CN107284309B - 积层复合材料及其制造方法 - Google Patents

积层复合材料及其制造方法 Download PDF

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CN107284309B
CN107284309B CN201610786129.9A CN201610786129A CN107284309B CN 107284309 B CN107284309 B CN 107284309B CN 201610786129 A CN201610786129 A CN 201610786129A CN 107284309 B CN107284309 B CN 107284309B
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layer
polyurethane
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dimensional mesh
polyether
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CN107284309A (zh
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冯崇智
罗国立
廖盛宏
王格峰
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San Fang Chemical Industry Co Ltd
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    • B32B27/00—Layered products comprising a layer of synthetic resin
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
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    • B32B5/26—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 also being fibrous or filamentary
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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    • B29L2031/58—Upholstery or cushions, e.g. vehicle upholstery or interior padding
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    • B32—LAYERED PRODUCTS
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    • B32B2250/00—Layers arrangement
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    • B32B2255/00—Coating on the layer surface
    • B32B2255/12—Coating on the layer surface on paper layer
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/28—Multiple coating on one surface
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    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/18—Fabrics, textiles
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    • B32B2307/724—Permeability to gases, adsorption
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Abstract

本发明关于一种积层复合材料及其制造方法。该积层复合材料包括立体网布、粘着层及树脂表面层。该立体网布具有复数根排列的纤维，以形成透气结构。该粘着层位于该立体网布的一表面上。该树脂表面层位于粘着层上，其中该树脂表面层具有至少一个聚氨酯溶液固化而成的层。

