# US 11,440,286 B2 · Laminate and skin material for vehicle interior member

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- Number: US 11,440,286 B2
- Document ID: US11440286B2
- Status: Granted
- Kind: B2
- Application number: 16/957,556
- Filed: 2018-12-21
- Published: 2020-10-08
- Granted: 2022-09-13
- Earliest claimed: 2017-12-25
- Assignees: Inoac Corporation; Inoac Technical Center Co., Ltd.
- Applicants: Inoac Corporation; Inoac Technical Center Co., Ltd.
- Inventors: Yuya Nagano; Hideo Ota; Takahiro Inoue; Shimpei Tokai
- Web page: https://patentgrep.com/patent/US11440286B2

## CPC

- B32B 5/18: characterised by features of a layer {of} foamed material
- C08G 18/1825: {having hydroxy or primary amino groups}
- B32B 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/026: {Knitted fabric}
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 5/32: {at least two} layers being foamed {and next to each other}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 9/025: {comprising leather}
- B32B 9/046: {of foam}
- B32B 27/065: {of foam}
- B32B 27/40: comprising polyurethanes
- C08G 18/12: using two or more compounds having active hydrogen in the first polymerisation step
- C08G 18/14: {Manufacture of cellular products}
- C08G 18/165: {covered by C08G18/18 and C08G18/24}
- C08G 18/18: containing secondary or tertiary amines or salts thereof
- C08G 18/244: {tin salts of carboxylic acids}
- C08G 18/4018: {Mixtures of compounds of group C08G18/42 with compounds of group C08G18/48}
- C08G 18/4202: {Two or more polyesters of different physical or chemical nature (C08G18/44 takes precedence)}
- C08G 18/4238: {derived from dicarboxylic acids and dialcohols}
- C08G 18/44: Polycarbonates
- C08G 18/48: Polyethers
- C08G 18/4825: {Polyethers containing two hydroxy groups (C08G18/4833 - C08G18/5096 take precedence)}
- C08G 18/4829: {Polyethers containing at least three hydroxy groups (C08G18/4833 - C08G18/5096 take precedence)}
- C08G 18/725: {Combination of polyisocyanates of C08G18/78 with other polyisocyanates}
- C08G 18/7621: {being toluene diisocyanate including isomer mixtures}
- C08G 18/7671: {containing only one alkylene bisphenyl group}
- C08G 18/797: {containing carbodiimide and/or uretone-imine groups}
- C08K 5/34922: {Melamine; Derivatives thereof}
- C08K 5/521: Esters of phosphoric acids, e.g. of H3PO4
- C09J 11/06: organic
- C09J 175/08: from polyethers
- B32B 2250/02: 2 layers
- B32B 2250/03: 3 layers
- B32B 2255/102: synthetic resin or rubber layer being a foamed layer
- B32B 2255/26: Polymeric coating
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2266/0278: Polyurethane
- B32B 2307/306: Resistant to heat
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2307/51: Elastic
- B32B 2307/72: Density
- B32B 2307/724: Permeability to gases, adsorption
- B32B 2307/732: Dimensional properties
- B32B 2307/734: Dimensional stability
- B32B 2307/748: Releasability
- B32B 2605/003: Interior finishings
- C08G 2110/0083: prepared using water as the sole blowing agent
- C08G 2170/20: Compositions for hot melt adhesives
- C08J 9/0038: {containing phosphorus}
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- C09J: ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES (preparation of glue or gelatine C09H)
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)

## Abstract

The present invention provides a laminate 10 including: a foamed polyurethane layer 11 obtained from a foamable polyurethane resin composition containing an active hydrogen group-containing tin ricinoleate and a phosphorus-containing solid flame retardant; and a coating layer 15 adhered to the foamed polyurethane layer 11 by a polyurethane hot melt adhesive 13 containing a polyurethane prepolymer (I) obtained by using a polyol component (A) and a polyisocyanate component (B) as raw materials, and a catalyst (II).

## Claims

### Claim 1

A laminate comprising:
a foamed polyurethane layer obtained from a foamable polyurethane resin composition containing a polyol, a polyisocyanate, a foaming agent, a catalyst and a flame retardant; and
a coating layer mounted on the foamed polyurethane layer,
wherein the foamable polyurethane resin composition contains an active hydrogen group-containing tin ricinoleate as the catalyst and a phosphorus-containing solid flame retardant as the flame retardant,
the foamed polyurethane layer and the coating layer are adhered by a polyurethane hot melt adhesive containing a polyurethane prepolymer (I) obtained by using a polyol component (A) and a polyisocyanate component (B) as raw materials, and a catalyst (II),
the polyisocyanate component (B) in the polyurethane hot melt adhesive contains more than 0.5 mass % and 10 mass % or less of a carbodiimide-modified diphenylmethane diisocyanate based on the total mass of polyisocyanate component (B), and
the catalyst (II) includes a reactive catalyst having a functional group that reacts with an isocyanate group.

### Claim 2 (depends on 1)

The laminate according to claim 1, wherein the reactive catalyst is a catalyst having one of the functional group that reacts with an isocyanate group and having a tertiary amine structure.

### Claim 3 (depends on 1)

The laminate according to claim 1, wherein
the polyol component (A) contains a crystalline polyester polyol (a-1) containing a condensation reaction product of an aliphatic dicarboxylic acid having 10 to 12 carbon atoms and an aliphatic diol having 4 to 6 carbon atoms, and a polyether polyol (a-2), and
a content of the polyether polyol (a-2) in the polyol component (A) is 30 mass % to 80 mass % based on 100 mass % of the polyol component (A).

### Claim 4 (depends on 3)

The laminate according to claim 3, wherein the crystalline polyester polyol (a-1) has a number average molecular weight of 1,000 to 5,000, and the polyether polyol (a-2) has a number average molecular weight of 1,000 to 4,000.

### Claim 5 (depends on 1)

The laminate according to claim 1, wherein the foamable polyurethane resin composition further contains, as the flame retardant, a melamine powder having an average particle diameter of 0.1 μm to 0.5 μm.

### Claim 6 (depends on 1)

The laminate according to claim 1, wherein the phosphorus-containing solid flame retardant in the foamable polyurethane resin composition is a phosphate ester compound.

### Claim 7 (depends on 1)

The laminate according to claim 1, wherein the polyol component (A) of the polyurethane prepolymer (I) in the polyurethane hot melt adhesive contains one or more polyols selected from the group consisting of an amorphous polyester polyol, a polycarbonate polyol, and a low molecular weight diol having a number average molecular weight of 500 or less.

### Claim 8 (depends on 1)

The laminate according to claim 1, wherein a surface layer is adhered by the polyurethane hot melt adhesive to a surface of the foamed polyurethane layer opposite to a surface on which the coating layer is mounted.

### Claim 9 (depends on 8)

A skin material for vehicle interior member, using the laminate according to claim 8.