U.S. patent application number 14/828901 was filed with the patent office on 2016-09-22 for thermoplastic artificial leather, method for manufacturing the same and thermoplastic composite laminate.
The applicant listed for this patent is San Fang Chemical Industry Co., Ltd.. Invention is credited to CHI-CHIN CHIANG, CHUNG-CHIH FENG, CHIH-YI LIN, KAO-LUNG YANG.
Application Number | 20160273159 14/828901 |
Document ID | / |
Family ID | 56924620 |
Filed Date | 2016-09-22 |
United States Patent
Application |
20160273159 |
Kind Code |
A1 |
FENG; CHUNG-CHIH ; et
al. |
September 22, 2016 |
THERMOPLASTIC ARTIFICIAL LEATHER, METHOD FOR MANUFACTURING THE SAME
AND THERMOPLASTIC COMPOSITE LAMINATE
Abstract
A thermoplastic artificial leather includes a thermoplastic
composite laminate and a textile base. The thermoplastic composite
laminate includes a foamed thermoplastic elastic layer, an unfoamed
thermoplastic elastic layer and a thermoplastic adhesive layer. The
foamed thermoplastic elastic layer has a first surface, a second
surface and a plurality of foamed structures. The second surface is
opposite to the first surface. The unfoamed thermoplastic elastic
layer is disposed on the first surface of the foamed thermoplastic
elastic layer. The thermoplastic adhesive layer is disposed on the
second surface of the foamed thermoplastic elastic layer. The
textile base is laminated on the thermoplastic adhesive layer of
the thermoplastic composite laminate.
Inventors: |
FENG; CHUNG-CHIH; (Kaohsiung
City, TW) ; LIN; CHIH-YI; (Kaohsiung City, TW)
; YANG; KAO-LUNG; (Kaohsiung City, TW) ; CHIANG;
CHI-CHIN; (Kaohsiung City, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
San Fang Chemical Industry Co., Ltd. |
Kaohsiung City |
|
TW |
|
|
Family ID: |
56924620 |
Appl. No.: |
14/828901 |
Filed: |
August 18, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 27/40 20130101;
B32B 27/36 20130101; B29C 48/37 20190201; B32B 7/12 20130101; B32B
2037/1215 20130101; D06N 3/0011 20130101; B29C 2948/92704 20190201;
B32B 5/18 20130101; B32B 2274/00 20130101; B29C 48/154 20190201;
B32B 27/32 20130101; B29C 48/49 20190201; B32B 5/024 20130101; B32B
27/065 20130101; B32B 2307/536 20130101; B32B 2307/732 20130101;
B32B 2266/0264 20130101; B32B 33/00 20130101; B29C 48/914 20190201;
B32B 5/245 20130101; B32B 2262/0276 20130101; D06N 2213/03
20130101; B29C 48/387 20190201; D06N 3/0006 20130101; B32B 5/022
20130101; B32B 2305/20 20130101; D06N 3/106 20130101; B29C 48/92
20190201; B32B 2266/025 20130101; B32B 2266/0278 20130101; B32B
2266/02 20130101; B32B 2305/188 20130101; D06N 3/0043 20130101;
B32B 2307/51 20130101; D06N 3/14 20130101; B29C 48/07 20190201;
B29C 48/21 20190201 |
International
Class: |
D06N 3/00 20060101
D06N003/00; B32B 5/18 20060101 B32B005/18; B32B 5/24 20060101
B32B005/24; B32B 7/12 20060101 B32B007/12 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 18, 2015 |
TW |
104108560 |
Claims
1. A thermoplastic artificial leather, comprising: a thermoplastic
composite laminate, which includes: a foamed thermoplastic elastic
layer having a first surface, a second surface and a plurality of
foamed structures, wherein the second surface is opposite to the
first surface; an unfoamed thermoplastic elastic layer disposed on
the first surface of the foamed thermoplastic elastic layer; and a
thermoplastic adhesive layer disposed on the second surface of the
foamed thermoplastic elastic layer; and a textile base laminated on
the thermoplastic adhesive layer of the thermoplastic composite
laminate.
2. The thermoplastic artificial leather of claim 1, wherein the
material of the foamed thermoplastic elastic layer is a
thermoplastic polyurethane (TPU), a thermoplastic polyester
elastomer (TPEE) or a thermoplastic polyolefin (TPO) elastomer.
3. The thermoplastic artificial leather of claim 1, wherein the
foamed structures of the foamed thermoplastic elastic layer have a
size of 20 to 300 microns inclusive.
