EP3390034A1

EP3390034A1 - Method for producing a coating film and a composite material

Info

Publication number: EP3390034A1
Application number: EP16816274.1A
Authority: EP
Inventors: Birgit Kammerer; Jesse James Smith; Philipp Schaefer
Original assignee: Konrad Hornschuch AG
Current assignee: Konrad Hornschuch AG
Priority date: 2015-12-18
Filing date: 2016-12-19
Publication date: 2018-10-24
Also published as: US11007759B2; WO2017103247A1; AT518103A2; US20190009508A1

Abstract

The invention relates to a method for producing a coating film that takes, if required, the shape of sheeting or panels, particularly for coating a carrier layer (3), if required textile materials and/or polyurethane shell foams and/or a textile carrier layer (3), wherein the coating film (100) has a, if required, multi-layered top layer (1) and a connecting layer (2) which is connected thereto and comprises, if required, a plurality of layers (2', 2"), for the purpose of connecting to said carrier layer (3). According to the invention, - as the connecting layer (2), a non-crosslinked polyurethane layer having thermoplastic properties and a strength of between 0.080 and 0.500 mm, preferably between 0.200 and 0.500 and particularly between 0.120 and 0.180 mm, is produced and connected to the upper layer (1), and - as the upper layer (1), a single-layered polyurethane layer or a preferably double-layered polyurethane layer constructed with an outer layer (1') and an inner layer (1"), not having thermoplastic properties or having a non-thermoplastic amorphous or predominantly amorphous structure, is used which is thinner than said connecting layer (2).

Description

Process for the preparation of a coating film and a composite material

The invention relates to a method according to the preamble of patent claim 1. Such coating films can be produced in the form of endless webs and wound into rolls for later use. If such coating films are produced in the form of rather smaller format plates, these can be stacked and stored. The coating films of the invention are used in particular for coating textile materials or carrier layers, wherein the coating films are either applied over the entire surface of the carrier layer or a Formatzuschnitt or applied only to portions of this support layer or the Formatzuschnittes. The carrier layers or size cuts provided with the coating film are further processed.

From WO 2008/077785 A1, a composite material is known, which has as a carrier layer a thermoplastic fleece made of polyurethane fibers. This structure has the disadvantage that the composite material is thermoplastic and collapses at a pressure of 1 kg / cm ² at a temperature of 140 ° C, so it becomes thin and hardens. Penetration of the middle layer, ie a thermoplastic TPU film into the carrier layer, does not occur; a textile carrier is not provided.

These objects are achieved with the method according to the invention of the type mentioned above by

- That as connecting layer a non-crosslinked, thermoplastic properties possessing polyurethane layer having a thickness between 0.080 and 0.500 mm, preferably between 0.100 and 0.500 mm, in particular between 0.120 and 0.180 mm, created and connected to the upper layer, and

- That as a top layer a single-layer or a preferably two-layer structure with an outer layer and inner layer, non-thermoplastic properties or non-thermoplastic, amorphous or predominantly amorphous structure having polyurethane layer is used, which is thinner than the connecting layer.

The aim of the invention is to provide a coating film which is adaptable and extremely resistant according to its strength to different uses. It should have excellent flex life and high tensile strength and can be easily connected to a textile support layer, for example by applying heat and / or pressure. The Manufacturing process should take into account the plasticity of the materials and lead to optimal bonding of the layers.

The composite material according to the invention should be used at temperatures between 90 and 145 ° C, as well as at pressures such as e.g. in shoe manufacture or in the interior finishing of automobiles, or even as they occur in practice, e.g. when steering wheels or dashboards in the area of the heating slots, occur, its properties do not change. The same applies to the test of lightfastness according to DIN EN ISO 105-B02 and the climate change test.

Furthermore, the upper layer should not become liquid and sticky at elevated temperatures in order to avoid skin injuries. Since it is known that thermoplastic polyurethanes can only be produced in a wide melting range, the composite material of WO 2008/077785 A1 has great disadvantages and can be used, for example, in can not be used for safety shoes or car interior trim. With a heat storage at 145 ° C, the shrinkage of the material changes by more than 10% and in the simultaneous presence of pressure it loses its strength and it is formed after cooling a thin, rigid, sheet-like structure, essentially caused by the fact that the fibers of Fleece of the carrier layer melt and the fleece character is lost.

Furthermore, the invention relates to a coating film, according to the preamble of claim 7. This coating film fulfills the tasks placed on it and avoids the disadvantages of the coating films known from the prior art. Furthermore, the invention relates to a method according to the preamble of claim 15, with which a composite material is prepared by bonding the coating film according to the invention with a textile support. Such an easily practicable process, which leads to an optimum quality of the composite material, is characterized in that

- That as connecting layer a non-crosslinked, thermoplastic properties possessing polyurethane layer having a thickness between 0.080 and 0.500 mm, preferably between 0, 100 and 0.500 mm, in particular between 0, 120 and 0, 180 mm, created and connected to the upper layer, and

- That as a top layer a single-layer or a preferably two-layer with an outer layer and inner layer built, non-thermoplastic properties or non-thermoplastic, amorphous or predominantly amorphous structure having polyurethane layer is used, which is thinner than the connecting layer is. Finally, the invention also relates to a composite material which can advantageously be produced by the process according to the invention and in practice has the highest resistance, dirt resistance, good tear and elongation behavior and high fatigue life.

The invention thus comprises a method and a coating film for the partial coating of textile materials or textile shaped sections, e.g. for the interior lining of automobiles or seat covers for automobiles. This application is primarily based on the object, materials, especially textiles, as used, inter alia, for car seat covers, particularly stressed areas such. the seat cheeks to reinforce, and optionally at the same time with additional functions, such as to provide a deviating color and / or structure. Thus, the gripping properties can be changed at the desired locations of the cover material and the abrasion resistance and soiling behavior can be partially improved. The majority of all car seats have a textile fabric based on a polyester fabric, often with a proportion of cotton fibers.

It is known that the parts of the seat which are subjected to a special load, such as e.g. the seat cheeks, headrests or also outer parts of the seat back, with a material deviating from the fabric, such as e.g. Leather, but especially leatherette. Imitation leather is here understood as meaning a textile carrier, such as woven or knitted fabric, with a PVC coating or a polyurethane coating, which has been applied directly or reversely in liquid or pasty form to the textile carrier.

In the manufacture of seat covers, a textile trim piece is connected to a leather or synthetic leather trim piece by stitching. Especially the textile areas of the seat, which come into contact with sweat, skin fat or other contaminants, quickly become soiled, become unsightly and can be protected by combination processing. The production of a seat cover made of different materials is very complicated by the multiple punching and sewing. Mainly lead different combinations of materials such as leather / fabric or imitation leather / fabric by their different elongation behavior and their different recovery properties after a short time to a drape, which must be prevented. Another disadvantage is that the abrasion-resistant and dirt-resistant materials, such as leather or artificial leather, about twice are heavy as the textile cover fabric. Frequently, however, the thicker leather or artificial leather overlays with their seams disturb the sense of comfort.

The invention is therefore inter alia based on the object to provide a method for the production of seat covers, in which the disadvantages mentioned do not occur.

It is advantageous if, as the connecting layer, a thermoplastic polyurethane layer is joined to the upper layer,

having a melting point according to Koflerbank between 95 and 165 ° C, preferably between 1 10 and 140 ° C,

and / or has a crystalline or partially crystalline structure,

and / or has a hardness between 70 to 98, preferably from 70 to 88, Shore A,

and / or based on aliphatic and / or aromatic polyester polyurethane and / or polyether polyurethane and / or

contains up to 5% by weight of colored pigments or is transparent,

and / or has a flex life according to DIN EN ISO 5402 of at least 125,000 bends at normal temperature.

The thermoplastic compound layer advantageously has a comparable, in particular the same hardness as the top layer and can be easily and quickly connected to the carrier layer due to their thermoplastic behavior. Deviations in hardness up to ± 10% are possible. The tie layer is well bendable and may also contain color pigments to form patterns.

