THERMOFUSIBLE SHEET MATERIAL

• US 20180057983A1
• Filed: 04/04/2016
• Published: 03/01/2018
• Est. Priority Date: 04/22/2015
• Status: Active Grant

• Current Assignee: Carl Freudenberg KG
• Original Assignee: Carl Freudenberg KG
• Inventors: Traser, Steffen, Kremser, Steffen
• Granted Patent: US 10,472,751 B2
• Time in Patent Office: Days
• CPC Class Codes: A41D 27/06 Stiffening-pieces
• CPC Class Codes: A41D 31/00 Materials specially adapted for outerwear
• CPC Class Codes: D04H 1/488 in combination with bonding agents
• CPC Class Codes: D04H 1/49 entanglement by fluid jet in combination with another consolidation means
• CPC Class Codes: D04H 1/66 at spaced points or locations D04H1/68 takes precedence
• CPC Class Codes: D04H 1/68 the bonding agent being applied in the form of foam
• CPC Class Codes: D06M 17/10 Polyurethanes polyurea
• CPC Class Codes: D06N 2209/123 Breathable
• CPC Class Codes: D06N 2211/10 Clothing
• CPC Class Codes: D06N 3/0043 characterised by their foraminous structure; Characteristics of the foamed layer or of cellular layers foraminous structure obtained by stretching D06N3/0029
• CPC Class Codes: D06N 3/0047 obtained by incorporating air, i.e. froth
• CPC Class Codes: D06N 3/005 obtained by blowing or swelling agent
• CPC Class Codes: D06N 3/0068 Polymeric granules, particles or powder, e.g. core-shell particles, microcapsules
• CPC Class Codes: D06N 3/146 characterised by the macromolecular diols used
• CPC Class Codes: D06N 3/183 the layers are one next to the other

Abstract

A thermofusible sheet material which can be used as a fusible interlining in the textile industry, has a carrier layer made from a textile material to which a polyurethane foam coating is applied. The polyurethane foam has a pore structure in which more than 50% of the pores have a diameter, measured according to DIN ASTM E 1294, which is in the range of 5 to 30 μm.

Claims

1. A thermally fusible fabric, configured for a fusible interlining in the textile industry, the fabric comprising:

a substrate comprising a textile material to which a coating of polyurethane foam is applied,

wherein the polyurethane foam comprises a thermoplastic polyurethane comprising, in reacted form,

bifunctional polyisocyanate (A) having an isocyanate content of from 5 to 65 wt. %,

polyol (B) comprising a polyester polyol, polyether polyol, polycaprolactone polyol, polycarbonate polyol, copolymer of polycaprolactone polyol, polytetrahydrofuran, or a mixture of two or more of any of these, and optionally,

a chain extender (C),

wherein the polyurethane foam has a pore structure in which more than 50% of the pores have a diameter, measured according to DIN ASTM E 1294, which is in a range of from 5 to 30 μ

m.

2. The fabric of claim 1, wherein the polyurethane foam has an average pore diameter in the range of from 5 to 30 μ

m.

3. The fabric of claim 1, comprising a proportion of foaming agent in the polyurethane foam of less than 1.5 wt. %, based on active, foaming constituents thereof.

4. The fabric of claim 1, wherein an average depth to which the polyurethane foam penetrates the substrate is less than 20 μ

m.

5. The fabric of claim 1, wherein the polyurethane foam has a degree of air permeability of more than 150 L/m²/s at 100 Pa, measured according to DIN EN ISO 9237.

6. The fabric of claim 1, wherein the polyurethane foam has an average layer thickness in a range of from 5 to 400 μ

m.

7. The fabric of claim 1, wherein the polyol (B) comprises polyester polyol and/or polyether polyol.

8. The fabric of claim 1, wherein the polyurethane has a degree of crosslinking of less than 0.1.

9. The fabric of claim 1, wherein the polyurethane foam is either planar or present as a pattern of dots.

10. The fabric of claim 1, further comprising:

a hot-melt adhesive, applied to the polyurethane foam and/or a side of the substrate facing away from the polyurethane foam.

11. The fabric of claim 1, wherein the polyurethane foam is formed as a bottom layer of a double-layer glue structure, on which a hot-melt adhesive top layer is arranged.

12. The fabric of claim 10, wherein the polyurethane foam and the hot-melt adhesive are formed as double dots, the polyurethane foam being designed as a pattern of bottom dots and the hot-melt adhesive being designed as a pattern of top dots.

16. The fabric of claim 1, wherein the thermoplastic polyurethane consists essentially of, in reacted form,

at least one of the bifunctional, preferably aliphatic, cycloaliphatic or aromatic polyisocyanate (A) having an isocyanate content of from 5 to 65 wt. %,

at least one of the polyol (B) selected from the group consisting of polyester polyol, polyether polyol, polycaprolactone polyol, polycarbonate polyol, copolymer of polycaprolactone polyol, polytetrahydrofuran and mixtures thereof, and

optionally, at least one of the chain extender (C).

17. The fabric of claim 1, wherein the polyisocyanate (A) is aliphatic.

18. The fabric of claim 1, wherein the polyisocyanate (A) is cycloaliphatic.

19. The fabric of claim 1, wherein the polyisocyanate (A) is aromatic.

20. The fabric of claim 1, wherein thermoplastic polyurethane comprises, in reacted form, the chain extender (C).

13. A method for producing a thermally fusible fabric, the method comprising:

a) providing a substrate,

b) foaming a polyurethane dispersion comprising a thermoplastic polyurethane comprising, as a transformation product,

a bifunctional polyisocyanate (A) having an isocyanate content of from 5 to 65 wt. %;

a polyol (B) comprising a polyester polyol, polyether polyol, polycaprolactone polyol, polycarbonate polyol, copolymer of polycaprolactone polyol, polytetrahydrofuran, or a mixture of two or more of any of these; and

optionally,

a chain extender (C), thereby forming a polyurethane foam having a pore structure in which more than 50% of the pores have a diameter, measured according to DIN ASTM E 1294, in a range of from 5 to 30 μ

m;

c) applying the polyurethane foam to one or more surface regions of the substrate, thereby obtaining a treated substrate; and

d) heat-treating the treated substrate to dry and simultaneously bond the polyurethane foam to the substrate, forming a coating.

14. The method of claim 13, wherein the polyurethane foam forms

a planar coating having a foam density of from 1 to 450 g/L

and/or

a pattern of dots having a foam density of from 1 to 700 g/L.

15. The method of claim 13 wherein a dispersion for the thermoplastic polyurethane comprises a crosslinking agent in an amount of less than 2 wt. %.