A laminated multilayer textured composite has an embossed fibrous outer layer bonded to one side of an adhesive layer to form a three-dimensional structure defined by all of fibers in depressed areas between elevated areas being fully embedded in the adhesive and most of the fibers in the elevated a
A laminated multilayer textured composite has an embossed fibrous outer layer bonded to one side of an adhesive layer to form a three-dimensional structure defined by all of fibers in depressed areas between elevated areas being fully embedded in the adhesive and most of the fibers in the elevated areas of the elevated areas being free of adhesive. The composite provides an abrasion resistant, surface stable material for covering floors, walls, furniture and the like. An optional backing layer can be simultaneously adhered to the second side of the adhesive layer primarily for improved cushioning and dimensional stability. The composite can be formed by a simultaneous pressure embossing and thermal laminating process.
대표청구항▼
What is claimed is: 1. A textured composite material comprising (a) an outer layer of fabric selected from the group consisting of knit, woven, stitch-bonded fabrics, felts, spunlaced fabrics, nonwoven webs of bonded fibers, nonwoven webs of entangled fibers and mixtures thereof, (b) an adjacent ad
What is claimed is: 1. A textured composite material comprising (a) an outer layer of fabric selected from the group consisting of knit, woven, stitch-bonded fabrics, felts, spunlaced fabrics, nonwoven webs of bonded fibers, nonwoven webs of entangled fibers and mixtures thereof, (b) an adjacent adhesive layer coextensive with the outer layer in which the composite material has a surface area comprising (i) depressed areas within which all the fibers are fully contacted by activated adhesive and have maintained structural identity of outer layer fibers, and (ii) elevated areas within which a major fraction of the lengths of the fibers of the outer layer are substantially free of inter-fiber bonding by the adhesive, and (c) a backing layer adjacent the adhesive layer opposite the outer layer, the backing layer having a thickness of about 2-20 mm. 2. The textured composite material of claim 1 in which the outer layer has a maximum thickness at each elevated area and the height of the elevated area above adjacent depressed areas is greater than the maximum thickness of such elevated area. 3. The textured composite material of claim 1 in which the outer layer together with the adhesive layer has a cross section profile defining a first contour at the surface of the outer layer and a second contour at the surface of the adhesive layer opposite the outer layer such that the first contour is undulated in phase with the second contour whereby peaks of the first contour align with corresponding peaks of the second contour and valleys of the first contour align with corresponding valleys of the second contour. 4. The textured composite material of claim 1 which defines a plane and in which portions of the fibers in the transition zones between the depressed areas and elevated areas at peripheral edges of the depressed areas are bound by activated adhesive in an orientation substantially normal to the plane. 5. The textured composite material of claim 1 in which individual fibers or linked fibers of the outer layer extend between at least two depressed areas. 6. The textured composite material of claim 1 in which the backing layer provides the material with absence of cupping or doming greater than 4 mm vertical deflection between center and edge of an 8 inch by 8 inch square sample of material which has been heated for 1 minute at 80�� C., cooled for 30 minutes, and immersed in water and then dried for 48 hours. 7. The textured composite material of claim 1 which is a floorcovering carpet. 8. The textured composite material of claim 1 in which every point within the elevated areas is less than 20 mm from a depressed area. 9. The textured composite material of claim 1 in which the backing layer has a thickness of at least 0.95 cm. 10. The textured composite material of claim 1 in which the backing layer has a basis weight of about 0.14-2.7 kg/m2 (4-80 oz./yd2). 11. The textured composite material of claim 10 in which a portion of the backing layer within the depressed areas is exposed. 12. The textured composite material of claim 11 in which the fabric of the outer layer has a color scheme and the backing layer has a color such that exposed backing layer in combination with the color scheme of the outer layer impart to the textured composite material a preselected color-coordinated appearance. 13. The textured composite material of claim 10 in which the basis weight is at least 0.68 kg/m2 (20 oz./yd2). 14. A textured composite material comprising an outer layer of fabric comprising fibers and an adjacent adhesive layer coextensive with the outer layer in which the composite material has a surface area comprising (i) depressed areas within which all the fibers are fully contacted by activated adhesive and have maintained structural identity of outer layer fibers, and (ii) elevated areas within which a major fraction of the lengths of the fibers of the outer layer are substantially free of inter-fiber bonding by the adhesive, in which the textured composite material further comprises a backing layer adjacent the adhesive layer opposite the outer layer, the backing layer having a basis weight of about 0.14-2.7 kg/m2 (4-80 oz./yd2) and a thickness of about 2-20 mm, in which a portion of the backing layer within the depressed areas is exposed, in which the fabric of the outer layer has a color scheme and the backing layer has a color such that exposed backing layer in combination with the color scheme of the outer layer impart to the textured composite material a preselected color-coordinated appearance, and in which the backing layer has a plurality of strata each stratum being of a different color, and in which preselected strata are exposed within preselected areas of exposed backing layer such that the exposed backing layer exhibits a color scheme comprising more than one color. 