AT12431U1 - FORMAT CUTTING - Google Patents

Abstract

The invention relates to a format cut comprising a carrier material (2) formed with a non-woven fabric and / or knitted fabric and / or woven fabric made of polyamide and / or polyester threads, in particular polyamide and / or polyester microfibers and / or cotton threads, in particular sheet-like or layered. and a coating (4) applied on the carrier material (2), which is formed with polyurethane dispersion on a structured silicone rubber backing or mold and, if appropriate via an adhesive layer (7) formed by polyurethane dispersion, is bonded to the carrier material (2) It is envisaged that the total polyurethane content of the foam blank (1) is 60 to 240 g / m 2, this basis weight also including any polyurethane already present in or incorporated in the backing material (2) and the basis weight of the backing material (2). , in particular including any Polyu contained therein rethan, 200 g / m2 to 450 g / m2

Description

Austrian Patent Office AT12 431 U1 2012-05-15

Description: The invention relates to a format cut according to the preamble of claim 1.

From DE 26 08 781 C2, a leather-like substrate with a textile carrier body is known, which is impregnated with a polymeric plastic foam. This carrier body consists of a fleece or knitted fabric, which is impregnated from its surface starting in a range between 20 and 60% of its total thickness. The plastic foam has open cells formed by introducing air and further includes closed cells forming hollow microspheres. On the ground surface, a thin PUR coating is applied. This carrier has a high carbon content due to the C02 gas contained in the hollow microspheres; The material is hard or leaves its feel to be desired. To achieve a nubuck-like appearance, the surface must be ground after the substrate coating.

From DE 200 10 978 U1 a substrate is known, which is provided on its surface with a coating of a crosslinked polyurethane layer, which is connected by an adhesive layer to the surface of the substrate. In the case of this substrate, there is, above all, the disadvantage that troublesome wrinkles remain during buckling and that there is no defined penetration of the applied coating into the carrier material.

According to DE 20 2004 004 807 a plastic coating is applied to a base body formed from fiber material. The main body consists of at least two layers, wherein the coating facing the layer of the carrier body is formed by a nonwoven fabric of microfibers, wherein the cavities between the microfibers are at least partially filled with a coagulated plastic material. Such a substrate contains a considerable amount of polyurethane and the amount of polyurethane used to bond the two webs approximates the amount of polyurethane used for the coating.

According to DE 203 18 906 U1, a thin coating is applied to a carrier, wherein the coating applied to the rough carrier surface coating tends to float, since no penetration of the coating is provided in the carrier.

The aim of the invention is to produce a Formatzuschnitt, which has excellent mechanical properties, in particular optimal Daugebiegungsverhalten even at temperatures below zero even at a thickness of 1 mm or more at low weight. Furthermore, the Formatzuschnitt high abrasion resistance and color and light fastness and high tensile strength and in particular have approximately the same extensibility and tear resistance in mutually perpendicular directions. Further, according to its intended use, the shape blank should have a coating which is either substantially waterproof, e.g. may be designed for motorcycle seats, seat covers or luggage or water vapor permeable, such. for car interior coverings, upholstery upholstery as well as shoe uppers. Furthermore, the Formatzuschnitt the structure of the textile substrate on the fine, soft and thin coating is not or not disturbing visible, the coating should be permanently connected to the textile substrate. Furthermore, the format cut according to the invention when touching by hand or when attached to the body, unlike conventional woven fabric imitation leather with a heavy thick coating to adapt in a very short time to the body temperature or adjust a temperature balance, so improved feel and increased comfort.

Furthermore, the applied on the textile substrate thin coating when kinking, even when kinking at an acute angle, no creases form, as is the case when a thin coating is on a light, voluminous nonwoven backing or if a thin Coating floats on a fibrous surface. One of the most important tasks is to provide a textile support with a coating which, above all, exhibits a textile and / or nubuck-like fine structure.

Another important task is also that the Formateuschnitte in small quantities, without expensive elaborate tools with each desired by the market surfaces in terms of appearance, feel and friction on different substrates that are cut out of web material, can be made. Another important task is to create a format cut which meets the limit requirements of the automotive industry with regard to carbon emissions and which has a favorable C02 balance in its production, taking into account all the components used and that with low water consumption.

These objects are in a Formatzuschnitt comprising a formed with a nonwoven fabric and / or knitted fabric and / or fabric of polyamide and / or polyester threads, in particular polyamide and / or polyester microfibers and / or cotton threads, in particular sheet-like or layered , Support material and a coating applied to the carrier material, which is formed with polyurethane dispersion on a structured Silikonkautschuktenterform or -form and, optionally via an adhesive layer formed with polyurethane dispersion is attached to the carrier material, according to the invention achieved in that the total polyurethane content of the Formatzuschnittes 60th up to 240 g / m 2, preferably 80 to 150 g / m 2, in particular 100 to 140 g / m 2, this weight per unit area also including polyurethane already present in the support material or introduced into it during its production and the basis weight of the support material together with al if present, polyurethane is 200 g / m2 to 450 g / m2, preferably 200 g / m2 to 350 g / m2, in particular 230 g / m2 to 270 g / m2.

The Formatzuschnitt invention is lightweight, durable and has a good extensibility and tear resistance, which are substantially homogeneous or similar in mutually perpendicular directions on its surface. The feel of the surface is pleasant and the surface can be structured or shaped as desired. The use of polyurethane dispersion is low and thus the Formatzuschnitt is inexpensive to produce.

The nonwoven-based carrier material may already contain a small amount of polyurethane for its solidification. But this polyurethane has a spongy structure and is therefore very light. This polyurethane content is extremely low and is at a support thickness of 0.9 mm below 70 g / m2.

In practice, the entire polyurethane content of Formatzuschnittes can be readily determined by dissolving out of the polyurethane with dimethylformamide and appropriate weighing the Formatzuschnittes before and after the dissolution of the polyurethane.

The selected basis weight of the textile substrate ensures a durable, but easy and inexpensive to produce base and can be well connected to the coating. Any other polymeric dispersion blends, such as e.g. Poly-acrylates or resins are dissolved out and count as polyurethane.

It is advantageous if the, applied in particular in the form of a film coating, a basis weight of 60 g / m2 to 240 g / m2, for special cases, a basis weight of 60 g / m2 to 160 g / m2 possesses. Including the embedded in the carrier material adhesive layer and possibly introduced in the support body during its production polyurethane, the amount is sufficient to cover the structure of the support material such that this structure is valuable to the viewer or the structure formed on the surface of the coating, even when stretched not disturbing, and that even the finest textile fiber structures, such as of carbon fabric, exactly reproduced.

In order to increase the adhesion of the coating or to improve the feel of the Formatzuschnittes, it can be provided that the fleeces or knitted fabrics used or tamped or are very easily roughened and optionally with a grain size > 400, 2/24 Austrian Patent Office AT12 431 U1 2012-05-15 in particular with a grain size of 450 to 900, sanded to eliminate knots and protuberances that might appear on the surface of the coating.

For the strength of the textile support and the durability of the applied coating, it is advantageous if dense as a support material, that is viewed with the naked eye, not or hardly transparent and / or not or hardly translucent knitted or nonwoven or fabric or a Composite knitted fabric / fleece or fabric / fleece are used.

It has been found that it is particularly advantageous if the knitted or woven fabric consists of cotton or at least contains cotton threads, and if the coating side has a very slight Velcro effect, which is caused by walking or grinding. The best results both in the production, but above all in finished cut-to-size pieces are achieved when the cotton knit or fabric has a basis weight between 100 and 200 g / m2 and the nonwoven to which it is bonded also has a basis weight between 100 and 200 g / m2. In particular, if such a nonwoven consists of polyester or polyamide fibers, these fibers may advantageously have a thickness of between 2 and 6 denier.

The cotton absorbs the water of the polyurethane dispersion rapidly and passes it on to the non-absorbent synthetic fibers. This simplifies the manufacturing process and saves energy for drying. The main advantage of this combination combination, however, is that when gluing the very fluffy surface of the knitted or woven fabric with the layer 4 'remain the finest structures that were transferred from the die to the coating surface, absolutely accurate even when stretched. This advantage arises because the fine short loop fibers in the layer 4 " or in the adhesive layer 7 are arranged horizontally or parallel to the surfaces and eliminate imperfections and support structures, especially when the support 2 in the wet layer 4 " is inserted and lightly pressed. The nonwovens with a fiber thickness in the denier region have a three-dimensional position of the fibers. The fibers are either solidified together by means of a jet of water or preferably by needling and optionally thermally shrunk. In this case it is important that they are soft and voluminous and have a thickness between 0.8 and 1.8 mm at a weight between 100 and 200 g / m2. The cotton knit or fabric may either be glued to the mat; Preferably, it is connected in the nonwoven production equal by means of needles on one side with this. Such a composite is durable and inexpensive and no additional adhesives are needed. This composite has an extremely high tear propagation resistance, which is important for the intended uses of the format cut.

