WO2004076154A1 - Membranes en mousse et stratifies - Google Patents

Membranes en mousse et stratifies Download PDF

Info

Publication number
WO2004076154A1
WO2004076154A1 PCT/GB2004/000809 GB2004000809W WO2004076154A1 WO 2004076154 A1 WO2004076154 A1 WO 2004076154A1 GB 2004000809 W GB2004000809 W GB 2004000809W WO 2004076154 A1 WO2004076154 A1 WO 2004076154A1
Authority
WO
WIPO (PCT)
Prior art keywords
foam
layer
laminate
textile fabric
liquid
Prior art date
Application number
PCT/GB2004/000809
Other languages
English (en)
Inventor
Philip Wayne Brindle
Original Assignee
Porvair International Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Porvair International Limited filed Critical Porvair International Limited
Publication of WO2004076154A1 publication Critical patent/WO2004076154A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
    • B29C44/32—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements
    • B29C44/326—Joining the preformed parts, e.g. to make flat or profiled sandwich laminates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • C—CHEMISTRY; METALLURGY
    • C14—SKINS; HIDES; PELTS; LEATHER
    • C14C—CHEMICAL TREATMENT OF HIDES, SKINS OR LEATHER, e.g. TANNING, IMPREGNATING, FINISHING; APPARATUS THEREFOR; COMPOSITIONS FOR TANNING
    • C14C11/00—Surface finishing of leather
    • C14C11/003—Surface finishing of leather using macromolecular compounds
    • C14C11/006—Surface finishing of leather using macromolecular compounds using polymeric products of isocyanates (or isothiocyanates) with compounds having active hydrogen
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
    • D06N3/0095—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by inversion technique; by transfer processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0084—Foaming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/06—Open cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/18—Fabrics, textiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/08—Natural leather
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
    • B32B2439/70—Food packaging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2535/00—Medical equipment, e.g. bandage, prostheses or catheter
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0008—Foam properties flexible

