DE102013003446A1 - Composite material comprises top layer comprising layer of solidified polyurethane dispersion or solidified polyurethane, middle layer joined to top layer and having e.g. polyvinyl chloride layer, and support layer joined with middle layer - Google Patents

Abstract

Composite material comprises: a top layer (1) comprising at least one layer of a solidified polyurethane dispersion or with solidified polyurethane; a middle layer (2) joined to the top layer comprising at least one layer made of soft polyvinyl chloride (PVC), PVC plastisol, PVC polymer, PVC copolymer and/or PVC mixed polymer; and a support layer (3) connected with the middle layer comprising a layer of polyester-based polyurethane foam, preferably an open-cell polyurethane peeling foam, which is formed with a polyester foam layer on the middle layer. Composite material comprises: a top layer (1) comprising at least one layer of a solidified polyurethane dispersion or with solidified polyurethane; a middle layer (2) joined to the top layer comprising at least one layer made of soft polyvinyl chloride (PVC), PVC plastisol, PVC polymer, PVC copolymer and/or PVC mixed polymer; and a support layer (3) connected with the middle layer comprising a layer of polyester-based polyurethane foam, preferably an open-cell polyurethane peeling foam, which is formed with a polyester foam layer on the middle layer comprising a thin microfibre fleece or a fabric layer, lay-up layer, hand knitted fabric-layer or a polyester fabric layer, laid fabric-layer, pluck-layer, crocheted-layer or knitted-layer.

Description

The invention relates to a novel composite material according to the preamble of patent claim 1.

There is a need for a lightweight, flame resistant, readily deformable and low cost composite material that can be used in particular for the automotive industry as interior trim, skylight, seat cover, etc. as well as bags, shoes, etc.

These objects are achieved with a composite material of the type mentioned above with the features set out in the characterizing part of patent claim 1.

The composite material according to the invention can be briefly heated to 210 ° C without the surface effect, for. As a nubuck or velor effect to lose. Structures of the surface are still preserved. The composite material according to the invention is non-destructively deformable and surface structurable in a simple manner and lasting. Furthermore, it is a very lightweight material. The aging behavior is also beneficial; existing plasticizers do not migrate.

Solidified, crosslinked polyurethane layers are thin due to the removal of water during solidification. Thick polyester layers are expensive, flammable and non-deformable. Therefore, usually thin polyurethane coatings are produced with a maximum thickness of 0.22 mm, including on the German utility model 20 2004 019 330 41 is referenced.

According to the prior art, coating dispersions are used which contain a maximum of 40% solids, so that a 60% shrinkage occurs.

The PVC or PVC polymer or mixed or copolymer materials used according to the invention do not shrink and retain their thickness or thickness because they gelled when solidified; By using blowing agents even increases in strength can be achieved. This results in a reduced weight and a much better thermal deformability, as in the composite materials according to the prior art. As a result, the cost of relatively expensive, also used as adhesive layers polyurethane dispersions are reduced because less and cheaper starting materials can be used and eliminates the energy for water evaporation.

Reference to the drawing, the invention is explained in more detail, for example.

In the 1 and 2 in each case a schematic section through different embodiments of a composite material according to the invention is shown in a large scale. The composite material basically comprises three essential layers, namely a top layer 1 , a middle layer 2 and a carrier layer 3 , In addition, additional layers can be provided.

The plasticizer-free upper layer 1 can be one or two layers 1' . 1'' comprises and consists of a solidified, crosslinked polyurethane dispersion based on aliphatic polyester and / or polycarbonate and has a structured surface 4 , The middle layer 2 connects the upper class 1 with the carrier layer 3 , The carrier layer 3 includes either, as in 2 a layer of polyester-based polyurethane foam or as shown in FIG 1 represented, a composite of a layer 5 a polyurethane foam based on polyester, in particular peelable foam, with a layer 8th made of textile material 6 or a textile layer formed with a polyester fiber fabric, knit fabric, sheet, knit or loop.

The back and outside of the carrier layer 3 can with an adhesive layer 9 , in particular a thermoplastic adhesive, or a layer 9 be provided from textile material.

For the education of the upper class 1 For example, an aqueous, predominantly or entirely aliphatic polyurethane dispersion based on polyester and / or polycarbonate is used. The finished upper class 1 is cross-linked and not thermoplastic. The fine structure of the surface 4 the upper class 1 is achieved in a conventional manner by being prepared on a correspondingly negatively structured pad or matrix made of silicone rubber or on a coated release paper. The surface 4 the upper class 1 can thus be finely structured and have the appearance of nubuck leather or velor. The finely structured surface may also have different structures, such. As logos or symbols, which be introduced by laser into the pad, in particular silicone rubber matrix, as z. B. in the US 6177198 B1 is described.