4. The thermoplastic artificial leather of claim 1, wherein the
foamed thermoplastic elastic layer has a foaming density reduction
rate of 40% to 90% inclusive and a Shore hardness of 50 A to 85 A
inclusive.
5. The thermoplastic artificial leather of claim 1, wherein the
material of the unfoamed thermoplastic elastic layer is a
thermoplastic polyurethane (TPU), a thermoplastic polyester
elastomer (TPEE) or a thermoplastic polyolefin (TPO) elastomer.
6. The thermoplastic artificial leather of claim 1, wherein the
thickness ratio of the unfoamed thermoplastic elastic layer to the
foamed thermoplastic elastic layer is 95:5 to 5:95 inclusive.
7. The thermoplastic artificial leather of claim 1, wherein the
unfoamed thermoplastic elastic layer has a Shore hardness of 60 A
to 80 A inclusive.
8. The thermoplastic artificial leather of claim 1, wherein the
material of the thermoplastic adhesive layer is a thermoplastic
polyurethane (TPU) or a water-based paste, and the textile base is
a nonwoven fabric or a woven fabric.
9. A method for manufacturing a thermoplastic artificial leather,
comprising: (a) preparing a thermoplastic composite laminate,
wherein the thermoplastic composite laminate includes a foamed
thermoplastic elastic layer, an unfoamed thermoplastic elastic
layer and a thermoplastic adhesive layer, the foamed thermoplastic
elastic layer has a first surface, a second surface opposite to the
first surface and a plurality of foamed structures, the unfoamed
thermoplastic elastic layer is disposed on the first surface of the
foamed thermoplastic elastic layer, and the thermoplastic adhesive
layer is disposed on the second surface of the foamed thermoplastic
elastic layer; and (b) laminating a textile base on the
thermoplastic adhesive layer of the thermoplastic composite
laminate.
10. The method of claim 9, wherein in the step (a), the method for
preparing the thermoplastic composite laminate includes: (a1)
providing a first raw material, a second raw material and a third
raw material, wherein the first raw material is used to prepare the
unfoamed thermoplastic elastic layer, the second raw material is
used to prepare the foamed thermoplastic elastic layer, and the
third raw material is used to prepare the thermoplastic adhesive
layer; and (a2) using an extruding apparatus to melt and then
co-extrude the first raw material, the second raw material and the
third raw material, to form the thermoplastic composite
laminate.
11. The method of claim 10, wherein in the step (a1), the first raw
material, the second raw material and the third raw material are a
thermoplastic polyurethane (TPU), a thermoplastic polyester
elastomer (TPEE), or a thermoplastic polyolefin (TPO)
elastomer.
12. The method of claim 10, wherein in the step (a1), the first raw
material has a melting point of 140.degree. C. to 165.degree. C.
inclusive, the second raw material has a melting point of
135.degree. C. to 150.degree. C. inclusive, and the third raw
material has a melting point of 90.degree. C. to 133.degree. C.
inclusive.
13. The method of claim 10, wherein in the step (a2), the second
raw material is processed by foaming, and the foaming method is
selected from the group consisting of microsphere foaming, nitrogen
foaming, carbon dioxide foaming and supercritical carbon dioxide
foaming.
14. The method of claim 9, wherein in the step (a), the method for
preparing the thermoplastic composite laminate includes: (a1)
providing a first raw material and a second raw material, wherein
the first raw material is used to prepare the unfoamed
thermoplastic elastic layer, and the second raw material is used to
prepare the foamed thermoplastic elastic layer; (a2) using an
extruding apparatus to melt and then co-extrude the first raw
material and the second raw material, to form the unfoamed
thermoplastic elastic layer and the foamed thermoplastic elastic
layer; and (a3) disposing a thermoplastic adhesive layer on the
second surface of the foamed thermoplastic elastic layer, thus
obtaining the thermoplastic composite laminate.
15. The method of claim 14, wherein in the step (a1), the first raw
material and the second raw material are a thermoplastic
polyurethane (TPU), a thermoplastic polyester elastomer (TPEE), or
a thermoplastic polyolefin (TPO) elastomer.
16. The method of claim 14, wherein in the step (a1), the first raw
material has a melting point of 140.degree. C. to 165.degree. C.
inclusive, and the second raw material has a melting point of
135.degree. C. to 150.degree. C. inclusive.
17. The method of claim 14, wherein in the step (a2), the second
raw material is processed by foaming.
18. The method of claim 17, wherein the foaming method is selected
from the group consisting of microsphere foaming, nitrogen foaming,
carbon dioxide foaming and supercritical carbon dioxide
foaming.
