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.

Description

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 produ...

AI Technical Summary

Benefits of technology

The present invention relates to composite materials that use a fibrous face layer combined with an adhesive layer to form a multi-layer structure. The fibrous face layer has loops of fibers that form loops and anchor into the adhesive layer, providing improved surface stability and retention of appearance under repeated loading. The adhesive layer is controlled to not penetrate into the top portion of the face layer, maintaining its textile feel. The fibrous face layer can be made with different types of fibrous layers and can also be embossed for a three-dimensional texture. The composite material can also have a three-layer structure with added structural rigidity. The invention provides a method for preparing the composite material by embedding the adhesive layer into the face layer and / or the backing layer using pressure and heat. The adhesive layer can be pre-integrated onto the layers or simultaneously penetrate into both layers during lamination. The adhesive layer can contain non-adhesive reinforcing or blended components and can also contain adhesive components in sufficient quantity to anchor and envelope the legs of the surface fiber loops descending into it.

Problems solved by technology

However, these products lack the textile hand, softness or sound dampening qualities of textile products.

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.

These hybrid structures, however, merely reduce but do not eliminate the limitations of regular tufted, velour, or flocked textile surfaces.

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.

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.

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.

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