Article cut to size

Patent metadata

Field	Value
Publication number	US-9427936-B2
Application number	US-201113813790-A
Country	US
Kind code	B2
Filing date	Jul 26, 2011
Priority date	Aug 4, 2010
Publication date	Aug 30, 2016
Grant date	Aug 30, 2016

Abstract

The invention relates to a multilayered cut-to-size format comprising a thin, polyurethane-based coating ( 2 ) bonded via a polyurethane adhesive layer ( 3 ) to a textile backing ( 4 ).
The invention provides that the backing ( 4 ) is a textile backing layer formed using a loop-formingly knitted fabric, a woven fabric or a fibrous non-woven web and having a thickness between 0.25 and 1.2 mm; there are capillaries in the coating ( 2 ); the solidified polyurethane dispersion ( 3 ) has a basis weight between 65 and 155 g/m 2 and reaches by between 0.02 and 0.55 mm into the backing ( 4 ) non-filmingly; the coating ( 2 ) has a thickness of 0.09 to 0.21 mm and a hardness between 25 and 55 Shore A; and the backing ( 4 ) is bonded on its side opposite the coating ( 2 ) to a layer ( 5 ) of polychloroprene foam which has a closed-cell structure of the foam rubber type and a density between 0.05 and 0.42 g/cm 3 , preferably between 0.06 to 0.28 g/cm 3 .

First claim

What is claimed is:

1. A multilayered cut-to-size format comprising:
a polyurethane layer having a thickness of 0.09 mm to 0.21 mm, a density city of 0.9 to 1.12 g/cm 3 , and a hardness of 25 Shore A to 55 Shore A, wherein the polyurethane layer contains 68 to 78 wt % of a solidified, cross-linked polyurethane dispersion and has a first surface, and a second surface opposite the first surface, and the polyurethane layer comprises capillaries within the layer wherein at least a portion of the capillaries extend through the layer from the first surface to the second surface;
a textile backing layer having a thickness of 0.25 mm to 1.2 mm and comprising textile fibers in a loop-formingly knitted fabric, a woven fabric or a fibrous nonwoven web, wherein the backing layer has a first surface disposed towards the polyurethane layer and a second surface opposite the first surface;
a polyurethane adhesive disposed between the second surface of the polyurethane layer and the first surface of the backing layer to retain the polyurethane layer with the backing layer, the polyurethane adhesive having a basis weight of 65 g/m 2 to 155 g/m 2 and extending into the backing layer 0.02 mm to 0.55 mm wherein the polyurethane adhesive at least partly sheaths the textile fibers and is not filmingly bound or attached to the textile fibers; and
a polychlorobrene foam layer bound with the second surface of the backing layer, the polychloroprene foam layer having a closed-cell structure of a foam rubber type and having a thickness of 1.0 mm to 4.5 mm and a density of 0.05 g/cm 3 to 0.42 g/cm 3 .

2. The multilayered cut-to-size format of claim 1 , wherein the polyurethane layer comprises a polyurethane dispersion patterned on a surface-patterned silicone rubber support.

3. The multilayered cut-to-size format of claim 1 , wherein the polychloroprene foam layer has a first surface bound with the second surface of the backing layer and second surface opposite the first surface, and the multilayered cut-to-size format further comprises one of:
a thin homogeneous skin of the same polychloroprene foam as the polychloroprene foam layer and having a thickness of 0.01 to 0.06 mm, or
a textile layer having a thickness of 0.15 to 0.95 mm bound to the second side of the polychloroprene foam layer.

4. The multilayered cut-to-size format of claim 1 , wherein the textile backing layer comprises synthetic and/or natural fibers with or without eiastomeric fibers.

5. The multilayered cut-to-size format of claim 1 , wherein the polychloroprene foam layer is bound with the second surface of the backing layer by one of:
direct adherence of the polychloroprene foam layer to the second surface of the backing layer by forming of the polychloroprene foam layer on the second surface of the backing layer, or
an additional adhesive adhering the polychloroprene foam layer with the second surface of the backing layer, wherein the additional adhesive comprises at least one of polychloroprene and polyurethane.

6. The rnultilayered cut-to-size format of claim 1 , wherein the polyurethane layer contains pigment particles and/or silicone particles.

7. The multilayered cut-to-size format of claim 1 , wherein the first surface of the polyurethane layer is configured to have an appearance of at least one of: grained leather, nubuck leather, textiles, sandpaper, a waffle pattern, patterns lasered directly or indirectly into a silicone rubber support, logos, carbon fabric, and a depiction of fibrous fine structuring.

8. The multilayered cut-to-size format of claim 1 , wherein at least one of the layers has a color different from a color of another of the layers.

9. The multilayered cut-to-size format of claim 1 , wherein the first surface of the polyurethane layer comprises a differentially patterned surface and optionally includes a region configured to have a nubuck leather type appearance and a carbon-fabric type appearance.

10. The multilayered cut-to-size format of claim 1 , further comprising microperforations extending through the cut-to-size format, from the first surface of the polyurethane layer, through the polyurethane layer, the adhesive, and the backing layer to the second surface of the backing layer, wherein the microperforations are configured to provide permeability for at least one of air and water vapor, and impermeability to water.

11. The multilayered cut-to-size format of claim 1 , wherein the cut-to-size format has a density between 0.20 g/cm 3 and 0.65 g/cm 3 depending on the thickness of the polychloroprene foam layer.

12. The multilayered cut-to-size format of claim 1 , wherein the polyurethane adhesive has a two-ply configuration wherein the second surface of the polyurethane layer has a first ply of the polyurethane adhesive applied thereon, and the first surface of the backing layer has a second ply of the polyurethane adhesive applied thereon and the two plies are bonded by heat and pressure.

13. The multilayered cut-to-size format of claim 1 , wherein the polyurethane layer is free of plasticizers.

14. The multilayered cut-to-size format of claim 12 , wherein the capillaries are sealed at the second side of the polyurethane layer by the first ply of the polyurethane adhesive.

15. The multilayered cut-to-size format of claim 1 , wherein the polyurethane layer comprises 1% to 15% by weight of silicone and/or silicone particles, wherein the silicone and/or the silicone particles comprise an emulsion and/or dispersion in the polyurethane layer.

16. The multilayered cut-to-size format of claim 1 , wherein the polyurethane adhesive comprises an aqueous polyurethane dispersion which in the cross-linked state has a hardness of less than 45 Shore A.

17. The multilayered cut-to-size format of claim 1 , wherein the polyurethane adhesive has an amorphous structure.

18. The multilayered cut-to-size format of claim 1 , wherein the polyurethane layer and/or the polyurethane adhesive comprise a 3% to 24% volume fraction of hollow microspheres having a size of 5 μm to 65 μm, wherein the hollow microspheres comprise at least one of plastic microspheres and glass microspheres.

Assignees

• Schaefer Philipp
• Lanxess Deutschland Gmbh

Inventors

• Schaefer Philipp

Classifications

• D06N3/0043

  characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers (foraminous structure obtained by stretching D06N3/0029) · CPC title

• Y10T428/24438

  Artificial wood or leather grain surface · CPC title

• Y10T428/15

  Sheet, web, or layer weakened to permit separation through thickness · CPC title

• D06N3/0097

  Release surface, e.g. separation sheets; Silicone papers · CPC title

• B32B25/16

  comprising polydienes {homopolymers} or poly-halodienes {homopolymers (B32B25/12 takes precedence)} · CPC title