In order to adapt the Formatzuschnitt to different applications, it can be provided that on the carrier material on its surface facing away from the coating at least one further layer of a light, bulky, preferably 3 to 6 mm thick, polyester or polyamide nonwoven with a foamed plastic dispersion adhesive is glued or laminated. It may also be provided for this purpose that the further layer is formed by a composite of a needle felt or polyester or polyamide nonwoven or a layer of a polyurethane peel foam or a chloroprene polymer foam with a knitted fabric, which composite at the back of the , preferably formed by a knitted fabric, carrier material is attached.

It may be advantageous if the polyurethane foam or the Polychlo-roprene has a density of 0.005 to 1.2 g / cm3, preferably 0.01 to 0.06 g / cm3 and / or if the needle felt a basis weight of 100 to 200 g / m 2, preferably 120 to 160 g / m 2, and an average thickness of 2 to 4 mm, preferably 2.5 to 3.5 mm, and / or if the back forming knit has a basis weight from 60 to 160 g / m 2, preferably from 80 to 120 g / m 2, in particular from 80 to 100 g / m 2.

The polyurethane expanded foam and the Polychloroprenschaum can substitute each other with equal effect. In particular, such format blanks can be used for the creation of upholstery, since a compliant and soft or shock-dampening trim can be produced, as is the case, for example, in motor vehicle upholstery, in particular in vehicle headliners , can be used, and in contrast to voluminous polymer foams has a very low total carbon emissions.

It has been found that it is advantageous if at least 30 wt .-%, preferably at most 20 wt .-%, of the total amount of solidified polyurethane dispersion contained in the Formatzuschnitt present in the support material and / or if the areas of the support material in the the polyurethane dispersion has penetrated controlled in their jobs, have a density which is between 15% and 55% above the density of the polyurethane dispersion-free areas of the support material, so that the overall result is a good bond with low weight.

For the purposes of the invention, it is advantageous if the polyurethane dispersions used are resin-modified.

It is advantageous if in the polyurethane dispersion of the coating and / or the adhesive layer 2 to 9 wt .-%, each based on the total weight of the polyurethane dispersion, possessing, optionally contact adhesive properties, synthetic resins are included.

It may further be provided if contained in the Formatzuschnitt polyurethane dispersions or polyurethane dispersion mixtures solids in the form of pigments, crosslinkers and / or thickeners are included.

Furthermore, it is particularly advantageous in terms of the improvement of the properties of the blanks, if the softness and / or surface tension and / or the fire behavior of the textile material contained therein chemicals are contained in the support layer.

It is preferably ensured in the new Formatzuschnittes that the polyurethane foam, preferably the polyurethane scarf foam, or the polychloroprene foam has a density of 0.005 to 1.2 g / cm3, preferably 0.01 to 0.06 g / cm3 , owns.

It is preferred if the needled nonwoven used a basis weight of 100 to 200 g / m2, preferably 120 to 160 g / m2, and an average thickness of 2 to 4 mm, preferably from 2.5 to 3.5 mm, and / or that the back-forming knitted fabric has a basis weight of 60 to 160 g / m 2, preferably 80 to 120 g / m 2, especially 80 to 100 g / m 2.

An advantageous construction of the Formatzuschnittes is achieved when the coating is constructed with two inseparable layers and a superficially located, superficially structured layer of polyurethane dispersion and an underlying and associated, with a linear structure possessing, optionally polyacrylates and or polyurethane-containing layer containing synthetic resins, wherein on the surface of the carrier material an adhesive layer formed with polyurethane is provided, which adhesive layer between 0.02 and 0.6 mm, preferably between 0.05 to 0.4 mm, in the carrier layer is embedded and increases the density of the carrier layer in this range by 15 to 55 wt .-% compared to the remaining areas of the carrier layer. Thus, a good durable coating is achieved, which can be well anchored in the fibers or cavities of the substrate. A well-retaining adhesive layer is obtained if the adhesive layer is formed with a layer of a polyurethane dispersion containing optionally having polyacrylates and / or resins and a basis weight of 20 to 80 g / m 2 and possibly the same chemical structure as the polyurethane dispersion layer to be bonded to the support material has.

The increase in the density of the carrier layer in the penetration region of the polyurethane adhesive dispersion by 15 to 55 wt .-%, preferably 20 to 35 wt .-%, especially with knitted backing layers ensures in addition to a good connection with the adhesive layer that also with strong expansion in both directions or perpendicular to each other directions to eg 15% of the textile structure of the knitted fabric on the upper surface of the thin soft coating is not disturbing and even the very fine structures, e.g. of carbon fibers, not be distorted. The controlled penetration of the polyurethane adhesive dispersion between 0.02 to 0.6 mm, preferably between 0.05 to 0.4 mm, into the carrier layer is controlled by applying a light pressure to the top of the carrier layer upon application of the dispersion. by means of an applicator roll, wherein the gap between the rollers to the desired penetration depth is narrower than the thickness of the carrier material and adhesive layer. Also, by means of a correspondingly applied surface or Walzensiebdruckes, but preferably by airless spraying with a line pressure of more than 60 bar, an appropriately introduced into the carrier adhesive layer can be formed. Particularly soft coatings are achieved when this adhesive dispersion or this density-increasing polyurethane dispersion is used as a so-called whipped foam with a density between 0.75 and 0.95 g / cm 3.

Preferably, the polyurethane dispersion of the adhesive layer is applied in a controlled manner or there is a controlled penetration of the dispersion or the adhesive layer in the carrier layer, especially in very soft textile supports such as polyurethane-free nonwovens or thin, open-mesh knitted or thin open-mesh fabrics, which with a thicker fleece are connected. In this case, the second layer is sprayed directly onto the applied, largely dry first layer in the matrix, and then the support material is placed on this still wet second adhesive layer and lightly pressed. In this case, the penetration depth of the dispersion of this layer in the carrier layer can be easily controlled or adjusted via the sprayed dispersion amount, its viscosity and the selected slight contact pressure after the carrier has been placed or placed in the wet dispersion. It is inventively of great advantage, when the wet adhesive dispersion penetrates through the open mesh of the thin, light knitted fabric or fabric into the surface of the nonwoven, so that the knitted or woven fabric is embedded in the solidified dispersion. This overall coating construction, in which all polyurethane layers are applied directly to the matrix, results in the molded section becoming more homogeneous and largely waterproof.

According to the invention an even better connection is achieved when the polyester knitted fabric or fabric or the polyamide knitted or woven fabric contains between 10 and 45 wt .-%, preferably between 20 and 30 wt .-%, cotton threads. Such a mixture also offers the advantage, during processing, that the cotton fibers absorb part of the water of the dispersion rapidly and that, as a result, the adhesive dispersion in or on the carrier layer dries faster.

It is therefore favorable if the fibers of the web are formed with polyester and / or polyamide and / or cotton.

It is advantageous if the yarns or threads of the fabric or fabric of polyester and / or polyamide optionally with a proportion of up to 40 wt .-%, preferably up to 45 wt .-%, cotton or Cotton threads and / or are formed only with cotton or cotton threads.

It is also preferable to have a trim piece in which it is provided that the adhesive layer is built up and crosslinked to 50 to 85% by weight of polyurethane having a crystalline structure and / or that it is 0.02 to 0.6 mm, in particular 0.05 to 0.4 mm deep from the surface directly or indirectly drawn into the support material of the Formatzuschnittes from the material surface ago and / or that the adhesive layer with a weight of 20 to 80 g / m2 from the surface on the Carrier material applied and at least partially embedded in the same.

A sizeable surface may be imparted to the molding blank when a structure is formed on the outer surface of the coating, the structured coating primarily showing the appearance of finely textured textile surfaces and / or a nubuck-like appearance. Also the appearance of ground rubber, abrasive paper or waffle patterns or of a technical fabric, such as e.g. a woven or knitted fabric made of glass or carbon fibers, or a so-called " technical " Appearance or a scar leather-like appearance can be provided.

In this sense, it may also be advantageous if the carrier material is formed with colored or different colors owning fibers or yarns and / or printed in color, and / or that the material of the coating is transparent or transparent-colored.

