Composite materials and processes for their production

Claim 2

A process for the production of a composite material of homogeneous or microporous plastic sheet and a polyurethane foam wherein said process comprises: a. applying a film of liquid plastics coating compound to a transfer support where it is allowed to solidify resulting in a homogeneous or microporous plastic sheet; b. spread coating on said plastic sheet a polyurethane ionomer latex foam having a gross density of 0.04 to 0.40 g/cm 3 produced by a churning process from an ionomeric polyurethane dispersion having i. a solids content of 45 to 62% by weight of polyurethane, ii. a viscosity of 10 to 70 seconds outflow time from a Ford measuring cup with a 4 mm nozzle, iii. a particle diameter of 0.05 to 1.0 μ, iv. an ionic group content of 2 to 40 milliequivalents per 100 g of polyurethane solids of ions selected from the group consisting of ##STR2## wherein R is hydrogen or a lower alkyl group, and v. a tensile strength of at least 40 kg/cm 2 when dried to a homogeneous polyurethane foil, and which contains i. 1-10% by weight of a foam stabilizing agent, based on the weight of solid polyurethane ii. 0-100% by weight of inorganic fillers based on the weight of solid polyurethane, iii. 0-30% by weight of crosslinking agent based on the weight of solid polyurethane, and iv. 0.1 to 10% by weight of thickener based on the weight of solid polyurethane; and c. thereafter removing said transfer support.

Claim 3

A process for the production of a composite material consisting of a homogeneous or microporous plastic sheet and a polyurethane foam wherein said process comprises: a. spreading on a transfer support a coating of an ionomer latex foam having a gross density of 0.04 to 0.40 g/cm 3 produced by a churning process from an ionomeric polyurethane dispersion having i. a solids content of 45 to 62% by weight of polyurethane, ii. a viscosity of 10 to 70 seconds outflow time from a Ford measuring cup with a 4 mm nozzle, iii. a particle diameter of 0.05 to 10 μ, iv. an ionic group content of 2 to 40 milliequivalents per 100 g of polyurethane solids of ions selected from the group consisting of ##STR3## wherein R is hydrogen or a lower alkyl group, and v. a tensile strength of at least 40 kg/cm 2 when dried to a homogeneous polyurethane foil, and which contains i. 1-10% by weight of a foam stabilizing agent, based on the weight of solid polyurethane, ii. 0-100% by weight of inorganic fillers based on the weight of solid polyurethane, iii. 0-30% by weight of crosslinking agent based on the weight of solid polyurethane, and iv. 0.1 to 10% by weight of thickener based on the weight of solid polyurethane; b. while said foam is still liquid, applying thereto, using light pressure, a self-supporting homogeneous or microporous plastic sheet; c. allowing the composite material to dry; and d. removing said transfer support.

Claim 4

A process for the production of a composite material consisting of a homogeneous or microporous plastic sheet and a polyurethane foam wherein said process comprises: a. spreading on a transfer support a coating of an ionomer latex foam having a gross density of 0.04 to 0.40 g/cm 3 produced by a churning process from an ionomeric polyurethane dispersion having i. a solids content of 45 to 62% by weight of polyurethane, ii. a viscosity of 10 to 70 seconds outflow time from a Ford measuring cup with a 4 mm nozzle, iii. a particle diameter of 0.05 to 10 μ, iv. an ionic group content of 2 to 40 milliequivalents per 100 g of polyurethane solids of ions selected from the group consisting of ##STR3## wherein R is hydrogen or a lower alkyl group, and v. a tensile strength of at least 40 kg/cm 2 when dried to a homogeneous polyurethane foil, and which contains i. 1-10% by weight of a foam stabilizing agent, based on the weight of solid polyurethane, ii. 0-100% by weight of inorganic fillers based on the weight of solid polyurethane, iii. 0-30% by weight of crosslinking agent based on the weight of solid polyurethane, and iv. 0.1 to 10% by weight of thickener based on the weight of solid polyurethane; b. while said foam is still liquid, applying thereto, using light pressure, a self-supporting homogeneous or microporous plastic sheet; c. allowing the composite material to dry; and d. removing said transfer support.

Claim 5

A process for the production of a composite material of a homogeneous or microporous plastic sheet and a polyurethane foam comprising: a. spread coating onto a transfer support a polyurethane ionomer latex foam having a gross density of 0.04 to 0.40 g/cm 3 produced by a churning process from an ionomeric polyurethane dispersion having i. a solids content of 45 to 62% by weight of polyurethane, ii. a viscosity of 10 to 70 seconds outflow time from a Ford measuring cup with a 4 mm nozzle, iii. a particle diameter of 0.05 to 1.0 μ, iv. an ionic group content of 2 to 40 milliequivalents per 100 g of polyurethane solids of ions selected from the group consisting of ##STR4## wherein R is hydrogen or a lower alkyl group, and v. a tensile strength of at least 40 kg/cm 2 when dried to a homogeneous polyurethane foil, and which contains i. 1-10% by weight of a foam stabilizing agent, based on the weight of solid polyurethane, ii. 0-100% by weight of inorganic fillers based on the weight of solid polyurethane, iii. 0-30% by weight of crosslinking agent based on the weight of solid polyurethane, and iv. 0.1 to 10% by weight of thickener based on the weight of solid polyurethane, b. allowing said foam to dry; c. applying to the dried foam a liquid plastic coating compound; d. allowing the plastic coating to dry and form a homogeneous or microporous plastic sheet; and e. then removing said transfer support.