For the combination of the top layer and the tie layer, it may be expedient if the top layer is bonded directly or using an adhesive layer of a crosslinked polyurethane dispersion with a thickness of 0.005 to 0.010 mm with the thermoplastic compound layer, which on the top layer and / or the tie layer is applied. Such an adhesive layer does not affect the properties of the composite of the upper layer and the bonding layer, but may be advantageous for the cohesion of the layers or their strength and bending properties.

For the top layer, it is advantageous if the top layer in the form of a layer of an aliphatic, crosslinked, solidified polyurethane dispersion on polycarbonate, Polyester and / or polyether base and / or mixtures thereof is formed and has a thickness between 0.0400 and 0.0950 mm, preferably between 0.050 and 0.080 mm, and / or

- is infusible, since its melting point is above 250 ° C and above its destruction point, and / or

is structured, possibly velor-like or nubuck-like or designed in the manner of a leather grain or with a geometric structure, or has the appearance of textile material or a carbon fiber fabric or a technical appearance and / or

contains between 2.5 and 15% by weight of colored pigments and / or has on its surface a multicolor print with a thickness of less than 0.010 mm.

The topsheet is not fusible because its melting point is above its destruct point and may be patterned as it is produced on a corresponding negative die or pad. Also, the topsheet may contain color pigments to form patterns. Despite the upper layer present in crosslinked or solidified form, it is possible to emboss the surface of the coating film hot after it has been attached to a corresponding carrier material, since the connecting layer is thermoplastic and can be subjected to permanent embossing.

To reinforce it can be provided that between the thermoplastic compound layer and the upper layer before joining these layers, a scrim of synthetic fibers having a basis weight between 5 to 20 g / m ^{2 is} inserted.

For some applications, it is advantageous if 4 to 20 wt .-% of flame retardant additives, optionally aluminum hydroxide, are added to the bonding layer and / or the top layer.

In practice, in particular for abrasion resistance and dirt sensitivity, it has been shown that it is advantageous for certain applications if the top layer and the bonding layer are formed with the same Shore A hardness and / or

if the upper layer and the adhesive layer are formed together with a smaller thickness than the bonding layer, and / or if the adhesive layer is formed with a basis weight of 5 to 20 g / m ² and / or a thickness of 0.002 to 0.010 mm, and / or

if a finishing layer of a maximum thickness of 0,010 mm is applied to the outer surface of the top layer and / or if color pigments having the top layer forming layers and / or different color in the tie layer are added and / or if one before their Crosslinking adhesive and / or adhesive properties having adhesive layer is used and connected after removal of water with the thermoplastic polyurethane film of the bonding layer.

A possible advantageous procedure in the production of the coating film is when the thermoplastic polyurethane film forming the bonding layer is deposited on a release paper or a polyolefin film after its production by extrusion before its connection with the top layer and / or if the contact and / or Adhesive adhesive properties having adhesive layer applied to the thermoplastic polyurethane film of the bonding layer and after removal of water, the top layer is applied or deposited on the bonding layer. It is also possible for the top layer to be applied or solidified directly onto the bonding layer in the form of a polyurethane dispersion, and then the bonding layer is bonded to the backing layer and the top layer is then embossed by means of heat and pressure.

In principle it can be provided that the non-thermoplastic top layer is connected directly or by means of an adhesive layer of a crosslinked polyurethane dispersion having a thickness of 0.005 to 0.010 mm with the thermoplastic compound layer. For patterning the coating film according to the invention, it can be provided that the two layers forming the top layer and / or the bonding layer contain different color pigments and / or that at least in partial areas of the top layer the outside layer of the top layer or the outside layer and the inside lying layer of the upper layer penetrating and reaching into the connecting layer recesses are formed with a laser. If the color pigments contained in the top layer and in the bonding layer have different colors, a pattern can be formed in this way by removing the material of the top layer and possibly also of parts of the bonding layer by selecting the position and shape of the recesses. It is of particular advantage that this coating film according to the invention can be stored and subjected to a later use, for which purpose it is only necessary to activate or heat the compound layer accordingly. The bonding layer can be applied over a full surface to a carrier layer or cover only partial areas of the carrier layer. This is particularly advantageous when textile materials are to be coated, and indeed at the points at which this material is particularly heavily strained.

It is therefore advantageous if the coating film with the bonding layer and the upper layer applied thereto may optionally only cover subregions of the carrier layer optionally composed of a plurality of optionally sewn sections, possibly covering regions of the carrier layer, and / or on a carrier layer present as a format cut, is applied or attached.

Coating foils can be used particularly advantageously for shoes, safety shoes, seat coverings, car interior trim, consoles in motor vehicles, furniture parts, child seats and bedside tables. The invention also relates to a method for producing a composite material which comprises a textile carrier layer which is at least partially coated with a coating film according to the invention.

Such a composite material could also be produced in such a way that a textile carrier layer, for example an artificial leather, is used, which has a textile carrier layer to which a surface layer has been applied whose composition corresponds to the bonding layer used according to the invention. In this way, by applying the top layer, a composite material according to the invention could be produced. However, according to the invention it is preferred to apply the coating film directly to the textile carrier material and to join it directly. For this purpose, a composite of the bonding layer and the top layer is applied to such a fabric, knitted fabric or polyester nonwoven fabric, or successively applied first the bonding layer on the textile material and then applied the top layer on the connecting layer connected to the textile material. As already mentioned, a coating film according to the invention is applied to the textile support which shows features of claims 7 to 14 and was produced using features 1 to 6. It is possible for recesses to be produced in the top layer and, if appropriate, in the bonding layer by material removal by means of a laser, which extend as far as the support layer and / or into it. Good resistance of the composite material is obtained if polyester fibers reinforced with cotton fibers are optionally used for the textile material of the carrier layer. A good adhesion of the bonding layer to the carrier layer results when the thermoplastic bonding layer by about 0.01 to 0.15 mm, preferably about 0.01 mm to 0.06 mm, in the carrier layer formed by a textile material during assembly the connecting layer and the carrier layer is pressed in and thus anchored in this. For a good connection, it is expedient if textile materials are used which are free of silicones, waxes or release agents and / or consist of flame-retardant fibers.

Finally, it can be done by making recesses in the composite material and / or in the coating film such that the number of recesses is selected such that the composite material has a water vapor permeability of greater than 1 mg / cm ² h, preferably greater than 2 mg / cm ² h, owns.

One possibility of producing the composite material is that the thermoplastic polyurethane layer forming the connecting layer is temporarily deposited on a release paper or a polyolefin film after its production by extrusion prior to its combination with the top layer and / or that the adhesive layer having contact or pressure-sensitive adhesive properties prior to its crosslinking applied to the thermoplastic polyurethane film of the bonding layer and after removal of water, the top layer is applied or deposited on the bonding layer. It is further possible, in particular for the formation of a leather exchange material, to apply the top layer to a structured base, preferably a silicone matrix or release paper, and to apply the bonding layer which may be already bonded to the backing layer, or, in particular, to form a sheet-like leather exchange material Bonding layer is added under the application of heat and pressure or by using a contact or pressure-sensitive adhesive, and that on its top a direct coating with a dispersion to form a Upper layer takes place, which after solidification by dehydration by means of heat, at a temperature between 90 and 160 ° C and pressure or by means of heat in the vacuum process is embossed. It can be advantageous if the bonding layer is placed together with the top layer on the carrier layer and the layers are bonded using heat and / or pressure.

Finally, the invention also relates to a composite material which has a top layer, a tie layer and a carrier layer, wherein the top layer and the tie layer are formed or realized by a coating film produced according to the invention or having the features according to the invention.

