Search

CN-122029051-A - Sheet comprising a polyurethane layer, method for the production and use

CN122029051ACN 122029051 ACN122029051 ACN 122029051ACN-122029051-A

Abstract

The present invention relates to a sheet comprising a support layer, an intermediate layer, and a cover layer, the intermediate layer comprising polyurethane having a gel content of at least 20%, the cover layer comprising thermoplastic polyurethane having a gel content of less than 10%, wherein the support layer is a textile layer and the intermediate layer is a dense layer, wherein the support layer and the intermediate layer only partially interpenetrate each other in their thickness direction to form a composite structure, wherein the thickness of the intermediate layer above the composite structure is at least 20 μm, a method of preparing the sheet, and the use of the sheet as a surface material in a vehicle interior.

Inventors

  • J. N. Ferrerada Motta
  • M. J. Silva Magallanes
  • I. M. da Silva Maya
  • P. D. Masiel Ferreira
  • S. P. da Silva Max
  • F. M. Dashilwalibero
  • H. I. Pereira da Costa Aguilar Ribeiro

Assignees

  • 汽车工业用TMG塑化织物及其他涂料公司

Dates

Publication Date
20260512
Application Date
20241008
Priority Date
20231227

Claims (14)

  1. 1. A sheet comprising a support layer, an intermediate layer and a cover layer, the intermediate layer comprising polyurethane having a gel content of at least 20% and the cover layer comprising thermoplastic polyurethane having a gel content of less than 10%, wherein the support layer is a textile layer and the intermediate layer is a dense layer, wherein the support layer and the intermediate layer only partially interpenetrate each other in their thickness direction to form a composite structure, wherein the thickness of the intermediate layer above the composite structure is at least 20 μm.
  2. 2. The sheet of claim 1, wherein the intermediate layer has a thickness of greater than 20 μιη to 300 μιη.
  3. 3. The sheet according to any one of the preceding claims, wherein the support layer is a fabric layer having a thickness of 200 to 1200 μιη, the intermediate layer has a thickness of greater than 50 to 300 μιη, and the cover layer has a thickness of 100 to 600 μιη.
  4. 4. The sheet according to any one of the preceding claims, wherein the support layer has a thickness of at least 800 μιη and the composite structure has a thickness of less than 40 μιη.
  5. 5. The sheet according to any of the preceding claims, which does not comprise polyvinyl chloride and does not comprise a plasticizer.
  6. 6. The sheet of any of the preceding claims, wherein the cover layer comprises a thermoplastic styrenic elastomer.
  7. 7. The sheet according to any one of the preceding claims, wherein the intermediate layer and the cover layer are directly bonded to each other or at least one additional layer is arranged between the intermediate layer and the cover layer.
  8. 8. The sheet of any of the preceding claims, wherein the polyurethane in the cover layer is aromatic.
  9. 9. The sheet of any one of the preceding claims, wherein the cover layer comprises a lower sub-layer and an upper sub-layer, wherein the lower sub-layer is directly bonded to the intermediate layer and has a shore a hardness according to DIN 53505 of at most 70, and the upper sub-layer has a shore a hardness according to DIN 53505 of at least 75.
  10. 10. The sheet of claim 9, wherein the lower and upper sublayers differ in their shore a hardness according to DIN 53505 by at least 10.
  11. 11. A method of making the sheet according to any one of claims 1 to 10, comprising: (i) a step of providing a two-component polyurethane system, (ii) a step of providing a layered structure consisting of the support layer and of a layer of the two-component polyurethane system, (iii) a step of curing to obtain the support layer coated with the intermediate layer, the intermediate layer containing a polyurethane having a gel content of at least 20%, or (I) a step of providing a polyurethane layer of a polyurethane composition based on water and/or solvent and containing polyurethane having a gel content of at least 20%, and at least partially removing said water and/or solvent, (ii) a step of providing a layered structure consisting of said support layer and said polyurethane layer, (iii) a step of removing the remaining water and/or solvent to obtain said intermediate layer; And, after any one of the above steps (i) to (iii), (iv) a step of applying a molten cover stock material containing polyurethane having a gel content of less than 10% onto the intermediate layer, and (v) a step of curing the cover stock material to obtain the sheet.
  12. 12. A sewn product obtainable by sewing the sheet according to any of claims 1 to 10, or a coated product obtainable by using the sheet according to any of claims 1 to 10 in a process of taping a substrate.
  13. 13. Use of a sheet according to any one of claims 1 to 10 as artificial leather.
  14. 14. Use of the sheet according to any one of claims 1 to 10 or the sewn or coated product according to claim 12 as a covering material in a vehicle interior.

