Fabric-faced composites and methods for making same
AssigneeDZS Inc.
InventorDimitri Peter Zafiroglu
Life of this patent
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Abstract
The present invention is directed to multiple layer composites 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 bonded to an adhesive layer such that the adhesive layer penetrates into the face layer. The face layer can have legs extending there from, and such legs are anchored by the adhesive layer to provide stronger attachment between the adhesive layer and the face layer. A backing layer may also be provided in contact with the adhesive layer such that the adhesive layer also embeds into the backing layer, and the legs extending from the face layer may penetrate into the backing layer.
Claims25
A composite comprising:
- (A) a fibrous face layer having a top surface and a bottom surface, (B) a solid adhesive film or solid adhesive fabric, and (C) a backing layer;
- wherein the bottom surface of the fibrous face layer faces the solid adhesive film or adhesive fabric,
- wherein the fibrous face layer comprises a non-woven fabric needled-punched to form a plurality of legs,
- wherein the legs are made from a portion of the fibrous face layer and the legs are extending away from the top surface of the fibrous face layer and through the bottom surface of the fibrous face layer,
- wherein the legs of the fibrous face layer are needle-punched through the face layer, and at least some of the legs are needled through the solid adhesive film or adhesive fabric and are thermally bonded to the adhesive film or adhesive fabric,
- wherein a portion of the adhesive in the adhesive film or adhesive fabric at least partially penetrates into the fibrous face layer and wherein the top surface of the fibrous face layer is substantially free of adhesive, and
- wherein at least some of the needle-punched legs are bonded to the backing layer.
A method for making a composite, the method comprising:
- (i) selecting a fibrous face layer comprising a plurality of fibers, wherein the face layer has a top surface and a bottom surface opposite the top surface;
- (ii) after the fibrous face layer is formed, placing an adhesive layer having a top surface and a bottom surface opposite the top surface, wherein the top surface of the adhesive layer is in direct contact with the bottom surface of the fibrous face layer;
- (iii) needle-punching the face layer to form a plurality of legs made from a portion of the fibrous face layer wherein the legs are extending away from the top surface of the fibrous face layer and into the adhesive layer;
- (iv) embedding the legs of the fibrous face layer in the adhesive layer, wherein the adhesive layer penetrates a distance of about ¼ to about ¾ of the thickness of the fibrous face layer to anchor the face layer in the adhesive layer;
- and
- (v) presenting the substantially adhesive free top surface of the fibrous face layer as a top surface of the composite.
Dependencies are inferred from the claim text.