Protective composite fabric and methods of making and using it

Abstract

The composite fabric includes a film, a first fibrous layer, a fabric layer, and a second fibrous layer. The film has a first side and a second side. The first fibrous layer has a first side connected to the second side of the film and a second side. The fabric layer has a first side connected to the second side of the first fibrous layer and a second side. The second fibrous layer has a first side connected to the second side of the fabric layer and a second side. The film may be a non-heat-shrinkable film. The composite fabric may include one or more retention members for contacting a surface on which the composite fabric is placed and preventing movement of the composite fabric relative to the surface.

Description

[Technical Field]

[0001] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 028,814, filed May 22, 2020, and U.S. Patent Application No. 17 / 324,450, filed May 19, 2021.

[0002] FIELD OF THE INVENTION The present invention relates to protective composite fabrics and methods of making and using protective composite fabrics. [Background technology]

[0003] Protective fabrics and other compositions can be used to protect surfaces and objects from corrosion, scratches, and other damage that can occur from contact with other objects, as well as from the elements, sunlight, the elements, and other harmful factors. Examples of such fabrics and compositions are described in U.S. Patent Nos. 6,696,120, 7,074,288, 8,828,487, and 8,883,284. U.S. Patent Application Publication No. 2003 / 0151159 A1 discloses a process for manufacturing a protective composite wrap. The process includes preparing a first thermoplastic resin and a vapor corrosion inhibitor, which are blended into a homogeneous blend and extruded as continuous thermoplastic filaments. The filaments are formed into a nonwoven fabric. The process also includes extruding a second thermoplastic resin as a continuous film and attaching the nonwoven fabric and the film face-to-face to form the protective composite wrap. European Patent Application Publication No. 3243939 A1 discloses a multi-layer nonwoven fabric in which the fibers in one layer have different denier or hydrophilicity than the fibers in the other layers. This structure allows for unidirectional water vapor transmission, facilitating moisture removal from the surface of the enclosed item and preventing corrosion-related damage. U.S. Patent Application Publication No. 2010 / 0215924 A1 discloses a membrane for use on inclined surfaces. One membrane embodiment includes an adhesive layer on one side to maintain the membrane on the inclined surface and protruding polymeric members on the other side to prevent slipping of people or objects on that side. WO 2017 / 172360 A1 discloses a washable multi-component floor mat. The floor mat includes a textile component and a base component. The textile component and base component are attached to each other by at least one surface adhesive means and at least one edge attachment means. WO2019 / 116174A1 discloses a sheet including a film layer having a front surface and a rear surface, and a fastener layer including a first hook-and-loop fastener member fixed to at least a portion of the rear surface of the film layer. The first hook-and-loop fastener member includes at least one of a loop material or a hook material.The loop material includes nonwovens or knits that can be engaged with the hook material. Summary of the Invention [Means for solving the problem]

[0004] In one embodiment of the present invention, the composite fabric includes a film, a first fibrous layer, a fabric layer, a second fibrous layer, and a plurality of retention members. The film has a first side and a second side. The first fibrous layer has a first side connected to the second side of the film and a second side. The fabric layer has a first side connected to the second side of the first fibrous layer and a second side. The second fibrous layer has a first side connected to the second side of the fabric layer and a second side. The retention members are connected to the second side of the second fibrous layer and extend from the second side of the second fibrous layer. The retention members are adapted to contact a surface on which the composite fabric is placed to prevent movement of the composite fabric relative to the surface.

[0005] In one embodiment, the film is a non-heat shrinkable film.

[0006] In other embodiments, the retaining member comprises a vapor corrosion inhibitor. In some embodiments, the retaining member comprises a contact corrosion inhibitor.

[0007] In other embodiments, the plurality of retention members form at least one pocket between one or more of the plurality of retention members and the second side of the second fibrous layer and the surface, and the composite fabric includes a vapor corrosion inhibitor, at least a portion of which collects in one or more of the pockets.