19. The method of claim 14, wherein in the step (a3), the material
of the thermoplastic adhesive layer is a thermoplastic polyurethane
(TPU), a thermoplastic polyester elastomer (TPEE), a thermoplastic
polyolefin (TPO) elastomer, or a water-based paste.
20. The method of claim 9, wherein in the step (b), the textile
base is a nonwoven fabric or a woven fabric.
Description
FIELD
[0001] The disclosure relates to an artificial leather and a
laminate, more particular to a thermoplastic artificial leather, a
method for manufacturing the thermoplastic artificial leather and a
thermoplastic composite laminate.
BACKGROUND
[0002] In conventional processes for manufacturing artificial
leather, no matter a dry coating process or a wet coating process,
an organic solvent (for example, DMF) is used. Although the organic
solvent can be recycled, establishment costs of a recycling
equipment are quite high and it is considerably difficult to fully
recycle. Therefore, it is difficult to achieve zero tolerance of
the organic solvent, thus not conforming to environment protection
requirements. Furthermore, the touch feeling and abrasion
resistance (stoll abrasion=1500-; testing method: NIKE G12) of the
artificial leather made by the conventional processes are generally
poor.
[0003] The conventional artificial leather and manufacturing method
thereof are analyzed in the following patent documents in the prior
art.
1. TW 1409375
[0004] Approach: A thermoplastic film is used and laminated on
modified cross-section fibers, and then processed to obtain a
leather.
[0005] Disadvantage: There is no foamed structure, the leather is
too hard, and the touch feeling is poor.
2. TW 1290568
[0006] Approach: A thermoplastic film is used for secondary
processing of the surface to cover a foamed layer, so as to obtain
a leather.
[0007] Disadvantage: The process efficiency of secondary processing
of the surface layer is poor.
3. TW 442392
[0008] Approach: A thermoplastic film is used and laminated on a
fabric to obtain a leather.
[0009] Disadvantage: There is no foamed structure, the leather is
too hard, and the touch feeling is poor.
[0010] Based on the foregoing analysis, it is necessary to provide
a thermoplastic artificial leather and a method for manufacturing
the thermoplastic artificial leather as well as thermoplastic
composite laminate, so as to solve the foregoing deficiencies in
the prior art.
SUMMARY OF THE INVENTION
[0011] In accordance with one aspect of the present disclosure, a
thermoplastic artificial leather includes a thermoplastic composite
laminate and a textile base. The thermoplastic composite laminate
includes a foamed thermoplastic elastic layer, an unfoamed
thermoplastic elastic layer and a thermoplastic adhesive layer. The
foamed thermoplastic elastic layer has a first surface, a second
surface and a plurality of foamed structures. The second surface is
opposite to the first surface. The unfoamed thermoplastic elastic
layer is disposed on the first surface of the foamed thermoplastic
elastic layer. The thermoplastic adhesive layer is disposed on the
second surface of the foamed thermoplastic elastic layer. The
textile base is laminated on the thermoplastic adhesive layer of
the thermoplastic composite laminate.
[0012] In accordance with another aspect of the present disclosure,
a method for manufacturing a thermoplastic artificial leather
includes step in which a thermoplastic composite laminate is
prepared, wherein the thermoplastic composite laminate includes a
foamed thermoplastic elastic layer, an unfoamed thermoplastic
elastic layer and a thermoplastic adhesive layer, the foamed
thermoplastic elastic layer has a first surface, a second surface
opposite to the first surface and a plurality of foamed structures,
the unfoamed thermoplastic elastic layer is disposed on the first
surface of the foamed thermoplastic elastic layer, and the
thermoplastic adhesive layer is disposed on the second surface of
the foamed thermoplastic elastic layer. The method continues with
step in which a textile base is laminated on the thermoplastic
adhesive layer of the thermoplastic composite laminate.
[0013] In accordance with another aspect of the present disclosure,
a thermoplastic composite laminate includes a foamed thermoplastic
elastic layer, an unfoamed thermoplastic elastic layer and a
thermoplastic adhesive layer. The foamed thermoplastic elastic
layer has a first surface, a second surface and a plurality of
foamed structures. The second surface is opposite to the first
surface. The unfoamed thermoplastic elastic layer is disposed on
the first surface of the foamed thermoplastic elastic layer. The
thermoplastic adhesive layer is disposed on the second surface of
the foamed thermoplastic elastic layer.