15. A textured composite material comprising an outer layer of fabric selected from the group consisting of knit, woven, stitch-bonded fabrics, felts, spunlaced fabrics, nonwoven webs of bonded fibers, nonwoven webs of entangled fibers and mixtures thereof and an adjacent adhesive layer coextensive with the outer layer in which the composite material has a surface area comprising (i) depressed areas within which all the fibers are fully contacted by the activated adhesive and have maintained structural identity of outer layer fibers, and (ii) elevated areas within which a major fraction of the lengths of the fibers of the outer layer are substantially free of inter-fiber bonding by the adhesive, in which the outer layer has a maximum thickness at each elevated, area and the height of the elevated area above adjacent depressed areas is greater than the maximum thickness of such elevated area, which textured composite material further comprises a backing layer adjacent the adhesive layer opposite the fibrous outer layer, the backing layer having a basis weight of about 0.14-2.7 kg/m2 (4-80 oz./yd2) and a thickness of about 2-20 mm, and which textured composite material further comprises a breathable barrier layer of a vapor transmissive, liquid permeation resistant film between the adhesive layer and the backing layer. 16. A textured composite material formed by a method comprising the steps of (a) providing a fabric selected from the group consisting of knit, woven, stitch-bonded fabrics, felts, spunlaced fabrics, nonwoven webs of bonded fibers, nonwoven webs of entangled fibers and mixtures thereof defining an outer layer of the textured composite material, (b) depositing an adhesive layer of activatable adhesive uniformly on a side of the fabric, (c) compressing the fabric and adhesive layer between an embossing tool having a plurality of protrusions directed toward the fabric and an opposing backup tool, thereby forming (i) depressed areas where the protrusions contact the fabric and adhesive layer, (ii) elevated areas where the fabric is free of contact with the protrusions, and (iii) opposite cross section profile contours of the outer layer and the adhesive layer of the composite which are undulated in phase such that peaks of the outer layer profile contour align with corresponding peaks of the adhesive layer profile contour and valleys of the outer layer profile contour align with corresponding valleys of the adhesive layer profile contour, (d) activating the adhesive in contact with the protrusions without melting the fibers of the fabric such that all of the fibers within the depressed areas become fully contacted by activated adhesive and such that the fibers in the elevated areas are substantially free of inter-fiber bonding by the adhesive, and (e) relieving compression of the fabric and adhesive layer. 17. The textured composite material of claim 16 which defines a plane and in which the backup tool comprises a plurality of protrusions intermeshing with the protrusions of the embossing tool such that portions of the fibers at peripheral edges of the depressed areas are bound by activated adhesive in an orientation substantially normal to the plane. 18. The textured composite material of claim 16 which defines a plane and in which the backup tool comprises an elastically deformable surface facing the embossing tool such that portions of the fibers at peripheral edges of the depressed areas are bound by activated adhesive in an orientation substantially normal to the plane. 19. The textured composite material of claim 16 which defines a plane and in which the method further comprises prior to the compressing step, the step of providing a backing layer adjacent the adhesive layer opposite the outer layer and in which the compressing step comprises penetrating the embossing tool into the backing layer such that portions of the fibers at peripheral edges of the depressed areas are bound by activated adhesive in an orientation substantially normal to the plane. 20. The textured composite material of claim 16 in which the method further comprises prior to the compressing step, the step of providing a backing layer adjacent the adhesive layer opposite the outer layer, the backing layer having a basis weight of about 0.68-2.7 kg/m2 (20-80 oz./yd2). 21. A textured composite material consisting essentially of (a) an outer layer of fabric selected from the group consisting of knit, woven, stitch-bonded fabrics, felts, spunlaced fabrics, nonwoven webs of bonded fibers, nonwoven webs of entangled fibers and mixtures thereof and (b) an adjacent adhesive layer coextensive with the outer layer in which the composite material has a surface area comprising (i) depressed areas within which all the fibers are fully contacted by activated adhesive and have maintained structural identity of outer layer fibers, and (ii) elevated areas within which a major fraction of the lengths of the fibers of the outer layer are substantially free of inter-fiber bonding by the adhesive in which the outer layer together with the adhesive layer has a cross section profile defining a first contour at the surface of the outer layer and a second contour at the surface of the adhesive layer opposite the outer layer such that the first contour is undulated in phase with the second contour whereby peaks of the first contour align with corresponding peaks of the second contour and valleys of the first contour align with corresponding valleys of the second contour. 22. The textile composite material of claim 21 in which defines a plane and portions of the fibers at peripheral edges of the depressed areas are bound by activated adhesive in an orientation substantially normal to the plane.
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