[0008] In some embodiments, the retaining member is made of epoxy. In other embodiments, the retaining member is made of polyurethane.

[0009] In another embodiment, the composite fabric further comprises a pH adjuster.

[0010] In one embodiment, the composite fabric includes an adhesive between the film and the first fibrous layer. In some embodiments, the composite fabric includes a vapor corrosion inhibitor in the adhesive. In another embodiment, the adhesive attaches the film to the first fibrous layer, and the water-saturated bond strength adhesion between the film and the first fibrous layer in the machine direction is at least 1,000 g / cm. In yet another embodiment, the adhesive attaches the film to the first fibrous layer, and the water-saturated bond strength adhesion between the film and the first fibrous layer in the cross-machine direction is at least 1,000 g / cm.

[0011] In one embodiment, the film is a multilayer film.

[0012] In another embodiment, the composite fabric includes an electromagnetic shield.

[0013] In one embodiment of the present invention, a composite fabric includes a non-heat-shrinkable film, a first fibrous layer, a fabric layer, and a second fibrous layer. The film has a first side and a second side. The first fibrous layer has a first side connected to the second side of the film and a second side. The fabric layer has a first side connected to the second side of the first fibrous layer and a second side. The second fibrous layer has a first side connected to the second side of the fabric layer and a second side.

[0014] In one embodiment, the composite fabric includes a plurality of retention members connected to and extending from the second side of the second fibrous layer, the retention members contacting a surface on which the composite fabric is placed to prevent movement of the composite fabric relative to the surface.

[0015] In other embodiments, the retaining member comprises a vapor corrosion inhibitor. In some embodiments, the retaining member comprises a contact corrosion inhibitor.

[0016] In other embodiments, the plurality of retention members form at least one pocket between one or more of the plurality of retention members and the second side of the second fibrous layer and the surface, and the composite fabric includes a vapor corrosion inhibitor, at least a portion of which collects in one or more of the pockets.

[0017] In some embodiments, the retaining member is made of epoxy. In other embodiments, the retaining member is made of polyurethane.

[0018] In another embodiment, the composite fabric further comprises a pH adjuster.

[0019] In one embodiment, the composite fabric includes an adhesive between the film and the first fibrous layer. In some embodiments, the composite fabric includes a vapor corrosion inhibitor in the adhesive. In another embodiment, the adhesive attaches the film to the first fibrous layer, and the water-saturated bond strength between the film and the first fibrous layer in the machine direction is at least 1,000 g / cm. In yet another embodiment, the adhesive attaches the film to the first fibrous layer, and the water-saturated bond strength between the film and the first fibrous layer in the cross-machine direction is at least 1,000 g / cm.

[0020] In one embodiment, the film is a multilayer film.

[0021] In another embodiment, the composite fabric includes an electromagnetic shield.

[0022] In one embodiment of the present invention, the composite fabric includes a first film, a first fibrous layer, a fabric layer, a second fibrous layer, a second film, and a plurality of retention members. The first film has a first side and a second side. The first fibrous layer has a first side connected to the second side of the first film and a second side. The fabric layer has a first side connected to the second side of the first fibrous layer and a second side. The second fibrous layer has a first side connected to the second side of the fabric layer and a second side. The second film has a first side connected to the second side of the second fibrous layer and a second side. The retention members are connected to the second side of the second film layer and extend from the second side of the second fibrous layer. The retention members are adapted to contact a surface on which the composite fabric is placed to prevent movement of the composite fabric relative to the surface.

[0023] In one embodiment of the present invention, a method of manufacturing a composite fabric includes providing a film, connecting a first fibrous layer to the film, connecting a fabric layer to the first fibrous layer, connecting a second fibrous layer to the fabric layer, and forming a plurality of retention members on the second fibrous layer.