It is advantageous for the bendability and extensibility of the composite material if the thermoplastic compound layer is introduced into the carrier layer formed by a textile material by approximately 0.010 to 0.15 mm, preferably approximately 0.01 mm to approximately 0.060 mm is pressed and anchored in this, preferably without having penetrated into the spaces between the yarn fibers.

The bonding layer 2 and the upper layer are inseparably bonded to each other, optionally over the thin adhesive layer 4. This adhesive layer 4 may optionally contain polyisocyanates as crosslinking agents.

The upper layer 1 consisting of two layers 1 ', 1 "can be formed on a negatively structured substrate, such as a silicone rubber matrix or a release paper, whereby the layer 1' is first formed on the substrate and the layer 1" is applied thereon. To create a seat cover, especially for motor vehicles, these seat covers can be made by sewing different format parts made of different textile materials. For example, thicker, higher quality textile materials are used for a seat center panel, whereas thinner, less expensive textiles can be used for the seat backs, but after joining with a coating film according to the invention have approximately the thickness of the higher-grade textile material and beyond outstanding mechanical, have physical and functional properties. In order to produce a composite material according to the invention or a coated format cut, the coating film, if present as a roll, or the coating film still lying on a release paper can be used directly after its production be placed on the textile material and optionally in a heated platen press or roller press a composite material can be created. Preference is given to plate presses in which the upper and lower heating plate have a controllable temperature between 100 to 180 ° C; the pressure to be applied is adjustable between 0.5 and 6 bar / cm ² . Usually, the textile material is arranged in the press below and the coating film of the invention is placed on this material. The residence time or the pressing process is about 10 seconds. After this time, the composite material can be removed from the press and, after cooling to room temperature, the release force for the bonded materials is between 10 and 20 N / cm. When looking at a cross-sectional view of the composite material according to the invention shows that by the effect of temperature plastically become material of the bonding layer has penetrated by about 0.01 to 0.15 mm, preferably by 0.01 to 0.06 mm, in the textile material and there anchored or connected to the material. The surface layer or a structured upper layer 1 has not changed.

It is possible to provide a coarsely structured textile material, for example made of polyester fibers, with a coating film 100 having a thickness of 0.15 mm in such a way that after bonding the coating film 100 to the textile material, the structure of the textile material is reduced is visible on the surface of the upper layer 1 of the coating film 100.

It can be avoided that the interspaces of the yarns used in the textile material or the carrier layer are filled by the polyurethane layer of the coating film, whereby a hardening of the textile carrier material or of the entire composite material is avoided. This can be achieved according to the invention if the bonding layer 2 has a high melt viscosity. Furthermore, it is important that the layer has a hardness between 65 to 90 Shore A and advantageously has a semi-crystalline or crystalline structure.

The thin water-repellent finish top layer contributes to the fact that the wet properties of the textile material are favorably influenced and thus changes in the connection between the textile material and the thermoplastic compound layer 2 can not occur.

It is advantageous if the film is not more than 0.08 mm to 0.16 mm in the case of a partial coating of a format cut 300. It may be advantageous if the Connecting layer more than 40% and up to 80% of their strength may even completely or completely in the carrier layer 3 is permanently pressed, wherein the melt viscosity of the coating film or the bonding layer 2 is selected such that the material of the bonding layer 2 between the cavities of the textile material or tissue penetrates, but does not penetrate into the fine cavities of the yarns or into the yarns from which the textile material is made.

It is particularly advantageous if the upper layer 1 and the connecting layer 2 have approximately the same thickness ± 10% and / or have approximately the same Shore A hardness ± 10%. Best results are achieved if, during hot pressing, the bonding layer penetrates completely or almost completely into the textile carrier material or into the carrier layer 3, but without filling the cavities within the yarns used. The connecting layer 2 is a crystalline or partially crystalline, especially to more than 50 wt .-% crystalline components having polyurethane layer and may consist of aliphatic and / or aromatic polyurethane or be constructed.

In the production of composite materials, in particular in the form of sheet material, and the upper layer 1 can be prepared on a substrate and this top layer 1 is applied as a bonding layer 2, a polyurethane dispersion having a pasty structure as laminating. In this pasty, that is no longer liquid laminating the textile carrier or the carrier layer 3 is placed and pressed. It should also be noted that the laminating composition is so pasty that it does not penetrate between the fine cavities of the yarns, so the textile material can develop no wicking against the laminating. In such a procedure, the penetration of the polyurethane layer forming the bonding layer 2 into the fabric can be determined exactly. In particular, a laminating composition is used which behaves thixotropically similar.

In practice it is found that uncoated textile materials have the same softness as textile materials coated according to the invention, but the durability, the dirt sensitivity and other properties of the coated textile material are higher than those of the uncoated material. It may be of particular advantage if the coating film 100 in its edge regions seamlessly or almost continuously into the uncoated, textile material. 3 goes over, especially if 50% of the thickness of the bonding layer 2 are anchored in the textile fabric.

The advantage of the procedure according to the invention is that the coating film 100 can be applied directly to the textile material without the use of an adhesive or a primer, and an optimal anchoring in the textile material takes place by penetration of the softened thermoplastic material of the connection layer 2. This prevents hardening and a decrease in tear propagation resistance. In contrast to polyurethane dispersions, which are applied for bonding to the textile support, the procedure according to the invention also leads to a very high wet adhesion. Even in long-term use, these retain their adhesiveness, which is between 10 and 20 N / cm; This also after a 24 hours water storage of the material. In conventional composite materials which have textile material bonded to a polyurethane top layer using primers and / or polyurethane dispersion adhesives applied to the textile material, the adhesiveness after water storage for 24 hours of the applied layer is sometimes reduced by 60%.

The advantage of the coating film 100 or procedure according to the invention is that a crystalline or partially crystalline compound layer 2 can be used which can be pressed into the carrier layer 3 in the plasticized or not yet or nearly liquid or pasty state. In contrast to conventional dispersions, this material contains no emulsifiers and, even after storage for 72 hours in a water bath, absorbs no or less than 5% by weight of water.

Since the topsheet 1 is not thermoplastic and is heat-resistant, it is not or not disturbed in its application to the coating material under heat and pressure. For this reason, it is advantageously prepared from a crosslinked or predominantly amorphous polyether- and / or polyester-based polyurethane dispersion. The formation of the surface structure of the upper layer 1 is preferably carried out in situ in the course of solidifying the dispersion on a negatively structured substrate or by direct coating of the bonding layer 2 with the upper layer 1 and subsequent hot embossing. The Shore A hardness is consistently measured by making and measuring a specimen of the dimensions required for the Shore A hardness measurement from the respective material. Fig. 1 shows a schematic section through a composite material according to the invention. FIG. 2 shows a plan view of a format cut partially provided with a coating film according to the invention. Fig. 3 shows a section through a composite material according to the invention. FIGS. 4 and 5 show a detail view of a trim blank with a coating foil as it can be used for a car seat.

1 shows a section through a composite material 200 according to the invention, which has a top layer 1, a bonding layer 2 and a carrier layer 3. The top layer 1 may comprise a plurality of layers, in particular it comprises two layers 1 'and 1 "The top layer 1 is connected to the bonding layer 2 via an adhesive layer 4, which may also be dispensed with, The bonding layer 2 may be one or more layers, advantageously with 2 layers 2 'and 2 ", be constructed. The backing layer 3 is a layer of textile material, e.g. a woven, knitted or non-woven polyester fiber. This textile material may contain cotton fibers.

The topsheet 1 is a layer of a crosslinked, solidified polyurethane dispersion made from an aliphatic polycarbonate polyurethane and / or polyester polyurethane and / or polyether polyurethane. The individual layers of the upper layer have essentially the same structure.

The upper layer 1 is not thermoplastic and advantageously thinner than the connecting layer 2.

The bonding layer 2 is at least one polyurethane layer which is not crosslinked and has thermoplastic properties and can be bonded to the top layer 1 with an adhesive layer 4, also made of polyurethane.

