Laminated sheet and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-9885148-B2
Application number	US-201314651734-A
Country	US
Kind code	B2
Filing date	Dec 13, 2013
Priority date	Dec 18, 2012
Publication date	Feb 6, 2018
Grant date	Feb 6, 2018

Abstract

A laminated sheet includes a base cloth layer having a porous structure obtained by impregnating a woven fabric, which has a tear strength by a trapezoid method of 150 N or more in the longitudinal direction and 100 N or more in the lateral direction, with a resin composition containing a polyurethane resin and an organic flame retardant, and a skin layer layered on the base cloth layer, and has plural air holes penetrating in the thickness direction.

First claim

The invention claimed is:

1. A laminated sheet, comprising:
a base cloth layer having a porous structure that is obtained by impregnating a woven fabric, which has a tear strength by a trapezoid method of 150 N or more in a longitudinal direction and 100 N or more in a lateral direction, with a resin composition containing a polyurethane resin and an organic flame retardant; and
a skin layer that is layered on the base cloth layer,
the laminated sheet having plural air holes penetrating in a thickness direction,
wherein the woven fabric is twilled using a No. 5 to No. 30 count single yarn as a warp yarn and a No. 10 to No. 40 count two-ply to four-ply twisted yarn as a weft yarn.

2. The laminated sheet according to claim 1 , wherein the organic flame retardant is a phosphorous flame retardant.

3. The laminated sheet according to claim 1 , further comprising an abrasion-resistant layer on the skin layer.

4. The laminated sheet according to claim 2 , further comprising an abrasion-resistant layer on the skin layer.

5. The laminated sheet according to claim 3 , wherein the abrasion-resistant layer comprises a resin, a lubricant, and a cross-linking agent.

6. The laminated sheet according to claim 4 , wherein the abrasion-resistant layer comprises a resin, a lubricant, and a cross-linking agent.

7. The laminated sheet according to claim 6 , wherein a hole diameter of each of the air holes is from 1.0 to 2.0 mm.

8. The laminated sheet according to claim 6 , wherein a hole diameter of each of the air holes is from 1.0 to 2.0 mm.

9. The laminated sheet according to claim 1 , wherein a content of the organic flame retardant in the base cloth layer is from 10 to 30 parts by mass with respect to 100 parts by mass of the polyurethane resin.

10. The laminated sheet according to claim 8 , wherein a content of the organic flame retardant in the base cloth layer is from 10 to 30 parts by mass with respect to 100 parts by mass of the polyurethane resin.

11. An automobile interior material, comprising the laminated sheet according to claim 1 .

12. An automobile interior material, comprising the laminated sheet according to claim 10 .

13. A method of manufacturing a laminated sheet according to claim 1 , the method comprising:
a step of impregnating a woven fabric, which has a tear strength by a trapezoid method of 150 N or more in a longitudinal direction and 100 N or more in a lateral direction, with a resin solution containing a polyurethane resin, an organic flame retardant, and a solvent,
a step of soaking the woven fabric, which has been impregnated with the resin solution, in water to remove the solvent from the woven fabric and solidify the polyurethane resin,
a step of drying the woven fabric, in which the polyurethane resin has been solidified, to form a base cloth layer having a porous structure,
a step of roughening one surface of the base cloth layer,
a step of forming a laminate in which a skin layer is layered on the roughened surface of the base cloth layer, and
a step of forming plural air holes that penetrate in a thickness direction of the laminate.

Assignees

• Kyowa Leather Cloth
• Toyota Motor Co Ltd

Inventors

• Sugiura Koji
• Fukumi Akinaka
• Kubo Kenji
• Tatematsu Takanori

Classifications

• B32B27/20

  using fillers, pigments, thixotroping agents · CPC title

• Y10T428/249953

  Composite having voids in a component [e.g., porous, cellular, etc.] · CPC title

• D06N3/0006

  using woven fabrics · CPC title

• B32B37/12

  characterised by using adhesives · CPC title

• Y10S428/921

  Fire or flameproofing · CPC title