Claims:WE CLAIM:
1. A multilayer composite material (100) comprising:
(i) a first modified polymer layer (A) having a surface coating density in the range of 50 to 500 GSM;
(ii) a second foamed modified polymer layer (B) having a surface coating density in the range of 40 to 600 GSM; and
(iii) a third fabric layer (C) having a surface coating density in the range of 50 to 350 GSM,
wherein, said modified polymer is an elastomer modified polyvinyl chloride PVC;
wherein, a lower surface of said second foamed polymer layer (B) and an upper surface of said third fabric layer (C) are bound together by an adhesive bonding (D); and
wherein, a lower surface of said first modified polymer layer (A) and an upper surface of said second foamed polymer layer (B) are bound together by a thermal bonding.
2. The multilayer composite material (100) as claimed in claim 1, wherein said elastomer is selected from the group consisting of a butadiene copolymer, an acrylonitrile copolymer and a combination thereof.
3. The multilayer composite material (100) as claimed in claim 1, wherein said second modified polymer layer (B) is foamed using a foaming agent.
4. The multilayer composite material (100) as claimed in claim 3, wherein said foaming agent is azodicarbonamide.
5. The multilayer composite material (100) as claimed in claim 1, wherein said adhesive bonding comprises:
• 100 parts of PVC powder; and
• 50 to 100 parts of a plasticizer medium.
6. The multilayer composite material (100) as claimed in claim 5, wherein said plasticizer medium is a viscous liquid selected from the group consisting of diisononyl phthalate (DINP), diisodecyl phthalate (DIDP), dioctylsebacate (DOS) and tri-2-ethylhexyl trimellitate (TOTM).
7. The multilayer composite material (100) as claimed in claim 1, wherein said third fabric layer (C) is acrylic fiber.
8. The multilayer composite material (100) as claimed in claim 1, wherein an upper surface of said first modified polymer layer (A) is coated with a coating layer (E) having a linear coating density in the range of 10 to 50 GLM.
9. The multilayer composite material (100) as claimed in claim 8, wherein said coating layer comprises:
• 100 parts of polyurethane resin selected from the group consisting of aromatic polyurethane resin and aliphatic polyurethane resin;
• 0.5 to 5.0 parts distilled water;
• 0.5 to 2.0 parts leveling agent;
• 0.2 to 1.5 parts defoaming agent;
• 0.2 to 2.5 parts matting agent; and
• 0.1 to 2.5 parts feel agent.
Dated this 16th Day of March, 2021

MOHAN RAJKUMAR DEWAN, IN/PA-25
of R.K. DEWAN & COMPANY
APPLICANT’S PATENT ATTORNEY
, Description:FIELD
The present disclosure relates to a multilayer composite material.
DEFINITION
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which it is used indicates otherwise.
The term “Surface coating density” refers to a mass of a coating material per unit area distributed over a surface, used to measure density of a layer.
The term “Linear coating density” refers to mass of a coating material per unit length, used to measure thickness of a layer.
The term “Compounding” refers to a process of blending polymer with additives. The final product is called a compound or composite.
The term “Leveling agent” refers to a chemical agent that work on the dye molecule and help in fixing the dye particles uniformly.
The term “Feel agent” refers to a chemical agent additive that is used to provide the haptic feel for the top layer.
The term “Defoaming agent” refers to a chemical additive that reduces and hinders the formation of foam in industrial process liquids.
The term “Matting agent” refers to a synthetic, fine amorphous silica products that modify the surface properties when incorporated in a coating, to scatter light diffusely in order to provide a matte finish to the coated product.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Artificial leather or leatherette is a sheet-like structure made of plasticized polyvinyl chloride on a textile backing layer and is well-known for the interior cladding of motor vehicles and for furniture, bags, or the like. It is extensively used in vehicles as covering of seats and of door inserts. As the demand for comfort and convenience is peaking every day and with that increases the demand for artificial leather.
However, till date no valuable achievement is as such disclosed which aims to increase durability and/or to avoid the appearance of creases, coating crack, and peel off on existing artificial leather materials.
There is, therefore, felt a need of a multilayer composite material, which is durable and comprises excellent mechanical and physical properties.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide a multilayer composite material.
