Composite laminated structure for shoe stiffener and preparing method thereof

Abstract

The present invention is related to a composite laminated structure for shoe stiffeners and preparing method thereof. The composite laminated structure comprises: a fabric core layer, and a hot-melt-adhesive layer covering and interpenetrating the fabric core layer, wherein the fabric core layer comprises a fabric having a fabric count of about 61 to 13 wpi and about 60 to 30 fpi and a weight more than or equal to 100 g/m 2 . Preparing methods for said composite laminated structure are very simple processes. With the fabric core layer, proper performances could be achieved with simple hot-melt-adhesives. High level of cheap fillers, such as recycled materials, inorganic fillers or the mixture thereof, could be added while still maintaining excellent split tear strength, resilience and bending stiffness. Thus, the use of virgin materials and the overall cost could be greatly reduced for shoe stiffeners.

1 . A composite laminated structure for a shoe stiffener, comprising:
 a fabric core layer;   a hot-melt-adhesive layer, which covers and interpenetrates the fabric core layer;   wherein the fabric core layer comprises a fabric having a fabric count of about 61 to 13 warp yarns per inch (wpi) and about 60 to 30 filling yarns per inch (fpi) and a weight more than or equal to 100 g/m 2 .   
     
     
         2 . The composite laminated structure of  claim 1 , wherein the composite laminated structure without a filler has a split tear strength greater than or equal to 87.5 kgf/cm. 
     
     
         3 . The composite laminated structure of  claim 1 , wherein the composite laminated structure has a resilience greater than or equal to 5.0 kgf. 
     
     
         4 . The composite laminated structure of  claim 1 , wherein the fabric core layer has a bending stiffness greater than 2000 mg·cm. 
     
     
         5 . The composite laminated structure of  claim 1 , wherein the fabric core layer has a bending stiffness of about 2000 to about 25000 mg·cm. 
     
     
         6 . The composite laminated structure of  claim 4 , wherein the bending stiffness is determined by using standard ISO 9073 and GB 18318 test methods. 
     
     
         7 . The composite laminated structure of  claim 1 , wherein the fabric core layer comprises: cloth about 61 warp yarns per inch (wpi) and about 60 filling yarns per inch (fpi) for cap interlining and cloth about 40 warp yarns per inch (wpi) and about 40 filling yarns per inch (fpi) for cap interlining. 
     
     
         8 . The composite laminated structure of  claim 1 , wherein the hot-melt-adhesive layer is a low application temperature hot-melt-adhesive layer having a softening temperature lower than 90° C. and a solidification time greater than one minute. 
     
     
         9 . The composite laminated structure of  claim 1 , wherein the hot-melt-adhesive layer comprises thermoplastic polyurethane (TPU) or polycaprolactone (CAPA). 
     
     
         10 . The composite laminated structure of  claim 1 , wherein the composite laminated structure further comprises at least an adhesive layer. 
     
     
         11 . The composite laminated structure of  claim 1 , wherein the hot-melt-adhesive layer further comprises a filler and a percentage of the filler in the hot-melt-adhesive layer is up to 90%. 
     
     
         12 . The composite laminated structure of  claim 11 , wherein the percentage of the filler in the hot-melt-adhesive layer is up to 80%. 
     
     
         13 . The composite laminated structure of  claim 11 , wherein the filler comprises: an inorganic filler material, an organic polymer material, or a combination thereof. 
     
     
         14 . The composite laminated structure of  claim 13 , wherein the organic polymer material is a recycled plastic material. 
     
     
         15 . The composite laminated structure of  claim 14 , wherein the organic polymer material is a recycled plastic material comprising: polycarbonate (PC), thermoplastic polyurethane (TPU), polyethylene terephthalate (PET), phenol-formaldehyde resin, urea-formaldehyde resin, melamine-formaldehyde resin, epoxy resin, unsaturated polyester resin, polyurethane, or a mixture thereof. 
     
     
         16 . A method for preparing the composite laminated structure of  claim 1 , comprising:
 providing a first hot-melt-adhesive material in a molten state;
 providing a fabric, wherein the fabric is placed onto the first hot-melt-adhesive material in the molten state; 
 providing a second hot-melt-adhesive material in a molten state, wherein the second hot-melt-adhesive material in the molten state is placed onto the fabric; and 
 co-extruding and laminating the first hot-melt-adhesive material in the molten state, the fabric and the second hot-melt-adhesive material in the molten state to form the composite laminated structure. 
   
     
     
         17 . The method of  claim 16 , wherein the method further comprises a step of coating an adhesive layer onto a surface of the composite laminated structure. 
     
     
         18 . A method for preparing the composite laminated structure of  claim 1 , comprising:
 providing a first hot-melt-adhesive material in a preheated mold;   providing a fabric, wherein the fabric is placed onto the first hot-melt-adhesive material;   providing a second hot-melt-adhesive material, wherein the second hot-melt-adhesive material is placed onto the fabric; and   forming the first hot melt adhesive material and the second hot melt adhesive material to be in a molten state in the mold, and pressing the first hot melt adhesive material in the molten state, the second hot melt adhesive material in the molten state and the fabric together to form the composite laminated structure.   
     
     
         19 . The method of  claim 18 , wherein the method further comprises a step of coating an adhesive layer onto a surface of the composite laminated structure. 
     
     
         20 . A method for preparing the composite laminated structure of  claim 1 , comprising:
 providing a hot-melt-adhesive material in a molten state;   providing a fabric, wherein the fabric is placed onto the hot-melt-adhesive material in the molten state; and   extruding and laminating the hot melt adhesive material in the molten state and the fabric to form the composite laminated structure.   
     
     
         21 . The method of  claim 20 , wherein the method further comprises a step of coating an adhesive layer onto a surface of the composite laminated structure. 
     
     
         22 . A method for preparing the composite laminated structure of  claim 1 , comprising:
 providing a hot-melt-adhesive material in a preheated mold;   providing a fabric, wherein the fabric is placed onto the hot-melt-adhesive material; and   forming the hot melt adhesive material to be in the molten state in the mold, and pressing the hot melt adhesive material in the molten state and the fabric together to form the composite laminated structure.   
     
     
         23 . The method of  claim 22 , wherein the method further comprises a step of coating an adhesive layer onto a surface of the composite laminated structure. 
     
     
         24 . A composite laminated structure for a shoe stiffener, comprising:
 a fabric core layer;   a first hot-melt-adhesive layer and a second hot-melt-adhesive layer, which cover opposite surfaces of the fabric core layer and interpenetrate the fabric core layer;   wherein the fabric core layer comprises a fabric having a fabric count of about 61 to 13 warp yarns per inch (wpi) and about 60 to 30 filling yarns per inch (fpi) and a weight more than or equal to 100 g/m 2 .   
     
     
         25 . The composite laminated structure of  claim 5 , wherein the bending stiffness is determined by using standard ISO 9073 and GB 18318 test methods.