Multi-layered material and a method for making the same

A method for making a multi-layered material, comprising the following steps:

• (a) forming a third polymer mixture on a release paper, the third polymer mixture containing a third polymer resin;
• (b) drying the third polymer mixture to form a surface layer;
• (c) foaming a second polymer mixture and then forming the foamed second polymer mixture on the surface layer, the second polymer mixture containing a second polymer resin, wherein the second polymer resin is an aqueous polymer resin, and the foaming method is physical foaming;
• (d) drying the second polymer mixture to form a second foamed layer, the second foamed layer having a plurality of second cells, wherein the second foamed layer has a density of 0.25 g/cm3 to 0.7 g/cm3, and a part of the second cells are in communication with each other;
• (e) foaming a first polymer mixture and then drying the foamed first polymer mixture to form a first foamed layer, the first polymer mixture containing a first polymer resin, the first foamed layer having a plurality of first cells, wherein the foaming method of step (c) is different from that of step (e), the variation in size of the second cells is different from that of the first cells, the first polymer resin has a solid content higher than 50%, the foaming method is chemical foaming, the first cells are not in communication with each other, and the variation in size of the first cells is smaller than that of the second cells;
• (f) forming the first foamed layer on the second foamed layer;
• and
• (g) laminating a substrate on the first foamed layer, the substrate being a fabric.

A method for making a multi-layered material, comprising the following steps:

• (a) forming a third polymer mixture on a release paper, the third polymer mixture containing a third polymer resin;
• (b) drying the third polymer mixture to form a surface layer;
• (c) foaming a second polymer mixture and then forming the foamed second polymer mixture on the surface layer, the second polymer mixture containing a second polymer resin, wherein the second polymer resin has a solid content higher than 50%, and the foaming method is chemical foaming;
• (d) drying the second polymer mixture to form a second foamed layer, the second foamed layer having a plurality of second cells, wherein the second cells are not in communication with each other;
• (e) foaming a first polymer mixture and then drying the foamed first polymer mixture to form a first foamed layer, the first polymer mixture containing a first polymer resin, the first foamed layer having a plurality of first cells, wherein the foaming method of step (c) is different from that of step (e), the variation in size of the second cells is different from that of the first cells, the first polymer resin is an aqueous polymer resin and the foaming method is physical foaming, the first foamed layer has a density of 0.25 g/cm3 to 0.7 g/cm3, a part of the first cells are in communication with each other, and the variation in size of the second cells is smaller than that of the first cells;
• (f) forming the first foamed layer on the second foamed layer;
• and
• (g) laminating a substrate on the first foamed layer, the substrate being a fabric.