# US 11,897,245 B2 · Laminated fabrics and protective covers with post-industrial and/or post-consumer content and methods of making laminated fabrics and protective covers with post-industrial and/or post consumer content

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- Number: US 11,897,245 B2
- Document ID: US11897245B2
- Status: Granted
- Kind: B2
- Application number: 17/555,576
- Filed: 2021-12-20
- Published: 2022-04-14
- Granted: 2024-02-13
- Earliest claimed: 2019-10-21
- Assignees: Transhield, Inc.
- Applicants: Transhield, Inc.
- Inventors: Seckin Ozol; Na Qi; Gregory L. Todt
- Web page: https://patentgrep.com/patent/US11897245B2

## CPC

- B29B 17/0026: {by agglomeration or compacting}
- B32B 5/022: {Non-woven fabric}
- B29B 17/02: Separating plastics from other materials
- B32B 5/08: the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres}
- B32B 5/24: one layer being a fibrous or filamentary layer
- B32B 7/028: Heat-shrinkability
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 27/06: as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)}
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/36: comprising polyesters
- B32B 37/1207: {Heat-activated adhesive (B32B37/04 takes precedence)}
- B32B 37/153: {at least one layer is extruded and immediately laminated while in semi-molten state}
- B29B 17/0412: {to large particles, e.g. beads, granules, flakes, slices}
- B29B 2017/0203: {Separating plastics from plastics}
- B29B 2017/0255: {using different melting or softening temperatures of the materials to be separated}
- B29B 2017/0476: {Cutting or tearing members, e.g. spiked or toothed cylinders or intermeshing rollers}
- B29K 2023/0633: {LDPE, i.e. low density polyethylene}
- B29K 2067/003: {PET, i.e. poylethylene terephthalate}
- B29L 2009/00: Layered products
- B32B 2037/1223: {film-shaped}
- B32B 2250/02: 2 layers
- B32B 2262/0253: Polyolefin fibres
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0284: Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
- B32B 2307/30: having particular thermal properties
- B32B 2307/31: Heat sealable
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/558: Impact strength, toughness
- B32B 2307/5825: Tear resistant
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/732: Dimensional properties
- B32B 2307/736: Shrinkable
- B32B 2367/00: Polyesters, e.g. PET, i.e. polyethylene terephthalate
- B32B 2571/00: Protective equipment
- Y02W 30/52: Mechanical processing of waste for the recovery of materials, e.g. crushing, shredding, separation or disassembly
- Y02W 30/62: Plastics recycling; Rubber recycling
- B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## Abstract

A method of recycling laminated fabrics and laminated fabric products and producing new laminated fabrics and laminated fabric products includes the steps of shredding scrap or used laminated fabric material, melt separating the polymers, pelletizing the melt separated polymers, extruding the pelletized material with at least one virgin material to form a film, and laminating the film to a nonwoven material to form a new laminated fabric. The scrap or recycled laminated fabric products can include plastic/polymer materials having different melting temperatures. The new laminated fabric can be utilized to produce new products, such as protective covers.

## Claims

### Claim 1

A method of protecting an object with a cover, including the steps of:
obtaining a laminated fabric including material from a recycled laminated fabric product, the recycled laminated fabric product having a first component that is a polymer, the first component having a melting point, and a second component having a melting point differing from the melting point of the first component by at least 100° C., the laminated fabric further including (a) a film layer including at least some of the first component from the recycled laminated fabric product and at least one virgin polymer resin, (b) a nonwoven layer, and (c) an adhesive between the film layer and the nonwoven layer;
forming the laminated fabric into a cover; and
placing the cover over the object to be protected;
wherein the step of obtaining a laminated fabric icluding material the recycled laminated fabric product includes making the laminated fabric by a process that includes the steps of (a) obtaining an existing laminated fabric product, the existing laminated fabric product having the first component and the second component (b) separating the first component of the existing laminated fabric product from the second component of the existing laminated fabric product, (c) forming the first component of the existing laminated fabric product into pellets, (d) providing the least one virgin polymer resin, (e) forming the pellets and the at least one virgin polymer resin into a film, (f) providing the nonwoven material, and (g) laminating the film to the nonwoven material via the adhesive.

