Composite material and manufacturing method thereof

Abstract

The invention provides a composite material and a manufacturing method thereof. The composite material comprises a laminated structure formed by co-extruding a thermoplastic elastomer and a modified thermoplastic elastomer. The composite material uses the thermoplastic elastomer and the modified thermoplastic elastomer, so that emissions in the manufacturing process can be greatly reduced, the manufacturing process is simple and stable, and the abrasive resistance of the composite material can be improved.

Description

Technical Field

[0001] The present invention relates to a composite material and a method for manufacturing the same, and more particularly, to a composite material containing a modified thermoplastic elastomer and a method for manufacturing the same. Background Art

[0002] As the requirements for environmental protection in countries around the world are increasing year by year, the regulations on emissions (such as volatile organic compounds, carbon emissions, etc.) during the manufacturing process of many items are becoming increasingly strict to reduce pollution to the environment. However, the materials used in the manufacturing of conventional composite materials are not environmentally friendly and the manufacturing process is complicated. Summary of the invention

[0003] In some embodiments, a composite material includes a laminate structure formed by co-extrusion of a thermoplastic elastomer and a modified thermoplastic elastomer.

[0004] In some embodiments, the thermoplastic elastomer includes a polyolefin elastomer (TPO), a polystyrene elastomer (TPR), a polyetherester elastomer (TPEE) or a polyamide elastomer (TPA), and the modified thermoplastic elastomer includes a thermoplastic polyurethane elastomer (TPU), a blend of a polyolefin elastomer (TPO) and maleic acid, a blend of a polyolefin elastomer (TPO) and a dynamically vulcanized polyolefin elastomer (TPV), or a thermoplastic rubber elastomer (TPS).

[0005] In some embodiments, based on 100 wt % of the total weight of the modified thermoplastic elastomer, the content of the maleic acid is less than or equal to 40 wt %.

[0006] In some embodiments, the composite material further includes a substrate layer, the laminated structure is disposed on the substrate layer, and the substrate layer includes nonwoven fabric, elastic fabric, woven fabric, microfiber fabric, thermoplastic elastomer or modified thermoplastic elastomer.

[0007] In some embodiments, the composite material further includes a surface layer, the surface layer is attached to the modified thermoplastic elastomer of the laminated structure, and the surface layer includes a thermoplastic polyurethane surface layer, a water-based polyurethane surface layer or a thermoplastic polyolefin surface layer.

[0008] In some embodiments, a method for manufacturing a composite material includes: providing a thermoplastic elastomer raw material and a modified thermoplastic elastomer raw material; and co-extruding the thermoplastic elastomer raw material and the modified thermoplastic elastomer raw material to form a laminated structure.

[0009] In some embodiments, the hardness of the thermoplastic elastomer raw material is 50A to 95A, and the hardness of the modified thermoplastic elastomer raw material is 50A to 95A.

[0010] In some embodiments, the co-extrusion temperature of the thermoplastic elastomer raw material and the modified thermoplastic elastomer raw material is 160°C to 230°C. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Aspects of some embodiments of the present invention will be readily understood from the following detailed description when read in conjunction with the accompanying drawings.It should be noted that the various structures may not be drawn to scale, and the dimensions of the various structures may be arbitrarily increased or reduced for clarity of discussion.

[0012] Figure 1 Schematic diagram showing a cross-section of a composite material according to some embodiments of the present disclosure.

[0013] Figure 2 Schematic diagram showing a cross-section of a composite material according to some embodiments of the present disclosure.

[0014] Figure 3 Schematic diagram showing a cross-section of a composite material according to some embodiments of the present disclosure.

[0015] Figure 4 Schematic diagram showing a cross-section of a composite material according to some embodiments of the present disclosure.

[0016] Figure 5 Schematic diagram showing a cross-section of a composite material according to some embodiments of the present disclosure.

[0017] Figure 6 Schematic diagram showing a cross-section of a composite material according to some embodiments of the present disclosure.

[0018] Figure 7 Schematic diagram showing one or more stages of some embodiments of methods of making composite materials according to the present disclosure.

[0019] Figure 8 Schematic diagram showing one or more stages of some embodiments of methods of making composite materials according to the present disclosure.