For protection it can be provided that on the surface of the coating a very thin, hydrophobic finish layer is applied in a thickness of less than 0.005 mm with nanoparticles of polysiloxane or wax or fluoropolymers or mixtures of these.

A cost-effective and environmentally friendly construction of the format cut, e.g. for car canopy is achieved when a bulky, lightweight up to 6 mm thick polyester fleece containing filaments made of PET bottle regenerate is applied to the back of the backing layer by means of a foamed dispersion adhesive.

The application of the coating to a flat, layer or plate-shaped blank of a carrier material is such that the coating is formed with or on a negatively structured pad or mold made of silicone rubber by solidification of a polyurethane-containing dispersion, to which a Polyurethane-containing dispersion layer is applied. After its solidification on the silicone substrate, this dispersion layer is bonded to the adhesive layer applied to the carrier layer, which is preferably chemically identical or very similar and can be foamed, preferably by means of heat and / or pressure. The outer surface of the coating is created or structured by the matrix. The coating is bonded to the adhesive layer in such a way that the still moist adhesive layer applied to the substrate is applied to the coating and the layers are pressed at a pressure of less than 0.3 kg / cm 2, preferably less than 0.15 kg / cm 2. or substantially pressure-free and at a temperature of less than 80 <€, preferably less than 65 ° C, connected.

Alternatively and preferably, the second layer, that is, the adhesive layer, not on the textile support, that is, the textile support layer, but applied directly to the solidified first layer of the coating and the carrier in this wet layer on or laid , lightly pressed and dried by means of heat and glued.

Such a format section is advantageously designed such that at a total thickness of 0.9 to 1.5 mm, the total surface weight of the Formatzuschnittes between 250 and 500 g / m2, in particular between 350 and 450 g / m2.

A pleasant haptic results when the coating is prepared with a polyurethane dispersion having a hardness of less than 68 Shore A, preferably less than 55 Shore A.

The carrier material has the corresponding lightness, a larger volume, a better feel and a softer feel, if on its back a fluffy fiber structure is formed. The yarns of the knitted or woven fabric are made of polyester or polyamide and may also contain up to 40 wt .-% cotton or be formed only with cotton threads. Nonwovens of polyester or polyamide fibers have at the same strength compared to comparable knitted fabrics or fabrics by more than 20% lower basis weight and thereby have a higher resistance to tearing and a more favorable elongation behavior. Especially the expensive microfiber webs with a sponge-like polyurethane impregnation already at a weight per unit area of 240 g / m 2 and coated according to the procedure according to the invention result in optimum size blanks with a thickness of 1.1 mm and a total basis weight of 310 g / m 2. These nonwovens are formed with a fiber thickness of about 0.7 dtex.

According to the invention, it is also possible to produce from the very inexpensive nonwovens of polyester or polyamide fibers having a fiber thickness of between 1 and 9 denier, preferably 2 to 4 denier, shape blanks which are very close to those made of microfibers They are even superior to them in terms of their low weight. In particular, good results are achieved in view of a very exact surface structure reproduction, which does not change during stretching by 15% and in which even the finest fiber structures of a molded carbon fabric in the thin coating three-dimensional carbon fiber typical unadulterated. This is achieved in that between the coating and the nonwoven a thin, lightweight, open-mesh or polyester or polyamide fabric is embedded in the adhesive or polyurethane layer.

Good durability and resistance of the coating are achieved when the structured top layer of the coating is prepared with a solidified polyurethane dispersion mixture containing between 2 and 10 wt .-% non-emigrable polysiloxane and is crosslinked. The layer of the coating lying below in the formate section, as well as the adhesive layer which is connected to the carrier material, can each be composed of 50 to 85% by weight of polyurethane having a crystalline structure. The adhesive layer on the surface of the carrier material is 0.02 to 0.6 mm, in particular 0.05 to 0.4 mm, deeply embedded in the absorbent material of the nonwoven material, optionally through a meshed knit or fabric from the surface of the carrier layer forth or confiscated.

Of particular importance according to the invention is that all layers contain a crosslinker and these layers are brought together at a time or placed on top of each other before the crosslinker takes effect, so that the crosslinking takes place simultaneously in all layers. In this way the layers are interlinked with each other as well as with the layers or not only is there a parallel crosslinking of the individual layers but also a cross-layer cross-linking. When creating the pattern cut, the adhesive layer which is drawn onto the carrier material is thus applied to the adhesive layer connected to the surface layer so that the two adhesive layers adhere to one another. This also contributes, if the coating and / or the adhesive layer in each case up to 50 wt .-%, preferably up to 25 wt .-%, polyacrylates based on the polyurethane content of the dispersion.

For a good connection, it is expedient if the thickness of the coating comprising the surface layer and the layer adhering thereto is 0.05 to 0.16 mm.

The adhesive layer is at a weight of 20 to 80 g / m2 from the surface in or on the carrier material on or applied and at least partially embedded in this.

Finally, the invention also relates to articles produced with a trim blank according to the invention, in particular in the form of motor vehicle interior wall coverings, e.g. Car roofs and upholstery, bags, suitcases, furniture covers, clothing, shoes, bicycle or motorcycle saddles or card cases. It is advantageous to use the format cuts according to the invention for the production of these articles.

In the following the invention will be explained in more detail with reference to the drawing, for example, in which in Fig. 1 and 2 is a schematic section through the structure of an inventive

Formatsuschnittes is shown.

Fig. 3 shows a plan view of the surface of a format blank according to the invention.

Fig. 4 shows an advantageous embodiment of a format according to the invention blank.

Fig. 5 shows a formatting cut, in which the carrier material with another

Layer is connected.

The format cut according to the invention comprises a layer with textile carrier material 2, which comprises a nonwoven and / or a knitted fabric or a woven fabric of synthetic fibers, in particular polyester fibers. On a nonwoven, for example, a knitted fabric which is not shown here can also be found, thin, open-meshed or wide-meshed knit or woven fabric which is constructed with synthetic threads or cotton threads.

For particularly soft and strong end products nonwovens are used with a fiber thickness between 0.7 dtex and 9 denier.

The knitted or woven fabrics used may be tamped and / or lightly fluffed on their coating side, in particular with a grain size &gt; 400, preferably with a grain size of 450 to 900, ground, are present, and preferably have on their back a pronounced fluffy structure.

On the layer of substrate 2, an adhesive layer 7 is applied directly or indirectly or this adhesive layer 7 is for the most part drawn into the layer of the substrate 2. Applied to this adhesive layer 7 is a coating 4 which comprises two layers, namely a structured superficial surface layer 4 'and a layer 4 "underneath this layer 4' used for bonding. The coating 4 is applied to the adhesive layer 7 such that the adhesive layer 4 &quot; on the adhesive layer 7 comes to rest and these two layers 4 ", 7 are connected together inextricably. On the outside of the top layer 4 'of the coating 4, a finish layer 5 can be applied.

The coating 4 including the polyurethane contained in the carrier material 2 and possibly in the adhesive layer 7 contain no solvent, as well as the carrier material. The format cut is therefore largely free of carbon-containing emissions and has also been produced in an environmentally friendly manner, even with very low water consumption.

The total polyurethane content of Formatzuschnittes 1 is 60 to 240 g / m2, preferably 80 to 150 g / m2, in particular 100 to 140 g / m2. This indicated basis weight also includes at most already present in the support material 2 polyurethane or polyurethane dispersion present, which was introduced in the course of the manufacturing process of the substrate 2 already in this.

It results according to the invention, a basis weight for the Formatzuschnitt, comprising the coating 4 and the substrate 2, from 250 g / m2 to 500 g / m2, preferably 350 g / m2 to 450 g / m2.

This results in a good connection between the coating 4 and the carrier material 2. Overall, however, provided that in the carrier material 2 a maximum of 20 to 80 g / m2 polyurethane dispersion are included, this content both already in the preparation of the carrier material 2 optionally introduced polyurethane as well as the penetration of the coating 4 in the area 3 polyurethane dispersion comprises.

On the surface of the coating 4, a very thin hydrophobic finish layer 5 in a thickness of less than 0.005 mm can be applied with nanoparticles of polysiloxane or of wax or of fluoropolymers or of mixtures of these.

