Decorative Nonwoven Laminate

Abstract

a) a first surface of a first nonwoven fabric attached to one or both of a) a first surface of a polymeric sheet or b) a second nonwoven fabric, wherein the first nonwoven fabric has a thickness of 15 g / m 2 ~500g / m 2 and the second nonwoven fabric has a basis weight of 15 g / m 2 ~1200g / m 2 and a colorant deposited on the second surface of the first nonwoven. A topical coating may or may not be applied to improve the durability of the printed surface layer.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 62 / 472,449, filed March 16, 2016, which is incorporated by reference herein in its entirety.

[0002] FIELD OF THE DISCLOSURE The present disclosure is directed to decorative nonwoven laminates, and in particular decorative nonwoven scrim laminates for automotive interiors. [Background technology]

[0003] In an effort to meet fuel economy regulations and improve the recyclability of parts utilized in vehicles while still maintaining the vehicle's ambiance or perceived comfort, various aspects of automotive interior design are being modernized. One consideration is the modification of materials utilized in interior applications, including floors, accessory mats, cargo mats, trunk linings, glove box linings, load floors, console and map pocket linings, seat backs and trim, package trays, outer wheel arch liners, and visible surfaces of underbody shields. Summary of the Invention [Problem to be solved by the invention]

[0004] While nonwoven materials may be known for use in laminate structures, for example, in carpet applications, there remains room for improvement to reduce the thickness and weight of nonwoven materials and to develop nonwoven products in which the nonwoven itself provides a decorative feature visible to the consumer. Additionally, it would be beneficial to provide a material that meets the above goals while exhibiting similar or enhanced durability and colorfastness compared to known needlepunched nonwoven products. [Means for solving the problem]

[0005] An aspect of the present disclosure relates to a method of forming a decorative nonwoven scrim laminate, the method comprising attaching a first surface of a first nonwoven to at least one of a) a first surface of a polymeric sheet or b) a second nonwoven to obtain a laminate, wherein the first nonwoven has a density of at least 15 g / m 2 ~500g / m 2 and the second nonwoven fabric has a basis weight of 15 g / m 2 ~1200g / m 2 The method further includes depositing a colorant on the second surface of the first nonwoven fabric.

[0006] Preferably, when present, the polymeric sheet comprises one or more polymeric materials selected from the following: polyethylene, polypropylene, polyester, polyamide, copolyester, ethyl vinyl acetate, thermoplastic elastomer, thermoplastic olefin, and combinations thereof. Furthermore, the polymeric sheet and the first nonwoven are preferably laminated upon application of heat, pressure, or both heat and pressure. In embodiments, the second nonwoven is attached to the second side of the polymeric sheet. In embodiments excluding the polymeric sheet, the first nonwoven and the second nonwoven are preferably mechanically bonded.

[0007] In any of the above embodiments, the colorant has a colorfastness of 225 kJ / m as measured by ISO 105-A02 / AATCC Evaluation Procedure 1 2 Preferably, the colorant exhibits a fade resistance level of the above performance. Furthermore, the colorant is preferably deposited by screen printing. Furthermore, the colorant preferably provides a checkerboard, houndstooth, wood grain, carbon fiber, camouflage, leather look, or other geometric pattern.

[0008] Additionally, in any of the above embodiments, a topical coating is deposited over the colorant and the second surface of the first nonwoven.

[0009] Additionally, in any of the above embodiments, the laminate may or may not be formed into a three-dimensional shape.

[0010] In another aspect, the present disclosure relates to a decorative nonwoven laminate, preferably made according to the above method, the laminate comprising a first surface of a first nonwoven attached to at least one of: a) a first surface of a polymeric sheet; or b) a second nonwoven, wherein the first nonwoven has a density of at least 15 g / m 2 ~500g / m 2 and the second nonwoven fabric has a basis weight of 15 g / m 2 ~1200g / m 2 The laminate also includes a colorant deposited on the second surface of the first nonwoven.

[0011] In a preferred embodiment, the colorant has a viscosity of 225 kJ / m as measured by ISO 105-A02 / AATCC Evaluation Procedure 1. 2 The colorants also preferably provide checkerboard, houndstooth, wood grain, carbon fiber, camouflage, leather, or other geometric patterns.