Definitions

  • the present invention relates to foam membranes and laminates incorporating them and, in particular, foam membranes and such laminates particularly suited for used in laminated performance fabrics and leathers, or alternatively in woundcare products such as wound dressings useful in the food packing industry.
  • a variety of processes are known for making laminated fabrics including a foam layer, particularly for fabrics exhibiting water-resistance with breathability (the ability to pass moisture vapour) and which have acceptable drape, feel and elasticity.
  • in-line lamination techniques using pre-formed sheets of material have been used to apply one or more further layers to substrates to produce a range of different fabrics.
  • a freestanding film is laminated to a heat-reactivated foam layer.
  • heat reactivation increases the overall manufacturing costs due to additional energy input.
  • the invention provides in one aspect a method of continuous in-line lamination of a foamed layer upon a moving carrier substrate, wherein a carrier substrate comprising a continuous sheet of carrier material is directed to a liquid foam application station in which an aqueous polymeric foam composition is applied as a liquid foam in a continuous manner upon a surface of the moving carrier substrate and the liquid foam layer thereby formed being allowed or caused to solidify, thereby forming a laminate comprising a solidified open-cell foamed layer adjacent to the carrier substrate.
  • the method optionally includes a step in which the substrate material not desired as part of the desired single or multiple layer end product and the remaining layer or layers are separated e.g. by mechanical splitting one from the other when the supplementary layer has formed a laminate with solid foam layer.
  • the textile fabric sheet where used as a supplementary layer, may be made of a fabric for use in apparel, although textile fabrics for other purposes may be used e.g. medical drapes, hi particular, any such textile fabric sheet as a supplementary layer may be made of a fabric for use in such apparel as garments, footwear, headwear or handwear.
  • the fabric may be filamentous or non-filamentous and when the former may be woven or non- woven.
  • the textile fabric sheet where used as a supplementary layer, is preferably one made of material which resists water permeation (e.g. a material which is hydrophobic) such as one which has been rendered hydrophobic by oleophobic treatment of the fabric or e.g. the fibres of which it may be made with a hydrophobicity-conferring agent such as a fmorocarbon resin, for example Scotchguard from 3M or Teflon from DUPONT.
  • a material which resists water permeation e.g. a material which is hydrophobic
  • a hydrophobicity-conferring agent such as a fmorocarbon resin, for example Scotchguard from 3M or Teflon from DUPONT.
  • the supplementary layer e.g. textile fabric sheet is made of water- vapour-permeable material suitable for imparting breathability thereto in an article of apparel.
  • Such textile fabrics are often termed "performance fabrics".
  • such textile fabric sheet may comprise a woven textile fabric (e.g. a textile fabric sheet which comprises synthetic textile fibres, such as polyester fibres) or the supplementary layer could comprise a leather fabric, for example a leather split for use in footwear.
  • the textile fabric sheet may comprise microfibre fabric made, for example, of a polyester such as a hydrophobic lightwoven polyester microfibre textile.
  • microfibre fabrics are widely used and commercially available, for example from Toray UK.
  • the fabric is Corona treated to provide additional adherence characteristics without affecting handle.
  • the preferred Corona power rating is between 75 and 600 /m 2 .
  • Corona treatment is preferably carried out at a power rating of from 150 to 300 W/m 2 (e.g. a rating of 200 to 250 W/m 2 such as about 255 W/m 2 ).
  • This method aspect of the invention is particularly advantageous in its application to hydrophobic fabrics such as hydrophobic woven fibrous textile fabrics or other textile non- leather fabrics as hereinbefore referred to in the context of the invention.
  • the textile fabric used in preferred embodiments of the invention will have a structure characterised by voids which admit the liquid foam to some extent. So admitted foam when solid forms a foam anchor in the body of the textile fabric.
  • a particularly significant embodiment of the invention therefore, provides a textile fabric sheet which, prior to its presentation to a liquid foam layer, has a structure which includes interstitial voids communicating to at least one face of said textile sheet and interstitially admissible to said liquid foam, the liquid foam and the textile fabric sheet being brought into interfacial contact such that liquid foam penetrates into the interstices of the textile fabric, formation of a composite sheet in which said foam forms a solid layer married to said textile fabric sheet producing solid foam forming a continuum between said foam layer and the interstices of said textile fabric to anchor the solid foam layer in the interstitial spaces of said textile fabric.