The coating 4 is bonded to the inseparable layers 4 'and 4 &quot; and comprises the superficially structured layer 4 'of polyurethane dispersion and the underlying layer 4 &quot; formed with a polyurethane dispersion containing a linear structure, optionally containing polyacrylates and / or synthetic resins. This polyurethane dispersion layer 4 &quot; is formed with the formed on the substrate 2, polyurethane-formed adhesive layer 7 as long as this layer (s) is still wet or wet or are connected. It is provided that the coating 4 is formed with a negatively structured pad or mold made of silicone rubber by solidification of a polyurethane-containing dispersion, which is connected to the surface of the carrier material 2 and the adhesive layer 7 or glued to this. The coating 4 is created or patterned with this die and applied while still wet, in particular largely free of pressure and with only a slight increase in temperature.

The layer 4 'of the coating 4 is formed in advance with a polyurethane dispersion on a heated or hot silicone pad or molded and solidified by drying; then the layer 4 &quot; applied, which is chemically identically or very similar. The layer 4 &quot; is firmly bonded to the soft adhesive layer 7, which is also chemically identical or very similar to the coating 4.

It is envisaged that in a preferred final thickness of about 1.2 mm, the weight per unit area of a format cut according to the invention is between 320 and 485 g / m2.

Since the fibers of the carrier material 2 are preferably made of polyester, the requirements of the vehicle industry, in particular with regard to the emission of organic compounds, not only met but considerably undercut. The blank according to the invention has a favorable CO 2 balance.

Furthermore, such a Formatzuschnitt in mutually perpendicular surface directions has an elongation at break of more than 20%, preferably of more than 40%, or is found at 15% elongation no disturbing change in the surface.

In order to be able to produce thicker shaped sections 1, a further layer 6, which is formed by a nonwoven, can be applied to the coating-free side or rear side of the carrier material 2. The application of multiple layers 6 is possible. Such an arrangement is shock-absorbing or has excellent sound-absorbing and safety features. Since the fibers can be regenerated or recycled from PET bottles, the production of such nonwovens is economical and environmentally friendly.

When the adhesive layer 7 is applied directly or indirectly, part of this dispersion penetrates in a controlled manner into the carrier material 2 into the region 3, which is about 0.02 to 0.6 mm, preferably 0.05 to 0.4 mm, thick , In this case, forms on the surface of the carrier material, when the adhesive dispersion was applied directly to this, a thin, torn adhesive film of less than 0.02 mm thickness. When the adhesive dispersion is indirect, that is, when the carrier layer is placed in the wet dispersion, a substantially homogeneous film forms on the carrier surface. In the region 3 where the dispersion has penetrated, after the dispersion has dried, the carrier material 2 has a density which lies between 15 and 55% above the density of the region of the carrier material 2 into which no polyurethane dispersion has penetrated. By the direct or indirect application of the adhesive dispersion on the carrier layer, the water-tightness and the water vapor permeability can be influenced or controlled.

In a preferred final thickness of the Formatzuschnittes 1 of 1 mm, this has a weight between 290 and 385 g / m2. The thickness or thickness was measured in accordance with DIN 53326 with a punch diameter of 25 mm and a spring pressure of 5 N.

The finer the fibers that form the yarns, the more fibers are needed and the larger the surface of the yarn or the microfibers used for the nonwoven and the better the compound of the polyurethane dispersion with the yarn or Microfibers of the fleece.

The formatting sections are in particular produced such that the substrate 2 is provided in the form of web material and corresponding blanks, for example, in a length of two meters and a width of 1.5 meters, are cut and on this area or plate-shaped carrier materials, the coating 4 is applied. This coating 4 is transferred from or directly to the silicone rubber matrix on the plate-shaped carrier material 2.

The coated surface 4 of a molding blank 2 can have different appearances and different functions in different surface areas. So could e.g. a portion of the molding blank having the appearance and properties of a carbon fiber fabric and having a low water vapor permeability, while another portion of the Formatchuschnittes has a nubuck leather-like appearance and a much higher water vapor permeability. It is important and of particular advantage that the two layers 4, 4 'of the coating 4 are manufactured on the matrix. The part of the carrier material 2 to be bonded or bonded to this coating 4 is the adhesive layer 7 applied directly or indirectly to the carrier material 2. A part or the majority of this adhesive layer 7 is controlled to increase the density of the carrier material 2 stored in this defined area 3. Through this structure, the tasks are optimally solved. It can be provided according to the invention that, for further improvement, the adhesive of the adhesive layer 7, which changes the density of the carrier material 2 in the region 3 along its penetration, is foamed, and stored as a so-called whipped foam with a corresponding amount of introduced air.

The introduced adhesive layer 7 or the dispersion of this layer introduced into the carrier material 2 has a double function. The adhesive layer 7 serves to increase the density of the carrier material 2, without filling the cavities or spaces between the yarn masses or the fibers or the cells of any sponge structure which may already be present in the carrier material 2, but also avoids closure of existing intermediate spaces and a resulting higher total weight. In addition, it has best adhesive properties.

In order to achieve optimum crosslinking between the individual layers, it is advantageous if the first layer 4 ', which is produced on the structured matrix, still contains 0.2 to 4% by weight of water, preferably a water content from 1 to 3 wt .-%, based on the solids content of the polyurethane dispersion possesses. Then, to form the adhesive layer 4 &quot; the dispersion applied wet. This applied dispersion is dried and still contains between 0.5 and 6 wt .-% water, based on the solids content of the polyurethane dispersion.

The polyurethane adhesive applied to the substrate 2 polyurethane adhesive layer 7 or the dispersion used for this purpose is wet with a water content between 4 and 25 wt .-%, based on the solids content of the polyurethane dispersion, applied and the layers 4 &quot; and the adhesive layer 7 are applied to each other, e.g. by applying the adhesive layer 7 with the carrier material 2 to the coating 4 formed in the female mold. In this case, the layer 4 &quot; with little pressure and possibly provided with little heating is provided. and the adhesive layer 7 is connected.

In this connection of the carrier material 2 with its still moist adhesive layer 7, this adhesive layer 7 is still extremely soft and can be modified or manipulated by pressure. Also the layers 4 'and 4 &quot; on the matrix are not yet crosslinked and contain residual water and are also very sensitive to pressure before crosslinking. Accordingly, synthetic resins or so-called resin-modified polyurethane dispersions are used according to the invention.

The layers 4 &quot; having strong contact adhesive properties prior to their crosslinking at normal or temperatures below 80 ° C. or 7 are good glued together. Such resin additives are in a range between 2 to 9 wt .-% based on the weight of the polyurethane dispersion. The use of a polyurethane dispersion with contact adhesive properties at room temperature or at temperatures below 80 ° C is important because the coating 4 is not yet crosslinked during compression or joining of the layers and contains residual water and thus is very sensitive to pressure. At elevated pressures and with increased adhesive activation temperature, the structure of the carrier material 2 on the coating surface could be very disturbing, but this can be avoided by appropriate process management.

The polyurethane dispersion mixtures used to form the coating 4 or the adhesive layer 7 could have additives, in particular pigments, crosslinkers or thickeners. These additives increase the solids content of the polyurethane dispersion to 38 to 54 wt .-%, based on the weight of the dispersion. The water content of the polyurethane dispersions used is between 46 and 62% by weight of the dispersion. 10/24 Austrian Patent Office AT12 431 U1 2012-05-15 In the preferred indirect coating, the adhesive dispersion 4 &quot; applied to the dry layer 4 '. The adhesive layer 4 &quot; in the die must be still wet when loading or placing the support material 2 or the dispersion used should still more than 75% of their original water content.

The polyurethane dispersion mixtures for layer 4 'after drying and final final crosslinking have a hardness of less than 68 Shore A, preferably less than 55 Shore A. Layer 4 &quot; and the adhesive layer 7 advantageously have a hardness of less than 48 Shore A, preferably between 20 and 35 Shore A.

Preferably, a Formatsuschnitt be constructed with a lower final strength with a carrier layer 2 of a knitted fabric or a fabric having a basis weight between 40 and 100 g / m2, which layer with a nonwoven with a basis weight between 80 and 240 g / m2, preferably 110 to 180 g / m2. Advantageously, the knitted fabric, the woven fabric and / or the nonwoven are in the form of sheet goods, which layers are tamper-resistant with each other. The coating side of such a textile composite is always the knitted or woven layer.

Optionally, the textile substrate 2 may be treated with the fabric handle and softness enhancing chemicals, such as e.g. Silicones and / or surface tension-affecting chemicals are treated. The carrier layer 2 may also contain chemicals that influence the fire behavior. Their weight proportions are not to be taken into account in the present parameter data concerning the weights of the applied layers and the carrier material with regard to the stated total weights etc.