[0012] In any of the above embodiments, the polymeric sheet is one or more polymeric materials selected from the following: polyethylene, polypropylene, polyester, polyamide, copolyester, ethyl vinyl acetate, thermoplastic elastomer, thermoplastic olefin, and combinations thereof. In an embodiment, a second nonwoven fabric is attached to the second surface of the polymeric sheet.

[0013] It should also be noted that the first nonwoven preferably exhibits a thickness ranging from 0.1 mm to 6.0 mm and an areal density ranging from 15 grams per square meter to 500 grams per square meter. Furthermore, if present, the polymeric sheet preferably exhibits a thickness ranging from 0.1 mm to 4.0 mm and an areal density ranging from 30 grams per square meter to 5,000 grams per square meter. Furthermore, if present, the second nonwoven preferably exhibits a thickness ranging from 0.1 mm to 12.0 mm and an areal density ranging from 15 grams per square meter to 1,200 grams per square meter.

[0014] In any of the above embodiments, a topical coating is deposited on the colorant and the second surface of the first nonwoven.

[0015] Additionally, in any of the above embodiments, the laminate may or may not exhibit a three-dimensional shape.

[0016] The above and other features of the present disclosure, and the manner in which they are accomplished, will become more apparent and better understood by reference to the following description of the embodiments described herein, taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0017] [Figure 1] 1 is a schematic diagram of an embodiment of a decorative nonwoven scrim laminate including a polymeric sheet. [Figure 2] 1 is a schematic diagram of an embodiment of a decorative nonwoven scrim laminate including a polymeric sheet, an optional second nonwoven, and a topical coating. [Figure 3] FIG. 2 is a schematic diagram of an embodiment of a decorative nonwoven scrim laminate including a second nonwoven. [Figure 4] FIG. 1 is a schematic diagram of an embodiment of a decorative nonwoven scrim laminate including a second nonwoven and a topical coating. [Figure 5] FIG. 10 is a further schematic diagram of yet another embodiment of a decorative nonwoven scrim laminate. [Figure 6] 1 is a photograph of an embodiment of a decorative nonwoven scrim laminate. [Figure 7] 1 is a photograph of an embodiment of a decorative nonwoven scrim laminate formed into a three-dimensional shape. [Figure 8] Photographs of alternative patterns including topical coatings formed into three-dimensional shapes. [Figure 9] This is a photo of a carbon fiber pattern. DETAILED DESCRIPTION OF THE INVENTION

[0018] The present disclosure is directed to decorative nonwoven laminates, particularly patterned nonwoven laminates for automotive interiors. The decorative nonwoven scrim laminate preferably comprises a spunbond, spunlace, or needlepunched nonwoven scrim layer attached to a) a first surface of a polymeric sheet or b) a second nonwoven and a colorant deposited on the second surface of the nonwoven scrim layer.

[0019] The decorative nonwoven laminate allows for the use of scrims, commonly used on the backside of automotive textiles, as a decorative surface layer. Furthermore, the decorative nonwoven scrim is lighter than nonwoven needlepunched materials currently utilized in similar applications. Furthermore, the method for forming the decorative nonwoven laminate herein expands color and pattern options to include patterns such as woodgrain and camouflage. Finally, the laminate herein has a thermal conductivity of 225 kJ / m2, as measured by ISO 105-A02 / AATCC Evaluation Procedure 1. 2 Achieve the above level of colorfastness.

[0020] As described above and illustrated in FIG. 1 , decorative nonwoven laminate 100 generally includes a first surface 102 of a first nonwoven layer 104 attached to a first surface 106 of a polymeric sheet 108. A colorant 110, such as a paint, dye, pigment, or ink, is deposited on a second surface 112 of first nonwoven 104, facing the first surface of the nonwoven.

[0021] The first nonwoven layer is itself preferably a spunbond, spunlace, or needlepunched scrim, formed from fibers preferably sourced from a thermoplastic polymeric material such as, but not limited to, polypropylene, high-density polyethylene (e.g., 0.94 g / cc to 0.96 g / cc), low-density polyethylene (0.91 g / cc to 0.92 g / cc), linear low-density polyethylene (e.g., 0.93 g / cc), polyester, polyamide (including nylon 6 and nylon 6,6), glycol-modified polyethylene terephthalate (PETg), or combinations thereof. The fibers also preferably exhibit a denier ranging from 0.7 denier to 45 denier, including all values ​​and ranges thereof. The use of the term scrim herein may be understood to refer to a web-like product, i.e., fibers overlapping one another. Spunbond refers to a nonwoven in which the fibers are spun and then dispersed into a web; for example, they may be directed by the use of deflectors or by air currents. Spunlaced nonwovens refer to the formation of entanglements in nonwoven fabrics, preferably achieved by water jetting, and the resulting bonded material is a nonwoven fabric with isotropic properties, meaning substantially similar strength in all directions. Needlepunched refers to nonwoven fabrics in which the fibers are mechanically entangled, achieved by repeatedly penetrating the fibrous web with barbed needles.