[0024] These and other features of the present invention will become apparent to those skilled in the art from the following detailed description of the embodiments of the invention and the accompanying drawings. [Brief explanation of the drawings]

[0025] [Figure 1] FIG. 1 is a cross-sectional view of a protective composite fabric according to one embodiment of the present invention. [Figure 2] FIG. 2 is a partially exploded view of the protective composite fabric shown in FIG. [Figure 3] FIG. 3 is a side view, in cross section, of a vehicle using a protective cover constructed from a protective composite fabric according to one embodiment of the present invention. [Figure 4] FIG. 4 is a detailed view of region 4 in FIG. [Figure 5] FIG. 5 is a cross-sectional view of a protective composite fabric according to another embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0026] 1 is a cross-sectional view of a protective composite fabric 10 according to one embodiment of the present invention. In the illustrated embodiment, the composite fabric 10 primarily includes a film 20, an adhesive 30, a first fibrous layer 40, a fabric layer 50, a second fibrous layer 60, and a plurality of retention members 70.

[0027] In the illustrated embodiment, film 20 includes first layer 21, second layer 22, and third layer 23. Film 20 is made of a non-heat-shrinkable thermoplastic material. In some embodiments of the present invention, first layer 21 is a polyurethane film, and in some embodiments, a high-yield-strength thermoplastic polyurethane film. An example of a suitable material for film 20 in some embodiments of the present invention includes, but is not limited to, ESTANE® 58277 TPU, available from Lubrizol Advanced Materials, Inc., Cleveland, Ohio. In the illustrated embodiment, second layer 22 of film 20 is a polyurethane film. Second layer 22 can be made of the same material as first layer 21, or it can be made of a different material. In the illustrated embodiment, third layer 23 of film 20 is also a polyurethane film. In some embodiments, third layer 23 is a high-yield-strength polyurethane film. In some embodiments, first layer 21 and third layer 23 are made of the same material. Film 20 may be produced, for example, by co-extruding first layer 21, second layer 22, and third layer 23 together. Alternatively, film 20 may be produced by extruding a cast film and / or a blown film. In one embodiment of the present invention, first layer 21, second layer 22, and third layer 23 are co-extruded to form film 20.

[0028] In some embodiments of the present invention, second layer 22 of film 20 is thicker than first layer 21 and third layer 23. In one embodiment, second layer 22 comprises about 60% of the total thickness of film 20, and first layer 21 and third layer 23 each comprise about 20% of the total thickness of film 20. In another embodiment, second layer 22 comprises about 70% of the total thickness of film 20, and first layer 21 and third layer 23 each comprise about 15% of the total thickness of film 20.

[0029] First layer 21 and / or third layer 23 may optionally include a pH adjuster 24. A relatively high pH level (i.e., a more alkaline environment) helps prevent mold growth and protect metal surfaces from corrosion. In use, first layer 21 faces outward from the surface to be protected and inhibits mold growth on the surface of a cover or other structure made from composite fabric 10 and on fabric layer 50. Third layer 23 inhibits mold growth on fabric layer 50. In various embodiments of the present invention, pH adjuster 24 is utilized in an amount effective to achieve a pH level between composite fabric 10 and the object to be protected of about 8 to about 13. In one embodiment of the present invention, pH adjuster 24 is selected to achieve a pH of at least 8. Suitable pH adjusters 24 include, but are not limited to, sodium acetate, wollastonite, calcium oxide, and / or calcium hydroxide. The pH adjuster 24 may be added directly to a layer of the film 20 or may be added as a pH adjusting component in the form of a masterbatch containing one or more pH adjusters 24 .

[0030] In the illustrated embodiment, film 20 is an inherently waterproof, highly water vapor permeable construction. This prevents liquid water from migrating through film 20 to the object protected by composite fabric 10, while simultaneously allowing water vapor to pass through composite fabric 10 from the vicinity of the object. In some embodiments of the invention, film 20 has a water vapor transmission rate of about 50 g / m² / day to about 200 g / m² / day at a thickness of 7.5 mils. In one embodiment, film 20 has a water vapor transmission rate of at least 50 g / m² / day. Thinner films 20 can be utilized to achieve even greater water vapor transmission rates, including a water vapor transmission rate of at least 500 g / m² / day.