There are also surface structures with a technical appearance, such as Waffelmuster, and / or a molding of the surface 4 with sandpaper of a grain size between 100 and 600 in question. As a result, a very fine structure can be created, which only becomes apparent at high magnification in their actual training.

In an embodiment of the invention, the elevations are - even without Mattierungsmittelzusätze in the polyurethane dispersion matter - and the wells always show more shine than the surveys.

The dullness of the elevations created by the desired surface texture, eg. B. that of a textile, or a waffle structure or any other structure transfers to a film and the elevations on this film before molding with silicone rubber - ie only the elevations - matted or roasted with sandpaper. This effect also significantly improves the feel and abrasion properties.

It is sufficient if the elevations protrude already 0.01 mm from the base. The elevations may be lines, circles, points, triangles or the like. To better understand what these surfaces can look like, the 3 to 6 ,

The upper class 1 has a thickness between 0.06 and 0.18 mm and a hardness of 20 to 90 Shore A, preferably from 20 to 75 Shore A. The upper layer 1 usually contains 2 to 6 wt .-% of pigments and / or 2 to 16 wt .-% polysiloxanes and / or 2 to 6 wt .-% crosslinker and / or 1 to 2 wt .-% waxes, each based on the Weight of the polyester and / or polycarbonate polyurethane dispersion used.

To better connect with the middle layer 2 To reach out to the upper class 1 alternatively or additionally up to 30% by weight of polyacrylates, based on the polyurethane content of the upper layer ( 1 ), contain. The upper class 1 is formed with a polyester and / or polycarbonate polyurethane dispersion which contains at least 75% by weight of aliphatic polyester and / or polycarbonate-based polyurethane and comprises at least one layer 1' . 1'' from the solidified, crosslinked polyurethane.

The middle layer 2 consists of soft PVC, PVC copolymer and / or PVC copolymer (also called plastisols). This starting material is used liquid or pasty and is solidified by gelling in heat without shrinking.

The textile material 6 the carrier layer 3 is advantageously formed from a polyester microfibre web, or polyester web, knits, slings, knits or sheets, optionally with a content of up to 40% by weight cotton fibers. The one for the carrier layer 3 polyester-based polyurethane foam used is advantageously an open-cell polyester-polyurethane foam foam and has a density of between 30 and 90 kg / m ³ when used alone as a carrier layer 3 is used, and has a density between 20 and 60 kg / m ³ when using textile material 6 connected by flame laminating and in a composite for the carrier layer 3 is used. The textile material 6 lies at the middle layer 2 facing side of the carrier layer 3 ,

One between the upper class 1 and the middle layer 2 optionally arranged primer layer 10 advantageously consists of a crosslinked layer formed predominantly of a polyester-polyurethane dispersion with a prior to their crosslinking linear or crystalline structure.

The middle layer 2 contains between 30 and 60 wt .-% of known plasticizer. It has a thickness between 0.11 and 0.95 mm, in particular 0.85 mm, and a basis weight between 105 and 400 g / m ² .

The material of the middle layer 2 may have a density of from 0.7 to 1.5 g / cm ³ , preferably from 0.85 to 1.1 g / cm ³ . It can usually contain per se known propellant, whereby this layer 2 may have a density of less than 0.9 g / cm ³ .

The optionally foamed material of the middle layer 2 penetrates 0.005 to 0.05 mm into the open cells of the polyester foam of the carrier layer 3 so that in this area a mixture, in particular a mixed foam, of polyester-polyurethane and PVC co- or copolymer is present. If the carrier layer 3 with textile material 6 is created, which by flame lamination with the foam of the carrier layer 3 connected, the layer can 8th made of textile polyester fibers 6 from the material of the middle layer 2 be penetrated. The PVC material penetrates the middle layer 2 in the interstices of the fibers of the textile layer 8th the carrier layer 3 and fill in this area 7 the free volume between the fibers is between 30 and 85% by volume.

The middle layer 2 serves as a connecting layer between the upper layer 1 and the carrier layer 3 , The middle layer 2 is under heat and pressure application, possibly by heating by high frequency, permanently deformable and also embossed. It is thermoplastic and contains 30 to 60 wt .-% solids such as PVC polymer and / or -Co- or -Mischpolymerisat; the rest are per se known plasticizers for PVC or for its copolymers or copolymers, pigments, blowing agents and / or polyvinyl acetates.