Fig. 2 shows an enlarged section through a Formatchuschnitt 1 and one recognizes a possible surface structure of the coating 4, which has been deducted from the silicone die. The surface has a structure formed with microwells 8, wherein between the microwells 8 ridges or surface areas 9 are formed, which represent a rough or matte and fine-fiber surface. Fig. 3 shows an enlarged plan view of such a surface of a Formatzuschnittes invention. It can be seen that the respective hollow recesses 8, which have a closed border, are not quite regular and may have different rounded but also possibly polyhedral shapes.

The carrier layer 2 can be constructed with woven, knitted or nonwoven fabrics. The backing layer 2 may also be provided with two different interconnected textiles, e.g. Knitted fleece or fabric nonwoven, to be constructed.

The carrier layer 2 consists of two interconnected, different layers, so the coating 4 is applied to the low-stretch textile material or knitted fabric or fabric and the used fleece is always located on the bottom or the coating 4 facing away Side of the format cut. The fleece is the softer and lighter part of the carrier material 2. This has a positive effect on the haptics and prevents permanent wrinkles when sharply buckling. Above all, even the fine surface structures remain unchanged by 15%, even during stretching.

Conveniently, the woven or knitted fabric of the carrier layer 2 on its surface facing away from the coating 4 can show a strong fluffy fiber structure. This formation on this surface is different from the formation of the coated side of the carrier layer 2, since there a strongly fluffy surface is transformed into a &quot; floating &quot; Coating, while a very slight fluff effect on the coating side, especially in knitted or woven fabrics of cotton threads is advantageous.

Advantageously, the basis weight of the carrier material 2 is 200 g / m 2 to 350 g / m 2. However, it is readily possible to provide format cuts with a basis weight of 200 g / m2 to 450 g / m2 and to achieve a good feel and a correspondingly high final thickness of 1.2 to 1.5 mm even at this basis weight. For this purpose, it may be advantageously provided that the rear side of a coating 11 opposite the coating 4

Knitted fabric or fabric-made carrier layer has a fluffy velvet or plush-like appearance. Since this fiber content only increases the final thickness, it may be desirable to use a knitted or woven fabric having a basis weight of between 350 and 400 g / m 2 to achieve greater thickness, with only the weight of the fibers protruding from the back surface already up to 120 g / m2. Although this fiber weight fraction does not contribute to the tear and tear propagation resistance; but overall it significantly improves the feel and prevents permanent wrinkling on sharp bends.

If the carrier material is formed with non-fluffy or non-velvet or plush-like knitted fabrics or fabrics, the weight per unit area is generally 200 to 350 g / m 2.

The layers 4 ', 4 &quot; are usually applied by spraying the polyurethane dispersion on the die, in particular by so-called airless method. The dispersion for forming the adhesive layer 7 can either be applied directly to the only wet, but dry-feeling layer 4 &quot; be sprayed by airless method, or applied by pouring. The carrier layer 2 is placed on or in the still wet dispersion of the adhesive layer 7 and lightly pressed. The dispersion for the adhesive layer 7 may also be slightly foamed in an airless spray application or be used in the form of a blown foam. The application of all layers 4 ', 4 "to the matrix is particularly economical and also leads to softer end products in the case of nonwoven backing layers.

In the case of knitted or woven backing layers having a denser fibrous structure on their coating side, it is advantageous to apply the dispersion for the adhesive layer 7 directly onto the textile material, preferably by spraying, in particular by the airless method.

It is advantageous if all layers 4 ', 4 &quot; and 7 wet or moist brought together or placed together and connected or crosslinked with the crosslinker contained in them. Thus, layers 4 'and 4 &quot; and the adhesive layer 7 firmly and permanently connected, even if the layers 4 ', 4 &quot; or 7 are formed with different polyurethane dispersions.

In the context of the invention, the fibers or yarns may have different colors, that is, the textile carrier layer 2 may also be formed mehrfärbig or structured. This is especially true for knitted fabric and fabric backing. The carrier layer 2 can also be printed multicolored with textile dyes. According to the invention, the coating 4 could be transparent or colored transparent in this case, whereby the colors of the carrier layer 2 remain visible.

When connecting a knitted or woven fabric to a nonwoven, it is expedient if the nonwoven is always at least 0.3 to 1.3 mm thicker than the knitted fabric or fabric with which it is at least tamper-resistant in any manner, either mechanically or adhesively. is bound.

Formatting blanks according to the invention were produced, which compared to comparable heavier commercially available materials improved durability with a low weight, increased abrasion resistance and increased tear strength and these known materials in terms of softness and haptics exceeded. In the following parameters of cut-to-size pieces are given, all of which showed substantially optimum performance characteristics at different total thicknesses: 1. A cut-to-size sheet 1 having a total basis weight of 370 g / m2 was prepared, the total basis weight of the backing layer being 240 g / m2. The carrier layer 2 made with a polyester knitted fabric had a fluffy back and a thickness of 0.85 mm. The total polyurethane content had a basis weight of 130 g / m2. The adhesive layer 7 had a penetration depth into the carrier layer 2 of 0.03 mm. The order of the adhesive layer 7 forming dispersion was carried out directly on the support layer 2. The total thickness 12/24 Austrian Patent Office AT12 431 U1 2012-05-15 the Formatsuschnittes was 1.0 mm.

2. It was created a Formatsuschnitt 1 with a total basis weight of 400 g / m2. The total basis weight of the carrier layer 2 was 290 g / m 2. The carrier layer 2 was made with a polyamide fabric and had a fluffy backing at a thickness of 0.9 mm. The total polyurethane content was 110 g / m2. The penetration depth of the adhesive layer 7 into the carrier layer 2 was 0.04 mm. The order of the adhesive layer 7 creating dispersion was carried out directly on the support layer 2. The total thickness of Formatzuschnittes 2 was 1.15 mm.

3. It was created a formatting blank 1 with a total weight of 355 g / m2. The backing layer 2 had a total basis weight of 215 g / m 2. The backing layer 2 had a thickness of 1.35 mm and was made with a wide-meshed polyamide knitted fabric reinforced with a nylon denier having a yarn denier of 3 denier. The total polyurethane content of the format cut was 140 g / m 2. The penetration depth of the adhesive layer 7 into the carrier layer was 0.08 mm. The order of the dispersion of the adhesive layer 7 on the carrier layer 2 was carried out indirectly, that is, the carrier layer 2 was placed on the adhesive layer 7 located in the die. The total thickness of the format cut was 1.35 mm.

4. It was created a Formatsuschnitt 1 with a total basis weight of 330 g / m2. The total basis weight of the carrier layer 2 was 235 g / m 2. The thickness of the carrier layer 2 was 1.70 mm and was made with a polyester nonwoven with threads of 3 denier. The total polyurethane content of the molding blank was 95 g / m 2. The penetration depth of the adhesive layer 7 into the carrier layer 2 was 0.04 mm. The dispersion of the adhesive layer 7 was applied indirectly to the carrier layer 2. The format cut has a total thickness of 1.80 mm.

5. A formatting blank 1 was created with a total basis weight of 380 g / m2. The total basis weight of the carrier layer 2 was 230 g / m 2. The thickness of the carrier layer was 1.50 mm. The carrier layer 2 was produced with a polyester fleece whose threads had a thickness of 3 deniers, to which fleece a cotton fabric was applied, to which the coating 4 was applied. The penetration depth of the adhesive layer 7 into the carrier layer 2 was 0.09 mm. The application of the adhesive layer 7 on the carrier layer 2 was carried out indirectly. The format cut has a total thickness of 1.65 mm.

6. A Formatsuschnitt 1 was created with a total basis weight of 395 g / m2. The total basis weight of the carrier layer 2 was 290 g / m 2. The thickness of the carrier layer 2 was 0.95 mm. The backing layer 2 was made with a polyester knitted fabric to which cotton was added, the knitted fabric containing 60% by weight of polyester and 40% by weight of cotton; The back of the knit was fluffy roughened. The total polyurethane content was 105 g / m2. The penetration depth of the adhesive layer 7 into the carrier layer 2 was 0.03 mm. The application of the adhesive layer 7 was carried out indirectly. The total thickness of the format cut was 1.15 mm.

7. A formatting blank 1 was made with a total basis weight of 350 g / m2. The total basis weight of the carrier layer 2 was 285 g / m 2. The backing layer 2 had a thickness of 1.0 mm and was made with a polyester microfiber nonwoven fabric provided with a spongy polyurethane incorporation. The total polyurethane content was 138 g / m2. The adhesive layer 7 penetrated into the carrier layer 2 0.025 mm. The application of the adhesive layer 7 on the carrier layer 2 was carried out directly. The format cut had a total thickness of 1.1 mm.