[0031] The adhesive 30 bonds the film 20 to the first fibrous layer 40. The adhesive 30 may be any adhesive sufficient to bond the film 20 to the first fibrous layer 40 in a manner that prevents delamination or unacceptable degradation of the composite fabric 10 during use, particularly in high temperature, high humidity, and / or wet environments. Examples of acceptable adhesives include, but are not limited to, polyurethane adhesives and hot melt styrene ethylene butadiene styrene (SEBS) adhesives. In one embodiment of the present invention, AL1262 adhesive containing a vapor corrosion inhibitor (VCI) is utilized. In another embodiment of the present invention, AL34-149-1 adhesive containing a VCI is utilized. These adhesives are available from Adherent Laboratories, Inc., St. Paul, Minnesota.

[0032] Various types of VCIs can be utilized in accordance with embodiments of the present invention. These VCIs may be amines, nitrites, nitrates, triazoles, and other volatile compounds. Certain chemicals are more effective at inhibiting corrosion of certain metals. For example, benzotriazole is a more effective VCI for copper, while cyclohexylamine carbonate is more effective with steel. Non-limiting examples of vapor corrosion inhibitors useful with embodiments of the present invention include primary, secondary, and tertiary aliphatic amines, aliphatic diamines, cycloaliphatic and aromatic amines, polymethylimines, long-chain ethanolamines, imidazolines, amine salts (e.g., amine salts of carbonic acid, carbamic acid, acetic acid, benzoic acid, oleic acid, nitrous acid, and chromic acid), acetylenic alcoholic alcohols, alkyl chromates, organic esters of nitrous acid, organic esters of phthalic acid, organic esters of carbonic acid, nitronaphthalenes, nitrobenzenes, amides, mixtures of nitrites with urea, urotropine, or ethanolamine, naphthol, thiourea derivatives, and heterocyclic compounds 65 and their salts, such as benzotriazole, tolyltriazole, mercaptobenzothiazole, nitrated or sulfonated petroleum derivatives, and organic acid derivatives.

[0033] In one embodiment of the present invention, the first fibrous layer 40 is a spunlaced nonwoven material. Acceptable materials for the first fibrous layer 40 can be natural or synthetic, including organic and inorganic fibers and bioplastic materials. Examples include, but are not limited to, cotton, viscose, rayon, acetate, polyamide, nylon, polyester, acrylic, polyethylene terephthalate ("PET"), polypropylene ("PP"), polyethylene ("PE"), polylactic acid ("PLA"), polyurethane, glass, and / or other fibers suitable for manufacturing spunlaced nonwoven materials. In one embodiment of the present invention, staple fibers are used to form the first fibrous layer 40, and the fibers are crimped staple fibers suitable for carding, hydroentangling, and heat drying. The denier of the fibers utilized can vary depending on the manufacturing method. In one embodiment of the present invention, the fibers have a denier of less than 3. In another embodiment, the fibers have a denier of 0.5 to 1.5. The basis weight of the first fibrous layer 40 can vary based on the intended use of the composite fabric 10. In one embodiment of the present invention, the basis weight of the first fibrous layer 40 is between 10 g / m and 100 g / m. In one embodiment of the present invention, the basis weight of the first fibrous layer 40 is 25 g / m.

[0034] To test the level of adhesion between film 20 and first fibrous layer 40 according to an embodiment of the present invention, several samples were prepared. The samples were made by applying adhesive 30 to film 20 and laminating film 20 to fibrous layer 40. One set of samples was made using AL34-149-1 adhesive ("Embodiment 1") and another set of samples was made using AL1262 adhesive ("Embodiment 2"). Both adhesives contained a vapor corrosion inhibitor. The following manufacturing specifications were used to make the samples:

[0035] [Table 1]

[0036] The film 20 is made from a non-heat shrinkable thermoplastic material so that it will not distort when in contact with the hot adhesive.