[0022] The first nonwoven layer 104 may exhibit a thickness ranging from 0.1 mm to 6.0 mm, inclusive, and an areal density ranging from 15 grams per square meter to 500 grams per square meter, inclusive, and all individual values ​​and ranges thereof. For example, the first nonwoven may preferably have an areal density ranging from 35 grams per square meter to 200 grams per square meter, or from 50 grams per square meter to 150 grams per square meter, or from 50 grams per square meter to 100 grams per square meter. The particular thickness and areal density may depend on the application for which the first nonwoven scrim layer is selected.

[0023] For example, in trunk applications, the first nonwoven layer preferably exhibits a thickness in the range of 0.1 to 6.0 mm, inclusive, and an areal density in the range of 15 grams per square meter to 500 grams per square meter, inclusive. Preferably, in trunk applications, the first nonwoven layer may have an areal density in the range of 60 grams per square meter to 130 grams per square meter, and even more preferably, in the range of 60 grams per square meter to 90 grams per square meter.

[0024] For flooring applications, the thickness of the first nonwoven fabric layer herein is preferably in the range of 0.1 to 6.0 mm, including all values ​​and ranges thereof, and the areal density of the first nonwoven fabric is preferably in the range of 60 grams per square meter to 200 grams per square meter, more preferably in the range of 60 grams per square meter to 150 grams per square meter, and even more preferably in the range of 60 grams per square meter to 130 grams per square meter.

[0025] The polymeric sheet is preferably a thermoplastic polymer such as, but not limited to, polyethylene (such as high density polyethylene (e.g., 0.94 g / cc to 0.96 g / cc), low density polyethylene (0.91 g / cc to 0.92 g / cc), or linear low density polyethylene (e.g., 0.93 g / cc)), polypropylene, ethyl vinyl acetate, thermoplastic elastomers, thermoplastic olefins, polyesters, copolyesters, polyamides (such as nylon 6 and nylon 6,6), or combinations thereof. In embodiments, the thermoplastic polymer may be crosslinked, or alternatively, a thermosetting polymer may be utilized. The polymeric sheet preferably exhibits a thickness ranging from 0.1 mm to 4.0 mm, inclusive, and an areal density ranging from 30 gsm to 5000 gsm, inclusive, inclusive.

[0026] One or more colorants are used to create a visual decorative appearance for the first nonwoven layer to be viewed by consumers. The colorants preferably include inks, paints, or dyes, such as pigment dyes. The colorants are preferably deposited to a thickness ranging from 0.01 mm to 0.3 mm. In particularly preferred embodiments, the colorants are deposited in a pattern, such as a checkerboard, houndstooth, woodgrain, carbon fiber, leather, camouflage, or other geometric pattern, which may be understood herein as a design including one or more geometric shapes. While the figures (see Figures 1-2) show the placement of the colorants at discrete locations on the surface of the first nonwoven layer, as in the case of identified patterns, it should be understood that the colorant (or colorants) can also be applied to the entire surface of the first nonwoven layer to form a colorant layer. The colorants may include black, gray, and white, as well as several other colors.

[0027] As shown in FIG. 2, the laminate 100 optionally includes a topical coating 114 and polymer sheet 108 deposited on the first nonwoven 104 to improve the overall durability of the first nonwoven material. The topical coating 114 may include, for example, a thermoplastic elastomer, a thermoplastic olefin, a polyurethane, a high-density polyethylene, a polypropylene, or a glycol-modified polyethylene terephthalate (PETg), or a combination thereof. When present, the topical coating 114 exhibits a thickness ranging from 0.1 mm to 3.0 mm, including all values ​​and ranges thereof. The weight of the topical coating may range from 15 gsm to 340 gsm, more specifically, from 30 gsm to 100 gsm. The topical layer may be smooth or have a grain applied to improve traction on floor surfaces. Taber abrasion testing of topically coated flooring can be as high as 15,000 cycles using an H18 wheel and a 1000 gm weight, compared to 1500 cycles for best-in-class nonwovens using an H18 wheel and a 1000 gm weight. Taber testing is based on SAE J1530 and / or ASTM D3884.