[0014] In accordance with another aspect of the present disclosure,
a thermoplastic composite laminate includes a foamed thermoplastic
elastic layer and an unfoamed thermoplastic elastic layer. The
foamed thermoplastic elastic layer has a first surface, a second
surface and a plurality of foamed structures. The second surface is
opposite to the first surface. The unfoamed thermoplastic elastic
layer is disposed on the first surface of the foamed thermoplastic
elastic layer.
[0015] In accordance with another aspect of the present disclosure,
a thermoplastic composite laminate includes a foamed thermoplastic
elastic layer and a thermoplastic adhesive layer. The foamed
thermoplastic elastic layer has a first surface, a second surface
and a plurality of foamed structures. The second surface is
opposite to the first surface. The thermoplastic adhesive layer is
disposed on the second surface of the foamed thermoplastic elastic
layer.
[0016] In the present disclosure, a three-layer composite structure
consisting of a foamed thermoplastic elastic layer, an unfoamed
thermoplastic elastic layer and a thermoplastic adhesive layer, a
two-layer composite structure consisting of a foamed thermoplastic
elastic layer and an unfoamed thermoplastic elastic layer, or a
two-layer composite structure consisting of a foamed thermoplastic
elastic layer and a thermoplastic adhesive layer can separately be
used to form a thermoplastic composite laminate; and by laminating
a textile base on the thermoplastic composite laminate, a
thermoplastic artificial leather with good abrasion resistance
(stoll abrasion=3000+; testing method: NIKE G12), a peeling
strength of greater than 4.0 kg/cm.sup.2 and a soft touch feeling
can be manufactured. Furthermore, the thermoplastic artificial
leather can be manufactured without use of any solvent, so as to
conform to the environment protection requirement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Aspects of the present disclosure are understood from the
following detailed description when read with the accompanying
figures. It is emphasized that, in accordance with the standard
practice in the industry, various features are not drawn to scale.
In fact, the dimensions of the various features may be arbitrarily
increased or reduced for clarity of discussion.
[0018] FIG. 1 shows a schematic structural view of a thermoplastic
artificial leather according to the present disclosure.
[0019] FIG. 2 is a flow diagram of a method for manufacturing a
thermoplastic artificial leather according to the present
disclosure.
[0020] FIGS. 3A and 3B show schematic diagrams of a method for
manufacturing a thermoplastic artificial leather according to the
present disclosure.
[0021] FIG. 4 shows a schematic view of a process for preparing a
thermoplastic composite laminate according to the present
disclosure.
[0022] FIG. 5 shows a schematic view of another process for
preparing a thermoplastic composite laminate according to the
present disclosure.
[0023] FIG. 6 is an optical microscopic photograph of a
cross-section of a thermoplastic artificial leather according to
the present disclosure.
[0024] FIG. 7 is another schematic structural view of a
thermoplastic composite laminate according to the present
disclosure.
[0025] FIG. 8 is another schematic structural view of a
thermoplastic artificial leather according to the present
disclosure.
[0026] FIG. 9 is a further schematic structural view of a
thermoplastic composite laminate according to the present
disclosure.
[0027] FIG. 10 is a further schematic structural view of a
thermoplastic artificial leather according to the present
disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0028] It is to be understood that the following disclosure
provides many different embodiments or examples, for implementing
different features of various embodiments. Specific examples of
components and arrangements are described below to simplify the
present disclosure. The present disclosure may, however, be
embodied in many different forms and should not be construed as
being limited to the embodiments set forth herein; rather, these
embodiments are provided so that this description will be thorough
and complete, and will fully convey the present disclosure to those
of ordinary skill in the art. It will be apparent, however, that
one or more embodiments may be practiced without these specific
details.
[0029] In addition, the present disclosure may repeat reference
numerals and/or letters in the various examples. This repetition is
for the purpose of simplicity and clarity and does not in itself
dictate a relationship between the various embodiments and/or
configurations discussed.
[0030] It will be understood that singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise.
[0031] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms; such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of the relevant art and the present
disclosure, and will not be interpreted in an idealized or overly
formal sense unless expressly so defined herein.
[0032] Referring to FIG. 1, which shows a schematic structural view
of a thermoplastic artificial leather according to the present
disclosure. The thermoplastic artificial leather 10 of the present
disclosure includes a thermoplastic composite laminate 12 and a
textile base 14.
[0033] The thermoplastic composite laminate 12 includes a foamed
thermoplastic elastic layer 122, an unfoamed thermoplastic elastic
layer 124 and a thermoplastic adhesive layer 126.
