초록

A soft cover for a vehicle is provided comprising a foam composite having a water resistant top layer, a flexible foam layer, and a protective bottom layer. The composite is flexible, dimensionally stable and tear resistant. Methods of manufacture and of use of the soft cover are also provided.

대표청구항 ▼

1. A soft cover for a vehicle, at least a portion of said cover comprising a foam composite havinga) a water resistant top layer, b) a flexible foam layer, and c) a protective bottom layer; said composite being flexible, dimensionally stable and tear resistant, wherein the flexible foam layer has a

1. A soft cover for a vehicle, at least a portion of said cover comprising a foam composite havinga) a water resistant top layer, b) a flexible foam layer, and c) a protective bottom layer; said composite being flexible, dimensionally stable and tear resistant, wherein the flexible foam layer has a thickness of from about 0.5 to about 1.5 mm. 2. The cover of claim 1, wherein the flexible foam layer comprises a plurality of foam layers having densities that are different from one another.3. The cover of claim 1, wherein the overall foam composite exhibits a Shore A hardness of about 45 to about 85.4. The cover of claim 1, wherein the overall foam composite exhibits a Shore A hardness of about 55 to about 75.5. The cover of claim 1, wherein the overall foam composite is sufficiently flexible to be bendable to an angle of 45 degree at a force less than about 300 g*cm as measured by the Cantilever Bending Test.6. The cover of claim 1, wherein the overall foam composite has a density of from about 15 to about 41 ounces per square yard.7. The cover of claim 1, wherein the overall foam composite has a density of from about 21 to about 30 ounces per square yard.8. The cover of claim 1, wherein the overall foam composite has a density of from about 18 to about 24 ounces per square yard.9. The cover of claim 1, wherein the water resistant top layer is a film.10. The cover of claim 1, wherein the water resistant top layer is a film formed from a film-forming plastic selected from the group consisting of poly(urethane)of s both of the poly(ether) and the poly(ester) form, poly(ester)s), flexible poly(vinyl)s, elastomeric poly(olefin)s, poly(isobutylene), neoprene, and low density poly(ethylene)s.11. The cover of claim 1, wherein the water resistant top layer comprises a fabric.12. The cover of claim 1, wherein the water resistant top layer comprises a woven fabric.13. The cover of claim 1, wherein the flexible foam layer has an internal cohesive strength of at least about 4.5 lbs/in.14. The cover of claim 1, wherein the flexible foam layer is a closed cell foam.15. The cover of claim 1, wherein the flexible foam layer is an open cell foam.16. The cover of claim 1, wherein the flexible foam layer is formed from a foamable polymer or copolymer selected from the group consisting of plasticized polyvinyl chloride, plasticized polyester, or plasticized polyolefin.17. A method of manufacturing a soft cover of claim 1, comprising the steps ofa) preparing a foam composite comprising the steps of i) preparing a three layer web construction comprising a water resistant top layer, a foam precursor film layer, and a protective bottom layer, and ii) exposing the three layer web construction to an activation temperature sufficient to expand the foam precursor film layer, thereby forming a foam composite; and b) cutting the foam composite to size for manufacturing a soft vehicle cover; and c) assembling a soft cover for a vehicle using the cut foam composite as prepared in step b). 18. A method of manufacturing a soft cover of claim 1, comprising the steps ofa) preparing a foam composite by assembling a three layer web construction comprising a water resistant top layer, a foam layer, and a protective bottom layer to form a foam composite; b) cutting the foam composite to size for manufacturing a soft vehicle cover; and c) assembling a soft cover for a vehicle using the cut foam composite as prepared in step b). 19. A method of use a soft cover, comprisinga) providing a soft cover of claim 1, b) attaching said soft cover to a vehicle in a manner for removably covering a portion of the vehicle. 20. The method of claim 19, wherein the soft cover is attached to retractably enclose a predetermined compartment in the vehicle.21. The cover of claim 1, wherein the protective bottom layer is a textile.22. The cover of claim 1, wherein the protective bottom layer is a sateen woven textile.23. The cover of claim 1, wherein the protective bottom layer is a 100% polyester sateen woven textile.