When the carrier layer 3 in both directions of its plane has an elongation at break of more than 45%, preferably more than 55%, the finished composite material also has an elongation at break in all directions of its areal extent of more than 45% and is thus readily vacuum-deformable, which is its high 3D Shape adaptability shows.

In the production of a composite material according to the invention, the procedure is such that the upper layer formed on a support and formed with aliphatic polyester and / or polycarbonate polyurethane 1 a layer of soft PVC paste or plasticised PVC plastisol or a PVC co- or Mischpolymerisat paste is applied. On the carrier layer is 3 in the form of a location 5 made of, in particular open-cell, polyurethane foam without textile material or in the form of a composite of a layer 8th a textile material 6 with a location 5 one, in particular open-cell, polyurethane foam or in the form of a layer of a textile polyester microfiber nonwoven fabric or such a fabric, scrims, slings, knitted or knitted fabric on the middle layer 2 applied.

For the time being, the applied aliphatic PU dispersion is solidified by drying on the negatively structured matrix or base until it contains no or less than 5% of water. Before the final networking of this upper class thus formed 1 becomes the pasty middle layer 2 to the upper class 1 applied. On this liquid or pasty layer is the carrier layer 3 put on and lightly pressed, so that the PVC material in the amount of 0.06 to 0.20 mm, preferably from 0.005 to 0.05 mm, in the layer 8th and / or into the open cells or intercellular spaces of the foam of the layer 5 the carrier layer 3 penetrates.

The applied textile, with the polyurethane foam of the layer 5 Connected textile material 6 has a basis weight of 60 to 240 g / m ² , preferably 60 to 160 g / m ² , and a thickness of between 0.10 and 0.65 mm, preferably between 0.20 and 0.55 mm.

The layer 5 made of open-cell polyurethane foam, in particular polyurethane foam, polyester-based has a thickness of 1.2 to 4.8 mm, preferably from 1.5 to 3.5 mm.

When the polyester-based open-celled polyurethane foam has a thickness of more than 1.5 mm, the heat used to gel the PVC-based center layer becomes 2 needed, disturbed. In this case, it is expedient that the Flammenkaschierung is made after the coating, since the foam acts as an insulator and the heat supply to the PVC material of the middle layer 2 with special needs.

If the layer 5 respectively. 3 is formed from the textile material (alone), it has a basis weight of 150 to 240 g / m ² and a thickness of 0.20 to 0.75 mm. This textile backing layer is formed with a polyester fabric, pads, loop, knits or knits, wherein a content of up to 40 wt .-% cotton fibers may be provided.

If this textile backing layer 3 respectively. 5 has a basis weight of 150 to 240 g / m ² , it is advantageous first to coat the same and then to connect with an open-cell foam by flame laminating.

If the upper class 1 contains more than 2 wt .-% polysiloxane or waxes as a handle, can on the solidified, not yet cross-linked upper layer 1 a thin primer layer 10 are applied from a polyester-based polyurethane dispersion having a predominantly crystalline (linear) structure which contains a crosslinker. This will be the connection of the upper class 1 with the middle layer 2 improved. These primer layer 10 has a thickness of 0.01 to 0.03 mm and contains crosslinking agents in an amount of 3 to 5 wt .-%, based on the weight of the polyurethane in the dispersion. This primer layer 10 has properties similar to those of the upper class 1 are comparable, and can, if it exists, to the upper class 1 be counted.

PVC plastisols are understood as meaning liquid or pasty compositions which comprise PVC polymers, PVC copolymers and / or PVC copolymers and also plasticizers in the amount of from 30 to 60% by weight, based on the total weight of the polymer material of the middle layer 2 , Such pasty masses are used as the middle layer 2 on the not yet fully networked upper class 1 applied and with the carrier layer 3 at a temperature of 55 to 190 ° C, preferably from 85 to 140 ° C, connected. The middle layer 2 Gels at this temperature, without shrinking or, without shrinking, solid and, if it contains a propellant, there is an increase in volume.

The back of the carrier layer 3 can with a layer 9 a heat-activatable adhesive, which is activated during hot-forming or deep drawing when applied to objects.

On the back of the carrier layer 3 For example, a thin microfibre web or a woven, knitted, looped, knitted or laid polyester fiber fabric having a basis weight between 20 and 70 g / m ^{2 may} be bonded by flame laminating. This can be done even if already at the middle layer 2 facing side of the carrier layer 3 a comparatively heavier textile material 6 is connected by flame laminating.

