Material for shoe upper

Abstract

Material (1) for a shoe upper, in particular for football boots, comprising: a. an inner polyurethane layer (10); b. an outer polyurethane layer (30); c. wherein the inner polyurethane layer (10) and the outer polyurethane layer (30) comprise thermosetting polyurethane; and d. a textile reinforcement layer (20, 35, 37) arranged between the inner polyurethane layer (10) and the outer polyurethane layer (30), wherein the textile reinforcement layer (20, 35, 37) comprises a non-thermoplastic material; e. wherein the textile reinforcement layer (20, 35, 37) has openings (36, 38, 41), and wherein the inner polyurethane layer (10) and the outer polyurethane layer (30) are connected to each other through the openings (36, 38, 41) of the textile reinforcement layer (20, 35, 37).

Description

1. Technical field The present invention relates to a material for a shoe upper, in particular for football boots, with a particularly low weight. 2. The state of the art Athletes cover long distances. To reduce the energy required, they want to reduce weight, especially in their sports shoes. Reduced weight requires less force during acceleration, thus relieving strain on the muscles of a player or runner. The material used for the upper (shoe shaft) plays a crucial role in determining the weight of a shoe, as it, along with the sole, dictates the overall weight of the athletic shoe. While the weight of the upper can theoretically be reduced by using less material, for example, by thinning it, the upper must also meet high quality standards, such as abrasion resistance, flexibility, lamination, and stability. Multi-layered or composite materials are particularly well-suited to meeting these diverse requirements. Various shoe uppers made of multilayered materials are known in the prior art, such as the combination of a textile material with a plastic layer. For example, DE 10 2009 028 627 A1 describes a shoe upper with textile materials, such as a nylon fabric. The textile material can be further reinforced on the outside and / or inside by a suitable coating, for example, a transparent layer of thermoplastic polyurethane (TPU) bonded to the textile material with hot melt adhesive. US 2010 / 0 037 483 A1 describes a material for a shoe upper in which fibers are arranged between a base layer and a top layer, preferably a thermoplastic polymer material, for example TPU. Similar materials for a composite material for a shoe upper are described in US 3 397 418 A, US 6 558 784 B1, and US 7 941 942 B2. Furthermore, US 2007 / 0 199 210 A1 describes a material in which a middle layer is arranged between a first layer and a second layer. The middle layer is a textile fabric, and the first and second layers are preferably made of a foam material, for example EVA foam. US Patent 2011 / 0088282A1 describes a composite material for a shoe upper consisting of an outer skin layer and a substrate layer, with a fabric layer sandwiched between them. The substrate layer may comprise a laminate with a first material layer (e.g., leather) and a second material layer (e.g., TPU). The outer skin layer may be made of TPU or a multilayer material, for example, an outer layer of thermosetting polyurethane (PUR) or TPU and an inner layer of TPU. Further state of the art is described in DE 39 19 763 A1 , US 6 171 680 B1 , WO 2010 / 110 661 A2 , US 4 263 356 A , DE 10 2007 045 739 A1 and US 2005 / 0 126 038 A1. However, the use of TPU has several disadvantages. For example, TPU discolors under light exposure (yellowing). This deteriorates the material's quality. TPU is also susceptible to hydrolysis, which can lead to delamination of material layers. Furthermore, a good bond between TPU and other materials usually requires an additional adhesive layer, which often results in increased weight, delamination of material layers, or poor material quality. In general, TPU has poor mechanical properties. For example, TPU is stiff and inflexible due to the required adhesive layer. However, omitting the adhesive layer also leads to problems. For example, a bond between TPU and PUR without an adhesive layer does not create a sufficient bond because different materials are used. It is therefore the object of the present invention to provide a composite material for a shoe upper for sports shoes that overcomes these disadvantages, is particularly lightweight without losing quality. 3. Summary of the invention This problem is solved by a material for a shoe upper, particularly for football boots, according to claim 1. The material comprises an inner polyurethane layer, an outer polyurethane layer, and a textile reinforcement layer. The textile reinforcement layer is arranged between the inner polyurethane layer and the outer polyurethane layer and comprises a non-thermoplastic material. The inner polyurethane layer and the outer polyurethane layer comprise thermosetting polyurethane. The textile reinforcement layer has openings through which the inner polyurethane layer and the outer polyurethane layer are connected to each other. The use of a polyurethane layer on both sides of the textile reinforcement layer has the advantage that a particularly good