  • non-hydrophobic fabrics structured with interstitial voids which admit foam also provide for firm anchorage of the foam within the textile fabric body. Care is required in practice, however, to avoid so-called “strike through”, and this applies in particular to non- hydrophobic fabrics. Strike through, a manifestation which occurs when the foam runs through the fabric layer, is particularly undesirable as it results in a stiffer, sometimes unacceptably stiff, laminate, which may also show visual defects. Practical solutions for strike through avoidance are described hereinafter in more detail.
  • a laminate of foam and polymer film may be applied to leather splits as a supplementary layer (e.g. foam to leather) to give performance advantages dependent upon the laminate chosen.
  • a supplementary layer e.g. foam to leather
  • the foam membranes of the present invention can be used in comfort footwear, non-polish footwear and hydrolysis-resistant footwear.
  • Application of a textile fabric supplementary layer to the foam can best be effected using inline lamination of such layer to the foam layer whilst still in liquid form.
  • Liquid foam can be formed as a moving liquid layer upon the carrier substrate using coating techniques well-known in art.
  • the liquid foam layer may be formed using knife- over-roll coating techniques (KOR techniques) or curtain coating.
  • the liquid foam is a preferably derived from a liquid foam precursor composition comprising the preferred polymer(s), a foaming agent together optionally with one or more of a rheology modifier, a foam stablizer, a foam booster, a foam-refining surfactant component, a cross-linking agent, and in embodiments adapted for use as woundcare dressings in the food packing industry: a metallic component.
  • the open-cell, water-based foam membrane comprises a polymer material, a foaming agent and a rheology modifier.
  • the foaming agent may, for example, be ammonium stearate.
  • the rheology modifier may, for example, be a polyacrylic acid or a hydrophobically-modified alkali-swellable emulsion.
  • the liquid foam precursor rheology should preferably be carefully monitored, evaluated and controlled, by choice of a rheology modifier, to provide a desired bubble size on foaming.
  • a finer bubble size is preferred for more robust end use applications, for example in foam membranes for lamination to leather splits or where the foam is to be applied to a thick resin layer forming a layer of the carrier substrate material.
  • Approximately 50% of the bubbles may, in practice, be less than 30 microns in diameter, on foaming, in the case of many embodiments of the metliod of the invention. Bubble size may have significant influence on the preferred properties of strength, feel and breathability of the end product foam layer or composite layers.
  • the rheology of the liquid form precursor should ideally be carefully controlled to prevent "strike-through” and maintain “handle” (i.e. the drape and feel of the end product).
  • a starting viscosity of 60Ps (as measured on a Brookfield RV viscometer ) is, for example, suitable to initiate the required foaming behaviour and indeed starting viscosity of the liquid foam precursor composition may be conveniently be 50 to 150Ps, 60 to 11 OPs being, however, more preferred.
  • a particularly preferred starting viscosity is lOOPs.
  • the rheology modifier if necessary, should in practice be carefully selected to be shear thinning in nature.
  • the foam composition needs to shear thin on mechanical foaming and on application to the substrate in order to achieve and maintain its desired fine bubble size.
  • the foam stabiliser is conveniently sodium lauryl sulphate.
  • the foam booster will be, for example, a cocoamide betaine.
  • foam-refining surfactant components if used may typically be amine oxides or a sulpho succinate or blends thereof.
  • polymer material as the principal polymeric component of the aqueous foam composition is dependent upon the end use.
  • Suitable polymer materials for the foam composition include polyurethanes, polyethylene vinyl acetate, polyethylene vinyl chloride, (meth) acrylic resin or a mixture of two or more thereof.
  • a polyurethane blended with a (meth) acrylic polymer is usually preferred to give the desirable physical and permeation properties for laminated fabric embodiments of the invention.
  • the principal polymer material of foam membranes for lamination to leather splits is most suitably a polyurethane or a copolymer comprising a high polyurethane content.
  • the liquid foam precursor composition is normally formulated to give a solids content (by weight) in water (or other aqueous medium) of 35% to 55%, preferably about 45%, with the polymer material accounting for 40% to 50% by weight (e.g. approximately 40% by weight) of the liquid foam.
  • Other components of the liquid foam precursor composition are typically included in total to less than 5% by weight, and more typically between 1 and 3% by weight. The percentages by weight are given based on the total weight of the liquid foam composition precursor.
  • the solidified foam becomes cross-linked in that the lamination method overall includes a cross-linking step.
  • the liquid foam precursor composition may include, as indicated above, a cross-linking agent.
  • the cross- linking agent may, for example, be a melamine formaldehyde cross-linking agent.