The composite material according to the invention allows almost any deformation under different conditions of use and is - if no perforations are formed - airtight and can thus with the application of heat and vacuum on objects, especially door panels, center consoles and the like. Of motor vehicles, mounted. In perforated or air-permeable form, the new composite material can be used as a car sky application.

Coatings formed with polyurethane dispersions are flammable per se. In order to meet the requirements with regard to fire behavior, flame-retardant chemicals are to be used which negatively alter the feel of the known composite material, harden the coating and are physiologically questionable. The solution according to the invention prevents here, in that the middle layer 2 is formed with plasticized PVC or with PVC co- or Mischpolymerisat and advantageously by at least 40% thicker or heavier, than the used, formed with the polyurethane layer on polyester and / or polycarbonate-based upper layer 1 , Furthermore, the middle layer 2 partly in the carrier layer 3 penetrated, so that - inseparable composite - can be dispensed flame retardant additives, especially if the carrier layer 3 itself fulfills the flame behavior prescribed by the automobile industry.

Particularly in the case of the composite materials currently used for the automotive industry, the disadvantage mentioned is that the polyurethane used is the upper layer 1 burns, whereby the addition of flame retardant, the properties of the composite materials adversely affecting substances is required. Such additives also make the composite material more expensive. If, as provided for the new composite material, PVC material used, we obtain a much improved flame behavior, since PVC is less flammable.

In the following table, some known PVC materials are available, which are available in the form of laminating pastes or plastisols, wherein the individual materials, the gelling or glass transition temperatures (TG) are specified. Used PVC TG ° C Pure copolymer PVC 80 E-PVC 79 Blend Copolymer PVC / PVC 76 E-PVC 80 Pure copolymer PVC, softer than TE 652 76

Such PVC mixtures have hitherto been used industrially variously, but not for the production of composite materials of the type according to the invention.

The specific gravity (density) of polyurethane materials is about 1.05 g / cm ³ . Soft PVC material usually has a specific gravity (density) of 1.1 to 1.4 g / cm ³ . However, it is possible to foam the PVC material used, thereby reducing its specific gravity (density). Overall, the PVC layer used according to the invention is 2 a bit thicker and a bit heavier than comparable polyurethane layers. The specific gravity (density) of the middle layer 2 can be reduced by foaming to 0.85 g / cm ³ .

The carrier layer 3 is advantageously formed with polyester open-cell polyurethane foam foam. Foamed foam is understood in the form of a sheet, plate or foil, which is obtained by layering or cutting off foam blocks. When separating the layers from each other, the open pore or cell structure is maintained. Task of the carrier layer 3 is the creation of a sound-, cold- and heat-insulating and moisture-absorbing layer; the inserted PVC middle layer 2 is airtight.

Because the formed PVC middle layer 2 is impermeable to micro-perforations can be formed in her later. These microperforations are on the surface of the layer 1 not visible. For automotive applications, especially for seats and skies, the composite material may be provided with visible perforations on the surface.

The ultimately cross-linked, solidified, formed from an aqueous polyester dispersion top layer 1 prevents the emigration of plasticizers from the middle layer 2 , The polyester-based polyurethane foam on the base layer 3 absorbs no or hardly any plasticizer according to a temperature endurance test over 240 hours at 80 ° C.

A preferred embodiment of the novel composite material provides that the carrier layer 3 consists solely of a polyurethane-based polyurethane foam, wherein in the connecting region the PVC of the middle layer 2 into the cells of the foam of the carrier layer 3 has penetrated. In this area, two very different polymers are primarily mechanically bonded together or anchored.

As a further embodiment, the polyurethane chip foam of the carrier layer 3 by flame lamination with a light weight, thin polyester microfibre web, or with a polyester fiber knit, loop, web, fabric or sheet (layer 8th ). The microfibers refer to the fleece, not to knitted fabrics, fabrics, slips, knits and scrims. Here the middle layer anchors itself 2 primarily in the cavities of the textile material 6 and when the textile material is thinner than 0.20 mm, penetrates through the same into the open cells of the peeling foam.

It is advantageous if the solidified and crosslinked upper layer 1 a hardness of from 20 to 90 Shore A, preferably from 30 to 65 Shore A, and the soft PVC center layer solidified by the gelling 2 the same or approximately the same Shore A hardness as the upper layer 1 , As a result, any expansion creases will be rented during stretching and creases for convex and concave bends.

Components such. As car door panels, have generally convex and concave shapes. The composite material according to the invention shows no changes in the surface after its loading or clamping.