As shown in FIG. 1, recesses 6, 6 'can be formed in the composite material 200 from the surface of the coating film 100 with a laser by appropriate material removal. Recesses 6 'lead from the surface of the coating film 100 into the interior of the bonding layer 2. The recesses 6 pass through both the top layer 1 and the bonding layer 2 and extend as far as the backing layer 3 or into it; In particular, they run into the carrier layer 3, when this is shown in Fig. 3, with material of Connecting layer 2 is filled in an edge region 20. These recesses 6, 6 'are used for the passage of air and / or water vapor.

FIG. 1 shows schematically how a coating film 100 according to the invention is placed on a carrier layer 3. FIG. 3 shows how the coating film 100 partially penetrates into the carrier layer 3. This penetration region 20 results in an inseparable connection between the connection layer 2 and the carrier layer 3. The top layer 1 and the connection layer 2 are inseparably connected to one another either by a direct connection during or after their production by means of heat and pressure or via the adhesive layer 4.

FIG. 2 shows a composite material which comprises two shape blanks 300, which are sewn together or connected by a seam 110. A coating film 100 according to the invention is applied over the seam and in the adjoining regions of the two format cuts 300, which covers the seam 110 and the parts of the format cut which are heavily stressed in this area in the intended use.

4 and 5 show a detail view of a composite material comprising a molding blank 300 covered with a coating film 100 and capable of presenting the back or seat of a car seat. The coating film 100 is in this case provided with different surface structures which may be formed on the die in the production on which the surface layer 1 or the outer layer of the top layer 1 is formed. By applying the coating film 100 on the carrier layer 3 or on the Formatzuschnitt 300 an existing surface structure is not or not disturbing changed.

It is also possible to pattern the cutout 300 provided with the coating film 100 after bonding the coating film to the molding blank 300 by hot pressing or to apply a pattern by hot deformation of the thermoplastic bonding layer 2. A gloss or fine structure change of the upper layer 1 is no longer possible after completion and crosslinking of the coating film 100, since the upper layer is a non-thermoplastic polyurethane layer, whereas the connecting layer 2 is a polyurethane layer possessing thermoplastic properties, which advantageously of a polyurethane granules was formed by extrusion. However, the topsheet 1 elastically adapts to the shape of the tie layer 2.

For a car seat, it has proven to be advantageous if the connecting layer 2 has a thickness of 0.140 mm and the top layer 1 has a thickness of 0.075 mm. The topsheet 1 is not thermoplastic, and the topsheet 1 and the tie layer 2 each have a hardness of 80 shore A. The thin non-thermoplastic topsheet 1 in combination with the thermoplastic tie layer 2 makes it possible to arbitrarily form the surface by hot stamping by means of an embossing roll. The topsheet 1 and the tie layer 2 were bonded with an adhesive layer 4 of 0.0080 mm thickness. The bonding layer 2 of the coating film 100 penetrated the support layer 3 by 60% of its thickness. In addition to having optimum performance characteristics, composite material 300 thus produced has a flex life of more than 160,000 bends at room temperature and a layer 2 to 3 adhesion of greater than 15 N / cm, even after 24 hours of water storage.

The film according to the invention is used, for example, for the partial application or coating of textile carrier materials, as used in the car. According to the invention, the layer 2 has a preferred thickness between 0.10 mm and 0.18 mm and penetrates the plastification medium heat and pressure, depending on the structure of the textile support, preferably up to 60% of their strength in the carrier layer 3 a. In coarse-meshed or open fabric structures, the layer 2 may also have a thickness of up to 0.25 mm and be pressed almost completely into the carrier layer 3.

In the production of web material in which the coating film 100 over the entire surface covers the carrier layer 3, the bonding layer 2 may have a higher thickness, preferably between 0.2 mm and 0.5 mm.

In the case of abrasion tests which were carried out in the same way for the textile material of the carrier layer 3 without coating and with the coating film 100 according to the invention (FIGS. 4 and 5), it was found that under the same load the textile material already has considerable roughening and torn areas, whereas the surface of the coating film 100 showed almost no changes. Figures 4 and 5 show a polyester fabric as used for car seats. The fabric is partially covered with the coating film 100. The thermoplastic Connecting layer 2 has a thickness of 0.1 mm and has penetrated 90% in the textile carrier 3. The top layer 1 has a thickness of 0.065 mm. In a Taber abrasion test (DIN 53109, friction wheel H18) carried out so that the friction wheel ran halfway over the textile material 3 and half over the coating film 100 of the composite material or the coated part, the fabric showed after 400 cycles severe damage, while the coated part has only a slight degree of gloss change, but otherwise remained undamaged.

The film of the bonding layer 2 has a softening range of about 80 to 165 ° C. The film remains soft and pasty up to this temperature and can be deformed or pressed with pressure; a melt through or a low-viscosity, without pressure flowable behavior is not present.

It is advantageous for the invention that the non-thermoplastic top layer 1 does not change at a temperature of 195 ° C., nor does the carrier layer 3 and also not the coating 3.1. These layers behave at 195 ° C similar to normal physical temperature.

Another object of the invention is to create a sheet-like composite material or a synthetic leather with a PUR coating, in which there are no difficulties with the so-called REACH specifications and in which the C02 attack is low or eliminated.

Problems with artificial leathers with a PU cover layer, a voluminous middle layer and a carrier causes the middle layer which is built up from so-called PUR high solids, PU prepolymers or a PUR-forming reaction mixture. These materials are liquid to pasty masses. For solidification of these materials temperatures of more than 100 ° C are required. This is not only a procedural disadvantage, but the solidified masses cause problems with the REACH specifications and the C0 ₂ specifications. These masses form the middle layer of the composite material, ie the layer between the textile support and the cover layer. Furthermore, these compounds are not thermoplastic and thus difficult to form by hot stamping.

It is also an object of the invention to create a sheet-like material in a simple and economical manner, which corresponds to the REACH specifications, wherein the connection between the carrier layer 3 and the connecting layer 2 is substantially improved, as well as the bending behavior and the Hydrolysis behavior of the composite material. The surface 1 of the material can be made arbitrarily by hot stamping by means of an embossing roller and its strength can remain this process completely or almost entirely. According to the invention, a thermoplastic, extruded PU film is used as the bonding layer 2. This film 2 is advantageously made of polyurethane granules containing no emigrable substances. This film 2 is in the heated state in which it is plastic and can flow under pressure, or after contact with a hot plate or roller, optionally with further heat and / or pressure application, connected to the carrier layer 3.

A contact heating lasts between 10 and 30 seconds. This heating process is well suited for size parts, but rather uneconomical for the production of sheet material.

It has been found that a film which can advantageously be used as a bonding layer 2, by means of flame treatment, similar to the flame lamination of a polyurethane foam, or by heating by infrared radiators without contact with a hot plate or hot roll, ie indirectly heated, in a time of less can be brought to melt or for connection to a textile carrier layer 3 as 2 seconds. As soon as the film has been plasticized or brought to a melting point, it can be brought into contact with the textile carrier layer 3, if appropriate by means of rollers.

The penetration depth of the bonding layer 2 or film into the carrier layer 3 (FIG. 3) depends on the structure of the carrier layer 3 and on the temperature of the film and the associated tack as well as the melt viscosity. Furthermore, the penetration also depends on the pressure with which the film 2 is pressed against the support layer 3 or pressed into it. According to the invention it can be provided that the connecting layer 2 or the film is placed after its extrusion on a temporary, optionally less than 1 mm thick, flexible support or rests on this, which advantageously has a higher melting point or at the required temperatures These temperatures are infusible, such as a silicone rubber film, a Teflon film, a polyester film, a coated, textile carrier material, or a release paper. Such a material can be used as a carrier as often as desired. From this temporary carrier, the softened film 2 is deposited on the carrier layer 3 and optionally pressed.

