Process for making a polyurethane foam sheet and composites including the sheet
First Claim
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1. A composite material comprising the following adjacent layers:
- a. a plastics sheet, andb. a sheet of mechanical foam having a density of about 0.04 to about 0.40 g/cm3 obtained by mechanically frothing a nonionogenic aqueous polyurethane dispersion havingi. a solids content of more than about 45% by weight of polyurethane,ii. a viscosity of about 10 to about 70 seconds outflow time from a Ford cup with 4 mm nozzle andiii. a particle diameter of less than 1.0μ
.
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Abstract
A process is provided for making a polyurethane mechanical foam adapted to be used as an interlayer between a plastic surface layer and a textile, the process involving frothing a non-ionic aqueous dispersion free from emulsifying agents of a polyurethane having a particle size of less than 1 micron, said dispersion containing more than 45% by weight polyurethane and a thickening agent whereby its viscosity of the dispersion is from about 10 to about 70 seconds with a Ford Cup having a 4 mm orifice to form a foamable mixture, spreading the frothed dispersion into a foamed film, and drying the resulting product.
78 Citations
27 Claims
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1. A composite material comprising the following adjacent layers:
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a. a plastics sheet, and b. a sheet of mechanical foam having a density of about 0.04 to about 0.40 g/cm3 obtained by mechanically frothing a nonionogenic aqueous polyurethane dispersion having i. a solids content of more than about 45% by weight of polyurethane, ii. a viscosity of about 10 to about 70 seconds outflow time from a Ford cup with 4 mm nozzle and iii. a particle diameter of less than 1.0μ
. - View Dependent Claims (2, 12, 18, 22, 23, 24)
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3. A composite material comprising the following adjacent layers;
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a. a woven or knitted textile layer or nonwoven web of a fibrous material, b. a foam layer having a density of about 0.04 to about 0.40 g/cm3 obtained by mechanically frothing a nonionogenic aqueous polyurethane dispersion having i. a solids content of more than about 45% by weight of polyurethane, ii. a viscosity of about 10 to about 70 seconds outflow time from a Ford cup with 4 mm nozzle and iii. a particle diameter of less than 1.0μ
, andc. a plastics sheet. - View Dependent Claims (25, 26, 27)
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4. A composite material comprising the following adjacent layers:
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a. a foam layer having a density of about 0.04 to about 0.40 g/cm3 obtained by mechanically frothing a nonionic aqueous polyurethane dispersion having i. a solids content of more than about 45% by weight of polyurethane, ii. a viscosity of about 10 to about 70 seconds outflow time from a Ford cup with 4 mm nozzle and iii. a particle diameter of less than 1.0μ
, andb. a fibrous textile layer.
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5. A self-supporting polyurethane foam sheet having a density of about 0.04 to about 0.40 g/cm3 which has been produced by mechanically frothing a nonionic aqueous polyurethane dispersion having
i. a solids content of more than about 45% by weight of polyurethane, ii. a viscosity of about 10 to about 70 seconds outflow time from a Ford cup with 4 mm nozzle and iii. a particle diameter of less than 1.0 μ - .
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6. In a process for producing a composite material from
a. a homogeneous or microporous plastics sheet and b. a polyurethane foam, the improvement which comprises applying a homogeneous or microporous plastic sheet to a release support, spread-coating on the sheet a polyurethane foam having a density of about 0.04 to about 0.40 g/cm3, which has been produced by mechanically frothing a nonionogenic aqueous polyurethane dispersion having i. a solids content of more than about 45% by weight polyurethane, ii. a viscosity of about 10 to about 70 seconds outflow time from a Ford cup with 4 mm nozzle and iii. a particle diameter of less than 1.0 μ - ,
and drying the coating and thereafter removing the release support. - View Dependent Claims (10, 11, 15, 16)
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7. A process for producing a composite material from
a. a homogeneous or microporous plastics sheet and b. a polyurethane foam, which comprises spread coating on a release support a polyurethane foam having a density of about 0.04 to about 0.40 g/cm3 which has been produced by mechanically frothing a nonionogenic aqueous polyurethane dispersion having i. a solids content of more than about 45% by weight of polyurethane, ii. a viscosity of about 10 to about 70 seconds outflow time from a Ford cup with 4 mm nozzle and iii. a particle diameter of less than 1.0 μ - ,
applying and lightly pressing a solid, self-supporting homogeneous or microporous plastics sheet to the still liquid foam, drying and removing the release support.
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8. A process for producing a composite material from
a. a homogeneous or microporous plastics sheet and b. a polyurethane foam, which comprises spread coating on a release support a polyurethane foam having a density of about 0.04 to about 0.40 g/cm3, which has been produced by mechanically frothing a nonionogenic aqueous polyurethane dispersion having i. a solids content of more than about 45% by weight of polyurethane, ii. a viscosity of about 10 to about 70 seconds outflow time from a Ford cup with 4 mm nozzle and iii. a particle diameter of less than 1.0 μ - ,
drying the coating, applying a liquid plastics coating compound on the coating, solidifying the liquid plastics coating compound on the layer of foam to produce a homogeneous or microporous plastics sheet and removing the release support.
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9. A process for producing a composite material from
a. a plastics sheet, b. a polyurethane foam and c. a textile material which comprises applying a homogeneous or microporous plastics sheet to a release support, spread coating on the sheet a polyurethane foam having a density of from about 0.04 to about 0.40 g/cm3, which has been produced by mechanically frothing a nonionogenic aqueous polyurethane dispersion having i. a solids content of more than about 45% by weight of polyurethane, ii. a viscosity of about 10 to about 70 seconds outflow time from a Ford cup with 4 mm nozzle and iii. a particle diameter of less than 1.0 μ - ,
applying a textile material to the foam while the foam is still liquid, drying and removing the release support. - View Dependent Claims (17)
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13. A process for producing a composite material consisting of a polyurethane foam and a woven or knitted textile material or consisting of a polyurethane foam and a non-woven web, which comprises spreadcoating a polyurethane foam having a density of from about 0.04 to about 0.40 g/cm3 which has been produced by mechanically frothing a nonionogenic aqueous polyurethane dispersion having
i. a solids content of more than about 45% by weight of polyurethane, ii. a viscosity of about 10 to about 70 seconds outflow time from a Ford cup with 4 mm nozzle and iii. a particle diameter of less than 1.0 μ - ,
on a release support and then laminating the coating to the textile material or to the non-woven web, drying the laminate and removing the release support.
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14. A process for producing a self-supporting polyurethane foam sheet which comprises preparing a spread-coatable polyurethane foam from a nonionic aqueous polyurethane dispersion having
a. a solids content of more than 45% by weight of polyurethane, b. a viscosity of 10-70 seconds outflow time from a Ford cup with 4 mm nozzle, c. a particle diameter of less than 1.0μ - , and
d. 0.1-10% by weight of thickener, based on the polyurethane solids content by the churning process, applying the foam to a release support, drying, and removing the release support.
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- 19. A process for making a polyurethane foam sheet adapted to be laminated with a textile which comprises mechanically frothing a nonionic aqueous dispersion free from emulsifying agents of a polyurethane having a particle size of less than 1 micron, said dispersion containing more than 45 % by weight polyurethane and a thickening agent whereby the viscosity of the dispersion is from about 10 to about 70 seconds with a Ford cup having a 4 mm orifice to form a foamable mixture stirring air into said mixture, spreading the frothed dispersion into a film and drying the resulting product.
Specification