To check the Shore A hardness, the aqueous dispersion batch of the upper layer becomes 1 made a 100 mm × 100 mm test specimen with a thickness of 5 mm. With the same dimensions, a test specimen is produced from the PVC plastisol. After a storage time of 24 hours at 22 ° C, the Shore A hardness is determined on the two test specimens.

When the carrier layer 3 is only made of polyurethane foam, it is advantageous if the foam is compacted on one side or on its two sides superficially. After peeling or splitting, one or both sides are treated by heat and in a manner known per se. As a result, a thin, but still liquid-permeable layer forms and the open-cell foam structure is slightly changed, so that open, larger cells in this area become smaller.

It has been found that the new composite material is due to its resistance to abrasion, bending, moisture and not least its tactile and aesthetic properties, as well as as a result its low weight, its high mechanical strength, shock absorption capacity for bags, especially for tablet and notebook bags, ideal.

According to the invention, it is advantageous if the upper layer 1 has a geometric structure and the elevations or lines on its surface by indirect grinding or roughening have a matte surface. As a result, not only the feel is significantly improved, but also the Abriebeigenschaften.

The following examples illustrate the invention in more detail:

Example 1:

To form the top layer of the novel composite material, a silicone rubber sheet having a flat surface having a negative velor surface structure was coated with an aqueous dispersion containing 80% by weight of an aliphatic polyester-polyurethane containing 3.5% by weight of a black, fine pigment and 2.5 wt .-% of conventional crosslinking agent applied and left there dry at a temperature of 30 ° C and preconsolidated.

Onto this top layer, a still flowable, pasty plastisol layer based on a customary PVC polymer with a customary blowing agent for the formation of a PVC foam polymer was applied by means of a doctor blade to form the middle layer.

A 0.25 mm thin polyester microfiber nonwoven layer was applied to the obtained in this way, still present pasty state middle layer, which had been applied by means of flame lamination on a 3.5 mm thick polyurethane peel foam layer carrier layer, wherein - like on the finished composite, the PVC copolymer had penetrated to a minor extent of less than 0.05 mm through the textile layer into the open cells of the skived foam of the backing and filled the space between the fibers of the web to approximately 65%.

The gelation of the middle layer was carried out by heating to 165 ° C.

There was obtained a composite material having a 0.15 mm thick top layer with a fine velor surface and a hardness of 55 Shore A whose basis weight was 0.95 g / m ² .

The inextricably associated with this topsheet PVC foam middle layer also had a density of 0.95 g / cm ³ and had a thickness of 0.35 mm.

The underside of the middle layer also inseparably connected, provided on the top side with the polyester microfiber nonwoven carrier layer had a density of 50 kg / m ³ and a thickness of 3.2 mm.

The composite material thus produced has a stretchability of at least 45% and is suitable after applying a heat-activatable adhesive to the underside of the carrier layer, in particular for a wrinkle-free, uniform lining of the interiors of passenger cars.

Example 2:

To form the two-ply topsheet, an aqueous dispersion containing 80% by weight of an aliphatic polycarbonate polyurethane was knife-coated as a first topsheet layer onto a flat silicone rubber sheet having a nubuck negative surface structure and allowed to dry readily.

Thereafter, an aqueous dispersion of substantially the same, a content of 80 wt .-% of an aliphatic polycarbonate polyurethane having a polyacrylate content of 20% was sprayed onto this first top layer layer.

Prior to their complete solidification and crosslinking to form the middle layer, a just flowable, pasty plastisol layer based on a customary PVC-polyethylene copolymer with a conventional blowing agent and 45% by weight of plasticizer, preferably likewise by means of a doctor blade, was applied to this top layer and let it foam.

On the obtained in this way, still pasty present PVC foam center layer was applied as a support layer, a 0.2 mm thin polyester fabric layer with a share of 20% cotton fibers, which in turn previously by flame lamination to a 1.8 mm thick Polyurethane Schälschaumschicht was tethered. This Schälschaumschicht was provided by means of adhesive on the underside with a thin fine tissue layer having a basis weight of 105 g / m ² .

A penetration depth of the PVC polymer of the middle layer into the open cells of the support layer was not determined.

The solidification of the thus obtained flat product with gelation of the middle layer was carried out at temperatures of 165 ° C.
Result: Composite material with two-ply, but one-piece, a fine nubuck structure on the outer surface exhibiting
Upper layer: total thickness: 0.15 mm; Hardness: 65 Shore A
Middle layer: foamed PVC plastisol, hardness: 67 Shore A; Density: 1.1 g / cm ³ ; Thickness: 0.85 mm; Basis weight: 210 g / m ²
Carrier layer: density: 82 kg / m ³ ; Thickness: 2.8 mm

This composite material is particularly suitable for the production of robust hand, file and tool bags.