The polyurethane dispersions used in these format cuts have the parameters specified in the description.

All created Formatsuschnitte 1 meet the demands placed on them. With regard to bending, the cut 4 achieved the worst results and the cut sections 3, 5 and 7 achieved the best results. The Formatsuschnitte 1, 2, 3, 5, 6 and 7 showed no disturbing visible surface changes even at an elongation of 15%. [00108] The size cuts 1, in which the dispersion of the adhesive layer 7 was applied indirectly to the material of the carrier layer 2, showed the better properties taking into account all the criteria. These format cuts are also simpler and more environmentally friendly to produce, because less energy is needed and these format cuts show better optics. These advantages are in particular due to the insertion of the carrier layer 2 on the still wet homogeneous layer 7, which has been applied to the coating 4 in the die.

In a Shore A hardness test, a test specimen having a thickness of 5 mm is prepared beforehand from the respectively used polyurethane-containing dispersion mixture and its hardness is determined.

Nonwovens whose fibers are in the denier range can be solidified by mechanical needling or by water jet or thermal fixing or are used in this solidified form. The position of their fibers is always three-dimensional.

Webs of microfibers are understood to mean those webs whose fibers are held together by incorporation in a wet, sponge-like polyurethane layer. Such webs take up at least twice their weight in water without dripping.

[00112] An &quot; indirect &quot; Application of the adhesive layer 7 means that the dispersion is spread over a support, ie in the present case a matrix on which the coating 4 or the layers 4 'and 4 &quot; are already formed, wet transferred to the material of the carrier layer 2 or brought into contact with it, just by applying the carrier layer 2 to the layers located in the die.

[00113] Under &quot; direct application &quot; it is understood that the dispersion of the adhesive layer 7 is applied directly to the carrier layer 2.

A low contact pressure is understood to mean a pressure which a pressure cylinder with a diameter of more than 300 mm exerts on the material of the carrier layer 2 with its pressure-elastic sheathing. Preferably, a maximum pressure of 0.3 kg / cm 2, preferably of at most 0.1 kg / cm 2 is provided.

FIG. 4 shows a particularly advantageous embodiment of a format cut according to the invention. This formatting cut has a knitted fabric or woven fabric in combination with a nonwoven fabric 6 as a carrier layer 2. The knitted or woven fabric is designed to be thin or wide-meshed. In the case of the particularly indirect application of the carrier layer 2 to the coating material or polyurethane layers 4 ', 4 "present in the matrix, the wet polyurethane dispersion is forced through the open or wide meshed knit or fabric and the dispersion penetrates into the nonwoven fabric 6 or the surface areas 3 of the web 6 a. The wide-mesh knitted fabric or fabric carrier 2 is thus embedded between the nonwoven 6 and the coating 4 in the adhesive layer 7.

The application of all layers of polyurethane dispersion onto the matrix is preferably carried out. The chemistry or composition for the coating 4 and the layer 4 &quot; as the adhesive layer are preferably identical. In the case of indirect application, in particular in the case of extremely absorbent textiles, the support or the support layer 2 may be directly, in particular without being polyurethane-coated, in the completely wet layer 4 ". be inserted. In this case, layer 4 &quot; also the chemistry for the otherwise provided adhesive layer 7, because the layer 4 &quot; directly and controlled penetrates into the carrier layer 2. A separate or specially applied adhesive layer 7 can be omitted in this case.

Dashed line in Fig. 4 is the polyurethane adhesive layer 4 &quot; 7 or 7, in which the woven fabric or knitted fabric 2 is embedded, which has penetrated into the nonwoven fabric 6 in the region 3 and which connects the layer 4 'or the coating 4 to the nonwoven fabric 6.

In Fig. 5 is a formatting cut is shown, which is comparable to the format cutout shown in Fig. 1. On the backing material 2, a layer 6 is connected on the back, which comprises a layer 8, which with a peelable foam made of polyurethane or a chloroprene or polyprene polymer foam or 14/24 Austrian Patent Office AT12 431 U1 2012-05-15 a needle felt or a polyester or polyamide nonwoven is formed, which layer 8 is connected to a knitted fabric 9.

In order to obtain a light, but at the same time thick or thick format cut, it can be provided that the further layer 6 is more than twice as thick as the carrier material 2 and has a basis weight of 40 to 60% of the total basis weight of the carrier material 2 ,

Particularly good results in terms of strength, lightness and durability arise when the polyurethane peel foam 8 or the chloroprene foam has a density of 0.005 to 0.12 g / cm3, preferably from 0.01 to 0.06 g / m3 , and optionally has an average thickness of 2 to 4 mm, preferably 2.5 to 3.5 mm, and / or if the needle felt used as layer 8 has a basis weight of 100 to 200 g / m2, preferably 120 to 160 g / m2 , and has an average thickness of 2 to 4 mm, preferably 2.5 to 3.5 mm, and / or if the back-forming knitted fabric 9 has a basis weight of 60 to 160 g / m 2, preferably 80 to 100 160 g / m 2 , owns.

The entire area blank contains a total of a small amount of polyurethane, if it is provided that the basis weight of the polyurethane foam 8 is a part of the basis weight of the entire polyurethane content of Formatzuschnittes 1. An inventive format cut with an additional layer 6 and this is shown in Fig. 5, is advantageously characterized in that the layer 6 is attached to the back of the support layer 2, and that optionally at a total thickness of 0.9 to 6 mm, preferably 2 to 5 m, the total weight of the Formatzuschnittes 1, in particular including the at least one attached to the back of the substrate 2 layer 6, between 250 and 600 g / m2, in particular between 270 and 550 g / m2.

The embodiment shown in Fig. 5 is particularly advantageous for use in car roofs or car interior trim, child seats in vehicles, as well as vehicle seat covers or parts thereof. Such a Formatsauschnitt has the desired strength at low weight, a pleasant feel and attenuates the best cushioning noise to a large extent. The reduction in weight of a trim blank on vehicles achieved over prior art materials is also of great importance in reducing CO 2 emissions and saving drive energy, which is particularly important in electrically powered vehicles. Even when used as a shoe upper material these properties are beneficial.

5, a textile carrier material 2 is bonded to the layer 6 and the format cut reaches a thickness of between 2 to 5 mm with a weight per unit area of 270 to 550 g / m.sup.2. The construction of the format cut comprises a woven or knitted fabric which contains not only synthetic fibers but also up to 50% by weight of cotton fibers. To this support material 2, the voluminous layer 6 is connected with a synthetic nonwoven or needle felt or a lightweight Polyurethananschalschaum or chloro-pren polymer foam. The backsheet of the molding blank 1 comprises the knit 9. The bulky nonwoven or foam layer 8 is, preferably more than twice as thick as the lightweight material or lightweight knitted substrate 2 and is the total basis weight of the substrate involved with a maximum of 50% by weight. In order to be able to dispense with materials to be bonded or laminated for bonding the individual layers, it is expedient if the different layers are joined together directly during the nonwoven production. If the layer 8 consists of more than 2 mm thick polyurethane foam, the textile support layer 2 and the layer formed with a knitted fabric 9 can be joined by known per se flame lamination with the Polyurethananschalschaum. In Chloroprenschäu-men, the knitted fabric 9 can be connected in the foam production with this. The polyurethane peel foam or the chloroprene foam each have a density of 0.005 to 0.12 g / cm 3, preferably from 0.01 to 0.06 g / cm 3. In principle, it is also possible to produce even thicker cut-to-size pieces by increasing the thickness of the layer 8 or of the layer formed with the knitted fabric 9 by increasing the thickness of the layer 5 mm Do not exceed the weight per unit area of 600 g / m2. Even with even larger thicknesses, a weight per unit area of 600 g / m.sup.2 is usually not exceeded, since the basis weights of the polyurethane foam foam or chloroprene foam used or a needle punched nonwoven used are very small.

The total polyurethane content of the provided with a layer 6 according to FIG. 5 Formatzuschnittes remains almost unchanged, because the layer 8 is created with a polyurethane foam and this foam is very light. For bonding with the textile carrier layer 2 and the knitted fabric 9 Flammkaschieren is used, so that no additional adhesive is required.

In the case of chloroprene foams, the layer 8 is preferably simultaneously bonded to the layer 9 during its production. It is possible to prevent the carrier layer 2 likewise with the layer 8 or with the chloroprene foam without additional adhesives or adhesive masses during its production.