Description

积层复合材料及其制造方法
【技术领域】
本发明涉及一种积层复合材料及其制造方法，特别是涉及一种具有立体网布的积层复合材料及其制造方法。
【背景技术】
现有车用座椅所使用的包覆材料通常必须包括泡棉，且其制作方法如下。首先，提供离型纸。接着，于该离型纸上涂布表层，且烘干该表层。接着。于该表层上形成粘着层。接着，于该粘着层上附着织布层，通常该织布层才材质为100％PET。接着，离型后，即可得到该包覆材。然而，此阶段的包覆材不能直接用以包覆坚硬的座椅本体，其必须再贴合一泡棉层于该PET织布层上才可使用。因此，在实际应用时，该泡棉层位于该包覆材与座椅本体之间，以提供缓冲，而增加使用者的舒适性。然而，上述现有制作方法较为复杂，且层数较多，导致制造成本较高。
因此，有必要提供一种创新的且富有进步性的积层复合材料及其制造方法，以解决上述问题。
【发明内容】
本发明提供一种积层复合材料，其包括立体网布、粘着层及树脂表面层。该立体网布具有复数根排列的纤维，以形成透气结构。该粘着层位于该立体网布的一表面上。该树脂表面层位于粘着层上，其中该树脂表面层具有至少一个聚氨酯(Polyurethane,PU)溶液固化而成的层。
本发明另提供一种积层复合材料的制造方法，包括以下步骤：(a)提供离型纸；(b)形成树脂表面层于该离型纸上，其中该树脂表面层具有至少一层聚氨酯(Polyurethane,PU)溶液；(c)形成粘着层于该树脂表面层上；及(d)附着立体网布于该粘着层上，其中该立体网布具有复数根排列的纤维，以形成透气结构。
【附图说明】
图1至图6显示本发明积层复合材料的制造方法的一实施例的制程步骤示意图。
图7显示本发明积层复合材料的另一实施例的剖视示意图。
图8显示本发明积层复合材料的另一实施例的剖视示意图。
【附图标记说明】
1 积层复合材料
1a 积层复合材料
1b 积层复合材料
10 离型纸
12 第一层
14 第二层
16 第三层
18 树脂表面层
18a 树脂表面层
20 粘着层
22 立体网布
22a 立体网布
221 顶层
222 底层
223 纤维
【具体实施方式】
参考图1至图6，显示本发明积层复合材料的制造方法的一实施例的制程步骤示意图。参考图1，提供离型纸10。本实施例为连续式生产，因此，该离型纸10为持续地进给/发送。
接着，形成树脂表面层18(图4)于该离型纸10上，其中该树脂表面层18具有至少一层聚氨酯(Polyurethane, PU)溶液固化而成的层。此外，在本实施例中，该树脂表面层18(图4)系持续形成，其形成方式如下所述。
参考图2，形成(例如：涂布)聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液于该离型纸10上。在本实施例中，该聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液的固含量为10重量％至20重量％，优选为12重量％至13重量％，且粘度为2000cps至3000cps，优选为2500cps。此外，该聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液持续地形成(例如：涂布)于该离型纸10上，其涂布量为342.5g/m2。在其他实施例中，可预先添加脱泡剂于该聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液中，以增加该聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液的均匀性(Homogeneous Status)。
接着，在约100℃的环境中烘干该聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液约90秒，以固化而形成第一层12。在本实施例中，该第一层12的厚度为0.01mm至0.04mm，优选为0.025mm。
参考图3，形成(例如：涂布)聚醚型聚氨酯(Polyether-polyurethane)溶液于该第一层12上。在本实施例中，该聚醚型聚氨酯(Polyether-polyurethane)溶液的固含量为10重量％至20重量％，优选为12重量％至13重量％，且粘度为2000cps至3000cps，优选为2500cps。在本实施例中，该聚醚型聚氨酯(Polyether-polyurethane)溶液的固含量及粘度与该聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液相同。然而，可以理解的是，该聚醚型聚氨酯(Polyether-polyurethane)溶液的固含量及粘度可以与该聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液不同。
此外，该聚醚型聚氨酯(Polyether-polyurethane)溶液持续地形成(例如：涂布)于该第一层12上，其涂布量为205.5g/m2。在本实施例中，该聚醚型聚氨酯(Polyether-polyurethane)溶液的涂布量小于该聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液的涂布量。
在其他实施例中，可预先添加脱泡剂于该聚醚型聚氨酯(Polyether-polyurethane)溶液中，以增加该聚醚型聚氨酯(Polyether-polyurethane)溶液的均匀性(Homogeneous Status)。
接着，在约100℃的环境中烘干该聚醚型聚氨酯(Polyether-polyurethane)溶液约90秒，以固化而形成第二层14。在本实施例中，该第二层14的厚度为0.01mm至0.04mm，优选为0.025mm。在本实施例中，该第二层14的厚度与该第一层12的厚度相同。然而，可以理解的是，该第二层14的厚度也可以不同于与该第一层12的厚度。
参考图4，形成(例如：涂布)一聚氨酯(Polyurethane,PU)溶液于该第二层14上。在本实施例中，该聚氨酯(Polyurethane,PU)溶液的固含量为80重量％至95重量％，优选为约90重量％，且粘度为2000cps至10000cps，优选为6000cps。在本实施例中，该聚氨酯(Polyurethane,PU)溶液的固含量为该聚醚型聚氨酯(Polyether-polyurethane)溶液的固含量的4倍至9.5倍。
此外，该聚氨酯(Polyurethane,PU)溶液持续地形成(例如：涂布)于该第二层14上，其涂布量为548.0g/m2。在本实施例中，该聚氨酯(Polyurethane,PU)溶液的涂布量大于该聚醚型聚氨酯(Polyether-polyurethane)溶液及该聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液的涂布量。