Claim 6

A process for the production of a composite material of a homogeneous or microporous plastic sheet and a polyurethane foam comprising: a. spread coating onto a transfer support a polyurethane ionomer latex foam having a gross density of 0.04 to 0.40 g/cm 3 produced by a churning process from an ionomeric polyurethane dispersion having i. a solids content of 45 to 62% by weight of polyurethane, ii. a viscosity of 10 to 70 seconds outflow time from a Ford measuring cup with a 4 mm nozzle, iii. a particle diameter of 0.05 to 1.0 μ, iv. an ionic group content of 2 to 40 milliequivalents per 100 g of polyurethane solids of ions selected from the group consisting of ##STR4## wherein R is hydrogen or a lower alkyl group, and v. a tensile strength of at least 40 kg/cm 2 when dried to a homogeneous polyurethane foil, and which contains i. 1-10% by weight of a foam stabilizing agent, based on the weight of solid polyurethane, ii. 0-100% by weight of inorganic fillers based on the weight of solid polyurethane, iii. 0-30% by weight of crosslinking agent based on the weight of solid polyurethane, and iv. 0.1 to 10% by weight of thickener based on the weight of solid polyurethane, b. allowing said foam to dry; c. applying to the dried foam a liquid plastic coating compound; d. allowing the plastic coating to dry and form a homogeneous or microporous plastic sheet; and e. then removing said transfer support.

Claim 7

The process of claim 1 wherein a textile material or fleece is placed on the liquid foam, the foam is then allowed to dry and the transfer support is removed.

Claim 8

The process of claim 1 wherein the plastic sheet is a microporous or homogeneous polyurethane sheet.

Claim 9

The process of claim 1 wherein the plastic sheet is a polyvinyl chloride sheet.

Claim 10

A process for the production of a self-supporting polyurethane foam sheet comprising spread coating a polyurethane ionomer latex foam on a transfer support wherein the polyurethane ionomer is an ionomeric polyurethane dispersion comprising which has a. a solids content of 45-62% by weight of polyurethane b. a viscosity of 10 to 70 seconds outflow time from a Ford measuring cup with 4 mm nozzle. c. a particle diameter of 0.05 to 1.0 μ d. an ionic group content of ##STR5## of 3-40 milliequivalents per 100 g of polyurethane solid content, fillers and which dispersion in addition contains i. 1-10% by weight of foam stabilizing agent, based on the polyurethane solid content. ii. 0-100% by weight of inorganic fillers, based on the polyurethane solid content, iii. 0-30% by weight of cross linking agent, based on the polyurethane solid content, iii. 0.1 to 10% by weight of thickeners, based on the polyurethane solid content.

Claim 11

A process for the production of a self-supporting polyurethane foam sheet comprising spread coating a polyurethane ionomer latex foam on a transfer support wherein the polyurethane ionomer is an ionomeric polyurethane dispersion comprising which has a. a solids content of 45-62% by weight of polyurethane b. a viscosity of 10 to 70 seconds outflow time from a Ford measuring cup with 4 mm nozzle. c. a particle diameter of 0.05 to 1.0 μ d. an ionic group content of ##STR5## of 3-40 milliequivalents per 100 g of polyurethane solid content, fillers and which dispersion in addition contains i. 1-10% by weight of foam stabilizing agent, based on the polyurethane solid content. ii. 0-100% by weight of inorganic fillers, based on the polyurethane solid content, iii. 0-30% by weight of cross linking agent, based on the polyurethane solid content, iii. 0.1 to 10% by weight of thickeners, based on the polyurethane solid content.

Claim 12

The process of claim 7 wherein the ionomeric polyurethane dispersion has a. 48 to 55% by weight of polyurethane b. a viscosity of 20 to 50 seconds outflow time from a Ford measuring cup with a 4 mm nozzle, c. a particle diameter of 0.07 to 0.30 μ and contains i. 3-8% by weight of foam stabilizing agent, based on polyurethane solid content, ii. 15-60% by weight, of inorganic fillers, based on the polyurethane solid content, iii. 5-12% by weight of cross-linking agent, based on the polyurethane solid content, iii. 10 to 5.0% by weight, of thickeners, based on the polyurethane solid content.