bond between the two polyurethane layers is achieved when the material is pressed under heat and pressure. In contrast, when using thermoplastic polyurethane (TPU), an additional hot-melt adhesive layer is required to obtain a reliable bond between the TPU and another TPU layer or other material. Eliminating the hot-melt adhesive layer results in a lower weight and simplifies the manufacturing process for the material according to the invention. In principle, the use of two polyurethane layers is advantageous because the same melting point and identical material properties lead to a better bond between the polyurethane layers than between a single polyurethane layer and TPU. The inner and outer polyurethane layers bond particularly well to each other through the openings in the textile reinforcement layer when pressure and heat are applied, for example during a pressing process, thus reliably enclosing the intervening textile reinforcement layer. This results in a material for a shoe upper that exhibits both the elastic properties of the polyurethane layers and the resistance and tensile strength of the textile reinforcement layer. The use of thermosetting polyurethane results in both the inner and outer polyurethane layers being elastic, making it particularly well-suited as a material for shoe uppers. In contrast, the use of TPU causes yellowing and hydrolysis (i.e., the chemical bonds break down in water). Unlike TPU, no additional adhesive layer is required, which reduces elasticity. Preferably, the inner and outer polyurethane layers consist of a mixture of polyester and polyether. A higher proportion of polyester leads to improved mechanical properties such as increased tensile strength or greater hardness. A higher proportion of polyether leads to improved chemical properties such as hydrolysis resistance and UV stability (due to aliphatic compounds in the polyether). In a preferred embodiment, the thermosetting polyurethane contains aliphatic isocyanate. The use of this material has the advantage that, unlike TPU, it does not yellow. The textile reinforcement layer is made of a non-thermoplastic material. This type of material offers advantages for the design and appearance of the material, as it does not melt under heat and pressure. The textile structure of the reinforcement layer is intended to be retained even during pressing. This is also beneficial for the feel of the material. Different structures within the textile reinforcement layer result in different designs and surface textures. Preferably, the openings in the textile reinforcement layer each have an area in the range of 0.25 mm² to 9 mm². A preferred diameter of the openings is in the range of 0.1–0.2 mm. These dimensions have proven particularly advantageous for achieving, on the one hand, a good bond between the inner and outer layers and, on the other hand, maintaining sufficient resistance in the textile reinforcement layer. In a preferred embodiment, the inner polyurethane layer comprises at least two polyurethane sublayers. Each polyurethane sublayer exhibits different properties. They can differ, for example, in thickness, material properties (such as melting point), or color. Two, several, or all sublayers can differ in their properties. In a preferred embodiment, the outer polyurethane layer also comprises at least two polyurethane sublayers. Each polyurethane sublayer exhibits different properties. They can differ, for example, in thickness, material properties (such as melting point), or color. Two, several, or all sublayers can differ in their properties. It is particularly advantageous if a first polyurethane sublayer has a lower melting point and is positioned closer to the textile reinforcement layer than a second polyurethane sublayer. Such an arrangement facilitates the fusion of the inner and outer polyurethane sublayers through the holes in the textile reinforcement layer because the first polyurethane sublayers of the inner and outer layers melt more quickly and therefore bond more readily, while the second polyurethane sublayers do not melt. This ensures that the appearance of the material's exterior remains unchanged. According to further aspects, the invention comprises a shoe upper made of the materials described above and a shoe with such a shoe upper. Another aspect is a process for manufacturing such a material for a shoe upper, in which a textile reinforcement layer is pressed between an inner polyurethane layer and an outer polyurethane layer under heat. This can be done, for example, using a press. Further advantageous embodiments are described in further dependent claims. 4. Brief description of the accompanying characters In the following, aspects of the present invention will be explained in more detail with reference to the accompanying figures. These figures show: Fig. 1: Schematic cross-sectional view of an embodiment of a material for a shoe upper according to the invention; Fig. 2: Schematic cross-sectional view of a second embodiment of a material for a shoe upper according to the invention; Fig. 3: Examples of materials for a textile reinforcement layer; Fig. 4: Schematic view of an embodiment of a material for a shoe upper according to the invention; Fig. 5: Illustration of the manufacture of a material according to the invention; and Fig. 6: Football boot with a material according to the invention. 