Another object of the present disclosure is to provide a multilayer composite material comprising excellent mechanical and physical properties such as microbial resistance, tear and scuff resistance, tensile strength and elongation.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure relates to a multilayer composite material (100). The composite material (100) comprises a first modified polymer layer (A) having a surface coating density in the range of 50 to 500 GSM; a second foamed modified polymer layer (B) having a surface coating density in the range of 40 to 600 GSM; and a third fabric layer (C) having a surface coating density in the range of 50 to 350 GSM. The modified polymer is an elastomer modified polyvinyl chloride PVC. Typically, a lower surface of the second foamed polymer layer (B) and an upper surface of the third fabric layer (C) are bound together by an adhesive bonding (D). Typically, a lower surface of first modified polymer layer (A) and an upper surface of the second foamed polymer layer (B) are bound together by a thermal bonding.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates the illustrative representation of a multilayer composite material (100) in accordance with the present disclosure.
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
Artificial leather or leatherette is a sheet-like structure made of plasticized polymer on a textile backing layer and is well-known for the interior cladding of motor vehicles and for furniture, bags, or the like. It is extensively used in vehicles as covering of seats and of door inserts. However, till date no valuable achievement is as such disclosed which aims to increase durability and/or to avoid the appearance of creases, coating crack, and peel off on existing artificial leather materials.
The present disclosure provides a multilayer composite material (100) being described in detail with reference to the Figure 1.
The multilayer composite material (100) comprises a first modified polymer layer (A) having a surface coating density in the range of 50 to 500 GSM; a second foamed modified polymer layer (B) having a surface coating density in the range of 40 to 600 GSM; and a third fabric layer (C) having a surface coating density in the range of 50 to 350 GSM.
In accordance with the present disclosure, a lower surface of the second foamed polymer layer (B) and an upper surface of the third fabric layer (C) are bound together by an adhesive bonding (D).
In accordance with the present disclosure, a lower surface of the first modified polymer layer (A) and an upper surface of the second foamed polymer layer (B) are bound together by a thermal bonding.
The modified polymer is an elastomer modified polyvinyl chloride PVC;
The elastomer is selected from the group consisting of a butadiene copolymer, an acrylonitrile copolymer and a combination thereof.
In accordance with the present disclosure, the second modified polymer layer (B) is foamed using a foaming agent. In accordance with the exemplary embodiment of the present disclosure, the foaming agent is azodicarbonamide.
In accordance with the present disclosure, the adhesive bonding comprises 80 to 120 parts of PVC powder; and 50 to 100 parts of a plasticizer medium.
The plasticizer medium is a viscous liquid selected from the group consisting of diisononyl phthalate (DINP), diisodecyl phthalate (DIDP), dioctylsebacate (DOS) and tri-2-ethylhexyl trimellitate (TOTM), Di(2-ethylhexyl) phthalate and Ditridecyl phthalate (DTDP)
The third fabric layer (C) is acrylic fiber.
In accordance with the present disclosure, an upper surface of the first modified polymer layer (A) is coated with a coating layer (E) having a linear coating density in the range of 10 to 50 GLM.
The coating layer comprises 100 parts of polyurethane resin, 0.5 to 5.0 parts distilled water, 0.5 to 2.0 parts leveling agent, 0.2 to 1.5 parts defoaming agent, 0.2 to 2.5 parts matting agent, and 0.1 to 2.5 parts feel agent
The polyurethane resin selected from the group consisting of aromatic polyurethane resin and aliphatic polyurethane resin.
The coating layer (E) is characterized by high heat resistance and high abrasion resistance.
The first layer comprising modified polymer provides UV resistance, heat resistance, abrasion resistance, scuff resistance, synthetic perspiration resistance, crocking resistance and crack resistance. The second layer comprising a foamed modified polymer provides compression and recovery, flex resistance and crack resistance to the multilayer composite material (100).The third fabric layer (C) comprising acrylic fiber provides inherent microbial resistance to the multilayer composite material (100).
The present disclosure further provides a process of manufacturing a multilayer composite material (100). In accordance with the present disclosure, the multilayer composite material (100) is prepared by transfer coating process, also called as knife coating process. The process involves the following steps.