Example 3:

To form the topsheet, an aqueous dispersion containing 82% by weight of an aliphatic polyester-polyurethane, crosslinker content 4% by weight, was sprayed onto a flat silicone rubber sheet having a fine waffle surface texture and left to dry and preconsolidate there ,

On the upper layer thus formed, a still flowable, pasty plastisol layer based on a customary PVC polymer having a conventional blowing agent content and 50% plasticizer was applied by means of a doctor blade to form the middle layer.

Prior to solidification, the 0.15 mm thin polyester knitted fabric layer was placed on the pasty middle layer thus obtained as part of the support layer, which knitted fabric layer was bonded by flame lamination to a 2.75 mm thick polyurethane skived foam layer.

At a temperature of 155 ° C, the gelation of the PVC center layer was made.
Result: Composite material:
Top layer with fine waffle pattern and logo on top: Thickness: 0.15 mm; Hardness: 78 Shore A
Middle layer: density 1.1 g / cm ³ ; Thickness: 0.70 mm; Basis weight: 180 g / m ²
Carrier layer: Textile layer and polyurethane peelable foam layer: Density: 70 kg / m ³ ; Thickness: 3.8 mm

The resulting composite material is particularly suitable for the production of highly durable flat computer, laptop and mobile phone cases.

Example 4:

To form the topsheet, a dispersion containing 90% by weight of an aliphatic polycarbonate polyurethane was poured onto a flat silicone rubber sheet having a negative velvet surface structure and allowed to dry and to pre-solidify there.

A flowable, pasty plastisol layer based on a PVC / PVC copolymer with conventional blowing agent was applied to this top layer to form the middle layer and foamed.

On the thus obtained, still pasty present middle layer, a 0.45 mm thin polyester fiber-gel layer was placed, which was connected by flame laminating to a 2.8 mm thick, open-cell polyurethane foam layer.

Heating to gel and solidify the middle layer to 145 ° C.
Result: composite material
Upper layer with velvet outer surface: Thickness: 0.15 mm, Hardness: 45 Shore A
Center layer: density 1.1 g / cm ³ , thickness: 0.8 mm, basis weight: 440 g / m ²
Support layer: Textile partial layer: Thickness: 0.32 mm, Basis weight: 120 g / m ²
Polyurethane peelable foam layer: density 0.60 kg / m ³ , thickness: 2.8 mm

This composite material can be used in particular for highly durable upholstery linings, in particular for motor vehicle interior spaces.

Example 5:

A two-ply topsheet was formed by applying to a flat silicone rubber sheet having a negative carbon fiber surface structure an aqueous dispersion containing 77% by weight of a 2% by weight black pigment, 5% by weight crosslinker and 1% by weight. % synthetic wax-containing aliphatic polyester-polyurethane was applied by means of a doctor, and to the same was applied prior to complete solidification, an aqueous dispersion of a substantially equal aliphatic polyester / polycarbonate polyurethane containing 10% of a polyacrylate. After drying and partial consolidation to form the middle layer, a pasty plastisol layer based on a conventional, pure PVC polymer with the usual blowing agent content was applied to this top layer by means of a doctor blade.

On the thus obtained, still pasty foam middle layer, a polyurethane foam was applied directly and intimately bonded to the middle layer.

Heat to 170 ° C for gelation of the middle layer.
Result: composite
Upper surface with carbon fiber surface: thickness: 0.18 mm; Hardness: 0.55 Shore A
Middle layer: density: 1 g / cm ³ ; Thickness: 0.9 mm; Basis weight 320 g / m ²
Support layer: foam layer: density: 82 kg / m ³ ; Thickness 3.8 mm

This composite material can be provided in particular for the lapping or lamination of technical equipment and, where appropriate, the walls and ceilings of rooms of buildings.

Example 6:

The topcoat was formed on a flat silicone rubber sheet having a nubuck negative surface structure to form a single-layered topsheet 1 an aqueous dispersion having a content of 82 wt .-% of an aliphatic polyester polyurethane sprayed and there partially solidified or allowed to dry. A pasty plastisol layer based on a PVC-polyethylene polymer with a conventional blowing agent, preferably by means of a doctor blade, was applied to this top layer to form the middle layer.