5. Detailed description of preferred embodiments Exemplary embodiments and modifications of the present invention are described in more detail below using a material for a shoe upper. This material is preferably used for sports shoes, and in particular for soccer shoes. However, it can also be used for other shoes, e.g., basketball shoes, where low weight and good mechanical properties are important, as described below. Fig. 1 shows a first embodiment of a material 1 for a shoe upper. In particular, Fig. 1 shows a schematic cross-section of such a material 1. The dimensions cannot be determined from this figure and are discussed in more detail below. As can be seen in Fig. 1, the material 1 has an inner polyurethane layer 10, a textile reinforcement layer 20, and an outer polyurethane layer 30. The textile reinforcement layer 20 is arranged between the inner polyurethane layer 10 and the outer polyurethane layer 30. The polyurethane layers 10 and 30 can be polyurethane films 10 and 30, respectively. However, the polyurethane layers 10 and 30 can also be cast. In the following, we will refer to polyurethane films 10 and 30, which are simply called PUR films 10 and 30. The designation inner PUR film 10 refers to the fact that this film is located on the inside of a shoe upper for which material 1 is used. The designation outer PUR film 30 refers to the fact that this film is located on the outside of a shoe upper for which material 1 is used. The inner PUR film 10, the textile reinforcement layer 20, and the outer PUR film 30 are pressed together under heat and pressure. During this process, the inner PUR film 10 and the outer PUR film 30 fuse together through the openings in the textile reinforcement layer 20, creating a reliable bond. Simultaneously, the inner PUR film 10 and the outer PUR film 30 enclose the threads of the textile reinforcement layer 20, thus establishing a connection between the textile reinforcement layer 20 and the PUR films 10 and 30. This will be discussed in more detail below. The inner PUR film 10 and the outer PUR film 30 contain a mixture of polyester and polyether. A higher proportion of polyester results in improved mechanical properties such as increased tensile strength and greater hardness. A higher proportion of polyether, due to aliphatic compounds in the polyether, leads to improved chemical properties such as UV stability and hydrolysis resistance. Preferably a polyester to polyether mixing ratio of 65% to 35% is used to ensure high cost efficiency and sufficient quality, especially UV stability and hydrolysis resistance. The blend of polyester and polyether gives the PUR film its advantageous properties, especially compared to TPU. One advantage of PUR film is its high elasticity compared to TPU. Furthermore, PUR film has better resistance to hydrolysis than TPU. In addition to polyether and polyester, the PUR film also contains polyisocyanate. Preferably, aliphatic polyisocyanate is used. This has the advantage that the PUR film does not yellow (UV stability) and is hydrolysis-resistant, which is a further advantage over the use of TPU. In one embodiment, the material 1 consists of the inner PUR film 10, the textile reinforcement layer 20 and the outer PUR film 30. The use of a PUR film 10, 30 on both sides of the textile reinforcement layer 20 has the advantage that a particularly good bond between the two PUR films 10, 30 is achieved when the material 1 is pressed under heat and pressure. In contrast, when using TPU, an additional hot-melt adhesive layer must be used to obtain a reliable bond between the TPU and another TPU layer or another material. Eliminating the hot-melt adhesive layer results in a lower weight and simplifies the manufacturing process for the material according to the invention. In principle, the use of two PUR films is advantageous because the same melting point and identical material properties lead to a better bond between the PUR films 10, 30 than between a PUR film and TPU. The bond between the PUR films 10 and 30 is only strong enough to meet the physical demands of a shoe upper, especially for soccer cleats, when combined with a suitable textile reinforcement layer 20 with sufficient mesh density. This eliminates the need for a hot-melt adhesive film, which negatively impacts the dynamic properties and weight of the material. The selection of the textile reinforcement layer 20 is of central importance, as it must be specifically adapted to the properties of the PUR films 10 and 30 to ensure a sufficient bond. The textile reinforcement layer 20 must be specifically developed to meet these requirements. The microstructure of the substrate, and especially the properties of the yarn used (e.g., roughened yarn), as well as the type of weaving technique, define the quality of the bond between the PUR films 10 and 30 and the textile reinforcement layer 20. For good transparency of material 1 and for a sufficient connection, either sufficiently large openings or many small