Pu composite and method of fabricating the same

Abstract

A PU composite and a method of fabricating the same are provided. The fabrication method includes: (a) providing a release paper; (b) coating a fabric layer on the release paper, the fabric layer containing a PU resin, an abrasion resistant, and a colorant; (c) drying the fabric layer; (d) coating a first laminated layer on the fabric layer; (e) drying the first laminated layer; (f) laminating a wet PU foam layer on the first laminated layer; (g) releasing the release paper to form a semi-product; (h) providing a plastic layer, which is of a thermoplastic; (i) coating a second laminated layer on the plastic layer; (j) drying the second laminated layer; and (k) laminating the semi-product of Step (g) on the second laminated layer, so as to form a PU composite. Compared with conventional PU composites, the PU composite of the present invention has better UV resistance, solvent resistance, and abrasion resistance.

1 . A method of fabricating a PU composite, comprising:
 (a) providing a release paper;   (b) coating a fabric layer on the release paper, the fabric layer comprising PU resin, abrasion resistant, and colorant;   (c) drying the fabric layer;   (d) coating a first laminated layer on the fabric layer;   (e) drying the first laminated layer;   (f) laminating a wet PU foam layer on the first laminated layer;   (g) releasing the release paper, so as to form a semi-product;   (h) providing a plastic layer, wherein the material of the plastic layer is thermoplastic;   (i) coating a second laminated layer on the plastic layer;   (j) drying the second laminated layer; and   (k) laminating the semi-product in Step (g) on the second laminated layer, so as to form a PU composite.   
     
     
         2 . The method as claimed in  claim 1 , wherein in Step (a), a surface of the release paper has a texture. 
     
     
         3 . The method as claimed in  claim 1 , wherein in Step (b), the fabric layer comprises 5-50 wt % of PU resin, 0.05-5 wt % of abrasion resistant, and 0.05-15 wt % of colorant. 
     
     
         4 . The method as claimed in  claim 1 , wherein in Step (b), the abrasion resistant comprises silicone. 
     
     
         5 . The method as claimed in  claim 1 , wherein in Step (b), the particle size of the colorant is less than 10 μm. 
     
     
         6 . The method as claimed in  claim 1 , further comprising a step of surface treatment after Step (g). 
     
     
         7 . The method as claimed in  claim 1 , wherein in Step (h), the material of the plastic layer is selected from the group consisting of polycarbonate (PC), acrylonitrile-butadiene-styrene copolymer (ABS), polyurethane (PU), acrylic, and mixtures thereof. 
     
     
         8 . A PU composite, comprising:
 a plastic layer, the material of the plastic layer being thermoplastic;   a second laminated layer, located on the plastic layer;   a wet PU foam layer, located on the second laminated layer;   a first laminated layer, located on the wet PU foam layer; and   a fabric layer, located on the first laminated layer, and comprising PU resin, abrasion resistant, and colorant.   
     
     
         9 . The PU composite as claimed in  claim 8 , wherein the material of the plastic layer is selected from the group consisting of PC, ABS, PU, acrylic, and mixtures thereof. 
     
     
         10 . The PU composite as claimed in  claim 8 , wherein the materials of the first laminated layer and the second laminated layer are selected from the group consisting of pressure-sensitive adhesive, moisture-curable resin, one-component resin, and two-component resin. 
     
     
         11 . The PU composite as claimed in  claim 8 , wherein a surface of the fabric layer has a texture. 
     
     
         12 . The PU composite as claimed in  claim 8 , wherein the fabric layer comprises 25-99.80 wt % of PU resin, 0.1-25 wt % of abrasion resistant, and 0.1-50 wt % of colorant. 
     
     
         13 . The PU composite as claimed in  claim 8 , wherein the abrasion resistant of the fabric layer comprises silicone. 
     
     
         14 . The PU composite as claimed in  claim 8 , wherein the particle size of the colorant of the fabric layer is less than 10 μm. 
     
     
         15 . The PU composite as claimed in  claim 8 , wherein the thickness of the plastic layer is 0.10-0.20 mm, the thickness of the second laminated layer is 0.01-0.15 mm, the thickness of the wet PU foam layer is 0.20-0.45 mm, the thickness of the first laminated layer is 0.01-0.15 mm, the thickness of the fabric layer is 0.01-0.05 mm, and the total thickness of the PU composite is 0.38-0.90 mm. 
     
     
         16 . The PU composite as claimed in  claim 8 , wherein the solvent resistance test of the surface of the fabric layer is tested and shown to be above Grade 4 according to AATCC GREY method. 
     
     
         17 . The PU composite as claimed in  claim 8 , wherein the surface abrasion test of the surface of the fabric layer is tested and shown to be up to 4000 times according to ASTM D3884 CS-10 1 Kg method. 
     
     
         18 . The PU composite as claimed in  claim 8 , wherein the UV resistance test of the surface of the fabric layer is tested and shown to be above Grade 3 according to ASTM G53 method.