[0028] In other embodiments, binder fibers may be utilized to improve the durability of the first nonwoven layer.

[0029] In any of the above embodiments, a second nonwoven layer 120 is optionally attached to the second surface 122 of the polymeric sheet, as shown in FIGS. 1-2. The second nonwoven may be a spunbond, spunlace, needlepunched, or airlaid nonwoven. The second nonwoven preferably exhibits a basis weight ranging from 15 grams per square meter to 1200 grams per square meter, inclusive, and a thickness ranging from 0.1 mm to 12.0 mm, inclusive, inclusive. The fibers forming the second nonwoven are preferably formed from a thermoplastic material, such as, but not limited to, polyester, cotton, copolyester, high-density polyethylene (e.g., 0.94 g / cc to 0.96 g / cc), low-density polyethylene (0.91 g / cc to 0.92 g / cc), linear low-density polyethylene (e.g., 0.93 g / cc), polypropylene, polyamide (e.g., nylon 6 or nylon 6,6), glycol-modified polyethylene terephthalate (PETg), and combinations thereof. Additionally, the denier of the fiber preferably ranges from 0.7 denier to 45 denier, inclusive of all values ​​and ranges therein.

[0030] Nonwoven laminates herein are preferably formed by attaching a first nonwoven to a first surface of a polymeric sheet. The first nonwoven can be attached by several methods, including extruding the polymeric sheet directly onto the first nonwoven or interlocking the fibers to some degree in the polymeric sheet while the polymeric sheet is still molten. In a particularly preferred embodiment, the first nonwoven and polymeric sheet are laminated together upon application of heat, pressure, or both heat and pressure to the first nonwoven and polymeric sheet. Additionally or alternatively, an adhesive layer can be provided between the first nonwoven and polymeric sheet to bond the layers together. If present, a second nonwoven layer may also be laminated to the polymeric sheet. The second nonwoven layer may be attached to the polymeric sheet simultaneously with, before, or after the first nonwoven is attached to the polymeric sheet.

[0031] In embodiments, the polymeric sheet may be omitted from the laminate, as shown in Figure 3. In such embodiments, the decorative nonwoven laminate 100 generally includes a first surface 102 of a first nonwoven layer 104 attached to a first surface 124 of a second nonwoven layer 120. As above, a colorant 110, such as a paint, dye, pigment, or ink, is deposited on a second surface 112 of the first nonwoven layer 104, which faces the first surface of the nonwoven layer.

[0032] Again, the first nonwoven layer is itself preferably a spunbond, spunlace, or needlepunched scrim, formed from fibers preferably sourced from a thermoplastic polymeric material such as, but not limited to, polypropylene, high-density polyethylene (e.g., 0.94 g / cc to 0.96 g / cc), low-density polyethylene (0.91 g / cc to 0.92 g / cc), linear low-density polyethylene (e.g., 0.93 g / cc), polyester, polyamide (including nylon 6 and nylon 6,6), glycol-modified polyethylene terephthalate (PETg), or combinations thereof. The fibers also preferably exhibit a denier ranging from 0.7 denier to 45 denier, including all values ​​and ranges therein. Use of the term scrim herein may also be understood to refer to a web-like product.

[0033] Similar to the above embodiment, the first nonwoven layer 104 may exhibit a thickness ranging from 0.1 mm to 6.0 mm, inclusive, and an areal density ranging from 15 grams per square meter to 500 grams per square meter, inclusive, and all individual values ​​and ranges thereof. For example, the first nonwoven may preferably have an areal density ranging from 35 grams per square meter to 200 grams per square meter, or from 50 grams per square meter to 150 grams per square meter, or from 50 grams per square meter to 130 grams per square meter. The particular thickness and areal density may depend on the application for which the first nonwoven scrim layer is selected.

[0034] Again, for trunk applications, the first nonwoven layer preferably exhibits a thickness in the range of 0.2 to 1.0 mm, inclusive, and an areal density in the range of 50 grams per square meter to 100 grams per square meter, inclusive. Preferably for trunk applications, the first nonwoven layer may have an areal density in the range of 60 grams per square meter to 130 grams per square meter, and even more preferably in the range of 60 grams per square meter to 90 grams per square meter.