[0020] Explanation of symbols

[0021] 1: Composite material

[0022] 1a: Composite material

[0023] 1b: Composite material

[0024] 1c: Composite material

[0025] 1d: Composite material

[0026] 1e: Composite material

[0027] 10: Base material layer

[0028] 10': Modified thermoplastic elastomer layer

[0029] 20: Thermoplastic elastomer

[0030] 20': Thermoplastic elastomer layer

[0031] 30: Modified thermoplastic elastomer

[0032] 40: Surface layer

[0033] 80: Laminated structure DETAILED DESCRIPTION

[0034] See also Figure 1 , which is a schematic cross-sectional view of a composite material 1 according to some embodiments of the present disclosure. The composite material 1 of the present invention includes a substrate layer 10, a laminate structure 80, and a surface layer 40. In some embodiments, the substrate layer 10 may include, but is not limited to, nonwoven fabrics, elastic fabrics, woven fabrics, microfiber fabrics, thermoplastic elastomers (thermoplasticelastomer, TPE) or modified thermoplastic elastomers (modified thermoplastic elastomer, m-TPE). In some embodiments, the thickness of the substrate layer 10 may be 0.05 mm to 2.0 mm.

[0035] The laminated structure 80 is disposed on the substrate layer 10. In some embodiments, the laminated structure 80 may be co-extruded by a thermoplastic elastomer (TPE) 20 and a modified thermoplastic elastomer (m-TPE) 30. In some embodiments, the thermoplastic elastomer 20 may include, but is not limited to, a thermoplastic polyolefin (TPO), a thermoplastic rubber (TPR), a thermoplastic polyetherester elastomer (TPEE), or a thermoplastic polyamide elastomer (TPA). In some embodiments, the thickness of the thermoplastic elastomer 20 may be less than or equal to the thickness of the substrate layer 10. In some embodiments, the thickness of the thermoplastic elastomer 20 may be 0.05 mm to 3.0 mm.

[0036] In some embodiments, the modified thermoplastic elastomer 30 may include, but is not limited to, thermoplastic polyurethane (TPU), a blend of polyolefin elastomer (TPO) and maleic acid, a blend of polyolefin elastomer (TPO) and dynamically vulcanized polyolefin elastomer (thermoplastic vulcanizate, TPV), or thermoplastic styrene (TPS).

[0037] In some embodiments, the purpose of using the blend of the polyolefin elastomer (TPO) and maleic acid is to modify the polyolefin elastomer (TPO) by the maleic acid so that the adhesion of the modified thermoplastic elastomer 30 can be greater than that of the thermoplastic elastomer 20. In some embodiments, the content of the maleic acid can be less than or equal to 40wt% based on the total weight of the modified thermoplastic elastomer 30 as 100wt%. When the content of the maleic acid is higher than 40wt%, the film-forming property of the modified thermoplastic elastomer 30 will be poor and it will not have processability. In some embodiments, the content of maleic acid may be 2 wt % to 38 wt %, 4 wt % to 36 wt %, 6 wt % to 34 wt %, 8 wt % to 32 wt %, 10 wt % to 30 wt %, 12 wt % to 28 wt %, 14 wt % to 26 wt %, 16 wt % to 24 wt % or 18 wt % to 22 wt %. In some embodiments, the thickness of the modified thermoplastic elastomer 30 may be less than or equal to the thickness of the thermoplastic elastomer 20. In some embodiments, the thickness of the modified thermoplastic elastomer 30 may be 0.05 mm to 3.0 mm.

[0038] The surface layer 40 is attached to the modified thermoplastic elastomer 30 of the laminated structure 80. In some embodiments, the surface layer 40 may include but is not limited to a thermoplastic polyurethane surface layer, a water-based polyurethane surface layer or a thermoplastic polyolefin surface layer. In some embodiments, the surface layer 40 may have a three-dimensional microstructure texture to increase the surface touch, texture or light and shadow effects. In some embodiments, the heat-resistant temperature of the surface layer 40 may be 60°C to 160°C. In some embodiments, the thickness of the surface layer 40 may be 0.01mm to 1.0mm.

[0039] In some embodiments, the surface layer 40 may be attached to the modified thermoplastic elastomer 30 of the laminated structure 80 via an adhesive layer (not shown). In other words, the adhesive layer is disposed between the surface layer 40 and the modified thermoplastic elastomer 30. In some embodiments, the material of the adhesive layer may include but is not limited to thermoplastic polyurethane, water-based polyurethane or thermoplastic polyolefin.