[0037] Samples of the present invention were immersed in water for 24 hours and tested for saturated bond strength adhesion according to ASTM Standard D1876 and compared to dry bond strength adhesion, also measured according to ASTM Standard D1876. Similar tests were performed on prior art composite fabric products utilizing heat-shrinkable films. The average results for five samples of the prior art and five samples of each of the two embodiments of the present invention are shown in the table below. In the table, "MD" refers to adhesion in the machine direction (i.e., along the length of the sample) and "CD" refers to adhesion in the cross direction (i.e., across the sample). Adhesion results are reported in g / cm.

[0038] [Table 2]

[0039] As shown in the table above, the adhesive strength of the prior art product significantly decreased after immersion in water. In contrast, the adhesive strength of Example 1 significantly increased. Furthermore, the adhesive strength of Example 2 significantly increased in the machine direction, with only minimal decrease in the cross direction.

[0040] The fabric layer 50 may be bonded to the first fibrous layer 40 by a hydroentanglement process, such as that used in known spunlace manufacturing processes. Unlike prior art devices that use scrims, the fabric layer 50 is a continuous web of material. In some embodiments of the present invention, the fabric layer 50 is a non-woven material. Examples of suitable fabric materials for the fabric layer 50 include, but are not limited to, knitted and spunbonded fabrics made from polyamide, nylon, polypropylene, polyester, polyamide, PLA, and / or polyurethane. In some embodiments of the present invention, the fabric layer 50 includes a vapor corrosion inhibitor 51. The VCIs described above with respect to the adhesive 30 are examples of VCIs suitable for incorporation into the fabric layer 50.

[0041] The second fibrous layer 60 may be made of the same materials and by the same methods and may have the same physical properties as those described above with respect to the first fibrous layer 40. In some embodiments of the invention, the second fibrous layer 60 is the same as the first fibrous layer 40. In other embodiments of the invention, the second fibrous layer 60 is different from the first fibrous layer 40. The second fibrous layer 60 may be bonded to the fabric layer 50 by a hydroentanglement process.

[0042] As noted above, in some embodiments of the present invention, first fibrous layer 40, fabric layer 50, and / or second fibrous layer 60 may be composed entirely or partially of PLA, such as PLA produced from corn or other renewable resources. PLA is biodegradable, making composite fabric 10 including PLA environmentally friendly.

[0043] In the illustrated embodiment, the retention member 70 is connected to and extends from one side of the second fibrous layer 60. The retention member 70 functions to resist movement, including sliding, of the composite fabric 10 across the surface of the object protected by the cover 10. The retention member 70 is fabricated from a material that provides sufficient frictional engagement with the surface of the object protected by the composite fabric 10. In one embodiment of the present invention, the retention member 70 is made from polyurethane. In one embodiment of the present invention, the retention member 70 is comprised of formulation FL2030, available from Key Polymer Corporation of Lawrence, Massachusetts. In another embodiment, the retention member 70 is made from epoxy. The retention member 70 may be fabricated using a thermosetting or thermoplastic ink printed onto the second fibrous layer 60. The ink used to fabricate the retention member 70 preferably has a viscosity of 30,000 centipoise or greater at ambient temperature, which facilitates the formation of a raised retention member 70. Certain samples of embodiments of the present invention were manufactured in part at Spectro Coating Corp. of Leominster, Massachusetts, on equipment that printed and dried retention member 70 onto second fibrous layer 60. Retention member 70 can be printed onto second fibrous layer 60 either before or after lamination to film 20.