According to the invention, the thermoplastic compound layer 2 may also initially be formed or produced separately from the non-thermoplastic top layer 1 and then brought together or joined to the top layer 1, which consists of an aqueous PU dispersion or of PUR dispersion mixtures and is not meltable. In this case, can be dispensed with a provisional carrier, especially if the upper layer 1 has a thickness between 0.06 and 0.12 mm and a hardness between 75 and 98 Shore A and thus can stabilize the softened bonding layer 2. The softened film 2 bonded or coated with the top layer 1 is deposited on the carrier layer 3.

Advantageously, when carrying out such method steps, the film or connecting layer 2 has a thickness of 0.2 to 0.6 mm.

It has been found that it is advantageous according to the invention to use as carrier layer 3 a textile material, preferably a knitted or woven fabric, in particular consisting of polyester fibers, having a basis weight of 300 g / m ² and a thickness of 0.65 mm and a 0 , 4 mm thick film as a bonding layer 2, which was heated by infrared irradiation to 125 to 145 ° C to connect. The film 2 penetrates between 0.05 to 0.25 mm in the carrier layer 3 or is pressed in this extent. A dry adhesion of 22 N and wet of 18 N according to DIN ISO 1 1644 is achieved. Thus, a firm connection between the connecting layer 2 and the carrier layer 3 and also an adhesion improvement is achieved in an economical manner. On the bonding layer 2, a polyurethane dispersion mixture is applied as the upper layer 1, which has a solids content of 40 to 60 wt .-% of polyurethane. Any existing PUR primer layer with a thickness of less than 0.01 mm between the cover layer 1 and the connection layer 2 is not taken into account in the layer design or dimensioning.

In the context of the invention, it is also possible to first connect the non-thermoplastic upper layer 1 with the thermoplastic compound layer 2 and then first to join the connecting layer 2 and the carrier layer 3. The topsheet 1 can be made in any case with the particular optics desired and then processed and be one or two-layered. The upper layer 1 may carry a thin, possibly non-thermoplastic finish layer of a PUR dispersion having a thickness of less than 0.01 mm.

According to the invention, the film used as the bonding layer 2 in the plastic, sticky state after leaving the extruder with the desired final support layer 3 is brought together by laying and optionally by means of one or more rollers, which optionally have an anti-sticking equipment on its surface, in the carrier. 3 pressed in the desired manner. This approach is not only economical, it also leads to inseparable compounds, especially if the melting point of the film 2 is between 125 and 175 ° C, preferably between 135 and 155 ° C. The carrier layer 3 is advantageously a textile material, in particular a knitted fabric or fabric of polyester fibers.

As is known, inexpensive thermoplastic polyurethane films based on aromatic polyester are not particularly resistant to hydrolysis. In accordance with the invention, however, inexpensive PUR films which have been prepared wholly or partly on an aromatic PUR basis also lead to a good resistance to hydrolysis of the finished composite material by forming the support 3 with a thin, hydrolysis-resistant coating 3.1 (FIG. 1) having a thickness of 0.05 to 0.3 mm provides. The hydrolysis-resistant coating 3.1 may consist of polyether- or polyester-based aliphatic polyurethane, of polyacrylate, of a layer of mixtures of these two materials, of flexible PVC or of copolymers containing PVC. This is particularly advantageous for textile material, in particular with an open structure. The coating 3.1 prevents the penetration of the film 2 into the carrier layer 3. The coating 3.1 is dry and combines with the heated film 2. The coating 3.1 consists either of solidified, optionally crosslinked, PUR dispersions or PUR mixtures. It is advantageous if the film 2 has a partially crystalline structure. If the coating 3.1 consists of a plastic such as polyacrylate or of a PVC-containing copolymer, a thin PUR dispersion adhesive layer is expedient as a primer.

On the solidified coating 3.1 on the support layer 3 can advantageously a thin primer layer of less than 0.01 mm from a PUR adhesive dispersion, which is not shown in the drawing, are applied. On the carrier 3 thus precoated, it is possible to apply the connecting layer 2 in the manner previously described either by plasticizing the film or applying the still soft film immediately after leaving the extruder.

The thin coating 3.1 prevents or impedes the ingress of moisture through the carrier layer 3 through to the connecting layer 2. The upper layer 1 formed with high-grade PU dispersions prevents the ingress of moisture from this side, so that the composite material does not or only insignificantly exhibits its firming properties even after a hydrolysis aging changed. It is particularly advantageous if the film 2 has a wide softening point and is also not liquid at the melting point, such as e.g. Polyamide or polystyrene. At temperatures of 75 to 1 10 ° C, although its surface is tacky, but it requires pressure to connect to the layer 3. With increasing temperature, the film 2 becomes sticky and pasty. Before its respective melting point, it is the most sticky and requires little pressure for connection to the carrier layer 3.

The invention is explained in greater detail on the basis of examples: Example 1 for a Composite Material as Plate Product:

An extruded aliphatic polyester-based TPU film 2 having a hardness of 78 Shore A and a thickness of 0.4 mm between 70 and 85 Shore A is heated in a heating platen press at a temperature of 130 ° C and under a pressure of 2 Bar pressed with a polyester knitted fabric as a carrier layer 3 with a weight per unit area of 300 g / m ² . The polyester knit contains 25% by weight of cotton fibers. At the temperature of 130 ° C, the TPU film becomes sticky and highly viscous or pasty. About the pressure and the temperature, the penetration depth is controlled in the carrier layer 3 and adjusted to the desired value of 45% of the thickness of the film 2. The residence time in the hot press is 10 to 20 s. After removal from the press, the composite material is reversed, ie, the topcoat 1 applied is formed on a patterned backing such as a negatively textured silicone die, on a negatively textured release paper, or on a laser textured Teflon or polypropylene sheet and with the liner 2 connected. All surface finishes, such as grain leather, suede, textiles or technical appearance such as sandpaper, are possible.

Example 2: TPU granules are plasticized in an extruder and pressed out of a slit like a film and placed on a textile support layer 3, for example on a knitted fabric or fabric, in the plastic state and optionally lightly pressed. The TPU film has a hardness of 82 Shore A, which is thus between 70 and 98 Shore A. It consists of an aromatic polyester polyurethane, has a thickness of 0.45 mm and 20%, optionally 5 to 25%, of their thickness embedded in the carrier layer 3. On the side opposite the textile carrier 3, the film 2 is joined to the top layer 1, which was formed from a non-thermoplastic polyester polyurethane dispersion. The top layer 1 has a thickness of 0.08 mm and a hardness of 88 Shore A. On the film 2, this top layer 1 is applied as a direct application by doctor blade or spray and after solidification receives an embossing. For this purpose, it is heated and receives the desired structure with an embossing roller. Optionally, the embossing roll itself is heated to a temperature between 100 and 180 ° C. The thin, non-thermoplastic coating can be embossed well in combination with the thicker, thermoplastic compound layer 2 by means of heat and pressure.

Example 3: A 250 g / m ² polyester knitted fabric having an open knit structure is provided with a thin coating 3.1 having a thickness of 0.05 mm. The coating 3.1 consists of a solidified polyurethane dispersion with a solids content of 50 wt .-%. The coating 3.1 also contains 40% by weight of polyacrylate having a solids content of 50% by weight. This layer is 0.07 mm, ie between 0.05 and 0.1 mm, penetrated into the carrier layer 3. After solidification, it is bonded to the TPU film, which has a thickness of 0.4 mm, in such a way that the TPU film 2 is heated to a temperature of 145 ° C. by means of infrared rays and at this temperature both parts are brought together become. After cooling, the composite material can be provided with the top layer 1 either directly or indirectly (reversing process).

The most economical method, the TPU film is created by extrusion and brought together in the still plastic state with the respective desired carrier 3. Example 4:

Leather, in particular split leather, according to the invention is provided with a maximum of 0.15 mm thick coating 3.1, on which then provided with the upper layer 1 TPU film 2 is thermally ironed. This procedure is particularly suitable for safety and athletic shoes.