[0040] The composite material 1 of the present invention uses the thermoplastic elastomer 20 and the modified thermoplastic elastomer 30 to significantly reduce emissions during the manufacturing process, and the manufacturing process is simple and stable, and the wear resistance of the composite material 1 can be improved.

[0041] See also Figure 2 , which is a schematic cross-sectional view showing a composite material 1a according to some embodiments of the present disclosure. Figure 2 The composite material 1a has and Figure 1 The composite material 1 has a similar structure, the difference being that: Figure 2 Composite material 1a omitted Figure 1 The substrate layer 10.

[0042] See also Figure 3 , which is a schematic cross-sectional view showing a composite material 1b according to some embodiments of the present disclosure. Figure 3 The composite material 1b has and Figure 1 The composite material 1 has a similar structure, the difference being that: Figure 3 Composite material 1b omitted Figure 1 The base material layer 10 and the surface layer 40 are formed, and the laminated structure 80 is disposed on the modified thermoplastic elastomer layer 10'.

[0043] See also Figure 4 , which is a schematic cross-sectional view showing a composite material 1c according to some embodiments of the present disclosure. Figure 4 The composite material 1c has and Figure 1 The composite material 1 has a similar structure, the difference being that: Figure 4 Composite material 1c omitted Figure 1 The surface layer 40.

[0044] See also Figure 5 , which is a schematic cross-sectional view showing a composite material 1d according to some embodiments of the present disclosure. Figure 5 The composite material 1d has and Figure 1 The composite material 1 has a similar structure, the difference being that: Figure 5 Composite material 1d omitted Figure 1 The modified thermoplastic elastomer 30.

[0045] See also Figure 6, which is a schematic cross-sectional view showing a composite material 1e according to some embodiments of the present disclosure. Figure 6 The composite material 1e has and Figure 5 The composite material 1d has a similar structure, the only difference being that: Figure 6 Composite material 1e omitted Figure 5 The surface layer 40 is formed, and the thermoplastic elastomer layer 20 ′ is disposed on the thermoplastic elastomer 20 .

[0046] Figures 7 and 8 Schematic diagram showing one or more stages of some embodiments of a method for making a composite material according to the present disclosure. In some embodiments, the method is for making a composite material such as Figure 1 The composite material 1 is shown.

[0047] See also Figure 7 , providing a substrate layer 10. Figure 7 The substrate layer 10 may be the same as Figure 1 The substrate layer 10 is provided.

[0048] See also Figure 8 , forming a stacked structure 80 on the substrate layer 10 . Figure 8 The laminated structure 80 may be the same as Figure 1 The laminated structure 80. Therefore, Figure 8 The laminated structure 80 may include Figure 1 Thermoplastic elastomer 20 and Figure 1 In some embodiments, the step of forming the laminate structure 80 may include:

[0049] A thermoplastic elastomer raw material and a modified thermoplastic elastomer raw material are provided. In some embodiments, the thermoplastic elastomer raw material may include but is not limited to polyolefin elastomer (TPO), polystyrene elastomer (TPR), polyether ester elastomer (TPEE) or polyamide elastomer (TPA). The modified thermoplastic elastomer raw material may include but is not limited to thermoplastic polyurethane elastomer (TPU), a blend of polyolefin elastomer (TPO) and maleic acid, a blend of polyolefin elastomer (TPO) and dynamically vulcanized polyolefin elastomer (TPV) or thermoplastic rubber elastomer (TPS). In some embodiments, the soft hardness of the thermoplastic elastomer raw material may be 50A to 95A, and the soft hardness of the modified thermoplastic elastomer raw material may be 50A to 95A.

[0050] The thermoplastic elastomer raw material and the modified thermoplastic elastomer raw material are co-extruded through a T-type co-extrusion die (not shown) to form the laminated structure 80 (including, for example, the thermoplastic elastomer 20 and the modified thermoplastic elastomer 30). In some embodiments, the co-extrusion temperature of the thermoplastic elastomer raw material and the modified thermoplastic elastomer raw material may be 160° C. to 230° C. In some embodiments, the laminated structure 80 (including, for example, the thermoplastic elastomer 20 and the modified thermoplastic elastomer 30) may be formed on the substrate layer 10 in a laminating manner.