[0034] The foamed thermoplastic elastic layer 122 has a first
surface 122A, a second surface 122B and a plurality of foamed
structures 122F. The second surface 122B is opposite to the first
surface 122A. In some embodiments, the material of the foamed
thermoplastic elastic layer 122 can be a thermoplastic polyurethane
(TPU), a thermoplastic polyester elastomer (TPEE) or a
thermoplastic polyolefin (TPO) elastomer, and preferably, the
foamed thermoplastic elastic layer 122 has a Shore hardness of 50A
to 85A inclusive.
[0035] Additionally, in order to enable the foamed thermoplastic
elastic layer 122 to provide the feeling of thick resilient
leather, preferably, the foamed thermoplastic elastic layer 122
should have a foaming density reduction rate (density after
foaming/density before foaming) of 40% to 90% inclusive, and the
foamed structures 122F should have a size of 20 to 300 microns
inclusive.
[0036] The unfoamed thermoplastic elastic layer 124 is disposed on
the first surface 122A of the foamed thermoplastic elastic layer
122. In some embodiments, the material of the unfoamed
thermoplastic elastic layer 124 can be a thermoplastic polyurethane
(TPU), a thermoplastic polyester elastomer (TPEE) or a
thermoplastic polyolefin (TPO) elastomer, and preferably, the
unfoamed thermoplastic elastic layer 124 has a Shore hardness of 60
A to 80 A inclusive.
[0037] Furthermore, in order to improve the thick feel and the
leather touch feeling of the thermoplastic artificial leather 10,
the thickness ratio of the unfoamed thermoplastic elastic layer 124
to the foamed thermoplastic elastic layer 122 is preferably 95:5 to
5:95 inclusive.
[0038] The thermoplastic adhesive layer 126 is disposed on the
second surface 122B of the foamed thermoplastic elastic layer 122.
In some embodiments, the thermoplastic adhesive layer 126 is a
hot-melt adhesive layer, and the material of the thermoplastic
adhesive layer 126 can be a thermoplastic polyurethane (TPU), a
thermoplastic polyester elastomer (TPEE), a thermoplastic
polyolefin (TPO) elastomer, or a water-based paste. Additionally,
if the thermoplastic adhesive layer 126 uses TPU, TPEE or TPO, the
thermoplastic adhesive layer 126 preferably has a Shore hardness of
60 A to 90 A inclusive.
[0039] The textile base 14 is laminated on the thermoplastic
adhesive layer 126 of the thermoplastic composite laminate 12. In
some embodiments, the textile base 14 can be a nonwoven fabric or a
woven fabric.
[0040] FIG. 2 is a flow diagram of a method for manufacturing a
thermoplastic artificial leather according to the present
disclosure. FIGS. 3A and 3B show schematic diagrams of a method for
manufacturing a thermoplastic artificial leather according to the
present disclosure.
[0041] With reference to step S21 in FIG. 2 and FIG. 3A, a
thermoplastic composite laminate 12 is prepared. In this step, the
thermoplastic composite laminate 12 includes a foamed thermoplastic
elastic layer 122, an unfoamed thermoplastic elastic layer 124 and
a thermoplastic adhesive layer 126. The foamed thermoplastic
elastic layer 122 has a first surface 122A, a second surface 122B
and a plurality of foamed structures 122F, and the second surface
122B is opposite to the first surface 122A. The unfoamed
thermoplastic elastic layer 124 is disposed on the first surface
122A of the foamed thermoplastic elastic layer 122. The
thermoplastic adhesive layer 126 is disposed on the second surface
122B of the foamed thermoplastic elastic layer 122.
[0042] Referring to FIG. 4, which shows a schematic view of a
process for preparing a thermoplastic composite laminate according
to the present disclosure. In some embodiments, the method for
preparing the thermoplastic composite laminate 12 includes:
[0043] Step 1: Provide a first raw material 31, a second raw
material 32 and a third raw material 33, wherein the first raw
material 31 is used to prepare the unfoamed thermoplastic elastic
layer 124, the second raw material 32 is used to prepare the foamed
thermoplastic elastic layer 122, and the third raw material 33 is
used to prepare the thermoplastic adhesive layer 126. In this step,
the first raw material 31, the second raw material 32 and the third
raw material 33 can be a thermoplastic polyurethane (TPU), a
thermoplastic polyester elastomer (TPEE), or a thermoplastic
polyolefin (TPO) elastomer. Preferably, the first raw material 31
has a melting point of 140.degree. C. to 165.degree. C. inclusive,
the second raw material 32 has a melting point of 135.degree. C. to
150.degree. C. inclusive, and the third raw material 33 has a
melting point of 90.degree. C. to 133.degree. C. inclusive.
