Claims
- 1. 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.sup.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 .mu.,
- 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.sup.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.
- 2. 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.sup.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 .mu.,
- 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.sup.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.
- 3. 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.sup.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 .mu.,
- 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.sup.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.
- 4. 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.
- 5. The process of claim 1 wherein the plastic sheet is a microporous or homogeneous polyurethane sheet.
- 6. The process of claim 1 wherein the plastic sheet is a polyvinyl chloride sheet.
- 7. 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 .mu.
- 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.
- 8. 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 .mu. 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.
- 9. 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.sup.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 .mu.,
- 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.sup.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.
- 10. A self-supporting polyurethane ionomer latex foam having a gross density of 0.04 to 0.40 g/cm.sup.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 .mu.,
- 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.sup.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.
Parent Case Info
This is a division, of application Ser. No. 373,354, filed June 25, 1973, now U.S. Pat. No. 3,989,870.
US Referenced Citations (3)
Number |
Name |
Date |
Kind |
3537947 |
Brazdzionis |
Nov 1970 |
|
3741854 |
De Goria |
Jun 1973 |
|
3772224 |
Marlin et al. |
Nov 1973 |
|
Divisions (1)
|
Number |
Date |
Country |
Parent |
373354 |
Jun 1973 |
|