[0044] Retention member 70 may include a corrosion inhibitor 71, which may be a VCI or a contact corrosion inhibitor. A contact corrosion inhibitor prevents corrosion of a metal upon contact with the metal. In embodiments of the present invention utilizing corrosion inhibitor 71, the ink used to manufacture retention member 70 has a pH of about 8 or greater, resulting in enhanced corrosion protection. The VCIs described above with respect to vapor corrosion inhibitor 51 are also suitable for use as corrosion inhibitor 71. Corrosion inhibitor 71 need not be the same as vapor corrosion inhibitor 51. If a contact corrosion inhibitor is used, it may be disposed on or near the exterior surface of retention member 70.

[0045] The composite fabric 10 can be formed in any one of a number of ways. In one embodiment of the present invention, the first fibrous layer 40, the fabric layer 50, and the second fibrous layer 60 are bonded together, for example, by a hydroentanglement process as described above. The retention members 70 are then formed on the second fibrous layer 60, for example, by printing as described above. The film 20 is then laminated to the first fibrous layer 40, as described above. Alternatively, the first fibrous layer 40, the fabric layer 50, and the second fibrous layer 60 are first bonded together, and then the film 20 is laminated to the first fibrous layer 40. The retention members 70 are then formed on the second fibrous layer 60.

[0046] The composite fabric 10 can be formed into any desired configuration. For example, as shown in FIG. 3, the composite fabric 10 can be formed into a custom-fit cover 100 specifically configured to protect a vehicle 110 having a surface 111. In use, the retaining member 70 contacts the surface 111 of the vehicle 110 (FIG. 4) and holds the remainder of the cover 100 away from the surface 111. In this way, if the second fibrous layer 60 becomes wet, the retaining member 70 holds the second fibrous layer 60 away from the surface 111, thereby keeping the surface 111 drier and preventing corrosion. This configuration also creates pockets in which VCI can collect. These pockets also aid in the evaporation of condensation. The retaining member 70 also helps secure the cover 100 to the vehicle 110, such as when a strong wind pushes the cover 100 toward or against the vehicle 110, and friction between the retaining member 70 and the surface 111 prevents the cover 100 from moving. In one embodiment of the present invention, retention member 70 is capable of retaining cover 100 on vehicle 110 under wind conditions ranging from about 119 km / hr to about 252 km / hr. Additionally, frictional heat generated by movement between retention member 70 and surface 111 promotes the release of vapor corrosion inhibitor 71, which helps prevent corrosion of vehicle 110 and surface 111. Additionally, over time, some of vapor corrosion inhibitor 71 will migrate from fabric layer 50 toward surface 111 of vehicle 110, helping to prevent corrosion.

[0047] FIG. 5 is a cross-sectional view of a composite fabric 200 according to another embodiment of the present invention. Similar to the embodiment of FIGS. 1 and 2, this embodiment includes a film 20, an adhesive 30, a first fibrous layer 40, a fabric layer 50, a second fibrous layer 60, and a retention member 70. However, the composite fabric 200 also includes a second film 20A between the second fibrous layer 60 and the retention member 70. The second film 20A can be connected to the second fibrous layer 60 by a second adhesive 30A in a manner similar to that described above for connecting the film 20 to the first fibrous layer 40. The second film 20A can be constructed in the same manner and from the same materials as described above for the film 20. The pH adjuster 24 described above can also be utilized as the pH adjuster 24A for the second film 20A. It should be noted, however, that the films 20 and 20A (and pH adjusters 24 and 24A) of a particular fabric 200 need not be constructed in the same manner or from the same materials. Any of the adhesives described above that are suitable for use as adhesive 30 are also suitable for use as adhesive 30A. However, different adhesives may be used for adhesive 30 and adhesive 30A in any given composite fabric 200. In another embodiment of the present invention, a retention member 70 is attached to both the film 20 and the second film 20A. The retention member 70 may be printed on the film 20 and / or the second film 20A either before or after laminating the films to the first fibrous layer 40 and the second fibrous layer 60.