The TPU film 2 in combination with the non-thermoplastic top layer 2 has outstanding flexing properties. The composite material is also extremely resistant to abrasion. 4000 cycles in the Taber process for wear resistance with friction wheel H18 (DIN EN ISO 17076-1) are easily fulfilled, whereas conventionally dressed leather does not survive more than 400 cycles.

This invention is particularly interesting for Tier-1, which produce interiors for cars, trucks and buses, especially seats, in which textile materials are heavily strained at stressed areas.

Claims

claims:

1 . Process for the preparation of a coating film optionally having the form of webs or plates, in particular for coating a carrier layer (3), optionally textile materials and / or a textile carrier layer (3), e.g. a woven or knitted fabric, wherein the coating film (100) has an optionally multilayer upper layer (1) and a connecting layer (2), possibly having a plurality of layers (2 ', 2 "), for connection to the carrier layer (3) characterized in that

- That as connecting layer (2) has a non-crosslinked, thermoplastic properties possessing polyurethane layer having a thickness between 0.080 and 0.500 mm, preferably between 0.100 and 0.500 mm, in particular between 0.120 and 0.180 mm, and connected to the upper layer (1), and

- That as a top layer (1) a single-layered or preferably two-layered with an outer layer (1 ') and inner layer (1 ") constructed, non-thermoplastic

Properties possessing or non-thermoplastic, amorphous or predominantly amorphous structure having polyurethane layer is used, which is thinner than the connecting layer (2).

2. The method according to claim 1, characterized in that as a bonding layer (2) a thermoplastic polyurethane layer with the upper layer (1) is connected,

and / or has a crystalline or partially crystalline structure,

and / or has a hardness between 70 and 98 Shore A, preferably between 70 and 88 Shore A,

contains up to 5% by weight of colored pigments or is transparent,

3. The method according to claim 1 or 2, characterized in that the upper layer (1) directly or using an adhesive layer (4) made of a crosslinked polyurethane dispersion having a thickness of 0.005 to 0.010 mm with the thermoplastic Connecting layer (2) is applied, which is applied to the upper layer (1) and / or the connecting layer (2).

4. The method according to any one of claims 1 to 3, characterized in that the upper layer (1) in the form of a layer of an aliphatic, crosslinked, solidified

Polyurethane, polyester and / or polyether-based polyurethane dispersion and / or mixtures thereof is formed and has a thickness between 0.0400 and 0.0950 mm, preferably between 0.050 and 0.080 mm, and / or

5. The method according to any one of claims 1 to 4, characterized

- That between the thermoplastic compound layer (2) and the upper layer (1) before joining these layers (1, 2), a scrim (40) of synthetic fibers having a basis weight between 5 to 20 g / m ^{2 is} inserted and / or

- That the compound layer (2) and / or the upper layer (1) 4 to 20 wt .-% flame retardant additives, optionally aluminum hydroxide, are added and / or

- That the upper layer (1) and the connecting layer (2) are formed with the same Shore A hardness and / or

- That the upper layer (1) and the adhesive layer (4) are formed together with a smaller thickness than the connecting layer (2), and / or

- That the adhesive layer (4) is formed with a basis weight of 5 to 20 g / m ² and / or a thickness of 0.002 to 0.010 mm, and / or

- That on the outer surface of the upper layer (1) a finish layer is applied with a maximum thickness of 0.010 mm and / or

- That in the two the upper layer (1) forming layers (1 ', 1 ") and / or color in the connecting layer (2) color possessing color pigments are added and / or - That an adhesive layer (4) having contact and / or pressure-sensitive adhesive properties prior to its crosslinking is used and, after removal of water, connected to the thermoplastic polyurethane film of the bonding layer (2).

6. The method according to any one of claims 1 to 5, characterized in that the compound layer (2) forming thermoplastic polyurethane film deposited after its production by extrusion before its connection with the top layer on a release paper or a Polyoleofinfolie and / or that prior to their crosslinking Adhesive layer (4) having contact and / or pressure-sensitive adhesive properties is applied to the thermoplastic polyurethane film of the bonding layer (2) and after removal of water the upper layer (1) is applied or deposited onto the bonding layer (2) or in that the upper layer (1) directly in the form of a Polyurethane dispersion is applied to the bonding layer (2) and bonded thereto and solidified, that thereafter the bonding layer (2) with the support layer (3) is connected and the upper layer (1) then receives an embossing by means of heat and pressure.

7. Coating film, comprising one, optionally multi-layer, upper layer (1) and connected thereto, optionally a plurality of layers (2 ', 2 ") having, connecting layer (2) for connection to a carrier layer (3), in particular prepared by a process according to one of claims 1 to 6, characterized

- That the bonding layer (2) is a non-crosslinked, thermoplastic properties possessing polyurethane layer having a thickness between 0.080 and 0.500 mm, preferably between 0.100 and 0.500 mm, in particular between 0.120 and 0.180 mm, and

that the upper layer (1) connected to the connecting layer (2) is constructed as a single layer or preferably in two layers with an outer layer (1 ') and an inner layer (1 ") and is a non-thermoplastic or non-thermoplastic polyurethane layer which is thinner than the Connecting layer (2) is.

8. Coating film according to claim 7, characterized in that the connecting layer (2) forming thermoplastic polyurethane layer has a melting point according to Koflerbank between 95 and 165 ° C, preferably between 1 10 and 140 ° C,

and / or has a crystalline or partially crystalline structure,

and / or has a hardness of 70 to 98, preferably 70 to 88, Shore A, and / or based on aliphatic and / or aromatic polyester polyurethane and / or polyether polyurethane,

and / or contains up to 5% by weight of colored pigments or is transparent,

- and / or has a flex life according to DIN EN ISO 5402 of at least 125,000 bends at normal temperature.

9. Coating film according to claim 7 or 8, characterized in that the non-thermoplastic top layer (1) directly or by means of an adhesive layer (4) made of a crosslinked polyurethane dispersion having a thickness of 0.005 to 0.010mm with the thermoplastic compound layer (2) is connected.

10. Coating film according to one of claims 7 to 9, characterized

- That the upper layer (1) is a layer of a crosslinked, solidified polyurethane dispersion on polyester and / or polyether and / or polycarbonate base and / or mixtures thereof and a thickness between 0.0400 and 0.0950 mm, preferably between 0.050 and Has 0.080 mm and / or

- That the hardness of the upper layer (1) is equal to the hardness of the bonding layer (2) or deviates by a maximum of 10% from the hardness of the bonding layer (2) and / or

- That the upper layer (1) is infusible and its melting point is above 250 ° C and above its destruction point and / or

- That the surface of the upper layer (1) is structured, possibly velor-like or nubuck-like or formed in the manner of a leather grain or with a geometric structure or the appearance of textile material or fabric or a carbon fiber fabric or a technical appearance and / or

- That the upper layer (1) contains between 2.5 and 15 wt .-% of colored pigments, and / or

- That between the thermoplastic compound layer (2) and the upper layer (1), a scrim (40) of synthetic fibers with a weight of 5 to 20 g / m ^{2 is} embedded and / or

- That the connecting layer (2) and / or the upper layer (1) 4 to 20 wt .-% flame retardant additives, optionally aluminum hydroxide, and / or

- That on the outer surface of the upper layer (1) a finish layer with a maximum thickness of 0.010 mm and / or a multi-color print with a thickness of less than 0.010 mm is applied.

1 1. Coating foil according to one of Claims 7 to 10, characterized

- That the upper layer (1) and the connecting layer (2) have the same Shore A hardness and / or - That the upper layer (1) and possibly associated with their adhesive layer (4) together have a smaller thickness than the connecting layer (2) and / or

- That between the upper layer (1) and the connecting layer (2) lying adhesive layer (4) has a basis weight of 5 to 20 g / m ² and / or a thickness of 0.002 to 0.010 mm and / or

- That the two the upper layer (1) forming layers (1 ', 1 ") and / or the connecting layer (2) color pigments possessing different color and / or

- That at least in partial areas of the upper layer (1), the outer layer (1 ') of the upper layer (1) or the outer layer (1) and the inner layer (1 ") of the upper layer (1) penetrating and into the connecting layer (2) reaching recesses (6) are formed with a laser.