On the middle layer obtained in this way, still present in pasty state, a 4.5 mm thick polyester fiber layer was placed with cotton fibers as a support layer and placed under light, two-dimensional pressure. Here, the plastisol material of the middle layer penetrated into the fiber interstices of the loop of the carrier layer.

The obtained 3-layer material was heated to 180 ° C to cause gelling and simultaneous foaming of the middle layer.

On the underside was the textile sling backing layer 5 provided with a 0.2 mm thin adhesive layer.
Result: composite material
Upper layer: Thickness: 0.12 mm; Basis weight: 390 g / m ² ; Hardness: 70 Shore A
Middle layer: PVC-polyethylene polymer foam: Hardness: 70 Shore A; Thickness: 0.09 g / cm ³ ; Basis weight: 180 g / m ²
Carrier layer: polyester slings with a cotton fiber content of 25% by weight;
Density: 75 kg / m ³ ; Thickness 3.8 mm

This composite material has proven to be particularly suitable for soft covers of vehicle interiors without wrinkling and with high conformability.

In the 3 to 6 For illustration purposes, various photographic representations of non-velvet, non-velor and non-nubuck top faces of the novel composites are shown.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 20200401933041 U [0005]
• US 6177198 B1 [0012]

Claims (22)

Composite material with a top layer ( 1 ), a middle layer ( 2 ) and a carrier layer ( 3 ), wherein the upper layer at least one layer ( 1' . 1'' ) comprising a solidified polyurethane dispersion or solidified polyurethane, characterized in that - the 1 ) middle layer ( 2 ) at least one layer ( 2 ' . 2 '' ) of PVC or PVC plastisol, in each case of PVC polymer, PVC copolymer and / or mixed PVC polymer, and - that with the middle layer ( 2 ) a carrier layer ( 3 ) connected to a layer ( 3 ) of a polyester-based polyurethane foam, preferably an open-celled polyurethane foamed foam, with one to the middle layer ( 2 ) a thin microfibre nonwoven or a fabric, scrim, sling, knitted or knitted fabric layer ( 8th ) comprising polyester foam layer ( 5 ) or with a polyester fabric, gauze, loop, knit or knit layer. Composite material according to claim 1, characterized in that the carrier layer ( 3 ) at its middle layer ( 2 ) facing side a layer ( 8th ) of textile material ( 6 ), preferably of a polyester microfibre web or of a woven, scrim, sling, knit or knitted fabric of polyester fibers alone or with up to 40% by weight of cotton fibers, based on polyester fibers. Composite material according to claim 1 or 2, characterized in that the upper layer ( 1 ) is formed with a solidified and at least partially crosslinked polyurethane dispersion based on polyester and / or polycarbonate, in particular with an aliphatic polyester and / or polycarbonate, and, based on their total weight, at least 75 wt .-% of aliphatic polyester and / or polycarbonate Polyurethane, optionally with the upper layer ( 1 ) present aliphatic polyester and / or polycarbonate polyurethane in the amount of 12 to 40 wt .-%, preferably 15 to 25 wt .-%, in crystalline structure. Composite material according to one of claims 1 to 3, characterized in that in the upper layer ( 1 ) Pigments in the amount of 2 to 6 wt .-%, and / or crosslinking agents in the amount of 2 to 6 wt .-%, and / or polysiloxanes in the amount of 2 to 16 wt .-%, and / or waxes in the amount of 1 to 2 wt .-%, each based on the total weight of the formation of the upper layer ( 1 ) used polyester and / or polycarbonate polyurethane dispersion, and / or polyacrylates up to 30 wt .-%, based on the polyurethane content of the upper layer ( 1 ) are included. Composite material according to one of claims 1 to 4, characterized in that the upper layer ( 1 ) with two layers ( 1' . 1'' ), wherein the two layers ( 1' . 1'' ) have mutually identical or mutually similar compositions and / or the near-surface layer ( 1' ) the upper class ( 1 ) is free of polyacrylates and in the layer below ( 1'' ), based on their total weight, a maximum of 30 wt .-%, advantageously 15 to 25 wt .