openings are needed. The textile reinforcement layer 20 alone has a tensile and tear strength of at least 30 N. The film alone has a tensile strength of 6 N. The combination of PUR films 10, 30 and textile reinforcement layer 20 has a tensile strength of at least 100 N. The polyurethane used for the PUR films 10 and 30 is preferably thermosetting polyurethane containing an additional hardener, which imparts its structural strength to the PUR film through heating during manufacturing. In contrast, TPU can be reshaped by reheating. The textile reinforcement layer 20 has openings that allow the inner PUR film 10 and the outer PUR film 30 to fuse together through these openings. This means that the openings extend through the entire thickness of the textile reinforcement layer 20. The material of the textile reinforcement layer 20 can be a non-thermoplastic material, so that only the inner PUR film 10 and the outer PUR film 30 fuse together. However, the material of the textile reinforcement layer 20 could also be a thermoplastic material (e.g., polyamide / nylon), so that this material also fuses with the PUR films. A non-thermoplastic material is preferred for the design and external appearance of material 1. The fusing of the films can lead to various color effects. The PUR films 10 and 30 can also be printed. Depending on the thickness of the textile reinforcement layer 20, its structure is perceptible through the PUR films and can also be visible if a transparent PUR film is used. In this way, various surface structures with different properties, e.g., different coefficients of friction, can be produced. Visual effects can also be achieved by using different materials for the textile reinforcement layer 20 and colors of the PUR films 10, 30. Fig. 2 shows a preferred embodiment of the material 1 for a shoe upper, in which the inner PUR film 10 comprises four film layers 11-14 and the outer PUR film 30 comprises four film layers 31-34. Each of these film layers preferably has a thickness of approximately 0.02 mm, so that the inner PUR film 10 and the outer PUR film 30 have a combined thickness of approximately 0.08 mm. In other embodiments, these dimensions can vary. In particular, the individual film layers 11-14 and 31-34 can have different thicknesses. The film layers are also referred to as sublayers. The use of film layers is advantageous, among other things, for maintaining a constant film thickness. For example, using four film layers, each 0.2 mm thick, results in a constant layer thickness of 0.8 mm. In another embodiment, the film layers have a thickness of 0.10 - 0.16 mm (see Fig. 4 below). Layer 14 of the inner PUR film 10 and layer 31 of the outer PUR film 30, both facing the textile reinforcement layer 20, can have a lower melting point than the outer film layers 11, 12, 13 and 32, 33, 34. Therefore, when pressing the material 1, the inner PUR film 10 and the outer PUR film 30 can fuse together under heat without requiring an additional adhesive layer and without the outer PUR film layers melting or changing their surface appearance. The inner film layers melt faster and thus facilitate fusion without altering the outer film layers. Layers 14 and 31 can, for example, have a melting point of 100–150 °C, preferably around 130 °C. The outer foil layers 11, 12, 13 and 32, 33, 34 can have a melting point of 150 - 200 °C, preferably about 160 °C. In another embodiment, further foil layers 13 and 32, which are adjacent to the above-mentioned foil layers 14 and 31, also have a lower melting point than the remaining foil layers 11, 12 and 33, 34. In further embodiments, the number of film layers and their thicknesses can vary. In particular, the inner PUR film 10 and the outer PUR film 30 can also have a different number of layers with different properties. The inner PUR film 10 and the outer PUR film 30 can thus be adapted to their function as the outer and inner surfaces of the shoe upper, respectively. For example, the outer PUR film 30 (or just the outermost film layer) could be designed for high abrasion resistance, which can be important for a soccer shoe. In principle, the polyurethane sublayers of the inner PUR film 10 and the outer PUR film 30 can each have different properties. They can differ, for example, in thickness (as described above), material properties (such as melting point), or color. Two, several, or all sublayers can differ in their properties. Another aspect of the invention relates to a shoe upper made of the previously described material and a shoe with such a shoe upper. As described above, different surface structures can be created by using various materials for the textile reinforcement layer 20, since the surface of the outer PUR film 30 can adapt to the underlying textile reinforcement layer 20, resulting in a textured surface. In this way, different textile reinforcement layers can create zones with varying surface textures in a shoe upper, each fulfilling different functions. For example, a soccer cleat can have zones that offer different levels of friction or grip upon contact with a ball. Areas of the soccer cleat frequently used for dribbling can be given a high-friction surface by selecting