接着，在约150℃的环境中烘干该聚氨酯(Polyurethane,PU)溶液约3分钟，以固化而形成第三层16。此时，该第一层12、该第二层14及该第三层16即形成该树脂表面层18。在本实施例中，该第三层16的厚度为0.3mm至0.5mm，优选为0.35至0.4mm。在本实施例中，该第三层16的厚度为该第二层14的厚度的50倍至13倍。
参考图5，形成(例如：涂布)粘着层20于该树脂表面层18的第三层16上。在本实施例中，该粘着层20的材质为聚氨酯(PU)接着剂、聚氯乙烯(PVC)接着剂、乙烯/醋酸乙烯酯共聚物(EVA)接着剂、热熔胶或其混合物，且该粘着层20的固含量大于10重量％。
该粘着层20持续地形成(例如：涂布)于该树脂表面层18的第三层16上，其涂布量为205.5g/m2。在本实施例中，该粘着层20的涂布量大约等于该聚醚型聚氨酯(Polyether-polyurethane)溶液的涂布量。
接着，附着立体网布22于该粘着层20上，其中该立体网布22具有复数根排列的纤维223，以形成透气结构。在本实施例中，该立体网布22持续地附着于该粘着层20上，以形成连续式生产。在本实施例中，该立体网布22的厚度为2.0mm至20mm。
在本实施例中，该立体网布22为三明治网布，其还具有顶层221及底层222，所述纤维223夹设于该顶层221及该底层222之间，且该立体网布22的顶层221附着至该粘着层20。在一实施例中，该顶层221及该底层222为编织层，且所述纤维223的一端接触该顶层221，所述纤维223的另一端接触该底层222。在该立体网布22中，所述纤维223排列或编织成特定图案，在一实施例中，每一所述纤维223的一端接触该顶层221，且每一所述纤维223的另一端接触该底层222，而彼此平行或略微交错。如图5所示，所述纤维223之间为透气通道，所述纤维223承受垂直方向的施力，且提供垂直方向的缓冲。
参考图6，移除该离型纸10，以制得积层复合材料1。在本实施例中，该离型纸10持续地与该树脂表面层18分离，且可持续地卷收该积层复合材料1。在本实施例中，该积层复合材料1即可直接做为包覆材，用以包覆例如车用座椅或其他坚硬的本体。换言之，在本实施例中，不须再贴附织布层及泡棉。与现有技术相比，本实施例的制作方法较为简化，且层数较少，因此制造成本较低。
请再参考图6，显示本发明积层复合材料的一实施例的剖视示意图。该积层复合材料1包括立体网布22、粘着层20及树脂表面层18。该立体网布22具有复数根排列的纤维223，以形成透气结构。在本实施例中，该立体网布22的厚度为2.0mm至20mm。在本实施例中，该立体网布22为三明治网布，其还具有顶层221及底层222，所述纤维223夹设于该顶层221及该底层222之间。在一实施例中，该顶层221及该底层222为编织层，且所述纤维223的一端接触该顶层221，所述纤维223的另一端接触该底层222。在该立体网布22中，所述纤维223排列或编织成特定图案，在一实施例中，每一所述纤维223的一端接触该顶层221，且每一所述纤维223的另一端接触该底层222，而彼此平行或略微交错。如图6所示，所述纤维223之间为透气通道，所述纤维223承受垂直方向的施力，且提供垂直方向的缓冲。
该粘着层20位于该立体网布22的顶层221的一表面上。在本实施例中，该粘着层20的材质为聚氨酯(PU)接着剂、聚氯乙烯(PVC)接着剂、乙烯/醋酸乙烯酯共聚物(EVA)接着剂、热熔胶或其混合物。
该树脂表面层18位于该粘着层20上，其中该树脂表面层18具有至少一聚氨酯(Polyurethane,PU)溶液固化而成的层。亦即，该树脂表面层18利用该粘着层20而粘附于该立体网布22上。在本实施例中，该树脂表面层18包括第一层12、第二层14及第三层16。该第三层16位于该粘着层20上，且该第三层16由聚氨酯(Polyurethane,PU)溶液所固化而成。在本实施例中，该聚氨酯(Polyurethane,PU)溶液的固含量为80重量％至95重量％，优选为约90重量％，且粘度为2000cps至10000cps，优选为6000cps。在本实施例中，该第三层16的厚度为0.3mm至0.5mm，优选为0.35至0.4mm。该第三层16为该树脂表面层18的主体部分。
该第二层14位于该第三层16上，且该第二层14由聚醚型聚氨酯(Polyether-polyurethane)溶液所固化而成。在本实施例中，该聚醚型聚氨酯(Polyether-polyurethane)溶液的固含量为10重量％至20重量％，优选为12重量％至13重量％，且粘度为2000cps至3000cps，优选为2500cps。在本实施例中，该第二层14的厚度为0.01mm至0.04mm，优选为0.025mm。在本实施例中，该第三层16的厚度为该第二层14的厚度的50倍至13倍。该第二层14用于粘着该第一层12及该第三层16。
该第一层12位于该第二14层上，且该第一层12由聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液所固化而成。在本实施例中，该聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液的固含量为10重量％至20重量％，优选为12重量％至13重量％，且粘度为2000cps至3000cps，优选为2500cps。在本实施例中，该第一层12的厚度为0.01mm至0.04mm，优选为0.025mm。在本实施例中，该第二层14的厚度与该第一层12的厚度相同。然而，可以理解的是，该第二层14的厚度也可以不同于与该第一层12的厚度。该第一层12的耐磨性较高，其为抗磨层，用以保护该积层复合材料1。
参考图7，显示本发明积层复合材料的另一实施例的剖视示意图。本实施例的积层复合材料1a与图6所示的积层复合材料1大致相同，其不同处如下所述。本实施例的积层复合材料1a的立体网布22a仅具有所述纤维223，而没有该顶层221及该底层222。因此，在本实施例中，该粘着层20直接位于该立体网布22的所述纤维223的一表面上。
参考图8，显示本发明积层复合材料的另一实施例的剖视示意图。本实施例的积层复合材料1b与图6所示的积层复合材料1大致相同，其不同处如下所述。本实施例的积层复合材料1b的树脂表面层18a为单层结构，而非三层结构。可以理解的是，该树脂表面层18a也可以是双层结构。
上述实施例仅为说明本发明的原理及其功效，并非限制本发明，因此本领域技术人员对上述实施例进行修改及变化仍不脱本发明的精神。本发明的权利范围应如所附的权利要求书范围所列。