Description

Sheet comprising a polyurethane layer, method for the production and use Technical Field The present invention relates to a sheet comprising a support layer, an intermediate layer comprising polyurethane having a high gel content, and a cover layer comprising polyurethane having a very low gel content, to a process for preparing said sheet, and to the use of said sheet as a surface material, such as artificial leather in a vehicle. Background EP 3 533 601 A1 discloses a composite structure comprising a low density foam layer, a fabric layer and a thermoplastic cover layer comprising polyolefin or polyvinyl chloride (PVC), optionally comprising a thermoplastic elastomer. The composite structure exhibits good tear properties and feel and is improved in terms of fold formation and handling during processing, particularly during sewing. EP 1 927 466 A1 discloses a flexible composite structure comprising a support layer, such as a textile layer, one or more polyurethane layers, and a lacquer layer. Technical problem to be solved by the invention The problem underlying the present invention is to combine the properties of thinness and good appearance with the properties of softness and flexibility to achieve good feel and handling during the cutting and sewing process and the press lamination/heat taping (EDGE WRAPPING). Disclosure of Invention The problem underlying the present invention is solved by providing a sheet according to the present invention. The present application encompasses the following preferred aspects. [1] A sheet comprising a support layer, an intermediate layer, and a cover layer, the intermediate layer comprising polyurethane having a gel content of at least 20% as component (a), the cover layer comprising thermoplastic polyurethane having a gel content of less than 10%, preferably less than 5%, as component (a), wherein the support layer and the intermediate layer only partially interpenetrate each other in their thickness direction to form a composite structure, the support layer preferably being a textile layer, the intermediate layer preferably being a dense layer, wherein the thickness of the intermediate layer above the composite structure is at least 20 μm. [1-1] The sheet according to aspect [1] is suitable for producing a sewn product obtainable by sewing the sheet, and preferably for producing a sewn product by folding the sheet, placing two A-side portions or B-side portions of the sheet together to provide a contact area, and sewing the two portions of the sheet in the contact area, or the sheet according to aspect [1] is suitable for producing a coated product obtainable by using the sheet in the process of taping a substrate, preferably thermally taping a substrate. [1-2] The sheet according to any one of the preceding aspects, wherein the thickness of the intermediate layer above the composite structure is at least 100 μm. [1-3] The sheet according to any one of the preceding aspects, wherein the content of the component (a) in the intermediate layer is at least 20 mass%, and the content of the component (a) in the cover layer is at least 50 mass%. [1-4] The sheet according to any one of the preceding aspects, wherein the extent of interpenetration of the support layer, which is defined as [ (thickness of the composite structure)/(thickness of the support layer) ]x100%, is 0.5% to 10%, preferably 0.5% to 2%. [1-5] The sheet according to any one of the preceding claims, wherein the degree of interpenetration of the intermediate layer, defined as [ (thickness of the composite structure)/(thickness of the intermediate layer) ]x100%, is from 5% to 50%, preferably from 10% to 20%. [1-6] The sheet according to any one of the preceding aspects, wherein the area density of the portion of the support layer that is part of the composite structure is at least 80%, preferably at least 90% of the area density of the support layer that is not part of the composite structure, as observed by microscopic examination of a cross section of the sheet. [1-7] The sheet according to any one of the preceding aspects, wherein the sheet has a seam strength (SEAM STRENGTH) of at least 400N according to tpjlr.52.417, wherein a sample of 100mm x 150 mm is stitched (stitch) and the seam strength is evaluated by applying a load at a rate of 300 mm/min and recording the maximum load in newtons at break, wherein the stitch (stitch) is a simple lock stitch (lock stitch) of a length of 4.2 mm-5.1 mm (5-6 pins per 25 mm) and extends from the cut edge of the test sample about 10 mm. [1-8] The sheet according to any one of the preceding aspects, wherein the cover layer is coated with a silicone layer having a thickness of at least 30 μm, and the silicone layer is coated with a paint layer having a thickness of less than 30 μm. [1-9] The sheet according to any one of the preceding aspects, wherein the sheet preferably shows no damage and no change after 100,000 flex cycles at room temperature, after 10,000 flex cy