Additionally, in order to make the first raw material 31, the
second raw material 32 and the third raw material 33 all have a
moisture content of less than 300 ppm, the first raw material 31,
the second raw material 32 and the third raw material 33 can be
processed by drying.
[0044] Step 2: Use an extruding apparatus 40 to melt and then
co-extrude the first raw material 31, the second raw material 32
and the third raw material 33, to form the thermoplastic composite
laminate 12. In this step, the second raw material 32 can be
processed by foaming, such that the foamed thermoplastic elastic
layer 122 can be prepared with the second raw material 32.
Preferably, the foaming method is selected from the group
consisting of microsphere foaming, nitrogen foaming, carbon dioxide
foaming and supercritical carbon dioxide foaming.
[0045] Referring to FIG. 5, which shows a schematic view of another
process for preparing a thermoplastic composite laminate according
to the present disclosure. In some embodiments, the method for
preparing the thermoplastic composite laminate 12 can include:
[0046] Step 1: Provide a first raw material 31 and a second raw
material 32, wherein the first raw material 31 is used to prepare
the unfoamed thermoplastic elastic layer 124, and the second raw
material 32 is used to prepare the foamed thermoplastic elastic
layer 122. In this step, the first raw material 31 and the second
raw material 32 can be a thermoplastic polyurethane (TPU), a
thermoplastic polyester elastomer (TPEE), or a thermoplastic
polyolefin (TPO) elastomer. Preferably, the first raw material 31
has a melting point of 140.degree. C. to 165.degree. C. inclusive,
and the second raw material 32 has a melting point of 135.degree.
C. to 150.degree. C. inclusive. Additionally, in order to make the
first raw material 31 and the second raw material 32 both have a
moisture content of less than 300 ppm, the first raw material 31
and the second raw material 32 can be processed by drying.
[0047] Step 2: Use an extruding apparatus 40 to melt and then
co-extrude the first raw material 31 and the second raw material
32, to form the unfoamed thermoplastic elastic layer 124 and the
foamed thermoplastic elastic layer 122. In this step, the second
raw material 32 can be processed by foaming, such that the foamed
thermoplastic elastic layer 122 can be prepared with the second raw
material 32. Preferably, the foaming method is selected from the
group consisting of microsphere foaming, nitrogen foaming, carbon
dioxide foaming and supercritical carbon dioxide foaming.
[0048] Step 3: Dispose a thermoplastic adhesive layer 126 on the
second surface 122B of the foamed thermoplastic elastic layer 122,
thus obtaining the thermoplastic composite laminate 12. In this
step, the thermoplastic adhesive layer 126 is a hot-melt adhesive
layer, and the material of the thermoplastic adhesive layer 126 can
be a thermoplastic polyurethane (TPU), a thermoplastic polyester
elastomer (TPEE), a thermoplastic polyolefin (TPO) elastomer, or a
water-based paste. Furthermore, the thermoplastic adhesive layer
126 preferably has a moisture content of less than 300 ppm.
[0049] With reference to step S22 in FIG. 2 and FIG. 3B, a textile
base 14 is laminated on the thermoplastic adhesive layer 126 of the
thermoplastic composite laminate 12. In this step, the textile base
14 can be a nonwoven fabric or a woven fabric.
[0050] FIG. 6 is an optical microscopic photograph of a
cross-section of a thermoplastic artificial leather according to
the present disclosure.
[0051] As shown in FIG. 6, the present disclosure uses the foamed
thermoplastic elastic layer 122, the unfoamed thermoplastic elastic
layer 124 and the thermoplastic adhesive layer 126 to form the
thermoplastic composite laminate 12; and by laminating the textile
base 14 on the thermoplastic composite laminate 12, a thermoplastic
artificial leather with good abrasion resistance (stoll
abrasion=3000+; testing method: NIKE G12), a peeling strength of
greater than 4.0 kg/cm.sup.2 and a soft touch feeling can be
manufactured. Furthermore, the thermoplastic artificial leather can
be manufactured without use of any solvent, so as to conform to the
environment protection requirement.
[0052] FIG. 7 is another schematic structural view of a
thermoplastic composite laminate according to the present
disclosure. FIG. 8 is another schematic structural view of a
thermoplastic artificial leather according to the present
disclosure.
[0053] Besides the three-layer composite structure consisting of
the foamed thermoplastic elastic layer 122, the unfoamed
thermoplastic elastic layer 124 and the thermoplastic adhesive
layer 126 as shown in FIG. 1, in another embodiment, as shown in
FIGS. 7 and 8, the thermoplastic composite laminate 12 can be a
two-layer composite structure consisting of the foamed
thermoplastic elastic layer 122 and the unfoamed thermoplastic
elastic layer 124. The unfoamed thermoplastic elastic layer 124 is
disposed on a first surface 122A of the foamed thermoplastic
elastic layer 122, and the textile base 14 can be laminated on the
foamed thermoplastic elastic layer 122 of the thermoplastic
composite laminate 12, thus obtaining the thermoplastic artificial
leather 10.