[0035] For flooring applications, the thickness of the first nonwoven fabric layer herein is preferably in the range of 0.2 to 1.5 mm, including all values ​​and ranges thereof, and the areal density of the first nonwoven fabric is preferably in the range of 60 grams per square meter to 200 grams per square meter, more preferably in the range of 60 grams per square meter to 150 grams per square meter, and even more preferably in the range of 60 grams per square meter to 130 grams per square meter.

[0036] The second nonwoven layer 120 attached to the first surface 102 of the nonwoven 104 is preferably a spunbond, spunlace, needlepunched, or airlaid nonwoven, and exhibits a basis weight ranging from 15 grams per square meter to 1200 grams per square meter, inclusive, and a thickness ranging from 0.1 mm to 12.0 mm, inclusive, and all values ​​and ranges therein. The fibers forming the second nonwoven are preferably formed from a thermoplastic material, such as, but not limited to, polyester, cotton, copolyester, high density polyethylene (e.g., 0.94 g / cc to 0.96 g / cc), low density polyethylene (0.91 g / cc to 0.92 g / cc), linear low density polyethylene (e.g., 0.93 g / cc), polypropylene, polyamide (e.g., nylon 6 or nylon 6,6), glycol-modified polyethylene terephthalate (PETg), and combinations thereof. Additionally, the denier of the fiber preferably ranges from 0.7 denier to 45 denier, inclusive of all values ​​and ranges therein.

[0037] Again, one or more colorants are used to create a visual decorative appearance for the first nonwoven layer to be seen by the consumer. The colorants preferably include inks, paints, or dyes, such as pigment dyes. The colorants are preferably deposited at thicknesses ranging from 0.01 mm to 0.3 mm. In particularly preferred embodiments, the colorants are deposited in patterns such as checkerboard, houndstooth, woodgrain, carbon fiber, leather, camouflage, or other geometric patterns. While the figures (see Figures 3 through 5) show the placement of colorants at discrete locations on the surface of the first nonwoven layer, as in the identified patterns, it should be understood that a colorant (or colorants) can also be applied to the entire surface of the first nonwoven layer to form a colorant layer. Colorants may include black, gray, and white, as well as several other colors.

[0038] As shown in FIG. 4, the laminate 100 optionally includes a topical coating 114 and colorant 110 deposited on the first nonwoven 104 to improve the overall durability of the first nonwoven material. Again, the topical coating 114 may include, for example, a thermoplastic elastomer, a thermoplastic olefin, a polyurethane, high-density polyethylene, a polypropylene, or a glycol-modified polyethylene terephthalate (PETg). When present, the topical coating 114 exhibits a thickness ranging from 0.1 mm to 3.0 mm, including all values ​​and ranges thereof. The weight of the topical coating may range from 15 gsm to 340 gsm, more specifically, from 30 gsm to 100 gsm. The topical layer may be smooth or have a grain applied to improve traction on floor surfaces. Taber abrasion testing of topically coated flooring can be as high as 15,000 cycles using an H18 wheel and a 1000 gm weight, compared to 1500 cycles for best-in-class nonwovens using an H18 wheel and a 1000 gm weight. Taber testing is based on SAE J1530 and / or ASTM D3884.

[0039] In other embodiments, binder fibers may be utilized to improve the durability of the first nonwoven layer.

[0040] The nonwoven-nonwoven laminates are preferably formed herein by several mechanical bonding methods, including forming a second nonwoven directly on the first nonwoven, interlocking the fibers of the nonwovens to some degree, or by needling the first nonwoven layer into the second nonwoven using an entanglement process such as needlepunching or hydroentanglement. In other embodiments, the nonwovens can be laminated together by applying heat, pressure, or both heat and pressure. Additionally or alternatively, an adhesive layer can be provided between the nonwovens to bond the layers together.

[0041] 5 illustrates a preferred embodiment in which the first nonwoven 104 and second nonwoven 120 are needlepunched or hydroentangled. As shown, some of the fibers 130 of the first nonwoven are forced, in some embodiments, through the second nonwoven, or conversely, the fibers of the second nonwoven are forced into the first nonwoven, or both. This mechanically interlocks the nonwovens without the need for additional adhesive materials. However, such adhesive materials may also be added to improve durability.