a suitable surface structure to facilitate good ball control. Fig. 3 shows two examples of textile reinforcement layers 35, 37. The size of the openings 36, 38 in the textile reinforcement layers 35, 37 is preferably from 0.25 mm² to 9 mm². In this size range, a good bond between the inner PUR film 10 and the outer PUR film 30 is still achieved without the mechanical properties of the textile reinforcement layer 20 being impaired by excessively large holes. In one embodiment, the diameter of the openings is in the range of 0.1–0.2 mm (see Fig. 4 below). The openings can assume numerous geometries, from circular to diamond-shaped. Preferably, the meshes, threads, or fibers of the textile reinforcement layer 20 are reinforced by horizontal or vertical threads to strengthen the shape of the geometries and achieve a better connection. In one embodiment, a flat textile reinforcement layer is used because a 3D structure is not desired. This means the surface should be as smooth as possible and the film should not melt into the textile reinforcement layer. In principle, both smooth and textured surfaces are possible. Although the resulting material 1 has a very low weight for a shoe upper, this material on the other hand meets quality tests in terms of abrasion resistance, flexibility, delamination, UV stability, hydrolysis resistance, mechanical stability (such as tensile strength, tear strength, seam strength) and other criteria. Fig. 4 shows an exploded view of an embodiment of material 1 for a shoe upper. The material 1 comprises an inner polyurethane film 10, a textile reinforcement layer 20, and an outer polyurethane film 30. The two films 10 and 30 are composed of film layers with a thickness in the range of 0.10–0.16 mm. The textile reinforcement layer 20 has a polyether thread and openings with a diameter in the range of 0.1–0.2 mm. It has a flat structure (2D mesh). The material 1 in Fig. 4 has a weight of approximately 27-28 g (A4 format), which corresponds to a weight of approximately 450-470 g / m2. The weight of the textile reinforcement layer 20 is approximately 8-12 g (A4 format), which corresponds to a weight of approximately 130-200 g / m². Accordingly, the weight of the inner polyurethane film 10 and the outer polyurethane film 30 is in the range of approximately 135-160 g / m² each. Fig. 5 illustrates the manufacturing process for a material 1, described above, by showing a schematic cross-section through the material before and after production. The upper part of Fig. 4 shows the material before production, and the lower part shows it after. The textile reinforcement layer 20 is indicated by circles, which may, for example, represent a cross-section through fibers of the textile reinforcement layer 20, and the intervening openings 41. By applying heat and pressure—indicated by the arrow in the center of Fig. 5—the inner PUR film 10 and the outer PUR film 30 can be fused together by liquid material filling the openings 41. The corresponding representations in Fig. 5 are purely schematic and do not represent any scale. A PUR film 10, 30 with several film layers, as shown in Fig. 2, is produced on a substrate. The layers are applied to the substrate one after the other in liquid form. All four film layers are then cured in an oven, resulting in a PUR film as described above. In one embodiment, the film layers can also be applied directly to the textile reinforcement layer 20. Fig. 6 shows a football boot 2 in which the previously described material 1 is used. In the lateral midfoot area of ​​the football boot, a section (band) 50 reinforced with aramid fibers (e.g., Kevlar®) is arranged to stabilize lateral movements. Section 50 supports the foot, particularly during movements where the foot is inwardly flexed. For example, section 50 supports the foot when landing on the ground with the leg angled inward. This reduces the risk of ankle sprains. The material 1 described above is thin, which is desirable for a lightweight sports shoe. However, this thinness also means that material 1 offers little cushioning. For certain applications, it may be desirable to increase the cushioning of material 1. Therefore, it is conceivable to introduce a cushioning layer on the inside of material 1 or between the PU films 10 and 30. This cushioning layer could be a PU foam that is injected between the layers, either across the entire surface or only in specific areas. To facilitate this, the PU films could be fused / welded together only in certain areas. The unconnected cavities could then be filled with compressed air, PU foam, or other cushioning materials. A three-dimensionally structured textile reinforcement layer (3D mesh or spacer mesh) could also provide damping. Such a textile reinforcement layer can also include areas of varying thicknesses. In a first area, where damping is desired and where the PU films are not to be bonded together, the textile reinforcement layer could be designed with a correspondingly greater thickness. In a second area, where no damping is desired and where the PU films are to be bonded together, the textile reinforcement layer could be designed to be correspondingly thin, as described above.

