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  Fabric-faced composites and methods for making sameUSPTO Application #: 20060183389Title: Fabric-faced composites and methods for making same Abstract: The present invention is directed to multiple layer composites (10) suitable for use as wall and floor coverings, among other uses, that provide a strong durable structure and a soft textile or fabric face. The composite includes a face layer (12) bonded to an adhesive layer (22) such that the adhesive layer (22) penetrates into the face layer (12). The face layer (12) can have legs (19, 34) extending there from, and such legs (19, 34) are anchored by the adhesive layer to provide stronger attachment between the adhesive layer and the face layer. A backing layer (26) may also be provided in contact with the adhesive layer (22) such that the adhesive layer also embeds into the backing layer (26), and the legs (19, 34) extending from the face layer may penetrate into the backing layer. (end of abstract)
Agent: The H.t. Than Law Group - Washington, DC, US Inventor: Dimitri Peter Zafiroglu USPTO Applicaton #: 20060183389 - Class: 442149000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Coated Or Impregnated Woven, Knit, Or Nonwoven Fabric Which Is Not (a) Associated With Another Preformed Layer Or Fiber Layer Or, (b) With Respect To Woven And Knit, Characterized, Respectively, By A Particular Or Differential Weave Or Knit, Wherein The Coating Or Impregnation Is Neither A Foamed Material Nor A Free Metal Or Alloy Layer, Coating Or Impregnation Intended To Function As An Adhesive To Solid Surfaces Subsequently Associated Therewith The Patent Description & Claims data below is from USPTO Patent Application 20060183389. Brief Patent Description - Full Patent Description - Patent Application Claims
TECHNICAL AREA [0001] The present invention relates to fabric-faced laminates for use as floor coverings. BACKGROUND [0002] Floor coverings are generally selected based upon a combination of factors including aesthetic features such as the look and feel of the floor covering and functional qualities such as retention of surface appearance, stain resistance, moisture resistance, ease of cleaning, and resistance to collection of dirt. For example, floor covering installations in high traffic areas or areas prone to moisture and stains such as kitchens generally use solid surface cover materials for the flooring or interior wall coverings such as wood, metal, marble, ceramic tile, vinyl or rubber. These products retain their surface appearance after heavy use and they are simple to keep clean. They also are resistant to stains and moisture, and less prone to harboring bacterial growth. However, these products lack the textile hand, softness or sound dampening qualities of textile products. [0003] In installations where aesthetic qualities such as texture and softness are desired, products such as tufted, knit, knotted or woven structures, including velour or velvet are used. These products provide softness and cushion, a soft textile hand and a degree of abrasion and wear resistance. Compared to rigid solid surfaced products, however, these floor coverings are less durable, tend to lose their texture with heavy use, because the pile tends to mat or to be crushed with heavy traffic, tend to collect dust and dirt, provide spaces that allow the growth of bacteria, and are difficult to clean and sanitize. [0004] Attempts have been made to create products having both the desired functional qualities of solid surface materials and the aesthetic qualities of textile or fabric materials. For example, hybrid structures with partially fibrous and partially solid faces are disclosed in U.S. Pat. No. 3,943,018. These hybrid structures, however, merely reduce but do not eliminate the limitations of regular tufted, velour, or flocked textile surfaces. [0005] Other attempts provide flat or profiled, e.g., sculpted, surfaces containing fibrous layers impregnated with a plastic matrix. Examples of fibrous layers impregnated with a plastic matrix are disclosed in U.S. Pat. Nos. 4,035,215, 4,098,629, and 6,063,473. These floor coverings generally have surfaces with a semi-fibrous feel, and the spaces between the fibers may be sufficiently sealed to prevent bacterial penetration and dirt collection. In addition, these floor coverings also provide a higher matting resistance than regular upright-oriented fiber structures. However, these floor covering products largely have a stiff leathery appearance rather than a soft textile feel, and the cost of preparing dimensionally-stable dense fibrous products, combined with the cost of impregnating and heat setting can be very high. [0006] U.S. Pat. No. 3,860,469 discloses another technique to produce inexpensive, dirt and bacterial growth resistant, and abrasion resistant surface covering materials with a textile fiber appearance in which flat or textured film-like skins are placed on top of a pile-like surface. The resultant floor covering products combine the qualities of carpet with the solidity of vinyl or rubber, but lack the textile quality and aesthetics of carpets. [0007] Other attempts assemble a basically flat textile fabric over a sublayer of adhesive backed with various layers of sub-surface reinforcement. For example, International Patent Publication No. WO 99/19557 discloses a woven face fabric backed by reinforcing layers, and U.S. Pat. No. 5,965,232 discloses a decorative fabric attached to dimensionally-stabilizing or cushioning layers. The fabric is further surface-stabilized. Laminates having a flat fabric face, however, tend to delaminate or fray at