[0054] FIG. 9 is a further schematic structural view of a
thermoplastic composite laminate according to the present
disclosure. FIG. 10 is a further schematic structural view of a
thermoplastic artificial leather according to the present
disclosure.
[0055] Besides the three-layer composite structure consisting of
the foamed thermoplastic elastic layer 122, the unfoamed
thermoplastic elastic layer 124 and the thermoplastic adhesive
layer 126 as shown in FIG. 1, in yet another embodiment, as shown
in FIGS. 9 and 10, the thermoplastic composite laminate 12 can be a
two-layer composite structure consisting of the foamed
thermoplastic elastic layer 122 and the thermoplastic adhesive
layer 126. The thermoplastic adhesive layer 126 is disposed on a
second surface 122B of the foamed thermoplastic elastic layer 122,
and the textile base 14 can be laminated on the thermoplastic
adhesive layer 126 of the thermoplastic composite laminate 12, thus
obtaining the thermoplastic artificial leather 10.
[0056] The present disclosure is illustrated in detail with the
following embodiments, but it does not mean that the present
disclosure is only limited to the content disclosed by these
embodiments.
Embodiment 1
[0057] Raw material: Thermoplastic polyurethane (TPU) is used as a
first raw material and a second raw material, and processed by
drying, to make the moisture content of TPU less than 300 ppm.
[0058] Temperature setting conditions: The temperatures set for a
first raw material extruder are respectively 100.degree. C.,
150.degree. C. and 185.degree. C. in sequence; the temperatures set
for a second raw material extruder are respectively 80.degree. C.,
145.degree. C. and 170.degree. C. in sequence, and microsphere
foaming functional EVA beads (0.5% to 3.5%) from SEKISUI (Japan)
are added; the temperature of a T-die mold is 180.degree. C.
[0059] Thickness setting: Gear pumps of the first raw material and
the second raw material are respectively adjusted to control the
thickness ratio of an unfoamed TPU layer to a TPU foaming layer to
1:3.
[0060] Through cooling by a chilling roller at a controlled speed
of 3.5 m/min to form a film, a TPU composite layer with a total
thickness of about 0.4 mm can be manufactured, wherein the unfoamed
TPU layer is 0.1 mm thick, and the TPU foaming layer is 0.3 mm
thick.
[0061] On a surface of the above TPU composite layer, a water-based
PU is processed using a PU dry laminating machine for surface
modification.
[0062] A 0.1 mm thick TPU hot-melt adhesive layer is disposed
between the TPU composite layer and a polyester melt-blown nonwoven
fabric, and the polyester melt-blown nonwoven fabric (weight: 300
g/m.sup.2) is laminated on the TPU composite layer through a roller
laminating machine under a condition that the roller surface
temperature is 120.degree. C., thus obtaining an
environmental-friendly TPU artificial leather.
Embodiment 2
[0063] Raw material: Thermoplastic polyurethane (TPU) is used as a
first raw material, a second raw material and a third raw material,
and processed by drying, to make the moisture content of TPU less
than 300 ppm.
[0064] Temperature setting conditions: The temperatures set for a
first raw material extruder are respectively 100.degree. C.,
150.degree. C. and 185.degree. C. in sequence; the temperatures set
for a second raw material extruder are respectively 80.degree. C.,
145.degree. C. and 170.degree. C. in sequence, and microsphere
foaming functional EVA beads (2% to 4%) from SEKISUI (Japan) are
added; the temperatures set for a third raw material extruder are
respectively 80.degree. C., 120.degree. C. and 160.degree. C. in
sequence; the temperature of a T-die mold is 180.degree. C.
[0065] Thickness setting: Gear pumps of the first raw material, the
second raw material and the third raw material are respectively
adjusted to control the thickness ratio of an unfoamed TPU layer, a
TPU foaming layer and a TPU hot-melt adhesive layer to
1:3.5:1.5.
[0066] Through cooling by a chilling roller at a controlled speed
of 2.8 m/min to form a film, a TPU composite laminate with a total
thickness of about 0.6 mm can be manufactured, wherein the unfoamed
TPU layer is 0.1 mm thick, the TPU foaming layer is 0.35 mm thick,
and the TPU hot-melt adhesive layer is 0.15 mm thick.