  • Formation of the solid foam layer from the liquid foam layer applied to the moving carrier substrate in practice may usually involve drying to drive off the water of the aqueous medium in which the solids of the foam composition are distributed. As noted above, there may also be cross-linking. Drying will in general be artificial drying at elevated temperature, for example in an oven, temperatures above 60°C (e.g. above 100°C) at which the materials of the composite sheet are thermally stable being suitable. Drying may be carried out as an alternative by exposing the foam to a flowing stream of air (or other gas) and, of course, a combination of such flow and elevated temperatures may well be adopted.
  • cross-linking of the foam composition is required, processing of the liquid foam will normally need to provide cross-linking conditions.
  • Thermally activated cross-linking agents achieve cross-linking typically at moderately elevated temperatures.
  • the required temperature in the case of melamine formaldehyde cross-linkers is in the region of 140°C and above and such temperatures are generally suitable for effecting drying of the foam layer mentioned above.
  • the thickness of the foam layer may, of course, vary quite widely.
  • the solid foam layer will have a thickness of 10 to 1000 microns.
  • the foam membrane is most commonly less than 100 micron thick and is preferably 20 to 50 microns thick (particularly about 35 microns thick). Thickness of liquid foam as applied to the moving carrier substrate will need to be set having regard to the desired solid foam layer thickness. This can be determined by simple experiment although it has been found in typical practice of the invention, the foam layer thickness changes little from liquid to solid form in the lamination method so that any particular liquid foam thickness tends to result in the equivalent solid foam thickness.
  • the carrier substrate material should be capable of withstanding drying temperatures adopted to solidify the liquid foam (and to withstand cross-linker activation temperatures where cross-linking is practiced), but this has not been a substantial practical burden in terms of substrate material selection.
  • the carrier substrate may be polymer-coated whilst moving in line before application thereto of the liquid foam composition.
  • Preferred embodiments of the invention incorporate a textile fabric sheet present as a layer disposed over the face of said foam layer remote from said carrier substrate, the method including the step of forming the layer of the liquid foam upon said substrate and, whilst said foam layer remains fluid at least at its face remote from said carrier substrate, bringing said textile fabric sheet into interfacial contact with said remote face of said foam layer.
  • the carrier substrate will in general consist of a carrier layer or comprise a carrier layer for supporting the foam as a liquid layer formed in line directly thereon or upon a secondary coating layer most preferably formed in line upon such carrier layer.
  • the carrier substrate may conveniently comprise a paper or a polymeric film material. Paper, where used, may be embossed.
  • Such polymeric film may be made of a polyalkylalkene, for example polymethylpentene.
  • the carrier substrate comprises a film which has a surface energy of 20 to 50 Dynes, for example 25 to 35 Dynes. Most preferably, such carrier substrate film has a surface energy of 28 to 30 Dynes.
  • the carrier substrate film is, for reasons already indicated, usually composed of a heat-resistant polymer, polymethylpentene being an example.
  • the carrier film should have a matt surface, typically with a degree of gloss of .5 + 0.5 Lange at 85FS.
  • the carrier film should also confer surface wettability.
  • the carrier film may be embossed or otherwise treated to impart a special finish or surface topography to the end product. For example, the carrier film may roughen an originally soft and blocky polymer layer so that it does not show any blocking behaviour.
  • the carrier substrate may comprise a carrier film coated with a secondary resin layer, conveniently a peelable resin, and in the case of laminates in which a supplementary leather layer is interfaced to a foam layer, the face of the latter remote from the leather material will most preferably carry a resin film, e.g. a polyurethane and/or acrylic film, the carrier substrate usually being stripped from the remainder of the laminated product once such can be accomplished without damage to the laminate.
  • a resin film e.g. a polyurethane and/or acrylic film
  • Such resin may be a hydrophilic resin such as a polyurethane elastomer having in particular a high polyethylene oxide content of, for example, between 50 and 70% by weight.
  • the resin is a linear urethane co-polymer, e.g.
  • the viscosity of the resin is conveniently lOPs regardless of resin identity (viscosity preferably being measured on a Brookfield RV viscometer).
  • the resin may be applied to the moving carrier substrate at a concentration of 15% solids in a solvent dispersion medium such as dimethylformamide (DMF).
  • DMF dimethylformamide
  • the resin may provide additional functionality to the foam membranes and may in particular impart improved waterproofness, durability and aesthetic control.
  • the resin coating may, for example, incorporate a colourant such as a pigment (e.g. carbon black) particularly in the case of laminates including a leather split destined as "artificial" leather in view of the richly coloured appearance in the end product simulating conventional real leather finishes.
  • the in-line lamination processing to form the required laminate is carried out to form a solid layer of a foam which has a density of from 0.15 to 0.55 g/cc. It is particularly preferred for the liquid foam to have a density on application of from 0.15 to 0.35g/cc.