[0042] In any of the above embodiments, a colorant is deposited on the first nonwoven fabric before or after forming the laminate. One or more layers of colorant can be applied by a printing process to create the desired decorative appearance, as described above. In preferred embodiments, the colorant is deposited on the nonwoven fabric using a printing process, and in particularly preferred embodiments, a screen printing process is used. Additionally or alternatively, other printing processes, such as flexographic printing or pad printing, may be used. If a topical coating is applied, the topical coating is applied after the colorant is deposited.

[0043] Additionally, any of the above laminate sheets may be formed into a three-dimensional shape using the application of pressure, heat, or a combination of heat and pressure before, after, or during application of the colorant. Such methods may therefore include thermoforming, compression molding, and vacuum forming. Three-dimensional shapes are understood herein to be three-dimensional because they may include protrusions or depressions extending from the laminate sheet.

[0044] Thus, automotive vehicles can include the decorative nonwoven laminates described herein to help achieve weight reduction goals while still maintaining the performance characteristics of previously utilized needlepunched facings. The nonwoven laminates can be utilized in flooring, accessory mats, cargo mats, trunk linings, glove box linings, console and map pocket linings, seat backs and trim, package trays, outer wheel arch liners, and visible surfaces of underbody shields. The decorative nonwoven laminates can be utilized in other applications where nonwovens currently provide a decorative layer.

[0045] The resulting laminate exhibits a relatively light weight, including a 53% weight loss in trunk material, while maintaining Taber abrasion properties specifically for trunks, passing OEM requirements (H10 500g 1200 cycles). Taber testing is based on SAE J1530 and / or ASTM D3884.

[0046] Additionally, the laminate must also pass the OEM Fade Test, demonstrating resistance to fading of at least 225kJ / m² and up to 451kJ / m² using a Xenon Test System, as measured by ISO 105-A02 / AATCC Evaluation Procedure 1 (and FLTM BO 116-01). The results are obtained visually by gray scale, and must pass with a minimum ranking of 4.

[0047] Figure 6 shows a photograph of an embodiment of a laminate described herein that includes a woodgrain pattern applied to a surface of a first nonwoven, in this case a spunbond. In addition to being in the form of a sheet exhibiting what is referred to herein as a two-dimensional shape, the laminate may also be formed into what is understood herein to be a three-dimensional shape, as shown in the photograph of an embodiment of the laminate provided in Figure 7. The three-dimensional shape can assume the shape of any automotive part in which such a nonwoven may be used, such as, but not limited to, floors, trunk liners, glove box liners, load floors, console and map pocket liners, seat backs and trim, package trays, outer wheel arch liners, and visible surfaces of underbody shields.

[0048] The foregoing description of several methods and embodiments has been presented for illustrative purposes. It is not intended to be exhaustive or to limit the claims to the precise steps and / or forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The scope of the present invention is intended to be defined by the claims appended hereto. [Explanation of symbols]

[0049] 100 decorative nonwoven laminate 102 First surface of first nonwoven fabric layer 104 First nonwoven fabric layer 106 First surface of polymer sheet 108 Polymer Sheet 110 Coloring Agents 112 second surface of first nonwoven fabric layer 114 Topical Coating 120 second nonwoven layer 122 Second Surface of Polymer Sheet 124 first surface of second nonwoven fabric layer 130 Fiber of first nonwoven fabric layer

Claims

1. 1. A method of forming a decorative nonwoven scrim laminate comprising: a step of attaching a first surface of a first nonwoven fabric to a first surface of a polymer sheet, the first nonwoven fabric having a thickness of 60 g / m ２ ~200g / m ２ and the fibers of the first nonwoven fabric have a denier value in the range of 0.7 denier to 45 denier; attaching a second nonwoven fabric to a second surface of the polymer sheet, the second nonwoven fabric having a thickness of 15 g / m ２ ~1200g / m ２ and depositing a colorant selected from ink, paint, or pigment dye onto the second surface of the first nonwoven fabric, the colorant having a thickness of 0.01 mm to 0.3 mm; depositing a topical coating over the colorant and the second surface of the first nonwoven; the first nonwoven fabric has a thickness of 0.1 mm to 6.0 mm, and the second nonwoven fabric has a thickness of 0.1 mm to 12.0 mm; The topical coating comprises a thermoplastic elastomer, a thermoplastic olefin, a polyurethane, a high density polyethylene, a polypropylene, or a glycol-modified polyethylene terephthalate (PETg), or a combination thereof, the topical coating having a thickness in the range of 0.1 mm to 3.0 mm, and the topical coating has a thickness of 15 g / m ２ ~340g / m ２ and The laminate with the colorant has a thermal conductivity of 225 kJ / m2 as measured by ISO 105-A02 / AATCC Evaluation Procedure 1. ２ to 451 kJ / m ２ and the topically coated side of the laminate has a Taber abrasion of 15,000 cycles using an H18 wheel, 1000 gm weight in accordance with ASTM D3884 or SAE J1530.