Initially, the modified PVC plastisol is coated on a moving release paper by knife and passed through oven at a temperature in the range of at 140 to 160°C to fuse and soften, thereby forming a first modified polymer layer (A). The first modified polymer layer (A) is then cooled to make it ready for the subsequent coating. In accordance with the present disclosure, the surface coating density of first modified polymer layer (A) is in the range of 50 to 500 GSM.
In the second step, the foamed PVC plastisol is coated on the first modified polymer layer (A) and passed through oven at a temperature in the range of at 140 to 185°C to fuse and soften, thereby forming a second foamed modified polymer layer (B). The second foamed modified polymer layer (B) is then cooled to make it ready for the subsequent coating. In accordance with the present disclosure, the in accordance with the present disclosure, the surface coating density of second foamed modified polymer layer (B) is in the range of 40 to 600 GSM.
In the third step, the adhesive is coated on the second foamed modified polymer layer (B) and passed through oven at a temperature in the range of at 140 to 185°C to fuse and soften, thereby forming an adhesive bonding (D). The adhesive bonding (D) is then cooled to make it ready for the subsequent coating. In accordance with the present disclosure, the surface coating density of the adhesive bonding (D) is in the range of 50 to 250 GSM.
In the fourth step, an upper surface of the first modified polymer layer (A) is coated with a coating layer (E) by offline process at 100 to 140 °C to obtain the finished product. In accordance with the present disclosure, the surface coating density of the coating layer (E) is in the range of 10 to 50 GLM.
In the last step, a third fabric layer (C) is laminated on the adhesive bonding (D) to obtain the multilayer composite material (100). In accordance with the present disclosure, the surface coating density of the third fabric layer (C) is in the range of 50 to 350 GLM.
In accordance with the present disclosure, the modified PVC plastisol is prepared compounding PVC with plasticizers, heat stabilizers, processing additives and fillers in high speed mixer to make PVC paste or PVC plastisol. Then the elastomer paste in an amount in the range of 10 to 50 parts is added to the PVC plastisol under stirring for a time period in the range of 20 to 60 minutes at a speed in the range of 500 to 1000 rpm to obtain the modified PVC plastisol.
Typically, elastomer paste is prepared by blending the elastomer with PVC in the plasticizer medium by high speed mixing process. Plasticizer 50 to 100 parts is taken in the high-speed mixer vessel and elastomer 100 parts is added to the plasticizer medium. The high-speed mixer is run at a speed in the range of 500 to 1000 rpm for a time period in the range of 1 to 3 hours, thereby allowing the plasticizer to migrate into the elastomer particle resulting in swelling of the elastomer particle. The viscosity of the elastomer paste will be controlled by the amount of plasticizer.
In accordance with the present disclosure, the foamed PVC plastisol is prepared compounding 100 parts of PVC powder with 50 to 100 parts of plasticizer will be in the plasticizer medium, followed by addition of heat stabilizers, pigments, UV stabilizers, antioxidants and foaming agent.
In accordance with the present disclosure, the adhesive is prepared by mixing 50 to 100 parts plasticizer with 100 parts of PVC powder in the plasticizer medium, followed by addition of heat stabilizers, white pigment.
In accordance with the present disclosure, the aqueous polyurethane coating is prepared by mixing 100 parts of polyurethane with 0.5 to 5.0 parts of distilled water, 0.5 to 2.0 parts of levelling agent, 0.2 to 1.5 parts of defoaming agent, 0.2 to 2.5 parts of matting agent and 0.1 to 2.5 parts of feel agent under stirring at a speed in the range of 100 to 200 rpm for 10 to 30 minutes to obtain an aqueous polyurethane coating.
The multilayer composite material of the present disclosure can be used for the interior cladding of house and for the automotive soft trim. The multilayer composite material of the present disclosure has a high crack resistance, high flex resistance, high abrasion resistance and it also decreases the fogging, thereby making it durable. Moreover, the process of manufacturing a multilayer composite material is simple and economical.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be tested to scale up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.
EXAMPLES
Example 1: Preparation of a multilayer composite material in accordance with the present disclosure
Step 1: Preparation of elastomer paste
50 to 100 parts of plasticizer medium comprising a viscous liquid selected from the group consisting of diisononyl phthalate (DINP), diisodecyl phthalate (DIDP), dioctylsebacate (DOS) and tri-2-ethylhexyl trimellitate (TOTM), di(2-ethylhexyl) phthalate and ditridecyl phthalate (DTDP); was taken in the high-speed mixer vessel. 10 -50 parts elastomer comprising butadiene or acrylonitrile copolymer or a blend of both; was added to the plasticizer medium and the resulting mixture was stirred at 600 rpm for 2 hours to obtain elastomer paste.