  • the apparatus shown in the figure comprises a carrier substrate film supply station 11 provided with a replenishable roll (not shown) of polymethylpentene carrier film 12 which is heat resistant under prevailing thermal exposure conditions.
  • a film transport pathway defined by rollers 13 A to 131 each of which is rotatably mounted and formed with a polished stainless steel surface.
  • the transport pathway just referred to passes through resin coating station 5 and transport region 6 to foam formation and foam layer application station 7, lamination station 9 and carrier finishing (or carrier film stripping and product take-up) station 10.
  • the direction of transport of the carrier film is represented by arrow A shown at various points on the transport pathway.
  • Resin coating station 5 comprises a coating applicator head represented generally by reference numeral 14, flowable resin composition from a supply (not shown) being delivered thereto via line 15.
  • the resin coating station 5 further comprises an oven 16 which is electrically heated to a temperature of 60° to 90°C to evaporate solvent from the resin.
  • Foam layer formation station 7 comprises a KOR (knife-over-roller) foam application device 17 connected to a foam supply (not shown) by line 18.
  • the foam supply will normally include a vessel in which the foam is produced mechanically in-situ immediately before application to the moving carrier substrate by injecting air into a suitable liquid foam precursor composition at the locus of an impeller mounted for rotation in the vessel.
  • a textile fabric supply station 8 comprising a replenishable textile fabric supply roll 19 and a Corona treatment device 21, a lamination assembly (not shown in detail but including rotatable stainless steel surfaced roller 22 which redirects the Corona treated face of the textile fabric web 20 to the surface of the still wet foam layer carried by carrier film 12) being provided to laminate the textile fabric web 20 to the foam layer.
  • Oven 24 is provided to solidify the foam by evaporating water therefrom and is electrically heated to a temperature of up to 150°C.
  • Product finishing station 10 is fed with now formed and dried laminate from roller 13 1 and includes a stripper device (not shown) for stripping the carrier film from the laminate.
  • the output from the stripper is to a laminate take-up station whose construction and make-up will be readily recognised by the skilled man as including an appropriate take-up roll but whose details have been omitted in the interests of simplicity.
  • the carrier film (whether resin coated or not) may be left intact, i.e. not removed from the remainder of the laminate.
  • the product finishing station maybe omitted or adapted by exclusion of a carrier wind up roll.
  • a polymer film/paper laminate carrier material namely Schoeller 165g TPX polymethylpentene (available from Felix Schoeller GmbH) is coated to a 60-300 micron wet (10-50 micron dry) thickness with a polyurethane resin derived from MDI, BDO and a high content (60%) PEO and having a molecular weight of approximately 100,000.
  • the polyurethane resin coating is applied as a 15wt% solids content in DMF dispersion having a viscosity of lOPs.
  • the polyurethane resin coating is dried by passing the resin coated film into an oven with air flow assistance at a temperature of 60-90°C to produce a carrier substrate consisting of polyurethane coated polymethylpentene film.
  • aqueous polymer foam precursor dispersion (available as Dispersion 16 285D from Noveon, Inc.) is in situ mechanically foamed then immediately after foaming applied subsequently to the moving carrier substrate in an amount of 20-200 g/m 2 (20g for fabric - 200g for leather dry weight per square metre). Whilst the foam layer is still wet, a Corona-treated hydrophobic lightwoven polyester microfibre having a weight of 50-150g/m 2 (available from Toray UK) is applied in line upon the still wet foam. The resulting laminate is dried and cured under cross-linking conditions in a further oven with air flow assistance at a temperature of 90-140°C.
  • the carrier substrate and the remainder of the laminate are then stripped one from the other to produce a 3 -layer laminate consisting of a textile fabric layer, a solidified foam layer having an open cell structure and a polyurethane film.
  • the solid foam layer has a thickness of up to 1000 micron and a density of 0.4g/cm 3 .
  • the open cells within the foam represented about 60% of the foam by volume.
  • "Epsom" embossed paper carrier from Arjo Wiggins is resin-coated in-line with a highly pigmented polyester based urethane solution in DMF before drying and coating with a mechanically in-situ foamed 50/50 blend of Witcobond 279-34 from Baxenden Chemicals and Hystretch V3 acrylic emulsion from Noveon Inc.
  • the first resin layer of the moving carrier substrate is typically 20-30 microns thick and the foamed layer is 400 microns thick at a density of 0.4g/cc.
  • the final product is removed from the carrier and wound or laminated inline directly onto leather splits.
  • an air flow control foamed membrane was produced for use in fabric systems.
  • the carrier substrate was Schoeller 165g TPX as in Example 1 which was not resin coated in any manner. Accordingly, in this embodiment, the moving carrier substrate initially consisted of two layers, namely a polymer film/paper laminate.