2. The method of claim 1 , wherein the colorant is deposited by screen printing.

3. 10. The method of claim 1, wherein the colorant is selected from ink, paint, or pigment dye and is deposited on the surface of the second side of the first nonwoven fabric at a thickness of 0.01 mm to 0.3 mm.

4. 10. The method of claim 1, wherein the polymeric sheet is one or more polymeric materials selected from the following: polyethylene, polypropylene, polyester, polyamide, copolyester, ethyl vinyl acetate, thermoplastic elastomer, thermoplastic olefin, and combinations thereof.

5. The method of claim 1 , wherein the polymeric sheet and the first nonwoven are laminated upon application of heat, pressure, or both heat and pressure.

6. The polymer sheet has a thickness of 0.1 mm to 4.0 mm and a weight of 30 g / m ２ Up to 5,000 g / m ２ The method of claim 1 , wherein the sheet has a basis weight of

7. The method of claim 1 further comprising forming the laminate into a three-dimensional shape.

8. a first nonwoven fabric, a first surface of the first nonwoven fabric being attached to a first surface of a polymer sheet, the first nonwoven fabric having a density of 60 g / m ２ ~200g / m ２ a first nonwoven fabric having a basis weight of 0.7 denier to 45 denier, and the fibers of the first nonwoven fabric having a denier value in the range of 0.7 denier to 45 denier; a second nonwoven fabric attached to a second surface of the polymer sheet, the second nonwoven fabric having a thickness of 15 g / m ２ ~1200g / m ２ a second nonwoven fabric having a basis weight of a colorant selected from an ink, paint, or pigment dye deposited on the second surface of the first nonwoven fabric, the colorant having a thickness of 0.01 mm to 0.3 mm; and a decorative nonwoven laminate comprising the colorant and a topical coating deposited on the second surface of the first nonwoven, the first nonwoven fabric has a thickness of 0.1 mm to 6.0 mm, and the second nonwoven fabric has a thickness of 0.1 mm to 12.0 mm; The topical coating comprises a thermoplastic elastomer, a thermoplastic olefin, a polyurethane, a high density polyethylene, a polypropylene, or a glycol-modified polyethylene terephthalate (PETg), or a combination thereof, the topical coating having a thickness in the range of 0.1 mm to 3.0 mm, and the topical coating has a thickness of 15 g / m ２ ~340g / m ２ and The laminate with the colorant has a thermal conductivity of 225 kJ / m2 as measured by ISO 105-A02 / AATCC Evaluation Procedure 1. ２ to 451 kJ / m ２ and the topically coated side of the laminate has a Taber abrasion of 15,000 cycles using an H18 wheel, 1000 gm weight in accordance with ASTM D3884 or SAE J1530.

9. 9. The decorative nonwoven laminate of claim 8, wherein the colorant is selected from ink, paint, or pigment dye and is deposited on the surface of the second side of the first nonwoven to a thickness of 0.01 mm to 0.3 mm.

10. 9. The decorative nonwoven laminate of claim 8, wherein the polymeric sheet is one or more polymeric materials selected from the following: polyethylene, polypropylene, polyester, polyamide, copolyester, ethyl vinyl acetate, thermoplastic elastomers, thermoplastic olefins, and combinations thereof.

11. The polymer sheet has a thickness of 0.1 mm to 4.0 mm and a weight of 30 g / m ２ Up to 5,000 g / m ２ 9. The decorative nonwoven laminate of claim 8 having a basis weight of

12. 9. The decorative nonwoven laminate of claim 8, wherein the second nonwoven is attached to the second surface of the polymeric sheet.

13. The decorative nonwoven laminate of claim 8 , wherein the laminate has a three-dimensional shape.

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