Thermoplastic artificial leather, method for manufacturing the same and thermoplastic composite laminate

Abstract

A thermoplastic artificial leather includes a thermoplastic composite laminate and a textile base. The thermoplastic composite laminate includes a foamed thermoplastic elastic layer, an unfoamed thermoplastic elastic layer and a thermoplastic adhesive layer. The foamed thermoplastic elastic layer has a first surface, a second surface and a plurality of foamed structures. The second surface is opposite to the first surface. The unfoamed thermoplastic elastic layer is disposed on the first surface of the foamed thermoplastic elastic layer. The thermoplastic adhesive layer is disposed on the second surface of the foamed thermoplastic elastic layer. The textile base is laminated on the thermoplastic adhesive layer of the thermoplastic composite laminate.

What is claimed is: 
     
         1 . A thermoplastic artificial leather, comprising:
 a thermoplastic composite laminate, which includes:   a foamed thermoplastic elastic layer having a first surface, a second surface and a plurality of foamed structures, wherein the second surface is opposite to the first surface;   an unfoamed thermoplastic elastic layer disposed on the first surface of the foamed thermoplastic elastic layer; and   a thermoplastic adhesive layer disposed on the second surface of the foamed thermoplastic elastic layer; and   a textile base laminated on the thermoplastic adhesive layer of the thermoplastic composite laminate.   
     
     
         2 . The thermoplastic artificial leather of  claim 1 , wherein the material of the foamed thermoplastic elastic layer is a thermoplastic polyurethane (TPU), a thermoplastic polyester elastomer (TPEE) or a thermoplastic polyolefin (TPO) elastomer. 
     
     
         3 . The thermoplastic artificial leather of  claim 1 , wherein the foamed structures of the foamed thermoplastic elastic layer have a size of 20 to 300 microns inclusive. 
     
     
         4 . The thermoplastic artificial leather of  claim 1 , wherein the foamed thermoplastic elastic layer has a foaming density reduction rate of 40% to 90% inclusive and a Shore hardness of 50 A to 85 A inclusive. 
     
     
         5 . The thermoplastic artificial leather of  claim 1 , wherein the material of the unfoamed thermoplastic elastic layer is a thermoplastic polyurethane (TPU), a thermoplastic polyester elastomer (TPEE) or a thermoplastic polyolefin (TPO) elastomer. 
     
     
         6 . The thermoplastic artificial leather of  claim 1 , wherein the thickness ratio of the unfoamed thermoplastic elastic layer to the foamed thermoplastic elastic layer is 95:5 to 5:95 inclusive. 
     
     
         7 . The thermoplastic artificial leather of  claim 1 , wherein the unfoamed thermoplastic elastic layer has a Shore hardness of 60 A to 80 A inclusive. 
     
     
         8 . The thermoplastic artificial leather of  claim 1 , wherein the material of the thermoplastic adhesive layer is a thermoplastic polyurethane (TPU) or a water-based paste, and the textile base is a nonwoven fabric or a woven fabric. 
     
     
         9 . A method for manufacturing a thermoplastic artificial leather, comprising:
 (a) preparing a thermoplastic composite laminate, wherein the thermoplastic composite laminate includes a foamed thermoplastic elastic layer, an unfoamed thermoplastic elastic layer and a thermoplastic adhesive layer, the foamed thermoplastic elastic layer has a first surface, a second surface opposite to the first surface and a plurality of foamed structures, the unfoamed thermoplastic elastic layer is disposed on the first surface of the foamed thermoplastic elastic layer, and the thermoplastic adhesive layer is disposed on the second surface of the foamed thermoplastic elastic layer; and   (b) laminating a textile base on the thermoplastic adhesive layer of the thermoplastic composite laminate.   
     
     
         10 . The method of  claim 9 , wherein in the step (a), the method for preparing the thermoplastic composite laminate includes:
 (a1) providing a first raw material, a second raw material and a third raw material, wherein the first raw material is used to prepare the unfoamed thermoplastic elastic layer, the second raw material is used to prepare the foamed thermoplastic elastic layer, and the third raw material is used to prepare the thermoplastic adhesive layer; and   (a2) using an extruding apparatus to melt and then co-extrude the first raw material, the second raw material and the third raw material, to form the thermoplastic composite laminate.   
     
     
         11 . The method of  claim 10 , wherein in the step (a1), the first raw material, the second raw material and the third raw material are a thermoplastic polyurethane (TPU), a thermoplastic polyester elastomer (TPEE), or a thermoplastic polyolefin (TPO) elastomer. 
     
     
         12 . The method of  claim 10 , wherein in the step (a1), the first raw material has a melting point of 140° C. to 165° C. inclusive, the second raw material has a melting point of 135° C. to 150° C. inclusive, and the third raw material has a melting point of 90° C. to 133° C. inclusive. 
     
     
         13 . The method of  claim 10 , wherein in the step (a2), the second raw material is processed by foaming, and the foaming method is selected from the group consisting of microsphere foaming, nitrogen foaming, carbon dioxide foaming and supercritical carbon dioxide foaming. 
     
     
         14 . The method of  claim 9 , wherein in the step (a), the method for preparing the thermoplastic composite laminate includes:
 (a1) providing a first raw material and a second raw material, wherein the first raw material is used to prepare the unfoamed thermoplastic elastic layer, and the second raw material is used to prepare the foamed thermoplastic elastic layer;   (a2) using an extruding apparatus to melt and then co-extrude the first raw material and the second raw material, to form the unfoamed thermoplastic elastic layer and the foamed thermoplastic elastic layer; and   (a3) disposing a thermoplastic adhesive layer on the second surface of the foamed thermoplastic elastic layer, thus obtaining the thermoplastic composite laminate.   
     
     
         15 . The method of  claim 14 , wherein in the step (a1), the first raw material and the second raw material are a thermoplastic polyurethane (TPU), a thermoplastic polyester elastomer (TPEE), or a thermoplastic polyolefin (TPO) elastomer. 
     
     
         16 . The method of  claim 14 , wherein in the step (a1), the first raw material has a melting point of 140° C. to 165° C. inclusive, and the second raw material has a melting point of 135° C. to 150° C. inclusive. 
     
     
         17 . The method of  claim 14 , wherein in the step (a2), the second raw material is processed by foaming. 
     
     
         18 . The method of  claim 17 , wherein the foaming method is selected from the group consisting of microsphere foaming, nitrogen foaming, carbon dioxide foaming and supercritical carbon dioxide foaming. 
     
     
         19 . The method of  claim 14 , wherein in the step (a3), the material of the thermoplastic adhesive layer is a thermoplastic polyurethane (TPU), a thermoplastic polyester elastomer (TPEE), a thermoplastic polyolefin (TPO) elastomer, or a water-based paste. 
     
     
         20 . The method of  claim 9 , wherein in the step (b), the textile base is a nonwoven fabric or a woven fabric.