Claims (6)

1.一种积层复合材料，包括：
立体网布，其具有复数根排列的纤维，以形成透气结构；
粘着层，位于该立体网布的一表面上；及
树脂表面层，位于粘着层上，其中该树脂表面层包括第一层、第二层及第三层，该第一层由聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液所固化而成，该第二层由聚醚型聚氨酯(Polyether-polyurethane)溶液所固化而成，该第三层由聚氨酯(Polyurethane,PU)溶液所固化而成，该第三层位于该粘着层上，该第二层位于该第三层上，该第一层位于该第二层上，其中该第一层的聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液的固含量为10重量％至20重量％，该第二层的聚醚型聚氨酯(Polyether-polyurethane)溶液的固含量为10重量％至20重量％，该第三层的聚氨酯(Polyurethane,PU)溶液的固含量为80重量％至95重量％，其中该第三层的厚度为该第二层的厚度的50倍至13倍。
2.如权利要求1所述的积层复合材料，其中该立体网布还具有顶层及底层，所述纤维夹设于该顶层及该底层之间，该粘着层位于该立体网布的顶层上。
3.如权利要求2所述的积层复合材料，其中所述纤维的一端接触该顶层，另一端接触该底层。
4.一种积层复合材料的制造方法，包括以下步骤：
(a)提供离型纸；
(b)形成树脂表面层于该离型纸上，其中该步骤(b)包括：
(b1)涂布聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液于该离型纸上，其中该聚碳酸酯型聚氨酯溶液的固含量为10重量％至20重量％；
(b2)烘干该聚碳酸酯型聚氨酯(Polycarbonate-polyurethane)溶液以形成第一层；
(b3)涂布聚醚型聚氨酯(Polyether-polyurethane)溶液于该第一层上，
其中该聚醚型聚氨酯溶液的固含量为10重量％至20重量％；
(b4)烘干该聚醚型聚氨酯(Polyether-polyurethane)溶液以形成第二层；
(b5)涂布聚氨酯(Polyurethane,PU)溶液于该第二层上，其中该聚氨酯溶液的固含量为80重量％至95重量％；及
(b6)烘干该聚氨酯(Polyurethane,PU)溶液以形成第三层，其中该第一层、该第二层及该第三层形成该树脂表面层，其中该第三层的厚度为该第二层的厚度的50倍至13倍；
(c)形成粘着层于该树脂表面层上；及
(d)附着立体网布于该粘着层上，其中该立体网布具有复数根排列的纤维，以形成透气结构。
5.如权利要求4所述的制造方法，其中该步骤(a)中持续进给该离型纸，该步骤(b)持续形成该树脂表面层，该步骤(c)持续形成该粘着层，该步骤(d)持续附着该立体网布，以形成连续式生产。
6.如权利要求4所述的制造方法，其中该步骤(d)中，该立体网布还具有顶层及底层，所述纤维夹设于该顶层及该底层之间，该立体网布的顶层附着至该粘着层。
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