Claims

Material (1) for a shoe upper, in particular for football boots, comprising: a. an inner polyurethane layer (10); b. an outer polyurethane layer (30); c. wherein the inner polyurethane layer (10) and the outer polyurethane layer (30) comprise thermosetting polyurethane; and d. a textile reinforcement layer (20, 35, 37) arranged between the inner polyurethane layer (10) and the outer polyurethane layer (30), wherein the textile reinforcement layer (20, 35, 37) comprises a non-thermoplastic material; e. wherein the textile reinforcement layer (20, 35, 37) has openings (36, 38, 41), and wherein the inner polyurethane layer (10) and the outer polyurethane layer (30) are connected to each other through the openings (36, 38, 41) of the textile reinforcement layer (20, 35, 37). Material (1) for a shoe upper according to the preceding claim, wherein the inner polyurethane layer (10) and the outer polyurethane layer (30) comprise a mixture of polyester and polyether. Material (1) for a shoe upper according to one of the preceding claims, wherein the inner polyurethane layer (10) and the outer polyurethane layer (30) comprise aliphatic isocyanate. Material (1) for a shoe upper according to one of the preceding claims, wherein the openings (36, 38, 41) each have an area in the range of 0.25 mm2- 9 mm2. Material (1) for a shoe upper according to one of the preceding claims, wherein the inner polyurethane layer (10) comprises a polyurethane film and / or the outer polyurethane layer (30) comprises a polyurethane film. Material (1) for a shoe upper according to one of the preceding claims, wherein the inner polyurethane layer (10) comprises at least two polyurethane sublayers (11-14). Material (1) for a shoe upper according to one of the preceding claims, wherein the outer polyurethane layer (30) comprises at least two polyurethane sublayers (31-34). Material (1) for a shoe upper according to one of claims 6 or 7, wherein the at least two polyurethane sublayers (11-14, 31-34) have different properties. Material (1) for a shoe upper according to one of the preceding claims, wherein the inner polyurethane layer (10) and the outer polyurethane layer (30) each have a first polyurethane sublayer (14; 31) and a second polyurethane sublayer (13; 32) with different melting points. Material (1) for a shoe upper according to the preceding claim, wherein the first polyurethane sublayer (14; 31) has a lower melting point and is arranged closer to the textile reinforcement layer (20, 35, 37) than the second polyurethane sublayer (13; 32). Material (1) for a shoe upper according to one of claims 9 or 10, wherein the melting point of the first polyurethane sublayer (14, 31) is between 100 °C and 150 °C. Material (1) for a shoe upper according to one of claims 9 to 11, wherein the first polyurethane sublayer (14, 31) is arranged directly on the textile reinforcement layer (20, 35, 37). Material (1) for a shoe upper according to one of claims 9 to 12, wherein the first polyurethane sublayer (14, 31) has a thickness of approximately 0.02 mm. Material (1) for a shoe upper according to one of claims 9 to 13, wherein the melting point of the second polyurethane sublayer (13, 32) is between 150 °C and 200 °C. Material (1) for a shoe upper according to one of the preceding claims, wherein the thickness of the inner polyurethane layer (10) and / or the outer polyurethane layer (30) is approximately 0.08 mm. Material (1) for a shoe upper according to one of the preceding claims, wherein the inner polyurethane layer (10) and / or the outer polyurethane layer (30) each comprise four polyurethane sublayers (11-14; 31-34). Material (1) for a shoe upper according to one of the preceding claims, wherein the outer polyurethane layer (30) is transparent. shoe upper comprising a material (1) according to one of the preceding claims. shoe upper comprising at least two materials (1) according to any one of claims 1-17. upper shoe according to the preceding claim, wherein the at least two materials (1) are arranged in different zones of the upper shoe. Shoe upper according to claim 19 or 20, wherein the at least two materials (1) are designed differently with respect to the textile reinforcement layer (20, 35, 37), the inner polyurethane layer (10) and / or the outer polyurethane layer (30). Shoe (2) with a shoe upper according to one of claims 18 - 21. A method for producing a material (1) for a shoe upper, comprising the following steps: a. Arranging a textile reinforcement layer (20, 35, 37) between an inner polyurethane layer (10) and an outer polyurethane layer (30), wherein the textile reinforcement layer (20, 35, 37) comprises a non-thermoplastic material, and wherein the textile reinforcement layer (20, 35, 37) has openings (36, 38, 41) through which the inner polyurethane layer (10) and the outer polyurethane layer (30) fuse together; and b. Pressing the textile reinforcement layer (20, 35, 37), the inner polyurethane layer (10) and the outer polyurethane layer (30) under heat and pressure. Method according to claim 23, further comprising the preceding step: c. Producing the inner polyurethane layer (10) and the outer polyurethane layer (30) by applying one or more sublayers (11-14; 31-34) to a substrate.

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