METHOD FOR PRODUCING A COMPOSITE, AND A COMPOSITE

Abstract

A composite and a method for producing a composite (1) of at least three layers, comprising a support (2), in particular a woven fabric, knitted fabric, net, non-woven fabric, mesh, or non-crimp fabric, a first polymer layer (3) which faces the support, and a second polymer layer (4) which faces away from the support and adjoins the first polymer layer (3). The at least three layers are combined under pressure and temperature conditions which are selected such that an at least partial penetration of the first polymer layer (3) into the support (2) is ensured, wherein the composite adhesion between the first polymer layer (3) and the support (2) is at least ≧0.2 N/mm.

Claims

1-14. (canceled)

15. A process for production of a composite made of at least three layers comprising: a backing, a first polymer layer facing toward the backing, a second polymer layer, adjacent to the first polymer layer, facing away from the backing, wherein said at least three layers are combined under conditions of pressure and temperature selected in such a way as to ensure at least partial penetration of said first polymer layer into said backing, where the strength of the bond between said first polymer layer and said backing is at least ≧0.2 N/mm.

16. The process as claimed in claim 15, wherein a viscosity of said first polymer layer is lower than a viscosity of said second polymer layer.

17. The process as claimed in claim 16, wherein said viscosity of said first polymer layer is at least ≧100 Pa*s.

18. The process as claimed in claim 15, wherein said second polymer layer does not penetrate into said backing.

19. The process as claimed in claim 15, wherein said first polymer layer does not fully penetrate the backing.

20. The process as claimed in claim 15, wherein said at least three layers are provided in succession; or a composite made of backing and of first polymer layer is provided and said second polymer layer is applied; or said first polymer layer is applied together with said second polymer layer onto said backing.

21. The process as claimed in claim 15, wherein said second polymer layer is impermeable to liquid but permeable to gas.

22. The process as claimed in claim 15, wherein a third polymer layer is applied onto said second polymer layer, or said first polymer layer is applied together with said second polymer layer and a third polymer layer onto said backing.

23. The process as claimed in claim 22, wherein a second backing is applied onto said third polymer layer.

24. A composite obtainable by a process as claimed in claim 15.

25. The composite as claimed in claim 24, wherein said second polymer layer is impermeable to liquid but permeable to gas.

26. The composite as claimed in claim 24, wherein a third polymer layer is applied onto said second polymer layer, or said first polymer layer is applied together with said second polymer layer and a third polymer layer onto said backing.

27. The composite as claimed in claim 26, wherein a second backing is applied onto said third polymer layer.

28. The composite as claimed in claim 24, wherein said second polymer layer does not penetrated into said backing.

29. The composite as claimed in claim 24, wherein said first polymer layer does not fully penetrate said backing.

Description

[0038] The invention is explained in more detail below with reference to depictions of inventive examples.

[0039] FIG. 1: is a diagram of a three-layer composite of the invention;

[0040] FIG. 2: is a diagram of a preferred five-layer composite;

[0041] FIG. 3: is a diagram of partial penetration of the first polymer layer into the adjacent backing;

[0042] FIG. 4: is a diagram of an example of viscosity measurement.

[0043] FIG. 1 shows a three-layer composite 1 which is composed of a backing 2, a first polymer layer 3 facing toward the backing 2 and a second polymer layer 4 facing away from the backing 2 and superposed on the first polymer layer 3 (cf. example 1). The second polymer layer 4 here does not penetrate substantially into the first polymer layer 3. It moreover does not penetrate into the backing 2.

[0044] FIG. 2 shows an alternative, preferred five-layer composite 1 (cf. example 2). The composite 1 has the following sequence of components: backing 2, first polymer layer 3, second polymer layer 4, third polymer layer 5 and second backing 6. The first polymer layer 3 and the third polymer layer 4 are in essence identical in their physical properties and chemical composition. The first polymer layer 3 provides the adhesion to the backing 2. The third polymer layer provides the adhesion to the second backing 6. The second polymer layer 4 has accordingly been positioned between the first polymer layer 3 and the third polymer layer 5, and is not in contact with the backing 2 and the second backing 6. The second polymer layer 4 is preferably impermeable to water and permeable to water vapor.

[0045] FIG. 3 is a diagram of a backing 2 and a first polymer layer 3 (cf. FIGS. 1 and 2; no other layers being shown). The backing 2 comprises a region 7. The design of the first polymer layer 3 is such that it penetrates partially into the backing 2 during the production of the composite 1 with resultant optimized adhesion. The region 7 corresponds to that region of the backing 2 into which the first polymer layer 3 has partially penetrated. The first polymer layer 3 does not fully penetrate the backing 2 here.

[0046] In the case of a five-ply composite (cf. FIG. 2), there is identical partial penetration (not shown) of the third polymer layer 4 into the second backing 6.

[0047] FIG. 4 shows the graphs A and B relating to an example of measurement of viscosity in a rotary viscometer. Graph A shows the dynamic-mechanical analysis and rheology (abbreviated to DMA). Graph B shows isothermal frequency responses. A thermoplastic adhesive film based on polyurethanes was used, marketed as Collano 36.304. The viscosity of the first layer is measured in a Physica MCR 301 rotary viscometer in a plate-on-plate arrangement with plate diameter 25 mm (abbreviated to PP25 in graph A). The temperature sweep is started where the first layer becomes liquid. This is the case above 120° C. in the example (cf. graph A). The frequency sweep is carried out at constant temperature. The frequency was 1 Hz. Heating rate was 3 K/min. The temperature is selected in such a way that the polymer layer is liquid. The frequency is varied from 0.1 rad/sec to 1000 rad/sec. In the isothermal frequency response, the first curve (K1) describes viscosity as a function of frequency at 150° C. (cf. graph B). The second curve (K2) describes the viscosity as a function of frequency at 190° C. (cf. graph B). The zero viscosity (η′.sub.0) in the case of the selected polymer is 5500 Pa*s at 150° C. and 900 Pa*s at 190° C. The equipment indicates the resistance of the viscoelastic melt to deflection in the form of shear modulus or loss modulus or in the form of viscosity.

[0048] Collano 36.304

[0049] T.sub.m (rheo)=120° C.

[0050] T.sub.g=−27° C.

[0051] η′.sub.0 (150° C.)=5500 Pa*s

[0052] η′.sub.0 (190° C.)=900 Pa*s