If the light, voluminous layer 8 is formed with a needle-punched nonwoven, then at least the knitted fabric 9 and possibly also the knitted fabric of the carrier layer 2 could already be bonded to the nonwoven of the layer 8 during production. Consequently, no additional adhesive, in particular polyurethane adhesive, is required here as well. Therefore, the very positive weight ratio between the textile carrier material and the total polyurethane content of a format cut remains unchanged low.

This weight saving is an essential criterion for the use of such surface blanks in motor vehicles with otherwise appropriate strength and durability properties.

In the following, the construction of a format section according to FIG. 5 will be explained in more detail by means of examples.

8. A Formatsauschnitt 1 was created, with a total basis weight of 560 g / m2. The total basis weight of the carrier layer 2 was 410 g / m 2. The total thickness of the Formatzuschnittes formed with the layers 2 and 6 was 3.8 mm. The backing layer 2 was made by using a knit fabric having 50% by weight of cotton fibers and 50% by weight of polyester fibers. The basis weight of this knitted fabric was 205 g / m 2. The tethered nonwoven 8 was formed with polyester fibers and had a basis weight of 110 g / m 2. The knitted fabric 9 used for the layer 6 on the back of the pattern cut was formed with polyester fibers and had a basis weight of 95 g / m 2. In nonwoven production, the light knits were bonded to the nonwoven by needling. The total basis weight of the polyurethane contained in the format cut was 150 g / m 2. This formed textile composite was placed with its surface on the wet, located on the die adhesive mass 7 and lightly pressed. The provided with the coating 4 Formatsuschnitt then had a total thickness of 3.95 mm.

[00130] 9. A shape blank 1 was made with a total basis weight of 530 g / m 2. The total basis weight of the three-layer support layer 2 was 390 g / m 2. The total thickness of the format cut was 3.5 mm. To this end, a polyester gauze having a basis weight of 185 g / m 2 and forming a surface was bonded to a layer 6 comprising a 110 g / m 2 polyethylene sheeting. The underside of the pattern cut formed a polyester knit 9 with a basis weight of 95 g / m2. The two knitted fabrics, that is to say the knitted fabric of the carrier layer 2 and the knitted fabric 9, were joined to the polyurethane chip foam 8 by flame lamination. For bonding the coating 4 to the carrier layer 2, adhesive mass 7 was halfway into the die to form the adhesive layer 4 'and half to the surface of the fabric of the carrier layer 2 to form the layer 4 &quot; applied. Both layers were brought together moist. The total polyurethane content of the molding blank had a basis weight of 230 g / m 2. The total thickness of the format cut was 4.3 mm. 16/24

Claims (46)