12. Coating film according to one of claims 7 to 1 1, characterized in that the connecting layer (2) of the coating film is connected to a carrier layer (3), which is formed by a textile material, preferably woven, knitted or nonwoven fabric, or by a Polyurethananschalschaum is

wherein the surface of the carrier layer (3) is coated or connected wholly or only in some areas with the coating film.

13. Coating film according to one of claims 7 to 12, characterized in that the coating film with the bonding layer (2) and the upper layer (1) applied thereto may optionally only be applied to subregions of the carrier layer (3), optionally composed of a plurality of optionally sewn sections. , optionally overlapping abutting regions of the carrier layer (3), and / or being applied or bonded to a carrier layer (3) present as a format cut.

14. Coating film according to one of claims 7 to 13, characterized in that it is part of an article, optionally a shoe, a Formatzuschnittes, a seat cover, a car interior panel, a car console, a furniture part, child seat or a hospital bed.

15. A method for producing a composite material comprising a, optionally multi-layered, upper layer (1), an associated with this, possibly a plurality of layers (2 ', 2 ") having, connecting layer (2) and one with the connection layer (2) bonded support layer (3) or one with a carrier layer (3) bonded coating film according to one of claims 7 to 14 or produced according to one of claims 1 to 6, characterized

that a, optionally coated, textile material, preferably a woven fabric, knitted fabric, polyester fleece or an optionally coated leather is used as carrier layer (3) and joined to the bonding layer (2),

- That as connecting layer (2) a non-crosslinked, thermoplastic properties possessing polyurethane layer having a thickness between 0.080 and 0.500 mm, preferably between 0.100 and 0.500 mm, in particular between 0.120 and 0.180 mm, used and connected to the upper layer (1), and

- That as a top layer (1) a single layer or preferably a two-layer with an outer layer (1 ') and inner layer (1 ") constructed, non-thermoplastic properties possessing, amorphous structure having polyurethane layer is used, which is thinner than the connecting layer (2).

16. The method according to claim 15, characterized in that the connecting layer (2) and associated with this upper layer (1) only on subregions of optionally composed of several, optionally sewn, sections composite support layer (3), optionally covering the joint areas, or on a carrier sheet (3) present as a format cut can be applied.

17. The method according to claim 15 or 16, characterized in that as carrier layer (3) a textile carrier, preferably a woven fabric, knitted fabric, polyester fleece or coated leather is used

18. The method according to any one of claims 15 to 17, characterized in that in particular for forming a leather exchange material on the carrier layer (3) connected to the connecting layer (2), the top layer (1) is applied or connected, and that after embossing this top layer (1) optionally applied to this one finish layer.

19. The method according to any one of claims 15 to 18, characterized in that on the underside of the upper layer (1) or on the upper side of the carrier layer (3) as a connecting layer (2) a thermoplastic polyurethane layer is applied, the

and / or has a hardness of 70 to 98, preferably 70 to 88, Shore A, and / or based on aliphatic and / or aromatic polyester polyurethane and / or polyether polyurethane, which has a crystalline or partially crystalline structure and / or

contains up to 5% by weight of colored pigments or is transparent,

20. The method according to any one of claims 15 to 19, characterized in that the upper layer (1) directly or using an adhesive layer (4), which consists of a crosslinked polyurethane dispersion with a thickness of 0.0050 to 0.0100 mm, with the thermoplastic compound layer (2) is connected, wherein the adhesive layer (4) is optionally applied to the upper layer (1) and / or the bonding layer (2).

21. Method according to one of claims 15 to 20, characterized in that an upper layer (1) is formed in the form of a layer of a crosslinked, solidified, aliphatic polyurethane dispersion based on polyester and / or polyether and / or polycarbonate, which has a thickness between 0 , 0400 and 0.0950 mm, preferably between 0.050 and 0.080 mm, and / or

- is infusible, since its melting point is above 250 ° C and / or above its destruction point, and / or

contains between 2.5 and 15% by weight of colored pigments and / or

- Has on its surface a multicolor printing, with a thickness of less than 0.010 mm and / or that in the upper layer (1) and optionally in the connecting layer (2) by material removal by means of laser recesses (6) are produced, up to the carrier layer (3) and / or extend into these and / or that for the textile material of the carrier layer (3) optionally with cotton fibers reinforced polyester fibers are used.

22. The method according to any one of claims 15 to 21, characterized in that the thermoplastic compound layer (2) by 0.01 to 0.15 mm, preferably 0.01 mm to 0.06 mm, in the of a textile material or a polyurethane foam peeling formed support layer (3) during assembly of the connecting layer (2) and the carrier layer (3) pressed in and thus anchored in this.

23. The method according to any one of claims 15 to 22, characterized

- That textile materials are used which are free of silicones, waxes or release agents and / or consist of flame retardant fibers and / or

- That between the thermoplastic compound layer (2) and the upper layer (1) a scrim (40) made of synthetic fibers having a basis weight between 5 to 20 g / m ^{2 is} inserted and / or

- That on the outer surface of the upper layer (1) a finish layer (25) with a maximum thickness of 0.010 mm and / or a multi-color print with a thickness of less than 0.010 mm is applied

- That the upper layer (1) and the connecting layer (2) are formed with the same or at most by 10% different Shore A hardness and / or

- That the upper layer (1) and the adhesive layer (4) are formed together with a smaller thickness than the connecting layer (2) and / or

- That the adhesive layer (4) is formed with a basis weight of 5 to 20 g / m ² and / or a thickness of 0.002 to 0.010 mm.

24. The method according to any one of claims 15 to 23, characterized in that the number of recesses (6) is selected such that the composite material has a water vapor permeability of greater than 1 mg / cm ² h, preferably greater than 2 mg / cm ² h , owns and / or that in the two the upper layer (1) forming layers (1 ', 1 ") and / or in the connecting layer (2) color possessing color pigments are entered and / or that prior to their networking contact or Adhesive adhesive properties adhesive layer (4) after removal of water with the thermoplastic polyurethane film of the bonding layer (2) is connected.

25. The method according to any one of claims 15 to 24, characterized in that the connecting layer (2) forming thermoplastic polyurethane layer after its production by extrusion before its connection with the upper layer (1) on a support, preferably on a release paper or a Polyoleofinfolie, is temporarily stored and / or that before their crosslinking contact or pressure-sensitive adhesive properties having adhesive layer (4) on the thermoplastic Applied polyurethane film of the bonding layer (2) and after removal of water, the top layer (1) is applied or deposited on the bonding layer (2).

26. The method according to any one of claims 15 to 25, characterized in that in particular for forming a leather exchange material, the upper layer (1) applied to a structured substrate, preferably silicone matrix or release paper and on which optionally with the carrier layer (3) already connected connecting layer (2 ) is applied or that in particular for forming a sheet-like leather exchange material, a textile sheet-sized carrier layer (3) with the bonding layer (2) under the application of heat and pressure or by using a contact or pressure-sensitive adhesive is connected, and that on its upper side a direct coating with a Dispersion for the formation of an upper layer (1) takes place, which after solidification by removal of water by means of heat, at a temperature between 90 and 160 ° C and pressure or by means of heat in the vacuum process is embossed.

27. The method according to any one of claims 15 to 26, characterized in that the connecting layer (2) is placed together with the upper layer (1) on the carrier layer (3) and the layers are bonded using heat and / or pressure.

28. The method according to any one of claims 15 to 27, characterized in that for adjusting the water vapor permeability with a laser in the upper layer (1) and the connecting layer (2), optionally up to the polyurethane-filled parts of the carrier layer (3) reaching, Recesses (6, 6 ') are formed.