the edges unless the fabric is thoroughly impregnated with adhesives. Unfortunately, impregnation with adhesives adversely affects the textile feel and cushioning quality of the laminate. [0008] Because of these shortcomings, the need remains to provide a surface covering material that combines the desirable properties of both solid surface coverings and textile-type coverings into a single product. Suitable surface coverings would have at least some of the desired properties of surface stability, edge fray resistance, thermal stability, structural stability, dimensional stability, dirt resistance, bacteria resistance, soft textile hand, cushioning, and appearance extending over a full spectrum of tufted, knit, non-woven, woven, velour and velvet products. SUMMARY OF THE INVENTION [0009] Composite materials in accordance with the present invention utilize a fibrous face layer combined with an adhesive layer to form a multi-layer structure. In order to provide the desired level of surface stability, the surface fibers of the fibrous face layer form loops, and the loops descend into the adhesive layer and are anchored in the adhesive layer. The loops are densely spaced and shallow. Although any portion of the fibers or legs of the looped fibers in the face layer can be dispersed in the adhesive, a significant amount or substantially all of the descending fibers are dispersed in the adhesive layer, which is in contact with the face layer. A characteristic of this invention is that short and densely spaced fiber loops embedded in adhesive provide improved surface stability and retention of appearance under repeated loading. Another characteristic is the resistance to cut-edge fraying. [0010] In order to maintain the desired aesthetic qualities of the composite material while achieving increased surface stability, the amount of penetration of the adhesive into the face layer is controlled. The adhesive layer is not allowed to penetrate into the top portion of the face layer. Therefore, the top of the face layer maintains its textile feel. [0011] Various types of fibrous face layer constructions can be used depending upon the aesthetics desired and a balance of cost vs. performance. Regardless of the type of fibrous layer used, all of the embodiments and arrangements illustrated herein have a relatively fine and dense surface texture and they can also be embossed to produce three-dimensional textured products. In addition, a three layer composite structure can be provided wherein a backing layer is also bonded or laminated to the adhesive layer such that the adhesive layer is disposed between the face layer and the backing layer. Added structural rigidity is provided by having the adhesive layer penetrate into the backing layer as well. [0012] To prepare a composite material in accordance with the present invention, a fibrous face layer is arranged to have a relatively smooth top surface with a high density of fiber loop legs extending down through the thickness of the face layer to the bottom surface. An adhesive layer is brought into direct contact with the bottom surface of the face layer and embedded into the face layer to cause the adhesive to penetrate partially into the thickness of the face layer. In order to embed the adhesive layer in the face layer, pressure and heat can be applied. For a three layer laminate, the backing layer can be brought into direct contact with the adhesive layer before the adhesive layer is embedded into the face layer, allowing the adhesive layer to simultaneously penetrate into the backing layer. The adhesive layer may be pre-integrated onto the face layer or onto the backing layer before lamination. The adhesive layer may also contain non-adhesive reinforcing or blended components. The backing layer may also contain adhesive components, which may replace the need for a separate adhesive layer, if the adhesive is present in sufficient quantity to anchor and envelope the legs of the surface fiber loops descending into it. BRIEF DESCRIPTION OF THE DRAWINGS [0013] FIG. 1 is a schematic representation of a three layer embodiment of the composite material in accordance with the present invention; [0014] FIG. 2 is schematic representation of another three layer embodiment of the composite material; [0015] FIG. 3 is a schematic representation of another three layer embodiment of the composite material; [0016] FIG. 4 is a schematic representation of another three layer embodiment of the composite material; [0017] FIG. 5 is a schematic representation of a non-woven fabric layer; [0018] FIG. 6 is schematic representation of a needle punched non-woven fabric layer; [0019] FIG. 7 is a schematic representation of a needle punched non-woven face layer embodiment of the present invention before lamination; [0020] FIG. 8 is schematic representation of a needle punched non-woven face layer embodiment of the present invention after lamination; Continue reading... Full patent description for Fabric-faced composites and methods for making same Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Fabric-faced composites and methods for making same patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Fabric-faced composites and methods for making same or other areas of interest. ### Previous Patent Application: Coloured polypropylene/polystyrene support Next Patent Application: Woven fabric and method of manufacturing the same Industry Class: Fabric (woven, knitted, or nonwoven textile or cloth, etc.) ### FreshPatents.com Support Thank you for viewing the Fabric-faced composites and methods for making same patent info. 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