Austrian Patent Office AT12 431 U1 2012-05-15 10. A formatting blank 1 was made with a total basis weight of 560 g / m2 and a thickness of 3.25 mm. To prepare this format section 1, a two millimeter thick chloroprene polymer foam having a density of 0.06 g / cm 3 was used, on top of which was a polyester knit having a basis weight of 120 g / m 2 and on its reverse side with a Polyester knitted fabric with a basis weight of 65 g / m2 was connected. This two-sided knitted layer 8 of chloroprene polymer foam was bonded with an adhesive to the back of the backing layer 2 consisting of a cotton / polyester fabric and having a basis weight of 160 g / m 2. The polyurethane coating had a basis weight of 115 gsm and was drawn into the substrate about 0.04 mm. Equivalent to a Polyurethananschalschaum comparable polyurethane foams can be used. Claims 1. A format cut comprising a carrier material (2) formed with a non-woven fabric and / or knitted fabric and / or woven fabric of polyamide and / or polyester threads, in particular polyamide and / or polyester microfibers and / or cotton threads, in particular sheet-like or layered and a coating (4) applied to the carrier material (2), which is formed with polyurethane dispersion on a structured silicone rubber backing or mold and, if appropriate via an adhesive layer (7) formed by polyurethane dispersion, being bonded to the carrier material (2) characterized in that - the total polyurethane content of the foam blank (1) is 60 to 240 g / m 2, preferably 80 to 150 g / m 2, in particular 100 to 140 g / m 2, this basis weight also being present in the substrate (2) at most in this incorporated in its preparation polyurethane and - the basis weight of the carrier material (2), given If appropriate, including at most polyurethane contained therein, 200 g / m2 to 450 g / m2, preferably 200 g / m2 to 350 g / m2, in particular 230 g / m2 to 270 g / m2. 2. Formatsuschnitt according to claim 1, characterized in that, in particular in the form of a film, applied coating (4) has a basis weight of 60 g / m2 to 240 g / m2, preferably from 60 g / m2 to 160 g / m2 , 3. Formatsuschnitt according to claim 1 or 2, characterized in that the used knitted or woven fabric and / or lightly ground, optionally with a grain size &gt; 400, in particular with a grain size of 450 to 900, ground, present. 4. Formatsuschnitt according to any one of claims 1 to 3, characterized in that as a carrier material (2) dense or translucent nonwovens or woven or knitted fabrics, or optionally such nonwovens with knitted or fabric overlays, are used, wherein the nonwovens of synthetic fibers and the Knitted fabric or fabric supports made of cotton fibers. 5. Formatsuschnitt according to one of claims 1 to 4, characterized in that on the carrier material (2) on the coating (4) averted surface at least one further layer (6), preferably of a light, bulky polyester or polyamide nonwoven, with a foamed plastic dispersion adhesive is glued or laminated. 6. Formatsuschnitt according to any one of claims 1 to 5, characterized in that in the carrier material (2) a maximum of 30 wt .-%, preferably at most 20 wt .-%, of the total amount in the Formatzuschnitt (1) contained solidified polyurethane dispersion present 24 Austrian Patent Office AT12 431 U1 2012-05-15 gen. 7. Formatsuschnitt according to any one of claims 1 to 6, characterized in that the polyurethane layer formed with adhesive dispersion (7) from 0.02 to 0.6 mm, preferably 0.05 to 0.4 mm, fed into the carrier layer (2) or . is introduced. 8. Formatsuschnitt according to any one of claims 1 to 7, characterized in that the areas (3) of the carrier material (2), in which the polyurethane dispersion of the adhesive layer (7) has penetrated during the application thereof, have a density which is between 15% and 55%, preferably between 20 and 35%, above the density of the remaining or the polyurethane-free regions of the carrier material (2). 9. Formatsuschnitt according to one of claims 1 to 8, characterized in that the adhesive layer (7) with 20 to 80 g / m2 applied to the carrier material (2), and optionally embedded in the same is. 10. Formatsuschnitt according to any one of claims 1 to 9, characterized in that the coating (4) is constructed with two interconnected layers and a superficially located, superficially structured layer (4 ') of polyurethane dispersion and an underlying and with the layer ( 4 ') comprises a layer (4 &quot;) formed with a linear structure, optionally containing polyacrylates and / or synthetic resins, optionally to improve the bond between the polyurethane-dispersed layer (4 &quot;) and the support material (2 &gt; ) between the polyurethane dispersion layer (4 ") and the surface of the carrier material (2) is the polyurethane layer formed and in this carrier material (2) at least partially retracted adhesive layer (7) is arranged. 11. Formatsuschnitt according to any one of claims 1 to 10, characterized in that the adhesive layer (7) has a basis weight of 20 to 80 g / m2 having, optionally polyacrylates and / or other synthetic resins containing polyurethane dispersion layer (4 "), which preferably has a chemical structure like the polyurethane dispersion layer (4 &quot;) mentioned in claim 9. 12. Formatsuschnitt according to one of claims 1 to 11, characterized in that the adhesive layer formed with polyurethane dispersion (7) to a maximum of 10 to 40%, preferably at most 10 to 20%, the thickness of the carrier material (2) is drawn into the same. 13. Formatsuschnitt according to one of claims 1 to 12, characterized in that on the surface of the coating (4) has a structure, said structured coating (4) the appearance of ground foam pieces, ground rubber, sandpaper or Waffelmustern or technical Fabric, such as a woven or knitted fabric made of glass or carbon fibers, or a suede structure or a scar leather or nubuck-like appearance. 14. Formatsuschnitt according to one of claims 1 to 13, characterized in that on the surface of the coating (4) a very thin, hydrophobic finish layer (5) in a thickness of less than 0.005 mm with nanoparticles of polysiloxane or wax or of fluoropolymers or of mixtures thereof is applied. 15. Formatsuschnitt according to one of claims 1 to 14, characterized in that the produced on a silicone matrix and on the carrier material (2) applied coating (4) including the adhesive layer (7) and in the carrier material (2) retracted polyurethane is free of organic, in particular used in the preparation of the polyurethane, solvents. 16. Formatsuschnitt according to one of claims 1 to 15, characterized in that at the back of the carrier material (2) - a - formed with PET bottles Regenerat threads or fibers containing - polyester nonwoven with a foamed dispersion adhesive is attached. 18/24 Austrian Patent Office AT12 431 U1 2012-05-15 17. Formatsuschnitt according to one of claims 1 to 16, characterized in that the coating (4) with the layers (4 ') and (4 ") is formed with a negatively structured pad or mold made of silicone rubber by solidification of a polyurethane-containing dispersion and the surface of the coating (4) is created or structured with this matrix. 18. Formatsuschnitt according to one of claims 1 to 17, characterized in that the Formatzuschnitt (1) as a flexible, flat structure, in particular in the form of plate-shaped pieces, is present. 19. Formatsuschnitt according to one of claims 1 to 18, characterized in that at the back of the carrier layer (2) at least one further layer (6) is arranged, and that optionally at a total thickness of the Formatsuschnitts (1) from 0.9 to 6 mm, preferably from 2 to 5 mm, the total weight thereof, including the at least one, on the back of the substrate (2) arranged layer (6) is between 250 and 600 g / m2, in particular between 270 and 550 g / m2. 20. Formatsuschnitt according to one of claims 1 to 19, characterized in that the coating (4) is made with a polyurethane dispersion having a hardness of less than 68 Shore A, preferably less than 55 Shore A. 21. Formatsuschnitt according to any one of claims 1 to 20, characterized in that the fibers of the nonwoven fabric are formed with polyester and / or polyamide and / or cotton. 22. Formatsuschnitt according to one of claims 1 to 21, characterized in that the yarns or threads of the fabric or fabric of polyester and / or polyamide optionally with a proportion of up to 40 wt .-%, preferably up to 45 wt. %, Cotton or cotton threads and / or are formed only with cotton or cotton threads. 23. Formatsuschnitt according to one of claims 1 to 22, characterized in that the coating (4) is made with a solidified polyurethane dispersion mixture containing between 2 and 10 wt .-% non-migrating polysiloxane and is crosslinked. 24. A format blank according to any one of claims 1 to 23, characterized in that the adhesive layer (7) to 50 to 85 wt .-% constructed and crosslinked with a crystalline structure possessing polyurethane and / or - that they 0.02 to 0, 6 mm, in particular 0.05 to 0.4 mm, deep from the surface directly or indirectly in the carrier material (2) of the Formatzuschnittes (1) is drawn from the material surface and / or - that the adhesive layer (7) with a Weight of 20 to 80 g / m2 applied from the surface on the substrate (2) and at least partially embedded in the same. 25. The molding blank according to claim 1, characterized in that the layer (4 ") acting as the adhesive layer and / or the adhesive layer (7) are each up to 50% by weight, preferably up to 25% by weight, Contain or contain polyacrylates and each have a hardness of less than 48 Shore A, preferably a hardness between 20 and 35 Shore A. 26. Formatsuschnitt according to any one of claims 1 to 25, characterized in that the common total thickness of the coating (4) and the adhesive layer (7) is 0.05 to 0.65 mm. 27. Formatsuschnitt according to any one of claims 1 to 26, characterized in that in all layers of the coating (4) and the adhesive layer (7), a crosslinking agent is contained and the individual layers are cross-linked by joining together while still wet. 19/24 Austrian Patent Office AT12 431 U1 2012-05-15 28. A format blank according to any one of claims 1 to 27, characterized in that contained therein polyester or Polyamidgewirke or fabrics between 10 and 45 wt .-%, preferably between 20 and 30 wt .-%, cotton threads. 29. A format blank according to any one of claims 1 to 27, characterized in that the cotton fabric or knitted fabric has a basis weight between 100 g / m2 and 200 g / m2 and a, optionally associated with these fabrics or knitted fabrics, a basis weight of 100 g / m2 to 200 g / m2. 30. A format cut according to any one of claims 1 to 29, characterized in that the polyurethane dispersions used are resin-modified. 31. Formatsuschnitt according to any one of claims 1 to 30, characterized in that in the polyurethane dispersion of the coating (4) and / or the adhesive layer (7) 2 to 9 wt .-%, each based on the total weight of the polyurethane dispersion, of, optionally possess contact adhesive properties, synthetic resins are included. 32. Formatsuschnitt according to one of claims 1 to 28, characterized in that the carrier layer (2) or the carrier material with two different elongation behavior, interconnected textile materials, such. Knitted fabric or fabric non-woven, is constructed, wherein the stretch poorer, thin textile material has a wide-mesh structure and the coating (4) and close to this low-stretch textiles, the coating (4) is applied, or wherein the stretch poorer textile material in the adhesive layer (7) is largely or completely embedded. 33. Formatsuschnitt according to one of claims 1 to 29, characterized in that the woven or knitted fabric of the carrier layer (2) or of the carrier material on its surface facing away from the coating (4) show a fluffy fiber structure. 34. Formatsuschnitt according to one of claims 1 to 30, characterized in that when forming the carrier layer (2) with different layers of woven fabrics, knitted fabrics and / or nonwovens, the coating (4) closer layer is formed with less stretch and an inserted nonwoven the Bottom of the carrier layer (2) as a soft and light component of the carrier layer (2) forms. 35. Formatsuschnitt according to one of claims 1 to 31, characterized in that all the layers (4, 4 ', 4 "and 7) brought wet or moist together or placed together and connected or crosslinked by means of the crosslinker contained in them , 36. Formatsuschnitt according to one of claims 1 to 32, characterized in that the carrier material (2) with colored or different colors owning fibers or yarns is formed and / or colored printed, and / or that the material of the coating (4) transparent or transparent-colored. 37. Formatsuschnitt according to any one of claims 1 to 33, characterized in that in the coating (4) up to 4 wt .-% transparent hollow microspheres made of plastic are included. 38. Formatsuschnitt according to one of claims 1 to 37, characterized in that contained in the polyurethane dispersions or polyurethane dispersion mixtures contained therein solids in the form of pigments, crosslinkers and / or thickeners. 39. Formatsuschnitt according to one of claims 1 to 38, characterized in that in the carrier layer (2) the softness and / or surface tension and / or the fire behavior of the textile material contained therein chemicals are contained. 40. Formateuschnitt according to one of claims 1 to 39, characterized in that the carrier layer (2) or the carrier material comprises a nonwoven, on which a wide-meshed, open fabric or knitted fabric is applied, wherein the adhesive layer (7) or the layer (4 &quot;) the fabric or knitted fabric penetrating into the surface areas of the nonwoven web is drawn. 41. Formatsuschnitt according to one of claims 1 to 40, characterized in that the further layer (6) of a composite needle felt (8) or polyester or polyamide nonwoven (8) or a layer of a polyurethane foam, preferably a polyurethane scarf foam ( 8) or a chloroprene polymer foam (8) with a knitted fabric (9) is formed, which composite is bonded to the back of, preferably formed by a knitted fabric, carrier material (2). 42. Formate blank according to claim 41, characterized in that the further layer (6) is more than twice as thick as the carrier material (2) and has a basis weight of 20 to 40% of the total basis weight of the carrier material (2). 43. A shaped blank according to claim 41 or 42, characterized in that the polyurethane foam, preferably the polyurethane peelable foam (8), or the polychloroprene foam (8) has a density of 0.005 to 1.2 g / cm 3, preferably 0, 01 to 0.06 g / cm3. 44. Formatsuschnitt according to any one of claims 1 to 43, characterized in that the needle felt (8) has a basis weight of 100 to 200 g / m2, preferably 120 to 160 g / m2, and an average thickness of 2 to 4 mm, preferably from 2.5 to 3.5 mm, and / or that the back-forming knitted fabric (9) has a basis weight of 60 to 160 g / m 2, preferably 80 to 120 g / m 2, especially 80 to 100 g / m 2 , 45. Formatsuschnitt according to one of claims 1 to 44, characterized in that the weight per unit area of the polyurethane foam, preferably the polyurethane scarf foam (8), a part of the basis weight of the entire polyurethane content of the Formatzuschnittes (1). 46. With a Formatzuschnitt (1) according to one of claims 1 to 45 formed objects in the form of automotive interior wall coverings and -stampungen, bags, suitcases, furniture covers, clothing, shoes, bicycle or motorcycle saddles or map pockets or use of such Formatsuschnitten for the preparation of these items. 3 sheets of drawings 21/24