  • the liquid foam precursor dispersion was polyurethane and/or acrylic based polymer, (although other polymer materials could be used providing an appropriate foam rheology, density and porosity).
  • in-line lamination of a supplementary material layer is optional, as is carrier removal.
  • Example 3 The procedure of Example 3 was repeated. In addition, the foamed membrane was treated with a hydrophobicity-conferring coating sprayed on in-line before winding, namely a coating of Teflon from DuPont.
  • Example 3 a The procedure of Example 3 a was repeated except that the foamed material was subsequently spray coated off line.
  • KB66 PUD based upon TMXDI from Cytec Industries and Terathane 2000MW polyol from Du Pont is available from Porvair and is supplied at 35-40% solids. This material is mechanically foamed and applied to a paper carrier (Super Bor Matt from Sappi) via conventional KOR coating techniques. The thickness of the finished membrane is 400 microns with a density of 0.25-0.3 g/cc. The material is dried and wound on to a reel with a matt finish polyethylene interleave (Hostophen available from Hoecht) to avoid blocking.
  • Hostophen available from Hoecht
  • PUD polyurethane dispersion
  • Hystretch V29 water based acrylonitrile latex
  • the open-cell solid foam layers produced in examples 4 and 5 of the invention can provide superior breathability compared to the conventional closed cell foams and other wound dressing products that are presently available.
  • Examples 4 and 5 demonstrate production of laminated foam membranes for use as wound dressings for operatives in the food packing industry.
  • the carrier substrate can be paper or TPX polymethylpentene film as in Example 1, the resin coating is used, being polyurethane based, the liquid foam precursor dispersion is based on polyurethane but also includes a metallic component namely distaloy DH available from Hoganas, to ensure the end product wound dressing is 'metal-detectable' being an industry requirement in the relevant food preparation and packing trades.
  • In line lamination is used based on PES (polyester) interleave and the carrier substrate is removed at product take up station 10.
  • Example 6 Example 6
  • CUR21 castor oil based PUD and U400N polyether based PUD are blended in a 50/50 mix with approriate thickeners, pigments and stabilisers.
  • approriate thickeners, pigments and stabilisers are blended in a 50/50 mix with approriate thickeners, pigments and stabilisers.
  • 125phr and 300phr of stainless steel powder (430L available from Osprey Metals) is added to make the compound metal detectable when converted in to a dry product.
  • This material is produced as per the procedure in Example 3.H owever, due to the mass of the metal the final density of the product is around lg/cc.
  • the material is manufactured at a thickness of 100-150 micron.
  • the open-cell solid foam in laminates produced according to the invention can provide superior breathability compared to conventional closed cell foams presently available.
  • the process provides a foam layer or a foam membrane laminate which can be used in a variety of applications to enhance functionality.
  • a particular advantage is that embodiments of the methods of the present invention can allow hydrophobically treated fabrics to be laminated in line to the foam layer whereas in conventional lamination techniques fabrics must be treated after lamination to give the required water- resistant/waterproof qualities.
  • the foam membrane laminates of the invention enjoy abrasion resistance as a result of the cushion effect of the foam layer.
  • Laminated fabrics of the present invention have several further advantages over products made using conventional lamination techniques, particularly in relation to handling characteristics in that they are soft and drapable.
  • the invention expressly includes within its scope as a preferred embodiment thereof a method of producing a water-resistant laminated textile product which method comprises treating the filaments of a filamentous woven or non- woven textile fabric with a hydrophobicity-imparting agent before and/or after their formation into a fabric, bringing said fabric into interfacial contact with a layer of a liquid aqueous polymer foam composition having an open-cell structure, said foam layer being supported upon a substrate comprising a separable carrier and said fabric being a sheet forming a part of said substrate exposed to said foam and/or a sheet disposed in contact interfacially with the face of said foam layer remote from said substrate, the ingredients and form of said foam composition being selected so that said foam composition is a liquid which is admitted to interstices within the filamentous structure of said fabric, evaporating water from said foam composition, and optionally crosslinking the polymer thereof, so that said foam solidifies as a continuum which extends from the foam layer to the depth of interstitial invasion of the fabric by
  • a particular embodiment of the invention is a multiple layer sheet-foam textile product comprising a textile fabric layer married directly to and interfacially in direct contact with a solid polymer foam layer having an open-cell structure, said textile fabric layer and solid polymer foam layer having no continuous or discontinuous layer of another material disposed there between but one or more layers differently disposed optionally being present.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)