[0051] See also Figure 1 , forming a surface layer 40 on the modified thermoplastic elastomer 30 of the laminate structure 80 to obtain Figure 1 The composite material 1 shown. In some embodiments, the surface layer 40 may include but is not limited to a thermoplastic polyurethane surface layer, a water-based polyurethane surface layer or a thermoplastic polyolefin surface layer. In some embodiments, the surface layer 40 may be surface treated so that the surface layer 40 has a light mist and a hand feel. In some embodiments, the surface layer 40 may be surface treated so that the surface layer 40 has a diversified surface. In some embodiments, the surface layer 40 may be embossed so that the surface layer 40 has diversified textures.

[0052] As shown in Table 1 below, the composite material of Example 1 corresponds to Figure 1 The composite material 1 of the invention example 2 corresponds to Figure 2 The composite material 1a of the invention example 3 corresponds to Figure 3 The composite material 1b of the invention example 4 corresponds to Figure 4 The composite material 1c of the invention example 5 corresponds to Figure 5 The composite material 1d of the invention example 6 corresponds to Figure 6 Composite material 1e. From the physical property test results in Table 1, it can be found that the wear resistance of the composite materials of Invention Examples 1 to 5 can reach more than 2000 cycles, and the wear resistance of Invention Examples 1, 2, and 5 can reach more than 3000 cycles. In addition, the current processing temperature requirement for composite embossing is about 220°C to 240°C, while the constituent materials of the composite materials of Invention Examples 1 to 6 can be embossed at 80°C to 160°C, which can reduce the overall processing temperature requirement.

[0053] Table 1. Physical property test results of Inventive Examples 1 to 6

[0054]

[0055] The above embodiments are only for explaining the principle and efficacy of the present invention, but not for limiting the present invention. The modifications and changes made by those skilled in the art to the above embodiments still do not violate the spirit of the present invention. The scope of rights of the present invention shall be as listed in the attached claims.

Claims

1. A composite material comprising a laminated structure formed by co-extrusion of a thermoplastic elastomer and a modified thermoplastic elastomer.

2. The composite material according to claim 1, wherein the thermoplastic elastomer comprises a polyolefin elastomer (TPO), a polystyrene elastomer (TPR), a polyether ester elastomer (TPEE) or a polyamide elastomer (TPA), and the modified thermoplastic elastomer comprises a thermoplastic polyurethane elastomer (TPU), a blend of a polyolefin elastomer (TPO) and maleic acid, a blend of a polyolefin elastomer (TPO) and a dynamically vulcanized polyolefin elastomer (TPV), or a thermoplastic rubber elastomer (TPS).

3. The composite material according to claim 2, wherein the content of the maleic acid is less than or equal to 40 wt%, based on 100 wt% of the total weight of the modified thermoplastic elastomer.

4. The composite material according to claim 1, further comprising a substrate layer, the laminated structure being disposed on the substrate layer, the substrate layer comprising nonwoven fabric, elastic fabric, woven fabric, microfiber fabric, thermoplastic elastomer or modified thermoplastic elastomer.

5. The composite material according to claim 1, further comprising a surface layer, wherein the surface layer is attached to the modified thermoplastic elastomer of the laminated structure, and the surface layer comprises a thermoplastic polyurethane surface layer, a waterborne polyurethane surface layer or a thermoplastic polyolefin surface layer.

6. A method for manufacturing a composite material, comprising: Provide thermoplastic elastomer raw materials and modified thermoplastic elastomer raw materials; as well as The thermoplastic elastomer raw material and the modified thermoplastic elastomer raw material are co-extruded to form a laminated structure.

7. The manufacturing method according to claim 6, wherein the thermoplastic elastomer raw material comprises a polyolefin elastomer (TPO), a polystyrene elastomer (TPR), a polyether ester elastomer (TPEE) or a polyamide elastomer (TPA), and the modified thermoplastic elastomer raw material comprises a thermoplastic polyurethane elastomer (TPU), a blend of a polyolefin elastomer (TPO) and maleic acid, a blend of a polyolefin elastomer (TPO) and a dynamically vulcanized polyolefin elastomer (TPV), or a thermoplastic rubber elastomer (TPS).

8. The manufacturing method according to claim 6, wherein the hardness of the thermoplastic elastomer raw material is 50A to 95A, and the hardness of the modified thermoplastic elastomer raw material is 50A to 95A.

9. The manufacturing method according to claim 6, wherein the co-extrusion temperature of the thermoplastic elastomer raw material and the modified thermoplastic elastomer raw material is 160°C to 230°C.

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