29. Composite material comprising a, optionally multilayer, upper layer (1), a connecting layer (2) connected thereto, possibly having a plurality of layers (2 ', 2'), and a carrier layer (3) connected to the connecting layer (2), in particular produced by a process according to one of Claims 15 to 28 or in particular using a coating film according to one of Claims 10 to 14, characterized

the backing layer (3) is a textile material, preferably a woven fabric, knitted fabric, polyester fleece or coated leather,

that the bonding layer (2) is a non-crosslinked, thermoplastic polyurethane layer having a thickness of between 0.08 and 0.50 mm, preferably between 0.100 and 0.500 mm, in particular between 0.12 and 0.18 mm, and has

- That the single-layer or preferably two-layer with an outer layer (1 ') and an inner layer (1 "), constructed upper layer (1) is a non-thermoplastic properties polyurethane layer which is thinner than the connecting layer (2).

30. A composite material according to claim 29, characterized in that the connecting layer (2) and the upper layer (1) connected thereto only to subregions of optionally composed of several, optionally with each other sewn, parts assembled, optionally a Formatzuschnitt performing carrier layer (3), optionally the impact areas of the subregions overlapping, are applied.

31. The composite material according to claim 29 or 30, characterized in that the connecting layer (2) forming thermoplastic polyurethane layer has a melting point according to Koflerbank between 95 and 165 ° C, preferably between 1 10 and 140 ° C,

and / or has a hardness of 70 to 98, preferably 70 to 88, Shore A, and / or polyesterpolyurethane and / or polyether polyurethane having aliphatic and / or aromatic, crystalline or partially crystalline structure,

and / or that this polyurethane layer contains up to 5% by weight of colored pigments or is transparent,

32. Composite material according to one of claims 29 to 31, characterized in that the upper layer (1) is optionally connected by means of an adhesive layer (4) made of a crosslinked polyurethane dispersion having a thickness of 0.005 to 0.010 mm with the thermoplastic compound layer (2).

33. Composite material according to one of claims 29 to 32, characterized in that the upper layer (1) is a layer of a crosslinked, solidified polyurethane dispersion on polyester and / or polyether and / or polycarbonate base or mixtures thereof and a thickness between 0.040 and 0.095 mm, preferably between 0.050 and 0.080 mm and / or - That the upper layer (1) has the same or a maximum of 10% of the hardness of the connecting layer (2) different Shore A hardness and / or

- That the upper layer (1) is infusible and its melting point is above 250 ° C and / or above its destruction point and / or

- That the surface of the upper layer (1) is structured, possibly velor-like or nubuck-like or shaped like a leather grain or with a geometric structure or has the appearance of textile fabric or a carbon fiber fabric or a technical appearance and / or

- That the upper layer (1) contains between 2.5 and 15 wt .-% of colored pigments or is transparent.

34. Composite material according to one of claims 29 to 33, characterized in that the textile material of the carrier layer (3) is formed with optionally reinforced with cotton fibers, polyester fibers.

35. Composite material according to one of claims 29 to 34, characterized in that the thermoplastic compound layer (2) introduced by 0.010 to 0.15 mm, preferably 0.01 mm to 0.060 mm, in the carrier layer formed by a textile material (3) or is pressed and anchored in this, preferably without having penetrated into the spaces between the yarn fibers.

36. Composite material according to one of claims 29 to 35, characterized

- That for the carrier layer (3) used textile material is free of silicones, waxes or release agents and / or consists of flame retardant fibers and / or

- That between the thermoplastic compound layer (2) and the upper layer (1) a scrim (40) made of synthetic fibers having a basis weight of 5 to 40 g / m ² , preferably from 10 to 40 g / m ² , is arranged and / or

- That on the outer surface of the upper layer (1) a finish layer (25) with a maximum thickness of 0.010 mm and / or a multi-color print with a thickness of less than 0.010 mm is applied and / or

- That the upper layer (1) and the connecting layer (2) are penetrated with recesses (6, 6 ') produced by laser treatment, which optionally extend to and / or into the carrier layer (3).

37. Composite material according to one of claims 29 to 36, characterized

- That the upper layer (1) and the connecting layer (2) have the same Shore A hardness, optionally with deviations of up to 10% from each other, and / or

- That the upper layer (1) and possibly provided and associated with their adhesive layer (4) together have a smaller thickness than the connecting layer

(2) and / or

- That optionally provided and with the upper layer (1) bonded adhesive layer (4) has a basis weight of 5 to 20 strains ² and / or has a thickness of 0.002 to 0.01 0mm.

38. Composite material according to one of claims 29 to 37, characterized

in that at least in partial regions of the upper layer (1) the outer layer (Γ) of the upper layer (1) or the outer layer (1) and the inner layer (1 ") penetrate and pass into the connecting layer (2) 6, 6 ') are formed with a laser and / or

- That the water vapor permeability of the composite material is greater than 2 mg / cm ² h.

39. Composite material according to one of claims 29 to 38, characterized in that the hardness and flexural rigidity of the carrier layer (3) after joining with the connecting layer (2) and the upper layer (1) is increased by less than 50%.

40. The article produced with a composite material according to any one of claims 29 to 39, optionally in the form of a shoe, a Formatchuschnittes, a seat cover, a car interior panel, a car console, a furniture part, a child seat or a hospital bed.

41. Method according to one of claims 15 to 28, characterized in that as the bonding layer (2) an extruded thermoplastic PU film is used, said film

- Is deposited directly after the extrusion on a temporary support and is transferred from this to the carrier layer (3), or immediately after extrusion with a layer forming, non-thermoplastic top layer (1) made of polyurethane and then together with this on the Carrier layer (3) is transferred or brought into contact with the carrier layer (3).

42. The method according to any one of claims 15 to 28 or 41, characterized

- that the extruded film (2) is deposited on the carrier layer (3) formed preferably by a textile material, in particular knitted fabric or fabric, and - optionally after heating the softened or plasticized film (2) into the carrier layer (3 ) 0.05 to 0.25 mm or 10 to 70% of the thickness of the film (2) is pressed.

43. The method according to any one of claims 15 to 28, 41 or 42, characterized in that the film (2) has a melting point between 125 and 175 ° C.

44. The method according to any one of claims 15 to 28 or 41 to 43, characterized in that the carrier layer (3) before applying the PUR film (2) with a coating (3.1), preferably an aliphatic dispersion based on polyether or a polyacrylate or a mixture of these two materials or a layer of soft PVC which has a thickness of 0.05 to 0.3 mm.

45. The method according to any one of claims 15 to 28 or 41 to 44, characterized in that the upper layer (1) is prepared on a substrate and on this upper layer (1) as a connecting layer (2) one, optionally thixotropic-like, PU Dispersion is applied with pasty structure and the textile carrier layer (3) is placed on this pasty laminating and pressed,

wherein optionally 10 to 70% of the thickness of the bonding layer (3) are pressed into the carrier layer (3).

46. The method according to any one of claims 15 to 28 or 41 to 45, characterized in that the film (2) directly after the extrusion on the carrier layer (3), preferably deposited on a textile material, and at a temperature of 100 to 175 ° C and a pressing pressure of 0.5 to 6 bar / cm ² with the carrier layer (3), optionally 5 to 20 s, is pressed.

47. Composite material according to one of claims 29 to 39, characterized in that the bonding layer (2) is an extruded thermoplastic polyurethane film having a melting point between 125 and 175 ° C and optionally by 10 to 70% of its thickness or by 0 , 05 to 0.25 mm in the carrier layer (3) is pressed.

48. Composite material according to one of claims 29 to 39 or 47, characterized in that on the carrier layer (3) a coating (3.1), preferably of an aliphatic PUR Disperision polyether-based or a polyacrylate layer or a mixture of these two materials or a layer made of soft PVC, which has a thickness of 0.05 to 0.3 mm, on or with which / which coating (3.1) the PUR film (2) is applied or connected.