-%, polyacrylates are included. Composite material according to one of claims 1 to 5, characterized in that the upper layer ( 1 ) is formed with a polyester and / or polycarbonate polyurethane which contains from 10 to 20% by weight of a linear (crystalline) polyester polyurethane, or else to the middle layer ( 2 ) a very thin primer layer ( 10 ) (Thickness: 0.01 to 0.03 mm) containing 10 to 50% by weight, in particular more than 25% by weight, of a linear or crystalline structure-containing polyester-polyurethane. Composite material according to one of claims 1 to 6, characterized in that on the upper layer ( 1 ) Hairs, convex elevations, concave depressions and / or structures are formed or embossed and / or that the one or two-layered upper layer ( 1 ) is created on a corresponding negatively textured base. Composite material according to one of claims 1 to 7, characterized in that the upper layer ( 1 ) a basis weight of 60 to 240 g / m ² , preferably from 60 to 160 g / m ³ , and / or a total thickness of 0.06 to 0.18 mm. Composite material according to one of claims 1 to 8, characterized in that the solidified, crosslinked upper layer ( 1 ) has a hardness of from 20 to 90 Shore A, in particular from 20 to 75 Shore A, and optionally has the middle layer solidified by gelling ( 2 ) each having the same or an approximately equal Shore A hardness. Composite material according to one of claims 1 to 9, characterized in that the middle layer ( 2 ) is formed with a foamed PVC polymer, PVC copolymer and / or PVC copolymer. Composite material according to one of claims 1 to 10, characterized in that the middle layer ( 2 ) 30 to 60 wt .-%, preferably 40 to 50 wt .-%, plasticizer, based on the total weight of the polymer or PVC material of the middle layer ( 2 ), and optionally further pigments, blowing agents, polymers, such as. As polyacrylates and / or polyvinyl acetates. Composite material according to one of claims 1 to 11, characterized in that the specific gravity (density) of the middle layer ( 2 ) Is 0.7 to 1.5 g / cm ³ , preferably 0.85 to 1.1 g / cm ³ , and / or that the thickness of the middle layer ( 2 ) 0.11 to 0.95 mm, preferably 0.12 to 0.45 mm, and / or that the middle layer ( 2 ) has a weight per unit area of 105 to 400 g / m ² , in particular of 130 to 400 g / m ² . Composite material according to one of claims 1 to 12, characterized in that the textile material ( 6 ) of the carrier layer ( 3 ) has a basis weight of 10 to 240 g / m ² , preferably of 30 to 110 g / m ² , and / or a thickness of 0.10 to 0.75 mm, preferably from 0.20 to 0.55 mm. Composite material according to one of claims 1 to 13, characterized in that the layer ( 5 ) of polyurethane foam of the carrier layer ( 3 ) has a density of 30 to 90 kg / m ³ if it does not carry a textile material layer, and in the presence of a textile material layer ( 8th ) has a density of 20 to 60 kg / m ³ , and that it has a thickness of 1.5 to 4.8 mm. Composite material according to one of claims 1 to 14, characterized in that the carrier layer ( 3 ) by a flame-laminating composite of a layer ( 5 ) of a polyester-based polyurethane foam and a layer ( 8th ) of a textile material ( 6 ) is created. Composite material according to one of claims 1 to 15, characterized in that the carrier layer ( 3 ) is formed with a polyester microfiber nonwoven or with a polyester fiber fabric, pads, loops, knits or warps, optionally containing up to 40% by weight of cotton fibers, this textile backing layer ( 3 ) has a basis weight of 60 to 240 g / m ² . Composite material according to one of claims 1 to 16, characterized in that the carrier layer ( 3 ) is extensible in both directions of the plane by at least 45%, preferably at least 55%. Composite material according to one of claims 1 to 17, characterized in that the PVC material of the middle layer ( 2 ) at least to the extent of 0.005 to 0.05 mm through the layer ( 8th ) of textile fabric ( 6 u. Like. In the open cells of the polyurethane foam of the carrier layer ( 3 ) has penetrated or introduced and, where appropriate, the fiber interspaces ( 7 ) to 30 to 85 vol.%, or in the case of the presence of a textile carrier layer ( 3 ) from 0.015 to 0.4 mm has penetrated into the same or in their free spaces. Composite material according to one of claims 1 to 18, characterized in that the polyurethane foam of the carrier layer ( 3 ) Contains welding aids and / or aids for their heating by means of high frequency. Composite material according to one of claims 1 to 19, characterized in that the carrier layer ( 3 ) on its back with a layer ( 9 ) coated with heat activatable adhesive or with a layer ( 9 ) is made of a thin, textile carrier in the form of a microfibre nonwoven fabric, mat, fabric, knitted fabric, knitted fabric or loop made of synthetic or natural fibers, this textile outer layer ( 9 ) has a basis weight of 20 to 70 g / m ² . Composite material according to one of claims 1 to 20, characterized in that the PVC material used is solvent-free. Composite material according to one of claims 1 to 21, characterized in that the middle layer ( 2 ) is at least 40% thicker than the upper layer ( 1 ).

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