所述的压花复合材料的制造方法，其中，所述组合步骤通过明火层压工艺进行。
18.根据权利要求10所述的压花复合材料的制造方法，其中，所述压花步骤包括以下步骤：
提供具有压花站的平坦压花装置；
将所述复合材料供给到所述压花站，所述压花站具有上部雕刻压花板和下部平板；以及
将所述上部雕刻压花板和所述下部平板按压在一起，以在所述复合材料上形成所述图案。
19.根据权利要求18所述的压花复合材料的制造方法，还包括以下步骤：
将所述上部雕刻压花板加热到约190℃的温度；以及
将所述下部平板加热到约200℃的温度，其中，所述加热步骤在所述按压步骤之前。
20.根据权利要求18所述的压花复合材料的制造方法，其中，所述按压步骤进行约5秒至约15秒的时间。
21.根据权利要求18所述的压花复合材料的制造方法，还包括对所述压花站施加约10psi至约30psi的压力。
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