### Claim 2 (depends on 1)

The method of claim 1, wherein the recycled laminated fabric product is heat shrinkable.

### Claim 3 (depends on 1)

The method of claim 1, wherein the content of material from the recycled laminated fabric product is less than 90% by weight of the laminated fabric.

### Claim 4 (depends on 1)

The method of claim 1, wherein the content of material from the recycled laminated fabric product is greater than 1% by weight of the laminated fabric.

### Claim 5 (depends on 1)

The method of claim 1, wherein the first component of the recycled laminated fabric product is a polyethylene polymer.

### Claim 6 (depends on 1)

The method of claim 1, wherein the second component of the recycled laminated fabric product is PET.

### Claim 7 (depends on 1)

The method of claim 1, wherein the film layer includes at least some of the second component from the recycled laminated fabric product.

### Claim 8 (depends on 1)

The method of claim 1, wherein the laminated fabric is heat sealable.

### Claim 9 (depends on 1)

The method of claim 1, wherein the first component of the recycled laminated fabric product and the at least one virgin resin are the same material.

### Claim 10 (depends on 1)

The method of claim 1, wherein the nonwoven layer is constructed at least in part from recycled material.

### Claim 11 (depends on 1)

The method of claim 1, wherein, the nonwoven layer is constructed entirely from recycled material.

### Claim 12 (depends on 1)

The method of claim 1, wherein forming the laminated fabric into a cover includes cutting the laminated fabric to a desired size.

### Claim 13 (depends on 1)

The method of claim 1, wherein forming the laminated fabric into a cover includes cutting the laminated fabric to a desired shape.

### Claim 14 (depends on 1)

The method of claim 1, wherein forming the laminated fabric into a cover includes forming the laminated fabric into a desired shape.

### Claim 15 (depends on 2)

The method of claim 2, further including the step of applying heat to the cover after the cover is placed over the item to be protected.

### Claim 16 (depends on 1)

The method according to claim 1, wherein the step of separating the first component of the existing laminated fabric product from the second component of the existing laminated fabric product is performed by melt separation.

### Claim 17 (depends on 1)

The method of claim 1, wherein the first component of the existing laminated fabric product and the at least one virgin polymer resin are the same material.

### Claim 18 (depends on 1)

The method of claim 1, wherein the pellets and the at least one virgin polymer resin are extruded to form a blown film.

### Claim 19 (depends on 1)

The method of claim 1, wherein the laminated fabric is heat shrinkable.

### Claim 20 (depends on 1)

The method of claim 1, wherein the first component of the existing laminated fabric product is a polyethylene polymer.

### Claim 21 (depends on 1)

The method of claim 1, wherein the second component of the existing laminated fabric product is PET.

### Claim 22 (depends on 1)

The method of claim 1, wherein the laminated fabric is heat sealable.

### Claim 23 (depends on 1)

The method of claim 1, further including the step of providing a second film and coextruding the film with the second film to form a multilayer film that is laminated to the nonwoven material.

### Claim 24 (depends on 1)

The method of claim 1, wherein forming the laminated fabric into a cover includes cutting the laminated fabric to a desired size.

### Claim 25 (depends on 1)

The method of claim 1, wherein forming the laminated fabric into a cover includes cutting the laminated fabric to a desired shape.

### Claim 26 (depends on 1)

The method of claim 1. wherein forming the laminated fabric into a cover includes forming the laminated fabric into a desired shape.

### Claim 27 (depends on 19)

The method of claim 19, further including the step of applying heat to the cover after the cover is placed over the item to be protected.

### Claim 28 (depends on 1)

The method of claim 1, wherein the laminated fabric is heat shrinkable.

### Claim 29 (depends on 1)

The method of claim 1, wherein the pellets include 6-12% PET by weight.