[0048] The composite fabric 200 can be formed in any one of a number of ways. In one embodiment of the present invention, the first fibrous layer 40, the fabric layer 50, and the second fibrous layer 60 are first joined together, and then the film 20 is laminated to the first fibrous layer 40. Additionally, the second film 20A is formed with the retention member 70 and then laminated to the second fibrous layer 60. Alternatively, the first fibrous layer 40, the fabric layer 50, and the second fibrous layer 60 are first joined together, and then the film 20 is laminated to the first fibrous layer 40, and the second film 20A is laminated to the second fibrous layer 60. The retention member 70 is then connected to the second film 20A.

[0049] In other embodiments of the present invention, infrared ("IR") shielding, radio frequency ("RF") shielding, electromagnetic pulse ("EMP") shielding, high-power microwave ("HPM") shielding, directed energy weapons ("DEW") shielding, and / or electromagnetic interference ("EMI") shielding can be incorporated into the fabrics and covers of the present invention. As used in this application, the terms "electromagnetic shielding" and "EMI shielding" include all of the types of shielding described above, as well as other types of shielding designed to block, inhibit, reduce, or otherwise impede infrared, electronic, radio, microwave, electrostatic, magnetic, and other similar forms of interference. Shielding electronic and other sensitive devices from such interference helps isolate the electrical equipment from its surroundings and may protect the device from electronic attacks, such as RFID virus attacks, in which malicious code is inserted into RFID tags to alter or corrupt data in an RFID system or device.

[0050] EMI shielding can be incorporated into the composite fabric 10 in a number of ways. For example, a conductive modifier, such as carbon or metal, can be incorporated into one or more layers of the composite fabric 10 to reduce the surface and volume resistivity of the layer so that static electricity can be dissipated and electromagnetic signals can be attenuated. Shielding materials can be incorporated into the films, fibrous layers, fabric layers, and / or retaining members of embodiments of the present invention. EMI shielding materials can be used to construct the films, fibrous layers, fabric layers, and / or retaining members of the composite fabric 10, can be incorporated as components of those portions of the composite fabric 10, and / or can be applied as a coating to those portions of the composite fabric 10. In some embodiments of the present invention, the EMI shielding material is incorporated into the adhesive 30. In other embodiments, another layer, such as a fabric layer, having EMI shielding functionality is included as an additional layer in the composite fabric 10.

[0051] For example, in some embodiments of the present invention, EMI shielding is provided by incorporating a carbon modifier into the components of the present invention in amounts of 5-25%. The carbon modifier in fiber form can be derived from polyacrylonitrile ("PAN"). In some embodiments of the present invention, PAN carbon fiber is incorporated in amounts up to 10% by weight of the composite fabric 10. EMI shielding values ​​of 30 dB to 50 dB can be achieved by incorporating approximately 50% by weight of PAN carbon fiber into the composite fabric 10. Microcarbon fiber can achieve similar EMI shielding values ​​with as little as 3% by weight of the composite fabric 10. Other effective EMI shielding materials include nickel-coated carbon fiber, stainless steel fiber (at levels of 5% to 10% by weight of the composite fabric 10), copper, and aluminum.

[0052] In some embodiments of the present invention, EMI shielding effectiveness of about 1 dB to about 100 dB or greater can be achieved by utilizing different coatings containing aluminum, silver, nickel, copper, or combinations of these materials. The coatings utilized can be solvent-based or water-based systems. One embodiment of the present invention utilizes a water-based silver coating, such as the 599-Z6098-01 series available from PPG Industries, Inc., Pittsburgh, Pennsylvania. This coating can be applied to the surface of the film, the surface of the fibrous layer, and / or the surface of the fabric layer. It can also be used to coat individual strands of the fibrous and fabric layers. The coating system can also be added to the support member, used to coat the support member, and / or incorporated into the VCI system of the support member.

[0053] In some embodiments of the present invention, one or more components of the composite fabric 10 are configured to form a Faraday cage or Faraday shield, which is particularly useful for blocking electromagnetic pulses that can disrupt, degrade, and / or damage electronic components.

