Method of forming a PVC scrim fabric laminate having superior scuff and abrasion resistance

1 . A laminate, comprising: a primer coated scrim fabric; and a cast extruded compounded PVC film, wherein said cast extruded compounded PVC film is comprised of: a thermoplastic polyvinyl chloride polymer (PVC), a thermoplastic polyurethane polymer (TPU), and a fluoroethylene polymer.

2 . The laminate, as claimed in claim 1 , wherein said TPU has a glass transition temperature of from about −10° C. to about −80° C.

3 . The laminate, as claimed in claim 1 , wherein said PVC is an extrusion grade further comprised of the requisite processing aids, colorants, thermal and light stabilizers, plasticizers, oils, and fillers.

4 . The laminate, as claimed in claim 1 , wherein said fluoroethylene polymer is predominately polytetrafluoroethylene (PTFE).

5 . The laminate, as claimed in claim 4 , wherein said PTFE is a micronized wax.

6 . The laminate, as claimed in claim 2 , wherein said TPU is a polyurethane having an oligomeric component selected from the group consisting of polycaprolactone, polypropylene glycol, polypropylene glycol ethylene glycol, polytetramethylene glycol, polyisobutylene glycol, oligomeric aliphatic polyesters, oligomeric polyacrylic hydroxyalkyl esters, hydroxylated polybutadiene, and blends thereof.

7 . The laminate, as claimed in claim 6 , wherein said TPU is an extrusion grade of an aliphatic polyester or polyether urethane or a blend thereof.

8 . The laminate, as claimed in claim 6 , wherein said TPU has a Taber Abrasion Resistance, as defined by ASTM D1044, of less than 75 mg per 1000 cycles using the H-22 wheel.

9 . The laminate according to claim 1 , wherein said cast extruded compounded PVC film is further comprised of at least one modifying component selected from the group consisting of processing aids, colorants, thermal and light stabilizers, plasticizers, oils, and fillers.

10 . The laminate, as claimed in claim 1 , wherein said cast extruded compounded PVC film has, by weight, 5 to 50 parts of TPU per 100 parts of PVC.

11 . The laminate, as claimed in claim 4 , wherein said cast extruded compounded PVC film has, by weight, 0.1 to 5.0 parts of PTFE per 100 parts of PVC.

12 . The laminate, as claimed in claim 1 , wherein said primer coated scrim fabric is an open scrim fabric coated with a high molecular weight polyurethane.

13 . The laminate, as claimed in claim 12 , wherein said high molecular weight polyurethane has a polyisocyanate cross-linker.

14 . The laminate, as claimed in claim 12 , wherein said high molecular weight polyurethane is an anionic polyurethane dispersion.

15 . The laminate, as claimed in claim 13 , wherein said polyisocyanate cross-linker is based on hexamethylene diisocyanate.

16 . The laminate, as claimed in claim 1 , wherein said laminate is further comprised of an extruded adhesive.

17 . The laminate, as claimed in claim 16 , wherein said extruded adhesive is comprised of an extrusion grade of PVC and an extrusion grade of TPU.

18 . A method for forming a laminate having superior scuff and abrasion resistance, said method comprising the steps of:

a) providing a compounded PVC, where said compounded PVC comprises a thermoplastic polyvinyl chloride polymer (PVC), a thermoplastic polyurethane polymer (TPU), and a fluoroethylene polymer;

b) extruding the compounded PVC forming a cast extruded compounded PVC film; and

c) laminating the compounded PVC film to a scrim fabric having a polyurethane primer coating.

19 . The method, as claimed in claim 18 , wherein said scrim fabric having the polyurethane primer coating is formed by steps comprised of:

i) dip coating a scrim fabric with a polyurethane primer coating;

ii) drying the polyurethane primer coating; and

iii) winding the primer coated scrim fabric.

20 . The method, as claimed in claim 19 , wherein said polyurethane primer coating is applied to the scrim fabric while it is being woven and is still on the loom.

21 . The method, as claimed in claim 19 , wherein said polyurethane primer coating is an aqueous dispersion of an anionic polyurethane and an aliphatic polyisocyanate.

22 . The method, as claimed in claim 19 , wherein said drying step is infrared drying.

23 . The method, as claimed in claim 18 , wherein said fluoroethylene polymer is predominately polytetrafluoroethylene (PTFE).

24 . The method, as claimed in claim 23 , wherein said PTFE is a micronized wax.

25 . The method, as claimed in claim 24 , wherein said compounded PVC is prepared by admixing the PVC, the TPU and the PTFE on a mix-extruder.

26 . The method, as claimed in claim 18 , wherein said extruding step is further comprised of:

extruding the compounded PVC through a die onto a two roll nip forming the compounded PVC film, where said die has a compression roll and a steel roll, and wherein said primer coated scrim fabric partially wraps the compression roll.

27 . The method, as claimed in claim 18 , wherein said method further comprises the step of:

d) annealing the laminate in an oven to reduce curl and minimize anisotropic distortions in the laminate.

28 . The method, as claimed in claim 27 , wherein said method further comprises the steps of:

e) cooling the laminate; and

f) winding the annealed laminate into a roll.

29 . The method, as claimed in claim 18 , wherein said extruding step further comprises:

co-extruding compounded PVC through a die onto a two roll nip forming the compounded PVC film, and extruding an adhesive between said film and said primer coated scrim fabric, where said die has a compression roll and a steel roll, and wherein said primer coated scrim fabric partially wraps the compression roll.

30 . A method for forming a laminate having superior scuff and abrasion resistance, said method comprising the steps of:

a) providing a compounded PVC film, where said compounded PVC film is comprised of PVC, TPU, and a fluoroethylene polymer;

b) providing a scrim fabric with a polyurethane primer coating;

c) providing an extrudable adhesive comprised of PVC and TPU;

d) extruding the adhesive through a die onto a two roll nip to which is fed the compounded PVC film and the primer coated scrim fabric, where said die has a compression roll and a steel roll, and wherein said primer coated scrim fabric partially wraps the compression roll; and

e) laminating the compounded PVC film to the primer coated scrim fabric.