Abstract

L'invention concerne un procédé de stratification en ligne en continu d'une couche en mousse sur un substrat support mobile, selon lequel un substrat support comprenant une feuille continue de matériau support (12) est dirigé vers une station (7) d'application de mousse liquide dans laquelle une composition aqueuse de mousse polymère à cellules ouvertes est appliquée sous forme de mousse liquide en continu sur une surface du substrat support mobile, ladite couche de mousse liquide ainsi formée étant amenée à se solidifier, cette solidification pouvant être provoquée, ce qui permet de former un stratifié comprenant une couche en mousse solidifiée adjacente audit substrat support.
PCT/GB2004/000809 2003-02-27 2004-02-27 Membranes en mousse et stratifies WO2004076154A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB0304479.9A GB0304479D0 (en) 2003-02-27 2003-02-27 Foam membranes and laminates
GB0304479.9 2003-02-27

Publications (1)

Publication Number Publication Date
WO2004076154A1 true WO2004076154A1 (fr) 2004-09-10

Family

ID=9953762

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2004/000809 WO2004076154A1 (fr) 2003-02-27 2004-02-27 Membranes en mousse et stratifies

Country Status (2)

Country Link
GB (1) GB0304479D0 (fr)
WO (1) WO2004076154A1 (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101803806A (zh) * 2010-03-08 2010-08-18 侯怡妤 弹性护具
EP2316640A1 (fr) * 2009-10-29 2011-05-04 I-Yung Hou Enveloppe protectrice souple
EP2439480A1 (fr) * 2010-10-11 2012-04-11 Pro-Systems S.p.A. Matériau composite pour protection ballistique et procédé de production associé
US8211255B2 (en) 2003-04-21 2012-07-03 Rynel Inc. Apparatus and methods for the attachment of materials to polyurethane foam, and articles made using them
US9074778B2 (en) 2009-11-04 2015-07-07 Ssw Holding Company, Inc. Cooking appliance surfaces having spill containment pattern
EP3191283A1 (fr) * 2014-09-11 2017-07-19 Huntsman International LLC Procédé de conception et de fabrication d'une rampe distributrice pour appliquer un mélange liquide expansible visqueux à un dispositif de stratification
WO2023281410A1 (fr) * 2021-07-08 2023-01-12 Mirko Gamenoni Stratifié en matériau souple

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3196062A (en) * 1961-09-27 1965-07-20 Du Pont Production of embossed plastic sheet material
GB1171932A (en) * 1965-11-01 1969-11-26 Freudenberg Carl Coated Articles.
US3652747A (en) * 1969-03-17 1972-03-28 Dainippon Ink & Chemicals Process for manufacturing synthetic leather
EP1279762A2 (fr) * 2001-07-23 2003-01-29 Koatsu Cloth Co., Ltd. Structure pour matériau similaire au cuir à surface structurée et procédé pour sa fabrication

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3196062A (en) * 1961-09-27 1965-07-20 Du Pont Production of embossed plastic sheet material
GB1171932A (en) * 1965-11-01 1969-11-26 Freudenberg Carl Coated Articles.
US3652747A (en) * 1969-03-17 1972-03-28 Dainippon Ink & Chemicals Process for manufacturing synthetic leather
EP1279762A2 (fr) * 2001-07-23 2003-01-29 Koatsu Cloth Co., Ltd. Structure pour matériau similaire au cuir à surface structurée et procédé pour sa fabrication