[0054] Covers made from the composite fabric 10 of the present invention can be manufactured by sewing, welding (e.g., impulse bar welding, ultrasonic welding, RFID welding, etc.), and / or other methods, however, using welding on the seams of the cover may improve EMI shielding capabilities.

[0055] While the present invention has been shown and described in detail, it is by way of example only and is not to be construed as limiting the present invention. Various modifications can be made to the embodiments disclosed herein without departing from the scope of the present invention. For example, the protective cover can be formed in configurations other than those shown and described herein and can be used to protect objects other than vehicles. Also, vapor corrosion inhibitors can be incorporated into the adhesive 30. Other modifications and variations are within the scope of the present invention.

Claims

1. A composite fabric, a film having a first side and a second side; a first fibrous layer having a first side connected to the second side of the film and a second side; a fabric layer having a first side connected to the second side of the first fibrous layer and a second side; a second fibrous layer having a first side connected to the second side of the fabric layer and a second side; a plurality of retaining members for contacting a surface on which the composite fabric is placed to prevent movement of the composite fabric relative to the surface; a steam corrosion inhibitor; the plurality of retention members are connected to and extend from the second side of the second fibrous layer, and the plurality of retention members form at least one pocket between one or more of the plurality of retention members, the second side of the second fibrous layer, and the surface; at least a portion of the vapor corrosion inhibitor collects in one or more of the pockets; The composite fabric wherein the retaining member includes a vapor corrosion inhibitor.

2. The composite fabric of claim 1 , wherein the film is a non-heat shrinkable film.

3. The composite fabric of claim 1 , wherein the retention member comprises a contact corrosion inhibitor.

4. The composite fabric of claim 1 , wherein the retention member is comprised of epoxy.

5. The composite fabric of claim 1 , wherein the retention member is constructed from polyurethane.

6. The composite fabric of claim 1 further comprising a pH adjuster.

7. The composite fabric of claim 1 further comprising an adhesive between the film and the first fibrous layer.

8. 8. The composite fabric of claim 7, further comprising a vapor corrosion inhibitor in the adhesive.

9. 8. The composite fabric of claim 7, wherein the adhesive adheres the film to the first fibrous layer, and the water-saturated bond strength adhesion between the film and the first fibrous layer in the machine direction is at least 1,000 g / cm as measured in accordance with ASTM standard D1876.

10. 8. The composite fabric of claim 7, wherein the adhesive adheres the film to the first fibrous layer, and the water saturated bond strength adhesion in the cross-machine direction between the film and the first fibrous layer is at least 1,000 g / cm as measured in accordance with ASTM standard D1876.

11. The composite fabric of claim 1 , wherein the film is a multi-layer film.

12. The composite fabric of claim 1 further comprising an electromagnetic shield.

13. A composite fabric, a first film having a first side and a second side; a first fibrous layer having a first side connected to the second side of the first film and a second side; a fabric layer having a first side connected to the second side of the first fibrous layer and a second side; a second fibrous layer having a first side connected to the second side of the fabric layer and a second side; a second film having a first side connected to the second side of the second fibrous layer and a second side; a plurality of retaining members for contacting a surface on which the composite fabric is placed to prevent movement of the composite fabric relative to the surface; a steam corrosion inhibitor; the plurality of retention members are connected to and extend from the second side of the second film, and the plurality of retention members form at least one pocket between one or more of the plurality of retention members, the second side of the second film, and the surface; at least a portion of the vapor corrosion inhibitor collects in one or more of the pockets; The composite fabric wherein the retaining member includes a vapor corrosion inhibitor.

14. 10. A method for making the composite fabric of claim 1, comprising: Providing the film, connecting a first fibrous layer to the film; connecting a fabric layer to the first fibrous layer; connecting a second fibrous layer to the fabric layer; forming a plurality of retention members on the second fibrous layer; A method comprising:

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