Step 2: Preparation of PVC plastisol
100 parts of PVC was mixed with 50-100 parts of plasticizer; 1 to 5 parts of heat stabilizer selected from Barium-zinc or calcium-zinc or potassium zinc additives; 1 - 2.5 parts of UV stabilizer selected from Benzotriazoles derivatives and HALS; 5 -10 parts of pigment selected from organic pigments, inorganic pigments and carbon pigments; 1-10 parts of precipitated calcium carbonate as filler and processing additives in the high-speed mixer for 30 minutes to obtain PVC plastisol.
Step 3: Preparation of a modified PVC plastisol
10 - 50 parts of the elastomer paste selected Butadiene or acrylonitrile copolymer or blend of thereof, was added to the PVC plastisol obtained in step 2 and stirred for 30 minutes at 600 rpm to obtain a modified PVC plastisol.
Step 4: Preparation of foamed PVC plastisol:
2 – 10 parts of azodicarbonamide (foaming agent) was mixed with 50-100 parts of PVC plastisol obtained in step 2 and stirred for 30- 45 minutes to obtain a foamed PVC plastisol.
Step 5: Preparation of aqueous polyurethane coating
100 parts of polyurethane resin whose solid content is 60 to 80% was mixed with 0.5 – 5.0 parts distilled water, 0.5 – 2.0 parts leveling agent, 0.2 – 1.5 parts defoaming agent, 0.2 – 2.5 parts matting agent and 0.1 -2.5 parts feel agent while stirring at a speed of 150 rpm for 15 minutes to obtain the aqueous polyurethane coating.
Step 6: Preparation of adhesive
50 -100 parts of plasticizer medium and 100 parts of PVC powder were mixed slowly into a mixer vessel, followed by addition of heat stabilizers and white pigment to adhesive.
Step 6: Preparation of a multilayer composite material
The modified PVC plastisol was coated on a moving release paper by knife and passed through oven at 150 °C, followed by cooling to obtain modified PVC layer (A) having the surface coating density of 50 to 350 GSM.
In the second step, the foamed PVC plastisol was coated on the first modified PVC layer (A) and passed through oven at 170°C, followed by cooling to obtain a second foamed modified polymer layer (B). The second foamed modified polymer layer (B) having the surface coating density of 50 to 500 GSM.
In the third step, the adhesive was coated on the second foamed PVC layer (B) and passed through oven at 160°C, followed by cooling to obtain an adhesive bonding (D) having the surface coating density of 10 to 50 GSM.
In the fourth step, an upper surface of the first modified PVC layer (A) was coated with a coating layer (E) by offline process at 120 °C to obtain the finished product having the surface coating density of 10 to 50 gram per linear meter (GLM).
In the last step, a third fabric layer (C) was laminated on the adhesive bonding (D) to obtain the multilayer composite material (100).
The multilayer composite material was tested for crack resistance, abrasion resistance, and flex resistance, breaking strength, tear strength and microbial resistance. Results are listed below is provided in Table 1.
Table 1: The test results for the multilayer composite material (100)
Tests Test condition Multilayer composite material (100)
Abrasion Resistance CS100, 1000g, 1000 cycles No texture loss, No coating failure
W-flex Min 100000 cycles No crack
Breaking strength ASTM D751 400 N
Tear strength ASTM D751 500 N
Crack resistance E–00–1586 No crack at -30°C
Microbial resistance, ASTM G21 Rating 0,
No microbial growth

As shown in Table 1, it can be seen that there is neither texture loss nor coating failure in the multilayer composite material; moreover there is no any microbial growth. Further, there is no crack found till the temperature of -30°C.
TECHNICAL ADVANCEMENTSAND ECONOMICAL SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a multilayer composite material that:
- provides a durable multilayer composite material for the interior cladding of house and for the automotive soft trim;
- provides a high crack resistance, high flex resistance, high abrasion resistance;
- provides an affordable industrial scale process of manufacturing a multilayer composite material; and
- decreases the fogging.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully revealed the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.