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8211255B2 (en) 2003-04-21 2012-07-03 Rynel Inc. Apparatus and methods for the attachment of materials to polyurethane foam, and articles made using them
EP2316640A1 (fr) * 2009-10-29 2011-05-04 I-Yung Hou Enveloppe protectrice souple
US9074778B2 (en) 2009-11-04 2015-07-07 Ssw Holding Company, Inc. Cooking appliance surfaces having spill containment pattern
CN101803806A (zh) * 2010-03-08 2010-08-18 侯怡妤 弹性护具
CN101803806B (zh) * 2010-03-08 2015-08-19 侯怡妤 弹性护具
EP2439480A1 (fr) * 2010-10-11 2012-04-11 Pro-Systems S.p.A. Matériau composite pour protection ballistique et procédé de production associé
EP3191283A1 (fr) * 2014-09-11 2017-07-19 Huntsman International LLC Procédé de conception et de fabrication d'une rampe distributrice pour appliquer un mélange liquide expansible visqueux à un dispositif de stratification
WO2023281410A1 (fr) * 2021-07-08 2023-01-12 Mirko Gamenoni Stratifié en matériau souple

Also Published As

Publication number Publication date
GB0304479D0 (en) 2003-04-02

Similar Documents

Publication Publication Date Title
US4774131A (en) Process for the production of polyurethane-coated textile surfaces, polyurethane-coated textile surfaces and their use in the production of breathable and waterproof clothing
US4863788A (en) Waterproof breathable microporous membrane with cellular foam adhesive
EP2261382B1 (fr) Produit en croûte de cuir et son procédé de fabrication
US3922402A (en) Production of artificial leather
JP4503096B1 (ja) 透湿防水性布帛およびその製造方法
JP5463089B2 (ja) 積層布帛およびその製造方法
Träubel New materials permeable to water vapor
JP4042016B2 (ja) 繊維シート状複合物の製造方法及び人工皮革
WO2000046301A1 (fr) Composition de resine urethane aqueuse permettant de fabriquer une matiere microporeuse, procede de fabrication d'un composite en feuilles fibreuses et d'un cuir synthetique
US20060008631A1 (en) Leather-like sheet and process for production thereof
Shim Bonding requirements in coating and laminating of textiles
WO2006046533A1 (fr) Procédé servant à produire un matériau composite poreux et matériau composite poreux
DE69927185T2 (de) Wasserdampfdurchlässiges, wasserdichtes material und verfahren zu dessen herstellung
HU178443B (en) Process for coating materials without solvents
WO2004076154A1 (fr) Membranes en mousse et stratifies
US20220090315A1 (en) Synthetic leather and method for manufacturing synthetic leather
TW201105509A (en) Method for preparing polyurethane laminate and polyurethane laminate obtained from the said method
JP5374299B2 (ja) 銀付調皮革様シートの製造方法
JP2004211262A (ja) 耐摩耗性の良好な皮革様シート
US4174414A (en) Production of synthetic suede leather
KR100198190B1 (ko) 습식 합성피혁의 제조방법 및 중간 생성물
JPS6017871B2 (ja) 皮革様シ−ト物の製造方法
JP2001354899A (ja) コーティング布帛およびその製造方法
US3573121A (en) Method of producing suede-like artificial leathers
JPS6354833B2 (fr)

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BW BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EC EE EG ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NA NI NO NZ OM PG PH PL PT RO RU SC SD SE SG SK SL SY TJ TM TN TR TT TZ UA UG US UZ VC VN YU ZA ZM ZW

AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): BW GH GM KE LS MW MZ SD SL SZ TZ UG ZM ZW AM AZ BY KG KZ MD RU TJ TM AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IT LU MC NL PT RO SE SI SK TR BF BJ CF CG CI CM GA GN GQ GW ML MR NE SN TD TG

121 Ep: the epo has been informed by wipo that ep was designated in this application
122 Ep: pct application non-entry in european phase