Claim 13

A process for the production of a composite material consisting of a plastic sheet, a polyurethane foam and a woven or knitted textile material or non-woven fleece comprising: a. applying to a layer of plastic sheet a polyurethane ionomer latex foam having a gross density of 0.04 to 0.40 g/cm 3 produced by a churning process from an ionomeric polyurethane dispersion having i. a solids content of 45 to 62% by weight of polyurethane, ii. a viscosity of 10 to 70 seconds outflow time from a Ford measuring cup with a 4 mm nozzle, iii. a particle diameter of 0.05 to 1.0 μ, iv. an ionic group content of 2 to 40 milliequivalents per 100 g of polyurethane solids of ions selected from the group consisting of ##STR6## wherein R is hydrogen or a lower alkyl group and v. a tensile strength of at least 40 kg/cm 2 when dried to a homogeneous polyurethane foil, and which contains i. 1-10% by weight of a foam stabilizing agent, based on the weight of solid polyurethane, ii. 0-100% by weight of inorganic fillers based on the weight of solid polyurethane, iii. 0-30% by weight of crosslinking agent based on the weight of solid polyurethane, and iv. 0.1 to 10% by weight of thickener based on the weight of solid polyurethane; b. carefully placing with light pressure on the foam while still wet, a woven or knitted textile material or non-woven fleece; and c. solidifying the composite material by drying.

Claim 14

A process for the production of a composite material consisting of a plastic sheet, a polyurethane foam and a woven or knitted textile material or non-woven fleece comprising: a. applying to a layer of plastic sheet a polyurethane ionomer latex foam having a gross density of 0.04 to 0.40 g/cm 3 produced by a churning process from an ionomeric polyurethane dispersion having i. a solids content of 45 to 62% by weight of polyurethane, ii. a viscosity of 10 to 70 seconds outflow time from a Ford measuring cup with a 4 mm nozzle, iii. a particle diameter of 0.05 to 1.0 μ, iv. an ionic group content of 2 to 40 milliequivalents per 100 g of polyurethane solids of ions selected from the group consisting of ##STR6## wherein R is hydrogen or a lower alkyl group and v. a tensile strength of at least 40 kg/cm 2 when dried to a homogeneous polyurethane foil, and which contains i. 1-10% by weight of a foam stabilizing agent, based on the weight of solid polyurethane, ii. 0-100% by weight of inorganic fillers based on the weight of solid polyurethane, iii. 0-30% by weight of crosslinking agent based on the weight of solid polyurethane, and iv. 0.1 to 10% by weight of thickener based on the weight of solid polyurethane; b. carefully placing with light pressure on the foam while still wet, a woven or knitted textile material or non-woven fleece; and c. solidifying the composite material by drying.

Claim 15

A self-supporting polyurethane ionomer latex foam having a gross density of 0.04 to 0.40 g/cm 3 produced from aqueous air whipped ionomeric polyurethane dispersions which have: i. a solids content of 45 to 62% by weight of polyurethane, ii. a viscosity of 10 to 70 seconds outflow time from a Ford measuring cup with a 4mm nozle, iii. A particle diameter of 0.05 to 1.0 μ, iv. an ionic group content of 3 to 40 milliequivalents per 100 g of polyurethane solids of ions selected from the group consisting of ##STR7## wherein R is hydrogen or a lower alkyl group, and v. a tensile strength of at least 40 kg/cm 2 when dried to a homogeneous polyurethane foil, and which contain i. 1-10% by weight of a foam stabilizing agent, based on the weight of solid polyurethane, ii. 0-100% by weight of inorganic fillers based on the weight of solid polyurethane, iii. 0-30% by weight of crosslinking agent based on the weight of solid polyurethane, and iv. 0.10 to 10% by weight of thickener based on the weight of solid polyurethane.

Claim 16

A self-supporting polyurethane ionomer latex foam having a gross density of 0.04 to 0.40 g/cm 3 produced from aqueous air whipped ionomeric polyurethane dispersions which have: i. a solids content of 45 to 62% by weight of polyurethane, ii. a viscosity of 10 to 70 seconds outflow time from a Ford measuring cup with a 4mm nozle, iii. A particle diameter of 0.05 to 1.0 μ, iv. an ionic group content of 3 to 40 milliequivalents per 100 g of polyurethane solids of ions selected from the group consisting of ##STR7## wherein R is hydrogen or a lower alkyl group, and v. a tensile strength of at least 40 kg/cm 2 when dried to a homogeneous polyurethane foil, and which contain i. 1-10% by weight of a foam stabilizing agent, based on the weight of solid polyurethane, ii. 0-100% by weight of inorganic fillers based on the weight of solid polyurethane, iii. 0-30% by weight of crosslinking agent based on the weight of solid polyurethane, and iv. 0.10 to 10% by weight of thickener based on the weight of solid polyurethane.