[0067] On a surface of the above TPU composite laminate, a
water-based PU is processed for surface modification.
[0068] A polyester needle-punched nonwoven fabric (thickness: 0.7
mm) is laminated on the TPU composite laminate through a roller
laminating machine under a condition that the roller surface
temperature is 120.degree. C., thus obtaining an
environmental-friendly TPU artificial leather.
Embodiment 3
[0069] Raw material: Thermoplastic polyurethane (TPU) is used as a
first raw material, a second raw material and a third raw material,
and processed by drying, to make the moisture content of TPU less
than 300 ppm.
[0070] Temperature setting conditions: The temperatures set for a
first raw material extruder are respectively 100.degree. C.,
150.degree. C. and 185.degree. C. in sequence; the temperatures set
for a second raw material extruder are respectively 80.degree. C.,
145.degree. C. and 170.degree. C. in sequence, and a supercritical
carbon dioxide with a condition of 200.degree. C./80 bar is
introduced through a pipeline; the temperatures set for a third raw
material extruder are respectively 80.degree. C., 120.degree. C.
and 160.degree. C. in sequence; the temperature of a T-die mold is
160.degree. C., and the pressure is controlled at 50 to 60 bar.
[0071] Thickness setting: Gear pumps of the first raw material, the
second raw material and the third raw material are respectively
adjusted to control the thickness ratio of an unfoamed TPU layer, a
TPU foaming layer and a TPU hot-melt adhesive layer to
1:3.5:1.5.
[0072] Through cooling by a chilling roller at a controlled speed
of 2.8 m/min to form a film, a TPU composite laminate with a total
thickness of about 0.6 mm can be manufactured, wherein the unfoamed
TPU layer is 0.1 mm thick, the TPU foaming layer is 0.35 mm thick,
and the TPU hot-melt adhesive layer is 0.15 mm thick.
[0073] On a surface of the above TPU composite laminate, a
water-based PU is processed using a PU dry laminating machine for
surface modification.
[0074] A polyester woven fabric (warp densities: 175 F/inch and
weft densities: 100 F/inch) is laminated on the TPU composite
laminate through a roller laminating machine under a condition that
the roller surface temperature is 120.degree. C., thus obtaining an
environmental-friendly TPU artificial leather.
Embodiment 4
[0075] Raw material: Thermoplastic polyurethane (TPU) is used as a
first raw material and a second raw material, and processed by
drying, to make the moisture content of TPU less than 300 ppm.
[0076] Temperature setting conditions: The temperatures set for a
first raw material extruder are respectively 100.degree. C.,
150.degree. C. and 185.degree. C. in sequence; the temperatures set
for a second raw material extruder are respectively 80.degree. C.,
145.degree. C. and 170.degree. C. in sequence, and microsphere
foaming functional EVA beads (0.5% to 3.5%) from SEKISUI (Japan)
are added; the temperature of a T-die mold is 180.degree. C.
[0077] Thickness setting: Gear pumps of the first raw material and
the second raw material are respectively adjusted to control the
thickness ratio of an unfoamed TPU layer to a TPU foaming layer to
1:3.
[0078] Through cooling by a chilling roller at a controlled speed
of 3.5 m/min to form a film, a TPU composite layer with a total
thickness of about 0.4 mm can be manufactured, wherein the unfoamed
TPU layer is 0.1 mm thick, and the TPU foaming layer is 0.3 mm
thick.
[0079] For the above TPU composite layer, a PU dry laminating
machine is used for surface modification of the PU surface.
[0080] A water-based paste is applied between the TPU composite
layer and a polyester woven fabric (warp densities: 175 F/inch and
weft densities: 100 F/inch), and the polyester woven fabric is
laminated on the TPU composite layer through a dry laminating
machine, thus obtaining an environmental-friendly TPU artificial
leather.
[0081] Moreover, the scope of the present application is not
intended to be limited to the particular embodiments of the
process, machine, manufacture, and composition of matter, means,
methods and steps described in the specification. As those skilled
in the art will readily appreciate form the present disclosure,
processes, machines, manufacture, compositions of matter, means,
methods, or steps, presently existing or later to be developed,
that perform substantially the same function or achieve
substantially the same result as the corresponding embodiments
described herein may be utilized according to the present
disclosure.
[0082] Accordingly, the appended claims are intended to include
within their scope such processes, machines, manufacture, and
compositions of matter, means, methods or steps. In addition, each
claim constitutes a separate embodiment, and the combination of
various claims and embodiments are within the scope of the
invention.
* * * * *